CARTRIDGE GP-TURBOCHARGER 1092197 - Caterpillar

Product Support Program For Replacing The 90° Water-cooled Exhaust Manifold Elbows On Certain 3208 Marine Engines
SMCS - 1059 PS8038
December 29, 1993
(Revised January 1995)
U-184
A-129
AU-97
B-67
E-143
O-112
TM-15 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.
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 "PS8038" 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.
This Program may be performed on applicable engines at the same time as the February 10, 1993 Service Letter, PS4893.
This Revised Service Letter replaces the December 29, 1993 Service Letter. A change was made to the TERMINATION DATE.
Termination Date
June 30, 1995Problem
The 7W1641 and/or 7W1642 Gaskets in the water-cooled exhaust manifolds of certain 3208 Marine Engines may leak.
Affected Product
Model & Identification Number
3208 (01Z1-26601)
Parts Needed
2 - 1045613 Gasket2 - 1045614 Gasket1 - 1045615 Elbow (right hand)1 - 1045616 Elbow (left hand)2 - 1045618 Gasket2 - 1045619 GasketAction Required
See attached rework procedure.
Service Claim Allowances
This is a 5.0-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
1. Remove the existing 4W7610 Elbow (right hand) and the 4W7611 Elbow (left hand).2. Install new gaskets along with a new 1045615 Elbow (right hand) and a new 1045616 Elbow (left hand).3. Use the Illustration 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.)