ISC, ISCe, QSC8.3, ISL, ISLe3, ISLe4 and QSL9 Engines – 011-007   Exhaust Manifold, Dry

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

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.

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

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

• Disconnect the batteries. Refer to Procedure 013-009 in Section 13.
• Drain the coolant. Refer to Procedure 008-018 in Section 8.
• Remove the air crossover tube and charge-air cooler hose. Refer to Procedure 010-019 in Section 10.
• Remove the EGR cooler vent line. Refer to Procedure 008-017 in Section 8.
• Disconnect the air intake and exhaust piping. Refer to Procedure 010-022 in Section 10.
• Remove the turbocharger, if used. Refer to Procedure 010-033 in Section 10.
• Remove the EGR cooler. Refer to Procedure 011-019 in Section 11.

Remove the capscrews, exhaust manifold, and gaskets.

Apply a thin coating of nickel-based high-temperature compound grease to the coarse threads of the manifold capscrews, after removal.

The exhaust manifold can be removed as an entire assembly. It is not necessary to disassemble the bellows and adaptor tube from the manifold before removing it from the cylinder head. When removing the manifold, both manifold pieces must be supported to minimize stress on the bellows.

Remove the v-band clamps from the Marman flanges.

Pull the two exhaust manifold sections apart.

Remove the bellows from the shorter exhaust manifold section.

Remove the adaptor from the longer exhaust manifold section.

Clean the sealing surfaces of the head and exhaust manifold.

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

Multi-piece Only

Clean the multi-piece sealing joint.

Use 240-grit cloth to remove carbon deposits from the Marman flange surface. In order to clean the flange surfaces, the manifold must be disassembled by removing both v-band clamps from the bellows. Once the v-band clamps are removed, the two exhaust manifold sections can be separated. Take care not to lose the exhaust manifold adaptor tube installed within the bellows.

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

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

Use steam to clean the exhaust manifold.

Dry with compressed air.

Inspect the exhaust manifold for cracks, soot streaking, leaks, and burnout.

NOTE: If the exhaust manifold is damaged, check the charge air cooler. A damaged charge air cooler can cause progressive damage to the exhaust manifold. Refer to Procedure 010-027 in Section 10.

Inspect the gasket surfaces for gouges, scratches, or burnout.

Measure the manifold surface for flatness. Place a ruler over all exhaust ports in the manifold. Measure, with a feeler gauge, the gap between the port surface and the ruler.

Exhaust Manifold Flatness

If any port measures out of specification, replace the manifold.

Check the manifold to cylinder head fit. If the manifold mounting capscrew holes do not line up with the tapped holes in the cylinder head, replace the exhaust manifold.

Slide the two v-band clamps over the Marman flanges of the exhaust manifold halves.

Slip the adaptor tube into the pilot port of the longer exhaust manifold half.

Slide the bellows onto the shorter exhaust manifold section.

Carefully bring the two exhaust manifold halves together so the adaptor tube is secured firmly between the two pilot ports of the manifold sections and so the bellows is secured firmly to the flanges and tighten the clamps so that they can be just barely rotated.

Install the manifold assembly on the engine by first inserting the capscrews through the top of the port and gasket on all cylinders.

Insert the capscrews into the bottom of the exhaust ports and gaskets.

Torque the exhaust manifold mounting capscrews and then torque the v-band clamps.

Follow the tightening sequence as shown in the illustration.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Install the EGR cooler. Refer to Procedure 011-019 in Section 11.
• Install the turbocharger. Refer to Procedure 010-033 in Section 10.
• Install the EGR cooler vent line. Refer to Procedure 008-017 in Section 8.
• Connect the air intake and exhaust pipe. Refer to Procedure 010-022 in Section 10.
• Connect the charge-air cooler hose and crossover tube. Refer to Procedure 010-019 in Section 10.
• Connect the batteries. Refer to Procedure 013-009 in Section 13.
• Operate the engine and check for leaks.