Usage:
3406 (92U),
3406B (7FB, 8TC, 4MG, 5YG),
3406C (3ZJ, 5KJ, 4CK),
3406E (5EK) Truck Engines
Reference: Truck Engine News, July 1993, Page 1, "New Exhaust Manifold End And Center Sections Used In Dry Type Exhaust Manifold Groups".
Description of Change: Longer studs and spacers are used in the cylinder head groups and exhaust manifold groups. The longer studs provide increased durability and are more resistant to bending fatigue.
The 106-1792 Stud is 100.0 mm (3.94 in) long, the former 4S-6137 Stud is 81.0 mm (3.19 in) long. The 108-3612 Spacer is 53.0 mm (2.07 in) long, the former 2S-3770 Spacer is 33.5 mm (1.32 in) long.
The torque specification for the manifold retaining nuts is different for 3406C and earlier engines and 3406E engines.
The turbocharger mounting face on the center manifold sections is in different locations. For mid mount turbochargers, the manifold mounting face is 12 degrees below horizontal. For center mount turbochargers, the manifold mounting face is 35.5 degrees below horizontal. For low mount turbochargers, the manifold mounting face is 67 degrees below horizontal. See Illustration 1.
Illustration 1. Turbocharger mounting face. Mid Mount (A). Center Mount (B). Low Mount (C).
Adaptable To:
3406C Truck Engine Equipped With 4W-4319 Exhaust Manifold Group Low Mount Turbocharger or 4W-4320 Exhaust Manifold Group Mid Mount Turbocharger
The longer studs and spacers are identified in Chart B and are in effect with 3406C Truck Engines 3ZJ47133, 4CK22610, and 5KJ8007. The longer studs and spacers are adaptable to earlier engines equipped with the same exhaust manifold group.
Earlier 4W-4320 Manifold Groups (mid mount turbocharger) with 4W-4384 or 9L-5848 Center Sections will require only eleven 106-1792 Studs and eleven 108-3612 Spacers and retain one 6L-8562 Stud which requires no spacer. Later 4W-4320 Manifold Groups with 6I-3655 or 101-7354 Center Sections will require the same quantity of studs and spacers shown in Chart B.
3406C Truck Engine Equipped With 105-1539 Exhaust Manifold Group Center Mount Turbocharger
The longer studs and spacers are identified in Chart C and are in effect with 3406C Truck Engines 3ZJ39816 and 4CK16043. The longer studs and spacers are adaptable to earlier engines equipped with the same exhaust manifold group.
3406E Truck Engine Equipped With 6I-3952 Exhaust Manifold Group Center Mount Turbocharger
The longer studs and spacers are identified in Chart D and are in effect with 3406E Truck Engine 5EK1572. The longer studs and spacers are adaptable to earlier engines equipped with the same exhaust manifold group.
3406E Truck Engine Equipped With 6I-3953 Exhaust Manifold Group Low Mount Turbocharger
The longer studs and spacers are identified in Chart E and are in effect with 3406E Truck Engine 5EK1572. The longer studs and spacers are adaptable to earlier engines equipped with the same exhaust manifold group.
3406E Truck Engine Equipped With 4P-5007 Exhaust Manifold Group Mid Mount Turbocharger
The longer studs and spacers are identified in Chart F and are in effect with 3406E Truck Engine 5EK5795. The longer studs and spacers are adaptable to earlier engines equipped with the same exhaust manifold group.
NOTE: A 9U-7224 Manifold Installation Guide is available to align the manifold studs in the center of the slotted and oversize manifold holes during installation of the exhaust manifold group. Three 9U-7224 Manifold Installation Guides are required for installation of the manifold.
Tighten the exhaust manifold retaining nuts in the sequence shown in Illustration 2. For 3406C and earlier Truck Engines, tighten the nuts to a torque of 38 ± 5 N·m (28 ± 4 lb ft). For 3406E Truck Engines, tighten the nuts to a torque of 52 ± 7 N·m (38 ± 5 lb ft).
Illustration 2. Tightening sequence for exhaust manifold retaining nuts.