Chrysler Full-Size Vans 1989-1998 Repair Guide

Exhaust Manifold

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REMOVAL & INSTALLATION



See Figures 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17 and 18

  1. Disconnect the negative battery cable.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. From underneath the vehicle, remove the bolts and nuts attaching the exhaust pipe to the exhaust manifold.
  6.  
  7. Lower the vehicle.
  8.  
  9. Remove the heat shield(s).
  10.  
  11. Remove the engine cover.
  12.  

It is a good idea to coat the manifold retaining bolts and studs with a suitable rust penetrant before attempting to loosen them.

  1. Remove the retaining bolts and studs on the exhaust manifold.
  2.  

Do not pry on the manifold, as this could cause the manifold to crack. If stuck, tap with a soft faced hammer to loosen.

  1. Remove the manifold from the cylinder block.
  2.  



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Fig. Fig. 1: The right side exhaust heat shield location



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Fig. Fig. 2: The left side exhaust heat shield location



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Fig. Fig. 3: The exhaust heat shields are held on by bolts and nuts located underneath the vehicle



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Fig. Fig. 4: Remove the heat shield after the bolts are loosened to gain access to the exhaust manifold retaining bolts and nuts



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Fig. Fig. 5: The flanges at the exhaust manifold-to-Y-pipe have to be removed to facilitate manifold removal. Note the highlighted bolt locations



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Fig. Fig. 6: Spray the flange bolts with a rust penetrant prior to loosening them. This may prevent them from breaking upon removal



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Fig. Fig. 7: Use a wrench or suitable tool to hold the nut at the top of the flange when removing the retaining bolt



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Fig. Fig. 8: When the bolts are removed, pull the flange back to allow enough room for the manifold to come out



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Fig. Fig. 9: Remove the EGR tube retaining nuts



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Fig. Fig. 10: Unfasten the fitting at the EGR valve to completely remove the EGR tube



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Fig. Fig. 11: Be sure to safely store the EGR tube after removal until reinstallation



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Fig. Fig. 12: Remember to pull the old EGR tube gasket off of the exhaust manifold, and replace it before installation



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Fig. Fig. 13: Remove the retaining bolts and nuts from the exhaust manifold(s)



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Fig. Fig. 14: Typical V6 manifold installation



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Fig. Fig. 15: Typical V8 manifold installation



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Fig. Fig. 16: Some of the exhaust manifold retaining hardware are bolts ...



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Fig. Fig. 17: ... and some of them are nuts. It is important to note their locations at removal to ease installation



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Fig. Fig. 18: After all the retaining hardware is removed, pull the exhaust manifold off the cylinder head and remove it from the engine

To install:
  1. Thoroughly clean the manifold and the cylinder head mating surfaces; no gasket is used.
  2.  
  3. Inspect the manifold for cracks before installation.
  4.  
  5. With a straightedge or suitable tool, inspect the manifold and the cylinder head mating surfaces for flatness.
  6.  
  7. On some models, inspect the heat valve located in the passenger side manifold for proper operation by checking to make sure that it turns freely.
  8.  
  9. Clean the threads in the cylinder head before installing the bolts.
  10.  

If the manifold studs came out with the nuts, replace the studs, applying sealant to the coarse ends.

  1. Position the manifold on the head, lining up the holes on the manifold with the studs. Install the nuts and conical washers on the studs.
  2.  
  3. Install two bolts with conical washers at the inner ends, and two bolts without washers on the center arm of the manifold.
  4.  
  5. Tighten the bolts and nuts, working from the center outward, to 25 ft. lbs. (34 Nm).
  6.  
  7. Install the heat shield(s) and tighten the screws to 55 inch lbs. (6 Nm).
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Install the flange at the exhaust pipe and the manifold junction. Tighten the bolts to 19 ft. lbs. (26 Nm).
  12.  
  13. Lower the vehicle.
  14.  
  15. Connect the negative battery cable.
  16.  
  17. Start the engine and check for exhaust leaks.
  18.  
  19. Install the engine cover.
  20.  

 
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