16861-ZY1-900 Honda TUBE B, FUEL

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 'PS50078' 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.
Termination Date
June 30, 2002Problem
Engines may need to be repaired due to cracked main bearing caps on certain 3508, 3512 and 3516 Engines used in off-highway trucks, track type tractors, hydraulic excavators and wheel loaders or generator set, industrial, marine, locomotive, marine auxiliary and vehicular applications. A process was omitted during the manufacturing of the cylinder block main caps on certain 3500 Engines. Because of the omitted process, the main cap may crack. This crack may be detected during a regular maintenance interval or in the worst case, the crack may not be detected until the engine fails.
Affected Product
Section 1 - Machine Engines
Group 1
776B (6JC1-UP)
777B (4YC1-UP)
776C (2TK1-UP)
777C (4XJ1-UP)
776D (5ER1-UP)
777D (3PR1-UP)
776D (AFS1-UP)
777D (AGC1-UP)
D11N (74Z1-UP, 4HK1-UP)
D11R (9TR1-UP, 9XR1-UP, 8ZR1-UP)
D11R (AAF1-UP, 7PZ1-UP)
992G (7HR1-UP, ADZ1-UP)
854G (1JW1-UP)
5130 (7TJ1-UP, 5ZL1-UP)
5130B (4CS1-UP)
Group 2
785C (1HW1-UP, APX1-UP)
785B (6HK1-UP)
777D HAA (2YW1-UP)
Group 3
789 (9ZC1-UP)
789B (7EK1-UP)
789C (2BW1-UP)
793 (3SJ1-UP)
793B (1HL1-UP)
793C (4AR1-UP4GZ1-UP, ATY1-UP)
785C HAA (5AZ1-UP)
5230 (7LL1-UP)
994 (9YF1-UP)
994D (3TZ1-UP)
Section 2 - Commercial Engines
Group 1
3508 (23Z1-UP, 5PW1-UP, 70Z1-UP, 3LS1-UP, 5XM1-UP, 97Y1-UP)
3508B (2HW1-UP, 4GM1-UP, 6PN1-UP, 5KW1-UP, 68Z1-UP, 95Y1-UP, 69Z1-UP, 96Y1-UP, 3HM1-UP, 9WN1-UP, 3PS1-UP, 5PS1-UP, 1TW1-UP, 2BM1-UP, 7SM1-UP, 3DM1-UP, 3DW1-UP)
Group 2
3512 (2WK1-UP, 1LM1-UP, 49Y1-UP, 65Z1-UP, 24Z1-UP, 67Z1-UP, 6WW1-UP, 3MS1-UP, 6PM1-UP, 50Y1-UP, 66Z1-UP, 3RS1-UP, 51Y1-UP, BAG1-UP, 3WS1-UP)
3512B (8EM1-UP, 2GW1-UP, 4TN1-UP, 7HM1-UP, 2EZ1-UP, 4AW1-UP, 6WN1-UP, 8RM1-UP, 6GW1-UP, 5AW1-UP, 3ZW1-UP, 8DF1-UP)
3512B M/ (1PW1-UP)
Group 3
3516 (3XS1-UP, 25Z1-UP, 5SJ1-UP, 73Z1-UP, 8TW1-UP, 27Z1-UP, 71Z1-UP, 29Z1-UP, 72Z1-UP, 3SS1-UP)
3516B (3CW1-UP, 8CN1-UP, 8KN1-UP, 4BW1-UP, 3NS1-UP, 7KM1-UP, 1NW1-UP, 6HN1-UP, 7RN1-UP, 8NW1-UP, 2JW1-UP, 9WF1-UP, 2FW1-UP, 9AN1-UP)
DV098 (3JS1-UP)
DV099 (2TS1-UP)
E110B (9HF1-UP)
Failure Identification:
The failure mode of a broken main cap can occur at any SMU. To identify a main bearing cap crack that qualifies for this program, the cap must have a crack similar to the cap in Illustration 1 below. The crack MUST initiate from the either fillet radius of the cap. The cap may only be cracked or may be broken in two pieces.
Main caps with cracks in any other position DO NOT qualify for the program.
Illustration 1Parts Needed
Group 1
1 - 1524994 Crankshaft Assembly (for 3508 only)-Or-1 - 1527625 Crankshaft Assembly (for 3508B)1 - 1153503 Block Group-Cylinder (for 3508 and 3508B)Group 2
1 - 1286786 Crankshaft Assembly (for 3512 and 3512B)1 - 1155154 Block Group-Cylinder (for 3512 and 3512B)Group 3
1 - 1286788 Crankshaft Assembly (for 3516 and 3516B)1 - 1155160 Block Group-Cylinder (for 3516 and 3516B)Action Required
See that attached Rework Procedure.
Service Claim Allowances
Option I: The dealer repairs failed engine.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
Section 1 - Guidelines for Reusable Parts and Special Instructions:
The following is a list of Guidelines for Reusable Parts and Special Instructions for 3500 Cylinder Blocks and 3500 Crankshafts. These publications are listed as a reference in the event that they are needed during the repairs.
3500 Cylinder Blocks
Guidelines for Reusable Parts
SEBF8076 'Specifications to Salvage Cylinder Block Contact Surfaces'SEBF8157 'Specification for Cylinder Blocks 3500 Family of Engines'SEBF8164 'Specifications for Liner Measurement and Salvage 3500 Family of Engines'SEBF8219 'Salvage of Cylinder Block Liner Bores for 3500 Family of Engines'SEBF8255 'Procedure to Install Top Deck Liner Seat Inserts in Cylinder Blocks of 3500 Engines'SEBF8263 'Procedure to Repair Top Deck Pitting on Cylinder Blocks of 3500 Engines'SEBF8291 'Top Deck Threaded Hole Repair in 3400 and 3500 Series Engines'SEBF8387 'Main Bearing Bolt Repair in 3400 and 3500 Series Engines' Special Instructions
SEHS8869 'Cylinder Block Salvage Procedure Using Belzona Ceramic R Metal'SMHS8418 'Cylinder Block Cleaning Procedure'SEHS8776 'Installation of Service Replacement Cylinder Block Group'SEHS9826 'Ordering Series B Replacement Cylinder Blocks for 3500 Series Engines'SMHS7606 'Use of 1P4000 Line Boring Tool Group' 3500 Crankshafts
Guidelines for Reusable Parts
SEBF8039 'Inspection of Crankshafts for Cracks'SEBF8043 'Visual Inspection of Crankshafts'SEBF8043 'Visual Inspection of Crankshafts'SEBF8041 'Crankshaft Measurement' Section 2 - Possible Failure Modes
There are two failure modes for broken main bearing caps. The first mode is an engine failure resulting from an undetected broken main bearing cap. This failure is destructive and usually results in a broken block and crankshaft. The engine is in an inoperable condition and must be repaired.
The second failure mode is cracked or broken main cap or caps. This type of failure is discovered during an inspection of the main cap using a magnetic particle inspection technique or visually noticing a broken main bearing cap. If a cracked or broken main cap is found, the engine should NOT be operated due to the risk of causing an engine failure, further damaging the engine.
For both failure modes, the engine will need to be repaired. Repair options will vary based on the circumstances of each failure. Section 3 outlines the repair options for each failure mode.
Section 3 - Engine Repair Options
All engines with cracked or broken main bearing caps will require the engine block to be replaced or line bored. This will require that the engine be removed and disassembled.
Once the engine has been disassembled, the block and crankshaft can be inspected and the determination made as to which repair option needs to be taken. The table below outlines the repair options for the cylinder block and crankshaft based on the extent of the failure.
Block and Crank Repair Options Matrix:
A cracked cap is defined as a cap that has cracked but is not broken in two separate pieces.
Block Repair Options:
Block Option 1 - Repair for a Cracked Cap(s) Only:
With a cracked cap only, the chance of contingent cylinder block damage is relatively low.However, the block still needs to be inspected for damage and reusability verified.
1. Inspect all other main bearing caps for cracks per Procedure 1. Cracked caps must be replaced.2. Inspect the 'Z-Lock' width per Procedure 2.3. Inspect and check all main bearing bores per SEBF 8157.4. Visually inspect entire block for damage. Provided above inspections determine the cylinder block is reusable, the cracked main bearing caps need to be replaced and the cylinder block must be line bored oversize.5. Replace cap and line