Chrysler Town & Country 2.8L Diesel Engine 2009 OEM Service Manual (P/N 81-270-08259)

• Covers 2009 Dodge Grand Caravan and Chrysler Town & Country applications equipped with the 2.8L RT common-rail diesel engine; this is a 382-page engine-only PDF, not the complete vehicle service manual.
• Follows compression testing, full engine assembly removal and installation, cylinder-head removal and installation, in-vehicle valve-seal work, and valve inspection and refacing.
• Details camshaft setup, camshaft-cap identification, hydraulic lifter and rocker-arm service, timing-belt replacement, tensioner adjustment, and crank/cam locking at the specified service position.
• Documents bottom-end repair, including crankshaft end play and bearing selection, balance-shaft timing, pistons, connecting rods, rings, front and rear crank seals, oil jets, oil pump, pickup, and pan.
• Includes intake and exhaust manifold, turbocharger, EGR cooler, air cleaner, oil cooler, filter housing, oil separator, oil-pressure sensor, and relief-valve removal and installation.
• Provides 652 numbered figures, grouped torque tables, dimensional and clearance specifications, head-gasket selection data, and dedicated VM-series service-tool references.

This 382-page service-information PDF carries a Mitchell Repair Information Company copyright footer and credits its figures to Chrysler LLC. Its scope is the 2.8L RT four-cylinder diesel used in the 2009 Grand Caravan and Town & Country. It identifies the cast-iron cylinder block, aluminum DOHC cylinder head with four valves per cylinder, variable-geometry turbocharger, charge-air cooling, and cooled EGR hardware. The specification pages also identify the CP3.2+ high-pressure pump, EDC16CP31 controller, and Piezo CRI 3.0 injectors. Because the procedures assume engine-lifting equipment, precision measuring instruments, and dedicated timing and holding fixtures, this manual is suited to experienced diesel technicians and well-equipped engine builders rather than first-time engine repair.

Cylinder Head and Valve Work

Coverage begins with gasket-surface preparation and a compression test, then moves into complete vehicle-level engine removal and installation. The cylinder-head chapter includes in-vehicle valve-seal replacement, head disassembly and cleaning, crack and flatness inspection, valve-spring checks, valve guide-to-stem clearance measurement, and valve-seat refacing. During head repair, the text covers removal of the common-rail lines, rail, injectors, EGR cooler, manifolds, and turbocharger connections that obstruct the assembly.

Head-gasket selection is tied to measured piston protrusion, with separate gasket-identification categories and a dedicated selection table. Reassembly coverage includes the illustrated cylinder-head bolt sequence, torque-angle stages, lifter and rocker-arm placement, camshaft-cap orientation, and camshaft installation.

Timing, Bottom End, and Lubrication

The timing chapters cover the belt, inner and outer covers, crank and cam sprockets, automatic tensioner, timing marks, locking-tool setup, belt-tension adjustment, and post-installation verification. Internal engine repair extends to the crankshaft, main and connecting-rod bearing selection, balance-shaft module timing, piston and connecting-rod service, piston-ring fitting, crankshaft seals, flexplate, transmission adapter plate, and internal vacuum pump.

Lubrication coverage is equally specific. Separate procedures address the oil cooler, filter and housing, piston-cooling jets, oil pan, pickup tube, pump, pressure sensor, oil separator, and pressure-relief valve. Intake and exhaust manifold repair, turbocharger removal and installation, and air-cleaner service round out the engine section.

Figures, Specifications, and Service Tools

Representative illustrations include Cylinder Head Bolt Tightening Sequence, Identifying Camshaft Cap & Cylinder Head Markings, Crankshaft Bearing Size Mark, Balance Shaft Bolt Tightening Sequence, Oil Pressure Relief Valve Components, and Exploded View of Timing Belt. The five torque-reference groups cover the engine block, cylinder head, front engine, rear engine, and accessory drive. Additional tables provide gasket selection, bearing identification, wear limits, flatness, clearances, oil-pressure data, and component dimensions.

Dedicated tools are identified by number and application, including VM 10010 for compression testing, VM 1055 for the pump/camshaft gear, VM 9991 and VM 9992 for camshaft and crankshaft locking, VM 10012 for the balance shaft, and VM 9993 for crankshaft seal installation.

Two cautions are especially important during repair. The engine must be set at the specified after-TDC position before cylinder-head-cover or timing-belt removal; incorrect positioning can lead to valve or piston damage during reassembly. The camshaft sprocket must be held with the specified gear-holder tool, since allowing the tone wheel to slip can put it out of time and require camshaft replacement.

This PDF does not contain full fuel-system diagnosis, cooling-system service, transmission repair, or vehicle wiring diagrams; those topics are referenced as separate service-information sections. High-pressure common-rail components and engine lifting require the prescribed safety procedures and properly rated shop equipment.