GrandCaravan 2008

Intake Manifold

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Removal & Installation



3.3L & 3.8L Engines
Lower Intake Manifold

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Perform the fuel system pressure release procedure before attempting any repairs.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the upper intake manifold. Refer to Intake Manifold, Removal & Installation, Upper Intake Manifold.
  8.  
  9. Remove the fuel line.
  10.  
  11. Remove the ignition coil (1) and the bracket (2).

    Click image to see an enlarged view

    Fig. Remove the ignition coil (1) and the bracket (2)-3.3L and 3.8L engines

  12.  
  13. Disconnect the heater supply hose and the Engine Coolant Temperature (ECT) sensor.
  14.  
  15. Disconnect the fuel injector wire harness.
  16.  
  17. Remove the fuel injectors and the rail assembly.
  18.  
  19. Remove the radiator upper hose.
  20.  
  21. Remove the lower intake manifold bolts.
  22.  
  23. Remove the lower intake manifold.
    CAUTION
    The intake manifold gasket is made of a very thin metal and may cause personal injury; handle with care.

  24.  
  25. Remove the intake manifold seal retainer bolt (2). Remove the intake manifold gasket (3).
  26.  
  27. Inspect and clean the manifold.

    Click image to see an enlarged view

    Fig. Remove the intake manifold seal retainer bolt and the intake manifold gasket-3.3L and 3.8L engines

  28.  

To install:

  1. Place a bead (approximately 1 / 4 inch in diameter) of MOPAR® Engine RTV GEN II onto each of the 4 manifold-to-cylinder head gasket corners (1).

    Click image to see an enlarged view

    Fig. Place a bead of RTV sealant onto each of the 4 manifold-to-cylinder head gasket corners (1)-3.3L and 3.8L engines

  2.  
  3. Carefully install a new intake manifold gasket. Tighten the end seal retainer screws to 105 inch lbs. (12 Nm).
  4.  
  5. Install the lower intake manifold. Install the bolts and tighten in the following steps:
    1. Step 1: 10 inch lbs. (1 Nm).
    2.  
    3. Step 2: 200 inch lbs. (22 Nm) in the sequence shown.
    4.  
    5. Step 3: Tighten again to 200 inch lbs. (22 Nm).

      Click image to see an enlarged view

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

    6.  

  6.  
  7. After the intake manifold is in place, inspect to make sure the seals are in place.
  8.  
  9. Install the fuel injectors and the rail assembly.
  10.  
  11. Connect the fuel injector electrical harness.
  12.  
  13. Connect the ECT sensor.
  14.  
  15. Connect the heater supply and the radiator upper hoses to the manifold.
  16.  
  17. Connect the fuel line.
  18.  
  19. Install the upper intake manifold. Refer to Intake Manifold, Removal & Installation, Upper Intake Manifold.
  20.  
  21. Connect the negative battery cable.
  22.  
  23. Fill the cooling system with the proper type and amount of fluid.
  24.  
  25. Connect the negative battery cable.
  26.  

Upper Intake Manifold

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Disconnect the Inlet Air Temperature (IAT) sensor electrical connector.
  6.  
  7. Remove the air inlet resonator-to-throttle body hose assembly.
  8.  
  9. Disconnect the EVAP hose at the throttle.
  10.  
  11. Disconnect the ETC wiring connector from the throttle body.
  12.  
  13. Disconnect the brake booster hose from the intake manifold.
  14.  
  15. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
  16.  
  17. Disconnect the PCV hose.
  18.  
  19. Remove the EGR tube.

    Click image to see an enlarged view

    Fig. Remove the EGR tube-3.3L and 3.8L engines

  20.  
  21. Remove the intake manifold bolts and remove the upper intake manifold.
  22.  
  23. Cover the lower intake manifold with a suitable cover while the upper manifold is removed.
  24.  
  25. Clean and inspect the upper intake manifold.
  26.  

To install:

  1. Install the MAP sensor and tighten to 15 inch lbs. (2 Nm).
    WARNING
    The special screws used for the composite manifold attached components must be installed slowly using hand tools only. This requirement is to prevent the melting of material that causes stripped threads. If threads become stripped, an oversize repair screw is available. For more information and procedure.

  2.  
  3. Remove the covering on the lower intake manifold and clean the surfaces.
  4.  
  5. Inspect the manifold gasket condition. Gaskets can be reused, if not damaged. Position a new gasket in the seal channel and press it lightly into place. Repeat the procedure for each gasket position.
  6.  
  7. Position the upper manifold on the lower manifold.
  8.  
  9. Apply MOPAR® Lock AND Seal Adhesive (Medium Strength Threadlocker) to each upper intake manifold bolt. Install and tighten the bolts to 105 inch lbs. (12 Nm) using the torque sequence.

    Click image to see an enlarged view

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

  10.  
  11. Connect the MAP sensor electrical connector.
  12.  
  13. Connect the brake booster hose to the intake manifold.
  14.  
  15. Install the EGR tube.
  16.  
  17. Connect the ETC connector to the throttle body.
  18.  
  19. Connect the EVAP hose to the throttle body.
  20.  
  21. Install the air cleaner and the air inlet hose assembly.
  22.  
  23. Connect the IAT sensor electrical connector.
  24.  
  25. Connect the battery negative cable.
  26.  

4.0L Engine
Lower Intake Manifold

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Perform the fuel pressure release procedure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Disconnect the upper radiator hose from the thermostat housing.
  8.  
  9. Remove the upper intake manifold. Refer to Intake Manifold, Removal & Installation, Upper Intake Manifold.
  10.  
  11. Reposition the power steering fluid reservoir and the bracket.
  12.  
  13. Disconnect the electrical connectors to fuel injectors and the coolant temperature sensor.
  14.  
  15. Disconnect the heater hose from the intake manifold.
  16.  
  17. Disconnect the coolant container hose at the thermostat housing.
  18.  
  19. Disconnect the fuel supply hose from the fuel rail.
  20.  
  21. Remove the bolts attaching the fuel rail.
  22.  
  23. Remove the fuel rail and the injectors as an assembly.
  24.  
  25. Remove the bolts attaching the lower intake manifold (1) and remove the manifold and the gasket (2).

    Click image to see an enlarged view

    Fig. Remove the lower intake manifold (1) and the gasket (2)-4.0L engine

  26.  

To install:

  1. Clean all the sealing surfaces.
    NOTE
    Make sure the extruded holes in the gasket are installed in the recessed holes in the cylinder head.

  2.  
  3. Position new gaskets and the intake manifold on the cylinder head surfaces.
  4.  
  5. Install the intake manifold bolts and gradually tighten in the sequence shown until a torque of 250 inch lbs. (28 Nm) is obtained.

    Click image to see an enlarged view

    Fig. Lower intake manifold tightening sequence-4.0L engine

  6.  
  7. Install the fuel rail and the injectors as an assembly.
  8.  
  9. Connect the fuel supply hose to fuel rail.
  10.  
  11. Connect the heater hose to the intake manifold.
  12.  
  13. Connect the coolant container to the thermostat housing.
  14.  
  15. Connect the electrical connectors to the fuel injectors and the coolant temperature sensor.
  16.  
  17. Install the power steering fluid reservoir and the bracket.
  18.  
  19. Install the upper intake manifold. Refer to Intake Manifold, Removal & Installation, Upper Intake Manifold.
  20.  
  21. Connect the upper radiator hose to the thermostat housing.
  22.  
  23. Fill the cooling system with the proper type and amount of fluid.
  24.  

Upper Intake Manifold

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air cleaner housing and the inlet hose.
  6.  
  7. Remove the engine cover.
  8.  
  9. Disconnect the ECT harness connector (1) from the throttle body (2).

    Click image to see an enlarged view

    Fig. Disconnect the ECT harness connector (1) from the throttle body (2)-4.0L engine

  10.  
  11. Remove the oil fill tube-to-upper intake manifold retaining bolt.
  12.  
  13. Remove the oil level tube-to-upper intake manifold retaining bolt.
  14.  
  15. Disconnect the electrical connectors from the following sensors and actuators:

    Manifold Tuning Valve (MTV), if equipped
     
    Short Runner Valve
     
    Exhaust Gas Recirculation (EGR)
     
    Throttle Position Sensor (TPS)
     
    Idle Air Control (IAC)
     
    Manifold Absolute Pressure (MAP)
     

  16.  
  17. Remove the alternator support bracket.
  18.  
  19. Disconnect the EGR tube.
  20.  
  21. Disconnect the vacuum hoses from the following:

    Positive Crankcase Ventilation (PCV) Valve
     
    EVAP Purge Solenoid
     
    Power Brake Booster
     

  22.  
  23. Remove the front and rear intake manifold support brackets (1).
  24.  
  25. Remove the upper intake manifold retaining bolts and the manifold. Clean all the gasket sealing surfaces.

    Click image to see an enlarged view

    Fig. Remove the front and rear intake manifold support brackets (1)-4.0L engine

  26.  

To install:

  1. Clean and inspect the gasket sealing surfaces.
  2.  
  3. Position a new gasket.
  4.  
  5. Install the throttle body on the upper intake, if required.
  6.  
  7. Install the upper intake manifold and hand start all the attaching bolts.
  8.  
  9. Tighten the bolts gradually starting in the center working outward until a torque of 105 inch lbs. (12 Nm) is obtained.
  10.  
  11. Install the front and rear intake manifold support brackets.
  12.  
  13. Install the oil level indicator and the oil fill tube to the intake manifold bolts.
  14.  
  15. Install the EGR tube.
  16.  
  17. Connect the vacuum lines to the following:

    Positive Crankcase Ventilation (PCV) Valve
     
    EVAP Purge Solenoid
     
    Power Brake Booster
     

  18.  
  19. Install the alternator support bracket.
  20.  
  21. Connect the electrical connectors to the following:

    Manifold Tuning Valve (MTV)
     
    Exhaust Gas Recirculation (EGR)
     
    Throttle Position Sensor (TPS)
     
    Idle Air Control (IAC)
     
    Manifold Absolute Pressure (MAP)
     

  22.  
  23. Install the ETC connector to the throttle body.
  24.  
  25. Install the air cleaner housing and the inlet hose.
  26.  
  27. Install the engine cover.
  28.  
  29. Connect the negative battery cable.
  30.  

 
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