Town & Country AWD V6-3.8L VIN L (2003)
Intake Manifold: Service and Repair
Intake Manifold Vacuum Port Repair
INTAKE MANIFOLD VACUUM PORT REPAIR
The composite intake manifold vacuum ports, can be repaired. Although, if the manifold plenum chamber is damaged or cracked, the manifold must
be replaced.
To repair a broken or damaged vacuum nipple (port) on the composite intake manifold, perform the following procedure:
NOTE: While performing this procedure, avoid getting the manifold material residue into the plenum chamber.
1. File or sand the remaining port back until a flat surface is obtained (plane normal to nipple (port) axis).
Fig.119
2. Drill out the nipple (port) base using a 7/16" (brake booster port) or 11/32" (LDP/speed control port ) drill bit (Fig. 119).
3. Using a 1/4"-18 NPT (brake booster port) or 1/8"-18 NPT (LDP/speed control port) pipe tap, cut internal threads (Fig. 119). Use caution to start
tap in a axis same as original nipple.
4. Apply Mopar Thread Sealant to threads of repair nipple(s).
5. Install repair nipple(s). Do not over torque repair nipple(s).
