ELEMENT-FUEL 1198901 - Caterpillar

Remove & Install Exhaust Manifold
Start By:a. remove turbocharger
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
The wire assemblies from the front side of the transformers have been previously disconnected. 1. Disconnect six wire assemblies (1) from the back side of the transformers.2. Remove five bolts and washers (3) from transformer mounting brackets (2).3. Remove the transformers and transformer mounting brackets (2) as a unit. 4. Disconnect coolant line (4).5. Remove coolant line (5).6. Disconnect coolant line (6). 7. Attach Tooling (A), chains and a suitable lifting device to the exhaust manifold as shown.8. Remove bolt (7) and move hose (8) out of the way. 9. Remove seven bolts and washers (9).10. Remove exhaust manifold (10). The weight of the exhaust manifold is approximately 36 kg (79 lb). 11. Remove old gasket material (11) from the joint faces of the cylinder head assembly and the exhaust manifold. The following steps are for the installation of the exhaust manifold. 12. Attach Tooling (A), chains and a suitable lifting device to exhaust manifold (10). The weight of the exhaust manifold is approximately 36 kg (79 lb). Coat the threads of bolts (9) with 4C-5599 Anti-Seize Compound before installation.13. Put exhaust manifold (10) in position on the cylinder head assembly and install bolts (9) finger tight only. Leave a gap of approximately 6.35 mm (.250 in)between the cylinder head assembly and the exhaust manifold for clearance to install the exhaust manifold gaskets.14. Slide three new exhaust manifold gaskets (11) between the cylinder head assembly and the exhaust manifold.15. Tighten bolts (9) to the standard torque value. 16. Connect coolant lines (4) and (6).17. Install coolant line (5). 18. Put hose (8) in position and install bolt (7).19. Remove Tooling (A). 20. Put the transformers and transformer mounting brackets (2) in position and install bolts and washers (3).21. Connect wire assemblies (1).22. Connect the wire assemblies to the front side of the transformers.End By:a. install turbocharger