2002/01/07 A New Exhaust Seal And A New Exhaust Manifold Sleeve Are Used In The Exhaust Manifold Groups {1059} Caterpillar

Machine Engines: with Mechanical Unit Injection

3500 Series

Engine: Machine with Electronic Unit Injection

3500 Series

Engine: Machine

3500B Series

Service Magazine, SEPD0611, 07 January 2002, "A New Exhaust Seal And A New Exhaust Manifold Sleeve Are Used In The Exhaust Manifold Groups". Disregard this article. Refer to the article that follows.

Description of Change: A new exhaust seal and a new exhaust manifold sleeve are used in the exhaust manifold groups on the engines that are listed above. See Illustration 1. The new seal and the new sleeve are used to connect some of the sections of the exhaust manifolds. Two new exhaust manifold sleeves and one new exhaust seal are used to replace one former exhaust manifold sleeve. The new seal and the new sleeve will allow some relative movement between the sections of the exhaust manifold. This will reduce some of the forces on the bolts that fasten the exhaust manifolds to the cylinder head. This will help prevent the bolts from breaking.

Illustration 1	g00810856
This illustration shows the top view of a typical exhaust manifold group. The 203-2143 Exhaust Manifold Sleeves (1) replace the 1W-5499 Exhaust Manifold Sleeves. The 203-2143 Exhaust Manifold Sleeves (2) replace the 153-7474 Exhaust Manifold Sleeves . (1) 203-2143 Exhaust Manifold Sleeve (2) 203-2143 Exhaust Manifold Sleeve (3) 127-8269 Exhaust Seal (X) Exhaust Manifold

A longer bolt (6) and a thicker spacer (4) are used to fasten the sections of the exhaust manifold to the cylinder heads. See Illustration 2. This change will help maintain force that fastens the sections of the exhaust manifold to the cylinder heads.

Illustration 2	g00850650
This illustration shows the front view of a typical exhaust manifold group. (4) 203-2163 High Temperature Spacer (5) 5M-2894 Hard Washer (6) 5P-3875 Bolt (X) Exhaust Manifold (Y) Cylinder Head

Adaptable To: Two new 203-2143 Exhaust Manifold Sleeves (1) and one 127-8269 Exhaust Seal (3) replace each 1W-5499 Exhaust Manifold Sleeve in the Exhaust Manifold Groups that are identified in Table 1. Illustration 1 shows the locations of the new sleeves (1) and seals (3) in a typical exhaust manifold group.

A new 203-2143 Exhaust Manifold Sleeve (2) replaces each 153-7474 Exhaust Manifold Sleeve in the Exhaust Manifold Groups that are identified in Table 1. Illustration 1 shows the locations of the new sleeves (2) in a typical exhaust manifold group. The 153-7474 Exhaust Manifold Sleeves can be reused if the inside diameter is enlarged. See Illustration 3 for the correct inside diameter.

Illustration 3	g00838928
This illustration shows a 153-7474 Exhaust Manifold Sleeve. Dimension (A) of the modified 153-7474 Exhaust Manifold Sleeve must equal 116.3 ± 0.025 mm (4.58 ± 0.0010 inch).

One new 203-2163 High Temperature Spacer (4) and one new 5P-3875 Bolt (6) replace each 198-0230 High Temperature Spacer and 5P-3961 Bolt in the Exhaust Manifold Groups that are identified in Table 1. Illustration 2 shows the location of the new spacers and bolts in a typical exhaust manifold group. Apply a light coat of 4C-5598 High Temperature Anti-Seize to the threads of the bolts (6) before the bolts are installed. Tighten bolts (6) to a torque of 50 ± 5 N·m (37 ± 4 lb ft).

Note: Do not overtighten the bolts (6) that fasten the exhaust manifolds to the cylinder heads. The bolts may fail if the bolts are overtightened.Table 2 lists the effectivity of the new components in the machine engines.

Table 1

Identification Of Exhaust Manifold Groups
Machine	Machine S/N	Part Number Of The Exhaust Manifold Group
Machines That Are Powered By 3508 Engines
D11N	4HK, 74Z	9Y-7673
D11R	8ZR
776B	6JC
776C	2TK
777B	4YC, 3NF
777C	4XJ
5130	7TJ, 5ZL
D11R	AAF, 9TR, 9XR, 7PZ	121-5731
776D	5ER, AFS
777C	4XJ
777D	AGC, 3PR
5130B	4CS
854G	AMP, 1JW	115-0550
992G	7HR, ADZ
Machines That Are Powered By 3512 Engines
784B	5RK	2W-0212
785	8GB
785B	6HK
777D HAA	2YW, AGY	103-0940
784C	2PZ
785C	1HW, APX
797	5YW	155-0425
Machines That Are Powered By 3516 Engines
789	9ZC	2W-3708
789B	7EK
789C	2BW
5230	7LL
793	3SJ	9Y-8910
793B	1HL
793C	4AR, ATY, 4GZ
785C HAA	5AZ	115-0561
789C	2BW
793C	ATY
994	9YF	7E-6698
994D	3TZ	117-0040

Table 2

Effectivity of the New Components in the Exhaust Manifold Groups
Type of Machine Engine	Serial Number of Machine Engine
3508	99W3547
3508B	2GR3602
3512	96Z938
3512 with EUI	4WJ1278
3512B	8BR718
3516	54Z1203
3516 with EUI	2PK1617
3516B	7TR1208
3524B	3TN475