2010 Dodge Grand Caravan Service & Repair Manual
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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
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
motorfan@tradebit.com
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
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1 - PRESSURE/VENT CAP
2009 Chrysler Town & Country LX
2009 ENGINE 2.8L Diesel - Service Information - Grand Caravan, Town & Country
motorfan@tradebit.com
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
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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
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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
motorfan@tradebit.com
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
motorfan@tradebit.com
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
motorfan@tradebit.com
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What's Included?
Lifetime Access
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Access PDF Contents & Bookmarks
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Print one or all pages of your manual
$36.99
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