Montana, Silhouette, Venture 2000-2005

Exhaust Manifold

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Removal & Installation



3.5L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the negative battery cable.
  4.  
  5. Remove the spark plug wires.
  6.  
  7. Remove the spark plugs.
  8.  
  9. For right side exhaust manifold, remove the following:

    EGR pipe from the exhaust manifold
     
    Heated oxygen sensor
     

  10.  
  11. Remove the exhaust manifold heat shield bolts.
  12.  
  13. Remove the exhaust manifold heat shields.
  14.  
  15. Remove the exhaust manifold nuts.
  16.  
  17. Remove the exhaust manifold and gasket.

    Click image to see an enlarged view

    Fig. Showing the RH exhaust manifold mounting position-3.5L engine



    Click image to see an enlarged view

    Fig. Showing the LH exhaust manifold mounting position-3.5L engine

  18.  

To install:

  1. Install the exhaust manifold studs. Tighten the exhaust manifold studs to 13 ft. lbs. (18 Nm).
  2.  
  3. Install the exhaust manifold gasket.
  4.  
  5. Install the exhaust manifold.
  6.  
  7. Install the exhaust manifold nuts. Tighten the exhaust manifold nuts working from the center out to 12 ft. lbs. (16 Nm).
  8.  
  9. Install the right side spark plugs. Tighten the spark plugs to 11 ft. lbs. (15 Nm).
  10.  
  11. Install the spark plug wires onto the spark plugs.
  12.  
  13. Install the lower exhaust manifold heat shield.
  14.  
  15. Install the upper exhaust manifold heat shield.
  16.  
  17. Install the exhaust manifold heat shield bolts. Tighten the exhaust manifold heat shield bolts to 89 inch lbs. (10 Nm).
  18.  
  19. For right exhaust manifold, coat the threads of the heated oxygen sensor with anti-seize compound.
  20.  
  21. Install the heated oxygen sensor. Tighten the heated oxygen sensor to 31 ft. lbs. (42 Nm).
  22.  
  23. Install the spark plug wires.
  24.  
  25. Reconnect the negative battery cable.
  26.  

3.9L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air intake assembly.
  6.  
  7. Remove the upper radiator hose.
  8.  
  9. Disconnect the heater hoses from the heater pipes.
  10.  
  11. Remove the nuts that hold the heater pipes to the throttle body and position the heater pipes aside.
  12.  
  13. Remove the exhaust crossover heat shield.

    Click image to see an enlarged view

    Fig. Remove the heat shield bolts (1) and remove the exhaust crossover heat shield (2)-3.9L engine

  14.  
  15. Remove the exhaust crossover pipe nuts and remove the crossover pipe.

    Click image to see an enlarged view

    Fig. Remove the mounting nuts (1) to remove the exhaust crossover pipe (2)-3.9L engine

  16.  
  17. Remove the exhaust manifold heat shield.
  18.  
  19. Remove the exhaust manifold mounting bolts.
  20.  
  21. Remove the exhaust manifold and gasket.
  22.  

To install:

  1. Position a new exhaust manifold gasket on the cylinder head and install the exhaust manifold.
  2.  
  3. Install the exhaust manifold bolts and tighten to 15 ft. lbs. (20 Nm).
  4.  
  5. Install the exhaust manifold heat shield. Tighten the bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Install the exhaust crossover pipe and tighten the nuts to 15 ft. lbs. (20 Nm).
  8.  
  9. Position the heater pipes back to their original position and connect the heater hoses.
  10.  
  11. Install the nuts holding the heater pipes to the throttle body.
  12.  
  13. Install the exhaust crossover heat shield and tighten the bolts to 89 inch lbs. (10 Nm).
  14.  
  15. Install the upper radiator hose.
  16.  
  17. Install the air intake assembly.
  18.  
  19. Connect the negative battery cable.
  20.  

Right Side
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the air intake assembly.
  6.  
  7. Remove the alternator.
  8.  
  9. Remove the ignition coil.
  10.  
  11. Disconnect the engine wiring harness connector from the heated oxygen sensor (HO2S).
  12.  
  13. Remove the HO2S.
  14.  
  15. Remove the nuts that hold the heater pipes to the throttle body and position the heater pipes aside.
  16.  
  17. Remove the exhaust crossover heat shield.
  18.  
  19. Remove the exhaust crossover pipe nuts and remove the crossover pipe.
  20.  
  21. Remove the catalytic converter.
  22.  
  23. Remove the exhaust manifold heat shield.
  24.  
  25. Remove the exhaust manifold mounting bolts.
  26.  
  27. Remove the exhaust manifold and gasket.
  28.  

To install:

  1. Position a new exhaust manifold gasket on the cylinder head and install the exhaust manifold.
  2.  
  3. Install the exhaust manifold bolts and tighten to 15 ft. lbs. (20 Nm).
  4.  
  5. Install the exhaust manifold heat shield. Tighten the bolts to 89 inch lbs. (10 Nm).
  6.  
  7. Install the catalytic converter.
  8.  
  9. Install the exhaust crossover pipe and tighten the nuts to 15 ft. lbs. (20 Nm).
  10.  
  11. Install the exhaust crossover heat shield and tighten the bolts to 89 inch lbs. (10 Nm).
  12.  
  13. Position the heater pipes back to their original position and connect the heater hoses.
  14.  
  15. Install the nuts holding the heater pipes to the throttle body.
  16.  
  17. Install the HO2S and tighten to 31 ft. lbs. (42 Nm). Connect the HO2S electrical connector.
  18.  
  19. Install the ignition coil.
  20.  
  21. Install the alternator.
  22.  
  23. Install the air intake assembly.
  24.  
  25. Connect the negative battery.
  26.  

Left Side (Front) Manifold

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.

Click image to see an enlarged view

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

  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. Left exhaust manifold 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.
  10.  

Right Side (Rear)

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.

Click image to see an enlarged view

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

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Windshield wiper motor cover
     
    Fuel injector sight shield
     
    Throttle body air inlet duct
     
    Accelerator cable bracket from the throttle body
     

  4.  
  5. Rotate the engine for access.

    Manifold Absolute Pressure (MAP) sensor
     
    Exhaust Gas Recirculation (EGR) valve
     
    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

     

  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
     
    Windshield wiper motor cover
     
    Fuel injector sight shield
     
    Negative battery cable
     

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

 
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