C4.4 Industrial Engine Caterpillar

Removal Procedure

1. Disconnect all hoses, tube assemblies and wire leads from the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" for more information.
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   Illustration 1	g01245092
   Typical example

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   Illustration 2	g01789673
   Tightening sequence for the exhaust manifold

2. Loosen bolts (4) in reverse numerical order to the sequence that is shown in Illustration 2.

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

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

   Note: Support the manifold as the bolts are removed.

4. Remove the assembly of exhaust manifold (3) and the turbocharger.

5. Remove exhaust manifold gasket (1).

6. Remove the turbocharger from exhaust manifold (3). Refer to Disassembly and Assembly, "Turbocharger - Remove" for more information.

7. If necessary, remove studs (2) from exhaust manifold (3).

Installation Procedure (Top Mounted Exhaust Manifold)

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Illustration 3	g01245092
Typical example

1. Ensure that the exhaust manifold is clean and free from damage. If necessary, replace the exhaust manifold. Clean the gasket surface of the cylinder head.

2. If necessary, install studs (2) to exhaust manifold (3). Tighten the studs to a torque of 18 N·m (13 lb ft).
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   Illustration 4	g01789677
   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. Install the tube assembly for the oil drain from the turbocharger to the cylinder block. Refer to Disassembly and Assembly, "Turbocharger - Install" for more information.

6. Align exhaust manifold (3) with Tooling (A). Install the exhaust manifold to the cylinder head.

7. Install new bolts (4) finger tight.

8. Remove Tooling (A). Install remaining bolts (4) finger tight.

9. Tighten bolts (4) to a torque of 40 N·m (30 lb ft) in the sequence that is shown in Illustration 4.

End By:

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