G3500 Engines Caterpillar

Assembly Procedure

1. Ensure that all of the oil passages in the cartridge housing, the back plate assembly, and the bearing are clean.

2. Place clean engine oil on all of the parts for the cartridge assembly during the assembly procedure.

   Note: Ensure that the round edge of the outside diameter of the snap rings is toward the bearing during installation.

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Illustration 1	g00594129
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3. Use Tooling (C) to install lower retaining ring (22) in the turbine end of the cartridge housing.

4. Install washer (21) and bearing (20) . Use Tooling (C) to install retaining ring (19) .

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Illustration 2	g00594131
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Illustration 3	g00594133
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5. Use Tooling (C) to install retaining ring (18) .

6. Install washer (23) and bearing (17) in the cartridge housing until washer (23) makes contact with retaining ring (18) .

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Illustration 4	g00594134
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7. Install thrust bearing (16) on the dowels in the cartridge housing. Ensure that the grooves in thrust bearing (16) are toward the outside.

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Illustration 5	g00594620
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8. Install seal ring (15) in the groove of the cartridge housing.

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Illustration 6	g00594621
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9. Install thrust collar (14) on the thrust bearing with the counterbore upward.

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Illustration 7	g00594622
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10. Install seal rings (13) on spacer (12) . The gaps in the rings should be 180 degrees away from each other.

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Illustration 8	g00594623
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11. Install spacer (12) in back plate assembly (11) .

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Illustration 9	g00594642
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Illustration 10	g00594647
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12. Align oil passage (24) in the cartridge housing with oil passage (25) in back plate assembly (11) .

13. Install back plate assembly (11) on the cartridge housing. Ensure that the spacer fits correctly in the counterbore of the thrust collar.

14. Install the locks and the bolts on back plate assembly (11) . Tighten the bolts per the torques in Table 2.
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    Table 2

    Torque Specs
    Bolt Size	Torque
    1/4-20	10 ± 1 N·m (89 ± 9 lb in)
    3/8-16	39 ± 2 N·m (29 ± 1 lb ft)
    6mm x 22	11 ± 1 N·m (97 ± 9 lb in)

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Illustration 11	g00594650
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15. Install turbine shaft (7) in Tooling (B) . Apply Tooling (E) in the groove for seal ring (8) . Ensure that Tooling (E) fills half of the groove. This creates a carbon dam under the seal ring.

16. Install seal ring (8) and shroud (9) .

17. Install the cartridge housing on the turbine shaft. Hold the spacer in position. Ensure that the seal ring on the turbine is correctly placed in the cartridge housing.

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Illustration 12	g00594652
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18. Install compressor wheel (6) .

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Illustration 13	g00594673
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NOTICE
Do Not place a side force on the shaft when the nut is removed or tightened. The shaft will bend and cause damage to the turbocharger.

19. Place clean engine oil on the threads of the turbine shaft and on the face of compressor wheel (6) that is under the nut. Tighten the nut to a torque of 16 ± 2 N·m (12 ± 1 lb ft).

20. Remove the nut. Apply Tooling (F) to the threads of the turbine shaft.

21. Apply Tooling (G) on the threads of the turbine shaft. Install the nut and tighten the nut to a torque of 4 N·m (35 lb in). Turn the nut for an additional 120 degrees (1/3 turn).

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Illustration 14	g00594677
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22. Place the cartridge assembly in a vise. Install Tooling (D) and check the end play of the shaft. The end play must not be more than 0.165 ± 0.085 mm (0.0065 ± 0.0033 inch).

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Illustration 15	g00594680
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23. Install turbine housing (4) on Tooling (A) . Install the cartridge assembly and clamp (5) in turbine housing (4) . Ensure that the marks on the housing and the cartridge are aligned.

24. Install clamp (5) . Tighten the clamp to a torque of 14 ± 1 N·m (10 ± 1 lb ft). Lightly tap the clamp with a soft hammer. Tighten the clamp to the same torque again.

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Illustration 16	g00594683
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25. Install clamp (2) and compressor housing (1) on the cartridge assembly. Install clamp (2) . Tighten the clamp to a torque of 14 ± 1 N·m (10 ± 1 lb ft). Lightly tap the clamp with a soft hammer. Tighten the clamp to the same torque again.

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