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For 1990-2009 cars only

Turbocharger Exhaust Pipe Replacement 6.6L (LB7) Engine

Removal Procedure


    Object Number: 668379  Size: SH
  1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Loosen the exhaust manifold pipe clamp.
  3. Slide the exhaust pipe clamp up onto the exhaust pipe.

  4. Object Number: 694338  Size: SH
  5. Remove the exhaust muffler nuts.

  6. Object Number: 694896  Size: SH
  7. Slide the exhaust manifold pipe hanger from the insulator.
  8. Remove the exhaust manifold pipe from the vehicle.

  9. Object Number: 702776  Size: SH
  10. If equipped with an automatic transmission, remove the transmission fluid fill tube to bellhousing nuts.
  11. Position the transmission fluid fill tube to the right side of the vehicle. The tube does not require removal from the transmission.

  12. Object Number: 777476  Size: SH
  13. Remove the right exhaust pipe to exhaust manifold (1) bolts.

  14. Object Number: 668425  Size: SH
  15. Remove the lower bolt (2) retaining the heat shield to the exhaust outlet.
  16. Lower the vehicle.

  17. Object Number: 310799  Size: SH
  18. Move the hood to the service position by moving the hood hinge bolts (1) to the service position (2).

  19. Object Number: 813243  Size: SH
  20. Loosen the outlet duct clamp at the upper intake manifold cover.
  21. Remove the upper intake manifold cover from the outlet duct.
  22. Remove the upper intake manifold cover.

  23. Object Number: 660382  Size: SH
  24. Remove the heat shield to turbocharger bolts.
  25. Remove the turbocharger heat shield.

  26. Object Number: 668425  Size: SH
  27. Remove the remaining bolts (1, 3) for the exhaust outlet heat shield.
  28. Remove the exhaust outlet heat shield.

  29. Object Number: 654540  Size: SH
  30. Remove the turbocharger exhaust pipe bolts/nuts.
  31. Remove the turbocharger exhaust pipe and gasket from the turbocharger.
  32. Position the turbocharger exhaust pipe to the side in order to access the right exhaust pipe to turbocharger bolts.
  33. The turbocharger exhaust pipe cannot be removed until the right exhaust pipe is removed.


    Object Number: 777476  Size: SH
  34. Remove the right exhaust pipe to turbocharger bolts (2).
  35. Remove the right exhaust pipe and gaskets.

  36. Object Number: 786908  Size: SH
  37. Remove the turbocharger exhaust pipe out the bottom of the vehicle.

Installation Procedure


    Object Number: 786908  Size: SH
  1. From under the vehicle, position the turbocharger exhaust pipe to rear of the engine Do not install the pipe to the turbocharger.

  2. Object Number: 777476  Size: SH
  3. Install the right exhaust pipe with NEW gasket to the turbocharger. Align the tabs on the gasket to face inward.
  4. 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.

  5. Install the exhaust pipe to turbocharger bolts (2).
  6. Tighten
    Tighten the bolts to 53 N·m (39 lb ft).


    Object Number: 654540  Size: SH
  7. Install the turbocharger exhaust pipe with a NEW gasket to the turbocharger.
  8. Install the turbocharger exhaust pipe bolts/nuts.
  9. Tighten
    Tighten the bolts/nuts to 53 N·m (39 lb ft).


    Object Number: 668425  Size: SH
  10. Install the turbocharger exhaust pipe heat shield.
  11. Install the upper turbocharger exhaust pipe heat shield bolts (1, 3).
  12. Tighten
    Tighten the bolts to 8 N·m (71 lb in).


    Object Number: 660382  Size: SH
  13. Install the turbocharger heat shield.
  14. Install the turbocharger heat shield bolts.
  15. Tighten
    Tighten the bolts to 9 N·m (80 lb in).


    Object Number: 668425  Size: SH
  16. Raise the vehicle.
  17. Install the lower turbocharger exhaust pipe heat shield bolt (2).
  18. Tighten
    Tighten the bolt to 8 N·m (71 lb in).


    Object Number: 702776  Size: SH
  19. If equipped with an automatic transmission, install the transmission fluid fill tube to bell housing nuts.
  20. Tighten
    Tighten the nuts 18 N·m (13 lb ft).


    Object Number: 777476  Size: SH
  21. Install the right exhaust pipe to the exhaust manifold with a NEW gasket. Align the tab on the gasket to face outward as shown.
  22. Install the right exhaust pipe to exhaust manifold bolts (1).
  23. Tighten
    Tighten the bolts to 53 N·m (39 lb ft).


    Object Number: 694896  Size: SH
  24. Install the exhaust manifold pipe hanger in the insulator.

  25. Object Number: 694338  Size: SH
  26. Install the exhaust muffler to the exhaust manifold pipe.
  27. Install the exhaust muffler nuts until snug.

  28. Object Number: 668379  Size: SH
  29. Slide the exhaust pipe clamp down and around the pipe connection.
  30. Tighten the exhaust pipe clamp.
  31. Tighten

        • Tighten the clamp to 15 N·m (11 lb ft).
        • Tighten the nuts to 40 N·m (30 lb ft).
  32. Lower the vehicle.

  33. Object Number: 813243  Size: SH
  34. Install the upper intake manifold sight shield.
  35. Install the upper intake manifold cover to the outlet duct.
  36. Tighten the outlet duct clamp at the upper intake manifold cover.
  37. Tighten
    Tighten the clamp to 6 N·m (53 lb in).


    Object Number: 310799  Size: SH
  38. Position the hood in the normal operating position by moving the hood hinge bolts from service position (2) to normal operating position (1).
  39. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  40. Inspect for exhaust leaks.

Turbocharger Exhaust Pipe Replacement 6.6L (LLY) Engine

Removal Procedure


    Object Number: 668379  Size: SH
  1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
  2. Loosen the exhaust manifold pipe clamp.
  3. Slide the exhaust pipe clamp up onto the exhaust pipe.

  4. Object Number: 694338  Size: SH
  5. Remove the exhaust muffler nuts.

  6. Object Number: 694896  Size: SH
  7. Slide the exhaust manifold pipe hanger out from the insulator.
  8. Remove the exhaust manifold pipe.

  9. Object Number: 702776  Size: SH
  10. If equipped with an automatic transmission, remove the transmission fluid fill tube to bellhousing nuts.
  11. Position the transmission fluid fill tube to the right side of the vehicle. The tube does not require removal from the transmission.
  12. Lower the vehicle.

  13. Object Number: 310799  Size: SH
  14. Move the hood to the service position by moving the hood hinge bolts (1) to the service position (2).
  15. Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).

  16. Object Number: 1335576  Size: SH
  17. Remove the turbocharger upper heat shield bolts.
  18. Remove the turbocharger upper heat shield.

  19. Object Number: 1334821  Size: SH
  20. Remove the exhaust outlet heat shield bolts.
  21. Remove the exhaust outlet heat shield.
  22. Remove the exhaust outlet to right exhaust pipe bracket bolt.

  23. Object Number: 1334826  Size: SH
  24. Loosen the exhaust outlet pipe clamp.

  25. Object Number: 1341232  Size: SH
  26. Remove the exhaust outlet pipe.

Installation Procedure


    Object Number: 1341232  Size: SH
  1. Install the exhaust outlet pipe.
  2. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1334826  Size: SH
  3. Tighten the exhaust outlet pipe clamp.
  4. Tighten
    Tighten the clamp to 15 N·m (11 lb ft).


    Object Number: 1334821  Size: SH
  5. Install the exhaust outlet to right exhaust pipe bracket bolt.
  6. Tighten
    Tighten the bolt to 34 N·m (25 lb ft).

  7. Install the exhaust outlet heat shield.
  8. Install the exhaust outlet heat shield bolts.
  9. Tighten
    Tighten the bolts to 8 N·m (71 lb in).


    Object Number: 1335576  Size: SH
  10. Install the turbocharger upper heat shield.
  11. Install the turbocharger upper heat shield bolts.
  12. Tighten
    Tighten the bolts to 9 N·m (80 lb in).

  13. Install the intake manifold cover. Refer to Intake Manifold Cover Replacement in Engine Mechanical - 6.6L (LLY).

  14. Object Number: 310799  Size: SH
  15. Remove the hood hinge bolts (1) from the service position (2) and position the hood in the normal position.
  16. Tighten
    Tighten the bolts to 25 N·m (18 lb ft).

  17. Raise the vehicle.

  18. Object Number: 702776  Size: SH
  19. If equipped with an automatic transmission, position the transmission fluid fill tube to the studs.
  20. Install the transmission fluid fill tube to bellhousing nuts.
  21. Tighten
    Tighten the nuts to 18 N·m (13 lb ft).


    Object Number: 694896  Size: SH
  22. Install the exhaust manifold pipe.
  23. Slide the exhaust manifold pipe hanger into the insulator.

  24. Object Number: 694338  Size: SH
  25. Install the exhaust muffler nuts until snug.

  26. Object Number: 668379  Size: SH
  27. Slide the exhaust pipe clamp down onto the exhaust pipe.
  28. Tighten the exhaust manifold pipe clamp.
  29. Tighten

        • Tighten the clamp to 15 N·m (11 lb ft).
        • Tighten the nuts to 40 N·m (30 lb ft).
  30. Lower the vehicle.