Question about 1999 Plymouth Grand Voyager

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How to remove rear exhaust manifold on 99 plymouth grand voyager 3.3 - fourth bolt over from driver side sticks out like a bolt without a head - how do i remove it to release the maniifold

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  • legacy314 Jun 07, 2010

    Thanks, you have given me many of ideas - I will try to JB Weld a wrench to one of the bolts and see if that works, if not i will score the nut and try to crack it off. Once again thanks for all your help.

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  • 8,197 Answers

Ok that fourth bolt ovet is a stud. you need to get a deap socket to remove the nut on that thraeded stud. Once you have the deap socket place it over the stud and remove the nut that you can not see.

If you have a small mirror you can use that to see the nut on the stud.

Here is what a deep socket looks like.



Good LuckHow to remove rear exhaust manifold on 99 plymouth - 85d1c07.jpg

Posted on Jun 07, 2010

  • 9 more comments 
  • legacy314 Jun 07, 2010

    I removed the bolt already - so the stud stays in place? Looking at new manifolds it does not show that stud as being there. I also removed 5 other bolts from the manifold, but I cannot get two of the four bolts to release at the catalytic converter - how do I get the exhaust manifold to drop enough as to get to the cylinder head bolts?

  • Jyackle5
    Jyackle5 Jun 07, 2010

    To get to the other bolts on the converter you might use an box wrench or a swivel on the socket. As for the stud yes it will stay in the block.

  • Jyackle5
    Jyackle5 Jun 07, 2010

    Here is a swivel








    Here is a box wrench




  • legacy314 Jun 07, 2010

    would the two bolts still holding the catalytic converter be the only things left holding the rear exhaust manifold in place or am i missing another bolt somewhere?



    the two bolts still on the catalytic converter are rounded - i have tried lubricant, box wrenches, pliers, etc. - any other ideas

  • Jyackle5
    Jyackle5 Jun 07, 2010

    Yes that would be the only things holding it on. If they are striped the only way to remove them is to cut them off and replace them. I could not tell you how to do that with out seeing the car here to help you.

  • Jyackle5
    Jyackle5 Jun 07, 2010
  • legacy314 Jun 07, 2010

    If I release the complete exhaust pipe would that allow the manifold to move out of my way to get to the cylinder heads?

  • Jyackle5
    Jyackle5 Jun 07, 2010

    Also if you have a nut/bolt stuck together where the rust has welded them together( especially undercar exhuast fastners, use a dremel and score the nut, hit it with a small chisel and a hammer and the nut will crack off, this is ofcourse if you do not have the right tools to do it, IE a nut splitter.

  • Jyackle5
    Jyackle5 Jun 07, 2010
  • Jyackle5
    Jyackle5 Jun 07, 2010

    Yes it will allow you to get to the heads if you remove the hole exhaust.

  • Jyackle5
    Jyackle5 Jun 07, 2010

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Cylinderhead torque stc.


Cylinder Head Removal & Installation SOHC To Remove:
  1. Relieve fuel system pressure.
  2. Remove timing belt cover. Camshaft timing marks kia-03-20-7032.gif

  3. Turn crankshaft until timing mark on front housing and the arrow "2" on the camshaft pulley align.
  4. Loosen lock bolt on tensioner.
  5. Pry tensioner away from timing belt and tighten lock bolt to relieve tension on the timing belt.
  6. Remove timing belt from camshaft pulley.
  7. Disconnect battery negative cable.
  8. Remove 3 bolts that secure accelerator cable and air intake hose to cylinder head cover.
  9. Detach accelerator cable and place off to side.
  10. Remove the following;
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    • Air ISC air hose
    • Breather hose
    • Vacuum hose from air intake hose
  11. Disconnect mass air flow sensor electrical connector.
  12. Remove air intake hose.
  13. Remove PCV valve from cylinder head cover.
  14. Remove ISC air hose from idle speed actuator.
  15. Remove air hose from behind intake manifold.
  16. Remove 2 screws from high tension wire protectors.
  17. Detach wire loom from holder at rear of cylinder head cover.
  18. Detach vacuum tube at rear of cylinder head cover.
  19. Remove vacuum pipe. Cylinder Head Cover kia-03-20-7042.gif

  20. Remove 7 cylinder head cover bolts.
  21. Remove cylinder head cover and gasket.
  22. Disconnect 2 ignition coil electrical connectors.
  23. Disconnect 2 fuel injection electrical connectors at rear of cylinder head.
  24. Disconnect the following electrical connectors;
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    • Throttle position sensor
    • Idle speed actuator
    • Oil pressure switch
    • EGR vacuum solenoid valve at intake manifold
  25. Disconnect heater hose from elbow.
  26. Disconnect brake booster vacuum hose and cruise control vacuum hose from surge tank.
  27. Detach wire harness from rear of cylinder head.
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  29. Disconnect fuel hose from fuel connector assembly.
  30. Remove grounding bracket.
  31. Remove 4 bolts and intake manifold bracket.
  32. Remove starter.
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  34. Disconnect water hoses from oil cooler.
  35. Disconnect fuel hose from fuel pipe.
  36. Remove exhaust manifold heat shield.
  37. Remove exhaust flange nuts and front exhaust bracket bolt.
  38. Lower exhaust system. Cylinder head bolt loosening sequence kia-03-20-7050.gif

  39. Loosen cylinder head bolts in 3 steps in proper sequence.
  40. Remove cylinder head bolts and washers.
  41. Remove cylinder head, intake manifold and exhaust manifold as an assembly.
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  7. Connect fuel hose to pipe.
  8. Connect 2 hoses to oil cooler.
  9. Attach water bypass hose to bypass pipe.
  10. Install starter and bolts. Tighten bolts to 34 ft lb (46 Nm).
  11. Install intake manifolds bracket and 4 bolts. Tighten bolts to 32 ft lb (45 Nm).
  12. Install grounding bracket.
  13. Connect fuel hose to fuel connector assembly.
  14. Connect the following electrical connectors;
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    • Throttle position sensor
    • Idle speed actuator
    • Oil pressure switch
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  15. Connect purge control solenoid vacuum hose to intake manifold.
  16. Attach wire harness from rear of cylinder head.
  17. Connect brake booster vacuum hose and cruise control vacuum hose to surge tank.
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  19. Connect 2 fuel injection electrical connectors at rear of cylinder head.
  20. Connect 2 ignition coil electrical connectors.
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  25. Connect loom holder to rear of cylinder head cover.
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