OEM 2001 Dodge Caravan Intake Manifold

2001 Dodge Caravan Intake Manifold Parts and Q&A

• Q: How to Service and Repair an Upper Intake Manifold on 2001 Dodge Caravan?

  A: Before handling the upper intake manifold, you should first disconnect the negative cable from the battery. Following that, pull the connector out of the inlet air temperature sensor, disconnect the air intake tube at the throttle body and take out the upper air cleaner housing. After that, remove the connectors from the Throttle Position Sensor (TPS), Idle Air Control (IAC) motor and MAP sensor. Disconnect the purge solenoid vacuum line, PCV valve vacuum line and remove the vacuum lines for the power brake booster, LDP, EGR transducer and speed control vacuum reservoir if you have them. Take the tubes used with the throttle, speed control and transaxle out of the throttle lever before removing the EGR tube. Take out the bracket bolt connecting the manifold support plate to the manifold and unscrew the oil dipstick from the tube. After removing the intake manifold bolts, remove the manifold from the engine and use something to cover it, so no debris enters the engine. See if all the manifold's important surfaces are flat to within 0.15 per 300 mm (0.006 in. per foot). If the surfaces are not flat or there are cracks, trade in the manifold. Wipe the sealing areas on the manifold and coat the perimeter of each lower intake manifold runner opening with a 1.5 mm (0.060 inch) bead of Mopar Gasket Maker. Set the upper intake manifold in place and tighten all the screws according to what is shown on the diagram, adjusting the torque to 28 Nm (250 in. lbs.) each time. Put back the engine oil dipstick, the upper bolt in the intake manifold and fasten it to the front support bracket with 28 Nm (250 in. lbs.) of torque. Fit the EGR tube, connect the throttle cable in the bracket and attach the throttle, speed control (if present) and transaxle control cables to the throttle lever. Reinstall the vacuum lines to the power brake booster, LDP, EGR transducer and speed control vacuum reservoir if the vehicle comes with them and then connect the vacuum lines of the purge solenoid and PCV valve. Finally, connect the MAP sensor, Throttle Position Sensor (TPS) and Idle Air Control (IAC) motor, put on the air cleaner upper housing and air intake tube to the throttle body, attach the inlet air temperature sensor connector and link the negative cable back to the battery.