Chrysler Pacifica. Manual — part 709
internal threads (Fig. 151). Use caution to start tap
in a axis same as original port.
(4) Apply Mopar
t Thread Sealant to threads of
repair port (s).
(5) Install repair port (s). Do not over torque
repair port (s).
REMOVAL - UPPER INTAKE MANIFOLD
(1) Disconnect battery negative cable.
(2) Disconnect inlet air temperature (IAT) sensor
electrical connector (Fig. 152).
(3) Remove air inlet resonator to throttle body
hose assembly.
(4) Disconnect
the
throttle
and
speed
control
cables from throttle body, separate the throttle
bracket from the upper intake manifold and set
aside. (Refer to 14 - FUEL SYSTEM/FUEL INJEC-
TION/THROTTLE CONTROL CABLE - REMOVAL).
(5) Disconnect the EVAP hose at the throttle (Fig.
153).
(6) Remove the EGR tube (Fig. 152).
(7) Disconnect the idle air control (IAC) motor and
throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 153).
(8) Disconnect
the
manifold
absolute
pressure
(MAP) sensor electrical connector (Fig. 152).
(9) Disconnect the PCV hose (Fig. 152).
(10) Disconnect the brake booster and cruise con-
trol vacuum hoses from intake manifold (Fig. 152).
(11) Remove intake manifold bolts and remove the
manifold.
(12) Cover the lower intake manifold with a suit-
able cover while the upper manifold is removed.
(13) Clean and inspect the upper intake manifold
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - CLEANING) and (Refer to 9 - ENGINE/
MANIFOLDS/INTAKE MANIFOLD - INSPECTION).
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
Check manifold for:
• Damage and cracks.
• Mounting surface distortion by using a straight-
edge and thickness gauge.
Fig. 151 Manifold Port (Nipple) Repair
1 - BRAKE BOOSTER PORT = 1/4
9
–18 NPT PIPE TAP
1 - LDP/SPEED CONTROL PORT = 1/8
9
–18 NPT PIPE TAP
2 - DRILL BIT = 7/16
9
BRAKE BOOSTER PORT
2 - DRILL BIT = 11/32
9
LDP/SPEED CONTROL PORT
3 - INTAKE MANIFOLD
CS
ENGINE 3.8L
9 - 191
INTAKE MANIFOLD - UPPER (Continued)
Fig. 152 3.8L COMPONENT LOCATION
1 - AIR CLEANER HOUSING
6 - BRAKE BOOSTER VACUUM HOSE
2 - INLET AIR TEMPERATURE SENSOR
7 - ACCELERATOR CABLE
3 - IDLE AIR CONTROL VALVE
8 - CRUISE CONTROL CABLE
4 - PCV HOSE
9 - MANIFOLD ABSOLUTE PRESSURE SENSOR
5 - EGR TUBE
10 - CRANK CASE BREATHER
9 - 192
ENGINE 3.8L
CS
INTAKE MANIFOLD - UPPER (Continued)
INSTALLATION - UPPER INTAKE MANIFOLD
(1) If the following components were removed from
manifold, install and tighten to specifications:
CAUTION: The special screws used for the compos-
ite manifold attached components must be installed
slowly using hand tools only. This requirement is to
prevent the melting of material that causes stripped
threads. If threads become stripped, an oversize
repair screw is available. For more information and
procedure (Refer to 9 - ENGINE/MANIFOLDS/IN-
TAKE MANIFOLD - STANDARD PROCEDURE - MAN-
IFOLD STRIPPED THREAD REPAIR).
• MAP sensor - 1.7 N·m (15 in. lbs.)
• Throttle cable bracket - 5.6 N·m (50 in. lbs.)
(2) Remove covering on lower intake manifold and
clean surfaces.
(3) Inspect manifold gasket condition. Gaskets can
be re-used, if not damaged. Position new gasket in
seal channel and press lightly in-place. Repeat proce-
dure for each gasket position.
(4) Position upper manifold on lower manifold.
(5) Apply Mopar
t Lock & Seal Adhesive (Medium
Strength Threadlocker) to each upper intake mani-
fold bolt. Install and tighten bolts to 12 N·m (105 in.
lbs.) following torque sequence in (Fig. 154).
(6) Connect the MAP sensor electrical connector
(Fig. 155).
(7) Connect the brake booster and cruise control
vacuum hose to intake manifold (Fig. 155).
CAUTION: The special screws used for attaching
the EGR tube to the manifold must be installed
slowly using hand tools only. This requirement is to
prevent the melting of material that causes stripped
threads. If threads become stripped, an oversize
repair screw is available. For more information and
procedure (Refer to 9 - ENGINE/MANIFOLDS/IN-
TAKE MANIFOLD - STANDARD PROCEDURE - MAN-
IFOLD STRIPPED THREAD REPAIR).
(8) Install the EGR tube.
Fig. 153 THROTTLE ASSEMBLY
1 - EGR TUBE
2 - ACCELERATOR CABLE
3 - CRUISE CONTROL CABLE
4 - FUEL INLET
5 - EVAP HOSE
6 - THROTTLE POSITION SENSOR
7 - PCV HOSE
8 - IDLE SPEED CONTROL
Fig. 154 UPPER MANIFOLD TIGHTENING
SEQUENCE
CS
ENGINE 3.8L
9 - 193
INTAKE MANIFOLD - UPPER (Continued)
Fig. 155 3.8L COMPONENT LOCATION
1 - AIR CLEANER HOUSING
6 - BRAKE BOOSTER VACUUM HOSE
2 - INLET AIR TEMPERATURE SENSOR
7 - ACCELERATOR CABLE
3 - IDLE AIR CONTROL VALVE
8 - CRUISE CONTROL CABLE
4 - PCV HOSE
9 - MANIFOLD ABSOLUTE PRESSURE SENSOR
5 - EGR TUBE
10 - CRANK CASE BREATHER
9 - 194
ENGINE 3.8L
CS
INTAKE MANIFOLD - UPPER (Continued)
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