2005 Chrysler T&C - Replacing Valve Cover Gaskets along with Upper and Lower Intake Manifold Gaskets. Shows the removal of the windshield wiper cowl. Trouble changing the PCV valve. New spark plugs and plug wires. 3.8L +++++++++++ DISASSEMBLY PROCEDURE: a OPTIONAL-Remove Cowl and windshield wiper motor assembly from fire wall (If replacing valve cover gaskets) b Remove the windshield wiper arms using a puller. Note angle and which one is "on top" c Disconnect the plug for the wiper motor d Disconnect the Windshield Washer Fluid tube going into the cowl e Loosen the two clamps holding the two drain tubes to the wiper motor assembly f Turn the two Philips head "locks" 90 degrees. These lock the cowl trim to the wiper motor assembly g Remove the six T20 torx screws from the cowl trim over the wiper motor assembly h Remove the cowl trim piece i Remove the four 10mm nuts from studs holding the straps on the upper side of the wiper motor assembly j Remove the four 13mm bolts holding the wiper motor assembly to the firewall k Remove the wiper motor assembly +++++++++++++++++++++ 1 Remove the negative battery terminal 2 Drain the cooling system - About a gallon will work. You can syphon out of the radiator 3 Disconnect the intake air temperature sensor 4 Remove the Intake air tube 5 Remove the air filter housing and breather tube to front valve cover 6 Remove the throttle and cruise control cables from the throttle body (They both come out the slot to the front) 7 Remove the Bracket holding the throttle and cruise control cables to the upper intake manifold 8 Remove the throttle and cruise control cables from the plastic clip attached to the power steering reservoir 9 Disconnect the Idle Air Motor / (AIS) Automatic Idle Speed 10 Disconnect the Throttle Position sensor (Does not have a Red lock tab) 11 Remove the vacuum hose from the throttle body - Vapor Purge Solenoid (~3/8" OD) 12 Disconnect the Manifold Absolute Pressure sensor (MAP) 13 Remove the PCV hose (or cut) 14 Disconnect the Power Brake Booster vacuum hose from the upper intake manifold (~1/2" OD) 15 Disconnect the Vacuum Leak Detector vacuum hose from the intake manifold (~1/8" OD) 16 Optional-Drain the power steering reservoir 17 Optional-Remove the power steering hoses from the power steering fluid reservoir and plug the hoses 18 Remove the power steering reservoir and move out of the way. Nut in back is 10mm and use 9" extension 19 Remove the EGR pipe from the upper intake manifold and the EGR valve. Save the gaskets 20 Remove the Upper Intake Manifold bolts 21 Remove the Upper Intake Manifold 22 Remove the Upper Intake Manifold gaskets 23 Plug the holes in the Lower Intake Manifold 24 Relieve fuel system pressure. At the Schrader valve 25 Disconnect the fuel line quick disconnect fitting to the fuel rail/injector assembly 26 Unplug the large electrical connector on the passenger side of the lower intake manifold (for fuel injectors) 27 Remove the spark plug wires (from the coil only unless you are replacing them, then remove completely) 28 Disconnect the electrical connector to the coil 29 Remove the coil 30 Remove the coil bracket 31 Disconnect the engine coolant temperature sensor (ETC). Has red lock tab on bottom 32 Remove the heater supply hose from lower intake manifold. Check the condition of the heater hoses 33 Remove the Upper radiator hose from the thermostat housing 34 Remove the Lower Intake Manifold bolts 35 Remove the Lower Intake Manifold 36 Remove the Lower Intake Manifold Gasket retaining bolts (2) 37 Remove the Lower Intake Manifold Gasket 38 Place a towel or rags in the lifter valley 39 OPTIONAL-Remove the valve covers and replace the gaskets 40 Replace the PCV valve in the back valve cover. In theory it just pulls out, but ….. 41 Remove the valve cover gaskets 42 Remove the valve cover bolts and replace the O-Ring type gaskets on each bolt 43 Install the valve cover gaskets in the valve cover 44 Install the valve cover bolts into the valve cover and seat them in the valve cover gaskets 45 Install the valve covers and torque to 105 in-lbs 46 OPTIONAL-Remove the spark plugs (The rear ones are easy to get to at this point)
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