3408E Engine Supplement for 769D Off-Highway Trucks and 771D Off-Highway Quarry Trucks Caterpillar

Removal Procedure

Start By:

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

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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

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Illustration 1	g00561061

1. Remove eight locknuts (1), the washers and eight spacers (7). Discard locknuts (1) after removal.

2. Remove exhaust manifold (5) from the engine. Remove four exhaust manifold gaskets (6). The weight of exhaust manifold (5) is 12 kg (27 lb). Discard exhaust manifold gaskets (6) after removal.

3. Remove two high temperature bolt (2), the locknuts and band clamps (4). Remove bellows (3). Discard high temperature bolts (2) after removal.

Installation Procedure

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Illustration 2	g00561061

1. Install bellows (3), two band clamps (4), two new high temperature bolts (2) and the new locknuts onto exhaust manifold (5) .

   Note: In order to ease installation, do not tighten the locknuts at this time.

2. Apply 5P-3931 Anti-Seize Compound to the threads of the studs before installation of locknuts (1) .

3. Position exhaust manifold (5) and four new exhaust manifold gaskets (6) on the engine. The weight of exhaust manifold (5) is 12 kg (27 lb). Install Tooling (A) (not shown) in one of the oversize holes of each section of exhaust manifold (5) .

4. Install eight spacers (7), eight new locknuts (1) and the washers to exhaust manifold (5) .

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Illustration 3	g00561085

5. Tighten locknuts (1) in the sequence that is shown in Illustration 3 to a torque of 20 ± 3 N·m (15 ± 2 lb ft).

6. Tighten locknuts (1) in the sequence that is shown in Illustration 6 to a torque of 38 ± 5 N·m (28 ± 4 lb ft).

7. Tighten the locknuts on two band clamps (4) .

End By: Install the turbocharger manifold. Refer to Disassembly and Assembly, "Turbocharger Manifold - Remove and Install".