C15 On-highway Engines Caterpillar

Removal Procedure

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NOTICE
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.

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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NOTICE
Failure to follow established procedures can lead to damage of the parts. To avoid damage to the parts, always identify and mark the parts so that the parts can be installed in the same location.

1. Put identification marks on the bellows for alignment and orientation during installation of the bellows.
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   Illustration 1	g01076580

2. Loosen clamp assembly (7). Loosen clamp assembly (2).
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   The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.

   Note: Refer to Special Instruction, REHS1728, "Application Guideline for the Bellows" for additional information on handling the bellows.

3. Remove duct (1) and bellows (6) from the turbochargers.

4. Loosen clamp assembly (4). Loosen clamp assembly (9).
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   The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.

   Note: Refer to Special Instruction, REHS1728, "Application Guideline for the Bellows" for additional information on handling the bellows.

5. Remove duct (5) and bellows (10) from the turbochargers.

6. Disconnect hose (8).

7. Disconnect hose assembly (3).

8. Disconnect hose assembly (11) (not shown).
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   Illustration 2	g01076587

9. Loosen clamp assembly (15).

   Note: Do not remove bellows (18) from the precooler.

10. Loosen clamp assembly (13).

    Note: It may be necessary to rotate the turbocharger housing in order to remove the turbocharger from the studs on the exhaust manifold.

11. Remove locknuts (12).

12. Use a suitable lifting device in order to remove turbocharger (14). The weight of the turbocharger is approximately 25 kg (55 lb).

    Note: It may be necessary to rotate the turbocharger housing in order to remove the turbocharger from the studs on the exhaust manifold.

13. Do not remove bellows (18) from the precooler. Remove backup ring (16) and seal (17) from bellows (18).

    Note: Do not reuse seal (17).

14. Remove turbocharger gasket (19) from the exhaust manifold.