Turbocharger Exhaust Pipe Replacement 6.6L Engine

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Loosen the exhaust manifold pipe clamp.
3. Slide the exhaust pipe clamp up onto the exhaust pipe.



4. Remove the exhaust muffler nuts.



5. Slide the exhaust manifold pipe hanger from the insulator.
6. Remove the exhaust manifold pipe from the vehicle.



7. If equipped with an automatic transmission, remove the transmission fluid fill tube to bellhousing nuts.
8. Position the transmission fluid fill tube to the right side of the vehicle. The tube does not require removal from the transmission.



9. Remove the right exhaust pipe to exhaust manifold (1) bolts.



10. Remove the lower bolt (2) retaining the heat shield to the exhaust outlet.
11. Lower the vehicle.



12. Move the hood to the service position by moving the hood hinge bolts (1) to the service position (2).



13. Loosen the outlet duct clamp at the upper intake manifold cover.
14. Remove the upper intake manifold cover from the outlet duct.
15. Remove the upper intake manifold cover.



16. Remove the heat shield to turbocharger bolts.
17. Remove the turbocharger heat shield.



18. Remove the remaining bolts (1, 3) for the exhaust outlet heat shield.
19. Remove the exhaust outlet heat shield.



20. Remove the turbocharger exhaust pipe bolts/nuts.
21. Remove the turbocharger exhaust pipe and gasket from the turbocharger.
22. Position the turbocharger exhaust pipe to the side in order to access the right exhaust pipe to turbocharger bolts.

The turbocharger exhaust pipe cannot be removed until the right exhaust pipe is removed.




23. Remove the right exhaust pipe to turbocharger bolts (2).
24. Remove the right exhaust pipe and gaskets.



25. Remove the turbocharger exhaust pipe out the bottom of the vehicle.

1. From under the vehicle, position the turbocharger exhaust pipe to rear of the engine Do not install the pipe to the turbocharger.



2. Install the right exhaust pipe with NEW gasket to the turbocharger. Align the tabs on the gasket to face inward.

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 pipe to turbocharger bolts (2).

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




4. Install the turbocharger exhaust pipe with a NEW gasket to the turbocharger.
5. Install the turbocharger exhaust pipe bolts/nuts.

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




6. Install the turbocharger exhaust pipe heat shield.
7. Install the upper turbocharger exhaust pipe heat shield bolts (1, 3).

Tighten
Tighten the bolts to 8 N·m (71 lb in).




8. Install the turbocharger heat shield.
9. Install the turbocharger heat shield bolts.

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




10. Raise the vehicle.
11. Install the lower turbocharger exhaust pipe heat shield bolt (2).

Tighten
Tighten the bolt to 8 N·m (71 lb in).




12. If equipped with an automatic transmission, install the transmission fluid fill tube to bell housing nuts.

Tighten
Tighten the nuts 18 N·m (13 lb ft).




13. Install the right exhaust pipe to the exhaust manifold with a NEW gasket. Align the tab on the gasket to face outward as shown.
14. Install the right exhaust pipe to exhaust manifold bolts (1).

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




15. Install the exhaust manifold pipe hanger in the insulator.



16. Install the exhaust muffler to the exhaust manifold pipe.
17. Install the exhaust muffler nuts until snug.



18. Slide the exhaust pipe clamp down and around the pipe connection.
19. Tighten the exhaust pipe clamp.

Tighten

•	Tighten the clamp to 40 N·m (30 lb ft).

•	Tighten the nuts to 40 N·m (30 lb ft).

20. Lower the vehicle.



21. Install the upper intake manifold sight shield.
22. Install the upper intake manifold cover to the outlet duct.
23. Tighten the outlet duct clamp at the upper intake manifold cover.

Tighten
Tighten the clamp to 6 N·m (53 lb in).




24. Position the hood in the normal operating position by moving the hood hinge bolts from service position (2) to normal operating position (1).

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

25. Inspect for exhaust leaks.