CEC

EFEF - DOCUMENT TEXT BY E/A

E/A ER
REL DATE

061275-119
16FEB07
STATUS

RELEASED & FINAL

STATUS DATE

07MAY07

|
REFERENCE DOCUMENTS
| ------------------------| SUPPLEMENT TO:
|
ACA NO:
WRITTEN BY: ANDREWS,TONY
|
EJR NO:
---------------------------------------------------------------------PURPOSE:

PROGRAM AUTHORIZATION NO

To release and structure new exhaust manifolds, manifold gasket

for ME03 6B, Avalon and MR03 ISBe 4 - and 6 cyl B-series.
Engine Model/Configuration Affected by this EJR: D0E, D31, D32,
D38,D40
DISCUSSION:
To replace the existing 2 piece ISBe 6 cylinder exhaust manifolds
4898113 / 4898123 with a one piece exhaust manifold 3979211 at P
phase with casting 3979210. New manifold is structured with new
2830444 exhaust manifold gasket, these are only compatible with the
new exhaust manifold's 15 degree chamfered outlet ports. New direct
replacement parts were released with the existing options and the
old parts obsoleted.
New 3979211 one piece manifold successfully passed all ESW
requirements completing 5,000 cycles on a rim cracker test. In
addition to this, CRTI have complete structural analysis at 700,
720, 740 and 760 degrees C using Cycle to Crack Initiation (CCI)
transient thermal analysis, Stress to Strength Ratio (SSR) and Model
Analysis all documented in DES-APM0676, DES-APM0686 and DES-APM0675
respectively. Applied Mechanics analysis for Port and Surface
Temperature, Stud Temperature, Displacement and Thermal analysis is
covered in Tech Report DAR6-2006-042.
To replace 4 cylinder 4897792 exhaust manifold with new 4939973
exhaust manifold and 4939980 exhaust manifold casting with chamfered
exhaust ports as per 6 cylinder manifold. New direct replacement
parts were released and structured in the existing options and the
old parts obsoleted. New 4939972 exhaust manifold successfully
passed all new source approval requirements including metallurgical
and dimensional checks that were completed. Engine testing was
completed on cycle 6 Euro 4, performance testing on both Euro 3 and
4 and in addition 580 hours Avalon endurance test and documented in
a CTR.
On TB91158, a structure error was fixed at the same time as only one
(instead of six) gaskets was structured.
One existing TB option that has nowhere used as it was recently
removed off the last config, is being obsoleted without having it's
structure changed.
Changes:
New direct placement parts for 6 cylinder:

Old Part

New Part

4898113 +4898123

3979211

(manifold,exhaust)

New direct replacement parts for 4 cylinder:

Old Part
New Part
4897792

4939973

(manifold,exhaust)

New direct replacement for both:

Old Part

New Part

3955339

2830444

(gasket,exhaust manifold)

As the existing exhaust manifold part numbers being replaced are

EEA controlled items they will be obsoleted and supeserseded on
later EEA release (062600-019).
This ER covers changes requested on PCRN/A
This ER closes out ACA94127
Verification/Validation: Applicable Engineering Standard Work has
been completed, requirements have been met and completed template is
attached.
PF3-PRNT PF4-STRU PF5-NOTE PF6-COMP PF7-TEXT PF8-INFO PF9-PLNT PF10-ITEM
MORE RECORDS FOR REQUEST, PRESS ENTER TO CONTINUE
07JAN15 04:02