G3516 Petroleum Engines Caterpillar

Exhaust Manifold - Install

Usage:

Installation Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	4C-5597	Anti-Seize Compound	-
B	5P-3975	Rubber Lubricant	-

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Inspect all O-rings, seals, and gaskets for wear and damage. Replace if necessary.
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Illustration 1 g06213212

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Illustration 2 g06214647

Note: Note the orientation of the V-band clamps (Z). The bolts on improperly installed clamps can damage the exhaust shields.
Attach tube and elbow assembly (13). Tighten the V-band clamps 12 to a torque of 7.5 ± 1 N·m (66.4± 9 lb in).
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Illustration 3 g06213150

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Illustration 4 g06213195
Use suitable cribbing to support the large elbow assembly (10) at position (Y).
Use a suitable lifting device to position the large elbow assembly (10) and install six bolts (9) and four bolts (11). The large elbow assembly (10) weighs approximately 46 kg (102 lb).
Apply Tooling (A) to studs and bearing surfaces to install six bolts (9) and four bolts (11).
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Illustration 5 g06213182
Use a suitable lifting device to position each manifold assembly (8). Each manifold assembly weighs approximately 125 kg (276 lb).
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Illustration 6 g06213160
Apply Tooling (A) and loosely install four bolts (7).
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Illustration 7 g06213033
Loosely install four bolts (6).
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Illustration 8 g06213006
Apply Tooling (A) to threads and bearing surfaces and loosely install four bolts (5). There are a total of 64 bolts.
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Illustration 9 g06212732

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Illustration 10 g06214910
Apply Tooling (B) to O-rings (W) and position elbow assemblies (4).
Loosely install two bolts (3). There are a total of 32 bolts.
Tighten bolts (3), (5), (6), and (7).
1. Tighten bolts (5) to a torque of 55 ± 5 N·m (41 ± 4 lb ft).
Remove cribbing (Y).
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Illustration 11 g06211529

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Illustration 12 g06214943
Apply Tooling (B) to O-rings (P) and position the water line assemblies (2).
Install eight bolts (1).

End By:

Install the exhaust bypass valve. Refer to Disassembly and Assembly, "Exhaust Bypass Valve - Remove and Install".
Install the exhaust shield. Refer to Disassembly and Assembly, "Exhaust Shield -Remove and Install".