Exhaust Manifold

Remove and replace exhaust manifolds on the 2005 Dodge Viper 8.3L V10, including oxygen sensor removal, heat shield removal, and manifold-to-head and manifold-to-catalytic converter disconnection.

Warnings

Tools required

Parts

• Exhaust manifold gasket set (10 gaskets, 2 per cylinder pair) × 1 — Use OEM specification
• Exhaust manifold-to-catalytic converter gaskets × 2 — Use OEM specification
• Exhaust manifold studs (if damaged) × 1 — Use OEM specification
• Heat shield hardware (if corroded) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake. Place wheel chocks behind rear wheels.
2. Allow engine to cool completely for minimum 2 hours if recently operated.
3. Disconnect negative battery cable to prevent accidental starter engagement.
4. Raise front of vehicle and support securely on jack stands rated for vehicle weight. Ensure adequate working clearance underneath.
5. Spray all exhaust manifold nuts, oxygen sensor threads, and exhaust flange bolts with penetrating oil. Allow to soak minimum 30 minutes (ideally 24 hours before starting work).
6. Remove engine cover if equipped by lifting upward from mounting grommets.
7. Have fire extinguisher accessible if using heat for seized fasteners.

Procedure

1. 1

   Remove oxygen sensors from manifolds
   Working from underneath vehicle, locate oxygen sensors (upstream sensors near each manifold and downstream sensors after the catalytic converters). Use oxygen sensor socket or 22mm crow's foot wrench to remove sensors. Turn counterclockwise. If sensors are seized, warm engine to approximately 150°F (hand-warm) to aid removal - do not work on hot engine. Inspect sensor threads and manifold bung threads for damage. Set sensors aside if reusing, or discard if replacing.
   Torque spec

   O2 Sensor47 Nm (35 lb-ft)
2. 2

   Remove heat shields from manifolds
   From engine bay, locate heat shields covering exhaust manifolds. Remove heat shield mounting bolts. Each shield is secured with 3-4 bolts to the manifold or cylinder head. Set shields and hardware aside. Inspect shields for cracks or excessive corrosion; replace if compromised.
   ⚠Heat shield bolts often corrode and may break. Have replacement hardware available.
   Torque spec

   Heat Shield Bolts10 Nm (7 lb-ft)
3. 3

   Disconnect exhaust pipes from manifolds
   Working from underneath, locate the exhaust flange connection where each manifold connects to the catalytic converter. Remove the flange bolts securing each connection (verify exact count against factory service manual). Use penetrating oil if bolts resist. Support exhaust pipe with jack stand or wire to prevent stress on downstream components once disconnected. Remove and discard old flange gaskets.
   ⚠Flange bolts are frequently seized. Apply heat carefully if needed, avoiding fuel lines and brake lines in vicinity.
   Torque spec

   Exhaust Flange Bolt45 Nm (33 lb-ft)
4. 4

   Remove manifold mounting nuts (outer bank - driver side or passenger side)
   Starting with the more accessible bank, remove all exhaust manifold fasteners securing the one-piece manifold to the cylinder head (verify exact fastener count against factory service manual). The Viper V10 has one one-piece cast exhaust manifold per bank covering all 5 cylinders on that side. Each manifold is secured to the cylinder head by multiple fasteners along its length (verify exact count against factory service manual). Work from the most accessible nuts first. Use socket with extensions as needed for rear cylinders. Keep nuts organized by position if reusing.
   ⚠If a stud begins to turn instead of the nut loosening, stop immediately. Apply more penetrating oil and allow to soak. Broken studs require cylinder head stud extraction.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
5. 5

   Remove exhaust manifolds from outer bank
   With all nuts removed, carefully work each manifold free from the cylinder head studs. The manifolds may be stuck to the head due to carbon buildup. Gently tap with rubber mallet if needed - do not pry against sealing surfaces. Remove the one-piece manifold as a single unit and lower carefully. Have assistant support weight during removal. Inspect manifolds for cracks, especially at port outlets and mounting flanges.
   ⚠Each manifold section weighs approximately 8-12 lbs and is awkward to maneuver in tight engine bay. Do not drop onto other components.
6. 6

   Clean manifold mounting surfaces on cylinder head
   Using plastic or brass gasket scraper, remove all old gasket material from cylinder head exhaust port faces. Do not use steel scrapers that could gouge aluminum surfaces. Use wire brush to clean cylinder head studs. Vacuum away all debris - do not allow gasket material to fall into exhaust ports. Inspect studs for damage or threading issues; replace any damaged studs before proceeding. Inspect cylinder head port faces for cracks or erosion.
   ℹ️Any debris left on sealing surfaces will cause exhaust leaks. Ensure surfaces are completely clean and flat.
7. 7

   Remove manifolds from inner bank (opposite side)
   Repeat steps 4-6 for the inner bank (more restricted access). Inner bank will require more extension combinations and may require removal of ancillary components for access. On passenger side, may need to work around A/C lines and power steering reservoir. On driver side, may need to work around brake master cylinder. Remove all 5 manifold nuts, remove 5 manifold sections, and clean all mounting surfaces.
   Torque spec

   Exhaust Manifold Nuts30 Nm (22 lb-ft)
8. 8

   Inspect and prepare new or refurbished manifolds
   If installing new or refurbished manifolds, inspect all mounting surfaces for flatness and cleanliness. Check all mounting stud holes are clear. If reusing original manifolds, inspect for cracks under bright light, paying attention to high-stress areas at port exits and flange areas. Minor surface rust is acceptable; deep pitting or cracks require replacement. Wire brush all manifold sealing surfaces.
   ℹ️Cracked manifolds will cause exhaust leaks and potential engine performance issues. Do not reuse damaged manifolds.
9. 9

   Install new manifold gaskets and position manifolds on inner bank
   Place new exhaust manifold gaskets onto cylinder head studs, aligning with exhaust ports. Gasket orientation is critical - raised bead or printing faces outward toward manifold. Carefully position the one-piece manifold onto the studs, ensuring gaskets remain properly aligned. Thread manifold nuts onto studs by hand to hold manifolds in position. Do not torque at this stage.
   ⚠Gasket misalignment will cause exhaust leaks. Verify each gasket is centered on port before installing manifold.
10. 10

    Torque inner bank manifold nuts
    Apply a thin coat of anti-seize compound to stud threads. Torque all manifold fasteners to specification (verify exact count against factory service manual). Tighten in the torque sequence specified by the factory service manual (typically center-outward, but verify the exact pattern). Use multiple passes: first pass to 50% of final torque, second pass to 75%, final pass to full specification. This ensures even gasket compression.
    ⚠Uneven torque sequence can warp manifolds or cause gasket failure. Follow hot-to-cold pattern strictly.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
11. 11

    Install manifolds and gaskets on outer bank
    Repeat steps 9-10 for outer bank. Install new gaskets on studs, position all 5 manifold sections, hand-thread nuts, then torque in hot-to-cold sequence using multi-pass method.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
12. 12

    Reconnect exhaust pipes to manifolds
    Install new exhaust flange gaskets at manifold-to-catalytic converter connections. Position exhaust pipes to manifold flanges and install flange bolts. Apply anti-seize to bolt threads. Torque flange bolts to specification. Verify exhaust pipe alignment - pipes should not be under stress or strain when connected.
    Torque spec

    Exhaust Flange Bolt45 Nm (33 lb-ft)
13. 13

    Reinstall heat shields
    Position heat shields over manifolds and install mounting bolts. Torque heat shield bolts to specification. Ensure shields do not contact any wiring or hoses and have adequate clearance from all moving components.
    Torque spec

    Heat Shield Bolts10 Nm (7 lb-ft)
14. 14

    Install oxygen sensors
    Apply a thin coat of anti-seize compound to oxygen sensor threads (avoid getting anti-seize on sensor tip). Thread sensors into manifold bungs by hand first to avoid cross-threading. Torque sensors to specification using oxygen sensor socket or crow's foot wrench. Reconnect oxygen sensor electrical connectors, ensuring connectors click fully into place and wiring is routed away from hot exhaust components.
    Torque spec

    O2 Sensor47 Nm (35 lb-ft)

Reassembly

1. Reinstall engine cover by pressing onto mounting grommets until fully seated.
2. Reconnect negative battery cable and tighten terminal clamp.
3. Lower vehicle from jack stands and remove wheel chocks.

Verification

• Start engine and allow to idle. Listen for exhaust leaks at manifold-to-head joints and manifold-to-catalytic converter flanges. Any ticking or hissing indicates leak - shut down and re-torque or inspect gaskets.
• With engine at idle, verify no unusual vibrations or rattling from exhaust system. Heat shields should not buzz or rattle.
• Allow engine to reach operating temperature and verify no exhaust smell in cabin, which would indicate leak.
• Scan for diagnostic trouble codes using scan tool. No oxygen sensor codes (P0131, P0132, P0137, P0138, P0151, P0152, P0157, P0158) should be present.
• After 50-100 miles of driving, re-torque all manifold nuts while engine is cold. Exhaust gaskets may compress slightly during initial heat cycles.

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