The Cat 3116 Engine. Know Your Engine. Facts, Engine Design, Design Info, And Common Failures.
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The Cat 3116 Engine is in a lot of trucks, RVs, boats, generators, equipment, and various other machines. This Cat engine with no Liners has a complicated fuel system and it is discussed in depth in this video, as well as the basic engine design. Thanks for watching.
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I enjoy your videos man. I start diesel school in January. Was in the medical field for 11 years, new decade for me, new adventure. Thanks again 🇺🇸👍
ThAt was the nicest way I have ever heard a mechanic explain the 3116 rack problem with that particular engine , most mechanics those 4 numbers begin making their faces red with frustrated looks that self explain tuning the fuel system , well done ,I don't believe you could have elaborated much more without losing it , thanks for keeping it professional
We're really fortunate we got a guy like you Ape! Not many people on TH-cam who do this stuff!
The 3116 was the engine I learned how diesel engines work at school!
Thank you for posting this video this will help me a ton when I am working on my M1078 2.5 ton truck.
I worked on crown buses with Detroit 6-71inline. Very similar fuel system. In fact once adjusted over head on 3116 using same basic method. Thanks for video
Great video, thanks Josh.The 3116 engines were a great engine considering the environment they lived in.Medium duty trucks usually get poor maintenance and little attention until something goes wrong.The 3116 would normally out live the truck it was in.
Hey Josh,
How much would I be looking at spending on a cat mechanic to inspect my 3116. I just bought it and I see 2 harnesses disconnected and the truck only had 1 of 3 batteries in the box. They added a prime pump on the return line. which I believe is not a good thing. So basically inspect to see what they did that they shouldn't have. Also the fuel filter looks bypassed. A little worried about this because I plan on running otr with this 95 gmc topkick with 3116 cat. Don't want to blow an injector
Excellent video very informative. I was just in the Middle East and cat is still selling the 3116 in the Middle East.
We have a 95 kodiak with a Reman that has been ran low on numerous times and smokes like no other. It starts to over heat over 45 but will not stop running, just gets harder and harder to start lol. We have a 92 with 430k and runs like new. Amazing motors!
awsome work these are such great videos man really a vary informed tech great stuff u clearly love what you do I am learning a lot
Excellent video. The 3116 is a good engine in most applications. The military still uses them in some vehicles but is slowly phasing them out. By far the worst thing about this engine was setting up the overhead. Other than that they were very reliable. The tooling and procedures to work on them was and is their biggest fault. As you had mentioned, this was their first venture into a small inline engine and it came out okay. Most parts are still available currently. Thanks for sharing the info on this engine.
Hi Ken. Setting up the overhead? Im not a mech, Im a fireman and part time general contractor. I have only one dump truck, it has a Cat 3116. So far, so good. I run this truck to the dump, full of concrete, and it runs strong, as if it had no load on it all. I love it so far. Having said that, Im the type that likes to take care of his equipment and do maintenance , to prevent problems. At any rate, I hope I never have to, set up the overhead, because I have no idea about that. Id have to take it to a mech, and that job sounds expensive , haha. Other than keeping filters clean, is there anything else I can do to my 3116, to keep it happy and running smooth?
Thanks Adept Ape. I m looking at buying a GMC with a 3116 in it. 137,000 km so it should some good days left. Not looking forward to dealing with an injector problem. Guess I'll let Toromont Cat deal with it. You make great videos.
Many thanks for the video, keepem coming bro.
great vid, we have one of the first 3116 in a custom made lo pro, first one made in the usa. Only has 134k miles on it, engine has been great. In 93 the dealer, chief white gmc in duncan ok, (they did the custom body from a detroit incomplete chassis), had a 3116 video in their dealership, in that video, it stated the 3116 came in 6 power settings, and the lower power settings 1 2 and 3 used round pistons, while higher power settings 4 5 and 6, used slightly oval pistons that "became round" on warm up, I was told we had power setting 4 in our engine.
Also, a lot of reference to japan was in that video.
Anyhow, truck has been way underutilized since 1993, its gmc door sticker does not say truck, it say recreational vehicle motorhome, and has car tags on it (because it was shipped as an INCOMPLETE CHASSIS the dealer builder was allowed to placard the truck as they deemed correct, and this allowed us to bypass all truck restrictions :O
Used to pull custom horse trailer
The engine has been great, the last few years it has been hard to start if it sits for a month or two, fires up then cuts off and have to crank it, i think the fuel leeches back down into the fuel tank, and we should be turning the fuel tanks off when stored, to prevent leakdown.
Great video I learned allot from you!!!
I never follow sis procedure when syncing these injectors. I had an old cat tech at our shop show me how to do it by eye in about ten mins. hasn't failed yet. love the videos man. yellow pays the bills lol
Jamie Spading I’m getting ready to do injectors on one can you guid me through this process? I’ll Venmo for you’re time.
Thanks for searing.. the injectors synch is really complicated process. Hope u will upload how to synch those.
As always, fantastic info Josh. Thanks
+Stephen Cox Thank you Mr. 50,000 subscriber man! Your channel is going gangbusters.
Adept Ape Sshhhh, the cops don't want you to know. But thank you. I stumbled into making 2 viral videos and lucked out. My schedule will clear up next month and we'll do the collaboration video.
+Stephen Cox Definitely before December hopefully, usually views are higher then for some reason. I still have your email, I'll send you one in the next couple weeks.
Adept Ape hello. I'm a new subscriber. I'm in the process of purchasing a 2006 Alfa motor home with an Allison tranny on a Freight liner chassis. It has the Cat 300 HP motor. It has 35,000 miles on it. The owner said he has not had any issues with the engine. Is there anything you recommend I do pre-inspection? I live in Vacaville, California. I'm not sure what state you live in but man I sure wish you lived close by so I could pay you big money to check out this engine. Lol any advice would be much appreciated. Thank you. Mike
Quit watching videos, get out and fix something.
Thanks Sir for a great information . 🖒
I just loved changing the injector sleeves on those, especially in a topkick. The racks weren't too bad to adjust. My bread and butter, when I worked at CAT, worked on a lot of HEUI engines as well. Not that hard to diagnose
I have a 3116 that I turned up a little bit and it's been a great engine I have it in a Kodiak tow truck with 420 thousand miles and only replace the turbo and had to replace the injectors and injectors cups. and every year run the rack
How'd you turn it up?
Thank you so much !
Most GMC Topkicks had this motor. The Cat 913 scraper had this motor to replace the 3208.
Thank you for explaining this.
This cat is in the topkicks. One of my favorite engines. They make the topkicks very reliable
Cat took on the 2 stroke Detroit system with this engine which is actually really reliable. It just takes a real mechanic to work on them & not a place for the plug n play guys.
Yes, a poorly engineered knock off of DDEC. And then huei. Go home cat, you're drunk.
Huh? 1992 was the last years for 2 cycles so not a competitor.
@@grantsmith3514 Nobody said "competitor" except you! The reference was to the common rail fuel system instead of a timed injector pump.
Exactly, I was going to write the same thing and then I saw you had, I spent 15 years working on high performance 92TAs and TIs on boats and it all looked the same to me as a 671, add the complication of syncing the 2 blocks would blow his mind but it was monthly job on Stewart Stephenson 16V92TAs with 147 injectors. There were 1,000s of people everywhere that could do that those GM 2 strokes where in everything.
Great video as always. Are you familiar with the 3408, my Grandfather's W900A had one. How long was it available OTR. Was it always mechanical or become electronic in later years. I've not found much information beyond marine applications. Thanks for sharing.
Can you do one of these aimed at 3126's? Specifically one towards school buses, Skoolies as some call them are getting popular, possibly touching on pros/cons of removing governors. I've heard you mention them, and I am curious on what is harder or easier on a school bus. I am building a conversion for my kid to live in for college. I love your explanations, pretty straight forward advice. Keep up the great videos!
+74deeds I did the C7 video and discuss the 3126 in there a little since they are very similar, but making a 3126 video is a good idea.
Awesome video. For the last 3 months I have started my own venture and have been working on school buses and seeing a lot of 3126 hoping you'll put out a video on those and common failures and most importantly a detailed how to diag a bad heui pump.. I mostly specialize in Mack and Volvo motors coming from the dealer myself.
I used to take the worst job. And got a lot of experience with 3116. As I had a grip of the 2stroke Detroit's it was a cake walk but we are a dying breed, used a carpenter tool a vernier caliper from harbor freight and some 1/4 all thread and and made my own injector height tool it worked out very well but you have to be real picky
Outstanding, good work.
gracias por la informacion, justo estoy por ver un 3116 la parte de los inyectores asi que me sirve de mucho este video.
Last time I had cat tech on-site i asked him if we should do the overhead on our 938G it has a mui 3116 in it he told me no rite quick lol. I already knew he would say that . Like you said that is the engines only downfall is anything with overhead . Although I managed to sneak some cam follower cover gaskets into one in our gmc . It was a total pain but I did it made a few new torch bent wrenches that day . Told boss worst case scenario it won't leak but will run funny and it will have to go to car for adjustments . It needs a camshaft and followers replaced but he didn't want to do it it is still running 6 years later to my surprise. If your curious i found the engine had been worked on before and the 5-6 follower shaft was installed backwards in the cover starving it of oil .rollers and cam lobes are chewed up but it doesn't make noise not sure how . Not my problem now as I quit the truck side and went to heavy equipment side
Dude, I just realized you look like a young Kyle Chandler, but you got a lot more you can teach people. Congrats
I should add that I have a 1991 Kodiak with a 3116. Since you said they came out in 1992.
Thanks
Man thanks for such great content. Have a 3116 in a Chevy Kodiak. Truck stalled a few weeks back. Not getting any fuel. Any info you can point me towards on the governor ?
Hi, great info and thanks for all your tips. We have a 3116 on a wheel loader and the no3 injector rod has a bad habit of slipping out. Changed afew rods already. Any idea on what might be the cause. Doesn't happen to other injectors. Also fuel timing tool not available where I am. Many thanks.
Hey Man, I'm totally New to diesel engines, i just volunteered to go to Florida for Hurricane cleanup, the truck im driving is a 1995 Gmc topkick with a 6 speed and a 3116 cat engine, well the truck runs great, except for b n a misquito fogger till it gets s warmed up... Its a 95 model and was last registered in 1998, so needless to say it has around 330k miles on it, cranks in 32 degree weather before turning over twice... Blowby tube no oil anywhere to be found, (slight rear main leak), no oil from anywhete else, takes awhile to warm the engine up, it will idle for hrs, total blue smoke, get it on tha road and warmed up it gets to a slight hint of smoke, i haven't taken tha valve cover off as of yet to see if tha drain valley is clogged and letn oil seep in thru tha valve seals, cause my Boss thinks its an injectir problem... I can't say i know much at all about smoke from injectors, just wouldnt figure it to be blue, with oil smell, and not fuel smell.... LOL, doesn't really use any oil to speak of.... And I'm Sure by watching Your videos you know exactly whats wrong, i sure wouldn't mind not leaving smoke signals for all to try and decifier from falling Feather, or Pooping Dog... LOL 😂
Thanks.
Muchas gracias!!
Thanks for the info =)
Thanks from Slam Bang fishing lodge west coast of Vancouver island Kyuquot sound we specialize in great fishing food and good times
Thanks so much for that video it really opened up my eyes on what I have in my truck I have one injector that's bad I was wondering should I just change all of them which I know that it will be expensive but I should have a good motor
Super helpful info at just the right time. Great work! Considering a vehicle with a 3116. Couple questions if I may: 1. If I have injector issues, can I just have a shop re-work the entire head with new stock injectors? Or 2. can I swap the head with a newer style system as on the newer engines to avoid this problem but still keep the 3116 block? Thanks.
I was wondering the exact same thing... If I just have the shop replace all of them at the same time would that set me up for a long time...
3116 = 3000 series 1.1 litre /cyl 6 cylinder. Try doing injector set in a mid mount fire engine, or any work for that matter makes all the other aplications a breeze to work on. You can do a rack sync on any cylinder seperately without desturbing the other settings except 1, if you do cyl 1 you must do all 6, the setting is actualy easy, interpreting the procedure is the tuff bit. If you have a hard start issue in mui engine there is a plastic check vallve in the fuel return line that needs replacing, costs about 10c and always looks like new but alows fuel to syphon back from the injectors at shut down we used to replace them yearly in some machines. Not good when your fire engine wont start. Cheers mate🍻
Explain how easy it is
Any special tools to.do so
Carlos Jackson yes mate you need the 1.1 L fuel setting group and the service manual. Its been 10 to 15 years since I last tuned one of these, those brain cells are long gone. Cheers mate 🍻
Thanks, the 3116cat is the design of Detroit engines
Thanks Josh. What should one expect for lifespan on a marine application. I'm looking at a 1997 boat/engine with 1900 hrs. survey or walk away?
I have a 3116 in an M35A3 military truck... zero problems if you do basic maintenance.
What is the best maintenance for them? Just bought a 1994 GMC Topkick Pickup and want to make sure I take good care of it.
Nice explanation... I have a problem with my 3114 engine.....when start the engine it crank for few second before staring. I opened the broker arm cover I notced the governor delay in pulling the fuel racks. What
makes the governor pull the fuel rack in the beginning of start of engine?
My respect
I have a '92 3116 (120K miles) in a Gillig Chassis HMC RV. Just had the turbo rebuilt, valves adjusted and they did the rack. I am concerned about the lubricity of the ultra low sulfur fuels and wondered if you believe I should add anything to the fuel, like a cetane booster. I normally purchase my fuel in Nevada while driving between CA and NV.
8:15 hahahahahaha local cat dealer in my area messed mine up good in my Kodiak. set the tolerances exactly backwards and crushed every cup and ruined most of the injectors
Are the racks on a 3116 as sensitive as the racks on the old 53, 71, and 92 series Detroit's?
I did a tear down and rebuild of a Cat 3116 in school. The intake was nasty, as if the seals in the turbo failed and shot oil into the intake. All of the bearings for the crankshaft and connecting rods were shot.
Question. I'm having oil and gas mixing in fuel filters. Truck is losing power and hesitating a alot. Was leaking a lot of oil now oil level is raising because gas is coming in. What could it be?
Thanks for the video I have a 3116 cat motor on a drill rig where i work and it's pushing black smoke would you have any experience on probable causes
check air restriction first
then rack adjustment
Thanks so much for the informative videos. I'm looking at a boat with a 2000 model Cat 3116 engine. Around 1900 hours. Should I consider not getting this boat due to the 3116 engine in it?
Have you ever had one race to the point it bent both pushrods on the same cylinder. Less than 30k miles but has been sitting. Ran fine. Gave it throttle. Fourth time on throttle it ran away and wouldn't cut off. Questioning governor or rack.. i have worked on diesels, but as you mentioned mechanical injector in a 1991 topkick. Never had one take off before like this.
Good ,ok tamks
I’m in the process of getting a 94schoolie with this engine and a Allison mt643trans is it easy to upgrade to another engine if the 3116 doesn’t work out?
I have a mechanical 3116 in a military truck that started knocking when the oil supply line to the governor fractured. The engine was shut down, but a CAT service tech recommended we replace the part, fill it with oil, and fire it up for ten seconds to see if the knocking was in the engine or in the governor. The engine stopped suddenly after 8 seconds. It's not fully seized - we can rotate the engine. Any chance this can be fixed, or is this engine dead?
In the mid to late 90's I worked on these all the time in marine apps. Cooling system venting issues, manifold updates, turbo updates, then injector cup sealing issues causing combustion gas in to the fuel rails under boost- Cat was authorizing all kinds of overtime and shipping replacement engines like crazy to keep the contract with Sea Ray- always twin engines in some very tight compartment. Eventually they got the issues fixed towards end of production and phasing them out for 3126's- one of the last sets of 3116's we sold is in a charter boat with over 10,000 on the clock.. no, I do not miss setting up the top end on these- the injector sync procedure would work better if each injector would have the exact same calibration at the exact same rack setting but they don't. Then you get a little fuel knock and it changes from hot to cold. Honestly I would not have one of these in a boat, a 5.9 cummins is a far better engine with a much easier to service aftercooler/heat exchanger. Go ahead and flame me, been working on marine stuff 35 years, Cummins 5.9 BTA is easier to work on than a Cat 3116 marine.
Is a 3126 a much better choice or is that a stay away from engine also(marine use)?
Spent my life behind 3406’s and c-15 in my own trucks.
Thanks in advance doghearder!
@@jeffw7644 The main difference in the 3126 aside for being a slightly bigger displacement is the sea water aftercooler vs a jacket water unit. They were good engines in the later serial numbers or the earlier ones when the bugs and reworks were carried out. I'd rather have a 3126 mechanical than the 3126'B" that superseded it later called the C7.
@@Jethrosgarage think you, so a 3116 has a sea water aftercooler vs 3126 has a jacketed aftercooler if I’m understanding you correctly....?
@@jeffw7644 Reverse that- 3116 JWAC 3126 SWAC.
@@Jethrosgarage 👍🏻
We are having trouble with our twin 3116 Cats on our 31 Cabo. One of our engines will no longer reach rpm, there is also quite a bit of diesel exhaust staining the back of the boat. Any ideas?
How do I change the coolant in the 3116 and where is the thermostat located on the 3116? thank you!
In a 3116 Marine engine what can cause a big lack of power?.......there are no air bubbles in the fuel return line
its a nice engine just that most people have a hard time adjusting timing
I see they have a lot of different horsepowers for the 3116. How to I determine which one do I have?
I have a 1997 chevy c6500. 3116 i ve owned for over 10 years with under 100k Mileage. The heater intake light will not come on anymore. I tested for power to the relay for the heater intake and there is power going there. I then replaced both the heater intake and the relay. And i still have the problem of the heater intake light not coming on. I talked with the mechanic at a local cat dealer and he mentioned that the control module needs replacing. Does this control module have to be programmed and is this the cause of the heater intake not getting a signal of temps for the light not to come on?
My 3116 runs good at first then loses power and if I pump the primer pump and open the air bleeder to let fuel run out it’ll run good for about 30-45 mins. It runs better on a full tank of fuel or first thing. Not sure if it’s sucking air or some kind of pump issue. Any ideas?
I have a 1993 top kick with the 3116 that was running rough at a idle when it cold but then would straighten out when warm. We drove it about 300 miles pulling some equipment and it ran fine we shut it off and now it won't run. Seems to be no fuel. We went thru the basics but we are having a hard time figuring put what is wrong any ideas? Any info would be great
Can the fuel shut-off solenoid stick to the governor and prevent startup after a month not using it ? I have one acting like the solenoid on the pump isnt good. But it click very nicely and Ohmed out perfectly. Just wondering if a governor can stick after leaving it for a month. Ran good prior. It's a marine 3116
Is there a engine swap to replace the 3116 in a top kick that will hook straight up to trans
Not bragging but I am one of those guys that can set up a rack on those types of engines like what's in the old Detroit two stroke diesels. The 8-71 racks are especially challenging cause u have to balance both sides, u go by a very delicate feel and pin drag like a brain surgeon so to speak. If u don't get it right in a truck they wouldn't pull a load very well.
Until they found a hill
Where are you located? Are you available to adjust a 3116?
@@RJ1999x ha ha. Don't need a jake, just carry a pic of a hill.
At least they sound like they're trying. At least they never built a heui engine.
@@randymagnum143 lol, true
Aahh, the dreaded 3116!!.. only thing I ever enjoyed about working on them is watching it leave when I was finished! Never worked on on-highway, just industrial and epg. After years of experience with them I've learned couple of things, if it needs cups buy a reman head, if the governor/transfer pump starts acting up buy a reman, if the engine is wore out buy a reman!!. Changing the head is faster and cheaper than fighting cups, the governor's aren't worth trying to repair locally vs the cost of a reman, and being an internal bore block, it's cheaper to buy a cat reman vs going thru local machine shops. There are tricks to setting the fuel system much quicker, but it still requires the cat fuel setting group. All in all I'm glad they are all gone from around here!
Question. I'm having oil and gas mixing in fuel filters. Truck is losing power and hesitating a alot. Was leaking a lot of oil now oil level is raising because gas is coming in. What could it be?
Correct me if I wrong but the 3508 and the 3512 first series had this set up to i remember seeing a rail with a small chain connected to the injector on 773b or 777b dump truck water cart I use to work on in the most mines
3500A and Early B models used this fuel rack setup
Question. I'm having oil and gas mixing in fuel filters. Truck is losing power and hesitating a alot. Was leaking a lot of oil now oil level is raising because gas is coming in. What could it be?
? My 1997 chevy 3116 diesel want crank i spray starting fluids n turbo crank up turn off ...need help thanks what can it be
Hi! You might be able to help me :) I'm looking for fuel consumption of Cat 330CL and Cat 950F machines. Can you help me, where i can find proper specs? Thx
How much power can be added/upgraded on the mechanical versions? What’s the best all data type software/book to get for maintenance?
Hi I had the viscous dampener off on my cat 3116 marine diesel. Not sure if it went back on exactly as it came off. Does this matter? Thanks any info would be great
is the 3116 crank and block the same as a 3126, and can you use a crank and block from a 3126 for a 3116 ?
I'm having an issue where I can start and run this 3116 all day long but as soon as I kill it, it won't start again for hours. It runs great but this is the only issue...grrrrrrr any ideas?
What would cause a 3116 to carry 80+psi of fuel delivery pressure?
Do you know which cat engine is in the military MTV 5 ton? I can not find which one, some say C7 and some seem to be 3116. If this is the case which one would I rather have?
I have a 3116 engine in a 1991 Chevy top kick and it seems to be starving for fuel. I changed fuel lines, filters and tightened up on all fittings. Could it be an injector problem, starting to loose hope on my truck, please help.
ADEPT APE what would be a good replacement engine to replace a 2002 3126, in an F650 what would have higher rev line more power an be more durable then an 3126
Butch Cassidy cummins
How much does it cost to replace the injectors and injectors cup on the 3619 In a top kick
Hi, I was planning on buying a LMTV for a long trip from Alaska to Argentina and has this engine (3116). So, what do you think, is this a good truck for the job? And if I get a problem like that, how expensive and easy to get parts would it be? Thanks for your vids!
I notice you didnt address the Soft Block issue...I am looking at a Searay with twin 3116s the info I read is scarying me off, any input? Thanks
I am getting ready to buy a 94 chevy Kodiak with the 3116 how urgent is the injector to be fixed and how much would something like that cost
I would get the injector fixed. If the injector gets stuck open it can wash out your cylinder and kill your engine. If you're going to do one I would do them all. As far as cost, just depends on your area and if you get your injectors rebuilt or replaced.
Thank you. Need that. Do a 3508. 😅
Hi, I saw some useful service & maintenance Manual on reliable-store dot com. I think this will surely help you, as I personally use their manuals for the maintenance purpose.
Hi, I am also having a 3508, I saw some really useful service manual on reliable-store dot com . I think this will help you.
Same problems with the heui model?
I’m currently working on a 90s year range Topkick with this 3116 Engine in it and I’m having a problem with the vehicle after installing 6 new injectors, started the vehicle for the third time and it’s just randomly shut off and I will not start. Have any pointers for me to look for ?
Where is the best place to add MAP sensor on this engine?
Why would fuel be leaking from front and top area of cylinder head just aft of fan surpentine pulley???
Good day. What is the best water separator for a manuel injection 3116? Thx
6:06 The term you're looking for to describe the fuel system on 3300's and 3400's is "inline pump".
I have a Marine 3116 rated at 350hp....it suddenly lost a lot of power after picking up bad fuel in the Bahamas. The tanks are now clean, there engine starts and runs well but tops out at 1200rpm. All boost hoses are in tact and there is is no black smoke and there are no air bubbles in the return line . Does the governor in the transfer pump have to open up from oil pressure or boost pressure?......late model mui injectors
I found a piece of steel , like a flake of rust in the bilge area,......when I searched it came from the intercooler and left a hole, ...therefore no boost pressure....I found the cause .
Are these much harder to set then the old 238 Detroit 2 strokes?
I have an old Top Kick GMC with this engine and a Detroit automatic transmission. I bought it for $3000.00 and it has 192,000 miles. The brakes didn't work, and the guy I bought it from had spent about $5000.00 to try and fix the Hydro-boost system. New pump, new master cylinder, new electric back up.
I took it all apart and found it was missing the check valve ball, so I fixed it for $0.38. The previous owner was not pleased.
I don't use it a lot, is there any thing I need to do so I don't damage the engine? I try to start it once a month otherwise the batteries drain down. I am thinking it may be a bad solenoid?
Anything that you can point me in the right direction would be greatly appreciated.
Smiles!
For which machines model in CAT this CAT 3116 engine used, kindly please revert us back