PRIORITY - ON CERTAIN 3176 ENGINES CONTROL GROUP (PERSONALITY MODULE), BOOST LINE CONNECTOR, GROUNDING STUD &/OR PISTON COO LING JETS MAY NEED TO BE REPLACED & ELECTRONIC UNIT EJECTORS MAY NEED TO BE INSPECTED - PI3419 - MAILED US, CANADA TRUCK TEPS Caterpillar

U-159
TT-10
PRIORITY  1705, 1331  PI3419
COMPLETION DATE  

February 28, 1990 August 31, 1990

***** Group 1 *****
The control group (personality module) and boost line connector need to be
replaced on certain 3176 Engines.
***** Group 2 *****
A new grounding stud has replaced the existing bolt on certain 3176 Engines.
***** Group 3 *****
Cooling jets may be cracked or broken on certain 3176 Engines.
***** Group 4 *****
Electronic unit injector (EUI) may leak fuel.

Model Identification Number
***** Group 1 *****
3176 2YG1624-1670, 1672-1680, 1682-1696, 1698-1700,
1702, 1704-1707, 1709, 1710, 1713-1725, 1727,
1729, 1731-1765, 1767-1773, 1775, 1777, 1778,
1780, 1782, 1783, 1785-1806, 1808-1813,
1815, 1816, 1818-1834, 1836-1846, 1848,
1851-1868, 1870-1878, 1881, 1882, 1884-1894,
1897, 1899-1903, 1905, 1907-1909, 1911,
1913-1916, 1918, 1919, 1922, 1924, 1926-1932,
1934-1935, 1937, 1939, 1940, 1942-1944, 1946,
1948, 1949, 1951-1953, 1955-1958, 1960-1964,
1967, 1968, 1971-1978, 1982, 1983, 1985, 1986,
1989, 1992, 1994-2005, 2007-2010, 2014-2015,
2018, 2019, 2021, 2023, 2025, 2027, 2030,
2032-2034, 2036, 2037, 2039, 2041-2042,
2045-2047, 2049, 2055, 2056, 2058, 2060, 2063,
2066-2069, 2072, 2073, 2075, 2079, 2082-2084,
2087, 2092-2094, 2096, 2097, 2099, 2104-2107,
2109, 2111, 2116, 2118, 2120, 2121, 2123, 2128,
2130, 2132-2135, 2140, 2142-2146, 2151, 2152,
2157-2159, 2168, 2169, 2171, 2179, 2182, 2195,
2202, 2207, 2209, 2217, 2230, 2231, 2269, 2270,
2273, 2279, 2283, 2287, 2290, 2296, 2300, 2307,
2315, 2317, 2319, 2324, 2331, 2334
+  ***** Group 2 *****
3176 2YG1624-1670, 1672-1680, 1682-1696, 1698-1700,
1702, 1704-1707, 1709, 1710, 1713-1725, 1727,
1729, 1731-1765, 1767-1773, 1775, 1777, 1778,
1780, 1782, 1783, 1785-1806, 1808-1813,
1815, 1816, 1818-1834, 1836-1846, 1848,
1851-1868, 1870-1878, 1881, 1882, 1884-1894,
1897, 1899-1903, 1905, 1907-1909, 1911,
1913-1916, 1918, 1919, 1922, 1924, 1926-1932,
1934, 1935, 1937, 1939, 1940, 1942-1944, 1946,
1948, 1949, 1951-1953, 1955-1958, 1960-1964,
1967, 1968, 1971-1978, 1982, 1983, 1985, 1986,
1989, 1992, 1994-2005, 2007-2010, 2014, 2015,
2018, 2019, 2021, 2023, 2025, 2027, 2030,
2032-2034, 2036, 2037, 2039, 2041, 2042,
2045-2047, 2049, 2055, 2056, 2058, 2060, 2063,
2066-2069, 2072, 2073, 2075, 2079, 2082-2084,
2087, 2092-2094, 2096, 2097, 2099, 2104-2107
+  ***** Group 3 *****
3176 2YG1624-1649, 1651-1654, 1656-1658, 1661-1668,
1970, 1672-1680, 1682, 1684-1700, 1702,
1704-1707, 1709, 1710, 1713-1718, 1720-1722,
1724, 1725, 1727, 1729, 1731-1735, 1737,
1739-1746, 1765, 1767-1773, 1775, 1777, 1780,
1782, 1786-1800, 1803, 1805, 1806, 1815,
1822-1829, 1831, 1834, 1838, 1840, 1841,
1844-1846, 1848, 1851, 1852, 1857, 1860, 1861,
1863, 1864, 1866, 1867, 1870-1876, 1878, 1884,
1907, 1909, 1914, 1916, 1918, 1922, 1928, 1929,
1931, 1943
***** Group 4 *****
3176 2YG1624-1626, 1629-1664, 1666-1668, 1670,
1672-1680, 1682-1696, 1698-1700, 1702,
1704-1707, 1709, 1710, 1713-1722, 1724, 1725
1727, 1729, 1731-1735, 1737-1746, 1765,
1767-1773, 1775, 1777, 1778, 1782, 1782, 1783,
1785-1806, 1808-1813, 1815, 1816, 1818-1834,
1836-1846, 1848, 1851-1864, 1866-1868,
1870-1878, 1881, 1882, 1884-1894, 1897,
1899-1903, 1905, 1907-1909, 1911, 1913-1916,
1918, 1919, 1922, 1924, 1926-1932, 1934, 1935,
1937, 1939, 1940, 1942-1944, 1946, 1948, 1949,
1951-1953, 1955-1958, 1960-1964, 1967, 1968,
1971-1978, 1982, 1983, 1985, 1986, 1989, 1992,
1994-2005, 2007-2010, 2014, 2015, 2018, 2019,
2021, 2023, 2025, 2027, 2030, 2032-2034, 2036,
2037, 2039, 2041, 2045-2047, 2049, 2055, 2056,
2058-2060, 2063, 2066-2069, 2072, 2073, 2075,
2079, 2082-2084, 2087, 2092-2094, 2096, 2097,
2099, 2104-2107, 2109, 2111, 2116, 2118, 2120,
2121, 2123, 2128, 2130, 2132-2135, 2139, 2140,
2142-2146, 2151, 2152, 2157, 2159, 2168, 2169,
2171, 2173, 2179, 2181, 2182, 2185, 2188, 2194,
2195, 2202, 2207, 2209, 2217, 2130, 2231, 2269,
2270, 2273, 2279, 2283, 2287, 2290, 2296, 2300,
2304, 2307, 2315, 2317, 2319, 2319, 2324, 2334

Dealers will need to order parts for this Program.
***** Group 1 *****
1 - 7E6045 Connector
1 - 3J1907 Seal
1 - 0R6088 Control Group (325 hp only)
1 - 0R6089 Control Group (300 hp only)
1 - 0R6090 Control Group (275 hp only)
1 - 0R6091 Control Group (250 hp only)
1 - 4W5140 Plate
***** Group 2 *****
3 - 9M1974 Washer
1 - 5P7970 Nut
1 - 9X2097 Bolt
***** Group 3 *****
6 - 9Y9269 Jet Assembly
1 - 617540 Seal
***** Group 4 *****
1 - 5P8066 Seal
1 - 8T5452 Seal
1 - 0R2833 Injector Group (250 - 275 hp only) or
1 - 0R2834 Injector Group (300 - 325 hp only)

See the attached rework procedures.

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

***** Group 1 And 2 *****
Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
(D/N) (Sell)  (C/L) (Sell)
100% 2.0 0 0  0 0
NOTE: This is a 2.0-hour job to do Group 1 and 2.
***** Group 3 *****
Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
(D/N) (Sell)  (C/L) (Sell)
100% 3.0 0 0  0 0
NOTE: This is a 3.0-hour job.
***** Group 4 *****
Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
(D/N) (Sell)  (C/L) (Sell)
100% 5.0 0 0  0 0
NOTE: This is a 5.0-hour job.

Handle the parts in accordance with your Warranty Bulletin on
warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach. (1-Owner Notification)
(2-Rework Procedure)
COPY OF 

 FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
PRIORITY - Control Group (Personality Module), Boost Line
Connector, Grounding Stud And/Or Piston Cooling Jets
Need To Be Replaced And Electronic Unit Injectors
Need To Be Inspected On Certain 3176 Engines
MODELS INVOLVED - 3176 Engines
Dear Caterpillar Product Owner:
The control group, boost line connector, grounding studs and/or piston
cooling jets need to be replaced on the products listed below. Also the
electronic unit injectors need to be inspected on the products listed below.
The repair will be done at no cost to you.
Contact your local Caterpillar dealer immediately and schedule a time to have
this service performed. The repair time for this service is approximately
eight to ten hours.
We regret the inconvenience this may cause you, but urge you to have this
service performed as soon as possible to prevent unscheduled downtime.
Caterpillar Inc.
Identification #(s)
Attached to August 7, 1989 Service Letter
Rework Procedures
***** Group 1 *****
Control Group (Personality Module)
1. Connect the ECAP or DDT to the 3176 Engine. (ECAP / DDT must contain
3176 SPM version 1.1.).
NOTE: Registered owners of ECAP / DDT service tools should have
received updated Service Program Module (SPM) through the mail.
You must have a version 1.1 to complete this procedure.
2. Record the vehicle speed calibration parameter PPM (pulse per mile).
This is a customer parameter determined by tire size, axle ratio and
chopper wheel teeth number.
3. Remove the existing control group (personality module) from the engine.
4. Install the new control group. See Table 1 and Illustration 1 to
determine control group needed.
Table 1
Remanufacture New Part No. To
Part No.  Stamp In "PERF SPEC"
250 hp 0R6091 9X4952
275 hp 0R6090 9X4951
300 hp 0R6089 9X4950
325 hp 0R6088 9X4949
5. Use ECAP or DDT Read / Change Parameter procedures to reprogram Pulse
Per Mile parameter with the number recorded in Step 1..
6. Stamp the new personality module part number in the "PERF SPEC" space on
a new 4W5140 Engine Information Plate. See Table 1 for appropriate part
number. Copy all other information from the existing information plate
to the new 4W5140 Engine Information Plate and install over the existing
information plate.
-2 of 9-
****** IMAGE: SEBE4110.00001.001
CAPTION: Illustration 1
Control Group (Personality Module)
-3 of 9-
Boost Line Connector
1. Disconnect the 9Y1133 Hose Assembly from the 2P1314 Connector at the
manifold.
2. Remove the existing 2P1314 Connector and 3J1907 Seal and replace with
the new 7E6045 Connector and 3J1907 Seal. See Illustration 2.
3. Disconnect the 307946 Elbow from the transducer housing.
4. Drain any existing water from the boost hose assembly.
5. Connect the 307946 Elbow to the transducer housing.
6. Connect the boost hose assembly to the 7E6045 Elbow at the manifold.
****** IMAGE: SEBE4110.00001.002
CAPTION: Illustration 2
Rear View Of Engine
-4 of 9-
***** Group 2 *****
Grounding Stud
1. Remove the existing ground bolt that connects the ground wires to the
cylinder head.
2. Clean off the stud mounting surface on the cylinder head with a wire
brush to remove dirt and paint.
3. Install the new 9X2097 Grounding Stud-Bolt with the new 9M1974 washer,
and the existing alternator ground wire, ECM ground wire and harness
ground wire (in that order) to the cylinder head. See Illustration 3.
4. Install a new 9M1974 Washer, the existing OEM wire to battery negative,
another new 9M1974 Washer and a new 5P7970 Nut to the other end of the
new 9X2097 Stud.
NOTE: Use new 9M1974 Washers to insure proper grounding connections.
****** IMAGE: SEBE4110.00001.003
CAPTION: Illustration 3
Rear View Of Engine
-5 of 9-
***** Group 3 *****
Piston Cooling Jets
1. Drain the oil and remove the oil pan and underframe.
2. Remove the existing cooling jet assemblies and replace with new 9Y9269
Jet Assemblies. Tighten to a torque of 25 +/- 7 N.m (18 +/- 5 lb ft).
3. Remove the existing O-Ring Seal and install the new 617540 O-Ring Seal
in the underframe.
4. Reuse the existing oil pan gasket and install the oil pan.
5. Change the oil filter and add oil to the required level.
-6 of 9-
***** Group 4 *****
Electronic Unit Injector Leakage Examination
1. Remove the valve cover, Jake Brake mechanism if equipped and valve cover
base.
2. Remove the valve rocker arm group.
3. Disconnect the fuel return line at the fuel manifold adapter (anti-
siphon block).
Install a cap on the return line fitting to allow pressurization of the
system. (Fitting size; No. 6 SAE). DO NOT remove the 7X0902 Return
Fitting. This is part of the pressure regulating valve assembly.
4. With a 3 mm hex wrench, loosen the three screws on top of each injector
solenoid, one at a time, and then tighten to 4 N.m (35 lb in).
5. Clean the injectors and the top of the cylinder head. Use shop air to
remove any accumulation of oil for inspection.
6. Pressurize/maintain fuel system at a pressure of 700 kPa (100 psi). Use
the fuel priming pump or adapt a regulated air supply to the transfer
pump inlet.
NOTE: System must be full of fuel.
7. Monitor the pressurized system periodically for 30 minutes.
8. Inspect for fuel leakage at the following locations, top of the
solenoid, solenoid to body joint, plunger to body joint, high pressure
plug and the O-ring seals. See Illustration 4.
9. Tighten 6V5219 Injector Clamp Bolts to 30 N.m (22 lb ft). If a bolt
turns at less than 15 N.m (11 lb ft), remove the injector and examine
for a damaged O-ring and/or the condition of the brass sleeve seat in
the cylinder head.
10. If fuel leakage is observed, remove the suspected injector(s) for
inspection and test. Examine lower injector O-ring for damage or
deterioration. Install injector(s) on the 1U6661 Injector Tester and
perform leakage tests as directed in Special Instruction SEHS8867 and
SEHS8884.
-7 of 9-
LEAK CRITERIA:
Leakdown Rate Test: A 30 second minimum time for pressure deterioration
from 4500 kPa (650 psi) to 2500 kPa (365 psi).
New Leakage Test: Maintain 5000 kPa (725 psi) pressure in the injector
and observe for an additional 90 seconds. There must not be visible
fuel accumulation at any of the following areas as shown in Illustration
4:
A. Screws at the top of the solenoid
B. Solenoid seals
C. Solenoid to body joint
D. High pressure plug
E. Cone to body or tip
NOTE: Fuel observed at the plunger to body joint (Item F) is not to be
considered in the Leakage Criteria. This location is judged per
the Leakdown Rate Test.
Before installation, test all replacement injectors from PARTS STOCK
ACTION NEEDED on the 1U6661 Tester except those identified with a YELLOW
paint mark on the solenoid.
11. At installation of the injector(s) evacuate any residual fuel from the
cylinder(s) to avoid hydraulic lock. Lubricate the two O-ring seals
with a liberal amount of STP Engine Oil Treatment. Tighten the hold
down bolts to a torque of 30 N.m (22 lb ft).
12. Adjust valve bridges to a new specification of contact plus 45 deg.
rotation. (Make the appropriate correction to your service manual.)
Adjust valves, injector rocker arms and Jake Brake as follows.
Valves: Inlet 0.38 mm (.015")
Exhaust 0.64 mm (.025")
Injectors: Contact plus 180 deg. rotation.
Jake: 1.14 mm (.045")
13. Assemble the engine.
-8 of 9-
****** IMAGE: SEBE4110.00001.004
CAPTION: Illustration 4
Injector
-9 of 9-
***** All Groups *****
1. Stamp "FJ" next to the serial number plate on the cylinder block after
the rework is completed.