How to Replace the Intake Manifold in a Chrysler Town & Country

The new 2008 Chrysler Town and Country LX offers a 3.3L V6 engine with 175 horsepower and a four-speed automatic transmission. The Touring model features a 3.8L V6 and a six-speed automatic transmission. Both engines are carried over from previous generations and were widely available from 1981 through 1992. Removing and installing the intake manifold in these two engines follows the same procedure.

Instructions

Remove the Intake Manifold

1

Remove the hose between the air cleaner and the throttle body, then disconnect the throttle cable. Remove the wiring harness from its bracket.

2

Pull the PCV and brake booster hoses from the air intake plenum. Disconnect the charge temperature sensor electrical connector and the vacuum harness connectors.

3

Lift out the plenum strut. Disconnect the MAP sensor and the oxygen sensor connectors, then pull the ground strap. Take the fuel hoses off the fuel rail. Use golf tees to plug the hoses to avoid fuel spillage.

4

Loosen and remove the upper intake manifold bolts and lift off the upper manifold. Pull the vacuum harness connector and remove the fuel tube retainer bracket screw and the fuel rail bolts.

5

Disconnect the cam sensor and remove the fuel rail injector wiring clip from the alternator bracket. Disconnect the coolant sensor and the engine temperature sensor. Take out the fuel rail.

6

Locate the upper radiator hose, the bypass hose and the rear intake hose and remove them. Loose and remove the manifold bolts and lift the manifold from the engine.

7

Take out the intake manifold seal retaining screws. Remove the gasket. Clean any clogged end water passage and all the fuel runners.

Install the Intake Manifold

8

Clean all the gasket mating surfaces and dry them. Use a drop of silicone sealer on each of the head gasket corners. Install the gasket and torn the end retains to 10 foot pounds.

9

Place the intake manifold on the engine and torque the bolts in sequence to 10 inch pounds on the first pass. Repeat the sequence and increase the torque to 17 foot pounds. Recheck each bolt for 17 foot pounds. Check the seals to make sure they are in place after the bolts are torqued.

10

Use clean engine oil to lubricate the injector O-rings. Put the fuel rail in place and install the bolts. Reconnect the cam sensor, the coolant temperature sensor and the engine temperature. Replace the fuel rail injector wiring clip to the alternator bracket.

11

Install the vacuum harness, then install the upper intake manifold with a new gasket. Set the bolts on and finger-tighten them.

12

Torque the mounting bolts to 21 foot pounds in sequence, starting at the center and working out in a criss-cross pattern. Torque the bracket bolts and strut bolts to 40 foot pounds.

13

Reconnect or install everything that was previously removed from the intake manifold and the throttle body. Connect the fuel hoses and push the fittings into place.

14

Install the air cleaner assembly. Connect the negative battery cable. Start the engine and check for oil, fuel or vacuum leaks.