CYLINDER GP-SWING 1918161 - Caterpillar

Remove and Install Turbochargers
For clarity purposes only one of the two turbochargers will be removed and installed. The procedural steps for both sides are identical. For picture purposes, the air intake shutoffs and the air intake tubes have been removed. It is not necessary to remove these items to remove and install the turbochargers.1. Remove air cleaner housings or air pipes leading to turbochargers.2. Drain the coolant from the engine cooling system. 3. Remove six bolts (1) and elbow (2) from water pipe (3). 4. Remove four bolts and flanges (4) and remove air pipe (5). 5. Remove twenty six bolts (6) and remove two portions (7) and (8) of the shroud covering the turbochargers 6. Remove pipe (3). Remove twenty two more bolts (9) and loosen the five remaining shrouds covering the turbochargers. Remove oil line (10) from the turbocharger and from the fitting below the turbocharger. 7. Remove two bolts (11) from the oil return line (12) and remove the oil return line. 8. Disconnect water lines (13) and (14). Remove the five remaining shrouds covering the turbochargers. It may be desirable to remove water lines (13) and (14) to allow more working room, however it is not necessary for removal of the turbochargers. 9. Remove three bolts (15) and three other bolts (17) and remove heat shield (16). Attach a hoist and strap to the turbocharger as illustrated. 10. Remove four bolts, nuts and washers (18) securing flange and exhaust pipe (19) to the exhaust inlet port of the turbocharger. 11. Remove eight bolts (20) securing the turbocharger to the exhaust elbow. Remove the turbocharger. Weight of the turbocharger is 61 kg (134 lb). Installation of the turbocharger is accomplished in the exact reverse order from removal.12. Install new exhaust gaskets between the turbocharger exhaust port and exhaust pipe (19). Pit 5P3931 Anti-seize Compound on the threads of bolts (18). Tighten the bolts to a torque of 135 15 N m (100 11 lb ft).13. Check the condition of all O-ring seals on all water and oil pipes. Replace if necessary. Put clean oil on the on the seals prior to installation.14. Install all portions of the shroud and start the bolts, however do not tighten any of the bolts until all are in position and aligned properly.15. Install new elbow gasket on the end of oil return tube (12).16. Check the engine oil level and replace any oil lost during turbocharger removal.17. Fill the cooling system with coolant to the correct level. See the Maintenance Manual for the correct fluid level. Use caution to avoid spilling coolant on exhaust manifolds and shields.18. Install air cleaner housings or air pipes leading to turbochargers.Disassemble and Assemble Turbocharger
Start By:a. remove turbocharger 1. Mark the three housings of the turbocharger for proper alignment at assembly. 2. Attach tooling (A) and a hoist to the turbocharger. The weight of the turbocharger is approximately 100 kg (220 lb). Remove eight bolts (1), the lock plates and four