Chrysler 68027492AB Exhaust Manifold

To remove the exhaust manifold to begin with one has to lift the front portion of the car and place it on jack stands. The exhaust pipe has to be disconnected from the exhaust manifold before lowering the vehicle body down. Next, air filter housing and bracket, exhaust manifold heat shield will be detached in the next step. To accomplish this, remove the bolt and nut which secures the electrical connector for the oxygen sensor and then release the sensor from the exhaust manifold. Loosen the mounting bolts to remove the exhaust manifold with the old gasket also. For the inspection, cracks or damages to the exhaust manifold should be checked, and if these are present then it can be replaced. Before installing the exhaust manifold, tighten the bolts and clean the threads with a wire brush on any bolts which are bent or broken. Scrape all the gasket material from both contacting surfaces, running the scraper carefully not to nick the surfaces as this will explain to leakage. Check the respective mating surface with a straight edge and a feeler gauge and in the event of excessive warpage it would be necessary to replace or machine them. For installation put a new gasket on the exhaust manifold and tighten the mounting bolts with hands only. Lift the front of the vehicle once more and tighten the exhaust pipe bolts by the use of your hand to sine the nuts. Tighten the exhaust manifold mounting bolts starting from the middle and then from the outside and then tighten exhaust pipe mounting bolts. The following steps, therefore, proceed in the reverse order from that of removal.

Before removing the exhaust manifold, it is recommended to detach the cable of the negative terminal of the battery. Then, safely lift the vehicle up and securely set on the jackstand, and then remove the engine splash shield at the passenger's side. Remove the upstream and downstream oxygen connectors and if the manifold is to be replaced both oxygen sensors ought to be removed. Remove the exhaust pipe from the exhaust manifold, disconnect the exhaust system hangers and put down the pipe assembly. Next step is to unscrew the bolts as well as take out the upper heat shield; then the exhaust manifold to cylinder head bolts as well as the exhaust manifold are taken out. Regarding installation, the mating surfaces should be cleaned from the gasket debris, and exhaust manifolds should be checked for distortion and crackages, using the precision straightedge when examining warpage. If a feeler gauge thicker than 0.030-inch can be inserted between the straightedge, and the mating surface, then you should take exhaust manifold(s) to the automotive machine shop for resurfacing. Install the exhaust manifold upside down with a new gasket and tighten the bolts by fingers only so as to observe the orientation of the gasket and the position of the cylinder designation as well as the exhaust ports. Loosen the bolts and then vice versa, starting from the center and moving to the edges to the torque indicated. Last of all, replace the rest of the components in the reverse order of removal, turn the engine on and look and listen for any exhaust leak at the interface of the exhaust manifolds and cylinder head; between the manifolds, the crossover pipe, and the catalytic converter.

Lift the front of the vehicle, and support it with jackstands; remove the exhaust pipe from the exhaust manifold, and lower the vehicle. Pull off the air filter housing or bracket, and the exhaust manifold heat shield. Disconnect the electrical connector of the oxygen sensor and take off the sensor from the exhaust manifold. Remove the mounting bolts to remove the exhaust manifold and along with the old manifold gasket. Check the exhaust manifold for signs of cracks or any form of damage, if any then the exhaust manifold need to be replaced. Scratch the threads of the exhaust manifold bolts with a wire brush and inspect them in case there is any damage; change such bolts. All gasket materials should be scrapped off the mating surfaces and checked for wear and crack lines. Confirm exhaust manifold warpage using a straight edge and come gauge to the mating surface and where any warpage exceeds limits the exhaust manifold should be replaced or have a flat surface made for the head at an automotive machine shop. Replace the exhaust manifold gasket, and tighten the bolts by hand then again lift the front of the car using the jack and set it on the jackstands. The exhaust pipe bolts must only be hand tightened, while the exhaust manifold nuts must be tightened from the centre, in a sequence, to the specified torque value, then the exhaust pipe bolts. After that, perform the steps of the removal but in the reverse order.

Remove the intake manifold. Apply penetrating oil to the threads of the exhaust manifold attaching studs and the exhaust pipe-to-manifold attaching bolts. For models from 1987 to 1999, remove the nuts securing the exhaust pipe to the exhaust manifold and detach the pipe. For models since 2000, remove the nuts securing the exhaust pipe assembly to the exhaust manifolds. For models from 1987 to 1999, remove the three nuts securing the exhaust manifold to the cylinder head and pull the manifold out of the engine. For 2000 models, remove the remaining nuts securing the exhaust manifolds to the cylinder head and pull both manifolds out of the engine. Remove all traces of old gasket material from the mating surfaces. If the manifold gasket was blown out, have the manifold checked for warpage by an automotive machine shop and repaired as necessary. Position a new gasket on the locating dowels and slide the manifold over the studs. Install the attaching nuts on the studs finger-tight. Reinstall the intake manifold and tighten all fasteners in the correct sequence to the specified torque. Reconnect the exhaust pipe, run the engine, and check for leaks.