Exhaust Manifold Replacement Front

1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
2. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
3. Remove the engine mount struts. Refer to Engine Mount Strut Replacement .
4. Remove the exhaust crossover pipe from the left (front) exhaust manifold. Refer to Exhaust Crossover Replacement .
5. Disconnect the left (front) spark plug wires. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
6. Remove the oil level indicator tube bracket. Refer to Oil Level Indicator and Tube Replacement .



7. Remove the left (front) engine lift bracket bolt and nut from the left (front) exhaust manifold.
8. Remove the left (front) engine lift bracket from the left (front) exhaust manifold.



9. Remove the left (front) exhaust manifold heat shield nuts.
10. Remove the left (front) exhaust manifold heat shield.



11. Remove the left (front) exhaust manifold retaining bolts and nuts.
12. Remove the left (front) exhaust manifold.
13. Remove the left (front) exhaust manifold gasket.

1. Install the left new (front) exhaust manifold gasket.
2. Install the left (front) 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.

3. Install the left (front) exhaust manifold bolts and nuts.

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




4. Install the left (front) exhaust manifold heat shield.
5. Install the left (front) exhaust manifold heat shield nuts.

Tighten
Tighten the left (front) exhaust manifold heat shield nuts to 20 N·m (15 lb ft).




6. Install the left (front) engine lift bracket to the left (front) exhaust manifold.
7. Install the left (front) engine lift bracket bolt and nut.

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

8. Install the oil level indicator tube bracket. Refer to Oil Level Indicator and Tube Replacement .
9. Connect the left (front) spark plug wires. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
10. Install the exhaust crossover to the left (front) exhaust manifold. Refer to Exhaust Crossover Replacement .
11. Install the engine mount struts. Refer to Engine Mount Strut Replacement .
12. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
13. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .

Exhaust Manifold Replacement Rear

1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
3. Remove the exhaust crossover pipe from the right (rear) exhaust manifold. Refer to Exhaust Crossover Replacement .
4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the EGR adapter pipe from the right (rear) exhaust manifold. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls - 3.8L.
6. Remove the three way catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
7. Remove the wiring harness and the heater hose retaining clips from the fuel injector sight shield bracket.
8. Remove the right (rear) spark plug wires. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.



9. Remove the right (rear) engine lift bracket bolt and nut.
10. Remove the right (rear) engine lift bracket.



11. Remove the fuel injector sight shield bracket nuts.
12. Remove the fuel injector sight shield bracket.



13. Remove the right (rear) exhaust manifold bolts and nuts, except for the bolt behind the oxygen sensor.
14. Lower the vehicle.
15. Rotate the engine forward for access.
16. Disconnect the oxygen sensor electrical connector.
17. Remove the remaining bolt and the right (rear) exhaust manifold.
18. Remove the right (rear) exhaust manifold gasket.



19. Remove the upper right (rear) exhaust manifold heat shield.



20. Remove the lower right (rear) exhaust manifold heat shield.
21. Remove the heated oxygen sensor (HO2S) from the right (rear) exhaust manifold. Refer to Heated Oxygen Sensor Replacement in Engine Controls - 3.8L.



22. Remove the exhaust manifold stud(s) if damaged.

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.

1. Install the exhaust manifold stud(s) if removed.

Tighten
Tighten the exhaust manifold stud(s) to 6 N·m (53 lb in).

2. Install the heated oxygen sensor (HO2S) to the right (rear) exhaust manifold. Refer to Heated Oxygen Sensor Replacement in Engine Controls - 3.8L.



3. Install the lower right (rear) exhaust manifold heat shield.



4. Install the upper right (rear) exhaust manifold heat shield.



5. Install the new right (rear) exhaust manifold gasket.
6. Install the right (rear) exhaust manifold.
7. Install the right (rear) exhaust manifold bolt behind the oxygen sensor.
8. Connect the oxygen sensor electrical connector.
9. Return the engine to the original position.
10. Raise the vehicle.
11. Install the remaining exhaust manifold bolts.

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




12. Install the fuel injector sight shield bracket.
13. Install the fuel injector sight shield bracket nuts.

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




14. Install the right (rear) engine lift bracket.
15. Install the right (rear) engine lift bracket bolt and nut.

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

16. Install the right (rear) spark plug wires. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
17. Install the wiring harness and the heater hose retaining clips to the fuel injector sight shield bracket.
18. Connect the three way catalytic converter pipe to the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.

Important: Whenever the EGR pipe is removed from the right (rear) exhaust manifold, the outlet pipe should be inspected for leaks during installation. If leaks are present, replace the EGR adapter. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls - 3.8L.

19. Install the EGR adapter pipe to the right (rear) exhaust manifold. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls - 3.8L.
20. Lower the vehicle.
21. Install the exhaust crossover pipe to the right (rear) exhaust manifold. Refer to Exhaust Crossover Replacement .
22. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
23. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.