OEM 2005 Chrysler Town & Country Intake Manifold

2005 Chrysler Town & Country Intake Manifold Parts and Q&A

• Q: How to Remove and Reinstall an Intake Manifold on 2005 Chrysler Town & Country?

  A: The first step before removing the intake manifold is to unplug the electrical connector to the Inlet Air Temperature (IAT) sensor and disconnect the negative cable from the battery. Then, disconnect the air inlet resonator to throttle body hose assembly, cut the throttle and speed control cables from the throttle body and remove the make-up air hose support clip from the throttle cable bracket. Take the Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors from the side of the throttle body and then disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector and vapor purge vacuum hose from the bottom of the throttle body. Take out the power steering hose and then remove the bolts and the nut of the reservoir, while lifting it so it comes off the lower mount. Loosen the intake manifold's nuts, fingertighten the hoses to remove them from the manifold, then take off the manifold. After removing the upper intake manifold, clean and look it over. Remove any old gaskets and clean all contacts that will make contact with the manifold. Check the manifold for any damage, cracks and if the surface is warped, using a straightedge and thickness gauge. For installation, handle each component the same as you would during assembly and check that the composite manifold screws are hand-installed slowly. Attach the MAP sensor, brake booster and LDP vacuum hose to their original ports on the intake manifold. After that, install the power steering reservoir and tighten its screws to 5.6 Nm (50 in. lbs.). Rebuild the connection between the air hose and throttle body, insert all of the TPS connector pins and make sure to connect the wiring of the AIS motor to the TPS. After that, put in the air cleaner and the inlet hose assembly, restore the IAT sensor connector and link up the battery's negative wire again.