Exhaust Manifold Replacement - Left Side

Exhaust Manifold Replacement - Left Side (6.6L)

Removal Procedure





1. Drain the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (Service and Repair)Cooling System Draining and Filling (Static Fill) (Service and Repair) .
2. Remove the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement .
3. Remove the glow plug control module. Refer to Glow Plug Control Module Replacement .
4. Remove the exhaust gas recirculation (EGR) cooler pipe bracket upper bolt (1).
5. Raise and suitably support the vehicle half way. Refer to Lifting and Jacking the Vehicle .




6. Perform the following steps working through the wheelhouse opening, remove the EGR cooler pipe lower bolt (1) at the oil cooler.
7. Reposition the EGR cooler pipe (2) out of the way.




8. Remove the exhaust pipe to exhaust manifold bolts (1).




9. Remove the exhaust manifold heat shield bolts (1) and shield (2).




10. Remove the exhaust manifold bolts and nuts in the sequence shown.
11. Remove the exhaust manifold and gasket. Discard the gasket.



Installation Procedure

Left Side:

1. Install the a NEW exhaust manifold gasket onto the manifold studs.
2. Position a NEW exhaust pipe gasket between the exhaust manifold and exhaust pipe. Align the tab on the gasket to face outward.
3. Install the exhaust manifold onto the studs.

Notice: Refer to Fastener Notice .

4. Install and tighten the exhaust manifold bolts and nuts in the sequence shown.

* Tighten the bolts/nuts to 57 N.m (42 lb ft).
* Tighten the 4 center bolts/nuts an additional pass to 57 N.m (42 lb ft).






5. Install and tighten the exhaust pipe to exhaust manifold bolts in the sequence shown (1, 2, and 3).

Tighten the bolts to 53 N.m (39 lb ft).





6. Position the exhaust manifold heat shield (2) to the manifold and install the bolts (1).

Tighten the bolts to 10 N.m (89 lb in).





7. Position the EGR cooler pipe (2) to the oil cooler.
8. Install the EGR cooler pipe lower bolt (1) at the oil cooler.

Tighten the bolt to 9 N.m (80 lb in).

9. Lower the vehicle.




10. Install the EGR cooler pipe bracket upper bolt (1).

Tighten the bolt to 9 N.m (80 lb in).

11. Install the glow plug control module. Refer to Glow Plug Control Module Replacement .
12. Install the charge air cooler inlet pipe. Refer to Charge Air Cooler Inlet Pipe Replacement .
13. Fill the cooling system. Refer to Cooling System Draining and Filling (Vac-N-Fill) (Service and Repair)Cooling System Draining and Filling (Static Fill) (Service and Repair) .