GUIDE 1100871 - Caterpillar

Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A − Henkel Corporation Anti-Seize Compound (C5-A) −
Illustration 1 g01841534
Typical Example
Failure to follow established procedures can lead to damage of the parts.To avoid damage to the parts, always identify and mark the parts so that the parts can be installed in the same location.
The ends of the bellows are very sharp. Injury could occur if the bellows are not handled properly. Handle the bellows by the convolutions.
Note: Refer to Special Instruction, REHS1728, "Application Guideline for the Bellows" for additional information on handling the bellows if the machine is equipped.Note: Ensure that all main surfaces are clean and free of debris.
Loosen clamp assembly (1) and disconnect the hose that attaches to the intake side of the turbocharger (not shown).
Remove clamp assemblies (2) and (6). Disconnect hose assembly (5) from the wastegate actuator.
Disconnect both tube assemblies (3) and (4).
Illustration 2 g01841575
Remove nuts (8) and discard the nuts. Use two people in order to remove turbocharger (7). The weight of turbocharger (7) is approximately 31 kg (70 lb).
Remove the gasket from the exhaust manifold.
Illustration 3 g02216274Note: Clamp assemblies (9) are single use only parts. Discard the clamp assemblies whenever loosened.
Loosen clamp assemblies (9) in order to separate the housings from the cartridge assembly. Discard clamp assemblies (9). Installation Procedure
Note: Check all of the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.
The alignment of the bellows is important. Improper alignment may lead to premature failure of the bellows. Misalignment can be identified by visually inspecting the convolutions for uniformity of compression.Inspect the bellows for damage prior to installation. If there is any damage to the convolutions, discard the bellows. Minor damage to the ends of the bellows may be repaired. However, if there is any difficulty in installation after the repair, discard the bellows.
Install turbocharger (7) in the reverse order.
Tighten new clamp assemblies (9) to a torque of 13.6 1.2 N m (120 11 lb in).
Apply Tooling (A) to the threads of the studs and to the threads of nuts (8). Tighten nuts (8) to a torque of 70 5 N m (52 4 lb ft).
Tighten clamp assemblies (2) to a torque of 8.5 2 N m (75. 17 lb in).
Tighten clamp assembly (6) to a torque of 12 4 N m (106 35 lb in).
Tighten clamp assembly (1) to a torque of 13.5 1 N m (119 9 lb in).