Course Code: N13 Engine Exhaust Manifold Service Study Guide

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1 Course Code: N13 Engine Exhaust Manifold Service Study Guide

2 2015 Navistar, Inc Navistar Drive, Lisle, IL All rights reserved. No part of this publication may be duplicated or stored in an information retrieval system without the express written permission of Navistar, Inc.

3 N13 Engine Exhaust Manifold Service Study Guide Table of Contents Introduction... 1 Objectives... 1 Before you Begin... 2 Front Exhaust Manifold Cuff Seal... 2 Rear Exhaust Manifold Cuff Seal... 4 Exhaust Manifold Assembly... 7 Conclusion... 9 NOTES... 9 THE INFORMATION PROVIDED WITHIN THIS COURSE IS FOR TRAINING PURPOSES ONLY. ALWAYS CONSULT THE LATEST SERVICE, DIAGNOSTIC, AND TOOL INFORMATION, LOCATED ON NAVISTAR S SERVICE PORTAL, PRIOR TO PERFORMING SERVICE ON NAVISTAR ENGINES, VEHICLES, AND EQUIPMENT. Introduction Welcome to the Navistar training course: 2015 N13 Engine Exhaust Manifold Service. This course is intended to demonstrate the inspection and replacement of the Exhaust Manifold and the Exhaust Manifold Cuffs on the 2015 N13 engine. Objectives The 2015 N13 uses a unique, 3 piece, exhaust manifold and exhaust manifold cuff seals. Upon completion of this course, the student will be able to: Inspect the exhaust system for leaks. Replace the front and rear exhaust cuff seals. Replace the exhaust manifold.

2015 N13 Engine Exhaust Manifold Service Study Guide 2 Before you begin this procedure: Before you Begin Park the vehicle on a level surface. Shift the transmission into Park or Neutral.

4 2015 N13 Engine Exhaust Manifold Service Study Guide 2 Before you begin this procedure: Before you Begin Park the vehicle on a level surface. Shift the transmission into Park or Neutral. Set the parking brake. Install a set of wheel chocks. Front Exhaust Manifold Cuff Seal Inspect exhaust leakage around the front exhaust manifold cuff seal by locating the front and center exhaust manifolds. If there is soot buildup around the front exhaust manifold cuff seal, the seal will need to be replaced. To replace the front exhaust manifold cuff seal, begin by removing the Air Cleaner Duct to access the engine. Disconnect the Open Breather Tube Assembly from the Crankcase Oil Separator (CCOS) outlet. Disconnect the Crankcase Oil Separator Speed (CCOSS) sensor from the CCOS. Remove the three CCOS mounting bolts and remove the CCOS from the oil module assembly. After gaining access to the front exhaust manifold cuff seal, remove the clamp securing the cuff seal. Then remove the two halves of the cuff seal from the exhaust manifold. To install a new exhaust manifold cuff seal ensure the exhaust manifold is clean and free of debris. Install the new exhaust manifold cuff seal onto the exhaust manifold and verify that the ceramic mat covers the connection point between the front and center exhaust manifolds. Secure the exhaust manifold cuff seal into place by installing the cuff seal clamp and tightening it to the proper torque specification.

5 N13 Engine Exhaust Manifold Service Study Guide Position the CCOS back onto the oil module assembly, and install the three mounting bolts. Tighten the mounting bolts to the proper torque specification. Then reconnect the CCOSS, reconnect the Open Breather Tube Assembly, and reinstall the Air Cleaner Duct.

2015 N13 Engine Exhaust Manifold Service Study Guide 4 Rear Exhaust Manifold Cuff Seal Inspect exhaust leakage around the rear exhaust manifold cuff seal by locating the rear and center exhaust

6 2015 N13 Engine Exhaust Manifold Service Study Guide 4 Rear Exhaust Manifold Cuff Seal Inspect exhaust leakage around the rear exhaust manifold cuff seal by locating the rear and center exhaust manifolds. If there is soot buildup around the rear exhaust manifold cuff seal, it will need to be replaced. To access the rear exhaust manifold cuff seal, start by removing the engine housing cover. Once access to the rear of the engine is gained, disconnect the engine harness from the Oxygen Sensor, NOx sensor, and the Aftertreatment Fuel Injector (AFTFI). Next, remove the Rear Coolant Manifold. Remove the two upper bolts from the Coolant Manifold Pipe support bracket, as well as the two bolts securing the Coolant Manifold Pipe to the EGR cooler. Remove the Coolant Manifold Pipe and support bracket assembly. After removing the five bolts from the outside EGR heat shield, remove the outside EGR heat shield from the rear exhaust manifold and EGR cooler. Remove the five bolts securing the rear exhaust manifold heat shield as well as the heat shield itself.

5 2015 N13 Engine Exhaust Manifold Service Study Guide After gaining access to the rear exhaust manifold cuff seal, remove the clamp securing the cuff seal.

7 N13 Engine Exhaust Manifold Service Study Guide After gaining access to the rear exhaust manifold cuff seal, remove the clamp securing the cuff seal. Then remove the two halves of the cuff seal from the exhaust manifold. To install a new exhaust manifold cuff seal, ensure the exhaust manifold is clean and free of debris. Install the new exhaust manifold cuff seal onto the exhaust manifold and verify that the ceramic mat covers the connection point between the rear and center exhaust manifolds. Secure the exhaust manifold cuff seal into place by installing the cuff seal clamp and tightening it to the proper torque specification.

2015 N13 Engine Exhaust Manifold Service Study Guide 6 Position the rear exhaust manifold heat shield and secure it into place with the mounting bolts.

Tighten all bolts to the proper torque specification. Position the Coolant Manifold Pipe and support bracket assembly into place and secure it with the mounting bolts.

8 2015 N13 Engine Exhaust Manifold Service Study Guide 6 Position the rear exhaust manifold heat shield and secure it into place with the mounting bolts. Tighten all bolts to the proper torque specification. Reinstall the outside EGR heat shield into place and secure it with the five mounting bolts. Tighten all bolts to the proper torque specification. Position the Coolant Manifold Pipe and support bracket assembly into place and secure it with the mounting bolts. Ensure all bolts are tightened to the proper torque specification. Next, install the Rear Coolant Manifold. Connect the engine harness to the Oxygen sensor, the NOx sensor, and the AFTFI. Once the engine has been reassembled, reinstall the engine housing cover.

7 2015 N13 Engine Exhaust Manifold Service Study Guide Exhaust Manifold Assembly In order to inspect the exhaust manifold assembly, it will first need to be accessed.

9 N13 Engine Exhaust Manifold Service Study Guide Exhaust Manifold Assembly In order to inspect the exhaust manifold assembly, it will first need to be accessed. Follow the proper procedures in the Engine Service Manual to remove the: Interstage Charge-Air-Cooler (ISCAC) Low Pressure (LP) Turbocharger assembly High Pressure (HP) Turbocharger assembly Rear Coolant Manifold Coolant Manifold Pipe Front and Rear Exhaust Manifold Heat Shields Rear EGR Bellows Tube Once the exhaust manifold is clearly visible, inspect the individual manifold sections for significant damage or pitting that could cause a leak. While inspecting for damage or pitting, inspect for signs of an exhaust leak between the exhaust manifold and the cylinder head. If the exhaust manifold is damaged or there is a leak at the cylinder head mating surface, replace the exhaust manifold assembly. To replace the exhaust manifold, remove and discard the bolts and sleeve spacers that secure the exhaust manifold assembly to the cylinder head. Carefully remove the exhaust manifold assembly from the engine. When installing a new exhaust manifold assembly, start by slightly loosening the two exhaust manifold cuff seal clamps so the individual sections of the manifold are able to rotate independently of each other.

10 2015 N13 Engine Exhaust Manifold Service Study Guide 8 TO PREVENT ENGINE DAMAGE, HAND TORQUE ALL FASTENERS OF THE EXHAUST MANIFOLDS. THE EXHAUST MANIFOLD HARDWARE HAS A SPECIAL HIGH-TEMPERATURE COATING WHICH WILL BE DAMAGED BY AIR TOOLS. TO PREVENT ENGINE DAMAGE, DO NOT REUSE SLEEVE SPACERS OR EXHAUST MANIFOLD BOLTS. TO PREVENT ENGINE DAMAGE, DO NOT APPLY ANTI-SEIZE COMPOUND TO THREADS. Install two alignment pins into the top right bolt hole of cylinders 2 and 5, install an exhaust manifold gasket onto each alignment pin, and carefully place exhaust manifold assembly into position using the alignment pins as guides. Install new bolts and sleeve spacers into the remaining bolt holes of cylinders 2 and 5. Then replace the alignment pins with new bolts and sleeve spacers. Once the manifold is supported by the bolts, loosely install the rear exhaust manifold gaskets, bolts, and sleeve spacers. Repeat this process, working towards the front of the engine, until all gaskets, bolts, and sleeve spacers have been installed. Once all of the bolts have been installed, tighten the bolts to the proper torque specification. Then tighten the two exhaust manifold cuff seal clamps to the proper torque specification. To reinstall the components that were removed to access the exhaust manifold, install the: Rear EGR Bellows Tube Front and Rear Exhaust Manifold Heat Shields Coolant Manifold Pipe Rear Coolant Manifold High Pressure (HP) Turbocharger assembly Low Pressure (LP) Turbocharger assembly Interstage Charge Air Cooler (ISCAC)

11 N13 Engine Exhaust Manifold Service Study Guide Conclusion This concludes the Navistar training course: 2015 N13 Exhaust Manifold Servicing. Thank you for your participation. NOTES

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