Turbocharger - Disassemble 318c exavator

Turbocharger - Disassemble

Disassembly Procedure

 

Start By:

1. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".

NOTICE : Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.

 NOTICE : 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, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.

1. Place an index mark on all of the components. The marks will help to align the components during the assembly procedure.

2. Remove two bolts (1) from the oil return line. Remove bolt (2) from the oil supply line.

3. Remove oil return line (3) from the cartridge.

4. Remove oil supply line (4) from the cartridge.

5. Remove gasket (5) from the cartridge.

6. Remove gasket (6) from the turbine housing.

7. Remove the bolt and nut (7) from clamp (8). Remove clamp (8) that secures the turbine housing (9) to the cartridge (10) .

8. Separate turbine housing (9) from the cartridge (10) .

9. Remove snap ring (11) from compressor housing (12) .

10. Separate compressor housing (12) from the cartridge (10) .

Muffler - Remove and Install

Disassembly and Assembly
318C Excavator3066 Engine Supplement

Muffler - Remove and Install

Removal Procedure

1. Open hood (1) .

2.Remove nuts (2) .Note: Nuts (2) are doubled on the turbocharger.

3. Loosen clamp (3). Slide clamp (3) onto pipe (4). Remove pipe (4), clamp (3), and the gasket that is between pipe (4) and the turbocharger.

4. Disconnect drain line (5) from the bottom of the muffler.

 

5. Remove U-bolts (6). Remove muffler (7). The weight of the muffler is approximately 16 kg (35 lb).

Installation Procedure

1. Place muffler (7) in position on the brackets in the engine compartment. The weight of the muffler is approximately 16 kg (35 lb). Install U-bolts (6) .

2. Connect drain line (5) to the bottom of the muffler.

3. Install a new gasket between pipe (4) and the turbocharger. Slide clamp (3) onto pipe (4). Install pipe (4) and clamp (3) on the turbocharger. Slide clamp (3) so that the clamp is half on pipe (4) and half on the muffler. Do not tighten clamp (3) at this time.

4. Apply 4C-5599 Anti-Seize Compound to the threads of nuts (2). Install nuts (2) .Note: Nuts (2) are doubled on the turbocharger.

5. Make sure that clamp (3) is half on pipe (4) and half on the muffler. Tighten clamp (3) .

6. Close hood (1) .

Drain Line (Muffler)

Specifications
318C and 319C Excavators Machine System Specifications

Media Number -RENR6688-01

Drain Line (Muffler)

(1) Torque for fitting ... 30 ± 3 N·m (22 ± 2 lb ft)

Air Inlet Manifold (In Chassis) - Remove

Air Inlet Manifold (In Chassis) - Remove

Removal Procedure

Start By:

1. Remove the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install".
2. Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".
3. Remove the air inlet heater. Refer to Disassembly and Assembly, "Air Inlet Heater - Remove and Install"

NOTICE :Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.

1. Remove bolts (1) from the bracket for the crankcase breather.

2. Remove bolt (2), the washer, and spacer (3) from the dipstick tube.

3. Remove bolts (4) and the washers.

4. Remove air inlet manifold (5) .

5. Remove gaskets (6) from the mating surfaces of the cylinder head and the air inlet manifold.

Exhaust Manifold - Remove and Install

Disassembly and Assembly
318C Excavator3066 Engine Supplement
Media Number -RENR6635-00 

Exhaust Manifold - Remove and Install

Removal Procedure

Start By:

1. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove". 

NOTICE : Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.

1. Remove the nuts (1) and washers that secure the exhaust manifold to the cylinder head assembly. The 3066 Engine has twelve nuts and washers while the 3064 Engine has eight nuts and washers.

2. Remove exhaust manifold (2) from the cylinder head assembly.

3. Remove exhaust manifold gasket (3) that is located between exhaust manifold (2) and the cylinder head assembly.Note: The 3066 Engine has two exhaust manifold gaskets, while the 3064 Engine has one exhaust manifold gasket.
   
   

   Installation Procedure

   NOTICE : Keep all parts clean from contaminants.
   Contaminants may cause rapid wear and shortened component life.

     

   

   1. Install exhaust manifold gasket (3) between exhaust manifold (2) and the cylinder head assembly.Note: The 3066 Engine has two exhaust manifold gaskets, while the 3064 Engine has one exhaust manifold gasket.
4. Place exhaust manifold (2) in position on the cylinder head.

3. Install the nuts (1) and the washers that secure the exhaust manifold to the cylinder head assembly. The 3066 Engine has twelve nuts and washers while the 3064 Engine has eight nuts and washers.

4. Tighten exhaust manifold nuts (1) to a torque of 18 ± 4 N·m (13 ± 3 lb ft).

End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".

 

Air Inlet Heater - Remove and Install

Disassembly and Assembly
318C Excavator3066 Engine Supplement

Media Number -RENR6635-00

Air Inlet Heater - Remove and Install

SMCS - 1090-010

Removal Procedure

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NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.

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1. Open the engine hood. Lock the engine hood in the OPEN position.

2. Remove rubber boot (1) from the electrical connector.

3. Remove nut (2) in order to disconnect electrical wire (3) from the air inlet heater.

4. Loosen hose clamp (4) in order to disconnect the air hose from the air inlet elbow.

5. Remove bolts (5) and the washers from the air inlet manifold.Note: Ground wire (6) will be disconnected when the bolt is removed.

6. Remove air inlet elbow (7) .

7. Remove air inlet heater (8) .

8. Remove gasket (9) from the air inlet heater.

Installation Procedure

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NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.----------------------------------------------------------------------------

Note: Gaskets and seals should always be replaced. A used gasket may not have the same sealing properties as a new gasket.

1. Install wire mesh filter (10) .

 

2. Install gasket (9) on the air inlet heater.

3. Install air inlet heater (8) .

4. Install air inlet elbow (7) .

Note: Make sure that ground wire (6) is connected when the bolt is installed.

5. Install bolts (5) in the air inlet manifold.

6. Tighten bolts (5) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

7. Connect the air inlet hose to the air inlet elbow. Tighten hose clamp (4) .

8. Connect electrical wire (3) to the air inlet heater. Install nut (2) .

9. Install rubber boot (1) on the electrical connector.

10. Close the engine hood.

Finding Top Center Position for No. 1 Piston

Finding Top Center Position for No. 1 Piston

Note: Refer to the Disassembly and Assembly for your machine for the removal of components.

Table 1

Required Tools
Callout	Part Number	Description	Quantity
A	299-9126	Crankshaft Turning Tool	1

1. Remove the valve mechanism cover from the engine.

 

2. Install Tooling (A) on the engine's flywheel housing. Use Tooling (A) in order to rotate the engine. Refer to Illustration 1.

3. Rotate the crankshaft clockwise when you face the front of the engine. Rotate the crankshaft until the pushrod for the inlet valve of the rear cylinder begins to tighten.

4. Rotate the crankshaft further by 1/8 of a turn in a clockwise direction. Insert a suitable lever between the rocker arm and the valve spring cap of the No. 1 inlet valve. Open the inlet valve. Put a spacer that is approximately 5 mm (0.2 inch) thick between the valve stem and the rocker arm.

5. Slowly rotate the crankshaft in a counterclockwise direction until the piston makes contact with the open valve. Make a temporary mark on the damper or the pulley. The temporary make must align accurately with the tip of the pointer.

6. Rotate the crankshaft in a clockwise direction by one or two degrees. Remove the spacer that is between the valve stem and the rocker arm. Rotate the crankshaft by 1/4 of a turn in a counterclockwise direction. Put a spacer that is approximately 5 mm (0.2 inch) thick between the valve stem and the rocker lever of the No. 1 inlet valve.

7. Slowly rotate the crankshaft clockwise until the piston makes contact with the open valve. Make another temporary mark on the damper or the pulley. The temporary mark must align accurately with the tip of the pointer.

8. Make a temporary mark at the center point between the two marks on the damper or the pulley. Remove the other two marks. Rotate the crankshaft by 1/8 of a turn in a counterclockwise direction. Remove the spacer between the valve stem and the rocker arm.

(1) Pointer
(2) Pulley

(3) Top center mark 

(1) Pointer (2) Pulley (3) Top center mark

9. Slowly rotate the crankshaft in a clockwise direction until the mark on the damper of the pulley (2), which was made in Step 8, aligns with the tip of the pointer (1). The No. 1 piston is now at the top center on the compression stroke. Refer to Illustration 2 and Illustration 3.