Avenger 2008

Exhaust Manifold

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Removal & Installation



2.4L Engine
  1. Remove engine cover (1).

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    Fig. Remove engine cover (1)

  2.  
  3. Disconnect negative cable from battery.
  4.  
  5. Remove bolts (2) attaching upper heat shield.

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    Fig. Remove bolts (2) attaching upper heat shield

  6.  
  7. Remove upper heat shield (1).
  8.  
  9. Disconnect exhaust pipe (1) from manifold.

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    Fig. Disconnect exhaust pipe (1) from manifold

  10.  
  11. Disconnect oxygen sensor electrical connector (3).
  12.  
  13. Remove manifold support bracket (2).

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    Fig. Remove manifold support bracket (2)

  14.  
  15. Remove lower exhaust manifold heat shield.
  16.  
  17. Remove exhaust manifold retaining fasteners.

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    Fig. Remove exhaust manifold retaining fasteners

  18.  
  19. Remove and discard manifold gasket.
  20.  

To install:

  1. Install a new exhaust manifold gasket.
  2.  
  3. Position exhaust manifold in place.
  4.  
  5. Tighten the exhaust manifold bolts to 25 ft. lbs. (34 Nm).
  6.  
  7. Install exhaust manifold heat shields. Tighten bolts to 105 inch lbs. (12 Nm).
  8.  
  9. Install exhaust manifold support bracket.
  10.  
  11. Install new catalytic converter gasket.
  12.  
  13. Install exhaust pipe to manifold. Tighten fasteners to 21 ft. lbs. (28 Nm).
  14.  
  15. Connect oxygen sensor electrical connector.
  16.  
  17. Connect negative battery cable.
  18.  
  19. Install engine cover.
  20.  

2.7L Engine
Front

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Remove the engine cover.
  4.  
  5. Disconnect and remove oxygen sensors (2) and (4).

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    Fig. Disconnect and remove oxygen sensors (2) and (4)

  6.  
  7. Remove the oil indicator tube and dipstick.
  8.  
  9. Remove the upper maniverter heat shield (2).

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    Fig. Remove the upper maniverter heat shield (2)

  10.  
  11. Remove the splash shield (2).

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    Fig. Remove the splash shield (2)

  12.  
  13. Remove the front maniverter to cross-under fasteners (1) and (2).

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    Fig. Remove the front maniverter to cross-under fasteners (1) and (2)

  14.  
  15. Remove front exhaust maniverter attaching bolts (1) and remove the front maniverter (2).

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    Fig. Remove front exhaust maniverter attaching bolts (1) and remove the front maniverter (2)

  16.  

To install:

  1. Clean gasket mounting surfaces.
  2.  
  3. Install a new gasket, the front maniverter, and the front exhaust maniverter attaching bolts. Tighten bolts to 17 ft. lbs. (23 Nm).
  4.  
  5. Install the front maniverter-to-cross-under fasteners. Tighten to 20 ft. lbs. (27 Nm).
  6.  
  7. Install the upper maniverter heat shield and the heat shield fasteners. Tighten fasteners to 106 inch lbs. (12 Nm).
  8.  
  9. Install the oil indicator tube and dipstick.
  10.  
  11. Install the oxygen sensors. Tighten sensors to 30 ft. lbs. (41 Nm).
  12.  
  13. Install the splash shield.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Install the engine cover.
  18.  

Rear

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Remove the engine cover.
  4.  
  5. Remove the splash shield (2).

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    Fig. Remove the splash shield (2)

  6.  
  7. Remove the exhaust system (2)

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    Fig. Remove the exhaust system (2)

  8.  
  9. Remove the cross-under pipe (3)

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    Fig. Remove the cross-under pipe (3)

  10.  
  11. Remove the lower EGR tube (1).

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    Fig. Remove the lower EGR tube (1)

  12.  
  13. Remove the oxygen sensors (2) and (4).

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    Fig. Remove the oxygen sensors (2) and (4)

  14.  
  15. Remove the rear maniverter heat shield (3).

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    Fig. Remove the rear maniverter heat shield (3)

  16.  
  17. Remove the rear maniverter fasteners (1) and the rear maniverter (2).

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    Fig. Remove the rear maniverter fasteners (1) and the rear maniverter (2)

  18.  

To install:

  1. Clean gasket mounting surfaces.
  2.  
  3. Install the rear maniverter gasket, the rear maniverter, and the rear maniverter fasteners. Tighten the rear maniverter fasteners to 17 ft. lbs. (23 Nm).
  4.  
  5. Install the rear maniverter heat shield. Tighten fasteners to 106 inch lbs. (12 Nm).
  6.  
  7. Install the oxygen sensors. Tighten sensors to 30 ft. lbs. (41 Nm).
  8.  
  9. Install the lower EGR tube.
  10.  
  11. Install the cross-under pipe.
  12.  
  13. Install the exhaust system.
  14.  
  15. Install the splash shield.
  16.  
  17. Connect the negative battery cable.
  18.  
  19. Install the engine cover.
  20.  

3.5L Engine
Front

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Remove the three fasteners (1), and remove the upper heat shield (2).

    Click image to see an enlarged view

    Fig. Remove the three fasteners, and remove the upper heat shield

  4.  
  5. Remove the 12 belly pan fasteners (1) and remove the belly pan (2).

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    Fig. Remove the 12 belly pan fasteners (1) and remove the belly pan (2)

  6.  
  7. Remove the front cross-under pipe bolts.

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    Fig. Remove the front cross-under pipe bolts

  8.  
  9. Disconnect and remove the front lower maniverter oxygen sensor.
  10.  
  11. Loosen the oil level indicator tube retaining bolt and position the dipstick out of the way.
  12.  
  13. Disconnect and remove the front upper maniverter oxygen sensor.
  14.  
  15. Remove the maniverter retaining bolts and maniverter.

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    Fig. Remove the maniverter retaining bolts and maniverter

  16.  

To install:

  1. Position the maniverter and gasket. Install the retaining bolts. Tighten bolts starting at the center working outward to 200 inch lbs. (23 Nm).
  2.  
  3. Install the upper heat shield, and torque nuts to 105 inch lbs. (12 Nm).
  4.  
  5. Install and connect the front upper maniverter oxygen sensor.
  6.  
  7. Position the oil level indicator tube and install the retaining bolt.
  8.  
  9. Install and connect the front lower maniverter oxygen sensor.
  10.  
  11. Install the maniverter cross under pipe retaining bolts. Tighten bolts to 275 inch lbs. (31 Nm).
  12.  
  13. Install the belly pan and the 12 belly pan fasteners.
  14.  
  15. Connect the negative battery cable.
  16.  

Rear

Specific to:

Chrysler Sebring 2008-2009

Dodge Avenger 2008-2009

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and support the vehicle.
  4.  
  5. Remove the 12 belly pan fasteners (1) and remove the belly pan (2).

    Click image to see an enlarged view

    Fig. Remove the 12 belly pan fasteners (1) and remove the belly pan (2)

  6.  
  7. Remove the right front halfshaft.
  8.  
  9. Remove the retainer nuts at the extension pipe.
  10.  
  11. Remove the retainer from the bracket to bell housing.
  12.  
  13. Remove the center crossmember.
  14.  
  15. Remove the exhaust maniverter cross-under pipe.

    Click image to see an enlarged view

    Fig. Exhaust system-3.5L engine

  16.  
  17. Remove the front extension pipe.
  18.  
  19. Disconnect and remove rear maniverter lower oxygen sensor.
  20.  
  21. Remove the lower heat shield retainers.
  22.  
  23. Remove the upper heat shield nuts.
  24.  
  25. Disconnect and remove the rear maniverter upper oxygen sensor and heat shields.
  26.  
  27. Remove the rear maniverter retaining bolts the rear maniverter.
  28.  

To install:

  1. Clean gasket surfaces.
  2.  
  3. Position the maniverter and gasket. Install the retaining bolts. Tighten bolts starting at the center working outward to 200 inch lbs. (23 Nm).
  4.  
  5. Install and connect the rear maniverter upper oxygen sensor.
  6.  
  7. Install the rear maniverter upper heat shield.
  8.  
  9. Install the rear maniverter lower heat shield.
  10.  
  11. Install and connect the rear maniverter lower oxygen sensor.
  12.  
  13. Install the front extension pipe.
  14.  
  15. Install the exhaust maniverter cross under pipe.
  16.  
  17. Install the center crossmember.
  18.  
  19. Install the bracket to bell housing retainer.
  20.  
  21. Position the extension pipe and install the retainer nuts.
  22.  
  23. Install the right front halfshaft.
  24.  
  25. Install the belly pan and the 12 belly pan fasteners.
  26.  
  27. Lower the vehicle.
  28.  
  29. Connect the negative battery cable.
  30.  

 
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