OEM 2006 Dodge Caravan Intake Manifold

2006 Dodge Caravan Intake Manifold Parts and Q&A

• Q: How to Service and Repair an Upper Intake Manifold on 2006 Dodge Caravan?

  A: Step one is to disconnect the negative battery cable when handling the upper intake manifold. After that, dissociate the connector from the inlet air temperature sensor and the air intake tube connected to the throttle body and next, pull off the upper air cleaner housing. After that, pull out the connectors from the Throttle Position Sensor (TPS), Idle Air Control (IAC) motor and MAP sensor. Pull out the vacuum lines attached to the purge solenoid, PCV valve, power brake booster, LDP, EGR valve transducer and speed control vacuum reservoir at the upper intake fittings. Cut the throttle, speed control and transaxle control cable exits from the throttle bracket and remove the EGR tube. Unbolt the upper intake manifold support bracket, unclip the oil dipstick and unbolt the upper intake manifold after you've placed a protective cover over the intake. Evaluate the manifold surfaces for being within 0.15 mm per 300 mm (0.006 inch per foot) from flatness and look for any cracks or strange shapes, changing the manifold if these issues are noticed. Prior to installation, wipe the manifold sealing surfaces and then put a 1.5 mm (0.060 in.) bead of Mopar Gasket Maker on the edge of the openings in the lower intake manifold runner. After installing the upper intake manifold, tighten each fastener by hand until they reach 28 Nm (250 in. lbs.), doing so for every fastener in the right sequence. Once again, fasten the engine oil dipstick and the upper bolt in the intake manifold, joining to the front support bracket, then tighten it using 28 Nm (250 in. lbs.). Fit the EGR tube back in, place the throttle cables into the bracket and attach the throttle and speed control (if present) cables to the throttle lever. The power brake booster, LDP, EGR transducer and speed control vacuum reservoir vacuum lines should be hooked up at the upper intake manifold fittings and then the vacuum lines for the purge solenoid and PCV valve should be joined together. Also, assemble the electrical connectors for the MAP sensor, Throttle Position Sensor (TPS) and Idle Air Control (IAC) motor, mount the upper air cleaner housing and air intake tube to the throttle body, install the inlet air temperature sensor connector and connect the negative cable to the car's battery.