FA510675 Force STARTER SUPPORT W/A609853

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PSP FOR REPAIRING A FAILED SLEEVE OR SLEEVE TO HEAD JOINT ON CERTAIN 3176 TRUCK ENGINES THAT HAVE FUEL DILUTION OF THE COO LANT - PS0471 - MAILED USAND CANADA, TRUCK TEPS - REVISED 03/91
  The information supplied in this service letter may not be valid after the termination date of this program.   Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
(Revised March 1991) U-149 TT-8 1101, 1201, 1250 PS0471 This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS0471" as Part Number, "7755" as Group Number, and "96" as Description Code. Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible. This Revised Service Letter replaces the July 19, 1990 Service Letter. Changes have been made to the Termination Date, Parts Needed, Action Required, Service Claim Allowances, and Parts Disposition. Termination Date
December 31, 1991
Problem
A failed sleeve or sleeve to head joint may cause fuel dilution of the cooling system on certain 3176 Truck Engines.
Affected Product
Model Identification Number 3176 2YG1-4901
Parts Needed
6 - 7C0324 Exhaust Manifold Gasket 4 - 7C2597 Manifold Gasket 5 - 8C3684 Antifreeze (Gal) 8 - 7E9438 Spacer 6 - 3H2388 Seal 6 - 4P1711 Spacer 6 - 5P3456 Fuel Manifold Seal 6 - 5P8066 O-ring (upper) 1 - 0R3254 Cylinder Head 1 - 1S7057 Turbo Gasket 6 - 8T0100 Bolt 8 - 6V1819 Bolt 1 - 7W2398 Turbo Gasket 3 - 7W5164 Inlet Manifold Gasket 6 - 9X3979 O-ring (lower) 1 - 9Y7044 Cylinder Head Gasket 5 - -- Distilled Water (Gal)
Action Required
***** Parts Stock ***** Remove from parts stock all 0R2828 and 0R2831 Cylinder Head Assemblies with package dates prior to December 1989. ***** Affected Product ***** 1. When it is necessary to replace a sleeve due to failure of the sleeve or the sleeve to head joint: a) Check for 3S stamped on the block next to the serial number plate. If block is stamped with 3S, change only the failed sleeve using 4P7135 Sleeves. The 4C6730 Roller Expander and 4C6714 Swage must be used to install the new sleeves. See Special Instruction SEHS9246. b) It is possible that a 0R3254 Cylinder Head may have been installed before this Service Letter was issued and the block may not be stamped. A 0R3254 Cylinder Head can be identified by the part number 4P7267 stamped on the left rear top surface of the head casting. If this is found, replace only the failed sleeve using 4P7135 Sleeves and the 4C6730 Roller Expander and 4C6714 Swage. Stamp 3S on the block next to the serial number plate after the repair. c) If block is not stamped 3S, replace the cylinder head with 0R3254 Cylinder Head. 2. Ream the injector sleeve seating surface in new head. See Special Instruction SEHS9246 Engine Disassembly 1. Remove cylinder head. 2. Check cylinder head bolt hole depth. If the bolt holes are shallow, tap the shallow holes to the correct depth. 3. Check liner projection - Spec. 0.13 +/- 0.08 mm (.005 +/- .003 in.). Replace spacer block if liner projection varies more than .004 in. from front to rear. SENR3909-03. 4. On engines with identification numbers 2YG1-3250, make sure the October 20, 1989 Service Letter - PS4375 is completed. (Injector rocker arms, exhaust rocker arms and pistons crowns). Off Engine Test and Assembly 1. Test electronic unit injectors for leaks and VOP on test bench. Reference attached leak test. Replace as necessary. Note: The part number of the O-ring retaining the contact button on top of the injector is 336044. 2. Install exhaust manifolds on new head using longer 6V1819 Bolts and 7E9438 Spacers on #1, #2, #5 and #6 cylinders. Tighten the bolts to a torque of 55 N.m (41 lb ft). Do not over tighten the bolts. Engine Assembly 1. Transfer the remaining components and install the new cylinder head. 2. Install the injectors using longer 8T0100 Bolts and 4P1711 Spacers. Tighten the bolts to a torque of 30 N.m (22 lb ft). Use liberal