IK1201253 ­ Big Bore Exhaust Manifold Service Procedures

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STATES, MEXICO, NEW ZEALAND

Document
ID:

IK1201253

Availability:

ISIS, FleetISIS, IsSIR

Revision:

15

Major System: ENGINES

Created:

1/8/2015

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English

Last
Modified:

6/7/2018

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Author:

Greg
Scheff

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Title : Big Bore Exhaust Manifold Service Procedures
Applies To : EPA 10 MaxxForce 11 & 13, 2013-2014 N13 Engines, 2015 N13 and A26 Engines.

CHANGE LOG
2018/06/07 ­ Feedback Response ­ Manifold mounting bolts to the head must be extracted if broken
2018/06/06 - Feedback Response - Diag step clarification
2018/06/04 - Feedback Response - N13B / A26 manifold service
2018/06/04 - Added note to discontinue attempts to extract broken exhaust bolts, warranty no longer covers these attempts.
2017/05/30 ­ Added 2015 N13 and A26 manifold service information.
2017/04/19 - Added manifold type ID information, revised diagnostic steps for each manifold type.




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

Qty

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IK1201253 ­ Big Bore Exhaust Manifold Service Procedures

Part Number

Notes

Kit, Rear Exhaust Manifold
Seal

2512186C92

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

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

7092423C92

-

Ceramic mat wrap assembly

Kit, Exhaust Manifold Seal

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1 or 2 As Required
Rear manifold bolt, spacer and gasket kit for thicker flange only

EXHAUST MANIFOLD VERSION IDENTIFICATION

Use the graphic above to identify which center section manifiold version you have, current thick flange or
earlier thin flange design. Use only the center section for the visual reference.

DIAGNOSTIC STEPS - LOCATE THE SOURCE OF THE EXHAUST LEAK

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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-Thin Flange Design. Perform
complete manifold replacement procedure
then proceed to step 5.
Yes­Thick Flange Design. Remove and
reseal complete manifold to head using new
gaskets, proceed to step 5.

2
No-Thin Flange Design. Perform rear
manifold replacement procedure then
proceed to step 5.
No­Thick Flange Design. Reseal rear
manifold section then proceed to step 5.

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-Thin Flange Design. Perform
complete manifold replacement procedure
then proceed to step 5.
Yes-Thick Flange Design. Remove and

3

reseal complete manifold to head using new
gaskets, proceed to step 5.

No. Proceed to step 4

Step Action
Inspect manifold slip joints 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
sections?

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?

Decision
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
6

Odor in cab:

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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

Common Manifold Bolt Failure Locations

It is not uncommon on units with higher mileage to have bolts break off in the
manifold sections, bellows tubes, or EGR valve during disassembly (See
Above). If this occurs, it is recommended to replace the part or component vs
attempting to extract the broken bolt(s). Warranty will no longer pay for
attempting to extract broken bolt(s) from these exhaust system
components.

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.

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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.

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).