Exhaust Manifold Replacement - Left Side 3.8 L Engine

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the catalytic converter. Refer to Catalytic Converter Replacement .
3. Remove the connector position assurance (CPA) lock.
4. Disconnect the wiring harness connector (1) from the oxygen sensor.
5. Remove the oxygen sensor connector from the spark plug wire harness bracket.



6. Remove the oxygen sensor.



7. Disconnect the numbers 1, 3 and 5 spark plug wires from the spark plugs.



8. Remove the numbers 3 and 5 spark plugs from the cylinder head.



9. Remove the two rear exhaust manifold studs and nut from the exhaust manifold.
10. Lower the vehicle.



11. Remove the number 1 spark plug from the cylinder head.



12. Remove the exhaust manifold heat shield nuts.
13. Remove the exhaust manifold heat shields.



14. Remove the exhaust manifold studs and nut from the exhaust manifold.
15. Remove the exhaust manifold and gasket from the cylinder head.
16. Remove the heat shield studs from the exhaust manifold, if necessary.

1. Install the heat shield studs to the exhaust manifold, if necessary.
2. Install the exhaust manifold gasket and manifold to the cylinder head studs.

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 front two exhaust manifold studs and nut to the exhaust manifold.

Tighten

•	Tighten the two front exhaust manifold studs to 15 N·m (11 lb ft).

•	Tighten the exhaust manifold nut to 18 N·m (13 lb ft).




4. Install the exhaust manifold heat shields.
5. Install the exhaust manifold heat shield nuts.

Tighten
Tighten the exhaust manifold heat shield nuts to 10 N·m (89 lb in).




6. Install the number 1 spark plug to the cylinder head.

Tighten
Tighten the number 1 spark plug to 27 N·m (20 lb ft).

7. Raise the vehicle.



8. Install the two rear exhaust manifold studs and nut to the exhaust manifold.

Tighten

•	Tighten the two rear exhaust manifold studs to 15 N·m (11 lb ft).

•	Tighten the exhaust manifold nut to 18 N·m (13 lb ft).




9. Install the numbers 3 and 5 spark plugs to the cylinder head.

Tighten
Tighten the numbers 3 and 5 spark plugs to 27 N·m (20 lb ft).




10. Connect the numbers 1, 3 and 5 spark plug wires to the spark plugs.



11. Install the oxygen sensor.

Tighten
Tighten the oxygen sensor to 42 N·m (31 lb ft).




12. Install the oxygen sensor connector to the spark plug wire harness bracket.
13. Connect the wire harness connector (1) to the oxygen sensor connector.
14. Install the CPA lock.
15. Install the catalytic converter. Refer to Catalytic Converter Replacement .
16. Lower the vehicle.

Exhaust Manifold Replacement - Left Side 5.7 L Engine

1. Remove the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side for the 5.7 L engine.
2. Remove the spark plugs. Refer to Spark Plug Replacement for the 5.7 L engine.
3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
4. Remove the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side .
5. Remove and discard the exhaust manifold bolts.
6. Remove the exhaust manifold and gasket.
7. Discard the gasket.



8. Remove the heat shield bolts (3) and heat shield (2) from the manifold (1), if required.

1. Install the exhaust manifold to the cylinder head. Refer to Exhaust Manifold Installation - Left Side .

Notice: Refer to Fastener Notice in the Preface section.




2. Install the heat shield (2) and heat shield bolts (3) to the manifold (1), if required.

Tighten
Tighten the heat shield bolts (3) to 9 N·m (80 lb in).

3. Install the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side .
4. Lower the vehicle.
5. Install the spark plugs. Refer to Spark Plug Replacement for the 5.7 L engine.
6. Install the left valve rocker arm cover. Refer to Valve Rocker Arm Cover Replacement - Left Side for the 5.7 L engine.