3034 Marine Engine Caterpillar

Exhaust Manifold - Remove and Install

Usage:

3034 CPP

Removal Procedure

Start By:

Drain the cooling system. If the engine uses Diesel Engine Antifreeze/Coolant (DEAC), refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change". If the engine uses Extended Life Coolant (ELC), refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".
Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".
Remove the heat exchanger. Refer to Disassembly and Assembly, "Heat Exchanger - Remove".

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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Illustration 1	g00810079

Loosen hose clamp (2) for coolant hose (1) .

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Remove attaching screws (5) and remove relays.

Remove two nuts (6) for the cover for the fuse panel and remove the cover from the fuse panel .

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Remove two bolts (7) and spacing collars (8) with nuts that secure the fuse panel to exhaust manifold (4). Remove the fuse panel from the exhaust manifold.

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Illustration 4	g00810051

Loosen hose clamp (9) and remove hose from exhaust manifold (4) .

Remove bolts (3) that attach exhaust manifold (4) to the engine cylinder head (11) .

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Illustration 5	g00810123

Remove four nuts (10) that attach exhaust manifold (4) to the engine cylinder head (11) .

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Illustration 6	g00810136

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Illustration 7	g00810140

Remove exhaust manifold (4) from engine cylinder head (11) .

Remove exhaust manifold gasket (12) from engine cylinder head (11) and exhaust manifold (4) .

Installation Procedure

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Illustration 8	g00810140

Clean the flange face of the cylinder head (11). Slide new gaskets (12) onto the studs (13) .

Install exhaust manifold (4) onto engine cylinder head (11) .

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Illustration 9	g00810079

Install bolts (3) that attach exhaust manifold (4) to the engine cylinder head (11) .

Install coolant hose (1) and tighten hose clamp (2) .

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Illustration 10	g00810123

Install four nuts (10) that attach exhaust manifold (4) to the engine cylinder head (11) .

Tighten the bolts (3) and tighten the nuts (10). Begin at the center of the exhaust manifold and work toward the ends. Tighten the bolts and nuts to a torque of 18 N·m (13 lb ft).

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Illustration 11	g00810051

Install the hose to exhaust manifold (4) and tighten hose clamp (9) .

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Illustration 12	g00810906

Install the fuse panel to the exhaust manifold. Install two bolts (7) and spacing collars (8) with nuts that secure the fuse panel to exhaust manifold (4).

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Illustration 13	g00809976

Install the cover for the fuse panel and tighten two nuts (6) that secure the cover to the fuse panel.

Install relays and tighten attaching screws (5) .

End By:

Install the heat exchanger. Refer to Disassembly and Assembly, "Heat Exchanger - Remove".
Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".
Fill the cooling system. If the engine uses Diesel Engine Antifreeze/Coolant (DEAC), refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change". If the engine uses Extended Life Coolant (ELC), refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".