Pacifica, 2003-2005

Valve Covers

Print

Removal & Installation



3.5L Engine
Left Side

CAUTION
Never start or run engine with cylinder head cover removed from the engine. damage or personal injury may occur.

  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Remove the upper intake manifold from the engine.
  4.  
  5. Cover lower intake manifold with a suitable cover during service.
  6.  
  7. Disconnect and remove the three ignition coils.
  8.  
  9. Remove the upper intake manifold support brackets from the front and rear of the engine.
  10.  
  11. Lift up on the wire harness track retaining tabs.
  12.  
  13. Remove the ground strap/resistor retaining bolt from the cylinder head cover.
  14.  
  15. Completely loosen the cylinder head cover retaining bolts and remove the cylinder head cover.
  16.  
  17. Remove the PCV valve from the valve cover assembly (if required).
  18.  
  19. Clean cylinder head and cover mating surfaces. Inspect and replace gasket and seals as necessary.

    Click image to see an enlarged view

    Fig. Remove the retaining bolts (2), then remove the valve cover (1)-3.5L engine, left side shown, right side similar

    Remove the retaining bolts (2), then remove the valve cover (1)-3.5L engine, left side shown, right side similar
  20.  

To install:

  1. To replace spark plug tube seals:
    1. Using a suitable pry tool, carefully remove tube seals.
    2.  
    3. Position new seal with the part number on seal facing cylinder head cover.
    4.  
    5. Install seals using Special Tool MD-998306.

      Click image to see an enlarged view

      Fig. Using the special tool (1) to install the spark plug seals (2)-3.5L engine

      Using the special tool (1) to install the spark plug seals (2)-3.5L engine
    6.  

  2.  
  3. Install PCV valve (if required)
  4.  
  5. Install cylinder head cover and bolts. Tighten to 105 inch lbs. (12 Nm).
  6.  
  7. Position the wiring harness on the cylinder head cover.
  8.  
  9. Reclip the wire harness track retaining tabs into the cover.
  10.  
  11. Install the ground strap/resistor retaining bolt onto the cylinder head cover.
  12.  
  13. Install the upper intake manifold support brackets onto the front and rear of the engine.
  14.  
  15. Install the ignition coils. Tighten mounting screws to 60 inch lbs. (6.7 Nm).
  16.  
  17. Connect the ignition coil electrical connectors.
  18.  
  19. Install upper intake manifold.
  20.  
  21. Connect the negative battery cable.
  22.  

Right Side

CAUTION
Never start or run engine with cylinder head cover removed from the engine. damage or personal injury may occur.

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the upper intake manifold from the engine.
  4.  
  5. Cover lower intake manifold with a suitable cover during service.
  6.  
  7. Disconnect and remove the three ignition coils.
  8.  
  9. Lift up on the wire harness track retaining tabs.
  10.  
  11. Remove the ground strap retaining bolt from the cylinder head cover.
  12.  
  13. Completely loosen the cylinder head cover retaining bolts and remove the cylinder head cover
  14.  
  15. Clean cylinder head and cover mating surfaces. Inspect and replace gasket and seals as necessary.
  16.  

To install:

  1. To replace spark plug tube seals:
    1. Using a suitable pry tool, carefully remove tube seals.
    2.  
    3. Position new seal with the part number on seal facing cylinder head cover.
    4.  
    5. Install seals using Special Tool MD-998306.

      Click image to see an enlarged view

      Fig. Using the special tool (1) to install the spark plug seals (2)-3.5L engine

      Using the special tool (1) to install the spark plug seals (2)-3.5L engine
    6.  

  2.  
  3. Install cylinder head cover bolts and tighten to 105 inch lbs. (12 Nm).
  4.  
  5. Install the ground strap retaining bolt to the cylinder head cover.
  6.  
  7. Install the wire harness track retaining nuts.
  8.  
  9. Install the ignition coils. Tighten mounting screws to 60 inch lbs. (6.7 Nm).
  10.  
  11. Connect the ignition coil electrical connectors.
  12.  
  13. Install upper intake manifold.
  14.  
  15. Connect the negative battery cable.
  16.  

3.8L Engine
Left Side
  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect spark plug wires from spark plugs.
  4.  
  5. Disconnect crankcase vent hose from cylinder head cover.
  6.  
  7. Remove cylinder head cover bolts.
  8.  
  9. Remove cylinder head cover and gasket.
  10.  
  11. Clean cylinder head and cylinder head cover mating surfaces. Inspect cylinder head cover surface for flatness. Replace gasket as necessary.
  12.  

To install:

  1. Assemble gasket to cylinder cover by inserting the fasteners through each bolt hole on cover and gasket.
  2.  
  3. Install the cylinder head cover and bolts.
  4.  
  5. Tighten cylinder head cover bolts to 105 inch lbs. (12 Nm).
  6.  
  7. Connect crankcase vent hose.
  8.  
  9. Connect spark plug wires to spark plugs.
  10.  

Right Side
  1. Disconnect negative cable from battery.
  2.  
  3. Disconnect spark plug wires from plugs.
  4.  
  5. Disconnect PCV hose from cylinder head cover.
  6.  
  7. Remove cylinder head cover bolts.
  8.  
  9. Remove cylinder head cover and gasket.
  10.  
  11. Clean cylinder head and cylinder head cover mating surfaces. Inspect cylinder head cover surface for flatness. Replace gasket as necessary.
  12.  

To install:

  1. Inspect seal on the cover bolt for wear or damage. Replace bolt assembly as necessary.
  2.  
  3. Inspect the PCV hose for damage. replace as necessary.
    NOTE
    The cylinder head cover bolts contain a torque limiter sleeve and a seal. The seal and torque sleeve is replaced with the bolt.

  4.  
  5. Assemble gasket to cylinder cover by inserting the bolt assemblies through each bolt hole on the cover and gasket.
  6.  
  7. Install cylinder head cover and bolts.
  8.  
  9. Tighten cylinder head cover bolts to 105 inch lbs. (12 Nm).
    NOTE
    Be sure that the PCV valve is properly seated inside the cylinder head cover protrusion and that the PCV hose completely covers the cylinder head cover protrusion.

  10.  
  11. Connect PCV hose to cylinder head cover.
  12.  
  13. Connect spark plug wires to spark plugs.
  14.  
  15. Connect negative cable to battery.
  16.  

 
label.common.footer.alt.autozoneLogo