Turbocharger Drain Tube Gasket May Leak Caterpillar

Problem:

There have been reports that the turbocharger oil drain gasket leaks. The support for the turbocharger heat shield guard is mounted to the drain tube. A possible cause of failure may be vibration in the drain tube.

Solution:

Support of the turbocharger heat shield mounted on the drain tube has been changed. A new support for the turbocharger heat shield guard can be installed to a bolt of the turbocharger mounting bracket.

A permanent solution to the problem is forthcoming. In the interim, the solution requires the installation of Part Number 171-3359, Support Assembly, or that the new support assembly be fabricated.

The following procedure lists the new parts required for fabrication, relocation, and installation of the new support for the turbocharger heat shield guard.

1. Procure the following parts:

Effective Serial Numbers:

The current heat shield support at the turbocharger drain tube will be eliminated from the production machines in the future. A similar (but not equal with this modification) design change will be on the future production units.

Illustration 1.

Typical View of Turbocharger Heat Shield Guard on the Engine.

Illustration 2.

Close Up View of the Turbocharger Heat Shield Guard for Modificaiton Purposes.

(1) Turbocharger Heat Shield Guard.

(2) Turbocharger Oil Drain Tube.

(3) Heat Shield Guard Support.

(4) Heat Shield Guard Support Retaining Bolt and Washers.

(5) Turbocharger Heat Shield Guard Retaining Bolts and Washers.

(6) New Hole Location for the New Support.

(7) Cutting Line for Modification.

Remove bolts and washers (5). Remove the turbocharger heat shield guard from the engine. Retain one set of bolt and washers (5) for the installation of the modified turbocharger heat shield guard.

Remove bolt and washers (4). Remove the heat shield guard support (3) from the engine. Scrap the heat shield guard support (3).

Illustration 3.

Modified Turbocharger Heat Shield Guard Base.

(A) 26.0 mm (1.02 in) for New Hole Location.

(B) 40.0 mm (1.57 in) for New Hole Location.

(1) Turbocharger Heat Shield Guard Before Modification.

(6) Location of 15 mm (.59 in) Diameter Hole for New Support.

(7) Cut Location for the Removal of the Piece of Turbocharger Heat Shield Guard Base (8).

Modify the turbocharger heat shield guard (1). Refer to Illustration 3. Remove the piece of the turbocharger heat shield guard base (8) by cutting at the dash lines (7).

Use Dimensions (A) and (B) in Illustration 3 to determine the center of the new support hole in the turbocharger heat shield guard. Drill a 15.0 mm (.59 in) diameter hole in guard (1) at location (6).

Illustration 4.

Location of the New Support.

Remove bolt (9) and nut to install new support.

Illustration 5.

A New Suppot Fabricated from Mild Steel.

(D) 28.0 ± 1.0 mm (1.10 ± .039 in),

(E) 16.0 mm (.63 in),

(F) 4.0 ± 1.0 mm (.16 ± .039 in),

(G) 20.0 ±1.0 mm (.79 ± .039 in),

(H) 22.0 ± 1.0 mm ±.87 ± .039 in),

(K) 20.0 ± 1.0 mm ±.787 ± .0393 in),

(M) 5.0 ± 1.0 mm (.20 ± .039 in) Radius,

(N) 18.5 ± 1.0 mm (.73 ± .039 in),

(P) 20.1 ± 1.0 mm X 45° (.79 ± .039 in X 45°),

(R) 14.4 mm (.57 in),

(S) 6.0 mm (.24 in),

(T) 27.2 ± 1.0 mm (1.07 ± .039 in),

(U) 15.0 ± 1.0 mm X 45° (.59 ± .039 in X 45°),

(V) 50.2 mm (1.98 in),

(W) 5.0 ± 1.0 mm X 45° (.20 ± .039 in X 45°),

(X) 59.3 ± 1.0 mm (2.33 ± .039 in),

(Y) 20.0 ± 1.0 mm (.79 ± .039 in) Radius,

(Z) 13.8 mm (.54 in) Dia. One hole

Illustration 6.

View B-B. Location of Hole in New Fabricated Support.

(AA) 12.0 mm (.47 in).

(BB) 10.0 mm (.39 in).

(CC) 10.5 mm (.41 in) Dia.

Refer to the dimensions in Illustration 5 and Illustration 6 to fabricate the new support. All corners are R6 maximum unless otherwise specified.

Illustration 7.

Fabrication of the New Support. Weld Nut to the Support.

Spot weld nut, part no. 8T3490, to the support. Refer to Illustration 7 for the location of the nut at the 13.8 mm (.54 in) diameter hole.

Illustration 8.

Installation of the New Support.

Illustration 9.

View C-C. Installation of the New Support on the Engine.

Illustration 10.

Installation of the New Support. Detail B. Close-up View of the Location of the New Components. (1) Modified Turbocharger Heat Shield Guard.

(1) Modified Turbocharger Heat Shield Guard.

(11) New Bolt, Part No. 5P7128.

(12) Reuse Bolt 8T4194.

(13) Reuse Washers 8M7145.

(14) New Nut, Part No. 2N2766.

(15) New Fabricated Support.

Refer to Illustration 4, Illustration 8, Illustration 9, and Illustration 10 for the installation of the modified turbocharger heat shield guard, the new fabricated support, and the components. Tighten nut (14) to a torque of 61± 7 N·m (44 ± 5 lb ft).

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