NOTE: The following steps are for Rear Gear Train engines only. Loosen the EGR cooler coolant inlet line support bracket capscrew (1) and remove the EGR cooler coolant inlet fitting (2). Rotate the EGR cooler coolant inlet fitting support bracket away from the coolant inlet. Disconnect and remove the EGR cooler coolant inlet line from… Read More »
Remove the EGR cooler to exhaust manifold capscrews and spacers (1) and the EGA cooler mounting capscrews (2). Remove the EGR assembly. Cover open connections with protective caps from the Air Handling Clean Care Kit, Part Number 4919498. NOTE: For Rear Gear Train engines, if pressure checking or removing the EGR cooler as part of… Read More »
If equipped , remove the pipe plug from the pressure tap located in the turbocharger exhaust outlet tubing or the inlet of the aftertreatment system . Install the service tool pressure gauge, Part Number ST1273, or equivalent, into the pressure tap location. Install the service tool pressure/vacuum module, Part Number 3164491 , or equivalent, into… Read More »
Use INSITE’M electronic service tool to check for fault codes. If any faults are present, follow the troubleshooting steps as outlined in the corresponding fault code troubleshooting procedure.
When measuring exhaust restriction, it is preferred that the measurement point be within 1 pipe diameter of the turbocharger outlet. If this requirement can not be met, make sure to inspect the exhaust outlet tubing between the turbocharger outlet and the exhaust pressure tap location for damage to the exhaust piping.
Apply high-temperature anti-seize compound to the exhaust manifold capscrew threads. Install the exhaust manifold , new gaskets, and spacers. Follow the tightening sequence shown in the illustration. NOTE: To aid in alignment of the exhaust manifold , two capscrew passages have a smaller diameter than the other passages. The location of these varies with manifold… Read More »
Mix roughly 1 to 2 ounces of exhaust manifold sealant into a small plastic disposabe cup. Mix thoroughly until the sealant is homogeneous. Use VersaChem® Qualco’M Part Number, 00160 or equivalent. Apply an even, liberal layer of exhaust manifold sealant 19 mm (0. 75 in] wide directly to the male end of the manifold. The… Read More »
Clean the sealing surfaces of the cylinder head and the exhaust manifold with a gasket scraper or a wire brush. Take caution to keep all debris out of the cylinder head. Dry with compressed air. Inspect the cylinder head bosses and turbocharger mounting studs for damage. Repair or replace as necessary. NOTE: If the exhaust… Read More »
If equipped, remove the exhaust manifold mounting capscrew lockplates. Remove the twelve exhaust manifold mounting capscrews and spacers. Remove the exhaust manifold. Cover open points in the exhaust manifold and cylinder head with heavy tape, if repair is delayed.
Visually inspect the area surrounding the two piece exhaust manifold slip joint. If signs of soot, discoloration, grease, or other exhaust leak symptoms are present, the two piece manifold must be assembled again with sealant. See the Slip Joint Repair information in the Install section of the procedure.