Exhaust Manifold Replacement - Right Side

Exhaust Manifold Replacement - Right Side (Diesel)

Removal Procedure

1. Remove the wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (GMC) Front Wheelhouse Liner Replacement - Right Side (Chevrolet) .

2. Disconnect the oxygen sensor.

3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.

4. Remove the catalytic converter. Refer to Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp)Catalytic Converter Replacement (L96 with E63) Catalytic Converter Replacement (L96 with E63)Catalytic Converter Replacement (L96 with ZW9) Catalytic Converter Replacement (L96 with ZW9)Catalytic Converter Replacement (L96 with Exhaust Flange) Catalytic Converter Replacement (L96 with Exhaust Flange).





5. Perform the following steps working through the wheelhouse opening, remove the exhaust pipe to turbocharger exhaust pipe bracket bolt (1).





6. Loosen the turbocharger exhaust pipe clamp nut (1).





7. Remove the turbocharger exhaust pipe (1) from the engine compartment.





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

9. Discard the exhaust gasket.





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





11. Remove the exhaust manifold bolts and nuts in the proper sequence.





12. Remove the exhaust manifold nuts (1) and bolts (2).

13. Discard the gasket (3) and remove the exhaust manifold (4).

Installation Procedure





1. Install a NEW exhaust manifold gasket (3) onto the studs.

2. Install the exhaust manifold onto the studs.

Right:

Caution:
Refer to Fastener Caution Fastener Caution.

3. Install and tighten the exhaust manifold bolts and nuts in the sequence shown and tighten to 57 Nm (42 lb ft).

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





5. Position the turbocharger exhaust manifold heat shield (2) to the manifold and install the exhaust manifold heat shield bolts (1). Tighten to 10 Nm (89 lb in).





6. Install a NEW gasket (1) to the exhaust manifold outlet pipe with the tabs (2) facing downward.





7. Tighten the exhaust manifold outlet pipe to exhaust manifold bolts in the sequence shown to 50 Nm (37 lb ft).





8. Install the turbocharger exhaust pipe (1) to the turbocharger and exhaust pipe bracket.





9. Tighten turbocharger exhaust pipe bracket bolt (1) to 34 Nm (25 lb ft).

10. Install the catalytic converter to the turbocharger exhaust pipe. Refer to Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp) Catalytic Converter Replacement (Gen IV Engines with Exhaust Clamp)Catalytic Converter Replacement (L96 with E63) Catalytic Converter Replacement (L96 with E63)Catalytic Converter Replacement (L96 with ZW9) Catalytic Converter Replacement (L96 with ZW9)Catalytic Converter Replacement (L96 with Exhaust Flange) Catalytic Converter Replacement (L96 with Exhaust Flange).

11. Install the wheelhouse liner. Refer to Front Wheelhouse Liner Replacement - Right Side (GMC) Front Wheelhouse Liner Replacement - Right Side (Chevrolet) .

12. Lower the vehicle.