Chrysler Full-Size Trucks 1989-1996 Repair Guide

Exhaust Manifold

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REMOVAL & INSTALLATION



2.5L Engine

Please refer to the combination manifold procedure for the 2.5L engine.

3.9L Engine

See Figure 1

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the hot air tube and heat shield, if necessary.
  4.  
  5. Raise the vehicle and safely support it on jackstands.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the hardware shown to detach the exhaust manifold-V6 engine

  1. Remove the exhaust pipe from the exhaust manifolds.
  2.  
  3. Lower the vehicle.
  4.  
  5. Take note of all conical washer locations and remove the bolts, nuts and washers attaching the manifold to the head.
  6.  
  7. Remove the manifold.
  8.  

To install:
  1. If either of the end studs came out with the nuts, install a new stud using sealer on the coarse threads.
  2.  
  3. Position the manifold on the end studs. Install conical washers and nuts on the studs.
  4.  
  5. Install the remaining bolts and washers in their proper locations. The inner bolts are not mounted with washers. Working outward from the center, tighten the bolts to 20 ft. lbs. (27 Nm) and the nuts to 15 ft. lbs. (20 Nm).
  6.  
  7. Install the exhaust pipe to the manifolds.
  8.  
  9. Connect the negative battery cable and check for exhaust leaks.
  10.  

5.2L and 5.9L Engines

See Figure 2

  1. Disconnect the exhaust manifold at the flange where it mates to the exhaust pipe.
  2.  
  3. If the vehicle is equipped with air injection and/or a heated air stove, remove them.
  4.  



Click image to see an enlarged view

Fig. Fig. 2: Remove the hardware shown to detach the exhaust manifold-V6 engine

  1. Remove the exhaust manifold by removing the securing bolts and washers. To reach these bolts, 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.
  2.  

To install:
  1. Clean the mounting surfaces so they are clean and dry.
  2.  
  3. Replace hardware, as necessary. Install a new gasket and the exhaust manifold. On the center branch of the exhaust manifold, no conical washers are used.
  4.  
  5. Install the air injection and/or heated air stove, if removed.
  6.  
  7. Install the exhaust pipe to the exhaust manifold flange.
  8.  

8.0L Engine

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the hardware that attaches the exhaust pipe to the exhaust manifold.
  6.  
  7. Lower the vehicle.
  8.  

  1. Remove the exhaust heat shields.
  2.  

  1. To remove the right exhaust manifold:
    1. Remove the EGR tube. Discard the gasket.
    2.  
    3. Remove the dipstick bracket from the manifold.
    4.  

  2.  
  3. Unbolt and remove the exhaust manifold. Discard the gasket.
  4.  

To install:
  1. Clean the surfaces so they are free of old material, oil, grease, etc, Inspect the surfaces for cracks and check flatness with a straightedge and feeler gauge. The mounting surfaces must be flat within 0.008 in./ft. (0.2mm/300mm).
  2.  
  3. Install a new gasket and the exhaust manifold(s). Once installed in the correct order, tighten the stud bolts and bolts to 16 ft. lbs. (22 Nm).
  4.  
  5. For the right side manifold:
    1. Install a new gasket and the EGR tube. Tighten the tube assembly nut to 25 ft. lbs. (34 Nm). Tighten the two EGR nuts to 175 inch lbs. (20 Nm).
    2.  
    3. Install the dipstick bracket to the manifold.
    4.  

  6.  
  7. Install the heat shield. Tighten the nuts onto the stud bolts to 175 inch lbs. (20 Nm).
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Install the exhaust pipe. Tighten the bolts to 25 ft. lbs. (34 Nm).
  12.  
  13. Lower the vehicle and connect the negative battery cable.
  14.  

Diesel Engine

See Figures 3 and 4

  1. Disconnect the negative battery cable.
  2.  
  3. Disconnect the air intake hose and exhaust pipe from the turbo.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: Fit the gaskets as shown for the exhaust manifold-diesel engine

  1. Remove the turbocharger and gasket.
  2.  



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Fig. Fig. 4: Tightening sequence for the diesel engine exhaust manifold

  1. Remove the cab heater supply and return lines.
  2.  
  3. Remove the exhaust manifold and gasket. Clean the gasket sealing surface.
  4.  

To install:
  1. Install the new gasket and manifold. Tighten the exhaust manifold bolts in sequence to 32 ft. lbs. (43 Nm).
  2.  
  3. Install the cab heater supply and return lines.
  4.  
  5. Install the turbocharger and gasket.
  6.  
  7. Connect the air intake and exhaust piping.
  8.  
  9. Connect the negative battery cable and check for exhaust leaks.
  10.  

 
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