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SERIES 60 EXHAUST MANIFOLD

Three-Piece Exhaust Manifold: 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 20529 . Three identical exhaust manifold gaskets are used between the manifold and the cylinder head. See Figure 20031 . ‪

Typical Exhaust Manifold Mounting

Note: Exhaust manifolds on Series 60G genset engines provide a heat shield for efficiency, see Figure 27850 .

Note: Exhaust manifolds on Series 60G automotive engines and on Series 60 keeled-cooled marine engines have an insulation wrap to contain heat. One-piece exhaust manifolds on Series 60 heat exchanger-cooled marine engines are water-cooled. See Figure 37020 .

1. Exhaust Manifold ‪

2. Heat Shield ‪

Typical Exhaust Manifold Mounting (Series 60G Genset Engine)

Typical Exhaust Manifold of a Pleasure Craft Marine

Repair or Replacement of the Exhaust Manifold

To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 21701 . ‪

Flowchart for Repair or Replacement of Exhaust System

Removal and Cleaning of the Exhaust System

Remove the exhaust manifold as follows: ‪

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

  1. Remove the turbocharger assembly. Refer to section (diesel) or refer to section (natural gas).
  2. Remove the bolts that secure the exhaust manifold to the cylinder head.
  3. Remove the three-piece manifold as an assembly or remove the one-piece manifold. Discard the three gaskets.

Cleaning of Exhaust Manifold

Clean the exhaust manifold prior to inspection as follows: ‪

  1. Remove any loose scale and carbon that may have accumulated on the internal walls of the manifold.
  2. Clean the manifold exterior with a wire brush.
Inspection of the Exhaust Manifold

Inspect the exhaust manifold as follows: ‪

  1. Visually inspect the exhaust manifold for cracks, especially in the bolt clamp areas.
    1. If exhaust manifold is cracked, replace with a new manifold. If it is necessary to replace individual sections of the three-piece exhaust manifold, clamp the manifold in a vise equipped with soft jaws. Use a brass drift and hammer to separate the pieces. Refer to section .
    2. If exhaust manifold is not damaged, reuse the component. Refer to section .
  2. Visually inspect manifold mounting bolts for damage.
    1. If bolts are excessively stretched, or if threads are excessively damaged, replace with new bolts. Refer to section .
    2. If bolts are not stretched or damaged, refer to section .
    3. Note: If bolt holes 3, 4, 5, and 6 are 12.6-13.7 mm (0.496 - 0.539 in.) diameter, they should be drilled out to 14.7-15.7 mm (0.577-0.618 in.) before the manifold is reinstalled on the engine. This provides an extra margin of safety for thermal expansion of the manifold. See Figure 21789 .


      Exhaust Manifold Torque Sequence

  3. Inspect manifold for leakage.
    1. Check the three-piece manifold for fretting near the slip joints.
    2. If there is exhaust manifold leakage refer to section .
  4. Inspect #1 location manifold mounting bolt for damage . See Figure 21789 .
    1. Check for broken or stressed bolt.
    2. If bolt is excessively stretched, or if threads are excessively damaged, and complete manifold assembly replacement is required, three new exhaust manifold kits having center sections with reduced bolt hole boss at the #1 location , see Figure 21789 , are available. The new kits (23512896 - high mount, 23512897 middle mount, and 23513470 - low mount) also include bolts, studs, spacers, and special graphite-composition gaskets required for complete manifold replacement.
    3. If bolt is excessively stretched, or if threads are excessively damaged, and if the exhaust manifold assembly is reusable, rework the center section reducing the height of the cast-in bolt hole boss, #1 location, on the center section, see Figure 21789 , by grinding it down to 22 mm (0.87 in.). An isolating washer will be installed in this location. Glass bead inner and outer diameters of the slip joints.

    4. Exhaust Manifolds Showing Location of Stressed Bolt and Bolt Torque Sequence

  5. Check one-piece, water-cooled exhaust manifold for cracks or obvious signs of coolant leakage and replace, if necessary.
  6. Inspect exhaust pipe hangers for cracks. Replace as required. Refer to OEM guidelines for proper replacement procedure.
  7. 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.
  8. Ensure the exhaust pipe is adequately supported. Refer to OEM guidelines to verify that the exhaust pipe is adequately supported.

Installation of Three-Piece Exhaust Manifold

Install the exhaust manifold as follows: ‪

  1. If disassembled, reassemble 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. Install eight of the bolts and spacers to the vacant holes. Finger-tighten the bolts.
  6. Remove the four guide studs.
  7. Install the remaining four manifold bolts and spacers to the holes from which the studs were removed.
  8. Torque the bolts to 58-73 Nm (43-54 lbft) using the tightening sequence. See Figure 21789 . For a wrapped exhaust manifold see Figure 36031 .

    Wrapped Manifold Bolt Torque Sequence

  9. Install the turbocharger assembly. Refer to section (diesel) or refer to section (gas).
  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 refer to section .
  13. Refer to section for verification of proper exhaust manifold installation.

Installation of Exhaust Manifold Slip Joint Seal Kit

To install the exhaust manifold slip joint seal kit perform the following steps: See Figure 44511 . ‪

1. Cover ‪

3. Cover ‪

2. Clamp ‪

4. Seal ‪

Exhaust Manifold Slip Joint Seal Kit

PERSONAL INJURY

To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing any component.

  1. Remove the turbocharger. Refer to Section .
  2. Remove exhaust manifold heat shield.
  3. For engines built before April 15, 2004, refer to Section for EGR valve and S-Pipe removal.
  4. For engines built after April 15, 2004, refer to Section and disconnect upper hot pipe from exhaust manifold.
  5. Remove exhaust manifold. Refer to Section
  6. Install seals onto exhaust manifold slip joint. Ensure the split line of the seal is positioned at the top of the manifold when the manifold is installed on engine.

    NOTICE:

    When installing covers ensure the large lip of the cover is located toward the turbocharger, and the area where the lip is removed is located toward the cylinder head. Do Not Align the split lines of the cover and seal. The seal split line should be 90 degrees from the cover split line. ‪

  7. Install cover on seal, ensure the split line of the cover is horizontal to the floor when manifold is installed on engine. See Figure 44100 .

    Location of Installed Covers and Seal

  8. Install clamp onto cover. Using large pliers compress clamp around cover and seal allowing clamp bolt to protrude. Install nut onto clamp bolt.

    Note: Do not fully tighten clamps to allow for adjustment after manifold and heat shield installation.

  9. Position bolt so that the nut is located toward the bottom of the manifold, when the manifold is installed on the engine.See Figure 44723 .

    Clamp Bolt and Nut Position When Installed on Exhaust Manifold

  10. Install exhaust manifold. Refer to Section .
  11. Install heat shield.
  12. Tighten nut on slip joint clamp until cover and split lines touch.
  13. For engines built before April 15, 2004 refer to Section for S-Pipe and EGR valve installation.
  14. For engines built after April 15, 2004, refer to Section for upper hot pipe and bellows installation.
  15. Install turbocharger. Refer to Section .

Installation of One-Piece Water-Cooled Exhaust Manifold

Install the one-piece water-cooled exhaust manifold as follows: (See Figure 35407 ). ‪

1. Bracket, Upper Manifold Support ‪

5. Spacer ‪

2. Bolt ‪

6. Bolt ‪

3. Stud ‪

7. Turbo Mounting Flange (part of exhaust manifold) ‪

4. Exhaust Manifold ‪

8. Bracket, Turbo Mounting ‪

One-Piece Water-Cooled Exhaust Manifold and Related Parts

  1. Install six exhaust manifold guide studs, J 36107 , into the cylinder head to hold the six exhaust manifold gaskets in the correct position and facilitate manifold installation.
  2. Install the exhaust gaskets (3) to the guide studs.
  3. Install the manifold to the guide studs.
  4. Install twelve of the bolts and spacers to the vacant holes. Finger-tighten the bolts.
  5. Remove the six guide studs.
  6. Install the remaining manifold bolts to the holes from which the studs were removed.
  7. Torque the bolts to 58-73 Nm (43-54 lbft) using the tightening sequence. See Figure 35406 .

    One-Piece Water-Cooled Exhaust Manifold Bolt Torque Sequence

  8. Install coolant inlet and outlet elbows to the exhaust manifold and attach coolant lines.
  9. Install the turbocharger assembly. Refer to section (diesel) or refer to section (gas).
  10. Install any other equipment that was removed for this procedure.
  11. Refer to section for the exhaust caution before proceeding. Start the engine and check for exhaust or coolant leaks.
  12. Refer to section for verification of proper exhaust manifold installation.