OEM 2001 Dodge Grand Caravan Intake Manifold

2001 Dodge Grand Caravan Intake Manifold Parts and Q&A

• Q: How to Service the Intake Manifold on a 3.8L Engine on 2001 Dodge Grand Caravan?

  A: Start by removing the negative battery cable and the electrical connection to the air inlet sensor before you service the upper intake manifold. Take the air inlet resonator out from the throttle body hose assembly, the throttle and speed control cables and unplug the make-up air hose support clip from the throttle cable bracket. The automatic idle speed (AIS) motor and throttle position sensor (TPS) cables from the throttle body, the manifold absolute pressure (MAP) sensor electrical connector, the EGR transducer vacuum hose from beneath the upper intake manifold and the vapor purge vacuum hose from the throttle body all need to be unplugged. Open the two bolts fastening the hoses and lift off the power steering reservoir from the PCV without cutting or breaking the hose. Once disconnected, have the brake booster and Leak Detection Pump (LDP) hoses off the intake manifold, then take out the intake manifold bolts and remove the manifold. Cover the portion of the intake that rests on the bottom with a material, discard the old gaskets and clean everything that should be sealed. Look for damage and distortion in the manifold's mounting surface using a ruler and a thickness gauge. If you took off any parts from the manifold, put them back in place and tighten both the MAP sensor (3.4 Nm or 30 in. lbs.) and the throttle cable bracket (12 Nm or 105 in. lbs.). Lift the covering from the lower intake manifold and wipe off any dirt. After that, lay a new intake manifold gasket on the bottom half. Set the upper manifold on those of the lower manifold and fasten and tighten the bolts following the correct sequence to 12 Nm (105 in. lbs.). Attach the MAP sensor electrical connector, fit the brake booster to its location and connect the LDP vacuum hose and PCV hose. Place the power steering reservoir and tighten its fasteners to 12 Nm (105 in, lbs.). Connect the EGR transducer vacuum hose, attach the new EGR tube and bolt it down with 12 Nm (105 in. lbs.) of torque and install the throttle and speed control cables. Fit the clip from the make-up air hose into the throttle cable, join the other end of the hose to the throttle body and restore the wiring links to the TPS and AIS motor. After that, connect the air cleaner and air inlet hose assembly, attach the inlet air sensor electrical cable and fix the battery negative connection.