C6.6 Marine Generator Set Caterpillar

Removal Procedure

Start By:

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

2. If necessary, remove the MCS sensor for the coolant temperature sensor (shutdown). Refer to Disassembly and Assembly, "Engine Sensor (High Coolant Temperature Switch) (Shutdown) - Remove and Install".

3. If necessary, remove the MCS sensor for the coolant temperature sensor. Refer to Disassembly and Assembly, "Engine Sensor (Coolant Temperature Switch) - Remove and Install".

4. If necessary, remove the MCS sensor for the coolant pressure sensor. Refer to Disassembly and Assembly, "Engine Sensor (Coolant Pressure Sender) - Remove and Install".

1. Drain the coolant from the cooling system to a level below the water temperature regulator, into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining procedure.
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   Illustration 1	g01547334

2. For a sea water cooled engine, remove the expansion tank. Refer to Disassembly and Assembly, "Expansion Tank - Remove and Install".

   For a engine with a radiator cooling system, remove the guards for the fan. Refer to Disassembly and Assembly, "Radiator - Remove and Install". Disconnect plastic tube assembly (4) from exhaust manifold (1).

3. Remove bolt (3) from the tube clip. Loosen the hose clamps and disconnect tube assembly from connection (2) on exhaust manifold (1).

4. Loosen the hose clamp and disconnect hose from connection (5) on exhaust manifold (1). Loosen the hose clamp and disconnect hose from connection (6) on exhaust manifold (1).
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   Illustration 2	g01547320

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   Illustration 3	g01608734
   Tightening sequence for exhaust manifold bolts

5. Loosen bolts (9) in reverse numerical order. Refer to Illustration 3.

   Note: This will help prevent distortion of the exhaust manifold.

6. Remove bolts (9) from exhaust manifold (1).

7. Remove bolts (11) from bracket (10) for the exhaust manifold.

   Note: Support the manifold as the bolts are removed.

8. Remove exhaust manifold (1).

9. Remove exhaust manifold gaskets (7).

10. If necessary, remove studs (8) from exhaust manifold (6).

Installation Procedure

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Illustration 4	g01608734

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Illustration 5	g01547320

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

2. If necessary, install studs (8) to exhaust manifold (1). Apply Tooling (A) to the threads of studs (8). Install studs to the manifold and tighten securely.

3. Apply Tooling (A) to the threads of bolts (9). Install bolts (9) to exhaust manifold (1) and a new gasket (7) to the exhaust manifold.

4. Position exhaust manifold (1) on support bracket (10) for the exhaust manifold. Install bolts (9) for the exhaust manifold finger tight. Install bolts (11) to the bracket for the exhaust manifold finger tight.

5. Tighten bolts (9) to a torque of 44 N·m (33 lb ft). Tighten the bolts in the sequence that is shown in Illustration 4.

6. Apply Tooling (A) to the threads of bolts (11). Tighten bolts (11) securely.
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   Illustration 6	g01547334

7. Connect tube assembly to connection (2) on the exhaust manifold and tighten the hose clamps securely. install bolt (3) to the tube clip. Tighten bolts (3) to a torque of 22 N·m (16 lb ft). Connect plastic tube assembly to connection (4) on exhaust manifold (1).

8. Connect hose to connection (5) on exhaust manifold (1) and tighten the hose clamp securely.

9. Connect hose to connection (6) on exhaust manifold (1) and tighten the hose clamp securely.

10. For a sea water cooled engine, install the expansion tank. Refer to Disassembly and Assembly, "Expansion Tank - Remove and Install".

    For Engines with a radiator cooling system, install the guards for the fan. Refer to Disassembly and Assembly, "Radiator - Remove and Install".

11. Refill the engine with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct procedure.

End By:

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

2. If necessary, install the MCS sensor for the coolant temperature sensor (shutdown). Refer to Disassembly and Assembly, "Engine Sensor (High Coolant Temperature Switch) (Shutdown) - Remove and Install".

3. If necessary, install the MCS sensor for the coolant temperature sensor. Refer to Disassembly and Assembly, "Engine Sensor (Coolant Temperature Switch) - Remove and Install".

4. If necessary, install the MCS sensor for the coolant Pressure sensor. Refer to Disassembly and Assembly, "Engine Sensor (Coolant Pressure Sender) - Remove and Install".