C6.6 Marine Generator Set Caterpillar

Removal Procedure

Start By:

1. Remove the fuel manifold and the bracket. Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove".

2. Remove the crankcase breather and the bracket. Refer to Disassembly and Assembly, "Crankcase Breather - Remove".

3. Remove the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Remove".

1. Remove tube assembly from the pressure relief valve.
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   Illustration 1	g01743614

2. Disconnect the harness assemblies from the boost pressure sensor and the air inlet temperature sensor. Slide the locking tabs into the unlocked position and disconnect harness assemblies.

3. If necessary, remove bolts (1) from inlet connection (2). Remove inlet connection (2) and O-ring seal (3).

4. Remove bolts (5) from inlet manifold (4).

5. Remove inlet manifold (4) from the cylinder head.

6. Remove O-ring seal (6) for the inlet manifold from the recess in inlet manifold (4).

7. Do not remove two dowel pins (7).

8. If necessary, remove the boost pressure sensor from the inlet manifold. Refer to Disassembly and Assembly, "Boost Pressure Sensor - Remove and Install".

9. If necessary, remove the inlet air temperature sensor from the inlet manifold. Refer to Disassembly and Assembly, "Inlet Air Temperture Sensor - Remove and Install".

Installation Procedure

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Illustration 2	g01609000

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Illustration 3	g01335892

1. Ensure that the inlet manifold is clean and free from damage. If necessary, replace the inlet manifold. If a new inlet manifold is installed, install two new dowel pins (7) to inlet manifold (4).

   Note: Do not install dowel pins to the cylinder head.

2. Clean the gasket surface of the cylinder head.

3. Align tag (8) to the slot at Position (Y) on the inlet manifold. Install a new seal (6) to the groove in inlet manifold (4). Ensure that the seal is correctly located.

4. Align dowel pins (7) to the holes in the cylinder head. Install inlet manifold (4) to the cylinder head.

5. Apply Tooling (A) to bolts (5). Install the bolts to inlet manifold (4).

6. Tighten the bolts to a torque of 22 N·m (16 lb ft) in the sequence that is shown in Illustration 3.

7. Ensure that inlet connection (2) is clean and free from damage. If necessary, replace the inlet connection.

8. Position a new O-ring seal (3) onto the inlet connection. Install inlet connection (2) to inlet manifold (4).

9. Install bolts (1) to inlet connection (2). Tighten the bolts to a torque of 22 N·m (16 lb ft).

10. If necessary, install the air temperature sensor. Refer to Disassembly and Assembly, "Inlet Air Temperature Sensor - Remove and Install".

11. If necessary, install the boost pressure sensor. Refer to Disassembly and Assembly, "Boost Pressure Sensor - Remove and Install".

12. Connect the harness assemblies to the boost pressure sensor and the air inlet temperature sensor. Slide the locking tabs into the locked position.

13. install tube assembly from the pressure relief valve.

End By:

1. Install the fuel manifold. Refer to Disassembly and Assembly, "Fuel Manifold - Install".

2. Install the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Remove".

3. Install the bracket for the breather and the breather. Refer to Disassembly and Assembly, "Crankcase Breather - Remove".