Chrysler Pacifica. Manual — part 669
(23) Remove right exhaust manifold (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST
MANIFOLD
-
REMOVAL).
(24) Lower vehicle.
(25) Remove the upper accessory drive belt idler
pulley (Fig. 18).
(26) Remove the belt tensioner (Fig. 18).
(27) Support the engine with a block of wood and
the floor jack.
(28) Remove the upper engine mount (Refer to 9 -
ENGINE/ENGINE MOUNTING/FRONT MOUNT -
REMOVAL).
(29) Remove the power steering reservoir bolts and
set reservoir aside.
(30) Remove the remaining outer timing belt cover
bolts and cover.
(31) Rotate the engine to TDC and align timing
belt marks.
(32) Remove the timing belt tensioner and reset
the tensioner (Refer to 9 - ENGINE/VALVE TIMING/
TMNG
BELT/CHAIN
TENSIONER&PULLEY
-
REMOVAL). (Fig. 17).
(33) Remove the timing belt (Refer to 9 - ENGINE/
VALVE
TIMING/TIMING
BELT/CHAIN
AND
SPROCKETS - REMOVAL).
(34) Remove the right valve cover to cylinder head
ground strap (Fig. 20).
(35) Remove the EGR valve and tube assembly
(Fig. 20).
(36) Remove the right cylinder head cover (Fig.
20).
(37) Remove the right rocker arm assembly (Fig.
21).
(38) Remove the right rear camshaft thrust plate.
(39) Counterhold the cam gear and remove the
right cam gear retaining bolt.
Fig. 18 ACCESSORY DRIVE BELT AND PULLEYS
1 - UPPER INTAKE MANIFOLD
2 - AIR CONDITIONING COMPRESSOR
3 - IDLER PULLEY
4 - ACCESSORY DRIVE BELT
5 - POWER STEERING PULLEY
6 - ACCESSORY DRIVE BELT TENSIONER
7 - GENERATOR
8 - IDLER PULLEYS
CS
ENGINE 3.5L
9 - 31
CYLINDER HEAD(S) (Continued)
Fig. 19 TIMING GEAR MARKS
1 - RIGHT CAMSHAFT GEAR ALIGNMENT MARK
7 - LEFT CAMSHAFT GEAR
2 - RIGHT CAMSHAFT GEAR
8 - LEFT CAMSHAFT GEAR ALIGNMENT MARK
3 - CYLINDER HEAD TO INNER TIMING BELT COVER BOLTS - RIGHT
9 - CRANKSHAFT GEAR ALIGNMENT MARK
4 - TIMING BELT
10 - CRANKSHAFT GEAR
5 - WATER PUMP PULLEY
11 - TIMING BELT TENSIONER PULLEY
6 - CYLINDER HEAD TO INNER TIMING BELT COVER BOLTS - LEFT
12 - TIMING BELT TENSIONER
Fig. 20 EGR VALVE AND TUBE
1 - EGR TUBE
2 - IGNITION COIL
3 - CYLINDER HEAD COVER
4 - RIGHT EXHAUST MANIFOLD
5 - EGR VALVE
Fig. 21 CAMSHAFT, ROCKER ARM ASSEMBLY AND
CYLINDER HEAD
1 - SPARK PLUG TUBE
2 - ROCKER ARM ASSEMBLY
3 - CAMSHAFT
4 - CAMSHAFT SEAL
9 - 32
ENGINE 3.5L
CS
CYLINDER HEAD(S) (Continued)
(40) Push the camshaft out of the back of the cyl-
inder head approximately 3.5 inches and remove the
cam gear (Fig. 22).
(41) Remove the inner timing cover to cylinder
head retaining bolts.
(42) Remove the cylinder head bolts in REVERSE
of tightening sequence (Fig. 22).
NOTE: Because of clearance restrictions when
removing the right cylinder head, the front four cyl-
inder head bolts must be loosened, raised and sup-
ported with a rubber band before the cylinder head
can be removed.
(43) Remove the cylinder head (Fig. 22).
(44) Clean and inspect all mating surfaces.
LEFT CYLINDER HEAD
(1) Perform the fuel relief procedure.
(2) Disconnect the negative battery cable.
(3) Drain cooling system (Refer to 7 - COOLING -
STANDARD PROCEDURE).
(4) Remove engine cover.
(5) Remove air cleaner element housing (Refer to 9
- ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - REMOVAL).
(6) Remove radiator close out panel.
(7) Remove radiator core support.
(8) Remove radiator fan assembly (Refer to 7 -
COOLING/ENGINE/RADIATOR FAN - REMOVAL).
(9) Disconnect the fuel line at the fuel rail.
(10) Remove the lower intake manifold (Refer to 9
-
ENGINE/MANIFOLDS/INTAKE
MANIFOLD
-
REMOVAL).
(11) Remove the left exhaust manifold (Refer to 9 -
ENGINE/MANIFOLDS/EXHAUST
MANIFOLD
-
REMOVAL).
(12) Remove the outer timing belt cover (Refer to 9
- ENGINE/VALVE TIMING/TIMING BELT / CHAIN
COVER(S) - REMOVAL).
(13) Rotate the engine to TDC and align the tim-
ing marks (Fig. 19).
(14) Remove the timing belt tensioner, timing belt,
then reset tensioner (Fig. 19).
(15) Remove the left cylinder head cover to cylin-
der head ground strap.
(16) Remove the left cylinder head cover.
(17) Remove the left rocker arm assembly.
(18) Remove the left camshaft thrust plate.
(19) Counterhold the left cam gear and remove the
cam gear retaining bolt (Fig. 19).
(20) Push the camshaft out of the back of the cyl-
inder head approximately 3.5 inches and remove the
cam gear.
(21) Remove the front timing belt housing to cylin-
der head bolts (Fig. 19).
(22) Remove the cylinder head bolts in REVERSE
of tightening sequence.
(23) Remove the cylinder head.
(24) Clean and inspect all mating surfaces.
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.
(3) Check cylinder head for flatness (Fig. 23).
(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.)
Fig. 22 RIGHT CYLINDER HEAD
1 - INNER TIMING BELT COVER
2 - CYLINDER HEAD BOLTS
3 - RUBBER BANDS
4 - SPARK PLUG TUBE
5 - CAMSHAFT
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ENGINE 3.5L
9 - 33
CYLINDER HEAD(S) (Continued)
• 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(S)
RIGHT CYLINDER HEAD
CAUTION: THE CYLINDER HEAD GASKETS ARE
NOT
INTERCHANGEABLE
BETWEEN
CYLINDER
HEADS AND ARE CLEARLY MARKED RIGHT OR
LEFT.
The cylinder head bolts are tightened using a
torque plus angle procedure. The bolts must be
examined BEFORE reuse. If the threads are
necked down the bolts must be replaced (Fig.
24)..
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 must be replaced
(Fig. 24).
CAUTION: When cleaning cylinder head and cylin-
der block surfaces, DO NOT use a metal scraper
because the surfaces could be cut or ground. Use
ONLY a wooden or plastic scraper (Refer to 9 -
ENGINE - STANDARD PROCEDURE - ENGINE GAS-
KET SURFACE PREPARATION).
(1) Clean sealing surfaces of cylinder head and
block.
CAUTION: Ensure that the correct head gaskets are
used and are oriented correctly on cylinder block.
(2) Install
head
gasket
over
locating
dowels.
Ensure the gasket is installed on the correct side of
engine.
NOTE: Before installing the cylinder head bolts,
lubricate the threads with engine oil.
(3) Insert the front four cylinder head bolts into
the cylinder head. Pull the bolts up to the top of their
travel and retain with rubber bands.
(4) Install the cylinder head over locating dowels
and finger tighten the head bolts.
(5) Tighten the cylinder head bolts in the sequence
shown in (Fig. 25). Using the 4 step torque-turn
method, tighten according to the following torque val-
ues:
• Step 1: All to 61 N·m (45 ft. lbs.)
• Step 2: All to 88 N·m (65 ft. lbs.)
• Step 3: All (again) to 88 N·m (65 ft. lbs.)
• Step 4: + 90° Turn Do not use a torque
wrench for this step.
(6) Bolt torque after 90° turn should be over 122
N·m (90 ft. lbs.) in the tightening direction. If not,
replace the bolt.
(7) Install the inner timing cover to cylinder head
bolts. Tighten bolts to 54 N·m (40 lbs.ft.).
Fig. 23 Checking Cylinder Head Flatness
Fig. 24 Check for Stretched Bolts
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
Fig. 25 Cylinder Head Bolt Tightening Sequence
9 - 34
ENGINE 3.5L
CS
CYLINDER HEAD(S) (Continued)
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