Chrysler Caravan/Voyager/Town n Country 1984-1995

Exhaust Manifold

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REMOVAL & INSTALLATION



2.6L Engines

See Figure 1



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Fig. Fig. 1: Exhaust manifold-2.6L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Remove the belt from the power steering pump.
  6.  
  7. Raise the vehicle and make sure it is supported safely.
  8.  
  9. Remove the exhaust pipe from the manifold.
  10.  
  11. Disconnect the air injection tube assembly from the exhaust manifold and lower the vehicle.
  12.  
  13. Remove the power steering pump assembly and move to one side.
  14.  
  15. Remove the heat cowl from the exhaust manifold.
  16.  
  17. Remove the exhaust manifold retaining nuts and remove the assembly from the vehicle.
  18.  
  19. Remove the carburetor air heater from the manifold.
  20.  
  21. Separate the exhaust manifold from the catalytic converter by removing the retaining screws.
  22.  

To install:
  1. Clean gasket material from cylinder head and exhaust manifold gasket surfaces. Check mating surfaces for cracks or distortion.
  2.  
  3. Install a new gasket between the exhaust manifold and catalytic converter. Install mounting screws and tighten to 32 Nm (24 ft. lbs.).
  4.  
  5. Install the carburetor air heater on manifold and tighten to 80 inch lbs. (9 Nm).
  6.  
  7. Lightly coat the new exhaust manifold gasket with sealant (P/N 3419115) or equivalent on cylinder head side.
  8.  
  9. Install the exhaust manifold and mounting nuts. Refer to the torque specification chart in this section for the proper tightening value.
  10.  
  11. Install the heat cowl onto the manifold, then tighten the bolts to 80 inch lbs. (9 Nm).
  12.  
  13. Install the air cleaner support bracket.
  14.  
  15. Install the power steering pump assembly.
  16.  
  17. Install the air injection tube assembly to air pump.
  18.  
  19. Raise the vehicle and install air injection tube assembly to exhaust manifold.
  20.  
  21. Install the exhaust pipe to manifold.
  22.  
  23. Lower the vehicle and install power steering belt.
  24.  
  25. Fill the cooling system.
  26.  
  27. Install the air cleaner assembly.
  28.  
  29. Connect the negative battery cable.
  30.  

3.0L Engines

See Figure 2



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Fig. Fig. 2: Manifold assemblies-3.0L engines

  1. Disconnect the negative battery cable.
  2.  
  3. Raise vehicle and support properly.
  4.  
  5. Disconnect the exhaust pipe from rear (cowl side) exhaust manifold at articulated joint.
  6.  
  7. Remove the EGR tube from the rear manifold and disconnect oxygen sensor lead.
  8.  
  9. Remove the attaching bolts from crossover pipe to manifold.
  10.  
  11. Remove the attaching nuts which retained manifold to cylinder head and remove manifold.
  12.  
  13. Lower the vehicle and remove bolt securing front heat shield to front exhaust manifold.
  14.  
  15. Remove the bolts retaining crossover pipe to front exhaust manifold and nuts retaining manifold to cylinder head. Remove manifold assembly.
  16.  

To install:
  1. Clean all gasket material from cylinder the head and exhaust manifold gasket surfaces. Check mating surfaces for cracks or distortion.
  2.  
  3. Install the new gasket with the numbers 1-3-5 stamped on the top on the rear bank. The gasket with the numbers 2-4-6 must be installed on the front bank (radiator side).
  4.  
  5. Install rear exhaust manifold and tighten attaching nuts to 15 ft. lbs. (20 Nm).
  6.  
  7. Install exhaust pipe to manifold and tighten shoulder bolts to 20 ft. lbs. (27 Nm).
  8.  
  9. Install crossover pipe to manifold and tighten bolts to 69 Nm (51 ft. lbs.).
  10.  
  11. Install oxygen sensor lead and EGR tube.
  12.  
  13. Install front exhaust manifold and attach exhaust crossover.
  14.  
  15. Install front manifold heat shield and tighten bolts to 10 ft. lbs. (14 Nm).
  16.  
  17. Connect the negative battery cable.
  18.  

3.3L and 3.8L Engines
  1. Disconnect the negative battery cable.
  2.  
  3. If removing the rear manifold, raise the vehicle and support safely. Disconnect the exhaust pipe at the articulated joint from the rear exhaust manifold.
  4.  
  5. Separate the EGR tube from the rear manifold and disconnect the oxygen sensor wire.
  6.  
  7. Remove the alternator/power steering support strut.
  8.  
  9. Remove the bolts attaching the crossover pipe to the manifold.
  10.  
  11. Remove the bolts attaching the manifold to the head and remove the manifold.
  12.  
  13. If removing the front manifold, remove the heat shield, bolts attaching the crossover pipe to the manifold and the nuts attaching the manifold to the head.
  14.  
  15. Remove the manifold from the engine.
  16.  
  17. The installation is the reverse of the removal procedure. Tighten all exhaust manifold attaching bolts to 17 ft. lbs. (23 Nm).
  18.  
  19. Start the engine and check for exhaust leaks.
  20.  

 
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