Exhaust Manifold Replacement - Right

Exhaust Manifold Replacement Right (3.8L)

Removal Procedure





1. Disconnect the battery ground (negative) cable.
2. Remove the fuel injector sight shield.
3. Remove the exhaust crossover pipe from the right exhaust manifold.
4. Raise and suitably support the vehicle.
5. Remove the EGR adapter pipe from the right exhaust manifold.
6. Remove the three-way catalytic converter from the right exhaust manifold.
7. Remove the wiring harness and the heater hose retaining clips from the fuel injector sight shield bracket.
8. Remove the right spark plug wires.
9. Remove the right engine lift bracket bolt and nut.





10. Remove the right engine lift bracket.





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





13. Remove the right exhaust manifold bolts and nuts, except for the bolt behind the oxygen sensor.
14. Lower the vehicle.
15. Rotate the engine forward for access.
16. Disconnect the oxygen sensor electrical connector.
17. Remove the remaining bolt and the right exhaust manifold.
18. Remove the right exhaust manifold gasket.





19. Remove the upper right exhaust manifold heat shield.





20. Remove the lower right exhaust manifold heat shield.
21. Remove the heated oxygen sensor from the right exhaust manifold.





22. Remove the exhaust manifold stud(s) if damaged.

Installation Procedure





1. Install the exhaust manifold stud(s) if removed.
2. Install the heated oxygen sensor to the right exhaust manifold.





3. Install the lower right exhaust manifold heat shield.





4. Install the upper right exhaust manifold heat shield.





5. Install the new right exhaust manifold gasket.
6. Install the right exhaust manifold.
7. Install the right exhaust manifold bolt behind the oxygen sensor.
8. Connect the oxygen sensor electrical connector.
9. Return the engine to the original position.
10. Raise the vehicle.

Notice: Refer to Fastener Notice in Service Precautions.

11. Install the remaining right exhaust manifold bolts and nuts.
- Tighten the right exhaust manifold bolts and nuts to 30 Nm (22 ft. lbs.).





12. Install the fuel injector sight shield bracket.
13. Install the fuel injector sight shield bracket nuts.
- Tighten the fuel injector sight shield bracket nuts to 30 Nm (22 ft. lbs.).





14. Install the right engine lift bracket.
15. Install the right engine lift bracket bolt and nut.
- Tighten the right engine lift bracket bolt and nut to 30 Nm (22 ft. lbs.).
16. Install the right spark plug wires.
17. Install the wiring harness and the heater hose retaining clips to the fuel injector sight shield bracket.
18. Install the three-way catalytic converter to the right exhaust manifold.

Important: Whenever the EGR pipe is removed from the right exhaust manifold, the outlet pipe should be inspected for leaks during installation. If leaks are present, replace the EGR adapter.

19. Install the EGR pipe to the right exhaust manifold.
- Tighten the EGR pipe bolt to 29 Nm (21 ft. lbs.).
20. Lower the vehicle.
21. Install the exhaust crossover pipe to the right exhaust manifold.
22. Install the fuel injector sight shield.
23. Connect the battery ground (negative) cable.