Chrysler Caravan/Voyager/Town and Country 1996-1999

Intake Manifold

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REMOVAL & INSTALLATION




CAUTION
The fuel injection system remains under pressure even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

2.4L Engine

See Figure 1



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Fig. Fig. 1: Lower intake manifold mounting points-2.4L engine

The 2.4L engine intake manifold is a long branch design made of cast aluminum. It is attached to the cylinder head with eight fasteners.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the air cleaner inlet hose from the throttle body.
  6.  
  7. Disconnect the throttle cable and speed control cable (if equipped) from the throttle lever and cable bracket. The cable(s) can be removed from the bracket by compressing the retaining tabs.
  8.  
  9. Detach the Idle Air Control (IAC) motor and Throttle Position Sensor (TPS) wiring connectors on the throttle body.
  10.  
  11. Disconnect the vacuum hoses from the intake plenum fittings.
  12.  
  13. Detach the electrical connectors from the Manifold Absolute Pressure (MAP) and Intake Air Temperature (IAT) sensors.
  14.  
  15. Detach the fuel line quick-disconnect fitting from the chassis fuel line tube by squeezing the retainer tabs together and pulling the fitting assembly from the fuel tube nipple. The retainer will remain on the fuel tube. Use shop towels to catch any spilled fuel.
  16.  
  17. Remove the EGR tube and gasket at the EGR valve.
  18.  
  19. Drain the cooling system and remove the accessory drive belt.
  20.  
  21. If necessary, remove the alternator mounting bracket.
  22.  
  23. Remove the mounting bolts that secure the bottom of the intake support bracket.
  24.  
  25. Remove the eight intake manifold fasteners and washers. Remove the intake manifold from the engine.
  26.  

To install:
  1. Thoroughly clean all parts. Check the mating surfaces for cracks or distortion.
  2.  
  3. Install a new intake manifold gasket and position the manifold on the cylinder head. Install and tighten the fasteners to 200 inch lbs. (23 Nm) starting from the center and working outward in both directions.
  4.  
  5. Install the mounting bolt that secures the bottom of the intake support bracket, and install the alternator mounting bracket (if removed).
  6.  
  7. Install the accessory drive belt and adjust to the proper tension.
  8.  
  9. Install the EGR gasket and tube to the EGR valve.
  10.  
  11. Inspect the quick-disconnect fittings for damage and repair as required. Lightly lube the fuel line tube with clean 30W engine oil. Reconnect the fuel hose quick-disconnect fitting to the chassis fuel tube. Push the quick-disconnect fitting onto the chassis fuel tube until it clicks into place. Check the connection by pulling on the fitting to insure it is locked in position.
  12.  
  13. Reconnect the MAP and IAT air temperature sensor wiring connectors.
  14.  
  15. Reconnect the vacuum hoses to the intake plenum fittings.
  16.  
  17. Reattach the IAC motor and TPS wiring connectors.
  18.  
  19. Install the throttle cables into the throttle cable bracket. Be sure to engage the retaining tabs.
  20.  
  21. Reconnect the throttle cable and speed control cable (if equipped) to the throttle lever.
  22.  
  23. Install the air cleaner inlet hose to the throttle body.
  24.  
  25. Refill the cooling system with a 50 / 50 mixture of clean, ethylene glycol antifreeze and water to the proper level.
  26.  
  27. Reconnect the negative battery cable.
  28.  
  29. Run the engine and check for leaks and proper operation.
  30.  

3.0L Engine

See Figures 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17 and 18



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Fig. Fig. 2: 3.0L intake and exhaust manifold exploded view

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the air cleaner-to-throttle body hose.
  8.  



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Fig. Fig. 3: First, label and remove the PCV valve hose from the rocker arm cover and valve ...



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Fig. Fig. 4: After removing the throttle body, disconnect any residual vacuum lines from the manifold plenum

  1. Remove the throttle cable and transaxle kickdown cable.
  2.  
  3. Remove the Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) electrical connectors from the throttle body. Detach the vacuum connections from throttle body.
  4.  
  5. Remove the PCV and brake booster hoses from the air intake plenum.
  6.  
  7. Remove the ignition coil from the intake plenum.
  8.  
  9. Remove the EGR tube from the intake plenum (if equipped).
  10.  
  11. Remove the electrical connection from the coolant temperature sensor.
  12.  
  13. Remove the vacuum connection from the fuel pressure regulator.
  14.  
  15. Remove the air intake connection from the air intake plenum. Remove the fuel hose-to-fuel rail connections.
  16.  
  17. Remove the air intake plenum-to-manifold bolts (8), and remove the air intake plenum and gasket.
  18.  


WARNING
Whenever the air intake plenum is removed, cover the intake manifold properly to keep objects from entering the cylinder head.

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Fig. Fig. 5: Loosen and remove the EGR tube flange-to-lower intake manifold mounting bolts ...



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Fig. Fig. 6: ... and remove the EGR tube itself from the intake manifold



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Fig. Fig. 7: Remove and label the vacuum hose from the front of the upper intake manifold plenum ...



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Fig. Fig. 8: ... then label and remove any electrical wires and connectors from the lower manifold


  1. Label and disconnect the fuel injector wiring harness from the engine wiring harness.
  2.  
  3. Disconnect the vacuum hose from the fuel rail, then remove the pressure regulator attaching bolts and remove the pressure regulator from the rail.
  4.  
  5. Remove the fuel rail attaching bolts and remove the fuel rail.
  6.  
  7. Remove the radiator hose from the thermostat housing and the heater hose from the pipe.
  8.  
  9. Remove the intake manifold attaching nuts and washers, and remove the intake manifold.
  10.  
  11. Clean the gasket material from the cylinder head and manifold gasket surface. Check for cracks or damaged mounting surfaces.
  12.  

To install:
  1. Install a new gasket on the intake surface of the cylinder head and install the intake manifold.
  2.  
  3. Install the intake manifold washers and nuts. Tighten the intake manifold attaching nuts, in sequence, to 15 ft. lbs. (20 Nm).
  4.  



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Fig. Fig. 9: Loosen and remove the upper-to-lower manifold fasteners ...



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Fig. Fig. 10: ... then lift the upper intake manifold plenum from the lower manifold



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Fig. Fig. 11: Disconnect the radiator-to-waterneck coolant hose from the waterneck and ...



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Fig. Fig. 12: ... disconnect the smaller coolant hose from the water box

  1. Clean the injectors and lubricate the injector O-rings with a drop of clean engine oil.
  2.  
  3. Place the tip of each injector into their ports. Push the assembly into place until the injectors are seated in their ports.
  4.  
  5. Install the fuel rail attaching bolts and tighten to 115 inch lbs. (13 Nm).
  6.  
  7. Install the fuel supply and return tube hold-down bolt and the vacuum crossover tube hold-down bolt. Tighten to 95 inch lbs. (11 Nm).
  8.  
  9. Connect the injector wiring harness to the engine wiring harness.
  10.  
  11. Remove the covering from the intake manifold.
  12.  
  13. Position the intake manifold gasket, beaded side up, on the intake manifold.
  14.  
  15. Place the air intake plenum in position. Install the attaching bolts and tighten, in sequence, to 115 inch lbs. (13 Nm).
  16.  
  17. Connect the fuel line to the fuel rail. Tighten the clamps to 10 inch lbs. (1 Nm).
  18.  
  19. Connect the vacuum hoses to the intake plenum.
  20.  
  21. Connect the electrical connection to the coolant temperature sensor.
  22.  
  23. Connect the EGR tube flange to the intake plenum (if equipped) and tighten to 15 ft. lbs. (20 Nm).
  24.  
  25. Reconnect the PCV hose and the brake booster supply hose to the intake plenum.
  26.  
  27. Reconnect the automatic idle speed control motor and TPS electrical connectors.
  28.  
  29. Connect the throttle body vacuum hoses and electrical connections.
  30.  
  31. Install the throttle cable and transaxle kickdown linkage.
  32.  
  33. Install the air inlet hose assembly.
  34.  



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Fig. Fig. 13: Loosen and remove the relay bracket-to-lower intake manifold attaching nut, ...



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Fig. Fig. 14: ... unscrew the bolt and ...



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Fig. Fig. 15: ... remove the relay and bracket from the engine

  1. Install the radiator and heater hose.
  2.  
  3. Refill the cooling system with a 50 / 50 mixture of clean, ethylene glycol antifreeze and water to the proper level.
  4.  
  5. Reconnect the negative battery cable. An engine oil and filter change is recommended.
  6.  
  7. Run the vehicle until it reaches operating temperature and check the cooling system, fuel system and engine for fuel, oil or coolant leaks.
  8.  



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Fig. Fig. 16: Remove the remaining lower intake manifold mounting bolts, then lift the manifold off of the engine



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Fig. Fig. 17: Tighten the intake manifold bolts in the correct sequence to prevent vacuum leaks-3.0L engine



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Fig. Fig. 18: Tighten the intake as shown-3.0L engine

3.3L and 3.8L Engines

See Figures 19, 20 and 21



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Fig. Fig. 19: On 3.3L and 3.8L engines, there are mounting brackets behind the plenum

  1. Properly relieve the fuel system pressure.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the wiper arm and blade assemblies.
  6.  
  7. Remove the cowl cover from the vehicle.
  8.  
  9. Open the hood. Detach the positive lock on the wiper unit electrical connector.
  10.  
  11. Detach the wiper unit electrical connector from the engine compartment wiring harness.
  12.  
  13. Disconnect the windshield washer hose from the hose coupling inside the wiper unit.
  14.  
  15. Remove the drain tubes from the bottom of the wiper unit.
  16.  
  17. Remove the sound absorbers from the ends of the wiper unit.
  18.  
  19. Remove the attaching nuts securing the wiper unit to the lower windshield fence.
  20.  
  21. Remove the attaching bolts securing the wiper unit to the dash panel.
  22.  
  23. Raise up the wiper unit from the from the weld-studs on the lower windshield fence and remove the wiper unit from the vehicle.
  24.  



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Fig. Fig. 20: 3.3L and 3.8L plenum-to-manifold attachment detail



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Fig. Fig. 21: Intake manifold removal-3.3L and 3.8L engines

  1. Drain the cooling system.
  2.  
  3. If equipped, remove the intake manifold cover.
  4.  
  5. Disconnect the air inlet resonator-to-throttle body hose assembly.
  6.  
  7. Disconnect the throttle cable and remove the wiring harness from the cable bracket.
  8.  
  9. Remove the Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors from the throttle body.
  10.  
  11. Remove the vacuum hose harness from the throttle body.
  12.  
  13. Remove the PCV and brake booster hoses from the air intake plenum.
  14.  
  15. Remove the EGR tube flange and the vacuum harness connectors from the intake plenum.
  16.  
  17. If equipped, detach the charge temperature sensor electrical connector. Remove the vacuum harness connectors from the intake plenum.
  18.  
  19. Remove the cylinder head-to-intake plenum strut.
  20.  
  21. Detach the MAP sensor wiring connector. Remove the engine mounted ground strap.
  22.  
  23. Remove the fuel hose quick-disconnect fittings from the fuel rail by pulling back on the fitting while pushing in the plastic ring. This may require the use of an open end wrench to push in the plastic ring. Be sure to plug the open fuel lines to prevent system contamination. Wrap a shop towel around the fuel hoses to absorb any fuel spill.
  24.  
  25. Remove the DIS coils and the alternator bracket to intake manifold bolt.
  26.  
  27. Remove the alternator wiring harness from the back of the upper intake manifold plenum.
  28.  
  29. Remove the attaching bolts and remove the upper intake manifold. Cover the intake manifold openings to prevent foreign material from entering the engine.
  30.  
  31. Remove the fuel tube retainer bracket bolt and fuel rail attaching bolts. Spread the retainer bracket to allow for clearance when removing the fuel tube.
  32.  
  33. Detach the cam sensor and coolant temperature sensor connectors.
  34.  
  35. Remove the injector wiring clip from the intake manifold water tube.
  36.  
  37. Remove the fuel rail. Be careful not to damage the fuel injector O-rings.
  38.  
  39. Remove the upper radiator hose, bypass hose and rear intake manifold hose.
  40.  
  41. Remove the intake manifold bolts and remove the manifold from the engine.
  42.  
  43. Remove the intake manifold seal retaining bolts and remove the manifold gasket.
  44.  
  45. Clean out any clogged end water passages and fuel runners.
  46.  

To install:
  1. Clean and dry all gasket mating surfaces.
  2.  
  3. Place a bead of approximately 1 / 4 in. (6mm) diameter of silicone sealant onto each of the four manifold-to-cylinder head gasket corners.
  4.  


CAUTION
The intake manifold gasket is made of very thin material and could cause personal injury. Handle with care.

  1. Carefully install the intake manifold gasket and tighten the end seal retainer bolts to 105 inch lbs. (12 Nm).
  2.  
  3. Install the intake manifold and eight retaining bolts and tighten to 10 inch lbs. (1 Nm). Then tighten the bolts, in sequence, to 200 inch lbs. (22 Nm).
  4.  
  5. When the bolts are tightened, inspect the seals to ensure that they have not become dislodged.
  6.  
  7. Lubricate the injector O-rings with clean oil to ease installation. Put the tip of each injector into its port and place the fuel rail in position. Install the fuel rail mounting bolts and tighten to 200 inch lbs. (22 Nm).
  8.  
  9. Install the fuel tube retaining bracket bolt. Tighten the bolt to 35 inch lbs. (4 Nm).
  10.  
  11. Connect the cam, coolant temperature and engine temperature sensors if equipped.
  12.  
  13. Install the upper intake manifold with a new intake manifold gasket. Install the bolts only finger-tight. Install the alternator bracket to intake manifold bolt and the cylinder head to intake manifold strut bolts. Tighten the intake manifold mounting bolts to 250 inch lbs. (28 Nm) starting from the middle and working outward.
  14.  
  15. Tighten the alternator bracket and cylinder head-to-intake manifold strut bolts to 40 ft. lbs. (54 Nm).
  16.  
  17. Connect the alternator wiring harness to the alternator and to the rear of the intake manifold.
  18.  
  19. Reconnect the ground strap and MAP sensor connectors.
  20.  
  21. Reconnect the intake plenum vacuum harness.
  22.  
  23. Install a new gasket and connect the EGR tube to the intake manifold. Tighten the retaining fasteners to 200 inch lbs. (22 Nm).
  24.  
  25. Clip the wiring harness into the throttle cable bracket hole. Reconnect the Throttle Position Sensor (TPS) and Automatic Idle Speed (AIS) control motor wiring connectors.
  26.  
  27. Reconnect the throttle body vacuum harness and install the ignition coils. Tighten the ignition coil fasteners to 105 inch lbs. (12 Nm).
  28.  
  29. Lightly lubricate the ends of the fuel lines with clean, 30W engine oil. Reconnect the fuel hoses to the rail. Push the fittings in until they click in place. Pull back on the quick-disconnect fittings to ensure that the fuel lines are securely locked in place.
  30.  
  31. Reconnect the throttle cable.
  32.  
  33. Reconnect the fuel injector wiring harness.
  34.  
  35. Install the air inlet resonator to throttle body hose assembly.
  36.  
  37. If equipped, install the intake manifold cover.
  38.  
  39. Install the wiper unit into the vehicle engine compartment. Be sure the wiper unit is installed properly over the weld-studs on the lower windshield fence. Install and tighten the attaching nuts to the weld-studs.
  40.  
  41. Install and tighten the attaching bolts securing the wiper unit to the dash panel.
  42.  
  43. Install the sound absorbers to each end of the wiper unit.
  44.  
  45. Install the drain tubes to the bottom of the wiper unit and reconnect the windshield washer hose to the hose coupling inside the wiper unit.
  46.  
  47. Reconnect the wiper unit wiring connector to the engine wiring harness.
  48.  
  49. Place the cowl cover onto the vehicle. Reconnect the right side windshield washer hose to the right washer nozzle located on the underside of the cowl cover.
  50.  

  1. Engage the retainers that secure the cowl cover to the front fender edge.
  2.  
  3. Install and tighten the wing nuts that secure the front of the cowl cover to the wiper module.
  4.  
  5. Engage the quarter turn fasteners that secure the outer ends of the cowl cover to the wiper module.
  6.  
  7. Install and tighten the bolts that hold the lower area of the cowl cover to the wiper module.
  8.  
  9. Reconnect the negative battery cable and verify that the wiper motor and wiper linkage are in the PARK position.
  10.  
  11. Install the wiper arm in correct position over the wiper arm pivot.
  12.  
  13. Install the wiper arm-to-wiper arm pivot retaining nut and tighten to 26 ft. lbs. (35 Nm).
  14.  
  15. Push down the wiper arm cap cover and engage the clip that secures the outside end of the cover to the wiper arm.
  16.  
  17. Reconnect the negative battery cable.
  18.  
  19. Operate the windshield wipers and ensure they work and park properly.
  20.  
  21. Refill the cooling system with a 50 / 50 mixture of clean, ethylene glycol antifreeze and water. Bleed the cooling system.
  22.  
  23. Start the engine. Check for leaks and proper engine operation.
  24.  

 
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