Exhaust Manifold Replacement Left

1. Disconnect the battery ground (negative) 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 - 3.5L.
3. Remove the engine mount strut. Refer to Engine Mount Strut Replacement in Engine Mechanical - 3.5L.
4. Remove the engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement .
5. Remove the engine cooling fans. Refer to Engine Cooling Fan Replacement in Engine Cooling.
6. Drain the engine coolant from the engine. Refer to Cooling System Draining and Filling in Engine Cooling.
7. Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
8. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
9. Remove the transaxle cooler lines from the radiator.
10. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.
11. Remove the generator. Refer to Generator Replacement in Engine Electrical.



12. Remove the exhaust manifold heat shield retaining bolts.
13. Remove the exhaust manifold heat shield.
14. Remove the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement .



15. Disconnect the vacuum tube (1) from the A.I.R. control valve.
16. Disconnect the feed pipe nut (3) from the exhaust manifold.
17. Remove the A.I.R. control valve retaining bolt.
18. Remove the A.I.R. control valve from the engine mount strut bracket.



19. Loosen the exhaust manifold bolts.




Important: DO NOT reuse the gasket.

20. Remove the left exhaust manifold to crossover pipe flange retaining studs (3) and the flange gasket (1).
21. Remove the exhaust manifold bolts (4).
22. Remove the exhaust manifold (5) and the gasket (6). DO NOT reuse the gasket.
23. Clean and inspect the exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection .

1. Install a new manifold to crossover flange gasket onto the manifold flange.

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.

2. Install the exhaust manifold to crossover pipe flange retaining studs.

Tighten
Tighten the exhaust manifold to crossover flange studs to 25 N·m (18 lb ft).

3. Position a new exhaust manifold gasket onto the manifold.
4. Install the exhaust manifold bolts.



5. Tighten the exhaust manifold bolts.

Tighten
Tighten the exhaust manifold bolts to 25 N·m (18 lb ft).




6. Install the A.I.R. control valve to the engine mount strut bracket.
7. Connect the feed pipe nut (3) to the exhaust manifold.
8. Install the A.I.R. control valve retaining bolt (2).
9. Connect the vacuum tube (1) to the A.I.R. control valve.
10. Install the control valve-to-engine mount strut bracket bolt.

Tighten
Tighten the control valve retaining bolt to 9 N·m (80 lb in).

11. Install the feed pipe nut (3).

Tighten
Tighten the feed pipe nut to 60 N·m (44 lb ft).

12. Install the oil level indicator and tube. Refer to Oil Level Indicator and Tube Replacement .



13. Place the exhaust manifold heat shield in position.
14. Install the heat shield retaining bolts.

Tighten
Tighten the heat shield retaining bolts to 9 N·m (80 lb in).

15. Install the generator. Refer to Generator Replacement in Engine Electrical.
16. Install the radiator. Refer to Radiator Replacement in Engine Cooling.
17. Connect the transaxle cooler lines to the radiator.
18. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
19. Install the radiator inlet hose. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
20. Fill the engine cooling system with engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
21. Install the radiator cooling fans. Refer to Engine Cooling Fan Replacement in Engine Cooling.
22. Install the engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement .
23. Install the engine mount strut. Refer to Engine Mount Strut Replacement in Engine Mechanical - 3.5L.
24. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.5L.
25. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

Exhaust Manifold Replacement Right

1. Disconnect the battery ground (negative) 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 .
3. Remove the throttle body air inlet duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.5L.
4. Remove the engine mount strut. Refer to Engine Mount Strut Replacement in Engine Mechanical - 3.5L.
5. Relieve the fuel pressure. Refer to Fuel Pressure Relief in Engine Controls - 3.5L.
6. Disconnect the fuel lines from the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 3.5L.
7. Disconnect the throttle control cable and the cruise control cable from the throttle linkage at the throttle body bracket. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.5L and Cruise Control Cable Replacement in Cruise Control.
8. Disconnect the transaxle selector range cable.
9. Remove the transaxle shift cable brackets and bolts. Refer to Range Selector Lever Cable Bracket Replacement in Automatic Transaxle - 4T65-E.
10. Remove the transaxle shift cable from the shift module. Refer to Range Selector Lever Cable Replacement in Automatic Transaxle - 4T65-E.
11. Disconnect the vacuum booster hose from the engine.
12. Disconnect the wiring harness connections from the engine and the transaxle.
13. Drain the engine coolant from the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
14. Remove the inlet radiator hose from the engine. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
15. Disconnect the transmission oil cooler lines from the radiator. Refer to Automatic Transmission Oil Cooler Hose Replacement in Automatic Transmission - 4T65-E.
16. Disconnect the surge tank inlet hose.
17. Disconnect the heater hoses from the engine. Refer to Heater Hoses Replacement (3.5L) in HVAC.
18. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
19. Remove the lower radiator air deflector. Refer to Radiator Air Baffle Assemblies and Deflectors in Engine Cooling.
20. Remove the battery cables from the retainers.
21. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
22. Remove the AC compressor. Refer to Compressor Replacement (3.5L) in HVAC.
23. Support the AC compressor.
24. Remove the wiring harness from the starter motor. Refer to Starter Motor Replacement in Engine Electrical.
25. Remove the three-way catalytic converter from the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
26. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
27. Remove the inner fender engine splash shields. Refer to Engine Splash Shield Replacement in Body Front End.
28. Remove the wheel speed sensor wiring harnesses from the lower control arms.
29. Remove the tie rod ends from the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.
30. Remove the lower ball joints from the steering knuckles. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
31. Disconnect the drive axles. Support the drive axles. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts.
32. Disconnect the intermediate shaft from the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column - Tilt.
33. Suitably secure the vehicle to the hoist.
34. Place the engine/frame support table under the vehicle.
35. Lower the vehicle to meet the engine/frame support table. Adjust the contact pads as necessary.
36. Remove the frame-to-body bolts. Refer to Frame Removal in Frame and Underbody.
37. Raise the body of vehicle.
38. Remove the right (rear) exhaust manifold exhaust crossover pipe bolts from the left (front) exhaust manifold.



39. Disconnect the EGR valve pipe (1) from the exhaust crossover pipe.



40. Remove the right (rear) exhaust manifold retaining bolts.



41. Remove the right (rear) exhaust manifold and the gasket. Do not reuse the gasket.
42. Clean and inspect the exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection .
43. Remove the oxygen sensor (1) and inspect the sensor for excessive deposits or damage. Replace the oxygen sensor if necessary. Refer to Heated Oxygen Sensor Replacement in Engine Controls - 3.5L.



44. Remove the exhaust manifold stud(s) if damaged.

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.

1. Install the exhaust manifold stud(s) if removed.

Tighten
Tighten the exhaust manifold stud(s) to 6 N·m (53 lb in).

2. Install the oxygen sensor. Refer to Heated Oxygen Sensor Replacement in Engine Controls - 3.5L.



3. Position a new right (rear) exhaust manifold gasket onto the right (rear) exhaust manifold.
4. Install the right (rear) exhaust manifold bolts.
5. Place the right (rear) exhaust manifold, gasket and bolts as an assembly in position on the cylinder head.



6. Install the right (rear) exhaust manifold retaining bolts.

Tighten
Tighten the right (rear) exhaust manifold bolts to 25 N·m (18 lb ft).

7. Install the right (rear) exhaust manifold exhaust crossover pipe bolts to the left (front) exhaust manifold.



8. Connect the EGR valve pipe nut (3) to the exhaust crossover pipe.

Tighten
Tighten the EGR to exhaust crossover pipe nut to 60 N·m (44 lb ft).

9. Lower the vehicle to the frame.
10. Install new frame-to-body bolts. Refer to Frame Removal in Frame and Underbody.
11. Raise the vehicle.
12. Remove the engine/frame support table from under the vehicle.
13. Install the intermediate shaft to the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column - Tilt.
14. Install the drive axles. Refer to Wheel Drive Shaft Replacement and Wheel Drive Shaft Replacement in Wheel Drive Shafts.
15. Install the lower ball joints to the steering knuckles. Refer to Lower Control Arm Ball Joint Replacement in Front Suspension.
16. Install the tie rod ends to the steering knuckles. Refer to Rack and Pinion Outer Tie Rod End Replacement in Power Steering System.
17. Install the wheel speed sensor wiring harnesses to the lower control arms.
18. Install the inner fender engine splash shields. Refer to Engine Splash Shield Replacement in Body Front End.
19. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
20. Install the three-way catalytic converter to the right (rear) exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
21. Install the starter motor wiring harness. Refer to Starter Motor Replacement in Engine Electrical.
22. Install the AC compressor. Refer to Compressor Replacement (3.5L) in HVAC.
23. Install the radiator outlet hose. Refer to Radiator Outlet Hose Replacement in Engine Cooling.
24. Install the battery cables to the retainers.
25. Install the lower radiator air deflector. Refer to Radiator Air Baffle Assemblies and Deflectors in Engine Cooling.
26. Remove the safety straps.
27. Lower the vehicle.
28. Connect the heater hoses to the engine. Refer to Heater Hoses Replacement (3.5L) in HVAC.
29. Install the surge tank inlet hose.
30. Connect the transmission oil cooler lines to the radiator. Refer to Automatic Transmission Oil Cooler Hose Replacement in Automatic Transmission - 4T65-E.
31. Install the radiator inlet hose to the radiator. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
32. Connect the wiring harness connections at the engine and the transaxle.
33. Connect the vacuum booster hose to the engine.
34. Install the transaxle shift cable to the shift module. Refer to Range Selector Lever Cable Replacement in Automatic Transaxle - 4T65-E.
35. Install the transaxle shift cable bracket and bolts. Refer to Range Selector Lever Cable Bracket Replacement in Automatic Transaxle - 4T65-E.
36. Connect the transaxle selector range cable.
37. Connect the throttle cable and the cruise control cable to the throttle linkage on the throttle body bracket. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.5L and Cruise Control Cable Replacement in Cruise Control.
38. Connect the fuel lines to the fuel rail. Refer to Fuel Injection Fuel Rail Assembly Replacement in Engine Controls - 3.5L.
39. Install the engine mount strut. Refer to Engine Mount Strut Replacement in Engine Mechanical - 3.5L.
40. Install the throttle body air inlet duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.5L.
41. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.5L.
42. Fill the cooling system with engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
43. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
44. Check for leaks from the following areas:

•	Cooling system

•

Engine

•	Transmission

•	Exhaust system