Service Manual

ISB, ISBe and QSB (Common Rail [...] Exhaust Manifold, Dry
Section 11 - Exhaust System - Group 11 Page 11-3
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WARNING
When using a steam cleaner, wear safety glasses or a
face shield, as well as protective clothing. Hot steam
can cause serious personal injury.
WARNING
Wear appropriate eye and face protection when using
compressed air. Flying debris and dirt can cause
personal injury.
Use steam to clean the exhaust manifold. Dry with
compressed air.
Clean the two-piece sealing joint.
NOTE: For two-piece exhaust manifolds, the sealing joint
must come apart. If the joint does not come apart,
replace the exhaust manifold.
Use 240-grit inert cloth to remove carbon deposits from
the sealing surfaces.
Inspect the parts for cracks and damage.
NOTE: If the exhaust manifold is damaged, check the
charge air cooler. A damaged charge-air cooler can cause
progressive damage to the exhaust manifold. Refer to
Procedure 010-027 in Section 10.
Check for exhaust system-related fault codes. Use
INSITE™ electronic service tool.
Inspect the gasket surfaces for gouges, scratches, or
burnout.
Inspect the two-piece sealing joint for signs of exhaust
leaks. If exhaust leaks are present at the joint, replace the
manifold.
Use a precision straightedge, Part Number 4918219, to
check the manifold mounting surfaces for flatness. Lay the
straightedge on edge across all ports and measure the
flatness with a feeler gauge.
Exhaust Manifold Flatness
mm in
0.20 MAX 0.008
If any port measures out of specification, machine or
replace the manifold.
NOTE: For multi-piece manifolds, each section must be
verified to be flat, independently. If either section is found
to be out of specification, replace both sections of the
manifold.
The assembled two-piece manifold is not required to
meet the flatness specification of the one piece manifold,
as some misalignment is allowed in the design of the
manifold. Some misalignment will be eliminated naturally
when the manifold capscrews are tightened to
specification during installation.