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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