Exhaust Manifold - Removal

REMOVAL





1. Disconnect and isolate the negative battery cable (1).





2. Remove the engine cover (2).





3. Disconnect the intake air temperature (IAT) sensor (5) connector.
4. Loosen the clamps at the throttle body and the air filter housing and remove the air tube (4).
5. Disconnect the make up air hose (MUA) (2).
6. Remove the air filter housing retaining bolt (3).
7. Remove the air filter housing.





8. Remove both front engine mounts (2) and mounting brackets Engine Mount Insulator - Removal.

CAUTION: When separating the catalytic converters from the manifolds, disconnect the oxygen sensor connectors. Allowing the catalytic converters hanging from the oxygen sensor wires damages the harness and/or sensors.





9. Raise and support the vehicle.
10. Disconnect the oxygen sensor electrical connectors (2).
11. Saturate the front exhaust pipe/catalytic converter retaining bolts and nuts with Mopar(R) Rust Penetrant or equivalent and allow 5 minutes for penetration.
12. Remove both catalytic converters (4) Catalytic Converter - Removal.






NOTE: Two knock sensors (1) are used, they are bolted to each side of the cylinder block under each exhaust manifold (3).

13. Remove the heat shields from the appropriate knock sensor (shield snaps onto sensor).
14. Disconnect the appropriate knock sensor electrical connector (3).

NOTE: Note the foam strip on the knock sensor retaining bolt threads. This foam is only used to retain the bolts to the knock sensors for plant assembly. It is not used as a sealant. Do not apply any adhesive, sealant or thread locking compound to these bolts.

15. Remove the appropriate knock sensor retaining bolt (2) and remove knock sensor (1).
16. Lower the vehicle.




LEFT SIDE:

NOTE: It is not necessary to remove the hoses from the coolant bottle for coolant bottle removal.

17. Remove coolant bottle retaining bolts (2) and position aside.





18. Using the sequence shown, remove the exhaust manifold retaining bolts.





19. Remove the exhaust manifold (2) and gasket.
20. Inspect the exhaust manifold for any damage Exhaust Manifold - Inspection.
21. Clean the exhaust manifold mating surfaces (1, 2).




RIGHT SIDE:
22. Remove the Power Distribution Center (PDC) and mounting bracket.
23. Unfasten the wire harness mounted on the right hand inner fender panel and position aside.





24. Remove the exhaust manifold heat shields.
25. Using the sequence shown, remove the exhaust manifold retaining bolts.
26. Remove the exhaust manifold (2) and gasket.
27. Inspect the exhaust manifold for any damage Exhaust Manifold - Inspection.
28. Clean the exhaust manifold mating surfaces.