Clean and Inspect.
Clean all traces of the old gaskets (7, Figure 9-82) from the mating surfaces.
Clean all rust, scale, and carbon from the male and female connections of the manifold sections (4, 5, and
6), if separated.
Inspect the capscrews (1) for damaged or stripped threads. Repair slightly damaged threads by chasing;
replace stripped capscrews.
Inspect the male and female slip-joints of the manifold connections (4, 5, and 6), if separated for evidence
of leakage as indicated by erosion or gas cutting. Replace any manifold section with gas cut or eroded
Inspect the gasket surfaces for warping or gas cutting. Repair or replace the manifolds in accordance with
step c, below.
Visually inspect the manifold sections (4, 5, and 6) for cracks. If cracks are suspected, inspect using
penetrant, inspect in accordance with MIL-L-6866. Repair or replace a cracked manifold section in
accordance with step c, below.
Replace any manifold section that is cracked through a gasket surface or slip-joint
Repair gas cut or warped gasket surfaces by surface grinding. A maximum of 0.0625 inch (1.588 mm)
may be removed to restore the surface. If material is removed from any gasket surface that joins with a
cylinder head, an equal amount of material must be removed from the surfaces of all three sections.
Replace any manifold section that is warped or gas cut to the extent that surface grinding in accordance
with step NO TAG, above, will not result in an acceptable gasket surface.
Coat the slip-joints of the manifold sections (4, 5, and 6, Figure 9-82) with anti-seize compound, MIL-A-
907, and assemble the sections. If necessary, tap the sections together with a plastic or rawhide mallet.
Coat new gaskets (7) with anti-seize compound, MIL-A-907, and position them on the cylinder heads.
Coat the washers (3), lockplates (2), and capscrews (1) with anti-seize compound, MIL-A-907, position the
assembled manifold sections (4, 5, and 6) on the cylinder heads, align the gaskets, and install the washers,
lockplates, and capscrew.
See Figure 9-81. Starting at the center manifold section (5, Figure 9-82), and working to each end (4 and
6), cross-tighten the capscrews (1) in three stages to 40 to 45 pound-feet (54 to 61 newton-meters), and
bend the tabs on the lockplates (2).
Install the aftercooler in accordance with paragraph 942.
9-45. WATER MANIFOLDS AND SEALS MAINTENANCE The water manifolds consist of water transfer tubes and
preformed packings that join each rocker arm housing. Repair or replace the components in accordance with Section II,
Cylinder Head Assemblies.