OEM 2005 Dodge Grand Caravan Intake Manifold

2005 Dodge Grand Caravan Intake Manifold Parts and Q&A

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

  A: To start the service and repair of the lower intake manifold, remove the pressure from the fuel lines and empty the cooling system. Get rid of the top part of the manifold, the line for fuel, ignition coil, its mount, the heater's hose and the engine coolant temperature sensor. Take out the fuel injector connector, pull off the injectors and assemble, replace the upper radiator hose and remove the intake manifold bolts. Gently remove the lower intake manifold, as the metal gasket inside is very delicate and needs careful handling. Unscrew all the intake manifold seal retainers and remove the gasket, inspect and clean the manifold by tossing the old gasket and wiping all around where the gasket was. Inspect the engine for damage, cracks, trapped water and changes in the cylinder head mount where they sit using a straightedge and thickness gauge. For the installation, spread a bead of Mopar Engine RTV GEN II onto each corner of the four manifold to cylinder head gaskets before placing in the new intake manifold gasket. Apply a torque force of 12 Nm (105 in. lbs.) to the screws holding the end seal retainer, fit the lower intake manifold, apply 1 Nm (10 in. lbs.) to each bolt, continue with 22 Nm (200 in. lbs.) in the correct order and finish off by torquing again to 22 Nm (200 in. lbs.). When the seals are in place, mount the fuel injectors and rail assembly, wire up the fuel injector electrical harness, engine coolant temperature sensor, heater supply and two radiator hoses to the manifold and run the fuel line and pipe back to the tank. After that, connect the upper intake manifold, the negative battery cable and fill all needed areas of the cooling system.