Procedures

Exhaust System Alignment - 6.7L Diesel

6.7L Diesel Engine with a Catalyst and Particulate Filter

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

2. Loosen the exhaust lower downpipe Torca(R) clamp.





3. Loosen the 2 exhaust lower downpipe-to-catalyst and particulate filter assembly bolts.





4. Remove and discard the 3 catalyst and particulate filter assembly-to-exhaust intermediate pipe nuts.
- Discard the catalyst and particulate filter assembly-to-exhaust intermediate pipe gasket.

5. NOTE: Do not tighten the catalyst and particulate filter assembly-to-exhaust intermediate pipe nuts at this time.

Loosely install 3 new catalyst and particulate filter assembly-to-exhaust intermediate pipe nuts.

- Install a new catalyst and particulate filter assembly-to-exhaust intermediate pipe gasket.

6. Remove and discard the 3 exhaust intermediate pipe-to-tailpipe nuts.
- Discard the exhaust intermediate pipe-to-tailpipe assembly gasket.

7. NOTE: Do not tighten the exhaust intermediate pipe-to-tailpipe nuts at this time.

Loosely install 3 new exhaust intermediate pipe-to-tailpipe nuts.

- Install a new exhaust intermediate pipe-to-tailpipe assembly gasket.

8. NOTE: Make sure the exhaust isolators are not torn, damaged or binding.

Beginning at the front of the vehicle, align the exhaust system to establish the maximum clearance and allowing the isolators to be at zero load.

9. NOTE: Make sure the exhaust upper and lower downpipes are fully seated together and aligned before tightening the Torca(R) clamp.

Tighten the exhaust lower downpipe Torca(R) clamp.

- Tighten to 55 Nm (41 lb-ft).





10. Tighten the 2 exhaust lower downpipe-to-catalyst and particulate filter assembly bolts.
- Tighten to 40 Nm (30 lb-ft).





11. Tighten the 3 new catalyst and particulate filter assembly-to-exhaust intermediate pipe nuts.
- Tighten to 55 Nm (41 lb-ft).

12. Tighten the 3 new exhaust intermediate pipe-to-tailpipe assembly nuts.
- Tighten to 55 Nm (41 lb-ft).

13. Start the engine and check the exhaust system for leaks.

6.7L Diesel Engine with a Muffler

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

2. Loosen the exhaust lower downpipe Torca(R) clamp.





3. Loosen the 2 exhaust lower downpipe-to-resonator bolts.





4. If equipped, loosen the resonator-to-intermediate pipe Torca(R) clamp.

5. Loosen the Torca(R) clamp on the muffler and tailpipe assembly inlet pipe.

6. NOTE: Make sure the exhaust isolators are not torn, damaged or binding.

Align the exhaust system to establish the maximum clearance and allowing the isolators to be at zero load.

7. NOTE: Make sure the alignment button on the intermediate pipe is fully inserted into the notch on the muffler and tailpipe assembly inlet pipe.

If equipped, tighten the intermediate pipe-to-muffler and tailpipe assembly Torca(R) clamp.

- Tighten to 55 Nm (41 lb-ft).





8. NOTE: Make sure the alignment button on the resonator outlet pipe is fully inserted into the notch on the muffler and tailpipe assembly inlet pipe or if equipped, intermediate pipe.

Tighten the resonator-to-muffler and tailpipe assembly inlet pipe or if equipped, resonator-to-intermediate pipe Torca(R) clamp.

- Tighten to 55 Nm (41 lb-ft).





9. NOTE: Make sure the exhaust upper and lower downpipes are fully seated together and aligned before tightening the Torca(R) clamp.

Tighten the exhaust lower downpipe Torca(R) clamp.

- Tighten to 55 Nm (41 lb-ft).





10. Tighten the 2 exhaust lower downpipe-to-resonator bolts.
- Tighten to 40 Nm (30 lb-ft).





11. Start the engine and check the exhaust system for leaks.