SECTION 5.
35
EXHAUST SYSTEM
EXHAUST SYSTEM
COMPONENTS
The exhaust system consists of the following components:
· Exhaust Manifold(s)
· Exhaust Thermocouples
· Turbocharger(s)
· Exhaust Wastegate(s)
· Exhaust Piping and Flexible Connections
(customer supplied)
NOTE: Since air/fuel ratio, ambient air temperature and
many other factors may affect exhaust gas tempera-
tures, call the Waukesha Engine, Field Service Depart-
ment if additional information is required.
DESCRIPTION
The exhaust port of each cylinder is connected to one
water-jacketed segment of the exhaust manifold. Each
water-cooled exhaust manifold assembly is comprised
of six individual segments. One exhaust manifold
segment is joined to the next by a manifold pilot.
Thermocouples are used to monitor engine exhaust
temperatures. High exhaust temperatures greatly in-
crease the potential for detonation and have a direct
impact on the life of many engine components.
One thermocouple is mounted in the exhaust port of
each exhaust manifold segment to measure the temper-
ature of the exhaust exiting the respective cylinder head
(see Figure 5.35-1). One thermocouple is also mounted
before each turbocharger and reflects the exhaust
temperature of the cylinder bank (an average of the
exhaust temperatures of each individual cylinder).
The leads from the exhaust thermocouples enter a
flexible thermocouple harness. The harness leads to a
bulkhead fitting at the junction box support bracket. A
lead is supplied to be installed to a customer-supplied
pyrometer to monitor engine exhaust temperatures.
FORM 6296 First Edition
A wastegate-controlled turbocharger, equipped with a
water-cooled center section, is provided for each
cylinder bank. The compressor side of the turbocharger
is part of the air induction system; the turbine side is part
of the exhaust system. When the turbine spins through
the expansion of exhaust gases exiting the engine, the
movement of the compressor wheel causes the air
passing through the air cleaner enroute to the carbure-
tor to be compressed.
A water-cooled exhaust wastegate is mounted at the
outlet of each exhaust manifold. The wastegate is a load
limiting device. At a predetermined point, intake man-
ifold pressure counteracts the tension of a spring and a
valve opens to bypass a portion of the engine exhaust
pressure around the turbocharger turbine. In this way,
the air intake boost pressure is held within an acceptable
range.
Exhaust gases driving (or bypassing) the turbine exit the
engine through the exhaust stack. Exhaust gases
passing the flexible exhaust connection are directed into
the atmosphere through customer-supplied exhaust
piping.
EXHAUST SYSTEM SPECIFICATIONS
The maximum exhaust system backpressure for all
engine models is 12 in. (305 mm) of water column at
1200 rpm, 145 BMEP (full load). Subtract 1 in. (25 mm)
of water column for each 100 rpm reduction. Subtract
1 in. (25 mm) of water column for each 10 BMEP
reduction. Do not apply these reductions beyond a
minimum exhaust system backpressure of 4 in.
(102 mm) of water column.
Based upon production test data in general, the
maximum exhaust temperature variation (on an engine
running at 1000 and 1200 rpm @ 138 BMEP on natural
gas fuel) between cylinders on the same bank is
approximately 100° F (38° C). The maximum exhaust
temperature variation between respective cylinders on
different banks (#1R versus #1L, #2R versus #2L, etc.)
is approximately 50° F (23.5° C).
5.35 -- 1
EXHAUST SYSTEM

EXHAUST MANIFOLD
LEFT BANK SECTION
TURBOCHARGER
EXHAUST INLET
ELBOW
13 EXHAUST
THERMOCOUPLE

12 9 7 5 3 1

REAR FRONT
14

11 10 8 6 4 2
RIGHT BANK
RETAINING CLIP

THERMOCOUPLE
THERMOCOUPLE HARNESS
LEADS 14 13 12 11 10 98 7 6 54 32 1

Figure 5.35-1. Exhaust Thermocouples Arrangement – 12 Cylinder

MEASURING EXHAUST SYSTEM CHECKING EXHAUST GAS TEMPERATURES

BACKPRESSURE
Monitor the exhaust system backpressure daily. The
maximum backpressure must not exceed specification.
1. Drill and tap a hole (1/4 in. NPT) in customer-sup-
plied exhaust piping. Place hole 12 in. (305 mm)
downstream from mating flange of Waukesha-supplied
flexible exhaust connection. Measurement must be
taken before silencer or catalytic converter, if provided,
and should be away from any bend or elbow in exhaust
piping.
2. Install tubing connector in hole. Use
non-corroding stainless steel fittings.
3. Connect one end of a water manometer to connector
and vent free end to atmosphere. Manometer line fitting
must not protrude beyond inner surface of exhaust pipe
or an inaccurate reading may result.
Exhaust temperatures can be an important diagnostics
tool. A very high exhaust temperature might indicate that
the air/fuel ratio is too rich. A very low temperature may
mean that a cylinder is not firing.
Check engine exhaust temperatures for each cylinder
daily. Monitor exhaust temperatures when engine is
running at rated speed and load.
One exhaust thermocouple is mounted in each exhaust
manifold segment. A thermocouple is also mounted
before each turbocharger.
only Be on alert for wide differences between cylinders or
between cylinder banks. The actual exhaust tempera-
ture readings are not as important as the variations that
may occur.
1. Rotate pyrometer selector switch to select cylinder to
be monitored.

4. Measure exhaust backpressure at rated speed and
load. Corrective action must be taken if backpressure
exceeds specified limit.
5. Excessive exhaust backpressure may be due to one
or more of following conditions:
NOTE: Right bank and left bank are determined by
standing at the flywheel end of the engine facing the
flywheel. The cylinders farthest from the flywheel on the
left and right side are the #1L and #1R cylinders,
respectively. Those closest to the flywheel are the #6L
and #6R cylinders (12 cylinder engines).

· undersized piping 2. Record temperature value for each cylinder.

· elbows, bends or sudden enlargements in piping

· plugged catalytic converter

· pipe obstructions

· exit losses

5.35 -- 2 FORM 6296 First Edition

 EXHAUST SYSTEM

EXHAUST MANIFOLD 5. Attach a suitable lifting device to exhaust manifold.

EXHAUST MANIFOLD REMOVAL 6. Remove capscrews and lock washers from each
water outlet elbow on exhaust manifold sections (see
Exercise care to avoid Figure 5.35-4).
bending or denting the
rocker arm oil supply tubes. Disregarding this
WATER OUTLET ELBOW EXHAUST MANIFOLD
information could result in product damage and/or
personal injury.

1. Refer to “Water Manifold Removal” and remove

water manifold and water outlet elbows from exhaust
manifold.

2. Refer to “Turbocharger Inlet Elbow Removal” and

remove turbocharger inlet elbow from end exhaust
manifold section.

3. Remove thermocouples from exhaust manifold sec-

tions (see Figure 5.35-2).

EXHAUST MANIFOLD THERMOCOUPLE

LEAD Figure 5.35-4. Water Outlet Elbows -- Rear Right
END SECTION

A new water jumper elbow has been developed for all

THERMOCOUPLE
Figure 5.35-2. Exhaust Thermocouple – Rear Left
4. Remove capscrews, lock washers, thermocouple
brackets and thermocouple conduit from exhaust man-
ifolds (see Figure 5.35-3).
VHP Series Four engines. The new water jumper elbow
uses a square cut O--ring seal instead of a gasket at the
cylinder head end. This results in longer life and a tighter
seal.
NOTE: Previous water elbows are not machined for the
new O--ring seal. If replacing either the previous water
jumper elbow (P/N 169892H) or gasket (P/N 153139B),
both the new water jumper elbow (P/N 169892J) and
O--ring seal (P/N 176883E) must be used (see
Figure 5.35-5 and Figure 5.35-6).
7. Remove and discard water outlet elbow gaskets
(seals) from upper and lower flanges of water outlet
elbows (see Figure 5.35-5 and Figure 5.35-6).
O--RING SEAL

WATER OUTLET
ELBOW CENTER BOSS

SEAL
THERMOCOUPLE
HARNESS
Figure 5.35-5. Current Water Jumper Elbow
(P/N 169892J)
Figure 5.35-3. Thermocouple Harness

FORM 6296 First Edition 5.35 -- 3

EXHAUST SYSTEM
GASKET
SEAL
Figure 5.35-6. Previous Water Jumper Elbow
(P/N 169892H)
8. Remove two upper 1/2 in. x 8-1/2 in. capscrews with
flat washers and two lower 1/2 in. x 5-1/2 in. capscrews
and flat washers (see Figure 5.35-7).
CAPSCREWS
CAPSCREWS
Figure 5.35-7. Exhaust Manifold End Sections
9. Remove three prelube motor air/gas supply tube
retaining clips.
10. Note location and remove breather tube brackets
and intercooler water pipe brackets from exhaust
manifold sections.
Do not attempt to lift the exhaust manifold without
providing adequate support for each section. Disre-
garding this information could result in severe
personal injury or death.
5.35 -- 4
The exhaust manifold weighs approximately 515 lb.
(234 kg). Use a suitable lifting device and exercise
caution during removal or installation to avoid
severe personal injury or death.
11. Using a suitable lifting device and ensuring that
each manifold section is properly supported, remove
exhaust manifold assembly from engine.
12. Remove and discard exhaust manifold gaskets
from cylinder heads or exhaust manifold sections (see
Figure 5.35-11).
13. Use masking tape to cover exhaust outlet port and
water outlet elbow flange on each cylinder head to
protect against dirt.
14. Remove gaskets/seals from upper and lower
flanges of water jumper elbows (see Figure 5.35-5 and
Figure 5.35-6).
EXHAUST MANIFOLD DISASSEMBLY
NOTE: The manifold pilots between the center sections
are wider than the ones between the outer sections. The
insulating ring used with the center manifolds pilots are
also wider.
1. Separate exhaust manifold sections and remove
manifold pilots (see Figure 5.35-11).
2. Remove hose clamps and insulating rings from
pilots.
3. Remove two capscrews, washers and manifold caps
from end manifold sections.
4. If required, remove countersunk pipe plugs from
exhaust manifold sections.
EXHAUST MANIFOLD ASSEMBLY
1. If removed, apply pipe sealant to threads, and install
countersunk pipe plugs on exhaust manifold sections
(two plugs per section). Install manifold caps in on end
exhaust manifold sections with two capscrews and
washers.
2. Line up exhaust manifold sections. Position insulat-
ing strips and hose clamps on manifold pilots. Ensure
that the #6 RB and #6 LB are positioned on the correct
end of the assembled manifold assembly.
FORM 6296 First Edition
 EXHAUST SYSTEM

During assembly of the

SMOOTH
manifold sections, use SIDE
caution to avoid pinching the insulating strips or
hose clamps between the manifold pilots and
exhaust manifold sections. Disregarding this in-
formation could result in product damage and/or
personal injury.

3. Install manifold pilots, insulating strips and hose

clamps between manifold sections. Press manifold
sections together.

NOTE: Align the screws on the hose clamps on a line

parallel with the countersunk pipe plugs. The seams of
the insulating strips should be aligned on a line parallel
with the upper holes for the longer (1/2 in. x 8-1/2 in.
capscrews) The open end of the seam should be Figure 5.35-9. Exhaust Manifold Gasket -- Cylinder
oriented downwards. Head Side

4. Tighten hose clamps on insulating strips.
EXHAUST MANIFOLD INSTALLATION
1. Remove protective masking tape from exhaust outlet
port and water outlet elbow flange on each cylinder
head.
3. Install in exhaust manifold two upper 1/2 in. x
8-1/2 in. capscrews with flat washers and two lower
1/2 in. x 5-1/2 in. capscrews and flat washers (see
Figure 5.35-10).
CAPSCREWS

NOTE: The exhaust manifold gasket contains a metal

seam that seals the inside of the gasket halves. This
seam is located on the exhaust manifold side of the
gasket (see Figure 5.35-8).

2. Place gasket on cylinder head exhaust port with

smooth side facing cylinder head and seam side facing
exhaust manifold (see Figure 5.35-8 and
Figure 5.35-9). Be sure that hole with copper grommet
lines up with water hole in casting. Do not use gasket if
grommet is missing or damaged.

CAPSCREWS
SEAM
Figure 5.35-10. Exhaust Manifold End Sections

GROMMET

Figure 5.35-8. Exhaust Manifold Gasket -- Exhaust

Manifold Side

FORM 6296 First Edition 5.35 -- 5

EXHAUST SYSTEM

2
13
11

8 14 12
11

1
2

15
9 6
3 19
7 18
16
8
17
1
10 18

11 14

ITEM NUMBER AND DESCRIPTION

1 Manifold 6 Manifold Pilot 11 Washer 16 Capscrew
2 Manifold 7 Insulating Ring 12 Capscrew 17 Capscrew
3 Plug 8 Clamp 13 Capscrew 18 Lock Washer
4 Insulating Ring 9 Manifold Cap 14 Ring Seal 19 Elbow
5 Manifold Pilot 10 Capscrew 15 Ring Seal
Figure 5.35-11. Exhaust Manifold

EXHAUST OUTLET PORT

REAR FRONT
ATTACH AIR/GAS SUPPLY TUBE RETAINING CLIPS

Figure 5.35-12. Exhaust Manifold -- Left Bank

5.35 -- 6 FORM 6296 First Edition

 EXHAUST SYSTEM

4. Attach three retaining clips (0.048 in. gauge, 1/2 in. WATER
EXHAUST
clamping diameter) to prelube motor air/gas supply tube OUTLET OUTLET WATER MANIFOLD
PORT PORT MOUNTING BRACKET
(37-1/2 in. long, 1/2 in. tube OD). BOLT HOLES
5. Pull 5-1/2 in. long capscrews from three sections
(numbers 1, 3 and 6) of left bank exhaust manifold (see
Figure 5.35-12). End section with exhaust outlet port is WATER
number 6. OUTLET
PORT
6. Attach prelube air/gas supply tube retaining clips and
insert capscrews back into left bank exhaust manifold
(see Figure 5.35-13). REAR END
SECTION

FRONT END
SECTION

Figure 5.35-14. Exhaust Manifold End Sections

8. Tighten outside short capscrew located in each end

section (front and rear) to 66 -- 70 ft-lb (89 -- 95 N×m) (see
Figure 5.35-15). Remove lifting device. Tighten remain-
ing capscrews to 66 -- 70 ft-lb (89 -- 95 N×m).

AIR/GAS RETAINING
SUPPLY TUBE CLIP

Figure 5.35-13. Prelube Motor Air/Gas Supply Tube

Do not attempt to lift the exhaust manifold without

providing adequate support for each section. Disre- OUTSIDE
garding this information could result in severe CAPSCREW
personal injury or death.
Figure 5.35-15. Exhaust Manifold End Sections

A new water jumper elbow has been developed for all

The exhaust manifold weighs approximately 515 lb.
(234 kg). Use a suitable lifting device and exercise
caution during removal or installation to avoid
severe personal injury or death.
Exercise care to avoid
bending or denting the
rocker arm oil supply tubes. Disregarding this
information could result in product damage and/or
personal injury.
7. Position exhaust manifold on cylinder bank. Be sure
that end section with exhaust outlet port is positioned at
rear of engine (see Figure 5.35-14).
VHP Series Four engines. The new water jumper elbow
uses a square cut O--ring seal instead of a gasket at the
cylinder head end. This results in longer life and a tighter
seal.
NOTE: Previous water elbows are not machined for the
new O--ring seal. If replacing either the previous water
jumper elbow (P/N 169892H) or gasket (P/N 153139B),
both the new water jumper elbow (P/N 169892J) and
O--ring seal (P/N 176883E) must be used (see
Figure 5.35-16 and Figure 5.35-17).
9. Apply 3M Scotch Gripâ 847 Rubber and Gasket
Adhesive to rectangular grooves of water outlet elbows.
Install new rubber seals in grooves (see Figure 5.35-16
and Figure 5.35-17).

FORM 6296 First Edition 5.35 -- 7

EXHAUST SYSTEM

11. Secure elbows to exhaust manifold with (oiled)

O--RING SEAL
1/2 in.--13 x 1-3/4 in. hex head capscrews and lock
washers (see Figure 5.35-18). Finger tighten only.

12. Alternately tighten four capscrews. Tighten

3/8 in.--16 x 4-1/2 in. ferryhead capscrews (elbows to
cylinder heads) to 27 – 29 ft-lb (37 – 39 N×m). Tighten
1/2 in.--13 x 1-3/4 in. hex head capscrews (elbows to
exhaust manifold) to 66 – 70 ft-lb (89 – 95 N×m).

13. Use a rubber mallet to seat manifold caps in front

end sections of right and left bank exhaust manifolds.
SEAL 14. Secure end cap to right bank exhaust manifold end
section with 1/2 in. x 1-5/8 in. capscrews and flat
Figure 5.35-16. Current Water Jumper Elbow
washers (see Figure 5.35-19).
(P/N 169892J)

GASKET

SEAL

Figure 5.35-17. Previous Water Jumper Elbow END COVER

(P/N 169892H)
10. Secure water outlet elbows to cylinder heads with
(oiled) 3/8 in.--16 x 4-1/2 in. ferryhead capscrews and
lock washers (see Figure 5.35-18). Finger tighten only.
WATER OUTLET ELBOW EXHAUST MANIFOLD
Figure 5.35-19. Exhaust Manifold End Cover
15. Install fasteners in auxiliary cooling water outlet
pipe support bracket (two capscrews, 1/2 in. x 2 in. with
lock washers and 1/4 in. spacers). Position bracket over
end cap of left bank exhaust manifold end section (see
Figure 5.35-20). Tighten capscrews.

END CAP

PIPE SUPPORT BRACKET

(AUXILIARY COOLING
Figure 5.35-18. Water Outlet Elbows -- Rear Right WATER OUTLET)

Figure 5.35-20. Exhaust Manifold -- Left Bank

5.35 -- 8 FORM 6296 First Edition

 EXHAUST SYSTEM

16. Inspect 12 stainless steel male connector tube 4. Remove four stainless steel capscrews, lock wash-
fittings (1/4 in. thermocouple OD) for galled or stretched ers and elbow gasket from exhaust inlet elbow and
threads. Replace fittings if necessary. exhaust manifold (see Figure 5.35-23).

17. Apply Bostik Never Seezâ Anti-Seize and Lubricat-

ing Compound [capable of withstanding temperatures EXHAUST INLET
ELBOW
up to 1800° F (982° C)] to large end of each male
connector tube fitting. Using 9/16 in. hex on connector
body, thread fitting into exhaust port of each segment of
exhaust manifold (see Figure 5.35-21).

EXHAUST MANIFOLD THERMOCOUPLE

END SECTION LEAD

EXHAUST
MANIFOLD

Figure 5.35-23. Exhaust Inlet Elbow -- Rear Left

THERMOCOUPLE
5. Support exhaust inlet elbow and remove four stain-
Figure 5.35-21. Exhaust Thermocouple – Rear Left less steel capscrews, stainless steel lock washers,
exhaust inlet elbow, exhaust bypass flange, and bypass
TURBOCHARGER EXHAUST INLET flange gasket, from exhaust manifold section and
exhaust bypass tee (see Figure 5.35-24).
ELBOWS
REMOVAL
1. Remove wastegate assemblies from left and right
exhaust inlet elbows.

2. Remove turbocharger assembly from exhaust inlet EXHAUST

elbow. BYPASS TEE

3. Remove heat shields from both exhaust elbows (see EXHAUST BYPASS
Figure 5.35-22). FLANGE
EXHAUST BYPASS
GASKET
RIGHT SIDE EXHAUST
ELBOW HEAT SHIELD
EXHAUST
INLET ELBOW

Figure 5.35-24. Exhaust Inlet Elbow

Figure 5.35-22. Right Side Elbow Heat Shield

FORM 6296 First Edition 5.35 -- 9

EXHAUST SYSTEM

INSTALLATION
1. Install a new compression gasket onto two plug hole
adapters. Apply Bostik Never Seezâ Anti-Seize and
Lubricating Compound to plug threads. Install a plug in
each exhaust inlet elbow (see Figure 5.35-25).
LIP (FACING
UPWARD)
PLUG HOLE

TURBOCHARGER EXHAUST Figure 5.35-26. Turbocharger Inlet Elbow Gasket

INLET ELBOW MANIFOLD
7. Secure turbocharger inlet elbow onto exhaust by-
Figure 5.35-25. Exhaust Inlet Elbow – Rear Left pass tee with four stainless steel capscrews and
stainless steel lock washers (see Figure 5.35-27). Do
2. Check four stainless steel wastegate mounting studs not fully tighten.
for burrs, nicks, cracks, galled or stretched threads and
other obvious damage. Replace as necessary.

3. Each wastegate mounting stud has fine and coarse

threads separated by a smooth center boss. Using a
small paintbrush, apply Bostik Never Seezâ Anti-Seize
and Lubricating Compound to coarsely threaded side. EXHAUST
BYPASS TEE
Do not install wastegate EXHAUST BYPASS
mounting studs with a FLANGE
pipe wrench or similar device. Use a collet type stud
driver to prevent damage to stud threads. Disre- EXHAUST BYPASS
GASKET
garding this information could result in product
damage and/or personal injury.
TURBOCHARGER
INLET ELBOW
4. Using a collet type stud driver, install each stud into
exhaust inlet elbow until last coarse thread is turned into Figure 5.35-27. Exhaust Inlet Elbow
casting.
NOTE: To improve clamping forces, two spacers have
5. With exhaust bypass port facing crankcase vee,
been added to each turbocharger inlet elbow to exhaust
position exhaust inlet elbow over exhaust outlet port.
manifold ferry head screw assembly.
6. With lip on inside diameter facing upward (see
8. Secure turbocharger inlet elbow onto exhaust man-
Figure 5.35-26), position a new stainless steel gasket
ifold with ferry head screws, spacers, and washers (see
over exhaust outlet.
Figure 5.35-28). New gasket should be installed. Install
washers under ferry head screws without spacer. Do not
fully tighten.

9. Install supports between turbocharger elbows and

intercooler plenums (see Figure 5.35-29).

5.35 -- 10 FORM 6296 First Edition

 EXHAUST SYSTEM

10. Tighten ferry head screws to 30--35 ft-lb (40.7--47.5 4. Remove exhaust elbow adapters from exhaust
N×m). Tighten elbow support bracket and bypass tee elbow (see Figure 5.35-30).
screws.
SUPPORT ADAPTER
SPACER AND STAINLESS FLANGE
STEEL CAPSCREW

Figure 5.35-28. Turbocharger Elbow Fasteners

EXHAUST ELBOW
TURBOCHARGER ELBOW SUPPORT BRACKETS
A support bracket is installed between turbocharger Figure 5.35-30. Exhaust Elbow Assembly
inlet elbow and intercooler plenum (see
Figure 5.35-29). 5. Remove four nuts, lock washers capscrews and
exhaust elbow from supporting brackets.

6. Remove four nuts, lock washers, washers, caps-

crews and two support brackets from supporting rails.

7. If required, remove eight capscrews, lock washers

and two support rails.

EXHAUST CONNECTIONS INSTALLATION

1. If removed, install two support rails with eight
capscrews and lock washers.

2. Install two support rails with four nuts, lock washers,

SUPPORT
BRACKET washers and capscrews.

3. Install exhaust elbow on supporting rails with four

Figure 5.35-29. Turbocharger Elbow Support Bracket
capscrews, lock washers and nuts (see
Figure 5.35-32). Use an angle finder to ensure exhaust
EXHAUST CONNECTIONS REMOVAL elbow is straight.
1. Remove V-Band coupling and flexible exhaust
NOTE: If realignment of the exhaust elbow is neces-
connection from exhaust outlet elbow (see
sary, loosen the slotted bolts to free the support brackets
Figure 5.35-31).
from the intercooler-mounted support rails and then
2. Remove V-Band and venturi (GSI models) from make the necessary adjustments.
exhaust elbow.

3. Remove exhaust bypass tee and sleeve from

exhaust elbow.

FORM 6296 First Edition 5.35 -- 11

EXHAUST SYSTEM

FLEXIBLE EXHAUST
CONNECTION

EXHAUST
BYPASS TEE

EXHAUST BYPASS
SLEEVE

EXHAUST ELBOW

EXHAUST ELBOW
ADAPTOR

SUPPORTS

SUPPORT RAIL

Figure 5.35-31. Exhaust Connections

5.35 -- 12 FORM 6296 First Edition

 EXHAUST SYSTEM

HEAT SHIELDS
ANGLE FINDER
INSTALLATION
VHP Series Four engines have heat shields over the
exhaust tee and both turbocharger inlet elbows.
1. Exhaust tee is held in place with two 5 in. diameter
U-bolts (see Figure 5.35-34).

EXTRACTOR
TUBE FLANGE

EXHAUST
BYPASS TEE

Figure 5.35-32. Exhaust Elbow Straightness

4. Install exhaust bypass sleeve and exhaust bypass

tee on exhaust elbow.

5. Install two exhaust elbow adapters (larger OD) into

inlet ports of exhaust elbow (see Figure 5.35-30 and U--BOLTS
Figure 5.35-33).

6. Install venturi (GSI models) with V-Band on exhaust
elbow.
7. Install flexible exhaust connection on exhaust elbow
(see Figure 5.35-31).
Figure 5.35-34. Exhaust Tee Heat Shield
2. Turbocharger inlet elbow heat shields are held in
place with 3/8 in.--1/6 x 3/4 in. stainless steel caps-
crews, flat washers and lockwashers (see
Figure 5.35-35 and Figure 5.35-36).

Figure 5.35-33. Exhaust Elbow Adapter

HEAT SHIELD

Figure 5.35-35. Left Side Inlet Elbow

FORM 6296 First Edition 5.35 -- 13

EXHAUST SYSTEM

4. Slide quick disconnect rubber boot over thermocou-

HEAT SHIELD ple harness.

5. Peel back stainless steel braid 1-1/4 in. (3.2 cm).

Remove any excess material.

6. Peel back insulation beneath braid 3/4 in. (1.9 cm).

Remove any excess material.

7. Separate positive and negative conductors. Positive

(+) conductor is yellow and negative (--) conductor is
red.

8. Peel back insulation of each conductor 3/8 in.

(9.5 mm) to expose bare wire. Remove any excess
material.

9. Separate male and female ends of quick disconnect

Figure 5.35-36. Right Side Inlet Elbow plug, if applicable.

THERMOCOUPLES 10. Loosen retaining screw from side of each prong.

Quick disconnect K--type exhaust thermocouples are 11. Slide red negative (--) conductor into larger diame-
recommended for use in the field. Using a quick ter prong until contact is made with the pinhole (see
disconnect, a faulty exhaust thermocouple can be Figure 5.35-37).
changed without removing the complete thermocouple
assembly from the engine. POSITIVE
INSULATION
JACKET CONDUCTOR
NOTE: It is recommended that all VHP engines that are (YELLOW)
RETAINING
currently using J--type thermocouples and have exhaust SCREWS
temperatures that exceed 1200° F (648.8° C) be
replaced with K--type thermocouples. The J--type is
good to 1400° F (760° C) maximum and experience NEGATIVE
shows that rapid deterioration occurs at that CONDUCTOR
temperature. The K--type is rated to 2282° F (1250° C). (RED)
If thermocouples are changed, then the pyrometer that
reads the thermocouples must be changed also.
Dynalco pyrometers that read the J--type
STAINLESS
thermocouples can be revised to accurately read the STEEL BRAID
K--type by Dynalco Controls Corporation of Fort
Lauderdale, Florida, 1 (954) 739--4300.
QUICK DISCONNECT
PLUG (FEMALE END)
P/N A740112 contains a thermocouple lead attached to
a male connector and a separate female connector. The
female connector requires installation. Figure 5.35-37. K--type Thermocouple

QUICK DISCONNECT INSTALLATION 12. Slide yellow positive (+) conductor into smaller
diameter prong until contact is made with pinhole.
NOTE: Variations in thermocouple wire lengths ad-
Tighten retaining screws.
versely affect the pyrometer readings. Errors will not
usually exceed ±1% of the total reading if the variations 13. Snap male end of plug into female end.
in wire length do not exceed 22 ft (6.7 m). Turbochar-
gers must be installed to equal depth and in the center of
exhaust streams to obtain consistent readings.

3. Remove faulty thermocouple by cutting lead [cut

approximately 12 in. (30.5 cm) from stem]. Do not cut
thermocouple harness short. Verify there will be enough
thermocouple wiring left to reach exhaust manifold (with
new thermocouple lead attached).
5.35 -- 14 FORM 6296 First Edition
 EXHAUST SYSTEM

EXHAUST THERMOCOUPLES INSTALLATION

FIFTH WATER ELBOW
NOTE: The customer connection for the exhaust ther-
mocouple harness is located on the junction box support
bracket (see Figure 5.35-38).

Figure 5.35-40. Thermocouple Harness End

4. Route thermocouple leads to each section of right

and left exhaust manifolds (see Figure 5.35-41). Secure
thermocouple leads with clips.

EXHAUST
THERMOCOUPLE
CONNECTOR

Figure 5.35-38. Junction Box Support Bulkhead

1. Install bulkhead connector end of thermocouple THERMOCOUPLE

harness in center hole. LEADS

2. Position thermocouple conduit along right bank Figure 5.35-41. Thermocouple Harness Leads
water outlet elbows. Be sure four closely spaced leads
exiting end of conduit are positioned at rear of engine 5. Secure four thermocouple end leads with clips (see
(see Figure 5.35-39). Figure 5.35-42).

THERMOCOUPLE
HARNESS

HARNESS CLIPS

EXHAUST
MANIFOLD Figure 5.35-42. Rear Thermocouple Leads

Figure 5.35-39. Thermocouple Harness
3. Thermocouple harness cover should end at fifth
water outlet elbow (see Figure 5.35-40). Four bare
leads drop down to #6 cylinder head water elbow.
6. Position a new ferrule nut and a new back and front
ferrule “K” Type. Lip on back ferrule must face large end
of front ferrule, while tapered end of front ferrule faces
connector body.

FORM 6296 First Edition 5.35 -- 15

EXHAUST SYSTEM
7. Insert thermocouples into male connector tube
fittings in each section of exhaust manifold (see
Figure 5.35-43).
THERMOCOUPLE
LEAD
THERMOCOUPLE
Figure 5.35-43. Exhaust Thermocouple – Rear Left
8. Route two leads to inlet elbows at top of two exhaust
manifold end sections (rear) (see Figure 5.35-44).
Figure 5.35-44. Thermocouple Harness – Turbo Elbow
9. Position a new ferrule nut and a new back and front
ferrule “K” Type. Lip on back ferrule must face large end
of front ferrule, while tapered end of front ferrule faces
connector body.
10. Insert thermocouples into male connector tube
fittings in each section of exhaust manifold (see
Figure 5.35-45).
5.35 -- 16
The thermocouple must
not contact the exhaust
manifold casting or an inaccurate pyrometer read-
ing will result. Disregarding this information could
result in product damage and/or personal injury.
11. Center tip of stem in exhaust passage. Distance
from exterior casting of exhaust manifold exhaust port to
portion of thermocouple perpendicular to tip of stem
should be 3-1/16 in. ±1/4 in. (see Figure 5.35-46).
THERMOCOUPLE CLEAN AND INSPECT
A wide variation between one cylinder and another, or
one bank and another, may indicate a dirty or faulty
thermocouple. Clean or replace the thermocouples as
required.
Do not use a battery
powered test light or
similar device to check the thermocouple circuit
without completely disconnecting the pyrometer.
Applying uncontrolled voltage to the pyrometer will
damage the instrument. Disregarding this
information could result in product damage and/or
personal injury.
1. Since a very small voltage is generated at the
thermocouple, verify that all electrical connections are in
good condition. All wire ends and terminal connections
must be clean and dry.
2. Check reading of thermocouple when heated.
Pyrometer dial should read up scale. Reading will be in
opposite direction if wiring was inadvertently reversed
during installation.
3. Turn panel mounted pyrometer selector to “Off”
position. Pyrometer temperature reading should be
equivalent to ambient air temperature.
The thermocouple assembly consists of two wires of
dissimilar metals connected within a protecting tube or
stem. A portable pyrometer measures the small electric
current generated by the thermocouple and translates
the voltage into a temperature reading.
4. Unthread ferrule nut (9/16 in. hex) from body of
thermocouple connector. A thermocouple connector is
mounted in exhaust port of each section of exhaust
manifold and in turbocharger exhaust inlet elbow(s).
5. Pull thermocouple out of exhaust passage.
6. Check thermocouple stem for carbon buildup. If
necessary, thoroughly clean thermocouple using sol-
vent and a soft wire brush.
7. Insert stem of thermocouple back into exhaust
passage. Tighten ferrule nut.
FORM 6296 First Edition
 EXHAUST SYSTEM

LEFT BANK EXHAUST

MANIFOLD
TURBOCHARGER SECTION
EXHAUST INLET
ELBOW
13 EXHAUST
THERMOCOUPLE

12 9 7 5 3 1

REAR FRONT
14

11 10 8 6 4 2

RETAINING CLIP

THERMOCOUPLE
THERMOCOUPLE HARNESS
LEADS 14 13 12 11 10 98 7 6 54 32 1

RIGHT BANK
Figure 5.35-45. Exhaust Thermocouples Arrangement

EXHAUST MANIFOLD
SECTION

MALE CONNECTOR TUBE FITTING

(STAINLESS STEEL)

THERMOCOUPLE

EXHAUST
PASSAGE

3-1/16² ±1/4

Figure 5.35-46. Exhaust Thermocouple Installation

FORM 6296 First Edition 5.35 -- 17

EXHAUST SYSTEM

WASTEGATES WASTEGATES -- LATE MODEL WATER INLET AND

OUTLET TUBES
BLEEDING AIR
All engines shipped after March 25, 2002, have
reconfigured wastegate tubing installed.
Trapped air in the
auxiliary cooling water The new wastegate water inlet and outlet tubes are
circuit leads to overheating that can result in connected to new intercooler water tubes instead of at
wastegate damage and premature engine failure. the rear of the intercooler.
Disregarding this information could result in This improved tube routing reduces the amount of stress
product damage and/or personal injury. that the tubes are subjected to and helps prevent
wastegate tube failures. If equipped with early model
Air bleed the auxiliary cooling water circuit at least once
wastegate water tubing and experiencing cracking or
each day. Always air bleed the circuit after refilling or
other failures complete the retrofit procedure (see
topping off the cooling system. Open and close the four
Table 5.35-2).
air bleed petcocks in the order listed, starting at the
lowest petcock in the system and ending at the highest. Table 5.35-2. Parts Required For Retrofit
Bleed one petcock at a time. The number of air bleed P/N DESCRIPTION QTY.
petcocks and their locations are shown in Table 5.35-1. 214067P Wastegate Water Inlet Tube, RB 1
Table 5.35-1. Air Bleed Petcocks – 214067M Wastegate Water Inlet Tube, LB 1
Auxiliary Cooling Water Circuit
214067V Wastegate Water Outlet Tube, RB 1
NUMBER OF LOCATION 214067R Wastegate Water Outlet Tube, LB 1
PETCOCKS
26750 1/4in. NPT Pipe Plug 2
Intercooler water inlet/outlet bonnets
2 (upper rear) A214100L* Pump To Intercooler Tube, Rear 1
Wastegate water return tube A214100L* Intercooler Water Outlet Tube, Rear 1
2 (rear right and left bank)
NOTE: *The engine’s existing intercooler water tubes may be
modified by drilling holes and welding 1/4 in. NPT connectors
(P/N 209242A) in the correct locations. See “Intercooler Water
Tube Modifications” in this section.

Always wear protective clothing when bleeding the
cooling system on a heated engine. Slowly loosen
the air bleed petcock to relieve any excess pres-
sure. Escaping steam and/or hot water could result
in severe personal injury or death.
1. Initial Bleed: Open air bleed petcock prior to engine
startup. A hissing sound often accompanies escape of
trapped air. Close petcock when hissing stops and water
begins to flow out in a solid steady stream.
2. Check Bleed: Start engine and reopen petcock.
Close petcock when hissing stops and water begins to
flow out in a solid steady stream.
3. Final Bleed: Once temperature of jacket water
circuit has stabilized (as indicated by temperature
gauge), reopen petcock. Close petcock when water
begins to flow out in a solid steady stream.
INTERCOOLER WATER TUBE MODIFICATIONS
Instead of replacing the intercooler water tubes, you can
modify the existing tubes by drilling holes and welding
1/4 in. NPT pipe couplings in the correct locations.
Complete the following steps to modify the intercooler
water tubes.
1. Remove tubing. Refer to Section 5.25 Cooling
System “Wastegate Tube Connections Removal” for
more information.
2. Locate and drill 0.91 in. (23 mm) holes in the tubes
according to the dimensions shown in Figure 5.35-47
and Figure 5.35-48.
Comply with the welder manufacturer’s recommen-
dations for procedures concerning the proper use
of the welder. Improper welder use can result in
severe injury or death.

5.35 -- 18 FORM 6296 First Edition

 EXHAUST SYSTEM

3. Weld 1/4 in. NPT couplings (P/N 209242A) with

water tight welds (see Figure 5.35-47). OUTLET PIPE

P/N 209242M 2.75²

69.8mm

1.47²
.12 37.3mm

OUTLET
PIPE

Figure 5.35-49. Turbocharger Water Outlet Tubes

Figure 5.35-47. Tube P/N A211700L To P/N A214100L
Modification 3. Open flexmaster couplings and remove intercooler
water inlet and outlet tubes from engine (see
Figure 5.35-50 and Figure 5.35-51).

.12 5.375²
P/N 209242A 136.5mm

FLEXMASTER FLEXMASTER
COUPLING COUPLING

Figure 5.35-50. Flexmaster Couplings

Figure 5.35-48. Tube P/N A211761E To P/N A214100M
Modification
FLEXMASTER
RETROFIT INSTRUCTIONS COUPLINGS

1. Drain coolant from auxiliary cooling water circuit.

2. Disconnect turbocharger water outlet tubes from

intercooler water outlet pipe (see Figure 5.35-49).

Figure 5.35-51. Flexmaster Couplings

FORM 6296 First Edition 5.35 -- 19

EXHAUST SYSTEM
NOTE: The intercooler water inlet and outlet tubes can
be replaced with new tubing, or the existing tubes can be
modified by drilling holes and welding 1/4 in. NPT
couplings. See “Intercooler Water Tubes Modifications”
in this section.
4. Install new (or modified) intercooler water tubes
(P/N A214100L and P/N A214100M) with wastegate
fittings on engine (see Figure 5.35-52 and
Figure 5.35-55).
WASTEGATE
FITTINGS
Figure 5.35-52. Intercooler Water Tubes
5. Remove pipe tees from reducer bushings and set
aside (see Figure 5.35-53). Pipe tees will be reused.
PIPE TEES
Figure 5.35-53. Intercooler Disconnections
6. Loosen ferrule nuts (9/16 in. hex) to detach com-
pressor discharge pressure sensing tubes from “Air”
5.35 -- 20
port at side of each wastegate (male elbow tube fitting –
both banks) (see Figure 5.35-54).
WASTEGATE WATER WASTEGATE WATER
SUPPLY TUBE (LB) RETURN TUBE (RB)
WATER RETURN
PIPE TEE
WATER SUPPLY
PIPE TEE
Figure 5.35-54. Intercooler/Wastegate Tube
Connections
7. Loosen ferrule nuts (11/16 in. hex) to detach two
water return tubes from wastegate water outlet ports
(male connector tube fitting – right bank; male elbow
tube fitting – left bank).
NOTE: The word “Water” appears just above the
wastegate base flange between the water inlet and
outlet ports, the side with the petcock is the outlet port.
8. Loosen ferrule nuts (11/16 in. hex) and detach two
water supply tubes from wastegate water inlet ports
(male elbow tube fitting – right bank; male connector
tube fitting – left bank) (see Figure 5.35-54).
9. Install 1/4 in. NPT pipe plugs into reducer bushings
installed in rear of intercooler.
10. Install new water inlet and outlet tubing to waste-
gates as shown in Figure 5.35-55. Reuse pipe tees,
drain cocks, flex elbows, pipe nipples, and flex connec-
tors as necessary. Apply pipe sealant to threads during
assembly.
11. Install new wastegate inlet and outlet tubing to
intercooler water tubes (see Figure 5.35-55).
FORM 6296 First Edition
 EXHAUST SYSTEM

INTERCOOLER WATER OUTLET

WATER INLET TUBE TUBE RB DRAIN COCK
TEE CONNECTOR WASTEGATE

PUMP TO
INTERCOOLER
TUBE
TEE
NIPPLE

TEE

WATER INLET
TEE TUBE RB
WATER OUTLET
TUBE LB

CONNECTOR

ELBOW
DRAIN COCK NIPPLE WATER INLET
TUBE LB

WASTEGATE
ELBOW

Figure 5.35-55. Retrofitted Wastegate Water Inlet And Outlet Tubes

FORM 6296 First Edition 5.35 -- 21

EXHAUST SYSTEM
WASTEGATES -- P/N 295645 SERIES
WASTEGATE REMOVAL -- P/N 295645 SERIES
1. Drain enough coolant from auxiliary cooling water
circuit to drop water level below level of wastegate(s). It
is not necessary to drain entire cooling system.
2. Loosen ferrule nuts (9/16 in. hex) to detach com-
pressor discharge pressure sensing tubes from “Air”
port at side of each wastegate (male elbow tube fitting –
both banks) (see Figure 5.35-56).
3. Loosen ferrule nuts (11/16 in. hex) to detach two
water return tubes from wastegate water outlet ports
(male connector tube fitting – right bank; male elbow
tube fitting – left bank).
NOTE: The word “Water” appears just above the
wastegate base flange between the water inlet and
outlet ports, the side with the petcock being the outlet
port.
WASTEGATE WATER WASTEGATE WATER
SUPPLY TUBE (LB) RETURN TUBE (RB)
WATER RETURN
PIPE TEE
WATER SUPPLY
PIPE TEE
Figure 5.35-56. Intercooler/Wastegate Tube
Connections
5.35 -- 22
4. Loosen ferrule nuts (11/16 in. hex) to detach two
water supply tubes from wastegate water inlet ports
(male elbow tube fitting – right bank; male connector
tube fitting – left bank) (see Figure 5.35-56).
5. Alternately loosen and remove four 3/8 in. stainless
steel lock nuts (thin) from wastegate mounting studs.
6. Alternately loosen and remove four 3/8 in. stainless
steel hex nuts (thick) from mounting studs. Remove
stainless steel lock washers.
7. Remove wastegates from mounting studs.
Do not allow gasket
material to enter the
turbocharger exhaust inlet elbow. Allowing gasket
material to enter the turbocharger exhaust inlet
elbow could result in product damage and/or
personal injury.
8. Remove gaskets from exhaust inlet elbows or
wastegate base flanges.
WASTEGATE INSTALLATION -- P/N 295645 SERIES
Deposits left on gasket
surfaces will cause
leaks. Exercise care to keep the gasket material out
of the turbo exhaust inlet elbows. Verify that the
gasket and gasket mating surfaces are clean and
completely free of grease and oil. Disregarding this
information could result in product damage and/or
personal injury.
1. Scrape gasket material from wastegate mounting
pad at top of exhaust inlet elbows.
2. Position a new gasket on wastegate mounting studs.
3. With compressor discharge air connection opposite
crankcase vee, male elbow tube fitting pointing to rear of
engine, position wastegates on mounting studs.
4. Position 3/8 in. stainless steel lock washers over
mounting studs.
5. Using a small paintbrush, apply Bostik Never-Seezâ
Anti-Seize and Lubricating Compound to threads of
mounting studs.
6. Thread 3/8--16 in. stainless steel hex nuts (thick)
onto mounting studs. Install nuts down until they contact
lock washers. Alternately tighten nuts to ensure waste-
gate does not tilt.
FORM 6296 First Edition
 EXHAUST SYSTEM

7. Install stainless steel lock nuts (thin) onto mounting
studs and tighten in an alternating pattern.
8. Finger tighten ferrule nuts (11/16 in. hex) to attach
two water supply tubes to wastegate water inlet ports
(male elbow tube fitting – right bank; male connector
tube fitting – left bank) (see Figure 5.35-57).
NOTE: The word “Water” appears just above the
wastegate base flange between the water inlet and outlet
ports, the side with the petcock being the outlet port.
11. Tighten ferrule nuts.
12. Refill or top off auxiliary cooling water circuit.
Trapped air in the
auxiliary cooling water
circuit leads to overheating that can result in
wastegate damage and premature engine failure.
Disregarding this information could result in prod-
uct damage and/or personal injury.

9. Finger tighten ferrule nuts (11/16 in. hex) to attach
two water return tubes to wastegate water outlet ports
(male connector tube fitting – right bank; male elbow
tube fitting – left bank).
10. Finger tighten ferrule nuts (9/16 in. hex) to attach
free end of compressor discharge pressure sensing
tubes to “Air” port at side of each wastegate (male elbow
tube fitting – both banks).
13. Bleed trapped air.
WASTEGATE DISASSEMBLY -- P/N 295645 SERIES
The wastegates have a diaphragm that may require
replacing. Servicing the wastegate is beyond the scope
of this manual. For detailed servicing instructions and a
list of parts, consult your local distributor.

LEFT BANK

WASTEGATE

TO OIL COOLER

FROM AUXILIARY
WATER PUMP

INTERCOOLER

RIGHT BANK

COMPRESSOR DISCHARGE PRESSURE SENSING TUBES WASTEGATE

WATER SUPPLY TUBES
WATER RETURN TUBES

Figure 5.35-57. Wastegate Connections

FORM 6296 First Edition 5.35 -- 23

EXHAUST SYSTEM

WASTEGATE ASSEMBLY -- P/N 295645 SERIES

TUBE
Wastegates for GSI engines use a vent fitting in the top ELBOW
(see Figure 5.35-58). Use pipe thread sealant and
install a 1/8 in. NPT pipe vent in the vent location.

VENT

Figure 5.35-60. LFPS Wastegate

Figure 5.35-58. GSI Wastegate

Use pipe thread sealant and install a 1/8 in. NPT pipe
nipple and 1/4 in. x 1/8 in. NPT reducing coupling in the
wastegate vents for LT engines (see Figure 5.35-59).
The couplings will accept piping for the backpressure
regulator.
Use pipe thread sealant and install a 1/8 in. NPT pipe
nipple and 1/4 in. coupling and tube elbow in the
wastegate vents for GSI engines equipped with the Low
Fuel Pressure System (see Figure 5.35-60). The el-
bows will accept vent piping to the air cleaner ducts.
VHP Series Four engines use a wastegate backpres-
sure regulator (see Figure 5.35-66). The wastegate
backpressure regulator is adjusted to control throttle
reserve. The regulator system include a wastegate
crossover tube and plenum.
LT WASTEGATE BACKPRESSURE
REGULATOR
LT WASTEGATE BACKPRESSURE REGULATOR
INSTALLATION
1. Regulator and support bracket are fastened to left
rear of crankcase (see Figure 5.35-61 and
Figure 5.35-66).
2. Fasten plenum to support bracket with two 2 in.
diameter clips (see Figure 5.35-62 and Figure 5.35-66).
SUPPORT BRACKET

REDUCING COUPLING

Figure 5.35-61. Support Bracket

Figure 5.35-59. LT Wastegate

5.35 -- 24 FORM 6296 First Edition

 EXHAUST SYSTEM

HEAT SHIELD PLENUM TUBE

PLENUM

PLENUM SUPPORT
BRACKET

Figure 5.35-62. Backpressure Regulator Plenum

Support Bracket

3. Use pipe thread sealant and install tube elbow, pipe

nipple, pipe elbow and tube tee in backpressure
regulator (see Figure 5.35-63 and Figure 5.35-66).
Install regulator to air cleaner tube and intake manifold Figure 5.35-64. Plenum Tube Installation
to regulator tube. Support tubes to each other with clips
3/8 in. diameter clips. 6. Use pipe thread sealant and install pipe tee and
cross over tube (see Figure 5.35-65 and
MANIFOLD TUBE Figure 5.35-66).

CROSS OVER TUBE

AIR CLEANER TUBE PLENUM TUBE

Figure 5.35-63. Regulator Tube Installation

4. Install backpressure regulator to plenum tube (see
Figure 5.35-63 and Figure 5.35-66).
5. Secure plenum to wastegate tube onto right side
wastegate tee (see Figure 5.35-64 and Figure 5.35-66).
Figure 5.35-65. Cross Over Tube
7. See Section 5.05 Fuel System for instructions on use
of back pressure regulator.

FORM 6296 First Edition 5.35 -- 25

EXHAUST SYSTEM

5
3

2
7
9
8 13 10
6
4
1
3

11
12
13
1

7
11
12
14
16
15
13 21
19

24 12
13
22

11 20
19
12 7
14
4

21

2
23

18 17
7 7

ITEM NUMBER AND DESCRIPTION

1 Wastegate 7 Male Tube Connector 13 Capscrew 19 Backpressure Regulator
2 Pipe Nipple 8 Plenum 14 Hex Nut 20 Regulator Bracket
3 Reducing Coupling 9 2² Diameter Clip 15 Plenum To Valve Tube 21 Male Tube Elbow
4 Tee 10 Plenum Bracket 16 Instruction Decal 22 Tube Clip
Wastegate To Regulator To Manifold
5 Wastegate Tube 11 Flat Washer 17 Pipe Elbow 23 Tube
Wastegate To Plenum Air Cleaner To Manifold
6 Tube 12 Lock Washer 18 Restrictor Element 24 Tube
Figure 5.35-66. LT Exhaust Backpressure Regulator

5.35 -- 26 FORM 6296 First Edition

 EXHAUST SYSTEM

LFPS WASTEGATE VENT TUBES 3. Left side tube is supported by a bracket and clip
attached to heat shield fasteners (see Figure 5.35-69).
1. Low Fuel Pressure System (LFPS) wastegates are
vented to air cleaners. Right side tube is supported by a
bracket and clip attached to heat shield fasteners (see VENT TUBE
Figure 5.35-67).

VENT TUBE

SUPPORT
CLIP

AIR CLEANER
CONNECTION

Figure 5.35-69. LB LFPS Wastegate Vent Tube

ENGINE ALTITUDE ADJUSTMENTS

SUPPORT CLIP Engines must be
derated for altitude. Ad-
Figure 5.35-67. RB LFPS Wastegate Vent Tube justing wastegates to obtain rated load at high
altitudes can result in turbocharger overspeed and
2. Right side tube is routed around oil separator and failure. Disregarding this information could result in
connected to air duct with a tube elbow (see product damage and/or personal injury.
Figure 5.35-68).
Wastegates can be adjusted to allow engine operation
above altitudes of 2000 ft. (610 m) This is only for GSI
VENT TUBE
engines maintaining 158 psi (1089 kPa) BMEP with
10% overload and LT engines maintaining 165 psi
(1138 kPa) BMEP with 10% overload.
The engine must be in good operating condition and
ignition system properly timed with the fuel system
adjusted according to Waukesha’s recommendations
before adjusting the wastegate(s).
The LT engine uses the same style of wastegate as the
GSI but has additional control on the vent port of the
wastegate to help maintain throttle reserve thought the
load range.
NOTE: The LT engines are equipped with a differential
pressure wastegate and typically do not require adjust-
ment for altitudes up to 5000 ft. (1524 m).
AIR CLEANER
CONNECTION

Figure 5.35-68. Right Side LFPS Wastegate Vent Tube

FORM 6296 First Edition 5.35 -- 27

EXHAUST SYSTEM

Do not attempt to adjust VALVE

the wastegate(s) to com- POPPET
pensate for engine wear and misadjustment. Disre-
garding this information could result in product
damage.
COMPRESSOR
DISCHARGE PRESSURE 2.46 IN.
Always verify that all SENSING CONNECTION (62.48 MM)
cylinders are firing be-
fore adjusting the wastegate. Individual exhaust
thermocouples have been provided for this pur-
pose. Failure to do so may cause serious engine
damage.

Wastegate adjustment
on one bank affects the
performance of the opposite bank cylinders. Ad-
justment of the left bank wastegate will change the
intake pressure of the right bank (and vice versa). DIAPHRAGM
Disregarding this information could result in prod-
uct damage.

Do not attempt to equal- JAM NUT

ize bank to bank pressur-
ADJUSTING
es by adjusting throttle plates out of SCREW
synchronization. Disregarding this information
could result in product damage.
PLUG
WASTEGATE ADJUSTMENT
Figure 5.35-70. Typical Wastegate
1. Remove wastegate from engine.
9. Slowly apply air to wastegate until pressure reading
2. Remove protective plug(s) from wastegate(s) adjust-
agrees with compressor discharge pressure specified
ing screw well (see Figure 5.35-70).
for that part number. Refer to Table 5.35-3,
3. Loosen jam nut. Table 5.35-4, Table 5.35-5 and Table 5.35-6 for specific
pressure readings. Confirm valve poppet distance is
4. Secure wastegate in vise with valve poppet on top. 2.46 in. (62.48 mm).

5. Attach air hose and appropriate pressure gauge to
compressor discharge pressure sensing connection
(see Figure 5.35-70).
6. Slowly apply air to wastegate until pressure reading
agrees with compressor discharge pressure specified
for that part number. Refer to Table 5.35-3,
Table 5.35-4, Table 5.35-5 and Table 5.35-6 for specific
pressure readings.
7. Turn adjustment screw until distance from face of
poppet to wastegate mounting face (without gasket) is
2.46 in. (62.48 mm) (see Figure 5.35-70).
8. Release pressure from wastegate completely and let
valve return to its seated position.
10. If valve poppet does not return to 2.46 in.
(62.48 mm), it is an indication that the valve is sticking
and not working freely. If slight vibration or tapping of the
valve assembly returns the valve to the 2.46 in.
(62.48 mm) dimension, the wastegate can be used. If
slight tapping or vibration does not return the valve to the
2.46 in. (62.48 mm) height, the wastegate is not opera-
tional and should be repaired or replaced.
11. Tighten jam nut.
12. Replace protective plug.
13. Reinstall wastegate on engine.

5.35 -- 28 FORM 6296 First Edition

 EXHAUST SYSTEM

Table 5.35-3. L5774LT Wastegate Adjustment ON--ENGINE ADJUSTMENT -- GSI ENGINES ONLY
WASTEGATE
ALTITUDE PART CALIBRATION PRESSURE NOTE: An on--engine adjustment of the wastegate can
FT. (M) NUMBER IN. (MM) HG GAUGE be performed on GSI engines only.
Up to 3000
295645S 27.1 (688.34) 1. Install pressure gauges with a 0 -- 30 in-Hg (0 --
(914.4)
762 mm-Hg) or 0 -- 15 psi (0 -- 103 kPa) range at the gas
NOTE: Wastegate calibration pressure is based on operation at regulator air pressure connections on each bank. This
1200 rpm 142 psi (979 kPa) BMEP @ 8.0% O2 .
connection links to the carburetor bonnet and is
Table 5.35-4. L5794LT Wastegate Adjustment normally used for sensing the air portion of gas/air when
setting the main fuel regulators (see Figure 5.35-71).
COMPRESSOR
ALTITUDE PART CALIBRATION PRESSURE
FT. (M) NUMBER IN. (MM) HG GAUGE
Up to 3000
295645R 31.7 (805.18)
(914.4)

NOTE: Wastegate calibration pressure is based on operation at

1200 rpm 165 psi (1138 kPa) BMEP @ 7.8% O2 .

Table 5.35-5. L5794GSI Wastegate Adjustment (Without

ESM System)
COMPRESSOR
ALTITUDE PART CALIBRATION PRESSURE
FT. (M) NUMBER IN. (MM) HG GAUGE
Up to 3000 FUEL GAS PRESSURE INSTALL
295645P 20.2 (513.08) REGULATOR GAUGE
(914.4)

Up to 5000
295645P 22 (558.80) Figure 5.35-71. Fuel Gas Pressure Regulator
(1524)
Up to 7000 NOTE: The compressor calibration pressures in Step 2
295645P 24 (609.60)
(2134)
should be close to the table value but do not need to be
Up to 8000
(2438)
295645P 25 (635.00) the exact value listed. Adjust wastegate(s) accordingly.

NOTE: Wastegate calibration pressure is based on operation at 2. With engine operating 1200 rpm at 158 psi
1200 rpm 158 psi (1089 kPa) BMEP. (1089 kPa) BMEP, compressor discharge pressure(s)
should fall within values listed in Table 5.35-3,
Table 5.35-6. L7044GSI Wastegate Adjustment
Table 5.35-4, Table 5.35-5 and Table 5.35-6. Adjust
COMPRESSOR wastegate(s) accordingly.
ALTITUDE PART DISCHARGE PRESSURE
FEET NUMBER INCHES HG GAUGE
NOTE: Adjustments on one wastegate of the VHP
Up to 3000
295645L 23.5 (596.90) 12 cylinder engine may result in a change in compressor
(914.4)
discharge pressure for both banks of the engine. Adjust
Up to 5000 the wastegates an equal amount on each bank for
295645L 26 (660.40)
(1524) coarse adjustment. If compressor discharge pressures
Up to 7000 between left bank and right bank differ by more than
295645R 28 (711.20) 1.5 in-Hg (38 mm-Hg), use small wastegate adjust-
(2134)
ments to balance compressor discharge pressures.
Up to 8000
295645R 29 (736.60)
(2438) NOTE: The LT engines are equipped with a differential
NOTE: Wastegate calibration pressure is based on operation at pressure wastegate and typically do not require adjust-
1200 rpm 158 psi (1089 kPa) BMEP. ment for altitude.

FORM 6296 First Edition 5.35 -- 29

EXHAUST SYSTEM

WASTEGATE BACKPRESSURE ADJUSTMENT ON

LT ENGINES -- WITHOUT THE ESM SYSTEM ADJUSTING
SCREW
The wastegate backpressure regulator for LT engines is
adjusted to control throttle reserve at full load. This
adjustment is intended for engines located in elevations
above 5000 ft. (1524m).
The wastegate system on the LT engine is designed to
control the differential pressure across the throttle plate
throughout the load range of the engine and to limit
overload operation.
The schematic shown in Figure 5.35-57 illustrates how
the wastegate system is designed. The vent on the top
of the wastegate is biased with intake manifold pres- BACKPRESSURE
REGULATOR
sure. This bias allows the wastegate spring adjustment
to set the differential pressure across the throttle plate.
Figure 5.35-72. LT Series Wastegate Backpressure
In order to limit maximum power or overload operation, Regulator -- Left Bank
the pressure bias must be removed. This is done with
the backpressure regulator. The regulator opens at a 2. Install a differential pressure gauge to measure
predetermined overload point and bleeds the intake throttle reserve between intake manifold and carburetor
manifold pressure off that allows the wastegate to open bonnet air pressure.
further, slowing down the turbocharger and limiting the
power output. 3. With the engine at rated load and speed, open the
wastegate backpressure regulator by turning the adjust-
The orifice and accumulator are installed to stabilize the
ing screw out (counterclockwise) until the throttle
differential wastegate control scheme.
reserve begins to drop. The throttle reserve should not
NOTE: The wastegate must be already set to specifica- fall below 12 in-Hg (304.8 mm-Hg) on either bank.
tion before performing this adjustment. See “Wastegate
Adjustment” for instructions. Do not operate the
engine at loads of
1. Before engine startup, close wastegate backpres- 200 BMEP or greater. Failure to adhere to this may
sure regulator by turning adjusting screw clockwise to
cause severe engine damage.
seat it completely (Figure 5.35-72).
4. Increase the load on the engine to 110% or highest
site load if less than 110%. Readjust backpressure
regulator screw until the throttle reserve is 7 ± 1 in-Hg
(177.8 ± 25.4 mm-Hg).

5.35 -- 30 FORM 6296 First Edition