SERVICE MANUAL
MANIFOLDS
Section 2
INSTALLATION
D and DT ENGINES ONLY
Install Manifolds as Follows:
1.
Install Intake manifold with NEW gasket. Be
sure manifold bolts are properly Indexed with
each gasket bolt hole. Failure to follow this
procedure can result In gasket misalignment.
2.
Secure intake manifold bolts with a torque of 27
N•m (20 Ibf-ft).
3.
Install exhaust manifold with NEW gasket.
4.
Use only specially hardened washers between
manifold studs & nuts. Manifolds may loosen if
non-specified washers are used. Torque
manifold stud nuts to 77 N•m (57 Ibf-ft).
5.
Reconnect fuel lines (3, Fig. 3 or 3, Fig. 3a) to
injection nozzle and pump. Torque fuel line
fittings to 47 N•m (35 Ibf-ft).
6.
Install the Turbocharger and outlet pipe (if
equipped).
DTI ENGINES ONLY
Reassemble Intercooler as Follows:
1.
Install core Into housing.
2.
Install cover onto housing.
3.
Install flanges onto water Inlet and outlet ports,
using new gaskets.
Install Intercooler and Exhaust Manifolds as Follows:
1.
Install Intercooler to cylinder head, using new
gaskets.
2.
Install aneroid tube (6, Fig. 4 or 5, Fig. 4a) and
fuel injection lines.
3.
Install exhaust manifold with a new gasket.
Torque bolts to 77 N•m (57 Ibf-ft).
4.
Install the Turbocharger and outlet pipe. Refer
to Turbocharger Section 1.
NOTE: IH "NEVER SEEZ" is to be used on all
exhaust system bolts, studs, fasteners, etc.
CGES-185-3
PRINTED IN UNITED STATES OF AMERICA
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