G3500 Engines Caterpillar

Removal Procedure

Start By:

1. Remove the turbochargers.

2. Remove the aftercooler.

1. Turn off the gas supply.
   Show/hide table

   Illustration 1	g00596844

2. Disconnect tube (1) from fitting on the gas pressure regulator.

3. Remove clamp (2) from the joint.
   Show/hide table

   Illustration 2	g00596753

4. Disconnect tube (1) from the carburetor.

5. Remove clamp (3).

6. Remove tubes (1) and (4).
   Show/hide table

   Illustration 3	g00596755

7. Remove bolts (5) that hold the exhaust manifold to the cylinder head.
   Show/hide table

   Illustration 4	g00596756

8. Remove tubes (6) from the exhaust manifold to the exhaust bypass.

9. Remove the bolts that hold the manifold for the wastegate to the exhaust manifold. The bolts are below tube (6).
   Show/hide table

   Illustration 5	g00596757

10. Remove bolts (7) that hold the exhaust manifold to the water temperature regulator housing.

11. Remove bolts (8) that hold the adapters to the exhaust manifold.
    Show/hide table

    Illustration 6	g00596758

    Show/hide table

    Illustration 7	g00596759

12. Attach a suitable lifting device to the exhaust manifold and remove bolts (9) that hold the exhaust manifold to the mounting bracket.

13. Remove the exhaust manifold. The exhaust manifold weighs approximately 287 kg (632 lb).