3608 Engine Caterpillar

Turbocharger - Assemble

Usage:

3608 1ZD

Assembly Procedure For The VTC 254 Turbocharger

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Illustration 1	g01296512

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	9U-6251	Suspension Yoke⁽¹⁾	1
B	126-8290	Spanner Wrench⁽²⁾	2
C	9U-6248	Guide Bolts⁽¹⁾	3
D	9U-6243	Extension Handle⁽³⁾	1
F	9U-6255	Turbocharger Tool⁽²⁾	1
H	503-1854	Hydraulic Puller⁽²⁾	1
M	1U-5230	Hand Hydraulic Pump⁽³⁾	1
N	8F-0024	Hose Assembly	2
P	9U-6246	Adapter Assembly⁽³⁾	1
Q	133-8951	Thrust Bearing Screw⁽³⁾	1
R	2J-3506	Full Nut	1
S	9U-7262	Plate	1
T	9U-6254	Shaft Assembly	1
U	5P-3931	Anti-Seize Compound	1
V	6V-2055	Grease	1
W	9S-3263	Thread Lock Compound	1
X	2S-3230	Lubricant	1
Y	8T-5096	Dial Indicator Test Group	1
Z	6V-2012	Depth Micrometer	1

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⁽¹⁾	This component is a part of the 9U-5105 Basic Engine Tool Group.
⁽²⁾	This component is a part of the 9U-6249 Cylinder Tool Group.
⁽³⁾	This component is a part of the 9U-6250 Hydraulic Pump.

Note: Use 8T-0447 Dial Calipers to measure the dimensions in the following procedure.

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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

Clean each part with clean solvent. Handle each part carefully in order to prevent damage to the parts. Dry the parts with compressed air.

Note: Refer to Disassembly and Assembly, "General Information (Reference Material)" for more information. Refer to page 7 for torque values.

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Illustration 2	g01294626

Position the cap, nozzle (34), and ring cover (32) on gas inlet housing (30). Apply Tooling (U) onto the bolts and the locking plates that hold the nozzle insert and the cover in position. Use new locking plates for replacement. Do not use the old locking plates.
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Illustration 3 g01294696
Attach a suitable lifting device to gas inlet housing (30). The weight of gas inlet housing (30) is approximately 41 kg (90 lb). Install gas inlet housing (30) in the original location on the bearing housing.
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Illustration 4 g01294702
Apply Tooling (U) onto the bolts. Install segments (28) to hold gas inlet housing (30) in place. Tighten the bolts to a torque of 58 ± 12 N·m (43 ± 9 lb ft).
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Illustration 5 g01294718
Install the insert and diffuser (27) into compressor housing (4). Install diffuser (27) in the original position in compressor housing (4). Tighten the bolts to a torque of 17 ± 3 N·m (13 ± 2 lb ft).
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Illustration 6 g01294767
Install cap (26) on the bearing housing.
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Illustration 7 g01294795
Assemble turbine bearing assembly (23) in the reverse order of the disassembly. Use a new bushing. Put turbine bearing assembly (23) in position in the bearing housing and install the socket head bolts to hold turbine bearing assembly (23).
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Illustration 8 g01294874
Install a new O-ring seal (36) on cover assembly (21). Apply clean engine oil to the O-ring seal. Align the bolt holes in cover assembly (21) with the threaded holes in the bearing housing. Install cover assembly (21).
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Illustration 9 g01294888
Apply Tooling (U) onto the bolts. Install cover (19) in position and install the bolts and locking plates that hold cover (19) in place.
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Illustration 10 g01294898
Bend locking plates (37) over the bolts.
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Illustration 11 g01294959
Apply Tooling (V) in the seal groove. Install a new piston ring seal (18) on shaft assembly (38).
Apply clean engine oil to the turbine end bearing surface of shaft assembly (38).
Carefully install shaft assembly (38) through the turbine bearing assembly.
Do not damage piston ring seal (18) during installation of the end cover. Ensure that piston ring seal (18) is in the center of the groove before piston ring seal (18) is installed into the end cover.
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Illustration 12 g01294974

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Illustration 13 g01294994
Turn thrust bearing (16) into Tooling (P).
Put thrust bearing (16) and Tooling (P) onto shaft assembly (38) (if equipped). Be sure that the dowels and the notches engage together.
Install Tooling (Q) into shaft assembly (38).
Hold Tooling (P) with Tooling (B) and Tooling (D). Turn Tooling (Q) with a wrench in a counterclockwise direction to install thrust bearing (16).
Install a new thrust bearing (16) onto shaft assembly (38). Take measurements at four locations that are spaced 90 degrees from each other. Ensure that Dimension (X) is 143.00 mm to 143.03 mm (5.630 inch to 5.631 inch).
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Illustration 14 g01295012
Apply clean engine oil to the end of the bearing surface that is toward the impeller assembly of shaft assembly (38).

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NOTICE

Replace the bushing in the compressor bearing assembly with a new part. Apply a light coat of clean engine oil to the bushing.
Assemble compressor bearing assembly (13) in the reverse order of the disassembly. Use a new bushing. Align the oil passage in compressor bearing assembly (13) with the oil passage in the bearing housing and install compressor bearing assembly (13). Use one of the socket head bolts as a guide. Apply Tooling (W) on the bolts.
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Illustration 15 g01295502
Install a new O-ring seal (39) on cover (19). Apply clean engine oil to O-ring seal (39).
Align the bolt holes in cover (19) with the bolt holes that are in the compressor bearing assembly. Install cover (19) into the bearing housing.
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Illustration 16 g01295558
Apply Tooling (X) in the seal groove in impeller assembly (6) and on piston ring seal (10).

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NOTICE

The turbine shaft must be clean and dry. Do not use grease, oil or any other lubricant on the turbine shaft.
Carefully put the compressor bearing assembly onto the turbine shaft.
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Illustration 17 g01296085
While impeller assembly (6) is being held with Tooling (B), use an extension to tighten Tooling (F) into impeller assembly (6).
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Illustration 18 g01296104
Use a 1/4 inch drive extension and a ratchet to install Tooling (T). Install Tooling (H), Tooling (S), and Tooling (R).
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Illustration 19 g01296181
Connect Tooling (M) and Tooling (N). Apply pressure with Tooling (M) to install impeller assembly (6) onto the shaft assembly.
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Illustration 20 g01296204
When movement stops, install Tooling (H) and Tooling (Y) to check the end clearance. The correct end clearance must be 0.10 to 0.20 mm (0.004 to 0.008 inch).
Remove Tooling (H) and Tooling (Y).
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Illustration 21 g01296217
Use Tooling (Z) to measure the dimension from the outside edge of the impeller assembly to the step surface that is inside the impeller assembly. The dimension must be measured at four locations and the measurements must be equal.
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Illustration 22 g01296225

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Illustration 23 g01296267
Install screw (9) and the disc spring (washer). Install the washer with the concave face away from the screw head.
Use Tooling (B) and Tooling (D) to hold the impeller assembly and tighten screw (9) to a torque of 48 ± 12 N·m (35 ± 9 lb ft).
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Illustration 24 g01296292
Install Tooling (C) at three equally spaced locations into the gas outlet housing.

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NOTICE

Keep the bearing housing in a vertical position so the turbine blades do not contact the insert (see photo inset).
Remove Tooling (C) and install the bolts.
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Illustration 25 g01296365
Attach Tooling (A) and a suitable lifting device to compressor housing (4). The weight of compressor housing (4) is approximately 95 kg (209 lb). Be sure that Tooling (A) is engaged with the rib.
Install Tooling (C) at three equally spaced locations in compressor housing (4).
Install a new O-ring seal (40) on the bearing housing. Apply clean engine oil to O-ring seal (40).
Carefully install compressor housing (4) onto the bearing housing in the original position.
Remove Tooling (C) and install the bolts and washers.
Tighten the outer bolts to a torque of 58 ± 12 N·m (43 ± 9 lb ft).
Tighten the inner bolts to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
Remove Tooling (A).
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Illustration 26 g01296367
Install elbow (1) and bolts (2).
Install protective covers over all the turbocharger openings to protect the turbocharger before installation.
The turbocharger must be filled with oil prior to operation on the engine. After installation of the turbocharger on the engine, fill the turbocharger with clean engine oil at the oil supply port. Connect the oil supply line after filling.