1. Remove the engine assembly. Refer to Engine Replacement in Engine-Engine Mechanical-3.5L.
2. Remove the right (rear) exhaust manifold exhaust crossover pipe bolts from the left (front) exhaust manifold.



3. Disconnect the EGR valve pipe (1) from the exhaust crossover pipe.



4. Remove the right (rear) exhaust manifold retaining bolts.



5. Remove the right (rear) exhaust manifold and the gasket. Do not reuse the gasket.
6. Clean and inspect the exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection - Right Side .
7. Remove the oxygen sensor (1) and inspect the sensor for excessive deposits or damage. Replace the oxygen sensor if necessary. Refer to Heated Oxygen Sensor 1 Replacement in Engine Controls - 3.5L.



8. Remove the exhaust manifold stud(s) if damaged.

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.

1. Install the exhaust manifold stud(s) if removed.

Tighten
Tighten the exhaust manifold stud(s) to 6 N·m (53 lb in).

2. Install the oxygen sensor. Refer to Heated Oxygen Sensor 1 Replacement in Engine Controls - 3.5L.



3. Position a new right (rear) exhaust manifold gasket onto the right (rear) exhaust manifold.
4. Install the right (rear) exhaust manifold bolts.
5. Place the right (rear) exhaust manifold, gasket and bolts as an assembly in position on the cylinder head.



6. Install the right (rear) exhaust manifold retaining bolts.

Tighten
Tighten the right (rear) exhaust manifold bolts to 25 N·m (18 lb ft).

7. Install the right (rear) exhaust manifold exhaust crossover pipe bolts to the left (front) exhaust manifold.



8. Connect the EGR valve pipe nut (3) to the exhaust crossover pipe.

Tighten
Tighten the EGR to exhaust crossover pipe nut to 60 N·m (44 lb ft).

9. Install the engine assembly. Refer to Engine Replacement in Engine-Engine Mechanical-3.5L.