0586968 EVINRUDE EMM - 40-50 HP

This Program must be administered as soon as possible. When reporting the repair, use "PI30077" as the Part number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI30077" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
Completion Date
March 31, 2001Termination Date
September 30, 2001Problem
Loose exhaust manifold bolts have been found on some 3126 marine engines in dealer inventory. The two bolts located on either side of the turbocharger mounting flange may not be tightened to the proper torque on some engines.
Affected Product
Model & Identification Number
3126 (1ZJ1-1360, 4EZ1-453)
Parts Needed
The following parts are NOT needed in every case. These parts will only be required if the initial inspection reveals loose exhaust manifold bolts.
2 - 2M9780 Seal (Water Lines Group)1 - 7C7613 Gasket (Exhaust Elbow Group)1 - 1S7057 Gasket (Turbo Oil Lines Group)1 - 7W2398 Gasket (Turbo Oil Lines Group)1 - 9M4849 Seal (Turbo Oil Lines Group)1 - 3J1907 Seal (Turbo Oil Lines Group)1 - 6V8397 Seal (Turbo Oil Lines Group)1 - 7C0358 Gasket (Oil Filler Group - RH Service)1 - 4F7391 Seal (Oil Filler Group - RH & LH Service)1 - 4P7704 Gasket (Turbo Group)4 - 3E8017 Locknut (Turbo Group)Action Required
See the attached Rework Procedure.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.(1-Owner Notification)(2-Rework Procedure)Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
Dealers should check for loose bolts with a finger or screw driver on the left (2) and right (3) side of the turbocharger mounting flange on all 3126 Marine Engines. If the bolt does not move, it is properly tightened. (See picture below). All 3126 engines, listed in the Affected Product section of this letter, that are found in dealer inventory and installed or loose in stock at boat OEMs can be inspected. If either bolt is loose, proceed as follows:
Exhaust Manifold Bolt Inspection Procedure
Refer to the Disassembly & Assembly Manual (SENR3611) for additional information on removing and installing the turbocharger and the exhaust manifold.
1. Remove the exhaust pipe on rear of turbocharger (for installed engines).2. Remove the turbo oil drain and oil supply tubes.3. Remove the turbo coolant drain line and supply line.4. Remove the turbocharger.5. Check all exhaust manifold bolts with a torque wrench using the torque sequence shown in the Disassembly & Assembly manual (SENR3611). The torque specification stated in the manual is incorrect. The correct value is 5515 N m.
6. Check bolts number 2 and 3 a second time. Additional Parts listed in the 'Parts Needed' section of this Service Letter are required when reinstalling the turbocharger.
7. Reinstall the turbocharger using a new 4P7704 gasket. Lubricate locknut face and thread with 1E2078 Anti-seize before assembly. Tighten locknut to 5415 N m.8. Reinstall the turbo oil drain and oil supply tubes with new gaskets and o-rings.9. Reinstall the turbo coolant drain line and supply line with new o-rings.10. Reinstall the exhaust pipe to rear of turbocharger using a new gasket. 11. Touch up the paint where needed.