C4.4 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	g01264131
   Typical example

2. Test actuator (6) 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 gasket surfaces of the exhaust manifold. 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 (7) to the exhaust manifold.

5. Position turbocharger (5) onto the exhaust manifold and install nuts (8). Tighten the nuts to a torque of 44 N·m (32 lb ft).

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

6. Position a new gasket (11) and tube assembly (13) onto turbocharger (5). Install bolts (12) finger tight.

7. Position a new gasket (15) onto the cylinder block. Install bolts (14) finger tight.

8. Tighten bolts (12) to a torque of 9 N·m (80 lb in). Tighten bolts (14) to a torque of 22 N·m (16 lb ft).

9. Lubricate the bearings of turbocharger (5) with clean engine oil through the oil inlet port. Rotate the shaft of the turbocharger in order to distribute the lubricant.

10. Position tube assembly (3) onto turbocharger (5). Install new washers (2) and banjo bolt (1) to tube assembly (3). Tighten the banjo bolt finger tight.

11. Install new washers (2) and banjo bolt (4) onto tube assembly (3). Connect the tube assembly to the cylinder block. Tighten the banjo bolt finger tight.

12. Tighten banjo bolts (1) and (4) to a torque of 18 N·m (13 lb ft).

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

13. Connect the hose to actuator (6). If necessary, secure tube assembly (3) to the tube assembly for actuator (6). Tube assembly (3) is secured to the tube assembly for the actuator by clips.

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

15. If the turbocharger has an adapter (9), position the adapter onto the turbocharger. Tighten three nuts (10) progressively. Tighten the nuts to a torque of 25 N·m (18 lb ft).

    Note: Ensure that the adapter is square with the face of the turbocharger.

16. Connect the air outlet hose to turbocharger (5).

    If the engine has an air pipe, install the air pipe and install the gasket to the cylinder head. Apply Tooling (A) to the bolts for the air pipe. Tighten the bolts 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.

17. Connect the air inlet hose to turbocharger (5).