Caravan, Grand Voyager, Town and Country, Voyager, 2000-2004

Intake Manifold

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Removal & Installation



3.0L 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:

    Negative battery cable
     
    Air cleaner and tube
     
    Accelerator cable
     
    Cruise control cable
     
    Idle Air Control (IAC) valve connector
     
    Throttle Position (TP) sensor connector
     
    Throttle body vacuum hose harness
     
    Positive Crankcase Ventilation (PCV) hose
     
    Brake booster vacuum line
     
    Ignition coil
     
    Engine Coolant Temperature (ECT) sensor connector
     
    Upper intake manifold vacuum lines
     
    Fuel line
     
    Upper intake manifold
     
    Fuel injector harness connectors
     
    Fuel supply manifold
     
    Radiator hose
     
    Heater hose
     
    Lower intake manifold
     

  8.  

To install:

Click image to see an enlarged view

Fig. Lower intake manifold torque sequence-3.0L engine



Click image to see an enlarged view

Fig. Upper intake manifold torque sequence-3.0L engine

  1. Install or connect the following:

    Lower intake manifold. Tighten the bolts in sequence and in several steps to 15 ft. lbs. (20 Nm).
     
    Heater hose
     
    Radiator hose
     
    Fuel supply manifold. Tighten the bolts to 115 inch lbs. (13 Nm).
     
    Fuel injector harness connectors
     
    Upper intake manifold. Tighten the bolts in sequence and in several steps to 115 inch lbs. (13 Nm).
     
    Fuel line
     
    Upper intake manifold vacuum lines
     
    ECT sensor connector
     
    Ignition coil
     
    Brake booster vacuum line
     
    PCV hose
     
    Throttle body vacuum hose harness
     
    TP sensor connector
     
    IAC valve connector
     
    Cruise control cable
     
    Accelerator cable
     
    Air cleaner and tube
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine, check for leaks and repair if necessary.
  6.  

3.3L & 3.8L Engines
  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:

    Negative battery cable
     
    Air cleaner and tube
     
    Idle Air Control (IAC) valve connector
     
    Accelerator cable
     
    Cruise control cable
     
    Make up air hose support clip from the throttle cable bracket
     
    Automatic Idle Speed (IAS) and Throttle Position (TP) sensor connectors
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    Exhaust Gas Recirculation (EGR) transducer connector, if equipped
     
    EGR tube, if equipped
     
    Vapor purge vacuum hose from the throttle body
     
    Positive Crankcase Ventilation (PCV) hose
     
    Power steering reservoir bolts and loosen the nut, lift the reservoir up to disengage the lower mount from the stud and position aside with the lines still attached.
     
    Brake booster and leak detection pump hoses
     
    Upper intake manifold
     
    Fuel line
     
    Ignition coil and bracket
     
    Heater supply hose and Engine Coolant temperature (ECT) sensor
     
    Fuel injector harness connectors
     
    Fuel supply manifold
     
    Upper radiator hose
     
    Lower intake manifold
     

  8.  

To install:

Click image to see an enlarged view

Fig. Lower intake manifold torque sequence-3.3L and 3.8L engines



Click image to see an enlarged view

Fig. Upper intake manifold torque sequence-3.3L and 3.8L engines

  1. Install a 1 / 4 inch bead of gasket maker onto each of the 4 manifold-to-cylinder head gasket corners.
  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
     
    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 and power steering reservoir 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 leak detection pump hoses
     



    Power steering reservoir
     
    PCV hose
     
    Vapor purge vacuum hose from the throttle body
     
    EGR tube, if equipped
     
    EGR transducer connector, if equipped
     
    MAP sensor connector
     
    IAS and TP sensor connectors
     
    Make up air hose support clip to the throttle cable bracket
     
    Cruise control cable
     
    Accelerator cable
     
    IAC valve connector
     
    Air cleaner and tube
     
    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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