C6.6 Marine Generator Set Caterpillar

Installation Procedure

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Illustration 1	g01608835

1. Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If any part of the turbocharger is worn or damaged, the complete turbocharger must be replaced.

2. Clean the gasket surfaces of exhaust manifold (13). If necessary, install studs (15) to the exhaust manifold. Apply Tooling (B) to the threads of studs (15). Install studs to the manifold and tighten securely.
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   Illustration 2	g01608859

3. If a new turbocharger is installed, bearing housing (17) and compressor housing (18) must be oriented to the correct positions. Follow Step 3.a through Step 3.d in order to orient the bearing housing and the compressor housing.

   1. Loosen band clamps (19) sufficiently in order to allow the housings to rotate.

      Note: If the band clamps are damaged, replace the band clamps.

   2. Carefully turn bearing housing (17) until the port for oil feed (16) is upward.

   3. Rotate compressor housing (18) until the compressor outlet is in the correct position. Refer to the turbocharger that was originally installed for the correct orientation.

   4. Ensure that band clamps (19) are correctly oriented. Refer to the turbocharger that was originally installed for the correct orientation. Tighten the band clamps finger tight.

4. Install a new gasket (14) to exhaust manifold (13).

5. Align turbocharger (6) with outlet hose. Install nuts (12). Tighten the nuts to a torque of 44 N·m (33 lb ft).
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   Illustration 3	g01608830

6. Ensure that tube assembly (3) and tube assembly (9) are clean and free from damage. Replace any damaged components.

7. Position a new gasket (6) and bolts (8) onto tube assembly (9).

8. Install tube assembly (9) to turbocharger (4). Tighten bolts (8) finger tight.

9. Position a new gasket (10) between the flange of tube assembly (9) and the cylinder block. Install bolts (11) finger tight.

10. Remove the plug from the oil inlet port. Lubricate the turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times in order to lubricate the bearings.

11. Use Tooling (A) in order to lubricate a new O-ring seal (5). Install O-ring seal (5) to tube assembly (3).

12. Install banjo bolt (1) and two new sealing washers (2) to tube assembly (3).

13. Install tube assembly (3) to the cylinder block and to turbocharger (4). Tighten banjo bolt (1) finger tight.

14. Install bolt (7) finger tight. Ensure that tube assembly (3) fits correctly.

15. If a new turbocharger has been installed, check that the orientation of the bearing housing is correct. If the orientation of the bearing housing is not correct, rotate the bearing housing until tube assembly (9) fits correctly. Tighten the band clamps to a torque of 13 N·m (9.6 lb ft).

16. Tighten banjo bolt (1) to a torque of 20 N·m (14 lb ft). Tighten bolt (7) to a torque of 22 N·m (16 lb ft).

17. Tighten bolts (8) and bolts (11) to a torque of 22 N·m (16 lb ft).

18. Connect the exhaust elbow and tighten band clamp securely.

19. Install the air inlet hose and tighten the hose clamp securely.

20. Tighten the hose clamp for the air outlet securely.