TownAndCountry 2008

Exhaust Manifold

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Removal & Installation



3.3L & 3.8L Engines
Left

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Remove the bolts attaching the crossover pipe (1) to the exhaust manifold.

    Click image to see an enlarged view

    Fig. Remove the bolts attaching the crossover pipe to the exhaust manifold-3.3L and 3.8L engines

  6.  
  7. Disconnect the left cylinder bank spark plug wires.
  8.  
  9. Remove the heat shield (2) attaching bolts.
  10.  
  11. Remove the bolts attaching the exhaust manifold (1) to the cylinder head.
  12.  
  13. Remove the exhaust manifold (1).
  14.  
  15. Inspect and clean the exhaust manifold.

    Click image to see an enlarged view

    Fig. Remove the LH exhaust manifold-3.3L and 3.8L engines

  16.  

To install:

  1. Position the exhaust manifold (1) on the cylinder head. Install the bolts to the center runner (cylinder No. 4) and initially tighten to 25 inch lbs. (3 Nm).
  2.  
  3. Using a new gasket, attach the crossover pipe (1) to the exhaust manifold and tighten the bolts to 30 ft. lbs. (41 Nm).
    NOTE
    Inspect the crossover pipe fasteners for damage from heat and corrosion. The cross-over bolts are made of a special stainless steel alloy. If replacement is required, OEM bolts are highly recommended.

  4.  
  5. Position the heat shield (2) on the exhaust manifold.
  6.  
  7. Install the remaining manifold attaching bolts (4). Tighten all the bolts to 17 ft. lbs. (23 Nm).
  8.  
  9. Install and tighten the heat shield attaching nut (3) to 105 inch lbs. (12 Nm).
  10.  
  11. Connect the battery negative cable.
  12.  

Right Exhaust Manifold

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the battery negative cable.
  4.  
  5. Remove the wiper module.
  6.  
  7. Disconnect the spark plug wires.
  8.  
  9. Remove the bolts (2) fastening the crossover pipe (1) to the exhaust manifold.

    Click image to see an enlarged view

    Fig. Remove the bolts attaching the crossover pipe to the exhaust manifold-3.3L and 3.8L engines

  10.  
  11. Disconnect and remove the upstream oxygen sensor.
  12.  
  13. Remove the heat shield attaching screws.
  14.  
  15. Remove the upper heat shield.
  16.  
  17. Raise the vehicle on a hoist and remove the accessory drive belt shield.
  18.  
  19. Disconnect the downstream oxygen sensor connector.
  20.  
  21. Disconnect the catalytic converter pipe from the exhaust manifold.
  22.  
  23. Remove the bolts attaching the exhaust manifold (5) to the cylinder head and remove the manifold.
  24.  
  25. Inspect and clean the manifold.

    Click image to see an enlarged view

    Fig. Remove the RH exhaust manifold-3.3L and 3.8L engines

  26.  

To install:

  1. Position the exhaust manifold (5) on the cylinder head and install the bolts to the center runner (cylinder No. 3) and initially tighten to 25 inch lbs. (3 Nm).
  2.  
  3. Using a new gasket, attach the crossover pipe (1) to the exhaust manifold and tighten the bolts to 30 ft. lbs. (41 Nm).
    NOTE
    Inspect the crossover pipe fasteners for damage from heat and corrosion. The cross-over bolts are made of a special stainless steel alloy. If replacement is required, OEM bolts are highly recommended.

  4.  
  5. Install the remaining manifold attaching bolts. Tighten all bolts to 17 ft. lbs. (23 Nm).
  6.  
  7. Install the heat shield (2, 4) and the attaching screws.
  8.  
  9. Install and connect the upstream oxygen sensor.
  10.  
  11. Raise the vehicle.
  12.  
  13. Attach the catalytic converter pipe (4) to the exhaust manifold using a new gasket and tighten the bolts to 27 ft. lbs. (37 Nm).

    Click image to see an enlarged view

    Fig. Attach the catalytic converter pipe to the exhaust manifold-3.3L and 3.8L engines

  14.  
  15. Connect the downstream oxygen sensor connector.
  16.  
  17. Install the accessory drive belt splash shield and lower the vehicle.
  18.  
  19. Install the wiper module.
  20.  
  21. Connect the battery negative cable.
  22.  

4.0L Engine
Left Side

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect and isolate the negative battery cable.
  4.  
  5. Remove the radiator cooling fan assembly. Refer to Engine Fan, removal & installation.
  6.  
  7. Loosen the oil level indicator tube retaining bolt and position the oil level indicator tube and the dipstick out of the way.
  8.  
  9. Disconnect the upstream oxygen sensor harness connector.
  10.  
  11. Disconnect the downstream oxygen sensor harness connector.
  12.  
  13. Remove the 3 upper heat shield retainers (1), then remove the upper heat shield (2).

    Click image to see an enlarged view

    Fig. Remove the 3 upper heat shield retainers (1), then remove the upper heat shield (2)-4.0L engine

  14.  
  15. Remove the lower exhaust manifold crossover pipe retaining bolts (1).

    Click image to see an enlarged view

    Fig. Remove the lower exhaust manifold crossover pipe retaining bolts (1)-4.0L engine

  16.  
  17. Remove the upper exhaust maniverter (manifold/converter) retaining bolts (1), and the exhaust maniverter.

    Click image to see an enlarged view

    Fig. Remove the upper exhaust maniverter (manifold/converter) retaining bolts (1), and the exhaust maniverter-4.0L engine

  18.  

To install:

  1. Clean all rear maniverter gasket mounting surfaces.
  2.  
  3. Position the exhaust manifold and a new gasket on the cylinder head. Install the fasteners (1). Tighten the bolts starting at the center working outward to 250 inch lbs. (28 Nm).
  4.  
  5. Install the lower exhaust manifold-to-cross-under pipe fasteners. Tighten the fasteners to 250 inch lbs. (28 Nm).
  6.  
  7. Install the exhaust maniverter upper heat shield and the fasteners. Tighten the fasteners to 105 inch lbs. (12 Nm).
  8.  
  9. If installing a new maniverter, transfer the O2 sensors from the existing front maniverter.
  10.  
  11. Reconnect the O2 sensor harness connectors.
  12.  
  13. Reposition the oil dipstick tube and install the retaining bolt (1).
  14.  
  15. Install the radiator cooling fan assembly. Refer to Engine Fan, removal & installation.
  16.  
  17. Connect the negative battery cable.
  18.  

Right Side

Specific to:

Chrysler Town & Country 2008-2009

Dodge Grand Caravan 2008-2009

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise and support the vehicle.
  6.  
  7. Disconnect the upstream oxygen sensor electrical connector.
  8.  
  9. Disconnect the downstream oxygen sensor electrical connector.
  10.  
  11. Remove the rear maniverter (manifold/converter) heat shield fasteners (1, 2), and remove the rear maniverter heat shield (3).

    Click image to see an enlarged view

    Fig. Remove the rear maniverter (manifold/converter) heat shield fasteners (1, 2), and remove the rear maniverter heat shield (3)-4.0L engine

  12.  
  13. Remove the lower exhaust maniverter-to-cross-under pipe bolts (1) from the maniverter (2).

    Click image to see an enlarged view

    Fig. Remove the lower exhaust maniverter-to-cross-under pipe bolts (1) from the maniverter (2)-4.0L engine

  14.  
  15. Remove the exhaust manifold inlet flange retaining fasteners and disconnect the exhaust system hangers from the pipe assembly.
    NOTE
    Be careful when removing the rear exhaust maniverter fasteners. The rear exhaust maniverter fasteners may be locked onto the studs in the cylinder head.

  16.  
  17. Remove the rear exhaust maniverter fasteners (1).
  18.  
  19. Remove the rear exhaust maniverter (2).

    Click image to see an enlarged view

    Fig. Remove the rear exhaust maniverter fasteners (1) and the rear exhaust maniverter (2)-4.0L engine

  20.  

To install:

  1. Clean the gasket surfaces.
  2.  
  3. Replace any damaged studs, or reinstall any studs that came out during removal. Tighten the studs to 20 inch lbs. (2 Nm).
  4.  
  5. Position the exhaust manifold and a new gasket on the studs in the cylinder head.
  6.  
  7. Tighten the rear maniverter fasteners starting at the center working outward to 17 ft. lbs. (23 Nm).
  8.  
  9. Install the exhaust system. Connect the exhaust system hangers from the pipe assembly and install the 3 exhaust manifold flange retaining fasteners (1). Tighten the fasteners to 22 ft. lbs. (30 Nm).

    Click image to see an enlarged view

    Fig. Install the exhaust system. Connect the exhaust system hangers from the pipe assembly (2) and install the exhaust manifold flange retaining fasteners (1)-4.0L engine

  10.  
  11. Install the rear maniverter heat shield (3), and install the rear maniverter heat shield fasteners (1) and (2). Tighten the rear maniverter heat shield bolts to 105 inch lbs. (12 Nm).
  12.  
  13. Install the lower exhaust maniverter-to-cross-under pipe bolts (1). Tighten to 250 inch lbs. (28 Nm).
  14.  
  15. If installing a new maniverter, transfer the existing oxygen sensors from the original maniverter.
  16.  
  17. Connect the downstream oxygen sensor electrical connector.
  18.  
  19. Connect the upstream oxygen sensor electrical connector.
  20.  
  21. Connect the negative battery cable.
  22.  

 
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