Series 60 – Section 7.3 Three-Piece Exhaust Manifold Without Fey Rings

Section 7.3
Three-Piece Exhaust Manifold Without Fey Rings

A three-piece, cast-iron exhaust manifold is attached to the cylinder head with twelve special alloy hardened bolts. The manifold has a square outlet flange which is bolted directly to the turbocharger turbine housing. See Figure "Typical Three-Piece Exhaust Manifold Mounting" . Three identical exhaust manifold gaskets are used between the manifold and the cylinder head. See Figure "Three-Piece Exhaust Manifold and Gasket Configurations" .‪

Figure 1. Typical Three-Piece Exhaust Manifold Mounting

Figure 2. Three-Piece Exhaust Manifold and Gasket Configurations

Section 7.3.1
Repair or Replacement of Three-Piece Exhaust Manifold without Fey Rings

To determine if repair or replacement is necessary, perform the following procedure. See Figure "Flowchart for Repair or Replacement of Three-Piece Exhaust Manifold without Fey Rings" .‪

Figure 3. Flowchart for Repair or Replacement of Three-Piece Exhaust Manifold without Fey Rings

Section 7.3.2
Removal of Three-Piece Exhaust Manifold without Fey Rings

Perform the following steps to remove the exhaust manifold.‪

Note: The exhaust manifold need not be cleaned prior to removal.

1. Remove the turbocharger assembly. Refer to "6.5.7 Installation of Turbocharger" .
2. Remove the bolts that secure the exhaust manifold and exhaust heat shields to the cylinder head.
3. Remove the heat shields.
4. Remove the three-piece manifold as an assembly and discard the three exhaust gaskets.

Note: The exhaust manifold should not be cleaned prior to inspection.

Section 7.3.3
Inspection of Three-Piece Exhaust Manifold without Fey Rings

Perform the following steps to inspect the three-piece exhaust manifold. ‪

1. Visually inspect the three exhaust manifold sections for cracks. If exhaust manifold sections are not damaged, reuse the components. If exhaust manifold sections are cracked, replace individual sections as required.
2. Check bolts Number 1, 3, and 6, as necessary, for stress and excessive stretching. See Figure "Location of Stressed Bolt and Bolt Torque Sequence" for the location of the bolts. Replace bolts if necessary.
   
   
   Numbers indicate bolt locations.

   Figure 4. Location of Stressed Bolt and Bolt Torque Sequence

3. Inspect the remaining exhaust manifold bolts for damage. Replace if necessary.
4. Inspect exhaust pipe hangers for cracks. Replace components as required. Refer to OEM guidelines for proper replacement procedure.
5. Inspect the flexible exhaust connection to ensure there is adequate flexibility to permit engine movement without stressing the turbocharger and exhaust manifold. Refer to OEM guidelines for proper flexibility specifications.
6. Ensure the exhaust pipe is adequately supported. Refer to OEM guidelines to verify that the exhaust pipe is adequately supported.
7. Clean the three-piece exhaust manifold, refer to "7.3.4 Cleaning of Three-piece Exhaust Manifold without Fey Rings" .

Section 7.3.4
Cleaning of Three-piece Exhaust Manifold without Fey Rings

Perform the following steps to clean the exhaust manifold.‪

1. Remove any loose scale and carbon that may have accumulated on the internal walls of the manifold sections.
2. Clean the manifold sections exterior with a wire brush.
3. When cleaning is complete, refer to "7.3.5 Installation of Three-Piece Exhaust Manifold without Fey Rings" .

Section 7.3.5
Installation of Three-Piece Exhaust Manifold without Fey Rings

Perform the following steps to install the exhaust manifold.‪

1. If disassembled, assemble the three pieces of the exhaust manifold.
2. Install four exhaust manifold guide studs (J–36107) into the cylinder head to hold the three exhaust manifold gaskets in the correct position, and facilitate manifold installation. For the modified bolt boss on the reusable center section, include one P/N: 23511667 exhaust manifold spacer under the bolts.

   Note: The bolt tightening pattern on cylinders 1, 2, and 3 reverses between middle-mount and high-mount exhaust manifolds. The exhaust gasket can be positioned either way. Ensure the guide studs and gaskets are positioned correctly for the manifold being installed.

3. Install the exhaust gaskets to the guide studs.
4. Install the assembled manifold to the guide studs.
5. Remove the four guide studs one at a time and install a bolt and spacer to secure the exhaust manifold to the cylinder head. Finger-tighten the bolts.
6. Install the remaining four bolts and spacers.
7. Remove the necessary bolts to install the exhaust heat shields.
8. Torque the bolts to 58-73 N·m (43-54 lb·ft) using the tightening sequence. See Figure "Location of Stressed Bolt and Bolt Torque Sequence" .
9. Install the turbocharger. Refer to "6.5.7 Installation of Turbocharger" .
10. Install any other equipment that was removed for this procedure.

    PERSONAL INJURY ‪
    Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.‪ Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system.

    PERSONAL INJURY ‪
    To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.‪

11. Start the engine and check for exhaust leaks.
12. If exhaust leaks are detected, contact the Detroit Diesel Customer Support Center for further information (313–592–5800).