TURBOCHARGER GP 3856862 - Caterpillar

Removal Procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
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Loosen the hose clamps and remove hose (1) from the air inlet manifold and the valve mechanism cover.
Do not let the tops of the fuel nozzles turn when the fuel line nuts are loosened or tightened.The nozzles will be damaged if the top of the nozzle turns in the body.If defective fuel injection nozzles are used, the incorrect shape of the fuel (spray pattern) will damage the engine.
Disconnect four fuel injection lines (2) from the fuel injection nozzles. Immediately cap all openings or plug all openings in order to prevent contamination.
Disconnect four fuel injection lines (3) from the fuel injection pump. Immediately cap all openings or plug all openings in order to prevent contamination.
Remove fuel injection lines (4) from the engine.
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Remove four bolts (5) and the eight washers from fuel return line (6) .
Remove fuel return line (6) from the engine.Installation Procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
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Put fuel return line (6) in position on the engine. Tighten the fuel return line to a torque of 20 N m (15 lb ft).
Install eight new washers and four bolts (5). Tighten the four bolts to a torque of 9 N m (80 lb in).
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Put fuel injection lines (4) in position on the engine.
Remove the caps from the fuel injection pump and from the fuel injection nozzles.
Do not let the tops of the fuel nozzles turn when the fuel line nuts are loosened or tightened.The nozzles will be damaged if the top of the nozzle turns in the body.If defective fuel injection nozzles are used, the incorrect shape of the fuel (spray pattern) will damage the engine.
Connect fuel injection lines (4) to the fuel injection pump with nuts (3). Tighten nuts (3) to a torque of 22 N m (16 lb ft).
Connect fuel injection lines (4) to the fuel injection nozzles with nuts (2). Tighten nuts (2) to a torque of 22 N m (16 lb ft).
Prime the fuel system. Refer to the Testing and Adjusting Module, "Fuel System" topic for more information.