Exhaust Manifold Replacement Left Side

1. Disconnect the battery negative cables from the batteries. Refer to Battery Cable in Engine Electrical.
2. Raise the vehicle enough to remove the left front wheel.
3. Remove the left front inner wheel housing from the vehicle.
4. Remove the heat shield from the front corner of the exhaust manifold.



5. Remove the exhaust manifold heat shield.
6. Remove the glow plugs from the cylinder head. Refer to Glow Plug Replacement - Left Side in Engine Controls 6-5 L.




Important: The exhaust pipe does not have to be removed when performing this service procedure, unless both exhaust manifolds are being replacement.

7. Remove the exhaust crossover pipe bolts from the exhaust manifolds. Refer to Exhaust Crossover Pipe Replacement in Engine Exhaust.



8. Remove the exhaust manifold from underneath the vehicle.
9. 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 manifold heat shield to the exhaust manifold.

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




4. 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 )
5. Install the exhaust crossover pipe from the left exhaust manifold to the turbocharger. Refer to Exhaust Crossover Pipe Replacement in Engine Exhaust.
6. Remove the safety stands and lower the vehicle.
7. Install the glow plugs to the cylinder head. Refer to Glow Plug Replacement - Left Side in Engine Controls-6.5L.
8. Install the left front inner wheel housing.
9. Install the left front wheel on the vehicle.
10. Connect the battery negative cables to the batteries. Refer to Battery Cable in Engine Electrical.

Exhaust Manifold Replacement Right Side

1. Disconnect both the battery negative cables from the batteries. Refer to Battery Cable in Engine Electrical.
2. Remove the air cleaner assembly from the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L.
3. Raise the vehicle just enough to remove the right front wheel.
4. Remove the right front inner wheel housing from the vehicle.

Important: The exhaust crossover pipe does not have to be removed when performing this service procedure, unless both exhaust manifolds are being replaced.

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 cylinder head. Refer to Glow Plug Replacement - Right Side in Engine Controls-6.5L.



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 the heat shield to the exhaust manifold.

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

4. Install the glow plugs in the cylinder head. Refer to Glow Plug Replacement - Right Side in Engine Controls-6.5L.
5. Install the turbocharger to the exhaust manifold. Refer to Turbocharger Replacement .
6. Install the air cleaner assembly to the vehicle. Refer to Air Cleaner Assembly Replacement in Engine Controls-6.5L.
7. Install the right front inner wheel housing to the vehicle.
8. Install the right front wheel to the vehicle.
9. Lower the vehicle.
10. Connect both the battery negative cables to the batteries. Refer to Battery Cable in Engine Electrical.