Upgrade to Air/Fuel Ratio Control, Nitrogen Oxide Sensor, and a Single Turbocharger for Enhanced Performance of G3508 Engines{1000, 1052, 1270, 191N} Caterpillar

Engine:

G3508 (S/N: WPN1-UP)

Introduction

Do not perform any procedure that is outlined in this Special Instruction and do not order any parts until the entire instruction has been read and understood.

This Special Instruction describes the installation of features that enhance the performance for engines with these characteristics:

• G3508

• 1400 rpm rated speed

• Twin turbochargers

• ADEM 3 Electronic Control Module (ECM)

This conversion includes the following changes:

• Twin turbocharger configuration to single turbocharger configuration

• Air/Fuel Ratio Control

• Nitrogen oxide sensor

Note: All engines with electric starting motors must be converted to air starting motors prior to this conversion.

Note: A remote advisor panel is highly recommended for this conversion.

Whenever questions arise about this product or about this Special Instruction, consult your local Caterpillar dealer for the latest available information.

References

The following reference materials may be necessary for this procedure:

• Disassembly and Assembly Manual, SENR6419

• Systems Operation/Testing and Adjusting, KENR5473, "Exhaust Temperature Module"

• Special Instruction, REHS2558, "Installation and Start-up Procedure for G3500 A3 Engines"

• Special Instruction, REHS3415, "G3508 Upgrade: Performance Enhancement for 1200 RPM and 1400 RPM Gas Compression Engines"

• Troubleshooting, RENR9353, "Gas 3500 A3 Engines", "Nitrogen Oxide Sensor - Calibrate"

• Informational Release Memo, PELJ1003, "G3508 Engine Upgrade Conversion to AFRC With a Nitrogen Oxide Sensor Including Twin to Single Turbocharger"

System Description

Illustration 1	g01478972
Typical engine configuration (1) Nitrogen oxide sensor group (2) ADEM 3 Electronic Control Module (ECM) (3) Exhaust Temperature Module (ETM) (4) Actuator for air/fuel ratio control (5) Engine interface box (EIB) (6) Fuel valve

Illustration 2	g01479912
Engine Interface Box (EIB) (7) Fuse (F3) main system fuse (8) Fuse (F4) throttle fuse (9) Fuse (F5) air/fuel ratio control fuse (10) Ground wire (11) Jumper wire (P200-C19) (12) - Battery (13) + Battery

Parts List

Common hardware items that are called out in the illustrations in this document are listed as an aid for assembly. The following items can be reused or provided by the customer. Nuts, bolts, washers, clips, cable straps and pipe nipples. These items are not part of the engine conversion arrangement.

Refer to Table 1 for common supplied hardware.

Table 1

Common Hardware
Quantity	Part Number	Description
Air Cleaner Group
4	0L-1351	Bolt
9	1A-2029	Bolt
7	5M-2894	Hard Washer
2	5P-8245	Hard Washer
2	7B-3235	Bolt
Water Lines Group
3	0L-2070	Bolt
5	0S-1594	Bolt
4	2A-4639	Bolt
3	2M-9780	O-Ring Seal
9	5M-2894	Hard Washer
1	5P-9299	Clip
1	7N-3368	Gasket
1	8M-0755	Connector
1	8S-4951	Cap
1	9S-8752	Full Nut
Turbocharger Lines Group
2	0S-1590	Bolt
2	0S-1594	Bolt
1	0S-1608	Bolt
1	2M-9780	O-Ring Seal
1	3B-1915	Bolt
1	4P-4460	Gasket
6	5M-2894	Hard Washer
2	5P-9890	O-Ring Seal
1	6V-4589	O-Ring Seal
1	7N-7559	Gasket
1	8L-2786	O-Ring Seal
2	8S-9191	Bolt
Aftercooler
34	0S-1594	Bolt
16	1A-2029	Bolt
2	3B-1915	Bolt
14	5M-2894	Hard Washer
4	9L-9132	Washer
Air Lines Group
1	1A-2029	Bolt
3	1A-5822	Bolt
4	5P-8245	Hard Washer
1	7L-4302	Gasket
1	8T-6765	Pipe Plug
1	9X-6458	Hard Washer
1	9X-8874	Bolt
2	6V-6809	O-Ring Seal
Water Lines Group
8	6V-9769	O-Ring Seal
4	1B-5355	Full Nut
Exhaust Manifold Group
16	0L-2070	Bolt
2	0S-1587	Bolt
2	0S-1588	Bolt
8	0S-1591	Bolt
4	0V-0375	Bolt
3	1A-1460	Bolt
16	1D-4706	Bolt
8	1F-7958	Full Nut
30	3E-6916	Full Nut
44	5M-2894	Hard Washer
2	5P-7128	Bolt
32	5P-8245	Hard Washer
18	7L-6443	Bolt
44	8C-8491	Hard Washer
2	8M-2295	Bolt
1	8T-6765	Pipe Plug
1	9S-1366	Bolt
2	9S-1374	Bolt
10	9S-8752	Full Nut
4	9X-8873	Bolt
4	168-7800	Locknut
8	238-4665	Taperlock Stud

Conversion Arrangement

• 330-1857 Conversion Ar (Twin turbocharger to single turbocharger)

Software

The ECM flash file is listed in Table 2. The flash file can be downloaded from the Service Information System (SIS).

Table 2

ECM Flash File
1400 RPM Engines
G3508	319-6463 Engine Ratings Electronic Software Gp

Ensure that the flash file is installed in the ADEM III ECM.

If the installation has a remote advisory panel, ensure that the correct software is installed. The software monitors the data from the nitrogen oxide sensor. Refer to Table 3.

Table 3

Remote Advisory Panel Software
G3508	317-0579 Monitor Software Gp

The software can be downloaded from Service Information System (SIS).

Engine Control Wiring Changes

Install the following parts for the existing ADEM III engine wiring. Refer to Table 4.

Table 4

G3508 Engine Control Wiring
Qty	Part Number	Description
1	337-0286	Engine Harness As
1	243-5752	Temperature Sensor Gp Right side of the engine at the turbocharger inlet
1	241-9591	Temperature Sensor Gp Left side of the engine at the turbocharger inlet
2	5N-2126	Adapter
1	317-4461	Sensor Harness As

The Engines That Are Currently Equipped with Air/Fuel Ratio Control

If the engines are currently equipped with air/fuel ratio control, order the parts that are listed in Table 5.

Table 5

Engines that are Currently Equipped with Air/Fuel Ratio Control
Qty	Part Number	Description
1	315-3584	Electronic Control Wiring Gp
1	315-3583	Sensor Mounting Gp
1	325-6488	Gas Conversion Gp

The Engines That Are Not Equipped with Air/Fuel Ratio Control

If the engines are not equipped with air/fuel ratio control, order the parts that are listed in Table 6.

Table 6

Engines that are Not Equipped with Air/Fuel Ratio Control
Qty	Part Number	Description
1	315-3584	Electronic Control Wiring Gp
1	315-3583	Sensor Mounting Gp
1	325-6492	Gas Conversion Gp

Remote Advisor Panel

A remote advisor panel is highly recommended for this conversion. Order the parts that are listed in Table 7.

Table 7

Remote Advisor Panel
Qty	Part Number	Description	Length
1	320-9978	Wiring Harness Fastener Gp
1	251-9466 (1)	Wiring Harness	6 m (20 ft)
1	251-9467 (1)	Wiring Harness	9 m (30 ft)
1	251-9468 (1)	Wiring Harness	15 m (50 ft)

( 1 )

Choose only one interconnect harness.

Options for the Customer Communication Module (CCM)

Choose one of the following options for your application.

• If the CCM is being replaced and a remote advisor panel is being added, use the 273-3110 Communication Electronic Control Module .

• If the CCM is being replaced and a remote advisor panel is not being added, use the 320-9980 Communication Installation Gp .

• If the CCM is not being replaced and a remote advisor panel is being added, use the 273-3107 Electronic Control Wiring Gp .

• If the CCM is not being replaced and a remote advisor panel is not being added, use the 320-9979 Communication Installation Gp .

Prepare the Engine

Before the engine is worked on, take the following precautions:

• Disconnect the cables from the engine battery.

• Drain the engine coolant.

• Shut off the gas supply to the engine.

• Ensure that any source of electricity is disconnected.

• Ensure that hydraulic pressure, or compressed air is relieved.

• Lock out the engine.

Remove the Wiring Harness

1. Uncouple all of the connectors for the main engine wiring harness.

2. Remove the clips, ties, and fasteners that fasten the main engine wiring harness to the engine.

3. Remove the main engine wiring harness.

Remove the Oxygen Sensor

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Illustration 3	g01686934
(1) Oxygen sensor

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Illustration 4	g01686953
(2) Adapter plate

1. Remove the oxygen sensor and the adapter plate. For certain applications, support the exhaust stack in order to access the adapter plate for the oxygen sensor.

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Illustration 5	g01686954
(3) Oxygen sensor buffer (4) Mounting bracket for the oxygen sensor buffer

2. Remove the oxygen sensor buffer and the bracket for the oxygen sensor buffer.

Remove the Components and Install the Components that are needed to Convert from Twin Turbocharger Configuration to Single Turbocharger Configuration.

Remove the Air Cleaners and the Mounting Brackets

ReferenceDisassembly and Assembly, SENR6419, "Air Cleaner - Remove and Install".

Illustration 6	g01458581
Rear view (1) 0L-1351 Bolt (2) 5M-2894 Hard Washer (3) 8N-5254 Reducer Hose (4) 9Y-1704 Air Cleaner Support (5) 8N-3378 Air Cleaner Gp (6) 8N-9729 Air Cleaner Housing Cover (7) 1A-2029 Bolt (8) 5P-4869 Hose Clamp (9) 6H-1717 Bolt (10) 5P-8245 Hard Washer (11) 5P-3860 Hose Clamp (12) 9Y-1707 Bracket As (13) 9Y-1705 Bracket As

1. Remove the air cleaners. Remove all the supports and brackets that fasten the air cleaners to the engine. Refer to Illustration 6.

2. Remove the hoses and the hose clamps.

Note: The 8N-3378 Air Cleaner Gp will be reused.

Remove the Vent Lines and Fittings

ReferenceDisassembly and Assembly, SENR6419, "Turbocharger - Remove".

Illustration 7	g01458623
Top view (1) 121-3211 Tube As (2) 2N-8037 Elbow (3) 011-5224 Reducing Bushing (4) 7H-7055 Clip (5) 8S-4950 Cap (6) 116-2390 Tube As (7) 4S-3652 Union Tee (8) 116-2394 Tube As (9) 121-3209 Tube As (10) 116-2392 Tube As (11) 121-3210 Tube As (12) 030-8145 Flared Reducer (13) 5H-0275 Fitting Nut (14) 003-8581 Union Tee

1. Remove the tubes and the fittings that connect to the turbochargers.

2. Remove the tubes and the fittings that connect to the exhaust bypass valve. Refer to Illustration 7.

Remove the Water Lines for the Turbochargers and for the Exhaust Elbow

ReferenceDisassembly and Assembly, SENR6419, "Turbocharger - Remove".

Illustration 8	g01458730
Rear view (1) 001-7004 Flared Fitting (2) 006-2325 Flared Elbow (3) 090-3000 Flared Elbow (4) 6V-8649 Flared Elbow (5) 2W-7963 Tube As (6) 2W-7964 Tube As (7) 0S-1594 Bolt (8) 5M-2894 Hard Washer (9) 4W-2109 Retainer (10) 4W-2110 Retaining Ring (11) 7L-4773 O-Ring Seal

Illustration 9	g01458750
Top view (12) 8C-6874 Connector (13) 6V-9746 O-Ring Seal (14) 9X-2398 Elbow (15) 293-5522 Hose As (16) 293-5524 Hose As (17) 5K-9090 O-Ring Seal (18) 8C-6875 Connector (19) 293-5523 Hose As (20) 131-4863 Elbow

Illustration 10	g01458765
Right side view (21) 001-7042 Elbow (22) 7C-3917 Tube As (23) 2W-7977 Tube As (24) 7E-6761 Housing (25) 7N-3368 Gasket

1. Remove the tube assemblies, the elbows, and the fittings that connect to the turbochargers and to the exhaust elbow. Refer to Illustrations 8, 9, and 10.

Remove the Oil Lines from the Turbochargers

ReferenceDisassembly and Assembly, SENR6419, "Turbocharger - Remove".

Illustration 11	g01458812
Rear view and right side view (1) 0S-1571 Bolt (2) 5M-2894 Hard Washer (3) 1S-6595 Oil Supply Gasket (4) 1S-4810 Oil Drain Gasket (5) 0S-1594 Bolt (6) 9Y-1040 Turbocharger Tube Assembly (7) 5P-9890 O-Ring Seal (8) 1W-7214 Drain Elbow (9) 4P-0692 Clamp As (10) 9Y-1042 Oil Tube As (11) 9Y-1039 Drain Tube As (12) 6V-4589 O-Ring Seal (13) 9Y-1041 Oil Tube As (14) 9M-4584 Connector (15) 0L-2070 Bolt (16) 250-1498 Elbow As (17) 252-8374 Gasket

1. Remove the tube assemblies, the elbows, and the fittings for the oil lines that connect to the turbochargers.

2. Remove the clamps, the gaskets, and any hardware. Refer to Illustration 11.

Remove the Air Lines for the Aftercooler

ReferenceDisassembly and Assembly, SENR6419, "Aftercooler - Remove and Install".

Illustration 12	g01458898
Top view (1) 9Y-3009 Pipe (2) 5P-8245 Hard Washer (3) 9S-1366 Bolt (4) 7L-4302 Gasket (5) 1A-5822 Bolt (6) 5M-2894 Hard Washer (7) 0L-1351 Bolt (8) 4W-3851 Bracket (9) 2W-7111 Flange (10) 8T-6765 Pipe Plug (11) 4P-4878 Tube As (12) 032-1268 Flared Elbow (13) 6V-2695 O-Ring Seal (14) 9Y-3010 Pipe (15) 4W-9725 Gasket (16) 7B-3235 Bolt (17) 4W-9726 Flange

1. Remove the air lines for the aftercooler. Refer to Illustration 12.

2. Leave flange (17) bolted to the aftercooler housing.

The following parts are reused:

• 5P-8245 Hard Washer

• 1A-5822 Bolt

• 5M-2894 Hard Washer

• 0L-1351 Bolt

• 4W-3851 Bracket

• 2W-7111 Flange

• 4W-9725 Gasket

• 7B-3235 Bolt

• 4W-9726 Flange

Remove the Turbochargers

ReferenceDisassembly and Assembly, SENR6419, "Exhaust Elbow - Remove and Install".Disassembly and Assembly, SENR6419, "Turbocharger - Remove".

Illustration 13	g01458921
Top view (1) 168-7800 Locknut (2) 4W-1454 Exhaust Adapter (3) 121-5736 Gasket (4) 107-3127 Turbocharger Gp (5) 0S-1594 Bolt (6) 5M-2894 Hard Washer (7) 4W-1478 Exhaust Seal (8) 4W-1455 Exhaust Coupling (9) 4W-2359 Gasket

Remove all parts that are identified in Illustration 13.

Remove the Aftercooler

ReferenceDisassembly and Assembly, SENR6419, "Aftercooler - Remove and Install".

Illustration 14	g01459005
Aftercooler (1) 3K-0360 O-Ring Seal (2) 9S-4185 O-Ring Plug (3) 7E-3350 Front Housing (4) 7W-6492 Pipe Plug (5) 8T-6765 Pipe Plug (6) 3D-2824 O-Ring Seal (7) 9S-4183 O-Ring Plug (8) 152-5705 Gasket (9) 4W-9852 Rear Housing (10) 0S-1594 Bolt (11) 5M-2894 Hard Washer (12) 1A-2029 Bolt (13) 9L-9132 Washer (14) 4W-6493 Plate (15) Core Assembly

1. Remove the aftercooler from the engine. Refer to Illustration 14.

2. Leave front housing (3) and core assembly (15) bolted together. Leave the plugs in front housing (3) .

All of the components are reused except for the following parts:

• 8T-6765 Pipe Plug

• 152-5705 Gasket

• 4W-9852 Rear Housing

Remove the Throttle Actuator

ReferenceDisassembly and Assembly, SENR6419, "Fuel Control Actuator - Remove and Install".

Illustration 15	g01459120
Top view (1) 9M-1974 Hard Washer (2) 5S-0003 Nut (3) 4B-3388 Bolt

Illustration 16	g01459121
Rear view (4) 119-5092 Rod (5) 4F-2294 Jam Nut (6) 7E-9748 Rod End (7) 114-9269 Sleeve (8) 263-5007 Throttle Lever (9) 8L-4496 Jam Nut (10) 6V-9163 Rod End

Illustration 17	g01459122
Right side view (11) 5M-2894 Hard Washer (12) 0S-1591 Bolt (13) 091-0081 Spacer (14) 6V-2317 Bolt (15) 1A-2029 Bolt

1. Remove the throttle actuator and remove the linkage for the throttle actuator.

2. Remove all of the parts from the engine. All parts that are reused are identified in Illustration 15, Illustration 16, and Illustration 17.

Remove the Carburetor

ReferenceDisassembly and Assembly, SENR6419, "Carburetor - Remove - High Pressure". Disassembly and Assembly, SENR6419, "Air Inlet Manifold - Remove and Install".

Illustration 18	g01459289
Right side view (1) 5P-8862 O-Ring Seal (2) 6V-5103 O-Ring Seal (3) 4W-9348 Flange (4) 4W-9002 Gasket (5) 0S-1587 Bolt (6) 5P-8245 Hard Washer (7) 1F-7958 Full Nut (8) 7E-4064 Carburetor Gp (9) 7W-7148 Coupling (10) 0S-1595 Bolt (11) 5P-8245 Hard Washer (12) 4W-7992 Gasket (13) 4P-8331 Adapter (14) 4W-9024 Gasket (15) 0S-1619 Bolt (16) 5M-2894 Hard Washer (17) 6W-6672 Spacer

Remove bolts (15), washers (16), and spacers (17). Then remove flange (3), carburetor (8), and inlet adapter (13) from the engine as a unit. Leave these components bolted together. Refer to Illustration 18.

The following parts will not be reused:

• Gasket (14)

• O-ring seal (1)

• O-ring seal (2)

Remove the Exhaust Bypass Valve

ReferenceDisassembly and Assembly, SENR6419, "Exhaust Bypass Valve - Remove and Install".

Illustration 19	g01459469
Exhaust bypass valve (1) 9G-5127 Breather (2) 4H-0553 Fitting (3) 146-0758 Exhaust Bypass (4) 032-1268 Flared Elbow (5) 1B-5355 Full Nut (6) 7C-9710 Gasket

Remove nuts (5) in order to remove the exhaust bypass valve from the engine. Refer to Illustration 19.

The following items will not be reused:

• Nuts (5)

• Gasket (6)

Remove the Exhaust Manifolds

ReferenceDisassembly and Assembly, SENR6419, "Exhaust Manifold - Remove - Water Cooled" Disassembly and Assembly, SENR6419, "Exhaust Elbow - Remove and Install".

Illustration 20	g01459609
(1) 4W-7283 Exhaust Elbow (2) 4W-7274 Bracket (3) 4W-7273 Bracket (4) 1A-5822 Bolt (5) 6M-9613 Bolt (6) 2W-5958 Support (7) 0S-1595 Bolt (8) 7D-1649 Hard Washer (9) 7E-2900 Plate (10) 5P-2603 Taperlock Stud (11) 121-5736 Gasket (12) 9Y-1568 Housing (13) 7C-6239 Exhaust Tee Assembly (14) 0S-1594 Bolt (15) 7C-3921 Exhaust Seal Ring (16) 2W-5713 Adapter (17) 8T-6761 Pipe Plug (18) 290-7082 Manifold (19) 9Y-3838 Manifold (20) 0S-0509 Bolt (21) 5M-2894 Hard Washer (22) 1D-4706 Bolt (23) 7E-4127 Gasket (24) 0L-2070 Bolt (25) 6L-8562 Taperlock Stud (26) 3E-7428 Pipe Plug (27) 0S-1591 Bolt (28) 9S-8752 Full Nut (29) 9L-9132 Washer (30) 1W-2860 Bracket (31) 0V-0375 Bolt (32) 5P-8245 Hard Washer (33) 8T-6762 Pipe Plug (34) 9X-8874 Bolt (35) 1W-2430 V-Band Clamp (36) 7C-3920 Exhaust Seal

1. Remove the exhaust manifolds and the exhaust elbow from the engine. Refer to Illustration 20.

2. Remove two seals (37) and eight seals (38). These seals will not be reused. Refer to Illustration 21 and Illustration 22.

Illustration 21	g01459761
Front view (37) 6V-6809 O-Ring Seal

Illustration 22	g01459756
Right side view (38) 6V-9769 O-Ring Seal

Install the Exhaust Manifolds and the Turbocharger

Install the Exhaust Manifolds

Illustration 23	g01459799
Exhaust manifold and hardware (1) 8T-6761 Pipe Plug (2) 305-2617 Manifold (3) 306-5169 Exhaust Elbow (4) 0S-1591 Bolt (5) 5M-2894 Hard Washer (6) 9S-8752 Full Nut (7) 305-2618 Manifold (8) 1D-4706 Bolt (9) 0L-2070 Bolt (10) 7E-4127 Gasket (11) 168-3349 Pipe Plug (12) 9V-0999 Spacer (13) 5P-8245 Hard Washer (14) 0V-0375 Bolt (15) 313-6932 Bracket As (16) 305-2621 Exhaust Elbow (17) 305-2635 Bracket As (18) 1A-1460 Bolt (19) 1F-7958 Full Nut (20) 0S-1587 Bolt (21) 3E-6916 Full Nut (22) 8C-8491 Hard Washer (23) 8M-2295 Bolt (24) 7L-6443 Bolt (25) 5P-7128 Bolt (26) 4W-1478 Exhaust Seal (27) 303-9357 Coupling (28) 219-3234 Exhaust Seal (29) 121-5736 Gasket (30) 168-7800 Locknut (31) 2N-9288 Taperlock Stud (32) 6V-3631 Full Nut (33) 6L-3143 Bolt (34) 1L-4473 Terminal Bushing (35) 9X-8873 Bolt (36) 9S-1374 Bolt

Illustration 24	g01460227
Exhaust manifold and hardware (37) 313-9550 Taperlock Stud (38) 305-2620 Elbow (39) 229-5333 Exhaust Seal (40) 207-1364 Bellows As (41) 141-1751 Gasket (42) 141-1732 Housing (43) 5P-2603 Taperlock Stud (44) 141-1747 Shield (45) 0S-1588 Bolt (46) 4J-4382 Pipe Plug (47) 1W-7810 Outlet Gasket (48) 311-6494 Exhaust Elbow (49) 3E-2331 Plug (50) 109-1086 Spacer (51) 133-9315 Band Clamp (52) 135-0171 Exhaust Seal (53) 135-0172 Exhaust Seal Ring (54) 308-3813 Bracket As (55) 9S-1366 Bolt (56) 7W-2124 Bracket (57) 313-6930 Bracket As

1. Apply 5P-3931 Anti-Seize Compound on the following items for the exhaust manifold:
   • Threads of bolts

   • Plugs

   • Studs

   • Nuts

2. Install one elbow (38) onto the taperlock studs of left-hand manifold (2) and right-hand manifold (7). Install seal (39) onto each manifold.

3. Fasten the elbow to the manifold with washer (22) and nut (21) .

   Simultaneously tighten the diagonally opposite nuts to the following torque. ... 55 ± 5 N·m (41 ± 4 lb ft)

   Tighten the nuts to the following torque again. ... 55 ± 5 N·m (41 ± 4 lb ft)

4. Clean the mating surfaces of the cylinder heads and the exhaust manifolds.

5. Fasten the exhaust manifolds to the cylinder heads with 16 bolts (8), 16 bolts (9) and 32 washers (5). Use eight gaskets (10) .

6. Apply 5P-3931 Anti-Seize Compound to the threads of the bolts.

   Torque ... 55 ± 5 N·m (41 ± 4 lb ft)

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Illustration 25	g01465427
(5) 5M-2894 Hard Washer (58) 1A-2029 Bolt (59) 0S-1590 Bolt (60) 9S-8752 Full Nut

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Illustration 26	g01465467
(61) 6V-6809 O-Ring Seal

7. Secure the exhaust manifold to the regulator housing. Use two new seals (61). Refer to Illustration 25 and Illustration 26.

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Illustration 27	g01465749
(62) 6V-9769 O-Ring Seal (63) 7E-8888 Elbow (64) 0S-1619 Bolt (65) 7E-8889 Tube (66) 5P-7204 O-Ring Seal (67) 1B-7182 Bolt (68) 7E-8890 Collar

8. Install the inlet tubes for the exhaust manifold. Refer to Illustration 27.

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Illustration 28	g01469871
(15) 313-6932 Bracket As (17) 305-2635 Bracket As (54) 308-3813 Bracket As (57) 313-6930 Bracket As

9. Install brackets (17), (15), (57), and (54). Refer to Illustrations 23, 24, and 28.

10. Assemble exhaust elbow (16) to bellows (40). Ensure that seals (39) have been installed.

    Simultaneously tighten the diagonally opposite nuts to the following torque. ... 55 ± 5 N·m (41 ± 4 lb ft)

    Tighten the nuts to the following torque again. ... 55 ± 5 N·m (41 ± 4 lb ft)

11. Install the assembled exhaust elbow (16) and bellows (40) to elbow (38). Ensure that seals (39) have been installed.

    Simultaneously tighten the diagonally opposite nuts to the following torque. ... 55 ± 5 N·m (41 ± 4 lb ft)

    Tighten the nuts to the following torque again. ... 55 ± 5 N·m (41 ± 4 lb ft)

12. Secure elbow (16) to bracket (17) with bolts (33), washers (13), and nuts (32) .

13. Install housing (42) and gasket (41). Secure housing (42) to exhaust elbow (16) at the front of the engine with bolts (24), washers (22) and nuts (21) .

    Torque ... 55 ± 5 N·m (41 ± 4 lb ft)

14. Secure housing (42) to exhaust elbow (16) at the rear of the engine with bolts (25) and nuts (21) .

    Torque ... 55 ± 5 N·m (41 ± 4 lb ft)

15. Install shield (44) to housing (42). Fasten the shield to the housing with bolts (45), washers (5), and nuts (6) .

    Torque ... 55 ± 5 N·m (41 ± 4 lb ft)

Install the Turbocharger

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Illustration 29	g01469845
(69) 305-4300 Turbocharger Gp

1. For this procedure, refer to Illustration 23. Install turbocharger (69) to exhaust elbow (16). Install gasket (29). Secure the turbocharger to the exhaust elbow with locknuts (30) .

   Torque ... 55 ± 5 N·m (41 ± 4 lb ft)

2. Assemble exhaust elbow (48), coupling (27), seal (26), and seal (28) .

3. Install the assembled parts to turbocharger (69). Fasten exhaust elbow (48) to bracket (54) with bolts (18), washers (13), and nuts (19) .

4. Install exhaust elbow (3) to exhaust elbow (48) and to housing (42). Secure exhaust elbow (3) to exhaust elbow (48) with clamp (51), seal (52), and seal (53) .

   Torque for the clamp ... 14 ± 1.5 N·m (10 ± 1 lb ft)

5. Secure exhaust elbow (3) to housing (42) with bolts (23), washers (22), and nuts (21). Ensure that gasket (47) has been installed.

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Illustration 30	g01477032

6. If necessary, loosen the clamp for the compressor housing in order to align the air inlet pipe. Refer to Illustration 30. After the air inlet pipe has been installed, tighten the clamp for the compressor housing.

   Torque ... 14 ± 1.5 N·m (10 ± 1 lb ft)

Install the Exhaust Bypass Valve

Illustration 31	g01461928
(1) Exhaust bypass valve (2) 5P-2603 Taperlock Stud (3) 7C-9710 Gasket (4) 141-1732 Housing

1. Install exhaust bypass valve (1) onto studs (2) of housing (4) .

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Illustration 32	g01461967
(5) 1B-5355 Full Nut

2. Use a new gasket (3) and new nuts (5) .

Install the Aftercooler

Illustration 33	g01469932
Top view (1) 5M-2894 Hard Washer (2) 3B-1915 Bolt (3) 152-5705 Gasket (4) 7E-3568 Aftercooler Core As (5) 0S-1594 Bolt (6) 7E-3350 Front Housing (7) 1A-2029 Bolt (8) 9S-4185 O-Ring Plug (9) 3K-0360 O-Ring Seal (10) 7W-6492 Pipe Plug (11) 305-2644 Housing

Illustration 34	g01469942
Right side view (12) 9S-4183 O-Ring Plug (13) 3D-2824 O-Ring Seal (14) 4W-6493 Plate (15) 9L-9132 Washer (16) 8T-6765 Pipe Plug

1. Reuse all of the components that were removed from the engine during disassembly except for the following parts:
   • 8T-6765 Pipe Plug

   • 152-5705 Gasket

   • 4W-9852 Rear Housing

2. The following new parts are used for installation of the aftercooler:
   • 305-2644 Housing

   • 152-5705 Gasket

   • 5M-2894 Hard Washer

   • 3B-1915 Bolt

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Illustration 35	g01470003
Left side view

3. Refer to Illustrations 33, 34, and 35.

Install the Carburetor and the Inlet Adapter

Illustration 36	g01459289
Right side view (1) 5P-8862 O-Ring Seal (2) 6V-5103 O-Ring Seal (3) 4W-9348 Flange (4) 4W-9002 Gasket (5) 0S-1587 Bolt (6) 5P-8245 Hard Washer (7) 1F-7958 Full Nut (8) 7E-4064 Carburetor Gp (9) 7W-7148 Coupling (10) 0S-1595 Bolt (11) 5P-8245 Hard Washer (12) 4W-7992 Gasket (13) 4P-8331 Adapter (14) 4W-9024 Gasket (15) 0S-1619 Bolt (16) 5M-2894 Hard Washer (17) 6W-6672 Spacer

1. Install the carburetor and the inlet adapter as a unit.

2. Fasten the carburetor and the inlet adapter to the inlet manifold with bolts (15), washers (16), and spacers (17). Install a new gasket (14) .

3. New seals (1) and (2) must be used with coupling (9) .

Install the Throttle Actuator

Table 8

Reference
Model	Part Number
G3508 high pressure	289-8546 Throttle Gp

Illustration 37	g01459120
Top view (1) 9M-1974 Hard Washer (2) 5S-0003 Nut (3) 4B-3388 Bolt

Illustration 38	g01459121
Rear view (4) 119-5092 Rod (5) 4F-2294 Jam Nut (6) 7E-9748 Rod End (7) 114-9269 Sleeve (8) 263-5007 Throttle Lever (9) 8L-4496 Jam Nut (10) 6V-9163 Rod End

Illustration 39	g01459122
Right side view (11) 5M-2894 Hard Washer (12) 0S-1591 Bolt (13) 091-0081 Spacer (14) 6V-2317 Bolt (15) 1A-2029 Bolt

1. Install the throttle actuator and install the linkage for the throttle actuator.

2. Reuse all parts that were removed from the engine. Refer to Illustrations 37, 38, and 39.

Install the Water Lines for the Turbocharger

Illustration 40	g01470322
Rear view (1) 306-5173 Plate (2) 5P-5613 Flared Cross (3) 305-2654 Tube As (4) 5P-9299 Clip (5) 0S-1594 Bolt (6) 5M-2894 Hard Washer (7) 9S-8752 Full Nut (8) 8M-0755 Connector (9) 305-2658 Bracket (10) 3R-9704 Elbow (11) 8M-0744 Flared Nut (12) 8M-0745 Flared Reducer (13) 004-3099 Connector (14) 6K-3607 Connector (15) 2M-9780 O-Ring Seal (16) 5P-8196 Plug (17) 0L-2070 Bolt

Illustration 41	g01470335
Right side view (18) 7N-7878 Cover Plate (19) 241-3283 Gasket (20) 2M-3881 Lug (21) 2A-4639 Bolt (22) 180-5044 Cover (23) 247-0708 O-Ring Seal (24) 305-2652 Tube As (25) 7L-7262 Flared Elbow (26) 305-2653 Tube As (27) 306-5172 Tube As (28) 7F-2050 Locknut (29) 2P-1281 Union (30) 8S-4951 Cap (31) 8T-6761 Pipe Plug (32) 305-2650 Tube As (33) 305-2651 Tube As (34) 005-4173 Elbow (35) 144-2980 Housing (36) 7N-3368 Gasket

Illustration 42	g01470858
Top view

Install the water lines for the turbocharger. Refer to Illustration 40, Illustration, and 41 Illustration 42.

Lubricate threads and bearing surfaces before assembly with 5P-3931 Anti-Seize Compound .

Lubricate O-ring seals with 1U-6396 O-Ring Assembly Compound .

Install the Oil Lines for the Turbocharger

Illustration 43	g01470695
Rear view (1) 5M-2894 Hard Washer (2) 8S-9191 Bolt (3) 6I-0805 Turbocharger Oil Adapter (4) 4P-4460 Gasket (5) 0S-1608 Bolt (6) 7N-7559 Gasket (7) 9Y-5814 Drain Elbow (8) 4K-8302 Clip (9) 305-2655 Hose As (10) 6K-3607 Connector (11) 6V-4589 O-Ring Seal (12) 9S-4190 O-Ring Plug (13) 2M-9780 O-Ring Seal (14) 8L-2786 O-Ring Seal (15) 030-7943 Elbow (16) 3B-1915 Bolt (17) 0S-1594 Bolt (18) 252-8374 Gasket (19) 4W-9890 Cover (20) 5P-9890 O-Ring Seal (21) 305-2649 Tube (22) 4W-2109 Retainer (23) 0S-1590 Bolt (24) 131-0484 Adapter

Install the oil lines for the turbocharger. Refer to Illustration 43.

Lubricate threads and bearing surfaces before assembly with 5P-3931 Anti-Seize Compound .

Lubricate sealing surfaces with clean engine oil.

Install the Turbocharger Air Lines

Illustration 44	g01470878
Right side view (1) 6V-3917 O-Ring Seal (2) 305-2648 Air Pipe (3) 8T-6765 Pipe Plug (4) 0S-1585 Bolt (5) 5P-8245 Hard Washer (6) 4W-9726 Flange (7) 4W-9725 Gasket (8) 313-6939 Tube As (9) 032-1268 Flared Elbow (10) 5P-8245 Hard Washer (11) 1A-5822 Bolt (12) 2W-7111 Flange (13) 7L-4302 Gasket (14) 9X-6458 Hard Washer (15) 1A-2029 Bolt (16) 9X-8874 Bolt (17) 4W-3851 Bracket (18) 6V-2695 O-Ring Seal

Install the air lines for the turbocharger and for the aftercooler. Refer to Illustration 44.

Lubricate O-ring seals with 1U-6396 O-Ring Assembly Compound .

The following parts are used for installing the air lines:

• 6V-3917 O-Ring Seal

• 305-2648 Air Pipe

• 8T-6765 Pipe Plug

• 313-6939 Tube As

• 032-1268 Flared Elbow

• 6V-2695 O-Ring Seal

• 7L-4302 Gasket

Install the Exhaust Shields

Illustration 45	g01471335
Top view (1) 306-5187 Shield As (2) 306-5188 Shield As (3) 306-5183 Shield As (4) 226-3939 Spring (5) 306-5186 Shield As (6) 306-5185 Shield As (7) 306-5184 Shield As

Install the shields for the exhaust. Refer to Illustration 45.

Install the Air Cleaner

Illustration 46	g01471361
Front view (1) 8N-3378 Air Cleaner Gp (2) 8N-5254 Reducer Hose (3) 5P-4869 Hose Clamp (4) 305-2660 Tube (5) 162-2177 Hose (6) 311-6493 Support (7) 7W-5760 Fastener (8) 8N-9729 Air Cleaner Housing Cover (9) 9X-6458 Hard Washer (10) 1A-2029 Bolt

Illustration 47	g01471387
Left side view (11) 0L-1351 Bolt (12) 5M-2894 Hard Washer (13) 313-6933 Support As (14) 5P-8245 Hard Washer (15) 7B-3235 Bolt

Install the air cleaner. Refer to Illustration 46 and Illustration 47.

Note: Reuse the 8N-3378 Air Cleaner Gp .

Install the Nitrogen Oxide Sensor

Table 9

Engine	Slack In Harness (A)  (1)	Slack In Harness (B)  (2)	Illustration
G3508	135 mm (5.3150 inch)	135 mm (5.3150 inch)	48, 49, and 50

( 1 )	The distance of the slack in the harness that is between the sensor and the support bracket
( 2 )	The distance of the slack in the harness that is between the buffer and the support bracket

Illustration 48	g01438808
Typical example (A) The distance of the slack in the harness that is between the sensor and the support bracket

Illustration 49	g01395328
Typical example (B) The distance of the slack in the harness that is between the buffer and the support bracket

Illustration 50	g01433088
G3508 (1) Adapter ring (2) Sensor (3) Support bracket (4) Sensor harness (5) Tie-wrap (A) The distance of the slack in the harness that is between the sensor and the support bracket (B) The distance of the slack in the harness that is between the buffer and the support bracket

1. Apply 5P-3931 Anti-Seize Compound to the threads of the sensor. Insert the sensor into the adapter ring for the exhaust. Tighten the sensor.

   Torque ... 50 ± 5 N·m (37 ± 4 lb ft)

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Illustration 51	g01513222
(6) 8-pin connector (7) Buffer (8) Harness to sensor (9) Mounting posts (10) Mounting plate

2. Install the buffer onto the two mounting posts. Verify that the buffer is flush with the mounting plate.

3. Replace the two spacers onto the mounting posts. Replace the cover for the buffer. The cover has a slot that is located over the pin on the mounting plate. This slot ensures that the cover for the buffer will align properly onto the mounting plate.

4. Replace the nuts and the washers onto the mounting posts. Tighten the nuts until the nuts are barely snug. This procedure allows movement of the cover for the buffer.

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Illustration 52	g01513234
(11) Tie-wrap (12) Tabs

5. Slide one of the tie-wraps over the wiring from the buffer to the 8-pin connector. Slide the other tie-wrap over the wiring from the buffer to the sensor. Ensure that the tie-wraps go around the metal tabs on the cover for the buffer. Pull the tab in order to tighten the tie-wrap as firmly as possible.

6. Tighten the nuts.

   Torque ... 5 ± 2 N·m (44 ± 18 lb in)

7. Pull the harness straight from the end of the sensor and mark the harness 135 mm (5.3150 inch) from the end of the sensor. Secure the harness to the support bracket at the marked location by using one of the included tie-wraps. Pull the tab in order to tighten the tie-wrap as firmly as possible.

   Note: Do not pull the sensor harness until the sensor harness is tight. Leave an arc of slack so that there is not any pull on the sensor.

8. Pull the sensor harness straight from the buffer. Verify that the slack in the harness from the point between the buffer and the support bracket is correct with the recommended slack. The slack is listed in Table 9. Secure the sensor harness to the support bracket near the buffer by using one of the included tie-wraps. Pull the tab in order to tighten the tie-wrap as firmly as possible.

9. Connect the 8-pin connector of the buffer to the engine harness.

Note: The sensor and the sensor buffer are integrated parts. The sensor and the sensor buffer must be replaced as a single component, if necessary.

Illustration 53	g01486215
Left side view (13) 304-4209 Nitrogen Oxide Sensor Gp (14) 311-6493 Support (15) 5M-2894 Hard Washer (16) 9S-8752 Full Nut (17) 0S-1594 Bolt (18) 4P-8134 Clip (19) 9X-6772 Cable Strap (20) 316-9297 Bracket As (21) 0S-1588 Bolt (22) 315-7845 Plate (23) 2B-2694 Bolt (24) 5S-0003 Nut (25) 8T-9655 Isolation Mount (26) 9N-0869 Hard Washer (27) 307-7359 Screw (28) 8T-4224 Hard Washer (29) 6V-8189 Nut

Illustration 54	g01486613
(30) 307-7356 Cover (31) 139-6535 Spring Pin (32) 7X-6315 Ground Strap

Illustration 55	g01483874
Nitrogen oxide sensor group that is installed

Note: The nitrogen oxide sensor must be calibrated before the engine is put into service. Use the 156-1060 Emissions Analyzer Gp or the 156-1070 Emissions Analyzer Gp in order to calibrate the sensor. Refer to Operating Manual, NEHS0713, "156-1060 & 156-1070 GAS EMISSION ANALYZER " and Operating Manual, NEHS0714, "156-1060 & 156-1070 EMISSION ANALYZER GROUP POCKET CARD TOOL OPERATING TIPS".

Note: Refer to ""Initial Start-up of the Engine" " in this document.

Install the Main Engine Harness Assembly

Install the 337-0286 Engine Harness As . Refer to Illustration 56, Illustration 57, Illustration 58, and Illustration 59 in order to secure the wiring harness to the engine. Connectors for the engine harness are shown in Illustration 60.

Illustration 56	g01493454
Left side view (1) 204-8000 Tie Anchor (2) 5M-2894 Hard Washer (3) 0S-1571 Bolt (4) 193-3973 Tie (5) 4W-9149 Spacer (6) 9X-6772 Cable Strap (7) 4P-7581 Clip (8) 0S-1594 Bolt (9) 251-9389 Bracket (10) 337-0286 Engine Harness As (11) 9S-8752 Full Nut (12) 9L-9132 Washer (13) 7X-0291 Bolt (14) 6B-6205 Spacer (15) 9S-3232 Clip (16) 9X-8874 Bolt (17) 5P-8245 Hard Washer (18) 230-7732 Mount (19) 9F-4831 Spacer (20) 4P-8134 Clip

Illustration 57	g01493473
Right side view (21) 0S-0509 Bolt (22) 9X-3495 Clip As (23) 7K-1181 Cable Strap

Illustration 58	g01493513
Rear view (24) 132-5789 Clip (25) 1F-7958 Full Nut (26) 4P-7429 Clip (27) 0S-1595 Bolt (28) 7W-2124 Bracket (29) 183-3108 Bracket

Illustration 59	g01493534
(30) 2S-2301 Spacer (31) 5S-0003 Nut (32) 9N-0869 Hard Washer (33) 0L-1351 Bolt (34) 2P-8977 Plate (35) 9X-6458 Hard Washer (36) 0L-1352 Bolt (37) 0S-1590 Bolt

Illustration 60	g01493553
Main engine harness connectors

Install the Remote Advisor Panel (if equipped)

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Illustration 61	g01290823
Typical remote advisor panel support

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Illustration 62	g01316757
Remote advisor panel

1. Install the remote advisor panel.

Table 10

Interconnect Harness
Part Number	Description	Length
251-9466	Wiring Harness	6 m (20 ft)
251-9467	Wiring Harness	9 m (30 ft)
251-9468	Wiring Harness	15 m (50 ft)

The remote advisor panel must be installed within 50 feet of the engine. Select the desired length for the interconnect harnesses. Refer to Table 10.

Visual Aids for Securing the Wiring Harness

The following illustrations are for use as a visual aid for securing the wiring harnesses.

Illustration 63	g01436890
Left side view (ECM)

Illustration 64	g01435850
Front view (ECM)

Illustration 65	g01436864
Hardware behind the support bracket for the ECM

Illustration 66	g01435928
Front view

Illustration 67	g01433009
Right side view

Illustration 68	g01435853
Right side view

Illustration 69	g01435870
Right side view

Illustration 70	g01435874
Right side view

Illustration 71	g01501975
Left side view

Illustration 72	g01501976
Left side view

Illustration 73	g01501977
Left side view

Illustration 74	g01435890
Left side view

Illustration 75	g01435895
Left side view

Illustration 76	g01435911
Left side view (harness for the throttle actuator)

Illustration 77	g01432542
Left side view (harness for the throttle actuator)

Illustration 78	g01436870
Top view (harness for throttle actuator )

Illustration 79	g01438279
Left side view (harness for the air/fuel ratio control actuator)

Illustration 80	g01438282
Left side view (harness for the air/fuel ratio control actuator)

Illustration 81	g01435940
Rear view (exhaust temperature module)

Illustration 82	g01501999
Rear view

Illustration 83	g01502001
Right side view

PL1000 Customer Communications Module (CCM)

The PL1000E customer communication module or the PL1000T customer communication module may be used with the G3508 with ADEM 3. The following publications are available for detailed information on these modules.

• Special Instruction, REHS2362, "Installation Guide for the 256-7512 PL1000E Communications ECM"

• Systems Operation/Testing and Adjusting, RENR8091, "PL1000E Communication ECM"

• Special Instruction, REHS2125, "Installation Guide for the 256-7511 PL1000T Communications ECM"

• Systems Operation/Testing and Adjusting, RENR7945, "PL1000T Communication ECM "

Initial Start-up of the Engine

ReferenceSpecial Instruction, REHS2558, "Installation and Initial Start-Up Procedure for G3500 A3 Engines"

ReferenceTroubleshooting, RENR9353, "Gas 3500 A3 Engines", "Nitrogen Oxide Sensor - Calibrate"

Register the Retrofit

Because retrofits to a prime product will change the configuration of the product, updating the configuration in SIMSi and AIMS is important. If the retrofit information is not provided, Caterpillar will not be able to provide important product updates.

The following information includes instructions on registering the updates and retrofits.

1. When performing a retrofit installation, record the vital information in Table 11.

   Note: If the procedure is performed by the customer, ask the customer to record the proper information.

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   Table 11

   Repair Date
   Product Serial Number
   Service Hours or Service Meter Units
   Removed Component Part Number (1)
   Removed Component Serial Number (1)
   Installed Component Part Number (2)
   Installed Component Serial Number (3)

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   ( 1 )	Only applies if a component is replaced by a retrofit component. If the product is an engine, and the product retrofit is a kit for upgrading the engine, disregard the "Removed Component" information. Refer to detailed instructions in Step 3 for more information.
   ( 2 )	Record the highest level retrofit kit, arrangement, or group part number.
   ( 3 )	Most retrofits will not have a serial number. Exceptions include emissions repower engines and diesel particulate filters.

2. Update the product configuration by entering the information from Table 11 into SIMSi and AIMS.

   Note: For retrofits that have a Caterpillar serial number, the AIMS application is "JIZ111-08". For retrofits that do not have a Caterpillar serial number, the AIMS application is "JIZ111-07".

3. For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit".