SERVICE MANUAL
MANIFOLDS
Section 2
CLEANING, INSPECTION & REPAIR
Clean Manifolds as Follows:
1.
Steam clean intake or intercooler and exhaust
manifolds (after removal and disassembly) to
dislodge dirt and carbon deposites.
Inspect and Repair Manifolds as Follows:
1.
Inspect the Intercooler or Intake manifold and
exhaust
manifold
bodies
and
flanges
for
CRACKS
and
DISTORTIONS.
Replace
damaged parts.
2.
Replace old gaskets with new gaskets at all
mating surfaces.
3.
DTI
ENGINE
ONLY:
After
disassembly,
pressure check intercooler core for leaks at 380
kPa (55 psi) core leak check pressure.
4.
Inspect exhaust manifold gasket flange for
warpage as follows:
a.
Install all cleaned exhaust manifold sections
(as a unit) to the cylinder head without
gaskets. Tighten with washers and nuts.
Torque to 81 N•m (60 Ibf-ft).
b.
Measure gap between cylinder head and
exhaust manifold gasket flange face with a
6 mm (1/4") wide feeler gauge. If 0.38 mm
(0.015") feeler gauge will pass gap in region
shown in Figure 6, resurfacing of exhaust
manifold gasket flanges must be performed
with all sections of manifold assembly
together. A maximum of 0.84 mm (0.025")
material can be removed.
Figure 6. - Exhaust Manifold Warpage
Resurface Exhaust Manifold Gasket Flanges as Follows:
1. Assemble ALL exhaust manifold sections.
2. Grind a maximum of 0.64 mm (0.025 in) material from gasket flanges.
3. After grinding, wash all mating surfaces with solvent to remove loose material.
CGES-185-3
PRINTED IN UNITED STATES OF AMERICA
Page 6
