Inlet Air Temperature Sensor Needs To Be Installed On Certain 1991 Model Year 3176 Truck Engines (7LG) Caterpillar

NOTE: 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.

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI3629" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3629"as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: This Service Letter replaces the terminated Service Letter dated December 31, 1991 - PI3545.

Completion Date

Termination Date

Problem

Certain 1991 model year 3176 Truck Engines need to be updated with an inlet air temperature sensor, control module, certification label, boost line, and miscellaneous installation hardware to comply with Federal, California, and Canadian emissions standards.

Affected Product
Model & Identification Number

3176(7LG739, 7LG743, 7LG745, 7LG747, 7LG754, 7LG756, 7LG757, 7LG759, 7LG761, 7LG762, 7LG765, 7LG767, 7LG773, 7LG774, 7LG778-780, 7LG790, 7LG792, 7LG797, 7LG799-800, 7LG803, 7LG810, 7LG811, 7LG813, 7LG817, 7LG820, 7LG823, 7LG828, 7LG832, 7LG837, 7LG842, 7LG844, 7LG847, 7LG852-854, 7LG859, 7LG872, 7LG875, 7LG878, 7LG879, 7LG883-886, 7LG888, 7LG895, 7LG896, 7LG903, 7LG910, 7LG911, 7LG913, 7LG917-922, 7LG926, 7LG930-932, 7LG934-937, 7LG943-945, 7LG948-950, 7LG959, 7LG964, 7LG965, 7LG974, 7LG975, 7LG978, 7LG982, 7LG983, 7LG986, 7LG987, 7LG993, 7LG995, 7LG999, 7LG1004, 7LG1006, 7LG1015, 7LG1026, 7LG1036, 7LG1057, 7LG1059, 7LG1060, 7LG1062, 7LG1065, 7LG1067, 7LG1072, 7LG1088, 7LG1089, 7LG1093, 7LG1095-1097, 7LG1104, 7LG1115-1117, 7LG1120, 7LG1121, 7LG1124, 7LG1125, 7LG1127, 7LG1133, 7LG1136, 7LG1143-1148, 7LG1154, 7LG1156, 7LG1160, 7LG1166, 7LG1171, 7LG1177, 7LG1178, 7LG1180, 7LG1183-1186, 7LG1189, 7LG1191, 7LG1196-1198, 7LG1205, 7LG1212, 7LG1213, 7LG1216, 7LG1224, 7LG1229, 7LG1232, 7LG1240, 7LG1243, 7LG1244, 7LG1253, 7LG1256-1258, 7LG1261, 7LG1262, 7LG1264, 7LG1268, 7LG1271, 7LG1278, 7LG1280, 7LG1281, 7LG1282, 7LG1286, 7LG1295, 7LG1302, 7LG1304, 7LG1308, 7LG1311, 7LG1315, 7LG1328, 7LG1333, 7LG1337, 7LG1345, 7LG1350, 7LG1352, 7LG1354, 7LG1359, 7LG1377, 7LG1378, 7LG1380, 7LG1381, 7LG1384, 7LG1386, 7LG1389-1392, 7LG1396, 7LG1399, 7LG1400, 7LG1402, 7LG1403, 7LG1405, 7LG1406, 7LG1409, 7LG1417, 7LG1419, 7LG1423, 7LG1457, 7LG1463, 7LG1482, 7LG1488, 7LG1490, 7LG1494, 7LG1496, 7LG1499, 7LG1505, 7LG1508, 7LG1513, 7LG1520, 7LG1521, 7LG1528, 7LG1529, 7LG1538, 7LG1541, 7LG1545, 7LG1546, 7LG1548, 7LG1555, 7LG1574-1576, 7LG1579, 7LG1584, 7LG1587, 7LG1590, 7LG1592, 7LG1593, 7LG1595, 7LG1600, 7LG1601, 7LG1609, 7LG1610, 7LG1612-1614, 7LG1616-1618, 7LG1624, 7LG1630, 7LG1633, 7LG1635, 7LG1656, 7LG1657, 7LG1665-1668, 7LG1680, 7LG1684, 7LG1686, 7LG1691, 7LG1694, 7LG1698, 7LG1707, 7LG1710, 7LG1714, 7LG1719, 7LG1723, 7LG1725, 7LG1732, 7LG1740, 7LG1748, 7LG1753, 7LG1795, 7LG1798, 7LG1799, 7LG1804, 7LG1813, 7LG1815, 7LG1831, 7LG1837, 7LG1840, 7LG1863, 7LG1873, 7LG1879, 7LG1885-1887, 7LG1900, 7LG1905, 7LG1911, 7LG1912, 7LG1918, 7LG1924, 7LG1925, 7LG1927, 7LG1930, 7LG1933, 7LG1936, 7LG1939, 7LG1940, 7LG1942, 7LG1944, 7LG1947, 7LG1950, 7LG1952-1956, 7LG1969, 7LG1970, 7LG1973, 7LG1978, 7LG1980, 7LG1983, 7LG1985, 7LG1988, 7LG1996, 7LG2008, 7LG2017, 7LG2020, 7LG2022, 7LG2025, 7LG2052, 7LG2053-2056, 7LG2058, 7LG2068, 7LG2069, 7LG2077, 7LG2079, 7LG2080, 7LG2084, 7LG2095, 7LG2096, 7LG2098, 7LG2101, 7LG2107, 7LG2108, 7LG2129, 7LG2132, 7LG2156, 7LG2160, 7LG2167, 7LG2188, 7LG2195, 7LG2199, 7LG2211, 7LG2215, 7LG2218, 7LG2229, 7LG2232, 7LG2246, 7LG2252, 7LG2253, 7LG2257, 7LG2258, 7LG2296, 7LG2299, 7LG2301, 7LG2305, 7LG2365, 7LG2382, 7LG2677, 7LG2747, 7LG2786, 7LG2796, 7LG2799, 7LG2801, 7LG2805, 7LG3307, 7LG3316, 7LG3319, 7LG3328)

Parts Needed

Dealers will need to order parts for this Program.

NOTE: All parts are common between engine models except the 6I1527, 6I1528, 6I1529, and 6I1530 Control Group Kits.

1 - 6I1527 Control Group Kit (250 HP)

1 - 6I1528 Control Group Kit (275 HP)

1 - 6I1529 Control Group Kit (300 HP)

1 - 6I1530 Control Group Kit (325 HP)

1 - 3J1907 O-Ring Seal

1 - 3J7355 Union

1 - 9L8493 Cap

1 - 4P9612 Extension Harness

4 - 3S2093 Tie

1 - 9S4182 Plug

1 - 2V3216 Clip

1 - 6V5048 O-Ring Seal

1 - 4W5140 Plate

3 - 7W5164 Gasket

1 - 9X3271 Adapter

1 - 9X5370 Control Group

1 - 9Y6139 Hose

1 - 9Y6186 Gasket

1 - 016449 Adapter

Action Required

See the attached procedure.

Owner Notification

U.S. and Canadian owners will receive the attached Owner Notification.

Service Claim Allowances

NOTE: This is a 4-hour job. No other labor operation segments are required, such as steam cleaning, troubleshooting, test after repair, travel time, or mileage.

Parts Disposition

U.S. And Canadian Dealers

NOTE: Transfer the protective cover from the new personality module to the old personality module to protect the electronics during shipment.

Return all control groups (personality modules) and a copy of a completed core credit reguest packing list to:

NOTE: MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE

Attach:

(1-Owner's Notification)

(2-Rework Procedure)

Copy Of Owner Notification For U.S. And Canadian Owners

Rework Procedure

1. Connect ECAP and clear any logged diagnostic code 37 " Fuel Pressure Sensor Fault" or diagnostic code 63 " Low Fuel Pressure Warning ". Repair any current fuel pressure problems.

2. Program new Full Load Setting (FLS) and Full Torque Setting (FTS) numbers using ECAP (factory passwords necessary). Get current FLS\FTS settings from Engine Information Plate on valve cover. See table 1 for new FLS\FTS settings.

Table 1

NOTE: If current FLS\FTS settings are not listed above refer to the attached Additional FLS\FTS Settings List.

Refer to SEHS9349 Tool Operating Manual "Using the NEXG4522 Truck Engine Functions Dual Service Program Module " - Read\Change System Configuration Parameters (pages 23-24) to program new FLS\FTS settings.

3. Remove inlet manifold from engine.

4. Locate and drill an 18 mm (.718") hole in the inlet manifold. Use a square to accurately locate the 75 mm (2.95 ") dimension. Center punch and pre-drill using a 6.35 mm (.25 ") drill bit. See Illustration 1.

NOTE: Location of drilled hole is critical.

5. Tap the drilled hole to "-14 NPTF using a 2P5534 Tapered Pipe Tap. Tap approximately 15 turns to allow full thread depth of the 9X3271 Adapter. Clean all chips and burrs from inside of inlet manifold.

6. Install 9X3271 Adapter into the tapped hole using 8T9011 Solvent Cleaner, 6V1541 Quick Cure Primer, and 7M7456 Bearing Mount. Install adapter and tighten to 60 N ·m (45 lb ft). See Illustration 1.

Illustration 1 - Install 9X3271 Adapter

7. Remove the plug on top of the inlet manifold and install the 016449 Adapter. See Illustration 2.

8. Plug the boost line connector on the end of the inlet manifold with the 9L8493 Cap. See Illustration 2.

Illustration 2 - Top View

9. Install inlet manifold using (3) 7W5164 Gaskets.

10. Remove the boost line from the transducer module and check for presence of water or corrosion. Clear any restriction and remove water from boost line using air pressure. Install boost line to transducer module.

11. Install the 9Y6139 Hose and 3J7355 Union between the existing boost line and the 016449 Adapter. Route the boost line between valve cover 1 and 2. See Illustration 2.

12. Install Inlet Air Temperature Sensor (part of 9X5370 Control Gp.) and 3J1907 O-Ring Seal into the inlet manifold 9X3271 Adapter. See Illustration 2.

13. Remove the existing fuel pressure sensor from the fuel filter base.

14. Install the 9S4182 Plug and 6V5048 O-Ring Seal into the fuel filter base to replace the fuel pressure sensor.

15. Connect one end of the 4P9612 Extension Harness to the inlet air temperature sensor (J21). Connect the other end of the harness to the old fuel pressure sensor connector (J16). See Illustration 2.

16. Install the 2V3216 Clip on the sensor harness and secure using valve cover bolt. See Illustration 2.

17. Route the 4P9612 Extension Harness between valve covers 1 and 2. Use (4) 3S2093 Tie Strap to secure harness and boost line. See Illustration 2 for tie locations.

18. Remove existing control group (personality module) from the engine. Install the protective cover removed from the new personality module.

19. Install new control group (personality module). Control group kit includes personality module, certification label, recall label, and permanent marker. See Table 2 and Illustration 3 to determine control group kit needed.

Table 2

NOTE: 4P6500 Recall Label included in control group kit.

Illustration 3

20. Stamp the new personality module part number in the " PERF SPEC" space on a new 4W5140 Engine Information Plate. See Table 2 for appropriate part number. Copy all other information from the existing information plate to the new 4W5140 Engine Information Plate. Clean existing plate and install the new plate on top of the existing information plate.

21. Clean existing certification label on engine valve cover. Note the "Date of Manufacture Month" which is punched out.

22. Punch a hole in the new certification label for the " Date of Manufacture Month" noted from the old certification label. See Table 2 for the appropriate certification label part number. Install the new certification label on top of the old certification label.

23. Print the "Dealer Code" on the 4P6500 EPA Recall Label using the black "permanent" marker included in the control group kit. Attach the recall label on the valve cover near the certification label.

24. Stamp "5V" on the engine block near the serial number plate.