F695783 Force SEAL

2. Remove the four bolts and clips (1), and remove exhaust elbow (2). 3. Remove water lines (3) and (4). 4. Remove the bolts that hold tubes (5) and (6) to the turbocharger. Disconnect tube (5) from the cylinder block, and remove the tube and gasket. 5. Remove the bolts that hold elbow (7) to the aftercooler housing, and remove the elbow and pipe (8) from the turbocharger as an assembly. 6. Loosen clamp (9).7. Fasten a hoist to the turbocharger. Remove four nuts (11), and remove turbocharger (10) and the gasket from the exhaust manifold. The weight of the turbocharger is 39 kg (86 lb). 8. Remove tube (6) from the engine, and remove the gasket and O-ring seal from the tube.Install Turbocharger
1. Put gasket (1) in position on the exhaust manifold.2. Put 5P-3931 Anti-Seize Compound on studs (3).3. Install the gasket and O-ring seal on tube (2). Put clean oil on the O-ring seal, and install tube (2) in the flywheel housing. 4. Put turbocharger (4) in position on the engine, and install the nuts that hold it. Tighten the nuts to a torque of 54 5 N m (40 4 lb ft). 5. Put the O-ring seal in position on pipe (6). Put clean oil on the O-ring seals, and install the pipe and elbow (5) in the turbocharger as an assembly.6. Put the gasket and elbow (5) in place on the aftercooler housing, and install the bolts. 7. Tighten clamps (8).8. Install the bolts that hold tube (2) to the turbocharger.9. Put the gasket and tube (7) in position on the turbocharger, and connect the tube to the cylinder block. Install the bolts that hold tube (7) to the turbocharger. 10. Install water lines (9) and (10). 11. Put exhaust elbow (11) in position on the turbocharger.12. Put 5P-3931 Anti-Seize Compound on the threads of bolts (13). Install clips (12) and bolts (13) to hold the exhaust elbow in place.13. Fill the cooling system with coolant to the correct level. See the Operation & Maintenance Manual.Disassemble Turbocharger
Start By:a. remove turbocharger FLUID SPILLAGE CONTAINMENT Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates. 1. Install the turbocharger on Tooling (A). Put marks on the three housings of the turbocharger for correct installation and alignment at assembly.2. Loosen "V" clamp (2), and remove compressor housing (1). 3. Loosen "V" clamp (3), and remove cartridge housing (4) from turbine housing (5). 4. Put the cartridge assembly in Tool (B) as shown.
When the nut is loosened, do not put a side force on the shaft.
5. Use Tool (C) and a universal socket, and remove the nut that holds compressor wheel (6).
Compressor wheel (6) has sharp edges and can cause personal injury if not handled carefully.
6. Put the cartridge assembly in Tool (D), and use a press (if necessary) to remove compressor wheel (6) from turbine wheel and shaft assembly (7). Do not let the turbine wheel and shaft assembly fall during removal of the compressor wheel.
The turbine wheel has sharp edges and can cause personal injury if not handled carefully.
7. Remove seal ring (8) and shroud (10) from turbine shaft (9). 8. Use Tool (E), and remove ring (11) that holds insert (12) on the cartridge housing. 9. Remove insert (12) with Tooling (F). 10. Remove O-ring seal (14) and sleeve (13) from insert (12). Remove the seal ring from sleeve (13). 11. Remove deflector (16) and ring (15) from the cartridge housing. 12. Remove bearing (18), sleeve (17) and the ring from the cartridge housing. 13. Use Tool (G), and remove ring (20). Remove bearing (19), and put a long dye mark on the top of the bearing. 14. Turn the cartridge assembly over. Use Tool (G), and remove ring (21). Remove bearing (22) from the cartridge housing, and put a short dye mark on the top of the bearing. The dye marks are used for identification of the bearings when they are installed.15. If necessary, remove the two rings that hold the bearings in position from the cartridge housing with Tool (F).16. Check all the parts of the turbocharger for damage. If the parts have damage, use new parts for replacement. See Special Instruction, SMHS6854, for Turbocharger Reconditioning. Also see Guideline For Reusable Parts, SEBF8018, and Analyzing Turbocharger Failure, FEG45138. Assemble Turbocharger
1. Make sure all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material.2. Put clean engine oil on all parts of the cartridge assembly.3. Make a replacement of the two inside rings that hold the bearings in position in the cartridge housing if necessary. Install the rings that hold the bearings in position with the round edges of the rings toward the bearings. 4. Install bearing (2) in the cartridge housing.5. Use Tool (A) to install ring (1) in the cartridge housing. 6. Turn the cartridge assembly over, and install bearing (4). Use Tool (A), and install ring (3) to hold the bearing in position. 7. Install ring (7), sleeve (6) and bearing (5) in the cartridge housing. Make sure the oil hole in bearing (5) is open and clean to prevent a bearing failure.