C6.6 Engines for Caterpillar Built Machines Inlet Manifold - Remove and Install Caterpillar

Removal Procedure

Start By:

1. If necessary, remove the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure.

2. Remove the fuel manifold. Refer to Disassembly and Assembly, "Fuel Manifold - Remove" for the correct procedure.

3. Remove the Electronic Control Module (ECM) mounting bracket. Refer to Disassembly and Assembly, "ECM Mounting Bracket - Remove and Install" for the correct procedure.

4. Remove the boost pressure sensor. Refer to Disassembly and Assembly, "Boost Pressure Sensor - Remove and Install" for the correct procedure.

5. Remove the air inlet temperature sensor. Refer to Disassembly and Assembly, "Inlet Air Temperature Sensor - Remove and Install" for the correct procedure.

1. If the engine is equipped, with a cover over the fuel system the cover will need to be removed.

2. Disconnect the breather hose from the separator for the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather - Remove" for the correct procedure.
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   Illustration 1	g01335890

3. Cut the cable straps that secure the harness assembly to inlet manifold (4). Position the harness assembly away from the inlet manifold.

4. Remove bolts (1) from inlet connection (2).

5. Remove inlet connection (2) and gasket (3) from inlet manifold (4).

6. Remove bolts (5).

7. Remove inlet manifold (4) from the cylinder head. Use a suitable tool to pry the inlet manifold from the cylinder head. Use the recess at Position (X) to pry the inlet manifold.

8. Remove inlet manifold seal (6) from the recess in inlet manifold (4).

9. Do not remove two dowel pins (7).

Installation Procedure

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Illustration 2	g01335909

1. Ensure that the inlet manifold is clean and free from damage. If necessary, replace the inlet manifold. If a new inlet manifold is installed, install two new dowel pins (7) to inlet manifold (4).

   Note: Do not install dowel pins to the cylinder head.

2. Clean the gasket surface of the cylinder head.

3. Align tag (8) to the slot at Position (Y) on the inlet manifold. Install new seal (6) to the groove in inlet manifold (4). Ensure that the seal is correctly located.

4. Align dowel pins (7) to the holes in the cylinder head. Install inlet manifold (4) to the cylinder head.

5. Apply Tooling (A) to bolts (5). Install the bolts to inlet manifold (4).
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   Illustration 3	g01335892

6. Tighten the bolts to a torque of 22 N·m (16 lb ft) in the sequence that is shown in Illustration 3.

7. Ensure that inlet connection (2) is clean and free from damage. If necessary, replace the inlet connection.

8. Position a new gasket (3) onto the inlet manifold. Install inlet connection (2) to inlet manifold (4).

9. Install bolts (1) to inlet connection (2). Tighten the bolts to a torque of 22 N·m (16 lb ft).

10. Install the air temperature sensor. Refer to Disassembly and Assembly, "Inlet Air Temperature Sensor - Remove and Install" for the correct procedure.

11. Install the boost pressure sensor. Refer to Disassembly and Assembly, "Boost Pressure Sensor - Remove and Install" for the correct procedure.

12. Position the harness assembly on the inlet manifold. Use new cable straps in order to secure the harness assembly.

13. Connect the breather hose to the separator for the crankcase breather (not shown). Refer to Disassembly and Assembly, "Crankcase Breather - Install" for the correct procedure.

14. If the engine is equipped, with a cover over the fuel system the cover will need to be installed.

End By:

1. Install the ECM mounting bracket. Refer to Disassembly and Assembly, "ECM Mounting Bracket - Remove and Install" for the correct procedure.

2. Install the fuel manifold. Refer to Disassembly and Assembly, "Fuel Manifold - Install" for the correct procedure.

3. If necessary, install the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install" for the correct procedure.