Exhaust Manifold Replacement - Left Side 6.0L Engine

1. Disconnect the battery ground cable from the battery. Refer to Battery Negative Cable Disconnection and Connection.
2. Remove the engine dress cover. Refer to Engine Cover Replacement.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
4. Remove the left side spark plug leads. Refer to Spark Plug Wire Replacement.
5. Remove the left side spark plugs from the cylinder head. Refer to Spark Plug Replacement.

Caution: Refer to Exhaust Service Caution in the Preface section.

Caution: Refer to Protective Goggles and Glove Caution in the Preface section.




6. Remove the exhaust manifold heat shield to exhaust manifold retaining bolts (2).
7. Remove the exhaust manifold heat shield (1).
8. Remove the engine coolant temperature sensor. Refer to Engine Coolant Temperature Sensor Replacement.




Important: The left catalytic converter to exhaust manifold retaining nuts (2) are single use parts. They must be discarded after removal.

9. Remove the left catalytic converter to exhaust manifold retaining nuts (2).

Discard the nuts.

10. Disconnect the left catalytic converter (3) from the exhaust manifold (4).
11. Loosen the exhaust manifold to cylinder head retaining bolts (1) working from the outside to the centre.

Important: Bolts with micro-encapsulated thread sealant must be discarded after removal.

12. Remove the exhaust manifold to cylinder head retaining bolts (1).

Discard the bolts.





Important: Make sure that the surrounding wiring harness and electrical connectors are not damaged when removing the exhaust manifold (2).

Important: The exhaust manifold gasket (1) and sealing ring (3) are single use parts. They must be discarded after removal.

13. Remove the exhaust manifold (2).

Discard the exhaust manifold gasket (1) and sealing ring (3).

Inspect

Notice: Refer to Exhaust Service Caution in the Preface section.

1. Before installation inspect for the following:

•	Damage to the gasket sealing surfaces.

•	Distortion of exhaust manifold mating surface.

•	Damage to the exhaust mounting holes.




2. Check for distortion on the mating surface of the exhaust manifold (3) by using a straight edge (1) and a feeler gauge (2).
3. Clean the exhaust manifold and catalytic converter flange mating surfaces.



4. Install a NEW exhaust manifold gasket (1) and NEW sealing ring (3) to the exhaust manifold (2).

Notice: Refer to Exhaust System Inspection Notice in the Preface section.

5. Install the exhaust manifold assembly to the engine.




Important: Do not fully tighten the exhaust manifold to cylinder head retaining bolts (1) at this stage.

6. Install the NEW exhaust manifold to cylinder head retaining bolts (1).

Do not fully tighten at this stage.

Important: Make sure the sealing ring is seated correctly.

7. Lift the left catalytic converter (3) up and forward to connect to the exhaust manifold (4).
8. Clean the threads of the exhaust manifold to catalytic converter retaining studs with a suitable cleaning solvent.

Notice: Refer to Fastener Notice in the Preface section.

9. Install the NEW left catalytic converter to exhaust manifold retaining nuts (2).

Tighten
Tighten the nuts to 45 N·m (33 lb ft).

10. Tighten the exhaust manifold to cylinder head retaining bolts (1) working from the centre to the outside.

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

11. Install the engine coolant temperature sensor. Refer to Engine Coolant Temperature Sensor Replacement .



12. Install the exhaust manifold heat shield (1).
13. Install the exhaust manifold heat shield to exhaust manifold retaining bolts (2).

Tighten
Tighten the bolts to 10 N·m (89 lb in).

14. Install the left side spark plugs to the cylinder head. Refer to Spark Plug Replacement.
15. Install the left side spark plug leads. Refer to Spark Plug Wire Replacement.
16. Install the air intake duct. Refer to Air Cleaner Assembly Replacement.
17. Install the engine dress cover. Refer to Engine Cover Replacement.
18. Connect the battery ground cable to the battery. Refer to Battery Negative Cable Disconnection and Connection.

Exhaust Manifold Replacement - Left Side 3.6L Engine

Caution: Refer to Exhaust Service Caution in the Preface section.

Caution: Refer to Protective Goggles and Glove Caution in the Preface section.

1. Ignition OFF.

Caution: Refer to Battery Disconnect Caution in the Preface section.

2. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
3. Remove the engine cover. Refer to Engine Cover Replacement.
4. Remove the left pre-catalytic convertor heated oxygen sensor (HO2S). Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1.
5. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Left Side .
6. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Removal .
7. Remove the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side .



8. Remove the battery positive cable retaining nut (1) from the starter motor solenoid.
9. Remove the battery positive cable (2) from the starter motor.




Important: Bolts with micro-encapsulated thread sealant must be discarded after removal.

10. Remove the exhaust manifold to cylinder head retaining bolts (1).

Discard the bolts.

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

11. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.




Important: Bolts with micro-encapsulated thread sealant must be discarded after removal.

12. Remove the exhaust manifold to cylinder head retaining bolts (1).

Discard the bolts.





Important: Make sure that the surrounding wiring harness and electrical connectors are not damaged when removing the exhaust manifold (2).

Important: The exhaust manifold gasket (1) and sealing ring (3) are single use parts. They must be discarded after removal.

13. Remove the exhaust manifold (2) from the engine assembly.
14. Separate the exhaust manifold (2) from the exhaust manifold gasket (1) and sealing ring (3).
15. Discard the exhaust manifold gasket (1) and sealing ring (3).

1. Inspect the exhaust manifold before installation. Refer to Exhaust Manifold Cleaning and Inspection - Left Side.




Important: Make sure the sealing ring is seated correctly.

2. Install a NEW exhaust manifold gasket (1) and NEW sealing ring (3) to the exhaust manifold (2).

Caution: Refer to Safety Glasses Caution in the Preface section.

Caution: Refer to Vehicle Lifting Caution in the Preface section.

3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.

Important: A suitable support must be used to support the exhaust manifold while the vehicle is being lowered.

4. Install the exhaust manifold assembly (2) to the engine.




Important: Do not fully tighten the exhaust manifold to cylinder head retaining bolts (1) at this stage.

5. Install NEW exhaust manifold to cylinder head retaining bolts (1).

Caution: Refer to Fastener Notice in the Preface section.

6. Tighten the exhaust manifold to cylinder head retaining bolts (1) working from the centre to the outside.

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

7. Lower the vehicle.




Important: Do not fully tighten the exhaust manifold to cylinder head retaining bolts (1) at this stage.

8. Install NEW exhaust manifold to cylinder head retaining bolts (1).
9. Tighten the exhaust manifold to cylinder head retaining bolts (1) working from the centre to the outside.

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




10. Install the battery positive cable (2) to the starter motor.
11. Install the battery positive cable retaining nut (1) to the starter motor solenoid.

Tighten
Tighten the nut to 10 N·m (89 lb in).

12. Install the left catalytic converter. Refer to Catalytic Converter Replacement - Left Side .
13. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement - Left Side .
14. Install the left pre-catalytic convertor HO2S. Refer to Heated Oxygen Sensor Replacement - Bank 2 Sensor 1 .
15. Install the engine cover. Refer to Engine Cover Replacement.
16. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .