Exhaust Seal Replacement Manifold Pipe Gasket 3100

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.




Notice: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.

Important: Exercise care when working near the heated oxygen sensor (HO2S). DO NOT cut the HO2S wire. Disconnect the HO2S BEFORE exhaust system removal or repositioning. Refer to Heated Oxygen Sensor Replacement in Engine Controls - 3.1L.

2. Remove the right (rear) exhaust manifold pipe stud nuts from the exhaust manifold studs.

Important: Suitably support the exhaust system when the exhaust system hangers are removed.

3. In order to remove the exhaust seal disconnect any hangers necessary to reposition the exhaust system.
4. Reposition the exhaust system.
5. Remove the exhaust manifold pipe gasket.
6. Inspect all of the components for the following:

•

Cracks

•

Bends

•	Stripped threads

•	Corrosion damage

•

Leaks

7. Replace any components as necessary.

1. Install the exhaust manifold pipe gasket.
2. Return the exhaust system to the proper position.
3. Connect any hangers.
4. Remove the exhaust system support.

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.

5. Install the right (rear) exhaust manifold pipe stud nuts to the exhaust manifold pipe studs.

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

6. Reconnect the HO2S. Refer to Heated Oxygen Sensor Replacement in Engine Controls - 3.1L.
7. Lower the vehicle.
8. Inspect the exhaust system for leaks and underbody contact.

Exhaust Seal Replacement Manifold Pipe Gasket 3800

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.




Notice: To prevent internal damage to the flexible coupling of the catalytic converter assembly, the converter must be supported. The vertical movement at the rear of the catalytic converter assembly must not exceed 6 degrees up or down.

Important: Exercise care when working near the heated oxygen sensor (HO2S). DO NOT cut the HO2S wire. Disconnect the HO2S BEFORE exhaust system removal or repositioning . Refer to Heated Oxygen Sensor Replacement in Engine Controls - 3.8L.

2. Remove the right (rear) exhaust manifold nuts from the exhaust manifold pipe studs.

Important: Suitably support the exhaust system where hangers are removed.

3. In order to remove the exhaust manifold pipe gasket disconnect any hangers necessary to reposition the exhaust system.
4. Reposition the exhaust system.
5. Remove the exhaust seal.
6. Inspect all of the components for the following damage:

•

Cracks

•

Bends

•	Stripped threads

•	Corrosion damage

•

Leaks

7. Replace the components as necessary.

1. Install the exhaust manifold pipe gasket.
2. Return the exhaust system to the proper position.
3. Connect any hangers.
4. Remove the exhaust system support.

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.

5. Install the right (rear) exhaust manifold pipe stud nuts to the exhaust manifold pipe studs.

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

6. Reconnect the HO2S. Refer to Heated Oxygen Sensor Replacement in Engine Controls - 3.8L.
7. Lower the vehicle.
8. Inspect the exhaust system for leaks and underbody contact.

Exhaust Seal Replacement Crossover Pipe Seal

The exhaust crossover pipe seal replacement procedure is covered in Engine Mechanical - 3.8L. Refer to Exhaust Crossover Replacement in Engine Mechanical - 3.8L.