IK1200949 ­ 2010 I­6 Exhaust Manifold Soot Accumulation and Operating Characteristics

Page 1 of 8

Countries:

CANADA, UNITED STATES, PUERTO
RICO

Document ID: IK1200949

Availability:

ISIS, Bus ISIS, FleetISIS

Revision:

6

Major System:
Current
Language:

ENGINES

Created:
Last
Modified:

9/24/2013

Author:

Erik Wass

English

Other Languages: NONE
Viewed:

6/16/2014

2748
Less Info

Coding Information

Hide Details

Copy Link

Copy Relative Link

Bookmark

Add to Favorites

Print

Provide Feedback

View My Bookmarks

Helpful

Not Helpful

33

7

Title : 2010 I-6 Exhaust Manifold Soot Accumulation and Operating Characteristics
Applies To : 2010 + MaxxForce DT, 9, 10 (ESN 3,300,000 and later)

Overview: Exhaust Manifold Operating Characteristics
Below are examples of normal exhaust manifold operating conditions that DO NOT require manifold/gasket replacement.


Exhaust manifold slip joint between ports 2 and 3 will intermittently leak upon initial cold start-up (aka slip joint blow by).

 The EGR Cooler to Exhaust manifold slip joint (Goose Neck) will also intermittently leak at initial cold start-up (normal).
 These brief “cold whiffs” of gas do not affect engine or after treatment performance, even though soot buildup may appear as if there
is a significant leak.
 Cold start-up “whiffs” seal upon initial engine temperature rise via thermal expansion.
 Black soot tracking is often found on the underside of the heat-shield and cast surfaces that are in close proximity of the slip joints and
goose neck fey rings. NOTE: YOU WILL NOT SEE HEAVY SOOT BUILDUP ON THE MANIFOLD JOINTS THEMSELVES DUE TO THE
HIGH MANIFOLD TEMPERATURES BURNING OFF ANY SOOT IT COMES IN CONTACT WITH.
 Soot buildup in these areas are often mis­diagnosed as gasket leaks. The key thing to look for to pinpoint a leaking gasket (without
removing the manifold) is to inspect for gasket damage specifically, not just soot buildup. Follow diagnostic procedure below for gasket
condition. IMPORTANT: It is NOT standard procedure anymore to remove the manifold to measure it for warping. If the manifold is
removed to replace a failed/blown out gasket, the manifold gets replaced and gets a cuff seal installed at the slip joint between ports 2
and 3. (note: in instances where the manifold is being removed/replaced, it is easier to install cuff on the manifold prior to mounting the
manifold to the head). Currently, there is not a cuff solution in place for the EGR slip joint. Cuff seal p/n is listed at the end of the article.
Note that all pictures taken below were from engines with 40­80 hrs and 1000­2000 miles on them.
Figure 1
Soot trail from a slip joint upon visual inspection of the manifold: Note the close proximity of the soot trail in relation to the slip joint where
the two manifolds come together. (Note the soot is not built up on the joint itself, just on the head surface)

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/2/2014

IK1200949 ­ 2010 I-6 Exhaust Manifold Soot Accumulation and Operating Characteristics

Page 2 of 8

Figure 1

Figure 2
shows a slip joint with soot tracking on the manifold flange and cylinder head surface. This comes from the manifold slip joint, not from
between the flange and cylinder head - often mistaken for a gasket leak. Once again, note that there is NO soot buildup on the joint itself.

Figure 2

Figure 3
shows the soot did not leak from the gasket mating surfaces of the exhaust manifold to the cylinder head. Notice there is no soot from the
inner seal ring of the gasket port to the outer edge of the gasket, just an outline of soot from the manifold flange. This soot buildup came
from an exterior source. (i.e. fey ring/slip joint leakage as shown above)

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/2/2014

IK1200949 ­ 2010 I-6 Exhaust Manifold Soot Accumulation and Operating Characteristics

Page 3 of 8

Figure 3

Figure 4
This is a heat shield (EGR ‘gooseneck’) connection at manifold. The source of soot at this specific location would be from the fey ring joint
(slip joint), which seals up with thermal expansion. If the fey rings themselves are seized in place or damaged then replace them
but please note that replacing the fey rings or the manifold may NOT eliminate soot buildup at this joint or under the heat shield. NOTE:
THIS WILL NOT CAUSE A REGEN OR PERFORMANCE ISSUE.

Figure 4

Figure 5
A “buckled” exhaust manifold gasket is not a defective part, the manifold and gaskets expand and contract (slide) with each thermal
expansion cycle.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/2/2014

IK1200949 ­ 2010 I-6 Exhaust Manifold Soot Accumulation and Operating Characteristics

Page 4 of 8

Figure 5

Note: All of the preceding conditions shown do not require manifold/gasket replacement. Soot trails at these areas WILL NOT
cause frequent regen's or performance issues.
If soot trails are found at the manifold slip joint between ports 2 and 3 and/or at the EGR connection of the manifold, DO NOT replace the
manifold/gasket based solely on these findings. Please see the diagnostic procedure below to determine if the manifold & gasket need to
be replaced or if a cuff seal only will suffice. There is currently no cuff seal correction for the EGR connection. NOTE: the p/n for the cuff
may come up as a Big Bore part - this will ALSO fit on 2010 Maxxforce DT, 9 and 10.
Manifold/Gasket Diagnostic Steps Below (option: interactive diag. link or written out, step-by-step procedure. Same procedures,
two different formats):
Automated Diagnostic link:
Click here for Soot buildup/Exhaust manifold gasket automated diagnostic procedure
Step Base Diag. Table:

Step

Action

Decision

Visually inspect entire
manifold/gasket area for soot.
Is there any soot
accumulation?

Yes: Proceed to step 2.

1

No: DO NOT remove the manifold. Install cuff seal
p/n: 7092423C91 at the slip joint between ports 2
and 3. END OF REPAIR.

2
Inspect for soot between ports
2/3. Is there any soot?

Yes: Proceed to step 3.

No: Proceed to step 4.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/2/2014

IK1200949 ­ 2010 I-6 Exhaust Manifold Soot Accumulation and Operating Characteristics

Page 5 of 8

3

THOROUGHLY review
the iKnow article you are
currently in: 1200949

Yes: See figures 1 and 2 just below this diag.
procedure for gasket position criteria and proceed to
step 4.


Inspect the top AND
bottom portion of the gasket.
Is the gasket slipped out of
place at #3?
No: Proceed to step 5.

4
Is the gasket position
acceptable per the criteria in
figures 1 and 2?

Yes: Proceed to step 5.

NO: Replace manifold and gasket with p/n:
7092501C9* and install cuff seal p/n: 7092423C91
on the slip joint between ports 2/3. END OF
REPAIR.

5
Inspect for soot near port 6. Is
there any soot?

Yes: Proceed to step 6.

No: Proceed to step 8.

6

THOROUGHLY review
the iKnow article you are
currently in: 1200949

Yes: See figures 3 and 4 just below this diag.
procedure below for gasket position criteria and
proceed to step 7.


Inspect the back of the
gasket at #6. Is the gasket
slipped out of place?
No: Proceed to step 8.
7
Is the gasket position
acceptableper the criteria in
figures 3 and 4?

Yes: Proceed to step 8.

No: Replace manifold and gasket with p/n:
7092501C9* and install cuff seal p/n: 7092423C91
on the slip joint between ports 2/3. END OF
REPAIR.

8
Inspect for soot in other areas
such as turbo housings, top of
EGR cooler housing, EGR
crossover pipe, exhaust
clamps etc. Is there any soot
found at these areas?

Yes:Proceed tostep 9.

No: Install cuff seal 7092423C91 at the slip joint
between ports 2 and 3. END OF REPAIR.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/2/2014

IK1200949 ­ 2010 I­6 Exhaust Manifold Soot Accumulation and Operating Characteristics

Page 6 of 8

9
Inspect turbo downpipe/doser
pipe gasket(s) for leaks or
loose v­band clamps. Were
any leaks detected?

Yes: Repair as necessary and install cuff seal
7092423C91 at the slip joint between ports 2 and 3.
END OF REPAIR.

No:Proceed to step 10.

10
Inspect the manifold for
cracks, particularly around
cylinder 4. Were any cracks
found?

Yes: Replace manifold and gasket with p/n:
7092501C9* and install cuff seal p/n: 7092423C91
on the slip joint between ports 2/3. END OF
REPAIR.

No: Please open a tech services case file with
description of the steps you have taken so far and
wait for assistance.

Figures that correlate to steps 3 and 6 of the diagnostic procedure above:
Figure 1 – “Good” manifold gasket, bottom of cyl. #3

Figure 2 ‐ "Bad" manifold gasket, bottom of cyl. #3

This image shows ACCEPTABLE gasket position –
if the gasket holes are aligned HALFWAY OR
BETTER with respect to the bolt hole in the head,
DO NOT replace the manifold or gasket. WITHOUT
removing the manifold, install cuff seal 7092423C91.
No case file/iApproval required.

This image shows UNACCEPTABLE gasket position – if the
gasket holes are misaligned or overlapped MORE THAN
HALFWAY across the bolt hole in the head, then replace the
manifold and gasket with kit: 7092501C92 or subsequent and
install cuff seal 7092423c91 at the slip joint between ports 2 and
3. No case file/iApproval required.

Figure 3 – “Good” manifold gasket, back of cyl. #6

Figure 4 ‐ "Bad" manifold gasket, back of cyl. #6

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/2/2014

IK1200949 ­ 2010 I-6 Exhaust Manifold Soot Accumulation and Operating Characteristics

This image shows ACCEPTABLE gasket
position – If the gasket is protruding out from
the manifold flange LESS THAN 3/8”, then DO
NOT replace the manifold or gasket.
WITHOUT removing the manifold, install cuff
seal 7092423C91 at the slip joint between
ports 2 and 3. No case file/iApproval required.

Figure 6 - Cuff Seal Assembly

Page 7 of 8

This image shows UNACCEPTABLE gasket position – If the gasket has
protruded out from the manifold flange MORE THAN than 3/8,” then replace
the manifold and gasket with kit: 7092501C92 or subsequent and install cuff
seal 7092423c91 at the slip joint between ports 2 and 3. No case file/iApproval
required.

Figure 7 - Cuff Seal Assembly (broken down)

Possible Part Number Needed:

PART

Cuff Seal

PART NUMBER

7092423c9*

Cuff Seal Standard Repair Times (cuff seal ONLY):
Click here for cuff seal SRT times

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/2/2014

IK1200949 ­ 2010 I­6 Exhaust Manifold Soot Accumulation and Operating Characteristics

Page 8 of 8

NOTE: Cuff seal SRT's are only to be applied when installing one on an EXISTING manifold (manifold NOT removed). Cuff seal SRT is
NOT to be added to a claim when a manifold & gasket are being replaced. This is included into the manifold & gasket SRT.
Below are examples of exhaust manifold conditions that will require manifold & gasket replacement. These include:
• Gasket damage that is UNACCEPTABLE per the diagnostic procedure, when gasket condition is questionable (not obviously blown
out)
• Squealing or noisy exhaust
• Obvious signs of manifold gasket failure - completely blown out, severely slid out of position or deemed "UNACCEPTABLE" per the
diagnostic procedure.
◦ The gasket damage must be consistent with the information in the diagnostic procedure (above)
◦ The diag. procedure needs to be followed to determine if a gasket has failed or is near failure without removing. The two most
common failures are #3 and #6. Look at the unused bolt hole at the bottom of #3 to see if it is misaligned more than halfway or
not. For #6, inspect to see if the gasket is protruding more than 3/8" away from the edge of the manifold flange. If the gasket
you are inspecting indicates a replacement is required per the diagnostic procedure replace the manifold and gasket and
install a cuff seal with the part numbers listed. NO CASE FILE NECESSARY.
• Cracked or damaged exhaust manifolds (no case file required, just photograph the crack in the manifold for warranty)
Warranty Coding:
Group

Noun

12000

356

12000

358

Possible Part Number Needed:

PART

Exhaust
manifold Kit

PART NUMBER

7092501C9*

Exhaust Manifold and gasket Standard Repair Times (Cuff seal installation included):
Click here for exhaust manifold+gasket SRT times
NOTE: No iApproval or case file is necessary for installing a cuff seal only (without removing manifold) or replacing a
CRACKED manifold.
Hide Details

Feedback Information
Viewed:

2747

Helpful:

33

Not Helpful: 7
No Feedback Found

Copyright © 2014 Navistar, Inc.

https://evalue.internationaldelivers.com/service_kb/DocTool/ArticleViewer.aspx?ControlID... 7/2/2014