2010/11/05 Caterpillar

Engine:

3406E (S/N: 2WS1-UP)

C-12 (S/N: 2KS1-UP)

C-15 (S/N: 6NZ1-UP; 9NZ1-UP)

C-16 (S/N: 7CZ1-UP)

Parts List

Procedure

Use the following procedure in order to install a wastegate cover kit into the turbocharger. This helps to ensure that the plug does not become damaged or missing.

Preparation

1. Ensure that the ignition is off, chock the wheels, and follow all shop safety regulations.

2. Allow engine, exhaust, turbocharger, and related components to cool completely before beginning service work.

3. Locate and visually inspect the turbocharger exhaust housing assembly. If the plug is damaged or missing continue with the following procedure.

4. Remove the exhaust pipe and other related hardware from the turbine housing outlet.

   Note: There is no need to disassemble or remove the turbocharger.

5. Verify that there is no other damage to the turbocharger. Make other repairs, if necessary.

Plug Installation

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Illustration 1	g02274033
(1) Turbine housing (A) Location of staking impressions

1. Visually inspect the cup plug bore and flat external surface. Use a die grinder or file to flatten these areas before installation, if staking impressions are large, resulting in excess raised metal. The area needs to be flat for proper settling. Refer to Illustration 1

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Illustration 2	g02274092
(B) Wastegate cavity

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Illustration 3	g02274195
(2) Plug (3) Long bolt (4) Cap

2. Insert the plug (2) into the turbine housing through the wastegate cavity (B). Refer to Illustration 2 and Illustration 3.

3. Insert long bolt (3) with cap (4) into plug (2) .

4. Use the long bolt from the outside and your hand on the inside of the housing in order to position the plug squarely inside the turbine housing bore.

   Note: The plug will be damaged when the plug is pulled into place by the installation bolt, if the plug is not squarely seated.

5. Continue threading long bolt (3) into plug (2). Tightening the plug draws plug into the bore. Tighten plug into the bore until the lip on plug begins to seat on the inside of the cast surface of the turbine housing.

Note: Long bolt to be used only as an installation bolt for seating plug. The long bolt must be replaced in order for the turbocharger to operate correctly.

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Illustration 4	g02324553
(2) Plug

6. Remove long bolt. Visually verify that plug (2) is properly seated.

7. Install cap with short bolt through the cap. Thread the short bolt into plug.

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Illustration 5	g02325514
(3) Short bolt

8. Torque short bolt to a torque of 33.3 ± 2 N·m (294.7 ± 17 lb in).

   Note: Do not use locking compound or anti-sieze compound.

9. Install the exhaust pipe and related hardware to the turbine housing outlet. Install the clamp that secures the exhaust pipe to the turbine housing.