3406C (PEEC III) Truck Engine Caterpillar

Illustration 1	g00493064
4P-1901 Turbocharger, 4P-1902 Turbocharger and 4P-1903 Turbocharger

(1) Compressor wheel nut

Install the compressor wheel nut at room temperature by using the following procedure.

1. Tighten the nut.

   ... 15.5 ± 1.5 N·m (11.4 ± 1.1 lb ft)

2. Remove the nut from the shaft. Apply 4C-9500 Quick Cure Primer on the threads of the shaft and nut. Then apply 9S-3263 Thread Lock Compound to the threads of the shaft and nut.

3. Tighten the nut.

   Torque for the nut ... 9 ± 2 N·m (7 ± 1 lb ft)

4. Tighten the nut for an additional amount.

   Rotate the nut in the tightening direction. ... 60 ± 5 degrees

Apply 5P-3931 Anti-Seize Compound to the nuts and bolts before assembly. Tighten the four nuts that hold the turbocharger to the exhaust manifold to the following torque. ... 55 ± 5 N·m (41 ± 4 lb ft)

Install the band clamps that hold the cartridge to the compressor housing by using the following procedure.

1. Position the compressor clamp assembly.

   Position of the compressor clamp assembly ... 15 ± 10 degrees outboard from bottom vertical

2. Tighten the clamps.

   Tighten the clamps to the following torque. ... 14 ± 1 N·m (10 ± 1 lb ft)

3. Tap the clamps lightly. Tap all the way around the clamp.

4. Tighten the clamps.

   Tighten the clamps to the following torque. ... 14 ± 1 N·m (10 ± 1 lb ft)

Note: On 4P-1902 Turbocharger , the air outlet must be 25.4 mm (1.0 inch) from the exhaust manifold.

Illustration 2	g00513208
4P-1917 Turbocharger and 4P-1918 Turbocharger

(1) Compressor wheel nut

Install the compressor wheel nut at room temperature by using the following procedure.

1. Tighten the nut.

   ... 15.5 ± 1.5 N·m (11.4 ± 1.1 lb ft)

2. Remove the nut from the shaft. Apply 4C-9500 Quick Cure Primer on the threads of the shaft and nut. Then apply 9S-3263 Thread Lock Compound to the threads of the shaft and nut.

3. Tighten the nut.

   Torque for the nut ... 4 ± 2 N·m (3 ± 1 lb ft)

4. Tighten the nut for an additional amount.

   Rotate the nut in the tightening direction. ... 90 ± 5 degrees

Apply 5P-3931 Anti-Seize Compound to the nuts and bolts before assembly. Tighten the four nuts that hold the turbocharger to the exhaust manifold to the following torque. ... 55 ± 9 N·m (41 ± 7 lb ft)

Install the band clamps that hold the cartridge to the compressor housing by using the following procedure.

1. Position the compressor clamp assembly.

   Position of the compressor clamp assembly ... 15 ± 10 degrees outboard from bottom vertical

2. Tighten the clamps.

   Tighten the clamps to the following torque. ... 14 ± 1 N·m (10 ± 1 lb ft)

3. Tap the clamps lightly. Tap all the way around the clamp.

4. Tighten the clamps.

   Tighten the clamps to the following torque. ... 14 ± 1 N·m (10 ± 1 lb ft)

Note: On 4P-1918 Turbocharger , the air outlet must be 17.5 mm (.69 inch) from the exhaust manifold.

Illustration 3	g00513267
4P-1905 Turbocharger, 4P-1913 Turbocharger and 4P-1914 Turbocharger

(1) Compressor wheel nut

Install the compressor wheel nut at room temperature by using the following procedure.

1. Apply a small amount of clean oil on the threads of the shaft.

2. Tighten the nut.

   ... 15.5 ± 1.5 N·m (11.4 ± 1.1 lb ft)

3. Remove the nut from the shaft. Apply 4C-9500 Quick Cure Primer on the threads of the shaft and nut. Then apply 9S-3263 Thread Lock Compound to the threads of the shaft and nut.

4. Tighten the nut.

   Torque for the nut ... 4 N·m (3 lb ft)

5. Tighten the nut for an additional amount.

   Rotate the nut in the tightening direction. ... 120 degrees

(2) Bolt

Torque for the three bolts ... 3.65 ± 0.25 N·m (32.31 ± 2.21 lb in)

(3) Bolt

Torque for the four bolts ... 11 ± 1 N·m (8 ± 1 lb ft)

Apply 5P-3931 Anti-Seize Compound to the nuts and bolts before assembly. Tighten the four nuts that hold the turbocharger to the exhaust manifold to the following torque. ... 55 ± 5 N·m (41 ± 4 lb ft)

Install the band clamps that hold the cartridge to the compressor housing by using the following procedure.

1. Position the compressor clamp assembly.

   Position of the compressor clamp assembly ... 15 ± 10 degrees outboard from bottom vertical

2. Tighten the clamps.

   Tighten the clamps to the following torque. ... 14 ± 1 N·m (10 ± 1 lb ft)

3. Tap the clamps lightly. Tap all the way around the clamp.

4. Tighten the clamps.

   Tighten the clamps to the following torque. ... 14 ± 1 N·m (10 ± 1 lb ft)

Note: On 4P-1914 Turbocharger , the air outlet must be 17.5 mm (.69 inch) from the exhaust manifold.

Illustration 4	g00493707
S4D

(1) Shaft

End play for new shaft ... 0.114 ± 0.038 mm (.0045 ± .0015 inch)

Maximum permissible end play of a worn shaft ... 0.20 mm (.008 inch)

(2) Thickness of the thrust bearing ... 5.36 ± 0.03 mm (.211 ± .001 inch)

Note: The thickness of the thrust bearing (2) is taken at the contact point between the thrust rings and the bearing.

(3) Bearing

Bore in a new bearing ... 16.035 to 16.043 mm (.6313 to .6316 inch)

Diameter of new shaft ... 15.997 to 16.005 mm (.6298 to .6301 inch)

Maximum permissible clearance between the bearing and the shaft ... 0.05 mm (.002 inch)

(4) Maximum permissible gap of the oil seal ring in the bore of the housing ... 0.25 mm (.010 inch)

(5) Compressor wheel

Install the compressor wheel at room temperature by using the following procedure.

1. Put compressor wheel on the shaft.

2. Put a small amount of clean engine oil on the threads.

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NOTICE
Do not bend or add stress to the shaft when the nut is loosened or tightened. Both the turbine and the compressor wheel must be prevented from rotating throughout the pretightening and/or tightening operation.

3. Tighten the nut.

   Tighten the nut to the following torque. ... 14 to 17 N·m (10 to 13 lb ft)

4. Remove the nut from the shaft. Apply 4C-9500 Quick Cure Primer on the threads of the shaft and nut. Then apply 9S-3263 Thread Lock Compound to the threads of the shaft and nut.

5. Tighten the nut.

   Tighten the nut to the following torque. ... 4 N·m (35 lb in)

6. Tighten the nut for an additional amount.

   Rotate the nut in the clockwise direction. ... 90 degrees

(6) Thickness of each thrust ring ... 2.553 ± 0.013 mm (.1005 ± .0005 inch)

(7) Bearing

Bore in the new housing ... 24.994 to 25.006 mm (.9840 to .9845 inch)

Outside diameter of new bearing ... 24.882 to 24.892 mm (.9796 to .9800 inch)

Maximum permissible clearance between the bearing and the bore in the housing ... 0.15 mm (.006 inch)

Tighten the four nuts that hold the turbocharger to the exhaust manifold to the following torque. ... 55 ± 5 N·m (41 ± 4 lb ft)

Tighten the four bolts that hold the turbocharger to the exhaust manifold to the following torque. ... 55 ± 5 N·m (41 ± 4 lb ft)

Note: Apply 5P-3931 Anti-Seize Compound to the nuts and bolts before assembly.

Install the band clamps that hold the cartridge to the compressor housing by using the following procedure.

1. Tighten the clamps.

   Tighten the clamps to the following torque. ... 14 ± 1.1 N·m (10 ± 1 lb ft)

2. Tap the clamps lightly. Tap all the way around the clamp.

3. Tighten the clamps.

   Tighten the clamps to the following torque. ... 14 ± 1.1 N·m (10 ± 1 lb ft)

Note: Put clean engine oil in the oil inlet of the turbocharger after assembly or before installation in order to provide lubrication at start-up and protection during storage.

Illustration 5	g00493786
TV75

(1) Tighten the bolts that hold the backplate to the following torque. ... 11 ± 1 N·m (8 ± 1 lb ft)

(2) Bearing

Bore in a new bearing ... 15.921 to 15.931 mm (.6268 to .6272 inch)

Diameter of bearing journals on the shaft ... 15.875 to 15.885 mm (.6250 to .6254 inch)

(3) Bearing

Bore in the housing ... 24.961 to 24.973 mm (.9827 to .9832 inch)

Outside diameter of new bearing ... 24.846 to 24.859 mm (.9782 to .9787 inch)

(4) Maximum permissible gap of the oil seal ring in the bore of the housing ... 0.20 to 0.38 mm (.008 to .015 inch)

(5) Tighten the bearing bolts to the following torque. ... 3.35 to 3.85 N·m (30 to 34 lb in)

(6) Compressor wheel

Install the compressor wheel at room temperature by using the following procedure.

1. Put compressor wheel on the shaft.

2. Put a small amount of clean engine oil on the threads.

Show/hide table

NOTICE
Do not bend or add stress to the shaft when the nut is loosened or tightened. Both the turbine and the compressor wheel must be prevented from rotating throughout the pretightening and/or tightening operation.

3. Tighten the nut.

   Tighten the nut to the following torque. ... 17 N·m (13 lb ft)

4. Loosen the nut on the shaft.

5. Tighten the nut.

   Tighten the nut to the following torque. ... 3.5 N·m (30 lb in)

6. Tighten the nut for an additional amount.

   Rotate the nut in the clockwise direction. ... 120 degrees

7. Remove the nut from the shaft. Apply 4C-9500 Quick Cure Primer on the threads of the shaft and nut. Then apply 9S-3263 Thread Lock Compound to the threads of the shaft and nut.

8. Tighten the nut.

   Tighten the nut to the following torque. ... 3.5 N·m (30 lb in)

9. Tighten the nut for an additional amount.

   Rotate the nut in the clockwise direction. ... 120 degrees

(1) Shaft

End play for the shaft ... 0.08 to 0.13 mm (.003 to .005 inch)

Maximum permissible end play of a worn shaft ... 0.20 mm (0.008 inch)

Tighten the four nuts that hold the turbocharger to the exhaust manifold to the following torque. ... 55 ± 5 N·m (41 ± 4 lb ft)

Tighten the four bolts that hold the turbocharger to the exhaust manifold to the following torque. ... 55 ± 5 N·m (41 ± 4 lb ft)

Note: Apply 5P-3931 Anti-Seize Compound to the nuts and bolts before assembly.

Install the band clamps that hold the cartridge to the compressor housing by using the following procedure.

1. Tighten the clamps.

   Tighten the clamps to the following torque. ... 14 ± 1.1 N·m (10 ± 1 lb ft)

2. Tap the clamps lightly. Tap all the way around the clamp.

3. Tighten the clamps.

   Tighten the clamps to the following torque. ... 14 ± 1.1 N·m (10 ± 1 lb ft)