Chrysler New Yorker. Manual — part 249
LEFT EXHAUST MANIFOLD
REMOVAL
(1) Disconnect negative cable from remote jumper
terminal.
(2) Raise vehicle on hoist.
(3) Remove exhaust system. Refer to procedure
outlined in this section.
(4) Loosen converter pipe support attaching bolt at
transaxle mount.
(5) Lower vehicle.
(6) Loosen and remove 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 manifold attaching bolts.
(11) Remove manifold.
INSTALLATION
(1) Install exhaust manifold. Tighten bolts starting
at the center working outward to 23 N·m (200 in.
lbs.).
(2) Install heat shields and tighten bolts to 12 N·m
(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
N·m (100 In. lbs.).
(6) Raise vehicle on hoist.
(7) Install and/or tighten nut attaching converter
pipe supports to transaxle brackets to 47 N·m (35 ft.
lbs.).
(8) Install exhaust system. Refer to procedure out-
lined in this section.
(9) Lower vehicle and connect negative cable.
CLEANING AND INSPECTION
INTAKE MANIFOLD
Check for:
• Damage and cracks of each section.
• Clogged water passages in end cross over and
clogged gas passages.
EXHAUST MANIFOLDS
Inspect exhaust manifolds for damage or cracks
and check distortion of the cylinder head mounting
surface with a straightedge and thickness gauge.
SPECIFICATIONS
TORQUE CHART
DESCRIPTION
TORQUE
Band (Torca) Clamp
Fastener . . . . . . . . . . . . . . . . . 61 N·m (45 ft. lbs.)
Catalytic Converter Pipe to Support Bracket
Nut . . . . . . . . . . . . . . . . . . . . . 47 N·m (35 ft. lbs.)
Exhaust Manifold to Catalytic Converter
V-Band Clamp . . . . . . . . . . . 11 N·m (100 in. lbs.)
Exhaust Manifold Mounting
Fasteners . . . . . . . . . . . . . . . 23 N·m (200 in. lbs.)
Exhaust Manifold Heat Shield Mounting
Fasteners . . . . . . . . . . . . . . . 12 N·m (105 in. lbs.)
Exhaust Support to Body Bracket
Fasteners . . . . . . . . . . . . . . . 25 N·m (215 in. lbs.)
Exhaust Support Bracket to Transmission
Fasteners . . . . . . . . . . . . . . . . 47 N·m (35 ft. lbs.)
Intake Manifold—Lower 2.7L
Fasteners . . . . . . . . . . . . . . . 12 N·m (105 in. lbs.)
Intake Manifold Plenum—Upper 2.7L
Fasteners . . . . . . . . . . . . . . . 12 N·m (105 in. lbs.)
Intake Manifold—Lower 3.2L
Bolts . . . . . . . . . . . . . . . . . . . 28 N·m (250 in. lbs.)
Intake Manifold Plenum—Upper 3.2L
Fasteners . . . . . . . . . . . . . . . 12 N·m (105 in. lbs.)
LH
EXHAUST SYSTEM AND INTAKE MANIFOLD
11 - 13
REMOVAL AND INSTALLATION (Continued)
EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page
page
GENERAL INFORMATION
CATALYTIC CONVERTERS . . . . . . . . . . . . . . . . . 1
EXHAUST GAS RECIRCULATION (EGR) . . . . . . . 1
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1
HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . . . . 1
DESCRIPTION AND OPERATION
EXHAUST MANIFOLDS . . . . . . . . . . . . . . . . . . . . 2
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . 2
DIAGNOSIS AND TESTING
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL AND INSTALLATION
CATALYTIC CONVERTERS . . . . . . . . . . . . . . . . . 5
EXHAUST MANIFOLDS . . . . . . . . . . . . . . . . . . . . 9
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3
INTAKE MANIFOLD—LOWER . . . . . . . . . . . . . . . 8
INTAKE MANIFOLD—UPPER . . . . . . . . . . . . . . . 6
MUFFLER AND FRONT RESONATOR . . . . . . . . . 4
TAILPIPE/REAR RESONATOR . . . . . . . . . . . . . . . 4
CLEANING AND INSPECTION
EXHAUST MANIFOLDS . . . . . . . . . . . . . . . . . . . 10
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION
EXHAUST SYSTEM
The exhaust system (Fig. 1) consist of two front
close coupled catalytic converters. Both converters
attach directly to the exhaust manifold using a
V-Band clamp. The exhaust down pipes exit the con-
verters and connect into the front resonator. The
front resonator, intermediate pipe, and muffler are
one single module. The rear resonator and tailpipe
connect to the muffler outlet. The upstream oxygen
sensors are located in each exhaust manifold. The
downstream oxygen sensors are located at the rear of
each catalytic converter.
CATALYTIC CONVERTERS
There is no regularly scheduled maintenance on
any Chrysler catalytic converter. Excessive heat may
cause bulging or other distortion, but excessive heat
will not be the fault of the converter. A fuel system or
ignition system malfunction that permits unburned
fuel to enter the converter will usually cause over-
heating. If a converter is heat damaged, correct
the cause of the damage at the same time the
converter is replaced. The entire converter
must be replaced. Inspect all other components
of
the
exhaust
system
for
heat
damage.
Unleaded gasoline must be used to avoid dam-
age to the catalyst core.
CAUTION: Due to exterior physical similarities of
some catalytic converters with pipe assemblies,
extreme care should be taken with replacement
parts.
There
is
internal
converter
differences
required in some parts of the country (particularly
vehicles built for a State with strict emission
requirements).
EXHAUST GAS RECIRCULATION (EGR)
To assist in the control of oxides of nitrogen (NOx)
in engine exhaust, all engines are equipped with an
exhaust gas recirculation (EGR) system. The use of
inert exhaust gas to dilute incoming air/fuel mixtures
lowers peak flame temperature during combustion,
thus limiting the formation of NOx.
Exhaust gases are routed through a tube from the
exhaust manifold to the intake manifold adaptor.
Where they are metered by the EGR valve into the
intake system. Refer to section 25, Emission Control
Systems for a complete description, diagnosis and the
proper service procedures.
HEAT SHIELDS
Heat shields are needed to protect both the car and
the environment from the high temperatures devel-
oped in the vicinity of the catalytic converters. Each
catalytic
converter
has
a
integral
heat
shield
attached to it and are not to be removed.
CAUTION: Avoid
application
of
rust
prevention
compounds or undercoating materials to exhaust
system heat shields on cars if equipped. Light over
spray near the edges is permitted. Application of
coating will greatly reduce the efficiency of the heat
shields resulting in excessive floor pan tempera-
tures and objectionable fumes.
300M
EXHAUST SYSTEM AND INTAKE MANIFOLD
11 - 1
The combustion reaction caused by the catalyst
releases additional heat in the exhaust system. Caus-
ing the temperature to increase in the area of the
reactor under severe operating conditions. Such con-
ditions can exist when the engine misfires or other-
wise does not operate at peak efficiency. Do not
remove spark plug wires from plugs or by any
other means short out cylinders if exhaust sys-
tem is equipped with catalytic converter. Fail-
ure of the catalytic converter can occur due to
temperature increases caused by unburned fuel
passing through the converter.
The use of the catalysts also involves some non-au-
tomotive problems. Unleaded gasoline must be used
to avoid poisoning the catalyst core. Do not allow
engine to operate above 1200 RPM in neutral for
extended periods over 5 minutes. This condition may
result in excessive exhaust system/floor pan temper-
atures because of no air movement under the vehicle.
DESCRIPTION AND OPERATION
INTAKE MANIFOLD
The intake manifold is made of a composite mate-
rial and is a cross-flow type with long runners to
improve air charge inertia. An active Short Runner
Valve (SRV) opens during certain operating condi-
tions to improve top end performance. A Manifold
Tuning Valve (MTV) connect the plenums at specific
engine speeds to maximize low RPM torque without
reducing high RPM power.
EXHAUST MANIFOLDS
The exhaust manifolds are a log type design. The
manifolds are made of nodular cast iron. The outlets
are designed for V-Band clamp attachment of close
coupled catalytic converters.
Fig. 1 Exhaust System—3.5L Engine
11 - 2
EXHAUST SYSTEM AND INTAKE MANIFOLD
300M
GENERAL INFORMATION (Continued)
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