Exhaust System: Service and Repair

Exhaust System Alignment

All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.

2. NOTE: New Torca(R) clamps and exhaust Y-pipe-to-exhaust manifold nuts must be installed when loosened.

Loosen all fasteners joining the exhaust system components.
3. If any of the Torca(R) clamps are loosened, note the orientation of the Torca(R) clamp, grind the spot weld and remove the old Torca(R) clamp.
4. Install a new Torca(R) clamp in the same orientation as the original and spot weld into place.
5. Beginning at the rear of the vehicle, the exhaust system should be aligned to establish the maximum clearance to its surrounding components. Make sure all fit pipes are pushed all the way into the preceding pipe and the pipe notches are fully seated and correctly lined up with the tabs.

Van/Wagon
6. Tighten the muffler and tailpipe assembly-to-exhaust intermediate pipe Torca(R) clamp.
^ Tighten to 55 Nm (41 ft. lbs).
7. Tighten the exhaust intermediate pipe-to-exhaust Y-pipe Torca(R) clamp.
^ Tighten to 55 Nm (41 ft. lbs).

Stripped chassis, 6.0L diesel
8. Tighten the muffler and tailpipe assembly-to-catalytic converter (or if equipped extension pipe) Torca(R) clamp.
^ Tighten to 55 Nm (41 ft. lbs).
9. If equipped, tighten the extension pipe-to-catalytic converter Torca(R) clamp.
^ Tighten to 55 Nm (41 ft. lbs).

Van/Wagon, stripped chassis
10. Tighten the upper exhaust manifold-to-exhaust Y-pipe nuts.
^ Tighten to 40 Nm (30 ft. lbs).
11. Tighten the lower exhaust manifold-to-exhaust Y-pipe nuts.
^ Tighten to 40 Nm (30 ft. lbs).

6.0L diesel
12. Tighten the exhaust downpipe-to-turbo clamp.
^ Tighten to 9 Nm (80 inch lbs).
13. Tighten the exhaust downpipe-to-catalytic converter nuts.
^ Tighten to 40 Nm (30 ft. lbs).

Stripped chassis
14. Tighten the exhaust Y-pipe-to-catalytic converter nuts.
^ Tighten to 40 Nm (30 ft. lbs).

All vehicles
15. Start the engine and check the exhaust system for leaks.