C7 PETROLEUM Petroleum Engine Caterpillar

Removal Procedure

Start By:

1. Remove the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather - Remove and Install".

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

1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
   Show/hide table

   Illustration 1	g01457128

2. Disconnect hose (6), tube assembly (2), and tube assembly (3) from exhaust manifold (9).

3. Remove hose assembly (1) and tube assembly (7) from the engine.

4. Disconnect hose assembly (4), hose assembly (5), and hose assemblies (11) from exhaust manifold (9). Loosen hose clamp (10).

5. Attach Tooling (A) and a suitable lifting device to exhaust manifold (9). The weight of exhaust manifold (9) is approximately 25 kg (55 lb).

6. Remove bolts (8) and remove exhaust manifold (9) from the cylinder head.

7. Remove the exhaust manifold gasket from the cylinder head.

Installation Procedure

Show/hide table

Illustration 2	g01457128

Show/hide table

Illustration 3	g01457171

1. Install Tooling (B) in the cylinder head.

2. Install the exhaust manifold gasket on Tooling (B) and the cylinder head.

3. Attach Tooling (A) and a suitable lifting device to exhaust manifold (9). The weight of exhaust manifold (9) is approximately 25 kg (55 lb).

4. Install exhaust manifold (9) on Tooling (B). Install bolts (8). Tighten the bolts finger tight. Remove Tooling (A) and Tooling (B) and install remaining bolts (8). Tighten the bolts by using the following procedure:

   1. Tighten Bolt (1) through Bolt (15) in a numerical sequence to a torque of 4 ± 1 N·m (35 ± 9 lb in).

   2. Tighten Bolt (1) through Bolt (12) in a numerical sequence to a torque of 55 ± 5 N·m (41 ± 4 lb ft).

   3. Tighten Bolt (13) through Bolt (15) in a numerical sequence to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

5. Tighten hose clamp (10) to a torque of 7.0 ± 0.5 N·m (62 ± 4 lb in). Connect hose assemblies (11), hose assembly (5), and hose assembly (4) to exhaust manifold (9).

6. Install tube assembly (7) and hose assembly (1) on the engine.

7. Connect tube assembly (3), tube assembly (2), and hose (6) to exhaust manifold (9).

8. Fill the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".

End By:

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

2. Install the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather - Remove and Install".