OEM 2004 Dodge Caravan Intake Manifold

2004 Dodge Caravan Intake Manifold Parts and Q&A

• Q: How to Service an Intake Manifold on 2004 Dodge Caravan?

  A: Before fixing the lower intake manifold, relax the fuel line pressure and ensure you cover openings on the engine to stop foreign matter from getting in. Remove the heater supply and radiator upper hoses from the intake manifold, unhook the fuel line and draw out the cooling system. Take off the coolant temperature sensor/fuel injector wire harness connector, get rid of the lower intake manifold support bracket upper bolts and unscrew the lower bolt of the support bracket. Remove the fuel injector harness and the screws attaching the power steering reservoir to the manifold. Then, take out the reservoir, but still leave the line attached. Disconnect the lower intake manifold bolts and carefully remove the manifold along with the gasket; then use a straight edge to check that it is perfectly flat, with no deviation greater than 0.15 mm per 300 mm (0.006 inch per foot) and that there is no sign of cracks or distortion, replacing it when needed. Reconnectica and torque any removed nuts by following this order: fuel rail bolts to 22 Nm (200 in. lbs.), coolant outlet connector bolts to 28 Nm (250 in. lbs.) and the coolant temperature sensor to 7 Nm (60 in. lbs.). Put a new gasket on the cylinder head and set the lower manifold in place, tightening all intake manifold bolts in the exact order to 28 Nm (250 in. lbs.). Continue until you have tightened everything that needs torquing. Put in the lower intake manifold support bracket bolts, then tighten the ones to the intake to 28 Nm and the one going into the engine block to 54 Nm. Bolt the power steering reservoir to the manifold after placing it, then attach both the fuel line and the coolant temperature sensor/fuel injector wiring harness electrical connector. Afterward, put in the radiator upper unit and the heater supply hoses and finally install the upper intake manifold and fill up the cooling system.