PT Cruiser Forum  
       

Go Back   PT Cruiser Forum > 2.4L Turbo Forums > General Turbo Discussions

PT Cruiser Forum

How am I supposed to remove the exhaust manifold?!

 
Reply
 
LinkBack Thread Tools Display Modes
  #1 (permalink)  
Old 12 Jan 2011, 09:25 am
Fresh Cruiser
 
Join Date: Dec 2009
Posts: 24
Default How am I supposed to remove the exhaust manifold?!

I am attempting to remove the cylinder head from my '03 GT. I've gotten it all of except for this *&^%#$@# exhaust manifold! How the heck am I supposed to get it off? I've considered removing it along with the turbo as an assembly with the head, but then how do I get the doggone exhaust system off of the exhaust manifold? What is the best way to go about doing this? Remove all pressure pipes from the turbo to the intercooler and snake a wrench up to the exhaust system? Before I lose my religion, I'd appreciate any help y'all can give me. Getting to the timing belt was a walk in the park compared to this!
Thanks
-Matt
Reply With Quote
  #2 (permalink)  
Old 12 Jan 2011, 10:49 am
UptownSport's Avatar
Veteran Cruiser
 
Join Date: Jan 2011
Location: 55403
Posts: 3,797
Default Re: How am I supposed to remove the exhaust manifold?!

Quote:
Originally Posted by kd4pbs View Post
I've considered removing it along with the turbo as an assembly with the head, but then how do I get the doggone exhaust system off of the exhaust manifold? Getting to the timing belt was a walk in the park compared to this!
Thanks
-Matt
YIKES! That says something! The belt was no fun!!!

Quote:
Originally Posted by kd4pbs View Post
I've considered removing it along with the turbo as an assembly with the head, but then how do I get the doggone exhaust system off of the exhaust manifold?
-Matt
I'd suggest removing the TC with the head- Last turbo car we had was in the 80's, and thats how we did it. The bolts look accessible from the bottom.

Otherwise:

Do you have a FSM? Otherwise no 'figures'
REMOVAL - TURBOCHARGER
CAUTION: IF TURBOCHARGER IS REPLACED DUE
TO A BEARING FAILURE, REPLACEMENT OF THE
OIL PRESSURE FEED LINE IS REQUIRED. OIL
RETURN TUBE SHOULD BE CLEANED ALSO.
NOTE: The turbocharger and exhaust manifold are
serviced as an assembly. Do Not attempt to remove
the turbocharger from the exhaust manifold.
Exhaust leaks will result. It is recommended that
the turbocharger elbow be replaced along with the
turbocharger/exhaust manifold assembly.
(1) Disconnect negative battery cable.
(2) Drain cooling system (Refer to 7 - COOLING/
ENGINE - STANDARD PROCEDURE - DRAINING
COOLING SYSTEM).
(3) Remove air cleaner housing and lid (Refer to 9
- ENGINE/AIR INTAKE SYSTEM/AIR CLEANER
HOUSING - REMOVAL).
(4) Disconnect clean air hose from turbocharger
(Fig. 21).
(5) Disconnect throttle and speed control cables at
throttle body.
(6) Disconnect electrical connectors from the following
components:
Inlet Air Temperature (IAT) Sensor
MAP Sensor
IAC Motor
Throttle Position Sensor
Ignition Coil Capacitor
(7) Disconnect air inlet hose at throttle body (Fig.
22).
(8) Disconnect vacuum hoses at throttle body and
upper intake manifold.
(9) Remove upper intake manifold support bracket
(10) Remove upper intake manifold (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL).
CAUTION: Cover lower intake manifold opening
with suitable cover to prevent any foreign objects
from entering.
(11) Remove turbocharger upper heat shield (Fig.
27).
(12) Disconnect oil supply line at turbocharger
(Fig. 24).
(13) Remove coolant return line (Fig. 24).
(14) Disconnect vacuum hoses from turbocharger.
(15) Raise vehicle on hoist.
(16) Disconnect muffler ground strap. Remove
muffler (Refer to 11 - EXHAUST SYSTEM/MUFFLER
- REMOVAL).
(17) Disconnect downstream oxygen sensor.
(18) Remove fasteners securing catalytic converter
to exhaust manifold (Fig. 25).
(19) Remove catalytic converter and intermediate
pipe as an assembly.
(20) Remove turbocharger to charge air cooler hose
assembly (Fig. 26).
(21) Remove turbocharger elbow support bracket
(Fig. 27).
(22) Remove turbocharger support bracket (Fig.
(23) Remove oil return tube (Fig. 24).
(24) Remove turbocharger coolant supply line (Fig.
24).
(25) Remove turbocharger lower heat shield (Fig.
27).
(26) Remove turbocharger elbow (Fig. 27).
(27) Remove lower exhaust manifold fasteners that
are accessible while vehicle is on hoist.
(28) Lower vehicle.
(29) Remove upper exhaust manifold fasteners.
(30) Remove turbocharger/exhaust manifold
assembly from above/between the engine and cowl
panel.
(31) Remove and discard exhaust manifold gasket.
Reply With Quote
  #3 (permalink)  
Old 12 Jan 2011, 01:53 pm
Fresh Cruiser
 
Join Date: Dec 2009
Posts: 24
Default Re: How am I supposed to remove the exhaust manifold?!

Very good - that's what I was figuring... taking a bunch more stuff off. LOL
Yep - It looks like I have a burnt valve in #3, as is indicated by low compression. So that's why the head is coming off. Plus it was time to replace the timing belt anyway.
Ugh... looks like I get to spend some nice quality time laying on my back under the car. Hopefully I can just drop the exhaust system down instead of removing most of it
This was very helpful - I do not have a FSM! Just a stupid Haynes manual that doesn't really tell me much about the turbo model.
Thanks!
Reply With Quote
  #4 (permalink)  
Old 13 Jan 2011, 10:39 pm
chris15's Avatar
Fanatic Cruiser
 
Join Date: Jan 2008
Location: Tampa, Florida
Posts: 977
Default Re: How am I supposed to remove the exhaust manifold?!

Unbolt the O2 housing from the downpipe and pull the motor with the turbo/exhaust mani still bolted to the head. That's your best bet. I've done it a few times that way.
__________________
2003 GT DC2 - Daily/Project
2001 PT Turbo- Detuning/Returning to "Stock"

GT - FID 1200cc injectors, DS Trinity with CMR tune, 3" O2/catless downpipe, 3" DP-back exhaust, 3bar MAP/TIP. Still a work-in-progress with tons of parts left to swap.

Reply With Quote
  #5 (permalink)  
Old 13 Jan 2011, 10:41 pm
Chromenut's Avatar
Obsessed Cruiser
 
Join Date: Nov 2007
Location: Mooresville, NC
Posts: 5,330
Default Re: How am I supposed to remove the exhaust manifold?!

Chris is batting 1000 today, so I say - ↑What he says!↑
__________________
...if I only had a brain...

I would need my own forum just to list my mods!!!
Remember, a PT Cruiser is not just a car, it's a way of life!
LAUS DEO SEMPER

Please visit the Tech Docs Library and you'll find many of your answers!
Reply With Quote
  #6 (permalink)  
Old 15 Jan 2011, 04:51 pm
Fresh Cruiser
 
Join Date: Dec 2009
Posts: 24
Unhappy Re: How am I supposed to remove the exhaust manifold?!

Pull the motor? No - nothing wrong with the starter or the HVAC.
Got the head off. Unbolted the catalytic converter and the oil and coolant lines, the pressure outlet line, and then pulled the whole thing right on out. Not joyed with what I found...
Some jerkwad at some point in time had heli-coiled the spark plugs on #1 and #3. These are the two cylinders that I have had issues with plugs burning up. For whatever reason, these two plugs extend farther into the combustion chamber, plus the heli-coil does not extend down into the cylinder head far enough, causing a large gap between the end few threads of the plug and the head. This means the plug ends up running hotter, there are sharp edges in the CC that run hot, and the whole mess leads to lots of preignition.
Time for a new cylinder head, IMHO.
Does anyone know a reputable remanufactured head dealer, and does anyone know if the turbo head is different from the NA head, as it is on the old 2.2/2.5 Mopar turbo I&II systems?
Here's a couple of pictures, just for grins & giggles...

Somethings a little wrong here...


Somethings REALLY wrong here...


It's supposed to look like this, damnit!

Last edited by kd4pbs; 15 Jan 2011 at 04:55 pm.
Reply With Quote
  #7 (permalink)  
Old 15 Jan 2011, 06:46 pm
UptownSport's Avatar
Veteran Cruiser
 
Join Date: Jan 2011
Location: 55403
Posts: 3,797
Default Re: How am I supposed to remove the exhaust manifold?!

My suggestion, before you condemn the head, exhaust (sorry) all possibilities of the different inserts.
For the gasket style, there were inserts instead of 'coils'. PT's are obviously different,
but perhaps they make them.

or

I'd be cheaper to have a inserts custom made if not.
Reply With Quote
  #8 (permalink)  
Old 15 Jan 2011, 07:19 pm
UptownSport's Avatar
Veteran Cruiser
 
Join Date: Jan 2011
Location: 55403
Posts: 3,797
Default Re: How am I supposed to remove the exhaust manifold?!

or
Reply With Quote
  #9 (permalink)  
Old 16 Jan 2011, 12:36 pm
Fresh Cruiser
 
Join Date: Dec 2009
Posts: 24
Default Re: How am I supposed to remove the exhaust manifold?!

The biggest issue I see is that the combustion chamber directly around where the plug enters the CC is messed up from drilling and tapping. This is an extremely important area to the spark plug; even they type of material it is made of effects the heat range of the plug. I think they drilled or tapped into the water jacket when they did this too; I have coolant that goes somewhere, even though it is at a very slow rate. The head gasket was intact and not compromised, and there are no leaks in the cylinder liner, as there is no coolant ever in the oil. This head was a remanufactured head in and of itself; I am pretty sure Chrysler never painted the head silver; this one has silver paint on it. Add to that the fact the plug extends too far into the chamber, and it's just not worth it I think. I found a reman head from Rams Cylinder Heads for $375... Has anyone dealt with this company?
Reply With Quote
  #10 (permalink)  
Old 16 Jan 2011, 01:09 pm
UptownSport's Avatar
Veteran Cruiser
 
Join Date: Jan 2011
Location: 55403
Posts: 3,797
Default Re: How am I supposed to remove the exhaust manifold?!

I would strongly suggest a used head, as you're finding, 'remanufactured'=junk

There's little reason to rebuild a head nowadays, guides, stems, seats don't wear appreciably,
although extreme mileage exh seats may get pitting.
So these clowns fix (in the worst way) what's not broken.
I'd bet they don't adjust stem height, either.
Guess where they'd get that exh valve from?
Turbo valve is different (and more expensive) than N/A. Guess which they'd use?

IF you can get the appropriate insert, I think it'd solve the leakage issue.
Have a machine shop drill so there's 100% threads, if they're unwilling go
someplace else.
I understand your concerns about heat range, but having 1/2 of the threads
out of contact and the plug extending far into the chamber is radical, not
a nominal difference such as a sleeve of different alloy.

This might be interesting to you:

Quote:
5170051AA $475.00
Engine - Cylinder head & valves - Cylinder head
Cylinder head, all models - 2.4l 2003
You can get 20-25% off if you shop around.
Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On


Similar Threads
Thread Thread Starter Forum Replies Last Post
Exhaust Manifold Help trieber Tech & Performance Forum 16 26 Dec 2011 10:22 am
wtb good used exhaust manifold anthony_plumlee Classifieds: Want To Buy 3 08 Aug 2011 04:48 am
01 & 02 same exhaust manifold? chuck2112 Tech & Performance Forum 1 29 Jan 2010 01:29 pm
Exhaust Manifold 2.0 versus 2.5 doocruise Tech & Performance Forum 3 08 Apr 2008 07:12 am
Exhaust manifold don668 General Turbo Discussions 4 22 Jan 2005 02:35 pm


All times are GMT -5. The time now is 09:24 am.




Powered by vBulletin® Version 3.8.2
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
LinkBacks Enabled by vBSEO 3.6.0 PL2 © 2011, Crawlability, Inc.
vB.Sponsors