Exhaust Manifold Replacement

TM 9-2320-363-34-1 · Chapter 3 — Power Package Maintenance

WARNING Exhaust manifold weighs 60 lb (27 kg). Use extreme caution during removal to prevent possible injury to personnel.

2. REMOVE REMAINING EIGHT BOLTS (1) AND EXHAUST MANIFOLD (3) FROM CYLINDER HEAD (4).

3. REMOVE AND DISCARD EXHAUST MANIFOLD GASKETS (5).

4. SECURE CENTER SECTION OF EXHAUST MANIFOLD (3) IN SOFT-JAWED VISE. USING BRASS DRIFT AND HAMMER ON CENTER SECTION SIDE OF FLANGES (6), DRIVE END SECTIONS OF EXHAUST MANIFOLD OFF.

5. IF DAMAGED, REMOVE AND DISCARD FOUR TURBOCHARGER MOUNTING STUDS (7).

TM page 3-69

Use general cleaning methods to clean all parts (page 2-30).

1. INSPECT EXHAUST MANIFOLD FOR CRACKS, PARTICULARLY IN MOUNTING BOLT BOSS AREAS. IF CRACKED, DISCARD EXHAUST MANIFOLD SECTION.

2. INSPECT ALL PARTS FOR WEAR OR DAMAGE.

WARNING Exhaust manifold weighs 60 lb (27 kg). Use extreme caution during installation to prevent possible injury to personnel.

1. SECURE CENTER SECTION OF EXHAUST MANIFOLD (1) IN SOFT-JAWED VISE.

NOTE Perform steps 2 and 3 if turbocharger mounting studs were removed.

2. INSTALL TWO NUTS (2) ON FOUR NEW TURBOCHARGER MOUNTING STUDS (3), USING ONE NUT AS JAM NUT.

3. THREAD NEW TURBOCHARGER MOUNTING STUDS (3) INTO EXHAUST MANIFOLD (1) UNTIL UNTHREADED PORTION OF STUD BOTTOMS AGAINST MOUNTING FLANGE. TIGHTEN STUDS TO 18-24 LB-FT (25-32 N.m). REMOVE TWO NUTS (2).

4. INSTALL END SECTIONS (4) ON CENTER SECTION OF EXHAUST MANIFOLD (1). POSITION AND SEAT END SECTIONS (4) BY TAPPING OUTBOARD SIDE OF FLANGE (5) WITH FIBER OR PLASTIC MALLET.

TM page 3-70 Change 1

Illustration from TM 9-2320-363-34-1 (PDF page 142)

5. INSTALL FOUR GUIDE STUDS (6) IN CYLINDER HEAD (7) IN BOLT HOLES NO. 1, NO. 3, NO. 10, AND NO. 12.

NOTE

Exhaust manifold gaskets can be installed with bead facing in or out. Make sure guide studs and exhaust manifold gaskets are positioned correctly for exhaust manifold installation.

6. INSTALL THREE NEW EXHAUST MANIFOLD GASKETS (8) ON GUIDE STUDS (6).

7. INSTALL EXHAUST MANIFOLD (1).

8. INSTALL EIGHT BOLTS (9) IN MOUNTING HOLES.

9. REMOVE FOUR GUIDE STUDS (6) AND INSTALL REMAINING FOUR BOLTS (9).

10. TIGHTEN BOLTS TO 43-54 LB-FT (58-73 N.m) IN SEQUENCE SHOWN.

NOTE Follow-on Maintenance:

Install turbocharger (page 3-101). Install breather tube (page 3-78).

TM page Change 1 3-70.1

Illustration from TM 9-2320-363-34-1 (PDF page 143)

This task covers: a. Removal b. Cleaning c. Inspection d. Installation

Applicable Configuration:                        Equipment Condition:

All except M915A2 and M916A1                     Reference              Condition Description

Tools and Special Equipment:                     Page 3-101             Turbocharger Removed

Shop Equipment, SC 4910-95CL-A31                 Page 3-78              Breather Tube Removed
Tool Kit, SC 5180-90-CL-N05
                                                 General Safety Instructions:
Materials/Parts:

Gasket (3)     P/N 23511666

TM page 3-70.2 Change 1

Illustration from TM 9-2320-363-34-1 (PDF page 144)

1. REMOVE THREE NUTS (1), HEAT SHIELD (2), THREE STUD BOLTS (3), TWO BOLTS (4), AND FIVE SPACERS (5) FROM EXHAUST MANIFOLD (6).

WARNING Exhaust manifold weighs 60 lb (27 kg). Use extreme caution during removal or installation to prevent possible injury to personnel.

2 REMOVE REMAINING SEVEN BOLTS (4), SPACERS (5) AND EXHAUST MANIFOLD (6) FROM CYLINDER HEAD (7).

NOTE Each of the three gaskets is in two pieces.

3. REMOVE AND DISCARD THREE GASKETS (8).

4. SECURE CENTER SECTION OF EXHAUST MANIFOLD (6) IN SOFT JAWED VISE. USING BRASS DRIFT, REMOVE EACH END SECTION (9) OF EXHAUST MANIFOLD.

5. IF DAMAGED, REMOVE AND DISCARD FOUR TURBOCHARGER MOUNTING STUDS (10).

Use general cleaning methods to clean all parts (page 2-30).

TM page Change 1 3-70.3

Illustration from TM 9-2320-363-34-1 (PDF page 145)

1. INSPECT EXHAUST MANIFOLD FOR CRACKS, PARTICULARLY IN MOUNTING BOLT BOSS AREAS. IF CRACKED, DISCARD EXHAUST MANIFOLD SECTION.

2. INSPECT ALL PARTS FOR DAMAGE

1. SECURE CENTER SECTION OF EXHAUST MANIFOLD (1) IN SOFT JAWED VISE.

NOTE Perform steps 2 and 3 if turbocharger mounting studs were removed.

2. INSTALL TWO NUTS (2) ON FOUR NEW TURBOCHARGER MOUNTING STUDS (3), USING ONE NUT AS JAM NUT.

3. THREAD NEW TURBOCHARGER MOUNTING STUDS (3) INTO EXHAUST MANIFOLD (1) UNTIL UNTHREADED PORTION OF STUD BOTTOMS AGAINST MOUNTING FLANGE. TORQUE STUDS TO 18-24 LB-FT (25-32 N.m). REMOVE TWO NUTS FROM EACH STUD.

4. INSTALL END SECTIONS (4) ON CENTER SECTION OF EXHAUST MANIFOLD (1). POSITION AND SEAT END SECTIONS BY TAPPING WITH FIBER OR PLASTIC MALLET.

5. INSTALL THREE NEW GASKETS (5), EXHAUST MANIFOLD (1), TWELVE SPACERS (6), NINE BOLTS (7), AND THREE STUD BOLTS (8) TO CYLINDER HEAD (9).

TM page 3-70.4 Change 1

Illustration from TM 9-2320-363-34-1 (PDF page 146)

6. TORQUE ALL BOLTS (7 AND 8) TO 43-54 LB-FT (58-73 N.m) IN SEQUENCE SHOWN.

NOTE Failure to cut the gaskets into two halves may result in leakage after installation

7. USING TIN SNIPS, CUT EACH OF THREE GASKETS (5) INTO TWO HALVES AS SHOWN

8. INSTALL HEAT SHIELD (10) WITH THREE NUTS (11).

NOTE Follow-on Maintenance: Install turbocharger (page 3-101). Install breather tube (page 3-78).

TM page 3-71