0387027 JOHNSON FUEL PUMP ASSY.

Table 1
Required Tools
Tool Part Number Part Description Qty
A 6V-2156 Link Bracket 2
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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products.Dispose of all fluids according to local regulations and mandates.
Illustration 1 g00603842
Replace the exhaust bypass (3).
Replace the six bolts (4). Tighten the bolts to a torque of 55 10 N m (35 7 lb ft).
Replace the four bolts (2).
Replace the bolts (1) in order to connect the linkage to the exhaust bypass.
Fasten a hoist and the Tool (A) to the turbocharger support. Remove the bolts that hold the support to the rear housing and remove the support. The weight of the support is 104 kg (230 lb).
Fasten a hoist and Tool (A) to the turbocharger.
Illustration 2 g00603826
Illustration 3 g00603835
Replace the turbocharger (6) on the support. The weight of the turbocharger is 372 kg (815 lb). Replace the four bolts (10).
Illustration 4 g00603838
Replace the water tube (18). Before you replace the tube, check the gasket for wear or damage. Replace the gasket, if necessary. Lubricate the seal on the water tube with glycerine before you install the component.
Replace two bolts (17).
Replace the oil tube (16) in the turbocharger. Before you replace the tube, check the seal for wear or damage. Replace the component, if necessary. Lubricate the seal with glycerin before you install the component. Note: Install the strainer assembly. The screen must be extended downward into the turbocharger housing at the oil inlet to the turbocharger.
Replace the oil tube (14) for the turbocharger. Check both gaskets for wear or damage. Replace the component, if necessary. Lubricate the seal with glycerin before you replace the component. Replace four bolts (12).
Replace the water tube assembly (13) and the gasket. Before you replace this assembly, check for wear or damage. Replace the component, if necessary. Lubricate the seal with glycerine before you install the component.
Replace the clamp bolt (15).
Replace four bolts (11).
Replace the elbow (9). Note: When you install the elbow, put a new gasket between the exhaust elbow and the turbocharger. Put 5P-3931 Anti-Seize Compound on the threads of the bolts. Install these bolts in the exhaust elbow. Tighten the bolts to a torque of 120 20 N m (90 15 lb ft). After you complete the installation, run the engine for five minutes at rated conditions. Then tighten the bolts to a torque of 135 15 N m (100 11 lb ft).
Replace six bolts (8).
Illustration 5 g00603833
Replace the air pressure module (22) on the support (21).
Replace the clamp bolt (20).
Replace the restriction line for the air inlet (20).
Replace the bolts (7) in order to attach the turbocharger to the bellows assemblies.
Connect the high temperature thermocouple (5) to the exhaust stack.
Illustration 6 g00603824
Replace two clamp bolts (24).
Replace the shield (23) and replace the other shield (25). Note: Be sure to remove the protective covers. These covers were placed over the openings of the turbocharger in order to prevent contamination.
Fill the cooling system with coolant to the correct level. Refer to the Maintenance Guide. End By:
Install the manifold shield in order to gain access to the turbocharger.