SEAT 1184083 - Caterpillar

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This special instruction provides the instructions for the installation of the turbocharger. Turbochargers are sensitive to contamination. This special instruction provides information on the acceptability of cracks that are in the turbine housing. Failure to follow any of the procedures may result in damage, a malfunction, or possible engine failure.The following items have been made available to help reduce premature Turbocharger failure due to contamination.
An instruction manual for turbocharger failures has also been published to assist in diagnosing turbocharger failures. The document is Special Instruction, SEBF9085, "Failure Modes of Turbochargers".
The correct procedures and tooling specifications must always be used. Failure to follow any of the procedures may result in damage, malfunction, or possible engine failure.
General
Clean the area around the turbocharger to remove potential contaminants.
Examine the turbocharger for potential causes of failure.
Examine the exhaust system and the exhaust manifold to ensure that no foreign material is present.
Examine the air cleaner, the aftercooler, and the ducting to ensure that no foreign material is present.
If there is any sign of oil on the compressor side, inspect the accumulator/oil separator and the aftercooler.
Oil that is left in the Air-To-Air Aftercooler can result in engine overspeed.
Work in an enclosed area or use tarps to minimize the entrance of airborne debris.
The bolts in the turbochargers may be intentionally left loose to facilitate the installation. Extra bolts may be required.Note: Turbochargers are carefully inspected and the components are compared to functional specifications. Upon visual inspection of turbochargers, you may find cracks in the wall that divides the turbine housing. On turbochargers, cracks are allowed along the radius of the wall that divides the turbine housing. Refer to Reuse And Salvage Guidelines, SEBF8018, Visual Inspection of Turbochargers for more information.
Illustration 1 g03476245
(1) Cracks in the divider wall
Illustration 2 g03476249
(1) Cracks in the divider wall
The turbine housing is designed to relieve thermal stress. The thermal stress is created by high exhaust temperature and relieved through cracks in the turbocharger divider wall (1). The cracks in the divider wall (1) will not affect operation of the turbocharger.Turbocharger Removal
Complete the following before you remove the turbocharger from the engine.
When the V-band clamps are correctly positioned, tighten the nuts of the V-band clamp to the specified torque. Gently tap around the clamp the clamps. Tighten the clamps again to the specified torque.
Tighten the bolts alternately to the recommended torque to prevent and cocking of the housings and damage to the housing and wheels.Note: Refer to the Specifications, "Turbocharger" in SIS (Directions in Additional Information section), the Operation and Maintenance Manual, or your dealer for torque values and additional information.Installation and Prelubing of the Turbocharger
Remove the old gasket from the mount of the exhaust manifold. Inspect the flange for cracks, erosion, and flatness. If necessary, replace the exhaust manifold.Note: If installing only a cartridge, inspect the existing turbine and compressor housings for damage on the mating surfaces and the internal contours.
Clean the passages from the engine exhaust manifold and the passages from the air filter to the