PIN 2D4209 - Caterpillar

Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 5P-3975 Rubber Lubricant 1
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Illustration 1 g02719461
Illustration 2 g02719579
Ensure that turbocharger (4) is clean and free from damage. Inspect the turbocharger for wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If any part of the turbocharger is worn or damaged, the complete turbocharger must be replaced.
If necessary, test the wastegate actuator for correct operation. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect". If the wastegate actuator is damaged or the wastegate actuator does not operate within the specified limits, the complete turbocharger must be replaced.
Clean the gasket surfaces of exhaust manifold (16). If necessary, install studs (17) to the exhaust manifold. Tighten the studs to a torque of 18 N m (160 lb in).
Position turbocharger (4) on exhaust manifold (16). Note: Ensure that the turbocharger is correctly oriented.
Install nuts (18). Note: Support the turbocharger as the nuts are installed.
Tighten nuts (18) to a torque of 44 N m (32 lb ft).
Illustration 3 g02719476
Ensure that tube assembly (14) and tube assembly (10) are clean, free from damage and restriction. Replace any damaged components.
Position a new gasket (8) (not shown) and bolts (9) onto tube assembly (14).
Install tube assembly (14) to turbocharger (4). Install bolts (9) finger tight.
Position a new gasket (15) (not shown) between the flange of tube assembly (10) and the cylinder block. Install bolts (13) finger tight.
Tighten bolts (9) and bolts (13) to a torque of 22 N m (195 lb in).
Remove the plug from oil inlet port (19). Refer to Illustration 2. Lubricate the turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times in order to lubricate the bearings.
Use Tooling (A) in order to lubricate a new O-ring seal (12) (not shown). Install O-ring seal (12) (not shown) to tube assembly (10).
Install tube assembly (10) to the cylinder block and position onto turbocharger (4).
Install bolt (11) finger tight. Ensure that tube assembly (10) installed correctly into the cylinder block.
Install banjo bolt (7) and two new sealing washers (6) (not shown) to tube assembly (10).
Tighten banjo bolt (7) to a torque of 20 N m (177 lb in).
Tighten bolt (11) to a torque of 22 N m (195 lb in).
If necessary, install the exhaust elbow. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install" for the correct procedure.
Connect the exhaust outlet tube assembly from the turbocharger, refer to the Original Equipment Manufactures (OEM) for the correct procedure.
If necessary, install the hose assembly to the wastegate actuator on the turbocharger.
Connect tube assembly (5) to turbocharger (4). Tighten hose clamp (3) securely.
Connect hose assembly (1) to turbocharger (4). Tighten hose clamp (2) securely.