COVER-TERMINAL 1989562 - Caterpillar

Installation Procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g03735742
Ensure that turbocharger (19) 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.
Test actuator (20) for correct operation. Refer to Systems Operation, Testing and Adjusting, "Turbocharger - Inspect" for more information. If the actuator is damaged or the actuator does not operate within the specified limits, the complete turbocharger must be replaced.
Illustration 2 g03735741
Clean the gasket surfaces of exhaust manifold (15). If necessary, install studs (16) (not shown) to turbocharger (19). Tighten the studs to a torque of 18 N m (13 lb ft).
Install a new gasket (18) (not shown) to the exhaust manifold.
Position turbocharger (19) onto exhaust manifold (15) and install nuts (17). Tighten the nuts to a torque of 44 N m (32 lb ft).Note: Do not use the actuator rod to lift the turbocharger.
Illustration 3 g03735740
Position a new gasket (9) (not shown) and a new gasket (10) (not shown) onto tube assembly (12).
Install tube assembly (12) onto the turbocharger and the cylinder block.
Install bolts (11) and bolts (13) finger tight.
Tighten bolts (11) to a torque of 9 N m (80 lb in). Tighten bolts (13) to a torque of 22 N m (16 lb ft).
Illustration 4 g03735744
Lubricate the bearings of turbocharger (19) with clean engine oil through oil inlet port (21). Rotate the shaft of the turbocharger to distribute the lubricant.
Position a new sealing washer (2) (not shown) onto banjo bolt (1). Install banjo bolt (1) into tube assembly (6) and install remaining new sealing washer (2) (not shown) to banjo bolt (1).
Position tube assembly (6) onto the turbocharger. Loosely tighten banjo bolt (1).
Position a new sealing washer (8) (not shown) onto banjo bolt (7). Install banjo bolt (7) to tube assembly (6) and install remaining new sealing washer (8) (not shown). Loosely tighten banjo bolt (6).
Tighten banjo bolt (7) to a torque of 40 N m (30 lb ft). Tighten banjo bolt (1) to a torque of 15 N m (133 lb in).Note: Ensure that the tube assembly does not come into contact with any other engine component.
Connect hose assembly (4) to wastegate actuator. Slide hose clamp (5) along hose assembly (4).Note: Ensure that hose clamp is correctly positioned on the hose assembly.
Connect the hose assemblies to turbocharger inlet (3) and for turbocharger outlet (14). Securely tighten the hose clamps.End By:
Install the exhaust elbow to the turbocharger. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install" for the correct procedure.