G3304 and G3306 Engines Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

1. Ensure that all of the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material.

2. Apply clean engine oil to all parts of the cartridge assembly.
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   Illustration 1	g00994048

   Note: Snap rings (1), (3), (4), and (7) must be installed with the round edge of the snap rings toward the bearing.

3. Use Tooling (A) in order to install snap rings (1) and (3). Install snap ring (1), bearing (2), and snap ring (3) in the compressor end of the cartridge housing.
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   Illustration 2	g00994076

4. Turn around the cartridge housing and use Tooling (A) in order to install snap rings (4) and (7).

5. Install snap ring (4), bearing (5), sleeve (6), and snap ring (7) in the turbine end of the cartridge housing.
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   Illustration 3	g00994079

6. Place oil seal ring (9) into position in cartridge housing (8). Check the end clearance for the seal ring. The maximum permissible end clearance is 0.23 mm (.009 inch).
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   Illustration 4	g00994082

7. Apply Tooling (F) in groove (10) to one half or more of the depth of the groove all the way around.
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   Illustration 5	g00994099

   Note: Be careful not to break oil seal ring (9) during installation.

8. Install oil seal ring (9) on turbine shaft (11).

   Note: Ensure that oil seal ring (9) on turbine shaft (11) is correctly installed in the cartridge housing.

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   Illustration 6	g00994102

9. Place shroud (12) in position on the cartridge housing.

10. Install turbine shaft (11) in the cartridge housing.
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    Illustration 7	g00994104

11. Install ring (13), bearing (16), sleeve (14), ring (17), and deflector (15) in the housing.
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    Illustration 8	g00994105

    Note: Install seal rings (19) on sleeve (18). Ensure that the gaps in the seal rings are turned 180°.

12. Install seal rings (19) in the groove of sleeve (18).
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    Illustration 9	g00994109

13. Install O-ring seal (21) on insert (20).

14. Install sleeve (18) in insert (20).

15. Place insert (20) in position over the turbine shaft in the housing.

16. Use Tooling (B) in order to install the snap ring that holds the insert in the housing.
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    Illustration 10	g00994111

17. Place the cartridge housing assembly in position on Tooling (C).

18. Place compressor wheel (22) in position on the turbine shaft.

    Note: Do not put a side force on the shaft when the nut is installed or removed.

19. Install the nut that holds the compressor wheel. Use a torque wrench and a universal socket of the correct size in order to tighten the nut to a torque of 28 ± 3 N·m (21 ± 2 lb ft).

20. Place the cartridge housing in a vise. Use Tooling (D) in order to check the shaft end play. The worn end play must be 0.140 ± 0.060 mm (0.0055 ± 0.0024 inch).
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    Illustration 11	g00994120

21. Install turbine housing (24) on Tooling (E). Place cartridge assembly (8) in position in turbine housing (24). Use the alignment marks on the cartridge housing as a guide. Apply Tooling (G) on the threads of clamps (23) and (26). Install clamp (23) and tighten the bolt to a torque of 13 ± 3 N·m (120 ± 25 lb in).

22. Install the O-ring seal on the cartridge assembly for the compressor housing.
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    Illustration 12	g00994121

23. Install compressor housing (25) on the cartridge assembly. Use the alignment marks on the compressor housing and the cartridge as a guide. Install clamp (26) and tighten the bolt to a torque of 13 ± 3 N·m (120 ± 25 lb in).

24. Tap completely around both clamps and tighten again to a torque of 13 ± 3 N·m (120 ± 25 lb in).

End By:

1. Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install" for the engine that is being serviced.