Chrysler Le Baron, Dodge Dynasty, Plymouth Acclaim. Instruction - page 14

EXHAUST MANIFOLDS

REMOVAL

(1) Raise vehicle and disconnect exhaust pipe from

rear (cowl side) exhaust manifold at articulated joint.

(2) Disconnect Oxygen Sensor lead wire at the rear

exhaust manifold (Fig. 18).

(3) Remove bolts attaching cross-over pipe to man-

ifold (Figs. 2 and 19).

(4) Remove nuts attaching rear manifold to cylin-

der head and remove manifold.

(5) Lower vehicle and remove screws attaching

front heat shield to front manifold (Fig. 2).

(6) Remove bolts fastening crossover pipe to front

exhaust manifold and nuts fastening manifold to cyl-
inder head. Remove assemblies.

INSPECTION

Inspect exhaust manifolds for damage or cracks

and check distortion of the cylinder head mounting
surface and exhaust crossover mounting surface with
a straightedge and thickness gauge (Fig. 20).

INSTALLATION

Install the gaskets with the numbers 1-3-5 em-

bossed on the top on the rear bank and those with
numbers 2-4-6 on the front (Radiator side) bank (Fig.
21).

(1) Install rear exhaust manifold and tighten at-

taching nuts to 20 N

Im (175 in. lbs.).

Fig. 15 Intake Plenum and Cylinder Head Mounting

Surface Specifications

Fig. 16 Nut Tightening Sequence for Intake (Cross)

Manifold

Fig. 17 Intake Plenum Tightening Sequence

Fig. 18 Separate Articulated Joint, Disconnect

Oxygen Sensor Wire

Fig. 19 Crossover Pipe

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EXHAUST SYSTEM AND INTAKE MANIFOLD

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(2) Attach exhaust pipe to exhaust manifold and

tighten shoulder bolt to 28 N

Im (250 in. lbs.)

(3) Attach crossover pipe to exhaust manifold and

tighten bolt to 69 N

Im (51 ft. lbs.)

(4) Connect heated oxygen sensor lead (Fig. 18).
(5) Install front exhaust manifold and attach ex-

haust crossover.

(6) Install front manifold heat shield and tighten

attaching screws to 15 N

Im (130 in. lbs.) (Fig. 2).

INTAKE/EXHAUST MANIFOLD SERVICE—3.3/3.8L
ENGINES

INTAKE MANIFOLD

REMOVAL

(1) Perform fuel system pressure release procedure,

Before attempting any repairs.

(2) Disconnect negative battery cable. Drain cool-

ing system. Refer to Cooling System, Group 7.

FUEL SYSTEM PRESSURE RELEASE PROCE-
DURE

The MPI fuel system is under a constant pressure

of about 330 kPa (48 psi). Before servicing the fuel
pump, fuel lines, fuel filter, throttle body or fuel
injector, the fuel system pressure must be released.

(a) Loosen fuel filler cap to release fuel tank pres-

sure.

(b) Disconnect injector wiring harness from engine

harness.

(c) Connect a jumper wire to ground terminal Num-

ber 1 of the injector harness (Fig. 1) to engine ground.

(d) Connect a jumper wire to the positive terminal

Number 2 of the injector harness (Fig. 1) and touch
the battery positive post for no longer than 5 seconds.
This releases system pressure.

(e) Remove jumper wires.
(f) Continue fuel system service.

(3) Remove air cleaner to throttle body hose assem-

bly (Fig. 2).

Fig. 20 Check Exhaust Manifold Mounting Surface

Fig. 21 Identify Exhaust Manifold Gaskets

Fig. 1 Injector Harness Connectors

Fig. 2 Throttle Body Assembly—3.3/3.8L Engines

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EXHAUST SYSTEM AND INTAKE MANIFOLD

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(4) Remove throttle cable (Fig. 3). Remove wiring

harness from throttle cable bracket.

(5) Remove automatic idle speed (AIS) motor and

throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 4).

(e) Remove jumper wires.
(f) Continue fuel system service.

(6) Remove vacuum hose harness from throttle

body (Fig. 4).

(7) Remove PCV and brake booster hoses from air

intake plenum (Fig. 5).

(8) Remove EGR tube flange from intake plenum

(Fig. 5).

(9) Disconnect Charge Temperature Sensor electri-

cal connector. Remove vacuum harness connectors
from Intake Plenum (Fig. 5).

(10) Remove cylinder head to intake plenum strut

(Fig. 5).

(11) Disconnect MAP Sensor and heated Oxygen

Sensor electrical connection. Remove the engine
mounted ground strap (Fig. 6).

Fig. 3 Throttle Cable Attachment

Fig. 4 Electrical and Vacuum Connection to Throttle

Body

Fig. 5 Electrical and Vacuum Connections To Intake

Manifold

Fig. 6 MAP Sensor Electrical Connector

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EXHAUST SYSTEM AND INTAKE MANIFOLD

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(12) Remove the fuel hose quick connect fittings

from the fuel rail using an open end wrench to push
in on the plastic ring located on the end of the fit-
tings. Gently pull the fittings from the fuel rail (Fig.
7).

WARNING:

WRAP

A

SHOP

TOWEL

AROUND

HOSES TO CATCH ANY GASOLINE SPILLAGE.

(13) Remove direct ignition system (DIS) coils and

generator bracket to intake manifold bolt (Fig. 8).

(14) Remove intake manifold bolts and rotate man-

ifold back over rear valve cover (Fig. 9).

(15) Cover intake manifold with suitable cover

when servicing (Fig. 10).

(16) Remove vacuum harness connector from Fuel

Pressure Regulator.

(17) Remove fuel tube retainer bracket screw and

fuel rail attaching bolts (Fig. 10). Spread the retainer
bracket to allow fuel tube removal clearance.

(18) Remove fuel rail injector wiring clip from the

generator bracket (Fig. 11).

(19) Disconnect cam sensor, coolant temperature

sensor, and engine temperature sensors.

(20) Remove fuel injector wiring clip from intake

manifold water tube.

(21) Remove fuel rail. Be careful not to damage

the rubber injector O-rings upon removal from their
ports (Fig. 12).

(22) Remove upper radiator hose, bypass hose and

rear intake manifold hose (Fig. 13).

(23) Remove intake manifold bolts. Remove intake

manifold.

(24) Remove intake manifold seal retainers screws

(Fig. 14). Remove intake manifold gasket.

INSPECTION

Check for:

• Damage and cracks of each section.

Fig. 7 Quick Connect Fuel Fittings to Fuel Rail

Fig. 8 Ignition Coils

Fig. 9 Intake Manifold Bolts

Fig. 10 Fuel Rail Attaching Bolts

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EXHAUST SYSTEM AND INTAKE MANIFOLD

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