C9 Marine Engines and C9 Marine Generator Sets Caterpillar

Removal Procedure

Start By:

1. Remove the alternator. Refer to Disassembly and Assembly, "Alternator - Remove and Install".

2. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".

3. Remove the heat exchanger. Refer to Disassembly and Assembly, "Heat Exchanger - Remove".

Show/hide table

Illustration 1	g01109322

1. Remove bolt (4) that secures the tube assembly to the bottom of exhaust manifold (1).

2. Disconnect hose (5) from the fitting at the bottom of the exhaust manifold (1).

3. Install Tooling (A) and a suitable lifting device on exhaust manifold (1). The weight of exhaust manifold (1) is approximately 43 kg (95 lb).

4. Remove bolts (2) and exhaust manifold (1) from the cylinder head.

5. Remove exhaust manifold gasket (5) from the cylinder head.

6. Remove studs (3) from the exhaust manifold.

Installation Procedure

Show/hide table

Illustration 2	g01109334

Show/hide table

Illustration 3	g03368419

1. Install new studs (3) in exhaust manifold (1). Tighten the studs to a torque of 35 ± 5 N·m (26 ± 4 lb ft).

2. Install Tooling (B) onto the cylinder head.

3. Apply Tooling (C) to both sides of exhaust manifold gasket (6) for Coolant Passage (Y) only. Install exhaust manifold gasket (6) on Tooling (B) and the cylinder head.

   Note: Do not apply Tooling (C) to the exhaust manifold gasket (6) for the exhaust passages.

4. Install Tooling (A) and a suitable lifting device to exhaust manifold (1). The weight of exhaust manifold (1) is approximately 43 kg (95 lb).

5. Install exhaust manifold (1) on Tooling (B). Install bolts (2). Tighten the bolts finger tight. Remove Tooling (A) and Tooling (B) and install remaining bolts (2). Tighten the bolts by using the following procedure:

   Note: The bolts that are marked "x" are 180 mm (7.1 inch) long. The rest of the bolts are 150 mm (5.9 inch) long.

   Show/hide table

   Illustration 4	g01109336

   1. Tighten Bolt (1) through Bolt (16) in a numerical sequence. Tighten the bolts to 4 ± 1 N·m (35 ± 9 lb in).

   2. Tighten Bolt (1) through Bolt (16) in a numerical sequence to 55 ± 5 N·m (41 ± 4 lb ft).

   3. Tighten Bolt (1) through Bolt (16) again in a numerical sequence to 55 ± 5 N·m (41 ± 4 lb ft).

6. Connect hose (5) to the fitting at the bottom of the exhaust manifold (1).

7. Install bolt (4) that secures the tube assembly to the bottom of exhaust manifold (1).

End By:

1. Install the heat exchanger. Refer to Disassembly and Assembly, "Heat Exchanger - Install".

2. Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".

3. Install the alternator. Refer to Disassembly and Assembly, "Alternator - Remove and Install".