Removing the exhaust manifold Cummins ISF2.8 Gazelle Next

Removing and refitting the Cummins ISF2.8 GAZelle Next exhaust manifold

We remove the exhaust manifold when repairing the cylinder head or replacing the manifold gasket.

We disconnect the battery negative terminal. The manifold is cast iron, secured to the cylinder head with eight M8 bolts with sleeves; the cylinder head–manifold gasket is a multi-layer metal gasket, and the manifold–turbocharger gasket is metal.

Terminal marked minus on the battery — We disconnect the battery negative terminal

We remove the air filter and the air supply hose (article — Replacing the air filter).

Air filter housing and air supply hose — We remove the air filter and the air supply hose

We remove the exhaust gas recirculation valve together with the heat exchanger.

Recirculation valve with heat exchanger on the engine — We remove the recirculation valve together with the heat exchanger

We undo the three nuts and one bolt securing the turbocharger to the manifold.

Three nuts and a bolt on the turbocharger flange — We undo the three nuts and one bolt securing the turbocharger to the manifold

We undo the securing bolt and detach from the manifold the bracket of the recirculation heat exchanger.

Bolt of the recirculation heat exchanger bracket — We detach from the manifold the recirculation heat exchanger bracket

We undo the eight bolts securing the exhaust manifold to the cylinder head.

Eight bolts on the exhaust manifold flange — We undo the eight bolts securing the exhaust manifold to the cylinder head

We take the bolts with sleeves out of the holes.

Bolts with sleeves taken out of the holes — We take the bolts with sleeves out of the holes

We carefully pull the exhaust manifold upwards.

Manifold raised upwards — We carefully pull the exhaust manifold upwards

Sliding the exhaust manifold off the mounting studs at the turbocharger flange, we remove it.

Manifold slid off the turbocharger studs — Sliding the manifold off the studs, we remove it

We remove the gasket between the cylinder head and the exhaust manifold.

Metal cylinder head–manifold gasket — We remove the gasket between the cylinder head and the exhaust manifold

We remove the gasket fitted between the manifold and the turbocharger.

Gasket between the manifold and the turbocharger — We remove the gasket between the manifold and the turbocharger

We clean the contact surfaces of the cylinder head and the exhaust manifold.

Using No. 240 abrasive paper, we remove the carbon deposits from the cylinder head contact surface.

We check the parts for the absence of cracks and other damage (if the exhaust manifold is damaged, the charge air cooler must be checked).

A fault in the charge air cooler can cause damage to the exhaust manifold.

Using a straightedge and a feeler gauge, we check the flatness deviation of the exhaust manifold support surfaces.

Straightedge and feeler gauge on the manifold support surface — We check the flatness deviation of the manifold support surfaces

Placing the straightedge over all the holes, we measure the flatness deviation with the feeler gauge.

If the flatness deviation of the exhaust manifold exceeds 0.13 mm, the manifold must be replaced or machined.

We apply graphite grease to the bolt threads.

We fit the gasket and the bolts securing the turbocharger to the exhaust manifold.

We fit the exhaust manifold to the cylinder head and lightly secure it with the bolts.

We tighten the exhaust manifold securing bolts in the sequence shown in the figure. Tightening torque: 42 N·m.

Diagram of the manifold bolt tightening sequence — We tighten the bolts in the sequence shown in the figure

We reassemble all parts in the reverse order.

We fill the engine coolant.