C7.1 Industrial Engine Exhaust Manifold - Remove and Install Caterpillar

Removal Procedure

Start By:

1. Remove the first stage turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove (First Stage Turbocharger)" for the correct procedure.

Note: Plug or cap all open ports with new plugs or caps.

Illustration 1	g02177350

1. Drain the coolant from the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.

2. Loosen bolts (1) for the support bracket.

3. Remove bolt (2) from clip for tube assembly.

4. Remove bolts (3) and bolts (11). Remove tube assembly (5) from the exhaust cooler and induction mixer.

5. Remove gasket (4) (not shown) and gasket (12) (not shown).

6. Remove bolts (7) and bolts (10). Remove tube assembly (6) from the exhaust cooler and from the cylinder head.

7. Remove gasket (8) (not shown) and gasket (9) (not shown).
   Show/hide table

   Illustration 2	g02177373

8. Cut cable straps (16).

9. Remove bolts (14) and bolts (18) from tube assembly (15). Remove the tube assembly (15) from the exhaust cooler.

10. Remove gasket (13) (not shown) and gasket (17) (not shown).
    Show/hide table

    Illustration 3	g01977645

    Show/hide table

    Illustration 4	g02367616

11. Remove bolts (24) and bolts (26) from tube assembly (25).

12. Loosen bolts (20) in reverse numerical order. Refer to Illustration 3.

    Note: Loosening the bolts in reverse numerical order will help prevent distortion of the exhaust manifold.

13. Remove bolts (20) and the spacers from exhaust manifold (19).

    Note: Support the manifold as the bolts are removed.

14. Remove exhaust manifold (19).

15. Remove exhaust manifold gaskets (21) (not shown) and exhaust manifold gaskets (22) (not shown).

16. Remove tube assembly (25). Remove gasket (23) (not shown) and gasket (27) (not shown).

Installation Procedure

Show/hide table

Illustration 5	g02177553
Two of Tooling (A) have threads on one end. This threaded end of Tooling (A) should be installed into Positions (Y).

Show/hide table

Illustration 6	g02367616

1. Ensure that exhaust manifold (19) is clean and free from damage. If necessary, replace the exhaust manifold. Clean the gasket surface of the cylinder head.

2. Position a new exhaust manifold gasket (21) (not shown) onto the cylinder head. Install Tooling (A) in Positions (X) and Positions (Y). Refer to Illustration 5.

   Note: Ensure that the exhaust manifold gaskets are correctly oriented.

3. Position a new exhaust manifold gasket (22) (not shown) onto the cylinder head. Install Tooling (A) in Positions (X) and Positions (Y). Refer to Illustration 5.

   Note: Ensure that the exhaust manifold gaskets are correctly oriented.

4. Position a new gasket (27) (not shown) onto a new tube assembly (25). Position tube assembly onto the NRS exhaust cooler and install new bolts (26) and tighten the bolts ensuring that the tube assembly can still move.

5. Position a new gasket (23) (not shown) onto tube assembly (25)

6. Align exhaust manifold (19) with Tooling (A). Install the exhaust manifold to the cylinder head.

7. Install bolts (24) for tube assembly (25) and tighten the bolts ensuring that the tube assembly can still move.

8. Install new bolts (20) and the spacers in the eight available position to exhaust manifold (19).

9. Tighten bolts (20) one to four to a torque of 44 N·m (32 lb ft). Tighten the bolts in the sequence that is shown in Illustration 5.

10. Remove Tooling (A). Install remaining new bolts (20) and the spacers to exhaust manifold (19).

11. Tighten remaining bolts (20) to a torque of 44 N·m (32 lb ft). Tighten the bolts in the sequence that is shown in Illustration 5.

12. Tighten bolts (24) and bolts (26) for tube assembly (25) to a torque of 22 N·m (195 lb in).
    Show/hide table

    Illustration 7	g02177373

13. Position a new gasket (13) (not shown) and a new gasket (17) (not shown) onto tube assembly (15).

14. Position tube assembly (15) onto the exhaust cooler and the cylinder head.

15. Install bolts (14) and bolts (18). Tighten bolts hand tight.

16. Tighten bolts (14) to a torque of 22 N·m (195 lb in).

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

17. Install new cable straps (16).

    Note: Ensure that the cable straps meet Original Equipment Manufacturers (OEM) specifications.

    Show/hide table

    Illustration 8	g02177350

18. Position a new gasket (8) (not shown) and a new gasket (9) (not shown) onto tube assembly (6).

19. Position tube assembly (6) onto the exhaust cooler and the cylinder head. Install bolts (7) and bolts (10). Tighten bolts hand tight.

20. Tighten bolts (7) to a torque of 22 N·m (195 lb in).

    Tighten bolts (10) to a torque of 18 N·m (159 lb in).

21. Ensure that tube assembly (6) is not stressed as the bolts are tightened.

22. Position a new gasket (4) (not shown) the induction mixer.

    Note: Ensure that the gasket is correctly installed the locating pins on the induction mixer.

23. Position a new gasket (12) (not shown) onto tube assembly (5).

24. Position tube assembly (5) between the bracket and the induction mixer. Install bolts (3) finger tight.

25. Position tube assembly (5) onto the exhaust cooler. Install bolts (11) finger tight.

26. Tighten bolts (11) to a torque of 18 N·m (159 lb in).

27. Tighten bolts (3) to a torque of 22 N·m (195 lb in).

    Tighten bolts (1) to a torque of 44 N·m (32 lb ft).

28. Install bolt (2) to clip for tube assembly. Tighten the bolt to a torque of 22 N·m (195 lb in).

29. Ensure that tube assembly (5) is not stressed as the bolts are tightened.

30. Install the first stage turbocharger. Refer to Disassembly and Assembly, "Turbocharger (First Stage Turbocharger) - Install" for the correct procedure.

31. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change" for the correct procedure.
    Show/hide table

    Illustration 9	g02177558

32. After the engine has been operated for 15 minutes, the engine should be stopped. Bolts (24) and bolts (26) should be checked for correct torque. Tighten bolts to a torque of 22 N·m (195 lb in).