Pacifica 2006-2008

Intake Manifold

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Removal & Installation



3.5L & 4.0L Engines
Lower
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Clean all gasket mating surfaces and inspect for distortion with a good straightedge.



    Upper radiator hose from the thermostat housing
     
    Upper intake manifold
     
    Power steering reservoir and position aside
     
    Fuel injector and Coolant temperature (CTS) sensor electrical connections
     
    Exhaust crossover bolt
     
    Heater hose from the intake manifold
     
    Coolant container hose at the thermostat housing
     
    Fuel supply hose from the rail
     
    Fuel rail bolts and rail with the injectors as an assembly
     
    Lower intake manifold bolts and manifold
     



    Click image to see an enlarged view

    Fig. Lower intake manifold and gasket-3.5L and 4.0L engines



    Click image to see an enlarged view

    Fig. Lower intake manifold tightening sequence-3.5L and 4.0L engines

  4.  

To install:


NOTE
Verify that all intake manifold and cylinder head sealing surfaces are clean.


NOTE
Be sure that the extruded holes in the gasket are installed in the recessed holes in the cylinder head

  1. Install or connect the following:

    Intake manifold gasket, then the lower manifold. Torque the bolts in the proper sequence to specification
     
    Fuel rail bolts and rail with the injectors as an assembly
     
    Fuel supply hose to the rail
     
    Heater hose to the intake manifold
     
    Coolant container hose to the thermostat housing
     
    Exhaust crossover bolt
     
    Fuel injector and CTS sensor electrical connections
     
    Power steering reservoir
     
    Upper intake manifold
     
    Upper radiator hose from the thermostat housing
     

  2.  
  3. Fill the cooling system and check for leaks.
  4.  

Upper
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner assembly
     
    Engine cover from the top of the intake manifold
     
    ECT harness connector, as required
     
    Accelerator and the speed control cable from the throttle lever
     
    Two cable bracket bolts and position the bracket aside
     
    Oil dipstick tube-to-upper intake bolt
     

  8.  
  9. Disconnect the following electrical connections:

    Manifold Tuning Valve (MTV)
     
    Sort Runner (SR) valve
     
    Exhaust Gas Recirculation (EGR) valve
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) motor
     
    Intake Air Temperature (IAT) sensor
     
    Manifold Absolute Pressure (MAP) sensor
     

  10.  
  11. Remove or disconnect the following:

    Alternator support bracket
     
    EGR tube
     

  12.  
  13. Disconnect the following vacuum lines:

    Positive Crankcase Ventilation (PCV) valve
     
    Evaporative Emissions (EVAP) solenoid
     
    Brake booster
     
    Front and rear manifold support brackets
     
    Intake plenum mounting bolts
     

  14.  
  15. Remove the intake manifold plenum from the intake manifold.
    NOTE
    Discard the old gasket. Cover the intake manifold openings with tape to keep debris from entering the engine.



    Click image to see an enlarged view

    Fig. Upper intake manifold and related components-3.5L and 4.0L engines



    Click image to see an enlarged view

    Fig. Upper intake manifold support bracket-left shown, right similar-3.5L and 4.0L engines

  16.  

To install:

  1. Install or connect the following:
    NOTE
    Do not overtighten bolts when working with light alloys.



    Intake manifold plenum with a new gasket in place. Torque the mounting bolts, working from the center outward, to 105 inch lbs. (12 Nm)
     



    Oil dipstick tube-to-upper intake bolt
     
    EGR tube
     

  2.  
  3. Connect the following vacuum lines:

    PCV valve
     
    EVAP solenoid
     
    Brake booster
     

  4.  
  5. Install or connect the following:

    Alternator support bracket
     

  6.  
  7. Connect the following electrical connections:

    MTV valve
     
    Sort Runner (SR) valve
     
    EGR valve
     
    TP sensor
     
    IAC motor
     
    IAT sensor
     
    MAP sensor
     

  8.  
  9. Install or connect the following:

    Cable bracket and bolts
     
    Accelerator and the speed control cable to the throttle lever
     
    Air cleaner assembly
     
    ECT harness connector, as required
     
    Engine cover
     
    Negative battery cable
     

  10.  
  11. Fill and bleed the cooling system.
  12.  
  13. Change the engine oil and filter.
  14.  
  15. Start the engine, check for fuel and coolant leaks and verify correct engine operation.
  16.  

3.8L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Remove or disconnect the following:
    CAUTION
    The intake manifold gasket is made of thin metal, handle with care to avoid injury.



    Negative battery cable
     
    Idle Air Temperature (IAT) sensor connector
     
    Air cleaner and tube
     
    Accelerator cable
     
    Cruise control cable
     
    EVAP hose from the throttle body
     
    Exhaust Gas Recirculation (EGR) tube
     
    Idle Air Control (IAC) motor and Throttle Position (TP) sensor connectors
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Positive Crankcase Ventilation (PCV) hose
     
    Brake booster and cruise control hoses
     
    Upper intake manifold bolts and manifold
     
    Fuel line
     
    Heater supply hose and Engine Coolant temperature (ECT) sensor
     
    Fuel injector harness connectors
     
    Fuel supply manifold with the injectors as an assembly
     
    Upper radiator hose
     
    Lower intake manifold bolts and manifold
     
    Intake manifold seal retainer screws and the gasket
     

  8.  
  9. Clean all gasket mating surfaces.
  10.  

To install:

Click image to see an enlarged view

Fig. Lower intake manifold torque sequence-3.8L engine



Click image to see an enlarged view

Fig. Upper intake manifold torque sequence-3.8L engine

  1. Install a 1 / 4 inch bead of gasket maker onto each of the 4 manifold-to-cylinder head gasket corners.

    Click image to see an enlarged view

    Fig. Install a 1/4 inch bead of gasket maker onto each of the 4 manifold-to-cylinder head gasket corners-3.8L engine

  2.  
  3. Install the lower intake manifold gasket and tighten the seal retainer screws to 105 inch lbs. (12 Nm)
  4.  
  5. Install the lower intake manifold and tighten the bolts in sequence, as follows:


    1. Step 1: 10 inch lbs. (1 Nm).
    2.  
    3. Step 2: 17 ft. lbs. (22 Nm).
    4.  
    5. Step 3: 17 ft. lbs. (22 Nm).
    6.  

  6.  
  7. Install or connect the following:

    Fuel supply manifold and injectors as an assembly
     
    Fuel injector harness connectors
     
    ECT sensor connector
     
    Heater supply hose
     
    Radiator hose
     
    Fuel line
     

  8.  
  9. Place a new gasket in the channel and press lightly in place.
    NOTE
    The special screws used to retain the EGR tube must be tightened slowly with hand tools only to avoid stripping the threads.



    Upper intake manifold. Apply Mopar®thread and lock adhesive (medium strength) to each upper intake manifold bolt. Tighten the bolts to 105 inch lbs. (12 Nm) in the sequence illustrated.
     
    MAP sensor connector
     
    Brake booster and cruise control hoses
     



    EGR tube
     
    Cruise control cable
     
    Accelerator cable
     
    EVAP hose
     
    IAC and TP sensor connectors
     
    Air cleaner and tube
     
    IAT connector
     
    PCV hose
     
    Negative battery cable
     

  10.  
  11. Fill the cooling system.
  12.  
  13. Start the engine, check for leaks and repair if necessary.
  14.  

 
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