Exhaust System And Intake Manifold - Chrysler 1998 Voyager Service Manual

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EXHAUST SYSTEM AND INTAKE MANIFOLD

GENERAL INFORMATION
CATALYTIC CONVERTERS . . . . . . . . . . . . . . . . . 1
EXHAUST FLEX-JOINT COUPLING . . . . . . . . . . . 2
EXHAUST GAS RECIRCULATION (EGR) . . . . . . . 2
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 1
HEAT SHIELDS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DESCRIPTION AND OPERATION
INTAKE/EXHAUST MANIFOLD-2.4L ENGINE . . 3
INTAKE/EXHAUST MANIFOLD-3.0L ENGINE . . 3
INTAKE/EXHAUST MANIFOLD-3.3/3.8L
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING
EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION
EXHAUST SYSTEM
The exhaust systems are produced in several con-
figurations, depending on engine and vehicle (Fig. 1).
AWD vehicles have a catalytic converter mounted
heat shield. The tailpipes, mufflers, and resonators
are tuned to each vehicle/powertrain combination.
CATALYTIC CONVERTERS
There is no regularly scheduled maintenance on
any Chrysler catalytic converter. If damaged, the con-
verter must be replaced.
EXHAUST SYSTEM AND INTAKE MANIFOLD
CONTENTS
page
Fig. 1 Exhaust System-Typical (All Vehicles)
REMOVAL AND INSTALLATION
EXHAUST MANIFOLD-2.4L ENGINE . . . . . . . . 8
EXHAUST MANIFOLD-3.0L ENGINE . . . . . . . 11
EXHAUST MANIFOLDS-3.3/3.8L ENGINE . . . 16
EXHAUST PIPES, MUFFLERS AND TAILPIPES . 4
INTAKE MANIFOLD LOWER-2.4L ENGINE . . . . 6
INTAKE MANIFOLD-3.0L ENGINE . . . . . . . . . . 8
INTAKE MANIFOLD-3.3/3.8L ENGINE . . . . . . 12
UPPER INTAKE MANIFOLD-2.4L ENGINE . . . . 4
CLEANING AND INSPECTION
EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . 17
INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . 17
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 18
CAUTION: Due to exterior physical similarities of
some catalytic converters with pipe assemblies,
extreme care should be taken with replacement
parts. There are internal converter differences
required in some parts of the country.
The combustion reaction caused by the catalyst
releases additional heat in the exhaust system. Caus-
ing temperature increases in the area of the reactor
under severe operating conditions. Such conditions
can exist when the engine misfires or otherwise does
not operate at peak efficiency. Do not remove spark
plug wires from plugs or by any other means short
out cylinders of the exhaust system if equipped with
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