So! Turns out Caterpillar isn't an engine company, it's a ******* garbage manual company. They tried to shake me down $500-actually the estimate was around $520 for the service manual for the 3116. I found one online for $40, which is approximately $45 more dollars than I should have to pay for a discontinued engine that cat doesn't even make parts for anymore. Information should be free.
It doesn't have a table of contents, it doesn't have an index, the components are listed in no particular order, and almost everything important gets referred to totally different manuals! A couple sections referred me to a ******* MICROFICHE. I've literally never seen a microfiche in person. This manual was compiled in 2008. For a motor from the mid 90's. There's few photos, the descriptions are vague, and apparently vicegrips are a serialized, specialized tool that requires-you guessed it-purchasing another manual to fully understand.
Anyway, the loss of power, top end speed, smokiness and rough starts all boiled down to a $5.33 rubber diaphram, called the FRC, fuel ratio control. Part number 6I-1564 and that’s an i after the 6.
Old one had a half-inch tear, and I was doing 20mph smoking like a six pack a day habit.
It restricts fuel flow if the turbo hasn't spooled up.
It's kind of a bastard to get to in that vehicle, and I'm real glad I put motorcycle pegs on the bumper below my engine compartment.