2.5 Intake Manifold Bolts

[anti-christ-comanche]

Doing some tinkering today and noticed that a couple of the bolts are missing.the ones that attach the manifold to the head.(this would probably explain the vacuum leak) anyone know the size of these guys would be greatly appreciated (p.s i did look in the bolt screw section wasn't there)

[dasbulliwagen]

Chrysler has a service bulletin about those bolts. It is common that they break, so they came out with a revised bolt kit that comes with some little plastic sleeves that are supposed to silde over the bolt and into the hole in the manifold before the nut goes on. I'm not sure what they are accomplishiong doing that, but thats what they want us to do. The bolt kit is available still from Chrysler. here's the TSB.

 

NO: 11-07-98 Rev. A SUBJECT: Outer Exhaust Manifold Studs Breaking DATE: Dec. 11, 1998

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-07-98, DATED JUL. 31, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF MODEL YEARS, CLEAN POINTS, AND NEW PARTS.

NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 2.5L ENGINE **(SALES CODE EPE)** BUILT PRIOR TO DEC. 7, 1998 (MDH 1207XX).

SYMPTOM/CONDITION:

The outer exhaust manifold studs may fatigue and break (Figure 1).

DIAGNOSIS:

Inspect either manifold stud for breakage. If breakage is noted, perform the Repair Procedure.

PARTS REQUIRED:

 

 

Qty Part No. Description **2 06036193AA Stud, Exhaust Manifold** **2 06036221AA Washer, Flat** **2 06036171AA Nut & Washer** 2 33003332 Spacer 1 53020112 Gasket, Intake REPAIR PROCEDURE:

This bulletin involves replacing both outer mounting studs, clamps, and nuts **with new parts** and tightening the outer studs to a reduced torque of **20 Nm (180 in. lbs.)**.

1. Remove the intake/exhaust manifold per service manual procedures to gain access to the broken stud(s).
2. Remove the outer studs from the cylinder head. Use a stud removal tool if possible or drill the broken stud from the head.
3. Install two new outer studs p/n 06036193AA into the cylinder block. **Torque the studs to 14 Nm (126 in. lbs.)**.
4. Clean any carbon deposits or debris from the exhaust manifold.
5. Reinstall the exhaust manifold. **Use only the new parts listed above to attach the outer ends (Figure 2).**
6. Torque the bolts in the order and specification as listed in Figure 2.

**NOTE: THE TORQUE SPECIFICATION FOR THE OUTER EXHAUST MANIFOLD STUDS HAVE BEEN REDUCED TO 20 NM (180 IN. LBS.)**.

POLICY:

Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

 

 

Labor Op. No. Time 09-45-01-92 2.0 Hrs. FAILURE CODE:

 

 

Code Description P8 New Part

[anti-christ-comanche]

 

Chrysler has a service bulletin about those bolts. It is common that they break, so they came out with a revised bolt kit that comes with some little plastic sleeves that are supposed to silde over the bolt and into the hole in the manifold before the nut goes on. I'm not sure what they are accomplishiong doing that, but thats what they want us to do. The bolt kit is available still from Chrysler. here's the TSB.

NO: 11-07-98 Rev. A SUBJECT: Outer Exhaust Manifold Studs Breaking DATE: Dec. 11, 1998

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 11-07-98, DATED JUL. 31, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF MODEL YEARS, CLEAN POINTS, AND NEW PARTS.

NOTE: THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 2.5L ENGINE **(SALES CODE EPE)** BUILT PRIOR TO DEC. 7, 1998 (MDH 1207XX). SYMPTOM/CONDITION:

The outer exhaust manifold studs may fatigue and break (Figure 1). DIAGNOSIS:

Inspect either manifold stud for breakage. If breakage is noted, perform the Repair Procedure. PARTS REQUIRED:

 

Qty Part No. Description **2 06036193AA Stud, Exhaust Manifold** **2 06036221AA Washer, Flat** **2 06036171AA Nut & Washer** 2 33003332 Spacer 1 53020112 Gasket, Intake REPAIR PROCEDURE:

This bulletin involves replacing both outer mounting studs, clamps, and nuts **with new parts** and tightening the outer studs to a reduced torque of **20 Nm (180 in. lbs.)**.

• Remove the intake/exhaust manifold per service manual procedures to gain access to the broken stud(s).
• Remove the outer studs from the cylinder head. Use a stud removal tool if possible or drill the broken stud from the head.
• Install two new outer studs p/n 06036193AA into the cylinder block. **Torque the studs to 14 Nm (126 in. lbs.)**.
• Clean any carbon deposits or debris from the exhaust manifold.
• Reinstall the exhaust manifold. **Use only the new parts listed above to attach the outer ends (Figure 2).**
• Torque the bolts in the order and specification as listed in Figure 2.

**NOTE: THE TORQUE SPECIFICATION FOR THE OUTER EXHAUST MANIFOLD STUDS HAVE BEEN REDUCED TO 20 NM (180 IN. LBS.)**. POLICY:

Reimbursable within the provisions of the warranty. TIME ALLOWANCE:

 

Labor Op. No. Time 09-45-01-92 2.0 Hrs. FAILURE CODE:

 

Code Description P8 New Part

That is great! Because I'm afraid of those breaking to but what about the intake manifold bolts the top ones??

[Kikapoo]

GReat I read this post years later.