3500 Engines Exhaust Manifold - Remove and Install Caterpillar

Removal Procedure

Start By:

1. Remove the air inlet manifold. Refer to Disassembly and Assembly, "Air Inlet Manifold - Remove and Install".

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Illustration 1	g02162817

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Illustration 2	g02162818

1. Remove the spring clips from the LH side of heat shield (1) .

2. Remove the back heat shield from the middle heat shield.

3. Remove the middle heat shield from the front heat shield.

4. Repeat the procedure on the RH side of heat shield (2) .

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Illustration 3	g02162839

Note: If the engine has a cap instead of an adapter for the exhaust bypass valve, removal of clamp assemblies (3) may not be necessary.

5. Loosen clamp assemblies (3) for the adapter for the exhaust bypass valve. Disconnect bellows assemblies (4) .

6. Remove bolts (11) . Disconnect manifold (10) from the turbocharger. Remove the gasket from the turbocharger.

7. Remove bolts (8) for the sections of exhaust manifold (7) . Remove bellows assemblies (9) and the seals.

8. Remove bolts (5) that attach exhaust manifold (7) to the cylinder heads.

9. Remove exhaust manifold (7) and exhaust manifold gasket (6) .

10. Repeat Steps 7 through 9 for the remaining exhaust manifolds.

Installation Procedure

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Illustration 4	g02162839

1. Apply Tooling (A) to the threads of bolts (5) . Place exhaust manifold gasket (6) and exhaust manifold (7) in position on the cylinder head. Install bolts (5) . Tighten the bolts that are diagonal to each other to a torque of 55 ± 5 N·m (41 ± 4 lb ft). Tighten the other bolts that are diagonal to each other to a torque of 55 ± 5 N·m (41 ± 4 lb ft).

Note: Ensure that the bellows assembly is in the proper orientation during installation. The direction of flow arrow must point in the correct direction. The spacing between the ridges of the bellows assembly should be equal.

2. Apply Tooling (A) to the threads, the bearing surfaces, and the inner surface of the bolts for exhaust manifold (7) . Install the seals, bellows assemblies (9) , and bolts (8) on exhaust manifold (7) . Tighten the bolts that are diagonal to each other to a torque of 55 ± 5 N·m (41 ± 4 lb ft). Tighten the other bolts that are diagonal to each other to a torque of 55 ± 5 N·m (41 ± 4 lb ft).

3. Repeat Steps 1 through 2 for the remaining exhaust manifolds.

4. Apply Tooling (A) to the threads, the bearing surfaces, and the inner surface of the bolts for the turbocharger. Install a new gasket and connect manifold (8) to the turbocharger. Install bolts (11) . Tighten the bolts to a torque of 54 ± 5 N·m (40 ± 4 lb ft).

5. Connect bellows assemblies (4) . Tighten clamp assemblies (3) for the adapter for the exhaust bypass valve.

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Illustration 5	g02162818

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Illustration 6	g02162817

6. Install the front heat shield. Slide the middle heat shield under the front heat shield.

7. Install by sliding the back heat shield under the middle heat shield.

8. Install the spring clips on LH side of heat shields (1) .

9. Repeat the procedure on the RH side of heat shield (2) .

End By: Install the air inlet manifold. Refer to Disassembly and Assembly, "Air Inlet Manifold - Remove and Install".