Exhaust Manifold Replacement - Right Side L36

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 - 3.8L.
2. Disconnect the heated oxygen sensor at the sensor pigtail.
3. Remove the right side spark plugs. Refer to Spark Plug Replacement in Engine Controls - 3.8L.



4. Remove the two nuts securing the power brake booster heat shield to the exhaust crossover.
5. Remove the power brake booster heat shield from the exhaust crossover.
6. Remove the two bolts attaching the exhaust crossover to the right exhaust manifold.
7. Remove the transaxle filler tube. Refer to Transmission Fluid Filler Tube and Seal Replacement in Automatic Transaxle - 4T65-E.
8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
9. Remove the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement .
10. Remove the heated oxygen sensor if replacement is necessary. Refer to Heated Oxygen Sensor 1 Replacement in Engine Controls - 3.8L.



11. Remove the fuel injector sight shield bracket retaining nuts.
12. Remove the fuel injector sight shield bracket.



13. Remove the right engine lift bracket retaining fasteners.
14. Remove the right engine lift bracket.



15. Remove the bolt (1) securing the EGR inlet pipe to the right exhaust manifold.
16. Remove the right exhaust manifold retaining fasteners.
17. Remove the right exhaust manifold and the gasket from the engine. Do not reuse the gasket.
18. Remove the exhaust crossover seal from the exhaust crossover. Do not reuse the seal.
19. Clean and inspect the right exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection in Engine Mechanical - 3.8L.

1. Place a NEW exhaust crossover seal over the exhaust crossover.



2. Place a NEW exhaust manifold gasket over the cylinder head studs.
3. Position the right exhaust manifold around the exhaust crossover and up to the right 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.

4. Install the right exhaust manifold fasteners.

Tighten
Tighten the exhaust manifold fasteners to 30 N·m (22 lb ft).

5. Install the bolt (1) securing the EGR inlet pipe to the right exhaust manifold.

Tighten
Tighten the EGR inlet pipe bolt to 30 N·m (22 lb ft).




6. Position the right engine lift bracket to the engine.
7. Install the right engine lift bracket retaining fasteners.

Tighten
Tighten the engine lift bracket retaining fasteners to 30 N·m (22 lb ft).




8. Position the fuel injector sight shield bracket to the engine.
9. Install the fuel injector sight shield bracket retaining nuts.

Tighten
Tighten the fuel injector sight shield bracket retaining nuts to 30 N·m (22 lb ft).

10. Install the heated oxygen sensor. Refer to Heated Oxygen Sensor 1 Replacement in Engine Controls - 3.8L.
11. Install the exhaust manifold pipe. Refer to Exhaust Manifold Pipe Replacement .
12. Lower the vehicle.
13. Install the transaxle filler tube. Refer to Transmission Fluid Filler Tube and Seal Replacement in Automatic Transaxle - 4T65-E.



14. Install the bolts securing the exhaust crossover to the right exhaust manifold.

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

15. Install the power brake booster heat shield to the exhaust crossover.
16. 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).

17. Install the right side spark plugs. Refer to Spark Plug Replacement in Engine Controls - 3.8L.
18. Connect the heated oxygen sensor at the sensor pigtail.
19. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.

Exhaust Manifold Replacement - Right Side LD8

Tools Required

J 42640 Steering Column Lock Pin

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. Disconnect the heated oxygen sensor (HO2S) at the sensor pigtail.

Notice: The wheels of the vehicle must be straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the coil assembly in the steering column to become uncentered which will cause damage to the coil assembly.




2. Lock the steering column by installing the J 42640 into the underside of the steering column.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement .



5. Remove the 2 nuts (2) attaching the secondary AIR tube (1) to the exhaust manifold (3).
6. Remove the secondary AIR tube (1) and the gasket from the exhaust manifold (3). Do not reuse the gasket.



7. Disconnect the post HO2S wiring harness retainer from the power steering gear heat shield.
8. Remove the 2 bolts securing the heat shield.
9. Remove the heat shield from the power steering gear.



10. Remove the rearward nut (3) securing the vehicle speed sensor heat shield (1).
11. Loosen the forward nut (2) in order to remove the heat shield (1).
12. Remove the heat shield (1) from the transaxle.



13. Disconnect the real time dampening sensor links (1) from the lower control arms.




Caution: Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or damage to the intermediate shaft. This damage may cause loss of steering control which could result in personal injury.

14. Remove the intermediate shaft pinch bolt.
15. Disconnect the intermediate shaft from the steering gear.



16. Remove the nut securing the right engine mount to the right engine mount bracket.



17. Remove the nut securing the left transaxle mount to the left transaxle mount bracket.



18. Support the rear of the engine frame with a tall screw jack.
19. Remove the 4 rearward engine frame-to-body bolts.
20. Lower the screw jack approximately 4 cm (1.5 in) allowing the rear of the engine frame to lower.
21. Remove the HO2S if replacement is necessary. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 in Engine Controls - 4.6L.



22. Remove the right exhaust manifold retaining bolts.
23. Remove the right exhaust manifold and the gasket from the engine. Do not reuse the gasket.
24. Clean and inspect the right exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection - Right Side in Engine Mechanical - 4.6L.

1. Place a NEW exhaust manifold gasket over the cylinder head studs.
2. Position the right exhaust manifold to the right 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.

3. Install the right exhaust manifold nuts.

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

4. Install the HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 1 Sensor 1 in Engine Controls - 4.6L.



5. Raise the engine cradle into position.
6. Install the 4 rearward engine frame-to-body bolts.

Tighten
Tighten the engine frame bolts to 191 N·m (141 lb ft).

7. Remove the screw jack.



8. Install the nut securing the left transaxle mount to the left transaxle mount bracket.

Tighten
Tighten the transaxle mount nut to 80 N·m (59 lb ft).




9. Install the nut securing the right engine mount to the right engine mount bracket.

Tighten
Tighten the engine mount nut to 80 N·m (59 lb ft).





Caution: When installing the intermediate shaft make sure that the shaft is seated prior to pinch bolt installation. If the pinch bolt is inserted into the coupling before shaft installation, the two mating shafts may disengage. Disengagement of the two mating shafts will cause loss of steering control which could result in personal injury.

10. Connect the intermediate shaft to the steering gear.
11. Install the intermediate shaft pinch bolt.

Tighten
Tighten the intermediate shaft pinch bolt to 45 N·m (33 lb ft).




12. Connect the real time dampening sensor links (1) to the lower control arms.



13. Position the vehicle speed sensor heat shield (1) to the studs on transaxle.
14. Install the retaining nuts (2, 3) securing the vehicle speed sensor heat shield to the transaxle.

Tighten
Tighten the vehicle speed sensor heat shield nuts to 50 N·m (37 lb ft).




15. Position the power steering gear heat shield to the power steering gear.
16. Install the 2 bolts securing the heat shield.

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

17. Connect the post HO2S wiring harness retainer to the heat shield.



18. Install the new gasket to the secondary AIR tube (1).
19. Install the 2 nuts (2) attaching the secondary AIR tube (1) to the exhaust manifold (3).

Tighten
Tighten the secondary AIR tube nuts to 12 N·m (106 lb in).

20. Install the rear exhaust manifold pipe. Refer to Exhaust Manifold Rear Pipe Replacement .
21. Lower the vehicle.



22. Remove the J 42640 from the steering column.
23. Connect the HO2S at the sensor pigtail.