VALVE-INLET 7E9578 - Caterpillar

Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Loctite C5-A Copper Anti-Seize Lubricant - Note: For bolted flange exhaust manifolds do not use tooling (A) on any exhaust clamps.
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Clamp assemblies MUST only be used once. Discard all clamp assemblies after use.
Bellows assemblies MUST only be used once. Discard all bellows assemblies after use.
Illustration 1 g06059308
Attach a suitable lifting device to turbocharger (43). The weight of turbocharger (43) is approximately 135 kg (300 lb).
Position turbocharger (43) on the mounting bracket. Apply Tooling (A) to the threads of bolts (45). Install bolts (45). Do not tighten bolts (45) at this time.
Install tube assembly (44). Connect tube (49), tube assembly (48), and tube assembly (46).Note: Ensure that the bellows assembly is in the proper orientation during installation. The spacing between the ridges of the bellows assembly should be equal.
Apply Tooling (A) to the threads, the bearing surfaces, and the inner surface of clamp assembly (47).
Install new bellows assembly (50), bolts (51), and new clamp assembly (47). Tighten clamp assembly (47) to a torque of 10 1 N m (90 9 lb in). Lightly tap around the diameter of the clamp assembly with a soft hammer. Tighten clamp assembly (47) to a torque of 10 1 N m (90 9 lb in).
Illustration 2 g06059301Note: Ensure that the bellows assembly is in the proper orientation during installation. The direction of flow arrow must point in the correct direction. The spacing between the ridges of the bellows assembly should be equal.
Apply Tooling (A) to the threads, the bearing surfaces, and the inner surface of clamp assemblies (41) and clamp assemblies (40).
Install new bellows assemblies, new clamp assemblies (41), and new clamp assemblies (40) on turbocharger (42). Tighten clamp assemblies (41) and clamp assemblies (40) to a torque of 7.5 1.0 N m (65 9 lb in). Lightly tap around the diameter of the clamp assemblies with a soft hammer. Tighten clamp assemblies (41) and clamp assemblies (40) to a torque of 7.5 1.0 N m (65 9 lb in).
Tighten bolt (45).
Illustration 3 g06074770
Install shield assemblies (38) and bolts (39).
Illustration 4 g06074764
Install brackets (36) and bolts (37).
Illustration 5 g06074733
Install bracket (34) and bolts (33).
Install temperature sensor (35).
Illustration 6 g06074704
Install bracket (31) and bolts (30).
Install temperature sensor (32).
Illustration 7 g06074573
Install shield assembly (29) and bolts (28).
Illustration 8 g06074557
Install bolts (27).
Illustration 9 g06074285
Install shield assembly (26) and bolts (25).
Illustration 10 g06074281
Install shield assembly (23) and bolts (24).
Illustration 11 g06074279
Install shield assembly (21) and shield assembly (22).
Install bolts (19) and bolts (20).
Illustration 12 g06074274
Install bracket (17), bracket (18), and bolts (16).
Illustration 13 g06074229
Connect lines (15).
Illustration 14 g06074144
Install cover (13) and bolts (14).
Illustration 15 g06045908
Install shield assembly (12).
Illustration 16 g06045883
Install shield assembly (9).
Connect spring assemblies (10).
Illustration 17 g06045879
Install shield assembly (7).
Connect spring assemblies (8).
Illustration 18 g06045853
Install shield assembly (6).
Connect spring assemblies (5).
Illustration 19 g06045816
Install air cleaner assembly (2).
Install bolts (4).
Connect hose (1) and loosen clamp (3).
Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".