1.03.017 GM 5.7 (350) Intake manifold installation and torque procedure

This Policy is complete waiting on field Service, Engineering, and EHSs approval

Purpose

The purpose of this procedure is to establish the minimum requirements for installing and properly torquing the engine intake manifold on General Motors 5.7 Vortec style engines as laid out in this procedure.

Procedure

This procedure applies to all General Motors 5.7 Vortec style engines on Flogistix skids equipped with the General Motors 5.7 Vortec engine drive units that are currently in service in the Field, Test Loop, at a Repair Shop, or in Storage Yards. Flogistix Service Technicians will perform the torque procedure as outlined in this procedure.

Before any work is performed a JSA needs to be done according to Flogistix procedure along with any Customer requirements before any work is started.

GM 5.7 Intake Manifold installation procedure

With the heads installed on the engine block make sure all intake surfaces are clean and free of any oil or sealant on the cylinder heads and engine block

1. Make sure the cylinder head intake surfaces and engine block end seal surfaces are clean

2. Apply a small amount of RTV Silicone sealant to the cylinder head side of the intake manifold gasket at each end. **See example below

Applying excessive amounts of sealant may prohibit the intake manifold gaskets from sealing properly

Do Not use any silicone sealant anywhere else in the intake manifold gasket. The molded o-ring material on the intake manifold gasket are designed to seal without chemical sealers.

3. Install the intake manifold gasket onto the cylinder head

Use the gasket locator pins on the intake manifold gaskets to locate the dowel holes in the cylinder head in order to properly locate the lower intake manifold gasket on the cylinder head

4. Apply a bead approximately 1/4" of RTV type silicone sealant to the front top of the engine block. As shown in the example below. Extend the silicone sealant onto each lower intake manifold gasket to endure proper seal in the corner of each gasket.

5. Apply a bead approximately 1/4" of RTV type silicone sealant to the top rear of the engine block as shown in the example below. Extend the silicone sealant onto each lower intake manifold gasket to endure proper seal in the corner of each gasket.

5. Set the Intake manifold in place on the cylinder block and heads as shown in the example below. (** Example picture below is for reference only the example shows a different model manifold)

6. Install the intake manifold bolts

7. Carefully tighten the intake manifold bolts evenly until the intake manifold has started to compress the molded o-ring portion of the intake manifold gasket. Proper intake manifold fastener tightening sequence and torque is critical. Always follow the tightening sequence, and torque the intake manifolds using the 3 step method. Failing to do so may distort the manifold or could cause improper crush of each side of the intake manifold gasket

8. See example below for correct intake manifold torque sequence. (** Example picture below is for reference only the example shows a different model manifold)

8.1 Tighten the bolts in sequence on the first pass to 27 lb in

8.2 Tighten the bolts in sequence on the second pass to 106 lb in

8.3 Tighten the bolts in sequence on the final pass to 11 lb ft

Responsibilities

Management - Management is responsible for implementing, supporting, and enforcing the requirements of this procedure to their respective locations/area.

EHSS - Responsible to assist in the implementation of this procedure and to review for effectiveness.

Employees, Contractors, Vendors, ETC. - Are responsible to follow the follow the requirements outlined in this procedure and ask for assistance

Scope

This procedure applies to all General Motors 5.7 Vortec style Natural Gas Engines and is applicable to all Flogistix employees, contractors, and temporary employees.

Hazards

Employees need to be aware of the possibility of extremely hot exhaust pipe surfaces, potential exposure and the inhalation of engine exhaust. Employees should be aware that units could contain flammable and toxic gasses. Potential for the possible hazards of gas ignition or fire, hot surfaces & fluids, rotating equipment. Risk of possible concentration of H2S. Hazardous gases could be in the units pressure vessels, cooler, or associated piping and risk of inhalation of hazardous gas fumes.

Safety

All Personal Protective Equipment (PPE) for normal Field Mechanical duties apply for this procedure.

Four Gas Monitor, which is outlined in the Flogistix EHSS Manual, PPE Section 8, Procedure 8.3

This procedure applies to all units in service in the field, at a service shop, or in any storage yard.

Insure Flogistix personnel have proper safety certification or site orientation if required by the Flogistix Customer.

Insure Flogistix personnel adhere to all Customers safety practices.

Proper use of required tools

Training

All employees shall be initially trained on the following topics:

• Employee Personal Protective Equipment (PPE)

• Lock Out Tag Out (LOTO) procedure according to Flogistix policy

• Methods and Observations that may be used to detect the presence or release of a hazardous chemicals or gas in the work place

Tools & Equipment Required

All employees performing this procedure shall be required to have the listed tools to perform job tasks:

• All required PPE according to Flogistix Safety Policy

• Lock Out Tag Out LOTO items to properly perform LOTO procedure according to Flogistix policy

• Basic Hand Tools to include metric sockets

• Torque Wrench capable of torquing 106 lb in and 11 ft lbs (Foot Pounds)

Approvals

Field Service approved by:

Date:

Engineering approved by:

Date:

EHSS approved by:

Date: