CHARGE AIR COOLER PIPING

Refer to Figure 3.2 .

Figure 3.2 Charge Air Cooler Piping

NOTE: Intercooler and connecting hardware is chassis mounted. Refer to the appropriate chassis and parts
publications for detailed information.
EXHAUST MANIFOLD

REMOVAL

1. Remove twelve (12) mounting bolts securing the three piece exhaust manifold sections to cylinder head
( Figure 3.5 ).

2. Remove exhaust manifold and one piece gasket.

CLEANING

1. The exhaust manifold is a three piece assembly and may be cleaned with a suitable non-caustic solvent or
steam cleaned.

2. After cleaning, blow dry using filtered compressed air.

Figure 3.4 Road Draft Tube Removal
Figure 3.5 Exhaust Manifold Removal
INSPECTION

1. Visually inspect exhaust manifold for cracks. Replace as required.

2. Inspect for warpage as follows ( Figure 3.6 ):

a. Install exhaust manifold to cylinder head WITHOUT GASKET . Tighten bolts to the special torque value.

b. Using a 0.25 mm (.010 in.) feeler gauge, measure gap between bolts at manifold flange to cylinder head
mating surface.

c. If feeler gauge will pass through, exhaust manifold requires resurfacing.

NOTE: A MAXIMUM OF 0.64 mm (0.025 in.) MATERIAL CAN BE GROUND OFF TO CORRECT
WARPAGE.

3. If warpage cannot be corrected by grinding, replace exhaust manifold.

INSTALLATION

1. Install exhaust manifold as follows:

a. Apply "Never-Seez" to the bolts.

b. Install assembled exhaust manifold with gasket to cylinder head.

c. Assure gasket alignment with bolt holes and install twelve (12) "prevailing torque" bolts.

NOTE: BE SURE EXHAUST MANIFOLD GASKET AND EXHAUST MANIFOLD ARE ALIGNED BEFORE
TIGHTENING BOLTS.

d. Tighten bolts to the special torque value ( Figure 3.7 ).

Figure 3.6 Checking Exhaust Manifold For Cracks And

Warpage
Figure 3.7 Installing Exhaust Manifold
SECTION 3: MANIFOLDS

See new specifications at end of manual called "Specifications, Special Torque Values, and Service Tools".

EXPLODED VIEWS

Refer to Figure 3.1 for the components which make up the exhaust manifold.

Figure 3.1 Exhaust Manifold Components

1. 1. Exhaust Manifold Gasket
2. 2. Front Exhaust Manifold
3. 3. Center Exhaust Manifold
4. 4. Rear Exhaust Manifold
MISCELLANEOUS INSTALLATION

Refer to the appropriate sections for the proper installation procedures for the following:

Turbocharger, if removed

Turbocharger oil supply tube, if removed

Turbocharger oil drain tube, if removed

Engine Mounted ECM Unit and Mounting Bracket, if equipped

Engine Wiring Harness

Figure 3.13 Installing Road Draft Tube To Valve Cover/Intake

Manifold
1. 1. Valve Cover/Intake Manifold
2. 2. Road Draft Tube O-Ring
3. 3. Road Draft Tube

Figure 3.14 Securing Road Draft Tube

MISCELLANEOUS REMOVAL

Refer to the appropriate section of this publication for the removal procedures for the following items:

Turbocharger Oil Feed Supply Tube, if required

Turbocharger Oil Drain Tube, if required

Turbocharger, if required

Engine Mounted ECM Unit and Mounting Bracket, if required

Engine Wiring Harness

ROAD DRAFT TUBE REMOVAL

REMOVE ROAD DRAFT TUBE

1. Remove two (2) bolts securing road draft tube to crankcase ( Figure 3.4 ).

2. Pull road draft tube out from valve cover/intake manifold and crankcase.
VALVE COVER/INTAKE MANIFOLD

REMOVAL

NOTE: BE SURE THE ROAD DRAFT TUBE HAS BEEN REMOVED FROM THE VALVE COVER/INTAKE
MANIFOLD. IF IT HAS NOT, REFER TO "DRAFT TUBE REMOVAL".

NOTE: If engine is equipped with an engine mounted Electronic Control Module (ECM), refer to the
"Electronic Section" for removal procedures. Remove the ECM and its mounting bracket.

1. Disconnect the wiring harness connector from valve cover/intake manifold. Refer to Figure 3.8 for engines
equipped with chassis mounted ECM unit or Figure 3.9 for engines equipped with engine mounted ECM unit.

2. Release the retaining tabs of the wiring harness connector ( 3, Figure 3.8 or 3, Figure 3.9 ). Push the
connector body toward the inside of the valve cover/intake manifold ( Figure 3.10 ). Remove the valve
cover/intake manifold and gasket from the cylinder head. Leave the wiring harness connected to the fuel
injectors.

Figure 3.8 Disconnect Wiring Harness

1. 1. Main Wiring Harness
2. 2. 31-Pin Connector
3. 3. Wiring Harness Connector Tabs
4. 4. Wiring Harness Connector
 Figure 3.9 Disconnect Wiring Harness
1. 1. ECM
2. 2. Wiring Harness Connector
3. 3. Wiring Harness Connector Tabs
 Figure 3.10 Wiring Harness Connector

3. Remove the thirteen (13) valve cover/intake manifold mounting capscrews ( Figure 3.11 ). Remove valve
cover/intake manifold and gasket from the cylinder head.

Figure 3.11 Valve Cover/Intake Manifold Removal

CLEANING

1. Clean valve cover/intake manifold using a suitable non-caustic solvent.

2. Throughly clean valve cover/intake manifold breather and dry using filtered compressed air.

3. Visually inspect the valve cover/intake manifold for any damages.

INSTALLATION

NOTE: If valve cover/intake manifold gasket is not damaged and in good condition, it can be reused.

1. Place gasket onto cylinder head.

2. Hold the valve cover/intake manifold over the engine. Place a new O-ring into the wiring harness connector
port and push the connector in until the tabs lock.

NOTE: BE SURE THE VALVE COVER/INTAKE MANIFOLD AND GASKET ALIGN PROPERLY.

3. Install the valve cover/intake manifold onto the cylinder head.

4. Secure valve cover/intake manifold to the cylinder head using thirteen (13) mounting capscrews ( Figure
3.12 ). Tighten to the special torque value.

Figure 3.12 Valve Cover/Intake Manifold Installation

5. Lubricate and install a new O-Ring onto the road draft tube ( Figure 3.13 ).

6. Insert the draft tube into the bore located on the rear right hand side of the valve cover/intake manifold.
Secure the road draft tube to the crankcase using two (2) mounting bolts and tighten ( Figure 3.14 ).
OLD STYLE AND NEW STYLE BREATHER ELEMENT LOCATIONS

Old Style And New Style Breather Element Locations

Refer to Figure 3.3 for the location of the old style and new style breather elements.

Figure 3.3 Underside Of Old Style And New Style Valve

Cover/Intake Manifolds