Chrysler NS, GS Repair Manual – No Guesswork on Exhaust and Intake

I’ve seen one too many intake manifolds come back because some tech used a generic torque value from a forum. You don’t work that way. Neither does this Chrysler NS, GS Repair Manual. It’s 24 pages of factory procedures for the exhaust system and intake manifold – the kind of documentation that keeps a job done once. Aftermarket stuff? I don’t trust it on torque specs. This is OEM, direct from Chrysler, and it shows.

Exhaust System and Intake Manifold Coverage

Open the manual and you’re inside the real TOC: EXHAUST SYSTEM AND INTAKE MANIFOLD. It covers catalytic converters, flex-joint coupling, EGR, heat shields, and every intake/exhaust manifold variant for the 2.4L, 3.0L, 3.3/3.8L, plus the 2.5L VM diesel addendum. The GROUP 11 ADDENDUM PAGES include the diesel-specific removal and installation – something a generic manual won’t touch. If you’re working on an NS or GS with a diesel, that section alone saves you hours of cross-referencing.

Torque Chart: Page 18 Specs You Need

Torque values are the difference between a leak-free seal and a warped flange. The Torque Chart on page 18 lists every fastener for exhaust manifolds, intake manifolds, and mounting brackets. No rounding up. No “tighten until it feels right.” I’ve had guys argue with me about using 20 lb-ft on a M8 exhaust stud – the chart says 18 lb-ft, and that’s what it takes. The manual also includes cleaning and inspection steps that tell you when a manifold is flat enough to reuse.

Engine-Specific Procedures – 2.4L, 3.0L, 3.3/3.8L

Each engine gets its own removal and installation sequence. For the 2.4L, you get UPPER INTAKE MANIFOLD—2.4L ENGINE and INTAKE MANIFOLD LOWER—2.4L ENGINE – separate sections because the upper and lower gaskets have different torque patterns. The 3.0L has a six-cylinder manifold with a specific crossing sequence. The 3.3/3.8L engines share a procedure but note the different EGR tube routing. Follow the order in the manual, not your memory. I’ve seen a 3.8L manifold crack because a tech skipped the tightening sequence – page 17 shows the correct bolt pattern.

Why OEM Factory Specs Beat Aftermarket

Aftermarket manuals often copy the diagrams but leave out critical notes. Chrysler included cautions like this one from page 1: “Due to exterior physical similarities of some catalytic converters with pipe assemblies, extreme care should be taken with replacement parts.” That kind of warning keeps you from bolting on the wrong converter and triggering a CEL. The OEM specification also covers Chrysler NS GS Wiring Diagram if you need the electrical side of the EGR solenoid. You’re not paying for someone’s second-hand interpretation – you’re getting the factory bulletin.

Diagnosis and Testing – Exhaust System

The DIAGNOSIS AND TESTING section walks you through checking for exhaust restrictions, leaks, and EGR flow problems. It tells you what backpressure readings are normal and when to suspect a clogged catalytic converter. Don’t start pulling parts until you run the tests on page 4. I’ve wasted a Saturday chasing a misfire that turned out to be a plugged flex joint – this manual would have caught it in ten minutes.

Cleaning and Inspection – Don’t Skip These Steps

Two pages dedicated to cleaning and inspecting intake and exhaust manifolds. The manual says to check for cracks on the mating surface, warping limits, and carbon buildup in the EGR passages. If you’re reusing a manifold, you need to know if it’s within factory flatness – the inspection procedure on page 18 gives you the spec. Skip it and you’ll be fighting a vacuum leak.

Related Manuals for Your Chrysler NS/GS

• Chrysler NS/GS Transaxle and Power Transfer Unit Service Manual – Section: Power
• Chrysler NS GS Tires & Wheels Service Manual

For the transmission side, you’ll want the Chrysler NS/GS Transaxle and Power Transfer Unit Service Manual – Section: Power to pair with this exhaust work. And if you’re lifting the vehicle, the Chrysler NS GS Tires & Wheels Service Manual covers wheel torque specs that often get overlooked.

External resources: For understanding the manual transmission specifics in the NS/GS, refer to the Manual Transmission Wikipedia entry and the Manual Transmission tutorial on YouTube. These aren’t replacement for the factory manual, but they help with the theory.

Does this manual cover the 2.5L VM Diesel engine?

Yes. The GROUP 11 ADDENDUM PAGES include removal and installation for the 2.5L VM Diesel, plus the intake/exhaust manifold description and torque chart. It’s a separate section, not a footnote.

What torque values are listed?

The torque chart on page 18. It lists all fasteners for exhaust manifolds, intake manifolds, catalytic converter brackets, and EGR pipe clamps. Don’t guess – use it.

You’ve got the parts, the lift, and the time. The one thing that stops a comeback is the right spec from the factory. Download the Factory Manual now and get the torque values, removal sequences, and inspection specs that keep your NS or GS exhaust system sealed tight.