G3612 and G3616 Engines Caterpillar

Illustration 1	g00484068
Left side of engine

(1) Aftercooler inlet line

(2) Adjusting bolt

(3) Housing

Bore in housing for shaft bearings ... 25.402 ± 0.010 mm (1.0001 ± 0.0004 inch)

Outside diameter of shaft bearings ... 25.529 ± 0.020 mm (1.0051 ± 0.0008 inch)

(4) Air inlet from turbocharger

(5) Cover assembly with adjusting bolt and locking nut

(6) Lever and linkage

(7) Adjustable rod

(8) Actuator

(9) Inlet port

(10) Outlet port

Note: Assemble the actuator so the inlet port and the outlet port are aligned. This is shown in Illustration 1. The ports on the actuator are stamped "Inlet" and "Outlet".

(11) Shaft

(12) Plate and mounting bolts

(13) Thrust washer

Width of groove in shaft for thrust washer ... 6.53 ± 0.10 mm (0.2571 ± 0.0039 inch)

Thickness of thrust washer ... 6.00 ± 0.05 mm (0.236 ± 0.002 inch)

Use the following procedure to assemble the choke and the actuator linkage.

1. While housing (3) is removed from the engine, install shaft (11) in the housing.

2. Assemble plate (12) to shaft (11). Leave the mounting bolts for the plate loose.

3. Install cover assembly (5) and thrust washer (13). Tighten the mounting bolts for the thrust washer.

   Torque ... 47 ± 9 N·m (35 ± 7 lb ft)

4. Hold the plate in the fully closed position while tightening the mounting bolts for the plate.

   Torque ... 12 ± 3 N·m (9 ± 2 lb ft)

5. Install assembled housing (3) and the gaskets on the engine.

6. Install the plate and the housing. Hold the plate in the closed position. Tighten adjusting bolt (2) until the adjusting bolt makes contact with the stop plate.

7. Tighten the adjusting bolt for an additional 1/4 turn. Tighten the locknut.

   Torque ... 25 ± 6 N·m (18 ± 4 lb ft)

   Note: Do not allow the adjusting bolt to turn while the locknut is tightened.

8. Install the lever and linkage (6) on the shaft.

Illustration 2	g00496202

Use the following procedure to adjust the actuator linkage.

1. With the choke plate in the fully closed position, assemble the actuator lever at angle (A) of 27 degrees from horizontal.

2. With the choke plate in the fully open position, assemble the actuator lever at angle (B) of 46 degrees from horizontal.

(14) Rod end nuts

Torque ... 25 ± 6 N·m (18 ± 4 lb ft)

Illustration 3	g00496203

1. With the choke plate in the fully closed position, assemble the lever for the choke at angle (C) of 45 degrees from horizontal. Assemble the actuator lever to angle (D) of 34 degrees from the horizontal.

2. With the choke plate in the fully open position, the lever for the choke should be at angle (E) of 30 degrees from horizontal. Assemble the actuator lever to angle (F) of 39 degrees from the horizontal.

(15) Rod end nuts

Torque ... 25 ± 6 N·m (18 ± 4 lb ft)