G3500 Engines Caterpillar

Assembly Procedure

Valve Lifters

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Illustration 1	g01051073

1. Install guide spring (10) in the valve lifter.

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Illustration 2	g01354290

2. Place valve lifter (9) in a container of clean engine oil prior to installation.

3. Install valve lifter (9) in the cylinder head.

   Note: Refer to the Specifications Module, "Valve Rocker Arms, Lifters, and Bridges" for additional information.

Inlet and Exhaust Valve Guides

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Illustration 3	g01354132

1. Place clean engine oil on the outside of the valve guides prior to installation.

2. Use Tooling (E) to install the valve guides. The valve guide should extend 26.00 ± 0.50 mm (1.024 ± 0.020 inch) above the surface of the cylinder head.

Inlet and Exhaust Valve Seat Inserts

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Illustration 4	g01354361

1. Cool valve seat inserts (11). Install valve seat inserts (11) with Tooling (F) .

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Illustration 5	g00598233

2. The orientation of the valve seat inserts is shown in Illustration 5.

Valve Train Bridge Dowels

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Illustration 6	g01051069

1. Use Tooling (G) to install bridge dowels (8). The bridge dowels must extend 66.5 ± 0.5 mm (2.62 ± 0.02 inch) above the surface of the cylinder head.

Inlet and Exhaust Valves

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Illustration 7	g00618922

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Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened.

1. Place clean engine oil on valves (7) and install valves (7) in the cylinder head.

2. Install seal (6), inner spring (4), outer spring (5), and valve rotator (3) on the valve stem and the valve guide.

3. Compress the valve spring with Tooling (A) and install retainer lock (2) .

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If the valve locks are not positioned correctly, the locks can be expelled when the spring pressure is released. To help prevent personal injury, stay away from the front of the valve retainer and springs. Ensure that the valve locks are positioned correctly.

4. Remove Tooling (A) and lightly tap the top of the valves with a hammer. This will ensure that the retainer locks are in the proper position.

5. Repeat Steps 1 through 4 for the remaining valves.

End By: Install the cylinder head.