Centinel System – Repair Manual – 011-007   Exhaust Manifold, Dry

NOTE: Some ISX CM870 engines are equipped with exhaust seal rings at the slip joints.

Operate the engine and inspect the exhaust manifold for leaks at the slip joints.

If the exhaust manifold is leaking at the slip joints, it
must be repaired.

NOTE: Some ISX CM871 engines are equipped with exhaust seal rings at the slip joints.

Operate the engine and inspect the exhaust manifold for leaks at the slip joints.

If the exhaust manifold is leaking at the slip joints, it
must be repaired.

WARNING  To reduce the possibility of personal injury from hot surfaces, allow the engine to cool before beginning work. Wear appropriate hand and eye protection.

Remove the turbocharger inlet piping. Refer to the OEM service manual.

Twist the graphite seal in order to open it, allowing it to be placed onto the exhaust manifold.

The chamfered edge of the graphite seal faces the exhaust manifold center section.

Slide the graphite seal ring over the exhaust manifold end section and press it against the center section.

Align the split in the graphite ring so the open ends point towards the parting line in the exhaust manifold, as shown in the illustration.

NOTE: The EGR water return tube was removed in the illustration in order to show the seal kit installation. The seal kit can be installed without removing the EGR water return tube.

Place the top cover over the slip joint and graphite seal with the notch in the cover towards the center of the exhaust manifold center section.

Because of tight clearances at the slip joint, it will possibly be necessary to press the cover down and roll it to the top of the slip joint.

NOTE: The EGR water return tube was removed in the illustration in order to show the seal kit installation. The seal kit can be installed without removing the EGR water return tube.

Place the bottom cover over the slip joint and graphite seal with the notch in the cover towards the center of the exhaust manifold center section.

CAUTION  To reduce the possibility of damage to the EGR cooler bellows, do not use the cooler bellows as a pivot point for a pry bar when compressing the covers.

NOTE: The EGR water return tube was removed in the illustration, in order to show the seal kit installation. The seal kit can be installed without removing the EGR water return tube.

Compress the two covers together. The use of a pry bar and/or mallet to accommodate the T bolt clamp will possibly be necessary.

The T bolt of the clamp can be removed to aid in installation.

Separate the clamp and place it over the two covers.

Tighten the clamp.

Or until the ends of the cover make contact.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

• Drain the cooling system.
  Refer to Procedure 008-018 in Section 8.
• Remove the charge air cooler piping. Refer to the OEM service manual.
• Remove the variable geometry turbocharger.
  Refer to Procedure 010-033 in Section 10.
• Remove the heat shield.
  Refer to Procedure 011-032 in Section 11.
• Remove the EGR valve.
  Refer to Procedure 011-022 in Section 11.

• Remove the turbocharger.
  Refer to Procedure 010-033 in Section 10.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

NOTE: Brush away any loose dirt from around the area of the air handling connections to avoid contamination of the interior of the engine.

• Drain the cooling system.
  Refer to Procedure 008-018 in Section 8.
• Remove the charge air cooler piping. Refer to the OEM service manual. Use protective caps from the Air Handling Clean Care Kit to cover the connection points.
• Remove the air intake pipe to the turbocharger. Refer to the OEM service manual. Use protective caps from the Cummins® Vehicle Air Plumbing Clean Care Kit to cover the connection points.
• Remove the variable geometry turbocharger (VGT).
  Refer to Procedure 010-033 in Section 10.
• Remove the exhaust gas pressure sensor tube.
  Refer to Procedure 011-027 in Section 11.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.

Remove two mounting capscrews and install two guide studs.

Remove the remaining mounting capscrews, the spacers, the exhaust manifold assembly and the gaskets.

Discard the gaskets.

Cover open points on the exhaust manifold and cylinder head using heavy tape.

Disassemble the exhaust manifold end sections.

Discard the exhaust seal ring on the slip-joint, if equipped.

Remove the exhaust manifold end sections.

Disassemble the exhaust manifold end sections.

WARNING  Wear safety glasses or a face shield, as well as protective clothing, to reduce the possibility of personal injury when using a steam cleaner or high-pressure water.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

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

Steam-clean and dry with compressed air.

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 in Section 10.

Inspect for cracks or other damage.

Inspect the manifold seal bore for wear.

Inspect the exhaust manifold turbocharger mounting flange for warping.

WARNING  Wear safety glasses or a face shield, as well as protective clothing, to reduce the possibility of personal injury when using a steam cleaner or high pressure water.

WARNING  Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

Steam clean and dry with compressed air.

Use a soft cloth or a shop towel wetted with a safety solvent to remove carbon deposits from the sealing surfaces.

Inspect the exhaust manifold turbocharger mounting flange for warpage. 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].

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 in Section 10.

Inspect for cracks or other damage.

Check that the exhaust seal is fully seated against the shoulder of the exhaust manifold male end section.

If the exhaust seal ring is
not fully seated against the shoulder, the exhaust seal ring
must be replaced.

Inspect the exhaust manifold seal bore for wear.

Inspect the exhaust seal ring for signs of damage or excessive wear.

The exhaust seal ring
must not show signs of dents or other signs of damage.

Measure the wear width on the exhaust seal ring.

The wear width
must not be more than 1mm [0.04 in] wide anywhere on the seal.

A wear width larger than 1 mm [0.04 in] indicates excessive wear and the exhaust seal
must be replaced.

The wear width
must be uniform around the seal ring. If one side of the exhaust seal ring is worn more than the other, the exhaust seal ring
must be replaced.

Inspect the exhaust manifold slip-joints for signs of soot leakage.

If there is no evidence of an exhaust leak from the slip-joints and there is
not visible cracks or damage, do
not remove the exhaust manifold seal rings.

If there is a failure or damage, remove the exhaust manifold seal rings.

Remove the exhaust seal rings, located within the slip-joint.

Use tin snips or side cuts, to cut half way through the seal in two locations about 25.4 mm [1 in] apart.

NOTE: Take care
not to damage the seal carrier surface.

Grasp the portion of the seal between the cuts with a pair of pliers.

Twist and pull the seal off of the exhaust manifold end sections.

Discard the exhaust seal rings.

Inspect the exhaust seal ring mating surfaces of the male and female sections of the exhaust manifolds.

If scratches or nicks can be felt with a fingernail on the exhaust seal ring mating surfaces, the exhaust manifold section must be replaced.

Cover the open points on the exhaust manifold with heavy tape to prevent engine contamination.

The exhaust manifold sections
must be assembled on a flat surface for proper alignment.

Install exhaust seal rings, if equipped.

Install the exhaust manifold end sections to the center section.

The exhaust manifold sections
must be assembled on a flat surface for proper alignment.

Install the exhaust manifold end sections to the center section.

Place the exhaust seal ring onto the lip of the Exhaust Seal Installer, Part Number 4918709.

Use a light coat of grease or clean engine oil to lubricate the exhaust seal ring during assembly onto the male and female sections of the exhaust manifolds.

Position the seal installer and seal ring in line with the sealing surface on the exhaust manifold and strike with a lead or dead blow hammer until the seal is fully seated.

Install the exhaust manifold end sections to the center section.

The end section bolt holes
must be 152.4 mm [6 in] center to center before installing onto the cylinder head.

Remove the tape from the open exhaust ports and cylinder head.

Install two guide studs into the center section mounting location.

Do
not use adhesive, grease, or heavy grease to hold the gaskets in place on the cylinder head.

Install a new center section gasket.

Special capscrews with spacers are required for this particular manifold.

Do
not use short capscrews.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.

Install the exhaust manifold over the guide studs.

Apply a film of high-temperature anti-seize compound to the capscrew threads to make sure of proper loading on capscrews.

Slide each manifold gasket between the exhaust manifold and the cylinder head.

Install the capscrews and spacers through the exhaust manifold and gasket into the cylinder head.

Remove the two guide studs and install the two remaining capscrews.

Tighten the capscrews in the sequence shown.

Install two guide studs into center section mounting location.

Install the center mounting gasket over the guide studs.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.

Install the exhaust manifold assembly on the guide pins.

Special capscrews with spacers are required for this particular manifold.

Do
not use short capscrews.

Slide each exhaust manifold gasket between the manifold and cylinder head.

Insert the exhaust manifold mounting capscrews and spacer through the manifold and gasket and start capscrews into the cylinder head.

To aid in future capscrew removal, apply a film of high-temperature anti-seize compound to the capscrew threads.

Remove the guide studs and install the remaining two capscrews.

Tighten the capscrews in the sequence shown.

Torque values given have been established using anti-seize compound as a lubricant.

• Install the EGR valve.
  Refer to Procedure 011-022 in Section 11.
• Install the heat shield.
  Refer to Procedure 011-032 in Section 11.
• Install the variable geometry turbocharger (VGT).
  Refer to Procedure 010-033 in Section 10.
• Install the charge air cooler piping. Refer to the OEM service manual.
• Fill the cooing system.
  Refer to Procedure 008-018 in Section 8.
• Operate the engine and check for air leaks and exhaust gas leaks.

• Install the turbocharger.
  Refer to Procedure 010-033 in Section 10.
• Operate the engine and check for air leaks and exhaust gas leaks.

• Install the exhaust gas pressure sensor tube.
  Refer to Procedure 011-027 in Section 11.
• Install the variable geometry tubes.
  Refer to Procedure 010-033 in Section 10.
• Remove the protective caps and heavy tape.
• Install the charge air cooler piping. Refer to the OEM service manual.
• Fill the cooling system.
  Refer to Procedure 008-018 in Section 8.
• Operate the engine and check for air leaks and exhaust gas leaks.