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How to take off upper intake manifold gasket 2002 dodge caravan

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6 Suggested Answers

6ya6ya
  • 2 Answers

SOURCE: I have freestanding Series 8 dishwasher. Lately during the filling cycle water hammer is occurring. How can this be resolved

Hi,
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Posted on Jan 02, 2017

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egstriker23
  • 44 Answers

SOURCE: I need to remove the upper intake manifold from my

First off, you need to label all of the electrical and vacuum lines connecting to the intake manifold. This will make reassembly much easier. Then, there is a torque sequence to be used during disassembly and reassembly.2cf4be0.gif
This image is of the TIGHTENING SEQUENCE. Reverse this to take the manifold off. This is important so that the upper intake manifold is not warped at all, which would decrease the quality of the seal. Be careful during disassembly and reassembly to avoid bending any lines or tubes. If things are in your way, disconnect them rather than pushing them to the side. This will avoid pinching inner linings which cannot be seen visually.

As for the gaskets, (as far as I am aware), Chrysler's (Dodge's) official stance on the manifold gaskets is that they are reusable. However, this is if they ALL look good under close inspection. Any tears, "melting", or other damage means the gaskets should all be replaced. They are not expensive, and I believe they all come as a set including both upper and lower gasket sets. Personally, I would recommend replacing them regardless. This would be a good preventative step to help extend the life of the vehicle. Also be sure to check the cooling line O-rings and replace them as necessary, following the criteria above.

Good luck and I hope this helps, even though I see it is a bit late.

Posted on Aug 02, 2009

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  • 5 Answers

SOURCE: Changing a 2002 Dodge Caravan headlight

Hello, You remove the headlamp assembly by removing the 3 bolts that hold it in place. The bolts are #1 in the following picture:

7e81e20.gif

Posted on Oct 23, 2008

  • 104 Answers

SOURCE: Need install instruction for starter on 2002 Dodge Caravan

This is alittle tricky getting to some of the bolts but its not too hard to do otherwise. 2 bolts hold on the starter IIRC they are 13mm bolts. make sure your battery is dissconected by the black cable. then there will be 2 nuts holding on the starter wires. one will be 8mm and the other 13mm. remove them with care cause the wires may and can break. when you remove starter check wires for corrosion or if they look fraigle. repair them if damaged.
then to put it back in is the same way you took it out. should take about 1.5 hrs total if you have never done it before.

Overall i would say skill level 3/10 only cause its trickey getting to that top bolt sometimes.

good luck,
Michael

Posted on Apr 29, 2009

  • 40 Answers

SOURCE: replacing intake manifold plenum

what the hell is the question here? nothing. remove old one and put new one in.

Posted on Sep 08, 2009

  • 149 Answers

SOURCE: 2002 dodge grand caravan fuse box

The fuse box is located under the hood. There is component map printed on the inside of the cover. This tells you on your model where the fuse or relay is located

Posted on Jan 19, 2010

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Need the torque specs for the upper intake bults on a 2002 chrysler sebring conv. 2.7L


4022caa.jpg

Fig. Intake manifold bolt torque sequence 2.7L engine

Upper intake manifold with a new gasket on the lower intake manifold and torque the bolts, in sequence, to: 105 inch lbs. (12 Nm)

Hope helps (remember to rate this answer). Good job.

Oct 11, 2010 | 2002 Chrysler Sebring

1 Answer

2000 Dodge Grand Caravan 3.3L Engine. few months ago I had coolant boiling over my surge tank. Initially the radiator cap lost its proper pressure capability but it wasn't the case but notice radiator had...


You can purchase an intake manifold gasket set from a local parts store. It should have the upper and lower intake gaskets contained in it. I see you plan on doing the valve cover gaskets as well. It might be a good idea to replace the plugs and wires at the same time to save some trouble down the road. I would recommend doing the oil change and change the thermostat at the same time as well.

Mar 07, 2017 | 2000 Dodge Caravan

2 Answers

Need to replace the intake manifold


3.8L Engine (most common) Upper Intake Manifold To Remove:
  1. Drain the cooling system.
  2. Remove or disconnect the following:
    • Negative battery cable.
    • Fuel injector sight shield.
    • Air cleaner intake duct.
    • Right spark plug wires from the ignition control module and reposition.
  3. Relieve the fuel pressure.
  4. Remove or disconnect the following:
    • Fuel rail assembly.
    • Brake booster hose from the vacuum source manifold in the upper intake manifold.
    • Exhaust Gas Recirculation Valve (EGR) wiring harness heat shield nut, bolt and the EGR heat shield.
    • Throttle body support bracket upper bolt.
  5. Disconnect the electrical connectors from the following:
    • EVAP purge solenoid
    • Throttle Position (T/P) sensor
    • Idle Air Control (IAC) valve
    • Manifold Absolute Pressure (MAP) sensor
    • Mass Air Flow (MAF) sensor
    • EVAP purge solenoid vacuum line from the throttle body.
    • Accelerator and the cruise control cables with the bracket from the throttle body.
  6. Remove or disconnect the following:
    • Upper intake manifold bolts and stud.
    • Clean the upper intake manifold bolt threads.
  7. Remove or disconnect the following:
    • Upper intake manifold by lifting the back of the intake and sliding the manifold forward from the throttle body support bracket.
    • Upper-to-lower intake manifold carrier gasket from the upper intake manifold.
  8. If the upper intake manifold is being replaced, remove the following:
    • Throttle body assembly.
    • Manifold Absolute Pressure (MAP) sensor.
    • Positive Crankcase Ventilation (PCV) valve.
    • Vacuum source manifold.
Upper intake manifold bolt torque sequence (3.8L engine) gm-03-38-530.gif

To Install:
  1. If the manifold was replaced, install or connect the following:
    • Vacuum source manifold.
    • Positive Crankcase Ventilation (PCV) valve.
    • Manifold Absolute Pressure (MAP) sensor.
    • Throttle body assembly.
    • Upper-to-lower intake manifold carrier gasket to the upper intake manifold.
  2. Carefully place the upper intake manifold onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold. NOTE: Apply thread lock compound, to the bolt threads before assembly.
  3. Install or connect the following:
    • Upper intake manifold. Tighten the upper intake manifold bolts in sequence to 89 in lbs (10 Nm)
    • Accelerator and the cruise control cables with the bracket to the throttle body.
    • EVAP purge solenoid vacuum line to the throttle body.
  4. Connect the electrical connectors to the following:
    • Mass Air Flow (MAF) sensor
    • Manifold Absolute Pressure (MAP) sensor
    • Idle Air Control (IAC) valve
    • Throttle Position (T/P) sensor
    • EVAP purge solenoid
  5. Install or connect the following:
    • Throttle body upper support bracket bolt. Tighten the bolt to 89 in lbs (10 Nm)
    • EGR valve wiring harness heat shield, nut and the bolt. Tighten the nut and the bolt to 89 in lbs (10 Nm)
    • Brake booster hose to the vacuum source manifold.
    • Fuel rail assembly.
    • Right spark plug wires.
    • Air cleaner intake duct.
    • Fuel injector sight shield.
  6. Connect the negative battery cable.
  7. Fill the cooling system.
  8. Inspect for fluid or vacuum leaks.
Lower Intake Manifold (W/O Supercharger) To Remove:
  1. Remove or disconnect the following:
    • Upper intake manifold.
    • Generator brace.
    • Drive belt tensioner with the mounting bracket and the heater water bypass inlet pipe.
    • Exhaust gas recirculation EGR outlet pipe bolt from the lower intake manifold.
    • Radiator inlet hose from the water outlet housing.
    • ECT sensor electrical connector.
    • Right upper engine mount strut bracket.
    • Generator brace bracket bolts.
    • Generator brace bracket.
    • Lower intake manifold bolts.
    • Lower intake manifold.
    • Lower intake manifold seals.
    • Lower intake manifold gaskets.
  2. If replacing the lower intake manifold, Remove or disconnect:
    • Water outlet housing bolt and stud
    • Water outlet housing
    • Gasket and the thermostat.
    • ECT sensor.
  3. Inspect the flatness of inlet flanges.
  4. Clean the intake manifold mating surfaces.
  5. Clean the intake manifold bolts and bolt holes of adhesive compound.
To Install:
  1. If removed, install the ECT sensor.
    • Tighten the ECT sensor to 18 ft. lbs. (25 Nm)
  2. If removed, install the thermostat, the gasket, and the water outlet housing.
  3. If removed, install the water outlet housing bolt and the stud.
    • Tighten the bolt and stud to 20 ft. lbs. (27 Nm)
  4. Install or connect the following:
    • Lower intake manifold gaskets. NOTE: Apply sealer GM P/N 12346286 (Canadian P/N 10953472) or equivalent to the ends of the intake manifold seals.
    • Lower intake manifold seals.
    • Lower intake manifold.
    • Lower intake manifold bolts.
    NOTE: Apply thread lock compound GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the two hidden bolts and ensure they are installed.
  5. Tighten the lower intake manifold bolts in sequence to 11 ft. lbs. (15 Nm) gmpc_v6_5.gif

  6. Install or connect the following:
    • Generator brace bracket.
    • Generator brace bracket bolts. Tighten the bolts to 37 ft. lbs. (50 Nm)
    • Right upper engine mount strut bracket.
    • ECT sensor electrical connector.
    • Radiator inlet hose to the water outlet housing.
    • EGR outlet pipe to the lower intake manifold.
    • EGR outlet pipe bolt to the lower intake manifold. Tighten the bolt to 21 ft. lbs. (29 Nm)
    • Drive belt tensioner.
    • Generator brace.
    • Upper intake manifold.
  7. Inspect for leaks.
Lower Intake Manifold (W/ Supercharger) To Remove:
  1. Disconnect the negative battery cable.
  2. Drain the cooling system.
  3. Remove the supercharger.
  4. Remove the thermostat housing.
  5. Remove the EGR pipe at the intake manifold.
  6. Disconnect the electrical connection at the temperature sensor.
  7. Remove the intake manifold and gaskets.
NOTE: The coolant bypass tube will release from the intake manifold when the manifold is removed.
To Install:
  1. Clean the gasket sealing surfaces.
  2. Install the intake manifold gaskets.
  3. Align the coolant bypass tube with the opening in the intake manifold and install the manifold. Tighten the bolts to 11 lb ft (15 Nm).
  4. Install the electrical connector to the temperature sensor.
  5. Install the EGR pipe to the intake manifold.
  6. Install the thermostat housing.
  7. Install the supercharger.
  8. Fill the cooling system.
  9. Connect the negative battery cable.

Aug 05, 2010 | 1997 Pontiac Grand Prix

1 Answer

How to change the back 3 spark plugs 98 dodge caravan 3.3


you have to remove the upper intake manifold

May 14, 2010 | 1998 Dodge Caravan

1 Answer

Missing vacuum line on 2000 Dodge Caravan 3.0L


I do not have the solution for you but I will make a suggestion if you do not get an answer from someone else. Find a 2000 Dodge Caravan like yours at a used car lot and pop the hood and take a look. That may be your quickest solution.

Nov 17, 2009 | 2000 Dodge Caravan

1 Answer

Intake manifold gasket / replace


3.8L Engine

NOTE The 3.8L (VIN K) non-supercharged engine uses a two-piece intake manifold consisting of an upper air plenum which mounts the throttle body and a lower intake manifold assembly which houses the fuel injectors. The 3.8L (VIN 1) supercharged engine uses a similar lower intake manifold. The supercharger serves as the upper manifold.
Lower Manifold

NOTE Two bolts which fasten the lower intake manifold to the cylinder head are accessible only after the upper intake manifold is removed. These bolts are located in the right front and left rear corners of the lower intake manifold. Remove the upper intake manifold to service the lower intake.
The 3.8L (VIN 1) supercharged engine uses a manifold similar to the 3.8L (VIN K), but the supercharger serves as the upper manifold.
  1. Disconnect the negative battery cable.
  2. On 3.8L (VIN 1) engines, remove the supercharger assembly. Please see the procedure in this section.
  3. Remove the upper intake manifold using the procedure above.
  4. Remove the EGR outlet pipe from the intake manifold.
  5. Detach the engine coolant temperature sensor wiring harness from the sensor.
  6. Remove the lower intake manifold bolts and carefully lift off the manifold.

To install:


0900c15280269f1b.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Lower intake manifold bolt torque sequence-3.8L (VIN K) engine
  1. Clean all parts well with degreaser, especially the gasket seal surfaces on the upper and lower manifold pieces and between the lower manifold and the cylinder heads..
  2. Install new gaskets to the cylinder heads and new seals to the engine block. Carefully lower the manifold into place. Apply thread-locking compound to the bolt threads. Make sure to install the two hidden bolts in the lower intake manifold. Hand start all bolts, then torque evenly to 11 ft. lbs. (15 Nm). Follow the toque sequence, starting in the center, then working outwards in a circle.
  3. Install the remaining components in the reverse order of the removal process.

Upper Intake Manifold (Plenum)
  1. Disconnect the negative battery cable.
  2. On 3.8L (VIN 1) engines, remove the supercharger assembly. Please see the procedure in this section.
  3. Tag for identification, then remove the right side spark plug wires.
  4. Disconnect the ignition wires from the fuel rail.
  5. Remove the fuel rail. Please see Section 5.
  6. Remove the cable bracket from the intake manifold.
  7. Remove the throttle body.


NOTE Two bolts which fasten the lower intake manifold to the cylinder head are accessible are accessible only after the upper intake manifold is removed. These bolts are located in the right front and left rear corners of the lower intake manifold.
  1. Remove the upper intake manifold bolts and carefully lift the upper intake manifold from the engine.



0900c15280269f1c.jpg enlarge_icon.gifenlarge_tooltip.gif Fig. Upper intake manifold and bolt torque sequence-3.8L (VIN K) engine
To install:
  1. Clean all parts well with degreaser, especially the gasket seal surfaces on the upper and lower manifold pieces.
  2. Install new gaskets to the cylinder heads and new seals to the engine block. Carefully lower the manifold into place. Make sure to install the two hidden bolts in the lower intake manifold. Hand start all bolts, then torque evenly to 89 inch lbs. (10 Nm). Follow the torque sequence, starting in the center, then working outwards in a circle.
  3. Install the remaining components in the reverse order of the removal process.

Sep 11, 2009 | 1999 Buick Regal

1 Answer

I need to remove the upper intake manifold from my 2004 dodge intrepid 2.7 l engine to replace the water outlet from coolant system. How do I remove and replace the manifold? Will I need a new gasket?


First off, you need to label all of the electrical and vacuum lines connecting to the intake manifold. This will make reassembly much easier. Then, there is a torque sequence to be used during disassembly and reassembly.2cf4be0.gif
This image is of the TIGHTENING SEQUENCE. Reverse this to take the manifold off. This is important so that the upper intake manifold is not warped at all, which would decrease the quality of the seal. Be careful during disassembly and reassembly to avoid bending any lines or tubes. If things are in your way, disconnect them rather than pushing them to the side. This will avoid pinching inner linings which cannot be seen visually.

As for the gaskets, (as far as I am aware), Chrysler's (Dodge's) official stance on the manifold gaskets is that they are reusable. However, this is if they ALL look good under close inspection. Any tears, "melting", or other damage means the gaskets should all be replaced. They are not expensive, and I believe they all come as a set including both upper and lower gasket sets. Personally, I would recommend replacing them regardless. This would be a good preventative step to help extend the life of the vehicle. Also be sure to check the cooling line O-rings and replace them as necessary, following the criteria above.

Good luck and I hope this helps, even though I see it is a bit late.

Jul 15, 2009 | 2004 Dodge Intrepid

1 Answer

1996 dodge caravan 3.8,had egr valve replaced


you got the head gasket on upside down, or you tore the intake manifold gasket.

Jun 22, 2009 | 1996 Dodge Caravan

1 Answer

Idle is rough in gear at stop 98 caravan 3.3L


I HAVE A 96 DODGE CARAVAN WITH A 3.8L ENGINE..I HAD SIMILAR PROBLEM AND IT WAS THE UPPER INTAKE PLENUM GASKET HAD PIECE MISSING OUT OF IT..MISSING ON #5 CYLINDER AS WELL..GASKET WAS ONLY ABOUT 10 BUCKS AND I REPLACED IT IN ABOUT 30 MINUTES..TOOK ALL BOLTS OUT OF MANIFOLD AND JUST LIFTED IT UP HIGH ENOUGH TO GET OLD GASKET OUT..MIND YOU..I'M AN EXPERIENCED CHRYSLER TECH AND DO A LOT OF ENGINE WORK..SQUIRT SOME BRAKE CLEANER AROUND UPPER INTAKE AND SEE IF ENGINE SMOOTHES OUT..LET ME KNOW WHAT HAPPENS

Jun 13, 2009 | 1998 Dodge Caravan

1 Answer

Where is the thermostat located?


  1. Disconnect the negative battery cable.
  2. Place a drain pan under the radiator drain and drain the cooling system to just below the thermostat level. Close the drain.
  3. Remove the upper radiator hose from the thermostat housing, then remove the housing.
  4. Remove the thermostat and discard the gasket. 0900c15280042100.jpgThermostat installation detail—3.0L engine 0900c15280042101.jpgThermostat installation detail—3.3L and 3.8L engines
To install:
  1. Clean the housing mating surfaces.
  2. Dip the new gasket in clean water and place it on the water box surface.
  3. Center the thermostat on the gasket, in the water box. 0900c15280042102.jpgRemove the radiator hose from the waterneck by loosening the hose clamp . . . 0900c15280042103.jpg. . . then loosen and remove the waterneck housing retaining bolts
  4. Make certain the bolt threads are clean. Threaded bolt holes exposed to coolant are subject to corrosion and should be cleaned with a small wire brush or correct size thread-cutting tap. Install the housing, making sure the thermostat is still in the recess, and tighten the retaining bolts to 105 inch lbs. (12 Nm) for 3.0L engine or to 21 ft. lbs. (28 Nm) for 3.3L and 3.8L engines. Reconnect the upper radiator hose and tighten the hose clamp.
  5. Connect the negative battery cable.
  6. Fill and bleed the engine cooling system with a clean 50/50 mixture of ethylene glycol antifreeze and water. 0900c15280042104.jpgLift the waterneck housing off of the lower intake manifold, then . . . 0900c15280042105.jpg. . . remove the thermostat out of its mounting flange
  7. Make sure the radiator is full and start the vehicle

Jan 09, 2009 | 2002 Dodge Caravan

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