17. Install rear exhaust manifold into middle exhaust manifold.

Figure 8: Rear

Exhaust Manifold

Item 1: Exhaust manifold gasket (2)
Item 2: EGR tube gasket
Item 3: Sleeve spacer (6)
Item 4: Torx® bolt (6) (New bolts are Hex Heads)
Item 5: Rear exhaust manifold

The new exhaust manifold gasket is symmetric and can be installed in any
orientation
18. Position two new exhaust manifold gaskets (Figure 8, Item 1) and install rear exhaust manifold (Figure 8, Item 5) assembly.
19. Install six new Hex bolts and six new sleeve spacers included in kit 2512878C91 (Figure 8, Items 4 and 3)
20. Alternately tighten six new exhaust manifold bolts working from the inside - out and torque to 25 lb­ft (34 N•m), recheck torque and then turn
bolts an additional 90 degrees.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 6/1/2017

IK1201253 ­ Big Bore Exhaust Manifold Service Procedures

Page 9 of 25

Figure 9: Rear Exhaust Manifold Ring Seal Packing

Item 1: Seal packing
21. Wrap seal packing (Figure 9, Item 1) around manifold ring joint and align so that seal ends meet at top of manifold.
22. Press seal packing tightly into joint with fingers.

Figure 10: Rear Exhaust Manifold Ring Seal Ceramic Mat Wrap

Item 1: Ceramic mat wrap
Item 2: Ceramic mat wrap joint
Item 3: Manifold midpoint
23. Wrap manifolds and seal packing with ceramic mat wrap, covering seal packing with thick end of ceramic mat wrap (Figure 10, Item 1).
24. Align ceramic mat wrap joint (Figure 10, Item 2) with manifold midpoint (Figure 10, Item 3).

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 6/1/2017

IK1201253 ­ Big Bore Exhaust Manifold Service Procedures

Page 10 of 25

Figure 11: Exhaust Manifold Ring Seal Cross Section

Item 1: Female manifold
Item 2: Shield
Item 3: Seal packing
Item 4: Ceramic wrap
Item 5: Beveled flange
Item 6: Male manifold

Verify shield completely covers ceramic mat wrap, and ceramic mat wrap
overlaps seal packing (Figure 11)
25. Install two shield halves with beveled flange (Figure 11, Item 5) covering seal packing (Figure 11, Item 3) end, and align shield joint with
manifold midpoint.

Figure 12: Rear

Exhaust Manifold Ring Seal

Item 1: Ring seal clamp #1

Ring seal clamp alignment must match the clamp alignment in Figure 12 to
prevent problems when installing the outboard EGR inlet tube.
26. Install #1 ring seal clamp (Figure 12, Item 1) center of shield.
27. Tighten #1 ring seal clamp to 2.58 lb-ft (3.5 N•m) while keeping the shield joint aligned with manifold midpoint.

For complete heat shield (cylinders 4 - 6), EGR heat shield and EGR inlet tube
installation procedures, refer to the appropriate Engine Service Manual.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 6/1/2017

IK1201253 - Big Bore Exhaust Manifold Service Procedures

Figure 13: EGR

Page 11 of 25

Heat Shield

Item 1: EGR heat shield
Item 2: M8 x 12 bolt (3)
28. Install EGR heat shield (Figure 13, Item 1) with five M8 x 12 bolts (Figure 13, Item 2).

Figure 14: Inboard EGR

Inlet Tube

Item 1: Inboard EGR inlet tube
Item 2: M8 x 25 heat-resistant bolt (2)
Item 3: Heat­resistant bolt (2)
Item 4: Rear exhaust manifold
29. Position two new EGR inlet tube gaskets, one to EGR valve and one to rear exhaust manifold (Figure 14, Item 4).
30. Install inboard EGR inlet tube and tighten bolts (Figure 14, Items 2 and 3) to 18 lb­ft (24 N­m).

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 6/1/2017

IK1201253 - Big Bore Exhaust Manifold Service Procedures

Figure 15: Outboard EGR

Page 12 of 25

Inlet Tube

Item 1: M8 x 25 heat-resistant bolt (4)
Itam 2: Middle exhaust manifold
Item 3: Outboard EGR inlet tube
31. Position two new EGR inlet tube gaskets, one to EGR valve and one to middle exhaust manifold (Figure 15, Item 2).
32. Install outboard EGR inlet tube and tighten bolts (Figure 15, Item 1) to 18 lb-ft (24 N-m).

Figure 16: Heat Shield

(Cylinders 4 - 6)

Item 1: Heat shield (cylinders 4 - 6)
Item 2: M8 x 25 heat-resistant bolt (2)
Item 3: 8.4 x 16 x 1.6 washer (3)
Item 4: M8 x 12 bolt (3)
33. Install heat shield (Figure 16, Item 1). Tighten bolts to 23 lb-ft (31 N-m).
34. Uncap fitting and connect AFI coolant supply tube to EGR coolant crossover manifold. Torque to 23 lb-ft (31 N-m).

For engine cover installation procedure, refer to proper CAB Service Manual
for the model of truck being serviced.
35. Install engine cover.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 6/1/2017

IK1201253 - Big Bore Exhaust Manifold Service Procedures

Page 13 of 25

36. Using Navistar Coolant Management Tool KL5007NAV, fill cooling system. Verify coolant is between MIN and MAX line of deaeration tank.
Add coolant as required.
37. Close and latch hood.
38. Remove wheel chocks.

Front Exhaust Manifold Ring Seal (Cuff) Removal / Installation
1. Bring truck into shop and park on flat surface.
2. Shift transmission to Park or Neutral, set parking brake and block wheels
3. Unlatch and open hood

Do NOT drain coolant and disconnect AFI coolant supply line when servicing
the front exhaust manifold ring seal.

Figure 17: HP Turbocharger Connections
Item 1: Air inlet duct clamp
Item 2: Air inlet duct
Item 3: HPCAC
Item 4: HPCAC clamp (2)
Item 5: HPCAC pipe
Item 6: HP turbocharger outlet duct
Item 7: LP turbocharger inlet duct
4. Remove air inlet duct clamp (Figure 17, Item 1) and remove air inlet duct (Figure 17, Item 2) from Low-Pressure (LP) turbocharger inlet duct (Figure 17, Item
7)
5. Remove two High-Pressure Charge Air Cooler (HPCAC) clamps (Figure 17, Item 4) and remove HPCAC pipe (Figure17, Item 5) from HPCAC (Figure 17,
Item 3) and HP turbocharger outlet duct (Figure 17, Item 6).
6. Install cap on HPCAC.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 6/1/2017

IK1201253 - Big Bore Exhaust Manifold Service Procedures

Page 14 of 25

Figure 18: HP and LP Turbocharger Connections
Item 1: LP turbocharger inlet duct
Item 2: MAF sensor connector
Item 3: TC2CIP sensor connector
Item 4: LP turbocharger inlet duct bolt (2)
Item 5: HP turbocharger outlet duct bolt (2)
Item 6: HP turbocharger outlet duct
Item 7: HP turbocharger
Item 8: AIT sensor connector
7. If equipped, disconnect Mass Air Flow (MAF) sensor connector (Figure 18, Item 2)
8. Disconnect Turbocharger 2 Compressor Inlet Pressure (TC2CIP) sensor connector (Figure 18, Item 3)
9. Disconnect Air Inlet Temperature (AIT) sensor connector (Figure 18, Item 8) and position engine harness aside.
10. Remove two HP turbocharger outlet duct bolts (Figure 18, Item 5) and HP turbocharger outlet duct (Figure 18, Item 6) from HP turbocharger (Figure 18, Item
7). Remove and discard O-ring seal.
11. Remove two LP turbocharger inlet duct bolts (Figure 18, Item 4) and LP turbocharger inlet duct (Figure 18, Item 1) from LP turbocharger. Remove and
discard O­ring Seal
12. Install plugs in turbocharger openings.

Figure 19: Coolant Supply Tubes
Item 1: Coolant return tube P-clamp (2)
Item 2: Coolant return tube
Item 3: Coolant supply tube
Item 4: HP turbocharger inlet duct bolt (2)

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 6/1/2017

IK1201253 - Big Bore Exhaust Manifold Service Procedures

Page 15 of 25

Item 5: HP turbocharger inlet duct
Item 6:Coolant supply tube P-clamp
Item 7: Coolant tube P-clamp bolt (2)
13. Remove two coolant tube P-clamps (Figure 19, Item 7) from two coolant return tube P-clamps (Figure 19, Item 1), coolant supply tube P-clamp (Figure 19,
Item 6), coolant return tube (Figure 19, Item 2) and coolant supply tube (Figure 19, Item 3).
14. Position coolant return tube (Figure 19, Item 2) and coolant supply tube (Figure 19, Item 3) aside.

The lower HP turbocharger inlet duct bolt does not come all the way out due
to interference with the waster reservoir. Removal of the washer reservoir is
not required.
15. Remove two HP turbocharger inlet duct bolts (Figure 19, Item 4) from HP turbocharger inlet duct (Figure 19, Item 5).

Figure 20: Air Control Valve
Item 1: ACV
Item 2: CCOS housing sensor connector
Item 3: CCOS housing outlet hose
16. Disconnect air supply line from Air Control Valve (ACV)
17. Remove three mounting bolts from ACV (Figure 20, Item 1) and position ACV aside.
18. Disconnect CCOS housing outlet hose (Figure 20, Item 3) from CCOS housing.
19. Disconnect CCOS housing sensor connector (Figure 20, Item 2).

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 6/1/2017

IK1201253 ­ Big Bore Exhaust Manifold Service Procedures

Page 16 of 25

Figure 21: Crankcase Breather Tube
Item 1: Crankcase breather tube
Item 2: Clamp
Item 3: Bolt
20. Remove bolt (Figure 21, Item 3) from clamp (Figure 21, Item 2) and position crankcase breather tube (Figure 21, Item 1) aside.

Figure 22: CCOS Housing
Item 1: CCOS housing
Item 2: HP turbocharger inlet duct
Item 3: Oil jet plate

Do NOT remove the four Torx bolts from the oil jet plate
21. Remove three CCOS housing bolts from CCOS housing (Figure 22, Item 1) and oil jet plate (Figure 22, Item 3)

While pulling out on the HP turbocharger inlet duct, maneuver and remove the
COOS housing up and out (Figure 22).

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 6/1/2017

IK1201253 ­ Big Bore Exhaust Manifold Service Procedures

Page 17 of 25

22. While pulling out HP turbocharger inlet duct (Figure 20, Item 2) remove CCOS housing (Figure 20, Item 1) from oil jet plate.
23. Cover CCOS mount openings with shop towel.

For complete EGR cooler L-bracket and exhaust manifold heat shield removal
procedures, refer to MaxxForce 11 and 13 Engine Service Manual

Figure 23: EGR Cooler L-Bracket
Item 1: EGR cooler L-bracket
Item 2: M8 x 25 heat-resistant bolt (4)
Item 3: Spacer
Item 4: Exhaust manifold heat shield
24. Remove EGR cooler L­bracket (Figure 23, Item 1)

Figure 24: Exhaust Manifold Heat Shield
Item 1: Exhaust manifold heat shield
Item 2: M8 x 12 bolt
25. Remove exhaust manifold heat shield (Figure 24, Item 1)

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 6/1/2017

IK1201253 ­ Big Bore Exhaust Manifold Service Procedures

Page 18 of 25

Figure 25: Front Exhaust Manifold Ring Seal
Item 1: Ring seal clamp #1
Item 2: Ring seal clamp #2
26. Remove and discard failed front exhaust manifold ring seal(s) if applicable (Figure 25, Items 1&2)

Figure 26: Front Exhaust Manifold Ring Seal Packing
Item 1: Seal packing
27. Wrap seal packing (Figure 26, Item 1) around manifold ring joint and align so that seal ends meet at top of manifold
28. Press seal packing tightly into joint with fingers

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 6/1/2017

IK1201253 ­ Big Bore Exhaust Manifold Service Procedures

Page 19 of 25

Figure 27: Front Exhaust Manifold Ring Seal Ceramic Mat Wrap
Item 1: Ceramic mat wrap
29. Wrap manifolds and seal packing with ceramic mat wrap (Figure 27, Item 1) covering seal packing with thick end of ceramic mat wrap.

Figure 28: Front Exhaust Manifold Ring Seal Ceramic Mat Wrap Alignment
Item 1: Ceramic mat wrap join
Item 2: Manifold midpoint
30. Align ceramic mat wrap joint (Figure 28, Item 1) with manifold midpoint (Figure 28, Item 2)

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 6/1/2017

IK1201253 ­ Big Bore Exhaust Manifold Service Procedures

Page 20 of 25

Figure 29: Front Exhaust Manifold Ring Seal Shields
Item 1: Beveled flange
Item 2: Manifold midpoint

Figure 30: Exhaust Manifold Ring Seal Cross Section
Item 1: Female manifold
Item 2: Shield
Item 3: Seal packing
Item 4: Ceramic wrap
Item 5: Beveled flange
Item 6: Male manifold

Verify shield completely covers ceramic mat wrap, and ceramic mat wrap
overlaps seal packing (Figure 30)
31. Install two shield halves with beveled flange (Figure 29, Item 1) on seal packing end and align join with manifold midpoint.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 6/1/2017

IK1201253 ­ Big Bore Exhaust Manifold Service Procedures

Page 21 of 25

Figure 31: Exhaust Manifold Ring Seal/Clamp

Ring seal clamp alignment must match the clamp alignment in to prevent
problems when installing the exhaust manifold heat shield.
32. Install ring seal clamp (Figure 31) center of shield.
33. Tighten 1 ring seal clamp to 2.58 lb-ft (3.5 N•m) while keeping the shield joint aligned with manifold midpoint.

For complete EGR cooler L-bracket and exhaust manifold heat shield
installation procedures and torque specifications, refer to MaxxForce 11 and
13 Engine service Manual.

Full Exhaust Manifold Replacement/Installation
Please follow the service procedures within the Service Manual to remove and install the front, center and rear manifold sections

2015 N13 and A26 EXHAUST MANIFOLD SERVICE
The latest exhaust manifolds used on the 2015 N13 and the A26 engine, do not have serviceable sections and do not use cuffs at the
joints. These manifolds come pre­assembled and cannot be serviced in the field.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 6/1/2017

IK1201253 ­ Big Bore Exhaust Manifold Service Procedures

Page 22 of 25

Current Manifold Joint Design

SERVICE PART(s) INFORMATION
Part Number

Description

2514916C94

2015 N13 Exhaust Manifold Assembly

2517630C91

A26 Exhaust Manifold Assembly

CURRENT REPAIR GUIDELINES
Visible exhaust leaking from the front or rear joints
• Replace complete manifold asssembly

Visible exhaust leaking from the mounting gaskets at the exhaust ports
• Remove the exhaust manifold, clean and inspect the components for reuse per the latest Service Manual
• If the manifold meets reuse guidelines, install the manifold using new gaskets and mounting hardware.
• If the manifold does not meet reuse guidelines, replace the complete manifold assembly.

Always use new mounting hardware and gaskets when installing the exhaust manifold to the head.

WARRANTY INFORMATION
Warranty Claim Coding:
Group:

12000 - Engine

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 6/1/2017

IK1201253 ­ Big Bore Exhaust Manifold Service Procedures

Noun:

Page 23 of 25

356 - Manifold Assembly, Exhaust
358 ­ Gasket, Exhaust Manifold
359 - Seal Ring, Exhaust Manifold

Standard Repair Times:

Step Description

Chassis

Engine

SRT

EPA10 MaxxForce
11/13

N12-6356U

WorkStar

EPA10 N13

N12-6356US

EPA10 MaxxForce
11/13

Q12-6356U

EPA10 N13

Q12-6356US

EPA10 MaxxForce