Chrysler Neon 1995-1999 Repair Guide

Exhaust Manifold

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REMOVAL & INSTALLATION



See Figures 1 through 14

  1. Disconnect the negative battery cable.
  2.  
  3. Remove the air cleaner assembly and bracket.
  4.  



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Fig. Fig. 1: Remove the air cleaner lid and element, then remove the air cleaner assembly mounting bolts



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Fig. Fig. 2: Make sure to remove all of the air cleaner assembly retainers ...



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Fig. Fig. 3: ... then remove the air cleaner assembly from the vehicle



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Fig. Fig. 4: Once the air cleaner assembly is removed, you can loosen and remove the oxygen sensor if necessary

  1. Unfasten the retainers, then separate the exhaust pipe from the manifold. If Low Emission Vehicle (LEV) equipped, discard the manifold-to-flex joint gasket.
  2.  



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Fig. Fig. 5: Remove the retainers, then separate the exhaust pipe from the manifold



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Fig. Fig. 6: View of the exhaust pipe-to-manifold retainers

  1. Unbolt the power steering pump reservoir and position it aside. Do NOT disconnect the fluid lines.
  2.  



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Fig. Fig. 7: To access the heat shield, unfasten the power steering reservoir mounting bolts ...



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Fig. Fig. 8: ... then position the power steering reservoir aside, but do not disconnect the fluid lines

  1. Unfasten the retainers, then remove the exhaust manifold heat shield.
  2.  



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Fig. Fig. 9: Remove the retainers, then remove the exhaust manifold heat shield



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Fig. Fig. 10: Location of the exhaust manifold heat shield fasteners

  1. For 1996-99 vehicles, detach the upstream heated oxygen sensor connector.
  2.  

It may be necessary to loosen the alternator bracket bolt to remove the outer exhaust manifold bolt.

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Fig. Fig. 11: Loosen the alternator bracket bolt shown ...



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Fig. Fig. 12: ... in order to remove the outer exhaust manifold bolt

  1. Remove the 8 exhaust manifold retaining fasteners, then remove the exhaust manifold and gasket.
  2.  



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Fig. Fig. 13: Unfasten the remaining exhaust manifold mounting bolts



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Fig. Fig. 14: ... then remove the exhaust manifold from the vehicle

  1. Discard the gasket, then thoroughly clean the mating surfaces.
  2.  

To install:
  1. Position a new gasket and the exhaust manifold it their proper positions. Apply Mopar stud and bearing mount, or equivalent, to the fasteners. Install the fasteners and tighten to 17 ft. lbs. (23 Nm), starting at the center and working outward in both directions. Repeat this procedure until all fasteners are tightened to specifications.
  2.  
  3. If loosened, tighten the alternator bracket bolt.
  4.  
  5. Install the exhaust manifold heat shield.
  6.  
  7. Place the power steering pump reservoir in position and secure with the mounting bolts.
  8.  
  9. If necessary, attach the upstream heated oxygen sensor.
  10.  
  11. Install the air cleaner bracket and assembly.
  12.  
  13. If Low Emission Vehicle (LEV) equipped, replace the manifold-to-flex fold gasket.
  14.  
  15. Attach the exhaust pipe to the manifold and tighten to 21 ft. lbs. (28 Nm).
  16.  
  17. Connect the negative battery cable.
  18.  

 
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