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    1999 Ford Taurus 3.0L EFI 6cyl

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    1720 S RIDGEWOOD A
    (386) 427-1210

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    GM Lumina/Grand Prix/Cutlass Supreme/Regal 1988-1996

    Exhaust Manifold

    Print

    REMOVAL & INSTALLATION



    2.2L Engine

    See Figure 1



    Click image to see an enlarged view

    Fig. Fig. 1: Exhaust manifold mounting-2.2L engine

    1. Disconnect the negative battery cable.
    2.  
    3. Detach the wiring harness from the oxygen sensor.
    4.  
    5. Remove the serpentine drive belt.
    6.  
    7. Remove the alternator.
    8.  
    9. Raise and safely support the vehicle.
    10.  
    11. Unfasten the retaining and separate the exhaust pipe from the manifold.
    12.  
    13. Carefully lower the vehicle.
    14.  
    15. Remove the bolt securing the oil fill tube to the engine block, then pull the tube from the engine.
    16.  
    17. If the coolant inlet pipe interferes with removal, disconnect the mounting bracket from the transaxle stud.
    18.  
    19. Unfasten the manifold retaining nuts, then remove the manifold from the cylinder head. Remove and discard the gasket from the mating surfaces.
    20.  

    To install:
    1. Install the manifold to the cylinder head, using a new gasket. Tighten the retaining nuts to 115 inch lbs. (13 Nm).
    2.  
    3. Raise and safely support the vehicle, then attach the exhaust pipe to the manifold. Tighten the retaining nuts to 18 ft. lbs. (25 Nm), then carefully lower the vehicle.
    4.  
    5. Install the alternator and serpentine drive belt.
    6.  
    7. If disconnected, attach the coolant inlet pipe.
    8.  
    9. Lubricate the oil fill tube seal, then install the tube.
    10.  
    11. Attach the wiring harness to the oxygen sensor.
    12.  
    13. Connect the negative battery cable.
    14.  
    15. Start the engine and check for exhaust leaks.
    16.  

    2.3L Engine

    See Figures 2, 3 and 4



    Click image to see an enlarged view

    Fig. Fig. 2: Remove the exhaust manifold heat shields-2.3L engine



    Click image to see an enlarged view

    Fig. Fig. 3: Remove the exhaust manifold brace-to-manifold bolt



    Click image to see an enlarged view

    Fig. Fig. 4: Exhaust manifold tightening sequence-2.3L engine

    1. Disconnect the negative battery cable.
    2.  
    3. Detach the oxygen sensor connector.
    4.  
    5. Remove the upper and lower exhaust manifold heat shields.
    6.  
    7. Unfasten the bolt that attaches the exhaust manifold brace to the manifold.
    8.  
    9. Break loose the manifold to exhaust pipe spring loaded bolts using a 13mm box wrench.
    10.  
    11. Raise the vehicle and support safely.
    12.  

    It is necessary to relieve the spring pressure from 1 bolt prior to removing the second bolt. If the spring pressure is not relieved it will cause the exhaust pipe to twist and bind up the bolt as it is removed.

    1. Remove the manifold to exhaust pipe bolts from the exhaust pipe flange as follows:
      1. Unscrew either bolt clockwise 4 turns.
      2.  
      3. Remove the other bolt.
      4.  
      5. Remove the first bolt.
      6.  

    2.  
    3. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold bolts.
    4.  
    5. Lower the vehicle.
    6.  
    7. Remove the exhaust manifold mounting bolts and remove the manifold.
    8.  

    To install:
    1. The installation is the reverse of the removal procedure.
    2.  
    3. Tighten the mounting bolts in sequence to 27 ft. lbs. (37 Nm). Install the exhaust pipe flange bolts evenly and gradually to avoid binding.
    4.  
    5. Connect the negative battery cable and check for leaks.
    6.  

    2.5L Engine
    1. Disconnect the negative battery cable.
    2.  
    3. Remove the torque strut bolts at the radiator panel and cylinder head.
    4.  
    5. Disconnect the oxygen sensor and remove the oil level indicator tube.
    6.  
    7. Raise and safely support the vehicle.
    8.  
    9. Remove the exhaust pipe from the manifold and lower the vehicle.
    10.  
    11. Bend the locking tabs away from the bolts and remove the retaining bolts and washers.
    12.  
    13. Remove the exhaust manifold and gasket. Discard the gasket.
    14.  

    To install:
    1. Clean the sealing surfaces of the cylinder head and manifold.
    2.  
    3. Lubricate the bolt threads with anti-seize compound and install the exhaust manifold with a new gasket.
    4.  
    5. Tighten the bolts to the specifications shown in the accompanying figure.
    6.  
    7. Bend the locking tabs against the bolts.
    8.  
    9. Raise and support the vehicle safely.
    10.  
    11. Attach the exhaust pipe to the manifold, then carefully lower the vehicle.
    12.  
    13. Install the oil level indicator tube, oxygen sensor and torque rod bracket at the cylinder head and radiator support.
    14.  
    15. Connect the negative battery cable.
    16.  

    2.8L and 1989-93 3.1L Engines

    See Figures 5, 6, 7, 8, 9, 10 and 11



    Click image to see an enlarged view

    Fig. Fig. 5: Unfasten the retaining bolts...



    Click image to see an enlarged view

    Fig. Fig. 6: ... then remove the torque strut mounting bracket



    Click image to see an enlarged view

    Fig. Fig. 7: Remove the heat shield



    Click image to see an enlarged view

    Fig. Fig. 8: Disconnect the exhaust crossover pipe



    Click image to see an enlarged view

    Fig. Fig. 9: Unfasten the exhaust manifold retaining bolts...



    Click image to see an enlarged view

    Fig. Fig. 10: ... then remove the front manifold from the vehicle



    Click image to see an enlarged view

    Fig. Fig. 11: Remove the exhaust manifold gasket and replace with a new one during installation

    LEFT SIDE
    1. Disconnect the negative battery cable.
    2.  
    3. Remove the coolant recovery bottle.
    4.  
    5. Relieve the accessory drive belt tension, then remove the belt.
    6.  
    7. If equipped, remove the A/C compressor mounting bolts and support the compressor aside. DO NOT disconnect the refrigerant lines.
    8.  
    9. Remove the right side engine torque strut. Unfasten the bolts retaining the A/C compressor (if equipped) and torque strut mounting bracket, then remove the bracket.
    10.  
    11. Remove the heat shield and crossover pipe at the manifold.
    12.  
    13. Unfasten the exhaust manifold mounting bolts and remove the manifold. Remove and discard the gasket.
    14.  

    To install:
    1. Clean the gasket mounting surfaces.
    2.  
    3. Install the exhaust manifold to the engine, loosely install the mounting bolts.
    4.  
    5. Install the exhaust crossover pipe. Tighten the exhaust manifold bolts to 18 ft. lbs. (25 Nm)
    6.  
    7. Attach the heat shield. Install the A/C compressor and torque strut mounting bracket.
    8.  
    9. Install the torque strut. Mount the A/C compressor.
    10.  
    11. Install the accessory drive belt.
    12.  
    13. Install the coolant recovery bottle.
    14.  
    15. Connect the negative battery cable.
    16.  

    RIGHT SIDE
    1. Disconnect the negative battery cable.
    2.  
    3. Raise and safely support the vehicle.
    4.  
    5. Remove the exhaust pipe at the crossover. Carefully lower the vehicle.
    6.  
    7. Remove the coolant recovery bottle and remove the engine torque struts.
    8.  
    9. Pull the engine forward and securely support it.
    10.  
    11. Remove the air cleaner, breather, mass air flow sensor and heat shield.
    12.  
    13. Remove the crossover at the manifold. Disconnect the accelerator and TV cables.
    14.  
    15. Unfasten the manifold mounting bolts, then remove the manifold. Remove and discard the gasket. Clean the manifold mounting surfaces.
    16.  

    To install:
    1. Install the exhaust manifold, loosely install the mounting bolts.
    2.  
    3. Attach the crossover at the manifold. Tighten the manifold mounting bolts to 18 ft. lbs. (25 Nm).
    4.  
    5. Connect the accelerator and TV cables.
    6.  
    7. Attach the air cleaner, breather and mass air flow sensor.
    8.  
    9. Remove the engine support and allow the engine to roll back into position.
    10.  
    11. Install the coolant recovery bottle and the engine torque struts.
    12.  
    13. Raise and safely support the vehicle. Install the exhaust pipe to the crossover.
    14.  
    15. Carefully lower the vehicle.
    16.  
    17. Connect the negative battery cable.
    18.  

    1994-96 3.1L Engines
    LEFT SIDE (FRONT)
    1. Disconnect the negative battery cable.
    2.  
    3. Remove the air cleaner and duct assembly.
    4.  
    5. Properly drain the engine cooling system into a suitable container.
    6.  
    7. Remove the engine mount strut assemblies from the engine.
    8.  
    9. Rotate the engine forward, as outlined earlier in this section.
    10.  
    11. Remove the coolant recovery reservoir.
    12.  
    13. Remove the serpentine drive belt.
    14.  
    15. Disconnect the upper and lower radiator hoses from the engine.
    16.  
    17. Detach the tie straps from the heater outlet pipe and the ignition wiring harness.
    18.  
    19. Disconnect the automatic transaxle vacuum module pipe assembly.
    20.  
    21. Remove the heater pipe from the heater core-to-water pump assembly.
    22.  
    23. Remove the exhaust crossover shield and pipe assemblies.
    24.  
    25. Remove the engine mount strut and the A/C compressor bracket, if equipped.
    26.  
    27. Remove the heat shield retaining bolts/screws, then remove the shield.
    28.  
    29. Unfasten the retaining nuts, then remove the front exhaust manifold assembly. Remove and discard the gasket.
    30.  
    31. Thoroughly clean all the gasket mating surfaces.
    32.  

    To install:
    1. Position a new gasket, then install the exhaust manifold and secure with the retaining nuts. Tighten the nuts to 11 ft. lbs. (15 Nm).
    2.  
    3. Install the heat shield and the retaining bolts/screws. Tighten to 89 inch lbs. (10 Nm).
    4.  
    5. Install the engine mount strut and the A/C mounting bracket, if equipped.
    6.  
    7. Install the exhaust crossover pipe and shield assemblies.
    8.  
    9. Fasten the heater pip to the heater core-to-water pump assembly.
    10.  
    11. Connect the automatic transaxle vacuum module pipe assembly.
    12.  
    13. Secure the tie straps around the heater outlet pipe and ignition wiring harness assembly.
    14.  
    15. Attach the upper and lower radiator hoses.
    16.  
    17. Install the serpentine drive belt.
    18.  
    19. Install the coolant recovery reservoir.
    20.  
    21. Rotate the engine assembly, as outlined earlier in this section.
    22.  
    23. Attach the engine mount strut assemblies at the engine assembly.
    24.  
    25. Refill the engine cooling system with the proper type and amount of coolant, then add two engine coolant sealant pellets, 3634621 or equivalent.
    26.  
    27. Install the air cleaner and duct assembly.
    28.  
    29. Connect the negative battery cable, then bleed the cooling system. Start the engine and check for proper operation.
    30.  

    RIGHT SIDE (REAR)
    1. Properly drain the engine coolant into a suitable container.
    2.  
    3. Remove the air cleaner and duct assembly.
    4.  
    5. Disconnect the negative battery cable.
    6.  
    7. Remove the engine mount strut assemblies at the engine assembly.
    8.  
    9. Disconnect the upper radiator hose from the engine.
    10.  
    11. Detach the tie straps from the heater outlet pipe and the ignition wiring harness.
    12.  
    13. Disconnect the automatic transaxle vacuum modulator pipe.
    14.  
    15. Remove the heater pipe from the heater core-to-water pump assembly.
    16.  
    17. Remove the exhaust crossover heat shield and pipe assemblies.
    18.  
    19. Detach the oxygen sensor connector.
    20.  
    21. Rotate the engine assembly, as outlined earlier in this section.
    22.  
    23. Raise and safely support the vehicle.
    24.  
    25. Unfasten the rear drivetrain the front suspension frame bolts/screws. Carefully lower the drivetrain and front suspension frame assembly.
    26.  
    27. Disconnect the exhaust pipe assembly.
    28.  
    29. Detach the EGR tube from the rear exhaust manifold assembly.
    30.  
    31. Remove the oxygen sensor.
    32.  
    33. Remove the automatic transaxle fluid filler tube and position aside.
    34.  
    35. Remove the retaining bolts/screws, then remove the upper and lower heat shields.
    36.  
    37. Unfasten the retaining nuts, then remove the manifold assembly and gasket. Discard the gasket.
    38.  
    39. Thoroughly clean the gasket mating surfaces.
    40.  

    To install:
    1. Install a new gasket, then position the exhaust manifold and secure with the retaining nuts. Tighten the nuts to 12 ft. lbs. (16 Nm).
    2.  
    3. Position the upper and lower heat shields, then install the retaining bolts/screws. Tighten to 89 inch lbs. (10 Nm).
    4.  
    5. Install the automatic transaxle fluid filler tube.
    6.  
    7. Install the oxygen sensor.
    8.  
    9. Attach the EGR tube assembly to the rear exhaust manifold.
    10.  
    11. Connect the exhaust pipe assembly.
    12.  
    13. Carefully raise the drivetrain and front suspension frame assembly, then secure with the retaining bolts/screws.
    14.  
    15. Carefully lower the vehicle.
    16.  
    17. Rotate the engine assembly, as outlined earlier in this section.
    18.  
    19. Attach the oxygen sensor electrical connector.
    20.  
    21. Install the exhaust crossover pipe and heat shield assemblies.
    22.  
    23. Attach the heater pipe to the heater core-to-water pump assembly.
    24.  
    25. Install the automatic transaxle vacuum modulator pipe.
    26.  
    27. Secure the tie straps around the heater outlet pipe and ignition wiring harness assembly.
    28.  
    29. Connect the upper radiator hose at the engine assembly.
    30.  
    31. Rotate the engine back to its original position.
    32.  
    33. Fasten the engine mount strut assemblies to the engine.
    34.  
    35. Refill the engine cooling system with the proper type and amount of coolant, then add two engine coolant sealant pellets, 3634621 or equivalent.
    36.  
    37. Install the air cleaner and duct assembly.
    38.  
    39. Connect the negative battery cable, then bleed the cooling system. Start the engine and check for proper operation.
    40.  

    1991-93 3.4L Engine
    LEFT SIDE (FRONT)

    See Figure 12

    Click image to see an enlarged view

    Fig. Fig. 12: Front exhaust manifold mounting-3.4L engine

    1. Remove air cleaner assembly. Disconnect the negative battery cable.
    2.  
    3. Remove exhaust crossover.
    4.  
    5. Remove the engine torque strut bracket at frame and position out of the way.
    6.  
    7. Remove the upper radiator shroud.
    8.  
    9. Remove the cooling fans.
    10.  
    11. For vehicles equipped with a manual transaxle, detach the front hose from air pipe.
    12.  
    13. Unfasten the front exhaust manifold retaining nuts, then remove the manifold. Remove the old gasket and discard.
    14.  

    To install:
    1. Position a new gasket, then install the manifold and heat shields. Install the manifold retaining nuts and tighten to 115 inch lbs. (14 Nm).
    2.  
    3. Install the cooling fans and the radiator shroud.
    4.  
    5. Move the torque strut into position and secure.
    6.  
    7. Install the exhaust crossover.
    8.  
    9. Install the air cleaner assembly.
    10.  
    11. Connect the negative battery cable, then start the engine and check for leaks.
    12.  

    RIGHT SIDE (REAR)-WITH AUTOMATIC TRANSAXLE
    See Figure 13


    Click image to see an enlarged view

    Fig. Fig. 13: Right side exhaust manifold mounting-1993 3.4L engine shown

    1. Disconnect the negative battery cable.
    2.  
    3. Remove right side cam carrier as follows:
      1. Remove intake plenum and right timing belt cover, as outlined in this section.
      2.  
      3. Tag and disconnect the right side spark plug wires.
      4.  
      5. Detach air/oil separator hose at cam carrier cover.
      6.  
      7. Remove cam carrier cover bolts and lift of cover. Remove gasket and O-rings from cover.
      8.  
      9. Remove secondary timing belt by removing secondary timing belt actuator and tensioner assembly and sliding belt from pulleys.
      10.  
      11. Install 6 sections of fuel line hoses under the camshaft and between the lifters. This will hold the lifters in the carrier. For this procedure use 5 / 16 in. (8mm) fuel line hose for exhaust valves and 7 / 32 in. (5.5mm) fuel line hose for the intake valves.
      12.  
      13. Remove exhaust crossover pipe and torque strut.
      14.  
      15. Remove torque strut bracket at engine. Remove front engine lift hook.
      16.  
      17. Unfasten the cam carrier mounting bolts and nuts and remove cam carrier.
      18.  
      19. Remove cam carrier gasket from cylinder head.
      20.  

    4.  
    5. Remove exhaust manifold to crossover pipe nuts.
    6.  
    7. Raise and safely support vehicle.
    8.  
    9. Disconnect the front exhaust pipe from the manifold. Carefully lower vehicle.
    10.  
    11. Detach electrical connector from oxygen sensor.
    12.  
    13. Unfasten the exhaust manifold nuts then remove the heat shield and manifold. Remove and discard the gasket.
    14.  

    To install:
    1. Clean all mating surfaces, then install manifold gasket and heat shields.
    2.  
    3. Install exhaust manifold. Tighten the retaining nuts to 116 inch lbs. (14 Nm).
    4.  
    5. Attach electrical connector to the oxygen sensor.
    6.  
    7. Raise and safely support vehicle.
    8.  
    9. Connect the exhaust pipe to the manifold. Carefully lower the vehicle.
    10.  
    11. Install exhaust crossover pipe.
    12.  
    13. Install right cam carrier as follows:
      1. Install new gasket on cam carrier to cylinder mounting surface.
      2.  
      3. Install cam hold-down tool J-38613 or equivalent, to carrier assembly.
      4.  
      5. Install cam carrier to cylinder head. Install mounting bolts and nuts. Torque bolts and nuts to 18 ft. lbs.
      6.  
      7. Remove lifter hold-down hoses and cam hold-down tool.
      8.  
      9. Install torque strut bracket to engine and install torque strut.
      10.  
      11. Install engine crossover pipe and engine lift hook.
      12.  
      13. Install secondary timing belt and cam carrier cover and gasket.
      14.  
      15. Attach the spark plug wires, as tagged during removal, then install the cover.
      16.  

    14.  
    15. Connect negative battery cable.
    16.  

    RIGHT SIDE (REAR)-WITH MANUAL TRANSAXLE
    See Figure 14
    1. Disconnect the negative battery cable.
    2.  
    3. Remove the exhaust crossover pipe.
    4.  
    5. Raise and safely support vehicle.
    6.  
    7. Remove the exhaust pipe and converter assembly.
    8.  
    9. Detach oxygen sensor connector.
    10.  
    11. Remove EGR pipe at manifold and manifold heat shields.
    12.  
    13. Unfasten the exhaust manifold retaining nuts, then remove the manifold and gasket.
    14.  

    To install:
    1. Clean all gasket mating surfaces.
    2.  
    3. Position a new gasket, then install the manifold. Tighten retaining nuts to 116 inch lbs. (14 Nm).
    4.  
    5. Install EGR pipe and heat shields to exhaust manifold.
    6.  
    7. Attach the electrical connector to the oxygen sensor.
    8.  
    9. Connect exhaust pipe to manifold, then carefully lower the vehicle.
    10.  
    11. Install exhaust crossover
    12.  
    13. Connect the negative battery cable.
    14.  

    1994-96 3.4L Engine
    LEFT SIDE (FRONT)
    1. Disconnect the negative battery cable.
    2.  
    3. Remove the air cleaner assembly.
    4.  
    5. Disconnect the exhaust crossover.
    6.  
    7. Remove the cooling fans.
    8.  
    9. Unfasten the exhaust manifold retaining nuts, then remove the exhaust manifold and heat shields.
    10.  
    11. Remove and discard the gasket. Thoroughly clean all gasket mating surfaces.
    12.  

    To install:
    1. Position a new gasket, then position the exhaust manifold and heat shield. Tighten the retaining nuts to 18 ft. lbs. (25 Nm).
    2.  
    3. Install the cooling fans.
    4.  
    5. Attach the exhaust crossover.
    6.  
    7. Install the air cleaner assembly.
    8.  
    9. Connect the negative battery cable, then start the engine and check for leaks.
    10.  

    RIGHT SIDE (REAR)
    See Figure 14


    Click image to see an enlarged view

    Fig. Fig. 14: Right side (rear) manifold mounting-1995 3.4L engine shown

    1. Disconnect the negative battery cable.
    2.  
    3. Remove the air cleaner assembly.
    4.  
    5. Disconnect the exhaust crossover.
    6.  
    7. Detach the EGR tube from the exhaust manifold.
    8.  
    9. Raise and safely support the vehicle.
    10.  
    11. Remove the front exhaust pipe and converter assembly.
    12.  
    13. Remove the oxygen sensor.
    14.  
    15. Disconnect the exhaust pipe from the heat shield.
    16.  
    17. Remove the rear alternator brace.
    18.  
    19. Remove the transaxle dipstick tube.
    20.  
    21. Detach the intermediate shaft from the steering gear.
    22.  
    23. Remove the exhaust manifold nuts.
    24.  
    25. Install a suitable jacking fixture to support the rear cradle. Unfasten the rear cradle bolts, then carefully lower the cradle.
    26.  
    27. Remove the steering gear heat shield.
    28.  
    29. Remove the exhaust manifold and heat shield. Remove and discard the gasket.
    30.  
    31. Thoroughly clean all gasket mating surfaces.
    32.  

    To install:
    1. Position a new gasket, then install the exhaust manifold and heat shield. Install the exhaust manifold retaining nuts and tighten to 115 inch lbs. (13 Nm).
    2.  
    3. Install the steering gear heat shield.
    4.  
    5. Carefully raise the cradle, then install the rear cradle retaining bolts. Carefully remove the jacking fixture.
    6.  
    7. Attach the intermediate shaft to the steering gear.
    8.  
    9. Install the transaxle dipstick tube.
    10.  
    11. Fasten the rear alternator brace.
    12.  
    13. Install the exhaust pipe front heat shield.
    14.  
    15. Install the oxygen sensor.
    16.  
    17. Attach the front exhaust pipe and converter assembly.
    18.  
    19. Carefully lower the vehicle.
    20.  
    21. Attach the EGR tube to exhaust manifold.
    22.  
    23. Install the front exhaust crossover pipe.
    24.  
    25. Install the air cleaner and duct assembly.
    26.  
    27. Connect the negative battery cable.
    28.  

    1991-92 3.8L Engine
    LEFT SIDE (FRONT)

    See Figure 15

    1. Disconnect the negative battery cable.
    2.  
    3. Remove the air cleaner assembly and disconnect the spark plug wires.
    4.  
    5. Disconnect the exhaust crossover pipe.
    6.  
    7. Remove the oil level indicator and tube from the manifold.
    8.  
    9. Disconnect the engine lift bracket and the air conditioner compressor support brace.
    10.  
    11. Remove the exhaust manifold.
    12.  

    To install:
    1. Clean the mating surfaces and loosely install the exhaust manifold and retaining bolts.
    2.  
    3. Install the crossover pipe to the manifold and support bracket.
    4.  
    5. Tighten the manifold retaining bolts to 41 ft. lbs. (55 Nm).
    6.  
    7. Install the engine lift bracket and the air conditioner compressor support brace.
    8.  
    9. Install the oil level indicator and tube to the manifold.
    10.  
    11. Install the air cleaner assembly and connect the spark plug wires.
    12.  
    13. Connect the negative battery cable.
    14.  

    RIGHT SIDE (REAR)
    See Figure 16
    1. Disconnect the negative battery cable.
    2.  
    3. Remove the air cleaner assembly and tag and disconnect the spark plug wires.
    4.  
    5. Disconnect the exhaust crossover pipe.
    6.  
    7. Remove the oil level indicator and tube from the manifold.
    8.  
    9. Detach the oxygen sensor electrical connector.
    10.  
    11. Disconnect the engine torque strut and bolt from the engine.
    12.  
    13. Remove the engine lift bracket from the engine.
    14.  
    15. Tag and disconnect the spark plugs from the right side rear bank.
    16.  
    17. Raise and support the vehicle safely.
    18.  
    19. Remove the front exhaust pipe and the converter from the vehicle.
    20.  
    21. Remove the right rear engine mount to frame nuts and lower the engine.
    22.  
    23. Use a floor jack to carefully raise and support safely the right rear corner of the engine for access.
    24.  
    25. Remove the exhaust manifold retaining bolts and remove the exhaust manifold.
    26.  

    To install:
    1. Clean the mating surfaces and loosely install the exhaust manifold and retaining bolts.
    2.  
    3. Install the crossover pipe to the manifold and support bracket.
    4.  
    5. Tighten the manifold retaining bolts to 41 ft. lbs. (55 Nm).
    6.  
    7. Carefully lower the engine and remove the floor jack.
    8.  
    9. Raise and support the vehicle safely.
    10.  
    11. Install the front exhaust pipe and the converter.
    12.  
    13. Install the right rear engine mount to frame nuts and lower the engine.
    14.  
    15. Tighten the crossover bolts.
    16.  
    17. Install the spark plugs to the right side rear bank.
    18.  
    19. Install the engine lift bracket to the engine.
    20.  
    21. Connect the oxygen sensor electrical connector.
    22.  
    23. Connect the engine torque strut and bolt to the engine and tighten to 41 ft. lbs. (55 Nm).
    24.  
    25. Install the oil level indicator and tube to the manifold.
    26.  
    27. Install the air cleaner assembly and connect the spark plug wires, as tagged during removal.
    28.  
    29. Connect the negative battery cable.
    30.  

    1993-96 3.8L Engine
    LEFT SIDE (FRONT)

    See Figure 15

    Click image to see an enlarged view

    Fig. Fig. 15: Front exhaust manifold removal-1995 3.8L engine shown, others similar

    1. Disconnect the negative battery cable.
    2.  
    3. Remove the exhaust manifold.
    4.  
    5. Remove the engine torque strut.
    6.  
    7. Remove the right side engine cooling fan.
    8.  
    9. Detach the front-to-rear exhaust manifold connection and heat shield.
    10.  
    11. Properly drain the cooling system into a suitable container.
    12.  
    13. Detach the upper radiator hose from the intake manifold.
    14.  
    15. Remove the fuel rail cover.
    16.  
    17. Detach the EGR adapter from the upper intake manifold pipe. Include the EGR cover and pipe retaining bolt.
    18.  
    19. Remove the EGR valve and adapter assembly, including the pipe at the manifold.
    20.  
    21. Remove the left engine lift hook.
    22.  
    23. Remove the engine torque strut bracket from the cylinder head.
    24.  
    25. Remove the oil level indicator tube from the exhaust manifold.
    26.  
    27. Tag and disconnect the spark plug wires from the plugs and rocker arm cover.
    28.  
    29. If equipped, remove the A/C compressor support brace from the exhaust manifold stud.
    30.  
    31. Remove the spark plugs.
    32.  
    33. Unfasten the exhaust manifold bolts, then remove the manifold. Remove and discard the gasket.
    34.  
    35. Thoroughly clean all gasket mating surfaces.
    36.  

    To install:
    1. Position a new gasket, then install the exhaust manifold. Tighten the retaining bolts/studs to 38 ft. lbs. (52 Nm).
    2.  
    3. Install the spark plugs.
    4.  
    5. If equipped, attach the A/C compressor bracket to the exhaust manifold stud.
    6.  
    7. Attach the spark plug wires to the rocker arm cover and plugs.
    8.  
    9. Install the oil level indicator tube assembly.
    10.  
    11. Fasten the engine torque strut bracket to the cylinder head.
    12.  
    13. Install the engine lift hook.
    14.  
    15. Install the EGR valve and adapter assembly.
    16.  
    17. Connect the EGR adapter to the upper intake manifold pipe.
    18.  
    19. Install the fuel rail cover.
    20.  
    21. Connect the upper radiator hose to the intake manifold.
    22.  
    23. Properly refill the cooling system.
    24.  
    25. Fasten the front-to-rear exhaust manifold connection and heat shield.
    26.  
    27. Install the right engine cooling fan.
    28.  
    29. Install the engine torque strut.
    30.  
    31. Connect the negative battery cable. Start the engine and check for leaks.
    32.  

    RIGHT SIDE (REAR)
    See Figure 16


    Click image to see an enlarged view

    Fig. Fig. 16: Rear exhaust manifold removal-1995 3.8L engine shown, others similar

    1. Remove the air cleaner and the fuel injector sight shield.
    2.  
    3. Disconnect the negative battery cable.
    4.  
    5. Remove the coolant recovery reservoir.
    6.  
    7. Detach the exhaust crossover pipe.
    8.  
    9. Remove the transaxle oil level indicator tube support brace bolt and tube for access.
    10.  
    11. Tag and disconnect the spark plug wires.
    12.  
    13. Detach the oxygen sensor electrical connector.
    14.  
    15. Remove the engine torque strut and bolt from the engine.
    16.  
    17. Remove the engine lift bracket from the manifold.
    18.  
    19. Remove the spark plugs from the rear bank.
    20.  
    21. Raise and safely support the vehicle.
    22.  
    23. Remove the front exhaust pipe and and converter from the vehicle.
    24.  
    25. Remove the right rear engine mount-to-frame nuts.
    26.  
    27. Carefully lower the vehicle.
    28.  
    29. Use a suitable floor jack at the right rear corner of the engine with a suitable support. Carefully raise the engine slightly for access.
    30.  
    31. Unfasten the manifold retaining bolts, then remove the manifold. Remove and discard the gasket. Thoroughly clean the gasket mating surfaces.
    32.  

    To install:
    1. Install a new gasket, then position the exhaust manifold and install the retaining bolts loosely. Install the exhaust crossover at the manifold, then loosely install the nuts.
    2.  
    3. Tighten the manifold bolts/studs to 38 ft. lbs. (52 Nm).
    4.  
    5. Carefully lower the engine and remove the floor jack.
    6.  
    7. Raise and safely support the vehicle.
    8.  
    9. Install the front exhaust pipe and converter to the vehicle.
    10.  
    11. Fasten the engine mount-to-frame nuts.
    12.  
    13. Carefully lower the vehicle.
    14.  
    15. Tighten the exhaust crossover nuts.
    16.  
    17. Install the engine lift brackets.
    18.  
    19. Install the spark plugs, then attach the oxygen sensor connector.
    20.  
    21. Install the transaxle oil level indicator tube and bolt.
    22.  
    23. Connect the spark plug wires, as tagged during removal.
    24.  
    25. Position the engine torque strut, then secure with the bolt and nut. Tighten the nut to 32 ft. lbs. (43 Nm).
    26.  
    27. Install the coolant recovery reservoir.
    28.  
    29. Connect the negative battery cable.
    30.  
    31. Install the fuel injector sight shield and air cleaner assembly.
    32.  
    33. Start the engine and check for leaks.
    34.  

     
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