2002 CHRYSLER TOWN AND COUNTRY timing chain

(7) Install the timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKET(S)
- INSTALLATION).
(8) Install the generator mount bracket. (Fig. 24)
(9) Install the generator.
(10) Install right engine mount bracket and engine
mount (Refer to 9 - ENGINE/ENGINE MOUNTING/
RIGHT MOUNT - INSTALLATION).
(11) Fill the cooling system (Refer to 7 - COOLING
- STANDARD PROCEDURE).
(12) Install the accessory drive belts (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION).
(13) Lower vehicle and connect battery cable.
WATER PUMP - 3.3/3.8L
DESCRIPTION
The water pump has a die-cast aluminum body
and a plastic impeller. It bolts directly to the timing
chain case cover, using a rubber seal for sealing (Fig.
27). It is driven by the accessory drive belt.
OPERATION
The water pump is the heart of the cooling system.
The coolant is pumped through the engine block, cyl-
inder head, heater core, and radiator.
REMOVAL
(1) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(2) Remove the accessory drive belt shield.
(3) Remove the accessory drive belt. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(4) Remove water pump pulley bolts (Fig. 27).
NOTE: To remove the water pump pulley, it MUST
first be positioned between water pump housing
and drive hub. The pulley can then be removed with
the water pump assembly.
(5) Rotate pulley until openings in pulley align
with water pump drive hub spokes (Fig. 28). Move
pulley inward between pump housing and hub (Fig.
28).
(6) Position pulley to allow access to water pump
mounting bolts. Remove water pump mounting bolts
(Fig. 29).
(7) Remove water pump with the pulley loosely
positioned between hub and the pump body.
(8) Remove and discard the seal.
Fig. 27 Water Pump - 3.3/3.8L Engine
1 - WATER PUMP
2 - PULLEY - WATER PUMP
3 - BOLT - PULLEY
4 - BOLT - WATER PUMP
5 - SEAL - WATER PUMP
Fig. 28 Water Pump Pulley Positioning
1 - HUB - WATER PUMP
2 - PULLEY - WATER PUMP
7 - 34 ENGINERS
WATER PUMP - 2.4L (Continued)
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(9) Clean seal groove and sealing surfaces on
pump and timing chain case cover. Take care not to
scratch or gouge sealing surfaces.
CLEANING
Clean gasket mating surfaces as necessary.
INSPECTION
Replace the water pump if it has any of the follow-
ing defects.
(1) Damage or cracks on the pump body.
(2) Coolant leaks; this will be evident by a wet
stream of coolant running down the pump body and
components below. A thin stain below the weep hole
reservoir slot (Fig. 30) is considered normal opera-
tion.
(3) Impeller rubs inside of chain case cover.
(4) Excessively loose or rough turning bearing.
NOTE: A weepage stain that is black, brown, or grey
is considered normal, if it is dry. If the weep
appears wet; pressure test the cooling system at
15±18 psi and observe the weep area. If weep area
remains unchanged, do not replace the water pump
for this condition. Replace the water pump, if a
steady flow of engine coolant is evident from the
weep hole/reservoir slot (Fig. 30) (shaft seal failure).
Be sure to perform a thorough analysis before
replacing water pump.
INSTALLATION
(1) Install new seal into water pump housing
groove (Fig. 31).NOTE: The water pump pulley MUST be positioned
loosely between the pump housing and drive hub
BEFORE water pump installation.
(2) Position the water pump pulley loosely between
pump housing and drive hub (Fig. 28).
(3) Install water pump and pulley to the timing
chain case cover (Fig. 27). Tighten water pump bolts
to 12 N´m (105 in. lbs.).
(4) Position pulley on water pump hub. Install
bolts and tighten to 28 N´m (250 in. lbs.) (Fig. 27).
Fig. 29 Water Pump Bolts - 3.3/3.8L Engine (Shown
Without Pulley)
1 - WATER PUMP
2 - BOLTS
Fig. 30 Water Pump Inspection - 3.3/3.8L Engine
Fig. 31 Water Pump Seal
1 - WATER PUMP HOUSING
2 - SEAL
3 - IMPELLER
RSENGINE7-35
WATER PUMP - 3.3/3.8L (Continued)
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(4) Install the inlet tube (Fig. 36). Tighten bolts to
28 N´m (250 in. lbs.).
(5) Connect radiator lower hose (Fig. 34) and
heater return hose (if equipped with engine oil
cooler) (Fig. 35) to the inlet tube.
(6) Install the drive belt splash shield and lower
vehicle.
(7) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
Fig. 34 RAD HOSES TO ENGINE - 3.3/3.8L
1 - UPPER HOSE
2 - LOWER HOSE
Fig. 35 Engine Oil Cooler Hoses (Engine Oil Cooler
Equipped)
1 - OIL COOLER INLET TUBE
2 - INLET HOSE
3 - OIL COOLER OUTLET TUBE
4 - OUTLET HOSE
5 - WATER PUMP INLET TUBE
Fig. 36 WATER PUMP INLET TUBE
1 - TIMING CHAIN COVER
2 - INLET TUBE
3 - BOLT
4 - BOLT
5 - O-RING
RSENGINE7-37
WATER PUMP INLET TUBE - 3.3/3.8L (Continued)
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WATER PUMP
DESCRIPTION
The water pump on the 2.5L CRD diesel has a die
cast aluminum housing. It bolts to a aluminum hous-
ing which attaches to the engine block (Fig. 14).
OPERATION
The water pump is used to circulate coolant
through the cooling system. The coolant is pumped
through the engine block, cylinder head, heater core,
EGR cooler, cabin heater, and radiator.
REMOVAL
REMOVAL - WATER PUMP
(1) Disconnect negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Remove timing belt inner and outer covers
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - REMOVAL).
(4) Remove water pump retaining bolts and pump
(Fig. 15).
REMOVAL - WATER PUMP HOUSING
(1) Disconnect negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(3) Remove both outer and inner timing belt covers
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - REMOVAL).
(4) Disconnect water pump housing to thermostat
housing bypass hose (Fig. 16).
(5) Remove the water pump housing retaining
nuts (Fig. 17).
(6) Remove water pump housing from engine block
(Fig. 17).
CLEANING
Clean gasket mating surfaces as necessary.
INSTALLATION
INSTALLATION - WATER PUMP
(1) Clean gasket mating surfaces as necessary.
(2) Place water pump and gasket in place. Install
water pump retaining bolts (Fig. 15). Torque bolts to
24.4N´m.
Fig. 14 WATER PUMP
1 - WATER PUMP HOUSING STUDS
2 - WATER PUMP
3 - RETAINING NUTS
4 - OIL COOLER RETAINING STUD
5 - OIL COOLER TO ENGINE BLOCK RETAINING BOLT
6 - OIL COOLER COOLANT HOSE
7 - ENGINE BLOCK
Fig. 15 WATER PUMP LOCATION
1 - CYLINDER HEAD
2 - ENGINE BLOCK
3 - OIL COOLER
4 - OIL FILTER HOUSING
5 - WATER PUMP
RGENGINE7a-23
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(3) Install both inner and outer timing belt covers
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - INSTALLATION).
(4) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(5) Connect negative battery cable.
INSTALLATION - WATER PUMP HOUSING
(1) Clean mating serfaces of water pump housing
and engine block as necessary.
(2) Place new o-ring in groove in water pump
housing (Fig. 18).
(3) Be sure lower radiator hose tube o-ring is in
place.
(4) Install water pump housing on lower radiator
hose tube and push on mounting studs (Fig. 17).
Torque retaining nuts to 24.4N´m.
(5) Connect water pump housing to thermostat
housing bypass hose (Fig. 16).
(6) Install both inner and outer timing belt covers
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT / CHAIN COVER(S) - INSTALLATION).
(7) Refill cooling system (Refer to 7 - COOLING/
ENGINE/COOLANT - STANDARD PROCEDURE).
(8) Connect negative battery cable.
Fig. 16 THERMOSTAT HOUSING LOCATION
1 - CYLINDER HEAD COVER
2 - THERMOSTAT HOUSING
3 - AIR BLEED
4 - WATER PUMP
5 - WATER PUMP HOUSING TO THERMOSTAT HOUSING
BYPASS HOSE
6 - E G R VA LV E
Fig. 17 WATER PUMP ASSEMBLY
1 - WATER PUMP HOUSING STUDS
2 - WATER PUMP
3 - RETAINING NUTS
4 - OIL COOLER RETAINING STUD
5 - OIL COOLER TO ENGINE BLOCK RETAINING BOLT
6 - OIL COOLER COOLANT HOSE
7 - ENGINE BLOCK
Fig. 18 WATER PUMP HOUSING O-RING
1 - WATER PUMP
2 - WATER PUMP HOUSING O-RING
3 - WATER PUMP HOUSING
7a - 24 ENGINERG
WATER PUMP (Continued)
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DIAGNOSIS AND TESTING - ENGINE
DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
DIAGNOSIS AND TESTING)
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES
ROUGH1. Idle speed too low. 1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic
Information)
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty ignition coil(s). 4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
9 - 4 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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SPECIFICATIONS - TORQUE
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Balance Shaft Carrier to
BlockÐBolts54 40 Ð
Balance Shaft Gear
CoverÐDouble Ended
Fastener12 Ð 105
Balance Shaft SprocketÐ
Bolt28 Ð 250
Balance Shaft Chain
TensionerÐBolts12 Ð 105
Balance Shaft Carrier
CoverÐBolts12 Ð 105
Camshaft SprocketÐBolt 101 75 Ð
Connecting Rod
CapÐBolts27 +
1¤4
turn20
+1¤4
turnÐ
Crankshaft Main Bearing
Cap/Bedplate
ÐM8 Bolts 28 250
ÐM11 Bolts 41 +
1¤4
Turn30
+1¤4
TurnÐ
Crankshaft Damper 136 100 Ð
Cylinder HeadÐBolts (Refer to 9 - ENGINE/
CYLINDER HEAD -
INSTALLATION)
Cylinder Head CoverÐ
Bolts12 Ð 105
Flex Plate to Crankshaft 95 70 Ð
Engine Mount Bracket
RightÐBolts61 45 Ð
Engine MountingÐBolts (Refer to 9 ENGINE/
ENGINE MOUNTING)
DESCRIPTION N´mFt.
Lbs.In.
Lbs.
Exhaust Manifold to
Cylinder HeadÐBolts19 Ð 170
Exhaust Manifold Heat
ShieldÐBolts12 Ð 105
Intake Manifold - Lower
ÐBolts28 Ð 250
Intake Manifold -
UpperÐBolts28 Ð 250
Oil Filter 12 Ð 105
Oil PanÐBolts 12 Ð 105
Oil Pan DrainÐPlug 27 20 Ð
Oil Pressure Switch 21 Ð 190
Oil Pump to BlockÐBolts 28 Ð 250
Oil Pump Cover
PlateÐBolts12 Ð 105
Oil Pump Pick-up
TubeÐBolt28 20 Ð
Oil Pump Relief
ValveÐCap41 30 Ð
Spark Plugs 18 13 Ð
Structural Collar (Refer to 9 - ENGINE/
ENGINE BLOCK/
STRUCTURAL COVER -
INSTALLATION)
Timing Belt Covers
- Front Covers to Rear
CoverÐBolts7Ð60
- Rear CoverÐM6 Bolts 12 Ð 105
ÐM8 Bolts 28 Ð 250
Timing Belt Tensioner
AssemblyÐBolts61 45 Ð
9 - 20 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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(13) Remove timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - REMOVAL)
(14) Remove timing belt idler pulley and rear tim-
ing belt cover. (Refer to 9 - ENGINE/VALVE TIM-
ING/TIMING BELT / CHAIN COVER(S) -
REMOVAL)
(15) Remove cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL)
(16) Remove camshafts (Refer to 9 - ENGINE/
CYLINDER HEAD/CAMSHAFT(S) - REMOVAL).
NOTE: Identify rocker arm position to ensure cor-
rect re-installation in original position, if reused.
(17) Remove rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - REMOVAL)
(18) Remove cylinder head bolts in REVERSE
sequence of tightening (Fig. 19).
(19) Remove cylinder head from engine block.
(20) Inspect and clean cylinder head. (Refer to 9 -
ENGINE/CYLINDER HEAD - INSPECTION) (Refer
to 9 - ENGINE/CYLINDER HEAD - CLEANING)
CLEANING
To ensure engine gasket sealing, proper surface
preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.
NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.
Remove all gasket material from cylinder head and
block (Refer to 9 - ENGINE - STANDARD PROCE-
DURE). Be careful not to gouge or scratch the alumi-
num head sealing surface.
Clean all engine oil passages.
INSPECTION
(1) Cylinder head must be flat within 0.1 mm
(0.004 in.) (Fig. 14).
(2) Inspect camshaft bearing journals for scoring.
(3) Remove carbon and varnish deposits from
inside of valve guides with a reliable guide cleaner.
(4) Using a small hole gauge and a micrometer,
measure valve guides in 3 places top, middle and bot-
tom (Fig. 15). (Refer to 9 - ENGINE - SPECIFICA-
TIONS) Replace guides if they are not within
specification.
(5) Check valve guide height (Fig. 16).
INSTALLATION - CYLINDER HEAD
NOTE: The Cylinder head bolts should be examined
BEFORE reuse. If the threads are necked down, the
bolts must be replaced (Fig. 17).
Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale, the bolt should be replaced.
(1) Before installing the bolts, the threads should
be coated with engine oil.
(2) Position cylinder head gasket on engine block
(Fig. 18).
(3) Install cylinder head on engine block.
(4) Tighten the cylinder head bolts in the sequence
shown in (Fig. 19). Using the 4 step torque turn
method, tighten according to the following values:
²First All to 34 N´m (25 ft. lbs.)
Fig. 14 Checking Cylinder Head Flatness
1 - FEELER GAUGE
2 - STRAIGHT EDGE
Fig. 15 Checking Wear on Valve GuideÐTypical
1-TOP
2 - MIDDLE
3 - BOTTOM
4 - CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT
LOCATIONS
9 - 26 ENGINE 2.4LRS
CYLINDER HEAD (Continued)
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