Exhaust Manifold Pipe Replacement 3.5L (L66)

1. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle .



2. Remove the oil pan bracket (2) and bolts (1, 3).



3. Remove the exhaust pipe flange to the catalytic converter nuts (3) .
4. Remove the exhaust pipe to mid muffler pipe nuts.
5. Remove the front exhaust pipe.
6. Fully remove and discard the used gaskets.

Notice: Excessive flexing of the exhaust pipe may damage the flex coupling. Limit flexing to 12 degrees.

1. Position pipe into vehicle, and install new gaskets onto converter studs.

Notice: Refer to Fastener Notice in the Preface section.

2. Assemble exhaust pipe to converters, install new nuts and tighten .

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

3. Install the new gasket (1) onto the exhaust pipe rear flange.



4. Assemble the front pipe to rear pipe, install the nuts and tighten.

Tighten
Tighten the front pipe-to-rear pipe nuts to 30 N·m (22 lb ft).




5. Install the oil pan bracket (2) and bolts (1, 3) and tighten.

Tighten
Tighten the bolts to 20 N·m (14 lb ft).

6. Lower the vehicle. Refer to Lifting and Jacking the Vehicle .
7. Start the engine and check for exhaust leaks.

Exhaust Manifold Pipe Replacement L61

Caution: Ensure that the vehicle is properly supported and squarely positioned. To help avoid personal injury when a vehicle is on a hoist, provide additional support for the vehicle on the opposite end from which the components are being removed.

Notice: Excessive flexing of the exhaust pipe may damage the flex coupling. Limit flexing to 12 degrees.

1. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle in General Information.

Important: Do not apply silicon products to the oxygen sensor.

2. Disconnect the electrical connector from the oxygen sensor (O2S).



3. Remove the nuts from the exhaust pipe flange to intermediate pipe and separate the flange from the studs.



4. Remove the nuts from the exhaust pipe flange to exhaust manifold.



5. Separate the hanger from the rubber isolator.
6. Separate the pipe flange from the manifold studs and remove the exhaust pipe.
7. Fully remove and discard used gaskets.
8. Remove the oxygen sensor if transferring to a new exhaust pipe.

1. Install a new gasket onto the exhaust manifold studs.

Notice: Refer to Fastener Notice in the Preface section.

2. Assemble the exhaust pipe to manifold. Install new nuts and tighten.

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




3. Install the new gasket onto the exhaust pipe flange.
4. Assemble the exhaust pipe to intermediate pipe. Install new nuts and tighten.

Tighten
Tighten the nuts to 30 N·m (22 lb ft).

5. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
6. Start the engine and check for exhaust leaks.