Freightliner Century Class. Manual — part 33
MOP Number
CAT CGI Bellows Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–02
Exhaust System Inspection (Noise Emission Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–01
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–00
Exhaust
49
Index, Alphabetical
49–00 Safety Precautions
Safety Precautions in this section apply to all
procedures within this group.
DANGER
When working on the vehicle, shut down the en-
gine, set the parking brake, and chock the tires.
Before working under the vehicle, always place
jack stands under the frame rails to ensure the
vehicle can not drop. Failure to follow these steps
could result in serious personal injury or death.
49–01 Exhaust System
Inspection (Noise
Emission Control)
In addition to inspecting the exhaust system at the
scheduled maintenance interval, inspect the exhaust
system if the noise level of the vehicle has in-
creased. Replace parts that show leakage, wear, or
damage, with genuine Freightliner parts.
Pre-EPA07 Exhaust System
Inspecting
1.
On all vehicles, check the condition of the muffler
body, the top stack, and the heat shield. See
. Check the inlet/outlet tubes for leakage,
dents, and corrosion, and check for holes in the
muffler. Replace parts as required. Use new
parts, equivalent to parts originally installed on
the vehicle. See Group 49 of the Century Class
Trucks Workshop Manual for replacement
procedures.
2.
Inspect the exhaust flex hose (see
) for
leakage, wear, or damage. Replace with new
parts if replacement is needed.
3.
Check for leakage at the V-band coupling, which
attaches the exhaust pipe to the turbocharger
exhaust outlet. See
If leakage exists, tighten the nut on the V-band
coupling 10 lbf·ft (14 N·m). If leakage persists,
install a new V-band coupling.
4.
Inspect the turbo outlet pipe, and replace it as
needed.
5.
Check the U-bolt clamps for tightness, and
tighten as needed.
6.
Check the isolator at the base of the exhaust
stack elbow(s) (see
), for cracking, dam-
age, and dry rot. Replace as needed.
7.
Check for leakage at all wide-band exhaust
clamps. See
, or
If leakage exists, tighten the nuts 40 to 60 lbf·ft
(54 to 81 N·m). If leakage persists, install a new
wide-band exhaust clamp. Do not re-use
Sealclamps.
01/06/99
1
2
2
3
3
f490170
1.
Exhaust Clamp
2.
Lower Heat Shield Fastener
3.
Upper Heat Shield Fastener
Fig. 1, Vertical Exhaust Stack and Heat Shield
Exhaust
49
49/1
EPA07 Exhaust System
Inspecting
IMPORTANT: The Environmental Protection
Agency’s 2007 regulations require lower ex-
haust emissions, thus requiring new exhaust
system components. See
. In particular
the after-treatment device (ATD), which is part
of the after-treatment system (ATS), requires
special attention during regularly scheduled
f490024a
1
2
3
06/01/93
4
1.
Flex Hose
2.
V-Band Coupling
3.
Exhaust Pipe
4.
Turbocharger Exhaust Outlet
Fig. 2, V-Band Coupling and Flex Hose
08/25/95
f490127
1
2
3
1.
Exhaust Pipe
2.
Exhaust Elbow Isolator
3.
Mounting Nut
Fig. 3, Exhaust Elbow Isolator
f490025a
05/28/93
Fig. 4, Donaldson Sealclamp Wide-Band Exhaust
Clamp
f490005a
10/05/94
Fig. 5, Torca Torctite Wide-Band Exhaust Clamp
f490214a
09/30/99
Fig. 6, Gemi Wide-Band Exhaust Clamp
Exhaust
49
49/2
maintenance inspections. If any discrepancies
are discovered, refer to the engine manufactur-
er’s service literature for repair instructions.
Definitions of ATS Components
Refer to the following list of definitions of ATS com-
ponents.
• After-Treatment System (ATS)—the entire ex-
haust system from the turbocharger to the ex-
haust stack or tail pipe.
• After-Treatment Device (ATD)—a muffler-like
canister that houses a DPF, DOC, and sensors.
• Diesel Particulate Filter (DPF)—a filter that col-
lects and holds particulate matter (soot and
ash).
• Diesel Oxidation Catalyst (DOC)—oxidizes hy-
drocarbons and reduces NOx.
• Sensors—detect temperatures and pressures in
the ATS.
Inspection
1.
Check for leakage at the clamp that attaches the
exhaust pipe to the turbocharger exhaust outlet.
If leakage exists, tighten the nut on the clamp to
the required torque. If leakage persists, install a
new clamp.
2.
Check the exhaust pipe, bellows, and each ex-
haust seal clamp for leakage, wear, cracks, or
damage. Replace damaged components as
needed. If leakage exists at a clamp, tighten the
nuts to the required torque. If leakage persists,
install a new exhaust seal clamp. Do not reuse
seal clamps. Once a seal clamp is loosened or
removed, it must be replaced.
NOTICE
A leak in the CGI piping, including the bellows,
will allow unfiltered air and contaminants into the
engine intake, and can cause serious engine dam-
age.
f490283
1
2
2
5
6
5
7
8
9
3
3
4
10/20/2006
A
A. Inspect this area of the canister for dents.
1.
Marmon Fitting at Inlet from Turbocharger
2.
DOC Temperature Sensor
3.
ATD Mounting Band
4.
DPF Intake Pressure Sensor
5.
DPF V-Band Mounting Clamps
6.
Sensor Housing
7.
DPF Outlet Temperature Sensor
8.
Exhaust Outlet Marmon Fitting
9.
DPF Outlet Pressure Sensor
Fig. 7, Typical After-Treatment Device
Exhaust
49
49/3
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