Exhaust Crossover Pipe Replacement 3.8L

1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
2. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .
3. Remove the exhaust crossover heat shield nuts (1).
4. Remove the exhaust crossover heat shield (2).



5. Remove the exhaust crossover pipe studs (3) and the bolts (2).
6. Remove the exhaust crossover pipe (1).
7. Remove the exhaust crossover pipe seal (4).

1. Install the exhaust crossover pipe seal (4) to the exhaust crossover pipe (1) at the right exhaust manifold connection.
2. Install the exhaust crossover pipe (1).

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 exhaust crossover pipe studs (3) and the bolts (2).

Tighten
Tighten the studs and the bolts to 20 N·m (15 lb ft).




4. Install the exhaust crossover heat shield (2).
5. Install the exhaust crossover heat shield nuts (1).

Tighten
Tighten the nuts to 25 N·m (18 lb ft).

6. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement .
7. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .

Exhaust Crossover Pipe Replacement 3.6L

1. Remove the left inner fender brace. Refer to Front Fender Upper Diagonal Brace Replacement .
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .



3. Remove the left front engine mount strut. Refer to Engine Mount Strut Replacement - Left Side .



4. Remove the right front engine mount strut. Refer to Engine Mount Strut Replacement - Right Side .



5. Remove the throttle body. Refer to Throttle Body Assembly Replacement .
6. Rotate the engine forward as far as possible.
7. Secure the engine with tie down straps.
8. Remove the downpipe attaching nuts.
9. Remove the two left bank and front right bank crossover pipe nuts.
10. Remove the left front tire and wheel. Refer to Tire and Wheel Removal and Installation .
11. Remove the left inner fender splash shield. Refer to Engine Splash Shield Replacement .
12. Remove the intermediate shaft bolt and separate the shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement
13. Support the left frame rail with a jack stand.

Important: DO NOT loosen the right side frame to body bolts.

14. Remove only the left two frame to body bolts. Refer to Frame Replacement .
15. Carefully lower the frame with the jack stand and remove the jack stand.
16. Remove the fourth exhaust crossover pipe nut.
17. Lower the vehicle.



18. Remove the transmission fluid filler tube. Refer to Transmission Fluid Filler Tube Replacement .



19. Remove the crossover pipe.

1. Install the crossover pipe.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the crossover nuts.

Tighten
Tighten the nuts to 34 N·m (25 lb ft).




3. Install the transmission fluid filler tube. Refer to Transmission Fluid Filler Tube Replacement .
4. Raise and support the vehicle.
5. Using a jack stand, raise the frame.
6. Install the left two frame bolts. Refer to Frame Replacement .
7. Remove the jack stand.
8. Install the intermediate shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement .
9. Install the left inner fender splash shield. Refer to Engine Splash Shield Replacement .
10. Install the left front tire and wheel. Refer to Tire and Wheel Removal and Installation .
11. Lower the vehicle.
12. Install the two left bank and front right bank crossover pipe nuts.
13. Install the downpipe attaching nuts.
14. Remove the tie down straps from the engine.
15. Rotate the engine back into the proper position.



16. Install the left front engine mount strut. Refer to Engine Mount Strut Replacement - Left Side



17. Install the right front engine mount strut. Refer to Engine Mount Strut Replacement - Right Side



18. Install the throttle body. Refer to Throttle Body Assembly Replacement .
19. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .



20. Install the left inner fender brace. Refer to Front Fender Upper Diagonal Brace Replacement .
21. Inspect the exhaust system for any leaks.