Removal Procedure
- Remove the throttle body air inlet duct. Refer to
Air Cleaner Inlet Duct Replacement
in Engine Controls - 3.5L.
- Disconnect the exhaust gas recirculation (EGR) pipe at the EGR valve.
- Unscrew the EGR pipe assembly nut from the exhaust manifold and remove the pipe from the vehicle.
- Remove the exhaust manifold heat shield bolts.
- Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle
.
- Remove the exhaust manifold heat shields.
- Remove the EGR pipe from the exhaust manifold and remove from the vehicle.
- Remove the exhaust manifold nuts.
- Remove the exhaust manifold.
- Remove the exhaust manifold gasket.
- Clean the engine right side exhaust manifold sealing surfaces and the cylinder head sealing surfaces.
Installation Procedure
- If removed, install the heated oxygen sensor (HO2S). Refer to
Heated Oxygen Sensor 1 Replacement
in Engine Controls - 3.5L.
- Install the exhaust manifold gasket.
- Install the exhaust manifold.
Notice: Refer to Fastener Notice in the Preface section.
- Install the exhaust manifold nuts.
Tighten
Tighten the exhaust manifold nuts to 16 N·m (12 lb ft).
- Install the exhaust manifold lower heat shield.
- Install the exhaust manifold upper heat shield.
- Install the exhaust manifold heat shield bolts.
Tighten
Tighten the exhaust manifold heat shield bolts to 10 N·m (89 lb in).
- Install the EGR valve pipe to the exhaust manifold.
Tighten
Tighten the EGR pipe nut to 25 N·m (18 lb ft).
- Install the catalytic converter. Refer to
Catalytic Converter Replacement
.
- Connect the HO2S electrical connector.
- Lower the vehicle.
- Install the exhaust crossover pipe nuts/studs to the engine right side exhaust manifold. Refer to
Exhaust Crossover Pipe Replacement
.
- Install the EGR pipe bolt to the EGR valve.
Tighten
Tighten the EGR pipe bolt to 25 N·m (18 lb ft).
- Install the throttle body air inlet duct. Refer to
Air Cleaner Inlet Duct Replacement
in Engine Controls - 3.5L.