After i discovered oil inside the tubes when trying to replace the spark plugs on my parents' 2000 Dodge Caravan 2.4L, I know it needs a new valve cover gasket and spark plug tube seals. Now I come from Hondas and Mitsubishis so replacing those is easy, but on this the intake manifold is in the way which adds an otherwise easy job to be more troublesome.

Is there a proper DIY on replacing the valve cover gaskets and tube seals on this thing? Been trying to find it but to no avail.

 

CYLINDER HEAD COVER

REMOVAL

1. Remove upper intake manifold. Refer to procedure in this section.
2. Remove nuts attaching front and rear intake manifold supports from cylinder head cover attaching studs.
3. Remove ignition coil pack and plug wires (Ignition Coil and Ground Strap) Remove ground strap.
4. Remove the cylinder head cover fasteners.
5. Remove cylinder head cover from cylinder head.

INSTALLATION

NOTE: Replace spark plug well seals when installing a new cylinder head cover gasket.

1. Clean all sealing surfaces.
2. Install new cylinder head cover gaskets and spark plug seals (Cylinder Head Cover Gasket and Spark Plug Seals) CAUTION: Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping.
3. Apply Mopar® Engine RTV GEN II at the camshaft cap corners and at the top edge of the 1/2 round seal.
4. Install cylinder head cover assembly to head and tighten fasteners in sequence shown in Cylinder Head Cover Tightening Sequence. Using the 3 step torque method:
   1. Tighten all fasteners to 4.5 N·m (40 in. lbs.)
   2. Tighten all fasteners to 9.0 N·m (80 in. lbs.)
   3. Tighten all fasteners to 12 N·m (105 in. lbs.)
5. Install ignition coil pack and plug wires. Tighten fasteners to 12 N·m (105 in. lbs.)
6. Install ground strap.
7. Install front and rear intake manifold support brackets and attaching nuts, but do not tighten at this time.
8. Install upper intake manifold. Refer to procedure in this section.
9. Final torque intake manifold support nuts to 28 N·m (250 in. lbs.)

INTAKE MANIFOLD - UPPER

REMOVAL

1. Disconnect negative cable from battery.
2. Disconnect air intake tube and resonator box from throttle body and remove.
3. Remove connector from throttle position sensor (TPS) Throttle Body Electrical Connectors
4. Remove connector from idle air control (IAC) motor Throttle Body Electrical Connectors
5. Remove connector from MAP sensor Intake Manifold Front Support Bracket and Map Sensor
6. Remove vacuum lines for purge solenoid and PCV valve at intake manifold Vacuum Line Connections
7. Remove vacuum lines for power brake booster and speed control vacuum reservoir at upper intake manifold fittings Vacuum Fitting at Rear of Upper Intake Manifold
8. Remove throttle cable and speed control cable (if equipped) from throttle lever Throttle Cable Attachment to Throttle Body
9. Remove throttle cables from bracket by compressing retaining tabs.
10. Remove two top bolts from intake manifold to rear support bracket and EGR tube Intake Manifold Rear Support Bracket
11. Remove upper bolt from intake manifold to front support bracket Intake Manifold Front Support Bracket and Map Sensor
12. Remove dipstick.
13. Remove dipstick tube CAUTION: Moving the dipstick tube will cause damage to the sealer, causing an oil leak. Dipstick tube must be sealed at cylinder block.
14. Remove upper intake manifold bolts. Remove upper intake manifold CAUTION: Cover intake manifold to prevent foreign material from entering engine.

INSTALLATION

1. Install new upper intake manifold gasket NOTE: Center outboard fastener is a double stud.
2. Tighten upper intake manifold fasteners starting at center and progressing outward in both directions. Tighten bolts to 28 N·m (250 in. lbs.) Repeat this procedures until all fasteners are at specified torque.
3. Install dipstick tube. Seal tube to cylinder block using Mopar® Stud & Bearing Mount Adhesive. Tighten dipstick tube fastener to 12 N·m (105 in. lbs.)
4. Install dipstick.
5. Install upper bolt in intake manifold to front support bracket Intake Manifold Front Support Bracket and Map Sensor Torque to 28 N·m (250 in. lbs.)
6. Install a new EGR tube gasket at intake manifold connection.
7. Install two upper bolts at intake manifold to rear support bracket and EGR tube Intake Manifold Rear Support Bracket Tighten bolts to 28 N·m (250 in. lbs.)
8. Install throttle cables in bracket.
9. Install throttle cable and speed control cable (if equipped) to throttle lever.
10. Install vacuum lines for power brake booster and speed control vacuum reservoir at upper intake manifold fittings.
11. Install vacuum lines for purge solenoid and PCV valve.
12. Install electrical connectors for MAP sensor, throttle position sensor (TPS), and idle air control (IAC) motor.
13. Install air intake tube and resonator box to throttle body.
14. Connect negative cable to battery.