Product Support Program For Cylinder Head Gasket Failures On Certain 3306 And 3306B Truck Engines Caterpillar

Only items directly referred to under the heading "Parts Needed" are applicable to this program.

If claiming more oil than specified in the Operation & Maintenance Guide, such as engines equipped with Luberfiners or extended oil change package, document the need for additional oil in the claim story.

Parts Disposition

COSA Dealers

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

All Other Dealers

Warranty claim parts that do not involve core credit must be held for 30 days after the Caterpillar Claims Register Date. Warranty claim parts that involve core credit must be held for 15 days after the Caterpillar Claims Register Date.

NOTE: Failure to clearly mark the areas of damage on all of the parts can result in claim credit being denied. Head To Block Joint Repair Guideline

Attach. (1-Rework Procedure)

Head To Block Joint Repair Guideline

NOTE: This is Caterpillar's recommended procedure for the repair of 3306 and 3306B Engine cylinder head gasket failures.

Contents

Fuel System

For governors that are not factory sealed, check fuel settings and record the actual and factory specifications in the Service Report. This program cannot be applied to engines not found within factory specs.

Exhaust Gas Leakage Tests

Exhaust leaking past the fire ring seal will normally escape into the atmosphere or coolant. Unless the leak is severe, detection of leakage into the coolant will require further investigative testing for verification.

Two methods can be used to verify head gasket fore ring damage.

If exhaust gas leakage is not detected and verified, this program does not apply.

1. Install a modified radiator cap, or cooling system test adapter, that prevents a buildup of system pressure for the bottle test. Run the engine until reaching operating temperature of 85°-99° C (186°-210° F). Fill a clear bottle with water and place the overflow tube or extension from the cap or adapter into the bottle. If exhaust gas is entering the cooling system, a consistent flow of bubbles will be visible in the water; fire ring damage is likely.

2. Install system pressurizing pump/gauge kit Part No. 9S8140 or equivalent and run the engine until reaching operating temperature of 85 °-99° C (186°-210° F). Pressurize the system to nominal pressure 35-48 kPa 5-7 PSI) with the pump and continue to run the engine. Monitor the gauge and if pressure continues to rise during engine operation, fire ring damage is likely.

With exhaust gas leakage verified and the governor settings found within factory specification, this program can be administered.

Clean

Steam clean the engine if needed before disassembly.

Cylinder Head - Bottom Deck

Thoroughly clean the cylinder head bottom deck with a wire wheel or Scotchbrite pad. If erosion or fire ring beat-in exceeds .025 mm (.001 ") in the fire ring sealing area as measured with the 8T0455 liner projection tool kit, repair by machining while maintaining minimum head thickness specifications of 98.89 mm (3.893 ").

If damage is excessive use a remanufactured cylinder head.

Spacer Plate

Thoroughly clean both sides of the steel spacer plate with a wire wheel or Scotchbrite pad. The standard spacer plate measures 9.970 mm ± .025 mm (.3925 ± .001"). If the spacer plate has corrosion damage the thickness may very an additional .025 mm (.001 ").

Cylinder Packs

NOTE: Do not measure liner projection before cylinder pack removal unless necessary to verify the workmanship of a previous repair.

Remove all cylinder packs from the engine using the 8T0812 puller or equivalent. Use care when removing the packs from the block to guard against inadvertent damage to the liner seat by the connecting rod/bolts. Refer to Guideline For Reusable Parts SEBF8068 "Cylinder Liners". Inspect each liner wall outer diameter for deep pitting {greater than 2.23 mm (.090 ")} that would prevent reusability.

NOTE: Regardless of other damage, liners with deep pitting caused by poor cooling system maintenance are not claimable under this program.

Remove the filler band and clean the liner flange/seat area on the remaining liners with a wire brush to allow for careful visual inspection. Liner flange thickness measurement is no longer a criteria to determine liner reusability under this program. Perform a visual inspection of the seating surface (bottom) of the liner flange per the reuse guide. Evidence of minor fretting/dark stains or discoloration is acceptable when it is circumferential and does not prevent the liner from sealing. Groups or patches of pits/erosion occurring in random patterns under the liner flange are not acceptable; DO NOT REUSE THE LINER. This type of extensive damage normally occurs adjacent to similar erosion on the cylinder block.

Mark the damaged area(s) with a paint stick or similar marker. See the Service Claim Allowances.

Cylinder Block - Top Deck

Clean the cylinder block top deck completely with wire brush or Scotchbrite pad. Use caution when cleaning around the liner bores with rotary abrasive pads. The liner seat can be damaged if pad is not held parallel with the block surface. This damage may allow the liner to sink after operation due to reduced seating area. After cleaning, use a flat file to dress the top deck to remove burrs and highlight the original factory milling marks. Carefully inspect each liner seat area for signs of measurable erosion. Determine measurable erosion with an 8T0455 liner projection gauge kit. Measurable erosion generally will destroy the milling mark pattern and exhibit a rough pebbly surface. If erosion directly under the liner flange measures .025 mm (.001 ") deep or more with the depth gauge, record these measurements in the Service Report.

Cylinder Block - Top Deck (cont)

Repair this damage by counterboring the block deck and installing the thinnest possible stainless steel insert from the part list. Measurable erosion occurring outside the immediate liner seat area is permissible. This erosion does not affect the stability of the liner nor the sealing ability of the head gasket. This erosion will not clean up by counterboring. A certain amount of measurable erosion under the water ferrules is permissible. Excessive erosion may be filled with 5P3321 Epoxy, 8T9022 RTV Compound, or liquid metal filler. Remove excess compound to level even with the block surface.

Cylinder Block - Counterbore For Liner Seat Inserts

NOTE: Counterboring all six liner seats to improve liner projection or removal of the engine to machine the top deck of the block is not claimable under this program.

Counterbore only the block liner seats that exhibit measurable erosion of .025 mm (.001 ") or greater. Generally, liner seat erosion resulting from head gasket failure require counterboring only one or two cylinder liner seats. Use only stainless steel inserts. (See parts list.)

Protect the crankshaft rod journals adjacent to the repair by covering with paper towels and taping. Cover the lifter bore area with paper towel or foam inserts. Tape or coat with heavy grease the oil supply dowel to prevent chip entry.

Install counterboring tool and tighten the hold down bolts to a torque of 68 N ·m (50 lb ft). A counterboring tool equipped with a speed handle provides a smoother cut than a tool equipped with a "Tee" style handle by reducing tool chatter caused by start-stop rotation. Machine a maximum of .10 mm (.004 ") for any one dial setting. Use a depth gauge to measure progress when nearing the depth needed to install the thinnest insert 9L5855 Insert .762 mm (.030") thick. Reduce machine depth to .001" per out until reaching the final depth. Measure to verify actual insert thickness and install insert so that it is flush with the top of the block within .013 mm (.0005 ") Ensure that the machined counterbore is level in four spots and free of tool chatter marks.

If counterboring to the depth of the thinnest insert does not clean up 100% of the erosion/crack damage, machine to the depth of the next insert. The 9L5856 Insert .035 mm (.035 ") thick. The 9L5858 Insert 1.143 mm (.045") is the thickest available insert. The maximum counterbore depth is 2.286 mm (.090 "), by stacking two 9L5858 Inserts.

NOTE: This in a new recommendation. The bore in the block for the insert should be 144.780 mm ± .076 mm (5.700 ± .003"). Contact your Caterpillar Dealer or Service Rep. if damage extends deeper than described above.

When machining is complete, deburr both edges of the counterbore with emery paper or #400 wet-dry sandpaper. Use a Wet-dry vacuum to remove cuttings from cylinder bores, water jacket and head bolt holes. Remove foam inserts, paper towels, tape and all other protective covers. If necessary, run threaded tap down head bolt holes to remove burrs and thoroughly clean out head bolt holes. Wash down cylinder block with solvent or use pressurized air to ensure block/crank/lifter bore cleanliness. Install inserts dry (no sealant).

Liner Projection

The liner projection specification is 0.033 - 0.175 mm (.0013"- .0069 ").

Replace all liner filler bands and o-rings. Lubricate the filler bands with oil and lubricate the O-rings with liquid soap. Install the cylinder packs with new connecting rod bearings before the filler bands swells. Install spacer plate gasket and spacer plate. Bolt down cylinder liners and spacer plate with 14 7Kl977 plastic washers, 14-8F1484 flat washers and 14-2S0736 hard washers, from the head bolt, and 14-0S1589 -11 × 1.75" bolts to bolt down the spacer plate and liner. (Refer to Illustration). This method alleviates the need for the "H" bar to hold down liners during projection. Tighten the bolts evenly in 4 intervals up to 95 N ·m (70 ft-lb) as shown in the service manual. Use the 8T0455 liner projection tool group to obtain four measurements on each liner flange next to the hold down bolts. Besides the allowable range for the entire set of liners 0.033 - 0.175 mm (0013-.0069 "), the maximum differential between the high and low measurements made at four places around each liner is 0.051 mm (.002 "). The average projection of liners next to each other must not be more than 0.051 mm (.002 "). The maximum difference of all average measurements of all liners must not exceed 0.102 mm (.004 ")

Head Bolts

Insert head bolts for reusability. Replace the head bolts that have surface damage (pitting or erosion) on the shank that cannot be polished smooth. Lightly coat the head bolt threads, washers and bottom of bolt heads with 6V4876 Molykote Paste. Use of this friction reducing paste will significantly improve the load on the gasket. Do not use oil.

Final Engine Assembly

Install the cylinder head bolts and tighten to the correct specifications and sequence as described in the Service Manual. The torque for the large head bolts is 250 ± 17 N·m (185 ± 13 lb ft).

Illustration 1 - 1. 0S1589 Bolt, 2. 2S0736 Washer, 3. 8F1484 Washer, 4. 7K1977 Washer

Illustration 2 - Install Bolts