Mopar 4448009 Exhaust Manifold

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To perform removal of the throttle body assembly and intake manifold together with the exhaust manifolds, it is necessary first of all to release the fuel system pressure and disconnect the negative terminal of the battery and to drain the cooling system. Next, discard the air cleaner, be sure to identify all the vacuum lines and loose them from their connectors, all electrical wires, and fuel lines and the accelerator cable from the throttle lever. If so provisioned, remove the power steering pump belt, then disconnect the power brake vacuum line to the intake manifold, then unscrew the water hoses from the coolant crossover. Lift the front part of the car with jack and fix it securely on jack stands; remove the exhaust pipe from the exhaust manifold. If fitted, unbolt the power steering pump and, with it out of the way, set aside, and then unbolt the intake manifold support bracket and sever the EGR tube from the exhaust manifold. Lose the intake manifold bolts, lower the car and unbolt the throttle body and intake manifold in one assembly, thereby detaching the throttle body and gasket from the intake manifold before placing the unit on the bench. Lose the exhaust manifold nuts and take off the exhaust manifold: dispose of old gaskets and clean all gasket contact areas. Manifolds should also be cleaned with solvent and dried by compressed air, and the mating surfaces should be examined flat in relation to the straightedge, feeler gauges and the manifolds themselves should be examined for cracks and distortion and if present they should either be replaced or resurfaced. Concerning installation, it is advisable to replace either manifold; if so, transfer the studs to the new manifold. For the SOHC apply a thin layer of gasket sealant then place the new gaskets on the manifold sides, place the exhaust manifold on the cylinder head then install the nuts and begin tightening at the center in a cross wise manner. Place the intake manifold on the head, lift the car and secure it properly on jack stands, using the new intake manifold bolts put them in loosely following the crisscross technique beginning at the middle. The rest of the procedure of installation is carried out in the reverse order to the removal procedure.

Clean the mating surfaces and check for warpage and cracks, repeating the previous inspection process.

If working on the rear manifold, disconnect the exhaust pipe flange bolts and the EGA tube.

Next, remove the air cleaner, clearly label and detach all vacuum lines, electrical wiring, and fuel lines, then detach the accelerator cable from the throttle linkage.

Allow the engine to cool completely, then drain the coolant and disconnect the coolant bypass tube if necessary.

Apply penetrating oil to the exhaust manifold fasteners and let it soak.