Exhaust Manifold Replacement - Left Side 8.1L
Removal Procedure
- Remove the oil level indicator
tube. Refer to
Oil Level Indicator and Tube Replacement
in Engine Mechanical - 8.1L.
- Raise and suitably support the vehicle with safety stands. Refer
to
Lifting and Jacking the Vehicle
in
General Information.
- Remove the exhaust manifold pipe nuts.
- Remove the exhaust pipe seal.
- Allow the muffler pipe to hang.
- Lower the vehicle.
Important: Twist the spark plug boot ½ turn in order to release the boot.
Pull on the spark plug boot only. Do not pull on the spark plug wire or the
wire could be damaged.
- Remove the spark plug wires from the spark plugs and ignition coils.
- Remove the spark plugs. Refer to
Spark Plug Replacement
in Engine Controls - 8.1L.
- Remove the exhaust manifold
heat shield nuts.
- Remove the heat shield.
- Remove the exhaust manifold
bolt and nuts.
- Remove the exhaust manifold and gasket. Discard the gasket.
- Clean and inspect the exhaust manifold. Refer to
Exhaust Manifold Cleaning and Inspection
in Engine Mechanical -
8.1L Unit Repair.
Installation Procedure
- Install a NEW gasket.
- 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.
- 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). |
- Install the exhaust manifold
heat shield.
- Install the exhaust manifold heat shield nuts.
Tighten
Tighten the exhaust manifold heat shield nuts to 25 N·m
(18 lb ft).
- Install the spark plugs. Refer to
Spark Plug Replacement
in Engine Controls - 8.1L.
Important: Fully install the spark plug wire by pushing on the exposed end of the
spark plug boot. Do not push the spark plug wire on the spark plug by using
the metal heat shield.
- Install the spark plug wires to the spark plugs and ignition coils.
- Raise and suitably support
the vehicle with safety stands.
- Raise the muffler pipe up to the manifold.
- Install the exhaust pipe seal.
- Install the exhaust manifold pipe nuts.
Tighten
Tighten the exhaust manifold pipe nuts to 50 N·m (37 lb ft).
- Lower the vehicle.
Exhaust Manifold Replacement - Left Side 6.6L
Removal Procedure
- Remove the engine cover. Refer to
Engine Cover Replacement
in Interior Trim.
- Remove the air cleaner. Refer to
Air Cleaner Replacement
in Engine Controls - 6.6L (LLY).
- Remove the charged air cooler outlet duct. Refer to
Charged Air Cooler Hoses/Pipes Replacement
in Engine Mechanical - 6.6L (LLY).
- Remove the bolt for the oil level indicator tube bracket in order to remove the exhaust manifold gasket.
- Remove the exhaust pipe to exhaust manifold bolts (2).
- Remove the exhaust manifold bolts/nuts.
- Remove the exhaust manifold.
7.1. | Remove the manifold from the rear stud. |
7.2. | Remove the manifold from the front stud. |
7.3. | Slide the manifold out the bottom, past the oil filter. |
- Remove and discard the exhaust manifold gasket.
Installation Procedure
- Install the exhaust manifold with gasket.
- Install the exhaust manifold bolts/nuts.
Notice: Refer to Fastener Notice in the Preface section.
- Use the sequence shown, to properly tighten the exhaust manifold bolts.
Tighten
- Tighten the exhaust manifold bolts/nut a first pass to 34 N·m (25 lb ft).
- Tighten the exhaust manifold bolts/nuts a final pass to 34 N·m (25 lb ft).
- Install the engine cover. Refer to
Engine Cover Replacement
in Interior Trim.
- Install the bolt for the oil level indicator tube bracket.
Tighten
Tighten the oil level indicator tube bracket bolt to 21 N·m (15 lb ft).
- Install the exhaust pipe gasket. Align the tab on the gasket to face outward.
- Install the exhaust pipe and the bolts (2) to the exhaust manifold.
Tighten
Tighten the exhaust pipe to exhaust manifold bolts to 53 N·m (39 lb ft).
- Install the charged air cooler outlet duct. Refer to
Charged Air Cooler Hoses/Pipes Replacement
in Engine Mechanical - 6.6L (LLY).
- Install the air cleaner. Refer to
Air Cleaner Replacement
in Engine Controls - 6.6L (LLY).
- Install the engine cover. Refer to
Engine Cover Replacement
in Interior Trim.