OEM 2004 Dodge Neon Exhaust Manifold

2004 Dodge Neon Exhaust Manifold Parts and Q&A

• Q: How to Service and Repair an Exhaust Manifold on 2004 Dodge Neon?

  A: Before you begin, take off the negative cable from the battery and lift the vehicle on a hoist. Remove the bolt connecting the wire harness heat shield to the exhaust manifold support bracket and then take off the exhaust manifold support bracket too. Remove the nuts or bolts that hold the exhaust system flex joint in place on the exhaust manifold flange and roll the exhaust backward so the flange studs clear the way when you lower the car. Withdraw the hose from the rear of the cylinder head cover and remove the oxygen sensor connector and its clip from the block. With the heat shield bolts removed, you can take off the upper heat shield. Grab the manifold bolts, remove them and pull the exhaust manifold out from the vehicle's top, between the cylinder head and cowl. If a gasket is installed, discard it and then clean all areas on the manifold and cylinder head. Look over the gasket surfaces of the manifold to ensure they are flat within 0.15 mm for every 300 mm and inspect the manifold for cracks or distortion, changing it as is appropriate. First, fit the exhaust manifold and gasket, next mount the exhaust manifold bolts and tighten them according to the order in the manual up to 23 Nm. Mount the heat shields at the outlet and outlet connections, place and tighten the heat shield bolts down to 11 Nm. Attach the oxygen sensor electrical harness clip to the connector and afterward attach the make-up air hose to the port on the cylinder head cover. After support lifts up the vehicle again, attach a fresh flex joint to the manifold gasket, link the exhaust to the manifold gasket and secure it with 28 Nm. Fit and tighten the exhaust manifold support bracket and then add the bolt that secures the wire harness heat shield to the bracket. Next, raise the car back to the ground and connect the negative cable to the battery.