Cummins ISX11.9 CM2250 – Service Manual 011-007   Exhaust Manifold, Dry

NOTE: ISX11.9 CM2250 engines are equipped with exhaust seal rings at the slip joints.

Operate the engine and inspect the exhaust manifold for leaks at the slip joints.

If the exhaust manifold is leaking at the slip joints, it must be repaired.

WARNING  Coolant is toxic. Keep away from children and pets. If not reused, dispose of in accordance with local environmental regulations.

WARNING  Do not remove the pressure cap from a hot engine. Wait until the coolant temperature is below 50°C [120°F] before removing the pressure cap. Heated coolant spray or steam can cause personal injury.

NOTE: Brush away any loose dirt from around the area of the air handling connections to avoid contamination of the interior of the engine.

NOTE: Use protective caps from the Air Handling Clean Care Kit, Part Number 4919799, to cover all open connection points.

• Drain the cooling system. Refer to Procedure 008-018 in Section 8.
• Remove the variable geometry turbocharger (VGT). Refer to Procedure 010-033 in Section 10.
• Loosen the bellows connection between the exhaust manifold and EGR cooler.
• Remove the EGR cooler. Refer to Procedure 011-019 in Section 11.
• Remove the exhaust gas pressure sensor tube. Refer to Procedure 011-027 in Section 11.
• Remove the exhaust manifold heat shield. Refer to Procedure 011-032 in Section 11.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.

Remove the two upper mounting capscrews and install two guide studs into the top center section mounting location.

Remove the remaining mounting capscrews, spacers, and the exhaust manifold assembly.

Remove and discard the gaskets.

Cover open points on the exhaust manifold and cylinder head using the heavy tape provided in the Air Handling Clean Care Kit, Part Number 4919799.

Disassemble the exhaust manifold end sections.

WARNING  Wear safety glasses or a face shield, as well as protective clothing, to reduce the possibility of personal injury when using a steam cleaner or high pressure water.

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

Steam clean the components.

Dry with compressed air.

Use a soft cloth or a shop towel wetted with a safety solvent to remove carbon deposits from the sealing surfaces.

Inspect the mounting surfaces for cleanliness and damage.

Inspect the exhaust manifold turbocharger mounting flange for warpage. The exhaust manifold mounting surface must be flat to within 0.25 mm [0.010 in]. The turbocharger mounting flange must have a surface flatness of 0.13 mm [0.005 in].

After cleaning, if visible gouges can be felt with your finger across the sealing bead area, it is not acceptable. Replace the manifold.

NOTE: A charge-air cooler malfunction can cause progressive damage to the exhaust manifold. If the exhaust manifold is damaged, check the charge-air cooler. Refer to Procedure 010-027 in Section 10.

Inspect for cracks or other damage.

Check that the exhaust seal is fully seated against the shoulder of the exhaust manifold male end section.

If the exhaust seal ring is not fully seated against the shoulder, the exhaust seal ring must be replaced.

Inspect the exhaust manifold seal bore for wear.

Inspect the exhaust seal ring for signs of damage or excessive wear.

The exhaust seal ring must not show signs of dents or other signs of damage.

Measure the wear width on the exhaust seal ring.

The wear width must not be more than 1mm [0.04 in] wide anywhere on the seal.

A wear width larger than 1 mm [0.04 in] indicates excessive wear and the exhaust seal must be replaced.

The wear width must be uniform around the seal ring. If one side of the exhaust seal ring is worn more than the other, the exhaust seal ring must be replaced.

Inspect the exhaust manifold slip-joints for signs of soot leakage.

If there is no evidence of an exhaust leak from the slip-joints and there are no visible cracks or other damage, do not remove the exhaust manifold seal rings.

If there is evidence of a malfunction or other damage, remove the exhaust manifold seal rings.

Remove the exhaust seal ring, located within the slip-joint.

Use tin snips or side cuts to cut half way through the seal in two locations about 25.4 mm [1 in] apart.

NOTE: Take care not to damage the seal carrier surface.

Grasp the portion of the seal between the cuts with a pair of pliers.

Twist and pull the seals off of the exhaust manifold end sections.

Discard the exhaust seal rings.

Inspect the exhaust seal ring mating surfaces of the male and female sections of the exhaust manifolds.

If scratches or nicks can be felt with a fingernail on the exhaust seal ring mating surfaces, the exhaust manifold section must be replaced.

Cover the open points on the exhaust manifold with heavy tape to prevent engine contamination.

Place the exhaust seal ring onto the lip of the Exhaust Seal Installer, Part Number 4918709.

Use a light coat of grease, or clean engine oil, to lubricate the exhaust seal ring during assembly onto the male and female sections of the exhaust manifolds.

Position the seal installer and seal ring in line with the sealing surface on the exhaust manifold and strike with a lead or dead blow hammer until the seal is fully seated.

Install the exhaust manifold end sections to the center section.

The end section bolt holes must be 152.4 mm [6 in] center to center before installing onto the cylinder head.

Remove the tape from the open exhaust ports and cylinder head.

Install two guide studs into the center section mounting location.

Do not use adhesive, grease, or heavy grease to hold the gaskets in place on the cylinder head.

Install a new center section gasket.

NOTE: Special capscrews with spacers are required for this manifold.

Do not use short capscrews.

WARNING  This component weighs 23 kg [50 lb] or more. To reduce the possibility of personal injury, use a hoist or get assistance to lift this component.

Install the exhaust manifold over the guide studs.

Apply a film of high-temperature anti-seize compound to the capscrew threads to make sure of proper loading on the capscrews.

Slide each manifold gasket between the exhaust manifold and the cylinder head.

Install the capscrews and spacers through the exhaust manifold and gasket into the cylinder head.

Remove the two guide studs and install the two remaining capscrews.

Tighten the capscrews in the sequence shown.

• Install the exhaust gas pressure sensor tube. Refer to Procedure 011-027 in Section 11.
• Install the EGR cooler inlet coollant connection. Refer to Procedure 011-031 in Section 11.
• Tighten the bellows connection between the exhaust manifold and EGR cooler. Refer to Procedure 011-024 in Section 11.
• Install the variable geometry turbocharger. Refer to Procedure 010-033 in Section 10.
• Install the exhaust manifold heat shield. Refer to Procedure 011-032 in Section 11.
• Remove the protective caps and heavy tape.
• Install the charge-air cooler piping. Refer to the OEM service manual.
• Fill the cooling system. Refer to Procedure 008-018 in Section 8.
• Operate the engine and check for air leaks and exhaust gas leaks.