5007160 EVINRUDE LOWER COVER Assy, Starboard

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 must be administered as soon as possible. When reporting the repair, use "PI3656" as the Part Number, "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 "PI3656" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and " Z" as the SIMS Description Code.
Although this Program is to be administered as described above on the Affected Product, parts should be removed from parts stock as soon as possible.
Completion Date
April 30, 1994Termination Date
October 31, 1994Problem
Moisture may enter past the seal of the 40-pin plug assembly between the main engine harness and the Electronic Control Module (ECM) on certain 3406E Engines. This moisture may cause corrosion on the connector terminals.
Affected Product
Model & Identification Number
3406E (5EK1-456, 5EK461-495, 5EK498-520, 5EK523-525, 5EK527-535, 5EK537-694)
Parts Needed
Dealers will need to order parts for this Program.
2 - 1106844 SealAction Required
See the attached procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
Parts Stock
Submit one claim for all 3E6285 Seals, 1003450 Inlet Air Temperature Sensors and 1022240 Fuel/Coolant Temperature Sensors removed from parts stock.
US and Canadian Dealers Only - When submitting a parts stock claim use 99Z00007 in the Product Identification Number Field.
Affected Product
This is a 1-hour job.
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
Parts Stock Action
1. Remove all 3E6285 Seals from parts stock.2. Inspect stock of 1003450 Inlet Air Temperature Sensors and 1022240 Fuel/Coolant Temperature Sensors. Remove from parts stock any sensor that does not have a tie wrap around the harness wire between the sensor body and connector.Affected Product
1. Disassemble the 40-pin connectors at P1/J1 and P2/J2 that connect the ECM to the vehicle and engine wiring harnesses.2. Remove the 40 pin connector seal from the vehicle harness connector and the engine harness connector. Use caution when removing the seal. The seal groove must not be scratched.3. The interior mating surfaces of the connectors must be cleaned prior to assembly. Clean these interior mating surfaces (ie. terminals, seals, pins, insulators) with a cotton swab and denatured alcohol. Do not use rubbing alcohol, solvents, or Caterpillar component cleaners 8T9011 or 4C4079 as these will damage certain connector materials. It is important that all corrosion and dirt is removed from the connector mating surfaces. Allow the connectors to dry before plugging them back together.
4. Install the new seals onto the harness connectors being careful to align the corners of the seal with the corners of the connectors.5. Lubricate the new seals with lithium grease before assembling the connectors. Examples of types of grease to use are "Lubriplate" AERO or DS-yes Lithium Grease. Do not use 8T9020 Dielectric Tune-Up Grease.
Apply a small bead of grease on one point on each seal and spread it on the entire seal area so that a thin film of grease coats the seals. Use sparingly so that excess grease does not contaminate the face of the connectors where the sockets are located. Remove any excess grease before assembly.7. Install the harness connectors into the ECM. Carefully align the harness connector to the ECM and tighten the connector screws to a torque of 2.25 0.25 m (20.0 2.0 lb in).