Product Support Program For Exhaust Valve Sticking On 1991 Model Year 3116 Truck Engines, 215 And 250 HP Only (2BK) 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 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 "PS4612" as Part Number, "7755" as Group Number, and "96" as Description Code.

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°C (15°F) or lower. Do all applicable portions of this Service Letter.

Termination Date

Problem

Exhaust valve sticking may occur at start up on 1991 model year 3116 Truck Engines rated 215 and 250 hp operating in areas with cold ambient temperatures. Engines rated 170 and 185 hp that have serial numbers beginning with "2BK" are NOT considered to be at risk, and are NOT ELIGIBLE for this update.

Removing four exhaust valve stem seal assemblies (cylinders 2, 3, 4, and 5) reduces the risk of valve sticking while still meeting emissions requirements. Installing a new coolant temperature switch and control module for the air inlet heater, will allow the heater to run up to 20 minutes in cold weather and improve combustion during cold starts. Increasing the engine speed to 1000-1200 rpm after starting in cold weather will decrease engine warm-up time.

Affected Product

Three groups of engines are affected:

Group 1 - Engines built WITH exhaust valve stem seal assemblies installed ON ALL CYLINDERS.

Group 2 - Engines built WITHOUT exhaust valve stem seal assemblies ON CYLINDERS 3 AND 4.

Group 3 - Engines which already have the exhaust valve stem seal assembly changes and new coolant temperature switch. This group of engines needs ONLY the new control module.

Serial number ranges for these three groups overlap due to factory rework.

A complete serial number list is shown below for each group.

The intent of this Service Letter is the same for Group 1 and Group 2 engines (exhaust valve seal changes, coolant temperature switch, and control module). The only difference is that Group 1 engines need 4 exhaust valve stem seal assemblies removed, and Group 2 engines need only 2 additional exhaust valve stem seal assemblies removed. Group 3 engines need ONLY the new control module because the valve seal changes and coolant temperature switch were added at the factory. The table below summarizes the changes being made.

NOTE: This program affects all 1991 and 1991-I model vehicles with 1991 model year 3116 Truck Engines rated 215 and 250 hp that have serial numbers beginning with "2BK" (1991 emissions).

A separate Service Letter, PS4568, dated March 19, 1991, has been issued to address a similar problem on 1990 model year truck engines that have serial numbers beginning with "7SF" (1990 emissions) in 1990 and 1991 model year vehicles.

Group 1

NOTE: Group 1 engines were built with all exhaust valve stem seal assemblies in place. The rework involving this group of engines requires installing new coolant temperature switch and control module, and removing the exhaust valve stem seals from cylinders 2, 3, 4, and 5.

Model & Identification Number

3116 (2BK1-791, 2BK794-796, 2BK798-801, 2BK803, 2BK804, 2BK806, 2BK808, 2BK812, 2BK815, 2BK819, 2BK823, 2BK826, 2BK827, 2BK829, 2BK831-835, 2BK839-844, 2BK848, 2BK850, 2BK852, 2BK853, 2BK856, 2BK858, 2BK861-864, 2BK868-870, 2BK872, 2BK873, 2BK875, 2BK877, 2BK883, 2BK885, 2BK886, 2BK890, 2BK892-894, 2BK896-903, 2BK905, 2BK906, 2BK909, 2BK910, 2BK912, , 2BK914, 2BK915, 2BK917, 2BK919-921, 2BK923-932, 2BK934, 2BK937, 2BK939, 2BK940, 2BK943, 2BK945-947, 2BK949-952, 2BK955, 2BK957, 2BK959-961, 2BK972, 2BK975, 2BK981, 2BK983-985, 2BK987, 2BK1011, 2BK1014-1016, 2BK1020-1023, 2BK1027, 2BK1032-1035, 2BK1037-1047, 2BK1049, 2BK1051-1057, 2BK1059-1062, 2BK1064-1075, 2BK1077-1084, 2BK1087, 2BK1088, 2BK1090-1092, 2BK1094, 2BK1096, 2BK1097, 2BK1100, 2BK1102, 2BK1105, 2BK1107, 2BK1110, 2BK1112, 2BK1116, 2BK1117, 2BK1122-1124, 2BK1127, 2BK1130, 2BK1131, 2BK1133, 2BK1135, 2BK1139, 2BK1147, 2BK1151, 2BK1152, 2BK1154, 2BK1155, 2BK1158, 2BK1159, 2BK1161, 2BK1163-1166, 2BK1169, 2BK1171, 2BK1172, 2BK1174-1177, 2BK1180, 2BK1182, 2BK1183, 2BK1185, 2BK1186, 2BK1189, 2BK1191, 2BK1193, 2BK1195, 2BK1201, 2BK1203, 2BK1208, 2BK1212, 2BK1213, 2BK1219, 2BK1222, 2BK1225, 2BK1226, 2BK1231, 2BK1233, 2BK1244, 2BK1251, 2BK1254, 2BK1260, 2BK1273, 2BK1277, 2BK1280, 2BK1283, 2BK1289, 2BK1290, 2BK1292, 2BK1298, 2BK1301, 2BK1303, 2BK1304, 2BK1307, 2BK1310, 2BK1313, 2BK1319, 2BK1321, 2BK1324, 2BK1326, 2BK1327, 2BK1329, 2BK1330, 2BK1333, 2BK1336, 2BK1339, 2BK1342, 2BK1357, 2BK1358, 2BK1360-1362, 2BK1364, 2BK1365, 2BK1368, 2BK1369, 2BK1371, 2BK1378, 2BK1382, 2BK1386, 2BK1389, 2BK1393, 2BK1399, 2BK1403, 2BK1407, 2BK1410, 2BK1415, 2BK1417, 2BK1421, 2BK1424, 2BK1428, 2BK1433, 2BK1436, 2BK1437, 2BK1440, 2BK1444, 2BK1448, 2BK1452, 2BK1456, 2BK1460, 2BK1501, 2BK1503, 2BK1507, 2BK1514, 2BK1526, 2BK1536, 2BK1544, 2BK1558, 2BK1567, 2BK1573, 2BK1576, 2BK1577, 2BK1580, 2BK1584, 2BK1591, 2BK1596, 2BK1619, 2BK1623, 2BK1660, 2BK1669, 2BK1672, 2BK1676, 2BK1678, 2BK1681, 2BK1687, 2BK1688, 2BK1697, 2BK1700, 2BK1701, 2BK1704, 2BK1712, 2BK1721, 2BK1734, 2BK1739, 2BK1740, 2BK1742, 2BK1744, 2BK1745, 2BK1746, 2BK1748, 2BK1750, 2BK1752, 2BK1754, 2BK1756, 2BK1758-1762, 2BK1764, 2BK1766, 2BK1768-1770, 2BK1772, 2BK1773, 2BK1781, 2BK1784, 2BK1786, 2BK1788, 2BK1790, 2BK1792, 2BK1794, 2BK1795, 2BK1798, 2BK1800, 2BK1802, 2BK1804, 2BK1813, 2BK1815-1820, 2BK1822, 2BK1824, 2BK1826-1828, 2BK1844, 2BK1846, 2BK1854-1856, 2BK1858-1862, 2BK1864, 2BK1866, 2BK1868, 2BK1870, 2BK1872, 2BK1874, 2BK1876-1881, 2BK1883, 2BK1893, 2BK1895, 2BK1897, 2BK1901, 2BK1905, 2BK1907, 2BK1909, 2BK1911, 2BK1918, 2BK1920, 2BK1922, 2BK1924, 2BK1928-1932, 2BK1934, 2BK1936, 2BK1938, 2BK1940, 2BK1942, 2BK1949, 2BK1953, 2BK1955, 2BK1957, 2BK1959, 2BK1961, 2BK1963, 2BK1965, 2BK1967-1971, 2BK1973, 2BK1975, 2BK1977-1979, 2BK1981, 2BK1982, 2BK1990, 2BK1993, 2BK1995, 2BK1997, 2BK1999, 2BK2001, 2BK2007, 2BK2009, 2BK2011, 2BK2013, 2BK2015, 2BK2022, 2BK2024, 2BK2026-2029, 2BK2031, 2BK2033, 2BK2035, 2BK2037, 2BK2050, 2BK2051, 2BK2053, 2BK2055, 2BK2057, 2BK2065-2070, 2BK2073, 2BK2075, 2BK2076, 2BK2078, 2BK2080, 2BK2081, 2BK2083, 2BK2085-2087, 2BK2090, 2BK2092, 2BK2103, 2BK2105, 2BK2106, 2BK2108, 2BK2120, 2BK2121, 2BK2123, 2BK2125, 2BK2126, 2BK2128-2132, 2BK2134, 2BK2135, 2BK2137, 2BK2139, 2BK2140, 2BK2168, 2BK2172, 2BK2174, 2BK2178, 2BK2180, 2BK2184, 2BK2186, 2BK2189, 2BK2193, 2BK2195, 2BK2197, 2BK2199, 2BK2201, 2BK2203-2205, 2BK2207, 2BK2209, 2BK2218, 2BK2226, 2BK2228, 2BK2230, 2BK2232, 2BK2233-2235, 2BK2237, 2BK2239, 2BK2241, 2BK2243, 2BK2245-2248, 2BK2263, 2BK2264, 2BK2272, 2BK2273, 2BK2275, 2BK2276, 2BK2295, 2BK2296, 2BK2301, 2BK2303-2305, 2BK2309, 2BK2310, 2BK2312, 2BK2313, 2BK2315, 2BK2317-2321, 2BK2325-2328, 2BK2330-2332, 2BK2347, 2BK2348, 2BK2350-2352, 2BK2354, 2BK2357, 2BK2359-2363, 2BK2365, 2BK2366, 2BK2368, 2BK2369, 2BK2371, 2BK2383, 2BK2387, 2BK2394, 2BK2398, 2BK2400, 2BK2402, 2BK2407, 2BK2409, 2BK2411, 2BK2412, 2BK2415, 2BK2422, 2BK2435, 2BK2437-2439, 2BK2441-2443, 2BK2445, 2BK2447-2449, 2BK2451, 2BK2453, 2BK2455, 2BK2457, 2BK2468, 2BK2469, 2BK2471, 2BK2479, 2BK2480, 2BK2484, 2BK2485, 2BK2487, 2BK2489-2492, 2BK2495-2497, 2BK2499, 2BK2501, 2BK2503, 2BK2504, 2BK2518, 2BK2520-2522, 2BK2527, 2BK2529, 2BK2530, 2BK2532, 2BK2533, 2BK2535, 2BK2536, 2BK2538, 2BK2539, 2BK2541, 2BK2542, 2BK2546, 2BK2552, 2BK2553, 2BK2557, 2BK2563-2565, 2BK2576-2578, 2BK2582, 2BK2585-2587, 2BK2589-2591, 2BK2611-2615, 2BK2617-2620, 2BK2622, 2BK2623, 2BK2625, 2BK2626, 2BK2628-2630, 2BK2632, 2BK2666, 2BK2667, 2BK2673-2675, 2BK2678, 2BK2683, 2BK2684, 2BK2686, 2BK2687, 2BK2689, 2BK2697, 2BK2698, 2BK2700, 2BK2708-2712, 2BK2714-2720, 2BK2722, 2BK2723, 2BK2725, 2BK2726, 2BK2728, 2BK2849, 2BK2774, 2BK2779, 2BK2780, 2BK2784, 2BK2785, 2BK2805, 2BK2817, 2BK2818, 2BK2820, 2BK2822, 2BK2824, 2BK2826-2833, 2BK2835-2838, 2BK2840-2842, 2BK2844, 2BK2845, 2BK2847, 2BK2849-2851, 2BK2855, 2BK2856, 2BK2868, 2BK2869, 2BK2881, 2BK2882, 2BK2890, 2BK2892, 2BK2895, 2BK2900, 2BK2901, 2BK2903, 2BK2904, 2BK2906, 2BK2909, 2BK2910, 2BK2930, 2BK2938, 2BK2946, 2BK2948, 2BK2949, 2BK2952, 2BK2955, 2BK2961, 2BK2963-2965, 2BK2967, 2BK2968, 2BK2970, 2BK2972, 2BK2973, 2BK3005, 2BK3006, 2BK3008, 2BK3018, 2BK3020, 2BK3022, 2BK3025, 2BK3027, 2BK3028, 2BK3031, 2BK3041, 2BK3042, 2BK3044-3046, 2BK3048, 2BK3050, 2BK3051, 2BK3053, 2BK3056-3058, 2BK3061, 2BK3066, 2BK3069, 2BK3071-3073, 2BK3075, 2BK3092, 2BK3097, 2BK3108, 2BK3113, 2BK3115, 2BK3122, 2BK3124, 2BK3126, 2BK3127, 2BK3129, 2BK3131, 2BK3132, 2BK3134, 2BK3136, 2BK3137, 2BK3149, 2BK3150, 2BK3152, 2BK3154, 2BK3155, 2BK3157, 2BK3162-3165, 2BK3173, 2BK3176, 2BK3179, 2BK3180, 2BK3182, 2BK3196, 2BK3197, 2BK3220, 2BK3222, 2BK3229-3231, 2BK3233, 2BK3234, 2BK3236, 2BK3238, 2BK3239, 2BK3241, 2BK3243-3245, 2BK3247, 2BK3248, 2BK3250, 2BK3262, 2BK3265, 2BK3267, 2BK3272, 2BK3275, 2BK3279-3281, 2BK3283, 2BK3288, 2BK3302, 2BK3331-3334, 2BK3337, 2BK3340, 2BK3345, 2BK3395, 2BK3399, 2BK3417, 2BK3418, 2BK3442, 2BK3457, 2BK3482, 2BK3510, 2BK3525, 2BK3586, 2BK3600, 2BK3602, 2BK3604, 2BK3606, 2BK3623, 2BK3628, 2BK3630, 2BK3632, 2BK3685, 2BK3699, 2BK3701, 2BK3708, 2BK3710, 2BK3711, 2BK3713, 2BK3716, 2BK3717, 2BK3719, 2BK3724, 2BK3736, 2BK3751, 2BK3783, 2BK3788, 2BK3818, 2BK3819, 2BK3822, 2BK3886, 2BK3888, 2BK3894, 2BK3895, 2BK3897, 2BK4009, 2BK4012, 2BK4015, 2BK4016)

Group 2

NOTE: Group 2 engines were built with exhaust valve stem seal assemblies removed from cylinders 3 and 4. The rework involving this group of engines requires installing new coolant temperature switch and control module, and removing the exhaust valve stem seal assemblies from cylinders 2 and 5.

Model & Identification Number

3116 (2BK836, 2BK855, 2BK867, 2BK876, 2BK879, 2BK889, 2BK911, 2BK933, 2BK935, 2BK938, 2BK944, 2BK953, 2BK954, 2BK970, 2BK982, 2BK988-991, 2BK993-998, 2BK1001, 2BK1002, 2BK1004, 2BK1006-1010, 2BK1013, 2BK1017-1019, 2BK1024-1026, 2BK1031, 2BK1050, 2BK1076, 2BK1085, 2BK1086, 2BK1089, 2BK1093, 2BK1099, 2BK1101, 2BK1103, 2BK1104, 2BK1109, 2BK1111, 2BK1115, 2BK1121, 2BK1126-1129, 2BK1132, 2BK1136-1138, 2BK1140-1143, 2BK1145, 2BK1153, 2BK1156, 2BK1167, 2BK1178, 2BK1188, 2BK1192, 2BK1197, 2BK1198, 2BK1207, 2BK1209, 2BK1210, 2BK1215, 2BK1216, 2BK1218, 2BK1223, 2BK1227, 2BK1229, 2BK1230, 2BK1234-1236, 2BK1238, 2BK1240, 2BK1243, 2BK1245, 2BK1247, 2BK1249, 2BK1252-1256, 2BK1261-1264, 2BK1267, 2BK1270, 2BK1275, 2BK1278, 2BK1279, 2BK1281, 2BK1284, 2BK1285, 2BK1287, 2BK1293, 2BK1297, 2BK1302, 2BK1308, 2BK1334, 2BK1341, 2BK1366, 2BK1373, 2BK1377, 2BK1384, 2BK1388, 2BK1391, 2BK1394, 2BK1397, 2BK1401, 2BK1404, 2BK1409, 2BK1411, 2BK1416, 2BK1418, 2BK1420, 2BK1422, 2BK1423, 2BK1426, 2BK1427, 2BK1430, 2BK1431, 2BK1435, 2BK1438, 2BK1439, 2BK1453, 2BK1461, 2BK1465, 2BK1468, 2BK1476, 2BK1479, 2BK1480, 2BK1483, 2BK1484, 2BK1491, 2BK1492, 2BK1495, 2BK1496, 2BK1499, 2BK1500, 2BK1505, 2BK1508, 2BK1511, 2BK1512, 2BK1516, 2BK1519, 2BK1522, 2BK1524, 2BK1528, 2BK1532, 2BK1535, 2BK1541, 2BK1543, 2BK1546, 2BK1550, 2BK1554, 2BK1557, 2BK1560, 2BK1562, 2BK1566, 2BK1568, 2BK1570, 2BK1574, 2BK1578, 2BK1583, 2BK1586, 2BK1589, 2BK1593, 2BK1601, 2BK1606, 2BK1609, 2BK1626, 2BK1632, 2BK1635, 2BK1638, 2BK1641, 2BK1644, 2BK1650, 2BK1653, 2BK1657, 2BK1666, 2BK1673, 2BK1679, 2BK1685, 2BK1707, 2BK1718, 2BK1821, 2BK1899, 2BK1954, 2BK2064, 2BK2071, 2BK2133, 2BK2138, 2BK2141, 2BK2143, 2BK2157, 2BK2162, 2BK2164, 2BK2166, 2BK2167, 2BK2169, 2BK2171, 2BK2173, 2BK2175, 2BK2176, 2BK2179, 2BK2185, 2BK2190-2192, 2BK2214, 2BK2220, 2BK2271, 2BK2294, 2BK2298, 2BK2300, 2BK2302, 2BK2314, 2BK2329, 2BK2395, 2BK2414, 2BK2418, 2BK2424, 2BK2493, 2BK2505, 2BK2506, 2BK2558, 2BK2560, 2BK2561, 2BK2584, 2BK2680-2682, 2BK2693, 2BK2713, 2BK2760, 2BK2764, 2BK2768, 2BK2786-2788, 2BK2862, 2BK2863, 2BK2865, 2BK2957, 2BK2959, 2BK2976, 2BK2978, 2BK2980, 2BK2981, 2BK2983, 2BK2985, 2BK2986, 2BK2988, 2BK3023, 2BK3055, 2BK3059, 2BK3062, 2BK3064, 2BK3077, 2BK3083, 2BK3084, 2BK3087, 2BK3089, 2BK3090, 2BK3094, 2BK3102, 2BK3125, 2BK3151, 2BK3158, 2BK2171, 2BK2178, 2BK3187, 2BK3188, 2BK2190, 2BK3192, 2BK3194, 2BK3199, 2BK3210, 2BK3228, 2BK3237, 2BK3256, 2BK3282, 2BK3284, 2BK3286, 2BK3287, 2BK3290-3301, 2BK3303, 2BK3305-3307, 2BK3309-3311, 2BK3313-3316, 2BK3336, 2BK3339, 2BK3342, 2BK3344, 2BK3349-3351, 2BK3353, 2BK3354, 2BK3356, 2BK3358-3360, 2BK3363, 2BK3365, 2BK3366, 2BK3368, 2BK3370, 2BK3371, 2BK3373, 2BK3375-3377, 2BK3409, 2BK3410, 2BK3412, 2BK3414, 2BK3441, 2BK3443, 2BK3444, 2BK3446, 2BK3450, 2BK3452, 2BK3453, 2BK3456, 2BK3459, 2BK3463-3466, 2BK3468-3470, 2BK3474, 2BK3475, 2BK3487, 2BK3490-3492, 2BK3494, 2BK3503, 2BK3504, 2BK3507, 2BK3508, 2BK3517, 2BK3529, 2BK3534, 2BK3539, 2BK3555, 2BK3568, 2BK3571, 2BK3574, 2BK3577, 2BK3579, 2BK3582-3584, 2BK3588, 2BK3591, 2BK3593, 2BK3595, 2BK3599, 2BK3629, 2BK3642, 2BK3658, 2BK3661, 2BK3663, 2BK3665, 2BK3666, 2BK3668-3670, 2BK3672, 2BK3674, 2BK3675, 2BK3677, 2BK3679-3682, 2BK3692, 2BK3693, 2BK3695, 2BK3696, 2BK3720-3722, 2BK3725, 2BK3726, 2BK3732, 2BK3747, 2BK3748, 2BK3756, 2BK3759, 2BK3762, 2BK3768, 2BK3771, 2BK3773, 2BK3779, 2BK3797, 2BK3823-3826, 2BK3828, 2BK3829, 2BK3832, 2BK3862, 2BK3902-3904, 2BK3906, 2BK3908, 2BK3909, 2BK3923, 2BK3924, 2BK3926, 2BK3940, 2BK3943, 2BK3949, 2BK3951, 2BK3952, 2BK3955, 2BK3957, 2BK3961, 2BK3962, 2BK3977, 2BK3998, 2BK4004, 2BK4005, 2BK4017, 2BK4018, 2BK4020, 2BK4021, 2BK4032, 2BK4038, 2BK4041, 2BK4046, 2BK4047, 2BK4050, 2BK4054, 2BK4055, 2BK4059, 2BK4114, 2BK4116-4118, 2BK4120, 2BK4129, 2BK4134, 2BK4136, 2BK4142, 2BK4145, 2BK4147, 2BK4149, 2BK4179, 2BK4190, 2BK4211, 2BK4213, 2BK4215, 2BK4217, 2BK4218, 2BK4220, 2BK4222, 2BK4237-4239, 2BK4241, 2BK4242, 2BK4247, 2BK4249, 2BK4251, 2BK4253, 2BK4271, 2BK4274, 2BK4292, 2BK4294, 2BK4298, 2BK4299, 2BK4301, 2BK4303, 2BK4305, 2BK4307, 2BK4312, 2BK4314, 2BK4317, 2BK4319, 2BK4326, 2BK4334, 2BK4337, 2BK4341, 2BK4343, 2BK4344, 2BK4365, 2BK4366, 2BK4368, 2BK4383, 2BK4407, 2BK4408, 2BK4410, 2BK4412, 2BK4414, 2BK4421, 2BK4423, 2BK4425, 2BK4438, 2BK4445, 2BK4453, 2BK4455, 2BK4472, 2BK4474, 2BK4498, 2BK4500, 2BK4502-4505, 2BK4512, 2BK4516, 2BK4517, 2BK4523, 2BK4526 -4528, 2BK4530, 2BK4541, 2BK4554, 2BK4561-4563, 2BK4567, 2BK4568, 2BK4570, 2BK4571, 2BK4577, 2BK4581, 2BK4583, 2BK4586, 2BK4588, 2BK4590, 2BK4592, 2BK4597, 2BK4598, 2BK4604, 2BK4607, 2BK4610, 2BK4612, 2BK4613, 2BK4616, 2BK4619, 2BK4620, 2BK4625, 2BK4627, 2BK4629, 2BK4631, 2BK4633, 2BK4635, 2BK4637, 2BK4639, 2BK4649, 2BK4654, 2BK4669, 2BK4677-4679, 2BK4682, 2BK4684-4688, 2BK4692, 2BK4694, 2BK4697, 2BK4700, 2BK4703, 2BK4706-4709, 2BK4711, 2BK4713, 2BK4717, 2BK4719, 2BK4722, 2BK4724, 2BK4728, 2BK4730, 2BK4731, 2BK4735, 2BK4742, 2BK4744, 2BK4746, 2BK4751, 2BK4753, 2BK4754, 2BK4756, 2BK4765, 2BK4769, 2BK4772, 2BK4779, 2BK4780, 2BK4782-4784, 2BK4794, 2BK4796, 2BK4798, 2BK4799, 2BK4801, 2BK4803, 2BK4807, 2BK4815, 2BK4823, 2BK4830, 2BK4831, 2BK4842, 2BK4853, 2BK4854, 2BK4856, 2BK4857, 2BK4859, 2BK4865, 2BK4866, 2BK4868-4874, 2BK4878, 2BK4879, 2BK4881-4888, 2BK4890, 2BK4896, 2BK4900, 2BK4902, 2BK4904, 2BK4905, 2BK4908, 2BK4919, 2BK4922, 2BK4923, 2BK4927, 2BK4929, 2BK4931, 2BK4933-4936, 2BK4938, 2BK4947, 2BK4951, 2BK4953-4955, 2BK4957, 2BK4959-4961, 2BK4964-4970, 2BK4972, 2BK4973, 2BK4975, 2BK4977-4981, 2BK4983, 2BK4996, 2BK4998, 2BK5011, 2BK5013, 2BK5015, 2BK5017-5019, 2BK5021, 2BK5023, 2BK5027, 2BK5028, 2BK5030, 2BK5032, 2BK5034, 2BK5035, 2BK5037-5039, 2BK5054, 2BK5057-5063, 2BK5066, 2BK5067, 2BK5069-5071, 2BK5073-5076, 2BK5084, 2BK5090, 2BK5092-5094, 2BK5097, 2BK5107, 2BK5109, 2BK5110, 2BK5113-5115, 2BK5117, 2BK5119, 2BK5121-5124, 2BK5126, 2BK5138-5141, 2BK5144, 2BK5145, 2BK5150, 2BK5151, 2BK5153-5157, 2BK5159-5166, 2BK5168-5173, 2BK5175-5185, 2BK5191, 2BK5198, 2BK5201-5204, 2BK5207-5218, 2BK5220, 2BK5222, 2BK5225, 2BK5227, 2BK5229, 2BK5233, 2BK5239, 2BK5241, 2BK5243, 2BK5245, 2BK5248, 2BK5250, 2BK5254, 2BK5257, 2BK5258, 2BK5261, 2BK5266, 2BK5267, 2BK5270, 2BK5272, 2BK5273, 2BK5275, 2BK5280, 2BK5288, 2BK5293, 2BK5304, 2BK5306, 2BK5308, 2BK5310, 2BK5312, 2BK5314, 2BK5316, 2BK5317, 2BK5319-5321, 2BK5323, 2BK5324, 2BK5327, 2BK5329-5335, 2BK5337, 2BK5339, 2BK5341, 2BK5343, 2BK5346-5349, 2BK5351, 2BK5353, 2BK5354, 2BK5357, 2BK5359-5368, 2BK5370-5372, 2BK5374, 2BK5375, 2BK5377, 2BK5378, 2BK5380, 2BK5381, 2BK5383-5392, 2BK5394-5403, 2BK5405, 2BK5407, 2BK5408, 2BK5410-5419, 2BK5421-5425, 2BK5427-5435, 2BK5437, 2BK5438, 2BK5440-5444, 2BK5446, 2BK5448, 2BK5449, 2BK5452, 2BK5454, 2BK5455, 2BK5457-5465, 2BK5468-5473, 2BK5475, 2BK5476, 2BK5479, 2BK5480, 2BK5483-5495, 2BK5497-5501, 2BK5503, 2BK5504, 2BK5506, 2BK5513, 2BK5517, 2BK5523, 2BK5524, 2BK5527, 2BK5531, 2BK5536, 2BK5537, 2BK5540, 2BK5542, 2BK5544-5546, 2BK5548, 2BK5550-5555, 2BK5557-5567, 2BK5570, 2BK5575, 2BK5576, 2BK5583, 2BK5585, 2BK5590, 2BK5596, 2BK5598, 2BK5603, 2BK5608, 2BK5610, 2BK5614-5619, 2BK5621, 2BK5622, 2BK5626, 2BK5628, 2BK5630, 2BK5634, 2BK5636, 2BK5638, 2BK5644, 2BK5646, 2BK5648, 2BK5650-5652, 2BK5655-5657, 2BK5659, 2BK5660, 2BK5662, 2BK5664, 2BK5665, 2BK5667, 2BK5668, 2BK5670, 2BK5671, 2BK5673, 2BK5679, 2BK5682, 2BK5687, 2BK5689, 2BK5690, 2BK5702, 2BK5705, 2BK5707, 2BK5709, 2BK5711, 2BK5716, 2BK5723-5727, 2BK5730, 2BK5732, 2BK5734, 2BK5736, 2BK5737, 2BK5752, 2BK5753, 2BK5758, 2BK5759, 2BK5768, 2BK5774, 2BK5775, 2BK5777, 2BK5779, 2BK5781, 2BK5786, 2BK5788, 2BK5801, 2BK5803, 2BK5804, 2BK5806, 2BK5808, 2BK5809, 2BK5811, 2BK5813, 2BK5815-5818, 2BK5820, 2BK5821, 2BK5823, 2BK5824, 2BK5826, 2BK5827, 2BK5829, 2BK5830, 2BK5839, 2BK5840, 2BK5842, 2BK5843, 2BK5845, 2BK5852, 2BK5857, 2BK5863, 2BK5865-5867, 2BK5878, 2BK5880-5882, 2BK5884, 2BK5887, 2BK5891, 2BK5894, 2BK5898, 2BK5899, 2BK5901, 2BK5909, 2BK5913, 2BK5917, 2BK5921, 2BK5926, 2BK5928, 2BK5930, 2BK5932, 2BK5950, 2BK5951, 2BK5957, 2BK5959, 2BK5963, 2BK5964, 2BK5966, 2BK5967, 2BK5971, 2BK5973, 2BK5975, 2BK5980, 2BK5981, 2BK5985, 2BK5986, 2BK5994, 2BK5995, 2BK5999, 2BK6001, 2BK6003, 2BK6009, 2BK6010, 2BK6019, 2BK6026, 2BK6027, 2BK6029, 2BK6031, 2BK6033, 2BK6035, 2BK6036, 2BK6038-6040, 2BK6043, 2BK6044, 2BK6046, 2BK6048, 2BK6049, 2BK6051, 2BK6065, 2BK6071, 2BK6079, 2BK6084, 2BK6087, 2BK6092, 2BK6099, 2BK6102, 2BK6104, 2BK6106, 2BK6107, 2BK6113, 2BK6149, 2BK6151, 2BK6153, 2BK6169, 2BK6172, 2BK6175, 2BK6188, 2BK6190, 2BK6194, 2BK6196, 2BK6197, 2BK6200, 2BK6204, 2BK6205, 2BK6238, 2BK6240, 2BK6242, 2BK6243, 2BK6246, 2BK6251, 2BK6254, 2BK6272, 2BK6277, 2BK6286, 2BK6291, 2BK6304, 2BK6327, 2BK6371, 2BK6373, 2BK6418, 2BK6428-6431, 2BK6450, 2BK6459, 2BK6466, 2BK6475, 2BK6481, 2BK6511, 2BK6515, 2BK6534, 2BK6598, 2BK6602, 2BK6604, 2BK6605, 2BK6607, 2BK6608, 2BK6611, 2BK6612, 2BK6624, 2BK6652, 2BK6688, 2BK6689, 2BK6701, 2BK6725, 2BK6755, 2BK6771, 2BK6772, 2BK6777, 2BK6788, 2BK6790, 2BK6792, 2BK6793, 2BK6795, 2BK6798, 2BK6800, 2BK6807, 2BK6813, 2BK6816, 2BK6819, 2BK6821, 2BK6829, 2BK6832, 2BK6840, 2BK6843, 2BK6845, 2BK6856, 2BK6857, 2BK6859, 2BK6861, 2BK6863, 2BK6865, 2BK6873, 2BK6879, 2BK6882, 2BK6884, 2BK6885, 2BK6887, 2BK6889, 2BK6891, 2BK6892, 2BK6902-6904, 2BK6914, 2BK6925, 2BK6929, 2BK6937, 2BK6940, 2BK6943, 2BK6944, 2BK6946, 2BK6947, 2BK6949, 2BK6950, 2BK6953, 2BK6962, 2BK6964, 2BK6966, 2BK6970, 2BK6972, 2BK6975, 2BK7005, 2BK7012, 2BK7013, 2BK7015, 2BK7016, 2BK7026, 2BK7030-7032, 2BK7037, 2BK7050, 2BK7052, 2BK7053, 2BK7056, 2BK7058, 2BK7060, 2BK7116, 2BK7129, 2BK7132, 2BK7134, 2BK7142, 2BK7159, 2BK7167, 2BK7171, 2BK7204, 2BK7210, 2BK7218, 2BK7221, 2BK7251, 2BK7253, 2BK7255, 2BK7258, 2BK7278, 2BK7329-7331, 2BK7343, 2BK7348, 2BK7361, 2BK7364, 2BK7389, 2BK7430-7434, 2BK7436, 2BK7438, 2BK7441, 2BK7443, 2BK7445, 2BK7554, 2BK7659, 2BK7781, 2BK8005, 2BK8038)

Group 3

NOTE: Group 3 engines were built with the new coolant temperature switch and exhaust valve stem seal changes. The ONLY update needed on Group 3 engines is to install the new 4P6602 Control Module Assembly.

NOTE: The following Group 3 engine serial numbers include only GMC TopKick and Chevrolet Kodiak vehicles. For other vehicle manufacturers, install the new control module if the engine serial number is below 2BK11138 and the engine is not listed in Group 1 or Group 2. Some engines may already have the new module installed by the vehicle manufacturer. Check the module part number located on the end of the plastic case.

Model & Identification Number

3116 (2BK809, 2BK882, 2BK887, 2BK907, 2BK916, 2BK918, 2BK922, 2BK948, 2BK956, 2BK958, 2BK962-969, 2BK971, 2BK973, 2BK974, 2BK976-978, 2BK986, 2BK992, 2BK999, 2BK1000, 2BK1003, 2BK1005, 2BK1036, 2BK1048, 2BK1058, 2BK1095, 2BK1098, 2BK1113, 2BK1119, 2BK1125, 2BK1144, 2BK1146, 2BK1148-1150, 2BK1157, 2BK1160, 2BK1162, 2BK1168, 2BK1170, 2BK1173, 2BK1179, 2BK1184, 2BK1190, 2BK1194, 2BK1196, 2BK1204-1206, 2BK1211, 2BK1214, 2BK1217, 2BK1221, 2BK1242, 2BK1248, 2BK1250, 2BK1257, 2BK1286, 2BK1295, 2BK1296, 2BK1300, 2BK1306, 2BK1309, 2BK1312, 2BK1315, 2BK1316, 2BK1335, 2BK1340, 2BK1346, 2BK1347, 2BK1353, 2BK1375, 2BK1380, 2BK1395, 2BK1412, 2BK1414, 2BK1419, 2BK1425, 2BK1429, 2BK1432, 2BK1434, 2BK1441, 2BK1442, 2BK1445, 2BK1449, 2BK1457, 2BK1464, 2BK1469, 2BK1472, 2BK1487, 2BK1488, 2BK1504, 2BK1506, 2BK1515, 2BK1534, 2BK1538, 2BK1597, 2BK1613, 2BK1620, 2BK1629, 2BK1647, 2BK1663, 2BK1682, 2BK1690, 2BK1695, 2BK1706, 2BK1710, 2BK1715, 2BK1722, 2BK1725, 2BK1727, 2BK1732, 2BK1737, 2BK1741, 2BK1837, 2BK1839, 2BK1849, 2BK1851, 2BK1853, 2BK1956, 2BK1980, 2BK2046, 2BK2048, 2BK2060, 2BK2062, 2BK2072, 2BK2089, 2BK2091, 2BK2161, 2BK2163, 2BK2206, 2BK2208, 2BK2270, 2BK2306, 2BK2316, 2BK2323, 2BK2324, 2BK2388, 2BK2392, 2BK2417, 2BK2420, 2BK2442, 2BK2498, 2BK2500, 2BK2502, 2BK2510, 2BK2575, 2BK2753, 2BK2754, 2BK2773, 2BK2795, 2BK2801, 2BK2864, 2BK2875, 2BK2888, 2BK2896, 2BK2899, 2BK2902, 2BK2944, 2BK3007, 2BK3019, 2BK3076, 2BK3078, 2BK3114, 2BK3142, 2BK3166, 2BK3169, 2BK3200, 2BK3209, 2BK3217, 2BK3246, 2BK3264, 2BK3273, 2BK3392, 2BK3393, 2BK3397, 2BK3398, 2BK3415, 2BK3419, 2BK3421-23, 2BK3425, 2BK3427, 2BK3472, 2BK3477, 2BK3488, 2BK3500, 2BK3501, 2BK3505, 2BK3509, 2BK3511, 2BK3513, 2BK3514, 2BK3516, 2BK3559, 2BK3597, 2BK3620, 2BK3624, 2BK3647, 2BK3652, 2BK3671, 2BK3715, 2BK3727, 2BK3749, 2BK3752, 2BK3763-3767, 2BK3770, 2BK3772, 2BK3774-3778, 2BK3780-3782, 2BK3784, 2BK3785-3787, 2BK3789-3792, 2BK3794, 2BK3796, 2BK3798-3801, 2BK3803, 2BK3804, 2BK3814, 2BK3821, 2BK3833, 2BK3835, 2BK3837, 2BK3844, 2BK3853, 2BK3854, 2BK3856, 2BK3859, 2BK3861, 2BK3863, 2BK3865-3868, 2BK3879, 2BK3881, 2BK3882, 2BK3883, 2BK3899, 2BK3900, 2BK3937, 2BK3938, 2BK3948, 2BK3954, 2BK3958, 2BK3959, 2BK3963, 2BK3964, 2BK3966, 2BK3967, 2BK3969-3972, 2BK3974, 2BK3978, 2BK3980, 2BK3981, 2BK3990, 2BK3991, 2BK3993, 2BK3997, 2BK4010, 2BK4013, 2BK4030, 2BK4040, 2BK4049, 2BK4058, 2BK4061, 2BK4063, 2BK4064, 2BK4068, 2BK4070, 2BK4072, 2BK4073, 2BK4075, 2BK4077-4079, 2BK4083, 2BK4090, 2BK4091, 2BK4093, 2BK4095, 2BK4096, 2BK4098, 2BK4107-4109, 2BK4111, 2BK4113, 2BK4131, 2BK4132, 2BK4144, 2BK4151, 2BK4153, 2BK4154, 2BK4156, 2BK4158, 2BK4159, 2BK4161-4163, 2BK4165, 2BK4167, 2BK4168, 2BK4170, 2BK4172-4174, 2BK4176, 2BK4191, 2BK4193, 2BK4194, 2BK4195, 2BK4197, 2BK4204-4206, 2BK4209, 2BK4214, 2BK4234, 2BK4236, 2BK4252, 2BK4254, 2BK4256, 2BK4258, 2BK4260, 2BK4262, 2BK4263, 2BK4272, 2BK4276, 2BK4280, 2BK4281, 2BK4287, 2BK4290, 2BK4296, 2BK4308, 2BK4310, 2BK4316, 2BK4350, 2BK4352, 2BK4354, 2BK4357, 2BK4370, 2BK4377, 2BK4385, 2BK4386, 2BK4388, 2BK4390, 2BK4392, 2BK4394, 2BK4397, 2BK4399, 2BK4401, 2BK4403, 2BK4405, 2BK4418, 2BK4419, 2BK4436, 2BK4439, 2BK4441, 2BK4443, 2BK4446, 2BK4448, 2BK4458, 2BK4465, 2BK4467, 2BK4469, 2BK4479, 2BK4481, 2BK4484, 2BK4486, 2BK4488, 2BK4489, 2BK4491, 2BK4493, 2BK4495, 2BK4521, 2BK4537, 2BK4539, 2BK4543, 2BK4545, 2BK4546, 2BK4556, 2BK4559, 2BK4566, 2BK4572, 2BK4574, 2BK4579, 2BK4589, 2BK4591, 2BK4608, 2BK4646, 2BK4648, 2BK4650, 2BK4652, 2BK4656, 2BK4658, 2BK4661, 2BK4664, 2BK4666, 2BK4668, 2BK4670, 2BK4672, 2BK4674, 2BK4676, 2BK4680, 2BK4705, 2BK4714, 2BK4715, 2BK4740, 2BK4747, 2BK4749, 2BK4758, 2BK4760, 2BK4761, 2BK4763, 2BK4767, 2BK4770, 2BK4774, 2BK4805, 2BK4817, 2BK4819, 2BK4821, 2BK4824, 2BK4826, 2BK4828, 2BK4833, 2BK4835, 2BK4838, 2BK4846, 2BK4847, 2BK4849, 2BK4876, 2BK4921, 2BK4924, 2BK4925, 2BK4939, 2BK4982, 2BK5064, 2BK5077, 2BK5111, 2BK5112, 2BK5152, 2BK5197, 2BK5199, 2BK5200, 2BK5221, 2BK5230, 2BK5232, 2BK5277, 2BK5315, 2BK5326, 2BK5328, 2BK5338, 2BK5340, 2BK5350, 2BK5352, 2BK5356, 2BK5358, 2BK5369, 2BK5373, 2BK5379, 2BK5406, 2BK5445, 2BK5451, 2BK5453, 2BK5466, 2BK5482, 2BK5502, 2BK5507, 2BK5508, 2BK5510, 2BK5511, 2BK5514, 2BK5515, 2BK5518-5520, 2BK5522, 2BK5526, 2BK5528, 2BK5530, 2BK5532, 2BK5533, 2BK5541, 2BK5568, 2BK5569, 2BK5571, 2BK5573, 2BK5574, 2BK5578, 2BK5580-5582, 2BK5586, 2BK5588, 2BK5592, 2BK5594, 2BK5605, 2BK5612, 2BK5624, 2BK5631, 2BK5633, 2BK5639, 2BK5642, 2BK5654, 2BK5658, 2BK5704, 2BK5706, 2BK5710, 2BK5750, 2BK5757, 2BK5761, 2BK5782, 2BK5784, 2BK5787, 2BK5814, 2BK5860-5862, 2BK5869, 2BK5911, 2BK5936, 2BK5937, 2BK5939, 2BK5941, 2BK5942, 2BK5953, 2BK5955, 2BK5998, 2BK6007, 2BK6011, 2BK6012, 2BK6020, 2BK6022, 2BK6024, 2BK6042, 2BK6054, 2BK6086, 2BK6088, 2BK6090, 2BK6093, 2BK6111, 2BK6116, 2BK6118, 2BK6121, 2BK6156, 2BK6158, 2BK6161, 2BK6171, 2BK6177, 2BK6180, 2BK6183, 2BK6187, 2BK6188, 2BK6193, 2BK6207, 2BK6235, 2BK6259, 2BK6261, 2BK6268, 2BK6275, 2BK6280, 2BK6289, 2BK6297, 2BK6299, 2BK6301, 2BK6302, 2BK6307, 2BK6320, 2BK6321, 2BK6324, 2BK6329, 2BK6331, 2BK6332, 2BK6340, 2BK6341, 2BK6414, 2BK6421, 2BK6424, 2BK6435, 2BK6438, 2BK6441, 2BK6446, 2BK6448, 2BK6453, 2BK6468, 2BK6486, 2BK6493, 2BK6521, 2BK6526, 2BK6531, 2BK6536, 2BK6549, 2BK6554, 2BK6558, 2BK6563, 2BK6572, 2BK6576, 2BK6581, 2BK6585, 2BK6606, 2BK6610, 2BK6616, 2BK6620, 2BK6634, 2BK6638, 2BK6642, 2BK6645, 2BK6650, 2BK6656, 2BK6659, 2BK6662, 2BK6666, 2BK6670, 2BK6673, 2BK6676, 2BK6680, 2BK6684, 2BK6692, 2BK6696, 2BK6698-6700, 2BK6702, 2BK6714, 2BK6718, 2BK6722, 2BK6732, 2BK6736, 2BK6740, 2BK6743, 2BK6746, 2BK6750, 2BK6754, 2BK6764, 2BK6776, 2BK6781, 2BK6782, 2BK6784-6786, 2BK6801, 2BK6803, 2BK6805, 2BK6817, 2BK6827, 2BK6830, 2BK6833, 2BK6835, 2BK6837, 2BK6838, 2BK6839, 2BK6841, 2BK6854, 2BK6858, 2BK6860, 2BK6862, 2BK6869, 2BK6871, 2BK6872, 2BK6893, 2BK6894, 2BK6895, 2BK6900, 2BK6908, 2BK6910, 2BK6912, 2BK6919, 2BK6920, 2BK6922-6924, 2BK6926, 2BK6928, 2BK6939, 2BK6941, 2BK6945, 2BK6848, 2BK6956, 2BK6961, 2BK6968, 2BK6976, 2BK6978, 2BK6981, 2BK6989, 2BK6994, 2BK6996, 2BK7000, 2BK7001, 2BK7003, 2BK7007, 2BK7014, 2BK7029, 2BK7033, 2BK7039, 2BK7041, 2BK7049, 2BK7054, 2BK7065, 2BK7066, 2BK7069, 2BK7079, 2BK7087, 2BK7089, 2BK7091, 2BK7095, 2BK7098, 2BK7100, 2BK7101, 2BK7105, 2BK7107, 2BK7109, 2BK7110, 2BK7114, 2BK7124, 2BK7127, 2BK7131, 2BK7135, 2BK7137, 2BK7139, 2BK7141, 2BK7144, 2BK7145, 2BK7148, 2BK7150, 2BK7156, 2BK7161, 2BK7165, 2BK7169, 2BK7173, 2BK7174, 2BK7176, 2BK7178, 2BK7180, 2BK7184, 2BK7186, 2BK7188, 2BK7189, 2BK7207, 2BK7208, 2BK7219, 2BK7220, 2BK7225-7229, 2BK7231-7233, 2BK7235, 2BK7236, 2BK7241, 2BK7245, 2BK7247, 2BK7248-7250, 2BK7252, 2BK7254, 2BK7256, 2BK7257, 2BK7259-7262, 2BK7277, 2BK7279-7283, 2BK7286, 2BK7288, 2BK7289, 2BK7293, 2BK7294, 2BK7297-7299, 2BK7301, 2BK7303, 2BK7304, 2BK7314-7316, 2BK7322, 2BK7324, 2BK7332, 2BK7334, 2BK7336, 2BK7338, 2BK7347, 2BK7356, 2BK7358, 2BK7363, 2BK7365, 2BK7366-7369, 2BK7371, 2BK7372, 2BK7377, 2BK7391, 2BK7399, 2BK7401, 2BK7403, 2BK7406, 2BK7408, 2BK7410 -7416, 2BK7447, 2BK7452, 2BK7454, 2BK7455, 2BK7457, 2BK7459, 2BK7461-7468, 2BK7474, 2BK7476, 2BK7478, 2BK7480, 2BK7484, 2BK7489, 2BK7491, 2BK7497-7500, 2BK7502, 2BK7504, 2BK7505, 2BK7536-7538, 2BK7540, 2BK7541, 2BK7543, 2BK7546-7549, 2BK7551, 2BK7553, 2BK7555, 2BK7561, 2BK7566, 2BK7567, 2BK7569, 2BK7570, 2BK7572, 2BK7573, 2BK7578-7581, 2BK7584, 2BK7585, 2BK7587, 2BK7588-7590, 2BK7595, 2BK7596, 2BK7599, 2BK7603, 2BK7609, 2BK7611, 2BK7613, 2BK7617, 2BK7623, 2BK7625, 2BK7627, 2BK7638, 2BK7640, 2BK7646, 2BK7648, 2BK7651, 2BK7653, 2BK7655, 2BK7657, 2BK7661, 2BK7664, , 2BK7665, 2BK7667, 2BK7669, 2BK7671, 2BK7673, 2BK7675-7677, 2BK7679, 2BK7685, 2BK7689, 2BK7690, 2BK7701, 2BK7703, 2BK7706, 2BK7707, 2BK7737, 2BK7806, 2BK7913, 2BK8018, 2BK8122, 2BK8126, 2BK8130, 2BK8136, 2BK8142, 2BK8178, 2BK8179, 2BK8229, 2BK8255, 2BK8265, 2BK8284, 2BK8306, 2BK8327, 2BK8334, 2BK8337, 2BK8338, 2BK8344, 2BK8350, 2BK8356, 2BK8365, 2BK8367, 2BK8369, 2BK8370, 2BK8380, 2BK8382, 2BK8384, 2BK8386, 2BK8388, 2BK8397, 2BK8398, 2BK8401, 2BK8406, 2BK8421, 2BK8431, 2BK8436, 2BK8469, 2BK8471, 2BK8474, 2BK8475, 2BK8477, 2BK8479, 2BK8481, 2BK8483, 2BK8485, 2BK8487-8491, 2BK8493, 2BK8494, 2BK8496, 2BK8498, 2BK8500, 2BK8502, 2BK8504-8506, 2BK8520-8522, 2BK8524, 2BK8526, 2BK8528-8530, 2BK8532, 2BK8534, 2BK8535, 2BK8537, 2BK8538, 2BK8540, 2BK8541, 2BK8543, 2BK8544, 2BK8546, 2BK8547, 2BK8549, 2BK8550, 2BK8552, 2BK8553, 2BK8555, 2BK8556, 2BK8558, 2BK8559, 2BK8564, 2BK8565, 2BK8567, 2BK8568, 2BK8570, 2BK8571, 2BK8573, 2BK8574, 2BK8576, 2BK8577, 2BK8580, 2BK8582-8585, 2BK8587, 2BK8588, 2BK8590, 2BK8591, 2BK8593, 2BK8594, 2BK8596, 2BK8597, 2BK8599, 2BK8600, 2BK8602, 2BK8603, 2BK8605, 2BK8612, 2BK8617, 2BK8618, 2BK8620, 2BK8621, 2BK8623, 2BK8628, 2BK8630, 2BK8632, 2BK8633-8635, 2BK8637, 2BK8638, 2BK8640, 2BK8641, 2BK8643, 2BK8644, 2BK8646, 2BK8648, 2BK8649, 2BK8651, 2BK8652, 2BK8654, 2BK8655, 2BK8657, 2BK8658, 2BK8663, 2BK8665, 2BK8666, 2BK8668, 2BK8669, 2BK8671, 2BK8672, 2BK8674, 2BK8676, 2BK8677, 2BK8678, 2BK8680, 2BK8681, 2BK8683, 2BK8685, 2BK8686, 2BK8688, 2BK8689, 2BK8691, 2BK8692, 2BK8694-8697, 2BK8699, 2BK8700, 2BK8702, 2BK8703, 2BK8710, 2BK8711, 2BK8714, 2BK8720, 2BK8722, 2BK8725, 2BK8729, 2BK8730, 2BK8732, 2BK8733, 2BK8735, 2BK8736, 2BK8738, 2BK8740, 2BK8741, 2BK8743, 2BK8744, 2BK8749, 2BK8751-8753, 2BK8756, 2BK8757, 2BK8759, 2BK8760, 2BK8762, 2BK8765, 2BK8767, 2BK8768, 2BK8770-8773, 2BK8775, 2BK8776, 2BK8778-8781, 2BK8783, 2BK8785, 2BK8787, 2BK8788, 2BK8801, 2BK8803, 2BK8807, 2BK8808, 2BK8810-8812, 2BK8814-8816, 2BK8818-8820, 2BK8822-8824, 2BK8826-8828, 2BK8830-8832, 2BK8836, 2BK8839, 2BK8840, 2BK8842, 2BK8843, 2BK8846-8848, 2BK8850-8852, 2BK8854-8856, 2BK8858-8860, 2BK8862-8864, 2BK8866-8868, 2BK8870-8872, 2BK8874, 2BK8875, 2BK8877, 2BK8883, 2BK8899, 2BK8901, 2BK8904, 2BK8905, 2BK8907, 2BK8908, 2BK8910-8913, 2BK8915, 2BK8916, 2BK8918, 2BK8925, 2BK8927, 2BK8928, 2BK8930-8932, 2BK8935, 2BK8936, 2BK8938, 2BK8939, 2BK8941, 2BK8942, 2BK8944, 2BK8945, 2BK8947-8950, 2BK8952, 2BK8953, 2BK8955, 2BK8956, 2BK8958, 2BK8959, 2BK8961, 2BK8962, 2BK8964, 2BK8965, 2BK8967, 2BK8968, 2BK8973, 2BK8975, 2BK8976, 2BK8978, 2BK8981, 2BK8986, 2BK8987, 2BK8990, 2BK8991, 2BK8994, 2BK8996, 2BK8997, 2BK8999, 2BK9000, 2BK9002, 2BK9003, 2BK9005, 2BK9006, 2BK9011, 2BK9014, 2BK9016, 2BK9017, 2BK9019, 2BK9022, 2BK9023, 2BK9025, 2BK9026, 2BK9028, 2BK9029, 2BK9031, 2BK9032, 2BK9034-9037, 2BK9039, 2BK9040, 2BK9042, 2BK9043, 2BK9045, 2BK9046, 2BK9048, 2BK9051, 2BK9052, 2BK9054, 2BK9055, 2BK9057, 2BK9063, 2BK9065, 2BK9066, 2BK9068, 2BK9071, 2BK9074, 2BK9076, 2BK9078, 2BK9080, 2BK9082, 2BK9084, 2BK9092, 2BK9094, 2BK9095, 2BK9097, 2BK9099, 2BK9100, 2BK9101-9103, 2BK9110, 2BK9112, 2BK9113, 2BK9116, 2BK9118, 2BK9120, 2BK9121, 2BK9122, 2BK9124, 2BK9126, 2BK9128, 2BK9131, 2BK9133, 2BK9134, 2BK9136-9138, 2BK9140, 2BK9142, 2BK9144-9147, 2BK9149, 2BK9150, 2BK9150, 2BK9152, 2BK9157, 2BK9162, 2BK9164, 2BK9165, 2BK9167, 2BK9169, 2BK9176, 2BK9178-9180, 2BK9182, 2BK9184, 2BK9186, 2BK9190, 2BK9194, 2BK9196, 2BK9198, 2BK9200, 2BK9202, 2BK9207-9209, 2BK9211, 2BK9213, 2BK9214, 2BK9216, 2BK9218-9220, 2BK9227, 2BK9229, 2BK9231, 2BK9233, 2BK9237, 2BK9240, 2BK9245, 2BK9246, 2BK9249, 2BK9250, 2BK9252, 2BK9253, 2BK9260, 2BK9261, 2BK9276, 2BK9284, 2BK9285, 2BK9288, 2BK9296, 2BK9299, 2BK9300, 2BK9301, 2BK9303, 2BK9304, 2BK9307-9312, 2BK9314-9316, 2BK9326, 2BK9327, 2BK9332, 2BK9333, 2BK9336-9338, 2BK9340, 2BK9341, 2BK9342, 2BK9344, 2BK9345, 2BK9346, 2BK9348, 2BK9349, 2BK9354, 2BK9356, 2BK9357, 2BK9379-9381, 2BK9392, 2BK9394-9396, 2BK9398-9400, 2BK9402-9404, 2BK9406-9711, 2BK9421, 2BK9429, 2BK9431, 2BK9433, 2BK9434, 2BK9436, 2BK9437, 2BK9438, 2BK9440, 2BK9441, 2BK9442, 2BK9444-9446, 2BK9450, 2BK9452, 2BK9453, 2BK9475-9478, 2BK9491-9493, 2BK9495-9497, 2BK9499-9504, 2BK9506-9508, 2BK9518, 2BK9526-9528, 2BK9530-9532, 2BK9534-9536, 2BK9538, 2BK9539, 2BK9544-9546, 2BK9559, 2BK9562, 2BK9563, 2BK9565, 2BK9566, 2BK9584-9589, 2BK9591-9593, 2BK9595-9597, 2BK9599-9601, 2BK9608-9610, 2BK9612, 2BK9613, 2BK9615-9617, 2BK9623, 2BK9624, 2BK9642, 2BK9643, 2BK9645, 2BK9646, 2BK9662, 2BK9664, 2BK9665, 2BK9666, 2BK9669, 2BK9672-9674, 2BK9676-9679, 2BK9688, 2BK9708-9710, 2BK9712, 2BK9713, 2BK9716-9718, 2BK9720-9722, 2BK9724-9726, 2BK9741, 2BK9743, 2BK9744, 2BK9752, 2BK9753, 2BK9756, 2BK9759, 2BK9760, 2BK9771, 2BK9772, 2BK9775, 2BK9776, 2BK9778, 2BK9781, 2BK9783, 2BK9802, 2BK9804-9806, 2BK9808-9810, 2BK9812-9814, 2BK9816-9718, 2BK9820, 2BK9821, 2BK9837, 2BK9839, 2BK9840, 2BK9847, 2BK9863, 2BK9900-9902, 2BK9904-9906, 2BK9908-9910, 2BK9912-9914, 2BK9916, 2BK9917, 2BK9927, 2BK9933, 2BK9935, 2BK9936, 2BK9943, 2BK9951, 2BK9958, 2BK9997, 2BK9999-10004, 2BK10008, 2BK10019, 2BK10021, 2BK10022, 2BK10026, 2BK10035, 2BK10039, 2BK10043, 2BK10053, 2BK10060, 2BK10066, 2BK10071, 2BK10074, 2BK10075, 2BK10176, 2BK10179, 2BK10182, 2BK10183, 2BK10186, 2BK10189, 2BK10190, 2BK10192, 2BK10193, 2BK10194, 2BK10208, 2BK10268, 2BK10271, 2BK10274, 2BK10287, 2BK10360, 2BK10432, 2BK10437, 2BK10458, 2BK10526, 2BK10530, 2BK10541, 2BK10559, 2BK10569, 2BK10572, 2BK10642, 2BK10650, 2BK10690, 2BK10693, 2BK10722, 2BK10738, 2BK10750, 2BK10767, 2BK10768, 2BK10778, 2BK10934, 2BK10939, 2BK10941, 2BK10945, 2BK10976, 2BK11001, 2BK11002, 2BK11003, 2BK11004, 2BK11008, 2BK11009, 2BK11022, 2BK11037, 2BK11039, 2BK11043, 2BK11058, 2BK11066, 2BK11082, 2BK11137)

Parts Needed

1 - 7E9425 Coolant Temperature Switch (Groups 1 and 2)

1 - 3J1907 O-ring Seal (For Coolant Switch) (Groups 1 and 2)

1 - 4P6602 Control Module As. (Groups 1, 2, and 3)

4 - 9Y7355 Seat (Valve Spring) (Groups 1 and 2)

Action Required

215 and 250 Hp Only

A. CONTROL MODULE: Replace the 7E9958 Air Inlet Heater Control Module with a 4P6602 Control Module Assembly on all Group 1, 2, and 3 engines.

The 7E5561 Control Module used a seven minute "ON" cycle. The 4P6602 Control Module is "ON" for ten minutes, then cycles "ON" ten seconds and "OFF" ten seconds for an additional ten minutes.

NOTE: No other updates are needed for Group 3 engines.

B. COOLANT TEMPERATURE SWITCH: For Group 1 and 2 engines, replace the 7E6106 Coolant temperature Switch in the regulator housing with a 7E9425 Switch and 3J1907 Seal.

The former switch turned the air inlet heater off when the jacket water temperature reached 29°C (85°F). The new switch turns the air inlet heater off when the jacket water reaches 49°C (120°F).

The 7E9425 Switch has already been installed in Group 3 engines.

C. EXHAUST VALVE SEALS: For Group 1 engines, remove the 9Y8847 Exhaust Valve Stem Seal Assembly and install 9Y7355 Seats under the exhaust valve springs on cylinders 2, 3, 4, and 5.

For Group 2 engines, remove the exhaust valve stem seal assembly from cylinders 2 and 5 only and install the 9Y7355 Seat under the valve springs. See Part C of the attached rework procedure.

The purpose of the 9Y7355 Seat under the valve spring is to make up the spring height difference when the seal assembly is removed.

The Group 3 engines already have the correct valve seal configuration and DO NOT need to have any valve seal assemblies removed.

Service Claim Allowances

NOTE: Any additional operations must be justified and explained in the claims story.

After Failure

Parts Disposition

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

Attach.

(1-Rework Procedure For 215, 250 Hp (2BK) 3116 Engines)

(2-Operating Instructions)

Rework Procedure For 215, 250 Hp (2BK) 3116 Engines

PART A: REPLACE CONTROL MODULE FOR AIR INLET HEATER

NOTE: Replacement of the control module assembly applies to Group 1, 2, and 3 engines.

... Unplug the vehicle wiring harness from the 7E9958 Control Module.

... Install the new 4P6602 Control Module and connect the harness to the new module.

Illustration 1. Location of Control Module

Be sure to 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 6).

PART B: REPLACE JACKET WATER TEMPERATURE SWITCH

NOTE: Replacement of the jacket water temperature switch applies to both Group 1 and Group 2 engines. The Group 3 engines already have the new switch.

The 7E9425 Switch replaces the 7E6106 Switch, which is the lower of the two switches in the regulator housing (See Illustration 2).

Illustration 2. Front View Of Engine

... Assemble a 3J1907 O-ring Seal on a 7E9425 Jacket Water Temperature Switch.

... Loosen the radiator cap slowly to release pressure. Install the cap to minimize coolant loss while changing the switch.

... Remove the original, 7E6106 Switch. Have a clean container under the engine to catch any coolant that may escape.

... Install the new, 7E9425 Switch.

... Fill the cooling system to normal level.

PART C - REMOVE EXHAUST VALVE STEM SEAL ASSEMBLIES

(Group 1 Engines) Cylinders 2, 3, 4, And 5

(Group 2 Engines) Cylinders 2 And 5

NOTE: The Group 3 engines already have the valve seals removed from cylinders 2, 3, 4, and 5.

Before Failure

The exhaust valve stem seal assemblies (See Illustration 3) may be removed with the head on the engine. Illustration 4 shows how to make an exhaust valve spring compressor tool to allow removal of the exhaust valve seal assembly without removing the rocker arm stands.

Illustration 3. Seal Assembly Removal

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° ( turn) CCW (as viewed from the flywheel) moves pistons 2 and 5 to TDC, and another 120° moves 3 and 4 to TDC.

NOTE: An easy way to know when the crankshaft has been turned 120° 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. Mark the damper as described above, then rotate the engine another 120° ( turn) until pistons 2 and 5 are at TDC

2. Loosen the valve lash adjusting screw for #2 exhaust valve to allow the exhaust 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 out of the way, remove the intake manifold bolt (See Illustration 5) adjacent to the exhaust valve spring. Compress the exhaust valve spring with the compressor tool shown in Illustration 4 using 1-6V5223 Bolt.

Illustration 4. Fabricate to compress springs.

NOTE: Use a 6V5223 Bolt with this fixture to compress exhaust valve springs.

Illustration 5. Remove Bolt (1).

4. Remove the exhaust valve keepers, compressor tool, retainer, and spring.

5. Remove and discard the entire exhaust valve seal assembly making sure not to mar the valve stem.

NOTE: The 9Y8847 Seal Assembly consists of three parts: inner rubber seal, tension ring, and outer metal support stand. All parts of the seal assembly must be removed.

6. Install 1-9Y7355 Seat under the exhaust valve spring. The seat replaces the metal portion of the valve seal assembly which had previously acted as a valve spring seat. 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 into position and install the push rod, making sure the bottom of the push rod is still seated on the lifter.

9. Repeat Steps 2 through 8 for #5 exhaust valve seal assembly removal.

10. Rotate the engine 120°.

NOTE: Skip this step for Group 2 engines. They don't have exhaust valve seal assemblies on cylinders 3 and 4.

11. Repeat Steps 2 through 8 for #3 and #4 exhaust valve seal removal.

NOTE: Skip this step for Group 2 engines. They don't have exhaust valve seal assemblies on cylinders 3 and 4.

12. Rotate engine to TDC #1 compression stroke. Set exhaust valve lash to 0.64 mm (0.25") on cylinders 3 and 5 (#5 only for Group 2 engines). After adjustment, tighten the locknut to a torque of 25 ± 7 N·m (18 ± 5 lb ft) and check adjustment again.

13. Rotate engine to TDC #6 compression stroke. Set exhaust valve lash to 0.64 mm (0.25") on cylinders 2 and 4 (#2 only for Group 2 engines). After adjustment, tighten the locknut to 25 ± 7 N·m (18 ± 5 lb ft) and check adjustment again.

14. Install the valve cover.

15. 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 6).

Illustration 6. Stamp Engine Information Plate.

After Failure Only

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 #2, 3, 4, and 5 exhaust valve stem seal assemblies off of cylinder heads. DO NOT reuse the metal portion of the 9Y8847 Seal Assembly. Use 9Y7355 Seats under the exhaust valve springs for cylinders where the exhaust valve stem seal assemblies have been removed.

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. 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.

7. Make sure that all other portions of this Service Letter have been completed.

Operating Instructions

When operating in cold weather conditions (below 0°C or 32°F):

1. Use an electric jacket water (block) heater, whenever possible, in temperatures below 0°C or 32°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 engine speed to 1000-1200 rpm. The increased idle speed will decrease 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°C (0°F)

... Minimum of 387 sq cm (60 sq in) of opening from -18 to 0°C (0 to 32°F).

... Fully opened or removed above 0°C (32°F).