Mopar 4693321AD Exhaust Manifold

The exhaust manifold is located at the right side of the cylinder head for the 207 on the 2014 and earlier models, while it is located at the left side of the cylinder head for the 207 on the 2015 and later models. For the removal of the exhaust manifold, on 2014 and earlier models, it is necessary to raise the car and secure it on jackstands, the exhaust pipe should be disconnected from the manifold with a note that on some models, the exhaust system may have to be removed for clearance purposes. In the next step, take out the heat shield and manifold brace and pull off the connector for oxygen sensor; also unbolt the mounting bolts for the removal of the manifold and the old gasket along with it. For the year 2015 and later, the process starts by the removal of the engine cover and the negative terminal of the battery and the two electrical connectors of the oxygen sensors. Following lifting of the car and the removal of the engine under tray, pull off the Catalytic converter to exhaust manifold nuts and throw away the old gasket. Lower the vehicle and unbolt the heat shield, after that undo the bolts on the manifold while lifting it out of the context of the engine. Check the exhaust manifold for cracks or damages and if it is, replace the part and check the threads of the mounting bolts and replace any that are damaged. Debond all gasket material gently to prevent scratching the surfaces and check for warpage using a straight edge and feeler gauge; more than 0.005 inches warpage needs a replacement of the warpage part or resurfacing. For installation, although there are no recommendations on using new sealant gasket, new gasket should be used without sealant then manifold is installed and bolt should be tightened gradually locating in the center of the manifold first then gradually to the outer most bolt to the required torque before removing the manifold in a reverse order.

Before undoing the exhaust manifold, you should first disarm the negative terminal on the battery, remote ground terminal. Then, raise the front of the vehicle and support it securely on jackstands, then undo the engine splash shield fasteners and shield. Then, the oxygen sensor electrical connectors should be unscrewed and the sensors taken out, then the crossunder pipe bolts should be removed in order to withdraw the crossunder pipe that is connected to the exhaust manifolds. On the rear manifold, disconnect the right front drive axel, lower the car and unbolt/nut the exhaust manifold heat shield to in order to remove the heat shields. Last, take mounting bolts and separate the manifold from the cylinder head and for this, it is preferable to use penetrating oil on bolts. As to installation, the mating surfaces must be washed to remove gasket debris the manifold must be examined for distortion and cracks, the use of a straightedge for warping is recommended. In the event of excessive wear, have the surfaces of the manifold' taken to an automotive machine business for refinishing. Align the exhaust manifold and place on a new gasket, tighten the mounting bolts by hand but just enough so that you can distinguish the direction of the cylinders and exhaust port. Loosened the mounting bolts in sequence starting with the middle and then, gradually to the completion of the desired torque value. The rest of the installation is done in the opposite of the removal as described above. You should check the exhaust systems for leaks, right after the installation of the exhaust manifold and before starting with the following steps Switch on the engine and look for any exhaust leak between the manifold and the cylinder head and also between the manifold and the exhaust pipe.

In vehicles made in 2014 and prior years, the exhaust manifold attaches to the back of the cylinder head, while vehicles from 2015 on use a front attachment. To remove the exhaust manifold, first lift your car with jackstands and keep it secure. Before working on the exhaust, untie the pipe from its junction with the manifold. Depending on your model, you may need to take down the entire exhaust to create enough room to work. Rake off the bolts and shield attaching the exhaust manifold heat shield, and unbolt the manifold brace. Pull the oxygen sensor's electrical plug and take the sensor off the exhaust manifold. To remove the exhaust manifold and its current gasket, unscrew all bolts from the three main positions - left, center, and right sides. Check the exhaust manifold for cracks and repairs that need to be made, and change it if needed. Cough any dirt off the threads of exhaust manifold bolts using a wire brush, then check them for damage and replace any broken ones. Scrape off any old gasket material from both surfaces with care, but don't grind into or mar them, as leaks can happen later. Check both surfaces - exhaust manifold and cylinder head - for alignment while holding a straight-running board against them. Gauge the gap with a feeler tool. When the surface steps out of position by too much, switch to either a replacement exhaust manifold or resurface the current one. Before putting the exhaust manifold on, place a fresh gasket without applying any sealer material. Attach the exhaust manifold, and slowly tighten the bolts, working our from the center first to the designated torque. The next parts go in the opposite order they came out.

To remove the exhaust manifold, first disconnect the negative battery cable from the remote ground terminal. Block the rear wheels, set the parking brake, raise the front of the vehicle, and support it securely on jackstands. Disconnect the downstream oxygen sensor connectors and remove the under-vehicle splash shield if equipped. Unbolt the exhaust pipes at the exhaust manifolds, then lower the vehicle. In the engine compartment, disconnect the oxygen sensor's electrical connector. If removing the rear exhaust manifold, detach the EGR pipe from the top of the manifold; if removing the front manifold, also remove the air filter housing and the engine oil dipstick tube. Remove the exhaust manifold upper heat shield mounting bolts and the heat shields, then detach the manifold from the cylinder head, applying penetrating lubricant to the bolts and threads beforehand. For installation, clean the mating surfaces to eliminate old gasket material and inspect the manifold for distortion and cracks, checking for warpage with a precision straightedge. If necessary, take the manifold to an automotive machine shop for resurfacing. Position the exhaust manifold with a new gasket and lower heat shields, installing the mounting bolts finger tight while ensuring the gaskets are correctly identified by cylinder designation and exhaust port position. Tighten the mounting bolts starting in the middle and working outward in several increments to the specified torque. The remainder of the installation follows the reverse order of removal. Finally, start the engine and check for exhaust leaks between the manifold and cylinder head as well as between the manifold and exhaust pipe.

On AWD models, the exhaust manifold and catalytic converter are combined into a single unit called a "maniverter." To begin removal, raise the vehicle and support it securely on jackstands. Disconnect the exhaust pipe from the exhaust manifold; on some models, it may be necessary to remove the exhaust system to create sufficient clearance for the manifold removal. Next, remove the exhaust manifold heat shield and the manifold brace. Unplug the electrical connector for the oxygen sensor and then remove the oxygen sensor from the exhaust manifold. Unscrew the mounting bolts to take off the exhaust manifold along with the old manifold gasket. For inspection, check the exhaust manifold for cracks and any obvious damage, replacing it if necessary. Clean the threads of the exhaust manifold bolts with a wire brush and inspect for damage, replacing any that are damaged. Use a scraper to remove all traces of gasket material from the mating surfaces and inspect them for wear and cracks, taking care not to scratch or gouge the surfaces. Inspect the exhaust manifold mating surface for warpage using a straightedge and feeler gauge, checking the cylinder head surface as well; if warpage exceeds specified limits, replacement or resurfacing is required. For installation, use a new exhaust manifold gasket without sealant, install the exhaust manifold, and tighten the mounting bolts gradually from the center outward to the specified torque. The remainder of the installation follows the reverse order of removal.

On AWD models, the exhaust manifold and catalytic converter are combined into a single unit called a "maniverter." To begin removal, raise the vehicle and support it securely on jackstands. Disconnect the exhaust pipe from the exhaust manifold; on some models, it may be necessary to remove the exhaust system to create sufficient clearance for the manifold removal. Next, remove the exhaust manifold heat shield and the manifold brace. Unplug the electrical connector for the oxygen sensor and then remove the oxygen sensor from the exhaust manifold. Unscrew the mounting bolts to take off the exhaust manifold along with the old manifold gasket. For inspection, check the exhaust manifold for cracks and any obvious damage, replacing it if necessary. Clean the threads of the exhaust manifold bolts with a wire brush and inspect for damage, replacing any that are damaged. Use a scraper to remove all traces of gasket material from the mating surfaces and inspect them for wear and cracks, taking care not to scratch or gouge the surfaces. Inspect the exhaust manifold mating surface for warpage using a straightedge and feeler gauge, checking the cylinder head surface as well; if warpage exceeds specified limits, replacement or resurfacing is required. For installation, use a new exhaust manifold gasket without sealant, install the exhaust manifold, and tighten the mounting bolts gradually from the center outward to the specified torque. The remainder of the installation follows the reverse order of removal.