Chrysler Pacifica Upper Intake leak

3.5 Pacifica Upper Intake Air leak

All right guys uh we have ourselves here uh a pacifica specifically this one’s a note 4 but um we have a problem with a common problem with the intake this is a 3.5 engine and i researched this online you get a lot of people saying this customer has had the same complaint uh the whistling noise on the pacifica and um i’ll tell you if you take it to the dealer

They’ll tell you to replace the upper intake which uh should cost you at the dealer around 2200 i believe the intake itself is like 18 or so i think 15 at cost wholesale so it is a pricey job and um me and my brother actually took this apart and uh we’re able to find where the issue is and this is a chronic problem so you do see them happen in a lot of the

Pacificas and um here you have the upper intake and you have the butterflies uh or flaps if you will that open and shut by this valve that connects to this tiny rod that then connects to the longer rod which runs through here through the whole thing that turns them now as you can tell the smaller rod let me turn sideways the smaller rod which should work

Aligned it’s crooked as you guys can tell right now and uh you’d normally get a check engine light for this because you get an evap leak because um and that’s why you hear the whistle if you open the hood of your car you will hear a whistle and now the cause of that the the rod is unaligned and this rod goes through right through that hole i don’t know if you

Can see that well but there’s actually a bearing in there and uh the way that works is the bearing the rod itself works really close to the bearing which should seal and there should be no air leak through here because this will be connected to the all this will be connected to the lower intake so they’ll be sealed by the gasket so there should be no leaks here

And uh what happens is as that is unaligned the longer yeah and uh there is a plastic pin over here which will pull out for you guys to see that’s what should that’s what like my brother said that holds the longer rod in place and uh when the rock the longer rod which turn the flaps is in place this smaller rod should be aligned which right now it is and i put

It that way just to show you guys and uh which causes play right here in which causes the leak and that’s when you you know you get a check engine light now what we did here is um we can show how there’s play in there it’s it’s very tiny so i don’t know if you guys can uh you know you can kind of feel it so you you but you can see how it moves and it shouldn’t

Move like that and that’s you know it is a quite small air leak but you will get a check engine light for that so what we do here is my brother now is going to pull the rod back in place so you guys can see how it should work that should be now we gotta put okay now i’ll show you that now that we have actually pulled it out that’s the pin that should normally

On my camera won’t focus but that’s the pin that should normally uh hold the longer rod in place but now what happens that pin is actually plastic so as time goes that you know normally grinds on the longer rod which eventually allows it to you know move forward which is the wrong way that it should work now i’m abroad we’ll connect that smaller rod again and

You will see the difference now you can tell how that rod is aligned instead of before it would go inward right here because that was you know that moved in but now it’s fully aligned and you know if you understand how this works uh now since the longer rod was pulled back uh now it works close enough to the bearing that’s in there and you know it should seal

And should have no air leak and you know this whole thing is sold in one piece so the issue is that at the dealer you can’t get anything separate and that’s why the repair comes out so pricey now uh the way we’ve come up with uh you know to make this work is since this pin which would be that one which would normally be you know all the way in that’s supposed

To lock the longer rod in place but since that pin uh like i said eventually it grinds on the other plastic piece and eventually it’ll also have play because you know it eats away from the pin itself now make sure you show that that’s the so you see that there’s this there’s a space right there and that’s how it normally should look if this the longer rod is in

The right place and like i said you will have you will have this smaller rod fully aligned and even a little bit out and that’s how it should be instead of you know normally how it was like that and it was you know ending about right here where this is now and so it should come out about i’d say about half an inch to you know and what three quarters of an inch

What happened when the the the rod goes in and what happens the the batten sits over here in this gap so that’s why it causes the leak yeah so that that that gap over here should be gold so the pin should be sits over here to hold the the rod on place yeah so that that’s why you see a little mark right there on that gap because the the once the bearing sets here

There’s no way it seals air and that’s why you get an air leak you know in here that’s why it’s quite a small air leak that’s why it even makes a whistling noise now this hole that you guys see right there i don’t have much light but um there’s a hole right there exactly that hole we’ve actually made because you know the customer doesn’t want to spend you know uh

Two thousand dollars to fix this you know it’s a check engine light it’s a leak it’s minor but you still won’t pass inspection at least in mass you won’t so that hole that we’ve made will now put uh we’ll we’ll show you guys we’ll put a screw in there first we have to uh align that yeah now we align the you know that gap where it’s shiny right there should align

With the hole which is normally where the you know where the original pin would be sitting once aligned once again the rod should be straight not going inward but going a little bit outwards you know and that’s how and that’s the proper way for it to work as you guys can see right here there’s no play at all right now and there’s no play because it’s sitting in

The right place tight on the bearing which should seal you know the air completely now like i said we’ve made that hole that you guys see right there and my brother will now put a screw in there now you you don’t whoever does this don’t put a gigantic screw because you don’t have much space to actually drill so we put a screw you know just big enough just get

From here tom because you’re gonna be able to see where’s the boat’s gonna sit on to hold the rod and you guys can see right there get enough light keep going just close enough and let’s go right there now you guys see once we put that screw there so the way this works is there’s plastic right here but then that gap that i showed you is in between the screw and

Then the part that goes through the bearing that’s right there the really small bearing is thick like this beginning part as well so it seals right on the bearing now if that part so the the part that’s shiny that i showed you guys that normally the you know the original pin should lock is in between the screw which now doesn’t allow the you know longer longer

Rod to move forward at all which is the entire issue because when it moves forward and that you know that metal piece that’s in between the this plastic piece is where the bearing is which the bearing the bearing size is you know bigger than that which causes you know space for air to get in and that’s where the entire issue happens and you know if you’re able

To do this it i guarantee you it’ll save you a lot of money you know the intake itself like i said is i i believe eighteen hundred dollars at least at my local dealer and uh so that’s good we’re gonna put some lock tight over here just to make sure the the screws aren’t gonna come out yeah it’s just it’s screwing the plastic so yeah and like yeah the intake is

Fully plastic so like i said you guys do have to be careful uh the size of the hole that you drill because you don’t want to you know drill a big hole and leave only a tiny bit of plastic right here because that will crack if you uh as you you know screw the the screw in uh so yeah that should solve the problem like i said so now uh the theory is that the longer

Rod won’t move forward which you know right now it should be on the bearing that’s right in here it should be sealed because it is a thicker piece of plastic inside that touches the bearing so that should seal there should be no air and if it works there should be no whistle when um on your engine uh when you know you take a look at it because uh normally there’d

Be a whistle where hissing sound um you know because the air will be getting in here and you should and it should give you a check engine light as well and like i said at the dealer they will recommend that you replace the upper intake but there will be tons of money all right i hope the video helps and uh if you guys have any questions please comment below i know

I didn’t rehearse the video so uh there’s a lot of uh explanation on top of you know another so if you guys have any questions just comment the video all right thank you

Transcribed from video
Chrysler Pacifica Upper Intake leak By Tom Gomes