Chrysler Pacifica. Manual — part 685
(8) Install the EGR tube (Refer to 25 - EMIS-
SIONS CONTROL/EXHAUST GAS RECIRCULA-
TION/VALVE - INSTALLATION).
(9) Connect vacuum lines to the following (Fig.
156):
• Positive Crankcase Ventilation (PCV) Valve
• EVAP Purge Solenoid
• Power Brake Booster
(10) Install alternator support bracket (Fig. 156).
(11) Connect electrical connectors to the following
(Fig. 157):
• Manifold Tuning Valve (MTV)
• Exhaust Gas Recirculation (EGR)
• Throttle Position Sensor (TPS)
• Idle Air Control (IAC)
• Manifold Absolute Pressure (MAP)
(12) Install the throttle and speed control cable
bracket and retaining bolts.
(13) Install throttle and speed control cables to
bracket and throttle arm. (Refer to 14 - FUEL SYS-
TEM/FUEL
INJECTION/THROTTLE
CONTROL
CABLE - INSTALLATION)
(14) Install air cleaner housing and inlet hose.
(15) Install the engine cover.
(16) Connect negative battery cable.
EXHAUST MANIFOLD - LEFT
REMOVAL - LEFT EXHAUST MANIFOLD
(1) Disconnect and isolate the negative battery
cable.
(2) Remove the radiator close out panel.
(3) Remove the radiator core support (Refer to 23 -
BODY/EXTERIOR/GRILLE OPENING REINFORCE-
MENT - REMOVAL).
(4) Remove the radiator cooling fan assembly.
(5) Loosen the oil level indicator tube retaining
bolt and position the dipstick out of the way.
(6) Remove the exhaust manifold crossover pipe
retaining bolts (Refer to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD - REMOVAL).
(7) Remove the exhaust manifold retaining bolts,
exhaust manifold, and discard gasket.
INSPECTION
(1) Inspect
exhaust
manifolds
for
damage
or
cracks.
(2) Check manifold flatness.
(3) Inspect the exhaust manifold gasket for obvi-
ous discoloration or distortion.
(4) Check distortion of the cylinder head mounting
surface with a straightedge and thickness gauge.
INSTALLATION - LEFT EXHAUST MANIFOLD
(1) Position the exhaust manifold and gasket.
Install the retaining bolts. Tighten bolts starting at
the center working outward to 23 N.m (200 in. lbs.)
(Fig. 161).
(2) Install the exhaust manifold crossover pipe
retaining bolts. Tighten bolts to 31 N.m (275 in. lbs.).
(3) Position the oil dipstick tube and install the
retaining bolt.
(4) Install the radiator cooling fan assembly.
(5) Install the radiator closure panel crossmember
(Refer to 23 - BODY/EXTERIOR/GRILLE OPENING
REINFORCEMENT - INSTALLATION).
(6) Install the radiator close out panel.
(7) Connect the negative battery cable.
EXHAUST MANIFOLD - RIGHT
REMOVAL - RIGHT EXHAUST MANIFOLD
(1) Disconnect the negative battery cable.
(2) Disconnect the upstream oxygen sensor electri-
cal connector.
(3) Remove the exhaust manifold crossover pipe
retaining bolts (Fig. 162).
(4) Raise and support the vehicle.
(5) Disconnect the downstream oxygen sensor elec-
trical connector.
Fig. 161 LEFT EXHAUST MANIFOLD
1 - OIL LEVEL INDICATOR TUBE RETAINING BOLT
2 - EXHAUST CROSS OVER PIPE UNION
CS
ENGINE 3.5L
9 - 95
INTAKE MANIFOLD (Continued)
(6) Remove the exhaust manifold flange retaining
bolts and disconnect the exhaust system hangers
from the pipe assembly.
(7) Remove the exhaust system from the vehicle.
(8) Remove the EGR tube support bracket bolt
(Fig. 162).
(9) Remove the lower exhaust manifold retaining
bolts (Fig. 162).
(10) Remove the oxygen sensor from the exhaust
manifold.
INSTALLATION - RIGHT EXHAUST MANIFOLD
(1) Clean gasket surfaces.
(2) Position the exhaust manifold and gasket.
Install the retaining bolts. Tighten bolts starting at
the center working outward to 23 N.m (200 in. lbs.)
(Fig. 162).
(3) Install exhaust system. Connect the exhaust
system hangers from the pipe assembly and install
the three exhaust manifold flange retaining bolts.
Tighten the bolts to 30 N.m (22 ft. lbs.).
(4) Connect the downstream oxygen sensor electri-
cal connector.
(5) Install the EGR tube retaining bracket (Fig.
162).
(6) Lower vehicle.
(7) Install the exhaust manifold crossover pipe
retaining bolts. Tighten bolts to 31 N.m (275 in. lbs.)
(Fig. 162).
(8) Connect the upstream oxygen sensor electrical
connector.
(9) Connect the negative battery cable.
CROSSOVER PIPE - EXHAUST
MANIFOLD
REMOVAL
(1) Remove the bolts and nuts attaching the cross-
over pipe the manifolds (Fig. 163).
(2) Remove the crossover pipe and gaskets. Dis-
card the gaskets.
INSTALLATION
(1) Position new gasket on left exhaust manifold.
(2) Position cross-over pipe to the manifold connec-
tions.
(3) Position new gasket on right exhaust manifold
and install the bolts. Tighten bolts to 41 N.m (30 ft.
lbs.)
(4) Install and tighten nuts to 41 N·m (30 ft. lbs.).
(Fig. 163)
(5) Install coolant recovery container (Refer to 7 -
COOLING/ENGINE/COOLANT RECOVERY CON-
TAINER - INSTALLATION).
Fig. 162 EGR VALVE AND TUBE
1 - EGR TUBE
2 - IGNITION COIL
3 - CYLINDER HEAD COVER
4 - RIGHT EXHAUST MANIFOLD
5 - EGR VALVE
Fig. 163 EXHAUST CROSS OVER PIPE
1 - CROSS OVER PIPE
9 - 96
ENGINE 3.5L
CS
EXHAUST MANIFOLD - RIGHT (Continued)
VALVE TIMING
DESCRIPTION
The timing drive system has been designed to pro-
vide quiet performance and reliability to support a
NON free-wheeling engine.
The timing drive components include a crankshaft
sprocket,
camshaft
sprockets,
tensioner
pulley,
hydraulic tensioner and a timing belt. The water
pump is driven by the back side of the timing belt.
The right and left camshaft sprockets are keyed and
not interchangeable because of the cam sensor
pick-up wheel on the left sprocket (Fig. 164).
FRONT TIMING BELT COVER
REMOVAL
(1) Perform fuel pressure release procedure. (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE).
(2) Disconnect negative battery cable.
(3) Raise vehicle on hoist.
(4) Remove accessory drive belt (Refer to 7 -
COOLING/ACCESSORY
DRIVE/DRIVE
BELTS
-
REMOVAL).
(5) Remove accessory drive belt tensioner.
(6)
Remove bolts for power steering pump. Repo-
sition power steering pump aside.
(7) Remove crankshaft damper (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL).
(8) Remove the lower front timing belt cover fas-
teners (Fig. 165).
(9) Lower the vehicle.
(10)
Support the engine with a floor jack.
(11) Remove the air cleaner housing (Refer to 9 -
ENGINE/AIR
INTAKE
SYSTEM/AIR
CLEANER
HOUSING - REMOVAL).
(12) Remove the front engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/FRONT MOUNT -
REMOVAL).
(13) Disconnect the fuel supply line at the fuel rail
(Fig. 166).
(14) Remove the upper timing belt cover bolts and
remove front timing belt cover (Refer to 9 - ENGINE/
AIR INTAKE SYSTEM/AIR CLEANER HOUSING -
REMOVAL).
INSTALLATION
NOTE: The timing cover bolts and both holes to the
engine block must be thoroughly cleaned and free
of oil residue before assembly. IN ADDITION add
thread sealant to the timing cover bolts that mount
to the oil pump (Refer to 9 - ENGINE/LUBRICATION/
OIL PUMP - INSTALLATION).
(1) Install front timing belt cover (Fig. 164).
Fig. 164 TIMING DRIVE SYSTEM
1 - FRONT TIMING COVER
2 - WATER PUMP
3 - TIMING BELT
4 - CRANKSHAFT SPROCKET
5 - CRANKSHAFT DAMPER
Fig. 165 LOWER TIMING BELT FRONT COVER
1 - POWER STEERING HOSE
2 - TIMING BELT TENSIONER
3 - IDLER PULLEY
CS
ENGINE 3.5L
9 - 97
(2) Install the upper engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/FRONT MOUNT -
INSTALLATION).
(3) Connect fuel supply line at fuel rail (Fig. 166).
(4) Install the air cleaner housing (Refer to 9 -
ENGINE/AIR
INTAKE
SYSTEM/AIR
CLEANER
HOUSING - INSTALLATION).
(5) Remove floor jack and raise vehicle.
(6) Install power steering pump fasteners. Tighten
bolts to 23 N·m (200 lbs. in..).
(7) Install
crankshaft
damper
(Refer
to
9
-
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
INSTALLATION).
(8) Install accessory drive belt tensioner. Torque
fastener to 28 N·m (250 in. lbs.).
(9) Install accessory drive belt (Refer to 7 - COOL-
ING/ACCESSORY DRIVE/DRIVE BELTS - INSTAL-
LATION).
(10) Lower vehicle.
(11) Connect negative battery cable.
REAR TIMING BELT COVER
REMOVAL
(1) Perform fuel pressure release procedure. (Refer
to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN-
DARD PROCEDURE).
(2) Disconnect the negative battery cable.
(3) Remove timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - REMOVAL).
(4) Remove camshaft sprockets (Refer to 9 -
ENGINE/VALVE
TIMING/TIMING
BELT/CHAIN
AND SPROCKETS - REMOVAL).
(5) Remove rear timing belt cover bolts (Fig. 167).
(6) Remove the rear cover.
NOTE: The rear timing belt cover has O-rings to
seal the water pump passages to cylinder block
(Fig. 167). Do not reuse the O-rings.
Fig. 166 UPPER TIMING BELT FRONT COVER
1 - FUEL RAIL
2 - GENERATOR
3 - IDLER PULLEY
4 - FUEL SUPPLY LINE
Fig. 167 Rear Timing Belt Cover Fasteners
1 - M8 FASTENERS (APPLY THREAD SEALANT)
2 - M10 FASTENERS
3 - M6 FASTENERS
4 - REAR TIMING BELT COVER
5 - M10 FASTENERS (STUD/NUT)
9 - 98
ENGINE 3.5L
CS
FRONT TIMING BELT COVER (Continued)
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