2002/01/01 Caterpillar

Engine:

G3606 (S/N: 3XF)

G3608 (S/N: 4WF)

G3612 (S/N: 1YG)

G3616 (S/N: 4CG)

The removal of the gas admission valve (GAV) on all G3600 engines requires the removal of the water manifolds and the disassembly of the GAV push rods. Use the following procedure for the disassembly and assembly of the GAV support assembly.

1. Drain the engine coolant.

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Illustration 1	g00854713

2. Remove the water manifold sections (1) that are shown in figure 1.

3. Remove the valve cover from the cylinder head.

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Illustration 2	g00854715

4. Remove the GAV pushrods (2). This can be done with a custom tool (3) or with another tool, which is at the discretion of the service technician. The tool compresses the GAV spring enough to remove the lower pushrod. When the lower pushrod is out of the way, the upper pushrod can be removed.

   Note: The lower pushrod can also be removed by loosening the adjusting screw. The GAV must be placed in the position that is required to adjust the lash setting. This is done by turning over the engine. Ensure that the engine is properly prelubed before turning.

   Note: Removal of the GAV does not require removal of the rocker arm assembly.

5. Remove the valve cover base (4) .

6. Remove the two bolts that hold the GAV support assembly in place.

7. Remove the GAV support assembly.

   Note: Prying may be required in order to free the GAV from the cylinder head bore. Be careful not to damage the GAV support during removal.

8. Perform the needed service on the GAV.

9. Reinstall all the hardware in the reverse order for reassembly of the GAV assembly.

   Note: The GAV lash setting must be reset after reassembly of the hardware.

10. Refill the cooling system.

11. Start the engine.

12. Check for leaks.

13. Make sure that the combustion characteristics of the cylinder with the repaired GAV are within the specifications at the rated speed and load conditions. Make the necessary adjustments in order to properly set the combustion characteristics of the cylinder.