2003 Dodge Grand Caravan 3.3 - Intake Manifold Gaskets Replaced

[Number_35]

This is related to my previous thread about struggling to disconnect the fuel line:

https://bobistheoilguy.com/forums/t...onnect-the-fuel-line-at-the-fuel-rail.384767/

The job went fairly well. I was dismayed by the high idle (c. 1200 RPM) after I finished, and went through all sorts of double-guessing my work. It turned out to be a vacuum line on the back (firewall side) of the upper intake manifold.

Pretty good access with the cowl off

And now the upper section, or plenum, is off.

And here's the lower intake manifold.

Here's a close-up of that problematic connector. I disconnected it farther upstream instead. I plan to replace this section of hose soon. An iffy connector is scary.

Here we are in the valley. Yuck!

And here's the valley with the gasket removed.

And here's the old gasket on its own.

This is the PCV valve. It would not come out. Because we only have the one vehicle, I wanted to minimize downtime, otherwise would have tried to get valve cover gaskets, remove the valve cover, and try to knock it out from inside. So it goes.

 

[2009Caraman]

I did this twice on my 2009 carava 3.3l. The 2nd time was because I didnt use enough rtv on that little seam. It leaked 2 days later. I hope you did.

 

[RAR]

You can’t get to it from inside the valve cover. There’s a piece that covers it from inside.

You either need to find a tool that can extract it by pulling it out straight up or replace the valve cover with new. These need doing on the bench to be done properly. The valve cover plastic is brittle after all the heat cycles and one wrong step and you’ll need to replace it anyway,

The replacement from Mopar comes with the new PCV installed. It’s what I did on a 3.8 in my nieces 2008 Chrysler. They aren’t horribly expensive.

Edit: I’d also change that PCV hose as well. Those get hard as a rock and will crack, making for a leak. The hose from Mopar isn’t expensive either.

 

[Number_35]

I did this twice on my 2009 carava 3.3l. The 2nd time was because I didnt use enough rtv on that little seam. It leaked 2 days later. I hope you did.

I hope I did! Time will tell.

 

[Number_35]

You can’t get to it from inside the valve cover. There’s a piece that covers it from inside.

You either need to find a tool that can extract it by pulling it out straight up or replace the valve cover with new. These need doing on the bench to be done properly. The valve cover plastic is brittle after all the heat cycles and one wrong step and you’ll need to replace it anyway,

The replacement from Mopar comes with the new PCV installed. It’s what I did on a 3.8 in my nieces 2008 Chrysler. They aren’t horribly expensive.

Edit: I’d also change that PCV hose as well. Those get hard as a rock and will crack, making for a leak. The hose from Mopar isn’t expensive either.

Should the PCV valve have a check valve in it, or is it just a metered orifice?

I put a section of hose on it, and was able to both blow and suck. If it is supposed to be one-way, it's not working right.

You're absolutely right, the PCV hose is very hard.

 

[Number_35]

Yesterday was hot (c. 30°C/86°F) and humid, and in late afternoon I was driving slowly in stop-and-go rush hour traffic, with the AC running. The ScanGauge reported 96°C (205°F).

I was pleased - before the repair, and under similar conditions, the coolant temperature would climb to 105°C (221°F).