How to Replace the Intake Manifold in a Dodge Caravan

by Editorial TeamUpdated November 07, 2017

Items you will need

  • Mechanic's toolset

  • Shop rags

How to Replace the Intake Manifold in a Dodge Caravan. Dodge revolutionized family transportation by introducing the Caravan. It was the first minivan, which inspired competition from virtually every auto maker. The Caravan has consistently forged new territory for minivans, and was the first to offer individual and double sliding doors. The 3.0L engine was the most popular from 1984 through 1988. For several years, it was regarded the most versatile and pleasant-to-drive and consistently topped sales charts.

Remove the Intake Manifold

Disconnect the negative battery cable from the battery. Release the pressure in the fuel system and drain the cooling system.

Remove the air cleaner, the throttle cable and the transaxle kickdown cable. Pull the vacuum and the electrical connections from the throttle body, and remove the air intake hose that runs from the air cleaner to the throttle body.

Locate the charge temperature and the coolant temperature sensor electrical connections and remove them. Remove the vacuum hose from the pressure regulator and the air connection from the intake manifold.

Loosen and remove the air intake plenum-to-manifold bolts. Take out the air intake plenum and the gasket.

Separate the fuel injector wiring harness from the engine wiring harness and disconnect it. Take off the pressure regulator attaching bolts and lift the pressure regulator from the rail.

Take the radiator hose from the thermostat housing and the heater hose from the pipe. Remove the intake manifold nuts and washers. Remove the intake manifold.

Clean the cylinder head and the manifold gasket surface. Check the surface for cracks or damage.

Install the Intake Manifold

Install a new gasket on the cylinder head intake surface and then install the intake manifold. Set the washers and nuts in place and tighten in sequence using the 17 foot pounds.

Use a drop of clean engine oil to clean the injectors and to lubricate the O-rings. Position the tip of each injector into the correct port. Push the assembly into place to seat the injectors.

Install the rail attaching bolts. Tighten them to 115 inch pounds. Install the pressure regulator to the rail and tighten the mounting bolts to 95 inch pounds. Connect the fuel supply and the return tube holddown bolt. Install the vacuum crossover tube hold-down bolt. Torque both to 95 inch pounds.

Connect the fuel pressure regulator hose and torque the clamps to 10 inch pounds. Connect the injector wiring harness to the engine wiring harness, then connect the vacuum harness to the fuel rail and the pressure regulator.

Uncover the manifold and set the gasket on the manifold, beaded side up. Place the plenum over the manifold. Set the bolts in place and tighten in sequence to 115 inc. lbs.

Reconnect the fuel line to the fuel rail and torque the clamps to 10 in. lbs. Connect the vacuum hoses, the electrical connections to the charge temperature sensor and the coolant temperature sensor, the EGR rube to the plenum, the throttle body vacuum hoses and electrical connections.

Attach the throttle cable and the kickdown linkage as well as the radiator and heater hose. Refill the cooling system with the appropriate amount and type of coolant. Connect the negative battery cable to the battery.


Before starting Step 5, cover the intake manifold to assure that foreign objects do not enter it.


Be aware that dogs and cats will drink coolant left in open containers or puddled on the floor. Ingestion is often fatal. Drain coolant into a container that can be sealed. Reuse the coolant unless it is contaminated or several years old.

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