Chrysler Pacifica. Manual — part 666
(59) Remove the lower steering column coupling
pin with special tool 6831–A, and separate union.
(Fig. 12).
(60) Remove both lower engine mount nuts (Fig.
13).
(61) Paint mark the front cradle to body location
and position the engine cradle support under the
vehicle (Fig. 13).
(62) Lower the vehicle until just above the cradle
support fixture (Fig. 13).
(63) Align the cradle support dowels with the cra-
dle access holes (Fig. 13).
(64) Adjust engine support fixture to fit flush with
the oil pan and adjust cradle support fixture arms to
fit flush with cradle (Fig. 14).
(65) Carefully lower the vehicle onto the cradle
support fixture.
(66) Remove the upper engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/FRONT MOUNT -
REMOVAL).
CAUTION: While slowly separating the body from
the cradle assembly, constant checks must be
made to assure proper positioning and that no
damage to other components or wiring harnesses
occur during separation.
(67) Carefully remove the front and rear cradle
mounting bolts and raise the vehicle to separate the
Fig. 12 STEERING COLUMN COUPLING
1 - LOWER STEERING COLUMN COUPLING ASSEMBLY
2 - INTERMEDIATE SHAFT TO STEERING GEAR
3 - PIN
4 - STEERING GEAR
5 - EXTENSION TO SHAFT BOLT
Fig. 13 CRADLE SUPPORT FIXTURE - REAR
1 - RIGHT LOWER ENGINE MOUNT
2 - RIGHT LOWER ENGINE MOUNT NUT
3 - ALIGNMENT DOWEL ACCESS HOLES
4 - CRADLE SUPPORT FIXTURE
Fig. 14 CRADLE SUPPORT FIXTURE - FRONT
1 - LEFT LOWER ENGINE MOUNT NUT
2 - CRADLE SUPPORT FIXTURE ARMS
3 - CRADLE SUPPORT FIXTURE ENGINE STABILIZER
CS
ENGINE 3.5L
9 - 19
ENGINE 3.5L (Continued)
engine, transmission and cradle assembly from the
vehicle.
(68) Connect engine lifting brackets to engine (Fig.
15)
(69) Separate the Power Transfer Unit (PTU), (if
equipped).
(70) Separate the engine and transmission from
the engine cradle using the lifting brackets. (Fig. 15).
(71) Separate the transmission from the engine.
INSTALLATION - ENGINE ASSEMBLY
(1) Install transmission and power transfer unit
(PTU) (if equipped), onto engine assembly.
(2) Mount engine assembly onto cradle assembly.
(3) Carefully position the engine cradle assembly
under the vehicle.
CAUTION: While slowly lowering the body to the
cradle assembly, constantly check to assure proper
positioning and no damage occurs to other compo-
nents or harnesses until union is made.
(4) Lower the vehicle until the union is made
between the cradle assembly and body, taking care to
align the cradle to body marks.
(5) Install the cradle supporting bolts and tighten
to 163 N·m (120 lbs. ft.).
(6) Install upper engine mount, tighten bolt to tim-
ing cover to 54 N·m (40 lbs. ft.). Tighten bolt to right
rail 68 N·m (50 lbs.ft.).
(7) Slowly raise the vehicle off of the engine cradle
support.
(8) Insert
drive
axles
into
steering
knuckles.
Tighten nut to 244 N·m (180 lbs. ft.). (Refer to 2 -
SUSPENSION/FRONT/HUB / BEARING - INSTAL-
LATION).
(9) Align front steering knuckles with struts and
install bolts. Tighten bolts to 244 N·m (180 lbs. ft.).
(Fig. 10). (Refer to 2 - SUSPENSION/FRONT/
KNUCKLE - INSTALLATION).
(10) Install front wheel speed sensor wire support
brackets to the struts (Fig. 10). Tighten bolts to 12
N·m (105 lbs. in.).
(11) Connect both front wheel speed sensors to
wiring harness.
(12) Install brake line support bracket to cradle
(Fig. 10). Tighten bolts to 12 N·m (105 lbs. in.).
(13) Connect sway bar links to front struts (Fig.
10).
(14) Raise vehicle.
(15) Install the steering column coupler pin.
(16) Connect the engine block heater (if equipped).
(17) Connect negative battery cable to transmis-
sion.
(18) Route engine wiring harness connector to
PCM and connect.
(19) Install inner fender wells.
(20) Connect both front driving lights to the front
fascia.
(21) Install front fascia.
(22) Install engine mount nuts and tighten to 101
N·m (75 lbs.ft.).
(23) Install flex plate to torque converter bolts.
Tighten bolts to 75 N·m (55 lbs.ft.).
(24) Install transmission inspection shield. Tighten
bolts to 12 N·m (105 lbs. in.).
(25) Install engine to transmission support collar-
.Tighten bolts to 54 N·m (40 lbs. ft.).
(26) Properly align and install the drive shaft
(Refer to 3 - DIFFERENTIAL & DRIVELINE/PRO-
PELLER SHAFT - INSTALLATION)
(27) Install
exhaust
system
(Refer
to
11
-
EXHAUST SYSTEM - INSTALLATION).
(28) Connect exhaust manifold and catalytic con-
verter oxygen sensor electrical connectors (Fig. 11).
(29) Connect starter wiring and properly position
harness wiring.
(30) Install front wheels.
(31) Lower the vehicle.
(32) Connect both front brake lines to the brake
system H.C.U. and tighten.
(33) Connect the ignition harness connector at the
intake manifold.
(34) Connect the engine wiring harness and the
ground wire on left frame rail
Fig. 15 ENGINE LIFTING BRACKET
1 - SUITABLE LIFTING CHAIN
2 - 8534-7 PART OF KIT 8534-12
3 - 8534-15 PART OF KIT 8534-12
9 - 20
ENGINE 3.5L
CS
ENGINE 3.5L (Continued)
(35) Connect transmission cooler lines to transmis-
sion (Fig. 9).
(36) Connect transmission shift cable.
(37) Connect transmission solenoid pack, input
and output sensors and transmission range sensor.
(38) Install the cruise control, power brake booster
and fuel vapor vacuum hoses to the engine.
(39) Connect throttle cable and cruise control cable
to throttle body (Fig. 7).
(40) Connect electrical connectors to generator.
(41) Connect oil pressure sending unit wiring har-
ness connector.
(42) Connect A/C electrical connector.
(43) Connect suction/discharge hose at air condi-
tioning compressor.
(44) Connect lower radiator hose to engine (Fig. 9).
(45) Connect heater hoses to heater core (Fig. 9).
(46) Connect coolant reservoir hose to thermostat
housing (Fig. 9).
(47) Connect the fuel line to the fuel rail.
(48) Install cooling fan assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - INSTALLA-
TION).
(49) Install radiator core support.
(50) Install radiator close out panel.
(51) Connect upper radiator hose (Fig. 9).
(52) Install the cruise control servo.
(53) Install air cleaner housing (Fig. 6).
(54) Install the engine cover (Fig. 6).
(55) Install new oil filter. Fill engine crankcase
with proper oil to correct level.
(56) Connect negative battery cable to battery.
(57) Fill the cooling system (Refer to 7 - COOL-
ING/ENGINE/COOLANT
-
STANDARD
PROCE-
DURE).
(58) Bleed brakes.
(59) Start engine and run until operating temper-
ature is reached and radiator fans cycle.
(60) Evacuate and recharge air conditioning.
(61) Check all fluid levels and properly fill.
(62) Check front end alignment.
SPECIFICATIONS
SPECIFICATIONS - 3.5L ENGINE
GENERAL SPECIFICATIONS
DESCRIPTION
SPECIFICATION
Type
60° SOHC V-6 24-Valve
Displacement
3.5L
Firing Order
1-2-3-4-5-6
Compression
Ratio
10:1
Lead Cylinder
#1 Right Bank
Metric
Standard
Displacement
3.5L Liters
214 cu. in.
Bore
96.0 mm
3.780 in.
Stroke
81.0 mm
3.189 in.
CYLINDER BLOCK
DESCRIPTION
SPECIFICATIONS
Metric
Standard
Cylinder Bore
Diameter
96.0 mm ±
0.0076
3.780 in. ±
0.0003 in.
Out-of-Round
(Max.)
0.076 mm
0.003 in.
Taper (Max.)
0.051 mm
0.002 in.
PISTONS
DESCRIPTION
SPECIFICATIONS
Metric
Standard
Material Type
Aluminum (Full Floating Pins)
Piston Diameter
95.98 mm ±
0.019 mm
3.7788 in. ±
0.0008 in.
Clearance at
Size Location
-0.007 to +0.047
mm
-0.003 to
+0.0018 in.
Piston Weight - A
438-443 grams
15.45-15.62 oz.
Piston Weight - B
433-438 grams
15.27-15.45 oz.
Piston Ring
Groove Diameter
#1
87.4-87.6 mm
3.441-3.449 in.
Piston Ring
Groove Diameter
#2
86.3-86.5 mm
3.397-3.4055 in.
Piston Ring
Groove Diameter
#3
85.8-86.0 mm
3.378-3.385 in.
CS
ENGINE 3.5L
9 - 21
ENGINE 3.5L (Continued)
PISTON PINS
DESCRIPTION
SPECIFICATIONS
Metric
Standard
Type
Full Floating
Clearance in
Piston
0.005-0.015
mm
0.002-0.0006 in.
Clearance in
Rod
0.007-0.018
mm
0.0003-0.007 in.
Diameter
23.997-24.000
mm
0.9448-0.9449
in.
PISTON RINGS
DESCRIPTION
SPECIFICATIONS
Metric
Standard
Ring Gap-Top
Compression
Ring
0.20-0.36 mm
0.008-0.014 in.
Ring Gap-2nd
Compression
Ring (Micro-
Napier
0.20-0.40 mm
0.0078-0.0157
in.
Ring Gap-Oil
Control (Steel
Rails)
0.25-0.76 mm
0.010-0.030 in.
PISTON RING SIDE CLEARANCE
DESCRIPTION
SPECIFICATIONS
Metric
Standard
Top and Second
Compression
Ring
0.04-0.08 mm
0.0016-0.0031
in.
Oil Ring (Steel
Rails
0.038-0.184
mm
0.0015-0.0073
in.
PISTON RING WIDTH
DESCRIPTION
SPECIFICATIONS
Metric
Standard
Top
Compression
Ring
1.17-1.19 mm
0.0461-0.0469
in.
2nd
Compression
Ring (Micro-
Napier
1.47-1.49 mm
0.058-0.059 in.
Oil Control
(Steel Rails)
0.445-0.470
mm
0.0176-0.0186
in.
CONNECTING RODS
DESCRIPTION
SPECIFICATIONS
Metric
Standard
Bearing
Clearance
0.038-0.074
mm
0.0015-0.0029
in.
Piston Pin Bore
Diameter
24.0076-
24.0153 mm
0.9452-0.9455
in.
Side Clearance
(MAX)
0.39 mm
0.0153 in.
Total Weight
(Less Bearing)
647 grams
22.8223 oz.
CRANKSHAFT MAIN BEARING JOURNALS
DESCRIPTION
SPECIFICATIONS
Metric
Standard
Diameter
63.987-64.013
mm
2.519-2.520 in.
Main Bearing
Diametrical
Clearance
0.036-0.065
mm
0.0014-0.0026
in.
MAX Allowable
0.080 mm
0.0031 in.
Out-of-Round
(MAX)
0.015 mm
0.0006 in.
Taper (MAX)
0.015
0.0006 in.
End Play
0.10-0.30 mm
0.004-0.012 in.
End Play (MAX)
0.43 mm
0.017 in.
9 - 22
ENGINE 3.5L
CS
ENGINE 3.5L (Continued)
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