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Chrysler Le Baron, Dodge Dynasty, Plymouth Acclaim. Manual - part 12

EXHAUST MANIFOLD

REMOVAL

(1) Disconnect exhaust pipe from manifold articu-

late joint.

(2) Disconnect the heated oxygen sensor electrical

connection.

(3) Remove 8 exhaust manifold retaining nuts and

remove exhaust manifold (Fig. 9).

CLEANING AND INSPECTION

(1) Discard gasket and clean all gasket surfaces of

manifolds and cylinder head.

(2) Test gasket surfaces for flatness with straight

edge. Surface must be flat within 0.15 mm per 300
mm (.006 in. per foot) of manifold length.

(3) Inspect manifolds for cracks or distortion.

EXHAUST MANIFOLD

INSTALLATION

(1) Install new two-sided grafoil or equivalent in-

take/exhaust manifold gasket. DO NOT APPLY
SEALER.

(2) Set exhaust manifold in place. Install and

tighten retaining nuts, starting at center and pro-
gressing outward in both directions to 23 N

Im (200

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

INTAKE MANIFOLD

INSTALLATION

(1) Position intake manifold, install, and tighten 8

retaining screws starting at center and progressing
outward in both directions to 23 N

Im (200 in. lbs.)

torque. Repeat this procedure until all screws are at
specified torque (Fig. 9).

(2) Install PCV vacuum harness and vacuum vapor

harness (Fig. 8).

(3) Connect vacuum hose from fuel pressure regu-

lator.

(4) Connect fuel injector wiring connector (Fig. 8).
(5) Close fuel tube clip around fuel tubes and in-

stall fastener.

(6) Lubricate the ends of the chassis fuel tubes

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
Fuel Hoses, Clamps and Quick Connect Fittings in
Group 14 Fuel Systems).

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

throttle position sensor (TPS) wiring connectors (Fig.
7).

(8) Connect accelerator and speed control cables.

Install brake booster vacuum supply hoses.

(9) Reconnect negative battery cable.
(10) Install air cleaner hose to throttle body assem-

bly (Fig. 6).

(11) With the DRBII Scan Tool use ASD Fuel Sys-

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

INTAKE/EXHAUST MANIFOLDS AND
TURBOCHARGER SERVICE—TURBO III ENGINE

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.

(3) Remove fresh air duct from air filter housing.

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

(4) Remove radiator hose to cylinder head (Fig. 2).
(5) Remove DIS Ignition Coils from intake mani-

fold (Fig. 3).

(6) Remove accelerator and speed control cables

(Fig. 4).

Fig. 9 Intake and Exhaust Manifolds Attaching

Points

EXHAUST SYSTEM AND INTAKE MANIFOLD

11 - 9

(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 throttle position sensor (TPS) wiring connectors
(Fig. 6).

(9) Remove PCV Breather/Separator box and vac-

uum harness assembly. Remove brake booster, vac-
uum vapor harness and fuel pressure regulator
harness from intake manifold (Fig. 7).

(10) Disconnect Fuel Injector Wiring Connector

(Fig. 8). Charge Temperature Wiring Connector (Fig.
7).

(11) Remove fuel supply and return hose quick

connect at fuel tube assembly (Fig. 9).

WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.

(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) Install new intake manifold gasket and intake

manifold onto cylinder head and tighten fasteners to
23 N

Im (200 in. lbs.) torque (Fig. 10).

(2) Install PCV Breather/Separator box and vac-

uum harness assembly. Connect brake booster, vac-
uum vapor harness and vacuum hose to fuel pressure
regulator (Fig. 7).

Fig. 1 Air Cleaner and Throttle Body

Assembly—Turbo III Engine

Fig. 2 Radiator to Cylinder Head Hose

Fig. 3 Distributorless Ignition Coil (DIS) Location

Fig. 4 Accelerator and Speed Control Cables

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EXHAUST SYSTEM AND INTAKE MANIFOLD

(3) Inspect quick connect fittings for damage, re-

place if necessary Refer to Fuel System, Group 14 for
procedure. Lube tube with clean 30w engine oil, Con-
nect fuel supply and return hoses to chassis tube as-
sembly. Check connection by pulling on connector to
insure it locked into position (Fig. 9).

(4) Connect Fuel Injector (Fig. 8), and Charge

Temperature Sensor wiring connectors (Fig. 7).

INTAKE MANIFOLD

(5) Connect Automatic Idle Speed (AIS) and Throt-

tle Position Sensor (TPS) wiring connectors (Fig. 6).

(6) Connect vacuum hoses to throttle body (Fig. 5).
(7) Install intercooler to throttle body hose and

clamp. Torque clamp to 3 N

Im (30 in. lbs.) (Fig. 5).

(8) Connect accelerator and speed control cables

(Fig. 4).

(9) Install DIS ignition coil pack. Tighten fasteners

to 12 N

Im (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 filter housing. In-

stall inlet hose assembly to Intercooler. Tighten
clamp to 3 N

Im (30 in. lbs.) torque (Fig. 1).

(12) Connect negative battery cable.
(13) With the DRBII Scan Tool use ASD Fuel Sys-

tem Test to pressurize system to check for leaks.

Fig. 5 Intercooler to Throttle Body Hose

Fig. 6 Automatic Idle Speed (AIS) Motor and

Throttle Position Sensor (TPS) Wiring Connectors

Fig. 7 Intake Manifold Electrical and Vacuum Hose

Connections

Fig. 8 Camshaft Sensor and Fuel Injectors Wiring

Connectors

EXHAUST SYSTEM AND INTAKE MANIFOLD

11 - 11

TURBOCHARGER

REMOVAL

The turbocharger is removed from below the vehi-

cle. Cylinder head removal for component accessibil-
ity is not required.

(1) Disconnect negative battery cable. Remove Air

Cleaner assembly (Fig. 1).

(2) From Above: Remove front engine mount

through bolt and rotate engine (Top) forward away
from cowl. Refer to Engine Removal in Engine,
Group 9.

(3) Remove Air Cleaner Support (Fig. 1).
(4) Disconnect Heated Oxygen sensor lead wire

and vacuum lines.

(5) Separate coolant return line from water box

and turbocharger housing (Fig. 11). Remove return
line from turbocharger.

(6) Separate oil feed line from turbocharger hous-

ing (Fig. 12).

(7) Remove three (two upper and one lower driver’s

side) nuts retaining turbocharger to manifold (Fig.
12).

(8) From Below: Remove right front wheel and

tire assembly.

(9) See Suspension, Group 2, and remove right

driveshaft assembly.

Air deflector may need to be removed from cross-

member.

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

bocharger housing and remove fitting and hose (Fig.
13).

(11) Remove turbocharger to block support bracket

(Fig. 13).

(12) Remove one remaining turbocharger to mani-

fold retaining nut (Fig. 12).

Fig. 11 Coolant Tube Routing

Fig. 12 Turbocharger Attaching Nuts

Fig. 9 Fuel Supply and Return Hose Connections

Fig. 10 Intake Manifold Attaching Bolts.

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EXHAUST SYSTEM AND INTAKE MANIFOLD

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