Pacifica, 2003-2005

Exhaust Manifold

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Removal & Installation



3.5L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Radiator close out panel
     
    Radiator core support and cooling fan assembly
     
    Oil dipstick tube bolt and move the tube aside
     
    Exhaust manifold crossover pipe bolts
     
    Exhaust manifold bolts and manifold
     

  4.  
  5. Inspect the manifold for damage or cracks. Check for distortion against a straight-edge or thickness gauge. Replace manifold if required.
  6.  
  7. Remove all traces of the old manifold gasket and clean both gasket mating surfaces.

    Click image to see an enlarged view

    Fig. The oil dipstick tube and exhaust crossover pipe bolts must be removed prior to removing the manifold-3.5L engine

    The oil dipstick tube and exhaust crossover pipe bolts must be removed prior to removing the manifold-3.5L engine
  8.  

To install:



Exhaust manifold and gasket, tighten the bolts to 200 inch lbs. (23 Nm)
 
Exhaust manifold crossover pipe and tighten the bolts to 275 inch lbs. (31 Nm)
 
Oil dipstick tube and secure the bolt
 
Radiator cooling fan assembly and core support
 
Radiator close out panel
 
Negative battery cable
 

Right Side
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust manifold crossover pipe bolts
     
    Downstream Oxygen (O 2 S) sensor electrical wiring
     
    Exhaust manifold flange bolts and the hangers from the pipe assembly
     
    Exhaust system from the vehicle
     
    Exhaust Gas Recirculation (EGR) tube support bracket bolt

    Click image to see an enlarged view

    Fig. Exhaust Gas Recirculation (EGR) valve and tube assembly-3.5L engine

    Exhaust Gas Recirculation (EGR) valve and tube assembly-3.5L engine
     
    Lower manifold bolts
     
    Manifold and gasket
     
    O 2 S from the manifold
     

  4.  
  5. Inspect the manifold for damage or cracks. Check for distortion against a straight-edge or thickness gauge. Replace manifold if required.
  6.  
  7. Remove all traces of the old manifold gasket and clean both gasket mating surfaces.
  8.  

To install:

  1. Install or connect the following:

    Exhaust manifold and gasket, tighten the bolts to 200 inch lbs. (23 Nm)
     
    Exhaust system to the vehicle
     
    Exhaust manifold flange bolts and the hangers to the pipe assembly. tighten the flange bolts to 22 ft. lbs. (30 Nm).
     
    Downstream O 2 S sensor electrical wiring
     
    EGR tube support bracket bolt
     
    Exhaust manifold crossover pipe bolts and tighten to 275 inch lbs. (31 Nm)
     
    O 2 S to the manifold
     
    Negative battery cable
     

  2.  

3.8L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Crossover pipe
     
    Spark plug wires
     
    Heat shield
     
    Exhaust manifold bolt
     
    Exhaust manifold and gasket
     

  4.  

To install:

  1. Position the exhaust manifold on the cylinder head and install the bolts to the center runner (cyl # 4), and temporarily tighten to 25 inch lbs. (2.8 Nm).
    NOTE
    Examine the crossover pipe bolts for damage caused due to heat or corrosion and replace using new OEM bolts if found to be defective.

  2.  
  3. Install a new gasket, attach the crossover pipe to the manifold and tighten the bolts to 30 ft. lbs. (41 Nm).
  4.  
  5. Install or connect the following:

    Remaining manifold bolts. Torque the fasteners to 17 ft. lbs. (23 Nm).
     
    Heat shield
     
    Negative battery cable
     

  6.  
  7. Start the engine and check for leaks.
  8.  

Right Side
  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Separate the exhaust pipe at the exhaust manifold.
  6.  
  7. Remove the bolts attaching the crossover pipe to exhaust manifold.
  8.  
  9. Remove the air cleaner housing.
  10.  
  11. Disconnect the Throttle Position (TP), Idle Air Control (IAC) sensor connectors and the purge vacuum hose from the throttle body.
  12.  
  13. Disconnect the upstream Oxygen (O 2 s) sensor connector.
  14.  
  15. Disconnect the spark plug wires from the plugs.
  16.  
  17. Remove bolts attaching the exhaust manifold to the cylinder head and remove the manifold.
  18.  
  19. Discard gasket, if equipped and clean all mating surfaces.
  20.  
  21. Position the exhaust manifold on the cylinder head and install the bolts to the center runner (cyl # 3), and temporarily tighten to 25 inch lbs. (2.8 Nm).
    NOTE
    Examine the crossover pipe bolts for damage caused due to heat or corrosion and replace using new OEM bolts if found to be defective.

  22.  
  23. Install a new gasket, attach the crossover pipe to the manifold and tighten the bolts to 30 ft. lbs. (41 Nm).
  24.  
  25. Install or connect the following:

    Remaining manifold bolts. Torque the fasteners to 17 ft. lbs. (23 Nm).
     

  26.  
  27. Install and connect the upstream O 2 s sensor.
  28.  
  29. Connect the spark plug.
  30.  
  31. Connect the IAC, TPS and the EVAP hose to the throttle body.
  32.  
  33. Install the air cleaner housing.
  34.  
  35. Attach the catalytic converter pipe to exhaust manifold using a new gasket and tighten bolts to 27 ft. lbs. (37 Nm).
  36.  
  37. Connect the negative battery cable.
  38.  
  39. Start the engine and check for leaks.
  40.  

 
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