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1 ALLDATA Online Dodge Truck Grand Caravan FWD V6-3.3L VIN R - Intake M... Page 1 of 10 REMOVAL 1. Remove windshield wiper module. 2. Perform fuel system pressure release procedure (before attempting any repairs).. 3. Drain the cooling system-only if lower intake manifold is to be removed. Refer to Cooling System for procedure. 4. Remove air inlet resonator to throttle body hose assembly. 5. Remove throttle cable.. 6. Remove wiring harness from throttle cable bracket. Fig Remove automatic idle speed (AIS) motor and throttle position sensor (TPS) wiring connectors from throttle body (Fig. 41). 8. Remove EGR transducer connector. 9. Remove vacuum hose harness from throttle body (Fig. 41). 10. Remove PCV and brake booster hoses from air intake plenum.
2 ALLDATA Online Dodge Truck Grand Caravan FWD V6-3.3L VIN R - Intake M... Page 2 of 10 Fig Disconnect MAP Sensor electrical connection (Fig. 42). 12. Remove EGR tube flange from intake plenum. 13. Remove vacuum harness connectors from intake plenum (Fin 42).
3 ALLDATA Online Dodge Truck Grand Caravan FWD V6-3.3L VIN R - Intake M... Page 3 of 10 Fig Remove cylinder head to intake plenum strut (Fig. 43). 15. Remove the engine mounted ground strap. Fig Remove the fuel hose quick connect fitting from the fuel line by using an open end wrench pushing in on the plastic ring located on the end of the fittings. Gently pull the fitting from the fuel line (Fig. 44). WARNING: WRAP A SHOP TOWEL AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE DURING REMOVAL.
4 ALLDATA Online Dodge Truck Grand Caravan FWD V6-3.3L VIN R - Intake M... Page 4 of 10 Fig Remove direct ignition system (DIS) coils and generator bracket to intake manifold bolt (Fig. 45). Fig. 46
5 ALLDATA Online Dodge Truck Grand Caravan FWD V6-3.3L VIN R - Intake M... Page 5 of Remove bolts from generator to intake manifold bracket. Loosen top generator mounting bolt, and move bracket up so intake manifold can clear mounting studs (Fig. 46). 19. Remove intake manifold bolts and remove the manifold (Fig. 46). Fig Cover intake manifold with suitable cover when servicing (Fin. 47). 21. Remove fuel tube retainer bracket screw and fuel rail attaching bolts (Fig. 47). Spread the retainer bracket to allow fuel tube removal clearance.
6 ALLDATA Online Dodge Truck Grand Caravan FWD V6-3.3L VIN R - Intake M... Page 6 of 10 Fig Disconnect cam sensor and coolant temperature sensor (Fig. 48). 23. Remove fuel injector wiring clip from intake manifold water tube.
7 ALLDATA Online Dodge Truck Grand Caravan FWD V6-3.3L VIN R - Intake M... Page 7 of 10 Fig Remove fuel rail. Be careful not to damage the rubber injector O-rings upon removal from their ports (Fig. 49).
8 ALLDATA Online Dodge Truck Grand Caravan FWD V6-3.3L VIN R - Intake M... Page 8 of 10 Fig Remove upper radiator hose, bypass hose and rear intake manifold hose (Fig. 50). 26. Remove intake manifold bolts. Remove intake manifold. 27. Inspect and clean manifold. Refer to Cleaning and Inspection for procedures. WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE PERSONAL INJURY, HANDLE WITH CARE. Fig Remove intake manifold seal retainers screws (Fig. 51). Remove into intake manifold gasket. INSTALLATION 1. Clean all surfaces of cylinder block and cylinder heads.
9 ALLDATA Online Dodge Truck Grand Caravan FWD V6-3.3L VIN R - Intake M... Page 9 of 10 Fig Place a drop (approximately 1/4 in. diameter) of Mopar Engine RTV GEN II onto each of the four manifold to cylinder head gasket corners (Fig. 52). 3. Carefully install the new intake manifold gasket (Fig. 51). Torque end seal retainer screws to 12 Nm (105 in. lbs.). 4. Install intake manifold and bolts and torque to 1 Nm (10 in. lbs.). Then torque bolts to 22 Nm (200 in. lbs.) in sequence shown in (Fig. 50). Then torque again to 22 Nm (200 in. lbs.). After intake manifold is in place, inspect to make sure seals are in place. 5. Make sure the injector holes are clean and all plugs have been removed. 6. Lube injector O-ring with a drop of clean engine oil to ease installation. 7. Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports (Fig. 49). 8. Install the fuel rail attaching bolts and torque to 22 Nm (200 in. lbs.) (Fig. 47). 9. Install fuel tube retaining bracket screw and torque to 4 Nm (35 in. lbs.) (Fig. 47). 10. Connect cam sensor and coolant temperature sensor (Fig. 48). 11. Remove covering on lower intake manifold and clean surface. 12. Position the new intake manifold gasket on lower manifold. Install upper manifold into place and tighten bolts and nuts only finger tight, at this time. NOTE: At no time should the studs be replaced with a bolt and washer. 13. Install the generator bracket to intake manifold bolt and the cylinder head to intake manifold strut bolts. (Do not torque.) 14. Torque intake manifold bolts to 28 Nm (250 in. lbs.) following torque sequence in (Fig. 46). 15. Torque generator bracket to intake manifold bolt to 54 Nm (40 ft. lbs.). 16. Torque the cylinder head to intake manifold strut bolts to 54 Nm (40 ft. lbs.)
10 ALLDATA Online Dodge Truck Grand Caravan FWD V6-3.3L VIN R - Intake... Page 10 of 10 (Fig. 43). 17. Connect ground strap and MAP sensor electrical connector. 18. Connect vacuum harness to intake plenum (Fig. 42). 19. Using a new gasket, connect the EGR tube flange to the intake manifold and torque to 22 Nm (200 in. lbs.). 20. Clip wiring harness into the hole in the throttle cable bracket. 21. Connect the wiring connectors to the throttle position sensor (TPS) and Automatic Idle Speed (AIS) motor (Fig. 41). 22. Connect vacuum harness to throttle body (Fig. 41). 23. Install the direct ignition system (DIS) coils. Torque fasteners to 12 Nm (105 in. lbs.) (Fig. 45). 24. Lubricate the end of the chassis fuel tube with 30 WT. oil. Connect fuel supply hose to chassis fuel tube assembly. Pull back on the quick connect fitting to ensure complete insertion (Fig. 44). 25. Install throttle cable Connect fuel injector wiring harness. 27. Install air cleaner and hose assembly. 28. Connect negative battery cable. 29. If drained, fill cooling system. Refer to Cooling System for procedure. 30. With the DRB Scan Tool use ASD Fuel System Test to pressurize system to check for leaks. CAUTION: When using the ASD Fuel System Test, The Auto Shutdown (ASD) Relay will remain energized for 7 minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected. 31. Install windshield wiper module.
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Page 1 of 31 Evan Groenke From: Daniel Lelovic [dlelovic@rogers.com] Sent: May 8, 2005 12:06 PM To: 'Evan Groenke' Subject: 2.5 L Engine Disassembly SECTION 303-01B: Engine 2.5L 2000 Contour/Mystique Workshop
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303-01A-1 DISASSEMBLY Engine Special Tool(s) Remover, Crankshaft Vibration Damper 303-101 (T74P-3616-A) Special Tool(s) Crankshaft Socket 303-674 303-01A-1 Remover, Crankshaft Vibration Damper 303-773
M-9424-M50CJ INTAKE MANIFOLD INSTALLATION INSTRUCTIONS
Please visit www.fordracingparts.com for the most current instruction information!!! PLEASE READ ALL OF THE FOLLOWING INSTRUCTIONS CAREFULLY PRIOR TO INSTALLATION. AT ANY TIME YOU DO NOT UNDERSTAND THE
Page 1 of 6 Section 03-01C: Engine, 7.5L MFI 1996 Bronco/F-Series Workshop Manual IN-VEHICLE SERVICE Procedure revision date: 06/19/2000 Cylinder Heads Removal SPECIAL SERVICE TOOL(S) REQUIRED Description
Engine Remove and Install ( ) Remove. Section Title. Special Tools. Workshop Equipment Trolley jack A Engine lifting tackle
Engine Remove and Install ( 4 0) Special Tools 068A 068A0-068A Engine lifting tackle -068A-0 Lifting eyebolts Workshop Equipment Trolley jack Materials High-temperature grease ESDM-C0-A Proprietary Tools
Vehicle Level Engine, Cooling and Exhaust Engine Intake Manifold Service and Repair. Service and Repair
Page 1 of 11 Home Account Contact ALLDATA Log Out Help BILL SEIDLES MITSUBISHI Select Vehicle New TSBs Technician's Reference Component Search: OK 2005 Suzuki Verona L6-2.5L Conversion Calculator Vehicle
EXHAUST GAS RECIRCULATION (EGR) SYSTEM
ENGINE EG169 EXHAUST GAS RECIRCULATION (EGR) SYSTEM (California only) EG170 ENGINE To reduce NOx emissions, part of the exhaust gases are recirculated through the EGR valve to the intake manifold to lower
Included: 2. Intake Block Off Plates 1. Exhaust Block Off Plate 1. Coolant Hose - Reroutes the EGR Cooler Coolant 12. Pieces of mounting hardware -
Included: 2. Intake Block Off Plates 1. Exhaust Block Off Plate 1. Coolant Hose - Reroutes the EGR Cooler Coolant 12. Pieces of mounting hardware - Nuts, Bolts, & Washers 2. Hose Clamps 1. Support Bracket
ENGINE AND EMISSION CONTROL
17-1 ENGINE AND EMISSION CONTROL CONTENTS EMISSION CONTROL SYSTEM... 2 GENERAL... 2 Outline of Changes... 2 GENERAL INFORMATION... 2 SERVICE SPECIFICATION... 2 VACUUM HOSE... 3 Vacuum Hose Piping Diagram...
CYLINDER HEAD GASKET (2AZ-FE)
190 REPLACEMENT 1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT (See page 111 ) 2. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER) 3. REMOVE CHAIN SUBASSY (See page
2006 Honda Civic SI Supercharger Kit Installation Instruction Kit #
2006 Honda Civic SI Supercharger Kit Installation Instruction Kit #350-091 3239 MONIER CIRCLE, STE.5 RANCHO CORDOVA, CA 95742 916.635.4550 FAX 916.635.4632 www.ct-engineering.com INS-157 VERSION: 3.25.2009
Page 1 of 5 2004 Pontiac GRAND PRIX Submodel: Engine Type: V6 Liters: 3.8 Fuel Delivery: FI Fuel: GAS Oil Pan Replacement Removal Procedure Disconnect the negative battery cable. Refer to Battery Negative
2002 Explorer Sport/Sport Trac Workshop Manual
Page 1 of 17 SECTION 303-01: Engine 4.0L Single Overhead Camshaft (SOHC) IN-VEHICLE REPAIR Procedure revision date: 07/13/2005 Cylinder Head Special Tool(s) Spark Plug Wire Remover 303-106 (T74P-6666-A)
Fuel System Diagnosis
Page 1 of 6 2001 Chevrolet Express Express, Savana (VIN G) Service Manual Engine Engine Controls - 5.0L and 5.7L Diagnostic Information and Procedures Document ID: 720867 Fuel System Diagnosis Circuit
EXHAUST GAS RECIRCULATION (EGR) SYSTEM (4A FE)
ENGINE EG121 EXHAUST GAS RECIRCULATION (EGR) SYSTEM (4AFE) EGR SYSTEM INSPECTION 1. INSPECT AND CLEAN FILTER IN EGR VACUUM MODULATOR (a) Remove the cap and filter. (b) Check the filter for contamination
ENGINE AND EMISSION CONTROL
17-1 ENGINE AND EMISSION CONTROL CONTENTS ENGINE CONTROL SYSTEM........ 3 SERVICE SPECIFICATION............... 3 ON-VEHICLE SERVICE.................. 3 Accelerator Cable Check and Adjustment... 3 ACCELERATOR
* PLEASE READ INSTRUCTIONS PRIOR TO INSTALLATION *
XDP Duramax LBZ EGR Race Track Kit Item Number: XD165 PACKING LIST: 1 LBZ EGR Plate for Up Pipe 5 M8x1.25-20mm Bolt 2 M10x1.5 Flange Hex Nut 1 LBZ EGR Plate for Intake 1 M8x1.25-45mm Bolt 1 M8x1.25 Flange
EG2 173 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
5SFE ENGINE EG2173 EXHAUST GAS RECIRCULATION (EGR) SYSTEM EG2174 5SFE ENGINE EGR SYSTEM INSPECTION 1. INSPECT AND CLEAN FILTER IN EGR VACUUM MODULATOR (a) Remove the cap and filter. (b) Check the filter
This information covers the proper replacement procedure for the EGR valve on the Volvo D16F engine.
Volvo Trucks North America Greensboro, NC USA EGR Valve, Replacement DService Bulletin Trucks Date Group No. Page 11.2006 254 24 1(17) EGR Valve Replacement D16F W2005772 This information covers the proper