C4.4 (Mech) Engines for Caterpillar Built Machines Caterpillar

Removal Procedure

Start By:

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

Illustration 1	g06123993
Typical example

Illustration 2	g06123994
Sequence for loosening the exhaust manifold

1. Loosen bolts (3) in reverse numerical order to the sequence that is shown in Illustration 2.

   Note: This will help prevent distortion of the exhaust manifold.

2. Remove bolts (3) from exhaust manifold (4).

   Note: Bolts (3) may be equipped with spacers. Record the position of the spacers. Support the manifold as the bolts are removed.

3. Remove exhaust manifold (4).

4. Remove exhaust manifold gasket (1).

5. If necessary, remove studs (2) from exhaust manifold (4).

Installation Procedure

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Illustration 3	g06123993
Typical example

1. Ensure that the exhaust manifold is clean and free from damage. Clean the joint face of the cylinder head.

2. If necessary, install studs (2) to exhaust manifold (4). Tighten the studs to a torque of 18 N·m (13 lb ft).
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   Illustration 4	g06123995
   Tightening sequence for the exhaust manifold

3. Install Tooling (A) to the cylinder head in positions (X). Refer to Illustration 4.

4. Position a new exhaust manifold gasket (1) onto Tooling (A).

   Note: Ensure that the exhaust manifold gasket is correctly oriented.

5. Align exhaust manifold (4) with Tooling (A). Install the exhaust manifold to the cylinder head.

   Note: If the engine has a top mounted turbocharger, the tube assembly for the oil drain must be connected to the cylinder block before the exhaust manifold is installed.

6. Install new bolts (3) finger tight.

   Note: Bolts (3) that were equipped with spacers. Install the spacer in the original position.

7. Remove Tooling (A). Install remaining bolts (3) finger tight.

8. Tighten bolts (3) to a torque of 33 N·m (292 lb in) in the sequence that is shown in Illustration 4.

End By:

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