Exhaust Manifold Replacement - Right Side 3.8L

1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.
2. Remove the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
3. Remove the exhaust crossover pipe from the right exhaust manifold. Refer to Exhaust Crossover Pipe Replacement .
4. Remove the AIR pipe, if equipped. Refer to Secondary Air Injection Shut-Off Valve Outlet Pipe/Hose Replacement in Engine Controls - 3.8L.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



6. Remove the exhaust manifold pipe stud nuts and the catalytic converter pipe from the right exhaust manifold.



7. Remove the exhaust gas recirculation (EGR) adapter pipe from the right exhaust manifold.
8. Lower the vehicle.
9. Rotate the engine to access the right side of the engine. Refer to Rotating the Engine for Service Access in Engine Mechanical - 3.8L.



10. Disconnect the heated oxygen (HO2S) sensor wiring harness connector (3) and remove the heated oxygen (HO2S) sensor connector (4) from the fuel injector sight shield bracket (1).
11. Remove the spark plug wires from the right side spark plugs. Refer to Spark Plug Wire Replacement in Engine Controls - 3.8L.



12. Remove the right engine lift bracket bolt and nut.
13. Remove the right engine lift bracket.



14. Remove the fuel injector sight shield bracket nuts.
15. Remove the fuel injector sight shield bracket.
16. Remove the transaxle fluid filler tube. Refer to Transmission Fluid Filler Tube Replacement in Automatic Transaxle - 4T65-E.



17. Remove the right exhaust manifold bolts and nuts.
18. Remove the right exhaust manifold.
19. Remove the right exhaust manifold gasket.



20. Remove the upper right exhaust manifold heat shield.



21. Remove the lower right exhaust manifold heat shield.
22. If replacing the right exhaust manifold, remove the heated oxygen sensor from the right exhaust manifold. Refer to Heated Oxygen Sensor 1 Replacement in Engine Controls - 3.8L.
23. Clean and inspect the right exhaust manifold mating surfaces.

1. If replacing the right exhaust manifold, install the heated oxygen sensor to the right exhaust manifold. Refer to Heated Oxygen Sensor 1 Replacement in Engine Controls - 3.8L.



2. Install the lower right exhaust manifold heat shield.



3. Install the upper right exhaust manifold heat shield.

Important: Whenever the EGR pipe is removed from the right exhaust manifold, the outlet pipe should be inspected for leaks during installation. If leaks are present, replace the EGR adapter.

4. Install the new right exhaust manifold gasket.



5. Install the right exhaust manifold.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Install the exhaust manifold bolts and nuts.

Tighten
Tighten the exhaust manifold bolts and nuts to 30 N·m (22 lb ft).

7. Install the transaxle fluid filler tube. Refer to Transmission Fluid Filler Tube Replacement in Automatic Transaxle - 4T65-E.



8. Install the fuel injector sight shield bracket.
9. Install the fuel injector sight shield bracket nuts.

Tighten
Tighten the fuel injector sight shield bracket nuts to 30 N·m (22 lb ft).




10. Install the right engine lift bracket.
11. Install the right engine lift bracket bolt and nut.

Tighten
Tighten the right engine lift bracket bolt and nut to 30 N·m (22 lb ft).

12. Install the right spark plug wires. Refer to Spark Plug Wire Replacement in Engine Controls - 3.8L.



13. Install the heated oxygen (HO2S) sensor electrical connector (4) to the fuel injector sight shield bracket (1) and connect the heated oxygen (HO2S) sensor wiring harness electrical connector (3).
14. Rotate the engine back to the original position.
15. Raise the vehicle.



16. Install the EGR adapter pipe and bolt to the right exhaust manifold.

Tighten
Tighten the EGR adapter pipe bolt to 29 N·m (21 lb ft).




17. Install the catalytic converter pipe to the right exhaust manifold.
18. Install the exhaust manifold pipe stud nuts to the exhaust manifold studs.

Tighten
Tighten the exhaust manifold pipe stud nuts to 32 N·m (24 lb ft).

19. Lower the vehicle.
20. Install the AIR pipe, if equipped. Refer to Secondary Air Injection Shut-Off Valve Outlet Pipe/Hose Replacement in Engine Controls - 3.8L.
21. Install the exhaust crossover pipe to the right exhaust manifold. Refer to Exhaust Crossover Pipe Replacement .
22. Install the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
23. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.

Exhaust Manifold Replacement - Right Side 3.4L

1. Remove the windshield wiper motor cover. Refer to Wiper Motor Cover Replacement in Wipers Washer System.
2. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls-3.4L.
3. Remove the accelerator cable bracket from the throttle body. Refer to Accelerator Control Cable Replacement in Engine Controls-3.4L.
4. Rotate the engine for service access. Refer to Rotating the Engine for Service Access .
5. Remove the manifold air pressure (MAP) sensor. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls-3.4L.
6. Remove the exhaust gas recirculation (EGR) pipe. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls-3.4L.
7. Remove the ignition module and the ignition coils with the bracket. Refer to Ignition Control Module Replacement in Engine Controls - 3.4L.
8. Remove the spark plug wires from the right side spark plugs. Refer to Spark Plug Wire Replacement in Engine Controls-3.4L.



9. Disconnect the heated oxygen (HO2S) sensor electrical connector.
10. Remove the evaporative emissions (EVAP) solenoid bracket.



11. Remove the exhaust crossover heat shield bolts.
12. Remove the exhaust crossover heat shield.
13. Remove the exhaust crossover pipe nuts from the right exhaust manifold. Refer to Exhaust Crossover Pipe Replacement .
14. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
15. Remove the catalytic converter. Refer to Catalytic Converter Replacement



16. Remove the exhaust manifold heat shield bolts.
17. Remove the exhaust manifold heat shields.



18. Remove the exhaust manifold nuts.
19. Remove the exhaust manifold.
20. Remove the exhaust manifold gasket.
21. Clean and inspect the right exhaust manifold mating surfaces.
22. If replacing the right exhaust manifold, remove the heated oxygen (HO2S) sensor. Refer to Heated Oxygen Sensor 1 Replacement in Engine Controls-3.4L.

1. If removed, install the heated oxygen (HO2S) sensor. Refer to Heated Oxygen Sensor 1 Replacement in Engine Controls - 3.4L.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.




2. Install the exhaust manifold gasket.
3. Install the exhaust manifold.
4. Install the exhaust manifold nuts.

Tighten
Tighten the exhaust manifold nuts to 16 N·m (12 lb ft).




5. Install the exhaust manifold lower heat shield.
6. Install the exhaust manifold upper heat shield.
7. Install the exhaust manifold heat shield bolts.

Tighten
Tighten the exhaust manifold heat shield bolts to 10 N·m (89 lb in).

8. Install the catalytic converter. Refer to Catalytic Converter Replacement
9. Lower the vehicle.
10. Install the exhaust crossover pipe nuts to the right exhaust manifold. Refer to Exhaust Crossover Pipe Replacement .



11. Install the exhaust crossover pipe heat shield.
12. Install the exhaust crossover pipe heat shield bolts.

Tighten
Tighten the exhaust crossover pipe heat shield bolts to 10 N·m (89 lb in).

13. Install the evaporative emissions (EVAP) solenoid bracket.



14. Connect the heated oxygen  (HO2S) sensor electrical connector.
15. Install the spark plug wires to the right side spark plugs. Refer to Spark Plug Wire Replacement in Engine Controls-3.4L.
16. Install the ignition module and the ignition coils with the bracket. Refer to Ignition Control Module Replacement in Engine Controls-3.4L.
17. Install the exhaust gas recirculation (EGR) valve to the intake manifold. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls-3.4L.
18. Install the manifold absolute pressure (MAP) sensor. Refer to Manifold Absolute Pressure Sensor Replacement Engine Controls-3.4L.
19. Rotate the engine back to the original position.
20. Install the accelerator cable bracket to the throttle body. Refer to Accelerator Control Cable Replacement in Engine Controls-3.4L.
21. Install the throttle body air inlet duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls-3.4L.
22. Install the windshield wiper motor cover. Refer to Wiper Motor Cover Replacement in Wipers Washer System.