PSP FOR EXHAUST VALVE STICKING ON 1990 MODEL YEAR 3116 TRUCK ENGINES - PS4568 - MAILED US AND CANADA, LIMITED TRUCK TEPS - THI S SL EFFECTIVE NOVEMBER 1, 1990 Caterpillar

(Effective November 1, 1990)
U-49
TT-2.1
1272  PS4568
NOTE: This Program can be administered either before or after a
failure. In either case the decision whether to apply the
Program is made by the dealer. When reporting the repair, use
"PS4568" as Part Number, "7755" as Group Number, and "96" as
Description Code.
NOTE: Whenever possible, this program should be implemented at the same
time as the October 20, 1990 Service Letter - PS4530 and the
January 20, 1991 Service Letter - PI1155.
NOTE: Although this program can be administered either before or after
failure, (exhaust valve sticking) it is recommended that it be
implemented before failure only in northern or high altitude
climates that regularly have winter temperatures of -10 deg. C
(15 deg. F) or lower. Do all applicable portions of this Service
Letter.

March 31, 1992

Exhaust valve sticking and/or excessive white smoke at startup has occurred
on certain 3116 Truck Engines operating in areas with cold ambient
temperatures. The items listed under Action Required help enhance the
combustion process, reduce occurrence of white smoke, and reduce exhaust
valve sticking. Field tests show good results in reducing both white smoke
and exhaust valve sticking when all of these items have been completed.

Model Identification Number
3116 7SF1-Up (1990 Emissions)
NOTE: This program affects all 1990 and 1991 model vehicles with 3116
Truck Engines that have engine serial numbers beginning with 7SF.
The 1991 or 1991-I vehicles equipped with a 3116 Truck Engine
having engine serial numbers beginning with 2BK are not affected
(1991 Emissions).

1 - 7E5254 Regulator - Temperature (7SF1-12502 Only)
1 - 7E9425 Coolant Temperature Switch
1 - 3J1907 O-Ring Seal (Coolant Temperature Switch)
1 - 3K0360 O-Ring Seal (Heater Return Line to Water Pump
Housing)
1 - 4P2684 Gasket - Water Regulator (7SF1-12502 Only)
1 - 4P6602 Module Heater Control
2 - 2S3440 Clamp (Radiator End Tank Nipple cap and Heater Hose
to Water Pump)
1 - 6V1438 Connector (Heater Return Line to Water Pump Housing)
1 - 4W5140 Plate (Use to correct the Engine Information Plate)
6 - 9Y7355 Seat (Valve Spring)
1 - * Cap-Radiator End Tank Nipple
1 - ** Winter front
* General Motors Part Number 15544596 or similar can be used.
** Procured from local supplier (Note: In Canada, GM part
number 10952232 Winter Front is available.)

(Refer to the attached procedure for specific instructions)
1. If applicable, make sure the October 20, 1990 Service Letter - PS4530
has been completed. (Product Support Program For Installing Stronger
Exhaust Valve Push Rods On Certain 3116 Truck Engines)
2. Install a winter front that can be opened as described below.
(Installation subject to customer approval.)
... The front should have a minimum opening dimension of at least 387
sq. cm (60 sq. in.)
... The front should be fastened to the hood and cover the entire grill,
including the gap around the grill between the edges of the grill
and the hood.
3. Replace the 7E5561 Air Inlet Heater Control Module with a 4P6602 Control
Module. See Part "A" of the attached rework procedure.
The 7E5561 Module used a 7 minute "On" cycle. The 4P6602 module is "On"
for 10 minutes, then cycles "On" 10 seconds, "Off" 10 seconds for an
additional 10 minutes.
4. Replace the 7E6106 Coolant Temperature Switch in the regulator housing
with a 7E9425 Switch and 3K0360 Seal. See Part "B" of the attached
rework procedure.
The former switch turned the air inlet heater off when the jacket water
temperature reached 85 deg. F. The new switch turns the air inlet
heater off when the jacket water reaches 120 deg. F.
5. On engines with serial numbers 7SF1-12502, replace the temperature
regulator and gasket with a new 7E5254 Regulator-Temperature and a
4P2684 Gasket See Part "B" of the attached rework procedure.
The new regulator has an internal vent valve to vent air from the
cooling system. Use of the new gasket in regulator housings on engines
7SF1-12502 is necessary to cover the old vent valve passage. There is
no need to remove the old vent valve.
6. Reroute the heater return hose from the radiator end tank to the bottom
fitting on the right side of the water pump. See Part "C" of the
attached rework procedure.
7. Remove the exhaust valve stem seals and install 9Y7355 Seats under the
exhaust valve springs. Do not remove the seals from the intake valves.
See Part "D" of the attached rework procedure.
8. Advance the fuel injection timing. See Part "D" of the attached rework
procedure. Refer to Step 15 under "Before Failure".

Product Caterpillar Dealer Suggested Customer Suggested
Miles Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
***** Install Winter Front *****
***** Reroute Heater Return Line *****
***** Replace Air Inlet Control Module And *****
***** Coolant Temperature Switch *****
0-150000 100% 6 0 0 0 0
150001- 100% 3 0 0 0 3
200000
NOTE: It is a 4-hour job to reroute the heater return line and replace
the control module and switch.
NOTE: It is a 2-hour job to install the winter front. Actual cost up
to a maximum of $150.00 US will be allowed towards the cost of
purchasing and installing a winter front.
***** Replace Temperature Regulator - 7SF1-12502 Only *****
0-150000 100% 1 0 0 0 0
150001- 100% .5 0 0 0 .5
200000
NOTE: It is a 1-hour job to replace the temperature regulator.
***** Before Failure Only *****
***** Remove Exhaust Valve Seals & Advance Timing *****
0-150000 100% 3* 0 0 0 0
150001- 100% 1.5* 0 0 0 1.5*
200000
NOTE: It is a 3-hour job to remove the exhaust valve seals and advance
the timing.
* Claim half the above amount if done in conjunction with the October
20, 1990 Service Letter - PS4530.
***** After Failure Only *****
***** Remove, Clean, & Install Cylinder Head *****
***** Remove Exhaust Valve Seals & Advance Timing *****
0-150000 100% 17 0 0 0 0
150001- 100% 8.5 0 0 0 8.5
200000
NOTE: It is a 17-hour job to remove, clean, and install the cylinder
head; remove the exhaust valve seals and advance the timing.
Reduce the amount claimed by 2.5 hours if done in conjunction
with the October 20, 1990 Service Letter - PS4530.

With the exception of the 7E5561 Control Module, handle the parts in
accordance with your Warranty Bulletin on warranty parts handling.
The 7E5561 Control Module must be retained by the dealer or returned to the
customer pending possible customer installation at a later date.
Attach. (1-Rework Procedure) (2-Operating Instructions)
Rework Procedure
PART A - AIR HEATER CONTROL MODULE REPLACEMENT
Remove the bolts holding the 7E5561 Control Module to the left side of the
cylinder block. Disconnect the wiring harness. Install the 4P6602 Control
Module on the block using the old bolts and washers. Connect the wiring
harness. See Illustration 1.
NOTE: The new control module is not used in production. It is
available for parts service to provide a longer "On" time for the
inlet air heater as a cold weather starting aid.
NOTE: Dealers should save the 7E5561 Control Module or return it to the
customer. In certain applications, the customer may object to
the increased electrical demand of the 4P6602 Control Module and
wish to have the 7E5561 Control Module installed again.
PART B - JACKET WATER TEMPERATURE SWITCH AND TEMPERATURE REGULATOR
... Drain the engine coolant into a clean container so it can be reused.
... Remove the old, 7E6106 Temperature Switch. This is the lower of the two
switches in the Regulator Housing (See Illustration 1). Replace it with
the new, 7E9425 Temperature Switch and 3J1907 Seal.
NOTE: The new temperature switch is not used in production. It is
available for parts service to provide a higher jacket water
reset temperature for the inlet air heater.
... Remove and replace the Temperature Regulator with a new, 7E5254
Temperature Regulator. Replace the Gasket with a new, 4P2684 Gasket (See
Illustration 2). This gasket will cover the air vent hole in the
Regulator Housing. Air venting when filling the engine with coolant will
be achieved through the vent valve in the new Regulator. There is no
need to remove or plug the old air vent valve since the new gasket covers
it. Replacement of the temperature regulator and gasket is necessary
only in engine serial numbers 7SF1 through 12502.
PART C - REROUTE THE HEATER RETURN HOSE TO THE WATER PUMP
... Disconnect the heater return hose from the radiator end tank.
... Cut off the expanded end of the hose (approximately 76 mm (3").
... Cover the radiator end tank nipple with 1-15544596 (GM Part Number) Cap
(or equivalent), and 1-2S3440 Clamp-Hose.
... Remove the 9S8005 Plug-O-Ring from the bottom fitting on the right hand
side of the water pump and install a 6V1438 Connector with a 3K0360 O-
Ring Seal in this location (See Illustration 3).
... Install the Heater Return Line over the 6V1438 Connector and secure with
1-2S3440 Clamp. Make sure that the hose is not kinked or in a position
to rub against the frame or other parts.
... Refill the cooling system to the proper level with the appropriate mix of
antifreeze and water.
PART D - REMOVE EXHAUST VALVE STEM SEALS AND ADVANCE TIMING
***** Before Failure *****
The exhaust valve stem seals (See Illustration 4) may be removed with the
head on the engine. Illustration 5 shows how to make an exhaust valve spring
compressor tool to allow removal of the exhaust valve seal without removing
the rocker arm stands.
TEPS dealers may obtain the spring compressor tool from their Caterpillar
dealer.
To prevent the valves from falling inside the cylinders, the pistons should
be at Top Dead Center (TDC). For 3116 engines, pistons 1 and 6 are at TDC
when the 8T0295 Bolt (part of the 1U6680 Fuel Setting Tool Group) engages the
timing hole. Turning the crankshaft 120 degrees (1/3 turn) CCW (as viewed
from the flywheel) moves pistons 2 and 5 to TDC, and another 120 degrees
moves 3 and 4 to TDC.
NOTE: An easy way to know when the crankshaft has been turned 120
degrees is to first mark TDC on the damper for pistons 1 and 6,
then measure the circumference of the damper. Divide the
circumference by 3 to determine how far apart the marks should be
on the damper. Mark the damper accordingly.
1. Rotate the crankshaft until pistons 1 and 6 are at TDC.
2. Loosen the valve lash adjusting screw for #1 exhaust valve to allow the
rocker arm to rotate free of the push rod. Leave the push rod seated on
the lifter shaft.
3. With the exhaust valve rocker arm rotated up and out of the way, remove
the intake manifold bolt (See Illustration 6) adjacent to the exhaust
valve spring. Compress the exhaust valve spring with the compressor
tool shown in Illustration 3 using 1-6V5223 Bolt.
4. Remove the exhaust valve keepers, compressor tool, retainer, and spring.
5. Remove the exhaust valve seal making sure not to mar the valve stem.
6. Install 1-9Y7355 Seat under the exhaust valve spring. Install the valve
spring and retainer. Compress the spring with the compressor tool and
install the keepers.
7. Remove the compressor tool. Install the intake manifold bolt. Tighten
the bolt to a torque of 25 +/- 7 N.m (18 +/- 5 Lb. ft.).
8. Rotate the rocker arm in to position and install the push rod making
sure the bottom of the push rod is still seated on the lifter.
9. Repeat Steps 2 thru 8 for #6 exhaust valve seal removal.
10. Rotate engine 120 degrees.
11. Repeat Steps 2 thru 8 for #2 and #5 exhaust valve seal removal.
12. Rotate engine 120 degrees.
13. Repeat Steps 2 thru 8 for #3 and #4 exhaust valve seal removal.
14. Rotate engine to TDC #1 compression stroke. Set exhaust valve lash
(0.64 mm (.025 in.)) on cylinders 1, 3, and 5. After adjustment,
tighten the locknut to a torque of 25 +/- 7 N.m (18 +/- 5 Lb. ft.) and
check adjustment again.
15. Rotate engine to TDC #6 compression stroke. Set exhaust valve lash
(0.64 mm (.025 in.)) on cylinders 2, 4, and 6. After adjustment, torque
the locknut to 25 +/- 7 N.m (18 +/- 5 Lb. ft.) and check adjustment
again.
16. Advance injector timing. Follow this procedure:
... Read the engine timing dimension from the engine information plate
on the valve cover.
... Subtract the following dimension from the timing dimension.
Engine Subtract Example
HP  Calculation
165/170 HP ...... 0.14 mm Information Plate reads 65.47 mm
-0.14 mm
-----------
New Timing Specification 65.33 mm
185 HP .......... 0.23 mm Information Plate reads 65.56 mm
-0.23 mm
-----------
New Timing Specification 65.33 mm
215/250 HP ...... 0.45 mm Information Plate reads 65.38 mm
-0.45 mm
-----------
New Timing Specification 64.93 mm
... Use the new, calculated dimension to set the injector timing
according to the procedure in the Service Manual.
17. Install the valve cover.
18. Stamp the new timing specification calculated in Step 15 and all other
required information on a 4W5140 Engine Information Plate. Install the
new plate over the original plate that is on the valve cover.
19. Stamp or etch "VS" in the upper right hand corner of the Engine
Information Plate to signify the Product Support Program has been
completed (See Illustration 7).
***** After Failure *****
1. Follow the procedure in the Service Manual. Remove the cylinder head
from the engine.
2. Remove all valves, springs, retainers and valve seals from the cylinder
head.
3. Clean all components thoroughly to remove deposits, including the inside
of the valve guides.
NOTE: Leave the exhaust valve stem seals off of cylinder heads. Use
9Y7355 Seats under the exhaust valve springs.
4. Assemble the cylinder head. Replace damaged parts as needed. Lubricate
the valve stems/guides with clean engine oil.
5. Install the cylinder head on the engine.
6. Refer to Steps 1 thru 19 of the "Part D Before Failure" instructions to
advance the injection timing and make the other necessary changes.
7. Change the crankcase oil and filter. If the unit is equipped with a
Luberfiner, be sure to drain and refill the Luberfiner also. Refer to
the Operation and Maintenance Manual for oil specifications and
capacities.
8. Make sure that all other portions of this Service Letter have been
completed
****** IMAGE: SEBE4541.00001.001
CAPTION: Illustration 1
****** IMAGE: SEBE4541.00001.002
CAPTION: Illustration 2
****** IMAGE: SEBE4541.00001.003
CAPTION: Illustration 3
****** IMAGE: SEBE4541.00001.004
CAPTION: Illustration 4
****** IMAGE: SEBE4541.00001.005
CAPTION: Illustration 5
****** IMAGE: SEBE4541.00001.006
CAPTION: Illustration 6
****** IMAGE: SEBE4541.00001.007
CAPTION: Illustration 7
Operating Instructions
When operating in cold weather conditions (below 0 deg. C or 32 deg. F)
1. Use an electric jacket water (Block) heater, whenever possible, in
temperatures below 0 deg. C (32 degrees F).
2. Use prescribed Starting Procedure given in the 3116 Operation and
Maintenance Manual. Use the air inlet heater "preheat" feature to aid
starting. After starting, raise the engine speed to 1000-1200 RPM. The
increased idle speed will decrease the engine warm-up time.
3. When air and oil pressures are normal, apply a load as soon as possible
to speed engine warm-up.
4. Limit unnecessary idle time to 10 minutes.
5. Operate on lightest fuel available.
- 37 API or higher.
- Cetane number of 42 or higher.
6. When a winter front is used, position it on the front of the hood so it
covers the entire grill area. Use the following operational guidelines:
... Fully covered (closed) below -18 deg. C (0 deg. F).
... Minimum of 387 sq. cm (60 sq. in.) of opening
from -18 deg. to 0 deg. C (0 deg. to 32 deg. F).
... Fully opened or removed above 0 deg. C (32 deg. F).