Detroit Diesel — EGR Exhaust Manifold Installation
Repair & overhaul
From a Detroit Diesel service manual — check it applies to your exact model before use.
Before you start
- The front, cylinders 1 and 2, exhaust manifold gasket has a diagonal cut along the end. Cylinders 3 – 6 use the same type of gasket. Ensure the exhaust manifold gaskets are installed in the correct location.
- Stud must be installed on exhaust manifold center piece before fitting the two end pieces of manifold into center piece.
- Upper heat shield bolt closest to front of engine is torqued before assembly is attached to engine due to impossible access after attachment to engine.
- The exhaust manifold gasket studs are to be removed after installing the EGR cooler support bracket.
Procedure
- Install the exhaust manifold guide studs to the cylinder head and mount the three exhaust manifold gaskets.
- Install stud with M8 nut with collar onto exhaust manifold center piece. Do not tighten nut.
- Install the fey rings (2 in each groove) in the two grooves of each exhaust manifold end piece.
- Fit fey-ring ends of exhaust manifold pieces into center part of exhaust manifold. Do not use lubricant.
- Bolt upper heat shield with six mounting bolts (M8 x 12mm). Finger-tighten; torque first bolt nearest front to 25 N·m (18 lb·ft).
- Bolt lower heat shield to upper heat shield with one captured bolt and washer (M8 x 12mm). Torque to 25 N·m (18 lb·ft).
- Install entire exhaust manifold assembly onto cylinder heads, lifting right (front) side first. Torque all 12 mounting bolts to 50 N·m (38 lb·ft), crisscross sequence.
- Torque remaining three lower heat shield mounting bolts to 25 N·m (18 lb·ft).
- Torque remaining five upper heat shield mounting bolts to 25 N·m (18 lb·ft).
- Install the fey rings (4 per groove) on the gas inlet pipe leading to exhaust manifold center piece. Do not use lubricant.
- Gently push gas inlet pipe into center exhaust manifold piece. Do not use lubricant.
- Push gas inlet pipe of heat exchanger into throttle valve. Tighten positioning clamp screw to 10 N·m (7 lb·ft).
- Screw nut onto stud in exhaust manifold. Fit stud in bracket attached to gas inlet pipe. Attach nut to outer edge of bracket.
- Adjust 219 mm (8.62 in.) dimension on stud; apply 25 N·m (18 lb·ft) tightening torques per Step One to Step Five of Figure 7-18.
Specs & values
- Upper/lower heat shield bolts: 25 N·m (18 lb·ft)
- 12 exhaust manifold mounting bolts: 50 N·m (38 lb·ft), crisscross sequence
- Throttle valve positioning clamp screw: 10 N·m (7 lb·ft)
- Stud dimension: 219 mm (8.62 in.)
- Stud nuts: 25 N·m (18 lb·ft)
Source: Detroit Diesel service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.