2002 CHRYSLER TOWN AND COUNTRY exhaust gasket

Possible indications of the cylinder head gasket
leaking between adjacent cylinders are:
²Loss of engine power
²Engine misfiring
²Poor fuel economy
Possible indications of the cylinder head gasket
leaking between a cylinder and an adjacent water
jacket are:
²Engine overheating
²Loss of coolant
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50±70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.
COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL - CYLINDER HEAD
(1) Perform fuel system pressure release procedure
before attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - SPECIFICA-
TIONS)
(2) Disconnect battery negative cable.
(3) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(4) Remove air filter housing and inlet tube.
(5) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
(6) Remove heater tube support bracket from cyl-
inder head.
(7) Disconnect radiator upper and heater supply
hoses from intake manifold water outlet connections.
(8) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Raise vehicle and remove exhaust pipe from
manifold.
(10) Remove power steering pump reservoir and
line support bracket from lower intake manifold and
set aside. Do not disconnect lines.
(11) Remove ignition coil and wires from engine.
(12) Disconnect cam sensor and fuel injector wir-
ing connectors.
Fig. 13 Cylinder Head and Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
RSENGINE 2.4L9-25
CYLINDER HEAD (Continued)
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²Second All to 68 N´m (50 ft. lbs.)
²Third All to 68 N´m (50 ft. lbs.)
CAUTION: Do not use a torque wrench for the fol-
lowing step.
²Fourth Turn an additional 1/4 Turn,
(5) Install rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - INSTALLA-
TION)
(6) Install camshafts. (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - INSTALLATION).
(7) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(8) Install timing belt rear cover and timing belt
idler pulley. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - INSTALLA-
TION)
(9) Install timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
(10) Connect cam sensor and fuel injectors wiring
connectors.
(11) Install ignition coil and wires. Connect igni-
tion coil wiring connector.
(12) Install power steering pump reservoir and
line support bracket to cylinder head.
(13) Raise vehicle and install the exhaust pipe to
the manifold.
(14) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(15) Install heater tube support bracket to cylinder
head.
(16) Connect radiator upper and heater hoses to
intake manifold water outlet connections.
(17) Install upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(18) Using new gaskets, install EGR tube and
tighten fasteners to 11 N´m (95 in. lbs.).
Fig. 16 Valve Guide Height
1 - VALVE GUIDE
2 - 13.25 - 13.75 MM
(.521 - .541 IN.)
3 - SPRING SEAT
Fig. 17 Checking Bolts for Stretching (Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
Fig. 18 Cylinder Head Gasket Positioning
1 - PART NUMBER FACES UP
2 - NO. 1 CYLINDER
Fig. 19 Cylinder Head Tightening Sequence
RSENGINE 2.4L9-27
CYLINDER HEAD (Continued)
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²Coolant outlet connector bolts - 28 N´m (250 in.
lbs.)
²Coolant temperature sensor - 7 N´m (60 in. lbs.)
(1) Position a new gasket on cylinder head and
install lower manifold.
(2) Install and tighten intake manifold fasteners to
28 N´m (250 in. lbs.) in the sequence shown in (Fig.
110). Repeat procedure until all bolts are at specified
torque.
(3) Install lower intake manifold support bracket
bolts (Fig. 109) and tighten to:
²Bolts to intake 28 N´m (250 in. lbs.)
²Bolt to engine block 54 N´m (40 ft. lbs.)
(4) Position power steering reservoir on manifold
and install bolts.(5) Connect the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(6) Connect coolant temperature sensor/fuel injec-
tor wiring harness electrical connector.
(7) Install the radiator upper and heater supply
hoses.
(8) Install the upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(9) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifold is made of Hi-Silicone Moly
nodular cast iron for strength and high tempera-
tures. The manifold attaches to the cylinder head.
OPERATION
The exhaust manifold collects the exhaust gasses
exiting the combustion chambers. Then it channels
the exhaust gasses to the exhaust pipe attached to
the manifold.
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
the exhaust manifold.
(2) Disconnect upstream oxygen sensor connector
at the rear of exhaust manifold.
(3) Remove the bolts attaching the manifold to the
cylinder head.
(4) Remove exhaust manifold.
(5) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/EXHAUST MANIFOLD - INSPEC-
TION)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
(1) Inspect manifold gasket surfaces for flatness
with straight edge. Surface must be flat within 0.15
mm per 300 mm (0.006 in. per foot) of manifold
length.
(2) Inspect manifolds for cracks or distortion.
Replace manifold as necessary.
INSTALLATION
(1) Install exhaust manifold with a new gasket.
Tighten attaching nuts in the sequence shown in
(Fig. 111) to 19 N´m (170 in. lbs.).
Fig. 109 Lower Intake Manifold Support Bracket
1 - SUPPORT BRACKET
2 - BOLTS - UPPER TO MANIFOLD
3 - BOLT - LOWER TO ENGINE BLOCK
Fig. 110 Lower Intake Manifold Tightening Sequence
9 - 62 ENGINE 2.4LRS
INTAKE MANIFOLD - LOWER (Continued)
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ENGINE 3.3/3.8L
TABLE OF CONTENTS
page page
ENGINE 3.3/3.8L
DESCRIPTION.........................76
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - INTRODUCTION...........77
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE...........78
DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - MECHANICAL.............80
DIAGNOSIS AND TESTING - ENGINE OIL
LEAK INSPECTION....................82
DIAGNOSIS AND TESTING - CYLINDER
COMPRESSION PRESSURE TEST........83
DIAGNOSIS AND TESTING - CYLINDER
COMBUSTION PRESSURE LEAKAGE
TEST...............................83
STANDARD PROCEDURE
STANDARD PROCEDURE - MEASURING
BEARING CLEARANCE USING
PLASTIGAGE........................84
STANDARD PROCEDURE - FORM-IN-
PLACE GASKETS AND SEALERS.........84
STANDARD PROCEDURE - ENGINE
GASKET SURFACE PREPARATION........85
STANDARD PROCEDURE - HYDROSTATIC
LOCKED ENGINE.....................86
STANDARD PROCEDURE - REPAIR OF
DAMAGED OR WORN THREADS.........86
STANDARD PROCEDURE - ENGINE CORE
AND OIL GALLERY PLUGS..............86
REMOVAL - ENGINE ASSEMBLY...........87
INSTALLATION - ENGINE ASSEMBLY........90
SPECIFICATIONS
3.3/3.8L ENGINE......................92
SPECIFICATIONS - TORQUE............95
SPECIAL TOOLS
3.3/3.8L ENGINE......................96
AIR CLEANER ELEMENT
REMOVAL.............................99
INSTALLATION.........................99
AIR CLEANER HOUSING
REMOVAL.............................99
INSTALLATION........................100
CYLINDER HEAD
DESCRIPTION........................100
OPERATION..........................100
DIAGNOSIS AND TESTINGÐCYLINDER HEAD
GASKET...........................100
REMOVAL - CYLINDER HEAD............100
CLEANING...........................101INSPECTION.........................101
INSTALLATION - CYLINDER HEAD.........102
CYLINDER HEAD COVER(S)
DESCRIPTION........................103
CYLINDER HEAD COVER - RIGHT
REMOVAL............................103
INSTALLATION........................103
CYLINDER HEAD COVER - LEFT
REMOVAL............................105
INSTALLATION........................105
INTAKE/EXHAUST VALVES & SEATS
DESCRIPTION........................105
OPERATION..........................105
STANDARD PROCEDURE - REFACING
VALVESANDVALVESEATS ............105
REMOVAL............................106
CLEANING...........................106
INSPECTION.........................106
INSTALLATION........................107
VALVE SPRINGS
DESCRIPTION........................107
OPERATION..........................107
REMOVAL
REMOVAL - CYLINDER HEAD OFF.......108
REMOVAL - CYLINDER HEAD ON........108
INSPECTION.........................109
INSTALLATION
INSTALLATION - CYLINDER HEAD OFF . . . 109
INSTALLATION - CYLINDER HEAD ON....109
ROCKER ARMS
DESCRIPTION
DESCRIPTION - ROCKER ARMS.........110
DESCRIPTION - PUSHRODS............110
OPERATION
OPERATION - ROCKER ARMS..........110
OPERATION - PUSHRODS.............110
REMOVAL - ROCKER ARMS AND SHAFT....110
DISASSEMBLY - ROCKER ARMS AND
SHAFT.............................110
ASSEMBLY - ROCKER ARMS AND SHAFT . . . 111
INSTALLATION - ROCKER ARMS AND
SHAFT.............................111
VALVE STEM SEALS
DESCRIPTION........................112
REMOVAL............................113
INSTALLATION........................113
ENGINE BLOCK
DESCRIPTION........................113
STANDARD PROCEDURE - CYLINDER BORE
HONING............................113
9 - 74 ENGINE 3.3/3.8LRS
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CONDITION POSSIBLE CAUSE CORRECTION
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap.
2. Contamination in fuel system. 2. Clean system and replace fuel
filter.
3. Faulty fuel pump. 3. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
4. Incorrect valve timing. 4. Correct valve timing.
5. Leaking cylinder head gasket. 5. Replace cylinder head gasket.
6. Low compression. 6. Test compression of each
cylinder.
7. Burned, warped, or pitted valves. 7. Replace valves.
8. Plugged or restricted exhaust
system.8. Perform exhaust restriction test.
(Refer to 11 - EXHAUST SYSTEM -
DIAGNOSIS AND TESTING) Install
new parts, as necessary.
9. Faulty ignition coil(s). 9. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
ENGINE MISSES ON
ACCELERATION1. Dirty or incorrectly gapped spark
plugs.1. Clean spark plugs and set gap.
2. Contamination in Fuel System. 2. Clean fuel system and replace
fuel filter.
3. Burned, warped, or pitted valves. 3. Replace valves.
4. Faulty ignition coil(s). 4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
ENGINE MISSES AT HIGH SPEED 1. Dirty or incorrect spark plug gap. 1. Clean spark plugs and set gap.
2. Faulty ignition coil(s). 2. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
3. Dirty fuel injector(s). 3. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
4. Contamination in fuel system. 4. Clean system and replace fuel
filter.
RSENGINE 3.3/3.8L9-79
ENGINE 3.3/3.8L (Continued)
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(33)AWD equipped:Remove the power transfer
unit (PTU) (Refer to 21 - TRANSMISSION/TRANS-
AXLE/POWER TRANSFER UNIT - REMOVAL).
(34) Disconnect exhaust pipe from the manifold
(Fig. 7).
(35) Remove front engine mount and bracket as an
assembly.
(36) Remove the engine rear mount bracket.
(37) Remove the engine to transaxle struts (Fig. 8).
(38) Remove transaxle case cover (Fig. 8).
(39) Remove flex plate to torque converter bolts.
Mark torque converter to flex plate for orientation for
reassembly.
(40) Remove the power steering pressure hose sup-
port clip attaching bolt.
(41) Disconnect the knock sensor electrical connec-
tor (3.8L only).(42) Disconnect the engine block heater electrical
connector (if equipped).
(43) Remove the accessory belt splash shield.
(44) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL).
(45) Disconnect the radiator lower hose.
(46) Remove air conditioning compressor from
engine.
(47) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
Fig. 7 Catalytic Converter to Exhaust Manifold
1 - FLAG NUT
2 - GASKET
3 - BOLT
4 - CATALYTIC CONVERTER
Fig. 8 POWERTRAIN SUPPORTS AND DUST COVER
1 - BRACKET - ENGINE REAR MOUNT
2 - BOLT - TRANSAXLE CASE COVER
3 - STRUT - TRANSAXLE TO ENGINE HORIZONTAL
4 - BOLT - HORIZONTAL STRUT
5 - BOLT - STRUT TO TRANSAXLE
6 - COVER - TRANSAXLE CASE LOWER
7 - STRUT - TRANSAXLE TO ENGINE
8 - BOLT - STRUT TO ENGINE
9 - BOLT - ENGINE REAR MOUNT BRACKET
9 - 88 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)
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DESCRIPTION SPECIFICATION
Bearing Clearance (Max.
allowable)0.127 mm
(0.005 in.)
End Play 0.254±0.508 mm
(0.010±0.020 in.)
(Max. allowable) 0.304 mm
(0.012 in.)
Camshaft Bearing
Diameter
No. 1 50.800±50.825 mm
(1.9999±2.0009 in.)
No. 2 50.393±50.419 mm
(1.9839±1.9849 in.)
No. 3 50.013±50.038 mm
(1.9690±1.9699 in.)
No. 4 49.606±49.632 mm
(1.9529±1.954 in.)
Exhaust Valve Timing
ClosesÐ3.3L (ATDC) 13É
ClosesÐ3.8L (ATDC) 18É
OpensÐ3.3L (BBDC) 43É
OpensÐ3.8L (BBDC) 46É
DurationÐ3.3L 236É
DurationÐ3.8L 244É
Intake Valve Timing
ClosesÐ3.3L (ABDC 52É
ClosesÐ3.8L (ABDC 63É
OpensÐ3.3L (ATDC) 6É
OpensÐ3.8L (ATDC) 1É
DurationÐ3.3L 226É
DurationÐ3.8L 242É
Valve OverlapÐ3.3L 7É
Valve OverlapÐ3.8L 17É
Lifters
Type Hydraulic Roller
Diameter O.D. 22.949±22.962 mm
(0.903±0.904 in.)
Clearance In Block 0.020±0.061 mm
0.0007±0.0024 in.)
Cylinder Head
Gasket Thickness
(Compressed)0.65±0.75 mm
(0.025±0.029 in.)DESCRIPTION SPECIFICATION
Valve Seat
Angle 44.5±45É
Valve Seat Runout
(Service Limits)0.0762 mm
(0.003 in.)
Valve Seat WidthÐIntake
& Exhaust1.50±2.00 mm
(0.057±0.078 in.)
Valve Guide
Guide Bore Diameter
(Std.)6.975±7.00 mm
(0.274±0.275 in.)
Valves
Valve Lift (Zero
Lash)ÐIntake & Exhaust
Ð3.3L 9.80 mm
(0.385 in.)
Ð3.8L 11.0 mm
(0.433 in.)
Face AngleÐIntake 45±45.5É
Face AngleÐExhaust 45±45.5É
Head DiameterÐIntake 47.87±48.13 mm
(1.88±1.89 in.)
Head DiameterÐExhaust 35.37±35.63 mm
(1.39±1.40 in.)
Valve Margin
Intake 0.825±0.973 mm
(0.032±0.038 in.)
Exhaust 1.565±1.713 mm
(0.061±0.067 in.)
Valve Length (Overall)
Intake 125.84±126.6 mm
(4.95±4.98 in.)
Exhaust 127.2±127.96 mm
(5.00±5.04 in.)
Valve Stem Tip Height
Intake (valve tip to spring
seat washer)48.1±49.7 mm
(1.89±1.95 in.)
Exhaust (valve tip to
spring seat washer)48.53±50.09 mm
(1.91±1.97 in.)
Valve Stem Diameter
Intake (Standard) 6.935±6.953 mm
(0.2730±0.2737 in.)
9 - 94 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)
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DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Exhaust Crossover
PipeÐBolts54 40 Ð
Intake Manifold -
LowerÐBolts23 Ð 200
Intake Manifold - Lower
Gasket RetainerÐBolts12 Ð 105
Intake Manifold
UpperÐBolts12 Ð 105
Lifter Yoke RetainerÐ
Bolts12 Ð 105
Oil Filter Attaching Fitting 54 40 Ð
Oil Cooler Attaching
Fitting27 20 Ð
Oil Filter 20 15 Ð
Oil Filter AdapterÐBolts 28 Ð 250
Oil Gallery Plug 27 20 Ð
Oil PanÐBolts 12 Ð 105
Oil Pan DrainÐPlug 27 20 Ð
Oil Pressure Switch 23 Ð 200
Oil Pump Cover
PlateÐScrews12 Ð 105
Oil Pump Pick-up
TubeÐBolt28 Ð 250
Oil Dipstick HousingÐ
Bolts48 35 Ð
Rocker Arm ShaftÐBolts 23 Ð 200
Spark Plug 16 12 Ð
Timing Chain Case Cover
ÐM8 Bolt 27 20 Ð
ÐM10 Bolt 54 40 Ð
Water PumpÐBolts 12 Ð 105
Water Pump PulleyÐ
Bolts28 Ð 250SPECIAL TOOLS
3.3/3.8L ENGINE
Dolly 6135
Cradle 6710A
Adapter 6909A
Adapter 8444
9 - 96 ENGINE 3.3/3.8LRS
ENGINE 3.3/3.8L (Continued)
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