Exhaust Manifold Replacement - Left Side L65

1. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
2. Remove the rubber splash guard between the left front inner wheel housing and the left front frame rail.



3. Remove the heat shield from the front corner of the exhaust manifold.



4. Remove the exhaust manifold heat shield.



5. Remove the heat shield from the center of the exhaust manifold.
6. Remove the glow plug from the left cylinder head. Refer to Glow Plug Replacement - Bank 1 in Engine Controls - 6.5L (L65).




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 bolts from the exhaust manifolds.



8. Remove the exhaust manifold bolts from the exhaust manifold.
9. Remove the exhaust manifold from underneath the vehicle.
10. Clean the threads on the exhaust manifold bolts and stud/nuts.

1. Install the exhaust manifold from underneath the vehicle.

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 and stud/nuts.

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

3. Install the exhaust crossover pipe to the exhaust manifolds. Refer to .



4. Install a new seal to the removed exhaust crossover pipe.
5. Install the exhaust crossover pipe to the exhaust manifold.
6. Install the exhaust crossover pipe bolts.

Tighten
Tighten the both sides crossover pipe bolts to 35 N·m (25 lb ft).




7. Install the heat shield to the center of the exhaust manifold.

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




8. Install the exhaust manifold heat shield to the exhaust manifold.

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




9. Install the exhaust shields to the front corner of the exhaust manifold.

Tighten

1. Tighten the bolts to 10 N·m (8 lb ft).
2. Tighten the nuts to 42 N·m (31 lb ft).
10. Install the glow plugs in the left cylinder head. Refer to Glow Plug Replacement - Bank 1 in Engine Controls - 6.5L (L65).



11. Install the rubber splash guard between the left front inner wheel housing and the left front frame rail.
12. Install the left front wheel on the vehicle. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.

Exhaust Manifold Replacement - Left 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. If equipped, remove the secondary air injection (AIR) pipe nut from the fuel rail stud.
7. If equipped, remove the AIR pipe bolts from the exhaust manifold.
8. If equipped, disconnect the AIR pipe from the AIR pump pipe.
9. If equipped, remove the AIR pipe.
10. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 8.1L.



11. Remove the exhaust manifold heat shield bolts and nuts.
12. Remove the exhaust manifold heat shield.



13. Remove the exhaust manifold bolt and nuts.
14. Remove the exhaust manifold.
15. 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 spark plugs. Refer to Spark Plug Replacement in Engine Controls - 8.1L.



7. If equipped, install a NEW AIR pipe gasket and the AIR pipe.
8. If equipped, connect the AIR pipe to the AIR pump pipe.
9. If equipped, install the AIR pipe bolts to the exhaust manifold.

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

10. 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).

11. Raise the vehicle.



12. Raise the catalytic converter into position.
13. Install NEW exhaust manifold seals.
14. Install the catalytic converter nuts.

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

15. Lower the vehicle.