Chrysler 4273099 Exhaust Manifold

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On these models, the cylinder head, complete with turbocharger assembly and intake and exhaust manifolds, must be removed as a unit before the manifolds can be removed. To begin the removal process, disconnect the negative cable at the battery and drain the cooling system. Then, raise the front of the vehicle and disconnect the exhaust pipe from the manifold. From under the vehicle, remove the turbocharger-to-engine block support bracket and loosen the oil drain back tube connector hose clamps. Lower the vehicle and in the engine compartment, remove the air cleaner assembly and disconnect throttle linkage and throttle body electrical connector and vacuum hoses. Secure the fuel rail out of the way and disconnect the upper radiator hose from the thermostat housing. Finally, remove the cylinder head with manifolds and turbocharger attached as an assembly. Once removed, clean the cylinder head and manifold gasket surfaces and inspect for any damage. To install, place a new gasket and then install the exhaust manifold and intake manifold, tightening the nuts and bolts to the specified torque. Connect the turbocharger outlet-to-intake manifold tube and place the turbocharger in position on the exhaust manifold. Install the coolant return tube, heat shield, throttle body air horn, and cylinder head. Connect the turbocharger oil feed line and reinstall the air cleaner assembly, fuel rail, turbocharger inlet coolant tube, and turbocharger housing-to-engine block support bracket. Reposition the oil drain back tube, reconnect the exhaust pipe and upper radiator hose, and fill the cooling system. Finally, reconnect the negative battery cable.

Disconnect the negative cable at the battery and place it out of the way. Depressurize the fuel system and drain the cooling system. Remove the air cleaner assembly and disconnect the vacuum, fuel, and electrical connections from the EFI throttle body. Disconnect the throttle linkage and remove the power steering pump drivebelt. Remove the power brake vacuum hose from the intake manifold. On some Canadian models, remove the coupling hose from the diverter valve-to-exhaust manifold air injection tube. Remove the water crossover hoses. Raise the vehicle and support it securely on jackstands. From under the vehicle, remove the power steering pump and intake manifold support bracket. Remove the EGR tube from the exhaust manifold and, on some Canadian models, remove the air injection tube assembly. Remove the intake manifold bolts and lower the vehicle. In the engine compartment, lift the intake manifold from the engine and remove the retaining nuts to detach the exhaust manifold. Carefully scrape all traces of gasket material and sealing compound from the cylinder head and manifold contact surfaces. Use a straight edge to check the gasket surfaces of the manifolds for flatness and inspect them for cracks and corrosion. Replace any damaged or warped manifolds. Apply a thin coat of gasket sealant to the manifold sides of the new gaskets and place them in position. Install the exhaust manifold and tighten the nuts in a criss-cross pattern. Place the intake manifold in position and tighten the retaining bolts in a criss-cross pattern. The remainder of the installation procedure is the reverse of removal.