Chrysler 4884234AB Manifold Exhaust

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Turbocharged models are equipped with an exhaust manifold and turbocharger assembly. If the exhaust manifold is damaged, it must be replaced as a complete unit. Begin by disconnecting the cable from the negative battery terminal, setting the parking brake, and blocking the rear wheels. Raise the vehicle and support it securely on jackstands. Remove the air filter housing and the coolant reservoir. Disconnect the MAP sensor and remove the power steering fluid reservoir from the cylinder head, positioning it off to the side without disconnecting the fluid lines. Remove the accelerator cable and the cruise control cable if equipped. Next, remove the upper heat shield bolts and the upper heat shield from the exhaust manifold, followed by the exhaust manifold support bracket. From under the vehicle, apply penetrating oil to the threads of the exhaust manifold-to-exhaust pipe studs and allow it to soak in before removing the exhaust pipe-to-exhaust manifold flange nuts. Remove the lower heat shield mounting nuts and the lower heat shield from the exhaust manifold, then remove the oxygen sensor. Proceed to remove the exhaust manifold bolts and nuts, followed by the exhaust manifold and gasket. Inspect the exhaust manifold for cracks and other obvious damage; if any damage is found, replace it. 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, the exhaust manifold or cylinder head must be replaced or resurfaced. For installation, coat the threads of the exhaust manifold bolts and studs with an anti-seize compound, install a new gasket, and then the manifold, tightening the fasteners in several stages from the center out to the specified torque. Complete the installation in reverse order of removal, and after finishing, run the engine to check for exhaust leaks.

In order to take away the exhaust manifold, one should visually set the parking brake, then block the rear wheels, then turn the ignition off, then unbend the cable from the negative terminal, then raise and safely jack-up the car. Secondly, the engine protection cover seen below the car should be unscrewed and next to that the wire harness heat shield that can also be unbolted from the car. To access the ULEV bolt locations: unbolt the heat shield located at the exhaust manifold location. Next take out the bolts holding the exhaust manifold support bracket and the heat shield on the exhaust manifold. Take penetrating oil and pour it on the threading of the exhaust manifold to exhaust pipe studs, allow it to work for some time, then remove the flange nuts of the exhaust pipe and the exhaust manifold to get them apart. If so, then it may be necessary to deliver the cruise control vacuum reservoir, and the vacuum hose connected to the rear part of the valve cover. Next, remove the oxygen sensor, the bolts and nuts of the exhaust manifold and then, the exhaust manifold with the gasket. Check the exhaust manifold for possible breakage or crack: if there is any circumstance, change the exhaust manifold. Attempts must be made to clean the threads of the exhaust manifold bolts and check its condition, if there any worn out one must be replaced. A scraper should also be used in order to shave the gasket material out of the two surfaces that they are to mate as well as look for signs that the gasket material has worn out or developed cracks. The exhaust manifold mating surface should also be checked for warpage using a straight edge and a feeler blade therefore if warpage exceeds a set limit the exhaust manifold should be replaced or resurfaced. To fit, apply anti-seize to the threads of the exhaust manifold bolts and studs, and fit a new gasket then the manifold, taking tightening the bolts in stages from the centre out to the specified torque. To complete the job you need to follow the removal steps in reverse and do not forget to take the engine for a spin to test for leaks.