Page 90 - CTS - Mechanic Diesel - TP

MECHANIC DIESEL - CITS

EXERCISE 3.5: Servicing the exhaust system

Objectives

At the end of this exercise you shall be able to
• remove and clean the manifold, silencer, tail pipe and refit
• remove and clean the catalytic converter, muffer and refit it.

Requirements

Tools/Instruments Materials/Components
• Trainees tools kit - 1 No. • Kerosene - as reqd.
• Scraper - 1 No. • Soap oil - as reqd.
• Straight edge - 1 No. • Cleaning cloth - as reqd.
• Feeler gauge - 1 No. • Emery sheet - as reqd.
• Scraper - 1 No. • Wire brush - as reqd.
Equipments/Machines • Manifold gaskets - as reqd.
• Diesel engine - 1 No.

Procedure

• Loosen the nuts (2) and disconnect the exhaust pipe (3) from the Fig 1
exhaust manifold (4). (Fig 1)

• Remove the exhaust manifold (4) from the cylinder head.
• Disconnect the exhaust pipe (3) and tailpipe (9), and catalytic
converter (11) from the muffler (10) after loosening the clamp bolts
and nuts. (Fig 2)
• Scrape the carbon deposits from the mounting faces of the manifold
with a scraper (8).
• Inspect the manifold flanges (5) for alignment of level by using a
straight edge (6).
• Scrape the carbon deposit from the exhaust manifold using a wire/
brush. (In some engines the exhaust manifold is in more than one
piece. Remove them separately and clean.)

• Inspect the exhaust manifold for any damage/crack. if necessary,
replace it.

Fig 2

• Inspect the tailpipe (9) and exhaust pipe (3) for
any crack/damage etc.
• Attach the scrapers (11) on the wire rope (12).
• Insert a wire rope (12) in the exhaust pipe (3) and
tailpipe (9) till it comes out at the other end. Clean
the exhaust pipe and tailpipe by passing a wire
rope through (Fig 3).

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