300M, Concorde, Intrepid, LHS, 1998-2004

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. Remove or disconnect the following:
    NOTE
    Do not reuse the V-band clamps.



    Negative battery cable
     
    Exhaust system
     
    V-band clamps and left catalytic converter
     

  4.  
  5. Loosen and rotate the transaxle dipstick tube out of the way.
  6.  
  7. Remove or disconnect the following:

    Engine wiring harness support bracket from the cylinder head
     
    Oxygen (O 2 S) sensor
     
    Engine oil dipstick tube and manifold heat shield
     
    Exhaust manifold bolts and manifold

    Click image to see an enlarged view

    Fig. Removal and installation of the left exhaust manifold-2.7L Engine shown

     

  8.  

To install:

  1. Remove all traces of the old manifold gasket and clean both gasket mating surfaces.
  2.  
  3. Install or connect the following:

    Exhaust manifold and new gasket and torque the bolts to 17 ft. lbs. (23 Nm) working from the center outward
     
    Heat shields and torque the bolts to 105 inch lbs. (12 Nm)
     
    O 2 S sensor
     
    Transaxle dipstick tube
     
    O-RING for the engine oil dipstick tube and tube
     
    Catalytic converter with a new V-band clamp and torque to 89 inch lbs. (10 Nm)
     
    Engine wiring harness support bracket to the cylinder head
     
    Exhaust system
     
    Negative battery cable
     

  4.  

Right Manifold
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Do not reuse the V-band clamps.



    Negative battery cable
     
    Air intake plenum and the air filter housing
     
    Battery cable housing tube-to-transaxle bolt
     
    Exhaust Gas Recirculation (EGR) valve and tube
     
    Oxygen (O 2 S) sensor
     
    V-band clamp from the manifold
     



    Heat shield
     
    Exhaust manifold
     

  4.  
  5. Remove all traces of the old manifold gasket and clean both gasket mating surfaces.
  6.  

To install:

  1. Install or connect the following:

    Exhaust manifold and new gasket. Torque the bolts to 17 ft. lbs. (23 Nm) working from the center outward.
     
    Heat shields and torque the bolts to 105 inch lbs. (12 Nm)
     
    New V-band clamp and torque to 100 inch lbs. (11.3 Nm)
     
    O 2 S sensor
     
    EGR valve and tube using new gaskets, then torque to 95 inch lbs. (11 Nm)
     
    Battery cable tube-to-transaxle and torque the bolt to 75 ft. lbs. (101 Nm)
     
    Air inlet plenum and air filter housing
     
    Negative battery cable
     

  2.  

3.2L & 3.5L Engines
Left Manifold
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Do not reuse the V-band clamps.



    Negative battery cable
     
    Exhaust pipes or system, as necessary from the exhaust manifold
     
    Loosen the converter pipe support attaching bolt at the transaxle mount
     
    V-Band clamp from the exhaust manifold connector
     



    Electrical connector harness bracket
     
    Heated Oxygen Sensor (HO 2 S) electrical connector and sensor
     
    Heat shield-to-exhaust manifold screws
     
    Exhaust manifold bolts and manifold
     

  4.  
  5. Inspect the manifold for damage or cracks. Check for distortion against a straight-edge or thickness gauge. Replace manifold if required.
  6.  
  7. Remove all traces of the old manifold gasket and clean both gasket mating surfaces.

    Click image to see an enlarged view

    Fig. Exploded view of the left side exhaust manifold mounting-3.5L engine

  8.  

To install:

  1. Install or connect the following:

    New manifold gasket and exhaust manifold to the cylinder head and torque to 17 ft. lbs. (23 Nm)
     
    Heat shield and torque the retaining screws to 11 ft. lbs. (15 Nm)
     
    HO 2 S and electrical connector
     
    Electrical connector bracket to brace
     
    New V-band clamp and tighten to 100 inch lbs. (11 Nm)
     
    Nut attaching converter pipe support to 35 ft. lbs. (47 Nm)
     
    Exhaust pipes/system to the manifold
     
    Negative battery cable
     

  2.  
  3. Operate the vehicle and inspect for exhaust leaks.
  4.  

Right Manifold
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Do not reuse the V-band clamps.



    Negative battery cable
     
    Exhaust pipes from the exhaust manifold
     
    Loosen the converter pipe support attaching bolt at the transaxle mount
     
    A/C belt, loosen only
     
    Air cleaner housing and air inlet tube
     
    V-Band clamp from the exhaust manifold connector
     



    A/C compressor bolts and position aside
     
    Engine oil dipstick
     
    A/C compressor bracket
     
    Heated Oxygen Sensor (HO 2 S) electrical connector and sensor
     
    Heat shield-to-exhaust manifold screws
     
    Exhaust manifold bolts and manifold
     

  4.  
  5. Inspect the manifold for damage or cracks. Check for distortion against a straight-edge or thickness gauge. Replace manifold if required.
  6.  
  7. Remove all traces of the old manifold gasket and clean both gasket mating surfaces.

    Click image to see an enlarged view

    Fig. Exploded view of the right side exhaust manifold mounting-3.5L engine

  8.  

To install:

  1. Install or connect the following:

    New manifold gasket and exhaust manifold to the cylinder head and torque to 17 ft. lbs. (23 Nm)
     
    Heat shield and torque the retaining screws to 11 ft. lbs. (15 Nm)
     
    HO 2 S and electrical connector
     
    A/C compressor mounting bracket
     
    New V-band clamp and tighten to 100 inch lbs. (11 Nm)
     
    Engine oil dipstick tube
     
    A/C compressor and drive belt
     
    New V-band clamp and tighten to 100 inch lbs. (11 Nm)
     
    Exhaust pipe to the exhaust manifold and torque the nuts to 21 ft. lbs. (28 Nm)
     
    Nut attaching converter pipe support to the transaxle mount. Torque to 35 ft. lbs. (47 Nm).
     
    Air cleaner housing and air inlet tube
     
    Negative battery cable
     

  2.  
  3. Operate the vehicle and inspect for exhaust leaks.
  4.  

 
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