Transcript
NUMBER:07 60-5
S.M. REF.: 7
ENGINE: 60
DATE: July 2007
SUBJECT: THREE–PIECE EXHAUST MANIFOLD PUBLICATION: 6SE2007
DETAILS AND REASON
The EPA07 Series 60 Service Manual has been revised. Procedures are revised and are available on Power Service Literature (PSL) or hard copy. 7.2.5 Assembly of Three-Piece Exhaust Manifold Perform the following steps to assemble the three-piece exhaust manifold:
NOTE: Ensure the bellows clamps are orientated correctly. Incorrect orientation will interfere with turbocharger installation. See Figure 1.
1. Rear Exhaust Manifold Clamp Orientation
3. EGR Upper Pipe Clamp Orientation
2. Front Exhaust Manifold Clamp Orientation
Figure 1
Exhaust Manifold Clamp Orientation NOTICE: Do not tighten the clamps at this time to avoid bending the bellows pipe.
1. Install the bellows pipe and inner tubes onto the exhaust manifold center housing with two clamps. Do not tighten the clamps. 2. Install the front and rear exhaust manifolds onto the bellows pipe with two clamps. Do not tighten the clamps. 3. Refer to section 7.2.6 to install the three-piece exhaust manifold to the cylinder head. 7.2.6 Installation of Three-Piece Exhaust Manifold
Perform the following steps to install the exhaust manifold: 1. Install six exhaust manifold guide studs (J–36107) into the cylinder head in locations 1, 2, 3, 4, 5, and 6 to hold the three exhaust manifold gaskets in the correct position and facilitate manifold installation see Figure 2.
Figure 2
Exhaust Manifold Guide Stud Location
NOTE: The exhaust gasket can be positioned either way. Ensure the guide studs and gaskets are positioned correctly for the manifold being installed.
2. Install the exhaust gaskets to the guide studs. 3. Install the assembled exhaust manifold to the guide studs in locations 1, 2, 3, 4, 5, and 6. NOTE: To avoid torsional stress on the bellows, verify that the bellows clamps are not torqued and the exhaust manifolds can twist on the bellows pipe.
4. Install mounting bolts and spacers in locations 7, 8, 9, 10, 11, and 12 . Torque mounting bolts to 25-35 N·m (18-25 lb·ft). The bolts should be tightened enough to hold the exhaust manifold assembly in place when the guide studs are removed.
5. Remove the guide studs, from location 1, 2, 3, 4, 5, and 6 making sure the exhaust manifold has not moved. NOTE: If the manifold moves while removing the guide studs, loosen all bolts and go back to step 4. NOTE: If guide pins are used verify gasket position before installing bolts.
6. Install mounting bolts and spacers in locations 1, 2, 3, 4, 5, and 6 and torque bolts to 55-66 N·m (41-49 lb·ft). 7. Torque bolts to 55-66 N·m (41-49 lb·ft) in locations 7, 8, 9, 10, 11 and 12. 8. Torque the four bellows clamps to 12-14 N·m (9-10 lb·ft).
NOTE: Ensure the bellows clamps are orientated correctly. Incorrect orientation will interfere with turbocharger installation. See Figure 3.
1. Rear exhaust Manifold Clamp Orientation
3. EGR Upper Pipe Clamp Orietation
2. Front Exhaust Manifold Clamp Orientation
Figure 3
Exhaust Manifold Clamp Orientation
9. Install the front and rear exhaust shields and EGR tube bracket and secure with bolts. See Figure 4.
1. Bolt
6. Inner Tube
11. Front Exhaust Shield
2. Spacer
7. Bellows
12. EGR Delivery Pipe Bracket
3. Rear Exhaust Manifold
8. Clamp
13. Bolt
4. Stud
9. Exhaust Manifold Gasket
14. Stud
5. Center Exhaust Manifold
Figure 4
10. Front Exhaust Manifold
Three Piece Exhaust Manifold and Related Parts
15. Rear Exhaust Manifold Shield
10. Torque bolts to 58-73 N·m (43-54 lb·ft) using the proper tightening sequence. 11. Install any other equipment that was removed for this procedure.
ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic.
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.
12. Start the engine and check for exhaust leaks. 13. If exhaust gas leaks are detected, contact the Detroit Diesel Customer Support Center for further information (313–592–5800).
ADDITIONAL SERVICE INFORMATION
Additional service information is available in the Detroit Diesel EPA07 Series 60 Service Manual, 6SE2007. The next revision to this manual will be in July 2007.
Detroit Diesel®, DDC®, Series 60® and the spinning arrows design are registered trademarks of Detroit Diesel Corporation. © Copyright 2007 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.
