Aztek, Rendezvous 2001-2005

Exhaust Manifold

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Removal & Installation



3.4L Engine

The exhaust manifolds are conventional iron castings. The left and right manifolds are connected by a crossover pipe. Use care with the exhaust manifold-to-cylinder head fasteners. The cylinder heads are aluminum.

Left (Front) Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Throttle body air inlet duct
     
    Right side engine mount strut bracket
     
    Radiator inlet hose
     
    Thermostat bypass pipe
     
    Exhaust crossover pipe heat shield
     
    Exhaust crossover pipe
     
    Left side exhaust manifold heat shield
     
    Left side exhaust manifold and discard the gasket

    Click image to see an enlarged view

    Fig. Exploded view of the exhaust crossover and heat shield mounting

     

  6.  

To install:

  1. Clean the gasket mounting surfaces.
  2.  
  3. Install or connect the following:

    Left side exhaust manifold gasket
     
    Left side exhaust manifold. Torque the nuts to 12 ft. lbs. (16 Nm).
     
    Left side exhaust manifold heat shield. Torque the fasteners to 89 inch lbs. (10 Nm).
     
    Exhaust crossover pipe. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Exhaust crossover pipe heat shield. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Thermostat bypass pipe. Torque the fastener to 18 ft. lbs. (25 Nm).
     
    Radiator inlet hose to the engine
     
    Right side engine mount strut bracket. Torque the bolts to 35 ft. lbs. (48 Nm).
     
    Throttle body air inlet duct
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system
  6.  
  7. Start the vehicle and check for leaks, repair if necessary.
  8.  
  9. Check and top off all fluid levels if necessary.

    Click image to see an enlarged view

    Fig. Left exhaust manifold mounting-3.4L and 3.5L Engines

  10.  

Left Side (Front)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Throttle body air inlet duct
     
    Right side engine mount strut bracket
     
    Radiator inlet hose
     
    Thermostat bypass pipe
     
    Exhaust crossover pipe heat shield
     
    Exhaust crossover pipe
     
    Left side exhaust manifold heat shield
     
    Left side exhaust manifold and discard the gasket

    Click image to see an enlarged view

    Fig. Exploded view of the exhaust crossover and heat shield mounting

     

  6.  

To install:

  1. Clean the gasket mounting surfaces.
  2.  
  3. Install or connect the following:

    Left side exhaust manifold gasket
     
    Left side exhaust manifold. Torque the nuts to 12 ft. lbs. (16 Nm).
     
    Left side exhaust manifold heat shield. Torque the fasteners to 89 inch lbs. (10 Nm).
     
    Exhaust crossover pipe. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Exhaust crossover pipe heat shield. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Thermostat bypass pipe. Torque the fastener to 18 ft. lbs. (25 Nm).
     
    Radiator inlet hose to the engine
     
    Right side engine mount strut bracket. Torque the bolts to 35 ft. lbs. (48 Nm).
     
    Throttle body air inlet duct
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system
  6.  
  7. Start the vehicle and check for leaks, repair if necessary.
  8.  
  9. Check and top off all fluid levels if necessary.

    Click image to see an enlarged view

    Fig. Left exhaust manifold mounting-3.4L engine

  10.  

Right (Rear) Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Throttle body air inlet duct
     
    Accelerator cable bracket from the throttle body
     
    Manifold Absolute Pressure (MAP) sensor
     
    Exhaust Gas Recirculation (EGR) valve
     

  4.  
  5. Rotate the engine for access.

    Ignition module
     
    Ignition coils and bracket
     
    Spark plug wires from the right bank spark plugs
     
    Heated Oxygen (HO 2 ) sensor electrical connector
     
    EVAP solenoid bracket
     
    Fasteners for the crossover pipe from the right bank exhaust manifold
     
    Catalytic converter
     
    Right side exhaust manifold heat shields
     
    Right side exhaust manifold
     
    Right side exhaust manifold gasket
     
    EGR valve pipe, if replacing the exhaust manifold
     
    HO 2 sensor, if replacing the exhaust manifold

    Click image to see an enlarged view

    Fig. Exploded view of the right exhaust manifold mounting-3.4L and 3.5L Engines

     

  6.  

To install:

  1. Clean the gasket mounting surfaces.
  2.  
  3. Install or connect the following:

    HO 2 sensor, if removed. Torque the sensor to 31 ft. lbs. (42 Nm).
     
    EGR valve pipe, if removed. Torque the fastener to 18 ft. lbs. (25 Nm).
     
    Exhaust manifold gasket
     
    Exhaust manifold. Torque the bolts to 12 ft. lbs. (16 Nm).
     
    Both manifold heat shields. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Catalytic converter. Torque the fasteners to 25 ft. lbs. (34 Nm).
     
    Exhaust manifold crossover pipe. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    HO 2 sensor electrical connector
     
    EVAP solenoid bracket
     
    Plug wires to the spark plugs
     
    Ignition module
     
    Ignition coils and bracket. Torque the fastener to 18 ft. lbs. (25 Nm).
     

  4.  
  5. Rotate the engine to its original position.
  6.  
  7. Install or connect the following:

    EGR valve to the intake manifold
     
    MAP sensor
     
    Accelerator cable bracket to the throttle body. Torque the bolt to 89 inch lbs. (10 Nm).
     
    Throttle body air inlet duct
     
    Negative battery cable
     

  8.  
  9. Start the engine and inspect for leaks, repair if necessary.
  10.  

Right Side (Rear)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Throttle body air inlet duct
     
    Accelerator cable bracket from the throttle body
     
    Manifold Absolute Pressure (MAP) sensor
     
    Exhaust Gas Recirculation (EGR) valve
     

  4.  
  5. Rotate the engine for access.

    Ignition module
     
    Ignition coils and bracket
     
    Spark plug wires from the right bank spark plugs
     
    Heated Oxygen (HO 2 ) sensor electrical connector
     
    EVAP solenoid bracket
     
    Fasteners for the crossover pipe from the right bank exhaust manifold
     
    Catalytic converter
     
    Right side exhaust manifold heat shields
     
    Right side exhaust manifold
     
    Right side exhaust manifold gasket
     
    EGR valve pipe, if replacing the exhaust manifold
     
    HO 2 sensor, if replacing the exhaust manifold

    Click image to see an enlarged view

    Fig. Exploded view of the right exhaust manifold mounting-3.4L engine

     

  6.  

To install:

  1. Clean the gasket mounting surfaces.
  2.  
  3. Install or connect the following:

    HO 2 sensor, if removed. Torque the sensor to 31 ft. lbs. (42 Nm).
     
    EGR valve pipe, if removed. Torque the fastener to 18 ft. lbs. (25 Nm).
     
    Exhaust manifold gasket
     
    Exhaust manifold. Torque the bolts to 12 ft. lbs. (16 Nm).
     
    Both manifold heat shields. Torque the bolts to 89 inch lbs. (10 Nm).
     
    Catalytic converter. Torque the fasteners to 25 ft. lbs. (34 Nm).
     
    Exhaust manifold crossover pipe. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    HO 2 sensor electrical connector
     
    EVAP solenoid bracket
     
    Plug wires to the spark plugs
     
    Ignition module
     
    Ignition coils and bracket. Torque the fastener to 18 ft. lbs. (25 Nm).
     

  4.  
  5. Rotate the engine to its original position.
  6.  
  7. Install or connect the following:

    EGR valve to the intake manifold
     
    MAP sensor
     
    Accelerator cable bracket to the throttle body. Torque the bolt to 89 inch lbs. (10 Nm).
     
    Throttle body air inlet duct
     
    Negative battery cable
     

  8.  
  9. Start the engine and inspect for leaks, repair if necessary.
  10.  

3.6L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the left torque strut bracket bolts.
  4.  
  5. Remove the left torque strut bracket.
  6.  
  7. Remove the left exhaust manifold heat shield bolts.
  8.  
  9. Remove the left exhaust manifold heat shield.
  10.  
  11. Remove the engine coolant temperature (ECT) sensor.
  12.  
  13. Disconnect the exhaust pipes from the manifold.
  14.  
  15. Remove the exhaust manifold bolts from the left cylinder head.
  16.  
  17. Remove the left exhaust manifold.
  18.  
  19. Remove and discard the exhaust manifold gasket.
  20.  

To install:

  1. Position a NEW exhaust manifold gasket onto the left exhaust manifold.
  2.  
  3. Install the exhaust manifold bolts into the left exhaust manifold.
  4.  
  5. Place the left exhaust manifold, exhaust manifold gasket and bolts as an assembly in position on the left cylinder head.
  6.  
  7. Install the exhaust manifold bolts into the left cylinder head. Tighten the exhaust manifold bolts to 18 ft. lbs. (25 Nm).
  8.  
  9. Connect the exhaust pipes.
  10.  
  11. Install the engine coolant temperature (ECT) sensor. Tighten the ECT sensor to 16 ft. lbs. (22 Nm).
  12.  
  13. Install NEW O-rings on the crankshaft position sensor.
  14.  
  15. Place the left exhaust manifold heat shield in position.
  16.  
  17. Install the exhaust manifold heat shield bolts. Tighten the exhaust manifold heat shield bolts to 89 inch lbs. (10 Nm).
  18.  
  19. Install the left torque strut bracket.
  20.  
  21. Install the left torque strut bracket bolts. Tighten the left torque strut bracket bolts to 37 ft. lbs. (50 Nm).
  22.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the right exhaust manifold heat shield bolts.
  4.  
  5. Remove the right exhaust manifold heat shield.
  6.  
  7. Remove the exhaust manifold bolts from the right cylinder head.
  8.  
  9. Remove the right exhaust manifold.
  10.  
  11. Remove and discard the exhaust manifold gasket.
  12.  
  13. Remove the block heater cartridge, if equipped.
  14.  
  15. Remove the right knock sensor bolt.
  16.  
  17. Remove the right knock sensor.
  18.  
  19. Remove the crankshaft position sensor bolt.
  20.  
  21. Remove the crankshaft position sensor.
  22.  
  23. Remove and discard the crankshaft position sensor O-ring, if damaged.
  24.  

To install

  1. Install a NEW O-ring on the crankshaft position sensor, if damaged.
  2.  
  3. Position the crankshaft position sensor into the cylinder block.
  4.  
  5. Install the crankshaft position sensor bolt. Tighten the crankshaft position sensor bolt to 89 inch lbs. (10 Nm).
  6.  
  7. Position the right knock sensor to the cylinder block as shown.

    Click image to see an enlarged view

    Fig. Proper knock sensor installation-3.6L engine

  8.  
  9. Install the knock sensor bolt. Tighten the knock sensor bolt to 17 ft. lbs. (23 Nm). Ensure proper knock sensor orientation.
  10.  
  11. Install the block heater cartridge, if equipped.
  12.  
  13. Position a NEW exhaust manifold gasket onto the right exhaust manifold.
  14.  
  15. Install the exhaust manifold bolts into the right exhaust manifold.
  16.  
  17. Place the right exhaust manifold, exhaust manifold gasket and bolts as an assembly in position on the right cylinder head.
  18.  
  19. Connect the exhaust pipes.
  20.  
  21. Install the exhaust manifold bolts into the right cylinder head. Tighten the exhaust manifold bolts to 18 ft. lbs. (25 Nm).
  22.  
  23. Place the right exhaust manifold heat shield in position.
  24.  
  25. Install the exhaust manifold heat shield bolts. Tighten the exhaust manifold heat shield bolts to 89 inch lbs. (10 Nm).
  26.  

 
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