Installation Instructions for the 4x4 Turbocharger Configuration for Certain 797F Off-Highway Truck Engines {0635, 1052, 1053, 1059, 108U, 1209, 1307, 1380, 1803, 5502} Caterpillar

Off-Highway Truck/Tractor

797F (S/N: LAJ1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

Safety Section

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

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Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.

Parts for the 487-5711 Housing As

Installation Procedure for the 487-5711 Housing As

Illustration 1	g06329860
(1) 357-4820 Hollow Dowel (2) 260-0400 Plug (3) 487-5710 Housing

1. Install 8 hollow dowels (1) onto the lifter assemblies for the cylinders shown in Illustration 1.

2. Install 4 plugs (2) into the side of housings (4).

3. Install the 4 housings using the previous bolts.

Parts for the 487-5738 Support and Mounting Gp

Installation Procedure for the 487-5738 Support and Mounting Gp

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Illustration 2	g06330097
(1) 6V-3535 Dowels

1. Install 4 dowels (1) in the locations shown in Illustration 2.
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   Illustration 3	g06330103
   (2) 488-0090 Support As (3) 487-5709 Supports (4) 488-0089 Support As (5) 8T-0375 Bolts (6) 9X-8268 Washers

2. Install the different mounts to the center of the engine.

   1. Install support assembly (2) to the rear location of the engine shown using 6 bolts (5) with 6 washers (6).

   2. Install supports (3) to the center locations shown using 6 bolts (5) with 6 washers (6) in each location.

   3. Install support assembly (4) to the front location of the engine shown using 6 bolts (5) with 6 washers (6).

Parts for the 501-8620 Exhaust Manifold Gp

Installation Procedure for the 501-8620 Exhaust Manifold Gp

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Illustration 4	g06330154
(1) 8T-7353 High Temperature Bolts (2) 8T-7934 Hard Washers (3) 246-4924 Gaskets (4) 465-0517 Bellows As (5) 490-6436 Band Clamps (6) 469-1488 Exhaust Manifolds (7) 469-1487 Exhaust Manifolds

1. Install gaskets (3) between the cylinder head and corresponding exhaust manifold for each step.

2. Install exhaust manifolds (6) in the locations shown in Illustration 4. Use 4 bolts (1) with 4 hard washers (2) to secure each exhaust manifold to the cylinder head.

3. Install exhaust manifolds (7) in the locations shown in Illustration 4. Use 4 bolts (1) with 4 hard washers (2) to secure each exhaust manifold to the cylinder head.

4. Attach bellows assemblies (4) to the exhaust manifold using band clamps (5).

   Note: Leave the band clamps hand tight until all the exhaust manifolds have been installed.

Parts for the 501-8621 Exhaust Manifold Gp

Installation Procedure for the 501-8621 Exhaust Manifold Gp

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Illustration 5	g06330198
(1) 246-4924 Gaskets (2) 8T-7353 High Temperature Bolts (3) 8T-7934 Hard Washers (4) 490-6436 Band Clamps (5) 469-1362 Exhaust Manifolds (6) 469-1458 Exhaust Manifolds (7) 465-0517 Bellows As

1. Install gaskets (1) between the cylinder head and corresponding exhaust manifold for each step.

2. Install exhaust manifolds (5) to the cylinder heads using 4 bolts (2) with 4 hard washers (3) on each section. Install bellows assemblies (7) between the exhaust manifolds using band clamps (4) before tightening any of the bolts for the exhaust manifolds.

   1. After installing the exhaust manifolds and bellow assemblies, tighten the band clamps up to the last one towards the front of the engine.
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   Illustration 6	g06330246

3. Install gaskets (1) between the cylinder head and corresponding exhaust manifold for each step.

4. Install exhaust manifolds (5) to the cylinder heads using 4 bolts (2) with 4 hard washers (3) on each section. Install bellows assemblies (7) between the exhaust manifolds using band clamps (4) before tightening any of the bolts for the exhaust manifolds.

   1. After installing the exhaust manifolds and bellow assemblies, tighten the band clamps up to the last one towards the front of the engine.

Parts for the 495-8007 Exhaust Manifold Gp

Installation Procedure for the 495-8007 Exhaust Manifold Gp

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Illustration 7	g06330520
(1) 246-4924 Gaskets (2) 314-5638 Bolts (3) 173-2090 Spacers (4) 490-6439 Band Clamps (5) 509-9719 Exhaust Manifolds (6) 509-9720 Exhaust Manifolds (7) Exhaust thermocouples

1. Install gaskets (1) between the exhaust manifolds and cylinder heads.

2. Install exhaust manifolds (5) using 4 bolts (2) with 4 spacers (3).

3. Install exhaust manifolds (6) using 4 bolts (2) with 4 spacers (3).

4. Tighten the band clamps (4) between the exhaust manifolds and previously installed bellow assemblies.

5. Install exhaust thermocouples (7) into the exhaust manifolds.

Parts for the 479-0458 Turbocharger Mounting Gp

Installation Procedure for the 479-0458 Turbocharger Mounting Gp

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Illustration 8	g06330728
(1) 3E-6785 O-Ring Seals

1. Install 8 o-ring seals (1) on the top of the front and rear housing as shown in Illustration 8.
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   Illustration 9	g06330829
   (2) 479-0459 Support As (22) 3P-1896 Cup Plugs

2. Install cups plugs (22) into support assembly (2).
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   Illustration 10	g06330734
   (2) 479-0459 Support As (3) 162-2776 Bolts (4) 9X-8268 Washers (5) 303-9441 Bolts (6) 198-4780 Hard Washers

   1. Install support assembly (2) to the top of the flywheel housing using 12 bolts (3) with 12 washers (4) on the outside of the support assembly. Use 2 bolts (5) with 2 hard washers (6) in the middle of the support assembly.

   2. Attach the bolts for the wiring harness to the front of the support assembly.
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      Illustration 11	g06330737
      (2) 479-0459 Support As (3) 162-2776 Bolts (4) 9X-8268 Washers (5) 303-9441 Bolts (6) 198-4780 Hard Washers

   3. Install support assembly (2) to the top of the front housing using 12 bolts (3) with 12 washers (4) on the outside of the support assembly. Use 2 bolts (5) with 2 hard washers (6) in the middle of the support assembly.

   4. Attach the bolts for the wiring harness to the front of the support assembly.
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   Illustration 12	g06330740
   (7) 490-6439 Band Clamps (8) 507-6390 Bellows As

3. Install bellows assemblies (8) with band clamps (7) on the previously installed exhaust manifolds.

   Note: The turbocharger support assembly should allow for tightening of the band clamps through holes in the front.

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   Illustration 13	g06330742
   (7) 490-6439 Band Clamps (8) 507-6390 Bellows As

   1. Install bellows assemblies (8) with band clamps (7) on the previously installed exhaust manifolds.

      Note: The turbocharger support assembly should allow for tightening of the band clamps through holes in the front.

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   Illustration 14	g06330745
   (9) 487-5708 Support As (10) 363-2031 Spacers (11) 367-7967 Bolts (12) 367-7968 Bolts (13) 345-3655 Supports

4. Install supports (9) in the center of the engine.

   1. Install supports (13) to support assemblies (9) and the cylinder heads. Attach the supports using 2 bolts (11) with 2 spacers (10) on the top of the support and bolt (12) with spacer (10) on the bottom of the support.
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   Illustration 15	g06330764
   (2) 479-0459 Support As (9) 487-5708 Support As (14) 6V-8197 Bolts (15) 5P-8245 Hard Washers (16) 360-5871 Bolts (17) 363-2030 Spacers

5. Install 4 bolts (14) with 4 hard washers (15) for each support to attach the supports to support assemblies (2).

   1. Install 4 bolts (15) with 4 spacers (16) into the center of support assemblies (9).
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   Illustration 16	g06330783
   (2) 479-0459 Support As (14) 6V-8197 Bolts (15) 5P-8245 Hard Washers (18) 480-4105 Support (19) 480-4106 Support (20) 8C-3107 O-Ring Seals (21) 137-0135 Dowels (22) 311-6030 Screen As (23) 6V-3535 Dowels

6. Install supports (18) and (19) to support assembly (2) and support assembly (9) on the rear of the engine. Fasten the supports using 8 bolts (14) with 8 hard washers (15) for each support.

   1. Install 4 o-ring seals (20) in the locations shown in the illustration above. Install 4 dowels (21) and 4 dowels (23) into the support assembly. Install 4 screen assemblies (22) into dowels (21).
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      Illustration 17	g06330787
      (2) 479-0459 Support As (14) 6V-8197 Bolts (15) 5P-8245 Hard Washers (18) 480-4105 Support (19) 480-4106 Support (20) 8C-3107 O-Ring Seals (21) 137-0135 Dowels (22) 311-6030 Screen As (23) 6V-3535 Dowels

   2. Install supports (18) and (19) to support assembly (2) and support assembly (9) on the front of the engine. Fasten the supports using 8 bolts (14) with 8 hard washers (15) for each support.

   3. Install 4 o-ring seals (20) in the locations shown in the illustration above. Install 4 dowels (21) and 4 dowels (23) into the support assembly. Install 4 screen assemblies (22) into dowels (21).

Parts for the 488-0891 Air Compressor Lines Gp

Installation Procedure for the 488-0891 Air Compressor Lines Gp

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Illustration 18	g06330896
(1) 428-9130 Gaskets

1. Install 2 gaskets (1) into the back of the 479-0459 Support As at each end of the engine.
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   Illustration 19	g06330936
   (2) 537-7207 Tube Assemblies (3) 6V-1820 Bolts (4) 6V-5839 Washers

2. Install 2 tube assemblies (2) to each of the 479-0459 Support As. Fasten the flanges for the tube assemblies using 4 bolts (3) with 4 washers (4).

   Note: Leave the bolts hand tight until the procedure is completed.

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   Illustration 20	g06330957
   (5) 495-8948 Bellows As (6) 495-8943 V-Band Clamps (7) 156-5745 Half Clamps (8) 488-0897 Adapters (9) 6V-8197 Bolts (10) 198-4767 Hard Washers

3. Install adapters (8) onto the end of the previously installed tube assemblies.

   1. Attach bellows assemblies (5) to the adapters using v-band clamps (6).

   2. Install 2 half clamps (7) around each tube assembly. Attach the half clamps to the support assemblies using 2 bolts (9) with 2 hard washers (10) for each set.
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   Illustration 21	g06330988
   (11) 491-2895 Bracket As (12) 6V-3303 Bolts (13) 9X-8268 Washers (14) 367-7968 Bolts (15) 363-2031 Spacers (16) 345-3655 Supports

4. Install supports (16) to the cylinder heads using bolts (14) with spacers (15). Install bracket assemblies (11) to the supports using 2 bolts (12) with 2 washers (13) for each support.
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   Illustration 22	g06331273
   (6) 495-8943 V-Band Clamps (7) 156-5745 Half Clamps (8) 488-0897 Adapters (10) 198-4767 Hard Washers (11) 491-2895 Bracket As (17) 488-0894 Tube As (18) 6V-5684 Bolts (19) 8T-3597 Weld Nut

5. Install adapters (8) onto the end of the bellows assemblies.

6. Install v-band clamps (6) onto the adapters, leaving the clamps loose until the installation is completed.

7. Install tube assemblies (17) between the bellows assemblies.

8. Install 2 half clamps (7) around each end of the tube assemblies.

9. Secure the half clamps to bracket assemblies (11) using 2 bolts (18), 2 hard washers (10), and weld nut (19) for each set of half clamps.

10. Tighten all the bolts and clamps that were left loose during the installation procedure.

Parts for the 535-8953 Turbocharger Gp

Installation Procedure for the 535-8953 Turbocharger Gp

Note: Keep all opening of the turbochargers plugged until installation of components is completed to prevent contamination.

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Illustration 23	g06331334
(1) 515-9211 Turbocharger Gp (2) 528-2364 Turbocharger Gp (3) 8T-0162 Bolts (4) 292-3198 Hard Washers (5) 6V-8154 Bolts

1. Install turbocharger groups (1) and turbocharger groups (2) onto the engine in the locations shown in Illustration 23.

   1. Fasten turbocharger group (1) using 4 bolts (3) with 4 hard washers (4) for each turbocharger.

   2. Fasten turbocharger group (4) using 4 bolts (5) with 4 hard washers (4).

Parts for the 542-1295 Turbocharger Water Lines Gp

Installation for the 542-1295 Turbocharger Water Lines Gp

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Illustration 24	g06331465
Rear of engine (1) 8C-4423 Plugs (2) 216-8578 O-Ring Seals (3) 8T-7494 Connectors (4) 250-2343 O-Ring Seals (5) 215-9090 Elbow (6) 6V-9839 Swivel Tee (7) 294-9072 O-Ring Seal (8) 6V-9832 Cap (9) 6V-5138 O-Ring Seal (10) 8T-7495 Connectors

1. Install the connectors, plugs, and swivel tees shown in Illustration 24 in the rear turbochargers.
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   Illustration 25	g06331499
   Front of the engine (1) 8C-4423 Plugs (2) 216-8578 O-Ring Seals (3) 8T-7494 Connectors (4) 250-2343 O-Ring Seals (5) 215-9090 Elbow (6) 6V-9839 Swivel Tee (7) 294-9072 O-Ring Seal (8) 6V-9832 Cap (9) 6V-5138 O-Ring Seal (10) 8T-7495 Connectors

   1. Install the connectors, plugs, and swivel tees shown in Illustration 25 in the front turbochargers.
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      Illustration 26	g06331519
      Front of the engine (1) 8C-4423 Plugs (2) 216-8578 O-Ring Seals (3) 8T-7494 Connectors (4) 250-2343 O-Ring Seals (5) 215-9090 Elbow (6) 6V-9839 Swivel Tee (7) 294-9072 O-Ring Seal (8) 6V-9832 Cap (9) 6V-5138 O-Ring Seal (10) 8T-7495 Connectors

   2. Install the connectors, plugs, and swivel tees shown in Illustration 26 in the front turbochargers.
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   Illustration 27	g06331734
   Front of engine (4) 250-2343 O-Ring Seals (8) 6V-9832 Cap (11) 478-8047 Hose and Tube As (12) 8T-1889 Clip (13) 8T-1890 Clip (14) 6V-4248 Bolt (15) 6V-5839 Washer (16) 353-7954 Grommet (17) 6V-9853 Elbow (18) 467-4724 Hose As (19) 122-9088 Tee (20) 6V-3251 O-Ring Seal

2. Install hose and tube assembly (11) between the bottom fitting of the low-pressure turbocharger and the top fitting of the high-pressure turbocharger.

   1. Secure the hose and tube assembly using grommet (16), clip (12), clip (13), bolt (14), and washer (15). Fasten the clips to the side of the turbocharger mount.

   2. Install elbow (17) with o-ring seal (4) to the bottom fitting of the high-pressure turbocharger.

   3. Install tee (19) with o-ring seal (4), o-ring seal (20), and cap (8) into the side cover of the turbocharger mount.

   4. Install hose assembly (18) between the elbow and tee.
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   Illustration 28	g06331766
   Front of engine (5) 215-9090 Elbow (12) 8T-1889 Clip (13) 8T-1890 Clip (14) 6V-4248 Bolt (15) 6V-5839 Washer (16) 353-7954 Grommet (18) 467-4724 Hose As (19) 122-9088 Tee (21) 478-8044 Hose and Tube As

3. Install hose and tube assembly (21) from the lower fitting of the low-pressure turbocharger to the top fitting of the high-pressure turbocharger.

   1. Secure the hose and tube assembly using grommet (16), clip (12), clip (13), bolt (14), and washer (15). Fasten the clips to the side of the turbocharger mount.

   2. Install hose assembly (18) between the lower fitting of the high-pressure turbocharger and elbow (5).
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   Illustration 29	g06331809
   Rear of engine (12) 8T-1889 Clip (13) 8T-1890 Clip (14) 6V-4248 Bolt (15) 6V-5839 Washer (16) 353-7954 Grommet (21) 478-8044 Hose and Tube As (22) 342-4467 Hose As (23) 478-3880 Bracket As (24) 091-9035 Spacer (25) 6V-5843 Bolt (26) 8T-1897 Clip (27) 8T-1898 Clip (28) 353-7952 Grommet

4. Install hose and tube assembly (21) to the lower fitting of the low-pressure turbocharger and the top fitting of the high-pressure turbocharger.

   1. Secure the hose and tube assembly using grommet (16), clip (12), clip (13), bolt (14), and washer (15). Fasten the clips to the side of the turbocharger mount.

   2. Install hose assembly (22) to the lower fitting of the high-pressure turbocharger.

   3. Install bracket assembly (23) using bolt (14) with washer (15).

   4. Install grommet (28) on hose assembly (22). Install clip (26) and clip (27) around the grommet.

   5. Secure the clips to the bracket assembly using bolt (25), washer (15), and spacer (24) as shown in Illustration 29.
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   Illustration 30	g06331883
   Rear of engine (6) 6V-9839 Swivel Tee (7) 294-9072 O-Ring Seal (11) 478-8047 Hose and Tube As (12) 8T-1889 Clip (13) 8T-1890 Clip (14) 6V-4248 Bolt (15) 6V-5839 Washer (16) 353-7954 Grommet (26) 8T-1897 Clip (27) 8T-1898 Clip (28) 353-7952 Grommet (29) 492-7997 Hose As (30) 320-3269 Bracket (31) 6V-1820 Bolt (32) 2Y-5829 Nut (33) 540-2486 Tube As (34) 6V-3822 Bolt (35) 437-7866 Plate As (36) 353-7953 Grommet

5. Install hose and tube assembly (11) to the lower fitting of the low-pressure turbocharger to the top fitting of the high-pressure turbocharger.

   1. Secure the hose and tube assembly using grommet (16), clip (12), clip (13), bolt (14), and washer (15). Fasten the clips to the side of the turbocharger mount.

6. Install swivel tee (6) with 3 o-ring seals (7) in the location shown in Illustration 30.

7. Install hose assembly (29) from the lower fitting of the high-pressure turbocharger to swivel tee (6).

   1. Install bracket (30) using bolt (14) with washer (15). Install grommet (28) on the hose assembly. Install clip (26) and clip (27) around the grommet.

   2. Secure the clips to bracket (30) using bolt (31), 2 washers (15), and nut (32).

8. Install tube assembly (33) to hose assembly (22).

   1. Install plate assembly (35) using bolt (34) with washer (15).

   2. Install 2 grommets (36) on hose assembly (22) in the locations shown in Illustration 30.

   3. Install clips (12) and clips (13) around the grommets.

   4. Attach the clips to the plate assemblies using bolts (14) with washers (15).

Parts for the 480-3874 Turbocharger Oil Lines Gp

Installation Procedure for the 480-3874 Turbocharger Oil Lines Gp

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Illustration 31	g06331965
Rear of engine (1) 467-4041 Manifold (2) 6V-5839 Washers (3) 6V-7981 Bolts (4) 6V-5266 O-Ring Seal (5) 6V-4249 Bolts (6) 274-1285 Manifold

1. Install manifold (1) with 2 bolts (3) and 2 washers (2).

   1. Install manifold (6) with o-ring seal (4), 2 bolts (5), and 2 washers (2).
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   Illustration 32	g06331971
   Front of engine (1) 467-4041 Manifold (2) 6V-5839 Washers (3) 6V-7981 Bolts (4) 6V-5266 O-Ring Seal (5) 6V-4249 Bolts (6) 274-1285 Manifold

2. Install manifold (1) with 2 bolts (3) and 2 washers (2).

   1. Install manifold (6) with o-ring seal (4), 2 bolts (5), and 2 washers (2).

   Note: The fittings for this step are the same for both ends of the engine.

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   Illustration 33	g06335737
   (7) 8T-7490 Tube Connector (8) 228-7103 O-Ring Seal (9) 228-7090 O-Ring Seal (10) 8T-7494 Connector (11) 228-7106 O-Ring Seal (12) 228-7092 O-Ring Seal (13) 227-0064 Connector (14) 228-7105 O-Ring Seals (15) 228-7091 O-Ring Seal (16) 6V-8632 Connector (17) 6V-8625 Elbow (18) 238-5080 O-Ring Seal (33) 464-1043 Adapter As

3. Install the connectors in the locations shown in Illustration 33.

   1. Install adapter assembly (33) into the front of the manifold.

   2. Install tube connector (7) with o-ring seal (8) and o-ring seal (9) into the top of the high-pressure turbochargers.

   3. Install connector (13) with o-ring seal (14) and o-ring seal (15) into the top of the low-pressure turbochargers.

   4. Install connector (10) with o-ring seal (11) and o-ring seal (12) into manifold (6) on the cylinder block.

   5. Install 2 connectors (15) with 4 o-ring seals (16) into manifold (1) on the front housing.

   6. Install 2 elbows (18) with o-ring seals (9) and o-ring seals (17) into the top of manifold (1).

   Note: The adapter assemblies for this step are the same for both ends of the engine.

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   Illustration 34	g06332173
   (19) 319-6227 Elbow As (20) 332-8562 Elbow As

4. Install elbow assemblies (19) on the high-pressure turbochargers. Install elbow assemblies (20) on the low-pressure turbochargers.

   Note: The components in this step are the same for the other end of the engine.

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   Illustration 35	g06335744
   Front of engine (2) 6V-5839 Washers (21) 467-4213 Tube As (22) 468-5534 Hose As (23) 353-7953 Grommets (24) 6V-4248 Bolts (25) 8T-1889 Clips (26) 8T-1890 Clips

5. Install hose assembly (22) to the fitting in the cylinder head. Fasten tube assembly (22) to the hose assembly.

   1. Secure the hose and tube assembly using grommets (23), bolts (24), washers (2), clips (25), and clips (26).
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   Illustration 36	g06332192
   Front of engine (2) 6V-5839 Washers (25) 8T-1889 Clips (26) 8T-1890 Clips (27) 361-2217 Hose As (28) 480-3831 Tube As (29) 480-3832 Tube As (30) 353-7954 Grommets (31) 6V-3822 Bolts (32) 127-5447 Spacers

6. Install hose assemblies (27) from the adapter assemblies in the top of the high-pressure turbochargers to the manifold.

   1. Install tube assembly (28) on the left-hand side low-pressure turbocharger from the top fitting to the side fitting on the manifold.

   2. Install tube assembly (29) on the right-hand side low-pressure turbocharger from the top fitting to the side fitting on the manifold.

   3. Install grommets (30) around the tube assemblies. Install clips (25) and clips (26) around the grommets.

   4. Secure the clips to the engine using bolts (31) washers (2), and spacers (32).

      Note: The washer goes on top of the clips and the spacers underneath the clips.

Parts for the 493-5806 Platform Gp

Installation Procedure for the 493-5806 Platform Gp

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Illustration 37	g06332242
(1) 473-1543 Brackets (2) 286-0693 Spacers (3) 6V-5843 Bolts

1. Install brackets (1) using 4 four bolts (3) with 4 spacers (2).
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   Illustration 38	g06332246
   (2) 286-0693 Spacers (3) 6V-5843 Bolts (4) 493-3828 Bracket As (5) 1P-2841 Spacers (6) 6V-5684 Bolts

2. Install bracket assembly (4) to brackets (1).

   1. Fasten the top of the bracket assembly using 4 bolts (3), and 4 spacers (2).

   2. Fasten the bottom of the bracket assembly using 4 bolts (6) with 4 spacers (5).
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   Illustration 39	g06332262
   (7) 498-5517 Tread Plate (8) 493-5209 Bracket (9) 284-3615 Hex Socket Screws (10) 5P-8245 Hard Washers

3. Install bracket (8) and then thread plate (7) on top of the bracket. Fasten them to bracket assembly (4) using 7 hex socket screws (9) with 7 hard washers (10).

Parts for the 489-9345 Exhaust Lines Gp

Installation Procedure for the 489-9345 Exhaust Lines Gp

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Illustration 40	g06332278
(1) 528-5563 Bellows As (2) 489-1412 Clamps

1. Install 4 bellow assemblies (1) with clamps (8) on the exhaust outlet for the low-pressure turbochargers.

   Note: Leave the clamps towards the middle of the engine loose until the exhaust piping is installed.

Parts for the 525-2461 Exhaust Manifold Gp

Installation for the 525-2461 Exhaust Manifold Gp

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Illustration 41	g06332297
(1) 524-8390 Exhaust Manifold (2) 524-8391 Exhaust Manifold (3) 465-0509 Brackets (4) 289-4084 Bolts (5) 198-4767 Hard Washers (6) 289-4081 Bolts

1. Install brackets (3) using 3 bolts (6) with 3 hard washers (5).

2. Install exhaust manifold (1) towards the rear of the engine. Install exhaust manifold (2) towards the front of the engine.

3. Attach the exhaust manifolds to the brackets using 3 bolts (6) with 3 hard washers (5). Attach the exhaust manifolds to the mounts using 4 bolts (4) with 4 hard washers (5) for each exhaust manifold.

4. Tighten the clamps between the exhaust manifolds and bellows assemblies after tightening the rest of the bolts.

Parts for the 489-4518 Air Lines Gp

Installation Procedure for the 489-4518 Air Lines Gp

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Illustration 42	g06332322
(1) 467-4241 Band Clamps (2) 450-5112 Band Clamps (3) 482-2804 Exhaust Elbows (4) 482-2803 Exhaust Elbows (5) 482-2917 Bellows As

1. Install 4 exhaust elbows (4) to the exhaust outlet of the high-pressure turbochargers using 4 clamps (2).

2. Install 4 bellows assemblies (5) to exhaust elbows (4) using 4 clamps (1).

3. Install 4 exhaust elbows (3) to the bellows assemblies and low-pressure turbochargers using 8 clamps (1).

Parts for the 491-2900 Air Lines Gp

Installation Procedure for the 491-2900 Air Lines Gp

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Illustration 43	g06332332
Front of the engine (1) 491-2898 Manifold (2) 491-2899 Manifold (3) 428-9130 Gaskets (4) 495-8943 V-Band Clamp (5) 495-8948 Bellows As (6) 6V-1820 Bolts (7) 6V-5839 Washers

1. Install gasket (3) into the mount where the manifolds will be installed.

   1. Install manifold (1) on the left side of the engine using 4 bolts (6) with 4 washers (7).

   2. Install bellows assembly (5) between the manifold and turbocharger turbine outlet. Secure the bellows assembly using 2 v-band clamps (4).

2. Install gasket (3) into the mount where the manifolds will be installed.

   1. Install manifold (2) on the left side of the engine using 4 bolts (6) with 4 washers (7).

   2. Install bellows assembly (5) between the manifold and turbocharger turbine outlet. Secure the bellows assembly using 2 v-band clamps (4).

Parts for the 491-2872 Air Lines Gp

Installation Procedure for the 491-2872 Air Lines Gp

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Illustration 44	g06332340
Front of the engine (1) 491-2874 Elbow (2) 491-2875 Elbow (3) 428-9130 Gaskets (4) 495-8943 V-Band Clamp (5) 495-8948 Bellows As (6) 6V-1820 Bolts (7) 6V-5839 Washers

1. Install gasket (3) into the mount where the elbow will be installed.

   1. Install elbow (1) on the left side of the engine using 4 bolts (6) with 4 washers (7).

   2. Install bellows assembly (5) between the elbow and turbocharger turbine outlet. Secure the bellows assembly using 2 v-band clamps (4).

2. Install gasket (3) into the mount where the elbow will be installed.

   1. Install elbow (2) on the right side of the engine using 4 bolts (6) with 4 washers (7).

   2. Install bellows assembly (5) between the elbow and turbocharger turbine outlet. Secure the bellows assembly using 2 v-band clamps (4).

Parts for the 495-8902 Air Compressor Lines Gp

Installation Procedure for the 495-8902 Air Compressor Lines Gp

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Illustration 45	g06332608
All four turbocharger sections use the same parts listed below. (1) 495-8926 Air Elbow (2) 495-8903 Tube As (3) 337-5340 Hose (4) 467-4241 Band Clamps (5) 495-8904 Adapters (6) 219-0314 Clamps

1. Install adapters (5) onto the compressor housing outlets.

2. Install tube assemblies (2) onto the adapters using band clamps (4).

3. Install hoses (3) onto the tube assemblies using 2 clamps (6).

4. Install air elbows (1) using 2 clamps (6) on one side and one band clamp (4) on the other side.

   Note: Ensure that the elbows are aligned with the shoulder on the low-pressure turbocharger compressor inlet.

Parts for the 532-4637 Breather Gp

Installation Procedure for the 532-4637 Breather Gp

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Illustration 46	g06332647
Left side front of engine (1) 388-3276 Breather As (2) 033-6031 O-Ring Seals (3) 4W-3034 Hose Clamps

1. Install o-ring seals (2) onto the valve cover adapters.

2. Install breather assemblies (1) onto the valve cover adapters using hose clamps (3).

Parts for the 532-4638 Fumes Disposal Gp

Installation for the 532-4638 Fumes Disposal Gp

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Illustration 47	g06332728
All 3 Fumes Disposal Groups use the same parts. (1) 484-1984 Tube (2) 396-2268 Tee Hose (3) 3E-7404 Hose Clamp (4) 478-2978 Bracket As (5) 6V-3822 Bolt (6) 198-4766 Hard Washer (7) 7X-7906 Clip (8) 7X-7907 Clip (9) 367-8480 Grommet (10) 8T-4194 Bolt (11) 198-4778 Hard Washer

1. Install bracket assembly (4) with 2 bolts (5) with 2 hard washers (6).

2. Install tee hose (2) with 3 hose clamps (3). Leave the hose clamps loose until installation is complete.

3. Install grommet (9) onto tube (1). Install the tube into the tee hose.

4. Install clip (7) and clip (8) around the grommet.

5. Secure the clips to the bracket assembly using bolt (10) with hard washer (11).

6. Tighten hose clamps (3).

Dynamometer Testing

1. Install 548-4807 Engine Software after installation of the hardware components is completed.

2. During dyno testing, the engine software should be configured to 3550 Hp to match the factory test data found in Engine Technical Marketing Information (TMI).