Breeze, Cirrus, Sebring Convertible and Sedan, Stratus Sedan, 1999-2005

Exhaust Manifold

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Removal & Installation




NOTE
Before servicing the vehicle, also refer to the precautions in the beginning of this section.

2.0L And 2.4L Engines
Non-PZEV Engines
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable from the left shock tower.
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

  4.  
  5. Remove or disconnect the following:

    Exhaust pipe from the exhaust manifold
     
    Exhaust manifold heat shield
     
    Heated Oxygen Sensor (HO 2 S), if necessary
     
    Exhaust manifold and discard the gasket
     

  6.  

To install:

Click image to see an enlarged view

Fig. Make sure the gasket mating surfaces are clean and flat before installing the exhaust manifold-2.0L engine



Click image to see an enlarged view

Fig. Be careful not to damage the oxygen sensor when servicing the manifold-2.4L engine



Click image to see an enlarged view

Fig. Exhaust manifold torque sequence-2.4L non-PZEV engines

  1. Thoroughly clean all parts. Clean all sealing surfaces of the manifold and cylinder head. Check the manifold gasket surface for flatness with a straightedge and feeler gauge. The surface must be flat within 0.006 inch (0.15mm) per foot (30cm) of manifold length. Inspect the manifold for cracks or distortion. Replace if necessary.
  2.  
  3. Install or connect the following:

    New gasket
     
    Exhaust manifold. Torque the bolts, starting at the center and working outward, to 17 ft. lbs. (23 Nm)
     
    HO 2 S sensor
     
    Heat shield
     
    Exhaust pipe and torque the fasteners to 21 ft. lbs. (28 Nm)
     
    Negative battery cable
     

  4.  
  5. Start the engine and allow it to idle while inspecting the manifold for exhaust leaks.
  6.  

PZEV Engines
  1. Disconnect negative battery cable.
  2.  
  3. Raise vehicle on hoist.
  4.  
  5. Remove the complete exhaust system.
  6.  
  7. Remove the rear engine mount and transaxle bracket.
  8.  
  9. Disconnect connector tube from check valve. Squeeze connector and pull.
  10.  
  11. Remove the exhaust manifold heat shield.
  12.  
  13. Disconnect oxygen sensor electrical connector.
  14.  
  15. Remove the exhaust manifold retaining fasteners and remove exhaust manifold.
  16.  
  17. Remove the and discard manifold gasket.

    Click image to see an enlarged view

    Fig. Exhaust manifold torque sequence-2.4L PZEV engines

  18.  

To install:

  1. Install the new exhaust manifold gasket. DO NOT APPLY SEALER.
  2.  
  3. Position exhaust manifold in place. Tighten fasteners in sequence shown to 17 ft. lbs. (23 Nm).
  4.  
  5. Install the exhaust manifold heat shield.
  6.  
  7. Install the check valve tighten bolts to 105 inch lbs. (12 Nm).
  8.  
  9. Connect connector tube to check valve by pushing fitting over check valve.
  10.  
  11. Connect oxygen sensor electrical connector.
  12.  
  13. Install the rear engine mount and transaxle bracket.
  14.  
  15. Install the exhaust system. Tighten fasteners to 21 ft. lbs. (28 Nm).
  16.  
  17. Lower vehicle.
  18.  
  19. Connect negative battery cable.
  20.  

2.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect battery negative cable from remote negative terminal on shock tower and properly isolate to prevent accidental reconnection.
  4.  
  5. Remove or disconnect the following:
    NOTE
    It may be necessary to remove the entire exhaust system.



    Exhaust pipe from manifold.
     



    Exhaust manifold heat shield
     
    8 exhaust manifold retaining fasteners and remove exhaust manifold
     

  6.  

To install:

  1. Position exhaust manifold in place with a new gasket.
  2.  
  3. Torque the nuts and bolts to 200 inch lbs. (23 Nm) starting at center and progressing outward in both directions.
  4.  
  5. Repeat this procedure until all fasteners are at specified torque.
  6.  
  7. Install exhaust manifold heat shield.
  8.  
  9. Attach exhaust pipe and tighten fasteners to 250 inch lbs. (28 Nm)

    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifold and related components-2.0L engine

  10.  

2.5L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Disconnect the negative battery cable from the left shock tower.
    NOTE
    The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

  4.  
  5. Remove or disconnect the following:

    Exhaust pipe from the rear (cowl side) exhaust manifold, at the flex joint
     
    Crossover pipe assembly
     
    Heated Oxygen Sensor (HO 2 S) from the rear manifold
     
    Power steering bracket
     
    Rear exhaust manifold heat shield
     
    Rear exhaust manifold and discard the gasket
     
    Front HO 2 S sensor
     
    Front manifold heat shield
     
    Front manifold
     

  6.  

To install:

  1. Thoroughly clean all parts. Inspect the exhaust manifolds for damage or cracks and check for distortion of the cylinder head sealing surface and exhaust crossover sealing surface with a straightedge and thickness gauge.
  2.  
  3. Install or connect the following:

    New front gasket
     
    Front manifold and torque the nuts to 22 ft. lbs. (30 Nm)
     
    Front exhaust manifold heat shield and torque the screws to: 10 ft. lbs. (13 Nm)
     
    Front HO 2 S sensor
     
    New rear gasket
     
    Rear exhaust manifold and torque the nuts to 22 ft. lbs. (30 Nm)
     
    Power steering bracket
     
    Crossover pipe and torque the nuts to 22 ft. lbs. (30 Nm)
     
    Rear HO 2 S sensor
     
    Exhaust pipe to the rear manifold and torque the bolts to 21 ft. lbs. (28 Nm)
     
    Negative battery cable
     

  4.  
  5. Lower the vehicle.
  6.  
  7. Start the engine and allow the engine to idle while inspecting the vehicle for exhaust leaks at the manifold.
  8.  

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

    Negative battery cable
     
    Cooling fan assembly
     
    Engine oil level dipstick and tube
     
    Engine hanger or lower heat shield, if equipped
     
    Exhaust pipe-to-exhaust manifold locknuts, separate the exhaust pipe and discard the gasket
     
    Exhaust manifold mounting fasteners, the exhaust manifold stay (brace), the exhaust manifold and the gasket

    Click image to see an enlarged view

    Fig. Exploded view of the exhaust manifold assembly and related components-2.5L engine

     

  4.  

To install:

  1. Clean all gasket material from the mating surfaces and check the manifold for cracks or warpage.
  2.  
  3. Install or connect the following:

    New gasket, manifold and stay (brace) and torque the fasteners, in a crisscross pattern, to 22 ft. lbs. (29 Nm)
     
    New gasket, install the exhaust pipe to the exhaust manifold and torque the nuts to 33 ft. lbs. (44 Nm).
     
    Engine hanger or lower heat shield, if equipped and torque the lower heat shield fasteners to 10 ft. lbs. (13 Nm)
     
    Engine oil level dipstick and tube
     
    Cooling fan assembly
     
    Negative battery cable
     

  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

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

    Negative battery cable
     
    Intake manifold plenum and plenum stay
     
    Heated Oxygen (HO 2 ) sensor
     
    Alternator
     
    Exhaust Gas Recirculation (EGR) pipe assembly
     
    Exhaust pipe-to-exhaust manifold locknuts, separate the exhaust pipe and discard the gasket
     
    Manifold heat shield, if equipped
     
    Exhaust manifold bolts, the exhaust manifold brace, the exhaust manifold and the gasket
     

  4.  

To install:

  1. Clean all gasket material from the mating surfaces and check the manifold for cracks or warpage.
  2.  
  3. Install or connect the following:

    New gasket, the manifold and manifold brace and torque the nuts, in a crisscross pattern, to 22 ft. lbs. (30 Nm)
     
    Manifold heat shield, if equipped
     
    Exhaust pipe-to-exhaust manifold using a new gasket and torque the nuts to 33 ft. lbs. (44 Nm)
     
    EGR pipe assembly
     
    Alternator
     
    HO 2 S sensor
     
    Intake manifold plenum and plenum stay (brace)
     
    Negative battery cable
     

  4.  
  5. Start the engine, check for exhaust leaks and repair if necessary.
  6.  

2.7L Engine
Front
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Cross under pipe
     
    Front catalytic converter
     
    Exhaust manifold and discard the gasket
     

  4.  

To install:

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Install or connect the following:

    Exhaust manifold with a new gasket. Torque the bolts, starting in the center and working outward, to 17 ft. lbs. (23 Nm)
     
    Front catalytic converter and heat shield and torque the bolts to 21 ft. lbs. (28 Nm)
     
    Cross under pipe and torque the bolts to 21 ft. lbs. (28 Nm)
     
    Negative battery cable
     

  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

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

    Negative battery cable
     
    Throttle body air inlet hose
     
    Air cleaner assembly
     
    Exhaust Gas Recirculation (EGR) tube from the exhaust manifold and EGR valve
     
    Exhaust system
     
    Cross under pipe
     
    Rear catalytic converter
     
    Rear Oxygen Sensor (O 2 S)
     
    Exhaust manifold and discard the gasket
     

  4.  

To install:

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Install or connect the following:

    Exhaust manifold with a new gasket. Torque the bolts, starting in the center and working outward, to 17 ft. lbs. (23 Nm)
     
    Rear catalytic converter and heat shield and torque the bolts to 21 ft. lbs. (28 Nm)
     
    Rear Oxygen Sensor (O 2 S)
     
    Cross under pipe and torque the bolts to 21 ft. lbs. (28 Nm)
     
    Exhaust system
     
    EGR tube with new gaskets
     
    Air cleaner assembly and air intake hose
     
    Negative battery cable
     

  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    Battery and tray
     
    Front exhaust pipe
     
    Air cleaner assembly
     
    Oil dipstick guide
     
    Strut tower bar
     
    Upper and lower heat shields
     
    Exhaust Gas Recirculation (EGR) pipe, left side only
     
    Exhaust manifold and discard the gasket
     

  4.  

To install:

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Install or connect the following:

    Exhaust manifold with a new gasket and torque the bolts to 33 ft. lbs. (44 Nm)
     
    EGR pipe, if removed. Torque the bolt to 13 ft. lbs. (18 Nm).
     
    Upper and lower heat shields and torque the bolts to 10 ft. lbs. (15 Nm)
     
    Strut tower bar
     
    Oil dipstick guide
     
    Air cleaner assembly
     
    Front exhaust pipe
     
    Battery and tray
     

  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

 
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