How to Remove Exhaust Manifold on Chrysler?

Chrysler Pacifica Exhaust manifold removal for 3.5L Engine, 3.8L Engine and 4.0L Engine.

The details for all 3 Engine models is provided.

The procedure to replace exhaust Manifold is as follows:-----

Removal & Installation

3.5L Engine
Left Side

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Radiator close out panel

   Radiator core support and cooling fan assembly

   Oil dipstick tube bolt and move the tube aside

   Exhaust manifold crossover pipe bolts

   Exhaust manifold bolts and manifold
3. Inspect the manifold for damage or cracks. Check for distortion against a straight-edge or thickness gauge. Replace manifold if required.
4. Remove all traces of the old manifold gasket and clean both gasket mating surfaces. 
   
   
   
   Fig. The oil dipstick tube and exhaust crossover pipe bolts must be removed prior to removing the manifold-3.5L engine

To install:

Exhaust manifold and gasket, tighten the bolts to 200 inch lbs. (23 Nm)

Exhaust manifold crossover pipe and tighten the bolts to 275 inch lbs. (31 Nm)

Oil dipstick tube and secure the bolt

Radiator cooling fan assembly and core support

Radiator close out panel

Negative battery cable

Right Side

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following: 
   
   
   Negative battery cable

   Exhaust manifold crossover pipe bolts

   Downstream Oxygen (O ₂ S) sensor electrical wiring

   Exhaust manifold flange bolts and the hangers from the pipe assembly

   Exhaust system from the vehicle

   Exhaust Gas Recirculation (EGR) tube support bracket bolt 
   
   
   

   Fig. Exhaust Gas Recirculation (EGR) valve and tube assembly-3.5L engine

   Lower manifold bolts

   Manifold and gasket

   O ₂ S from the manifold
3. Inspect the manifold for damage or cracks. Check for distortion against a straight-edge or thickness gauge. Replace manifold if required.
4. Remove all traces of the old manifold gasket and clean both gasket mating surfaces.

To install:

1. Install or connect the following:
   
   
   Exhaust manifold and gasket, tighten the bolts to 200 inch lbs. (23 Nm)

   Exhaust system to the vehicle

   Exhaust manifold flange bolts and the hangers to the pipe assembly. tighten the flange bolts to 22 ft. lbs. (30 Nm).

   Downstream O ₂ S sensor electrical wiring

   EGR tube support bracket bolt

   Exhaust manifold crossover pipe bolts and tighten to 275 inch lbs. (31 Nm)

   O ₂ S to the manifold

   Negative battery cable

3.8L Engine
Left Side

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Crossover pipe

   Spark plug wires

   Heat shield

   Exhaust manifold bolt

   Exhaust manifold and gasket

To install:

1. Position the exhaust manifold on the cylinder head and install the bolts to the center runner (cyl No. 4), and temporarily tighten to 25 inch lbs. (2.8 Nm).
   
   NOTE

   Examine the crossover pipe bolts for damage caused due to heat or corrosion and replace using new OEM bolts if found to be defective.
2. Install a new gasket, attach the crossover pipe to the manifold and tighten the bolts to 30 ft. lbs. (41 Nm).
3. Install or connect the following:
   
   
   Remaining manifold bolts. Torque the fasteners to 17 ft. lbs. (23 Nm).

   Heat shield

   Negative battery cable
4. Start the engine and check for leaks.

Right Side

1. Disconnect the negative battery cable.
2. Raise and safely support the vehicle.
3. Separate the exhaust pipe at the exhaust manifold.
4. Remove the bolts attaching the crossover pipe to exhaust manifold.
5. Remove the air cleaner housing.
6. Disconnect the Throttle Position (TP), Idle Air Control (IAC) sensor connectors and the purge vacuum hose from the throttle body.
7. Disconnect the upstream Oxygen (O ₂ s) sensor connector.
8. Disconnect the spark plug wires from the plugs.
9. Remove bolts attaching the exhaust manifold to the cylinder head and remove the manifold.
10. Discard gasket, if equipped and clean all mating surfaces.
11. Position the exhaust manifold on the cylinder head and install the bolts to the center runner (cyl No. 3), and temporarily tighten to 25 inch lbs. (2.8 Nm).
    
    NOTE

    Examine the crossover pipe bolts for damage caused due to heat or corrosion and replace using new OEM bolts if found to be defective.
12. Install a new gasket, attach the crossover pipe to the manifold and tighten the bolts to 30 ft. lbs. (41 Nm).
13. Install or connect the following:
    
    
    Remaining manifold bolts. Torque the fasteners to 17 ft. lbs. (23 Nm).
14. Install and connect the upstream O ₂ s sensor.
15. Connect the spark plug.
16. Connect the IAC, TPS and the EVAP hose to the throttle body.
17. Install the air cleaner housing.
18. Attach the catalytic converter pipe to exhaust manifold using a new gasket and tighten bolts to 27 ft. lbs. (37 Nm).
19. Connect the negative battery cable.
20. Start the engine and check for leaks.

4.0L Engine
Left Side

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect the negative battery cable.
3. Remove the radiator close out panel.
4. Remove the radiator core support.
5. Remove the radiator cooling fan assembly.
6. Loosen the oil level indicator tube retaining bolt and position the assembly out of the way.
7. Disconnect both oxygen sensor electrical connectors.
8. Remove the three upper heat shield retainers and remove the upper heat shield.
9. Remove the lower exhaust manifold crossover pipe retaining bolts.
10. Remove the exhaust manifold retaining bolts.
11. Remove the exhaust manifold from the vehicle.

To install:

1. Installation is the reverse of the removal procedure.
2. Install the retaining bolts. Tighten them to 200 inch lbs, starting at the center and working outward.
3. Tighten the crossover pipe retaining bolts to 275 inch lbs.

Right Side

1. Before servicing the vehicle, refer to the Precautions section.
2. Disconnect the negative battery cable.
3. Raise and support the vehicle safely.
4. Disconnect both oxygen sensor electrical connectors.
5. Remove the rear heat shield retainers and remove the heat shield.
6. Remove the exhaust manifold inlet flange retaining fasteners. Disconnect the exhaust system hangers from the pipe assembly.
7. Remove the exhaust manifold retaining bolts.
8. Remove the exhaust manifold from the vehicle.

To install:

1. Installation is the reverse of the removal procedure.
2. Replace any damaged studs, as required. Tighten the studs to 20 inch lbs.
3. Install the retaining bolts. Tighten them to 200 inch lbs, starting at the center and working outward.
4. Tighten the exhaust system hangers to 22 ft. lbs.
5. Tighten the heat shield retaining bolts to 105 inch lbs.
6. Tighten the crossover pipe retaining bolts to 250 inch lbs.

These details will help.

Thanks.           

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html