PSP FOR REPAIRING A FAILED SLEEVE OR SLEEVE TO HEAD JOINT ON CERTAIN 3176 TRUCK ENGINES THAT HAVE FUEL DILUTION OF THE COO LANT - PS0471 - MAILED USAND CANADA, TRUCK TEPS - REVISED 03/91 Caterpillar

(Revised March 1991)
U-149
TT-8
1101, 1201, 1250  PS0471
NOTE: This Program can only be administered after a failure
occurs. The decision whether to apply the Program is made
by the dealer. When reporting the repair, use "PS0471" as
Part Number, "7755" as Group Number, and "96" as
Description Code.
NOTE: Although this Program is to be administered as described above on
the Affected Product, parts should be removed from parts stock as
soon as possible.
NOTE: This Revised Service Letter replaces the July 19, 1990 Service
Letter. Changes have been made to the Termination Date, Parts
Needed, Action Required, Service Claim Allowances, and Parts
Disposition.

December 31, 1991

A failed sleeve or sleeve to head joint may cause fuel dilution of the
cooling system on certain 3176 Truck Engines.

Model Identification Number
3176 2YG1-4901

6 - 7C0324 Exhaust Manifold Gasket
4 - 7C2597 Manifold Gasket
5 - 8C3684 Antifreeze (Gal)
8 - 7E9438 Spacer
6 - 3H2388 Seal
6 - 4P1711 Spacer
6 - 5P3456 Fuel Manifold Seal
6 - 5P8066 O-ring (upper)
1 - 0R3254 Cylinder Head
1 - 1S7057 Turbo Gasket
6 - 8T0100 Bolt
8 - 6V1819 Bolt
1 - 7W2398 Turbo Gasket
3 - 7W5164 Inlet Manifold Gasket
6 - 9X3979 O-ring (lower)
1 - 9Y7044 Cylinder Head Gasket
5 - -- Distilled Water (Gal)

***** Parts Stock *****
Remove from parts stock all 0R2828 and 0R2831 Cylinder Head Assemblies with
package dates prior to December 1989.
***** Affected Product *****
1. When it is necessary to replace a sleeve due to failure of the sleeve or
the sleeve to head joint:
a) Check for 3S stamped on the block next to the serial number plate. If
block is stamped with 3S, change only the failed sleeve using 4P7135
Sleeves. The 4C6730 Roller Expander and 4C6714 Swage must be used to
install the new sleeves. See Special Instruction SEHS9246.
b) It is possible that a 0R3254 Cylinder Head may have been installed
before this Service Letter was issued and the block may not be
stamped.
A 0R3254 Cylinder Head can be identified by the part number 4P7267
stamped on the left rear top surface of the head casting. If this is
found, replace only the failed sleeve using 4P7135 Sleeves and the
4C6730 Roller Expander and 4C6714 Swage. Stamp 3S on the block next
to the serial number plate after the repair.
c) If block is not stamped 3S, replace the cylinder head with 0R3254
Cylinder Head.
2. Ream the injector sleeve seating surface in new head. See Special
Instruction SEHS9246
Engine Disassembly
1. Remove cylinder head.
2. Check cylinder head bolt hole depth. If the bolt holes are shallow, tap
the shallow holes to the correct depth.
3. Check liner projection - Spec. 0.13 +/- 0.08 mm (.005 +/- .003 in.).
Replace spacer block if liner projection varies more than .004 in. from
front to rear. SENR3909-03.
4. On engines with identification numbers 2YG1-3250, make sure the October
20, 1989 Service Letter - PS4375 is completed. (Injector rocker arms,
exhaust rocker arms and pistons crowns).
Off Engine Test and Assembly
1. Test electronic unit injectors for leaks and VOP on test bench.
Reference attached leak test. Replace as necessary.
Note: The part number of the O-ring retaining the contact button on top
of the injector is 336044.
2. Install exhaust manifolds on new head using longer 6V1819 Bolts and
7E9438 Spacers on #1, #2, #5 and #6 cylinders. Tighten the bolts to a
torque of 55 N.m (41 lb ft). Do not over tighten the bolts.
Engine Assembly
1. Transfer the remaining components and install the new cylinder head.
2. Install the injectors using longer 8T0100 Bolts and 4P1711 Spacers.
Tighten the bolts to a torque of 30 N.m (22 lb ft). Use liberal amounts
of a thick lubricant on the o-rings to avoid cutting the o-rings during
installation.
3. Test for fuel leaks past the upper o-ring seals by blocking the fuel
return line and pressurizing to 690 kPa (100 psi) (observe for 3
minutes).
Note: It is not necessary to check for injector leaks as
this was done on the test bench.
4. Install the rocker arm assemblies and push tubes. Adjust valves and
bridges.
Note: Bridge adjustment is contact plus 45 degrees.
5. If the engine is equipped with a Jacobs Brake, replace original Jacobs
studs with Jacobs bolts (014800) if the studs have caused damage to the
pedestal. After replacing the studs with bolts, it will be necessary to
use an additional 6-7X0909 Bolts (short) during valve adjustment.
After valve adjustment, remove the short bolts and install the Jacobs
Brake.
6. Attach air filter, lines etc. - complete engine installation.
7. Flush and fill cooling system. Flush for 30 minutes minimum using
4C4609/4C4613 Cleaner (may use 6V4511 as a substitute). Fill the
cooling system using a 50% mixture of low silicate antifreeze and
distilled water. If Caterpillar antifreeze is not used, add 6% cooling
system conditioner.

***** Parts Stock *****
Submit one claim for all 0R2828 and 0R2831 Cylinder Head Assemblies removed
from parts stock with package dates prior to December 1989.
***** Affected Product *****
Product Caterpillar Dealer Suggested Customer Suggested
miles Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
(C/L) (Sell)
0-300,000 100% 20 0 0 0 0
NOTE: This is a 20-hour job.
NOTE: Authorized expenses include the cost of antifreeze, conditioner
and cooling system cleaner. Additional parts and labor for
damaged components such as the spacer block, injectors, etc.
should be filed on a separate claim.

Handle the parts in accordance with your Warranty Bulletin on warranty parts
handling.
If a porous cylinder head is to be returned for a core credit, mark the
porous areas and write "Do Not Remanufacture" on the cylinder head.