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MBE 4000 EGREXHAUSTMANIFOLD

The EGRexhaust manifold is a three-piece manifold. The manifold assembly is assembled apart from the cylinder heads, then the entire assembly is installed to the heads. ‪

EGRExhaust Manifold Removal

Remove the EGRexhaust manifold as follows: ‪

Note: Although not shown in the below graphic, the heat exchanger and heat exchanger bracket are still installed on the engine before the exhaust manifold is removed.

  1. Remove the bolt that attaches the smaller front heat shield to the main heat shield, then remove the three bolts attaching the shield to the bottom of the exhaust manifold. Now remove the heat shield. See Figure 44109 .

    1. Upper or Main Heat Shield ‪

    2. Lower or Front Heat Shield ‪

    Removal or Installation of the Exhaust Manifold Front Heat Shield

    Note: Upper or main heat shield must remain on the exhaust manifold assembly until the assembly is removed due to inaccessibility of some of the heat shield mounting bolts.

  2. Loosen and remove outside nut that is resting on outside face of stud bracket. See Figure 44121 .

    1. Stud Bracket ‪

    3. Stud ‪

    2. Stud Nut ‪

    4. Exhaust Gas Inlet Pipe (Hot Pipe) ‪

    Removing Stud from Exhaust Manifold and Inlet Pipe

  3. Loosen center nut on stud that is resting on the inside, against the intake manifold center piece. See Figure 44121 .

    Note: If the inside nut that rests against the stud bracket is NOTloosened or moved at this point, it is possible that the stud dimension adjustment will remain the same without needing further adjustment when reinstalled.

    Note: Stud and stud bracket should be loose enough to allow removal of the exhaust manifold inlet pipe.

  4. Loosen and remove bolt from positioning clamp which holds the gas inlet pipe to the throttle valve. See Figure 44120 .

    Removing or Installing Positioning Clamp to Throttle Inlet Pipe

  5. Gently pull exhaust manifold gas inlet pipe from center piece of exhaust manifold and from throttle valve (see arrows in graphic). Remove the fey rings (four per groove) on the gas inlet pipe leading to the exhaust manifold center piece. See Figure 44123 .

    Exhaust Manifold Gas Inlet Pipe Removal

  6. Remove the twelve bolts connecting the three-piece exhaust manifold to the block; remove the exhaust manifold assembly by first lowering the left side, then the right side out from under the heat exchanger bracket (not shown in graphic). See Figure 44124 .

    Removing or Installing Three-piece Exhaust Manifold Assembly

  7. Remove the six mounting bolts from the main or upper heat shield at this point. Remove the heat shield. See Figure 44109 .

    1. Upper or Main Heat Shield ‪

    2. Lower or Front Heat Shield ‪

    Removing Upper Heat Shield

  8. Remove the stud and M8 nut and collar still attached to the center exhaust manifold piece.
  9. Remove the two side pieces of the exhaust manifold from the center piece. See Figure 44112 .

    Three Piece Exhaust Manifold Assembly

  10. Remove the fey rings (2 in each groove) from the two grooves of each exhaust manifold end piece. See Figure 44111 .

    1. Fey Ring ‪

    2. Exhaust Manifold Grooves ‪

    Installing or Removing Rings in Exhaust Manifold Grooves

    Note: EGRcooler and cooler bracket will need to be removed before removing the exhaust manifold gaskets. Refer to section .

  11. Remove exhaust manifold two-piece gasket from cylinder heads. See Figure 44110 .

    1. Two-Piece Gasket ‪

    3. Gasket Overlap (Rear overlaps the Front) ‪

    2. Guide Studs ‪

    Removal or Installation of Exhaust Manifold Gaskets

EGRExhaust Manifold Installation

Install the EGRexhaust manifold as follows: ‪

Note: The three-piece exhaust manifold and its related parts are first put together as an assembly; it is then mounted to the cylinder heads as one unit.

  1. Install the exhaust manifold guide studs to the cylinder head and mount the two exhaust manifold gaskets. The rear gasket will overlap the front in the center of block. See Figure 44110 .

    NOTICE:

    There is a front and rear exhaust manifold gasket and the rear gasket is marked with a deep notch on top. The front gasket must be installed before the rear gasket can be installed. ‪

    Note: At this point, the heat exchanger and heat exchanger mounting bracket should be installed on the block, but the remaining exhaust manifold installation graphics will not show these two parts installed.

    Note: The exhaust manifold gasket studs are to be removed after installing the EGRcooler support bracket.

  2. Install stud with M8 nut with collar onto exhaust manifold center piece. Do not tighten nut at this point.

    Note: Stud must be installed on exhaust manifold center piece before fitting the two end pieces of manifold into center piece.

    1. Stud ‪

    3. Exhaust Manifold Center Piece ‪

    2. M8 Nut with Collar ‪

    Installing Stud in Exhaust Manifold Center Piece

  3. Install the fey rings (2 in each groove) in the two grooves of each exhaust manifold end piece. See Figure 44111 .

    1. Fey Rings (2 per groove) ‪

    2. Exhaust Manifold Grooves ‪

    Installing or Removing Rings in Exhaust Manifold Grooves

  4. Fit fey-ring ends of exhaust manifold pieces into center part of exhaust manifold. Do not use lubricant. See Figure 44112 .
  5. Bolt upper heat shield to exhaust manifold using the six mounting bolts (M8 x 12mm). Finger-tighten all of the bolts, but torque the first bolt nearest the front part of the manifold to 25 Nm (19 lbft).

    Note: Upper heat shield bolt that is closest to front of engine is torqued before assembly is attached to engine due to impossible access after attachment to engine.

  6. Bolt the lower heat shield to the upper heat shield with one captured bolt and washer (M8 x 12mm). Torque to 25 Nm (19 lbft).
  7. Install the entire exhaust manifold assembly onto the cylinder heads by lifting the right side (or front) into place first, followed by the left (or rear). Install all exhaust manifold bolts, and then torque all 12 mounting bolts to 50 Nm (38 lbft), using a crisscross sequence.
  8. Torque remaining three mounting bolts (captured bolt and washer type) of the lower heat shield to the exhaust manifold. Torque to 25 Nm (19 lbft).
  9. Torque remaining five mounting bolts (captured bolt and washer type) of the upper heat shield to the exhaust manifold. Torque to 25 Nm (19 lbft).
  10. Install the fey rings (4 per groove) on the gas inlet pipe leading to exhaust manifold center piece. Do not use lubricant.
  11. Gently push gas inlet pipe into center exhaust manifold piece. Do not use lubricant.
  12. Push gas inlet pipe of heat exchanger into throttle valve. Tighten screw at bottom of positioning clamp on throttle valve assembly. Clamp must be tightened to 10 Nm (7 lbft) after stud adjustment. Refer to step .
  13. Screw the nut onto stud installed in exhaust manifold. Fit stud in the bracket that is attached to the gas inlet pipe. Attach a nut to the outer edge of bracket also.
  14. Adjust 219 mm dimension on stud by doing the following:
    1. Apply 25 Nm (19 lbft) tightening torque to the nut on exhaust manifold. Position stud to avoid any friction between the exhaust manifold and the gas inlet pipe. See Step One in see Figure 44091 .

      Stud Adjustment

    2. Adjust dimension to 219 mm (8.62 in.). This measurement is from the machined face of manifold to the resting face on the pipe. See Step Two in see Figure 44091 .
    3. Bring nut against the resting face on pipe (internal). See Step Three in see Figure 44091 .
    4. Apply 25 Nm (19 lbft) tightening torque to nut on resting face on pipe (external). See Step Four in see Figure 44091 .
    5. Apply 25 Nm (19 lbft) tightening torque to nut on resting face on pipe (internal). See Step Five in see Figure 44091 .