Chrysler 68045559AB Exhaust Manifold

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Delete the turbocharger. Remove the nuts and clamps that retain the heater lines to the exhaust manifold. In case of such models, take off the screw that holds the heater tube(s) onto this exhaust manifold. Ensure to put aside your spacers. Remove the housing for the air filter together with air intake duct hose. On models so equipped, remove heat shield/noise reduction panel from exhaust manifold. Remove EGR cooler. Take out rear bolt lock plates. Take away Exhaust Manifold Bolts, Exhaust Manifold Gaskets and Spacers. Clean both mounting surfaces on manifold and cylinder head and clean threads on exhaust manifold mounting bolts.. Apply new gaskets to manifolds ensuring antiseize compound is applied to bolt threads.. Start tightening manifold bolts from center ones gradually proceeding outward following torque sequence given below until all are tightened as specified in torque specification.. Rest of installation is reverse of removal.NOTE: This stud goes into the hole for the lower rear and two front cylinders.

Disconnect the cable from the negative terminal of the battery. Block the rear wheels, set the parking brake, raise the front of the vehicle and support it securely on jackstands. Unbolt the exhaust pipe from the exhaust manifold. Note: On V8 models, you must soak the nuts for at least five minutes with penetrating oil, then replace the fasteners with new ones. Remove the drive belt. Drain the engine coolant below the level of the heater hoses. Remove the air inlet duct and air filter housing. Remove the air conditioning compressor. Remove the air conditioning accumulator bracket fastener. Disconnect the heater hoses from the engine. Remove the starter. Remove the exhaust manifold heat shields. Remove the exhaust manifold mounting bolts and remove the manifold from the vehicle. Lower the exhaust manifold and remove it from under the vehicle. Clean the mating surfaces to remove all traces of old gasket material, then inspect the manifold for distortion and cracks. Warpage can be checked with a precision straightedge held against the mating flange. II a feeler gauge thicker than 0.030-inch can be inserted between the straightedge and flange surface, take the manifold to an automotive machine shop for resurfacing. Place the exhaust manifold in position with a new gasket and install the mounting bolts linger tight. Starting in the middle and working out toward the ends, tighten the mounting bolts in several increments, to the torque. Tighten the heat shield bolts to the torque. Install the remaining components in the reverse order of removal. If you're working on a right-side exhaust manifold on a V8 engine, refill the cooling system. Start the engine and check for exhaust leaks between the manifold and cylinder head and between the manifold and exhaust pipe.

Disconnect the cable from the negative terminal of the battery. Block the rear wheels, set the parking brake, raise the front of the vehicle and support it securely on jackstands. Unbolt the exhaust pipe from the exhaust manifold. Note: On V8 models, you must soak the nuts for at least five minutes with penetrating oil, then replace the fasteners with new ones. Remove the drive belt. Drain the engine coolant below the level of the heater hoses. Remove the air inlet duct and air filter housing. Remove the air conditioning compressor. Remove the air conditioning accumulator bracket fastener. Disconnect the heater hoses from the engine. Remove the starter. Remove the exhaust manifold heat shields. Remove the exhaust manifold mounting bolts and remove the manifold from the vehicle. Lower the exhaust manifold and remove it from under the vehicle. Clean the mating surfaces to remove all traces of old gasket material, then inspect the manifold for distortion and cracks. Warpage can be checked with a precision straightedge held against the mating flange. II a feeler gauge thicker than 0.030-inch can be inserted between the straightedge and flange surface, take the manifold to an automotive machine shop for resurfacing. Place the exhaust manifold in position with a new gasket and install the mounting bolts linger tight. Starting in the middle and working out toward the ends, tighten the mounting bolts in several increments, to the torque. Tighten the heat shield bolts to the torque. Install the remaining components in the reverse order of removal. If you're working on a right-side exhaust manifold on a V8 engine, refill the cooling system. Start the engine and check for exhaust leaks between the manifold and cylinder head and between the manifold and exhaust pipe.

Start the engine and check for exhaust leaks between the manifold and cylinder head as well as between the manifold and exhaust pipe.

Reverse the removal procedure by cleaning the manifold and head gasket surfaces, checking for cracks and flatness, and replacing the exhaust manifold gaskets.

It can be checked with a precision straightedge held against the mating flange. If a feeler gauge thicker than 0.030-inch can be inserted between the straightedge and flange surface, the manifold should be taken to an automotive machine shop for resurfacing.

Raise the vehicle and support it securely on jackstands.

Lower the vehicle and remove the heat shield nuts and the heat shield. Then, remove the bolts retaining the exhaust manifold to the cylinder head, starting with the center ones and working toward the outer bolts. It's important to organize the bolts so they can be installed in their original positions.

Clean the mounting surfaces of the manifold and the cylinder head. Clean the threads of the exhaust manifold mounting bolts.

It can be checked with a precision straightedge held against the mating flange. If a feeler gauge thicker than 0.030-inch can be inserted between the straightedge and flange surface, the manifold should be taken to an automotive machine shop for resurfacing.

Attach an engine support fixture or an engine hoist to the engine lift points with a chain. Remove the engine mount through-bolts, then raise the engine enough to get access to the exhaust manifold bolts.

The studs go in the holes for the front two cylinders, and an additional one goes at the lower rear.

Use new gaskets and apply anti-seize compound on the bolt threads.

Refill the cooling system before starting the engine.

The bolts and brackets retaining the heater line(s) to the exhaust manifold. The bolt retaining the heater pipe(s) to the exhaust manifold. The air filter housing and the air intake hose. The heat shield/noise reduction panel from the exhaust manifold. The EGR cooler. The rear bolt lock plates. The exhaust manifold bolts, exhaust manifold, gaskets, and spacers.

Lower the vehicle and remove the heat shield nuts and the heat shield. Then, remove the bolts retaining the exhaust manifold to the cylinder head, starting with the center ones and working toward the outer bolts. It's important to organize the bolts so they can be installed in their original positions.

Disconnect the exhaust pipe-to-manifold connections. It's recommended to apply penetrating oil on the studs/bolts and let it soak in for about 10 minutes before attempting to remove them. Note that it may be easier to disconnect the oxygen sensors and remove the front exhaust pipes completely.