C4.4 Industrial Engine Caterpillar

Installation Procedure

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Illustration 1	g01784893
Typical example

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

2. Test wastegate actuator (20) for correct operation. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect". If the wastegate actuator is damaged or the wastegate actuator does not operate within the specified limits, the complete turbocharger must be replaced.
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   Illustration 2	g01782773

3. Clean the gasket surfaces of the exhaust manifold (1). If necessary, install studs (18) to the exhaust manifold. Tighten the studs to a torque of 18 N·m (13 lb ft).

   Note: Support the exhaust manifold during installation of the turbocharger.

4. Install a new gasket (16) to exhaust manifold (1).

5. Position turbocharger (13) on exhaust manifold (1).

6. Install nuts (14). Tighten the nuts to a torque of 44 N·m (32 lb ft).

7. Ensure that tube assembly (6) is clean and free from damage. Replace any damaged components.

8. Position a new gasket (15) and bolts (17) onto tube assembly (6).

9. Install tube assembly (6) to turbocharger (13). Tighten bolts (17) finger tight.

10. Install exhaust manifold (1) and the assembly of the turbocharger to the cylinder head. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install" for the correct procedure.

11. Remove the plug from oil inlet port (19). Refer to Illustration 1. Lubricate the turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times in order to lubricate the bearings.

12. Ensure that tube assembly (2) is clean and free from damage. Replace any damaged components.

13. Install banjo bolt (11) and new sealing washers (12) to tube assembly (2).
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    Illustration 3	g01780893

14. Install banjo bolt (7) and new sealing washers (9) to tube assembly (2).

15. Install tube assembly (2) to turbocharger (13). Tighten banjo bolt (11) finger tight. Refer to Illustration 2.

16. Tighten banjo bolt (7) to the cylinder block finger tight.

17. Position a new gasket (8) between the flange of tube assembly (6) and the cylinder block. Install bolts (10) finger tight.

18. Tighten banjo bolt (7) to a torque of 20 N·m (14 lb ft). Tighten bolts (10) to a torque of 22 N·m (16 lb ft).

19. Tighten banjo bolt (11) to a torque of 20 N·m (14 lb ft). Tighten bolts (17) to a torque of 9 N·m (80 lb in). Refer to Illustration 2.

20. Install bolt (3) for the tube clip to the cylinder block. Tighten bolt (3) to a torque of 44 N·m (32 lb ft).

21. Install bolt (5) and spacer (4) for the tube clip to the cylinder block. Tighten bolt (5) to a torque of 44 N·m (32 lb ft).

22. If the turbocharger has an exhaust elbow, install the exhaust elbow. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install".

23. Connect the exhaust pipe.

24. If the turbocharger has a remote wastegate solenoid, connect the hose to the actuator on the turbocharger. Connect the hose assembly for the wastegate solenoid to the tube assembly for the oil feed on the turbocharger. The hose assembly is secured with clips.

25. Connect the air outlet hose to turbocharger (13).

    If the engine has an air pipe, install the air pipe and install the gasket to the cylinder head. Apply Tooling (A) to the fasteners for the air pipe. Tighten the fasteners to a torque of 22 N·m (16 lb ft).

    Tighten the hose clamps to a torque of 5 N·m (44 lb in).

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

26. Connect the air inlet hose to turbocharger (13).