Exhaust Manifold Replacement Left

1. Remove the two bolts attaching the left exhaust manifold to the crossover pipe.
2. Disconnect the spark plug wires from the spark plugs.
3. Remove the oil level indicator and the tube. Refer to Oil Level Indicator and Tube Replacement .
4. Remove lift bracket and retaining bolts.



5. Remove the exhaust manifold studs and bolts.
6. Remove the exhaust manifold.

1. Install the exhaust manifold to the cylinder head.

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 studs and bolts.

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

3. Install the oil level indicator and the tube. Refer to Oil Level Indicator and Tube Replacement .
4. Reconnect the spark plug wires.



5. Install the two bolts attaching the left exhaust manifold to the exhaust crossover pipe.

Tighten
Tighten the bolts to 18 N·m (13 lb ft).

6. Install lift bracket.

Exhaust Manifold Replacement Right

Important: Inspect the EGR outlet pipe for leaks, whenever the pipe is removed from the right hand exhaust manifold. If a leak exists, replace the EGR adapter.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
4. Remove the brake booster heatshield.
5. Remove the crossover pipe. Refer to Exhaust Crossover Replacement .
6. Remove the engine wire harness for the retainer on the right hand engine lift hook.
7. Disconnect the spark plug wires from the 2,4 and 6 spark plugs and set aside.
8. Remove the oxygen sensor electrical connector.
9. Remove the oxygen sensor. Refer to Heated Oxygen Sensor Replacement in Engine Controls - 3.8L.
10. Remove the EGR feed pipe bolt at the manifold.
11. Remove the transmission oil level indicator.
12. Raise the vehicle. Suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
13. Remove the transmission oil level indicator tube and seal. Refer to Transmission Fluid Filler Tube Replacement in Transmission.
14. Remove the exhaust manifold flange nuts.
15. Remove the front exhaust pipe from the exhaust manifold. Refer to Front Pipe Replacement in Engine Exhaust.



16. Remove the engine lift bracket.



17. Remove the exhaust manifold nuts and bolts.
18. Remove the exhaust manifold.

1. Install the exhaust manifold and gasket.

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 studs and bolts.

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




3. Install the engine lift bracket.
4. Raise the vehicle. Suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Install the front exhaust pipe. Refer to Front Pipe Replacement in Engine Exhaust.
6. Install the transmission oil level indicator tube and seal. Refer to Transmission Fluid Filler Tube Replacement in Transmission.
7. Lower the vehicle.
8. Install the transmission oil level indicator.
9. Install EGR feed pipe to the manifold.
10. Install the oxygen sensor electrical connector.
11. Install the oxygen sensor. Refer to Heated Oxygen Sensor Replacement in Engine Controls - 3.8L.
12. Connect the spark plug wires to the spark plugs.
13. Install engine wire harness retainer to engine lift hook bracket.
14. Install the crossover pipe. Refer to Exhaust Crossover Replacement .
15. Install the power brake booster heatshield.
16. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
17. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
18. Connect the negative battery cable.

Exhaust Manifold Replacement w/NC1

Important: Inspect the EGR outlet pipe for leaks, whenever the pipe is removed from the right hand exhaust manifold. If a leak exists, replace the EGR adapter.

Caution: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.

1. Disconnect the negative battery cable.
2. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
4. Remove the brake booster heatshield.
5. Remove the crossover pipe. Refer to Exhaust Crossover Replacement .
6. Remove the engine wire harness for the retainer on the right hand engine lift hook.
7. Disconnect the spark plug wires from the 2,4 and 6 spark plugs and set aside.
8. Remove the oxygen sensor electrical connector.
9. Remove the oxygen sensor. Refer to Heated Oxygen Sensor Replacement in Engine Controls - 3.8L.



10. Remove the EGR feed pipe bolt at the manifold.
11. Remove the EGR mounting bracket.



12. Remove the air injection pipe assembly nuts.
13. Remove the air injection pipe.



14. Remove vacuum solenoid and lines.



15. Remove the air injection check valve bolts.
16. Remove the air injection check valve.



17. Remove the fuel injector sight shield mounting bracket.
18. Remove the transmission oil level indicator.
19. Raise the vehicle. Suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
20. Remove the transmission oil level indicator tube and seal. Refer to Transmission Fluid Filler Tube Replacement in Transmission.
21. Remove the exhaust manifold flange nuts.
22. Remove the front exhaust pipe from the exhaust manifold. Refer to Front Pipe Replacement in Engine Exhaust.



23. Remove the engine lift bracket.



24. Remove the exhaust manifold nuts and bolts.
25. Remove the exhaust manifold.

1. Install the exhaust manifold and gasket.

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 studs and bolts.

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




3. Install the engine lift bracket.
4. Raise the vehicle. Suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
5. Install the front exhaust pipe. Refer to Front Pipe Replacement in Engine Exhaust.
6. Install the transmission oil level indicator tube and seal. Refer to Transmission Fluid Filler Tube Replacement in Transmission.
7. Lower the vehicle.



8. Install the fuel injector sight shield mounting bracket.



9. Install the air injection check valve bolts.

Tighten
Tighten to10 N·m (89 lb in).




10. Install vacuum solenoid and lines.

Tighten
Tighten to10 N·m (89 lb in).




11. Install the air injection pipe assembly nuts.

Tighten
Tighten the studs and the bolts to10 N·m (89 lb in).




12. Install the EGR valve mounting bracket.

Tighten
Tighten to 50 N·m (37 lb ft).

13. Install the EGR to the exhaust manifold.

Tighten
Tighten to 29 N·m (21 lb ft).

14. Install the transmission oil level indicator.
15. Install the oxygen sensor electrical connector.
16. Install the oxygen sensor. Refer to Heated Oxygen Sensor Replacement in Engine Controls - 3.8L.
17. Connect the spark plug wires to the spark plugs.
18. Install engine wire harness retainer to engine lift hook bracket.
19. Install the crossover pipe. Refer to Exhaust Crossover Replacement .
20. Install the power brake booster heatshield.
21. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
22. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
23. Connect the negative battery cable.