Chrysler Full-Size Trucks 1967-1988 Repair Guide

Exhaust Manifold

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REMOVAL & INSTALLATION



It is always advisable to purchase new parts before proceeding with a job. Exhaust gaskets and down pipe gaskets can be purchased separately if need be. If you are planning on doing more than this procedure, a head set, which comes with all gaskets will do just as good. It is also advisable to look at the engine to see if while you are doing a job, you may need to replace a hose or wire that could be damaged. Even though it may not pertain to the current procedure, it can't take but a minute to fix another problem about to occur.

V6 and V8 Gasoline Engines

See Figures 1, 2 and 3

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the exhaust manifold at the flange where it mates to the exhaust pipe.
  4.  
  5. If the vehicle is equipped with air injection and/or a carburetor-heated air stove, remove them.
  6.  
  7. Remove the exhaust manifold by removing the securing nuts, washers and screws. To reach these pieces, it may be necessary to jack the engine slightly off its front mounts. When the exhaust manifold is removed, sometimes the securing studs will screw out with the nuts. If this occurs, the studs must be replaced with the aid of sealing compound on the coarse thread ends. If this is not done, water leaks may develop at the studs.
  8.  



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Fig. Fig. 1: V8 Exhaust Manifold

  1. Remove any gasket material left behind on the manifold and cylinder head.
  2.  
  3. Inspect the manifold for cracks, flatness, or warping which can occur and cause a leak. You would need to purchase a new manifold in this case.
  4.  



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Fig. Fig. 2: V6 Exhaust Manifold

To install:
  1. Position the arms of the manifolds on the studs of the cylinder head with a new gasket between them. Install conical washers and nuts on studs.
  2.  
  3. Install the two screws and conical washers at inner ends of outboard arms of manifold. Install two screws without washers on center arm of the manifold. Tighten the screws and nuts (starting at the center arm and working outwards) to 20 ft. lbs. (27 Nm).
  4.  



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Fig. Fig. 3: Exhaust manifold mounting-238 V6 Engine

  1. Assemble the exhaust pipe to the manifold, and secure with bolts, nuts and washers, tightening to 25 ft. lbs. (34 Nm).
  2.  

Diesel Engines
  1. Disconnect the battery ground cable.
  2.  
  3. Remove the air cleaner.
  4.  
  5. Remove the exhaust manifold heat shield.
  6.  
  7. Disconnect the exhaust pipe from the manifold.
  8.  
  9. Remove the exhaust manifold bridges and manifold hold-down bolts.
  10.  
  11. Remove the manifold and gaskets.
  12.  
  13. Inspect the manifold for cracks and heat damage. The gasket surfaces must be flat within 0.008 in. (0.20mm).
  14.  

To install:
  1. Install the gasket and manifold. Install exhaust manifold bridges and hold-down bolts. Tighten to specifications.
  2.  
  3. Connect the exhaust pipe to the manifold, tighten nuts. Install the heatshield.
  4.  
  5. Install the air cleaner, then connect the battery cable.
  6.  
  7. Check for leaks.
  8.  

 
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