2002 CHRYSLER TOWN AND COUNTRY timing

(9) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(10) Install accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(11) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(12) Install right engine mount assembly.
(13) Install air cleaner housing.
(14) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(15) Connect negative battery cable.
TIMING BELT IDLER PULLEY
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support engine and remove right engine
mount.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - REMOVAL).
NOTE: Idler pulley retaining bolts are LHD thread.
(10) Remove timing belt idler pulleys (Fig. 95).
INSTALLATION
(1) Install timing belt idler pulleys (Fig. 95).
Torque bolts to 47.1N´m.
(2) Install timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT/CHAIN AND
SPROCKETS - INSTALLATION) .
(3) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(4) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).(5) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(6) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(7) Install right engine mount.
(8) Install air cleaner housing.
(9) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(10) Connect negative battery cable.
Fig. 95 TIMING BELT AND SPROCKETS
1 -CAMSHAFT SPROCKETS
2 - INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET RETAINING NUT
4 - TIMING BELT
5 - TIMING BELT TENSIONER RETAINING BOLT
6 - TIMING BELT TENSIONER
7 - TENSIONER ALIGNMENT PIN
8 - IDLER PULLEY
9 - CAMSHAFT SPROCKET RETAINING BOLT
9a - 58 ENGINERG
TIMING BELT / CHAIN COVER(S) (Continued)
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TMNG BELT/CHAIN
TENSIONER
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing.
(4) Support engine and remove right engine
mount.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Loosen and remove timing belt tensioner (Fig.
96).
INSTALLATION
(1) Install timing belt tensioner and retaining bolt
(Fig. 96).
(2) Adjust timing belt tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TMNG BELT/CHAIN
TENSIONER&PULLEY - ADJUSTMENTS) .
(3) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(4) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(5) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).(6) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(7) Install right engine mount.
(8) Install air cleaner housing.
(9) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(10) Connect negative battery cable.Fig. 96 TIMING BELT AND SPROCKETS
1 -CAMSHAFT SPROCKETS
2 - INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET RETAINING NUT
4 - TIMING BELT
5 - TIMING BELT TENSIONER RETAINING BOLT
6 - TIMING BELT TENSIONER
7 - TENSIONER ALIGNMENT PIN
8 - IDLER PULLEY
9 - CAMSHAFT SPROCKET RETAINING BOLT
RGENGINE9a-59
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ADJUSTMENTS
ADJUSTMENT - TIMING BELT TENSIONER
(1) With timing belt outer cover removed and tim-
ing belt installed.
(2) Loosen timing belt tensioner (Fig. 97).
(3) Align timing belt tensioner spring stop with
tensioner as shown (Fig. 98) and torque timing belt
tensioner retaining bolt to 34.7N´m.
(4) Rotate engine 2 complete revolution and then
recheck tensioner alignment. Readjust tensioner
alignment as necessary.
TIMING BELT/CHAIN AND
SPROCKETS
REMOVAL
CAUTION: Before removing the timing belt, the
engine must put at 90É after TDC. Failure to do so
could result in valve and/or piston damage during
reassembly. (Refer to 9 - ENGINE/VALVE TIMING -
STANDARD PROCEDURE)
(1) Disconnect negative battery cable.
(2) Remove engine cover (Refer to 9 - ENGINE -
REMOVAL).
(3) Remove air cleaner housing assembly.
(4) Support engine and remove right engine
mount.
(5) Remove power steering belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(6) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(7) Remove vibration damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
Fig. 97 TIMING BELT TENSIONER ADJUSTMENT
1 - TIMING BELT IDLER PULLEY
2 - ENGINE FRONT COVER
3 - CRANKSHAFT HUB
4 - TIMING BELT TENSIONER
5 - TIMING BELT
Fig. 98 TIMING BELT TENSIONER ALIGNMENT
1 - TENSIONER SPRING STOP
2 - TIMING BELT TENSIONER
3 - TIMING BELT TENSIONER
4 - TIMING BELT
5 - TIMING BELT INNER COVER
9a - 60 ENGINERG
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(8) Remove timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(9) Loosen timing belt tensioner and remove tim-
ing belt (Fig. 99).
INSTALLATION
(1) With both camshaft alignment pins still
installed and the engine locked at 90É after TDC.
(2) Align timing mark on injection pump sprocket
with timing mark on timing belt (Fig. 100).(3) Install timing belt.
(4) Adjust the timing belt tensioner (Refer to 9 -
ENGINE/VALVE TIMING/TMNG BELT/CHAIN
TENSIONER&PULLEY - ADJUSTMENTS) .
(5) Remove both camshaft alignment pins from cyl-
inder head cover/intake manifold and engine locking
pin from engine block (Refer to 9 - ENGINE/VALVE
TIMING - STANDARD PROCEDURE).
(6) Install timing belt outer cover (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION).
(7) Install vibration damper (Refer to 9 - ENGINE/
ENGINE BLOCK/VIBRATION DAMPER - INSTAL-
LATION).
(8) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(9) Install power steering belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(10) Install right engine mount.
(11) Install air cleaner housing.
(12) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(13) Connect negative battery cable.
Fig. 99 TIMING BELT AND SPROCKETS
1 -CAMSHAFT SPROCKETS
2 - INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET RETAINING NUT
4 - TIMING BELT
5 - TIMING BELT TENSIONER RETAINING BOLT
6 - TIMING BELT TENSIONER
7 - TENSIONER ALIGNMENT PIN
8 - IDLER PULLEY
9 - CAMSHAFT SPROCKET RETAINING BOLT
Fig. 100 INJECTION PUMP GEAR TIMING MARKS
1 - TIMING MARK ON COVER
2 - TIMING MARK ON INJECTION PUMP SPROCKET
3 - INJECTION PUMP SPROCKET
RGENGINE9a-61
TIMING BELT/CHAIN AND SPROCKETS (Continued)
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FUEL INJECTION
OPERATION
OPERATION - INJECTION SYSTEM
All engines used in this section have a sequential
Multi-Port Electronic Fuel Injection system. The MPI
system is computer regulated and provides precise
air/fuel ratios for all driving conditions. The Power-
train Control Module (PCM) operates the fuel injec-
tion system.
The PCM regulates:
²Ignition timing
²Air/fuel ratio
²Emission control devices
²Cooling fan
²Charging system
²Idle speed
²Vehicle speed control
Various sensors provide the inputs necessary for
the PCM to correctly operate these systems. In addi-
tion to the sensors, various switches also provide
inputs to the PCM.
The PCM can adapt its programming to meet
changing operating conditions.
Fuel is injected into the intake port above the
intake valve in precise metered amounts through
electrically operated injectors. The PCM fires the
injectors in a specific sequence. Under most operat-
ing conditions, the PCM maintains an air fuel ratio
of 14.7 parts air to 1 part fuel by constantly adjust-
ing injector pulse width. Injector pulse width is the
length of time the injector is open.
The PCM adjusts injector pulse width by opening
and closing the ground path to the injector. Engine
RPM (speed) and manifold absolute pressure (air
density) are theprimaryinputs that determine
injector pulse width.
OPERATION - MODES OF OPERATION
As input signals to the PCM change, the PCM
adjusts its response to output devices. For example,
the PCM must calculate a different injector pulse
width and ignition timing for idle than it does for
Wide Open Throttle (WOT). There are several differ-
ent modes of operation that determine how the PCM
responds to the various input signals.
There are two different areas of operation, OPEN
LOOP and CLOSED LOOP.
During OPEN LOOP modes the PCM receives
input signals and responds according to preset PCM
programming. Inputs from the upstream and down-
stream heated oxygen sensors are not monitored dur-
ing OPEN LOOP modes, except for heated oxygensensor diagnostics (they are checked for shorted con-
ditions at all times).
During CLOSED LOOP modes the PCM monitors
the inputs from the upstream and downstream
heated oxygen sensors. The upstream heated oxygen
sensor input tells the PCM if the calculated injector
pulse width resulted in the ideal air-fuel ratio of 14.7
to one. By monitoring the exhaust oxygen content
through the upstream heated oxygen sensor, the
PCM can fine tune injector pulse width. Fine tuning
injector pulse width allows the PCM to achieve opti-
mum fuel economy combined with low emissions.
For the PCM to enter CLOSED LOOP operation,
the following must occur:
(1) Engine coolant temperature must be over 35ÉF.
²If the coolant is over 35ÉF the PCM will wait 38
seconds.
²If the coolant is over 50ÉF the PCM will wait 15
seconds.
²If the coolant is over 167ÉF the PCM will wait 3
seconds.
(2) For other temperatures the PCM will interpo-
late the correct waiting time.
(3) O2 sensor must read either greater than 0.745
volts or less than 0.29 volt.
(4) The multi-port fuel injection systems has the
following modes of operation:
²Ignition switch ON (Zero RPM)
²Engine start-up
²Engine warm-up
²Cruise
²Idle
²Acceleration
²Deceleration
²Wide Open Throttle
²Ignition switch OFF
(5) The engine start-up (crank), engine warm-up,
deceleration with fuel shutoff and wide open throttle
modes are OPEN LOOP modes. Under most operat-
ing conditions, the acceleration, deceleration (with
A/C on), idle and cruise modes,with the engine at
operating temperatureare CLOSED LOOP modes.
IGNITION SWITCH ON (ZERO RPM) MODE
When the ignition switch activates the fuel injec-
tion system, the following actions occur:
²The PCM monitors the engine coolant tempera-
ture sensor and throttle position sensor input. The
PCM determines basic fuel injector pulse width from
this input.
²The PCM determines atmospheric air pressure
from the MAP sensor input to modify injector pulse
width.
When the key is in the ON position and the engine
is not running (zero rpm), the Auto Shutdown (ASD)
and fuel pump relays de-energize after approximately
RSFUEL INJECTION14-17
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1 second. Therefore, battery voltage is not supplied to
the fuel pump, ignition coil, fuel injectors and heated
oxygen sensors.
ENGINE START-UP MODE
This is an OPEN LOOP mode. If the vehicle is in
park or neutral (automatic transaxles) or the clutch
pedal is depressed (manual transaxles) the ignition
switch energizes the starter relay. The following
actions occur when the starter motor is engaged.
²If the PCM receives the camshaft position sensor
and crankshaft position sensor signals, it energizes
the Auto Shutdown (ASD) relay and fuel pump relay.
If the PCM does not receive both signals within
approximately one second, it will not energize the
ASD relay and fuel pump relay. The ASD and fuel
pump relays supply battery voltage to the fuel pump,
fuel injectors, ignition coil, (EGR solenoid and PCV
heater if equipped) and heated oxygen sensors.
²The PCM energizes the injectors (on the 69É
degree falling edge) for a calculated pulse width until
it determines crankshaft position from the camshaft
position sensor and crankshaft position sensor sig-
nals. The PCM determines crankshaft position within
1 engine revolution.
²After determining crankshaft position, the PCM
begins energizing the injectors in sequence. It adjusts
injector pulse width and controls injector synchroni-
zation by turning the individual ground paths to the
injectors On and Off.
²When the engine idles within  64 RPM of its
target RPM, the PCM compares current MAP sensor
value with the atmospheric pressure value received
during the Ignition Switch On (zero RPM) mode.
Once the ASD and fuel pump relays have been
energized, the PCM determines injector pulse width
based on the following:
²MAP
²Engine RPM
²Battery voltage
²Engine coolant temperature
²Inlet/Intake air temperature (IAT)
²Throttle position
²The number of engine revolutions since cranking
was initiated
During Start-up the PCM maintains ignition tim-
ing at 9É BTDC.
ENGINE WARM-UP MODE
This is an OPEN LOOP mode. The following inputs
are received by the PCM:
²Manifold Absolute Pressure (MAP)
²Crankshaft position (engine speed)
²Engine coolant temperature
²Inlet/Intake air temperature (IAT)
²Camshaft position²Knock sensor
²Throttle position
²A/C switch
²Battery voltage
²Vehicle speed
²Speed control
²O2 sensors
The PCM adjusts injector pulse width and controls
injector synchronization by turning the individual
ground paths to the injectors On and Off.
The PCM adjusts ignition timing and engine idle
speed. Engine idle speed is adjusted through the idle
air control motor.
CRUISE OR IDLE MODE
When the engine is at operating temperature this
is a CLOSED LOOP mode. During cruising or idle
the following inputs are received by the PCM:
²Manifold absolute pressure
²Crankshaft position (engine speed)
²Inlet/Intake air temperature
²Engine coolant temperature
²Camshaft position
²Knock sensor
²Throttle position
²Exhaust gas oxygen content
²A/C control positions
²Battery voltage
²Vehicle speed
The PCM adjusts injector pulse width and controls
injector synchronization by turning the individual
ground paths to the injectors On and Off.
The PCM adjusts engine idle speed and ignition
timing. The PCM adjusts the air/fuel ratio according
to the oxygen content in the exhaust gas (measured
by the upstream and downstream heated oxygen sen-
sor).
The PCM monitors for engine misfire. During
active misfire and depending on the severity, the
PCM either continuously illuminates or flashes the
malfunction indicator lamp (Check Engine light on
instrument panel). Also, the PCM stores an engine
misfire DTC in memory, if 2nd trip with fault.
The PCM performs several diagnostic routines.
They include:
²Oxygen sensor monitor
²Downstream heated oxygen sensor diagnostics
during open loop operation (except for shorted)
²Fuel system monitor
²EGR monitor (if equipped)
²Purge system monitor
²Catalyst efficiency monitor
²All inputs monitored for proper voltage range,
rationality.
²All monitored components (refer to the Emission
section for On-Board Diagnostics).
14 - 18 FUEL INJECTIONRS
FUEL INJECTION (Continued)
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OPERATION
The crankshaft position sensor detects slots cut
into the transmission driveplate extension (Fig. 6).
There are 3 sets of slots. Each set contains 4 slots,
for a total of 12 slots (Fig. 7). Basic timing is set by
the position of the last slot in each group. Once the
Powertrain Control Module (PCM) senses the last
slot, it determines crankshaft position (which piston
will next be at TDC) from the camshaft position sen-
sor input. The 4 pulses generated by the crankshaft
position sensor represent the 69É, 49É, 29É, and 9É
BTDC marks. It may take the PCM one engine rev-
olution to determine crankshaft position.
The PCM uses crankshaft position reference to
determine injector sequence, ignition timing and the
presence of misfire. Once the PCM determines crank-
shaft position, it begins energizing the injectors in
sequence.
REMOVAL
(1) Disconnect the negative battery cable.
(2) Raise vehicle and support.
(3) Disconnect the electrical connector (Fig. 8).
(4) Remove crankshaft sensor bolt.
(5) Remove the crankshaft sensor.
INSTALLATION - 2.4L
(1) Install the crankshaft sensor.
(2) Install crankshaft sensor bolt and tighten.
(3) Connect the electrical connector (Fig. 8).(4) Lower vehicle.
(5) Connect the negative battery cable.
ENGINE SPEED SENSOR
DESCRIPTION
The PCM receives a signal from the TCM and the
transaxle output speed sensor over the bus communi-
cation line to indicate vehicle speed on automatic
transmission cars. On Manual transmission cars (if
equipped) vehicle, a dedicated vehicle speed sensor is
connected to the PCM.
Fig. 6 Crankshaft Position Sensor
1 - CRANKSHAFT POSITION SENSOR
Fig. 7 Timing Slots
1 - TORQUE CONVERTER DRIVE PLATE
2 - SLOTS
Fig. 8 CRANKSHAFT SENSOR 2.4L
14 - 24 FUEL INJECTIONRS
CRANKSHAFT POSITION SENSOR (Continued)
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REMOVAL
When servicing throttle body components, always
reassemble components with new O-rings and seals
where applicable. Never use lubricants on O-rings or
seals, damage may result. If assembly of component
is difficult, use water to aid assembly. Use care when
removing hoses to prevent damage to hose or hose
nipple.
(1) Disconnect negative cable from battery.
(2) Remove electrical connector from idle air con-
trol motor.
(3) Remove idle air control motor mounting screws.
(4) Remove motor from throttle body. Ensure the
O-rings is removed with the motor.
INSTALLATION
When servicing throttle body components, always
reassemble components with new O-rings and seals
where applicable. Never use lubricants on O-rings or
seals, damage may result. If assembly of component
is difficult,a light coat of engine oil may be
applied to the O-RINGS ONLY (Fig. 16)to aid
assembly. Use care when removing hoses to prevent
damage to hose or hose nipple.
(1) The new idle air control motor has a new
O-ring installed on it. For 2.4L only, if pintle mea-
sures more than 1 inch (25 mm) it must be retracted.
Use the DRB Idle Air Control Motor Open/Close Test
to retract the pintle (battery must be connected.)
(2) Carefully place idle air control motor into
throttle body.
(3) Install mounting screw(s). Tighten screws to 2
N´m (17 in. lbs.) torque.
(4) Connect electrical connector to idle air control
motor.
(5) Connect negative cable to battery.
INLET AIR TEMPERATURE
SENSOR
DESCRIPTION
The IAT Sensor is a Negative Temperature Coeffi-
cient (NTC) Sensor that provides information to the
PCM regarding the temperature of the air entering
the intake manifold (Fig. 17).
OPERATION
Inlet/Intake Air Temperature
The inlet air temperature sensor replaces the
intake air temperature sensor and the battery tem-
perature sensor. The PCM uses the information from
the inlet air temperature sensor to determine values
to use as an intake air temperature sensor and a bat-
tery temperature sensor.
The Intake Air Temperature (IAT) sensor value is
used by the PCM to determine air density.
The PCM uses this information to calculate:
²Injector pulse width
²Adjustment of ignition timing (to prevent spark
knock at high intake air temperatures)
Battery Temperature
The inlet air temperature sensor replaces the
intake air temperature sensor and the battery tem-
perature sensor. The PCM uses the information from
the inlet air temperature sensor to determine values
for the PCM to use as an intake air temperature sen-
sor and a battery temperature sensor.
The battery temperature information along with
data from monitored line voltage (B+), is used by the
PCM to vary the battery charging rate. System volt-
Fig. 16 O-RINGS
1 - O-rings
Fig. 17 3.3/3.8L IAT SENSOR
14 - 28 FUEL INJECTIONRS
IDLE AIR CONTROL MOTOR (Continued)
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