IK1201253 ­ Big Bore Exhaust Manifold Service Procedures

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IK1201253

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1/8/2015

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10/7/2015
Ben
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Title : Big Bore Exhaust Manifold Service Procedures
Applies To : EPA 10 MaxxForce 11, 13 and N13 Engines

CHANGE LOG
2015/10/07 - Updated torque spec for bellows tubes and heat shields
2015/10/05 - Fixed wording for step 19 (new bolts are Hex heads not Torx), Updated
SRT table/formatting
2015/08/25 - Initial Article Release




DESCRIPTION
This document will guide the user through step based procedures for troubleshooting and part replacement for exhaust manifold repairs.
This document replaces/retires:
- IK1200883
- TSI-13-12-10
- TSI-13-12-12

SYMPTOMS
Diagnostic Trouble Codes:
Not Applicable
Customer Observations or Concerns:
- Visible soot around the slip joints of the exhaust manifold
- Visible soot at the cylinder head to exhaust manifold interface
­ Exhaust odor present in the cab
- Possible low power

SPECIAL TOOLS
Tool Description
Coolant Management System

Tool Number

Comments

KL5007NAV

Instructions
Link

Tools Resource Center

SERVICE PARTS INFORMATION
Kit Description

Part Number

Qty

Notes

As Required

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IK1201253 ­ Big Bore Exhaust Manifold Service Procedures

Kit, Rear Exhaust Manifold
Seal

2512186C91

1

Manifold, Exhaust Rear

3005196C2

1

As Required

Manifold, Exhaust Rear

3018581C1

1

New, Thicker Flange

Manifold, Exhaust Middle

3018582C1

1

New, Thicker Flange

Manifold, Exhaust Front

3018583C1

1

New, Thicker Flange

Kit, Fey Rings (11L & 13L)

3007423C92

Kit, Rear Exhaust Manifold
Seal

2512878C91

1

Rear manifold bolt, spacer and
gasket kit for thicker flange only

Kit, Exhaust Bolts w/ Gaskets

2512877C91

1

Full manifold bolt, spacer and
gasket kit for thicker flange only

Kit, Cowl Tray

2511806C91

1

As Required

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1 or 2 As Required

DIAGNOSTIC STEPS

These diagnostic steps should be used if the driver has stated there is an exhaust odor in
the cab while the engine is running or if soot has been identified around the exhaust
manifold during routine maintenance or during another repair.

Step Action
Inspect engine for exhaust leaks/visible soot:

1

Decision
Yes. Proceed to step 2

Is there an exhaust leak (visible soot) at the cylinder head to manifold joint at cylinder No. Proceed to step 3
5 and/or cylinder 6?

Step Action
Inspect engine for exhaust leaks/visible soot:
Is there an exhaust leak (visible soot) at the cylinder head to manifold joint at any
other cylinder besides 5 and/or 6?

Decision
Yes. Perform complete manifold
replacement procedure then proceed to
step 5

2
No. Perform rear manifold replacement
procedure then proceed to step 5

Step Action
Inspect engine for exhaust leaks/visible soot:
3

Is there an exhaust leak (visible soot) at the cylinder head to manifold joint at any
other cylinder besides 5 and/or 6?

Decision
Yes. Perform complete manifold
replacement procedure then proceed to
step 5
No. Proceed to step 4

Step Action

Decision

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IK1201253 ­ Big Bore Exhaust Manifold Service Procedures

Inspect engine for exhaust leaks/visible soot:
4

Is there an exhaust leak (visible soot) at the exhaust manifold slip joints, the
connections between the front and middle or middle and rear exhaust manifold
pieces.

Step Action
Odor in cab:
5

If the driver has stated there is an odor in the cab inspect the hot side tubes
(bellows) for cracks. Are the tube cracked?

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Yes. Perform exhaust cuff procedure then
proceed to step 5
No. Proceed to step 5

Decision
Yes. Replace tubes per service manual
then proceed to step 6
No. Proceed to step 6

Step Action
Odor in cab:
6

If the driver has stated there is an odor in the cab perform the cowl tray repair
procedure

OVERVIEW
• Updated exhaust manifolds released (3018583C1, 3018582C1 and 3018581C1) which have thicker flanges and requires different

gaskets, bolts and spacers
◦ If ONLY replacing the rear section manifold you may use the thicker/updated flange manifold (3018581C1) which replaces the
old rear manifold (3005196C2), in combination with the original front and center manifold sections
◦ If the front or center section manifold needs replacement, and all sections are the "thinner" flange, replace all 3 sections to the
thicker/updated flange manifold following the service procedures in the Engine Service Manual

REPAIR STEPS
Rear (#5 and #6) Exhaust Manifold Removal and Installation
1. Bring truck into shop and park on flat surface.
2. Shift transmission to Park or Neutral, set parking brake, and install wheel chocks.
3. Unlatch and open hood.
4. Using Navistar Coolant Management Tool KL5007NAV, drain coolant.

To access rear exhaust manifold, remove engine cover. Refer to the proper CAB Service
Manual for the model of truck being serviced.
5. Remove engine cover.
6. Disconnect Aftertreatment Fuel Injector (AFI) coolant supply tube from EGR coolant crossover manifold and cap fitting.

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Figure 1: 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)
7. Remove heat shield (cylinders 4 - 6) (Figure 1, Item 1).

Figure 2: Outboard EGR Inlet Tube

Item 1: M8 x 25 heat-resistant bolt (4)
Itam 2: Middle exhaust manifold
Item 3: EGR inlet tube (cylinders 1 - 3)
8. Remove outboard EGR inlet tube and two gaskets (Figure 2, Item 3). Discard gaskets and bolts (Figure 2, Item 1).

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Figure 3: 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
9. Remove inboard EGR inlet tube and two tube gaskets (Figure 3, Item 1) . Discard gaskets and bolts (Figure 3, Items 2 & 3)

Figure 4: EGR Heat Shield

Item 1: EGR heat shield
Item 2: M8 x 12 bolt (3)
10. Remove EGR heat shield (Figure 4, Item 1).

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Figure 5: Rear Exhaust Manifold Ring Seal

Item 1: Ring seal clamp #1
11. If engine is equipped with an exhaust manifold ring seal, remove and discard (Figure 5, Item 1)

Figure 6: Rear Exhaust Manifold

Item 1: Exhaust manifold gasket (2)
Item 2: EGR tube gasket
Item 3: Sleeve spacer (6)
Item 4: Torx® bolt (6)
Item 5: Rear exhaust manifold
13. Separate rear exhaust manifold (Figure 6, Item 5) section from middle exhaust manifold.

Do not use air tools or abrasive pads to clean parts. Rear exhaust manifold sealing
surfaces may be cleaned with steam or suitable non-caustic solvents.
14. Clean rear exhaust manifold gasket sealing surfaces.

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Figure 7: Cylinder Head

Item 1: #5 and #6 exhaust manifold gasket sealing surfaces
Item 2: Middle exhaust manifold bore
15. Clean #5 and #6 exhaust manifold gasket sealing surfaces (Figure 7, Item 1) on cylinder head.

Exhaust leaks at the exhaust manifold joint will be resolved with the installation of the
exhaust manifold ring seal kit. Any grooves or wear in the center section manifold do not
need to be addressed.
16. Clean inside middle exhaust manifold bore (Figure 7, Item 2).

To prevent engine damage, hand torque all fasteners of the exhaust manifolds. The exhaust
manifold hardware has a special high-temperature coating that will be damaged by air tools.

To prevent engine damage, do NOT reuse sleeve spacers or exhaust manifold bolts
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

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Item 3: Sleeve spacer (6)
Item 4: Torx® bolt (6) (New bolts are Hex Heads)
Item 5: Rear exhaust manifold

Ensure that the raised part of exhaust manifold gasket faces out towards exhaust
manifold
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.

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

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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).

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.

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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.

Figure 13: EGR

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

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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 lb-ft (24 N-m).

Figure 15: Outboard EGR

Inlet Tube

Item 1: M8 x 25 heat-resistant bolt (4)