Home » ISX11.9 CM2250 - Service Manual » Cummins ISX11.9 CM2250 – Service Manual 010-023   Air Intake Manifold

Cummins ISX11.9 CM2250 – Service Manual 010-023   Air Intake Manifold

Preparatory Steps

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 WARNING 

Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.
  • Disconnect the battery. Refer to the OEM service manual.
  • Disconnect the intake manifold air pressure/ temperature sensor from the engine harness. Refer to Procedure 019-159 in Section 19.
  • Disconnect the wire harness attachments from the air intake manifold.
  • Remove the air intake connection. Refer to Procedure 010-080 in Section 10.
  • Remove the charge-air piping connection to the air intake manifold. Refer to the OEM service manual.
  • Disconnect the air compressor supply line from the air intake manifold.  Refer to Procedure 012-024 in Section 12.
  • Remove the air compressor line mounting hardware. Refer to the OEM service manual.
  • Disconnect the air compressor discharge tube mounting hardware from the bottom side of the air intake manifold. Refer to the OEM service manual.
  • Remove the EGR crossover tube. Refer to Procedure 011-070 in Section 11.
  • Remove the ether injection hardware from the air intake manifold, if applicable. Refer to the OEM service manual.
  • Remove the intake air shutoff valve from the air intake manifold, if applicable. Refer to Procedure 010-143 in Section 10.
  • Remove the oil dipstick attachment hardware from the air intake manifold. Refer to the OEM service manual.
  • Disconnect the breather drain tube from the air intake manifold. Refer to Procedure 003-001 in Section 3.

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Remove

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Remove the four capscrews that hold the air intake manifold to the cylinder head.

Remove and discard the gasket.

Cover the cylinder head intake ports to prevent debris from entering the engine while the air intake manifold is removed.

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Clean and Inspect for Reuse

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 WARNING 

When using solvents, acids, or alkaline materials for cleaning, follow the manufacturer’s recommendations for use. Wear goggles and protective clothing to reduce the possibility of personal injury.
 WARNING 

Wear appropriate eye and face protection when using compressed air. Flying debris and dirt can cause personal injury.

NOTE: Before cleaning the inside of the air intake manifold, be sure to remove the air pressure/temperature sensor.

Clean the intake manifold gasket surface.

Clean the air intake manifold. Saturate the inside of the air intake with safety solvent.

Mineral based solvents can then be used, if the expected results with the safety solvent are not obtained.

Clean the debris with a non-abrasive brush.

Dry the air intake manifold with compressed air.

Inspect the air intake manifold for cracks and other damage.

Replace the air intake manifold if damage is found

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When inspecting the air intake manifold for oil or debris from the air system malfunction, also inspect the intake ports in the cylinder head for oil and debris.

Some soot buildup inside the cylinder head is normal and will not affect engine performance.

Clean the air intake to cylinder head surface with Scotch-Brite™ 7448 abrasive pad or a gasket scraper. Do not use power tools combined with an abrasive pad to clean the gasket surfaces.

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Clean the air intake manifold mounting capscrews.

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Inspect the air intake manifold mounting capscrews for stripped threads and other damage.

Replace the mounting capscrews if damage is found.

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Install

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If previously taped off, remove the tape from the cylinder head prior to installing the intake manifold.

Install two guide pins in the top two intake manifold capscrew mounting holes in the cylinder head before installing a new gasket.

Install the air intake manifold gasket over the guide pins.

Install the air intake manifold over the guide pins.

Install and hand-tighten the bottom two capscrews.

Remove the two guide pins and finish installing the remaining two capscrews hand-tight.

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Tighten the capscrews in the sequence illustrated.

Torque Value:  47  n.m  [35 ft-lb]

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Finishing Steps

TOC

 WARNING 

Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.
  • Connect the breather drain tube to the air intake manifold. Refer to Procedure 003-001 in Section 3.
  • Install the oil dipstick attachment hardware to the air intake manifold. Refer to the OEM service manual.
  • If removed, install the intake air shutoff valve to the air intake manifold. Refer to Procedure 010-143 in Section 10.
  • If removed, install the ether injection hardware to the air intake manifold. Refer to the OEM service manual.
  • Install the EGR crossover tube. Refer to Procedure 011-070 in Section 11.
  • Connect the air compressor discharge tube mounting hardware to the bottom side of the air intake manifold. Refer to the OEM service manual.
  • Install the air compressor line mounting hardware. Refer to the OEM service manual.
  • Connect the air compressor supply line to the air intake manifold.  Refer to Procedure 012-024 in Section 12.
  • Install the charge-air piping connection to the air intake manifold. Refer to the OEM service manual.
  • Install the air intake connection. Refer to Procedure 010-080 in Section 10.
  • Connect the wiring harness attachments to the air intake manifold.
  • Connect the intake manifold air pressure/ temperature sensor to the engine harness. Refer to Procedure 019-159 in Section 19.
  • Connect the batteries. Refer to the OEM service manual.
  • Operate the engine and check for leaks and proper operation.

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Last Modified:  03-Aug-2010