OEM 2002 Dodge Grand Caravan Intake Manifold

2002 Dodge Grand Caravan Intake Manifold Parts and Q&A

• Q: How to Service and Repair an Intake Manifold on 2002 Dodge Grand Caravan?

  A: To start, release the pressure in the fuel system and drain the coolant from the engine before servicing the lower intake manifold. Lift out the upper intake manifold, cut the fuel line, remove the ignition coil and its attachment, uninstall the heater hose and remove the coolant temperature sensor. Take out the bolts on the lower intake manifold after disconnecting the fuel injector wire harness, removing the fuel injectors and rail assembly, radiator upper hose and pulling out intake manifold bolts. Treat the intake manifold gasket gently because it is not made of thick metal. Take out the intake manifold seal retainers screws and the gasket, check and clean the manifold by removing the old gasket and cleaning all necessary sealing surfaces. Check around for breaks, leaks, blocked tubes and a damaged cylinder head mount using a straight edge and gauge. When installing, first add a bead of Mopar Engine RTV GEN II onto each manifold to head gasket corner, place the new intake manifold gasket on top and tighten the end seal retainer screws to 12 Nm (105 in. lbs.). Attach the lower intake manifold, turn the bolts to 1 Nm (10 in. lbs.), then torque them to 22 Nm (200 in. lbs.), in the given order and then repeat the last torque to 22 Nm (200 in. lbs.). After you secure the seals, mount the fuel injector rail and injectors, attach the electrical harness, fit the sensor for engine temperature, the heater supply pipe and the two upper radiator hoses. Connect the fuel line, put the upper intake manifold into place, link the negative battery cable and fill the cooling system.