C7.1 Industrial Engine Turbocharger - Install - Second Stage Turbocharger Caterpillar

Installation Procedure

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Illustration 1	g02176247

1. Ensure that turbocharger (8) is clean and free from damage. Inspect the turbocharger for wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If any part of the turbocharger is worn or damaged, the complete turbocharger must be replaced.

2. If necessary, follow Step 2.a through Step 2.b in order to install bracket (24) onto cylinder block (25).

   1. If necessary, install studs (27) (not shown) to the cylinder block. Tighten the studs to a torque of 18 N·m (159 lb in).

   2. Position bracket (24) onto cylinder block (25). Install nuts (26) hand tight.

3. If necessary, install studs (23) to turbocharger (8). Tighten the studs to a torque of 18 N·m (159 lb in).
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   Illustration 2	g02356216

4. Position turbocharger (8) onto bracket (24).

5. Loosely install nuts (28).

6. Move turbocharger (8) in the Direction (C) to ensure that studs (23) of turbocharger (8) is positioned most forward position in the holes in bracket (24).

7. Hand tighten nuts (28).
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   Illustration 3	g02352357

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   Illustration 4	g02352633

8. Use Tooling (B) in order to align the second stage turbocharger and the first stage turbocharger.

   Note: Ensure that the bracket for the turbocharger is correctly positioned onto the turbocharger and the cylinder block.

9. Tighten nuts (28) to a torque of 44 N·m (32 lb ft). Tighten the nuts in the sequence that is shown in Illustration 4.

   Tighten nuts (26) to a torque of 44 N·m (32 lb ft). Tighten the nuts in the sequence that is shown in Illustration 3.

10. Remove Tooling (B).

    Note: Ensure that the second stage turbocharger and the first stage turbocharger are correctly aligned.

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    Illustration 5	g02176246

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    Illustration 6	g02176278

11. Remove plugs and caps from tube assemblies. Ensure that tube assembly (14) and tube assembly (20) are clean and free from damage. Replace any damaged components.

12. Install a new gasket (21) (not shown) onto tube assembly (20).

13. Position a new gasket (19) (not shown) onto tube assembly (20).

14. Remove the plug from the drain port of the turbocharger. Remove the plug from the cylinder block.

15. Position tube assembly (20) into the cylinder block and install bolts (22) finger tight.

16. Position tube assembly (20) onto turbocharger (8) and install bolts (18) finger tight.

17. Tighten bolts (18) and bolt (22) to a torque of 22 N·m (195 lb in).

18. Remove the plug from oil inlet port (29) for turbocharger (8). Lubricate the turbocharger bearings with clean engine oil through oil inlet port (29). Rotate the wheel of the compressor several times in order to lubricate the bearings.

19. Position a new gasket (15) (not shown) onto tube assembly (14) and install bolts (13).

    Note: Holes in the gasket have serration that hold the bolts captive.

20. Position tube assembly (14) onto turbocharger (8). Tighten bolts (13) finger tight.

21. Remove plug from cylinder block for the oil feed tube assembly. Install new sealing washers (16) (not shown) and banjo bolt (17) to tube assembly (14). Tighten banjo bolt (17) finger tight.

22. Tighten bolts (13) to a torque of 22 N·m (195 lb in). Tighten banjo bolt (17) to a torque of 33 N·m (292 lb in). Refer to Illustration 5.
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    Illustration 7	g02176245

23. Connect hose assembly (9) onto turbocharger (8) and loosely install bolt (10).

24. Use Tooling (A) to lubricate the allen head bolt for V-band clamp (4). Position V-band clamp (4) onto air duct (5).

25. Remove plugs from the ports of the turbochargers

26. Position hose assembly (12) and air duct (5) onto the outlet of turbocharger (8) and the inlet of turbocharger (3). Tighten the allen head bolt for V-band clamp to a torque of 12 N·m (106 lb in).

    Note: Ensure that the allen head bolt for the V-band clamp does not contact any other engine component.

27. Tighten hose clamps (11) to a torque of 6 N·m (53 lb in).

28. Install bolt (6) (not shown).

29. Tighten bolt (10) and bolt (6) (not shown) to a torque of 22 N·m (195 lb in).

30. Use Tooling (A) to lubricate the allen head bolt for V-band clamp (2). Position V-band clamp (2) onto elbow (1).

31. Use Tooling (A) to lubricate the allen head bolt for V-band clamp (7). Position V-band clamp (7) onto turbocharger (8).

32. Position elbow (1) onto turbocharger (8) and turbocharger (3).

33. Tighten allen head bolt for V-band clamp (2) and V-band clamp (7) finger tight. Ensure that the V-band clamps are seated correctly onto the turbochargers.

34. Tighten allen head bolts for V-band clamp (2) and V-band clamp (7) to a torque of 12 N·m (106 lb in).

35. Connect the air inlet hose to the turbocharger and tighten the hose clamp securely.

End By:

1. Install flexible exhaust pipe that connects the turbocharger to the clean emission module. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install" for the correct procedure.