Exhaust Manifold Replacement - Right Side 4.8L, 5.3L, and 6.0L Engines

1. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement for the 4.8L, 5.3L, and 6.0L engines.



2. Remove the ignition coils. Refer to Ignition Coil Replacement for the 4.8L, 5.3L, and 6.0L engines.
3. Remove the spark plugs. Refer to Spark Plug Replacement for the 4.8L, 5.3L, and 6.0L engines.
4. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle .
5. Remove the exhaust manifold pipe nuts.
6. Lower the vehicle.



7. If equipped, remove the bolts (1, 2, and 3) attaching the exhaust gas recirculation (EGR) valve pipe to the following:

•	Intake manifold

•	Cylinder head

•	Exhaust manifold

8. Remove the EGR valve pipe and gaskets, if equipped.

With mild force, pull the EGR valve pipe from the intake manifold.

9. Remove the O-ring seal from the EGR valve pipe, if equipped.
10. Discard the gasket and the O-ring seal.



11. Remove the exhaust manifold bolts, manifold, and gasket. Discard the bolts.
12. Discard the gasket.



13. Remove the heat shield bolts (1), and shield (2) from the exhaust manifold (1), if necessary.
14. Clean and inspect the exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection for the 4.8L, 5.3L engines, and 6.0L Unit Repair.

1. Install the exhaust manifold to the cylinder head. Refer to Exhaust Manifold Installation - Right Side .



2. Apply a light coating of clean engine oil to a NEW O-ring seal and install the seal onto the EGR valve pipe.
3. Install the EGR pipe.

Notice: Refer to Fastener Notice in the Preface section.

4. Install the EGR valve pipe bolts until snug.

Tighten

1. Tighten the intake manifold bolt (1) to 10 N·m (89 lb in).
2. Tighten the cylinder head bolts (2) to 50 N·m (37 lb ft).
3. Tighten the exhaust manifold bolts (3) to 30 N·m (22 lb ft).
5. Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 4.8L, 5.3L, and 6.0L.
6. Install the ignition coils. Refer to Ignition Coil Replacement in Engine Controls - 4.8L, 5.3L, and 6.0L.
7. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement for the 4.8L, 5.3L, and 6.0L engines.
8. Raise the vehicle.



9. Install the exhaust manifold pipe nuts.

Tighten
Tighten the nuts to 50 N·m (37 lb ft).

10. Lower the vehicle.

Exhaust Manifold Replacement - Right Side 8.1L Engine

1. Remove the wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.
2. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement in Engine Mechanical - 8.1L.

Important: Twist the spark plug boot one-half turn in order to release the boot. Pull on the spark plug boot only. Do not pull on the spark plug or the wire could be damaged.

3. Remove the spark plug wires from the spark plugs and ignition coils.
4. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 8.1L.



5. Remove the exhaust gas recirculation (EGR) pipe nuts from the exhaust manifold.
6. Remove the EGR pipe bracket bolt.
7. Remove and discard the EGR pipe gasket.
8. Reposition the EGR pipe.
9. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.



10. Remove the exhaust manifold heat shield bolts and nuts.
11. Remove the exhaust manifold heat shield.
12. Lower the vehicle.



13. Remove the exhaust manifold bolt and nuts.
14. Remove the exhaust manifold.
15. Remove and discard the exhaust manifold gasket.
16. If reusing the exhaust manifold, clean and inspect the exhaust manifold. Refer to Exhaust Manifold Cleaning and Inspection in Engine Mechanical - 8.1L Unit Repair.

1. Install a NEW exhaust manifold gasket.
2. 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.

3. Install the exhaust manifold bolt and nuts.

Tighten

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

•	Tighten the nuts to 16 N·m (12 lb ft).

4. Raise the vehicle.



5. Install the exhaust manifold heat shield.
6. Install the exhaust manifold heat shield bolts and nuts.

Tighten
Tighten the bolts and nuts to 25 N·m (18 lb ft).

7. Lower the vehicle.



8. Position the EGR.
9. Install a NEW EGR pipe gasket.
10. Install the EGR pipe bracket bolt.

Tighten
Tighten the bolt to 50 N·m (37 lb ft).

11. Install the EGR pipe nuts to the exhaust manifold.

Tighten
Tighten the nuts to 30 N·m (22 lb ft).

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




Important: Fully install the spark plug wires by pushing on the exposed end of the spark plug boot. Do not push the spark plug wire on to the spark plug by using the metal heat shield.

13. Install the spark plug wires to the spark plugs and ignition coils.
14. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement in Engine Mechanical - 8.1L.
15. Install the wheelhouse panel. Refer to Wheelhouse Panel Replacement in Body Front End.