EXHAUST MANIFOLD

TM 9-2815-225-34&P · Work Package 0025 00

DISASSEMBLY, CLEANING AND INSPECTION, ASSEMBLY

INITIAL SETUP

Tools and Special Tools
 General mechanic’s tool kit:
    automotive (Item 1, WP 0061 00)
 Maintenance and repair shop equipment:
    automotive (Item 2, WP 0061 00)
 Automotive maintenance and repair
    supplemental set no. 2 (Item 3, WP 0061 00)

Materials/Parts
 Antiseize compound (Item 7, WP 0060 00)
 Pipe sealant (Item 25, WP 0060 00)
 Two spacer inserts
   (Item 1, Table 9, WP 0062 00)

Equipment Condition
 Exhaust manifold removed from engine
   (WP 0009 00).

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DISASSEMBLY

NOTE Big Cam I engines utilize a conventional log-type exhaust manifold. Big Cam III engines utilize a pulse-type exhaust manifold and a new design exhaust manifold with 2 spacer inserts. Disassembly and assembly of exhaust manifolds are basically alike for both engines. Exhaust manifold parts are fitted together tightly and may require extreme force to separate. Perform steps 1 through 3 for Big Cam I.

1. Remove front exhaust manifold (1) and rear exhaust manifold (4) from center exhaust manifold (2).

2. Remove two pipe plugs (3) from center exhaust manifold (2).

3. Remove four turbocharger mounting studs (5) from center exhaust manifold (2).

NOTE Perform steps 4 and 5 for Big Cam III.

4. Remove front exhaust manifold (6) and rear exhaust manifold (9) from center exhaust manifold (7).

5. Remove four turbocharger mounting studs (8) from center exhaust manifold (7).

NOTE Perform steps 6 through 8 for Big Cam III new design.

6. Remove front exhaust manifold (10) and rear exhaust manifold (14) from spacer inserts (11).

7. Remove two spacer inserts (11) from center exhaust manifold (12). Discard spacer inserts (11).

8. Remove four turbocharger mounting studs (13) from center exhaust manifold (12).

CLEANING AND INSPECTION

1. For general parts cleaning information, refer to CLEANING, WP 0051 00.

2. For general parts inspection information, refer to INSPECTION, WP 0051 00.

NOTE Replace any part that does not pass visual inspection or is outside specified wear limits.

3. Inspect front exhaust manifold (1), (6), and (10), center exhaust manifold (2), (7), and (12), and rear exhaust manifold (4), (9), and (14) for cracks, distortion, and corrosion.

4. Inspect turbocharger mounting studs (5), (8), and (13) for stripped threads. Repair all damaged threads.

5. Inspect center exhaust manifold (2), (7), and (12) for stripped threads or damaged holes. Repair all damaged threads and holes.

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ASSEMBLY

NOTE Perform steps 1 through 4 for Big Cam III new design.

1. Install four turbocharger mounting studs (4) in center exhaust manifold (3).

2. Install two new spacer inserts (2) in center exhaust manifold (3).

3. Apply antiseize compound to mating surfaces of front exhaust manifold (1), spacer inserts (2), and rear exhaust manifold (5).

4. Install front exhaust manifold (1) and rear exhaust manifold (5) on spacer inserts (2).

NOTE Perform steps 5 through 7 for Big Cam III.

5. Install four turbocharger mounting studs (8) in center exhaust manifold (7).

6. Apply antiseize compound to mating surfaces of front exhaust manifold (6), center exhaust manifold (7), and rear exhaust manifold (9).

7. Install front exhaust manifold (6) and rear exhaust manifold (9) on center exhaust manifold (7).

NOTE Perform steps 8 through 11 for Big Cam I.

8. Install 4 turbocharger mounting studs (14) in center exhaust manifold (11).

9. Apply pipe sealant on 2 pipe plugs (12) and install pipe plugs (12) in center exhaust manifold (11).

10. Apply antiseize compound to mating surfaces of front exhaust manifold (10), center exhaust manifold (11), and rear exhaust manifold (13).

11. Install front exhaust manifold (10) and rear exhaust manifold (13) on center exhaust manifold (11).

12. Install exhaust manifold on engine (WP 0046 00).

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