C6.6 Engines for Caterpillar Built Machines Exhaust Manifold - Remove and Install - Top Mounted Exhaust Manifold Caterpillar

Removal Procedure

1. Disconnect all hoses, tube assemblies and wire leads from the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" Steps 1 through 7.
   Show/hide table

   Illustration 1	g01335809

   Show/hide table

   Illustration 2	g01335810

2. Loosen bolts (4) and (6) in reverse numerical order. Refer to Illustration 2.

   Note: This will help prevent distortion of the exhaust manifold.

3. Remove center bolts (4) from exhaust manifold (3). Remove outer bolts (6) and spacers (5) from exhaust manifold (3).

   Note: Support the manifold as the bolts are removed.

4. Remove the assembly of exhaust manifold (3) and turbocharger.

5. Remove exhaust manifold gaskets (1).

6. Remove the turbocharger from exhaust manifold (3). Refer to Disassembly and Assembly, "Turbocharger - Remove" Steps 8 through 15.

7. If necessary, remove studs (2) from exhaust manifold (3).

Installation Procedure (Top Mounted Exhaust Manifold)

Illustration 3	g01335810

Illustration 4	g01335809

1. Ensure that the exhaust manifold is clean and free from damage. If necessary, replace the exhaust manifold. Clean the mating surface of the cylinder head.

2. If necessary, install studs (2) to exhaust manifold (3). Tighten the studs to a torque of 18 N·m (13 lb ft).

3. Install the turbocharger to the exhaust manifold. Refer to Disassembly and Assembly, "Turbocharger - Install" Steps 1 through 14.

4. Install Tooling (A) to the cylinder head in positions (X). Refer to Illustration 3.

5. Position two new exhaust manifold gaskets (1) onto Tooling (A).

   Note: Ensure that the word TOP is outward and upward.

6. Align exhaust manifold (3) with Tooling (A). Install the exhaust manifold to the cylinder head.

7. If bolts (4) and (6) have been previously used, the bolts should be thoroughly cleaned. Tooling (B) should be applied to the first two threads of the bolts.

   Note: Do not apply Tooling (B) to new bolts.

8. Install bolts (4) finger tight. Install bolts (6) and spacers (5) finger tight.

9. Remove Tooling (A). Install remaining bolts (4) finger tight. Install remaining bolts (6) and spacers (5) finger tight.

10. Tighten bolts (4) and (6) to a torque of 44 N·m (32 lb ft). Tighten the bolts in the sequence that is shown in Illustration 3.

11. Connect all hoses, tube assemblies and wire leads from the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install" Steps 16 through 24.