COMMON AR 3905044 - Caterpillar

Removal Procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
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.Dispose of all fluids according to local regulations and mandates.
Note: Plug and cap all open ports and tube assemblies.
Disconnect the hose assemblies from the turbocharger inlet and the turbocharger outlet. Refer to the Original Equipment Manufactures (OEM) for the correct procedure.
Disconnect the exhaust tube assembly. Refer to the OEM for the correct procedure.
If the turbocharger has an exhaust elbow, remove the exhaust elbow. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install" for the correct procedure.
Illustration 1 g03374196
Slide clip (2) along hose (3). Disconnect the hose from actuator (1).
Remove bolts (6) from the clip for tube assembly (5). Position the tube assembly away from cylinder block.
Remove bolt (7) and spacer (8) (not shown).
Remove bolt (12) and spacer (13).
Remove bolt (10) from tube assembly (9).
Remove tube assembly (9) from the cylinder block. Remove O-ring seal (11) (not shown).
Remove bolts (15) from tube assembly (14). Remove gasket (16) (not shown).
Remove exhaust manifold (4) and the assembly of the turbocharger from the cylinder head. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install" for the correct procedure.
Illustration 2 g03374197
Place exhaust manifold (4) and the assembly of turbocharger (19) in a suitable support.
Remove banjo bolt (17) and remove sealing washers (18) (not shown).
Remove tube assembly (9) from turbocharger (4).
Remove bolts (23) from tube assembly (14). Support the tube assembly as the bolts are removed.
Remove gasket (21) (not shown).
Prior to and during removal of nuts (20) apply releasing fluid to the bolts. Remove nuts (20).
Remove turbocharger (19) from exhaust manifold (4).
Remove spacer (22).
If necessary, remove studs (24) from exhaust manifold (4).