Turbocharger - Remove and Install
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| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | - | Loctite Nickel Anti-Seize | - |
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| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
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| NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Disconnect harness assembly (3). Remove hose clamp (2).
- Use a suitable lifting device to remove air cleaner (5). The weight of air cleaner (5) is approximately
37 kg (82 lb) . - Remove bolts (1), bolts (4), and air cleaner (5).
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Illustration 2 g03841197 - Remove bolt (11). Disconnect harness assembly (10).
- Use a suitable lifting device to remove air cleaner (7). The weight of air cleaner (7) is approximately
37 kg (82 lb) . - Remove bolts (6), bolts (9), hose clamp (8), and air cleaner (7).
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Illustration 3 g03841239 - Disconnect hose assembly (12), tube assembly (13), and tube assembly (14).
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Illustration 4 g03841245 Bellow assemblies are to be one time use only. - Remove band clamps (15), band clamps (17), bellows assembly (16), and bellows assembly (18).
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Illustration 5 g03841307 - Remove reducer hose (19).
- Use a suitable lifting device to remove turbocharger (20). The weight of turbocharger (20) is approximately
67 kg (148 lb) . - Remove band clamp (22), bolts (21), and turbocharger (20).
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Illustration 6 g03841340 - Remove elbow (23), elbow (24), plugs (25), and adapter (26).
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Illustration 7 g03841383 Bellow assemblies are to be one time use only. - Remove band clamps (27), band clamps (29), bellows assembly (28), and bellows assembly (30).
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Illustration 8 g03841401 - Disconnect hose assembly (31), tube assembly (32), and tube assembly (33).
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Illustration 9 g03841416 - Remove reducer hose (36).
- Use a suitable lifting device to remove turbocharger (37). The weight of turbocharger (37) is approximately
116 kg (256 lb) . - Remove band clamp (34), bolts (35), and turbocharger (37).
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Illustration 10 g03841424 - Remove adapter (38), elbow (39), plug (40), and adapter (41).
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| Illustration 1 | g03841163 |
- Install turbocharger (37) and turbocharger (20) in the reverse order of removal.
- Apply Tooling (A) to the threads of bolts (35) and bolts (21).
- Apply Tooling (A) to the threads, bearing surfaces, and inside diameter of band clamp (34), band clamps (29), band clamps (27), band clamp (22), band clamps (17), and band clamps (15).
- Tighten band clamp (34) and band clamp (22) to a torque of
20 ± 2 N·m (177 ± 18 lb in) . Tap band clamp (34) and band clamp (22) around circumference and retighten to a torque of20 ± 2 N·m (177 ± 18 lb in) . - Tighten band clamps (29), band clamps (27), band clamps (17), and band clamps (15) to a torque of
7.5 ± 1 N·m (66 ± 9 lb in) .
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