0438347 JOHNSON ENGINE COVER ASSY.

Personal injury can result from hot coolant, steam and alkali.At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand.Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns.Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.
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.
Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
Drain the radiator coolant below the turbocharger.
Illustration 1 g00695774
Remove turbocharger shields (1) .
Illustration 2 g00695788
Disconnect coolant tube (2) from the turbocharger and remove the gasket. Disconnect the remaining end of coolant tube (2) and remove coolant tube (2) from the machine.
Disconnect coolant tube (3) from the turbocharger and remove the gasket.
Remove two engine oil lines (5) from turbocharger (4) and remove the gaskets.
Remove two bolts, two washers, and two retainers (6) from turbocharger (4) .
Illustration 3 g00695793
Remove four bolts (7), the nuts, and the washers that hold the crossover tube to the aftercooler. Remove the gasket.
Remove crossover tube (8) from the machine and remove the two O-ring seals.
Illustration 4 g00695799
Remove the six mounting bolts and nuts (9) from the base of the turbocharger.
Illustration 5 g00695802
Disconnect the elbow from turbocharger (4) at this joint and remove two O-ring seals. Remove the turbocharger from the exhaust manifold. Remove the gasket.Installation Procedure
Note: O-ring seals, gaskets, and seals should always be replaced. A used O-ring may not have the same sealing properties as a new O-ring seal. A reconditioning procedure should not be degraded because of a low cost component such as an O-ring seal or a gasket. Use 1U-6396 O-Ring Assembly Compound during the assembly procedure.
Illustration 6 g00695802
Install the new gasket. Position the turbocharger on the exhaust manifold. Install two O-ring seals on the elbow and connect the elbow to turbocharger (4) at this joint.
Illustration 7 g00695799
Apply 5P-3931 Anti-Seize Compound to the threads of six bolts (9) before installation. Tighten bolts (9) to a torque of 47 9 N m (35 7 lb ft).
Illustration 8 g00695793
Install two O-ring seals on crossover tube (8) and install crossover tube (8) in turbocharger (4) .
Install the gasket. Install four bolts (7), the nuts, and the washers that hold crossover tube (8) to the aftercooler.
Illustration 9 g00695788
Install two retainers, two washers, and two bolts (6) on turbocharger (4) .
Install the gaskets on engine oil lines (5). Install two engine oil lines (5) on turbocharger (4) .
Install the gasket and connect coolant tube (3) to turbocharger (4). Install the gasket and connect coolant tube (2) to turbocharger (4). Connect the remaining end of coolant tub