3C7-00012-0 Tohatsu PISTON RING 2ND (STANDARD)

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 g01114005
Clean the outer surfaces of the turbocharger (1).
Loosen the hose clamps (4). Remove the air inlet hose (5).
Illustration 2 g01114003
Remove the exhaust pipe (not shown) from the exhaust elbow (21). Refer to the OEM provided information for the correct procedure in order to remove the exhaust pipe.
Remove the setscrews (15) and remove the support bracket for the turbocharger (16). Note the position of the support bracket for installation.
Remove the setscrews (22). Remove the exhaust elbow (21) from the turbocharger (1). Remove the gasket for the exhaust elbow (20) from the turbocharger. Discard the gasket.
Place a suitable container below the turbocharger (1) in order to collect any spillage of oil.
Remove the banjo bolt (3). Remove the oil supply tube assembly (8). Remove the washers (2) from the turbocharger. Discard the washers. If necessary, remove the setscrews (not shown) for the tube clips (6). Remove the setscrews (7). Remove the oil supply tube assembly (8) from the cylinder block. Remove the O-ring (9). Discard the O-ring.
Remove the setscrews (13). Remove the oil drain tube assembly (11) from the turbocharger. Remove the joint (14) and discard the joint. If necessary, remove the setscrews (12) and remove the oil drain tube assembly (11) from the cylinder block. Remove the joint (10). Discard the joint.
Remove the nuts (19) and the washers (18). Remove the turbocharger (1) from the exhaust manifold. Remove the turbocharger gasket (23) from the exhaust manifold. Discard the gasket. If necessary, remove the studs (17) from the exhaust manifold. Note: Do not use the actuator rod of the wastegate to lift the turbocharger.
Inspect the turbocharger for damage. If the turbocharger is damaged use a new part for replacement. Refer to Testing and Adjusting, "Wastegate - Test".
Install suitable plastic plugs into the oil supply and into the oil drain ports of the turbocharger (1). Install suitable plastic covers to the inlet and to the outlet of the turbocharger. Install suitable plastic plugs to the oil supply tube assembly (8) and to the oil drain tube assembly (11). Installation procedure
Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Remove all of the plastic plugs from all of the ports of the turbocharger (1). Clean the mating surfaces of the exhaust manifold and the turbocharger.
Illustration 3 g01114003
Ensure that all of the turbocharger inlet and outlet ports are clean and free from restrictions. The turbocharger shaft must rotate freely.
If the studs (17) were previously removed, install the studs into the exhaust manifold. Install a new gasket (23) over the studs (17). Note: Do not use any sealant on the gasket (23).Note: Do not use the actuator rod of the wastegate to lift the turbocharger (1).
Position the turbocharger (1) onto the exhaust manifold.
Install the washers (18) and install the nuts (19). Tighten the nuts to a torque of 25 N m (18 lb ft).
Lubricate the bearing housing of the turbocharger (1) with clean engine oil. Apply the lubricant through the oil supply port (24).
Illustration 4 g01114005
Clean the oil supply tube assembly (8) and the oil drain tube assembly (11). Inspect the oil supply tube assembly and the oil drain tube assembly. If necessary, replace the tube assemblies.
Position a new joint (14) and the oil drain tube assembly (11) onto the bottom of the turbocharger. Install the setscrews (13). Tighten the setscrews to a torque of 10 N m (7 lb ft).
If necessary, position a new joint (10) and the oil drain tube assembly (11) onto the cylinder block. Install the setscrews (12). Tighten the setscrews to a torque of 10 N m (7 lb ft).
Position the new washers (2) and the oil supply tube assembly (8) onto the turbocharger (1). Install the banjo bolt (3). Tighten the banjo bolt to a torque of 18 N m (13 lb ft).
If necessary, install a new O-ring (9) and the oil supply tube assembly (8) to the cylinder block. Install the setscrews (7). Tighten the setscrews to a torque of 10 N m (7 lb ft).
If necessary, install the spacer (not shown) and install the setscrews (not shown) to the tube clips (6). Torque the setscrews to 10 N m (7 lb ft). Note: Ensure that the oil supply tube assembly (8) does not come into contact with any other component when the assembly is installed onto the engine.
Clean the mating surfaces of the exhaust elbow (21). Position a new gasket (20) and the exhaust elbow (21) on the turbocharger (1). Install the setscrews (22). Tighten the setscrews to a torque of 32 N m (24 lb ft).
Install the set screws (15) and install the support bracket for the turbocharger (16). Tighten the setscrews to a torque of 25 N m (18 lb ft).
Ensure that the inlet hose (5) is clean and free from defects or restrictions. Loosely install the hose clamps (4) to the air inlet hose (5). Install the air inlet hose to the connection of the inlet manifold and to the inlet of the turbocharger. Tighten the hose clamps. Note: Do not use oil or grease in order to install the air inlet hose. In order to install a new air inlet hose, lubricate the connection of the inlet manifold and lubricate the inlet of the turbocharger with a solution of water and 5% soap.
Position the exhaust pipe onto the exhaust elbow (21). Refer to the OEM information for the correct procedure in order to install the exhaust pipe.