Caution: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Caution: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in serious personal injury.

1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8 L.
2. Remove the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.8 L.



3. Remove the two nuts securing the power brake booster heat shield to the exhaust crossover.
4. Remove the power brake booster heat shield from the exhaust crossover.



5. Remove the four bolts attaching the exhaust crossover to the exhaust manifolds.
6. Remove the exhaust crossover from the engine. Do not reuse the seal.

Notice: When inspecting or replacing exhaust system components, make sure there is adequate clearance from all points on the underbody to prevent overheating of the floor pan and possible damage to the passenger compartment insulation and trim materials.

1. Place the NEW exhaust crossover seal over the exhaust crossover.
2. Insert the exhaust crossover into 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.

3. Install the bolts securing the exhaust crossover to the exhaust manifolds.

Tighten
Tighten the exhaust crossover bolts to 20 N·m (15 lb ft).




4. Install the power brake booster heat shield to the exhaust crossover.
5. Install the two nuts securing the power brake booster heat shield to the exhaust crossover.

Tighten
Tighten the power brake booster heat shield nuts to 20 N·m (15 lb ft).

6. Install the air cleaner intake duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.8 L.
7. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8 L.