Chrysler Voyager 1984-1990 Exhaust System Bolt Torque Specifications
This page details the recommended torque specifications for all exhaust system bolts on the 1984-1990 Chrysler Voyager. Proper torque is critical for a leak-free and secure exhaust system.
Important Information
Safety guidelines and reference information for proper torque application
Safety First
- Always verify torque specifications with your vehicle's factory service manual
- Use properly calibrated torque wrenches
- Replace all torque-to-yield (TTY) bolts - they are single-use only
- When in doubt, consult a professional mechanic
Quick Reference Guide
Quick Reference Guide
Common Torque Patterns
Star Pattern
Used for wheels and other circular bolt patterns
Cross Pattern
Used for gaskets and cover plates
Sequential Pattern
Used for head bolts and other critical components
Common Mistakes to Avoid
Common Mistakes to Avoid
Over-tightening
Exceeding the specified torque value can stretch or break fasteners, damage threads, or crack components.
Always use a calibrated torque wrench and follow specifications exactly.
Incorrect Torque Sequence
Tightening bolts in the wrong order can cause uneven pressure distribution and potential leaks or damage.
Follow the manufacturer's specified torque sequence pattern.
Dirty Threads
Dirt, rust, or old thread locker can affect torque readings and proper fastener tension.
Clean and inspect all threads before assembly. Use new thread locker if specified.
Reusing TTY Bolts
Torque-to-yield bolts are designed to stretch and must not be reused.
Always replace TTY bolts with new ones. They are single-use only.
Dry vs. Lubricated
Not accounting for whether torque specs are for dry or lubricated fasteners can lead to incorrect tension.
Check if specs are for dry or lubricated threads. Use specified lubricant when required.
Recommended Tools
Recommended Tools
Torque Wrench (1/4" Drive)
Torque Wrench (3/8" Drive)
Torque Wrench (1/2" Drive)
Angle Gauge
Torque Wrench Care
- Calibrate annually or after 5,000 clicks
- Store at lowest setting
- Keep clean and lubricated
Search Specifications
Search by component name, bolt size, or description
Torque Calculator
Convert between different torque units
Exhaust Manifold
Specifications for bolts and studs associated with the exhaust manifold, which mounts directly to the engine cylinder head.
1 Exhaust Manifold to Cylinder Head Bolts
M10 x 1.5
Exhaust Manifold to Cylinder Head Bolts
M10 x 1.5Torque Value
Important Notes
2 Exhaust Manifold Flange to Exhaust Pipe/Converter Bolts/Studs
M10 x 1.5
Exhaust Manifold Flange to Exhaust Pipe/Converter Bolts/Studs
M10 x 1.5Torque Value
Important Notes
Catalytic Converter
Specifications for bolts connecting the catalytic converter to the exhaust system.
1 Catalytic Converter Inlet Flange Bolts
M10 x 1.5
Catalytic Converter Inlet Flange Bolts
M10 x 1.5Torque Value
Important Notes
2 Catalytic Converter Outlet Flange Bolts
M10 x 1.5
Catalytic Converter Outlet Flange Bolts
M10 x 1.5Torque Value
Important Notes
Muffler And Tailpipe
Specifications for bolts and clamps connecting the muffler and tailpipe to the exhaust system.
1 Muffler Inlet Pipe Flange Bolts
M10 x 1.5
Muffler Inlet Pipe Flange Bolts
M10 x 1.5Torque Value
Important Notes
2 Muffler Inlet Pipe U-Clamp
M10 x 1.5
Muffler Inlet Pipe U-Clamp
M10 x 1.5Torque Value
Important Notes
3 Muffler Outlet Pipe Flange Bolts
M10 x 1.5
Muffler Outlet Pipe Flange Bolts
M10 x 1.5Torque Value
Important Notes
4 Muffler Outlet Pipe U-Clamp
M10 x 1.5
Muffler Outlet Pipe U-Clamp
M10 x 1.5Torque Value
Important Notes
Exhaust Hangers
Specifications for bolts and fasteners securing exhaust hangers to the vehicle's chassis.
1 Exhaust Hanger Bolts/Fasteners
M8 x 1.25
Exhaust Hanger Bolts/Fasteners
M8 x 1.25Torque Value
Important Notes
Oxygen Sensor
Specifications for the oxygen sensor installed in the exhaust system.
1 Oxygen Sensor
M18 x 1.5
Oxygen Sensor
M18 x 1.5Torque Value
Important Notes
Troubleshooting Guide
Common issues, diagnostic steps, and prevention guidelines
Common Issues
Bolt stretching, stripped threads, uneven torque patterns
Common Issues
Bolt stretching, stripped threads, uneven torque patterns
Loose Components
Symptoms:
- Rattling or vibration noises
- Visible movement in components
- Uneven panel gaps
Solutions:
- Clean threads and mounting surfaces
- Replace damaged fasteners
- Apply proper torque in sequence
- Use thread locker if specified
Stripped Fasteners
Symptoms:
- Unable to achieve proper torque
- Fastener spins freely
- Visible thread damage
Solutions:
- Use thread repair kit if appropriate
- Install thread insert (HeliCoil)
- Replace component if threaded hole is damaged
- Upgrade to higher grade fastener if recommended
Overtightened Components
Symptoms:
- Cracked or deformed parts
- Broken fasteners
- Compressed gaskets or seals
Solutions:
- Replace damaged components
- Use new fasteners
- Follow proper torque sequence
- Verify correct torque specifications
Diagnostic Steps
Visual inspection, torque verification, thread assessment
Diagnostic Steps
Visual inspection, torque verification, thread assessment
Visual Inspection
Inspect the affected area for any visible signs of damage or wear
- Check for cracks or deformation
- Look for signs of excessive wear
- Verify proper fastener installation
Torque Verification
Verify the torque applied to the fasteners
- Check the torque wrench calibration
- Verify the torque specification
- Compare the applied torque to the specification
Thread Assessment
Assess the condition of the threads
- Check for signs of thread damage
- Verify the thread type and size
- Check for proper thread engagement
Prevention Guidelines
Best practices, maintenance tips, tool care
Prevention Guidelines
Best practices, maintenance tips, tool care
Best Practices
- Always follow the recommended torque specification
- Use the correct type and size of fasteners
- Verify the torque wrench calibration regularly
Maintenance Tips
- Regularly inspect the affected area for signs of wear or damage
- Replace damaged or worn-out components promptly
- Keep the work area clean and organized
Tool Care
- Regularly clean and maintain the torque wrench
- Store the torque wrench in a dry and secure location
- Verify the torque wrench calibration before each use
Frequently Asked Questions
Find answers to common questions about torque specifications
Q1 Why is using the correct torque specification important for exhaust bolts?
Why is using the correct torque specification important for exhaust bolts?
Using the correct torque specification ensures a proper seal and prevents exhaust leaks. Under-torquing can cause leaks and over-torquing can damage the threads or the exhaust manifold/pipe, potentially leading to costly repairs. For example, if the bolts connecting the exhaust manifold to the engine are not torqued correctly, it can lead to exhaust gases leaking into the engine bay, and in some cases, into the passenger compartment.
Q2 What happens if I over-torque the exhaust bolts?
What happens if I over-torque the exhaust bolts?
Over-torquing exhaust bolts can stretch or break the bolts, damage the threads in the manifold or exhaust pipe flanges, and crush the gasket, leading to exhaust leaks. This could require re-tapping threads or even replacing the affected components. For example, if the bolts attaching the exhaust pipe to the catalytic converter are over-tightened, the flange can crack or become warped.
Q3 Can I reuse exhaust gaskets?
Can I reuse exhaust gaskets?
It is generally not recommended to reuse exhaust gaskets. Gaskets are designed to crush and conform to the mating surfaces, creating a tight seal. Once compressed, they may not provide the same seal if reused. Reusing them often leads to exhaust leaks and the need to redo the job. Always use new gaskets when replacing exhaust components.
Q4 How often should I check the torque on my exhaust bolts?
How often should I check the torque on my exhaust bolts?
It's a good practice to check the torque on exhaust bolts after a few heat cycles after initially tightening them (e.g., after driving the vehicle a few times). After that, you can check them annually or during routine maintenance checks. Vibration and heat can cause bolts to loosen over time. For example, if you just replaced your exhaust system, after a week's worth of driving, go back and re-check the torque on those newly installed bolts.
Q5 Are there any special tools I need for torquing exhaust bolts?
Are there any special tools I need for torquing exhaust bolts?
You'll typically need a torque wrench to accurately tighten bolts to the specified torque. Using a standard wrench and 'guessing' the torque will likely result in issues. For exhaust work in general, a good socket set with various extensions and possibly some penetrating oil will make life easier. A flexible exhaust hanger removal tool can also be invaluable.
Environmental Considerations
Temperature, humidity, and seasonal effects on torque specifications
Temperature Effects
Includes: High Heat, Cold Weather, Thermal Cycling
Temperature Effects
Includes: High Heat, Cold Weather, Thermal Cycling
Temperature can significantly impact torque values and fastener behavior
Cold Weather
Effects:
- Increased material brittleness
- Higher torque required due to thread contraction
- Reduced thread lubricant effectiveness
Recommendations:
- Allow components to warm to room temperature when possible
- Consider using winter-grade thread lubricants
- Check torque values more frequently during winter months
Hot Weather
Effects:
- Thermal expansion of components
- Decreased friction in threads
- Accelerated lubricant breakdown
Recommendations:
- Check torque when components are at normal operating temperature
- Use temperature-resistant thread lockers
- Consider re-torquing after heat cycles
Humidity and Corrosion
Covers: Rust Prevention, Salt Exposure, Moisture Control
Humidity and Corrosion
Covers: Rust Prevention, Salt Exposure, Moisture Control
Moisture and corrosion can affect fastener integrity and torque values
High Humidity
Effects:
- Accelerated corrosion formation
- Reduced friction coefficient
- Potential thread seizing
Prevention:
- Use corrosion-resistant fasteners
- Apply appropriate anti-seize compounds
- Maintain proper protective coatings
Salt Exposure
Effects:
- Rapid corrosion development
- Thread damage
- Seized fasteners
Prevention:
- Regular underbody washing
- Use of sacrificial anodes where appropriate
- Application of protective coatings
Seasonal Maintenance
Spring, Summer, Fall, and Winter maintenance schedules
Seasonal Maintenance
Spring, Summer, Fall, and Winter maintenance schedules
Spring
- Inspect for winter damage
- Clean and protect exposed fasteners
- Check torque on critical components
Summer
- Monitor heat-affected components
- Check expansion-related loosening
- Inspect cooling system mounts
Fall
- Prepare for winter conditions
- Apply corrosion protection
- Verify all fasteners are properly torqued
Winter
- More frequent inspection of critical fasteners
- Check for salt damage
- Monitor suspension component torque
Related Resources
Tools, service procedures, and technical bulletins
Recommended Tools
Torque Wrench
A calibrated torque wrench is essential for applying precise torque to exhaust bolts.
- 1/2 inch drive recommended
- Range should include 15-30 ft-lbs
Socket Set
A set of standard sockets in various sizes is needed to fit the exhaust bolts.
- Typically 13mm, 14mm, and 15mm
- 6-point sockets are preferred
Extension Bar
An extension bar may be necessary to reach some exhaust bolts.
- 3-inch or 6-inch length
- 1/2 inch drive to match torque wrench
Penetrating Oil
Penetrating oil can help loosen corroded exhaust bolts.
- Spray type for easy application
- High-quality formula for best results
Service Procedures
Exhaust Manifold Bolt Torque Procedure
This procedure outlines the steps for torquing the bolts connecting the exhaust manifold to the engine cylinder head.
- Apply penetrating oil to exhaust manifold bolts if they appear rusty or corroded.
- Use the correct socket size to install the bolts finger tight.
- Using the torque wrench, tighten all bolts to 18 ft-lbs in a criss-cross pattern.
- Re-check the torque of all bolts in the same pattern to ensure proper tightening.
- Start engine to check for any exhaust leaks.
Exhaust Pipe Flange Bolt Torque Procedure
This procedure outlines the steps for torquing the bolts at the exhaust pipe flange connections.
- Apply penetrating oil to exhaust pipe flange bolts if they appear rusty or corroded.
- Install the bolts finger tight.
- Tighten bolts to 25 ft-lbs using the correct sized socket and torque wrench.
- Re-check the torque of all bolts to ensure proper tightening.
- Start engine to check for any exhaust leaks.
Exhaust System Mounting Bracket Torque Procedure
This procedure outlines the steps for torquing the bolts of the brackets supporting the exhaust system.
- Apply penetrating oil to mounting bracket bolts if they appear rusty or corroded.
- Install the bolts finger tight.
- Tighten bolts to 20 ft-lbs using the correct sized socket and torque wrench.
- Re-check the torque of all bolts to ensure proper tightening.
Technical Service Bulletins
Exhaust Manifold Bolt Corrosion Issues
1989-05-15This bulletin addresses common corrosion problems with exhaust manifold bolts due to exposure to moisture and heat cycling.
Resolution: Apply anti-seize compound to bolt threads during re-installation. Inspect bolts and manifold regularly.
Exhaust Flange Leaks Due to Improper Torque
1987-11-20This bulletin addresses issues with exhaust leaks occurring at the pipe flanges due to improper tightening of bolts after service or replacement.
Resolution: Always torque exhaust flange bolts to the manufacturer's specified torque using a calibrated torque wrench. Replace any distorted flanges or bolts.
Exhaust Hanger Bolt Stripping Issues
1986-02-28This bulletin addresses the issue of stripping of exhaust system mounting bracket bolt threads due to over torquing.
Resolution: Ensure correct torque of 20 ft-lbs is never exceeded. Replace any bolts which show signs of stripping.
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Technical Information
- All specifications, including torque values, fluid capacities, and maintenance procedures, should be verified against your vehicle's factory service manual.
- Vehicle specifications and procedures may vary by model year, trim level, and region.
- Always follow the manufacturer's recommended procedures and safety precautions.
- Working on vehicles can be dangerous. Always take proper safety precautions and use appropriate safety equipment.
- If you're unsure about any procedure, consult a qualified professional mechanic.