Reassembly of the Throttle Body for Certain G3516B Engines{1265} Caterpillar

Engine:

G3516B (S/N: ZBB1-UP; CSC1-UP; ZBC1-UP)

Introduction

Do not perform any procedure that is outlined in this Special Instruction until you read and understand the information that is contained in this document.

Required Parts

Illustration 1	g02160572
(1) 151-8669 Throttle Body (2) 175-3131 Carrier (3) 8H-0708 Bolts (4) 6V-9178 O-Ring Seal (5) 175-3125 Spring (6) 6V-1232 Screw (7) 151-8670 O-Ring Seal (8) 175-3127 Seats (9) 175-3136 Cover (10) 5L-4035 Retaining Ring (11) 6V-8837 Bolt (12) 151-8673 Throttle Plate (13) 5H-9899 Retaining Ring (14) 5P-6836 Bearing (15) 175-3129 Shaft (16) 175-3148 Ball Bearing

Reassembly of the Throttle Valve

If the parts are visibly dirty, then wash all of the parts except the bearings and the carrier assembly. Do not use ultrasonics on te parts that made of anodized aluminum. Use an air gun to blow out the carrier assembly.

Installing the Throttle Housing Bearing

Illustration 2	g02160632
(1) 151-8669 Throttle Body (16) 175-3148 Ball Bearing

Use an appropriately sized socket or pipe to press bearing (16) into the body (1) .

Note: Ensure that the bearing is pressed into the body evenly.

Installing the Shaft and the Throttle Plate

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Illustration 3	g02160818
(1) Throttle Body (12) 151-8673 Throttle Plate (15) 175-3129 Shaft (17) "TOP"

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Illustration 4	g02160878
(10) 5L-4035 Retaining Ring (13) 5H-9899 Retaining Ring (15) Shaft

1. Hold the throttle plate (12) inside the throttle body (1) with the word "TOP" (17) in the position shown in Illustration 3.

2. Insert the shaft (15) in the throttle body (1) through the throttle plate (12) into the bearing (13) .

3. Install retaining ring (10) into the groove on shaft (15)

   Note: When starting from the closed position, the shaft and the butterfly plate must rotate clockwise to the open position.

Installing the Carrier Assembly

Illustration 5	g02161654
(2) 175-3131 Carrier (5) 175-3125 Spring (7) 151-8670 O-Ring Seal (8) 175-3127 Seat (15) Shaft (18) Glyd seal

Illustration 6	g02161663
(3) 8H-0708 Bolt (10) Retaining Ring (14) 5P-6836 Bearing (15) Shaft

1. Apply petroleum jelly to the O-ring (7). Install the O-ring on carrier (2) .

2. Apply a film of petroleum jelly to the large diameter portion the shaft (15) and to the glyd seal (18) in the carrier (2). Gently install the carrier assembly in the throttle body (1). Be careful not to damage the glyd seal. Insert the assembly into the throttle body until the flange of the assembly is flush with the face of the housing.

3. Apply Loctite 243 to four screws (3). Use the screws to secure the carrier (2) to the throttle body. Torque the screws to 2.8 N·m (25 lb in).

4. Install one spring seat (8), spring (5), and the other spring seat into the counter-bore of the carrier.

5. Slide bearing (14) and retaining ring (10) onto the shaft (15). Using an appropriately sized socket or pipe, push the bearing and retaining ring against the spring force. Apply pressure until the bearing and the retaining rings snaps into place. Ensure that the retaining ring is fully seated in the groove of the shaft.

   Note: Ensure that the bearing is pressed into the body evenly.

Securing the Throttle Plate and Installing the End Cap

Illustration 7	g02161969
(1) Throttle body (11) 6V-8837 Bolt (12) Throttle plate

Illustration 8	g02161970
(1) Throttle body (6) 6V-1232 Screw (9) 175-3136 Cover (4) 6V-9178 O-Ring Seal (16) Ball bearing

1. Install three bolts (11) through throttle plate (12) and start into the shaft.

2. Using an appropriately sized socket or pipe ensure that the bearing (16) is fully seated the body (1) .

   Note: Ensure that the bearing is pressed into the body evenly.

3. Close the side of the throttle plate (12) with the word "TOP". Hold the throttle plate in the closed position while tightening the center screw. This action will ensure that the throttle plate is properly located in the throat of the throttle. Tighten the screws to a torque of 8.1 N·m (72 lb in)

4. Rotate the throttle plate to ensure that the plate moves smoothly without scraping the throat of the throttle. Recheck that the bearing is still fully seated in the body.

5. Apply petroleum jelly to O-ring (4). Install the O-ring around the collar of end cap (9)

6. Apply Loctite 243 to the end cap screws (6). Secure the end cap to the throttle body. Tighten the screws to a torque of 0.8 N·m (7 lb in).