C12.9 Marine Engines Caterpillar

Removal Procedure

Start By:

1. Remove high-pressure turbocharger.

2. Remove expansion tank.

3. Remove air cleaner.

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Illustration 1	g06073994

1. Remove clamp (2) and disconnect hose (4). Remove bolts (7) and tube assembly (6). Remove two bolts (3), clamp (5) and tube assembly (1).
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   Illustration 2	g06074171

2. Disconnect harness assembly (8) and position out of the way. Remove three bolts (10) and remove tube assembly (9).
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   Illustration 3	g06074489

3. Remove bolt (12) and remove tube assembly (11).
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   Illustration 4	g06074507

4. Remove bolts (13) and bracket (17). Remove bolts (16) and remove pipe (18). Remove pipe (14) and bypass valve (15).
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   Illustration 5	g06074624

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   Illustration 6	g06074596

5. Remove bolts (19) and bolts (20). Remove P-clips (21) and P-clips (23). Remove bolts (22) and bolts (24). Remove tube assembly (25) and tube assembly (26).
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   Illustration 7	g06074736

6. Remove bolt (27).
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   Illustration 8	g06074769

7. Remove bolt (29) and remove tube assembly (28). Remove nut (31) and remove bracket (30). Remove P-clip (32). Disconnect and remove tube assembly (33). Remove bolt (35) and remove bracket (34).
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   Illustration 9	g06074780

8. Remove bolts (37) and remove bracket (36). Remove bolts (38) and remove (39).
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   Illustration 10	g06075220

9. Remove bolts (40) and bolt (42). Remove bonding straps (41).
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   Illustration 11	g06074905

10. Install Tooling (A) and attach a suitable lifting device. Remove eight bolts (43) and remove two nuts (46). Remove studs (45). Remove engine exhaust manifold (44).
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    Illustration 12	g06075308

11. Remove fitting (47). Remove gaskets (48). Remove adapters (50) and remove eight O-rings (49).

Installation Procedure

1. Install engine exhaust manifold (44) in the reverse order of removal.

   1. Tighten fitting (47) to a torque of 40 ± 4 N·m (30 ± 3 lb ft).

   2. Tighten studs (45) to a torque of 38 ± 4 N·m (28 ± 3 lb ft).
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      Illustration 13	g06076006

   3. Tighten stud-bolts (46) and bolts (43) to a preliminary torque of 30 ± 3 N·m (266 ± 27 lb in) in the order depicted in Illustration 13. Next, tighten stud-bolts (46) and bolts (43) to a final torque of 62 ± 5 N·m (45.72872 ± 3.68780 lb ft) in the order depicted in Illustration 13.

   4. Tighten bolts (38) to a torque of 25 ± 3 N·m (221 ± 27 lb in).

   5. Tighten bolts (37) to a torque of 25 ± 3 N·m (221 ± 27 lb in).

   6. Tighten bolts (35) to a torque of 25 ± 3 N·m (221 ± 27 lb in).

   7. Tighten bolt (32) to a torque of 10 ± 1 N·m (89 ± 9 lb in).

   8. Tighten bolt (31) to a torque of 45 ± 5 N·m (33 ± 4 lb ft).

   9. Tighten bolt (29) to a torque of 35 ± 4 N·m (26 ± 3 lb ft).

   10. Tighten bolts (24) to a torque of 25 ± 3 N·m (221 ± 27 lb in).

   11. Tighten bolts (23) to a torque of 25 ± 3 N·m (221 ± 27 lb in).

   12. Tighten bolts (22) to a torque of 25 ± 3 N·m (221 ± 27 lb in).

   13. Tighten bolts (21) to a torque of 25 ± 3 N·m (221 ± 27 lb in).

   14. Tighten bolts (20) to a torque of 25 ± 3 N·m (221 ± 27 lb in).

   15. Tighten bolts (19) to a torque of 25 ± 3 N·m (221 ± 27 lb in).

   16. Tighten bolts (16) to a torque of 23 ± 2 N·m (204± 18 lb in).

   17. Tighten bolts (13) to a torque of 23 ± 2 N·m (204± 18 lb in).

   18. Tighten bolts (12) to a torque of 18 ± 2 N·m (159 ± 18 lb in).

   19. Tighten bolts (10) to a torque of 23 ± 2 N·m (204± 18 lb in).

   20. Tighten bolts (7) to a torque of 25 ± 3 N·m (221 ± 27 lb in).

   21. Tighten bolts (5) to a torque of 10 ± 1 N·m (89 ± 9 lb in).

   22. Tighten bolts (3) to a torque of 25 ± 3 N·m (221 ± 27 lb in).

   23. Tighten bolts (2) to a torque of 3.25 ± 0.25 N·m (29 ± 2 lb in).