5005444 EVINRUDE FUEL RAIL Assy, Supply

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 only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS5226" 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.
This Revised Service Letter replaces the January 12, 1997 Service Letter. Changes have been made to the Termination Date and Service Claim Allowances.
Termination Date
January 31, 1999Problem
The current engine wiring harness may adversely affect the output signals of the engine speed/timing and boost sensors. The resulting symptons may include active or logged engine speed/timing sensor diagnostic faults, active or logged boost pressure sensor diagnostic faults, engine speed miss ("burp"), and/or poor response.
Affected Product
Model & Identification Number
3406E (5EK67193-85345)
Parts Needed
1 - 1387020 Harness Kit (includes special instruction REHS0054)Action Required
See attached rework procedure.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
Repair Conditions
Complete the following rework procedure if any of the following conditions are present.
I. The engine is being serviced for an engine speed/timing sensor failure that has necessitated the replacement of the sensor.-OR-
II. The engine is being serviced for a performance complaint, there are logged boost pressure sensor diagnostic faults (not active), and there are no wiring, ECM, or connector problems as determined by following proper troubleshooting procedures (complete this procedure without replacing the boost pressure sensor).-OR-
III. The engine is being serviced for active boost pressure sensor diagnostic faults and there are no wiring, ECM, or connector problems as determined by following proper troubleshooting procedures (sensor replacement should only take place if the diagnostic fault is still active after this procedure has been completed). Rework Procedure
1. Turn the ignition key OFF, engine OFF.2. Disconnect the engine harness from the ECM (J2/P2 connector).3. One at a time, remove the wires designated in Table 1 from the P2 connector and insert the corresponding wire from the 1387020 Harness Assembly into the P2 connector. (See Illustration 1).Sensor and Labor to troubleshoot and R&I must be claimed as standard warranty.
Table 1
Illustration 14. Connect the P2 connector to the ECM.5. Disconnect the P5 connector from the J5 connector on the valve cover base.6. Connect the 12-Pin connector on the 1387020 Wiring Harness to the J5 connector on the valve cover base.7. See the Illustration 2 for the recommended routing of the 1387020 Harness Assembly.8. Start the engine. Check the operation of the engine and the engine compression brake at low, medium, and high settings (if installed). Check for active diagnostic codes using a service tool.9. Use tie straps to secure the 1387020 Harness Assembly in the recommended position and away from any contact points that might abrade the harness.10. Use tie straps to secure the disconnected engine harness wires or cut them off at the braiding.
Illustration 2