855391 Mercruiser POWER RELAY-MAIN

Start By:
Remove the aftercooler. Refer to Disassembly and Assembly, "Aftercooler - Remove and Install". The information is in this manual.
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 Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines.Dispose of all fluids according to local regulations and mandates.
Note: Put identification marks on all lines, hoses, wires, and tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to prevent contaminating the oil system.
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Loosen clamps (2) and (4) from hose (3) .
Remove hose (3) from air cleaner (1) and turbocharger (5) .
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Loosen hose clamp (7) and remove hose (6) from turbocharger (5) .
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Disconnect oil tube assembly (9) at nut (8) . Remove two bolts (10) , the hard washers, and oil tube assembly (9) from turbocharger (5) .
Remove the gasket that was between oil tube assembly (9) and turbocharger (5) . Remove the O-ring seal that was under nut (8) .
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Loosen exhaust clamp (12) from exhaust pipe (13) . Remove retaining clamp (11) that secures exhaust pipe (13) to turbocharger (5) .
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This is a view from a point that is below the engine compartment.
Remove two bolts (14) and the hard washers from oil drain line (15) . Remove two bolts (16) from adapter (17) .
Remove oil drain line (15) and adapter (17) as a unit from turbocharger (5) and the engine block. Remove the gasket from underneath oil drain line (15) .
Remove the O-ring seal from adapter (17) .
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Fasten a hoist and a nylon lifting strap to turbocharger (5) .
Remove four locknuts (18) that secure turbocharger (5) to exhaust manifold (19) . Remove turbocharger (5) and the gasket from exhaust manifold (19) . The weight of turbocharger (5) is 18 kg (40 lb) .Installation Procedure
Note: Check the condition of the O-ring seals and the gaskets that were removed from the turbocharger. If the O-ring seals or gaskets are worn or damaged, replace the components with new Caterpillar parts.
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Fasten a hoist and a nylon lifting strap to turbocharger (5) .
Position turbocharger (5) and the gasket to exhaust manifold (19) . The weight of turbocharger (5) is 18 kg (40 lb) .
Lubricate four locknuts (18) with 5P-3931 Anti-Seize Compound before installation. Install four locknuts (18) that secure turbocharger (5) to exhaust manifold (19) .
Tighten locknuts (18) to a torque of 54 5 N m (40 4 lb ft) .
Remove the nylon lifting strap and the hoist from the turbocharger.
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Install the O-ring seal in adapter (17) .
Install the gasket between turbocharger (5) and oil drain line (15) . Install oil drain line (15) and adapter (17) as a unit to turbocharger (5) and the engine block.
Install two bolts (14) and the hard washers that secure oil drain line (15) to turbocharger (5) .
Install two bolts (16) that secure adapter (17) to the engine block.
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Install retaining clamp (11) that secures exhaust pipe (13) to turbocharger (5) .
Tighten exhaust clamp (12) to exhaust pipe (13) .