Exhaust Manifold Replacement - Right Side L65

1. Remove the air cleaner assembly from the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls - 6.5L (L65).
2. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.



3. Remove the rubber splash guard between the wheel housing and the frame rail.
4. Remove the turbocharger assembly from the exhaust manifold. Refer to Turbocharger Replacement in Engine Mechanical - 6.5 L.
5. Remove the glow plugs from the right cylinder head. Refer to Glow Plug Replacement - Bank 2 in Engine Controls - 6.5L (L65).



6. Remove the heat shield from the exhaust manifold.




Important: If servicing only one exhaust manifold, loosen the exhaust crossover pipe at the opposite exhaust manifold being serviced and secure out of the way.

7. Remove the exhaust crossover pipe from the exhaust manifold.



8. Remove the exhaust manifold bolts and stud/nuts from the cylinder head.
9. Remove the exhaust manifold from the cylinder head.
10. Clean and inspect the sealing surface of the cylinder head.
11. Clean the threads on the exhaust manifold bolts and stud/nuts.

1. Install the exhaust manifold to the cylinder head.

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.

2. Install the exhaust manifold bolts.

Tighten
Tighten the bolts and stud/nuts to 35 N·m (26 lb ft).




3. Install a new seal for the removed exhaust crossover pipe.
4. Install the crossover pipe to the exhaust manifold.
5. Install the bolts for the exhaust cross over pipe.

Tighten
Tighten the crossover pipe bolts to 34 N·m (25 lb ft).




6. Install the heat shield to the exhaust manifold.

Tighten
Tighten the bolts and stud/nuts to 50 N·m (37 lb ft).

7. Install the glow plugs in the cylinder head. Refer to Glow Plug Replacement - Bank 2 in Engine Controls - 6.5L (L65).
8. Install the turbocharger to the exhaust manifold. Refer to Turbocharger Replacement in Engine Mechanical - 6.5 L.



9. Install the splash guard between the wheel housing and the frame rail.
10. Install the right front wheel to the vehicle. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
11. Install the air cleaner assembly to the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls - 6.5L (L65).

Exhaust Manifold Replacement - Right Side L18

1. Raise and suitably support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the catalytic converter nuts.
3. Remove the exhaust manifold seals.
4. Allow the catalytic converter to hang.
5. Lower the vehicle.
6. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement in Engine Mechanical - 8.1L.



7. If equipped, remove the secondary air injection (AIR) pipe nut from the fuel rail stud.
8. If equipped, remove the AIR pipe bolts from the exhaust manifold.
9. If equipped, disconnect the AIR pipe from the AIR pump pipe.
10. If equipped, remove the AIR pipe.



11. If equipped, remove the AIR pump pipe bolt from the cylinder head.
12. If equipped, remove the AIR pump pipe.
13. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 8.1 L.



14. Remove the exhaust gas recirculation (EGR) pipe nuts from the exhaust manifold.
15. Remove the EGR pipe bolts from the adapter plate.
16. Remove the EGR pipe bracket bolt.
17. Remove the EGR pipe and gaskets.



18. Remove the exhaust manifold heat shield bolts and nuts.
19. Remove the exhaust manifold heat shield.



20. Remove the exhaust manifold bolt and nuts.
21. Remove the exhaust manifold.
22. Remove and discard the exhaust manifold gasket.

1. Install a NEW exhaust manifold gasket.
2. Install the exhaust manifold.

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.

3. Install the exhaust manifold bolt and nuts.

Tighten

•	Tighten the exhaust manifold bolt to 35 N·m (26 lb ft).

•	Tighten the exhaust manifold nuts to 16 N·m (12 lb ft).




4. Install the exhaust manifold heat shield.
5. Install the exhaust manifold heat shield bolts and nuts.

Tighten
Tighten the exhaust manifold heat shield bolts and nuts to 25 N·m (18 lb ft).




6. Install the EGR pipe and NEW gaskets.
7. Install the EGR pipe bolts to the adapter plate until snug.
8. Install the EGR pipe nuts to the exhaust manifold until snug.
9. Install the EGR pipe bracket bolt until snug.

Tighten

•	Tighten the EGR pipe bolts to the adapter plate to 30 N·m (22 lb ft).

•	Tighten the EGR pipe nuts to the exhaust manifold to 30 N·m (22 lb ft).

•	Tighten the EGR pipe bracket bolt to 50 N·m (37 lb ft).

10. Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 8.1L.



11. If equipped, install the AIR pump pipe.
12. If equipped, install the AIR pump pipe bolt to the cylinder head.

Tighten
Tighten the AIR pump pipe bolt to 50 N·m (37 lb ft).




13. If equipped, install a NEW AIR pipe gasket and the AIR pipe.
14. If equipped, connect the AIR pipe to the AIR pump pipe.
15. If equipped, install the AIR pipe bolts to the exhaust manifold.

Tighten
Tighten the AIR pipe bolts to 25 N·m (18 lb ft).

16. If equipped, install the AIR pipe nut to the fuel rail stud.

Tighten
Tighten the AIR pipe nut to 12 N·m (106 lb in).

17. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement in Engine Mechanical - 8.1L.
18. Raise the vehicle.



19. Raise the catalytic converter into position.
20. Install the exhaust manifold seals.
21. Install the catalytic converter nuts.

Tighten
Tighten the catalytic converter nuts to 64 N·m (47 lb ft).

22. Lower the vehicle.