Chrysler Cirrus/Stratus/Sebring/Avenger/Breeze 1995-1998

Exhaust Manifold

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REMOVAL & INSTALLATION



2.0L DOHC Engine

See Figures 1 and 2

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air intake hose and the small air hose connection.
  4.  
  5. Properly drain the engine coolant.
  6.  
  7. Disconnect the upper radiator hose from the thermostat housing.
  8.  
  9. Disengage the control wiring harness connection.
  10.  
  11. Remove the water pipe assembly and the engine oil level dipstick.
  12.  
  13. Remove the heat shield and the engine hanger.
  14.  



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Fig. Fig. 1: Exhaust manifold heat shield-4-cylinder engines

  1. Remove the pulsed secondary air injection valve, if equipped.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the exhaust pipe-to-exhaust manifold locknuts and separate the exhaust pipe. Discard the gasket.
  6.  
  7. Lower the vehicle.
  8.  
  9. Loosen the mounting fasteners, and remove the exhaust manifold.
  10.  



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Fig. Fig. 2: Exhaust manifold-4-cylinder engines

To install:
  1. Clean all gasket material from the mating surfaces and check the manifold for cracks or warpage.
  2.  
  3. Install a new gasket and install the manifold. Tighten the fasteners, in a crisscross pattern to 17 ft. lbs. (23 Nm).
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Install the exhaust pipe to the exhaust manifold with a new gasket and new locknuts. Tighten the nuts to 33 ft. lbs. (44 Nm).
  8.  
  9. Lower the vehicle.
  10.  
  11. Install the pulsed secondary air injection valve, if equipped.
  12.  
  13. Install the heat shield and the engine hanger.
  14.  
  15. Engage the control wiring harness connection.
  16.  
  17. Connect the upper radiator hose to the thermostat housing.
  18.  
  19. Properly refill the engine cooling system.
  20.  
  21. Install the air intake hose and the small air hose connection.
  22.  
  23. Connect the negative battery cable, then start the engine and check for exhaust leaks.
  24.  

2.0L SOHC and 2.4L DOHC Engines

See Figures 1 and 2

  1. Disconnect the negative battery cable from the left strut tower. 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.
  2.  
  3. Disconnect the exhaust pipe from the exhaust manifold. Apply penetrating oil on the exhaust manifold-to-exhaust pipe flange bolts to aid in removal. It may be necessary to remove the entire exhaust system.
  4.  
  5. Remove the exhaust manifold heat shield.
  6.  
  7. Disconnect the heated oxygen sensor, if necessary.
  8.  
  9. Remove the 8 manifold attaching bolts and remove the manifold from the vehicle.
  10.  

To install:
  1. Thoroughly clean all parts. Discard the gasket and 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 inches per foot (0.152mm per 30.48cm) of manifold length. Inspect the manifold for cracks or distortion. Replace if necessary.
  2.  
  3. Install the manifold into the vehicle with a new gasket. DO NOT APPLY SEALER.
  4.  
  5. Reinstall the 8 manifold bolts and tighten, starting at the center and working outward in both directions. Tighten to 200 inch lbs. (23 Nm).
  6.  
  7. Reconnect the heated oxygen sensor.
  8.  
  9. Reinstall the heat shield.
  10.  
  11. Reinstall the exhaust pipe and tighten the fasteners to 250 inch lbs. (28 Nm).
  12.  
  13. Reconnect the negative battery cable. Start the engine and allow it to idle while inspecting the manifold for exhaust leaks.
  14.  

2.5L (VIN N) Engine

FRONT BANK SIDE

See Figure 3

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the cooling fan motor assembly. Refer to the procedure later in this section.
  4.  
  5. Remove the engine oil level dipstick and tube.
  6.  
  7. Remove the engine hanger or lower heat shield, if equipped.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Remove the exhaust pipe-to-exhaust manifold locknuts and separate the exhaust pipe. Discard the gasket.
  12.  
  13. Lower the vehicle.
  14.  
  15. Remove the exhaust manifold mounting fasteners, exhaust manifold stay (brace), exhaust manifold and gasket.
  16.  



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Fig. Fig. 3: Exhaust manifold assembly-2.5L VIN N engine

To install:
  1. Clean all gasket material from the mating surfaces and check the manifold for cracks or warpage.
  2.  
  3. Install a new gasket, then install the manifold and manifold stay (brace). Tighten the fasteners, in a crisscross pattern to 22 ft. lbs. (29 Nm).
  4.  
  5. Raise and safely support the vehicle.
  6.  
  7. Install the exhaust pipe to the exhaust manifold with a new gasket. Tighten the nuts to 33 ft. lbs. (44 Nm).
  8.  
  9. Lower the vehicle.
  10.  
  11. Install the engine hanger or lower heat shield, if equipped. Tighten the lower heat shield fasteners to 10 ft. lbs. (13 Nm).
  12.  
  13. Install the engine oil level dipstick and tube.
  14.  
  15. Install the cooling fan motor assembly, as outlined later in this section.
  16.  
  17. Connect the negative battery cable, then start the engine and check for exhaust leaks.
  18.  

REAR BANK SIDE

See Figure 3

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the intake manifold plenum and the plenum stay, as outlined earlier in this section.
  4.  
  5. Remove the heated oxygen sensor.
  6.  
  7. Remove the alternator, as described in Engine Electrical .
  8.  
  9. Remove the EGR pipe assembly.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Remove the exhaust pipe-to-exhaust manifold locknuts and separate the exhaust pipe. Discard the gasket.
  14.  
  15. Lower the vehicle.
  16.  
  17. If equipped, remove the manifold heat shield.
  18.  
  19. Remove the exhaust manifold mounting bolts, exhaust manifold stay (brace), exhaust manifold and gasket.
  20.  

To install:
  1. Clean all gasket material from the mating surfaces and check the manifold for cracks or warpage.
  2.  
  3. Install a new gasket and install the manifold and manifold stay (brace). Tighten the nuts, in a crisscross pattern to 22 ft. lbs. (30 Nm).
  4.  
  5. Install the manifold heat shield, if equipped.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Install the exhaust pipe to the exhaust manifold with a new gasket. Tighten the nuts to 33 ft. lbs. (44 Nm).
  10.  
  11. Lower the vehicle.
  12.  
  13. Install the EGR pipe assembly.
  14.  
  15. Install the alternator and the oxygen sensor.
  16.  
  17. Install the intake manifold plenum and the plenum stay (brace).
  18.  
  19. Connect the negative battery cable, then start the engine and check for exhaust leaks.
  20.  

2.5L (VIN H) Engine

See Figures 4 through 12

  1. Disconnect the negative battery cable from the left strut tower. 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.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Disconnect the exhaust pipe connection to the rear (cowl side) exhaust manifold at the flex joint.
  6.  



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Fig. Fig. 4: The crossunder pipe can be separated from the rear exhaust manifold extension pipe (1) or the exhaust manifold flange (2)



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Fig. Fig. 5: Remove the exhaust pipe-to-manifold flange gasket



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Fig. Fig. 6: Remove the retaining nuts and separate the main exhaust pipe from the rear exhaust manifold

It may be necessary to remove the whole exhaust system. Refer to procedure later in this section.

  1. Remove the bolts attaching the cross-over pipe to the manifolds and remove the assembly.
  2.  
  3. Disconnect the oxygen sensor lead wire at the rear manifold. Remove the oxygen sensor at the rear exhaust manifold.
  4.  
  5. Remove the power steering bracket.
  6.  
  7. Remove the rear exhaust manifold heat shield.
  8.  
  9. Remove the rear manifold attaching nuts and remove the rear manifold.
  10.  



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Fig. Fig. 7: Using a crow's foot wrench or O2 sensor socket, remove the oxygen sensor from the exhaust manifold

  1. Lower the vehicle and detach the front heated oxygen sensor wiring connector. Remove the front heated oxygen sensor.
  2.  
  3. Remove the front manifold heat shield.
  4.  



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Fig. Fig. 8: Remove the exhaust manifold heat shield retainers ...



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Fig. Fig. 9: ... then pull out the front exhaust manifold heat shield



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Fig. Fig. 10: Remove the exhaust manifold-to-cylinder head mounting bolts ...



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Fig. Fig. 11: ... then remove the front exhaust manifold from the vehicle



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Fig. Fig. 12: Remove the exhaust manifold-to-cylinder head gasket

If necessary, remove the EGR transducer mounting bracket and oil level dipstick tube for easier removal.

  1. Remove the front manifold securing nuts, then remove the front manifold.
  2.  

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 a new front manifold gasket.
  4.  
  5. Install the front manifold and tighten the nuts to 22 ft. lbs. (30 Nm).
  6.  
  7. Install the front exhaust manifold heat shield and tighten the mounting screws to 130 inch lbs. (15 Nm).
  8.  
  9. Install the front heated oxygen sensor. Engage the oxygen sensor wiring connector.
  10.  
  11. Raise and safely support the vehicle.
  12.  
  13. Install a new rear exhaust manifold gasket. Install the rear exhaust manifold.
  14.  
  15. Tighten the manifold nuts to 22 ft. lbs. (30 Nm).
  16.  
  17. Install the rear exhaust manifold heat shield and tighten the mounting screws to 115 inch lbs. (13 Nm).
  18.  
  19. Install the power steering bracket.
  20.  
  21. Install the crossover pipe and tighten the nuts to 22 ft. lbs. (30 Nm).
  22.  
  23. Install the rear heated oxygen sensor. Connect the rear heated oxygen sensor lead.
  24.  
  25. Connect the exhaust pipe to the rear manifold. Tighten the exhaust pipe-to-rear exhaust manifold flange mounting bolts to 21 ft. lbs. (28 Nm).
  26.  
  27. Lower the vehicle. Reconnect the negative battery cable. Start the engine and allow the engine to idle while inspecting the vehicle for exhaust leaks at the manifold.
  28.  

 
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