C15 and C18 On-Highway Engines Exhaust Manifold - Remove and Install Caterpillar


Exhaust Manifold - Remove and Install
`
1.1. Removal Procedure
2.1. Installation Procedure

Removal Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
361-5661  Bellows Tool Assembly 
6V-6640  Loctite Hi-Temp Flange Sealant 
Loctite C5-A Copper Anti-seize Lubricant 
165-4638  Guide 

Start By:

  1. Remove the turbocharger.


NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.




    Illustration 1g02494237

    ------ CAUTION! ------

    The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.


  1. Remove clamp assembly (2) and position tube assembly (1) out of the way.

  2. Remove bolts (3) and remove heat shield assembly (4).

  3. Remove tube assembly (5).

    Note: Refer to Special Instruction, REHS1728, "Application Guideline for the Bellows" for additional information on handling the bellows.

  4. Remove clamp assemblies (6). Use Tooling (A) to remove bellows (7). Discard the clamps and bellows.

  5. Remove bolts (8) and (10). Remove tube assembly (9).


    Illustration 2g02824658

  6. Remove nuts (11) and the spacers. Remove studs (12). Discard nuts (11).

  7. Remove exhaust manifold assembly (13) and remove the gaskets.


    Illustration 3g02824677

  8. Remove studs (17).

    Note: Note the orientation of the exhaust manifold sections for use in installation procedure.

  9. Separate exhaust manifold sections (14), (15), and (16).

Installation Procedure

  1. Install exhaust manifold assembly (13) in the reverse order of removal.

    1. Tighten studs (17) to a torque of 35 ± 5 N·m (26 ± 4 lb ft). The torque tool speed should not exceed 100 RPM.

    2. Apply Tooling (B) to the outside diameter of exhaust manifold sections (14) and (16). Apply Tooling (B) to the inside diameter of exhaust manifold sections (15). Remove any excess sealant from assembled joint.

    3. Install bellows (7) with the flow arrow pointing towards the exhaust cooler. Total misalignment of the bellows is 1.50 mm (0.060 inch) lateral and 1.50 mm (0.060 inch) axial.

    4. Tighten clamps assemblies (6) to a torque of 7.5 ± 1 N·m (66 ± 9 lb in).

    5. Tighten studs (12) to a torque of 35 ± 5 N·m (26 ± 4 lb ft). The torque tool speed should not exceed 100 RPM.


      Illustration 4g01381130

    6. Apply Tooling (C) to nuts (11).

    7. Install Tooling (D) at Locations (X), for one hole per manifold section. Position the spacers and install nuts (11). Hand tighten nuts (11). Remove Tooling (D).

    8. Tighten nuts (11) in the above sequence to a torque of 20 ± 3 N·m (177 ± 27 lb in). Tighten nuts (11) again in the above sequence to a torque of 50 ± 5 N·m (37 ± 4.0 lb ft).

Information System:

C15 and C18 On-Highway Engines Solenoid Valve (ARD Main Fuel) - Remove and Install
C15 and C18 On-Highway Engines Exhaust Gas Valve (NRS) - Assemble
C15 and C18 On-Highway Engines Air Control Valve - Remove and Install
C15 and C18 On-Highway Engines Turbocharger - Remove and Install
C15 and C18 On-Highway Engines Electronic Unit Injector Sleeve - Remove and Install
C15 and C18 On-Highway Engines Electronic Unit Injector - Remove and Install
C15 and C18 On-Highway Engines Exhaust Cooler (NRS) - Remove and Install
C15 and C18 On-Highway Engines Fuel Manifold (ARD) - Remove and Install
C15 and C18 On-Highway Engines Fuel Pressure Regulator - Remove and Install
C15 and C18 On-Highway Engines Fuel Transfer Pump - Remove and Install
C15 and C18 On-Highway Engines Fuel Filter Base - Remove and Install - Secondary
3500 Petroleum Engines and Petroleum Generator Sets Gauges and Indicators
14L Motor Grader Pressure Sensor (ARD Main Fuel) - Remove and Install
14L Motor Grader Pressure Sensor (ARD Pilot Fuel) - Remove and Install
C9.3 Tier 4 Final Engines Valve Mechanism Cover
C13, C15, and C18 Tier 4 Final Engines Turbocharger
C13, C15, and C18 Tier 4 Final Engines Turbocharger
C13, C15, and C18 Tier 4 Final Engines Turbocharger
C13, C15, and C18 Tier 4 Final Engines Engine Oil Pan
16M Series 3, 16, 18M Series 3 and 18 Motor Grader Oil Filter (Hydraulic Return)
C15 and C18 On-Highway Engines Diesel Particulate Filter - Remove and Install - Clean Emissions Module
14L Motor Grader Machine Systems Fan and Fan Guard - Remove and Install
434-6509 Water Ferrule Pressure Tool{0374, 0599, 0701, 0703, 1100}
C15 and C18 Engines for Caterpillar Built Machines Electronic Unit Injector Mechanism