Pacifica 2006-2008

Engine

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Removal & Installation



3.5L & 4.0L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil.
  4.  
  5. Drain the engine coolant.
  6.  
  7. Properly relieve the fuel system pressure.
  8.  
  9. Remove or disconnect the following:

    Negative battery cable
     
    Hood, as necessary
     
    Cruise control servo
     
    Radiator closure panel
     
    Radiator core support
     
    Upper radiator hose
     
    Cooling fan
     
    Air cleaner assembly
     

  10.  
  11. Recover the A/C system refrigerant using approved recycling equipment.
    WARNING
    Secure the steering wheel to prevent it rotating which may cause damage to the steering column clock spring.



    Throttle and cruise control cable from the throttle body
     
    Cruise control and power brake booster vacuum hoses from the engine
     
    Transmission wiring harness from the solenoid pack, input and output sensors and the range sensor connectors
     
    Engine wiring harness grounds from the inner frame rail
     
    Transmission shift cable
     
    Transmission cooler lines
     
    Engine block heater connector, if equipped
     
    Coolant reservoir houses from the thermostat housing
     
    Heater hoses from the heater core
     
    Upper radiator hoses from the thermostat housing
     
    Brake lines from the Hydraulic Control Unit (HCU)
     
    A/C suction discharge hoses from the compressor and plug the openings
     
    Lower radiator hose from the engine outlet
     
    A/C clutch connection
     
    Oil pressure sender and alternator connections
     
    Fuel supply line from the fuel rail
     
    Ignition harness connection at the intake manifold
     
    Front wheel
     
    Left inner fender well
     
    Engine harness from the Powertrain Control Module (PCM)
     
    Left wheel speed sensor and retainer
     
    Left sway bar link from the strut
     
    Left drive axle nut
     
    Both left front steering knuckle pinch bolts
     
    Left steering knuckle from the strut and support the knuckle
     
    Negative battery cable from the transmission
     
    Left fascia screws
     
    Right inner fender well
     
    Right fascia screws
     
    Right wheel speed sensor and retainer
     
    Right sway bar link from the strut
     
    Right drive axle nut
     
    Both right front steering knuckle pinch bolts
     
    Right steering knuckle from the strut and support the knuckle
     
    Fascia driving lamps, if equipped
     
    Front fascia
     
    Starter connectors and harness retainers
     
    Oxygen (O 2 S) sensor electrical wiring at the exhaust manifold and catalytic converter
     
    Exhaust from the manifold
     
    Driveshaft after marking the position at the front and rear of the shaft. This will help with installation and retain driveshaft balance.
     
    Engine-to-transmission plate
     
    Transmission inspection plate
     
    Flex plate-to-torque converter bolt

    Click image to see an enlarged view

    Fig. Exploded view of the front cradle assembly-3.5L and 4.0L engines



    Click image to see an enlarged view

    Fig. Lower steering column coupling assembly-3.5L and 4.0L engines

     

  12.  
  13. Remove or disconnect the following:

    Lower steering column coupling pin using tool 6831-A and separate the union
     
    Both lower engine mount bolts
     

  14.  
  15. Matchmark using paint the front cradle-to-body location and position the engine cradle support under the vehicle.

    Click image to see an enlarged view

    Fig. Rear cradle support fixture mounting-3.5L and 4.0L engines



    Click image to see an enlarged view

    Fig. Adjust the cradle support fixture to fit flush with the cradle-3.5L and 4.0L engines

  16.  
  17. Remove or disconnect the following:
  18.  
  19. Lower the vehicle until it is just above the cradle
  20.  
  21. Align the cradle support dowels with cradle access holes and adjust the engine support fixture to fit flush with the oil pan and adjust the cradle support fixture support to fit flush with the cradle.
  22.  
  23. Carefully lower the vehicle onto the cradle.
  24.  
  25. Remove the upper engine mount
  26.  
  27. Very carefully remove the front and rear cradle mounting bolts and raise the vehicle to separate the engine/transmission and cradle from the vehicle.
  28.  
  29. Connect lifting brackets to the engine, separate the Power Transfer Unit (PTU), if equipped.
  30.  
  31. Separate the engine from transmission using the lift brackets.

    Click image to see an enlarged view

    Fig. Use suitable lift brackets and a hoist assembly to separate the engine from the transaxle-3.5L and 4.0L engines

  32.  

To install:

  1. Installation is the reverse of removal, please note the following important specifications.
  2.  
  3. Remove or disconnect the following:

    Cradle supporting bolts: 120 ft. lbs. (163 Nm)
     
    Upper engine mount bolt to timing cover to 40 ft. lbs. (54 Nm) and the bolt to right rail to 50 ft. lbs. (68 Nm)
     
    Drive axle-to-steering knuckle nut to 180 ft. lbs. (244 Nm)
     
    Steering knuckle-to-strut bolts to 180 ft. lbs. (244 Nm)
     
    Front speed sensor support bracket bolts to 105 inch lbs. (12 Nm)
     
    Brake line support bracket bolts to 105 inch lbs. (12 Nm)
     
    Flex plate-to-torque converter bolts to 55 ft. lbs. (75 Nm)
     
    Engine-to-transmission support collar bolts to 40 ft. lbs. (54 Nm)
     

  4.  
  5. Fill the cooling system to the proper level.
  6.  
  7. Fill the engine with clean oil.
  8.  
  9. Bleed the brakes.
  10.  
  11. Recharge the A/C system
  12.  
  13. Check wheel alignment.
  14.  
  15. Start the vehicle, check for leaks and repair if necessary.
  16.  

3.8L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Relieve the fuel system pressure.
  8.  
  9. Recover the A/C refrigerant.
  10.  
  11. Secure the steering wheel in the straight ahead position.
  12.  
  13. Disconnect the CCV hose from the left cylinder head cover.
  14.  
  15. Remove the air cleaner cover and housing.
  16.  
  17. Disconnect the throttle and cruise control cables from the throttle body, separate the cables from the bracket and set to one side.
  18.  
  19. Disconnect the cruise control and power brake booster vacuum hoses and set aside.
  20.  
  21. Disconnect the upper radiator hose from the thermostat housing and the lower radiator hose from the radiator.
  22.  
  23. Disconnect the heater hoses and coolant reservoir hose from the intake manifold.
  24.  
  25. Disconnect the transmission controller and transmission sensor wire harness connectors.
  26.  
  27. Disconnect the brake controller wire harness connector.
  28.  
  29. Disconnect the transmission shift cable and remove the cable from the bracket.
  30.  
  31. Disconnect the transmission lines using tool 8875.
  32.  
  33. Disconnect the alternator electrical connectors.
  34.  
  35. Disconnect the fuel line from fuel rail
  36.  
  37. Disconnect the EVAP hose from the throttle body.
  38.  
  39. Disconnect the Throttle Position (TP), Idle Air Control (IAC) motor, Heated Oxygen (HO O 2s), Camshaft Position (CMP), Manifold Absolute Pressure (MAP) sensors and the two engine wiring harness connectors. Remove the harness from the cover studs and set aside.
  40.  
  41. Disconnect the purge solenoid harness connector.
  42.  
  43. Remove engine wiring harness retainer from the left cylinder head cover and the oil dipstick tube.
  44.  
  45. Disconnect the A/C electrical connector, and both A/C lines from the compressor. Cover and seal all openings of hoses and compressor to avoid contamination.
  46.  
  47. Disconnect the oil pressure sending unit.
  48.  
  49. Disconnect the coolant hose at the engine oil cooler.
  50.  
  51. Raise and support the vehicle and remove the front wheels.
  52.  
  53. Remove the front fascia.
  54.  
  55. Disconnect the starter wiring and push pin.
  56.  
  57. Remove the flex plate inspection cover.
  58.  
  59. Rotate the engine at the crankshaft pulley bolt and remove the torque converter bolts.
  60.  
  61. Disconnect the rear O O 2s sensor and remove the exhaust system.
  62.  
  63. Separate the steering column intermediate shaft from the steering gear using tool No. 6831-A.

    Click image to see an enlarged view

    Fig. Exploded view of the steering column coupling-3.8L engine

  64.  
  65. Disconnect the Knock (KS) sensor wiring harness connector and remove the Crankshaft Position (CKP) sensor.
  66.  
  67. Disconnect the in block heater, if equipped.
  68.  
  69. Disconnect the left wheel speed sensor and sensor harness push pin from the body, and set the harness aside.
  70.  
  71. Disconnect the left upper stabilizer link.
  72.  
  73. Disconnect the left strut to steering knuckle bolts and separate the union.
  74.  
  75. Disconnect the right wheel speed sensor and sensor harness push pin from the body, and set the harness aside.
  76.  
  77. Disconnect the right upper stabilizer link.
  78.  
  79. Disconnect the right strut to steering knuckle bolts and separate the union.
  80.  
  81. Disconnect the engine harness ground at the transmission.
  82.  
  83. Disconnect the rear transmission mount from the body.
  84.  
  85. Set up and adjust the cradle support fixture arms and dowels, refer to the accompanying illustrations for cradle support set up. Paint mark the cradle to body location at all four cradle bolt positions.
    CAUTION
    Do not apply the total vehicle weight on the cradle support fixture.

  86.  
  87. Lower the front cradle onto the table and remove all four front cradle mount bolts.
    NOTE
    Use a brake pedal prop rod and depress the brake pedal to prevent excessive brake fluid loss when the brake system is open.

  88.  
  89. Disconnect both front brake lines at the brake controller and route aside.
  90.  
  91. Disconnect the right front engine mount.
  92.  
  93. Remove the left powertrain torque strut to frame bracket bolt.
    CAUTION
    While slowly separating the body from the cradle assembly, constant checks must be performed to assure proper positioning and that no damage occurs during separation.

  94.  
  95. Carefully raise the vehicle off of the engine and cradle assembly.
  96.  
  97. Connect an engine lift bracket, using tool No. 8534-8 to the left cylinder head and tool No. 8534-7 to the right cylinder head.

    Click image to see an enlarged view

    Fig. View of the front cradle support positioning-3.8L engine



    Click image to see an enlarged view

    Fig. View of the rear cradle support positioning-3.8L engine



    Click image to see an enlarged view

    Fig. Exploded view of the front cradle assembly-3.8L engine

  98.  
  99. Separate the engine and transmission from the cradle using the lift brackets.
  100.  
  101. Separate the transmission from the engine.
  102.  

To install:

  1. Installation is the reverse of removal, keep in mind the following important steps and torque values.
    CAUTION
    While slowly lowering the body to the cradle assembly, constantly check to assure proper positioning and no damage occurs to other components until union is made.

  2.  
  3. Tighten the cradle supporting bolts to 120 ft. lbs. (163 Nm).
  4.  
  5. Install the right engine mount. tighten the bolts to the timing cover to 40 ft. lbs. 54 Nm) and the bolts to the right rail to 50 ft. lbs. (68 Nm).
  6.  
  7. Tighten the rear transmission torque strut bolts to 40 ft. lbs. (54 Nm).
  8.  
  9. Tighten the left front strut to steering knuckle bolts to 60 ft. lbs. (81 Nm) and then tighten an additional 90 degrees.
  10.  
  11. Tighten the left stabilizer link to 65 ft. lbs. (88 Nm).
  12.  
  13. Tighten the right front strut to steering knuckle bolts to 60 ft. lbs. (81 Nm) and then tighten an additional 90 degrees.
  14.  
  15. Tighten the right stabilizer link. Tighten to 65 ft. lbs. (88 Nm).
  16.  
  17. Tighten the torque converter bolts to 65 ft. lbs. (88 Nm).
  18.  
  19. Fill the cooling system.
  20.  
  21. Fill the engine with clean oil.
  22.  
  23. Recharge the A/C system.
  24.  
  25. Start the engine and check for leaks.
  26.  

 
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