Chrysler Pacifica. Manual — part 710
(9) Connect throttle and speed control cables to
throttle body (Fig. 156)
(10) Connect the EVAP hose to the throttle body.
(11) Connect the wiring connectors to the throttle
position sensor (TPS) and idle air control (IAC)
motor. (Fig. 156)
(12) Install air cleaner and air inlet hose assembly.
(13) Connect the inlet air temperature (IAT) sen-
sor electrical connector.
(14) Connect battery negative cable.
INTAKE MANIFOLD - LOWER
REMOVAL - LOWER INTAKE MANIFOLD
(1) Perform fuel system pressure release procedure
(before attempting any repairs). (Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - STANDARD
PROCEDURE)
(2) Drain the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(3) Remove the upper intake manifold. (Refer to 9
-
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
REMOVAL)
(4) Remove the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/FUEL LINES - STANDARD
PROCEDURE) (Refer to 14 - FUEL SYSTEM/FUEL
DELIVERY/QUICK CONNECT FITTING - STAN-
DARD PROCEDURE)
(5) Remove ignition coil and bracket (Fig. 157).
(6) Disconnect heater supply hose and engine cool-
ant temperature sensor (Fig. 158).
(7) Disconnect the fuel injector wire harness.
(8) Remove the fuel injectors and rail assembly
(Fig. 157).
(9) Remove radiator upper hose.
(10) Remove the intake manifold bolts.
(11) Remove lower intake manifold (Fig. 159).
WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.
(12) Remove intake manifold seal retainers screws
(Fig. 159). Remove intake manifold gasket.
(13) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
INSPECTION) (Refer to 9 - ENGINE/MANIFOLDS/
INTAKE MANIFOLD - CLEANING)
Fig. 156 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. 157 FUEL RAIL & IGNITION.COIL & BRACKET
1 - FUEL RAIL
2 - BOLT - FUEL RAIL
3 - NUT - IGNITION COIL
4 - BOLT - IGNITION COIL
5 - IGNITION COIL
6 - BRACKET - IGNITION COIL
7 - STUD - IGNITION COIL
8 - SEPARATOR - SPARK PLUG CABLE
9 - BRACKET - SPARK PLUG CABLE SEPARATOR
10 - BOLT - SEPARATOR BRACKET
11 - BRACKET - SPARK PLUG CABLE SEPARATOR
CS
ENGINE 3.8L
9 - 195
INTAKE MANIFOLD - UPPER (Continued)
CLEANING
(1) Discard gasket(s).
(2) Clean all sealing surfaces.
INSPECTION
Check for:
• Damage and cracks of each section.
• Clogged water passages in end cross-overs (if
equipped).
• Check for cylinder head mounting surface distor-
tion using a straightedge and thickness gauge. (Refer
to 9 - ENGINE/CYLINDER HEAD - INSPECTION)
INSTALLATION - LOWER INTAKE MANIFOLD
(1) Place a bead (approximately 1/4 in. diameter)
of Mopar
t Engine RTV GEN II onto each of the four
manifold to cylinder head gasket corners (Fig. 160).
(2) Carefully install the new intake manifold gas-
ket (Fig. 159). Tighten end seal retainer screws to 12
N·m (105 in. lbs.).
(3) Install lower intake manifold (Fig. 159). Install
the bolts and torque to 1 N·m (10 in. lbs.). Then
torque bolts to 22 N·m (200 in. lbs.) in sequence
shown in (Fig. 161). Then torque again to 22 N·m
(200 in. lbs.). After intake manifold is in place,
inspect to make sure seals are in place.
(4) Install the fuel injectors and rail assembly.
(Refer to 14 - FUEL SYSTEM/FUEL DELIVERY/
FUEL RAIL - INSTALLATION)
(5) Connect fuel injector electrical harness.
Fig. 158 COOLANT TEMPERATURE SENSOR &
HEATER SUPPLY
1 - ENGINE COOLANT TEMPERATURE SENSOR
2 - CONNECTOR - ENGINE COOLANT SENSOR
3 - FITTING - HEATER SUPPLY
Fig. 159 INTAKE MANIFOLD - LOWER
1 - INTAKE MANIFOLD - LOWER
2 - BOLT - GASKET END SEAL RETAINER
3 - GASKET
4 - BOLT - LOWER INTAKE MANIFOLD
Fig. 160 SEALER LOCATIONS
1 - SEALER LOCATIONS
9 - 196
ENGINE 3.8L
CS
INTAKE MANIFOLD - LOWER (Continued)
(6) Connect the engine coolant temperature sensor.
(7) Connect the heater supply and radiator upper
hoses to manifold.
(8) Connect the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL
DELIVERY/QUICK
CONNECT
FIT-
TING - STANDARD PROCEDURE)
(9) Install the upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
INSTALLATION)
(10) Connect negative battery cable.
(11) Fill the cooling system. (Refer to 7 - COOL-
ING - STANDARD PROCEDURE)
(12) Connect the negative battery cable.
EXHAUST MANIFOLD - RIGHT
REMOVAL
(1) Disconnect battery negative cable.
(2) Raise and support the vehicle.
(3) Separate the exhaust pipe at the exhaust man-
ifold.
(4) Remove
bolts
fastening
crossover
pipe
to
exhaust manifold (Fig. 162).
(5) Lower the vehicle.
(6) Remove the air cleaner housing.
(7) Disconnect the TPS, IAC and purge vacuum
hose from the throttle body (Fig. 163).
(8) Disconnect the upstream oxygen sensor (Fig.
163).
(9) Disconnect the spark plug wires at the spark
plugs.
(10) Remove bolts attaching exhaust manifold to
cylinder head and remove manifold (Fig. 163).
(11) Inspect and clean manifold. (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST
MANIFOLD
-
CLEANING) (Refer to 9 - ENGINE/MANIFOLDS/
EXHAUST MANIFOLD - INSPECTION)
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. 164).
Fig. 161 LOWER MANIFOLD TIGHTENING
SEQUENCE
Fig. 162 CROSS-OVER PIPE
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
Fig. 163 RIGHT EXHAUST MANIFOLD
1 - PCV VALVE
2 - IAC MOTOR
3 - TP SENSOR
4 - RIGHT EXHAUST MANIFOLD
5 -OXYGEN SENSOR
CS
ENGINE 3.8L
9 - 197
INTAKE MANIFOLD - LOWER (Continued)
Manifold surface flatness limits should not exceed
1.0 mm (0.039 in.).
INSTALLATION
(1) Position exhaust manifold on cylinder head and
install bolts to center runner (cylinder #3) and initial
tighten to 2.8 N·m (25 in. lbs.) (Fig. 165).
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.
(2) Using a new gasket, attach crossover pipe to
exhaust manifold and tighten bolts to 41 N·m (30 ft.
lbs.) (Fig. 166).
(3) Install the remaining manifold attaching bolts.
Tighten all bolts to 23 N·m (200 in. lbs.).
(4) Install and connect upstream oxygen sensor
(Fig. 167).
(5) Connect the spark plug wires to the spark
plugs.
Fig. 164 Check Exhaust Manifold Mounting
1 - STRAIGHT EDGE
2 - CROSSOVER PIPE MOUNTING SURFACE
3 - FEELER GAUGE
Fig. 165 EXHAUST MANIFOLD - RIGHT
1 - SCREW - HEAT SHIELD
2 - HEAT SHIELD - UPPER
3 - BOLT - EXHAUST MANIFOLD
4 - HEAT SHIELD - LOWER
5 - EXHAUST MANIFOLD - RIGHT
6 - OXYGEN SENSOR - UPSTREAM
Fig. 166 CROSS-OVER PIPE
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
4 - FLAG NUT
Fig. 167 RIGHT EXHAUST MANIFOLD
1 - PCV VALVE
2 - IAC MOTOR
3 - TP SENSOR
4 - RIGHT EXHAUST MANIFOLD
5 -OXYGEN SENSOR
9 - 198
ENGINE 3.8L
CS
EXHAUST MANIFOLD - RIGHT (Continued)
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