PLUNGER 6D2192 - Caterpillar

Removal Procedure
Start By:
Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" for the correct procedure.
Illustration 1 g02699657
Illustration 2 g02699661
Loosen bolts (1) in reverse numerical order. Refer to Illustration 2. Note: Loosen the bolts in reverse numerical order will help prevent distortion of the exhaust manifold.
Remove bolts (1) and spacers (2) from exhaust manifold (4). Note: Support the manifold as the bolts are removed.
Remove exhaust manifold (4).
Remove exhaust manifold gasket (3) (not shown) and gasket (5) (not shown).
If necessary, remove studs (6) from exhaust manifold (4). Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Guide Stud
(M10 by 100 mm) 4
B - Loctite 575 1
Illustration 3 g02699676
Illustration 4 g02699657
Ensure that the exhaust manifold is clean and free from damage. If necessary, replace the exhaust manifold. Clean the gasket face of the cylinder head.
If necessary, install studs (6) to exhaust manifold (4). Tighten the studs to a torque of 18 N m (159 lb in).
Install Tooling (A) to the cylinder head in Positions (X). Refer to Illustration 3.
Position new gasket (3) (not shown) and gasket (5) (not shown) onto Tooling (A). Note: Ensure that the words “Cylinder Head Side” is facing to wards the cylinder head.
Align exhaust manifold (4) with Tooling (A). Install the exhaust manifold to the cylinder head.
If bolts (1) have been previously used. Clean and inspect bolts (1). Apply Tooling (B) to the first two threads of the bolts. Note: Do not apply Tooling (B) to new bolts.
Install bolts (1) and spacers (2) hand tight.
Remove Tooling (A). Install remaining bolts (1) and spacers (2) hand tight.
Tighten bolts (1) to a torque of 44 N m (32 lb ft). Tighten the bolts in the sequence that is shown in Illustration 3. End By:
Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install" for the correct procedure.