Chrysler Dodge Caravan 2002 Manual page 1263

9 - 62 ENGINE 2.4L
INTAKE MANIFOLD - LOWER (Continued)
Fig. 109 Lower Intake Manifold Support Bracket
1 - SUPPORT BRACKET
2 - BOLTS - UPPER TO MANIFOLD
3 - BOLT - LOWER TO ENGINE BLOCK
• Coolant outlet connector bolts - 28 N·m (250 in.
lbs.)
• Coolant temperature sensor - 7 N·m (60 in. lbs.)
(1) Position a new gasket on cylinder head and
install lower manifold.
(2) Install and tighten intake manifold fasteners to
28 N·m (250 in. lbs.) in the sequence shown in (Fig.
110). Repeat procedure until all bolts are at specified
torque.
Fig. 110 Lower Intake Manifold Tightening Sequence
(3) Install lower intake manifold support bracket
bolts (Fig. 109) and tighten to:
• Bolts to intake 28 N·m (250 in. lbs.)
• Bolt to engine block 54 N·m (40 ft. lbs.)
(4) Position power steering reservoir on manifold
and install bolts.
(5) Connect the fuel line. (Refer to 14 - FUEL SYS-
TEM/FUEL DELIVERY/QUICK
TING - STANDARD PROCEDURE)
(6) Connect coolant temperature sensor/fuel injec-
tor wiring harness electrical connector.
(7) Install the radiator upper and heater supply
hoses.
(8) Install the upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE
INSTALLATION)
(9) Fill the cooling system. (Refer to 7 - COOLING
- STANDARD PROCEDURE)
EXHAUST MANIFOLD
DESCRIPTION
The exhaust manifold is made of Hi-Silicone Moly
nodular cast iron for strength and high tempera-
tures. The manifold attaches to the cylinder head.
OPERATION
The exhaust manifold collects the exhaust gasses
exiting the combustion chambers. Then it channels
the exhaust gasses to the exhaust pipe attached to
the manifold.
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
the exhaust manifold.
(2) Disconnect upstream oxygen sensor connector
at the rear of exhaust manifold.
(3) Remove the bolts attaching the manifold to the
cylinder head.
(4) Remove exhaust manifold.
(5) Inspect the manifold. (Refer to 9 - ENGINE/
MANIFOLDS/EXHAUST MANIFOLD - INSPEC-
TION)
CLEANING
(1) Discard gasket (if equipped) and clean all sur-
faces of manifold and cylinder head.
INSPECTION
(1) Inspect manifold gasket surfaces for flatness
with straight edge. Surface must be flat within 0.15
mm per 300 mm (0.006 in. per foot) of manifold
length.
(2) Inspect manifolds for cracks or distortion.
Replace manifold as necessary.
INSTALLATION
(1) Install exhaust manifold with a new gasket.
Tighten attaching nuts in the sequence shown in
(Fig. 111) to 19 N·m (170 in. lbs.).
RS
CONNECT FIT-
MANIFOLD -