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Old 02-22-2012, 09:13 PM   #1
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8.3 330 ISC Exhaust Manifold

I'm in the process of installing the Banks Powerpack system on my motorhome, a 2003 40' Diplomat and have a question regarding the exhaust manifold. I attached a picture of what appears to be an expansion joint in the manifold and also what might be signs of leakage at the joint. Has anybody looked closely at theirs and seen the same thing? I attached a pic of the whole manifold also just for good measure.

Thanks
Jeff
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Old 02-22-2012, 09:53 PM   #2
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I would say that is either and expansion joint which is pretty unusual or there are some applications for that motor where the exhaust manifold can only be fitted in two pieces which I have seen before. Yes it does look like a very small leak but so small that I would leave it alone.
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Old 02-23-2012, 08:07 AM   #3
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Originally Posted by jckc779 View Post
I'm in the process of installing the Banks Powerpack system on my motorhome, a 2003 40' Diplomat and have a question regarding the exhaust manifold. I attached a picture of what appears to be an expansion joint in the manifold and also what might be signs of leakage at the joint. Has anybody looked closely at theirs and seen the same thing? I attached a pic of the whole manifold also just for good measure.

Thanks
Jeff
I have a 99 Alpine with the same problem. My leak is very minor and does not seem to get any worse. Yes, it is a two piece manifold. It is my understanding that a cracked manifold has been a common problem with this engine. I checked with Cummins Northwest, Yakima, Wa 60 days ago, they had everything I needed, about $700. How many studs are going to brake off in the head?? Its more job than I want. Will the B\anks system increase the pressure on the manifold?????? Pac Brake has an updated kit that increases the brake power. good wishes, old trucker.
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Old 02-23-2012, 04:37 PM   #4
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What you're seeing there is pretty normal. The two or four cylinders in the middle are connected with the center piece, the two on the outside are thru the connected ends. Reason, well the exhause manifold expands and contracts at different rates than the block, and a full manifold would crack after a little use. The two joints are just metal on metal so a little minor leaking may occur and is okay. Take them apart by lightly taping with a hammer, back together the same way.

I've had trouble on an ISC and my ISM with the gaskets blowing out and leaking and have pulled them both for repair. If you're going to pull a manifold start out a week ahead of time spraying the bolts twice a day with some nut buster so you don't break so many head bolts. I got them all off my ISM last spring without breaking any. Before you reinstall take the manifold to a machine shop and have the manifold reground flat and straight so you don't have blown gaskets right off the bat.

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Old 02-23-2012, 04:47 PM   #5
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Two piece manifold is standard. I do see some carbon but not enough to get exercised about. If the manifold cracks you will want to replace it. I believe I read about an aftermarket manifold that should be a better fit and not crack (different steel recipe). Its a few hour job to replace. IIWMI'd get some good anti-seize on all the threaded connections while goofing around in there.
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Old 02-24-2012, 07:32 PM   #6
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Thanks for your inputs. I'm going to leave it for now and address it later if it gets bad. I don't want to take a chance with the manifold bolts right now.

Jeff
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Old 02-24-2012, 09:20 PM   #7
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Jeff, I am in 100% agreement with you. I can bet money that one of those manifold bolts will brake if not more. So what would you do if you took it off????? Buy another one the same and it will leak the same. Can you hear it leaking?
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Old 02-25-2012, 12:37 PM   #8
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Mike, I recently started hearing a squeal at full boost and with the Pacbrake on. That's why I was taking a close look at the manifold. It's not real loud and I still get full boost and the performance seems fine. I plan on doing a pressure test on the intake side (cooler and hoses) but that wouldn't explain the same squeal with the Pacbrake on. My guess is the squeal is coming from this leak but I'll live with it for now and monitor it. The guy at my local Cal Pacific said squeals usually come from pin holes in the manifold. That's about all he offered. He wouldn't even show the picture I took to a tech to ask if it looked normal or not. I looked and couldn't find anything obvious although it's hard to get a good look at every surface with it installed.
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Old 02-25-2012, 01:27 PM   #9
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That is an expansion joint. They leak a little when cold. As the manifold heats up and expands they usually seal up.
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Old 02-25-2012, 06:19 PM   #10
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Thanks for your inputs. I'm going to leave it for now and address it later if it gets bad. I don't want to take a chance with the manifold bolts right now.

Jeff
Jeff I changed out the front of the 2 piece manifold a couple yrs ago on our ISC 350 and for the 5 or 6 days I was waiting on parts I sprayed two or three times a day with PB Blaster, I didnt have any problems on any of the manifold or turbo bolts also had to pull both manifolds because the new gaskets were lots thicker than the old style, I did the same thing years earlier on a ISB, I soaked with a good penetrate before attempting to remove the manifold with the same results NO broken studs.
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Old 02-26-2012, 03:37 PM   #11
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You might want to check all of your clamps on the air side. That squeal you hear also comes from boost pressure leaking past the rubber if the clamps are not tight enough or they have a pinhole in them.

Good luck, jeff
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