Exhaust System: Service and Repair

Exhaust System Alignment - 6.4L Diesel

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Vehicle Jacking and Lifting.

2. NOTE: Do not loosen the Oxidation Catalytic Converter (OC)-to-Diesel Particulate Filter (DPF) nuts.

Loosen all fasteners joining the exhaust system components.

- Discard all fasteners and the turbocharger-to-downpipe gasket.

3. Loosely install new exhaust downpipe-to-OC bolts.

4. Install a new exhaust downpipe-to-turbocharger gasket.

5. Install the exhaust downpipe to the turbocharger and a new exhaust downpipe-to-turbocharger clamp.
- Make sure the exhaust downpipe clip is over the lip on the turbocharger.
- Align the new exhaust downpipe-to-turbocharger clamp so that the exhaust downpipe clip and the opening in the exhaust downpipe-to-turbocharger clamp are aligned and tightened to maintain position.

- Align the downpipe so that the area just above the flat in the pipe is approximately 20 mm (0.787 in) from the frame.

- Tighten to 10 Nm (89 lb-in).

6. Tighten the exhaust downpipe-to-OC bolts.
- Tighten to 40 Nm (30 lb-ft).

7. Tighten the exhaust downpipe-to-turbocharger clamp.
- Tighten to 15 Nm (133 lb-in).

8. Make sure the DPF button is fully inserted into the button slot on the tail pipe or, if equipped, the exhaust intermediate pipe; then tighten the DPF-to-muffler Torca(R) clamp or, if equipped, the exhaust intermediate pipe Torca(R) clamp.
- Tighten to 55 Nm (41 lb-ft).





9. If equipped, make sure the button on the exhaust intermediate pipe is fully inserted into the button slot on the tail pipe and tighten the muffler and tail pipe-to-exhaust intermediate pipe Torca(R) clamp.
- Tighten to 55 Nm (41 lb-ft).





10. Start the engine and check the exhaust system for leaks.