OEM Dodge Intrepid Exhaust Manifold

Dodge Intrepid Exhaust Manifold Parts and Q&A

• Exhaust Manifold, Driver Side
  4663763
  Q: How to Service and Repair the Left Exhaust Manifold on Dodge Intrepid?

  A:

  Before service, cut the ground cable from the battery terminal and hoist the vehicle. Make sure to remove the exhaust system and left Catalytic Converter, without reusing the V-Band clamp. Take out the bolt on the transmission dipstick tube and turn the housing away from the engine, followed by lowering the car. Take out the screws connecting the two electrical connectors and harness to the support bracket and then remove the engine wiring harness support bracket from the cylinder head. Release the Oxygen Sensor connector on the exhaust manifold and remove the sensor; then get rid of the engine oil dipstick tube. After removing the heat shield screws and heat shields, take out the attaching bolts to remove the exhaust manifold. Inspect the manifolds for cracks or other signs of damage, watch for discoloration in the exhaust manifold gasket and check the head mounting surface for distortion by fitting a straightedge across it and using a thickness gauge. To install, put on the exhaust manifold and gasket and tighten the screws in the center before going to the edges to a tension of 23 Nm (200 inch lbs.). Hold the heat shields in place, tighten their screws to 12 Nm (105 inch lbs.), put in the oxygen sensor and attach the electrical cable. Raise the vehicle a second time to fit the bolt for the transmission dipstick tube, set the O-ring on the engine oil dipstick tube and slide the tube back in. Instead of the old part, bolt on the left catalytic converter with a new V-Band clamp tightened to 10 Nm (100 inch lbs.). Then put the engine wiring harness support bracket onto the cylinder head and join the harness to the bracket. Give the exhaust a fresh fit and link the negative cable back.
• Exhaust Manifold, Passenger Side
  4792456AC
  Q: How to Maintain the Right and Left Exhaust Manifold on Dodge Intrepid?

  A:

  The first step to installing the correct exhaust manifold is to take off the negative cable from the remote jumper terminal and then to take out the air intake plenum and air filter housing. After that, remove the bolt linking the battery cable housing tube to the transmission housing, along with the bolts that secure the EGR Tube to the exhaust manifold and EGR Valve and toss out the old gaskets. Separate the electrical connection and take out the Oxygen Sensor put on the exhaust manifold. Take the clamp connecting the manifold to the Catalytic Converter off and make sure not to reuse it. Remember to remove the screws attaching the heat shield, then remove the heat shields as well as the bolts fastening the exhaust manifold and the manifold should be removed as well. During installation, position the exhaust manifold and the gasket, then tighten the bolts by beginning in the center and moving clockwise to 23 Nm (200 inch lbs.). Secure the heat shields again and tighten them with 12 Nm (105 inch lbs.) force, then install a new V-Band clamp, making sure it gets tightened to 10 Nm (100 inch lbs.). Reattach the oxygen sensor and plug its electrical connector in, then place the EGR tube with new gaskets, tightening the screws to 95 inch lbs. Fasten the battery cable housing tube to the transmission housing with a bolt until it reaches 101 Nm (75 ft. lbs.), then re-attach the air intake plenum and air filter housing and put back the negative cable at the end. For the left exhaust manifold, take off the negative lead from the remote jumper and raise the car with a hoist. Take out the exhaust system and the left catalytic converter, but don't use the V-Band clamp later. After removing the bolt holding the transmission dipstick tube, turn the housing away from the engine and lower the vehicle. Screw the support bracket out of the cylinder head and remove the electrical wiring harness from it. Cut the high voltage power to the vehicle, then unplug the oxygen sensor adapter, lift the oxygen sensor and remove the engine oil dipstick tube. Take out the screws and heat shields that connect the catalytic converter to the car and then add in the box to remove the exhaust manifold. Put the gasket and manifold in place and attach the bolts starting at the middle and working your way out to 23 Nm (200 inch lbs.) tightness. After clamping the heat shields, tighten the screws to 12 Nm (105 inch lbs.). Once that's done, put in the oxygen sensor and link the electrical connector. Put the car on the hoist, fit the attachment bolt for the transmission dipstick tube, add an O-ring to the engine oil dipstick tube and place the tube back in position. Reattach the catalytic converter, securing it with a new V-Band clamp tightened to 10 Nm (100 inch lbs.) and then attach the engine wiring harness support bracket to the head of the cylinder and connect the connectors to this bracket. Once done, install the exhaust system again and reattach the negative cable.