C4.4 Marine Generator Set Caterpillar

Removal Procedure

Start By:

1. Drain the cooling system into a suitable container for storage or disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct draining procedure.

1. The engine can start automatically. Ensure that the power supply is isolated before any service or repairs is performed.
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   Illustration 1	g03719550

2. Remove exhaust elbow (3) from turbocharger (2). Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install" for the correct procedure.

3. Loosen hose clamps (1) and remove hose assembly (7) from turbocharger (2) and air cleaner (4).

4. Remove the nut and bolt (6) from clamp (7).

5. Loosen hose clamps (4). Loosen the allen head bolt on V-band clamp (8) for tube assembly (10). Remove the tube assembly from turbocharger (2) and the hose assembly.
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   Illustration 2	g03719551

6. Disconnect tube assembly (14) from turbocharger (2). Remove O-ring seal (15) not shown).

7. Remove bolts (12) from tube assembly (11). Position the tube assembly away from the turbocharger. Remove gasket (13) (not shown).

8. Remove bolts (17) from tube assembly (18). Position the tube assembly away from the turbocharger. Remove gasket (16) (not shown).

9. Remove bolts (20) and nuts (21) (not shown) from turbocharger (2).

10. Remove turbocharger (2) from exhaust manifold (22). Remove gasket (19) (not shown).
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    Illustration 3	g03719564

11. Follow Steps 4.a through 19 in order to remove tube assembly (11) and tube assembly (17).

    1. Remove bolts (26) from tube assembly (17). Remove the tube assembly from the cylinder block. Remove gasket (25) (not shown).

       Note: Plug the port for the oil feed to the turbocharger with a suitable plug.

    2. Remove engine oil pressure sensor (23). Refer to Disassemble and Assemble, "Engine Oil Pressure Sensor ((Low Oil Pressure Shutdown Switch) - Remove and Install" for the correct procedure.

    3. Remove bolt (27) from the clip.

    4. Remove banjo bolt (7) and remove tube assembly (11). Remove sealing washers (24) (not shown).

       Note: Plug the port for the oil feed to the turbocharger with a suitable plug.

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    Illustration 4	g03719607

12. Follow Steps 27 through 28 in order to remove elbow connection (29), adapter (32), studs (34), stubs (35) from turbocharger (2).

    1. Make temporary mark on elbow connection (29) for installation purposes. loosen locking nut (30) and remove the elbow connection from adapter (32). Remove O-ring seal (31) (not shown).

    2. Place turbocharger (2) in a suitable support. Remove adapter (32) from the turbocharger. Remove sealing washer (33) (not shown).

    3. Remove studs (34) and studs (35) from turbocharger (2).

Installation Procedure

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

2. Ensure that the tube assemblies are clean, free from damage, and restriction. Replace any component that is worn, damaged, or not free from restriction.
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   Illustration 5	g03719607

3. Follow Steps 3.a through 3.f in order to install elbow connection (29), adapter (32), studs (34), stubs (35) to turbocharger (2).

   1. Apply Tooling (A) to the threads of studs (34).

   2. Apply Tooling (B) to the threads of stubs (35).

   3. Install stubs (35) to turbocharger (2). Ensure that the studs are installed in the correct position. Tighten the studs to a torque of 18 N·m (159 lb in).

   4. Install stubs (34) to turbocharger (2). Tighten the studs to a torque of 11 N·m (97 lb in).

   5. Install a new sealing washer (33) (not shown) to adapter (32). Install the adapter to turbocharger (2). Tighten the adapter to a torque of 260 N·m (191.76560 lb ft).

   6. Install a new O-ring seal (31) (not shown) to elbow connection (29). Install the elbow connection to adapter (32) and align with the temporary mark. Tighten locking nut (30) to a torque of 50 N·m (37 lb ft).
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   Illustration 6	g03719564

4. Follow Steps 4.a through 4.c in order to install tube assembly (11) and tube assembly (17).

   1. Remove plugs from port of the cylinder block and the tube assembly. Position tube assembly (11) onto the cylinder block. Install bolt (27) to the clip hand tight.

   2. Install a new sealing washer (24) (not shown) onto banjo bolt (7). Install the banjo bolt to tube assembly (11) and install remaining new sealing washer (24) (not shown) to the banjo bolt. Hand tighten the banjo bolt.

   3. Remove plugs from port of the cylinder block and the tube assembly. Position a new gasket (25) (not shown) onto tube assembly (17). Position the tube assembly and install bolts (26) hand tight.
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   Illustration 7	g03720342

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   Illustration 8	g03719551

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   Illustration 9	g03720364

5. If a new turbocharger (2) is to be installed, bearing housing (39) and compressor housing (40) must be oriented to the correct positions. Follow Step 5.a through Step 5.b in order to orient the bearing housing and the compressor housing.

   1. Loosen bolts (37) and bolts (38).

   2. Ensure that bearing housing (39) and compressor housing (40) rotates freely. Position the bearing housing in the upward position.

6. Clean the gasket surfaces of exhaust manifold (22). Position a new gasket (19) (not shown) onto the exhaust manifold. Ensure that the gasket is correctly orientated.

7. Position turbocharger (2) onto exhaust manifold (22).

8. Apply Tooling (B) to the threads of bolts (20) and nuts (21) (not shown). Install the nuts and the bolts to turbocharger (2) hand tight.

9. Install a new gasket (16) (not shown) between tube assembly (18) and turbocharger (2). Install bolts (17) hand tight.

10. Lubricate the bearings of turbocharger (2) with clean engine oil through oil inlet port (36). Rotate the shaft of the turbocharger in order to distribute the lubricant.

11. Install a new gasket (13) (not shown) between tube assembly (11) and turbocharger (2). Install bolts (12) hand tight.

12. Install a new O-ring seal (15) (not shown), ensure that the O-ring seal is correctly seated into the elbow connection. Connect tube assembly (14) to turbocharger (2).

13. Tighten bolts (20) and nuts (21) (not shown) to a torque of 44 N·m (32 lb ft).

14. Tighten bolts (17) and bolts (26) to a torque of 22 N·m (195 lb in).

15. Tighten bolts (12) to a torque of 22 N·m (195 lb in).

16. Tighten banjo bolt (28) to a torque of 45 N·m (33 lb ft).

17. Tighten bolt (27) for the clip to a torque of 44 N·m (32 lb ft). Ensure that the clip is not strained as the bolt is tightened.

18. Tighten tube assembly (14) to a torque of 27 N·m (239 lb in).

19. Install engine oil pressure sensor (23). Refer to Disassemble and Assemble, "Engine Oil Pressure Sensor ((Low Oil Pressure Shutdown Switch) - Remove and Install" for the correct procedure.

20. Tighten bolts (38) to a torque of 18 N·m (159 lb in).
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    Illustration 10	g03719550

21. Install tube assembly (10) to turbocharger (2) and the hose assembly. Install V-band clamp (8) to the tube assembly and the turbocharger, ensure that the V-band clamp is correctly seated. Hand tight the allen head bolt on the V-band clamp.

22. Install the nut and bolt (6) to clamp (7). Hand tighten the nut and bolt.

23. Tighten bolts (37) to a torque of 18 N·m (159 lb in). Refer to Illustration 7.

24. Tighten allen head bolt for V-band clamp (8) to a torque of 12 N·m (106 lb in).

25. Tighten the nut and bolt (6) for clamp (7) to a torque of 44 N·m (32 lb ft). Ensure that the clamp (7) is not strained as the nut and bolt is tightened.

26. Tighten hose clamps (5) to a torque of 7 N·m (62 lb in).

27. Install hose assembly (7) to turbocharger (2) and air cleaner (4). Tighten hose clamps (1) to a torque of 7 N·m (62 lb in).

28. Install exhaust elbow (3) to turbocharger (2). Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install" for the correct procedure.

End By:

1. Refill the cooling system. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change" for the correct filling procedure.