Pacifica, 2003-2005

Removal & Installation

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3.5L Engine



  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Remove cap from power steering fluid reservoir.
  4.  
  5. Using a siphon pump, remove as much power steering fluid as possible from power steering fluid reservoir.
  6.  
  7. Remove engine appearance cover.
  8.  
  9. Remove upper radiator closure panel, as follows
    1. Remove four push pins attaching radiator closure panel to radiator crossmember.
    2.  
    3. Remove one bolt on each side attaching to radiator crossmember.
    4.  
    5. Remove six screws attaching radiator closure to the upper grille.
    6.  
    7. Remove radiator closure panel from vehicle.

      Click image to see an enlarged view

      Fig. To remove the radiator closure panel (3), remove the push pins (1), bolts (2) and attaching screws (4)

      To remove the radiator closure panel (3), remove the push pins (1), bolts (2) and attaching screws (4)
    8.  

  10.  
  11. Remove power steering fluid reservoir, as follows:
    1. Remove clamp attaching return hose to power steering fluid reservoir. Remove hose from reservoir.
    2.  
    3. Remove clamp attaching supply hose to power steering fluid reservoir. Remove hose from reservoir.
    4.  
    5. Remove two upper mounting bolts securing reservoir in place.
    6.  
    7. Loosen, but do not remove, lower mounting bolt securing reservoir in place.
    8.  
    9. Slide reservoir upward, off lower mounting bolt.
    10.  

  12.  
  13. Remove clamp, then remove fluid supply hose from pump.
  14.  
  15. Disconnect pressure hose from pump.
  16.  
  17. Remove generator wiring harness routing clip from pump.
  18.  
  19. Raise and safely support the vehicle.
  20.  
  21. Remove right front tire and wheel assembly.
  22.  
  23. Remove drive belt splash shield.
  24.  
  25. Remove nut, then hose tube routing clamp at A/C compressor mounted bracket.
  26.  
  27. Remove nuts mounting front and rear motor mounts to engine cradle (one nut each mount).
  28.  
  29. Remove accessory drive belt, as outlined in Engine Mechanical.
  30.  
  31. Carefully lower the vehicle.
  32.  
  33. Remove air cleaner housing, as follows:
    1. Disconnect the Intake Air Temperature (IAT) sensor wiring harness connector.
    2.  
    3. Remove the air inlet hose at the throttle body.
    4.  
    5. Disconnect the air circulation hose at the element housing.
    6.  
    7. Remove the housing retaining bolt.
    8.  
    9. Pull housing up and off of the locating pin.
    10.  
    11. Remove element housing from vehicle.
    12.  

  34.  
  35. Remove two bolts fastening right motor mount to frame rail.
  36.  
  37. Move pressure and return hoses away from pump toward cooling module as far as possible without bending lines.
  38.  
  39. Place floor jack with an appropriate sized block of wood on it below engine oil pan.
    WARNING
    When lifting engine, DO NOT raise engine more than necessary or damage to driveline half shaft (and possibly other components) will occur.

  40.  
  41. Carefully raise accessory drive end of engine with floor jack approximately 2 inches (or just enough to access pump mounting bolts).
  42.  
  43. Remove three pump mounting bolts through pulley.
  44.  
  45. Remove pump (with pulley) from engine compartment.

    Click image to see an enlarged view

    Fig. Pump mounting bracket on engine (1), power steering pump (2) and mounting bolts (3)

    Pump mounting bracket on engine (1), power steering pump (2) and mounting bolts (3)
  46.  

To install:

  1. Install power steering pump back in engine compartment using reverse order of its removal.
  2.  
  3. Install power steering pump on its mounting bracket.
  4.  
  5. Install three power steering pump mounting bolts through pulley. Tighten pump mounting bolts to 17 ft. lbs. (23 Nm).
  6.  
  7. Lower floor jack allowing engine to return to normal position. Remove jack.
  8.  
  9. Install two bolts fastening right motor mount to frame rail. Tighten bolts to 50 ft. lbs. (68 Nm).
  10.  
  11. Reposition pressure and return hoses to their original locations at pump.
    NOTE
    Before installing power steering pressure hose on power steering pump, replace O-ring on end of power steering pressure hose. Lubricate O-ring using clean power steering fluid.

  12.  
  13. Install pressure hose into pump fitting. Thread pressure hose tube nut into pump and tighten to 23 ft. lbs. (31 Nm).
  14.  
  15. Raise vehicle.
  16.  
  17. Install nuts mounting front and rear motor mounts to engine cradle (one nut each mount). Tighten nuts to 75 ft. lbs. (102 Nm).
  18.  
  19. Install accessory drive belt.
  20.  
  21. Place pressure and return hoses on A/C compressor mounted bracket and install routing clamp and nut. Tighten the nut to 105 inch lbs. (12 Nm).
  22.  
  23. Install drive belt splash shield.
  24.  
  25. Install tire and wheel assembly. Tighten the lug nuts to 100 ft. lbs. (135 Nm).
  26.  
  27. Lower vehicle.
  28.  
  29. Install air cleaner housing, as follows:
    1. Install housing into vehicle and the locating pin.
    2.  
    3. Install housing retaining bolt.
    4.  
    5. Connect the air inlet hose to the throttle body and tighten clamp.
    6.  
    7. Connect the air circulation hose to housing.
    8.  
    9. Connect the IAT sensor wiring harness connector.
    10.  

  30.  
  31. Install generator wiring harness routing clip into pump.
  32.  
  33. Slide fluid supply hose onto pump fitting and install clamp securing it in place.
  34.  
  35. Install power steering fluid reservoir, as follows:
    1. Slide fluid reservoir over lower mounting bolt and into place on engine.
    2.  
    3. Install two upper mounting bolts securing reservoir in place.
    4.  
    5. Tighten all three reservoir mounting bolts to 105 inch lbs. (12 Nm).
    6.  
    7. Install supply hose onto reservoir. Slide hose clamp into position on fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting.
    8.  
    9. Install return hose onto reservoir. Slide hose clamp into position on fluid reservoir and attach it. Be sure hose clamp in installed past bead on fluid reservoir fitting.
    10.  

  36.  
  37. Install upper radiator closure panel, as follows:
    1. Place radiator closure panel into position.
    2.  
    3. Install one bolt on each side attaching to radiator crossmember.
    4.  
    5. Install four push pins attaching radiator closure panel to radiator crossmember.
    6.  
    7. Install six screws attaching radiator closure to the upper grille.
    8.  

  38.  
  39. Install engine appearance cover.
  40.  
  41. Connect negative (-) battery cable on negative battery post.
  42.  
  43. Fill and bleed power steering system using Power Steering Pump Initial Operation Procedure.
  44.  
  45. Inspect for leaks.
  46.  

3.8L Engine



  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Remove cap from power steering fluid reservoir.
  4.  
  5. Using a siphon pump, remove as much power steering fluid as possible from power steering fluid reservoir.
  6.  
  7. Remove air cleaner housing, as follows:
    1. Disconnect the Intake Air Temperature (IAT) sensor wiring harness connector.
    2.  
    3. Remove the air inlet hose at the throttle body.
    4.  
    5. Disconnect the air circulation hose at the element housing.
    6.  
    7. Remove the housing retaining bolt.
    8.  
    9. Pull housing up and off of the locating pin.
    10.  
    11. Remove element housing from vehicle.
    12.  

  8.  
  9. Remove accessory drive belt.
  10.  
  11. Remove clamp, then remove return hose at reservoir.
  12.  
  13. Unthread tube nut and remove pressure hose at pump.
  14.  
  15. Remove three pump mounting bolts through pulley.

    Click image to see an enlarged view

    Fig. Remove the power steering pump mounting bolts (2) through the openings in the pulley (1)

    Remove the power steering pump mounting bolts (2) through the openings in the pulley (1)
  16.  
  17. Remove pump (with pulley and reservoir) from engine compartment.
  18.  

To install:

  1. Position power steering pump on engine.
  2.  
  3. Install three power steering pump mounting bolts through pulley. Tighten pump mounting bolts to 16 ft. lbs. (23 Nm).
    NOTE
    Before installing power steering pressure hose on power steering pump, replace O-ring on end of power steering pressure hose. Lubricate the O-ring using clean power steering fluid.

  4.  
  5. Install pressure hose into pump fitting.
  6.  
  7. Thread pressure hose tube nut into pump and tighten to 23 ft. lbs. (31 Nm).
  8.  
  9. Slide return hose onto reservoir fitting and install clamp securing it in place.
  10.  
  11. Install accessory drive belt.
  12.  
  13. Install air cleaner housing, as follows:
    1. Install housing into vehicle and the locating pin.
    2.  
    3. Install housing retaining bolt.
    4.  
    5. Connect the air inlet hose to the throttle body and tighten clamp.
    6.  
    7. Connect the air circulation hose to housing.
    8.  
    9. Connect the IAT sensor wiring harness connector.
    10.  

  14.  
  15. Connect the negative battery cable.
  16.  
  17. Fill and bleed power steering system using the Power Steering Pump Initial Operation Procedure.
  18.  
  19. Check the power steering pump for leaks.
  20.  

 
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