Chrysler 4781038AB Exhaust Manifold

To remove the exhaust manifold, first disconnect the cable from the negative terminal of the battery, set the parking brake, and block the rear wheels. Raise the front of the vehicle and support it securely on jackstands. Apply penetrating oil to the exhaust pipe-to-manifold fasteners to facilitate removal, then detach the exhaust pipe from the exhaust manifold at the flex-joint. Disconnect the wiring harness from the upstream oxygen sensor and remove the exhaust manifold bolts along with the manifold itself. The exhaust pipe may need to be removed to ease the manifold's removal. For inspection, clean the exhaust manifold bolts with a wire brush and replace any that are damaged. Use a scraper to eliminate all gasket material from the exhaust flange mating surfaces, inspecting them for wear and cracks while being cautious not to damage the sealing surface. Check the exhaust manifold-to-cylinder head mating surface for warpage using a straightedge and feeler gauge, and do the same for the cylinder head; if warpage exceeds limits, replacement or resurfacing is necessary. For installation, apply Loctite No. 271 to the mounting bolt threads, install a new dry gasket, the manifold, and bolts, tightening them in stages from the center to the outer bolts to the specified torque. Reinstall the remaining components in reverse order of removal, ensuring a new gasket is placed between the exhaust manifold and exhaust pipe, then run the engine to check for exhaust leaks.

Disconnect the cable from the negative terminal of the battery. For the removal of the rear exhaust manifold, first remove the cowl cover and the wiper unit, then disconnect the rear bank of spark plug wires. Unbolt the crossover pipe where it joins the rear exhaust manifold, disconnect and remove the upstream oxygen sensor connector, and then remove the upstream oxygen sensor. Next, remove the bolts and the upper heat shield, raise the vehicle and support it securely on jackstands, and remove the engine splash shield from the passenger's side. Loosen the power steering pump support strut lower bolt, disconnect the downstream oxygen sensor connector, and remove the bolts to disconnect the catalytic converter from the exhaust manifold. Lower the vehicle and remove the power steering pump support strut upper bolt, then remove the bolts attaching the rear exhaust manifold to the cylinder head and take out the rear exhaust manifold. For the front exhaust manifold, unbolt the crossover pipe where it joins the front exhaust manifold, disconnect the front bank of spark plug wires, remove the bolts and the upper heat shield, and then remove the bolts attaching the front exhaust manifold to the cylinder head. For installation, clean the mating surfaces to remove all traces of old gasket material and inspect the exhaust manifolds for distortion and cracks, checking for warpage with a precision straight edge. If a feeler gauge thicker than 0.030-inch can be inserted between the straightedge and the mating surface, take the exhaust manifold(s) to an automotive machine shop for resurfacing. Place the exhaust manifold in position with a new gasket and install the mounting bolts finger tight, ensuring to identify the exhaust manifold gasket by the correct cylinder designation and the position of the exhaust ports on the gasket. Starting in the middle and working out toward the ends, tighten the bolts to the specified torque. The installation of the remaining components follows the reverse order of removal. Finally, start the engine and check for exhaust leaks between the exhaust manifolds and the cylinder heads, as well as between the exhaust manifolds, crossover pipe, and catalytic converter.