300, 300C & Magnum 2006-2008, Charger 2006-2008

Exhaust Manifold

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Removal & Installation



2.7L Engine
Left Manifold
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect negative battery cable located in trunk.
  4.  
  5. Disconnect intake air temperature sensor connector.
  6.  
  7. Remove air cleaner housing assembly.
  8.  
  9. Remove oil dipstick tube.
  10.  
  11. Disconnect and remove oxygen sensor.
  12.  
  13. Remove upper heat shield and lower heat shield.
  14.  
  15. Raise and safely support the vehicle.
  16.  
  17. Disconnect downstream oxygen sensor connector.
  18.  
  19. Remove exhaust pipe from manifold.
  20.  
  21. Remove exhaust manifold attaching bolts and remove manifold.

    Click image to see an enlarged view

    Fig. Left side exhaust manifold. (1) upper heat shield, (2) oxygen sensor, (3) manifold, (4) lower heat shield-3.5L engine

  22.  

To install:

  1. Inspect exhaust manifolds for damage or cracks.
  2.  
  3. Check manifold flatness.
  4.  
  5. Inspect the exhaust manifold gasket for obvious discoloration or distortion.
  6.  
  7. Check distortion of the cylinder head mounting surface with a straight-edge and thickness gauge.
  8.  
  9. Install exhaust manifold gasket and manifold. Tighten bolts starting at the center working outward to 200 inch lbs. (23 Nm).
  10.  
  11. Install manifold lower heat shield and upper heat shield. Tighten fasteners to 21 ft. lbs. (28 Nm).
  12.  
  13. If removed, install the exhaust pipe bolts and cross brace. Tighten bolts to 40 ft. lbs. (55 Nm).
  14.  
  15. Tighten manifold ball flange nut to 106 inch lbs. (12 Nm).
  16.  
  17. Check clearance between exhaust module and fuel tank. Clearance should be 16mm (0.62 in.).
  18.  
  19. Check clearance at rear tunnel reinforcement. Clearance should be 15-20mm (0.59-0.78 in.).
  20.  
  21. Adjust clearance as necessary.
  22.  
  23. Tighten ball flange nuts to 25 ft. lbs. (34 Nm).
  24.  
  25. Connect downstream oxygen sensor connectors.
  26.  
  27. Lower vehicle.
  28.  
  29. Install oxygen sensor and connect electrical connector.
  30.  
  31. Connect negative battery cable.
  32.  

Right Manifold
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect negative battery cable located in trunk.
  4.  
  5. Disconnect and remove upstream oxygen sensor.
  6.  
  7. Raise vehicle.
  8.  
  9. Remove EGR tube at EGR valve.
  10.  
  11. Remove EGR tube at manifold.
  12.  
  13. Disconnect downstream oxygen sensor electrical connector.
  14.  
  15. Disconnect exhaust pipe from manifold.
  16.  
  17. Remove upper heat shield and lower heat shield.
  18.  
  19. Remove manifold attaching bolts and remove manifold.

    Click image to see an enlarged view

    Fig. Right side exhaust manifold. (1) EGR tube, (2) upper heat shield, (3) lower heat shield, (4) manifold, (5) oxygen sensor-2.7L engine

  20.  

To install:

  1. Inspect exhaust manifolds for damage or cracks.
  2.  
  3. Check manifold flatness.
  4.  
  5. Inspect the exhaust manifold gasket for obvious discoloration or distortion.
  6.  
  7. Check distortion of the cylinder head mounting surface with a straight-edge and thickness gauge.
  8.  
  9. Install exhaust manifold gasket and manifold. Tighten bolts working from center outwards to 200 inch lbs. (23 Nm).
  10.  
  11. If removed, install bolts and cross brace. Tighten bolts to 40 ft. lbs. (55 Nm).
  12.  
  13. Tighten manifold ball flange nut to 106 inch lbs. (12 Nm).
  14.  
  15. Check clearance between exhaust module and fuel tank. Clearance should be 16mm (0.62 in.).
  16.  
  17. Check clearance at rear tunnel reinforcement. Clearance should be 15-20mm (0.59-0.78 in.).
  18.  
  19. Adjust clearance as necessary.
  20.  
  21. Tighten ball flange nuts to 25 ft. lbs. (34 Nm).
  22.  
  23. Connect oxygen sensor connectors.
  24.  
  25. Install lower heat shield and upper heat shield.
  26.  
  27. Install oxygen sensor and connect electrical connector.
  28.  
  29. Connect downstream oxygen sensor electrical connector.
  30.  
  31. Lower vehicle.
  32.  
  33. Install EGR tube using new gaskets. Tighten screws to 95 inch lbs. (11 Nm).
  34.  
  35. Connect negative battery cable.
  36.  

3.5L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect and isolate the negative battery cable.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Separate the front exhaust pipe to manifold union.
  8.  
  9. Lower the vehicle.
  10.  
  11. Disconnect and remove the oxygen sensor from the exhaust manifold.
  12.  
  13. Remove the exhaust manifold shield retaining bolts, exhaust manifold, and discard gasket.

    Click image to see an enlarged view

    Fig. Left side exhaust manifold-3.5L engine

  14.  

To install:

  1. Inspect exhaust manifolds for damage or cracks.
  2.  
  3. Check manifold flatness.
  4.  
  5. Inspect the exhaust manifold gasket for obvious discoloration or distortion.
  6.  
  7. Check distortion of the cylinder head mounting surface with a straight-edge and thickness gauge.
    NOTE
    If replacing the exhaust manifold, tighten the exhaust outlet studs to manifold to 29 ft. lbs. (40 Nm).

  8.  
  9. Position the exhaust manifold and gasket. Install the retaining bolts. Tighten 4 bolts starting at the center working outward to 17 ft. lbs. (23 Nm).
  10.  
  11. Install the exhaust manifold heat shields. Tighten the bolts to 105 inch lbs. (12 Nm).
  12.  
  13. Tighten the out most stud nuts to 73 inch lbs. (8 Nm).
  14.  
  15. Connect the oxygen sensor.
  16.  
  17. Raise and support the vehicle.
  18.  
  19. Connect the exhaust pipe to manifold union. Tighten the exhaust stud nuts to 25 ft. lbs. (34 Nm).
  20.  
  21. Connect the negative battery cable.
  22.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Disconnect the upstream oxygen sensor electrical connector.
  6.  
  7. Raise and support the vehicle.
  8.  
  9. Remove the exhaust manifold to exhaust pipe flange retaining bolts.
  10.  
  11. Lower the vehicle.
  12.  
  13. Remove the exhaust manifold heat shield and manifold.
  14.  
  15. Remove the oxygen sensor from the exhaust manifold.

    Click image to see an enlarged view

    Fig. Right side exhaust manifold-3.5L engine

  16.  

To install:

  1. Clean gasket surfaces.
    NOTE
    If replacing the exhaust manifold, tighten the exhaust outlet studs to 29 ft. lbs. (39 Nm).

  2.  
  3. Position the exhaust manifold and gasket. Install the retaining bolts. Tighten 4 bolts starting at the center working outward to 17 ft. lbs. (23 Nm).
  4.  
  5. Install the heat shields. Tighten the heat shield fasteners to 105 inch lbs. (12 Nm).
  6.  
  7. Tighten the 2 out most nuts to 73 inch lbs. (8 Nm).
  8.  
  9. Connect the oxygen sensor.
  10.  
  11. Raise and support the vehicle.
  12.  
  13. Connect the front exhaust pipe to exhaust manifold. Tighten the fasteners to 25 ft. lbs. (34 Nm).
  14.  
  15. Connect the negative battery cable.
  16.  

5.7L Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect negative battery cable.
  4.  
  5. Raise vehicle.
  6.  
  7. Remove exhaust pipe to manifold bolts.

    Click image to see an enlarged view

    Fig. Engine mount. (1) stud bolts, (2) nuts, (3) mount, (4) stud bolts-5.7L engine

  8.  
  9. Remove engine mount to frame fasteners.
  10.  
  11. Using suitable jack, raise engine enough to remove manifolds.
    WARNING
    Do not damage engine harness while raising the engine.

  12.  
  13. Remove the engine mount.
  14.  
  15. Remove heat shield.

    Click image to see an enlarged view

    Fig. Exhaust manifold loosening/tightening sequence-5.7L engine

  16.  
  17. Remove manifold bolts using sequence provided.
  18.  
  19. Remove manifold and gasket.
  20.  

To install:

  1. Clean mating surfaces on cylinder head and manifold. Wash with solvent and blow dry with compressed air.
  2.  
  3. Inspect manifold for cracks.
  4.  
  5. Inspect mating surfaces of manifold for flatness with a straight-edge. Gasket surfaces must be flat within 0.2 mm per 300 mm (0.008 inch per foot).
  6.  
  7. Install manifold gasket and manifold.
  8.  
  9. Install manifold bolts and tighten to 18 ft. lbs. (25 Nm).
  10.  
  11. Install heat shield and tighten nuts to 70 inch lbs. (8 Nm).
  12.  
  13. Install engine mounts. Torque to 70 ft. lbs. (95 Nm).
  14.  
  15. Lower engine.
    WARNING
    Do not damage engine harness while lowering the engine.

  16.  
  17. Install and tighten right and left side engine mount to frame fasteners. Torque to 70 ft. lbs. (95 Nm).
  18.  
  19. Install exhaust flange to pipe bolts.
  20.  
  21. Lower vehicle.
  22.  
  23. Connect negative battery cable.
  24.  

 
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