Product Support Program For Installing A New Expansion Tank Pressure Cap, Coolant Recovery Bottle, And Water Line Fitting On Certain 3208 Marine Engines Caterpillar

Product Support Program For Installing A New Expansion Tank Pressure Cap, Coolant Recovery Bottle, And Water Line Fitting On Certain 3208 Marine Engines

February 10, 1993
(Revised December 1993)
U-20
A-14
AU-14
B-8
E-15
O-12
TM-2

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 "PS4893" 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 February 10, 1993 (Revised April 1993) Service Letter. Changes have been made to the Affected Product, Parts Needed, and Rework Procedure.

NOTE: This Program may be performed on applicable engines at the same time as the December 29, 1993 Service Letter - PS8038.

Termination Date

Problem

The 7W1641 and/or 7W1642 Gaskets in the water-cooled exhaust manifolds of certain 3208 Marine Engines may fail due to a loss of coolant.

Affected Product
Model & Identification Number

3208 (01Z10000-25414, 01Z25418-25461, 01Z25464-25467, 01Z25471, 01Z25473, 01Z25474, 01Z25476, 01Z25478-25480, 01Z25482-25485, 01Z25487-25490, 01Z25495-25498, 01Z25501-25540, 01Z25545-25553, 01Z25556-25573, 01Z25575-25577, 01Z25580, 01Z25581, 01Z25583, 01Z25592-25595, 01Z25597, 01Z25598, 01Z25603, 01Z25606, 01Z25618, 01Z25621, 01Z25626, 01Z25628, 01Z25636-25638, 01Z25640, 01Z25644-25649, 01Z25653, 01Z25656-25660, 01Z25662, 01Z25663, 01Z25667, 01Z25669, 01Z25670, 01Z25672, 01Z25675-25677, 01Z25679-25681, 01Z25684, 01Z25685, 01Z25689-25691, 01Z25694, 01Z25725, 01Z25727, 01Z25730-25735, 01Z25737, 01Z25739-25741, 01Z25743-25747, 01Z25749, 01Z25752, 01Z25754, 01Z25756-25759, 01Z25761, 01Z25763, 01Z25765, 01Z25767-25770, 01Z25772, 01Z25774, 01Z25776-25804)

Parts Needed

1 - 8C3681 Hose-Bulk (200 cm)

1 - 4J7207 Hose

2 - 9M7958 Clamp

2 - 1P4278 Clamp-Hose

1 - 361865 Cap

1 - 1029223 Recovery Group

1 - 1031746 Elbow

Action Required

See attached Rework Procedure.

Service Claim Allowances

NOTE: This is a 2.0-hour job.

Parts Disposition

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

Attach.

(1-Rework Procedure)

Rework Procedure

Before Failure

1. Replace the existing 68865 Radiator Cap, with a new 361865 Radiator Cap.

2. Replace the water line fitting on the front, right hand side of the front cover, part number 7W1820 Elbow, with a new 1031746 Elbow. Use a new 4J7207 Hose and 9M7958 Clamps with the new elbow.

3. Install a new 1029223 Coolant Recovery Bottle Group. The bottle must be installed with a minimum of three bolts holding it in place. Placement may be anywhere within the hull of the boat, within 3 feet (1 meter) of the top of the expansion tank and no farther away than the length of the hose provided with the group.

After Failure Only

1. Repair the failed exhaust manifold group as necessary using new 7W1641 and 7W1642 Gaskets.

NOTE: Use the lllustration and specifications below for tightening the exhaust manifold bolts.

A. Tighten bolts (A) through (D), in alphabetical order, finger tight.

B. Tighten bolts (A) and (B), in alphabetical order, to a torque of 13 ± 7 N.m (10 ± 5 lb ft).

C. Tighten bolts (A) and (B), in alphabetical order, to a torque of 55 ± 10 N.m (41 ± 7 lb ft).

D. Tighten bolts (C) to a torque of 55 ± 10 N.m (41 ± 7 lb ft).

E. Tighten bolts (A) and (B), in alphabetical order, to a torque of 55 ± 10 N.m (41 ± 7 lb ft).

F. Tighten bolts (D) to a torque of 105 ± 20 N.m (75 ± 10 lb ft).

2. Replace the existing 68865 Radiator Cap, with a new 361865 Radiator Cap.

3. Replace the water line fitting on the front, right hand side of the front cover, part number 7W1820 Elbow, with a new 1031746 Elbow. Use a new 4J7207 Hose and 9M7958 Clamps with the new elbow.

4. Install a new 1029223 Coolant Recovery Bottle Group. The bottle must be installed with a minimum of three bolts holding it in place. Placement may be anywhere within the hull of the boat, within 3 feet (1 meter) of the top of the expansion tank and no farther away than the length of the hose provided with the group.