Intrepid V6-3.5L VIN K (2003)
Exhaust Manifold: Service and Repair
Exhaust Manifold - Left
EXHAUST MANIFOLD LEFT
REMOVAL
1. Disconnect negative cable from remote jumper terminal.
2. Raise the vehicle on hoist.
3. Remove the exhaust system.
4. Loosen converter pipe support attaching bolt at transaxle mount.
5. Lower the vehicle.
6. Loosen and remove the V-Band clamp at exhaust manifold connector.
NOTE: Do not reuse V-Band clamp.
7. Remove electrical connector harness bracket.
8. Disconnect oxygen sensor electrical connector and remove sensor from manifold.
9. Remove heat shield attaching bolts and remove heat shield.
10. Remove exhaust manifold attaching bolts.
11. Remove exhaust manifold and gasket.
INSPECTION
1. Inspect exhaust manifolds for damage or cracks.
2. Check manifold flatness.
3. Inspect the exhaust manifold gasket for obvious discoloration or distortion.
4. Check distortion of the cylinder head mounting surface with a straightedge and thickness gauge.
INSTALLATION
1. Install the exhaust manifold and gasket. Tighten bolts starting at the center working outward to 23 Nm (200 in. lbs.).
2. Install heat shields and tighten bolts to 12 Nm (105 in. lbs.).
3. Install oxygen sensor to manifold and connect electrical connector.
4. Attach electrical connector bracket to brace.
5. Install a new V-Band clamp and tighten to 11 Nm (100 in. lbs.).
6. Raise vehicle on hoist.
7. Install and/or tighten nut attaching converter pipe support to transaxle mount to 47 Nm (35 ft. lbs.).
8. Install the exhaust system.
9. Lower vehicle and connect negative cable.
