Removal (Lower): Removal & Installation Chrysler LHS II

Installation

Clean and inspect mating surfaces. Gaskets can be reused if free from cuts or tears. Ensure fuel injectors and wiring harnesses are out of way. Tighten all bolts to specification and in correct sequence. See TORQUE SPECIFICATIONS table. (Scheme 8)and (Scheme 9). To complete installation reverse removal procedures.

Scheme 7

Scheme 8

Scheme 9

Remove upper intake manifold. See INTAKE MANIFOLD. Cover lower intake manifold openings. Disconnect ignition coil connectors and remove ignition coils. Remove valve cover bolts and valve covers. Inspect spark plug tube seals. (Scheme 10) If necessary, use a suitable pry tool and carefullyremove tube seals.

Scheme 10

Clean cylinder head and valve cover mating surfaces. Replace valve cover gasket and spark plug tube seals as necessary. If replacing spark plug tube seals, position NEW seals so that part number on seal faces cylinder head cover. Install seals using Spark Plug Tube Seal Installer (MB-998306). (Scheme 11) To complete installation, reverse removal procedure. Tighten all bolts to specification. See TORQUE SPECIFICATIONS table.

Scheme 11

Remove cylinder head cover(s). See CYLINDER HEAD COVERS. Using suitable locking pliers, remove the spark plug tube from the cylinder head and discard tube. (Scheme 12)

Scheme 12

Clean area around spark plug with parts cleaner. Apply MOPAR® Stud and Bearing Mount to a new tube in a .118" (3 mm) wide area, approximately .039" (1 mm) from the bottom of the tube. Install sealer end of the tube into the cylinder head. Then carefully install the tube into the cylinder head using a hard wood block and mallet. Install the tube until it is seated into the bottom of the bore. Install cylinder head covers. See CYLINDER HEAD COVERS .

Scheme 13

Scheme 14

1. Raise vehicle on hoist.
2. Disconnect exhaust system at front resonator from extension pipes.
3. Loosen or remove nut attaching right pipe to transaxle bracket.
4. Loosen extension pipe band clamp. (Scheme 13)
5. Remove right side converter extension pipe.
6. Lower vehicle.
7. Remove air cleaner assembly with air inlet hose. (Scheme 14)
8. Remove SRV (Single Runner Valve) vacuum reservoir and control valve assembly at right rear of engine (3.2L Engine Only).
9. Remove fastener attaching exhaust pipe front support to transaxle.
10. Disconnect downstream oxygen sensor connector and remove sensor from converter pipe.
11. Loosen and remove V-Band clamp at exhaust manifold.
12. Remove converter from engine compartment.

1. Position a NEW V-Band clamp onto the exhaust manifold outlet. (Scheme 13) DO NOT latch the clamp's T-bolt at this time.
2. Install catalytic converter. If necessary, stretch open the V-Band clamp to allow the converter to engage the manifold outlet.
3. Latch the V-Band clamp T-bolt.
4. Raise vehicle on hoist.
5. Install right side converter extension pipe, but do not tighten clamp at this time.
6. Lower vehicle on hoist.
7. Tighten V-Band clamp to 11 N.m (100 in. lbs.).
8. Install downstream oxygen sensor and connect electrical connector.
9. Install SRV (Single Runner Valve) vacuum reservoir and control valve assembly at right rear of engine. (3.2L Engine Only).
10. Install air cleaner assembly with air inlet hose. (Scheme 14)
11. Raise vehicle on hoist.
12. Tighten extension pipe band clamp to 61 N.m (45 ft. lbs.).
13. Install and/or tighten nut attaching extension pipe to transaxle bracket to 47 N.m (35 ft. lbs.).
14. Install nut attaching exhaust pipe front support to bracket on transaxle housing/differential cover and tighten to 47 N.m (35 ft. lbs.).
15. Install exhaust system to extension pipes.
16. Lower vehicle.

1. Loosen and remove V-Band clamp at exhaust manifold joint. (Scheme 13)
2. Hoist vehicle.
3. Remove exhaust system at front resonator from extension pipes.
4. Disconnect downstream oxygen sensor electrical connector and remove sensor from converter pipe
5. Remove nut attaching left pipe to transaxle bracket. Remove U-bracket and isolator from the pipe hanger. (Scheme 13)
6. Remove fastener attaching exhaust pipe front support to transaxle. This will provide removal clearance.
7. Remove converter from below vehicle

1. Install converter.
2. Attach a NEW V-Band clamp and tighten to 11 N.m (100 in. lbs.). (Scheme 13)
3. Install the front support U-bracket with isolator onto pipe hanger.
4. Install front support fastener. Install bolt attaching left pipe to transaxle rear bracket.
5. Install downstream oxygen sensor and connect electrical connector.
6. Install exhaust system at front resonator to extension pipes.
7. Lower vehicle.