Exhaust Manifold Replacement - Left Side (6.0L Engine)

Exhaust Manifold Replacement - Left Side (6.0L Engine)

Removal Procedure

1. Disconnect the battery ground cable from the battery. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .
2. Remove the engine dress cover. Refer to Engine Cover Replacement (Service and Repair) .
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair) .
4. Remove the left side spark plug leads. Refer to Spark Plug Wire Replacement (Service and Repair) .
5. Remove the left side spark plugs from the cylinder head. Refer to Spark Plug Replacement (Service and Repair) .




Caution: Refer to Exhaust Service Caution (Service Precautions) .
Caution: Refer to Protective Goggles and Glove Caution (Protective Goggles and Glove Warning) .
6. Remove the exhaust manifold heat shield to exhaust manifold retaining bolts (2).
7. Remove the exhaust manifold heat shield (1).
8. Remove the engine coolant temperature sensor. Refer to Engine Coolant Temperature Sensor Replacement (Service and Repair) .





Important: The left catalytic converter to exhaust manifold retaining nuts (2) are single use parts. They must be discarded after removal.


9. Remove the left catalytic converter to exhaust manifold retaining nuts (2).
Discard the nuts.
10. Disconnect the left catalytic converter (3) from the exhaust manifold (4).
11. Loosen the exhaust manifold to cylinder head retaining bolts (1) working from the outside to the centre.

Important: Bolts with micro-encapsulated thread sealant must be discarded after removal.


12. Remove the exhaust manifold to cylinder head retaining bolts (1).
Discard the bolts.





Important: Make sure that the surrounding wiring harness and electrical connectors are not damaged when removing the exhaust manifold (2).



Important: The exhaust manifold gasket (1) and sealing ring (3) are single use parts. They must be discarded after removal.


13. Remove the exhaust manifold (2).
Discard the exhaust manifold gasket (1) and sealing ring (3).



Installation Procedure


Inspect

Notice: Refer to Exhaust Service Caution (Service Precautions) .

1. Before installation inspect for the following:

* Damage to the gasket sealing surfaces.
* Distortion of exhaust manifold mating surface.
* Damage to the exhaust mounting holes.





2. Check for distortion on the mating surface of the exhaust manifold (3) by using a straight edge (1) and a feeler gauge (2).
3. Clean the exhaust manifold and catalytic converter flange mating surfaces.




4. Install a NEW exhaust manifold gasket (1) and NEW sealing ring (3) to the exhaust manifold (2).

Notice: Refer to Exhaust System Inspection Notice (Service Precautions) .

5. Install the exhaust manifold assembly to the engine.





Important: Do not fully tighten the exhaust manifold to cylinder head retaining bolts (1) at this stage.


6. Install the NEW exhaust manifold to cylinder head retaining bolts (1).
Do not fully tighten at this stage.

Important: Make sure the sealing ring is seated correctly.


7. Lift the left catalytic converter (3) up and forward to connect to the exhaust manifold (4).
8. Clean the threads of the exhaust manifold to catalytic converter retaining studs with a suitable cleaning solvent.

Notice: Refer to Fastener Notice (Fastener Notice) .

9. Install the NEW left catalytic converter to exhaust manifold retaining nuts (2).

Tighten the nuts to 45 N.m (33 lb ft).

10. Tighten the exhaust manifold to cylinder head retaining bolts (1) working from the centre to the outside.

Tighten the bolts to 20 N.m (15 lb ft).

11. Install the engine coolant temperature sensor. Refer to Engine Coolant Temperature Sensor Replacement (Service and Repair) .




12. Install the exhaust manifold heat shield (1).
13. Install the exhaust manifold heat shield to exhaust manifold retaining bolts (2).

Tighten the bolts to 10 N.m (89 lb in).

14. Install the left side spark plugs to the cylinder head. Refer to Spark Plug Replacement (Service and Repair) .
15. Install the left side spark plug leads. Refer to Spark Plug Wire Replacement (Service and Repair) .
16. Install the air intake duct. Refer to Air Cleaner Assembly Replacement (Service and Repair) .
17. Install the engine dress cover. Refer to Engine Cover Replacement (Service and Repair) .
18. Connect the battery ground cable to the battery. Refer to Battery Negative Cable Disconnection and Connection (Service and Repair) .