SHIM 1K3963 - Caterpillar

Removal Procedure
Start By:
If the engine is equipped with a turbocharger, remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove and Install" for the correct procedure.
For C2.2 remove tube assembly from the exhaust gas recirculation valve and the exhaust cooler (NRS). Refer to Disassembly and Assembly, "Exhaust Gas Recirculation Valve - Remove and Install" and refer to Disassembly and Assembly, " Exhaust Cooler (NRS) - Remove and Install" for the correct procedure.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g03333215
Illustration 2 g03333158
Loosen bolts (3) and nuts (5) in reverse numerical sequence that is shown in Illustration 1.
Remove nuts (5) and bolts (3).
Remove bolt (7) from the air pump bracket. Remove bracket (8).
Remove shield (2) from exhaust manifold (1).
Remove exhaust manifold (1) from cylinder head (10).
Remove gasket (9) (not shown) from cylinder head (10).
If necessary, for C2.2 remove the exhaust gas recirculation valve from exhaust manifold (1). Refer to Disassembly and Assembly, "Exhaust Gas Recirculation Valve - Remove and Install" for the correct procedure.
If necessary, remove studs (4) (not shown) from exhaust manifold (1). Note position of studs for installation purposes.
If necessary, remove studs (6) (not shown) from cylinder head (10). Note position of studs for installation purposes. Installation Procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Ensure that the gasket surfaces of the cylinder head and the exhaust manifold are clean and free from damage.
Illustration 3 g03333215
Illustration 4 g03333158
If necessary, for C2.2 install the exhaust gas recirculation valve to exhaust manifold (1). Refer to Disassembly and Assembly, "Exhaust Gas Recirculation Valve - Remove and Install" for the correct procedure.
If necessary, install studs (6) (not shown) to cylinder head (10). Ensure that the studs are installed in the correct position on the cylinder head.
Tighten studs (6) to a torque of 25 N m (221 lb in).
If necessary, install studs (4) (not shown) to exhaust manifold (1). Ensure that the studs are installed in the correct position on the exhaust manifold.
Tighten studs (4) to a torque of 25 N m (221 lb in).
Position a new gasket (9) (not shown) onto cylinder head (10). Ensure that the gasket is correctly orientated.
Align exhaust manifold (1) with studs (6) (not shown). Install exhaust manifold (1) onto cylinder head (10).
Position shield (2) onto exhaust manifold (1) Install nut (5) and bolts (3) to shield (2) hand tight.
Position bracket (8) onto the air pump and exhaust manifold (1) Ensure that the bracket is correctly orientated.
Install bolt (7) to the air pump bracket hand tight.
Install bolt (3) exhaust manifold (1) hand tight.
Install remaining bolts (3) and nut (5) hand tight.
Tighten nuts (5) and bolts (3) to a torque of 25 N m (221 lb in). Tighten the bolts and nuts in the sequence that is shown in Illustration 1.
Tighten bolt (7) to a torque of 25 N m (221 lb in). End By:
If the engine is equipped with a turbocharger, install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove and Install" for the correct procedure.
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