Chrysler Pacifica. Manual — part 711
(6) Connect the IAC,TPS and the EVAP hose to
the throttle body.
(7) Install the air cleaner housing.
(8) Raise the vehicle.
(9) Attach catalytic converter pipe to exhaust man-
ifold using new gasket and tighten bolts to 37 N·m
(27 ft. lbs.)
(10) Connect battery negative cable.
EXHAUST MANIFOLD - LEFT
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove
bolts
attaching
crossover
pipe
to
exhaust manifold (Fig. 168).
(3) Disconnect left cylinder bank spark plug wires.
(4) Remove heat shield attaching bolts (Fig. 169).
(5) Remove bolts attaching exhaust manifold to
cylinder head (Fig. 169).
(6) Remove the exhaust manifold (Fig. 169).
(7) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST
MANIFOLD
-
INSPECTION) (Refer to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD - CLEANING).
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface and exhaust crossover mounting surface with
a straightedge and thickness gauge (Fig. 170).
Manifold surface flatness limits should not exceed
1.0 mm (0.039 in.).
Fig. 168 CROSS-OVER PIPE
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
Fig. 169 EXHAUST MANIFOLD - LEFT
1 - EXHAUST MANIFOLD - LEFT BANK
2 - HEAT SHIELD
3 - NUT - HEAT SHIELD
4 - BOLT - EXHAUST MANIFOLD
Fig. 170 Check Exhaust Manifold Mounting
1 - STRAIGHT EDGE
2 - CROSSOVER PIPE MOUNTING SURFACE
3 - FEELER GAUGE
CS
ENGINE 3.8L
9 - 199
EXHAUST MANIFOLD - RIGHT (Continued)
INSTALLATION
(1) Position exhaust manifold on cylinder head
(Fig. 171). Install bolts to center runner (cylinder #4)
and initial tighten to 2.8 N·m (25 in. lbs.).
(2) Using a new gasket, attach crossover pipe to
exhaust manifold and tighten bolts to 41 N·m (30 ft.
lbs.) (Fig. 172).
NOTE: Inspect crossover pipe fasteners for damage
from heat and corrosion. The cross-over bolts are
made of a special stainless steel alloy. If replace-
ment is required, OEM bolts are highly recom-
mended.
(3) Position heat shield on manifold (Fig. 171).
(4) Install the remaining manifold attaching bolts.
Tighten all bolts to 23 N·m (200 in. lbs.).
(5) Install and tighten heat shield attaching nut to
12 N·m (105 in. lbs.) (Fig. 171).
(6) Connect battery negative cable.
VALVE TIMING
STANDARD PROCEDURE
STANDARD PROCEDURE - VALVE TIMING
VERIFICATION
(1) Remove front cylinder head cover and all 6
spark plugs.
(2) Rotate engine until the #2 piston is at TDC of
the compression stroke.
(3) Install a degree wheel on the crankshaft pulley.
(4) With proper adaptor, install a dial indicator
into #2 spark plug hole. Using the indicator find TDC
on the compression stroke.
(5) Position the degree wheel to zero.
(6) Remove dial indicator from spark plug hole.
(7) Place a 5.08 mm (0.200 in.) spacer between the
valve stem tip of #2 intake valve and rocker arm pad.
Allow tappet to bleed down to give a solid tappet
effect.
(8) Install a dial indicator so plunger contacts the
#2 intake valve spring retainer as nearly perpendic-
ular as possible. Zero the indicator.
(9)
Rotate the engine clockwise until the intake
valve has lifted .254 mm (0.010 in.).
CAUTION: Do not turn crankshaft any further clock-
wise as intake valve might bottom and result in
serious damage.
(10) Degree wheel should read 6 degrees BTDC to
6 degrees ATDC.
STANDARD PROCEDURE - MEASURING
TIMING CHAIN WEAR
NOTE: This procedure must be performed with the
timing chain cover removed (Refer to 9 - ENGINE/
VALVE TIMING/TIMING CHAIN COVER - REMOVAL).
(1) Position a scale next to timing chain so that
any movement of chain may be measured (Fig. 173).
(2) Position a torque wrench and socket on the
camshaft sprocket attaching bolt. Apply force in the
direction of crankshaft rotation to take up slack to
the following torque:
• 41 N·m (30 ft. lb.) with cylinder heads installed
• 20 N·m (15 ft. lb.) with cylinder heads removed
Fig. 171 EXHAUST MANIFOLD - LEFT
1 - EXHAUST MANIFOLD - LEFT BANK
2 - HEAT SHIELD
3 - NUT - HEAT SHIELD
4 - BOLT - EXHAUST MANIFOLD
Fig. 172 CROSS-OVER PIPE
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
9 - 200
ENGINE 3.8L
CS
EXHAUST MANIFOLD - LEFT (Continued)
NOTE:
With
torque
applied
to
the
camshaft
sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block crankshaft to
prevent rotation.
(3) Holding a measuring scale along edge of chain
links (Fig. 173).
(4) Apply force in the reverse direction to the fol-
lowing torque:
• 41 N·m (30 ft. lb.) with cylinder heads installed
• 20 N·m (15 ft. lb.) with cylinder heads removed
(5) Measure amount of sprocket/chain movement.
(6) Install a new timing chain and sprockets if
movement exceeds 3.175 mm (1/8 in.).
TIMING CHAIN COVER
REMOVAL
(1) Perform the fuel pressure relief procedure
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY -
STANDARD PROCEDURE).
(2) Disconnect negative cable from battery.
(3) Evacuate air conditioning (Refer to 24 - HEAT-
ING & AIR CONDITIONING/PLUMBING - STAN-
DARD PROCEDURE).
(4) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(5) Remove the air cleaner assembly (Refer to 9 -
ENGINE/AIR
INTAKE
SYSTEM/AIR
CLEANER
HOUSING - REMOVAL).
(6) Loosen the water pump pulley bolts (Fig. 175).
(7) Remove the accessory drive belt and belt ten-
sioner (Refer to 7 - COOLING/ACCESSORY DRIVE/
DRIVE BELTS - REMOVAL).
(8) Remove power steering pump fasteners and set
pump aside (Fig. 175).
(9) Remove the generator (Refer to 8 - ELECTRI-
CAL/CHARGING/GENERATOR - REMOVAL).
(10) Disconnect the air conditioning compressor
clutch electrical connector and suction discharge
hoses (Fig. 175).
(11) Remove the oil level indicator tube.
(12) Raise vehicle on hoist.
(13) Drain engine oil.
(14) Remove right wheel and inner splash shield.
Fig. 173 Measuring Timing Chain Wear
1 - TORQUE WRENCH
Fig. 174 TIMING CHAIN COVER AND GASKET
1 - GASKET
2 - TIMING CHAIN COVER
Fig. 175 ACCESSORY DRIVE BELT
1 - POWER STEERING
2 - GENERATOR
3 - ENGINE OIL COOLER
4 - AIR CONDITIONING COMPRESSOR
5 - IDLER PULLEY
6 - BELT TENSIONER
7 - CRANKSHAFT DAMPER
8 - WATER PUMP
CS
ENGINE 3.8L
9 - 201
VALVE TIMING (Continued)
(15) Remove oil pan. (Refer to 9 - ENGINE/LU-
BRICATION/OIL PAN - REMOVAL).
(16) Disconnect the lower radiator hose and oil
cooler hose at the coolant cross over pipe (Fig. 176).
(17) Separate the power steering lines from the
A/C bracket and bracket at cradle.
(18) Separate the air conditioning compressor from
the engine and set aside.
(19) Remove crankshaft vibration damper using
special tool #8454 and insert #8450. (Refer to 9 -
ENGINE/ENGINE BLOCK/VIBRATION DAMPER -
REMOVAL)
(20) Remove the coolant cross over pipe fasteners
and pipe (Fig. 176).
(21) Remove accessible lower timing cover fasten-
ers through the wheel well (Fig. 174).
(22) Remove camshaft position sensor from timing
chain cover (Fig. 177).
(23) Remove the water pump, for cover removal
clearance. (Refer to 7 - COOLING/ENGINE/WATER
PUMP - REMOVAL).
(24) Support the engine with a floor jack and
remove the upper engine mount assembly.
(25) Remove the timing chain cover fasteners and
remove timing chain cover (Fig. 174).
INSTALLATION
CAUTION: Crankshaft oil seal must be removed to
insure correct oil pump engagement.
(1) Be sure mating surfaces of chain case cover
and cylinder block are clean and free from burrs.
NOTE: DO NOT USE SEALER ON COVER GASKET
(2) Position new gasket on timing cover (Fig. 178).
Adhere new gasket to chain case cover, making sure
that the lower edge of the gasket is 0.5 mm (0.020
in.) beyond the lower edge of the cover.
Fig. 176 COOLANT CROSS OVER PIPE
1 - FLOW TO OIL COOLER
2 - FLOW TO RADIATOR
3 - PIPE
4 - FLOW FROM WATER PUMP
Fig. 177 ENGINE MOUNT BRACKET
1 - CAMSHAFT SENSOR
2 - BOLT - CAMSHAFT SENSOR
3 - BOLT - MOUNT BRACKET (VERTICAL)
4 - BRACKET - ENGINE MOUNT
5 - BOLT - MOUNT BRACKET (HORIZONTAL)
6 - PULLEY - IDLER
7 - BOLT - IDLER PULLEY
8 - SPACER - IDLER PULLEY BOLT
9 - BOLT - MOUNT BRACKET (HORIZONTAL)
Fig. 178 TIMING CHAIN COVER AND GASKET
1 - GASKET
2 - TIMING CHAIN COVER
9 - 202
ENGINE 3.8L
CS
TIMING CHAIN COVER (Continued)
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