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EXHAUST SYSTEM AND INTAKE MANIFOLD

C O N T E N T S

page page

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . 4

TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . 26

GENERAL INFORMATION

Throughout this group, references may be made to

a particular vehicle by letter or number designation.

A char t showing th e breakdown of th ese designations

is included in the Introduction Section at the front of

this service m anu al.

EXHAUST SYSTEMSThe exhaust systems are produced in several con-

figurations, depending on engine and car line (Fig. 1).

O n e s ys t e m h a s a n u n d e r fl oor ca t a l yt i c c on v er t e r,

ot h e r s ys t e m s r e qu i r e fr on t m ou n t e d ca t a l yt i c c on -

v er t e r s . S om e t u r b och a r g e d e n gi n es r e qu i r e, a n u n -

derfloor converter/resonator assembly. Tail pipes,

mufflers, and resonators are sized and tuned to each

vehicle/powertrain combination (Fig. 2).

EXHAUST BALL JOINT COUPLING

A e x h a u s t b a ll joi n t cou p li n g (F i g. 3 ) i s u s e d t o

secure the exhaust pipe to the engine manifold. Thisl ivin g join t a ct u a lly m ov es b a ck a n d for t h a s t h e

engine moves, preventing breaka ge t hat could occur

fr om t h e b a ck -a n d -for t h m ot ion of a t r a n s ve r se

mounted engine.

T h e e xh a u s t b a ll joi n t con s is t s of t w o b o lt s , t w o

springs, and a ball joint seal r ing which is a separate

part from the exhaust pipe.

Fig. 1 Exhaust System

EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1

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CATALYTIC CONVERTER

T h e r e i s n o r e gu l a r ly s ch e d u le d m a i n t en a n c e on

any Chrysler catalytic converter. If damaged, the con-

verter must be replaced.

CAUTION: Due to exterior physical similarities of

some catalytic converters with pipe assemblies, ex-treme care should be taken with replacement parts.

There is internal converter differences required insome parts of the country (particularly California

vehicles). The 2.2/2.5L engines equipped with a manualtransmission will have an adaptor for a air injection tube.

HEAT SHIELDS

Heat shields (Fig. 4) are needed to protect both the

car and the environment from the high temperatures

Fig. 3 Ball Joint Connection

Fig. 4 Heat Shield Installation

Fig. 2 Exhaust System Components

11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD

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developed in the vicinity of the catalytic converters.

2.2/2.5L engines equipped with manu al tran smission

where air is injected into th e catalytic converter’s, a

heat shield is welded on the front converter.

Refer t o Body an d Sh eet Meta l, Group 23 for service

procedures.

CAUTION: Avoid application of rust prevention com-pounds or undercoating materials to exhaust sys-tem floor pan heat shields on cars if equipped. Lightoverspray near the edges is permitted. Applicationof coating will greatly reduce the efficiency of the

heat shields resulting in excessive floor pan tem-peratures and objectionable fumes.

The combustion reaction caused by the catalyst re-

leases additional h eat in th e exhaust system. Causing

t e m p e r a t u r e i n c r e a s e s i n t h e a r e a o f t h e r e a c t o r u n -

der severe operating conditions. Such conditions can

exist when the engine misfires or otherwise does not

operate at peak efficiency. D o n o t remove spark plugw ir e s f r om p lu g s o r b y a n y ot h e r m e a n s s h or t ou t

cylinders if exhaust system is equipped with catalytic

converter. Failure of the catalytic converter can occur

d u e t o t e m pe r a t u r e in cr e a se s ca u s ed b y u n b u r n ed

fuel passing through the converter.

T h e u s e of t h e ca t a l ys t s a l so i n vol ve s s om e n on -

a u t o m ot i ve p r ob le m s . U n l ea d e d g a sol in e m u s t b e

used to avoid poisoning th e cata lyst core. Do n ot allow

e n gin e t o op er a t e a b ov e 1 20 0 R P M in n e u t ra l for

extended periods over 5 minutes. This condition may

result in excessive exhaust system/floor pan tempera-

tures because of no air movement under the vehicle.

EXHAUST GAS RECIRCULATION (EGR) SYS-

T EM

To assist in the control of oxides of nitrogen (NOx)

in engine exhaust, some engines are equipped with an

exhaust gas recirculation system. The use of exhaust

gas to dilute incoming air/fuel mixtures lowers peak

flame temperatures during combustion, thus l imiting

the formation of NOx.

E x h a u s t g a s e s a r e t a k e n f r o m o p e n i n g s i n t h e e x -

hau st gas crossover passage in t he inta ke m anifold.

REFER TO SECTION 25 EMISSION SYSTEMS FOR

A C OM P L E TE D E S CR I P TI O N , D I AG N O SI S AN D

SERVICE PROCEDURES ON THE EXHAUST GAS

RECIRCULATION S YSTEM AND COMPONE NTS.

EXHAUST SYSTEM DIAGNOSIS


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SERVI CE PROCEDURES

INDEX

page page

Exhaust Pipes, Mufflers and Tailpipes . . . . . . . . . . . 4Intake and Exhaust Manifolds Service—TBI Engine . . 6Intake and Exhaust Manifolds—TBI Engine . . . . . . . 5Intake/Exhaust Manifold Service—3.0L Engine . . . 15Intake/Exhaust Manifold Service—3.3/3.8L Engines . 20

Intake/Exhaust Manifolds and TurbochargerService—Turbo I Engines . . . . . . . . . . . . . . . . . . 8

Intake/Exhaust Manifolds and TurbochargerService—Turbo III Engine . . . . . . . . . . . . . . . . . 11

EXHAUST PIPES, MUFFLERS AND TAILPIPES

REMOVAL

(1) Raise vehicle on hoist and apply penetrating oil

to clamp bolts and nuts of component being removed.

(2) Tail pipes are integral with the muffler (Fig. 5).

Remove clamp at slip joint. Separate at slip joint.

(3) Remove clamps and supports (Figs. 6, 7, 8, and

9) from exhaust system to permit alignment of parts

dur ing a ssembly.

(4) When removing tailpipe, raise rear of vehicle to

r e li ev e b od y w ei gh t fr om r e a r s p r in g s t o p r ov id e

clearan ce between pipe and r ear axle parts.

(5 ) C le a n e n d s of p ip e s a n d /or m u ffl er t o a s s u r e

m a t i n g of a l l p a r t s . D is ca r d b r ok e n or w or n i n su l a -

tors, rusted clamps, supports and attaching parts.

W h e n r e p l a c e m e n t i s r e q u i r e d o n a n y c o m p o -

n e n t o f t h e e x h a u s t s y s t e m , i t i s m o s t i m p o r t a n t

t h a t o r i g i n a l e q u i p m e n t p a r t s ( o r t h e i r e q u i v a -

l e n t ) b e u s e d ;

•

To insure proper alignment with other parts in thesystem.

• Provide a cceptable exhau st noise levels and does

not change exhaust system back pressure that could

affect emissions an d performa nce.

INSTALLATION

(1) Assemble ball joint connection pipes, supports

and clamps loosely to permit alignment of all parts.

Fig. 7 Underfloor Converter or Extension Pipe Support—2 Places

Fig. 5 Tail Pipe with Muffler—Typical

Fig. 6 Insulator Tail Pipe and Muffler Support


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(2 ) B eg in n i n g a t t h e b a ll joi n t , a l ig n a n d t or q u e

shoulder bolts (Fig. 3).

(3 ) Wor k i n g fr om t h e fr on t of s ys t e m , a l ig n a n d

cla m p e a ch com p on e n t t o m a in t a in p os it ion a n d

proper clearance with underbody parts (Fig. 10).

(4 ) T ig h t en a l l c la m p s a n d s u p p or t s t o t h e p r op e r

torques and clearances.

INTAKE AND EXHAUST M ANIFOLDS—TBI ENGINE

INTAKE M ANIFOLD

N a t u r a ll y As p i r a te d D ie -ca s t a l u m in u m l on g -

branch fan design with remote plenum. The throttle

body is installed on the upper plenum of the manifold.

EXHAUST M ANIFOLD

All high strength iron casting that intermesh with

t h e in t a k e m a n ifold . F or s t a n da r d e n gin e s a fou r

branch design collects and directs exhau st gases to

th e conical (ar ticulat ed joint connection) outlet.

THROTTLE BODY AIR HEATER

The throttle body air heater (Fig. 1) is attached to

the exhaust manifold and is removable.

Inspect air heater connector tube; replace if dam-

aged. Refer to E mission Control Systems Group 25,

Fig. 9 First Slip Joint Connection

Fig. 10 Exhaust Clearance

Fig. 8 Front Tail Pipe Uni-Clamp


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for diagnostic and service procedures on the air con-

t r o l v a l v e a n d t e m p e r a t u r e s e n s o r l o c a t e d i n t h e a i r

cleaner.

INTAKE AND EXHAUST MANIFOLDS SERVICE— TBIENGINE

Intake and exhaust manifolds use a one piece gas-

ket. Service procedures requiring removal and instal-

lation ( of either ) must include both manifolds.

FUEL SY STEM PRESSURE RELEASE PROCE-

DURE T h e F u e l S y s t e m i s u n d e r a c o n s t a n t p r e s s u r e

o f a t l e a s t 2 6 5 k P a ( 3 9 p s i ) . B e f o re s e r v i c in g t h e

f ue l pum p, f ue l l i ne s , f ue l f i l t e r , t hr o t t l e bo dy o r

f u e l i n j e c t o r , t h e f u e l s y s t e m p r e s s u r e m u s t b e

r e l e a s e d .

(a) Loosen fuel filler cap t o release fuel ta nk pres-

sure.

(b) Disconnect injector wiring harn ess from en-

gine harness.

(c) C on n e ct a ju m p e r w ir e t o g r ou n d t e r m in a l

Number 1 of the injector harness (Fig. 2) to engine

ground.

(d) Connect a jumper wire to the positive termi-

n a l N u m b e r 2 o f t h e i n j e c t o r h a r n e s s ( F i g . 2 ) a n d

touch the battery positive post for no longer than 5

seconds. This releases system pressure.

(e) Remove jumper wires.

(f) Continu e fuel system service.

REMOVAL

(1) Perform fuel system pressure release procedure

b e f o re a t t e m p t i n g a n y r e p a i rs .

(2) Disconnect negat ive batt ery cable. Drain cooling

system. Refer t o Cooling System, Gr oup 7 for proce-

dure.

(3) Remove air cleaner and disconnect a ll vacuumlines, electrical wiring and fuel l ines from throttle

body.

(4) Remove throttle linkage.

(5) Loosen power steering pump and remove belt.

(6) Remove power brake vacuum hose from intake

manifold.

(7) Disconnect EGR tube from intake manifold and

remove water hoses from water crossover.

(8 ) R a is e v eh i cl e a n d r e m ov e e xh a u s t p ip e fr om

manifold.

(9) Remove power steering pump assembly and set

aside.(10) Remove intake manifold retaining screws (Fig.

3).

(11) Lower vehicle an d r emove inta ke m an ifold.

(12) Remove exhaust manifold retaining nuts (Fig.

3).

(13) Remove exhau st m anifold.

Fig. 3 Intake and Exhaust Manifold Attaching Points—2.2/2.5L Engines

Fig. 1 Air Heater—TBI Engine

Fig. 2 Injector Harness Connector


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CLEANING AND INSPECTION

(1) Discard gaskets and clean all gasket surfaces on

both manifolds and on cylinder head.

(2) Test gasket surfaces of manifolds for flatness

w it h a s t r a i gh t e d ge . S u r fa ce s m u s t b e f la t w it h i n

0.15mm per 300mm (.006 in. per foot) of manifold

length.

(3) Inspect ma nifolds for cra cks a nd distortion.

INSTALLATION

(1) Install a new intake and exhaust manifold gas-

ket. Coat steel gasket l ightly with Gasket Sealer on

manifold side. D o n o t coat composition gasket with

(any) sealer.

(2) Set exhaust manifold in place. Tighten retain-

i n g n u t s s t a r t i n g a t c e n t e r a n d p r o g r e s s i n g o u t w a r d

i n b ot h d ir e ct i on s t o 2 3 N¼m (200 in. lbs.) torque.

Repeat this procedure until all nuts are at specified

torque.

(3) Set intake manifold in place.

(4 ) R a is e v eh icl e a n d t ig h te n r e t a in in g s cr e ws

s t a r t i n g a t ce n t e r a n d p r og r es s in g ou t w a r d i n b ot h

d ir e ct i on s t o 2 3 N¼m (200 in. lbs.) torque (Fig. 3).

Repeat this procedure until all screws are at specified

torque.

(5) Reverse removal procedures 1-9 for insta llat ion.

(6) With the DRB II use ASD Fuel System Test topressurize system to check for leaks.

CAUTION: When using the ASD Fuel System Test,

the Auto Shutdown (ASD) relay will remain ener-

gized for 7 minutes or until the ignition switch is

turned to the OFF position, or Stop All Test is se-

lected.

Fig. 4 Turbocharged Engine Components


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INTAKE/EXHAUST MANIFOLDS AND TURBO-CHARGER SERVICE— TURBO I ENGINES

INTAKE M ANIFOLD

The manifold is die-cast aluminum with upper ple-

n u m a n d 4 t u b e s l o w e r r u n n e r s . T h e s e a t t a c h t o t h e

cylinder head, with each runner leading directly to a

cylinder.

The manifold is also machined for fuel rail attach-

m e n t a n d i n je ct or i n st a l la t i on . T h e t h r o t t le b od y i s

installed on the upper plenum of the manifold.

EXHAUST M ANIFOLD

T h e t u r b och a r g e r e qu i pp e d e n gi n e e xh a u s t m a n i -

fold is a modified log- type design with a machined

outlet t o match a nd retain the turbochar ger assembly.

E x h a u s t g a s es , p a s s ed d ir e ct l y t o t h e t u r b och a r g e r

exit through a conical articulated joint connection

outlet machined into th e turbochar ger housing.

Intake and exhaust manifolds use a one piece gas-

ket. Service procedures requiring removal and instal-lation of either must include both manifolds.

INTAKE M ANIFOLD

REMOVAL



(2) Disconnect negative bat tery cable. Dra in cooling

system. See Cooling System, Group 7.

(3) Remove air cleaner hose clamp to throttle body

and remove air cleaner assembly (Fig. 5).

(4) Remove a ccelerator a nd speed cont rol cables.

(5) Disconnect automatic idle speed (AIS) motor

and throttle position sensor (TPS) wiring connectors.

(6) Disconnect vacuum hoses from th rottle body.

(7) Disconnect Detonation Sensor, Fuel Injector

Wiring Connector, Wiring Connector.

(8 ) R em ov e s u pp ly a n d r e t u r n h os e a t fu e l t u b e

assembly (Fig. 6).

WARNING: WRAP SHOP TOWELS AROUND HOSES

TO CATCH ANY GASOLINE SPILLAGE.

(9 ) U si ng 2 w r en ch e s, on e on t h e fu e l p r es su r e

r e g u l a t o r a n d t h e o t h e r o n t h e f u e l r e t u r n t u b e n u t

loosen tube nut. Open fuel tube clip and remove fuel

tube.

(1 0) D is con n e ct fu e l p r e ss u r e r e gu l a t or v a cu u m

hose from regulator.

(11) Remove fuel pressure regulator to fuel rail a t-

taching nuts (2).

(12) Remove fuel pressure regulator from fuel rail.(13) Remove PCV vacuum har ness, brak e booster,

and vacuum vapor harness from intake manifold (Fig.

6).

(14) Disconnect Detonation (Knock) Sen sor E lectri-

cal Connector (Fig. 7).

(15) Remove fuel rail to intake manifold attaching

screws (Fig. 7).

(16) Remove fuel rail a nd injector a ssembly by pull-

ing rail so that the injectors come straight out of their

ports.

(17) Be careful not to dam age t he rubber injector

O-rings upon removal from the ports.

(18) Remove fuel r ail a ssembly from vehicle.

Fig. 5 Air Cleaner and Throttle Body

Assembly—Turbo I Engine

Fig. 6 Electrical and Vacuum Hose Connection


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(19) Cover injector ports with suitable covering

while injectors are being serviced (Fig. 8).

(2 0) D o n ot r e m ov e fu e l i n je ct or s u n t i l fu e l r a i l

assembly h as been completely r emoved from vehicle.

TURBOCHARGER

REMOVAL

Turbochargers are removed from below the vehicle.

Cylinder head removal for component accessibility is

not required.

(1) F r o m Ab o v e : R em ov e fr on t e n gi n e m ou n t

t h r o u gh b ol t a n d r ot a t e e n gi n e ( t op ) f or w a r d a w a y

from cowl. Refer to Engine, Group 9 and see (Fig. 3)

in Engine Removal section.

(2) Separate coolant line from water box and turbo-

charger housing (Fig. 4). Remove line an d fitting from

turbocharger.

(3) Separate oil feed l ine from turbocharger hous-

ing.

(4) Remove wast e gate rod-to-gate r etaining clip.

(5) Remove th ree t wo upper a nd one lower dr iver’s

side nuts retaining turbocharger to manifold. Discon-

nect 02

sensor lead wire a nd vacuum lines.

(6) F r om B e lo w : R em ov e r i gh t fr on t w h e el a n d

tire assembly.

(7 ) S ee S u sp en s ion , G r ou p 2 , a n d r e m ov e r igh t

driveshaft assembly.

(8) Remove turbocharger to block support bracket(Fig. 4).

(9) Separate oil drain back tube fi t t ing from turbo-

charger housing and remove fitting and hose.

(10) Remove remaining turbochar ger to manifold

retaining nut.

(11) Disconnect articulated exhaust pipe joint from

turbocharger housing.

(12) Remove lower coolant l ine and turbochar ger

inlet fitting.

(13) Lift turbocharger off manifold mounting studs

and lower assembly down and out of vehicle.

INTAKE/EXHAUST MANIFOLDS—TURBO I EN- GINE

REMOVAL

R em ov e 8 i n t a k e m a n i fol d s c r ew s a n d w a s h er a s -

semblies and remove intake manifold (Fig. 9).

Remove 8 exhaust manifold retaining nuts and re-

move exha ust ma nifold (Fig. 9).


(1) Discard gasket and clean all gasket surfaces of

manifolds and cylinder head.

Fig. 7 Fuel Rail Attaching Screws

Fig. 8 Detonation (Knock Sensor) and PCV Vacuum Nipple

Fig. 9 Intake and Exhaust Manifolds—Turbocharged Engines


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(2) Test gasket surfaces for flatness with straight

e d ge . S u r fa ce m u s t b e f la t w it h i n 0 .1 5 m m p e r 3 00

mm (.006 in. per foot) of man ifold length.

(3) Inspect m an ifolds for cra cks or distortion.

INTAKE/EXHAUST MANIFOLDS—TURBO I EN-

GINE

INSTALLATION

(1 ) I n s t a ll n e w t w o-s id e d g r a foi l or e qu i va l en t

i n t a k e/e xh a u s t m a n i fol d g a sk e t . D O N O T AP P LY

SEALER.

(2) Position intake manifold, install , and t ighten 8

r e t a in i n g s c r ew s s t a r t i n g a t ce n t e r a n d p r og r es s in g

o u t w a r d i n b o t h d i r e c t i o n s t o 2 3 N¼m (200 in. lbs.)

torque. Repeat this procedure until all screws are at

specified torque (Fig. 9).

(3 ) S et e xh a u s t m a n ifold in p la ce . I n st a ll a n d

t igh t e n r e t a in in g n u t s , s t a r t i n g a t ce n t er a n d p r o-

gressing outward in both directions to 23 N¼m (200

in. lbs.) torque. Repeat this procedure until all nutsare at specified torque.

(4) Install cowl mounted heat shield.

TURBOCHARGER

INSTALLATION

(1) Position turbocharger on exhaust manifold. Ap-

p ly a n t i s ei ze com p ou n d , t o t h r e a d s a n d i n st a l l o n e

l ow er p a s s en g er s id e r e t a in i n g n u t . R et a i n in g n u t s

tightening torque is 54 N¼m (40 ft. lbs.).

(2) Apply thread sealant to lower inlet coolant line

fitting and install fitting into turbocharger housing.

(3) Inst all lower coolant line.(4) Install oil drain back tube and fi t t ing with new

gasket to turbocharger housing.

(5 ) I n s t a l l a n d t i gh t e n t u r b och a r g e r t o b lock s u p -

port bracket and install screws finger t ight. Tighten

block screw FIRST to 54 N¼m (40 ft. lbs.) torque, th en

tighten screw to turbocharger housing to 27 N¼m (20

ft. lbs. ) torque.

(6 ) R ep os it i on e xh a u s t p ip e . T ig h t en a r t i cu l a t ed

joint shoulder bolts t o 28 N¼m (250 in. lbs.) torque.

(7 ) S ee S u s pe n sion , G r ou p 2 , a n d in s t a ll r ig h t

driveshaft and wheel and tire assembly.

(8) F ro m Ab o v e : I n st a ll t h r e e t u r b och a r ge r t o

m a n i fol d r e t a in i n g n u t s . T ig h t en t o 5 4 N¼m (4 0 f t .

lbs.) torque.

(9) Reconn ect 02

sensor electrical connection a nd

v a cu u m l in e s a n d i n s t a ll w a s t e g a t e r od -t o-g a t e r e -

ta ining clip.

(1 0) A t t a ch oi l fe ed l in e t o t u r b och a r g er b ea r i n g

h ou s in g. Ti gh t e n fit t in g t o 1 4 N¼m (1 25 in . lb s.)

torque.

(11) Apply t h r ea d sea la n t t o wa t er

box/turbocharger, return coolant line end fittings. In-

stall coolant l ine and t ighten fi t t ings to 41 N ¼m (30

ft. lbs.) torque.

(1 2) Al ig n fr on t e n gi n e m ou n t i n cr os s m em b er

b r a c k e t . I n s t a l l t h r o u g h b o l t a n d t i g h t e n t o 5 4 N ¼m

(40 ft. lbs.) torque.

FUEL RAIL

INSTALLATION

(1 ) B e s u r e i n je ct or s a r e s e a t ed i n t o t h e r e ce iv ercup, with lock ring in place.

(2) Install injector wiring h arn ess t o injectors a nd

fast en into wiring clips.

(3) Make sure the injector holes are clean and all

plugs have been removed.

(4) Lube injector O-rings with a drop of clean en-

gine oil to ease installation.

(5 ) I n s t a l l t h e i n je ct or a s s em b ly i n t o t h e ir h ol es

a n d i n s t a l l t h e 2 a t t a c h i n g b o l t s a n d g r o u n d s t r a p s .

F u e l r a i l a s s em b ly m u s t b e d r a w n i nt o t h e in t a k e

manifold evenly making sure each injector enters i ts

own hole. Once all injectors are seated t ighten bolts

to 22.5 N¼m (200 in. lbs.) torque (Fig. 7).

(6) Lube O-ring of fuel pressure regulator with a

drop of clean engine oil and install into the receiver

cup on fuel rail.

(7 ) I n s t a ll a t t a c h in g n u t s a n d t i gh t e n t o 7 N¼m (65

in. lbs.) torque.

(8 ) I n s t a l l P C V s ys t e m h os e h a r n e s s a n d v a cu u m

hose harness (Fig. 6).

(9 ) Re con n e ct a cce le r a t or l in k a g e. I n s t a ll b r a k e

booster vacuum supply hoses.

(1 0) I n s t a l l a i r cl ea n e r h os es a n d a i r cl ea n e r a s -

sembly.

(11 ) Re con n e ct v a cu u m h os e fr om fu e l p r e ss u r eregulator.

(12) Connect fuel return tube t o fuel pressure r egu-

l a t o r a n d t i g h t e n t u b e n u t t o 2 8 N¼m (250 in. lbs.)

torque (Fig. 7). Close fuel tube clip around fuel tubes

and install fastener.

(1 3) L u b r i ca t e t h e e n d s of t h e ch a s s is fu e l t u b e s

with 30 wt oil . Connect fuel supply and return hoses

to chassis fuel tube assembly. pull back on the quick

connect fitting to ensure complete insertion. (Refer to

F u e l H os e s, C la m p s a n d Q u ick C on n e ct F i t t in g s i n

Group 14 Fuel Systems).

(14) Conn ect fuel injector, detonat ion (knock) sen -

sor wiring connector (Fig. 6).

(15) Fill cooling system. See Drain and Refill in

Cooling System , Gr oup 7.

(16) Reconnect negative bat tery cable.

(17) With t he DRB II use ASD Fu el System Test to

pressurize system to check for leaks.

CAUTION: When using the ASD Fuel System Test,the Auto Shutdown (ASD) relay will remain ener-

gized for 7 minutes or until the ignition switch isturned to the OFF position, or Stop All Test is se-lected.


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TU RBO BYPASS VALVE SERVICE

(1) Remove vacuum hose from valve.

(2) Apply 15 in. Hg of vacuum to valve. If vacuum

h ol ds , b yp a s s v a lv e O K (F i g. 1 0). I f v a cu u m l ea k s

replace air cleaner assembly (Fig. 11).

INTAKE/EXHAUST MANIFOLDS AND TURBO-CHARGER SERVICE—TURBO II I ENGINE

INTAKE M ANIFOLD

REMOVAL



(2) Disconnect negative bat tery cable. Dra in cooling

system. Refer t o Cooling System, Group 7.

(3) Remove fresh air duct from air fi lter housing.

Remove inlet hose from the intercooler (Fig. 1).

(4) Remove ra diator h ose to cylinder head (Fig. 2).

(5) Remove DIS Ignition Coils from int ak e man ifold

(Fig. 3).

(6) Remove accelerator and speed control cables

(Fig. 4).

(7) Disconnect Intercooler to throttle body outlet

hose. Disconnect vacuum hoses from throttle body

and remove harness (Fig. 5).

(8) Disconnect automatic idle speed (AIS) motor

and th rottle position sensor (TPS) wiring conn ectors

(Fig. 6).

(9 ) R em ove P C V B re at h er /S ep a ra t or b ox a n d

v a cu u m h a r n e s s a s s em b ly. R em ov e b r a k e b oos t e r,

v a cu u m v a por h a r n e s s a n d fu e l p r e s s u r e r e gu l a t or

harness from intake manifold (Fig. 7).

Fig. 10 Turbo Air Cleaner Bypass Valve

Fig. 11 Bypass Valve and Air Cleaner Assembly

Fig. 1 Air Cleaner and Throttle Body

Assembly—Turbo III Engine

Fig. 2 Radiator to Cylinder Head Hose


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(10) Disconnect Fuel Injector Wiring Connector

(Fig. 8). Charge Temperature Wiring Connector (Fig.

7).

(11) Remove fuel supply and return hose quick con-

nect at fuel tube assembly (Fig. 9).



Fig. 6 Automatic Idle Speed (AIS) Motor and Throttle Position Sensor (TPS) Wiring Connectors

Fig. 7 Intake Manifold Electrical and Vacuum Hose Connections

Fig. 3 Distributorless Ignition Coil (DIS) Location

Fig. 4 Accelerator and Speed Control Cables

Fig. 5 Intercooler to Throttle Body Hose


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(12) Remove 8 intake manifold screws and washer

assemblies and remove intake manifold (Fig. 10).

INSTALLATION

Before installing manifold. Refer to Cleaning and

Inspection of this section to check manifold for dam-

age.

( 1 ) I n s t a l l n e w i n t a k e m a n i f o l d g a s k e t a n d i n t a k e

manifold onto cylinder head and t ighten fasteners to

23 N¼m (200 in. lbs.) torque (Fig. 10).

(2) I ns ta ll P CV B rea t her /S ep ar a tor box a n dv a cu u m h a r n e s s a s s em b ly. C on n e ct b r a k e b oos t e r,

vacuum vapor harness and vacuum hose to fuel pres-

sure regulator (Fig. 7).

(3) Inspect quick connect fi t t ings for damage, re-

place if necessary Refer to Fuel System, Group 14 for

procedure. Lube tube with clean 30w engine oil, Con-

n e ct fu e l s u p p ly a n d r e t u r n h os es t o ch a s sis t u b e

assembly. Check connection by pulling on connector to

insure it locked into position (Fig. 9).

(4) Conn ect Fu el Injector (Fig. 8), and Ch arge Tem-

perature Sensor wiring connectors (Fig. 7).

INTAKE M ANIFOLD

(5 ) C on n ect Au t om a t ic I dle S pe ed (AI S) a n d

Throttle Position Sensor (TPS) wiring connectors (Fig.

6).(6) Conn ect vacuum hoses to th rottle body (Fig. 5).

(7 ) I n st a l l i n t er cool er t o t h r o t t le b od y h os e a n d

clamp. Torque clamp to 3 N¼m (30 in. lbs.) (Fig. 5).

(8) Connect accelerator and speed contr ol cables

(Fig. 4).

(9) Inst all DIS Ignition Coil pack. Tight en fasten ers

to 12 N¼m (105 in. lbs.) torque (Fig. 3).

(10) Install upper radiator hose and spring clamps

(Fig. 2). Fill Cooling System, Refer to Cooling System,

Group 7.

(11) Install fresh air duct to air f i l ter housing. In-

sta ll inlet hose a ssembly to Int ercooler. Tighten clamp

t o 3 N¼m (30 in. lbs.) torque (Fig. 1).

(12) Connect negative battery cable.




the Auto Shutdown (ASD) relay will remain ener-gized for 7 minutes or until the ignition switch isturned to the OFF position, or Stop All Test is se-lected.

TURBOCHARGER

REMOVAL

Turbochargers are removed from below the vehicle.

Cylinder head removal for component accessibility is

not required.

(1) Disconnect n egative bat tery cable. Remove Air

Cleaner assembly (Fig. 1).

(2) F r om Ab o v e : R em ov e fr on t e n gin e m ou n t

through bolt and rotate engine (Top) forward away

from cowl. Refer to En gine Removal in En gine, Group

9.

(3) Remove Air Cleaner Support (Fig. 1).

Fig. 8 Camshaft Sensor and Fuel Injectors Wiring

Connectors

Fig. 9 Fuel Supply and Return Hose Connections

Fig. 10 Intake Manifold Attaching Bolts.


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(4) Disconnect 02 s en s or le a d w ir e a n d v a cu u m

lines.

(5) Separate coolant return line from water box and

turbocharger housing (Fig. 11). Remove r eturn l ine

from tur bocha rger.

(6) Separate oil feed l ine from turbocharger hous-

ing (Fig. 12).

(7) Remove th ree (two upper an d one lower driver’s

s id e ) n u t s r e t a in i n g t u r b och a r g e r t o m a n i fol d (F i g.

12).

(8) F ro m B e lo w : R em ov e r i gh t fr on t w h e el a n dtire assembly.

(9 ) Se e S u s pe n sion , G r ou p 2 , a n d r e mov e r igh t

d r iv es h a ft a s s em b ly. Ai r d e fl ect or m a y n e e d t o b e

removed from crossmember.

(10) Separate oil drain back tube fitting from turbo-

ch a r g e r h ou s in g a n d r e m ov e fi t t in g a n d h os e (F i g.

13).

(11) Remove turbocharger to block support bracket

(Fig. 13).

(12) Remove one remaining turbocharger to mani-

fold retaining nut (Fig. 12).

(13) Disconnect articulated exhaust pipe joint from

turbocharger housing.

(14) Remove turbocharger coolant inlet line assem-

bly from engine (Fig. 11).

(15) Lift turbocharger off manifold mounting studs

and lower assembly down and out of vehicle.

EXHAUST M ANIFOLD

REMOVAL

Remove 9 exhaust man ifold retaining fasteners and

remove exhau st man ifold (Fig. 14).


(1) Discard gasket and clean all gasket surfaces of

manifolds and cylinder head.(2) Test man ifold gasket sur faces for flatn ess with

s t r a i gh t e d ge . S u r f a ce m u s t b e f la t w it h i n 0 .1 5 m m

per 300 mm (.006 in. per foot) of man ifold length.

(3) Inspect man ifolds for cracks or distortion. Re-

place manifold if necessary.

EXHAUST M ANIFOLD

INSTALLATION

(1) Install new manifold gasket. DO NOT APPLY

SEALER.

Fig. 11 Coolant Tube Routing

Fig. 12 Turbocharger Attaching Nuts

Fig. 13 Oil Return Tube and Support Bracket

Fig. 14 Exhaust Manifold—Turbo III Engine


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(2) Set exhaust manifold in place. Tighten retain-

ing nuts and bolt , starting at center and progressing

o u t w a r d i n b o t h d i r e c t i o n s t o 2 3 N¼m (200 in. lbs.)

torque. Repeat this procedure until all fasteners are

at specified torque (Fig. 14).

TURBOCHARGER

INSTALLATION

(1) Position turbocharger on exhaust manifold. Ap-

p ly a n t is eize com p ou n d t o t h r e a ds a n d in s t a ll t h e

lower (passenger side) retaining n ut (Fig. 12). Tight en

n u t t o 54 N¼m (40 ft. lbs.) torque.

(2 ) A pp ly t h r e a d s ea l a n t t o l ow er (i n le t ) cool a n t

line fi t t ing an d install f it t ing into tu rbocharger hous-

ing (Fig. 11).

(3) Install lower coolant l ine assembly to engine

(Fig. 11).

(4) Install oil drain back tube a nd fi t t ing (with new

gasket) to turbocharger housing (Fig. 13).

(5 ) I n s t a l l t u r b och a r g e r t o b lock s u p p or t b r a ck e t

an d install screws finger tight (Fig. 13). Tighten block

s cr e w F I R ST t o 5 4 N¼m (4 0 ft . l bs .) t or q u e , t h e n

tighten screw to turbocharger housing to 27 N¼m (20

ft. lbs.) torque.

(6 ) R ep os it i on e xh a u s t p ip e . T ig h t en a r t i cu l a t ed

joint shoulder bolts t o 28 N¼m (250 in. lbs.) torque.

(7 ) S ee S u s pe n sion , G r ou p 2 , a n d in s t a ll r ig h t

d r iv es h a ft a n d w h e el a n d t i r e a s s em b ly. I n s t a ll a i r

deflector on crossmember.

(8) F r o m Ab o v e : I n s t a ll t h r e e t u r b och a r g e r t o

m a n i fol d r e t a in i n g n u t s . T ig h t en t o 5 4 N¼m (4 0 f t .

lbs.) torque (Fig. 12).(9) Reconn ect 0

2sensor electrical connection a nd

vacuum lines.

(1 0) A t t a ch oi l fe ed l in e t o t u r b och a r g er b ea r i n g

h ou s in g. Ti gh t e n fit t in g t o 1 4 N¼m (1 25 in . lb s.)

torque (Fig. 12).

(11) Insta ll coolant l ine and t ighten fi t t ings to 41

N¼m (30 ft. lbs.) torque (Fig. 11).

(12) Install Air Cleaner support (Fig. 1).

(1 3) Al ig n fr on t e n gi n e m ou n t i n cr os s m em b er

b r a c k e t . I n s t a l l t h r o u g h b o l t a n d t i g h t e n t o 5 4 N ¼m

(40 ft. lbs.) torque.

(14) Insta ll Air Cleaner a ssembly (Fig. 1).

(15) Fill Cooling System. Refer to Cooling System,

Group 7 for procedure.

INTAKE/EXHAUST MANIFOLD SERVICE— 3. 0L EN-GINE

The intake system has a large air intake plenum of

a lu m in u m a ll oy a n d a cr os s t yp e in t a k e m a n ifold

(Fig. 2).

T h e e xh a u s t m a n i fol ds a r e m a d e of d u c t il e c a s t

i r o n w i t h t h e f r o n t b a n k a n d r e a r b a n k i n d e p e n d e n t

of e a ch ot h e r. T h e e x h a u s t fr om t h e fr on t b a n k e x-

hau st manifold is led t hrough on exhau st crossover

p i p e t o b e c o m b i n e d w i t h t h e r e a r b a n k e x h a u s t a t

the exhaust outlet t o the exhaust pipe (Fig. 2).

INTAKE PLENUM/MANIFOLD

REMOVAL


( be f o r e a t t e m pt i ng a ny r e pa i r s ) .(2) Disconnect negat ive batt ery cable. Drain cooling

system. See Cooling System, Group 7.

(3) Remove a ir cleaner to t hrottle body hose (Fig.

4).


DURE

T h e M P I f u e l s y s t e m i s u n d e r a c o n s t a n t p r e s -

s u r e o f a b o u t 3 30 k P a ( 48 p s i ) . B e fo r e s e r v i c in g

t h e f u e l p u m p , fu e l l in e s , f u e l f il te r, t h ro t tl e

b o d y o r f u e l i n j e c t o r , t h e f u e l s y s t e m p r e s s u r e

m u s t b e r e l e a s e d .


sure.

(b) Disconnect injector wiring har ness from en-

gine harness.



ground.






(f) Cont inue fuel system service.

(4) Remove throttle cable and transaxle kickdown

linkage (Fig. 5).

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

throttle position sensor (TPS) wiring connectors from

th rottle body (Fig. 6).

(6 ) Re m ov e va cu u m h os e h a r n e ss fr om t h r ot t le

body (Fig. 6).

Fig. 1 Injector Harness Connector


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(7) Remove PCV and Brake booster hoses from Air

I n t a k e P l e n u m .

(8) Remove Ignition Coil from Intake Plenum (Fig.

7).(9) Remove wiring connectors from coolant tem-

perature sensor (Fig. 8).

(10) Remove vacuum connections from Air Intake

Plenum vacuum connector.

(11) Remove fuel h oses from fuel r ail (Fig. 8).



(12) Remove (8) Fa steners from Air Intake Plenum

to In tak e Ma nifold (Fig. 9).

(13) Remove Air In tak e Plenu m (Fig. 10).

(1 4) Cov er i n t a k e m a n i fol d w it h s u it a b le cov erwhen servicing.

(15) Remove vacuum hoses from fuel rail and fuel

pressur e r egulator (Fig. 11).

(16) Disconnect Fuel Injector wiring har ness from

engine wiring harness (Fig. 12).

(17) Remove fuel pressure regulator attaching bolts

and remove regulator from rail (Fig. 13). B e c a r e f u l

n o t t o d a m a g e t h e r u b b e r i n j e c t o r O-r i n g s u p o n

r e m o v a l f r o m t he po r t s .

(18) Remove fuel ra il att aching bolts and l ift fuel

rail assembly from intake manifold.

(19) Separate radiator hose from thermostat hous-

ing and heater hose from heater pipe.

(2 0) R e m ov e (8 ) n u t a n d w a s h er a s s em b li es a n d

remove inta ke man ifold (Fig. 1).

INSPECTION

Check for:

• Dama ge an d cra cks of each section (Fig. 13).

• Clogged water passages in end cross overs.

Fig. 2 Intake and Exhaust Manifolds— 3.0L Engine

Fig. 3 Throttle Body Assembly 3.0L


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• Check for distortion of the cylinder head mounting

s u r fa ce u s in g a s t r a ig h te dg e a n d t h ick n es s ga u g e

(Fig. 14). Refer to (Fig. 15) for Specifications.

INSTALLATION

(1) Position new intake manifold gaskets on cylin-

der head and install intake (cross) manifold.

(2 ) I n st a ll (8 ) n u t s a n d w a sh e r s a n d t ig h te n i n

several steps in order shown in (Fig. 16) to 20 N¼m

(174 in. lbs.).

( 3 ) M a k e s u r e t h e i n j e c t o r h o l e s a r e c l e a n a n d a l l


(4) Lube injector O-ring with a drop of clean engine

oil to ease installation.

(5 ) P u t t h e t ip of e a ch in je ct or in t o t h e ir p or t s .

P u s h t h e a s s e m b l y i n t o p l a c e u n t i l t h e i n j e c t o r s a r e

seated in the ports.(6 ) In s t a ll t h e (3 ) fu e l r a il a t t a ch in g b ol ts a n d

torque to 13 N¼m (115 in. lbs.).

(7 ) I n s t a ll fu e l p r e ss u r e r e gu l a t or on t o fu e l r a i l.

I n s t a ll a t t a c h in g b ol t s t o i n t a k e m a n i fol d. Tor q u e

r e gu l a t or n u t s a n d b r a ck e t b o lt s t o 1 0 N¼m (9 5 i n .

lbs.) (Fig. 12).

(8) Install fuel supply and return tube hold-down

bolt and the vacuum crossover tube hold-down bolt

and torque to 10 N¼m (95 in. lbs.).

(9) Connect fuel injector wiring har ness to engine

wiring ha rn ess (Fig. 11).

(10) Connect vacuum harn ess to fuel pressure regu-

lator and fuel rail assembly (Fig. 10).

(11) Remove covering from lower inta ke man ifold

and clean surface.

(12) Place intake man ifold gaskets w i t h b e a d e d

s e a l a n t s i d e u p on lower manifold. Put air intake in

p la ce . I n s t a ll a t t a c h in g fa s t e n er s (8 ) a n d t i gh t e n i n

several steps in sequence shown (Fig. 17) to 13 N¼m

(115 in. lbs.).

(13) Connect fuel l ine to fuel rail (Fig. 7). Torque

hose clamps to 1 N¼m (10 in. lbs.).

(14) Connect vacuum har ness to air intake plenum.

Fig. 4 Throttle Cable Attachment

Fig. 5 Electrical and Vacuum Connections to Throttle Body

Fig. 6 Ignition Coil Removal

Fig. 7 Coolant Temperature Sensor Electrical Con- nections


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(15) Connect coolant tempera tur e sensor electr ical

connector to sensor (Fig. 7).

(16) Connect PCV and brake booster supply hose to

intake plenum.

(17) Connect automatic idle speed (AIS) motor and

throttle position sensor (TPS) electrical connectors

(Fig. 5).

(1 8) Con n e ct va cu u m va p or h a r n e ss t o t h r ot t le

body (Fig. 5).

(19) Install throttle cable and transaxle kickdown

linkage (Fig. 4).

(20) Install air inlet hose assembly (Fig. 3).

(2 1) I n s t a ll r a d i a t or t o t h e r m os t a t h ou s in g h os e

and heater hose to heater pipe nipple.(22) Fill cooling system, see Refill ing System in

Cooling, Group 7.

(23) Connect negative battery cable.





gized for 7 minutes or until the ignition switch is

turned to the OFF position, or Stop All Test is se-

lected.

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 man ifold (Fig. 18).

Fig. 8 Air Intake Plenum to Intake Manifold Attach- ing Bolts

Fig. 9 Removing Air Intake Plenum

Fig. 10 Vacuum Connections for Fuel Rail and Fuel Pressure Regulator

Fig. 11 Fuel Injector Wiring Harness

Fig. 12 Fuel Pressure Regulator to Fuel Rail Assem-

bly


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(3) Remove bolts at taching cross-over p ipe to ma ni-

fold (Figs. 2 and 19).

(4) Remove nut s atta ching r ear manifold t o cylin-

der head and remove manifold.

(5 ) L ow er v eh i cl e a n d r e m ov e s cr e w s a t t a c h in g

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

(6) Remove bolts fast ening crossover pipe t o front

exhaust manifold a nd nut s fastening m anifold t o cyl-

inder head. Remove assemblies.

INSPECTION

I n s p ect e xh a u s t m a n i fol ds for d a m a g e or cr a ck s

and check distortion of the cylinder h ead mounting

Fig. 13 Check Intake (Cross) Manifold Mounting Surface

Fig. 14 Check Intake Plenum Mounting Surfaces

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


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surface and exhaust crossover mounting surface with

a straightedge and thickness gauge (Fig. 20).

INSTALLATION

I n st a ll t h e ga s k et s w it h t h e n u m b er s 1 -3 -5 e m -

b o s s e d o n t h e t o p o n t h e r e a r b a n k a n d t h o s e w i t h

numbers 2-4-6 on the front (Radiator side) bank (Fig.

21).

(1 ) I n s t a ll r e a r e xh a u s t m a n i fol d a n d t i gh t e n a t -

taching nuts to 20 N¼m (175 in. lbs.).

(2 ) A t t a ch e xh a u s t p ip e t o e xh a u s t m a n i fol d a n dtighten shoulder bolt to 28 N¼m (250 in. lbs.)

(3) Attach crossover pipe to exhaust manifold a nd

tighten bolt to 69 N¼m (51 ft. lbs.)

(4) Conn ect heat ed oxygen sensor lead (Fig. 18).

(5 ) I n s t a l l f r on t e xh a u s t m a n i fol d a n d a t t a c h e x-

hau st crossover.

(6 ) I n s t a l l fr on t m a n i fol d h e a t s h ie ld a n d t i gh t e n

atta ching screws to 15 N¼m (130 in. lbs.) (Fig. 2).

INTAKE/EXHAUST MANIFOLD SERVICE— 3. 3/3. 8LENGINES

INTAKE M ANIFOLD

REMOVAL

(1) Perform fuel system pressure release procedure,

B e f o re a t t e m p t i n g a n y r e p a i rs .

(2) Disconnect negat ive batt ery cable. Drain cooling

system. Refer t o Cooling System, Gr oup 7.


DURE

T h e M P I f u e l s y s t e m i s u n d e r a c o n s t a n t p r e s -s u r e o f a b o u t 3 30 k P a ( 48 p s i ) . B e fo r e s e r v i c in g

t h e f u e l p u m p , fu e l l in e s , f u e l f il te r, t h ro t tl e

b o d y o r f u e l i n j e c t o r , t h e f u e l s y s t e m p r e s s u r e

m u s t b e r e l e a s e d .


sure.

(b) Disconnect injector wiring har ness from en-

gine harness.



ground.

Fig. 18 Separate Articulated Joint, Disconnect Oxy- gen Sensor Wire

Fig. 19 Crossover Pipe

Fig. 20 Check Exhaust Manifold Mounting Surface

Fig. 21 Identify Exhaust Manifold Gaskets


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

bly (Fig. 2).

(4) Remove thr ottle cable (Fig. 3). Remove wiring

harness from throttle cable bracket.

(5) Remove a utomatic idle speed (AIS) motor and

throttle position sensor (TPS) wiring connectors from

throttle body (Fig. 4).



(6 ) Re m ov e v a cu u m h os e h a r n e ss fr om t h r ot t le

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 harn ess connectors

from Intake Plenum (Fig. 5).

(10) Remove cylinder head to intake plenum strut

(Fig. 5).

Fig. 1 Injector Harness Connectors

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

Fig. 3 Throttle Cable Attachment

Fig. 4 Electrical and Vacuum Connection to Throttle Body


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(11) Disconnect MAP Sensor and heated Oxygen

S e n sor e le ct r i ca l con n e ct i on . R em ov e t h e e n gi n e

mounted ground strap (Fig. 6).

(12) Remove the fuel hose quick connect fi t t ingsfrom the fuel rail using an open end wrench to push

i n on t h e p la s t i c r in g l oca t e d on t h e e n d o f t h e fi t -

t ings. Gently pull the fi t t ings from the fuel rail (Fig.

7).

WARNING: WRAP A SHOP TOWEL AROUND HOSES


(13) Remove direct ignition system (DIS) coils an d

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

(14) Remove intake manifold bolts and rotate mani-

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

(1 5) Cov er i n t a k e m a n i fol d w it h s u it a b le cov er

when servicing (Fig. 10).

(16) Remove vacuum harn ess connector from Fuel

Pressure Regulator.

(17) Remove fuel tube retainer bracket screw a ndfuel rail attaching bolts (Fig. 10). Spread the retainer

bracket to allow fuel tube removal clearance.

(18) Remove fuel rail injector wiring clip from the

alternator bracket (Fig. 11).

(19) Disconnect cam sensor, coolant temperatur e

sensor, and engine temperatur e 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).

Fig. 5 Electrical and Vacuum Connections To Intake Manifold

Fig. 6 MAP Sensor Electrical Connector

Fig. 7 Quick Connect Fuel Fittings to Fuel Rail

Fig. 8 Ignition Coils


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(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 int ake man ifold gasket.

INSPECTION

Check for:

• Damage and cracks of each section.

• C log ge d w a t e r p a s s a ge s i n e n d cr os s ov er s a n d

clogged gas passages.

INTAKE M ANIFOLD

INSTALLATION

(1) Clean all su rfaces of cylinder block and cylinder

heads.

(2) Place a drop (about 1/4 in. diameter) of Mopar

Silicone Rubber Adhesive Sealant or equivalent, onto

e a ch of t h e f o ur man ifold to cylinder head gasket

corners (Fig. 15).

WARNING: INTAKE MANIFOLD GASKET IS MADE

OF VERY THIN METAL AND MAY CAUSE PERSONALINJURY, HANDLE WITH CARE.

(3 ) Ca r e fu l ly i n s t a ll t h e i n t a k e m a n i fol d g a s ke t

(Fig. 14). Tighten end seal retainer screws to 12 N¼m

(105 in. lbs.) torque.

(4 ) I n st a ll in t a ke m a n ifold a n d (8 ) b olt s a n d

t i g h t e n t o 1 N¼m (10 in. lbs.) torque. Then retighten

b olt s t o 2 2 N¼m (2 00 i n . l b s .) t or q u e i n s e qu e n ce

shown in (Fig. 13). Then retighten again to 22 N¼m

Fig. 9 Intake Manifold Bolts

Fig. 10 Fuel Rail Attaching Bolts

Fig. 11 Fuel Injector Wiring Clip

Fig. 12 Fuel Rail Removal


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(200 in. lbs.)torque. After intake manifold is in place,

i n s p e c t t o m a k e s u r e s e a l s a r e i n p l a c e .

( 5 ) M a k e s u r e t h e i n j e c t o r h o l e s a r e c l e a n a n d a l l


(6) Lube injector O-ring with a drop of clean engine

oil to ease installation.

(7 ) P u t t h e t i p of e a c h i n je ct or i n t o t h e i r p or t s .

P u s h t h e a s s e m b l y i n t o p l a c e u n t i l t h e i n j e c t o r s a r e

seated in the ports (Fig. 12).

(8 ) In s t a ll t h e (4 ) fu e l r a il a t t a ch in g b olt s a n d

tighten to 22 N¼m (200 in. lbs.) torque (Fig. 10).

(9 ) I n s t a ll fu e l t u b e r e t a in i n g b r a ck e t s cr e w a n dtighten to 4 N¼m (35 in. lbs.) torque (Fig. 10).

(10) Reconnect cam sensor, coolant temperatur e

sensor and engine temperature sensors (Fig. 11).

(11) Install fuel injector harness wiring clips on the

a l t er n a t o r b r a ck e t a n d i n t a k e m a n i fol d w a t e r t u b e

(Fig. 11).

(12) Connect fuel pressure regulator vacuum line.

(13) Remove covering on lower inta ke m anifold an d

clean sur face.

(14) Place intake manifold gasket on lower mani-

fold. Put upper manifold into place and install bolts

finger tight.( 1 5 ) I n s t a l l t h e a l t e r n a t o r b r a c k e t t o i n t a k e m a n i -

fol d b ol t a n d t h e cy li n de r h e a d t o i n t a k e m a n i fol d

strut bolts. D o n o t t o r q u e .

(16) Tighten intake manifold bolts to 28 N¼m (250

in. lbs.) torque in the sequence shown in (Fig. 9).

(17) Tighten alternator bracket to intake manifold

bolt to 54 N¼m (40 ft. lbs.) torque (Fig. 8).

(18) Tighten the cylinder h ead to intake manifold

strut bolts to 54 N¼m (40 ft. lbs.) torque (Fig. 5).

(19) Connect ground strap, MAP and heated oxygen

sensor electrical connectors (Fig. 6).

(20) Connect char ge temperatur e sensor electrical

conn ector (Fig. 5).(2 1) C on n e ct v a cu u m h a r n e ss t o i n ta k e p le n u m

(Fig. 5).

(2 2) U s in g a n e w ga s k et , con n e ct t h e E G R t u b e

flange to the intake manifold and t ighten to 22 N¼m

(200 in. lbs.) torque.

(2 3) C lip w ir in g h a r n es s in t o t h e h ole in t h e

throttle cable bracket.

(24) Connect the wiring connectors to t he throttle

p os it i on s e n sor T P S a n d a u t o m a t ic i dl e s p ee d A I S

motor (Fig. 4).

(25) Connect vacuum harness to throttle body (Fig.

4).

(26) Install t he direct ignition system DIS coils.

Tighten fasteners to 12 N¼m (105 in. lbs.) torque (Fig.

8).

(2 7) L u b r i ca t e t h e e n d s of t h e ch a s s is fu e l t u b e s

with 30 wt oil . Connect fuel supply and return hoses

to chassis fuel tube assembly. pull back on the quick

connect fitting to ensu re complete insertion (Fig. 7).

(R efe r t o F u e l H os e s, C la m p s a n d Q u ick C on n e ct

Fittings in Group 14 Fuel Systems).

(28) Inst all th rottle cable (Fig. 3).

(29) Conn ect fuel injector wiring ha rn ess.

(30) Install air cleaner and hose assembly (Fig. 2).

Fig. 13 Intake Manifold Removal and Installation

Fig. 14 Intake Manifold Gasket

Fig. 15 Intake Manifold Gasket Sealing


8/3/2019 92FWD_11


(31) Connect negative battery cable. Fill Cooling

System. See Cooling System, Group 7.

(32) With t he DRB II use ASD Fu el System Test t o




gized for 7 minutes or until the ignition switch isturned to the OFF position, or Stop All Test is se-

lected.

EXHAUST MANIFOLDS

REMOVAL

(1) Raise vehicle and disconnect exhaust pipe from

rear cowl side exhaust manifold at articulated joint.

(2) Separate EGR tube from rear manifold and dis-

connect Heated Oxygen Sensor lead wire (Fig. 16).

(3 ) R em ov e Al t er n a t o r /P ow er S t e er i n g S u p p or t

Strut (Fig. 16).(4) Remove bolts at taching cross-over p ipe to ma ni-

fold (Fig. 16).

(5) Remove bolts atta ching rear man ifold to cylin-

der head and remove manifold.

(6 ) L ow er v eh i cl e a n d r e m ov e s cr e ws a t t a c h in g

front heat shield to front manifold (Fig. 17).(7) Remove bolts fastening crossover pipe t o front

exhaust manifold and nuts fastening manifold to cyl-

inder head. Remove a ssemblies (Fig. 18).

INSPECTION

Inspect exhaust manifolds for damage or cracks and

check distortion of th e cylinder h ead mounting sur-

face and exhaust crossover mounting surface with a

straightedge and thickness gauge (Fig. 19).

EXHAUST M ANIFOLD

INSTALLATION

(1 ) I n s t a ll r e a r e xh a u s t m a n i fol d a n d t i gh t e n a t -

taching bolts to 23 N¼m (200 in. lbs.) torque.

Fig. 16 EGR Tube, Heated Oxygen Sensor and Alternator/Power Steering Strut

Fig. 17 Heat Shield

Fig. 18 Crossover Pipe

Fig. 19 Check Exhaust Manifold Mounting Surface


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(2 ) At t a c h e xh a u s t p ip e t o e xh a u s t m a n i fol d a n d

tighten shoulder bolt to 28 N¼m (250 in. lbs.) torque.

(3) Attach crossover pipe to exhau st man ifold a nd

tighten bolt to 33 N¼m (25 ft. lbs.) torque and connect

heat ed oxygen sensor lead (Fig. 16).

(4) Inst all EGR Tube and Alternator/Power Steer-

ing Strut (Fig. 16).

(5 ) I n s t a l l f r on t e xh a u s t m a n i fol d a n d a t t a c h e x-

haust crossover (Fig. 18).

(6 ) I n s t a l l fr on t m a n i fol d h e a t s h ie ld a n d t i gh t e n

atta ching screws t o 23 N¼m (200 in. lbs.) torque (Fig.

17).

TORQUE SPECIFICATION


92FWD_11

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