We have a 1998 Dodge Grand Caravan and it is having problems starting. We wonder if it is a computer problem as the fuel gauge remains on empty even when we know it has a full tank of gas. The digital mileage indicator doesn't light up either but the lights inside of the van work and the radio works. Under the hood, the intake manifold was extremely hot.
This is so frustrating and it has happened to us twice in the last week.
The question is --Why is the intake manifold extremely hot?
intake manifolds have cold air running through them so any heat there indicates a major problem
determine why and you will be on the way to figuring out the fix
As a pointer
The EGR valve is used to recirculate exhaust gas back into the induction system to lower the burn temperature and to burn of unused gas content
it is very possible that the unit is malfunctioning and that is why the inlet is so hot
run the fault codes to determine the area to fix
SOURCE: 98 dodge caravan problems
I had the same issue with my dodge caravan and after several attempts by the dealer to fix it, it turned out to be a broken wire. They replaced the relay and it would work for a while and then go blank again. Have the wires checked thoroughly.
SOURCE: Broken bolt housing for thermostat gooseneck cover on intake mani
Hello, The only thing you can do is weld the broken area and the drill and tap the hole.
Go to http://www.durafix.com/ and they have a solution for you. Good luck and let me know how you make out.
SOURCE: does the upper intake manifold have to be torqued
No, but it is a real good idea. I would,it keeps you from breaking stuff.
SOURCE: 1993 Dodge Caravan - 207,000 kms
Hi, concerning the left turn signal, this is caused by a faulty or defective flasher relay switch. this is easily replaced and once replaced with a new relay, it will fix this erratic flashing issue you are having. Now, concerning the gas gauge issue. the reason for the non response here is because of a malfunctioning sending unit that is located inside the actual tank. it is part of the fuel pump assembly and it will need to be replaced.
OK, this is concerning the dead radio issue. i would first check the fuse to see if it is ok. if the radio fuse is fine, this will more than likely be an internal circuit issue within the radio itself and, you will have to replace the factory radio. most factory radio systems tend to get really hot and this is not good. it usually ruins the internal circuit board in time, completely rendering the radio useless. i would still make sure the fuse is good. it could be as simple as a blown radio fuse. i will post a step by step guide below that will help you replace the flasher relay.
FLASHER RELAY SWITCH REPLACEMENT GUIDE--
Step1
Locate the fuse box under the dash on the driver's side of the Caravan. Look near the emergency brake.
The fuse box cover has two finger screws that you should loosen to
remove the cover. Inside you will see a collection of fuses and in the
upper right corner a few relays.
Step2
Find the turn signal hazard flasher relay in the upper right corner of
the fuse box. It should be easy to spot as it is the biggest of the
relays in the box. Remove the relay and replace it into the socket from
which you just pulled the bad relay. The placement into the socket is
tight and can be difficult, but be patient and take your time.
Step3
Look to make sure it ended up in the correct position. Close the fuse
cover and tighten the finger screws. Start the Caravan and test all the
light functions. Make sure that the turn lights blink and that the
hazard lights work properly.
Please rate and god bless:)
SOURCE: What are the torque specs in lbs for cam, exhaust
cam sprocket is 250 in. lbs. cam tensioner and bearing caps are 105 in. lbs. exhuast manifold is 200 in. lbs. intake is 105 in. lbs
connect into the distributor cap. If you don't see a distributor, you may have a model with a distributorless ignition system.
Step2
Find the ignition coil. On a Dodge Caravan,
the ignition coil is at the back of the intake manifold. Disconnect the
negative battery cable to prevent injury while you work.
Step3
Determine whether you need to remove the windshield wiper/motor module assembly. This won't be necessary on all models.
Step4
Disengage the connector securing the wiring harness connector to the Dodge Caravan ignition coil. Then, disconnect the ignition wire from the ignition coil.
Step5
Use a socket set to remove the mounting bolts. There are upper and
lower mounting bolts. Separate the ignition coil from the mounting
bracket.
Install the New Ignition Coil
Step1
Insert the new ignition coil. Mount the Dodge Caravan ignition coil to the mounting bracket.
Step2
Attach the mounted assembly to the intake manifold. With a Torque
wrench, tighten the fasteners securing the ignition coil to the
mounting bracket with 96 inch pounds of torque (10 Nm).
Step3
Tighten the bolts that secure the intake manifold to the bracket with 115 inch pounds of torque (13 Nm).
Step4
Connect the wire harness and any other parts you removed, including the negative battery cable.
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