Chrysler 4448009 Exhaust Manifold

To access the manifold for replacement, put off the car's negative terminal and take off the air filter system. Enable the motor to cool so that the coolant is almost drained and eliminate the coolant bypass tube if required. Remove the crossed bolt of the exhaust system and you can get the lower bolt situated at the engine area. The exhaust manifold heat shield must be unbolted then detached appropriately from its position. Remove all the mounting bolts of the manifold and use penetrating lubricant during the process of removing the manifold and the cylinder head. Remove the old gasket and the mating surfaces to ensure that there is no deposit on them and also you should inspect the manifold for distortions and cracks by using a straight edge to check for warpage. Install the exhaust manifold in position with a new gasket and tighten the mounting bolts using finger only, and ensure that the precise position of the gasket is used. Round off the bolts from the middle and continue tightening to the torque level. If there is any of the higher or higher numbered part left reinstall them in the reverse sequence, then engage the engine to check for exhaust leak. To access the rear manifold, you have to remove the negative battery cable and the EGR tube and then remove the heat shield and the cross over pipe nuts. Remove the wire of the oxygen sensor, engage the parking brake, chock the rear wheels and then jack-up the front part of the car on jack-stands. Before that, loosen the two-exhaust pipe to manifold bolts-if necessary, apply penetrating oil-and then take off the exhaust manifold. Copper to be cleaned with surfaces belonging to the mating part to be checked for warpage and cracks, the process followed is the previous inspection process. Locate the new exhaust manifold into position adding a new gasket, tighten the bolts only slightly in the center and then tighten in a circular motion outward fashion. Install the other components back in reverse manner and the start the engine and check for exhaust leakages.

To perform removal of the throttle body assembly and intake manifold together with the exhaust manifolds, it is necessary first of all to release the fuel system pressure and disconnect the negative terminal of the battery and to drain the cooling system. Next, discard the air cleaner, be sure to identify all the vacuum lines and loose them from their connectors, all electrical wires, and fuel lines and the accelerator cable from the throttle lever. If so provisioned, remove the power steering pump belt, then disconnect the power brake vacuum line to the intake manifold, then unscrew the water hoses from the coolant crossover. Lift the front part of the car with jack and fix it securely on jack stands; remove the exhaust pipe from the exhaust manifold. If fitted, unbolt the power steering pump and, with it out of the way, set aside, and then unbolt the intake manifold support bracket and sever the EGR tube from the exhaust manifold. Lose the intake manifold bolts, lower the car and unbolt the throttle body and intake manifold in one assembly, thereby detaching the throttle body and gasket from the intake manifold before placing the unit on the bench. Lose the exhaust manifold nuts and take off the exhaust manifold: dispose of old gaskets and clean all gasket contact areas. Manifolds should also be cleaned with solvent and dried by compressed air, and the mating surfaces should be examined flat in relation to the straightedge, feeler gauges and the manifolds themselves should be examined for cracks and distortion and if present they should either be replaced or resurfaced. Concerning installation, it is advisable to replace either manifold; if so, transfer the studs to the new manifold. For the SOHC apply a thin layer of gasket sealant then place the new gaskets on the manifold sides, place the exhaust manifold on the cylinder head then install the nuts and begin tightening at the center in a cross wise manner. Place the intake manifold on the head, lift the car and secure it properly on jack stands, using the new intake manifold bolts put them in loosely following the crisscross technique beginning at the middle. The rest of the procedure of installation is carried out in the reverse order to the removal procedure.