3608 Engine Caterpillar

Removal Procedure

Note: Refer to Disassembly and Assembly, "General Information (Reference Material)" for more information.

1. Remove the exhaust manifold shields.

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Illustration 1	g01422361

2. Disconnect the thermocouples from adapter (8) from the exhaust manifold segments that are being removed.

3. Attach a suitable lifting device to exhaust manifold (3). The weight of exhaust manifold (3) is approximately 28 kg (62 lb).

4. Remove bolts (1) that mount exhaust manifold (3) to bellows (2) .

5. Remove bolts (7) that mount exhaust manifold (3) to the cylinder head.

6. Remove exhaust manifold (3) and the gasket.

7. Repeat Step 3 through Step 6 for all of the bellows and the exhaust manifolds.

8. If necessary, remove adapter (8), plug (6), plug (5), the cap for adapter (4), and adapter (4) .

9. Remove the bolts in order to disconnect the turbocharger.

Installation Procedure

Note: Refer to Disassembly and Assembly, "General Information (Reference Material)" for more information.

Note: Apply Tooling (A) to the bolts for the bellows, the manifold bolts, the washers' faces, the plugs, and the adapters before installation.

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Illustration 2	g01422361

1. Attach a suitable lifting device to exhaust manifold (3). The weight of exhaust manifold (3) is approximately 28 kg (62 lb).

2. Position exhaust manifold (3) and a new gasket on the cylinder head. Install bolts (7). Tighten bolts (7) until the head of the bolt makes contact with the washers.

3. Position bellows (2) and new gaskets on exhaust manifold (3). Install bolts (1). Tighten bolts (1) until there are one or two threads remaining.

4. Ensure that all of the bellows are free to rotate after the exhaust manifolds are in place.

5. Repeat Step 1 through Step 4 for all of the bellows and the exhaust manifolds.

6. Tighten bolts (7) to a torque of 120 ± 20 N·m (90 ± 15 lb ft).

7. Tighten bolts (1) from the exhaust manifold to bellows (2) to a torque of 55 ± 10 N·m (40 ± 7 lb ft).

8. Install plug (6). Tighten plug (6) to a torque of 130 ± 15 N·m (96 ± 11 lb ft).

9. Install plug (5). Tighten plug (5) to a torque of 130 ± 15 N·m (96 ± 11 lb ft).

10. Install adapter (4). Tighten adapter (4) to a torque of 200 ± 25 N·m (150 ± 18 lb ft).

11. Install the cap for adapter (4). Tighten the cap to a torque of 12 ± 3 N·m (106 ± 27 lb in).

12. Install adapter (8). Tighten adapter (8) to a torque of 200 ± 25 N·m (150 ± 18 lb ft).

13. Connect the turbocharger. Install the bolts and tighten the bolts to a torque of 240 ± 40 N·m (177 ± 30 lb ft).

14. Install all of the thermocouples in adapter (8) .

    Note: Run the engine at the rated engine speed for a minimum of five minutes. Tighten the bolts from the manifold to the cylinder head to a torque of 120 ± 20 N·m (90 ± 15 lb ft).

15. Install the exhaust manifold shields.