Air Inlet and Exhaust System

C12 Marine Engine C1Z00001-UP(SEBP4002 - 54) - Documentation Page 1 of 4
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Product: MARINE ENGINE

Model: C12 MARINE ENGINE C1Z
Configuration: C12 Marine Engine C1Z00001-UP
Disassembly and Assembly

C12 Marine Engines
Media Number -RENR9405-01 Publication Date -01/09/2008 Date Updated -15/09/2008
i03624897
Aftercooler - Install
SMCS - 1063-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 2
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/m... 9/2/2022
Illustration 1 g01106947
1. Install housing (10) .
2. Install bolts (9) , bolts (11) , and bolts (12) .
3. Attach Tooling (A) and a suitable lifting device to aftercooler core (1) . The weight of the
aftercooler core is approximately 36 kg (80 lb).
4. Install new gaskets and aftercooler core (1) .
5. Install cover (7) .
6. Install bolts (8) .
7. Tighten the bolts in a numerical sequence to a torque of 28 ± 7 N·m (21 ± 5 lb ft). Tighten the
bolts again in a numerical sequence to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
8. Connect tube assembly (6) .
9. Connect tube assembly (3) and tube assembly (5) .
11. Refill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Refill
Capacities and Recommendations".
Copyright 1993 - 2022 Caterpillar Inc. Fri Sep 2 13:31:56 UTC+0530 2022
All Rights Reserved.
Private Network For SIS Licensees.
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C12 Marine Engines
i03624894
Aftercooler - Remove
SMCS - 1063-011
Removal Procedure
Table 1
Required Tools
NOTICE
NOTICE
Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations".
2. Disconnect tube assembly (2) and tube assembly (4) .
4. Disconnect tube assembly (6) .
5. Attach Tooling (A) and a suitable lifting device to aftercooler core (1) . The weight of the
aftercooler core is approximately 36 kg (80 lb).
6. Remove bolts (8) .
7. Remove cover (7) .
8. Remove aftercooler core (1) and the gaskets.
9. Remove bolts (9) , bolts (11) , and bolts (12) .
10. Remove housing (10) .
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C12 Marine Engines
i02187451
Exhaust Manifold - Remove and Install

SMCS - 1059-010
Removal Procedure
Table 1
Required Tools
Start By:
A. Remove the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Remove".
NOTICE
NOTICE


containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
1. Disconnect hose assembly (1) .
2. Disconnect hose (5), hose (6), hose (8), and hose (9) .
4. Remove tube (3) .
5. Attach Tooling (A) and a suitable lifting device to exhaust manifold (10) and the turbocharger.
The weight of the exhaust manifold and the turbocharger is approximately 91 kg (200 lb).
7. Remove exhaust manifold (10) and the turbocharger.
Table 2
Required Tools
2. Install exhaust manifold (10) and the turbocharger.
3. Install bolts (4). Tighten the bolts in a numerical sequence.
4. Install tube (3) .
6. Connect hose (5), hose (6), hose (8), and hose (9) .
7. Connect hose assembly (1) .
End By: Install the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Install".
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C12 Marine Engines
i02187451
Exhaust Manifold - Remove and Install

SMCS - 1059-010
Removal Procedure
Table 1
Required Tools
Start By:
A. Remove the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Remove".
NOTICE
NOTICE


containing fluids.

2. Disconnect hose (5), hose (6), hose (8), and hose (9) .
7. Remove exhaust manifold (10) and the turbocharger.
Table 2
Required Tools
2. Install exhaust manifold (10) and the turbocharger.
3. Install bolts (4). Tighten the bolts in a numerical sequence.
6. Connect hose (5), hose (6), hose (8), and hose (9) .
End By: Install the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Install".
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C12 Marine Engines
i02187209
Turbocharger - Assemble
SMCS - 1052-016
Assembly Procedure
NOTICE
1. Ensure that the following parts are aligned correctly upon assembly: turbine housing (4),
cartridge (5) and compressor cover (1) .
2. Install turbine housing (4) on cartridge (5) .
3. Install compressor cover (1) on cartridge (5) .
4. Tighten clamp (2) and clamp (3) to a torque of 14 ± 1 N·m (124 ± 9 lb in).
5. Gently tap clamp (2) and clamp (3) with a soft faced hammer.
6. Tighten clamp (2) and clamp (3) again to a torque of 14 ± 1 N·m (124 ± 9 lb in).
End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".
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C12 Marine Engines
i02187183
Turbocharger - Disassemble
SMCS - 1052-015
Disassembly Procedure
Start By:
A. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".
NOTICE
1. Mark the turbocharger housings for alignment upon assembly.
2. Loosen clamp (2) and clamp (3) .
3. Remove compressor cover (1) from cartridge (5) .
4. Remove turbine housing (4) from cartridge (5) .
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C12 Marine Engines
i04001215
Turbocharger - Install
SMCS - 1052-012
Table 1
Required Tools
A 5P-3931 Anti-Seize Compound -
NOTICE
1. Attach a suitable lifting device to turbocharger (6) . The weight of the turbocharger is
approximately 34 kg (75 lb).
Note: Discard the nuts after use. Use new nuts for installation.
2. Apply Tooling (A) to the studs for the turbocharger. Install turbocharger (6) and the gasket.
Install nuts (7) .
3. Connect tube assembly (8) .
4. Connect hose (9) .
8. Connect hose (1) .
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C12 Marine Engines
i02187107
Turbocharger - Remove
SMCS - 1052-011
Removal Procedure
NOTICE
NOTICE

containing fluids.

1. Disconnect hose (1) .
5. Disconnect hose (9) .
6. Disconnect tube assembly (8) .
7. Attach a suitable lifting device to turbocharger (6). The weight of the turbocharger is
approximately 34 kg (75 lb). Remove nuts (7) .
8. Remove turbocharger (6) and the gasket.
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Specifications
C12 Marine Engines
Media Number -SENR9642-05 Publication Date -01/06/2009 Date Updated -09/04/2019
i03630146
Aftercooler
SMCS - 1063
(1) Tighten bolt (1) through bolt (23) in a numerical sequence to the following torque: ... 28 ± 7 N·m
(21 ± 5 lb ft)
(24) Lubricate the bore (24) lightly with glycerin or an equivalent.
(25) Apply 5P-3931 Anti-Seize Compound to the threads of the bolt before installation.
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Specifications
C12 Marine Engines
i02874973
Turbocharger
SMCS - 1052
Typical example
(1) Clamps
To tighten the clamps on the turbocharger, use the following procedure:
1. Tighten the clamp.
Tighten the clamp to the following torque. ... 14 ± 1 N·m (10 ± 1 lb ft)
2. Gently tap the clamp with a soft faced hammer.
3. Again tighten the clamp.
Tighten the clamp to the following torque. ... 14 ± 1 N·m (10 ± 1 lb ft)
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Systems Operation
C12 Marine Engine
i01770376
Air Inlet and Exhaust System

SMCS - 1050
(1) Inlet valves
(2) Exhaust valves
(3) Inlet manifold
(4) Exhaust manifold
(5) Water inlet for the aftercooler
(6) Water outlet for the aftercooler
(7) Aftercooler
(8) Air inlet
(9) Exhaust outlet
(10) Compressor
(11) Turbine
The components of the air inlet and exhaust system control the quality of air and the amount of air
that is available for combustion. The components of the air inlet and exhaust system are the following
components:
• Air cleaner
• Turbocharger
• Aftercooler
• Cylinder head
• Valves and valve system components
• Piston and cylinder
• Inlet manifold
• Exhaust manifold
Note: The following description of the operation of the air inlet and exhaust system assumes that the
engine is developing boost pressure.
Inlet air passes through the air cleaner into the air inlet (8) of the turbocharger compressor wheel (10).
The turbocharger will supply more volume of air into the engine. This compressing of the air is
referred to as boost. The compressing of air causes the air temperature to rise to about 204 °C (400 °
F). As the air flows through the aftercooler (7) the temperature of the compressed air lowers to about
46 °C (115 °F). Cooling of the inlet air causes the air to become more dense. This increases
combustion efficiency and this increases horsepower output.
From the aftercooler, air enters the inlet manifold (3). Air flow from the inlet manifold (3) into the
cylinders is controlled by inlet valves (1). There are two inlet valves and two exhaust valves (2) for
each cylinder. The inlet valves open at the top center position before the piston moves toward the
bottom center position. This is called the inlet stroke. When the inlet valves open, cooled compressed
air from the inlet port enters the cylinder. The inlet valves close as the piston reaches the bottom
center position. The piston begins to travel back to the top center position on the compression stroke.
The air in the cylinder is compressed to a very high temperature. When the piston is near the end of
the compression stroke, fuel is injected into the cylinder and mixes with the air. This causes
combustion to start in the cylinder. Once combustion starts, the combustion force pushes the piston
toward the bottom center position. This is called the power stroke. The exhaust valves open when the
piston moves toward the bottom center position and the exhaust gases are pushed through the exhaust
port into exhaust manifold (4) as the piston travels toward top center on the exhaust stroke. The
exhaust valves close and the cycle starts again. The complete cycle consists of four strokes:
• Inlet
• Compression
• Power
• Exhaust
Exhaust gases from the exhaust manifold (4) enter the turbine side of the turbocharger. The exhaust
gas temperature causes the turbine wheel (11) in the turbocharger to turn. The turbine wheel is
connected to the shaft that drives the compressor wheel. Exhaust gases from the turbine wheel exit the
turbocharger (9) .
Turbocharger
Turbocharger
(1) Air inlet
(2) Compressor housing
(3) Compressor wheel
(4) Bearing
(5) Oil Inlet port
(6) Bearing
(7) Turbine housing
(8) Turbine wheel
(9) Exhaust outlet
(10) Oil outlet port
(11) Exhaust inlet
All of the air that enters the engine passes through the turbocharger. All of the exhaust gases from the
engine pass through the turbocharger.
The exhaust gases enter turbine housing (7) through exhaust inlet (11). The exhaust gas pushes on the
blades of the turbine wheel (8). The turbine wheel is connected by a shaft to the compressor wheel
(3) .
Air that passes through the air filters enters the compressor housing air inlet (1) by the rotation of
compressor wheel (3). The compressor wheel causes the inlet air to be pushed into the inlet side of the
engine. Boost pressure is caused when the compressor wheel pushes more air into the inlet side of the
engine. This results in a positive inlet manifold pressure that exceeds atmospheric pressure. This
allows the engine to burn more fuel. When the engine burns more fuel the engine produces more
power.
When the throttle is opened, more fuel is injected into the cylinders. The combustion of this additional
fuel produces greater exhaust temperature. The additional exhaust temperature causes the turbine and
the compressor wheels of the turbocharger to turn faster. As the compressor wheel turns faster, more
air is forced into the cylinders. The increased flow of air gives the engine more power by allowing the
engine to burn the additional fuel with greater efficiency.
(12) Canister
(13) Actuating lever
(14) Line (boost pressure)
Some turbochargers use a wastegate. The operation of the wastegate is controlled by boost pressure.
At high boost pressures, the wastegate opens bypassing exhaust gases. At low boost pressure, the
wastegate closes in order to increase exhaust temperature to the turbocharger.
When the engine is operating under conditions of low boost, a spring pushes on a diaphragm in
canister (12). This action moves actuating lever (13) in order to close the valve of the wastegate.
Closing the valve of the wastegate allows the turbocharger to operate at maximum performance.
As the boost pressure increases against the diaphragm in canister (12), the valve of the wastegate is
opened. When the valve of the wastegate is opened, the rpm of the turbocharger is limited by
bypassing a portion of the exhaust gases around the turbine wheel of the turbocharger.
Note: The turbocharger with a wastegate is preset at the factory and no adjustment can be made.
Bearings (4) and (6) for the turbocharger use engine oil under pressure for lubrication and cooling.
The oil comes in through oil inlet port (5). The oil then goes through passages in the center section in
order to lubricate the bearings. This oil also cools the bearings. Oil from the turbocharger goes out
through oil outlet port (10) in the bottom of the center section. The oil then goes back to the engine oil
pan.
Valve System Components
Valve system components
(1) Valve bridge
(2) Valve rotator
(3) Rocker arm
(4) Pushrod
(5) Valve springs
(6) Valves
(7) Valve guide
(8) Camshaft
(9) Lifter or follower
The valve train controls the flow of inlet air and exhaust gases into the cylinders and out of the
cylinders during engine operation. The camshaft (6) controls the timing of the valves during engine
operation.
The crankshaft gear drives the camshaft gear through an idler gear. The camshaft must be timed to the
crankshaft in order to get the correct relation between the piston position and the valve position.
The camshaft has three camshaft lobes for each cylinder. One camshaft lobe operates the inlet valves.
One camshaft lobe operates the exhaust valves. One camshaft lobe operates the unit injector. The
camshaft lobes cause the follower and the pushrod to push on the rocker arm in order to actuate the
valves and the unit injector.
Each cylinder has two inlet valves and two exhaust valves. Valve springs hold the valves closed and
the valve springs resist the opening of the valves. This ensures that the valves will close at high rpm
and under high boost pressures. Valve rotators cause the valves to rotate while the engine is running.
The rotation of the valves prevents the valves from burning by constantly changing the contact area of
the valve face and the valve seat. This rotation gives the valves longer service life.
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Testing and Adjusting

C12 Marine Engine
i04525210
Exhaust Temperature - Test

SMCS - 1088-081
Table 1
Required Tools
Part Number Part Name Qty
349-4200 Thermometer 1
When the engine runs at low idle, the temperature of an exhaust manifold port can indicate the
condition of a fuel injection nozzle.
A low temperature indicates that no fuel is flowing to the cylinder. An inoperative fuel injection
nozzle or a problem with the fuel injection pump could cause this low temperature.
A high temperature can indicate that too much fuel is flowing to the cylinder. A malfunctioning fuel
injection nozzle could cause this high temperature.
Use the 349-4200 Thermometer to check exhaust temperature. The manual that comes with the 349-
4200 Thermometer contains the complete operating and maintenance instructions.
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C12 Marine Engine
i01655469
Inlet Manifold Pressure - Test

SMCS - 1058-081
The efficiency of an engine can be checked by making a comparison of the pressure in the inlet
manifold with the information given in the TMI (Technical Marketing Information). The information
is also listed on the Fuel Setting and the Service Information System. This test is used when there is a
decrease of horsepower from the engine, yet there is no real sign of a problem with the engine.
The correct pressure for the inlet manifold is listed in the TMI (Technical Marketing Information).
The correct pressure is also on the Fuel Setting And the related Service Information System.
Development of this information is performed under the following conditions:
• 99 kPa (29.7 in Hg) dry barometric pressure
• 29 °C (85 °F) outside air temperature
• 35 API rated fuel
On a turbocharged, aftercooled engine, a change in the fuel rating will change the horsepower. A
change in the fuel rating will change the inlet manifold pressure. If the fuel is rated above 35 API, the
inlet manifold pressure can be less than the pressure given in the TMI (Technical Marketing
Information). The pressure will also be less than the pressure that is listed on the Fuel Setting And the
Related Service Information System. If the fuel is rated below 35 API, the inlet manifold pressure can
be more than the pressure listed in the TMI (Technical Marketing Information). The pressure will also
be more than the pressure that is listed on the Fuel Setting And the Related Service Information
System.
Note: Ensure that the air inlet and the exhaust are not restricted when you are checking the inlet
manifold pressure.
Pressure test location on inlet manifold
(1) Plug
Table 1
Tools Needed
Part Number Part Name Quantity
1U-5470 Engine Pressure Group 1
1U-5470 Engine Pressure Group
Refer to Special Instruction, SEHS8907, "Using the 1U-5470 Engine Pressure Group " for the
instructions that are needed to use the 1U-5470 Engine Pressure Group .
Use the following procedure in order to measure the inlet manifold pressure:
1. Remove plug (1) from the inlet manifold.
2. Connect the 1U-5470 Engine Pressure Group to the inlet manifold at the pressure test location.
3. Record the value.
4. Compare the value that was recorded in Step 3 to the pressure that is given in the TMI
(Technical Marketing Information). The correct pressure is also given in the Fuel Setting And
Related Information Microfiche.
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C12 Marine Engine
i06191873
Turbocharger - Inspect
SMCS - 1052-040
Hot engine components can cause injury from burns. Before

performing maintenance on the engine, allow the engine and the
components to cool.
Personal injury can result from rotating and moving parts.
Stay clear of all rotating and moving parts.
Never attempt adjustments while the machine is moving or the engine is

running unless otherwise specified.
The machine must be parked on a level surface and the engine stopped.
NOTICE
NOTICE

performance of inspection, maintenance, testing, adjusting, and repair
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Before you begin inspection of the turbocharger, be sure that the inlet air restriction is within the
specifications for your engine. Be sure that the exhaust system restriction is within the specifications
for your engine. Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System -
Inspect".
The condition of the turbocharger will have definite effects on engine performance. Use the following
inspections and procedures to determine the condition of the turbocharger.
• Inspection of the Compressor and the Compressor Housing
• Inspection of the Turbine Wheel and the Turbine Housing
• Inspection of the Wastegate
Inspection of the Compressor and the Compressor Housing

Remove air piping from the compressor inlet.
1. Inspect the compressor wheel for damage from a foreign object. If there is damage, determine
the source of the foreign object. As required, clean the inlet system and repair the intake
system. Replace the turbocharger. If there is no damage, go to Step 3.
2. Clean the compressor wheel and clean the compressor housing if you find buildup of foreign
material. If there is no buildup of foreign material, go to Step 3.
3. Turn the rotating assembly by hand. While you turn the assembly, push the assembly sideways.
The assembly should turn freely. The compressor wheel should not rub the compressor housing.
Replace the turbocharger if the compressor wheel rubs the compressor wheel housing. If there
is no rubbing or scraping, go to Step 4.
4. Inspect the compressor and the compressor wheel housing for oil leakage. An oil leak from the
compressor may deposit oil in the aftercooler. Drain and clean the aftercooler if you find oil in
the aftercooler.
a. Check the oil level in the crankcase. If the oil level is too high, adjust the oil level.
b. Inspect the air cleaner element for restriction. If restriction is found, correct the problem.
c. Inspect the engine crankcase breather. Clean the engine crankcase breather or replace the
engine crankcase breather if the engine crankcase breather is plugged.
d. Remove the oil drain line for the turbocharger. Inspect the drain opening. Inspect the oil
drain line. Inspect the area between the bearings of the rotating assembly shaft. Look for
oil sludge. Inspect the oil drain hole for oil sludge. Inspect the oil drain line for oil sludge
in the drain line. If necessary, clean the rotating assembly shaft. If necessary, clean the oil
drain hole. If necessary, clean the oil drain line.
e. Remove the supply line for the turbocharger. Inspect the opening of the supply line.
Inspect the supply line for oil sludge. If necessary, clean the supply line.
f. If Steps 4.a through 4.e did not reveal the source of the oil leakage, the turbocharger has
internal damage. Replace the turbocharger.
Inspection of the Turbine Wheel and the Turbine Housing

Remove the air piping from the turbine housing.
(1) Turbine Housing
(2) Turbine Wheel
(3) Turbocharger
1. Inspect the turbine for damage by a foreign object. If there is damage, determine the source of
the foreign object. Replace turbocharger (3). If there is no damage, go to Step 2.
2. Inspect turbine wheel (2) for buildup of carbon and other foreign material. Inspect turbine
housing (1) for buildup of carbon and foreign material. Clean turbine wheel (2) and clean
turbine housing (1) if you find buildup of carbon or foreign material. If there is no buildup of
carbon or foreign material, go to Step 3.
3. Turn the rotating assembly by hand. While you turn the assembly, push the assembly sideways.
The assembly should turn freely. Turbine wheel (2) should not rub turbine wheel housing (1).
Replace turbocharger (3) if turbine wheel (2) rubs turbine housing (1). If there is no rubbing or
scraping, go to Step 4.
4. Inspect the turbine and turbine housing (1) for oil leakage. Inspect the turbine and turbine
housing (1) for oil coking. Some oil coking may be cleaned. Heavy oil coking may require
replacement of the turbocharger. If the oil is coming from the turbocharger center housing go to
Step 4.a. Otherwise go to "Inspection of the Wastegate".
a. Remove the oil drain line for the turbocharger. Inspect the drain opening. Inspect the area
between the bearings of the rotating assembly shaft. Look for oil sludge. Inspect the oil
drain hole for oil sludge. Inspect the oil drain line for oil sludge. If necessary, clean the
rotating assembly shaft. If necessary, clean the drain opening. If necessary, clean the
drain line.
b. If crankcase pressure is high, or if the oil drain is restricted, pressure in the center housing
may be greater than the pressure of turbine housing (1). Oil flow may be forced in the
wrong direction and the oil may not drain. Check the crankcase pressure and correct any
problems.
c. If the oil drain line is damaged, replace the oil drain line.
d. Check the routing of the oil drain line. Eliminate any sharp restrictive bends. Make sure
that the oil drain line is not too close to the engine exhaust manifold.
e. If Steps 4.a through 4.d did not reveal the source of the oil leakage, turbocharger (3) has
internal damage. Replace turbocharger (3) .
Inspection of the Wastegate

Note: Not all engines are equipped with wastegates.
The wastegate controls the amount of exhaust gas that is allowed to bypass the turbine side of the
turbocharger. This valve then controls the rpm of the turbocharger.
When the engine operates in conditions of low boost (lug), a spring presses against a diaphragm in the
canister. The actuating rod will move and the wastegate will close. Then, the turbocharger can operate
at maximum performance.
When the boost pressure increases against the diaphragm in the canister, the wastegate will open. The
rpm of the turbocharger becomes limited. The rpm limitation occurs because a portion of the exhaust
gases bypass the turbine wheel of the turbocharger.
The following levels of boost pressure indicate a problem with the wastegate:
• Too high at full load conditions
• Too low at all lug conditions
Note: The housing assembly for the wastegate is preset at the factory and no adjustments can be
made.
NOTICE
If the high idle rpm or the engine rating is higher than given in the
Technical Marketing Information (TMI) for the height above sea level
at which the engine is operated, there can be damage to engine or to

turbocharger parts. Damage will result when increased heat and/or
friction due to the higher engine output goes beyond the engine cooling
and lubrication system's abilities.
The boost pressure controls the maximum rpm of the turbocharger, because the boost pressure
controls the position of the wastegate. The following factors also affect the maximum rpm of the
turbocharger:
• The engine rating
• The horsepower demand on the engine
• The high idle rpm
• The height above sea level for engine operation
• Inlet air restriction
• Exhaust system restriction
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Troubleshooting
3406E, C12, C15 and C18 Marine Engines
i02450055
E025 High Inlet Air Temperature Derate

SMCS - 1050-038-TA
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects inlet air temperature that exceeds the trip point
temperature. Information on default settings and ranges for this event can be found in
Troubleshooting, "Event Codes".
System Response:
The ECM will log the event.
• The engine power is derated.
There may be a problem with the engine.
Test Step 1. Check the Engine's Air Inlet and Exhaust Systems
A. Check for a restriction in the air inlet system. A restriction of the air that is coming into the
engine can cause high cylinder temperatures. High cylinder temperatures cause higher than
normal temperatures in the cooling system.
B. Check for a restriction in the exhaust system. A restriction of the air that is coming out of the
engine can cause high cylinder temperatures.
Results:
Continue to the next test step.
Test Step 2. Check for an Extreme Operating Environment
A. Consider high ambient temperatures. When ambient temperatures are too high for the rating of
the cooling system, there is not enough of a temperature difference between the ambient air and
coolant temperatures.
B. Consider high altitude operation. The cooling capability of the cooling system is reduced at
higher altitudes. A pressurized cooling system that is large enough to keep the coolant from
boiling must be used.
C. The engine may be running in the lug condition. When the load that is applied to the engine is
too large, the engine will run in the lug condition. When the engine is running in the lug
condition, engine rpm does not increase with an increase of fuel. This lower engine rpm causes
a reduction in coolant flow through the system.
Expected Result:
A thorough inspection of the engine revealed a problem.
Results:
• OK - There is a problem with the engine.
Repair: Repair the problem. Ensure that the repair eliminates the problem.
STOP
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Troubleshooting
i02450081
E027 High Inlet Air Temperature Warning

SMCS - 1050-038-TA
Conditions Which Generate This Code:
The Electronic Control Module (ECM) detects inlet air temperature that exceeds the trip point
temperature. Information on default settings and ranges for this event can be found in
Troubleshooting, "Event Codes".
System Response:
The ECM will log the event.
• There are no performance effects.
Test Step 1. Check the Engine's Air Inlet and Exhaust Systems
A. Check for a restriction in the air inlet system. A restriction of the air that is coming into the
engine can cause high cylinder temperatures. High cylinder temperatures cause higher than
normal temperatures in the cooling system.
B. Check for a restriction in the exhaust system. A restriction of the air that is coming out of the
engine can cause high cylinder temperatures.
Results:
Continue to the next test step.
Test Step 2. Check for an Extreme Operating Environment
A. Consider high ambient temperatures. When ambient temperatures are too high for the rating of
the cooling system, there is not enough of a temperature difference between the ambient air and
coolant temperatures.
B. Consider high altitude operation. The cooling capability of the cooling system is reduced at
higher altitudes. A pressurized cooling system that is large enough to keep the coolant from
boiling must be used.
C. The engine may be running in the lug condition. When the load that is applied to the engine is
too large, the engine will run in the lug condition. When the engine is running in the lug
condition, engine rpm does not increase with an increase of fuel. This lower engine rpm causes
a reduction in coolant flow through the system.
Expected Result:
A thorough inspection of the engine revealed a problem.
Results:
• OK - There is a problem with the engine.
Repair: Repair the problem. Ensure that the repair eliminates the problem.
STOP
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Troubleshooting
i05451574
Engine Has Early Wear

SMCS - 1000-035
Probable Causes
• Incorrect maintenance intervals and/or incorrect oil
• Contaminated engine oil
• Low oil pressure
• Leaks in the air system
• Inspect the fuel filters for contamination.
Recommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 1
Troubleshooting Test Steps Values Results
1. Incorrect Maintenance Intervals and/or Maintenance Result: The engine oil was
Incorrect Oil intervals changed at the interval that is
recommended by the engines
A. Use engine oil that is recommended and Operation and Maintenance
change the engine oil at the interval that is Manual.
recommended by the engines Operation and
Maintenance Manual. Proceed to Test Step 2.
Result: The engine oil was not
changed at the interval that is

recommended by the engines
Operation and Maintenance
Manual.
Use at least the minimum grade

of Cat oil.
Change the engine oil at the

interval that is recommended.
Repair or replace any damaged
parts.
2. Contaminated Engine Oil

Result: The oil is
A. Obtain an S-O-S oil analysis. The analysis
contaminated.
will contribute to a better understanding of oil
contamination.
Determine the reason for any
contamination of the engine oil
B. Check the oil filter bypass valve.
and make the necessary repairs.
Drain the crankcase and refill
If the oil filter bypass valve is open, the oil will
the crankcase with clean engine
not be filtered. Check the oil filter bypass valve
Contamination oil. Install new engine oil
for a weak spring or for a broken spring. If the
filters. Refer to the engines
spring is broken, replace the spring. Verify that
Operation and Maintenance
the oil bypass valve is operating correctly.
Manual.
Refer to the Disassembly and Assembly
manual.
Result: The oil is not
contaminated.
Refer to the Caterpillar guidelines for
"Reusability and Salvage/Repair" for
Proceed to Test Step 3.
determining if the replacement of parts is
necessary in order to perform a quality repair.
3. Low Oil Pressure Restriction Result: The inlet tube has a

restriction.
A. Engine oil that is contaminated with another
liquid can cause low engine oil pressure. High Clear the obstruction. Verify
engine oil level can be an indication of the repair.
contamination. Obtain an analysis of the engine
oil. Result: The inlet tube does not
have a restriction.
B. The inlet screen of the suction tube for the
engine oil pump can have a restriction. This Proceed to Test Step 4.
restriction will cause cavitation and a loss of
engine oil pressure. Check the inlet screen on
the suction tube and remove any material that
may be restricting engine oil flow.
When some components of the engine show

wear in a short time, the cause can be a
restriction in a passage for engine oil. An
indicator for the engine oil pressure may
indicate sufficient pressure, but a component is
worn due to a lack of lubrication. In such a
case, look at the passage for the engine oil
supply to the component. Refer to Systems
Operation/Testing and Adjusting, "Lubrication
System" for additional information.
4. Leaks in Air System Result: There are no air leaks.
A. A leak in the air intake system may allow Proceed to Test Step 5.
unfiltered air into the engine. Inspect the air Air leak
intake system for streaks which may indicate a Result: There are air leaks.
leakage of unfiltered air. Inspect all of the
gaskets and the connections. Repair any leaks.
Result: The fuel has

contamination.
5. Inspect the Fuel Filters for Contamination
Determine the cause of any
A. Remove the fuel filters. Inspect the fuel
contamination and make the
filters for contamination. Contaminants in the Fuel filters
necessary repairs.
fuel such as hydrogen sulfide and sulfur can
lead to the formation of acids in the crankcase.
Install new fuel filters. Refer to
Obtain a fuel analysis.
the Operation and Maintenance
Manual.
Complete the procedure in the order in which the steps are listed.
The procedure corrected the issue. Return the engine to service.
The procedure did not correct the issue.
Contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer
with the Dealer Solutions Network (DSN).
Shutdown SIS
Previous Screen

Troubleshooting
i02234636
Engine Oil in Exhaust System

SMCS - 1050-035; 1348-035
Probable Causes
• Failed turbocharger seals
• Worn valve guide seals or faulty valve guide seals
• Worn valve guides
• Worn piston rings
• Scored cylinder liners or worn cylinder liners
Recommended Actions
Failed Turbocharger Seals
Check the inlet manifold and the exhaust manifold for oil. If oil is present, replace the turbocharger.
Worn Valve Guide Seals or Faulty Valve Guide Seals

Inspect the valve guide seals for wear and for damage. Replace the valve guide seals, if necessary.
Worn Valve Guides

Inspect the valve guides for wear. Refer to the Specification manual for the maximum permissible
wear of the valve guides. If necessary, recondition the cylinder head.
Worn Piston Rings
Piston rings that have excessive wear can cause too much pressure in the crankcase. The additional
pressure in the crankcase will cause more than the normal amount of crankcase blowby from the
crankcase breather. Use the 8T-2700 Blowby/Air Flow Indicator to check the amount of crankcase
blowby. The test procedure is in Special Instruction, SEHS8712. Inspect piston rings and install new
parts, as required.
Scored Cylinder Walls or Worn Cylinder Walls

Inspect the cylinder liners for damage. Hone the cylinder liners in order to remove the scoring. If
necessary, install new liners.
Shutdown SIS
Previous Screen

Troubleshooting
i02455931
Excessive Black Smoke

SMCS - 1088-035
Probable Causes
• Air inlet system or exhaust system
• Engine speed/timing sensors
• Valve lash
• Electronic unit injector
• Intake manifold (boost) pressure sensor, rated fuel position and/or FRC fuel position
• Flash file
• Fuel quality
Recommended Actions
Air Inlet System or Exhaust System
1. Check the air inlet system for restrictions and/or for leaks.
a. Check for an air filter restriction.
b. Check for derates and for alarms.
c. Perform a visual inspection of the system for restrictions and/or for leaks.
2. Ensure that the turbocharger has not failed.
3. Check the exhaust system for restrictions.
4. Repair any leaks that were found. Remove any restrictions that were found. Replace any
damaged components that were found.
Engine Speed/Timing Sensors

1. Check the calibration of the engine speed/timing sensor. Refer to calibration procedures
Troubleshooting, "Engine Speed/Timing Sensor - Calibrate".
2. Verify that the crankshaft and the camshaft drive gears are set with the proper orientation. Refer
to the Disassembly and Assembly manual.
Valve Lash
Check the valve lash. Refer to Systems Operation/Testing and Adjusting.
Electronic Unit Injector

1. Ensure that the electronic unit injector connectors (J300/P300) are fully connected and free of
corrosion.
2. Ensure that the ECM connector (J2/P2) is fully connected and free of corrosion.
3. Connect the Caterpillar Electronic Technician (ET). Run the cylinder cutout test in order to
identify any misfiring cylinders.
Refer to the diagnostic functional test Troubleshooting, "Injector Solenoid Circuit - Test".
Intake Manifold (Boost) Pressure Sensor, Rated Fuel Position and/or FRC Fuel
Position
1. Monitor the status of "Fuel Position" and "Rated Fuel Limit" while the engine is operating
under full load. If "Fuel Position" equals "Rated Fuel Limit" and "Fuel Position" is less than
"FRC Fuel Limit", the Electronic Control Module (ECM) is providing the correct control.
Otherwise, proceed to the next Step.
2. Verify that there are no active diagnostic codes.
3. Monitor the status of "Intake Manifold (Boost) Pressure" and "Atmospheric Pressure" on the
Caterpillar Electronic Technician (ET). When the engine is not running, "Boost Pressure"
should be 0 kPa (0 psi).
Note: A problem with the FRC will only cause black smoke during acceleration. A problem
with the FRC will not cause black smoke during steady state operation.
Flash File
Verify that the correct flash file is installed. Refer to programming parameters Troubleshooting,
"Flash Programming".
Fuel Quality
1. Check fuel quality.
2. Cold weather adversely affects the characteristics of the fuel. For information on improving the
characteristics of the fuel during cold weather operation, refer to the Operation and
Maintenance Manual.
Shutdown SIS
Previous Screen

Troubleshooting
i05902924
Excessive Fuel Consumption

SMCS - 1250-035
Probable Causes
• Engine operation
• Fuel leaks
• Fuel quality
• Engine speed/timing
• Unit injectors
• Air inlet and exhaust system
• Accessory equipment
Recommended Actions
Table 1
Engine
1. Engine Operation Operation Result: Cat ET shows no sign of
excessive idle time and/or high load
A. Use Caterpillar Electronic Technician factor.
(ET) to check the "Current Totals" for
excessive idle time and/or for a high load Proceed to Test Step 2.
factor which would be indicative of poor
Result: Cat ET shows signs of
operating habits. excessive idle time and/or high load

factor.
Repair: Make the necessary repairs

and return to service.
Result: The fuel pressure during

engine cranking and after the fuel
filter is within specifications.

2. Fuel Leaks
Result: The fuel pressure during
A. Check the fuel pressure during engine
engine cranking and after the fuel
cranking.
filter is not within specifications.
B. Check the fuel pressure after the fuel Fuel Leaks
Repair: If the fuel pressure is low,
filter.
replace the fuel filters. If the fuel
pressure is still low, check the
Refer to the Systems Operation and Testing
following items:
and Adjusting for the correct pressure
values.
- Fuel Transfer Pump
- Fuel Transfer Pump Coupling
- Fuel Pressure Regulating Valve
Result: The fuel quality is correct.

3. Fuel Quality
Result: The fuel quality is not
A. Verify that the fuel quality is correct. correct.
Fuel Quality
Note: Cold weather adversely affects the Repair: Refer to the Operation and
characteristics of the fuel. Maintenance Manual for information
on improving the characteristics of
the fuel during cold-weather
operation.
Timing
4. Engine Speed/Timing Signal Result: The speed/timing sensor is
operating properly.
A. Perform a speed/timing sensor
calibration. Proceed to Test Step 5.
Refer to Troubleshooting, "Engine Result: The speed/timing sensor is
Speed/Timing Sensor - Calibrate" for not operating properly.

troubleshooting information.
Repair: Repair the speed/timing
sensor.
Verify that the repair eliminated the
problem.
5. Unit Injectors
Result: The connectors were
correctly installed and the test were
A. Check for correct installation of the
successful.
J1/P1 and J2/P2 Electronic Control Module
(ECM) connectors and the unit injector
connectors.
Result: The connectors were not
B. Perform the "Injector Solenoid Test" on
installed correctly and the test were
Cat ET in order to determine if all of the Fuel
not successful.
injector solenoids are being energized by Injectors
the ECM.
Repair: Reinstall the connectors
correctly and remove the suspect
C. Perform the "Cylinder Cutout Test" in
injector, and install a new electronic
order to identify any injectors that might be
unit injector. Refer to Disassembly
misfiring.
and Assembly.
Ensure that the repairs have
Refer to Troubleshooting, "Injector
determined the problem.
Solenoid - Test".
Result: There are restrictions in the

6. Air Inlet and Exhaust System air inlet or exhaust system.
A. Check the air filter restriction indicator, Repair: Make the necessary repairs.
if equipped. Clean plugged air filter or Verify that the repair eliminated the
replace plugged air filters. Refer to the Restrictions problem.
Operation and Maintenance Manual.
Result: There are no restrictions in
B. Check the air inlet and exhaust system the air inlet or exhaust system.
for restrictions and/or leaks.
Engine
7. Accessory Equipment Accessories Result: There is no engine
accessories creating an excessive
A. Check all accessory equipment for load on the engine.
problems that may create excessive load on
the engine. STOP
Result: An engine accessory is

creating an excessive load.
Repair: Repair the engine accessory.

Verify that the repair eliminated the
problem.
Shutdown SIS
Previous Screen

Troubleshooting
i05909383
Excessive White Smoke

SMCS - 1088-035
Note: Some white smoke may be present during cold start-up conditions when the engine is operating
normally. If the white smoke persists, there may be a problem.
Probable Causes
• Diagnostic codes
• Cold mode
• Starting aids (if applicable)
• Water temperature regulators
• Unit injectors
• Flash file
• Fuel supply
• Component wear
• Cooling system
• Engine timing
Recommended Actions
Table 1
Diagnostic
1. Diagnostic Codes Codes Result: A diagnostic code is
not active or logged.
A. Establish communication between Cat
Electronic Technician (Cat ET) and the ECM. Proceed to Test Step 2.
Refer to Troubleshooting"Electronic Service
Tools", if necessary. Result: A diagnostic code is
active or logged.
Repair: Troubleshoot any

codes before continuing with
this procedure. Verify that
the repair eliminated the
problem.
Result: The engine is not

2. Cold Mode operating in cold mode.
A. Use Cat ET to verify that the engine has exited Proceed to Test Step 3.
cold mode. Cold mode operation may slow throttle
response. Cold Mode Result: The engine has not
exited from the cold mode.
If the engine is operating in cold mode, an indicator
will be displayed on the top of any of the status Repair: This is normal
screen. operation. Return the engine
to service.
Result: The air inlet heater

and the ether injection system
3. Starting Aids are operating correctly.
A. Ensure that the air inlet heater is operating Proceed to Test Step 4.
correctly. Refer to the diagnostic functional test
Troubleshooting"Air Inlet Heater Circuit - Test". Result: The air inlet heater
Starting Aid
and/or the ether injection
B. Ensure that the ether injection system is system is not operating
operating correctly. Refer to the diagnostic correctly.
functional test Troubleshooting, "Ether Injection
System - Test". Repair: Make the necessary
repairs. Verify that the repair
eliminated the problem.
Temperature
4. Water Temperature Regulators Regulator Result: The water
temperature regulator is
A. Check the water temperature regulators for operating properly.
correct operation. Refer to Testing and Adjusting. Proceed to Test Step 5.
Result: The water

temperature regulator is not
operating properly.
Repair: If necessary, replace

the water temperature
regulators.
Verify that the repair
eliminated the problem.
Result: The test was

successful.

5. Unit Injectors
Result: The test was NOT
A. Perform the "Cylinder Cutout Test" in order to
successful.
identify any injector that might be misfiring.
Fuel
Injectors Repair: Remove the suspect
Use similar conditions for the test that were
injector, and install a new
experienced during operation. Refer to the
electronic unit injector. Refer
diagnostic functional test Troubleshooting "Injector
to Disassembly and
Solenoid Circuit -Test".
Assembly.
Ensure that the repairs have

determined the problem.
Result: The correct flash file

is properly installed on the
ECM.

6. Flash File
Result: The incorrect flash
Flash File file is installed on the ECM.
A. Ensure that the correct flash file is properly
installed on the ECM.
Repair: Download the
correct flash file and install
properly to the ECM.
Refer to programming
parameters Troubleshooting,
"Flash Programming".
Fuel Supply
7. Fuel Supply Result: The fuel system is
operating properly.
A. Inspect the fuel system components.
B. Check for the correct fuel pressure.
Result: The fuel system is
C. Check the fuel quality. not operating properly.
Low cetane fuel can create white smoke. Replace Repair: Make the necessary
the fuel with a higher cetane fuel. In temperatures repairs. Verify that the repair
below 0° C (32° F), check for solidified fuel (wax). eliminated the problem.
Refer to Applied Failure Analysis, SEBD0717,
"Diesel Fuels and Your Engine". If necessary,
replace the fuel with a higher cetane fuel.
8. Component Wear Result: There is no excessive

component wear found in the
A. Check the engine for the following problems: engine.
- Excessive Valve Wear Proceed to Test Step 9.

Component
- Piston Wear Result: There is excessive
Wear
component wear found in the
- Ring Wear engine.
- Liner Wear Repair: Repair or replace the

excessive component and
- Reduced Compression Pressure return engine to service.
Result: There were no

coolant leaks found in the
engine or coolant found in
the cylinder or exhaust.
9. Cooling System
A. Check the engine for coolant leaks. Cooling
Result: There is coolant
System
leaks found in the engine
B. Check for coolant in the cylinder and for coolant
and/or coolant found in the
in the exhaust system
cylinder or exhaust.
Repair: Make the necessary

repairs to the engine and
return to service.
Engine
10. Engine Timing Timing Result: The
crankshaft/camshaft gears are
A. Check the calibration of the engine speed/timing aligned properly and the
sensors. Refer to the Troubleshooting, "Engine engine speed/timing sensor
Speed/Timing Sensor - Calibrate". are calibrated correct.
B. Verify that the crankshaft and camshaft drive STOP

gears are properly oriented. Refer to the engines
Disassembly and Assembly manual. Result: The
crankshaft/camshaft gears are
not aligned properly and/or
the engine speed/timing
sensor is not calibrated
correct.
Repair: Realign the

crankshaft/camshaft gears
and/or properly calibrate the
engine speed/timing sensor.
Shutdown SIS
Previous Screen

Troubleshooting
i05915209
Exhaust Temperature Is Too High

SMCS - 1088-035-TA
Probable Causes
• Diagnostic codes
• Electrical connectors
Recommended Actions
Table 1
Result: Active codes were found when

connected to Cat ET.
1. Diagnostic codes Repair: Troubleshoot any codes that

present before continuing with this
Diagnostic
A. Connect the Cat® Electronic Codes
procedure.
Technician (Cat ET) and check for active
codes and/or logged codes. Result: No Active codes were found
when connected to Cat ET.
Electrical
2. Check the condition of the Connectors Result: There is no problem in the
connectors at the ECM. connectors and/or wiring.
A. Check for the correct installations of Proceed to Test Step 3.

the J2/P2 ECM connectors.
Result: There is a problem in the
B. Check the J300/P300 injector connectors and/or wiring.
solenoid harness connector.
Repair: Refer to the diagnostic
functional test Troubleshooting,
"Electrical Connectors - Inspect".
3. Air Inlet and Exhaust System Result: There are no restrictions or

leaks in the air inlet or exhaust system.
A. Check the air inlet system, air filter,
air inlet piping, and exhaust system for STOP
restrictions and/or leaks.
Result: There are restrictions and leaks
Restrictions
B. Repair any leaks that were found. in the air inlet and/or exhaust system.
Remove any restrictions that were found
and replace any damaged components Repair: Make the necessary repairs,
that were found. and refer to System Operation/Testing
and Adjusting, "Air Inlet and Exhaust
C. Check the air inlet manifold pressure. System".
Shutdown SIS
Previous Screen

Troubleshooting
i01865253
Low Power/Poor or No Response to Throttle

SMCS - 1000-035
Note: If the vessel is equipped with a Multi-Station Control System (MSCS), refer to Service Manual,
RENR7651, "Marine Multi-Station Control System" for the proper troubleshooting procedure.
Probable Causes
• Selected engine rating parameters
• Cold Mode
• Active engine derate
• Electrical connections to the ECM
• Throttle signal
• Circuit for electronic unit injectors
• Fuel supply
• Boost pressure sensor
Recommended Actions
Note: If the problem only occurs under certain conditions, test the engine under those conditions.
Examples of certain conditions are high rpm, full load and engine operating temperature.
Troubleshooting the symptoms under other conditions can give misleading results.
Selected Engine Rating Parameters
Verify that the complaint is not due to a normal operation such as a programmed parameter. Connect
the electronic service tool and verify that the parameters are programmed correctly.
Verify that the injector codes have been programmed.
Cold Mode
1. Use the electronic service tool to verify that the engine has exited Cold Mode. Cold Mode
operation may cause the engine to run rough and engine power may be limited.
2. Observe the status of the coolant temperature on the electronic service tool. Verify that the
reading is valid.
Active Engine Derate

Use the electronic service tool to check for logged engine derates. Refer to the section
Troubleshooting, "Troubleshooting with an Event Code" for the specific events that are applicable to
this application. A derate status flag will appear on the electronic service tool if an active engine
derate is occurring.
Electrical Connections to the ECM

Check the associated wiring for damage, abrasion, corrosion or incorrect attachment on the following
connectors: J1/P1 and J2/P2 ECM connectors, J61/P61 Customer Connector and J403/P403 Primary
Throttle Position Sensor connector and J404/P404 Secondary Throttle Position Sensor connector.
Refer to Troubleshooting, "Electrical Connectors-Inspect" for additional information.
Throttle Position Sensor

Connect an Electronic Service Tool to the service tool connector. Turn the keyswitch to the ON with
the engine OFF.
Monitor the throttle position from low idle to full throttle. The duty cycle should be between 5 and 10
percent at low idle. The duty cycle will increase to 90 to 95 percent at full throttle. Refer to
Troubleshooting, "Throttle Position Sensor Circuit - Test" for additional information if the change in
the throttle position is erratic or if the change in the throttle position is out of the specified range.
Circuit for the Electronic Unit Injector

Inspect the J2/P2 ECM connector and the J300/P300 Unit Injector connector for proper connections.
Refer to Troubleshooting, " Electrical Connectors - Inspect". Connect an Electronic Service Tool and
cut out each cylinder in order to isolate the misfiring cylinder or cylinders. If the results are
inconclusive, shut off half of the cylinders and repeat the cylinder cutout test on the active cylinders
that are remaining in order to locate those cylinders that are missing. Refer to Troubleshooting,
"Injector Solenoid Circuit - Test".
Fuel Supply
Check for a problem with the fuel supply and verify the fuel pressure. For further information, refer to
Testing and Adjusting, "Fuel System".
Boost pressure sensor

1. Monitor the status of "Fuel Position" and "Rated Fuel Limit" on the electronic service tool. If
"Fuel Position" does not equal "Rated Fuel Limit", then check the boost pressure.
2. Verify that there are no active diagnostic codes that are associated with the boost pressure
sensor.
3. Monitor the status of "Boost Pressure" for normal operation on the electronic service tool.
Air Inlet and Exhaust System

Check air inlet and exhaust systems for restrictions and leaks. Refer to Testing and Adjusting, "Air
Inlet and Exhaust System". Look for an indication of the Warning Lamp or restriction indicators that
are tripped if the filters are equipped with these devices. These indicators are associated with plugged
filters. Replace the plugged air filters or clean the plugged air filters per the guidelines for operation
and maintenance., Repair any leaks that are found in the system.

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C12 Marine Engine C1Z00001-UP(SEBP4002 - 54) - Documentation Page 1 of 4

Product: MARINE ENGINE

Disassembly and Assembly

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Install housing (10) .

2. Install bolts (9) , bolts (11) , and bolts (12) .

4. Install new gaskets and aftercooler core (1) .

5. Install cover (7) .

6. Install bolts (8) .

8. Connect tube assembly (6) .

9. Connect tube assembly (3) and tube assembly (5) .

10. Connect tube assembly (2) and tube assembly (4) .

Product: MARINE ENGINE

Disassembly and Assembly

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Care must be taken to ensure that fluids are contained during

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Dispose of all fluids according to local regulations and mandates.

2. Disconnect tube assembly (2) and tube assembly (4) .

3. Disconnect tube assembly (3) and tube assembly (5) .

4. Disconnect tube assembly (6) .

6. Remove bolts (8) .

7. Remove cover (7) .

8. Remove aftercooler core (1) and the gaskets.

9. Remove bolts (9) , bolts (11) , and bolts (12) .

10. Remove housing (10) .

Product: MARINE ENGINE

Disassembly and Assembly

Exhaust Manifold - Remove and Install

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

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Care must be taken to ensure that fluids are contained during

before opening any compartment or disassembling any component

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Dispose of all fluids according to local regulations and mandates.

1. Disconnect hose assembly (1) .

3. Disconnect tube assembly (2) and tube assembly (7) .

4. Remove tube (3) .

6. Remove bolts (4) .

7. Remove exhaust manifold (10) and the turbocharger.

2. Install exhaust manifold (10) and the turbocharger.

3. Install bolts (4). Tighten the bolts in a numerical sequence.

4. Install tube (3) .

5. Connect tube assembly (2) and tube assembly (7) .

7. Connect hose assembly (1) .

Product: MARINE ENGINE

Disassembly and Assembly

Exhaust Manifold - Remove and Install

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

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Care must be taken to ensure that fluids are contained during

before opening any compartment or disassembling any component

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Dispose of all fluids according to local regulations and mandates.

1. Disconnect hose assembly (1) .