PRODUCT SUPPORT PROGRAM FOR REPAIRING LEAKS BETWEEN THE TURBOCHARGER TURBINE HOUSING AND THE EXHAUST ELBOW ON CERTAIN 3508, 3512, AND 3516 ENGINES

Usage:

SEBE7984-02

May 12, 2002
(Revised September 2003)
U-95
A-68
AU-64
S-64
H-63
O-81

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*After failure only*	PRODUCT SUPPORT PROGRAM FOR REPAIRING LEAKS BETWEEN THE TURBOCHARGER TURBINE HOUSING AND THE EXHAUST ELBOW ON CERTAIN 3508, 3512, AND 3516 ENGINES
1052		PS50433

NOTE: This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS50433" as the Part number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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 Revised Service Letter replaces the May 12, 2002 (Revised October 2002) Service Letter. Changes have been made to the Termination Date and the Affected Product.

TERMINATION DATE

December 31, 2003

PROBLEM

Certain 3508, 3512, and 3516 turbocharger turbine housing to exhaust elbow joints may leak exhaust in certain applications.

AFFECTED PRODUCT

There are three different groups included in this program. Group 1 includes engine configurations that have in-line turbochargers and 1240215 exhaust elbow. Group 2 includes engine configurations that have in-line turbochargers and 1476618 exhaust elbow. Group 3 includes engine configurations that have off-set turbochargers and 1628864 exhaust elbow.

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Model	Identification Number
Group 1
3508	9WN2-15 96Y1509-2000 3HM2-14 3PS168-196
3508B	7SM28-535, 537, 539-600 3DM81-264 2BM113-166 3DW144-162 5PS208-281 BAG2-17 CBB111-164 1TW233-295
3512	66Z583-662, 911 914
3512B	2GW216-325 4AW384-388, 390-406, 413-420, 423-441, 443-481, 483-484, 486, 488-500, 502-610, 612-649, 658-707
3512B M/	1PW309-400
DV096	4DR1
Group 2
3512B	3ZW121-123, 130-143, 146-151, 153-154, 156-157, 160-165, 167-168, 170-171, 175-177, 182-186, 193-194, 197-207, 211-212, 216-219, 229-246, 248, 258, 260, 263-270, 274-284 8DF177-186
3512	3RS308, 309 3WS333
Group 3
3512B	2EZ215-268 4TN253, 257, 260-261, 263, 265-266, 269-277, 281-285, 287-449, 451-517 7HM209-211, 214-218, 221-228, 233-234 2AF194-305 8EM326-394, 396-398, 402 BRC146-147 PWG100-109
3516B	8KN382-386, 400-407, 410-420, 425-429, 433, 435, 442-447, 449-454 CBN256-262
3512B PU	6RZ357

PARTS NEEDED

Group 1

16 - 6V6753 BOLT-HIGH TE
2 - 1419290 BELLOWS AS
4 - 2071354 GASKET-EXH M

Group 2

16 - 6V6753 BOLT-HIGH TE
2 - 1880468 BELLOWS AS
4 - 2071382 GASKET-EXHAU

Group 3

12 - 6V1943 BOLT-HIGH TE
8 - 6V6753 BOLT-HIGH TE
2 - 1880469 BELLOWS AS
4 - 2071382 GASKET-EXHAU

ACTION REQUIRED

See the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

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Component hours	Caterpillar		Dealer Suggested		Customer Suggested
Component hours	Parts	Labor Hrs	Parts	Labor Hrs	Parts	Labor Hrs
0-3000	100%	3.0	0	0	0	0
3001-7000	50%	1.5	0	0	50%	1.5
7001-Up	0%	0	0	0	100%	3.0
NOTE: This is a 3.0?hr job.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

Rework Procedure

Remove exhaust heat shield sections surrounding the turbocharger.
Remove all the bolts that retain the half flanges in the turbine housing and the exhaust elbow.
Remove the half flanges.
Remove the bellows.
Remove the gaskets.
Clean the sealing surfaces on the half flanges, turbine housing and exhaust elbow.
Check the sealing surfaces for indications of material erosion.
If a component's sealing surfaces show erosion or are not flat, then that component must be replaced.
Install new gaskets.
Install new bellows.
Re-install half flanges, unless judged non-reusable as per step 8. If non-reusable, install new half flanges.
Install new bolts to retain the half flanges in the turbine housing and the exhaust elbow. Anti-sieze must be used on the bolt threads and under head area.
Torque the bolts to 54 +/- 5 N·m (40 +/- 4 lb-ft).
Install the exhaust heat shield sections surrounding the turbocharger.
Do not re-install the fabricated metal shields that cover the top of the turbine housing if the engine was so equipped (engines in group 1 and group 2). The part numbers of these shields are: 1408937, 1408938, 1480842, 1480843, 1496511, 1496512, 1496513, and 1496514. These shields are no longer required and may contribute to improper bolt torque at the shield mounting location.