Exhaust Manifold Replacement - Left Side 4.3L

1. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
2. Disconnect the engine coolant temperature (ECT) gage sensor electrical connector.



3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the left front tire.
5. Remove the left fender wheelhouse extension (1).
6. Remove the catalytic converter assembly.



7. Remove the EGR valve inlet pipe from the exhaust manifold.



8. Remove the spark plug wires from the spark plugs.
9. Remove the spark plug wire support bolts.
10. Remove the spark plug wire support with the spark plug wires.
11. Remove the spark plugs.
12. Remove the AIR pipe from the exhaust manifold.



13. Remove the exhaust manifold, gaskets and the spark plug wire shields from underneath the vehicle.
14. Clean all gasket surfaces.

Important: To assist in installing the exhaust manifold to the engine, the tabs on a NEW exhaust manifold gasket will hold the gasket and the bolts in place.

1. Sub-assemble the NEW gaskets, the spark plug wire shields, and the bolts to the exhaust manifold.
2. Ensure that the exhaust manifold bolts are held in place by the tabs on the exhaust manifold gaskets.
3. Install the exhaust manifold.



4. Install the spark plugs.
5. Install the spark plug wires to the spark plugs.
6. Install the AIR pipe to 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.

7. Install the spark plug wire support and bolts.

Tighten
Tighten the spark plug wire support bolts to 12 N·m (106 lb in).




8. Install the EGR valve inlet pipe to the exhaust manifold.

Tighten
Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N·m (22 lb ft).

9. Install the catalytic converter assembly.



10. Install the fender wheelhouse extension (1).
11. Install the left front tire.
12. Lower the vehicle.



13. Connect the ECT gage sensor electrical connector.
14. Install the engine cover.

Exhaust Manifold Replacement - Left Side 5.7L

1. Remove the exhaust pipe from the exhaust manifold.
2. Remove the engine cover.
3. Disconnect the EGR valve pipe from the exhaust manifold.
4. Remove the spark plugs.
5. Remove the exhaust manifold.
6. Clean all sealing surfaces.

1. Install the exhaust manifold.
2. Connect the EGR valve pipe to the manifold.
3. Install the spark plugs.
4. Install the exhaust pipe to the exhaust manifold.
5. Install the engine cover.

Exhaust Manifold Replacement - Left Side 8.1L

1. Remove the left catalytic converter. Refer to Catalytic Converter Replacement .
2. Lower the vehicle.
3. Remove the engine cover. Refer to Engine Cover Replacement in Interior Trim.
4. If equipped, remove the secondary air injection (AIR) pipe nut from the fuel rail stud.
5. If equipped, remove the AIR pipe bolts from the exhaust manifold.
6. If equipped, disconnect the AIR pipe from the AIR pump pipe.
7. If equipped, remove the AIR pipe.
8. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 8.1L.



9. Remove the exhaust manifold heat shield bolts and nuts.
10. Reposition the exhaust manifold heat shield.
11. Raise and suitably support the vehicle with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.



12. Remove the exhaust manifold bolt and nuts.
13. Remove the exhaust manifold and heat shield.
14. Remove and discard the exhaust manifold gasket.

1. Install a NEW exhaust manifold gasket.
2. Install the exhaust manifold and heat shield.

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. Lower the vehicle.



5. Position the exhaust manifold heat shield.
6. 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).

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



8. If equipped, install the AIR pipe.
9. If equipped, connect the AIR pipe to the AIR pump pipe.
10. If equipped, install the AIR pipe bolts to the exhaust manifold.

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

11. 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).

12. Install the engine cover. Refer to Engine Cover Replacement in Interior Trim.
13. Raise the engine.
14. Install the left catalytic converter. Refer to Catalytic Converter Replacement .

Exhaust Manifold Replacement - Left Side 6.5L

1. Remove the engine cover from the vehicle. Refer to Engine Cover Replacement in Interior Trim.
2. Remove the transmission oil level indicator tube.
3. Raise the vehicle enough to remove the left front wheel to gain access to the glow plugs.
4. Remove the splash shields from the frame to the wheel housing. Refer to Wheelhouse Splash Shield Replacement in Body Front End.



5. Remove the left exhaust pipe clamp from the exhaust manifold pipe to the turbocharger.
6. Remove the left exhaust pipe clamp from exhaust pipe to the exhaust manifold.
7. Remove the left exhaust pipe.

Important: To remove the glow plugs from No. 1 and 3 cylinders, you may have to remove them through the wheel well.




8. Remove the glow plugs from the cylinder head.
9. Raise the vehicle and support with safety stands. Refer to Lifting and Jacking the Vehicle in General Information.



10. Remove the exhaust manifold bolts.
11. Remove the left exhaust manifold from the cylinder head.
12. Inspect and clean the sealing surfaces on the cylinder head and the exhaust manifold.

1. Install the left 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 left exhaust manifold bolts.

Tighten
Tighten the bolts to 35 N·m (26 lb ft).

Important: In order to ensure heat shield clearance, locate the exhaust pipe clamps as shown.

3. Slide the exhaust clamps over the exhaust manifold and turbocharger.



4. Install the exhaust pipe from the turbocharger to the exhaust manifold.
5. Install the left side exhaust pipe.
6. Place the clamps in the correct position.
7. Tighten the clamps at the exhaust manifold.

Tighten
Tighten the clamps to 10 N·m (90 lb in).




8. Install the glow plugs in the cylinder head.
9. Install the splash shields from the frame to the wheel housing. Refer to Wheelhouse Splash Shield Replacement in Body Front End.
10. Install the left wheel (if removed).
11. Lower the vehicle



12. Install the transmission oil level indicator tube.
13. Install the engine cover in the vehicle. Refer to Engine Cover Replacement in Interior Trim.