For 1990-2009 cars

## Exhaust Manifold Replacement Engine Left Side

### Removal Procedure

1. Remove the throttle body air inlet duct. Refer to Air Filter Element Replacement in Engine Controls - 3.4L.
2. Drain the engine coolant from the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
3. Remove the right engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement .
4. Disconnect the inlet radiator hose from the engine. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
5. Remove the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement in Engine Cooling.
6. Remove the exhaust crossover pipe bolts from the engine left side exhaust manifold. Refer to Exhaust Crossover Removal .
7. Remove the exhaust manifold heat shield bolts.
8. Remove the exhaust manifold heat shield.
9. Remove the exhaust manifold nuts.
10. Remove the exhaust manifold.
11. Remove the exhaust manifold gasket.
12. Clean the engine left side exhaust manifold to the engine left side cylinder head sealing surfaces. Refer to Exhaust Manifold Cleaning and Inspection .

### Installation Procedure

1. Install the exhaust manifold gasket.
2. Install the 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.

3. Install the exhaust manifold nuts.

Tighten
Tighten the exhaust manifold nuts to 16 N·m (12 lb ft).

4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts.

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

6. Install the exhaust crossover pipe. Refer to Exhaust Crossover Installation .
7. Install the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement in Engine Cooling.
8. Connect the inlet radiator hose to the engine. Refer to Radiator Inlet Hose Replacement in Engine Cooling.
9. Install the right engine mount strut bracket. Refer to Engine Mount Strut Bracket Replacement .
10. Fill the cooling system with engine coolant. Refer to Cooling System Draining and Filling in Engine Cooling.
11. Install the throttle body air inlet duct. Refer to Air Filter Element Replacement in Engine Controls - 3.4L.

## Exhaust Manifold Replacement Engine Right Side

### Removal Procedure

1. Remove the windshield wiper motor cover. Refer to Wiper Module Cover Replacement in Wipers Washer System.
2. Remove the throttle body air inlet duct. Refer to Air Filter Element Replacement in Engine Controls - 3.4L.
3. Remove the accelerator cable bracket from the throttle body. Refer to Accelerator Control Cable Replacement in Engine Controls - 3.4L.
4. Remove the manifold air pressure (MAP) sensor. Refer to Manifold Absolute Pressure Sensor Replacement in Engine Controls - 3.4L.
5. Remove the exhaust gas recirculation (EGR) valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls - 3.4L.
6. Rotate the engine for service access. Refer to Rotating the Engine for Service Access .
7. Remove the ignition module and the ignition coils with the bracket.
8. Remove the spark plug wires from the engine right bank spark plugs.
9. Disconnect the oxygen sensor electrical connector.
10. Remove the evaporative emissions (EVAP) solenoid bracket.
11. Remove the exhaust crossover pipe nuts/studs from the engine right bank exhaust manifold. Refer to Exhaust Crossover Removal .
12. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
13. Remove the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
14. Remove the exhaust manifold heat shield bolts.
15. Remove the exhaust manifold heat shields.
16. Remove the exhaust manifold nuts.
17. Remove the exhaust manifold.
18. Remove the exhaust manifold gasket.
19. Lower the vehicle.
20. Clean the engine right side exhaust manifold sealing surfaces and the cylinder head sealing surfaces. Refer to Exhaust Manifold Cleaning and Inspection .
21. If you are REPLACING the engine right side exhaust manifold, remove the Exhaust Gas Recirculation (EGR) valve pipe.
22. If you are REPLACING the engine right side exhaust manifold, remove the Heated Oxygen Sensor (HO2S). Refer to Heated Oxygen Sensor Replacement in Engine Controls - 3.4L.

### Installation Procedure

1. If removed, install the Heated Oxygen Sensor (HO2S). Refer to Heated Oxygen Sensor Replacement in Engine Controls - 3.4L.
2. If removed, install the exhaust gas recirculation (EGR) valve pipe.
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Install the exhaust manifold gasket.
5. Install the 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 nuts.

Tighten
Tighten the exhaust manifold nuts to 16 N·m (12 lb ft).

7. Install the exhaust manifold lower heat shield.
8. Install the exhaust manifold upper heat shield.
9. Install the exhaust manifold heat shield bolts.

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

10. Install the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
11. Lower the vehicle.
12. Install the exhaust crossover pipe nuts/studs to the engine right side exhaust manifold. Refer to Exhaust Crossover Installation .
13. Install the exhaust crossover pipe heat shield. Refer to Exhaust Crossover Installation .
14. Lower the vehicle.
15. Connect the Heated Oxygen Sensor (HO2S) electrical connector.
16. Install the EVAP solenoid bracket.
17. Install the spark plug wires to the engine right bank spark plugs.
18. Install the ignition module and the ignition coils with the bracket.
19. Rotate the engine back to the original position. Refer to Rotating the Engine for Service Access .
20. Install the EGR valve to the intake manifold. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls - 3.4L.
21. Install the MAP sensor. Refer to Manifold Absolute Pressure Sensor Replacement Engine Controls - 3.4L.
22. Install the accelerator cable bracket to the throttle body. Refer to Accelerator Control Cable Replacement in Engine Controls - 3.4L.
23. Install the throttle body air inlet duct. Refer to Air Filter Element Replacement in Engine Controls - 3.4L.
24. Install the windshield wiper motor cover. Refer to Wiper Module Cover Replacement in Wipers Washer System.