Turbocharger - Install - Turbocharger Top Mounted
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C6.6 Engines for Caterpillar Built Machines
[KENR6081]
C6.6 Engines for Caterpillar Built Machines
Turbocharger - Install - Side Mounted Turbocharger
C6.6 Engines for Caterpillar Built Machines
Wastegate Solenoid - Remove and Install
AIR INLET AND EXHAUST SYSTEM
TURBOCHARGER GP
C6.6 Engines for Caterpillar Built Machines
Turbocharger - Remove - Side Mounted Turbocharger
C6.6 Engines for Caterpillar Built Machines
Turbocharger - Remove - Turbocharger Top Mounted
C6.6 Engines for Caterpillar Built Machines
Turbocharger - Install - Side Mounted Turbocharger
C6.6 Engines for Caterpillar Built Machines
Turbocharger - Install - Turbocharger Top Mounted
C6.6 Engines for Caterpillar Built Machines
Wastegate Solenoid - Remove and Install
1.1. Installation Procedure
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Required Tools | |||
Tool | Part Number | Part Description | Qty |
A | 1U-6396 | O-Ring Assembly Compound |
1 |
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NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Ensure that the turbocharger is clean and free from damage. Inspect the turbocharger for wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more information. If the turbocharger is worn, the complete turbocharger must be replaced.
- Test the wastegate actuator (19) for correct operation. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect". If the wastegate actuator is damaged or the wastegate actuator does not operate within the specified limits, the wastegate actuator must be replaced. Refer to Disassembly and Assembly, "Turbocharger - Dissassemble" and refer to Disassembly and Assembly, "Turbocharger - Assemble" for more information.
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Illustration 2 g01335756 - Clean the mating surfaces of the exhaust manifold (1). If necessary, install studs (16) to the exhaust manifold. Tighten the studs to a torque of
18 N·m (13 lb ft) .Note: Support the exhaust manifold during installation of the turbocharger.
- Install a new joint (15) to exhaust manifold (1).
- Position turbocharger (12) on exhaust manifold (1).
Note: Ensure that the turbocharger is correctly oriented.
- Install nuts (11). Tighten the nuts to a torque of
44 N·m (32 lb ft) . - If a new turbocharger is installed, bearing housing (18) and compressor housing (20) must be oriented to the correct positions. Refer to Illustration 1. Follow Steps 7.a through 7.d in order to orient the bearing housing and the compressor housing.
- Loosen band clamps (21) sufficiently in order to allow the housings to rotate.
Note: If the band clamps are damaged, replace the band clamps.
- Carefully turn bearing housing (18) until the port for oil feed (17) is upward.
- Rotate compressor housing (20) until the compressor outlet is in the correct position. Refer to the turbocharger that was originally installed for the correct orientation.
- Ensure that band clamps (21) are correctly oriented. Refer to the turbocharger that was originally installed for the correct orientation. Tighten the band clamps finger tight.
- Loosen band clamps (21) sufficiently in order to allow the housings to rotate.
- Ensure that tube assemblies (4) and (7) are clean and free from damage. Replace any damaged components.
- Position a new joint (13) and bolts (14) onto tube assembly (4).
- Install tube assembly (4) to turbocharger (12). Tighten bolts (14) finger tight.
- Remove the plug from oil inlet port (17). Refer to Illustration 1. Lubricate the turbocharger bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor several times in order to lubricate the bearings.
- Install banjo bolt (9) and new sealing washers (10) to tube assembly (7).
- Use Tooling (A) in order to lubricate a new O-ring seal (6). Install O-ring seal (6) to tube assembly (7). Refer to Illustration 3.
- Install tube assembly (7) to turbocharger (12). Tighten banjo bolt (9) finger tight.
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Illustration 3 g01335754 - Install exhaust manifold (1) and the assembly of the turbocharger to the cylinder head. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install" for the correct procedure.
- Install bolt (8) finger tight. Ensure that tube assembly (7) fits correctly.
- Position a new joint (3) between the flange of tube assembly (4) and the cylinder block. Install bolts (5) finger tight.
- If a new turbocharger has been installed, check that the orientation of bearing housing (18) is correct. If the orientation of the bearing housing is not correct, rotate the bearing housing until tube assemblies (4) and (7) fit correctly. Tighten band clamps (21) to a torque of
13 N·m (9.6 lb ft) . - Tighten banjo bolt (9) to a torque of
20 N·m (14 lb ft) . Tighten bolt (5) and (8) to a torque of22 N·m (16 lb ft) . - Install the bolts for tube clips (2) to the cylinder block. Tighten bolt (2) to a torque of
44 N·m (32 lb ft) . - If the turbocharger has an exhaust elbow, install the exhaust elbow. Refer to Disassembly and Assembly, "Exhaust Elbow - Remove and Install".
- If the turbocharger has a remote wastegate solenoid, connect the hose for the solenoid to the turbocharger.
- Connect the air inlet hose and tighten the hose clamp.
- Connect the air outlet hose to the turbocharger and tighten the hose clamp.
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Illustration 1 | g01335496 |
Typical example |
Information System:
C6.6 Engines for Caterpillar Built Machines
Turbocharger - Install - Side Mounted Turbocharger
C6.6 Engines for Caterpillar Built Machines
Turbocharger - Remove - Turbocharger Top Mounted
C6.6 Engines for Caterpillar Built Machines
Turbocharger - Remove - Side Mounted Turbocharger
C6.6 Engines for Caterpillar Built Machines
Fuel Injection Pump Gear - Install
C6.6 Engines for Caterpillar Built Machines
Fuel Injection Pump Gear - Remove
C6.6 Engines for Caterpillar Built Machines
Fuel Injection Pump - Install
C6.6 Engines for Caterpillar Built Machines
Fuel Injection Pump - Remove
C6.6 Engines for Caterpillar Built Machines
Fuel Injection Lines - Install
C6.6 Engines for Caterpillar Built Machines
Fuel Injection Lines - Remove
C6.6 Engines for Caterpillar Built Machines
Fuel Manifold (Rail) - Remove and Install
C6.6 Engines for Caterpillar Built Machines
Fuel Transfer Pump - Install
C6.6 Engines for Caterpillar Built Machines
Fuel Transfer Pump - Remove
C6.6 Engines for Caterpillar Built Machines
Wastegate Solenoid - Remove and Install
C6.6 Engines for Caterpillar Built Machines
Exhaust Manifold - Remove and Install - Side Mounted Exhaust Manifold
C6.6 Engines for Caterpillar Built Machines
Exhaust Manifold - Remove and Install - Top Mounted Exhaust Manifold
C6.6 Engines for Caterpillar Built Machines
Exhaust Elbow - Remove and Install
C6.6 Engines for Caterpillar Built Machines
Inlet Manifold - Remove and Install
C6.6 Engines for Caterpillar Built Machines
Inlet and Exhaust Valve Springs - Remove and Install
C6.6 Engines for Caterpillar Built Machines
Inlet and Exhaust Valves - Remove and Install
C6.6 Engines for Caterpillar Built Machines
Engine Oil Filter Base - Remove and Install
C6.6 Engines for Caterpillar Built Machines
Engine Oil Cooler - Remove - Engine Oil Cooler with a Low Mounted Filter Base
C6.6 Engines for Caterpillar Built Machines
Engine Oil Cooler - Remove - Engine Oil Cooler with a High Mounted Filter Base
EquipmentManager Dealer Administrator Manual
Major Repair
C6.6 Engines for Caterpillar Built Machines
Engine Oil Cooler - Install - Engine Oil Cooler with a Low Mounted Filter Base