G6 2005-2007

Exhaust Manifold

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Removal & Installation



2.4L Engines
  1. Remove the exhaust manifold heat shield.
  2.  
  3. Remove the block heater, if equipped.
  4.  
  5. Remove the oxygen sensor.
  6.  
  7. Remove the exhaust manifold.

    Click image to see an enlarged view

    Fig. Exhaust manifold tightening sequence-2.4L engine

  8.  

To install:

  1. Clean the gasket mating surface and install a new exhaust manifold gasket.
  2.  
  3. Install new exhaust manifold studs and tighten to 89 inch lbs. (10 Nm).
  4.  
  5. Install the exhaust manifold and finger tighten the bolts.
  6.  
  7. Tighten the bolts in sequence to 10 ft. lbs. (14 Nm).
  8.  
  9. Coat the threads of the oxygen sensor with anti-seize.
  10.  
  11. Install the oxygen sensor and tighten to 31 ft. lbs. (42 Nm).
  12.  
  13. Install the exhaust manifold heat shield.
  14.  

3.5L Engine
Left Side
  1. Remove the air intake duct.
  2.  
  3. Remove the Connector Position Assurance (CPA) retainer.
  4.  
  5. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
  6.  
  7. Remove the HO2S using an approved tool.
  8.  
  9. Remove the exhaust manifold heat shield bolts and shield.
  10.  
  11. Remove the upper exhaust manifold nuts.
  12.  
  13. Raise and support the vehicle.
  14.  
  15. Remove the front catalytic converter.
  16.  
  17. Remove the lower exhaust manifold nuts.
  18.  
  19. Remove the exhaust manifold.
  20.  
  21. Remove and discard the exhaust manifold gasket.
  22.  

To install:

Click image to see an enlarged view

Fig. Left exhaust manifold-3.5L engine

  1. Install a new exhaust manifold gasket onto the cylinder head studs.
  2.  
  3. Install the exhaust manifold.
  4.  
  5. Install the exhaust manifold nuts and tighten to 12 ft. lbs. (16 Nm).
  6.  
  7. Install new gasket and converter nuts, tighten to 23 ft. lbs. (31 Nm).
  8.  

Right Side
  1. Remove the generator.
  2.  
  3. Remove the Connector Position Assurance (CPA) retainer.
  4.  
  5. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector.
    WARNING
    The HO2S uses a permanently attached pigtail and connector. This pigtail should not be removed from the sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.

  6.  
  7. Remove the HO2S using approved tool.
  8.  
  9. Remove the exhaust gas recirculation (EGR) pipe bolts (3). Reposition the pipe slightly.
  10.  
  11. Remove the upper exhaust manifold nuts.
  12.  
  13. Remove the rear catalytic converter.
  14.  
  15. Remove the lower exhaust manifold nuts.
  16.  
  17. Remove the exhaust manifold.
  18.  
  19. Remove and discard the exhaust manifold gasket.
  20.  

To install:

Click image to see an enlarged view

Fig. Right exhaust manifold-3.5L engine

  1. Install a new exhaust manifold gasket onto the cylinder head studs.
  2.  
  3. Install the exhaust manifold.
  4.  
  5. Install the exhaust manifold nuts and tighten to 12 ft. lbs.(16 Nm).
  6.  
  7. Install the rear catalytic converter.
  8.  
  9. Install new gasket and converter nuts, tighten to 23 ft. lbs. (31 Nm).
  10.  

3.6L Engine
Left Side
  1. Remove the exhaust manifold heat shield.
  2.  
  3. Remove the oil level indicator.
  4.  
  5. Remove the catalytic converter to exhaust manifold nuts.
  6.  
  7. Remove the exhaust manifold bolts.
  8.  
  9. Remove the exhaust manifold and gasket. Discard the gasket.

    Click image to see an enlarged view

    Fig. Left exhaust manifold-3.6L engine

  10.  

To install:

  1. Install one exhaust manifold bolt to the exhaust manifold.
  2.  
  3. Install the new exhaust manifold gasket onto the cylinder head and bolt.
  4.  
  5. Install the exhaust manifold (with gasket) to the catalytic converter and the cylinder head.
  6.  
  7. Install the remaining exhaust manifold bolts and tighten to 15 ft. lbs. (20 Nm).
  8.  
  9. Install the catalytic converter to exhaust manifold nuts and tighten to 33 ft. lbs. (45 Nm).
  10.  
  11. Install the oil level indicator with new tube seal, and tighten mounting bolt to 89 inch. lbs. (10 Nm).
  12.  
  13. Install the exhaust manifold heat shield.
  14.  

Right Side
  1. Raise and safely support the vehicle.
  2.  
  3. Remove the catalytic converter.
  4.  
  5. Remove the exhaust manifold lower bolts.
  6.  
  7. Lower the vehicle half way.
  8.  
  9. Remove the exhaust manifold upper bolts.
  10.  
  11. Remove the exhaust manifold.
  12.  
  13. Remove and discard the exhaust manifold gasket.
  14.  

To install:

  1. Install one upper exhaust manifold bolt to the exhaust manifold.
  2.  
  3. Place the new exhaust manifold gasket onto the bolt.
  4.  
  5. Position and install the exhaust manifold (with gasket) to the cylinder head.
  6.  
  7. Loosely install the remaining upper exhaust manifold bolts.
  8.  
  9. Raise and support the vehicle.
  10.  
  11. Loosely install the lower exhaust manifold bolts.

    Click image to see an enlarged view

    Fig. Right exhaust manifold-3.6L engine

  12.  
  13. Tighten the exhaust manifold bolts 15 ft. lbs. (20 Nm).
  14.  
  15. Install the catalytic converter and tighten the mounting nuts to 33 Ft. Lbs. (45 Nm).
  16.  

3.9L Engine
Left Side
  1. Remove the air cleaner outlet duct.
  2.  
  3. Remove the Connector Position Assurance (CPA) retainer.
  4.  
  5. Disconnect the heated oxygen sensor (HO2S) electrical connector.
  6.  
  7. Remove the HO2S clip from the oil level indicator tube bracket.
    WARNING
    The HO2S uses a permanently attached pigtail and connector. This pigtail should not be removed from the sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.

  8.  
  9. Remove the HO2S using approved tool.
  10.  
  11. Remove the exhaust manifold heat shield bolts.
  12.  
  13. Remove the exhaust manifold heat shield.
  14.  
  15. Remove the upper exhaust manifold bolts.
  16.  
  17. Raise and support the vehicle.
  18.  
  19. Remove the left catalytic converter.
  20.  
  21. Remove the lower exhaust manifold bolts.
  22.  
  23. Remove the exhaust manifold.
  24.  
  25. Remove and discard the exhaust manifold gasket.
  26.  

To install:

Click image to see an enlarged view

Fig. Left exhaust manifold-3.9L engine

  1. Install a NEW exhaust manifold gasket onto the cylinder head studs.
  2.  
  3. Install the exhaust manifold.
  4.  
  5. Install the exhaust manifold bolts and tighten to 15 ft. lbs. (20 Nm).
  6.  
  7. Install the left catalytic converter.
  8.  
  9. Lower the vehicle.
  10.  
  11. Install the exhaust manifold heat shield and mounting bolts, tighten to 89 inch. lbs. (10 Nm).
    NOTE
    Whenever the oxygen sensor is removed, coat the threads with nickel-based anti-seize compound.

  12.  
  13. Install the HO2S using approved tool and tighten to 31 ft. lbs. (42 Nm).
  14.  
  15. Connect the HO2S electrical connector.
  16.  
  17. Install the CPA retainer.
  18.  
  19. Install the HO2S clip to the oil level indicator tube bracket.
  20.  
  21. Install the air cleaner outlet duct.
  22.  

Right (6-Speed M/T)
  1. Remove the generator.
  2.  
  3. Remove the connector position assurance (CPA) retainer (5).
  4.  
  5. Disconnect the engine harness electrical connector (4) heated oxygen sensor (HO2S) electrical connector (4).
  6.  
  7. Remove the HO2S clip (3) from the oil level indicator tube bracket.
    WARNING
    The HO2S uses a permanently attached pigtail and connector. This pigtail should not be removed from the sensor. Damage or removal of the pigtail or connector will affect proper operation of the sensor.

  8.  
  9. Remove the HO2S using approved tool.
  10.  
  11. Remove the exhaust manifold shield bolts.
  12.  
  13. Remove the exhaust manifold shield.
  14.  
  15. Remove the upper exhaust manifold bolts.
  16.  
  17. Remove the right catalytic converter.
  18.  
  19. Remove the lower exhaust manifold bolt.
  20.  
  21. Remove the exhaust manifold.
  22.  
  23. Remove and discard the exhaust manifold gasket.
  24.  

To install:

Click image to see an enlarged view

Fig. Right exhaust manifold-3.9L engine

  1. Install a new exhaust manifold gasket onto the cylinder head studs.
  2.  
  3. Install the exhaust manifold.
  4.  
  5. Install the exhaust manifold bolts and tighten to 15 ft. lbs. (20 Nm).
  6.  
  7. Install the right catalytic converter.
  8.  
  9. Install the exhaust manifold shield.
  10.  
  11. Install the exhaust manifold shield bolts and tighten to 89 inch. lbs. (10 Nm).
    NOTE
    Whenever the oxygen sensor is removed, coat the threads with nickel-based anti-seize compound.

  12.  
  13. Install the HO2S using approved tool and tighten to 31 ft. lbs. (42 Nm).
  14.  
  15. Connect the engine harness electrical connector to the HO2S electrical connector.
  16.  
  17. Install the CPA retainer.
  18.  
  19. Install the HO2S clip to the oil level indicator tube bracket.
  20.  
  21. Install the generator.
  22.  

 
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