Chrysler Full-Size Trucks 1997-2000 Repair Guide

Exhaust Manifold

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REMOVAL & INSTALLATION



Common Steps

NOTE
The following steps are common to all models. Read this information before beginning the specific procedures for your vehicle.

  1. New gaskets are required on installation. Purchase these before beginning.
  2.  
  3. Access to exhaust manifold components is easier if the vehicle is raised.
  4.  


CAUTION
Obey all applicable safety procedures for jacking, supporting, and working beneath the vehicle.

  1. Disconnect the battery negative cable(s).
  2.  
  3. Check manifolds and header pipes for any sensor(s) which may be fitted to them and disconnect the wiring if it interferes with removal.
  4.  
  5. Remove the heat shield(s), if fitted.
  6.  
  7. Disconnecting the header(s) from the exhaust pipe(s) may be easier from beneath the vehicle.
  8.  
  9. Wire brush the threads of any accessible fasteners. Apply penetrating fluid to fasteners to ease disassembly.
  10.  
  11. Do NOT strike the manifold or exhaust pipe with a hammer. Use a plastic mallet to prevent damage.
  12.  
  13. Clean all mating surfaces before installation.
  14.  
  15. Anti-seize compound applied to the threads of nuts and bolts will make future removal easier.
  16.  
  17. Tighten all hardware evenly and to the proper torque. Manifold nuts and bolts should be tightened from the center outwards. Do NOT attempt to drive the manifold home by running down the nuts or bolts.
  18.  
  19. After installation is complete, start the engine and check for leaks.
  20.  


NOTE
If the studs come out of the block when the nuts are loosened, the use of new studs is recommended. Coat the threads of the new studs with an adhesive/sealer. This will help prevent oil leaks.



Click image to see an enlarged view

Fig. Spray hardware with penetrating fluid. Brittle metal may snap if the fastener is forced

2.5L Engine
  1. Perform the "Common Steps" above.
  2.  
  3. Remove the exhaust pipe nuts and disconnect the exhaust pipe from the exhaust manifold.
  4.  
  5. Remove the intake manifold.
  6.  
  7. Remove the exhaust manifold.
  8.  
  9. Install a new intake manifold gasket over the alignment dowels.
  10.  
  11. Install the exhaust manifold assembly. Be sure it is centrally located over the end studs and spacer.
  12.  
  13. Referring back to the appropriate figure under "Intake Manifold Removal", tighten the bolt 1 to 30 ft. lbs. (41 Nm).
  14.  
  15. Install the intake manifold. Tighten bolts 2 through 5 to 23 ft. lbs. (31 Nm).
  16.  
  17. Install the exhaust manifold spacers over the mounting studs.
  18.  
  19. Tighten nuts 6 and 7 to 23 ft. lbs. (31 Nm).
  20.  
  21. The remainder of the procedure is the reverse of removal. Tighten the exhaust pipe nuts to 23 ft. lbs. (31 Nm).
  22.  

4.7L Engine
  1. Perform the "Common Steps" above.
  2.  
  3. Remove the left side manifold by undoing the exhaust pipe nuts and the manifold bolts on the cylinder head.
  4.  
  5. For the right side manifold:
    1. Remove the air cleaner and resonator assemblies and the air inlet hose.
    2.  
    3. Remove the accessory drive belt.
    4.  
    5. Remove the A/C compressor and set it to one side.
    6.  
    7. Remove the A/C accumulator support bracket fastener.
    8.  
    9. Drain the radiator and remove the heater hoses at the engine.
    10.  
    11. Remove the heat shield.
    12.  
    13. Remove the upper exhaust manifold fasteners.
    14.  
    15. Disconnect the exhaust pipe.
    16.  
    17. Remove the starter.
    18.  
    19. Remove the lower exhaust manifold fasteners. Remove the manifold.
    20.  

  6.  
  7. Installation is the reverse of removal. Tighten manifold hardware to 18 ft. lbs. (25 Nm).
  8.  
  9. Tighten the heat shield fasteners to 72 inch lbs. (8 Nm), then loosen 45º.
  10.  



Click image to see an enlarged view

Fig. Exhaust manifold and heat shield assembly-4.7L

3.9L, 5.2L, 5.9L Gasoline engines
  1. Perform the "Common Steps" above.
  2.  
  3. Remove the exhaust pipe to manifold nuts.
  4.  
  5. Remove the nuts and bolts securing the manifold to the head.
  6.  
  7. Installation is the reverse of removal. Tighten cylinder head hardware to 18 ft. lbs. (24 Nm). Tighten exhaust pipe nuts to 20 ft. lbs. (27 Nm).
  8.  



Click image to see an enlarged view

Fig. Disconnecting the manifold-to-exhaust pipe nuts-typical



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Fig. Exhaust manifold and mounting hardware-5.2L shown

8.0L Engine
  1. Perform the "Common Steps" above.
  2.  
  3. Remove the exhaust pipe to manifold nuts and bolts.
  4.  
  5. Remove the dipstick bracket (right side).
  6.  
  7. Remove the bolts securing the manifold to the head.
  8.  
  9. Installation is the reverse of removal. Tighten hardware to 16 ft. lbs. (22 Nm).
  10.  

Diesel Engine
  1. Perform the "Common Steps" above.
  2.  
  3. Disconnect the exhaust pipe from the turbocharger.
  4.  
  5. Remove the turbocharger. See "Turbocharger" for procedures.
  6.  
  7. Remove the cab heater return pipe nut from the exhaust manifold stud. Position tube out of the way.
  8.  
  9. Remove the fasteners and separate the exhaust manifold from the head.
  10.  
  11. Installation is the reverse of removal. Tighten the manifold hardware evenly and in a cross pattern starting in the center and working outwards. Proper torque is 32 ft. lbs. (43 Nm).
  12.  
  13. Install the turbocharger. See "Turbocharger" for procedures.
  14.  



Click image to see an enlarged view

Fig. Exhaust manifold assembly and tightening sequence-Diesel

 
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