Exhaust Manifold Replacement - Right Side 3.1L

1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls-3.1L.
3. Remove the exhaust crossover pipe heat shield. Refer to Exhaust Crossover Pipe Replacement .
4. Remove the exhaust crossover pipe nuts from the right exhaust manifold. Refer to Exhaust Crossover Pipe Replacement .
5. Disconnect the heated oxygen sensor (HO2S) connector.
6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
7. Remove the 3-way catalytic converter pipe from the right exhaust manifold. Refer to Catalytic Converter Replacement .



8. Remove the exhaust gas recirculation (EGR) tube from the right exhaust manifold. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls - 3.1L.



9. Remove the exhaust manifold upper heat shield bolts.
10. Remove the exhaust manifold upper heat shield.



11. Remove the exhaust manifold lower heat shield bolts.
12. Remove the exhaust manifold lower heat shield.



13. Remove the exhaust manifold nuts.
14. Remove the exhaust manifold.
15. Remove the right exhaust manifold gasket.
16. Clean and inspect the exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection in Engine Mechanical-3.1L Unit Repair.



17. Remove the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor 1 Replacement in Engine Controls - 3.1L.

1. Install the heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor 1 Replacement in Engine Controls - 3.1L.



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

4. Install the exhaust manifold nuts.

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




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

Tighten
Tighten the bolts to 10 N·m (89 lb in).




7. Install the exhaust manifold upper heat shield.
8. Install the exhaust manifold upper heat shield bolts.

Tighten
Tighten the bolts to 10 N·m (89 lb in).




9. Install the exhaust gas recirculation (EGR) tube to the right exhaust manifold. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls - 3.1L.
10. Install the 3-way catalytic converter pipe to the right exhaust manifold. Refer to Catalytic Converter Replacement .
11. Lower the vehicle.
12. Connect the heated oxygen sensor (HO2S) wiring harness connector.
13. Install the exhaust crossover pipe nuts to the right exhaust manifold. Refer to Exhaust Crossover Pipe Replacement .
14. Install the exhaust crossover pipe heat shield. Refer to Exhaust Crossover Pipe Replacement .
15. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls-3.1L.
16. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

Exhaust Manifold Replacement - Right Side 3.8L

1. Disconnect the battery ground 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 in Engine Mechanical-3.8L.
3. Remove the exhaust crossover pipe from the right exhaust manifold. Refer to Exhaust Crossover Pipe Replacement .
4. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Remove the 3-way catalytic converter from the right exhaust manifold. Refer to Catalytic Converter Replacement .



6. Remove the EGR adapter pipe from the right exhaust manifold.
7. Lower the vehicle.
8. Remove the wiring harness and the heater hose retaining clips from the fuel injector sight shield bracket.
9. Remove the right spark plug wires. Refer to Spark Plug Wire Replacement in Engine Controls - 3.8L.



10. Remove the engine lift bracket bolt and the nut.
11. Remove the engine lift bracket.



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



14. Remove the exhaust manifold bolts and the nuts, except for the bolt behind the heated oxygen sensor.
15. Rotate the engine forward for access. Refer to Rotating the Engine for Service Access in Engine Mechanical-3.8L.
16. Disconnect the heated oxygen sensor electrical connector.
17. Remove the remaining bolt and the exhaust manifold.
18. Remove the exhaust manifold gasket.



19. Remove the upper exhaust manifold heat shield.



20. Remove the lower exhaust manifold heat shield.
21. Remove the heated oxygen sensor from the exhaust manifold. Refer to Heated Oxygen Sensor 1 Replacement in Engine Controls - 3.8L.



22. Remove the exhaust manifold studs if damaged.
23. Clean and inspect the exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection in Engine Mechanical-3.8L Unit Repair.

1. Install the exhaust manifold studs if removed.
2. Install the heated oxygen sensor to the right exhaust manifold. Refer to Heated Oxygen Sensor 1 Replacement in Engine Controls - 3.8L.



3. Install the lower exhaust manifold heat shield.



4. Install the upper exhaust manifold heat shield.



5. Install the new exhaust manifold gasket.
6. Install the exhaust manifold.
7. Install the exhaust manifold bolt behind the oxygen sensor.
8. Connect the heated oxygen sensor electrical connector.
9. Return the engine to the original position.

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.

10. Install the remaining exhaust manifold bolts and nuts.

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




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

Tighten
Tighten the nuts to 30 N·m (22 lb ft).




13. Install the engine lift bracket.
14. Install the engine lift bracket bolt and the nut.

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

15. Install the right spark plug wires. Refer to Spark Plug Wire Replacement in Engine Controls-3.8L.
16. Install the wiring harness and the heater hose retaining clips to the fuel injector sight shield bracket.
17. Raise the vehicle.




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.

18. Install the EGR pipe to the right exhaust manifold.
19. Install the EGR pipe bolt.

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

20. Install the 3-way catalytic converter to the right exhaust manifold. Refer to Catalytic Converter Replacement .
21. Lower the vehicle.



22. Install the exhaust crossover pipe to the right exhaust manifold. Refer to Exhaust Crossover Pipe Replacement .
23. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical-3.8L.
24. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.