Product Support Program For Reworking Valve Guides On Certain 3196 Marine Engines Caterpillar

Product Support Program For Reworking Valve Guides On Certain 3196 Marine Engines

April 22, 1997
(Revised June 1997)
U-108
A-91
H-30
O-84
TM-3

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 "PS4032" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the April 22, 1997 Service Letter. Changes have been made to the Affected Product and Action Required.

Termination Date

Problem

The exhaust valve guide bores may be undersized on certain 3196 Marine Engines.

Affected Product
Model & Identification Number

Group 1

3196 (2XR442, 2XR443, 2XR450-543)

Engines with the 1382003 Head Assembly (number stamped in the right rear corner of the cylinder head).

Group 2

3196 (2XR441, 2XR444-449)

Engines with the 1323251 Head Aseembly (number stamped in the right rear corner of the cylinder head) must be replaced.

Parts Needed

Group 1

1 - 7B5932 Gasket (for turbocharger oil supply tube)

1 - 7E5555 Gasket (for shunt line)

1 - 7E7912 Gasket (for regulator housing)

1 - 1S4810 Gasket-Oil Drain (for turbocharger oil drain tube)

4 - 1182797 Gasket (for water manifold)

1 - 1260065 Gasket Assembly - Cylinder Head

Group 2

1 - 7B5932 Gasket (for turbocharger oil supply tube)

1 - 7E5555 Gasket (for shunt line)

1 - 7E7912 Gasket (for regulator housing)

1 - 1S4810 Gasket-Oil Drain (for turbocharger oil drain tube)

3 - 1006437 Gasket (for exhaust manifold)

4 - 1182797 Gasket (for water manifold)

1 - 1260065 Gasket Assembly - Cylinder Head

1 - 1382002 Cylinder Head Group

Action Required

See the attached rework procedure.

Service Claim Allowances

Labor Breakdown

NOTE: An additional 4 hours may be claimed for preparing new cylinder heads in the Group 2 Affected Product.

Parts Disposition

Return the cylinder heads to:

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

Attach.

(1-Rework Procedure)

Rework Procedure

Group 1

Engines with the 1382003 Cylinder Head Assembly (number stamped on the right rear corner of the cylinder head)requires reaming the exhaust valve guide.

1. Remove the cylinder head.

2. Remove the exhaust valves from the cylinder head.

3. Use a 5P5173 Ream to enlarge the bore .373 ± .001" (9.484 ± .026 mm) on each exhaust valve guide. This ream is part of the 5P5170 Knurling Group or the 6V7770 Valve Guide Kit.

4. Clean each exhaust valve guide with soap and water using the 1P5571 " Brush from the 1P5580 Brush Kit.

5. Install the exhaust valves using 8T2998 Camshaft break-in lubricate.

6. Install the cylinder head on the engine using the attached tightening procedure.

Group 2

Engines with the 1323251 Cylinder Head Assembly (number stamped on the right rear corner of the cylinder head) must be replaced.

1. Remove the cylinder head.

2. Remove the exhaust valves from the new 1322002 Cylinder Head Assembly.

3. Use a 5P5173 Ream to enlarge the bore .373 ± .001" (9.484 ± .026 mm) on each exhaust valve guide. This ream is part of the 5P5170 Knurling Group or the 6V0770 Valve Guide Kit.

4. Clean each exhaust valve guide with soap and water using the 1P5571 " Brush from the 1P5580 Brush Kit.

5. Install the exhaust valves using 8T2998 Camshaft Break-in Lubricant.

6. Install the cylinder head using the attached tightening procedure.

Tightening Procedure

NOTE: Lubricate bolts with 2P2506 Thread Lubricant prior to assembly.

1. Tighten bolts 1 through 26 by numerical sequence to a torque of 160 ± 15 N·m (120 ± 11 lb ft).

2. Re-tighten Bolts 1 through 26 by numerical sequence to a torque of 160 ± 15 N·m (120 ±11 lb ft).

Type II (Reduced Shank) Cylinder Head Assembly Mounting Bolt

3. Turn each bolt 90 degrees.

4. Tighten bolts 27 through 33 to 28 ± 7 N·m (20 ± 5 lb ft).

Cylinder Head