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    2009 Dodge/Ram Truck Sprinter 3500 Van 3.0L Turbo Diesel 6cyl

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    Chrysler Caravan/Voyager/Town and Country 1996-1999

    Exhaust Manifold

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    REMOVAL & INSTALLATION



    2.4L Engine

    See Figure 1

    1. Disconnect the negative battery cable.
    2.  
    3. Raise and safely support the vehicle.
    4.  
    5. Disconnect the exhaust pipe from the exhaust manifold at the flex joint. Apply penetrating oil on the exhaust manifold-to-exhaust pipe flange bolts to aid in removal. It may be necessary to remove the entire exhaust system.
    6.  
    7. Detach the oxygen sensor wiring connector at the rear of the exhaust manifold.
    8.  
    9. Remove the eight manifold attaching bolts and remove the manifold from the cylinder head.
    10.  



    Click image to see an enlarged view

    Fig. Fig. 1: Tighten the exhaust manifold bolts in the sequence shown to prevent exhaust leaks-2.4L engine (Removal should be in reverse order)

    To install:
    1. Thoroughly clean all parts. Discard the gasket (if equipped) and clean all gasket surfaces of the manifold and cylinder head. Test the manifold gasket surface for flatness with a straightedge and feeler gauge. The surface must be flat within 0.006 inches per foot (0.15mm per 30cm) of manifold length. Inspect the manifold for cracks or distortion. Replace if necessary.
    2.  
    3. Install the manifold to the vehicle with a new gasket. DO NOT APPLY SEALER.
    4.  
    5. Install the eight manifold bolts and tighten, starting at the center and working outward in both directions, to 17 ft. lbs. (23 Nm).
    6.  
    7. Reconnect the oxygen sensor wiring connector.
    8.  
    9. Reconnect the exhaust pipe to the exhaust manifold and tighten the fasteners to 20 ft. lbs. (28 Nm).
    10.  
    11. Reconnect the negative battery cable. Start the engine and allow it to idle while inspecting the manifold for exhaust leaks.
    12.  

    3.0L Engine

    See Figures 2, 3, 4, 5, 6, 7, 8 and 9



    Click image to see an enlarged view

    Fig. Fig. 2: To remove an exhaust manifold, unbolt the heat shield ...



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    Fig. Fig. 3: ... and remove it to access the manifold fasteners



    Click image to see an enlarged view

    Fig. Fig. 4: Use an extension if necessary to access the manifold fasteners



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    Fig. Fig. 5: In addition to removing the exhaust pipe from the manifold, be sure to remove the crossover pipe-to-exhaust manifold fasteners

    1. Disconnect the negative battery cable. Raise and safely support the vehicle.
    2.  
    3. Disconnect the exhaust pipe from the rear exhaust manifold, at the flex joint.
    4.  
    5. Remove the rear exhaust manifold heat shield.
    6.  
    7. Remove the rear exhaust manifold-to-cylinder head nuts and remove the exhaust manifold.
    8.  
    9. Remove the crossover pipe-to-exhaust manifold attaching bolts.
    10.  
    11. Lower the vehicle and remove the heat shield from the front exhaust manifold.
    12.  
    13. Remove the bolts fastening the crossover pipe to the front exhaust manifold. Remove the front exhaust manifold-to-cylinder head nuts and remove the exhaust manifold.
    14.  
    15. Clean the gasket mounting surfaces. Inspect the manifolds for cracks, flatness and/or damage.
    16.  

    To install:

    Install the gasket with the numbers 1-3-5 embossed on the top on the rear bank and those with the numbers 2-4-6 on the front (radiator side) bank.

    1. Raise and safely support the vehicle.
    2.  
    3. Install the new gasket and rear exhaust manifold to the cylinder head. Install and tighten the rear exhaust manifold-to-cylinder head nuts to 175 inch lbs. (20 Nm).
    4.  



    Click image to see an enlarged view

    Fig. Fig. 6: With everything unfastened, the manifold can be removed from the cylinder head



    Click image to see an enlarged view

    Fig. Fig. 7: Always use a new gasket to prevent leakage (Note how the exhaust manifold gasket doubles as a heat shield)



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    Fig. Fig. 8: Before installing the exhaust manifold, clean both the cylinder head ...



    Click image to see an enlarged view

    Fig. Fig. 9: ... and manifold mating surfaces, to ensure a clean surface for the new gaskets to seal properly

    1. Attach the exhaust pipe to the exhaust manifold and tighten the shoulder bolts to 20 ft. lbs. (28 Nm)
    2.  
    3. Attach the crossover pipe to the exhaust manifold and tighten the bolts to 51 ft. lbs. (69 Nm).
    4.  
    5. Install the rear exhaust manifold heat shield and tighten the heat shield mounting fasteners to 130 inch lbs. (15 Nm).
    6.  
    7. Connect the EGR tube to the rear manifold, if removed, and reconnect the oxygen sensor.
    8.  
    9. Lower the vehicle.
    10.  
    11. Install the front exhaust manifold and attach the exhaust crossover pipe. Tighten the bolts to 51 ft. lbs. (69 Nm).
    12.  
    13. Install the front exhaust manifold heat shield and tighten the bolts to 130 inch lbs. (15 Nm).
    14.  
    15. Reconnect the negative battery cable. Start the engine and check for exhaust leaks.
    16.  

    3.3L and 3.8L Engines

    See Figures 10, 11 and 12



    Click image to see an enlarged view

    Fig. Fig. 10: Rear exhaust manifold mounting detail-3.3 and 3.8L engines

    1. Disconnect the negative battery cable.
    2.  
    3. Remove the accessory drive belt.
    4.  
    5. Remove the alternator.
    6.  
    7. Raise and safely support the vehicle.
    8.  
    9. Disconnect the exhaust pipe from the rear exhaust manifold at the flex joint.
    10.  
    11. Separate the EGR tube from the exhaust manifold and disconnect the oxygen sensor.
    12.  
    13. Remove the alternator/power steering support strut.
    14.  
    15. Remove the crossover pipe attaching bolts to the rear exhaust manifold.
    16.  
    17. Remove the rear exhaust manifold heat shield.
    18.  



    Click image to see an enlarged view

    Fig. Fig. 11: Front exhaust manifold mounting detail-3.3 and 3.8L engines



    Click image to see an enlarged view

    Fig. Fig. 12: Crossover pipe mounting detail-3.3 and 3.8L engines

    1. Remove the rear manifold-to-cylinder head nuts, then remove the rear manifold.
    2.  
    3. Lower the vehicle and remove the front exhaust manifold heat shield.
    4.  
    5. Remove the front exhaust manifold crossover pipe bolts.
    6.  
    7. Remove the front manifold-to-cylinder head nuts, then remove the front exhaust manifold.
    8.  
    9. Clean the mounting surfaces. Inspect the manifolds for cracks or other damage. With a straightedge and feeler gauge, check for flatness. Standard is 0.004 in. (0.1mm) with 0.008 in. (0.2mm) out-of-flatness the service limit. If distorted beyond these specifications, replace the manifold.
    10.  

    To install:
    1. Raise and safely support the vehicle.
    2.  
    3. Install the new gasket and rear manifold. Tighten the manifold-to-cylinder head nuts to 17 ft. lbs. (23 Nm).
    4.  
    5. Install the rear exhaust manifold heat shield. Tighten the heat shield mounting fasteners to 17 ft. lbs. (23 Nm).
    6.  
    7. Install the alternator unit.
    8.  
    9. Connect the exhaust pipe to the exhaust manifold and tighten the bolt to 20 ft. lbs. (28 Nm).
    10.  
    11. Connect the crossover pipe to the rear manifold and tighten the bolts to 25 ft. lbs. (33 Nm).
    12.  
    13. Connect the oxygen sensor.
    14.  
    15. Connect the EGR tube to the exhaust manifold and install the alternator/power steering support strut.
    16.  
    17. Lower the vehicle.
    18.  
    19. Install the new gasket and front exhaust manifold to the cylinder head. Tighten the exhaust manifold-to-cylinder head nuts to 17 ft. lbs. (23 Nm).
    20.  
    21. Connect the crossover pipe to the front manifold.
    22.  
    23. Install the front manifold heat shield. Tighten the heat shield mounting fasteners to 200 inch lbs. (23 Nm).
    24.  
    25. Install the accessory drive belt.
    26.  
    27. Reconnect the negative battery cable.
    28.  
    29. Start the engine and check for exhaust leaks.
    30.  

     
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