Exhaust Manifold Replacement Left

1. Disconnect the battery negative cables from the batteries. Refer to Battery Replacement in Engine Electrical.
2. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.



3. Remove the rubber splash guard between the left front inner wheel housing and the left front frame rail.



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



5. Remove the exhaust manifold heat shield.



6. Remove the heat shield from the center of the exhaust manifold.
7. Remove the glow plug from the left cylinder head. Refer to Glow Plug Replacement - Left Side in Engine Controls-- 6.5 L-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.

8. Remove the exhaust crossover pipe bolts from the exhaust manifolds.



9. Remove the exhaust manifold bolts from the exhaust manifold.
10. Remove the exhaust manifold from underneath the vehicle.
11. 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 Exhaust Crossover Pipe Replacement in Engine Exhaust.



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

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




5. 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).




6. 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 ).
7. Install the glow plugs in the left cylinder head. Refer to Glow Plug Replacement - Left Side in Engine Controls-6.5L-L-65.
8. Install the rubber splash guard between the left front inner wheel housing and the left front frame rail. Refer to Wheelhouse Splash Shield Replacement in Body Front End.
9. Install the left front wheel on the vehicle. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
10. Connect the battery negative cables to the batteries. Refer to Battery Replacement in Engine Electrical.

Exhaust Manifold Replacement Right

1. Disconnect both the battery negative cables from the batteries. Refer to Battery Replacement in Engine Electrical.
2. Remove the air cleaner assembly from the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L-L65.
3. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.



4. Remove the rubber splash guard between the wheel housing and the frame rail.
5. Remove the turbocharger assembly from the exhaust manifold. Refer to Turbocharger Replacement .
6. Remove the heat shield from the exhaust manifold.
7. Remove the glow plugs from the right cylinder head. Refer to Glow Plug Replacement - Right Side 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.

8. Remove the bolts and nuts from the right exhaust manifold.



9. Remove the exhaust manifold bolts and stud/nuts from the cylinder head.
10. Remove the exhaust manifold from the cylinder head.
11. Clean and inspect the sealing surface of the cylinder head.
12. 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 the nuts and bolts for the exhaust cross over pipe. Refer to Exhaust Crossover Pipe Replacement in Engine Exhaust.



4. Install the heat shield to the exhaust manifold.

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

5. Install the glow plugs in the cylinder head. Refer to Glow Plug Replacement - Right Side in Engine Controls-6.5L-L65.
6. Install the turbocharger to the exhaust manifold. Refer to Turbocharger Replacement .
7. Install the splash guard between the wheel housing and the frame rail. Refer to Wheelhouse Splash Shield Replacement in Body Front End.
8. Install the right front wheel to the vehicle. Tire and Wheel Removal and Installation in Tires and Wheels.
9. Install the air cleaner assembly to the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L --L65.
10. Connect both the battery negative cables to the batteries. Refer to Battery Replacement in Engine Electrical.