Turbocharger - Remove and Install
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Required Tools | |||
Tool | Part Number | Part Description | Qty |
A | 395-1590 | Lifting Eye Assembly | 2 |
B | - | Never-Seez Marine Grade | 1 |
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NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
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NOTICE |
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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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
- Remove bolts (1) and shield (2).
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Illustration 2 g03856526 - Remove bolts (3) and shield (4).
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Illustration 3 g03856537 - Remove bolts (5) and shield (6).
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Illustration 4 g03856543 - Remove bolts (7) and cover (8).
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Illustration 5 g03856546 - Remove bolts (9) and cover (10).
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Illustration 6 g03856553 - Remove bolts (11) and shield (12).
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Illustration 7 g03856555 - Disconnect spring latches (14) and remove cover (13).
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Illustration 8 g03856557 - Remove bolts (15) and bracket (16).
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Illustration 9 g03856559 - Remove bolts (17) and shield (18).
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Illustration 10 g03856562 - Remove bolts (19) and shield (20).
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Illustration 11 g03856564 Show/hide tableIllustration 12 g03856566 - Remove bolts (21) and (23) and shield (22).
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Illustration 13 g03856569 Show/hide tableIllustration 14 g03856571 - Remove bolts (24) and (25) and shield (26).
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Illustration 15 g03856575 - Remove bolts (27) and shield (28).
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Illustration 16 g03856579 - Remove bolts (29) and cover (30).
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Illustration 17 g03856581 - Remove bolts (31) and shield (32).
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Illustration 18 g03856582 - Remove bolts (33) and shield (34).
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Illustration 19 g03856589 - Remove bolts (35) and shield (36).
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Illustration 20 g03856587 - Remove bolts (37) and cover (38). Disconnect latches (39).
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Illustration 21 g03856610 - Remove bolts (40) and cover (41).
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Illustration 22 g03856593 - Remove bolts (43) and cover (42).
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Illustration 23 g03856622 - Remove bolts (44) and cover (45).
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Illustration 24 g03856633 - Remove bolts (47) and shield (46).
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Illustration 25 g03860579 - Remove bolts (48) from the bellows.
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Illustration 26 g03860580 - Remove bolts (49) and elbow and bellows assembly (50). Remove the gaskets.
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Illustration 27 g03860582 - Disconnect tube assembly (53). Remove bolts (51) and air inlet elbow (52).
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Illustration 28 g03860583 - Attach Tooling (A) and a suitable lifting device to turbocharger (54). The weight of turbocharger (54) is approximately
819 kg (1806 lb) . Remove bolts (55) and remove turbocharger (54). Remove the O-ring seals from the oil return tube.Show/hide tableIllustration 29 g03860584 - Disconnect latches (56). Remove bolts (58) and remove shield assembly (57).
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Illustration 30 g03860586 - Remove bolts (60) and shield assembly (59).
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Illustration 31 g03860588 Show/hide tableIllustration 32 g03860589 - Remove bolts (61) and (62) and remove shield assemblies (63).
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Illustration 1 | g03856524 |
- Apply Tooling (B) to all of the hardware for the exhaust shielding and the turbo shielding prior to installation.
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Illustration 33 g03860589 Show/hide tableIllustration 34 g03860588 - Position shield assemblies (63) and install bolts (62) and (61).
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Illustration 35 g03860586 - Install shield assembly (59) and install bolts (60).
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Illustration 36 g03860584 - Install shield assembly (57) and install bolts (58). Connect latches (56).
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Illustration 37 g03860583 - Attach Tooling (A) and a suitable lifting device onto turbocharger (54). The weight of turbocharger (54) is approximately
819 kg (1806 lb) . - Install new O-ring seals on the oil return tube. Install turbocharger (54) onto the mounting bracket and install bolts (55).
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Illustration 38 g03860582 - Install air inlet elbow (52) and install bolts (51). Connect tube assembly (53).
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Illustration 39 g03860580 - Position elbow and bellows assembly (50) and install bolts (49). Tighten bolts (49) that attach the compressor housing to the bellows to a torque of
120 ± 20 N·m (89 ± 15 lb ft) . Tighten bolts (49) that attach the elbow to the air inlet shutoff to a torque of47 ± 9 N·m (35 ± 7 lb ft) .Show/hide tableIllustration 40 g03860579 - Apply Tooling (B) to bolts (48). Install bolts (48) and tighten to a torque of
135 ± 20 N·m (100 ± 15 lb ft) .Show/hide tableIllustration 41 g03856633 - Install shield (46) and bolts (47).
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Illustration 42 g03856622 Show/hide tableIllustration 43 g03856593 Show/hide tableIllustration 44 g03856610 - Install covers (45), (42), (41), and bolts (44), (43), and (40).
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Illustration 45 g03856587 - Install cover (38). Connect latches (39) and install bolts (37).
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Illustration 46 g03856589 - Install cover (36) and bolts (35).
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Illustration 47 g03856582 - Install cover (34) and bolts (33).
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Illustration 48 g03856581 - Install shield (32) and bolts (31).
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Illustration 49 g03856579 - Install cover (30) and bolts (29).
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Illustration 50 g03856575 - Install shield (28) and bolts (27).
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Illustration 51 g03856571 Show/hide tableIllustration 52 g03856569 - Install shield (26), bolts (25), and (24).
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Illustration 53 g03856566 Show/hide tableIllustration 54 g03856564 - Install shield (22), bolts (23), and (21).
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Illustration 55 g03856562 - Install shield (20) and bolts (19).
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Illustration 56 g03856559 - Install shield (18) and bolts (17).
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Illustration 57 g03856557 - Install bracket (16) and bolts (15).
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Illustration 58 g03856555 - Install cover (13) and connect spring latches (14).
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Illustration 59 g03856553 - Install shield (12) and bolts (11).
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Illustration 60 g03856546 Show/hide tableIllustration 61 g03856543 - Install covers (10) and (8). Install bolts (9) and (7).
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Illustration 62 g03856537 - Install shield (6) and bolts (5).
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Illustration 63 g03856526 - Install shield (4) and bolts (3).
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Illustration 64 g03856524 - Install shield (2) and bolts (1).
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