C7.1 Marine Engine Caterpillar

Removal Procedure

Start By:

1. Drain the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedures.

1. The engine can start automatically. Ensure that the power supply is isolated before any service or repairs is performed.

2. Disconnect the exhaust elbow from the turbocharger.

3. Disconnect the air inlet from the turbocharger.

4. Loosen clamp and disconnect the air outlet hose from the turbocharger.

5. Remove the blanket from the turbocharger.

6. Disconnect the tube assembly from turbocharger turbine housing.
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   Illustration 1	g03343661

7. Follow Steps 7.a through 7.c in order to remove hose and tube assembly (2).

   1. Remove bolts (1).

   2. Remove banjo bolt (7) and remove sealing washers (9).

   3. Remove hose and tube assembly (2) from the cylinder block. Remove gasket (3).

      Note: Plug the port for the oil feed to the turbocharger with a suitable plug.

8. Follow Steps 8.a through 8.c in order to remove hose and tube assembly (8).

   1. Remove bolts (10).

   2. Remove bolts (6) and remove hose and tube assembly (8) from turbocharger (4).

      Note: Plug the port for the tube assembly to the turbocharger with a suitable plug.

   3. Remove gasket (5) and remove gasket (11).
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   Illustration 2	g03343708

9. Remove bolts (15) and nuts (16) from turbocharger (4) and remove turbocharger (4) from exhaust manifold (14). Discard bolts (15) and nuts (16).

10. Remove gasket (13).

11. If necessary, remove studs (12) from turbocharger (12).

Installation Procedure

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Illustration 3	g03343708

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 (14). If necessary, install studs (12) to the turbocharger. Apply Tooling (B) to the threads of studs (12). Install studs to the turbocharger and tighten securely.
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   Illustration 4	g03372483
   Typical Example

3. If a new turbocharger is installed, bearing housing (18) and compressor housing (19) 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 (20) 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 (18) until the port for oil feed (17) is upward.

   3. Rotate compressor housing (19) 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 (20) 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 (13) to exhaust manifold (14).

5. Align turbocharger (4) with outlet hose. Install new bolts (15) and new nuts (16). Tighten the nuts and the bolts to a torque of 44 N·m (33 lb ft).
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   Illustration 5	g03343661

6. Ensure that hose and tube assembly (2) and (8) are clean and free from damage. Replace any damaged components.

7. Position a new gasket (3) and bolts (1) onto hose and tube assembly (2).

8. Install hose and tube assembly (2) to turbocharger (4). Tighten bolts (1) finger tight.

9. Position a new gasket (11) between the hose and tube assembly (8) and the cylinder block. Install bolts (10) finger tight.

10. Position a new gasket (5) and bolts (6) on to hose and tube assembly (8). Install tube assembly (8) to turbocharger. Tighten bolts (6) finger tight.

11. 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.

12. Install banjo bolt (7) and two new sealing washers (9) to hose and tube assembly (2).

13. Install hose and tube assembly (2) to the cylinder block and to turbocharger (4). Tighten banjo bolt (7) finger tight.

14. 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).

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

16. Tighten bolts (6) and bolts (10) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

17. Tighten bolts (1) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

18. Connect the exhaust elbow to the turbo.

19. Install the air inlet hose.

20. Connect air outlet hose to the turbocharger.

21. Connect tube assembly to the turbocharger turbine housing.

End By:

1. Refill the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining and filling procedures.