OEM 2005 Dodge Caravan Intake Manifold

2005 Dodge Caravan Intake Manifold Parts and Q&A

• Q: How to Service and Repair an Intake Manifold on 2005 Dodge Caravan?

  A: Before servicing or repairing the lower intake manifold, first empty the fuel pressure in the system. Detach the upper intake manifold and remember to close the openings so that debris won't enter the engine. Take off the fuel line and let the cooling system drain. Remove the upper hoses attached to the heater supply and radiator and then pull out the connector for the coolant temperature/fuel injector wires. Take away the upper bracket bolts and start loosening the lower bolt of the lower intake manifold support bracket. Release the fuel injector harness and remove the bolts joining the power steering reservoir to the manifold, but do not separate the reservoir from its line. Take off the fasteners for the lower intake manifold and the manifold itself, then use a straight edge to see if it is flat within 0.15 mm per 300 mm (0.006 inch per foot) of its length and check for cracks or if it is misshapen, changing it if required. Research says fuel rail bolts should be torqued to 22 Nm, the coolant outlet connector bolts to 28 Nm and the coolant temperature sensor to 7 Nm when installing. Set the new gasket under the cylinder head and fit the lower manifold, followed by hand-tightening the bolts, using a torque wrench to bring them to 28 Nm (250 in. lbs.) in the right sequence, repeating for all of them. Connect the bolts from the lower intake manifold to the support bracket and tighten them to 28 Nm (250 in. lbs.) to the intake and to 54 Nm (40 ft. lbs.) to the engine block. Set the power steering reservoir on the manifold, secure it with the bolts and attach both the fuel line and the cooling temperature sensor/fuel injector wiring harness. Connector hoses: attach the heating supply hose as the radiator upper, then attach the top intake manifold and finally add coolant to the cooling system.