CYLINDER & SEAL GP-BOOM 1232081 - Caterpillar

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
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
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
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 RemovalTEPS 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.
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 TDC2. 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