AutoZone 2002 Chrysler Truck Town & Country AWD 3.8L MFI 6cyl | Repair Guides | Engine Mechanical | Engine Mechanical Components | Intake Manifold | AutoZone.com

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    2002 Chrysler Truck Town & Country AWD 3.8L MFI 6cyl

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    DeVille, Eldorado, Seville 1999-2005

    Intake Manifold

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    Removal & Installation



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

      Negative battery cable
       
      Intake manifold heat shield
       
      Sight shield
       
      Coil module connectors from the coil modules located on the valve covers
       
      Positive Crankcase Ventilation (PCV) hose and valve from the valve cover
       
      Fuel regulator vacuum tube
       
      Vacuum tubes from the AIR solenoid
       
      Fuel inlet and return lines
       
      Fuel rail bracket retaining nut at the rear lift bracket
       
      2 pushnuts attaching the engine coolant heater wire and set it aside, if equipped
       
      Fuel injector electrical connections
       
      Fuel rail and injectors
       
      Plenum duct clamp at the rear of the intake manifold, loosen
       
      Intake manifold bolts and the manifold
       

    8.  
    9. Clean the manifold mating surfaces.
    10.  

    To install:

    Click image to see an enlarged view

    Fig. Intake manifold torque sequence- 4.6L engines

    1. Grease the inside edge of the rubber plenum duct.
    2.  
    3. Position the intake manifold by performing the following sub-steps:
      1. Place the rear of the intake manifold into the plenum duct.
      2.  
      3. Place the front of the intake manifold downward on to the cylinder heads.
      4.  

    4.  
    5. Install the intake manifold bolts and torque to 89 inch lbs. (10 Nm) in the sequence illustrated. DO NOT torque the intake manifold bolts when the engine is HOT or at operating temperature.
    6.  
    7. Make sure the plenum duct is fully attached to the rear of the intake manifold and tighten the plenum duct clamp to 20 inch lbs. (2.25 Nm).
    8.  
    9. Install or connect the following:

      Fuel rail and injectors and tighten the rail retainers to 89 inch lbs. (10 Nm)
       
      Fuel injector electrical connections
       
      Alternator coolant pipe/surge tank pipe and position onto the fuel rail studs
       
      Engine coolant heater wire onto the studs and install the pushnuts, if equipped
       
      Fuel rail bracket retaining nut at the rear lift bracket and tighten to 89 inch lbs. (10 Nm)
       
      Fuel inlet and return lines
       
      Vacuum tubes to the AIR solenoid
       
      Fuel regulator vacuum tube
       
      Positive Crankcase Ventilation (PCV) valve and hose to the valve cover
       
      Coil module connectors to the coil modules located on the valve covers
       
      Sight shield
       
      Intake manifold heat shield
       
      Negative battery cable
       

    10.  
    11. Fill and bleed the cooling system.
    12.  

     
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