Chrysler Pacifica. Manual — part 695

AIR CLEANER ELEMENT

REMOVAL

(1) Disconnect the IAT sensor (Fig. 21).
(2) Disconnect the CCV hose (Fig. 21).
(3) Separate the air inlet tube from the throttle

body (Fig. 21).

(4) Remove the air cleaner cover bolts (Fig. 21).

(5) Lift cover and pull toward the engine and

remove cover tabs from air cleaner housing.

(6) Lift cover and remove the filter (Fig. 22).

INSTALLATION

(1) Install the air filter element into air box (Fig.

23).

(2) Move cover so that the tabs insert into the air

cleaner housing.

Fig. 21 AIR CLEANER COVER

1 - INTAKE AIR TEMPERATURE SENSOR
2 - CRANK CASE VENTILATION HOSE
3 - BOLT

Fig. 22 AIR CLEANER ELEMENT

1 - AIR CLEANER COVER
2 - AIR CLEANER ELEMENT
3 - AIR CLEANER HOUSING

Fig. 23 AIR CLEANER ELEMENT

1 - AIR CLEANER COVER
2 - AIR CLEANER ELEMENT
3 - AIR CLEANER HOUSING

Fig. 24 AIR CLEANER COVER

1 - INTAKE AIR TEMPERATURE SENSOR
2 - CRANK CASE VENTILATION HOSE
3 - BOLT

CS

ENGINE 3.8L

9 - 135

(3) Position the cover down over the element and

lower housing and tighten the fasteners (Fig. 24).

(4) Connect the air inlet tube to the throttle body

and tighten the clamp.

(5) Connect the IAT sensor (Fig. 24).
(6) Connect the CCV hose (Fig. 24).

AIR CLEANER HOUSING

REMOVAL

(1) Disconnect the negative battery cable.
(2) Disconnect the inlet air temperature sensor

(Fig. 25).

(3) Disconnect the CCV hose from the air cleaner

cover (Fig. 25).

(4) Remove the air inlet tube to throttle body (Fig.

25).

(5) Remove the bolt for air cleaner housing at

upper radiator cross member (Fig. 25).

(6) Pull air box up and off over the single locating

pin.

(7) Remove air box from vehicle.

INSTALLATION

(1) Install air cleaner housing into vehicle and

onto the locating pin.

(2) Install bolt to hold air cleaner housing to the

upper radiator cross member (Fig. 26).

(3) Install the air inlet tube to the throttle body

and tighten clamp (Fig. 26).

(4) Connect the IAT sensor (Fig. 26).
(5) Connect the CCV hose to the air cleaner cover

(Fig. 26).

(6) Connect the negative battery cable.

Fig. 25 AIR CLEANER COVER

1 - INTAKE AIR TEMPERATURE SENSOR
2 - CRANK CASE VENTILATION HOSE
3 - BOLT

Fig. 26 AIR CLEANER COVER

1 - INTAKE AIR TEMPERATURE SENSOR
2 - CRANK CASE VENTILATION HOSE
3 - BOLT

9 - 136

ENGINE 3.8L

CS

AIR CLEANER ELEMENT (Continued)

CYLINDER HEAD

DESCRIPTION

The

aluminum

cylinder

heads

(Fig.

27)

are

designed to create high flow combustion chambers to
improve performance, while minimizing the change
to the burn rate in the chamber. The cylinder head
incorporates the combustion chamber. Two valves
per-cylinder are used with inserted valve seats and
guides. A multi-layer steel (MLS) type gasket is used
between the cylinder head and engine block.

DIAGNOSIS AND TESTING

CYLINDER HEAD GASKET

A cylinder head gasket leak can be located between

adjacent cylinders or between a cylinder and the
adjacent water jacket.

Possible indications of the cylinder head gasket

leaking between adjacent cylinders are:

• Loss of engine power

• Engine misfiring

• Poor fuel economy
Possible indications of the cylinder head gasket

leaking between a cylinder and an adjacent water
jacket are:

• Engine overheating

• Loss of coolant

• Excessive steam (white smoke) emitting from

exhaust

• Coolant foaming

CYLINDER-TO-CYLINDER LEAKAGE TEST

To determine if an engine cylinder head gasket is

leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50–70%
reduction in compression pressure.

Fig. 27 VALVE COMPONENTS

1 - VALVE LOCKS

5 - SPRING SEATS

2 - RETAINERS

6 - CYLINDER HEAD

3 - VALVE SPRINGS

7 - VALVE - EXHAUST

4 - VALVE STEM SEALS

8 - VALVE - INTAKE

CS

ENGINE 3.8L

9 - 137

CYLINDER-TO-WATER JACKET LEAKAGE TEST

WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.

VISUAL TEST METHOD

With the engine cool, remove the coolant pressure

cap. Start the engine and allow it to warm up until
thermostat opens.

If a large combustion/compression pressure leak

exists, bubbles will be visible in the coolant.

COOLING SYSTEM TESTER METHOD

WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE

PRESSURE

BUILT

UP,

BY

CONTINUOUS

ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).

Install Cooling System Tester 7700 or equivalent to

pressure cap neck. Start the engine and observe the
tester’s pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.

CHEMICAL TEST METHOD

Combustion leaks into the cooling system can also

be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.

REMOVAL - CYLINDER HEAD

(1) Drain the cooling system. (Refer to 7 - COOL-

ING - STANDARD PROCEDURE)

(2) Disconnect negative cable from battery.
(3) Remove upper and lower intake manifolds.

(Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI-
FOLD - REMOVAL)

WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.

(4) Remove the cylinder head covers. (Refer to 9 -

ENGINE/CYLINDER

HEAD/CYLINDER

HEAD

COVER(S) - REMOVAL)

(5) Remove the spark plugs from cylinder head.
(6) Remove the oil level indicator and tube (Fig.

28).

(7) Remove exhaust manifold(s). (Refer to 9 -

ENGINE/MANIFOLDS/EXHAUST

MANIFOLD

-

REMOVAL)

(8) Remove rocker arm and shaft assemblies.

(Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
ARMS - REMOVAL) Remove push rods and mark
positions to ensure installation in original loca-
tions.

(9) Remove the eight head bolts from each cylinder

head and remove cylinder heads (Fig. 27).

CLEANING

To ensure engine gasket sealing, proper surface

preparation must be performed, especially with the
use of aluminum engine components and multi-layer
steel cylinder head gaskets.

NOTE: Multi-Layer Steel (MLS) head gaskets require
a scratch free sealing surface.

Remove all gasket material from cylinder head and

block (Refer to 9 - ENGINE - STANDARD PROCE-
DURE). Be careful not to gouge or scratch the alumi-
num head sealing surface.

Clean all engine oil passages.

INSPECTION

(1) Before cleaning, check for leaks, damage and

cracks.

(2) Clean cylinder head and oil passages.

Fig. 28 OIL LEVEL INDICATOR & TUBE

1 - INDICATOR
2 - BOLT
3 - TUBE

9 - 138

ENGINE 3.8L

CS

CYLINDER HEAD (Continued)