Exhaust Manifold Replacement 7.8L With CTF

1. Remove the front exhaust pipe. Refer to Front Pipe Replacement .
2. Remove the exhaust gas recirculation (EGR) pipe. Refer to Exhaust Gas Recirculation Pipe Replacement .
3. Remove the 2 heat shield bolts.
4. Remove the turbocharger. Refer to Turbocharger Replacement .



5. Remove the exhaust manifold nuts (1-12), washers, spacers and heat shield.
6. Remove the exhaust manifold with the gasket.

1. Install the exhaust manifold and gasket to the cylinder head.
2. Install the exhaust manifold nuts, washers, spacers and the heat shield.
3. Install the 2 heat shield bolts.
4. Install the EGR pipe. Refer to Exhaust Gas Recirculation Pipe Replacement .

Notice: Refer to Fastener Notice in the Preface section.

5. Tighten the exhaust manifold nuts in the proper sequence.

Tighten

•	Tighten the nuts (7, 12) to 34 N·m (25 lb ft).

•	Tighten the nuts (1-6, 8-11) to 55 N·m (41 lb ft).

6. Install the turbocharger. Refer to Turbocharger Replacement .
7. Install the front exhaust pipe. Refer to Front Pipe Replacement .

Exhaust Manifold Replacement Without CTF

1. Remove the turbocharger assembly. Refer to Turbocharger Replacement in Engine Controls - 7.8L.
2. Remove the front exhaust pipe. Refer to Front Pipe Replacement .
3. Remove the exhaust manifold nuts, bolts, washers and the spacers.
4. Remove the exhaust manifold with the gasket.

1. Install the exhaust manifold and gasket to the cylinder head.
2. Install the exhaust manifold nuts, bolts, washers and the spacers.

Notice: Refer to Fastener Notice in the Preface section.




3. Tighten the exhaust manifold nuts and bolts in the proper sequence.

Tighten
Tighten the nuts and bolts to 34 N·m (25 lb ft).

4. Install the front exhaust pipe. Refer to Front Pipe Replacement .
5. Install the turbocharger assembly. Refer to Turbocharger Replacement in Engine Controls - 7.8L.