Exhaust Manifold Replacement Left Front

1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
2. Remove the engine mount struts. Refer to Engine Mount Strut Replacement .
3. Remove the exhaust crossover pipe from the left exhaust manifold. Refer to Exhaust Crossover Replacement .
4. Disconnect the left spark plug wires. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
5. Remove the oil level indicator tube bracket. Refer to Oil Level Indicator and Tube Replacement .
6. Refer to Exhaust Manifold Removal in order to remove the following components:

6.1.	exhaust manifold heat shield

6.2.	engine lift hook

6.3.	exhaust manifold

6.4.	exhaust manifold gasket

1. Refer to Exhaust Manifold Installation in order to install the following components:

1.1.	exhaust manifold gasket

1.2.	exhaust manifold

1.3.	engine lift hook

1.4.	exhaust manifold heat shield

2. Install the oil level indicator tube bracket. Refer to Oil Level Indicator and Tube Replacement .
3. Connect the left spark plug wires. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
4. Install the exhaust crossover to the left exhaust manifold. Refer to Exhaust Crossover Replacement .
5. Install the engine mount struts. Refer to Engine Mount Strut Replacement .
6. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .

Exhaust Manifold Replacement Right Rear

1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .
2. Remove the cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.
3. Remove the exhaust crossover pipe from the right exhaust manifold. Refer to Exhaust Crossover Replacement .



4. Remove the EGR adapter pipe from the right exhaust manifold.
5. Remove the AIR pipe, if equipped. Refer to Secondary Air Injection Combination Valve/Pipe Replacement in Engine Controls - 3.8L.
6. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
7. Disconnect the catalytic converter pipe from the right exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
8. Lower the vehicle.
9. Disconnect and remove the heated oxygen sensor pigtail lead from the generator bracket brace.
10. Disconnect the right spark plug wires. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
11. Remove the right engine lift bracket bolt and nut.
12. Remove the right engine lift bracket.
13. Remove the fuel injector sight shield bracket nuts.
14. Remove the fuel injector sight shield bracket.
15. Remove the transaxle fluid filler tube. Refer to Transmission Fluid Filler Tube Replacement in Automatic Transaxle -- 4T65-E.



16. Remove the right exhaust manifold bolts and nuts.
17. Remove 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. If replacing the right exhaust manifold, remove the heated oxygen sensor from the right exhaust manifold. Refer to Heated Oxygen Sensor Replacement in Engine Controls - 3.8L.

1. If replacing the right exhaust manifold, install the heated oxygen sensor to the right exhaust manifold. Refer to Heated Oxygen Sensor Replacement in Engine Controls - 3.8L.



2. Install the lower right exhaust manifold heat shield.



3. Install the upper right exhaust manifold heat shield.

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.

4. Install the new right exhaust manifold gasket.
5. Install the right exhaust manifold.

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.

6. Install the exhaust manifold bolts and nuts.

Tighten
Tighten the exhaust manifold bolts and nuts to 30 N·m (22 lb ft).

7. Install the transaxle fluid filler tube. Refer to Transmission Fluid Filler Tube Replacement in Automatic Transaxle -- 4T65-E.
8. Install the fuel injector sight shield bracket.
9. Install the fuel injector sight shield bracket nuts.

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

10. Install the right engine lift bracket.
11. Install the right engine lift bracket bolt and nut.

Tighten
Tighten the right engine lift bracket bolt and nut to 30 N·m (22 lb ft).

12. Install the right spark plug wires. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
13. Install the wiring harness and the heater hose retaining clips to the fuel injector sight shield bracket.
14. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
15. Connect the catalytic converter pipe to the right exhaust manifold. Refer to Catalytic Converter Replacement in Engine Exhaust.
16. Lower the vehicle.
17. Install the AIR pipe, if equipped. Refer to Secondary Air Injection Combination Valve/Pipe Replacement in Engine Controls - 3.8L.



18. Install the EGR adapter pipe to the right exhaust manifold. Refer to Engine Controls - 3.8L.
19. Install the exhaust crossover pipe to the right exhaust manifold. Refer to Exhaust Crossover Replacement .
20. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement .