2002 CHRYSLER TOWN AND COUNTRY service

(4) Remove camshaft thrust plate (Fig. 47).
(5) Install a long bolt into front of camshaft to
facilitate removal of the camshaft.
(6) Remove the camshaft (Fig. 47), being careful
not to damage cam bearings with the cam lobes.
NOTE: The camshaft bearings are serviced with the
engine block.
INSPECTION
(1) Check the cam lobes and bearing surfaces for
abnormal wear and damage (Fig. 49). Replace cam-
shaft as required.
NOTE: If camshaft is replaced due to lobe wear or
damage, always replace the lifters.
(2) Measure the lobe actual wear (unworn area -
wear zone = actual wear) (Fig. 49) and replace cam-
shaft if out of limit. Standard value is 0.0254 mm
(0.001 in.), wearlimitis 0.254 mm (0.010 in.).
INSTALLATION
(1) Lubricate camshaft lobes and camshaft bearing
journals with engine oil.
(2) Install a long bolt into the camshaft to assist in
the installation of the camshaft.
(3) Carefully install the camshaft in engine block.
(4) Install camshaft thrust plate and bolts (Fig.
47). Tighten to 12 N´m (105 in. lbs.) torque.
(5) Measure camshaft end play. (Refer to 9 -
ENGINE - SPECIFICATIONS) If not within specifi-
cations, replace thrust plate.(6) Install the timing chain and sprockets. (Refer
to 9 - ENGINE/VALVE TIMING/TIMING BELT/
CHAIN AND SPROCKETS - INSTALLATION)
NOTE: When camshaft is replaced, all of the
hydraulic lifters must be replaced also.
(7) Install the hydraulic lifters (Refer to 9 -
ENGINE/ENGINE BLOCK/HYDRAULIC LIFTERS
(CAM IN BLOCK) - INSTALLATION). Each lifter
reused must be installed in the same position from
which it was removed.
(8) Install the timing chain cover. (Refer to 9 -
ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - INSTALLATION)
(9) Install the cylinder heads. (Refer to 9 -
ENGINE/CYLINDER HEAD - INSTALLATION)
(10) Install the cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)
(11) Install the lower and upper intake manifolds.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - INSTALLATION)
(12) Install the engine assembly. (Refer to 9 -
ENGINE - INSTALLATION)
CONNECTING ROD BEARINGS
STANDARD PROCEDURE - MEASURING
CONNECTING ROD BEARING CLEARANCE
The bearing caps are not interchangeable and
should be marked at removal to ensure correct
assembly. The bearing shells must be installed with
the tangs inserted into the machined grooves in the
rods and caps. Install cap with the tangs on the same
side as the rod. Fit all rods on one bank until com-
plete. Connecting rod bearings are available in the
standard size and the following undersizes: 0.025
mm (0.001 in.) and 0.250 mm (0.010 in.).
CAUTION: Install the bearings in pairs. Do not use a
new bearing half with an old bearing half. Do not
file the rods or bearing caps.
Measure connecting rod journal for taper and out-
of-round. (Refer to 9 - ENGINE/ENGINE BLOCK/
CRANKSHAFT - INSPECTION)
The connecting rod bearing clearances can be
determined by use of Plastigage or the equivalent.
The following is the recommended procedure for the
use of Plastigage:
(1) Rotate the crankshaft until the connecting rod
to be checked is at the bottom of its stroke.
(2) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
Fig. 49 Checking Camshaft for Wear (Typical)
1 - UNWORN AREA
2 - ACTUAL WEAR
3 - BEARING JOURNAL
4 - LOBE
5 - WEAR ZONE
RSENGINE 3.3/3.8L9 - 115
CAMSHAFT & BEARINGS (IN BLOCK) (Continued)
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Upper and lower number 2 bearing halves are
flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves
in the engine (Fig. 59). All bearing cap bolts removed
during service procedures are to be cleaned and
lubricated with engine oil before installation. Bearing
shells are available in standard and the following
undersizes: 0.025 mm (0.001 in.) and 0.254 mm
(0.010 in). Never install an undersize bearing that
will reduce clearance below specifications.
CRANKSHAFT BEARING OIL CLEARANCE
Inspect the crankshaft bearing journals. (Refer to 9
- ENGINE/ENGINE BLOCK/CRANKSHAFT -
INSPECTION)
Engine crankshaft bearing clearances can be deter-
mined by use of Plastigage or the equivalent. The fol-lowing is the recommended procedures for the use of
Plastigage with the engine in the vehicle or engine
on a repair stand.
PLASTIGAGE METHODÐENGINE IN-VEHICLE
NOTE: The total clearance of the main bearings can
only be determined with the engine in the vehicle
by removing the weight of the crankshaft. This can
be accomplished by either of two following meth-
ods:
(1) Preferred method:
a. Shim the bearings adjacent to the bearing to be
checked in order to remove the clearance between
upper bearing shell and the crankshaft. This can be
accomplished by placing a minimum of 0.254 mm
(0.010 in.) shim (e. g. cardboard, matchbook cover,
etc.) between the bearing shell and the bearing cap
on the adjacent bearings and tightening bolts to
14±20 N´m (10±15 ft. lbs.).
²When checking #1 main bearing shim #2 main
bearing.
²When checking #2 main bearing shim #1 & #3
main bearing.
²When checking #3 main bearing shim #2 & #4
main bearing.
²When checking #4 main bearing shim #3 main
bearing.
NOTE: Remove all shims before reassembling
engine.
(2) Alternative Method:
a. Support the weight of the crankshaft with a
jack under the counterweight adjacent to the bearing
being checked.
(3) Remove oil film from surface to be checked.
Plastigage is soluble in oil.
(4) Place a piece of Plastigage across the entire
width of the bearing shell in the cap approximately
6.35 mm (1/4 in.) off center and away from the oil
holes (Fig. 60). (In addition, suspected areas can be
checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing
being checked to the proper specifications.
(5) Remove the bearing cap and compare the width
of the flattened Plastigage (Fig. 61) with the scale
provided on the package. Locate the band closest to
the same width. This band shows the amount of
clearance in thousandths. Differences in readings
between the ends indicate the amount of taper
present. Record all readings taken. (Refer to 9 -
ENGINE - SPECIFICATIONS)Plastigage gener-
ally is accompanied by two scales. One scale is
in inches, the other is a metric scale.
Fig. 58 Main Bearing Cap Identification
Fig. 59 Main Bearing Identification
1 - OIL GROOVES
2 - OIL HOLES
3 - UPPER BEARINGS
4 - LOWER BEARINGS
9 - 120 ENGINE 3.3/3.8LRS
CRANKSHAFT MAIN BEARINGS (Continued)
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ENGINE
TABLE OF CONTENTS
page page
ENGINE 2.5L TURBO DIESEL
DESCRIPTION
DESCRIPTION - 2.5L COMMON RAIL
DIESEL ENGINE.......................2
DESCRIPTION - ENGINE COVER..........3
REMOVAL
REMOVAL - 2.5L DIESEL ENGINE..........3
REMOVAL - ENGINE COVER.............6
INSTALLATION
INSTALLATION - 2.5L TURBO DIESEL
ENGINE..............................7
INSTALLATION - ENGINE COVER..........7
SPECIFICATIONS
SPECIFICATIONS - 2.5L COMMON RAIL
DIESEL ENGINE.......................8
SPECIFICATIONS - TORQUE............10
SPECIAL TOOLS.......................12
CYLINDER HEAD
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE
SERVICE............................17
STANDARD PROCEDURE - MEASURING
PISTON PROTRUSION.................18
REMOVAL.............................19
CLEANING............................21
INSPECTION..........................21
INSTALLATION.........................21
CAMSHAFT(S)
DESCRIPTION.........................22
OPERATION...........................22
REMOVAL.............................22
INSTALLATION.........................23
CYLINDER HEAD COVER(S)
DESCRIPTION.........................24
REMOVAL.............................24
INSTALLATION.........................25
CAMSHAFT OIL SEAL(S)
REMOVAL.............................27
INSTALLATION.........................27
ROCKER ARMS
DESCRIPTION.........................27
OPERATION...........................27
REMOVAL.............................27
INSTALLATION.........................28
HYDRAULIC LIFTERS
DESCRIPTION.........................29
REMOVAL.............................29
INSPECTION..........................30
INSTALLATION.........................30ENGINE BLOCK
DESCRIPTION.........................30
CRANKSHAFT
DESCRIPTION.........................30
OPERATION...........................30
STANDARD PROCEDURE - CHECKING
CRANKSHAFT END PLAY...............31
REMOVAL.............................31
INSTALLATION.........................32
CYLINDER LINERS
DESCRIPTION.........................33
REMOVAL.............................33
INSPECTION..........................34
INSTALLATION.........................34
INTERNAL VACUUM PUMP
DESCRIPTION.........................35
REMOVAL.............................35
INSTALLATION.........................35
PISTON & CONNECTING ROD
DESCRIPTION.........................36
STANDARD PROCEDURE - PISTON RING
FITTING.............................36
REMOVAL.............................36
INSPECTION..........................38
INSTALLATION.........................39
CRANKSHAFT OIL SEAL - FRONT
REMOVAL.............................41
INSTALLATION.........................41
VIBRATION DAMPER
REMOVAL.............................42
INSTALLATION.........................42
ENGINE COVER - FRONT
DESCRIPTION.........................43
REMOVAL.............................43
INSTALLATION.........................43
CRANKSHAFT MAIN BEARINGS
REMOVAL.............................44
INSTALLATION.........................45
CRANKSHAFT OIL SEAL - REAR
REMOVAL.............................46
INSTALLATION.........................46
OIL PAN
REMOVAL.............................46
INSTALLATION.........................46
OIL PUMP
REMOVAL
REMOVAL...........................47
REMOVAL...........................47
RGENGINE9a-1
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SPECIFICATIONS - TORQUE
2.5L DIESEL TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Oil Pump Bolts 10.8 8 96
Vacuum Pump Bolts 10.8 8 96
Crankshaft Gear Bolts 10.8 8 96
Crankshaft Position
Sensor Bolts10.8 8 96
Flywheel Bolts - Refer to
the Service Procedure
Cylinder Head Bolts -
Refer to the Service
Procedure
Reluctor Wheel Bolts 14.6 11 130
Rear Main Bearing
Support Bolts27.5 21 240
Oil Cooler to Engine Block
Bolt47.1 35 Ð
Oil Cooler Mounting Stud 50 37 Ð
Water Pump Housing Nuts 24.4 18 212
Connecting Rod Bolts -
Refer to the Service
Procedure
Balance Shaft Bolts 32.4 24 Ð
Oil Jet Bolts 10.8 8 96
Oil Pan Bolts 11.8 8 96
Crankshaft Hub Bolt 304 225 Ð
Front Engine Cover Bolts 11.8 8 96
Transmission to Engine
Bolts83.4 62 Ð
Cylinder Head Cover /
Intake Manifold Bolts27.5 20 Ð
Camshaft Access Plugs 80 59 Ð
Oil Separator Bolts 10.8 8 96
Camshaft Position Sensor
Bolt10.8 8 96
Boost Pressure / Intake
Air Temp. Sensor Bolts5.4 Ð 48
Accessory Drive Bracket
Bolts47.1 35 Ð
Vacuum Line Fitting Bolt 56.9 42 Ð
Fuel Pump Nuts 27.5 21 Ð
Fuel Line Fittings at Pump 27.5 21 Ð
Inner Timing Belt Cover
Bolts
9a - 10 ENGINERG
ENGINE 2.5L TURBO DIESEL (Continued)
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CYLINDER HEAD
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE SERVICE
This procedure is done with the engine cylinder
head removed from the block.
DISASSEMBLY
(1) Remove the engine cylinder head from the cyl-
inder block. Refer to cylinder head removal and
installation in this section.
(2) Use Valve Spring Compressor Tool and com-
press each valve spring.
(3) Remove the valve locks, retainers, and springs.
(4) Use an Arkansas smooth stone or a jewelers
file to remove any burrs on the top of the valve stem,
especially around the groove for the locks.
(5) Remove the valves, and place them in a rack in
the same order as removed.
VALVE CLEANING
(1) Clean all carbon deposits from the combustion
chambers, valve ports, valve stems, valve stem
guides and head.
(2) Clean all grime and gasket material from the
engine cylinder head machined gasket surface.
INSPECTION
(1) Inspect for cracks in the combustion chambers
and valve ports.
(2) Inspect for cracks on the exhaust seat.
(3) Inspect for cracks in the gasket surface at each
coolant passage.
(4) Inspect valves for burned, cracked or warped
heads.
(5) Inspect for scuffed or bent valve stems.
(6) Replace valves displaying any damage.
(7) Check valve spring height (Fig. 11).
VALVE REFACING
(1) Use a valve refacing machine to reface the
intake and exhaust valves to the specified angle.
(2) After refacing, a margin of at least 4.52-4.49
mm (.178-.177 inch) must remain (Fig. 12). If the
margin is less than 4.49 mm (.177 inch), the valve
must be replaced.
VALVE SEAT REFACING
(1) Install a pilot of the correct size in the valve
guide bore. Reface the valve seat to the specified
angle with a good dressing stone. Remove only
enough metal to provide a smooth finish.
(2) Use tapered stones to obtain the specified seat
width when required.
VALVE STAND DOWN
Valve stand down is to maintain the adequate com-
pression ratio.
(1) Invert cylinder head.
(2) Fit each valve to its respective valve guide.
(3) Using a straight edge and feeler gauge, check
valve head stand down: Inlet valve head stand down
1.08 to 1.34 mm (.042 to .052 ins.) and exhaust valve
stand down .99 to 1.25 mm (.035 to .049 ins.).
(4) If valve head stand down is not in accordance
with above, discard original valves, check stand down
with new valves and recut valve seat inserts to
obtain correct stand down.
VALVE GUIDES
(1) Valve Guides height requirement.
(2) Measurement A (Fig. 13): 16.50 - 17.00 mm.
Measurment B : 14.50 - 15.00 mm.
VALVE STEM-TO-GUIDE CLEARANCE
MEASUREMENT
(1) Measure and record internal diameter of valve
guides. Valve guide internal diameter is 8.0 to 8.015
mm (.3149 to .3155 ins.).
(2) Measure valve stems and record diameters.
Intake valve stem diameter 7.94 to 7.96 mm (.3125 to
Fig. 11 VALVE SPRING CHART
LOAD Kg HEIGHT mm STATE
P1 0.00 H1 45.26 FREE LENGTH
P2 182-5
+10%H2 38.00 VALVE CLOSED
P3 395 5% H3 28.20 VALVE OPEN
RGENGINE9a-17
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(9) Remove plug in cylinder head cover/intake
manifold and insert VM.1052 to lock intake camshaft
in position (Fig. 87).
(10) At this point the timing belt can be removed
for service.
(11) After engine service is completed and timing
belt reinstalled, remove both camshaft locking pins
from cylinder head cover/intake manifold.
(12) Install both camshaft access plugs.
(13) Remove 90É after TDC engine locking pin.
(14) Install starter motor (Refer to 8 - ELECTRI-
CAL/STARTING/STARTER MOTOR - INSTALLA-
TION).
(15) Install generator (Refer to 8 - ELECTRICAL/
CHARGING/GENERATOR - INSTALLATION).
(16) Install engine cover (Refer to 9 - ENGINE -
INSTALLATION).
(17) Install front wiper unit (Refer to 8 - ELEC-
TRICAL/WIPERS/WASHERS/WIPER MODULE -
INSTALLATION).
(18) Connect negative battery cable.BALANCE SHAFT
DESCRIPTION
The 2.5L Common Rail Diesel engine is equipped
with two nodular cast iron balance shafts in a cast
aluminum carrier. The balance shaft assembly is
mounted to the engine block (Fig. 88).
OPERATION
The balance shaft is driven by the crankshaft. The
balance shafts are connected by heelical gears. The
dual-counter rotating shafts decrease second order
vertical shaking forces caused by component move-
ment.
Fig. 87 INTAKE CAMSHAFT LOCKING PIN VM.1052
1 - TIMING BELT INNER COVER
2 - GLOW PLUG ELECTRICAL CONNECTOR
3 - CYLINDER HEAD COVER/INTAKE MANIFOLD
4 - FUEL RAIL
5 - INTAKE CAMSHAFT LOCKING PIN VM.1052
Fig. 88 BALANCE SHAFT ASSEMBLY
1 - BALANCE SHAFT
2 - OIL JET RETAINING BOLT
3 - OIL JET
4 - ENGINE BLOCK
5 - CRANKSHAFT
6 - BALANCE SHAFT RETAINING BOLTS
7 - OIL DIPSTICK TUBE RETAINER
8 - RUBBER BUSHING
9 - RETAINING BOLT
9a - 54 ENGINERG
VALVE TIMING (Continued)
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EXHAUST SYSTEM
TABLE OF CONTENTS
page page
EXHAUST SYSTEM
DESCRIPTION..........................1
OPERATION............................2
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EXCESSIVE
EXHAUST SYSTEM NOISE...............2
DIAGNOSIS AND TESTING - EXHAUST
SYSTEM RESTRICTION CHECK...........2
INSPECTION...........................3
ADJUSTMENTS.........................3
SPECIFICATIONS
TORQUE.............................3
SPECIAL TOOLS
EXHAUST SYSTEM.....................4
CATALYTIC CONVERTER
DESCRIPTION..........................4
OPERATION............................4REMOVAL.............................5
INSPECTION...........................6
INSTALLATION..........................6
CROSS-OVER PIPE - 3.3/3.8L
REMOVAL.............................6
INSTALLATION..........................6
HEAT SHIELDS
DESCRIPTION..........................6
OPERATION............................7
REMOVAL.............................7
INSTALLATION..........................7
MUFFLER
REMOVAL.............................7
INSTALLATION..........................8
RESONATOR
REMOVAL.............................9
INSTALLATION..........................9
EXHAUST SYSTEM
DESCRIPTION
The exhaust system consists of a catalytic converter,
muffler, and a resonator with connecting pipes in-be-
tween (Fig. 1). The system is serviced in two sections;
the catalytic converter and pipe, and the muffler and
resonator with connecting pipe. A band clamp is usedto connect the joint between the two components.
Three support hanger rods with rubber isolators are
used to support and isolate the exhaust system. A flex-
ible joint, integral to the catalytic converter, allows for
engine movement. On vehicles equipped with AWD, an
additional heat shield is mounted to the catalytic con-
verter. The exhaust system is tuned for each vehicle/
powertrain combination.
Fig. 1 Exhaust System - Typical (All Vehicles)
1 - CATALYTIC CONVERTER 4 - SUPPORT - RESONATOR
2 - BAND CLAMP 5 - RESONATOR
3 - SUPPORTS - MUFFLER 6 - MUFFLER
RSEXHAUST SYSTEM11-1
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OPERATION
The exhaust system contains, quiets, and cleans
the exhaust gases generated by the engine.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - EXCESSIVE
EXHAUST SYSTEM NOISE
CONDITION POSSIBLE CAUSES CORRECTION
EXCESSIVE EXHAUST NOISE
(UNDER HOOD)1. Exhaust manifold cracked or
broken.1. Replace manifold.
2. Manifold to cylinder head leak. 2. Tighten manifold and/or replace
gasket.
3. EGR Valve to manifold gasket
leakage.3. Tighten fasteners or replace
gasket.
4. EGR Valve to EGR tube gasket
leakage.4. Tighten fasteners or replace
gasket.
5. EGR tube to manifold tube
leakage.5. Tighten tube nut.
6. Exhaust flex-joint to manifold
leak.6. Tighten joint fasteners and/or
replace gasket.
7. Exhaust flex-joint. 7. Replace catalytic converter
assembly.
8. Pipe and shell noise from front
exhaust pipe.8. Characteristic of single wall pipe.
EXCESSIVE EXHAUST NOISE 1. Leak at exhaust pipe joints. 1. Tighten clamps at leaking joints.
2. Burned or rusted out muffler
assembly or exhaust pipe.2. Replace muffler resonator tailpipe
assembly or exhaust pipe with
catalytic converter assembly.
3. Burned or rusted out resonator. 3. Replace muffler resonator tailpipe
assembly.
4. Restriction in exhaust system. 4. Perform Exhaust System
Restriction Check. Replace
component as necessary.
5. Converter material in muffler. 5. Replace muffler and converter
assemblies. Check fuel injection and
ignition systems for proper
operation.
DIAGNOSIS AND TESTING - EXHAUST SYSTEM
RESTRICTION CHECK
Exhaust system restriction can be checked by mea-
suring back pressure using the DRB IIItand PEP
module pressure tester.WARNING: THE NORMAL OPERATING TEMPERA-
TURE OF THE EXHAUST SYSTEM IS VERY HIGH.
THEREFORE, NEVER WORK AROUND OR ATTEMPT
TO SERVICE ANY PART OF THE EXHAUST SYSTEM
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE
TAKEN WHEN WORKING NEAR THE CATALYTIC
CONVERTER. THE TEMPERATURE OF THE CON-
VERTER RISES TO A HIGH LEVEL AFTER A SHORT
PERIOD OF ENGINE OPERATION TIME.
11 - 2 EXHAUST SYSTEMRS
EXHAUST SYSTEM (Continued)
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