OEM 2004 Dodge Grand Caravan Intake Manifold

2004 Dodge Grand Caravan Intake Manifold Parts and Q&A

• Q: How to Remove and Reinstall the Intake Manifold on 2004 Dodge Grand Caravan?

  A: Take out the negative battery cable and then disconnect the inlet air temperature sensor connector to remove the upper intake manifold. With that done, you should next remove the air inlet resonator to throttle body hose assembly, cut the cables attaching to the throttle body and detach the make-up air hose support clip from the throttle cable bracket. First, detach the Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) cables from the end of the throttle body, then the Manifold Absolute Pressure (MAP) sensor connector, vapor purge vacuum hose and PCV hose. Loose each bolt that is holding the reservoir, then elevate it and detach the reservoir from the lower mount without disabling the hose. Separate and remove the brake booster and Leak Detection Pump (LDP) hoses from the intake manifold. After that, unbolt the intake manifold and take it out. When inspecting and cleaning the upper intake manifold, cover the lower intake manifold, get rid of the seal gaskets and wipe all sealing surfaces. Examine the manifold for harm, cracks and any distortion of the mounting surface with a straightedge and a gauge. When installing, replace any missing components and tighten everything to the right specification, with hand tools used carefully to prevent damaging the special screws. Position the MAP sensor with a force of 1.7 Nm (15 in. lbs.) and the throttle cable bracket with a force of 5.6 Nm (50 in. lbs.). Take off the cover from the lower intake manifold, wipe down all the surfaces and examine the gasket. If the gasket is not harmed or damaged, use it again, but change it if needed. Attach the upper manifold to the lower manifold and fasten everything with 12 Nm (105 in. lbs.) of torque using the right sequence. Put the MAP sensor wires into theplace where the electrical connector attaches and join the brake booster to the bottom of the intake header. After that, hook the LDP v h hose to the cantilever bracket, then attach the power steering reservoir, tightening until it reaches 5.6 Nm (50 in. lbs.). Arrays the wiring from the throttle and speed control to the throttle body, hooks up the make-up air hose clip and assembles the wiring for the TPS and AIS motor. After that, fit the air cleaner and air inlet hose assembly, repair the IAT sensor socket and secure the cable of the battery's negative terminal.