2008-2009 Chrysler / Dodge (RT) Town & Country, Caravan And Voyager Service Repair Workshop Manual

2009 ENGINE 2.8L Diesel - Service Information - Grand Caravan, Town & Country DESCRIPTION DESCRIPTION The 2.8L (2776 cc) four-cylinder "common rail" direct injection engine is an in-line overhead valve design. The engine utilize a cast iron cylinder block. The engine has a one piece aluminum cylinder head with four valves per cylinder and dual overhead cam shafts. The 2.8L is turbocharged, intercooled and also equipped with a EGR cooler. The identification stamp for the 2.8L is located on the right side of the engine block, below the turbocharger. The engine code label is located on the front timing cover and is the same as the engine I.D. and serial number. There is also a fuel system label on the front timing cover used for fuel system identification during ECM programming. STANDARD PROCEDURE ENGINE GASKET SURFACE PREPARATION Fig. 1: Proper Tool Usage For Surface Preparation Courtesy of CHRYSLER LLC 1 - ABRASIVE PAD 2 - 3M ROLOC™ BRISTLE DISC 3 - PLASTIC SCRAPER 2009 Chrysler Town & Country LX 2009 ENGINE 2.8L Diesel - Service Information - Grand Caravan, Town & Country 2009 Chrysler Town & Country LX 2009 ENGINE 2.8L Diesel - Service Information - Grand Caravan, Town & Country

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. Never use the following to clean gasket surfaces:  Metal scraper  Abrasive pad or paper to clean cylinder block and head  High speed power tool with an abrasive pad (1), 3M Roloc™ Bristle Disc (2), or a wire brush (3) Only use the following for cleaning gasket surfaces:  Solvent or a commercially available gasket remover  Plastic scraper  Sealing surfaces must be free of grease or oil residue. Clean surfaces with Mopar® brake parts cleaner (or equivalent) COMPRESSION TEST 1. Warm up the engine to operating temperature (approximately 80°C). 2. Shut off the engine. 3. Remove the engine cover. 4. Disconnect the fuel feed and return lines from the fuel filter. 5. Use a vacuum pump connected to the return line until no more fuel comes out. 6. Remove the fuel injectors. 7. Cranks the engine with the starter to remove combustion residue in the cylinders. 8. Install the compression test adapter 10010 into the injector hole of the cylinder to be tested. Install the injector retainer bolts and tighten. 9. Test compression pressure by cranking the engine with the starter for at least eight revolutions. 10. Measure the pressure in all of the cylinders. 11. The maximum allowable compression difference between cylinders is 10 bar (44 psi.) 12. Remove tool 10010. 13. Replace the high pressure fuel line. 14. Install the fuel injectors. 15. Install the engine cover. REMOVAL REMOVAL NOTE: Multi-Layer Steel (MLS) head gaskets require a scratch free sealing surface. 2009 Chrysler Town & Country LX 2009 ENGINE 2.8L Diesel - Service Information - Grand Caravan, Town & Country

Fig. 2: Intake Air Box Courtesy of CHRYSLER LLC 1. Remove the intake air box (4). See Engine/Air Intake System/BODY, Air Cleaner - Removal . 2. Disconnect the harness connector from the valve (2) in the turbocharger air inlet tube. Fig. 3: Battery Cables Courtesy of CHRYSLER LLC 3. Disconnect the battery cables (1) and (4). 4. Remove the battery (5). Refer to Electrical - Engine Systems/Battery System/BATTERY - Removal . 2009 Chrysler Town & Country LX 2009 ENGINE 2.8L Diesel - Service Information - Grand Caravan, Town & Country

Fig. 4: Battery Tray Courtesy of CHRYSLER LLC 5. Remove the battery tray (3). Refer to Electrical - Engine Systems/Battery System/TRAY, Battery - Removal . Fig. 5: Coolant Recovery Container - Diesel Courtesy of CHRYSLER LLC 1 - PRESSURE/VENT CAP 2009 Chrysler Town & Country LX 2009 ENGINE 2.8L Diesel - Service Information - Grand Caravan, Town & Country

6. Drain the coolant. Refer to Cooling - Standard Procedure . 7. Remove the coolant recovery bottle. Refer to Cooling/Engine/BOTTLE, Coolant Recovery - Removal . Fig. 6: Coolant Bottle Bracket Courtesy of CHRYSLER LLC 8. Remove the fasteners (1), and the coolant overflow bottle bracket. 2 - BRAKE MASTER CYLINDER 3 - BATTERY 4 - BATTERY SHIELD 5 - COOLANT RECOVERY CONTAINER RETAINING CLIP 6 - ENGINE COVER 7 - COOLANT RECOVERY CONTAINER 2009 Chrysler Town & Country LX 2009 ENGINE 2.8L Diesel - Service Information - Grand Caravan, Town & Country

Fig. 7: Engine Harness Connectors Courtesy of CHRYSLER LLC 9. Disconnect the engine harness connectors (1) and (2) from the ECM. Fig. 8: Charge Air Cooler Hoses Courtesy of CHRYSLER LLC 10. Remove the fastener (3) from the cylinder head. 11. Disconnect the charge air cooler hoses (2). 2009 Chrysler Town & Country LX 2009 ENGINE 2.8L Diesel - Service Information - Grand Caravan, Town & Country

Fig. 9: Heater Core Lines Courtesy of CHRYSLER LLC 12. Disconnect the heater core lines (1). Fig. 10: Front Lower Splash Shield Courtesy of CHRYSLER LLC 13. Remove the fasteners (1) and the front lower splash shield (2). 2009 Chrysler Town & Country LX 2009 ENGINE 2.8L Diesel - Service Information - Grand Caravan, Town & Country

Fig. 11: Left & Right Front Inner Fender Well Courtesy of CHRYSLER LLC 14. Remove the front tires. Refer to Tires and Wheels - Removal . 15. Remove the left and right front inner fender well (1). Refer to Body/Exterior/SHIELD, Splash - Removal . Fig. 12: Right & Left Half Shafts Courtesy of CHRYSLER LLC 2009 Chrysler Town & Country LX 2009 ENGINE 2.8L Diesel - Service Information - Grand Caravan, Town & Country

16. Remove the axle nut (2) from the right and left half shafts (1). Then remove both half shafts from the vehicle. Refer to Differential and Driveline/Half Shaft - Removal . Fig. 13: Diesel Oxidation Catalyst (DOC)/Diesel Particulate Filter (DPF) Courtesy of CHRYSLER LLC 17. Remove the fasteners and disconnect the exhaust system from the exhaust manifold. Refer to Exhaust System/CONVERTER, Catalytic - Removal 18. Disconnect the oxygen sensors. Fig. 14: Turbocharger Air Inlet Tube & Crankcase Vent Hose Heater Electrical Connector Courtesy of CHRYSLER LLC 19. Disconnect the harness connector from the PCV heater, (2) and remove the turbocharger air inlet (1). 2009 Chrysler Town & Country LX 2009 ENGINE 2.8L Diesel - Service Information - Grand Caravan, Town & Country

20. Disconnect all the injection, glow plug, EGR solenoid, Fuel pressure sensor and oxygen sensor electrical connectors or wiring harness. 21. Disconnect all the ground straps to the engine. Fig. 15: Electrical Connectors At Case Courtesy of CHRYSLER LLC 22. Disconnect the electrical connectors (1 thru 5) to the transmission. 2009 Chrysler Town & Country LX 2009 ENGINE 2.8L Diesel - Service Information - Grand Caravan, Town & Country

2008-2009 Chrysler / Dodge (RT) Town & Country, Caravan And Voyager Service Repair Workshop Manual

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