2005 CHRYSLER TOWN AND COUNTRY CYLINDER HEAD REMOVAL

The 24-valve overhead system is a "low-maintenance"
design. Routine adjustments are no longer
necessary, however, measurement should still take
place when trouble-shooting performance problems,
or upon completion of a repair that includes removal
and installation of the valve train components or
injectors.
(1) Disconnect battery negative cables.
(2) Remove cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - REMOVAL).
(3) Using the crankshaft barring tool #7471-B,
rotate crankshaft to align damper TDC mark to
12:00 o'clock position.
(a) If both number one cylinder rocker levers are
loose, continue to next step.
(b) If both number one clylinder rocker levers
are not loose, rotate crankshaft 360 degrees.
(4) With the engine in this position, valve lash can
be measured at the following rocker arms: INTAKE
1-2-4 / EXHAUST 1-3-5. Measure the valve lash by
inserting a feeler gauge between the rocker arm
socket and crosshead (Fig. 32). Refer to VALVE
LASH LIMIT CHART for the correct specifications. If
the measurement falls within the limits, adjustment/
resetting is not necessary. If measurement
finds the lash outside of the limits, adjustment/resetting
is required.
VALVE LASH LIMIT CHART
0.152 mm ( 0.006 in.)
MIN.
0.381 mm (0.015 in.)
MIN.
0.381 mm (0.015 in.)
MAX.
0.762 mm (0.030 in.)
MAX.
note:
If measured valve lash falls within these
specifications, no adjustment/reset is necessary.
Engine operation within these ranges has no adverse
affect on performance, emissions, fuel economy or
level of engine noise.
(5) If adjustment/resetting is required, loosen the
lock nut on rocker arms and turn the adjusting screw
until the desired lash is obtained:
² INTAKE 0.254 mm (0.010 in.)
² EXHAUST 0.508 mm (0.020 in.) Tighten the
lock nut to 24 Nm (18 ft. lbs.) and re-check the valve
lash.
(6) Using the crankshaft barring tool, rotate the
crankshaft one revolution (360°) to align the
damper TDC mark to the 12 o'clock position.
(7) With the engine in this position, valve lash can
be measured at the remaining rocker arms: INTAKE
3-5-6 / EXHAUST 2-4-6. Use the same method as
above for determining whether adjustment is necessary,
and adjust those that are found to be outside of
the limits.
(8) Install the cylinder head cover (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION).
(9) Connect the battery negative cables.

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Here are the cylinder head torque specs for Chrysler Town And Country 3.3l:
You will find a tightening sequence in the cylinder head bolt location-tighten the head bolts 1 to 8 accordingly using the four-step torque turn method
Here are the steps:
1. Bolts 1 - 8 to 61 N•m (45 ft-lb)
2. Bolts 1 - 8 to 88 N•m (65 ft-lb)
3. Bolts 1 - 8 (again) to 88 N•m (65 ft-lb)
4. Bolts 1 - 8 turn an additional 1/4 Turn, this step does not require you to use a torque wrench
Remember, after 1/4 turn, the bolt torque should be over 122 N•m (90 ft-lb). Otherwise, buy new bolts. Once all that is done, tighten head bolt number 9 Cylinder Head Bolts Location and use Tightening Sequence to 33 N•m (25 ft-lb)

possible bad injector - recomend have injector checked and or do compression test on cylinder # 2

when looking at the left hand side of the engine ( from the front or belt side ) it would usually be down on the block to the side of the crankshaft damper pulley and 4-5 inches back from the front of the engine.

below are the instruction you well need to remove head .....good luck Removal Procedure

1. Remove the air cleaner element.
2. Remove the air cleaner outlet resonator. .
3. Remove the powertrain control module (PCM) and engine wire harness bracket and related hoses and connections.
4. Remove the generator.
5. Remove the intake manifold.
6. Remove the exhaust manifold. Do not remove the exhaust pipe from the manifold. Only have the manifold pushed off to the side of the engine.
7. Position the A/C line out of the way towards the front of the vehicle.
8. Disconnect the following cross-vehicle engine wiring harness connectors:
• Engine coolant temperature sensor • Manifold absolute pressure (MAP) sensor • Ignition coils • Harness clamps at power steering pump • Wiring harness fastener at the right front inner fender • Throttle body • Camshaft sensors • Camshaft actuators • Fuel rail • Heated oxygen sensor (HO2S)
9. Set aside the cross-vehicle engine wiring harness on the left side of the vehicle.
10. Remove the camshaft cover.
    
11. Partially drain the cooling system.


12. Before performing one of the top dead center (TDC) procedures, break loose both the exhaust and intake camshaft sprocket bolts. Use a 25 mm (1 in) open end wrench on the camshaft hexes to hold the camshaft from turning. DO NOT remove the bolts.
13. Perform one of the following methods for the service timing procedure.
    
14. First Method--Rotate the engine clockwise by hand to TDC on the compression stroke by using a piston TDC indicator tool and/or dial indicator in the number 1 cylinder.
    
15. First Method (continued)--The TDC indicator tool graduation marks on the shaft should note top of the piston stroke.
    
16. First Method (continued)--When the piston is at TDC, the flats at the rear of the camshafts will be facing up and level when using a straight edge across the camshaft flats.
    
17. Second Method--Rotate the crankshaft in the engine rotational direction clockwise until the number 1 piston is at TDC on the compression stroke. The word Delphi on the exhaust camshaft position actuator will be parallel with the cylinder head to cam cover mating surface. When the piston is at TDC, the flats at the rear of the camshafts will be facing up and level when using a straight edge across the camshaft flats. A 0.005 inch feeler gauge should not slide under the straight edge (1).
    
18. Use a white paint pen or equivalent to place a reference mark on the harmonic balancer to the front cover for alignment purposes.
19. Lower the vehicle.
Important: If the timing is correct (TDC compression stroke number 1 cylinder), the camshaft flats will be in the up position.
Install J 44221 to the back of the camshafts.

20. Remove the upper timing chain guide to the cylinder head.
    
21. Clean the timing chain and gears with brake cleaner or suitable solvent. Use a white paint pen or equivalent to place a reference mark on both timing gear sprockets and the timing chain to mark location prior to disassembly. It is recommended that the paint marks be in the 12 o'clock position.


22. Install EN-48464 . It is important to install the tool with the proper orientation and to ensure that it is seated square against the timing chain and against the timing cover center bolt.



23. The narrow ramp of the wedge tool needs to be placed so that it faces the timing chain.
24. The wedge tool should be lightly seated using a couple of very light taps with a small plastic or brass hammer. The wedge tool will be fully seated against the tensioner after it moves about 25 mm (1 in).
25. Once the tool is correctly installed, unscrew the handle and remove the handle


26. Remove both upper cylinder head access hole plugs from the front of the cylinder head.
27. Remove the 1 long and 2 short cylinder head bolts next to the exhaust and intake timing chain tensioner shoes and discard the bolts.
28. Remove both upper timing chain tensioner shoe bolts.
29. Remove the exhaust and the intake camshaft sprocket bolts. Discard the bolts.



30. Carefully remove the exhaust and intake camshaft sprockets with the timing chain from the exhaust and intake camshafts. The illustration shows the exhaust camshaft sprocket already removed.



31. Remove the sprockets from the chain, tie a piece of mechanic's wire on the timing chain and let it drop.



32. Before removing the cylinder head bolts, use a drift punch and hammer to shock the bolts. This will ensure that the cylinder head bolts will not strip out the threads in the engine block or break. If a bolt breaks during engine disassembly, EN-47702 is available to assist in the removal of the remaining bolt segment.
    
33. Remove the cylinder head bolts. Discard the bolts.
    
34. Remove the cylinder head.
35. Place the cylinder head on a flat, clean surface with the combustion chambers face up, in order to prevent damage to the deck face.
    
36. Remove the cylinder head gasket.
Discard the gasket.

37. Remove all remaining gasket material from the engine block.
38. Inspect the cylinder head gasket mating surface on the engine block.
39. Clean and inspect the cylinder head.
40. Disassemble the cylinder head if necessary.

chain. R&R instructions from autozone.com pasted below. let me know if you have any more questions.

REMOVAL & INSTALLATION
SOHC Engine See Figures 1, 2, 3 and 4

1. Disconnect the negative battery cable.
2. Remove the timing chain front cover.

During timing chain and sprocket removal, position the crankshaft 90 degrees past Top Dead Center (TDC), to make sure the pistons will not contact the valves upon assembly.

1. Carefully rotate the crankshaft clockwise so the timing mark on the crankshaft sprocket and keyway align with the main bearing cap split line (90 degrees past TDC).
2. Remove bolts, then remove the timing guides and tensioner.
3. Remove the camshaft sprocket bolt, using a 7 / 8 in. (21mm) wrench to hold the camshaft. Then remove the timing chain and camshaft sprocket. Remove the crankshaft sprocket, if necessary.

To install:

1. Inspect the chain for wear and damage. Check the inside diameter of the chain, it should be no more than 16.77 in. (426mm). Inspect the chain guides for wear or cracks and the timing sprockets for teeth or key wear. Replace components as necessary.
2. Verify that the crankshaft is positioned 90 degrees clockwise past TDC from the keyway (keyway at 3 o'clock).
3. Bring the camshaft up to No. 1 TDC by loosely installing the sprocket and rotating the sprocket until the timing pin can be inserted. The camshaft contains wrench flats to assist in turning the shaft. The dowel pin should be at 12 o'clock when the camshaft is at TDC and a timing pin ( 3 / 16 in. drill bit) should then install at about the 8 o'clock position.
4. If removed, install the crankshaft sprocket, then rotate the crankshaft counterclockwise 90 degrees up to No. 1 TDC (keyway at 12 o'clock).
5. Position the chain under the crankshaft sprocket and over the camshaft sprocket. If necessary remove the camshaft sprocket, then slide the camshaft sprocket into position with the chain already engaged. The timing chain should be positioned so that one silver link plate aligns with the reference mark on the camshaft sprocket and the other aligns with the downward tooth (at the 6 o'clock position) on the crankshaft sprocket. The letters FRT on the camshaft sprocket must face forward, away from the cylinder head and excess chain slack should be located on the tensioner side of the block.
6. Temporarily install the timing pin to verify proper alignment of the camshaft and sprocket, then install and tighten the sprocket bolt to 75 ft. lbs. (102 Nm). Again, use a wrench on the camshaft flats to hold the shaft in position while tightening the bolt. Do not allow the camshaft retaining bolt to torque against the timing pin or cylinder head damage will result.
7. Install the chain guides with the words FRONT facing out. Install the fixed guide first and verify the chain is snug against the guide, then install the pivot guide. Tighten the bolts to 19 ft. lbs. (26 Nm) and verify that the pivot guide moves freely.
8. Retract the tensioner plunger and pin the ratchet lever using a 1 / 8 in. No. 31 drill bit inserted in the alignment hole at the bottom front of the component. Install the tensioner and tighten the bolts to 14 ft. lbs. (19 Nm), then remove the drill bit.
9. Make one final check to verify all components are properly timed, then remove all timing pins.
10. Install the timing chain front cover.
11. Connect the negative battery cable, start the engine and check for leaks.
    

Fig. Fig. 1: At 90 degrees past TDC, the crankshaft sprocket timing mark and keyway will align with the main bearing cap split line

Fig. Fig. 2: Exploded view of the timing chain and sprocket assembly-SOHC engine

Fig. Fig. 3: Insert the timing pin to ensure that the camshaft is at No. 1 TDC-SOHC engine

Fig. Fig. 4: When the camshaft is at TDC, rotate the crankshaft counterclockwise 90 degrees to achieve TDC

Tighten the cylinder head bolts 1 - 8 in the sequence shown in Cylinder Head Bolts Location and Tightening Sequence Using the 4 step torque turn method, tighten according to the following values:
Step 1: Bolts 1 - 8 to 61 N·m (45 ft. lbs.)
Step 2: Bolts 1 - 8 to 88 N·m (65 ft. lbs.)
Step 3: Bolts 1 - 8 (again) to 88 N·m (65 ft. lbs.)
Step 4: Bolts 1 - 8 turn an additional 1/4 Turn. (Do not use a torque wrench for this step.)
NOTE: Bolt torque after 1/4 turn should be over 122 N·m (90 ft. lbs.) If not, replace the bolt.

Tighten head bolt number 9 Cylinder Head Bolts Location and Tightening Sequence to 33 N·m (25 ft. lbs.) after head bolts 1 - 8 have been tighten to specifications.

P0404 IS EGR POSITION SENSOR PERFORMANCE..YOU NEED A NEW EGR VALVE..RECOMMEND DISCONNECTING BATTERY WHILE REPLACING EGR VALVE..SOMETIMES CODE WILL NOT GO AWAY EVEN AFTER REPLACING VALVE AND CLEARING CODE WITH SCANNER..VALVE IS LOCATED ABOVE ALTERNATOR ON END OF CYLINDER HEAD..THE BOTTOM BOLT CAN BE TRICKY TO REMOVE AND HAVE HAD TO REMOVE ALTERNATOR TO GET BOLT OUT..YOU WILL NEED A NEW GASKET FOR TUBE AS WELL..ABOUT 120 BUCKS FROM DEALER(CAN)