ALTERNATOR GP-CHARGING 2W9649 - Caterpillar

Removal Procedure
Start By:
Remove the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Remove and Install".
Remove the air inlet manifold. Refer to Disassembly and Assembly, "Air Inlet Manifold - Remove and Install".
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: It is possible to remove the exhaust manifolds without removing the air inlet manifold first. However, the procedure is more difficult. The aftercooler must be removed before the exhaust manifolds are removed.Note: The following procedures describe the removal of the 3508B exhaust manifold.
Illustration 1 g01116210
Remove bolts (2) that attach exhaust manifold (1) to the turbocharger.
Illustration 2 g01116213
3508B exhaust manifold
Remove bolts (3). Remove manifold (4) and sleeves (5). Note: Manifold (4) is not used on the 3512B exhaust manifold or the 3516B exhaust manifold.
Remove bolts (7). Remove bracket (10).
Attach a suitable lifting device to exhaust manifold (1). The weight of the exhaust manifold is approximately 47 kg (104 lb). Remove bolts (8) that attach the exhaust manifold to the cylinder heads. Note: The weight of the 3512B exhaust manifold is approximately 66 kg (146 lb). The weight of the 3516B exhaust manifold is approximately 92 kg (203 lb).
Remove the exhaust manifold. Remove exhaust manifold gaskets (9). Remove gaskets (6).
Illustration 3 g01116240
Remove bolts (12). Remove sleeve (11) and manifold (13).
Remove bolts (12). Remove sleeves (11) and manifolds (14) from the exhaust manifold. Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 5P-3931 Anti-Seize Compound -
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Note: The following procedures describe the installation of the 3508B exhaust manifold.
Illustration 4 g01116240
Install sleeve (11) and manifolds (14) on the exhaust manifold. Apply Tooling (A) to the threads of bolts (12). Install bolts (12) and tighten to a torque of 55 5 N m (41 4 lb ft).
Install sleeve (11) and manifold (13) on the exhaust manifold. Apply Tooling (A) to the threads of bolts (12). Install bolts (12) and tighten to a torque of 55 5 N m (41 4 lb ft).
Illustration 5 g01116444
3508B exhaust manifold
Attach a suitable lifting device to exhaust manifold (1). The weight of the 3508B exhaust manifold is approximately 47 kg (104 lb). Note: The weight of the 3512B exhaust manifold is approximately 66 kg (146 lb). The weight of the 3516B exhaust manifold is approximately 92 kg (203 lb).
Install new exhaust manifold gasket (9) and position the exhaust manifold onto the cylinder head. Apply Tooling (A) to the threads of bolts (8). Install bolts (8) and tighten to a torque of 50 5 N m (37 4 lb ft).
Install sleeve (4) and manifold (3) on the exhaust manifold. Apply Tooling (A) to the threads of bolts (5). Install bolts (5) and tighten to a torque of 55 5 N m (41 4 lb ft). Note: Manifold (4) is not used on the 3512B exhaust manifold or the 3516B exhaust manifold.
Illustration 6 g01116440
Install new gasket (6) between exhaust manifold (1) and the turbocharger. Apply Tooling (A) to the threads