07 3.8L Grand Caravan Intake Gasket Replacement

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Dec 9, 2013 | 07:31 PM
  #1  
Anyone have a good set of instructions for Removal and Replacement of the Intake Manifold Gasket for a 2007 Grand Caravan with the 3.8L Engine?

Just started leaking fluid to the outside of the Engine Block. Does not appear to be an internal leak.
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Dec 10, 2013 | 12:33 AM
  #2  
Engine, 3.3L/3.8L/Manifolds/MANIFOLD, Intake, Lower/Removal

REMOVAL - LOWER INTAKE MANIFOLD.
1. Perform fuel system pressure release procedure (before attempting any repairs).
2. Drain the cooling system.
3. Remove the upper intake manifold.
4. Remove the fuel line.
5. Remove ignition coil and bracket.
6. Disconnect heater supply hose and engine coolant temperature sensor.
7. Disconnect the fuel injector wire harness.
8. Remove the fuel injectors and rail assembly.
9. Remove radiator upper hose.
10. Remove the intake manifold bolts.
11. Remove lower intake manifold.
WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE PERSONAL INJURY, HANDLE WITH CARE.
12. Remove intake manifold seal retainers screws. Remove intake manifold gasket.
13. Inspect and clean manifold.
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Dec 10, 2013 | 09:09 AM
  #3  
Excellent,

Can you also provide the procedure for releasing the fuel system pressure?

I've not done this before.

Thanks
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Dec 10, 2013 | 10:13 AM
  #4  
It should be a quick release. Push in and pull the black ring back and pull. Watch out for gas pressure.
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Dec 14, 2013 | 09:28 AM
  #5  
Headed out the garage in a bit, start tearing things down to replace the gasket. Is there any need for Silicone or Permatex when installing the new gasket.
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Dec 14, 2013 | 04:01 PM
  #6  
Link for Bolt Torque Sequence and Torques if anyone wants to know.

http://www.justanswer.com/dodge/4zvs...-03-dodge.html
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