M11 Series – Service Manual – 011-007   Exhaust Manifold, Dry

Remove the air piping from the turbocharger.

Remove the turbocharger.

Refer to Procedure 010-033.

Remove two upper capscrews from the end sections of the exhaust manifold
and install two guide studs, Part No. 3376488.

Remove the remaining capscrews, exhaust manifold assembly and gaskets.

Remove the exhaust manifold end sections.

WARNING  When using a steam cleaner, wear protective clothing, as well as safety glasses or a face shield. Hot steam can cause serious personal injury.

Use 240-grit emery cloth to remove carbon deposits from the sealing
surfaces.

Use steam to clean the exhaust manifold. Dry with compressed air.

Inspect the parts for cracks or damage.

NOTE: A charge air cooler failure can cause progressive damage to the exhaust
manifold. If the exhaust manifold is damaged, check the charge air cooler.

Refer to Procedure 010-027.

Inspect the mounting surfaces for flatness.

The exhaust manifold mounting surface

must be flat to within 0.25 mm [0.010 in]. The turbocharger mounting flange

must have
a surface flatness of 0.13 mm [0.005 in].

If these surfaces are

not within the flatness specifications, refer to L10 Alternative Repair Manual:

Bulletin No. 3810310.

Install the exhaust manifold end sections to the center section.

Install two guide studs, Part No. 3376488, in the two top end holes
of the cylinder head exhaust ports.

Install a new gasket over each guide stud.

Do

not use any kind of adhesive to hold the gaskets.

To aid in future capscrew removal, apply a coating of high temperature
antiseize compound to the capscrew threads.

Install the exhaust manifold, tubular spacers, and capscrews.

NOTE: The exhaust manifold can be titled back enough to install a new gasket on each exhaust port as the capscrews are being installed.

Tighten the capscrews in the sequence shown.

NOTE: The torque values given have been established using antiseize compound as a lubricant.

Install the turbocharger.

Refer to Procedure 010-033.

Install the air piping to the turbocharger. Refer to the manufacturer’s
specifications for the correct torque value.

Operate the engine to check for leaks.