Chrysler Pacifica. Manual — part 696
(3) Check cylinder head for flatness (Fig. 29).
(4) Cylinder head must be flat within:
• Standard dimension = less than 0.05 mm (0.002
inch.)
• Service Limit = 0.2 mm (0.008 inch.)
• Grinding Limit = Maximum of 0.2 mm (0.008
inch.) is permitted.
CAUTION: 0.20 mm (0.008 in.) MAX is a combined
total dimension of the stock removal limit from cyl-
inder head and block top surface (Deck) together.
INSTALLATION - CYLINDER HEAD
(1) Clean all sealing surfaces of engine block and
cylinder heads. (Refer to 9 - ENGINE - STANDARD
PROCEDURE)
(2) Position new gasket(s) on engine block (Fig.
30). The left bank gasket is identified with the “L”
stamped in the exposed area of the gasket located at
front of engine (shown in (Fig. 30)). The right bank
gasket is identified with a “R” stamped in the
exposed area of the gasket also, but is located at the
rear of the engine.
(3) The cylinder head bolts are torqued using
the torque yield method, they should be exam-
ined BEFORE reuse. If the threads are necked
down, the bolts must be replaced (Fig. 31).
(4) Necking can be checked by holding a scale or
straight edge against the threads. If all the threads
do not contact the scale the bolt should be replaced.
(5) Tighten the cylinder head bolts 1–8 in the
sequence shown in (Fig. 32). Using the 4 step torque
turn method, tighten according to the following val-
ues:
• Step 1: Bolts 1 – 8 to 61 N·m (45 ft. lbs.)
• Step 2: Bolts 1 – 8 to 88 N·m (65 ft. lbs.)
• Step 3: Bolts 1 – 8 (again) to 88 N·m (65 ft. lbs.)
• Step 4: Bolts 1 – 8 turn an additional 1/4 Turn.
(Do not use a torque wrench for this step.)
NOTE: Bolt torque after 1/4 turn should be over 122
N·m (90 ft. lbs.). If not, replace the bolt.
(6) Inspect and replace worn or bent push rods.
(7) Install the push rods.
Fig. 29 Checking Cylinder Head Flatness—Typical
Fig. 30 CYLINDER HEAD GASKET
1 - CYLINDER HEAD GASKET
2 - LOCATION IDENTIFICATION (L = LEFT BANK, R = RIGHT
BANK)
Fig. 31 Check for Stretched Bolts
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
Fig. 32 CYLINDER HEAD TIGHTENING SEQ
CS
ENGINE 3.8L
9 - 139
CYLINDER HEAD (Continued)
(8) Install the rocker arm and shaft assemblies.
(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARMS - INSTALLATION)
(9) Install the cylinder head covers. (Refer to 9 -
ENGINE/CYLINDER
HEAD/CYLINDER
HEAD
COVER(S) - INSTALLATION)
(10) Install the exhaust manifolds. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST
MANIFOLD
-
INSTALLATION)
(11) Install new O-ring on oil level indicator tube.
Install oil level indicator tube assembly (Fig. 140).
(12) Install the spark plugs.
(13) Install upper and lower intake manifolds.
(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - INSTALLATION)
(14) Fill the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(15) Connect negative cable to battery.
CYLINDER HEAD COVER(S)
DESCRIPTION
The cylinder head covers are made of composite
material. The covers are sealed with steel reinforced
silicon rubber gaskets. The cylinder head cover uses
rubber isolators at each fastener location (Fig. 33).
NOTE: Due to the tight packaging near the cylinder
head covers, which makes spill clean-up difficult, a
spill during an engine oil change may be misinter-
preted as an oil leak. When investigating an oil leak
in the location of the cylinder head covers and
intake manifold, follow the procedure found in Oil
Leak Diagnosis (Refer to 9 - ENGINE - DIAGNOSIS
AND TESTING) for determining the source of a leak.
CYLINDER HEAD COVER -
RIGHT
REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect spark plug wires from plugs.
(3) Disconnect PCV hose from cylinder head cover
(Fig. 34).
(4) Remove cylinder head cover bolts.
(5) Remove cylinder head cover and gasket (Fig.
35).
Fig. 33 CYLINDER HEAD COVER
1 - CYLINDER HEAD COVER
2 - BOLT
Fig. 34 PCV HOSE
1 - HOSE
2 - PCV VALVE
9 - 140
ENGINE 3.8L
CS
CYLINDER HEAD (Continued)
INSTALLATION
(1) Clean cylinder head and cylinder head cover
mating surfaces. Inspect cylinder head cover surface
for flatness. Replace gasket as necessary.
(2) Inspect seal on the cover bolt for wear or dam-
age (Fig. 35). Replace bolt assembly as necessary.
(3) Inspect the PCV hose for damage. replace as
necessary.
NOTE: The cylinder head cover bolts contain a
torque limiter sleeve and a seal (Fig. 35). The seal
and torque sleeve is replaced with the bolt.
(4) Assemble gasket to cylinder cover by inserting
the bolt assemblies through each bolt hole on the
cover and gasket (Fig. 35).
(5) Install cylinder head cover and bolts (Fig. 36).
(6) Tighten cylinder head cover bolts to 12 N·m
(105 in. lbs.) (Fig. 36).
NOTE: Be sure that the PCV valve is properly
seated inside the cylinder head cover protrusion
and that the PCV hose completely covers the cylin-
der head cover protrusion.
(7) Connect PCV hose to cylinder head cover (Fig.
37).
(8) Connect spark plug wires to spark plugs.
(9) Connect negative cable to battery.
CYLINDER HEAD COVER -
LEFT
REMOVAL
(1) Disconnect spark plug wires from spark plugs.
(2) Disconnect crankcase vent hose from cylinder
head cover.
(3) Remove cylinder head cover bolts.
(4) Remove cylinder head cover and gasket.
INSTALLATION
(1) Clean cylinder head and cylinder head cover
mating surfaces. Inspect cylinder head cover surface
for flatness. Replace gasket as necessary.
(2) Assemble gasket to cylinder cover by inserting
the fasteners through each bolt hole on cover and
gasket (Fig. 35).
(3) Install the cylinder head cover and bolts.
Fig. 35 CYLINDER HEAD COVER GASKET
1 - CYLINDER HEAD COVER
2 - BOLT
3 - SEAL (SERVICED WITH BOLT)
4 - GASKET
Fig. 36 CYLINDER HEAD COVER
1 - CYLINDER HEAD COVER
2 - BOLT
Fig. 37 PCV HOSE
1 - HOSE
2 - PCV VALVE
CS
ENGINE 3.8L
9 - 141
CYLINDER HEAD COVER - RIGHT (Continued)
(4) Tighten cylinder head cover bolts to 12 N·m
(105 in. lbs.) (Fig. 37).
(5) Connect crankcase vent hose.
(6) Connect spark plug wires to spark plugs.
INTAKE/EXHAUST VALVES &
SEATS
DESCRIPTION
The valves have chrome plated valve stems with
four-bead lock grooves. The valve stem seals are
made of Viton rubber.
OPERATION
The two valves per cylinder are opened using roller
hydraulic lifters, push rods, and rocker arms.
STANDARD PROCEDURE - REFACING VALVES
AND VALVE SEATS
The intake and exhaust valves and seats are
machined to specific angles (Fig. 38).
VALVES
(1) Inspect the remaining margin after the valves
are refaced (Fig. 39). (Refer to 9 - ENGINE - SPEC-
IFICATIONS)
VALVE SEATS
CAUTION: Remove metal from valve seat only. Do
not remove material from cylinder head (Fig. 40).
Fig. 38 VALVE FACE AND SEAT
1 - VALVE FACE WIDTH
2 - VALVE FACE ANGLE
3 - SEAT ANGLE
4 - SEAT CONTACT AREA
Fig. 39 Intake and Exhaust Valve Refacing
1 - VALVE FACE
2 - VALVE MARGIN
Fig. 40 Refacing Valve Seats
1 - REFACING STONE MUST NOT CUT INTO CYLINDER HEAD
2 - STONE
3 - PILOT
4 - SEAT
9 - 142
ENGINE 3.8L
CS
CYLINDER HEAD COVER - LEFT (Continued)
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