C3.3 Industrial Engine Caterpillar

Installation Procedure

1. Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the turbocharger is worn, the complete turbocharger must be replaced.
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   Illustration 1	g01380209
   Typical example

2. Test actuator (14) for correct operation. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect". If the actuator is damaged or the actuator does not operate within the specified limits, the complete turbocharger must be replaced.

3. Clean the mating surfaces of the exhaust elbow. If necessary, install the studs to the exhaust manifold. Tighten the studs to a torque of 18 N·m (13 lb ft).

4. Install a new gasket (9) onto the turbocharger.

5. Position turbocharger (16) onto the exhaust elbow and install nuts (12). Tighten the nuts to a torque of 44 N·m (32 lb ft).

   Note: Do not use the actuator rod (14) to lift the turbocharger.

6. If necessary, install tube assembly (19) to the cylinder block. Install a new joint (21) onto tube assembly (19). Position tube assembly onto the cylinder block and install bolts (20) finger tight.

7. Position a new joint (17) onto tube assembly (19). Install tube assembly to turbocharger (16). Install bolts (18) finger tight.

8. The turbocharger has different sized bolts (18) and (20). Tighten M6 bolts to a torque of 9 N·m (80 lb in). Tighten M8 bolts to a torque of 22 N·m (16 lb ft).

9. Lubricate the bearings of turbocharger (16) with clean engine oil through the oil inlet port. Rotate the shaft of the turbocharger in order to distribute the lubricant.

10. If necessary, Install tube assembly (7). Install new washers (11) and banjo bolt (8) to tube assembly (7). Connect the tube assembly to the cylinder block. Tighten the banjo bolt finger tight.

11. Position tube assembly (7) onto turbocharger (16). Install new washers (6) and banjo bolt (5) to tube assembly (7). Tighten the banjo bolt finger tight.

12. Tighten banjo bolts (5) and (8) to a torque of 20 N·m (15 lb ft).

    Note: Ensure that the tube assembly does not come into contact with any other engine components.

13. If the turbocharger was equipped with a adapter (10), install a new gasket (15) (not shown) and position the adapter (10) onto the turbocharger. Install nuts (13). Tighten the nuts to a torque of 44 N·m (33 lb ft).
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    Illustration 2	g01419266

14. If the engine was equipped with an air pipe, install air pipe (2) and a new gasket (3) (not shown) to the cylinder head. Apply Tooling (A) to bolts (1) for the air pipe. Install bolts,and tighten the bolts to a torque of 22 N·m (16 lb ft).

15. Tighten hose clamps (4) securely.

    Note: If the air outlet hose has a reflective heat shield, ensure that the reflective heat shield is installed toward the engine.

16. Connect the air inlet hose to the turbocharger.