Aspen 2007, Durango 2005-2007

Exhaust Manifold

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Removal & Installation



3.7L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust manifold heat shields
     
    Exhaust Gas Recirculation (EGR) tube
     
    Exhaust Y-pipe
     
    Exhaust manifolds
     

  4.  

To install:


NOTE
If the exhaust manifold studs came out with the nuts when removing the exhaust manifolds, replace them with new studs.



Click image to see an enlarged view

Fig. Exhaust manifold fastener locations-3.7L engines

  1. Install or connect the following:

    Exhaust manifolds. Torque the fasteners to 20 ft. lbs. (27 Nm), starting with the center nuts and work out to the ends.
     
    Exhaust Y-pipe
     
    EGR tube
     
    Exhaust manifold heat shields
     
    Negative battery cable
     

  2.  
  3. Start the engine, check for leaks and repair if necessary.
  4.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust manifold heat shields
     
    Exhaust Gas Recirculation (EGR) tube
     
    Exhaust Y-pipe
     
    Exhaust manifolds
     

  4.  

To install:


NOTE
If the exhaust manifold studs came out with the nuts when removing the exhaust manifolds, replace them with new studs.



Click image to see an enlarged view

Fig. Exhaust manifold fastener locations-3.7L engines

  1. Install or connect the following:

    Exhaust manifolds. Torque the fasteners to 20 ft. lbs. (27 Nm), starting with the center nuts and work out to the ends.
     
    Exhaust Y-pipe
     
    EGR tube
     
    Exhaust manifold heat shields
     
    Negative battery cable
     

  2.  
  3. Start the engine, check for leaks and repair if necessary.
  4.  

4.7L Engine
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Battery
     
    Power distribution center
     
    Battery tray
     
    Windshield washer fluid bottle
     
    Air cleaner assembly
     
    Accessory drive belt
     
    A/C compressor
     
    A/C accumulator bracket
     
    Heater hoses
     
    Exhaust manifold heat shields
     
    Exhaust Y-pipe
     
    Starter motor
     
    Exhaust manifolds

    Click image to see an enlarged view

    Fig. Left side exhaust manifold installation; right side similar-4.7L engine

     

  6.  

To install:

  1. Install or connect the following:

    Exhaust manifolds, using new gaskets. Tighten the bolts to 18 ft. lbs. (25 Nm), starting with the inner bolts and work out to the ends.
     
    Starter motor
     
    Exhaust Y-pipe
     
    Exhaust manifold heat shields
     
    Heater hoses
     
    A/C accumulator bracket
     
    A/C compressor
     
    Accessory drive belt
     
    Air cleaner assembly
     
    Windshield washer fluid bottle
     
    Battery tray
     
    Power distribution center
     
    Battery
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Battery
     
    Power distribution center
     
    Battery tray
     
    Windshield washer fluid bottle
     
    Air cleaner assembly
     
    Accessory drive belt
     
    A/C compressor
     
    A/C accumulator bracket
     
    Heater hoses
     
    Exhaust manifold heat shields
     
    Exhaust Y-pipe
     
    Starter motor
     
    Exhaust manifolds

    Click image to see an enlarged view

    Fig. Left side exhaust manifold installation; right side similar-4.7L engine

     

  6.  

To install:

  1. Install or connect the following:

    Exhaust manifolds, using new gaskets. Tighten the bolts to 18 ft. lbs. (25 Nm), starting with the inner bolts and work out to the ends.
     
    Starter motor
     
    Exhaust Y-pipe
     
    Exhaust manifold heat shields
     
    Heater hoses
     
    A/C accumulator bracket
     
    A/C compressor
     
    Accessory drive belt
     
    Air cleaner assembly
     
    Windshield washer fluid bottle
     
    Battery tray
     
    Power distribution center
     
    Battery
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

5.7L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Battery
     
    Exhaust pipe-to-manifold bolts
     

  6.  
  7. Install an engine crane. Remove the right and left mount through bolts. Raise the engine just enough to provide clearance for manifold removal.
  8.  
  9. Remove or disconnect the following:

    Exhaust manifold heat shields
     
    Exhaust manifolds

    Click image to see an enlarged view

    Fig. Exhaust manifold bolt torque sequences-5.7L engine

     

  10.  

To install:

  1. Install or connect the following:

    Exhaust manifolds, using new gaskets. Tighten the bolts to 18 ft. lbs. (25 Nm), starting with the inner bolts and work out to the ends.
     
    Exhaust manifold heat shields
     

  2.  
  3. Install the right and left mount through bolts. Remove the crane.
  4.  
  5. Install or connect the following:

    Exhaust pipe-to-manifold bolts
     
    Battery
     

  6.  

  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Battery
     
    Exhaust pipe-to-manifold bolts
     

  6.  
  7. Install an engine crane. Remove the right and left mount through bolts. Raise the engine just enough to provide clearance for manifold removal.
  8.  
  9. Remove or disconnect the following:

    Exhaust manifold heat shields
     
    Exhaust manifolds

    Click image to see an enlarged view

    Fig. Exhaust manifold bolt torque sequences-5.7L engine

     

  10.  

To install:

  1. Install or connect the following:

    Exhaust manifolds, using new gaskets. Tighten the bolts to 18 ft. lbs. (25 Nm), starting with the inner bolts and work out to the ends.
     
    Exhaust manifold heat shields
     

  2.  
  3. Install the right and left mount through bolts. Remove the crane.
  4.  
  5. Install or connect the following:

    Exhaust pipe-to-manifold bolts
     
    Battery
     

  6.  

5.9L Engines
  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Exhaust manifold heat shields
     
    Exhaust Gas Recirculation (EGR) tube
     
    Exhaust Y-pipe
     
    Exhaust manifolds
     

  4.  

To install:


NOTE
If the exhaust manifold studs came out with the nuts when removing the exhaust manifolds, replace them with new studs.



Click image to see an enlarged view

Fig. Exhaust manifold fastener locations-5.9L engines

  1. Install or connect the following:

    Exhaust manifolds. Tighten the fasteners to 20 ft. lbs. (27 Nm), starting with the center nuts and work out to the ends.
     
    Exhaust Y-pipe
     
    EGR tube
     
    Exhaust manifold heat shields
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the engine and check for leaks.
  6.  

 
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