Caravan, Grand Voyager, Town and Country, Voyager, 2000-2004

Exhaust Manifold

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Removal & Installation



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

    Negative battery cable
     
    Exhaust front pipe
     
    Heated Oxygen Sensor (HO 2 S) connectors
     
    Exhaust manifold heat shields
     
    Exhaust crossover pipe
     
    Exhaust manifolds
     

  4.  

To install:

  1. Install or connect the following:

    Exhaust manifolds. Torque the fasteners to 15 ft. lbs. (20 Nm).
     
    Exhaust crossover pipe. Torque the fasteners to 51 ft. lbs. (69 Nm).
     
    Exhaust manifold heat shields
     
    HO 2 S connectors
     
    Exhaust front pipe. Torque the fasteners to 21 ft. lbs. (28 Nm).
     
    Negative battery cable
     

  2.  
  3. Start the engine and check for leaks.
  4.  

3.3L & 3.8L Engines
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Crossover pipe
     
    Spark plug wires
     
    Heat shield
     
    Exhaust manifold bolt
     
    Exhaust manifold and gasket
     

  4.  

To install:

  1. Position the exhaust manifold on the cylinder head and install the bolts to the center runner (cyl # 4), and temporarily tighten to 25 inch lbs. (2.8 Nm).
    NOTE
    Examine the crossover pipe bolts for damage caused due to heat or corrosion and replace using new OEM bolts if found to be defective.

  2.  
  3. Install a new gasket, attach the crossover pipe to the manifold and tighten the bolts to 30 ft. lbs. (41 Nm).
  4.  
  5. Install or connect the following:

    Remaining manifold bolts. Torque the fasteners to 17 ft. lbs. (23 Nm).
     
    Heat shield
     
    Negative battery cable
     

  6.  
  7. Start the engine and check for leaks.
  8.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Wiper module
     
    Spark plug wires
     
    Crossover pipe
     
    Upstream Oxygen Sensor (O 2 S) connectors
     
    Heat shield
     
    Accessory drive belt
     
    Power steering pump support strut lower bolt
     
    Downstream O 2 S connectors
     
    Catalytic converter pipe from the manifold
     
    Power steering support strut upper bolt and strut
     
    Exhaust manifold bolt
     
    Exhaust manifold and gasket
     

  4.  

To install:

  1. Position the exhaust manifold on the cylinder head and install the bolts to the center runner (cyl # 3), and temporarily tighten to 25 inch lbs. (2.8 Nm).
    NOTE
    Examine the crossover pipe bolts for damage caused due to heat or corrosion and replace using new OEM bolts if found to be defective.

  2.  
  3. Install a new gasket, attach the crossover pipe to the manifold and tighten the bolts to 30 ft. lbs. (41 Nm).
  4.  
  5. Install or connect the following:

    Remaining manifold bolts. Torque the fasteners to 17 ft. lbs. (23 Nm).
     
    Power steering support strut and upper bolt
     
    Heat shield
     
    Upstream O 2 S connectors
     
    Catalytic converter pipe to the manifold
     
    Downstream O 2 S connectors
     
    Power steering pump support strut lower bolt
     
    Accessory drive belt
     
    Spark plug wires
     
    Wiper module
     
    Negative battery cable
     

  6.  
  7. Start the engine and check for leaks.
  8.  

 
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