MUFFLER GP 7W6425 - Caterpillar

Removal Procedure
Sulfuric Acid Burn Hazard may cause serious personal injury or death.The exhaust gas cooler may contain a small amount of sulfuric acid. The use of fuel with sulfur levels greater than 15 ppm may increase the amount of sulfuric acid formed. The sulfuric acid may spill from the cooler during service of the engine. The sulfuric acid will burn the eyes, skin and clothing on contact. Always wear the appropriate personal protective equipment (PPE) that is noted on a material safety data sheet (MSDS) for sulfuric acid. Always follow the directions for first aid that are noted on a material safety data sheet (MSDS) for sulfuric acid.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g02169793
Loosen hose clamps (8). Disconnect hose assembly (7) from connection (9) for inlet air control (6).
Slide locking tab for engine wiring harness assembly (1) into the unlocked position. Disconnect engine wiring harness assembly (1) from wiring harness assembly (4) for the NRS valve. Slide the connection for wiring harness assembly (4) from bracket (2).
Slide locking tab for the engine wiring harness assembly into the unlocked position. Disconnect the engine wiring harness assembly from wiring harness assembly for wastegate solenoid (5). Slide connection for wiring harness assembly for wastegate solenoid (5) from bracket (2).
Slide locking tab for engine wiring harness assembly (10) into the unlocked position. Disconnect the engine wiring harness assembly from engine inlet throttle valve (11).
Cut all the cable straps in order to allow the engine wiring harness assembly to be positioned away from inlet air control assembly (6).
Loosen hose clamps (12) on the hose assembly that connects inlet air control assembly (6) to inlet elbow (13).
Illustration 2 g02169794
Illustration 3 g02351557
Disconnect temperature sensor (16) from the inlet air control assembly. Refer to Disassembly and Assembly, "Temperature Sensor (Cooled Exhaust Gas) - Remove and Install" for the correct procedure.
Slide clip (19) along the hose assembly. Remove the hose assembly from the wastegate actuator.
Loosen banjo bolt (22) for tube assembly (23).
Remove bolt (17) (not shown) and bolt (24) from tube assembly (23).
Remove banjo bolt (22) and remove sealing washers (21) (not shown).
Remove tube assembly (23) from inlet air control assembly (6).
remove hose clamp (18) and hose clamp (20). Remove hose assembly (26) and hose assembly (27) from the connections on inlet air control assembly (6).
Remove bolts (14) and remove bolts (25).
Remove inlet air control assembly (6).
Remove gasket (15) (not shown) from inlet air control assembly (6).
Illustration 4 g02169795
If necessary, follow Step 17.a through Step 17.c in order to remove bracket (29).
Cut cable straps (31).
Remove bolts (28).
Remove bracket (29) from cylinder head (30).