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This is the location for
thermocouple placement
on a 2nd Gen Dodge 5.9L
Cummins. Make an
impression with a center
punch where the X is in
this photo. You
should be drilling in
the center of the rear
exhaust manifold port
(for cylinders 4-6).
Start with a small pilot
hole and work your way
up to a size "R" drill
bit (0.339") increasing
1 drill bit size at a
time. This will cause
all shavings to remain
small and dust-like.
While drilling and
tapping have a helper
hold a vacuum cleaner
next to the hole. There is no need to coat
your bits with grease or
lube. You want all of
the shavings to remain
dry so that they will
come out without
sticking when you vacuum
out the hole. Using a
1/8" NPT tap, tap the
hole. Apply a small
amount of anti-seize
lubricant to the threads
of the thermocouple
fitting and tighten.
Insert the probe with
its nut and ferrule.
You want the tip of the
probe to be in the
center of the exhaust
flow.
Tech Tip: Do not
perform this while the
engine is running. Some
company’s recommend this
practice, as it is their
belief that the exhaust
pressure going through
the manifold will push
the shavings out through
the hole you are
drilling. We do not
subscribe to this
belief. Working on a
running engine greatly
increases your chance of
injury. Also, while
uncommon, if your drill
bit happens to break off
inside the manifold, it
has no place to go but
through the turbo. If
the engine were not
running you can always
take whatever action
necessary to remove the
broken piece before you
start the engine. The
practice of coating your
drill bits with grease
is also a very bad idea.
The flutes of a drill
bit are designed to
remove chips outward. By
loading these flutes up
with grease, all you
would be doing is making
it more difficult for
them to perform as
designed. Also, grease
will cause some of the
shavings to stick on the
inside of the manifold,
making it difficult to
remove later with a
vacuum cleaner. |