807252 1 Mercruiser THERMOSTAT (140 DEGREES)

This Program must be administered as soon as possible. When reporting the repair, use "PI3147" 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 "PI3147" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
Refer to your Warranty Bulletin for detailed information with regard to Product Improvement Programs.
Completion Date
November 30, 1998Termination Date
November 30, 1998Problem
Certain 3116 and 3126 2-Valve Engines built from January 28 through February 6, 1998 with CBS heads are suspect to have improper installation of the brass injector sleeve.
Affected Product
Model & Identification Number
3116 (2WG6414-6426 5EN01269, 5EN1270, 5EN1273-1280, 5EN1282 4KG7773-7795 4KG31268NM3029-3043 9ZR771-774 )
Parts Needed
1 - 1192940 Gasket* - 1193061 Sleeve*(as required)Action Required
See the attached procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
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
1. Check to see if the head is supplied by CBS or Gosselies. The part number is located on the front of the head on the governor side beside the lifting eye, just above the front cover. In Marine applications, it is best viewed using a light to look between the expansion tank and heat exchanger.If it is a dot-matrix, then the head is from Gosselies. If the part number is stamped, then it is from CBS.
If the head is from Gosselies (dot-matrix part number), then the engine is good and no further work is needed.
If the head is from CBS (Stamped part number) then further inspection/rework is required.
2. If the head is from CBS, remove the valve cover.3. Using a sliding caliper, align the caliper vertically using the edge of the injector spring, measure and record the distance from the timing ledge on the injector to the top face of the head for each cylinder. This measurement will be in the range of 8.39 mm but can vary from engine to engine.4. If the variation from cylinder to cylinder on the same engine is less than 0.40 mm, then the engine is good. Re-install the valve cover. No further inspection is necessary.5. If the variation from cylinder to cylinder on the same engine is greater than 0.40 mm, recheck to verify measurements, if the difference is still greater than 0.40 mm, proceed to Step 6.6. Remove all (6) injectors. Using a depth gage with flat end and a 0.75 inch diameter steel ball dropped into the sleeve, check and record the distance from the top face of the head to the top of the steel ball. This measurement should be 2.583 0.18 inches (65.61 0.46 mm).7. Remove the injector sleeve on any cylinder that the measurement from step 6 is less than 2.565 inch (65.15 mm) and replace with a new sleeve. Ream each sleeve lightly to get a good seat for the injector. 8. Remove the tip o-ring from the injectors (if there is one installed), install the injectors, tighten hold-down bolt to 14 Nm using a torque wrench, reset injector synchronization, re-install rocker arms making certain that all push-rods are in the sockets, reset injector timing and valve lash.9. Install valve cover.