G3508J, G3516J, and G3520J Engines Caterpillar

Removal Procedure

Start By:

1. Remove turbochargers.

2. Remove aftercooler.

3. Remove exhaust shield

1. Turn off the gas supply.

2. Drain the coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining procedure.
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   Illustration 1	g06010310

3. Disconnect tube (1) from fitting on the gas pressure regulator.

4. Remove clamp (2) from the joint. Remove the tube assembly.
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   Illustration 2	g06010704

5. Remove sensor (3) .

6. Remove bolts (4) and tube assembly (7).

7. Remove bolts (6) and exhaust bellows (5).
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   Illustration 3	g06010720

8. Remove bolt (8) . Unplug and remove harness assembly (9).

9. Remove sensor (10).
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   Illustration 4	g06010340

10. Remove the tube assemblies from the line assembly fittings (11). Remove line assembly fittings (11) from the exhaust manifold.
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    Illustration 5	g06010696

11. Attach a suitable lifting device to the exhaust manifold.

12. Remove bolts (12) that hold the exhaust manifold to the cylinder head.
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    Illustration 6	g06010626

13. Remove bolts (13) that hold the exhaust manifold to the water temperature regulator housing.

14. Remove bolts (14) that hold the adapters to the exhaust manifold.
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    Illustration 7	g06011540

15. Attach a suitable lifting device to remove the exhaust manifold.

    The weight of exhaust manifold (15) on the G3508 Engine is approximately 99 kg (220 lb).

    The weight of exhaust manifold (15) on the G3516 Engine is approximately 287 kg (635 lb).

    The weight of exhaust manifold (15) on the G3520 Engine is approximately 362 kg (800 lb).

16. Repeat this process on the opposite side.