806705 Mercruiser Y-FITTING

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PSP FOR INSTALLATION OF NEW HARDENED OIL PUMP RELIEF VALVE GUIDE - TURBOCHARGED 3208 ENGINES - PS0221 - MAILED US AND CAN ADA, CACO, COFA, CFEL, COSA, BRAZIL, TRUCK TEPS, MARINE TEPS, AGRICULATURE TEPS
  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.
PRODUCT SUPPORT PROGRAM FOR INSTALLATION OF NEW HARDENED OIL PUMP RELIEF VALVE GUIDE Turbocharged 3208 Engines, 1315, 1304, PS0221 U-39 A-24 AU-31 B-13 C-36 E-21 O-27 TT-2 TA-2 TM-2 Problem There has been unusual wear of the oil pump relief valve guide in some applications. See Illustration 1. A wear step in the guide can prevent full travel of the relief valve plunger and cause high oil pressure during cold starts. See Illustration 2. The high oil pressure may cause the oil filter gasket to rupture, resulting in loss of oil and possible engine damage. A new heat treated guide with a slightly different hole pattern is now used in production. ILLUSTRATION 1 (SEE ILLUSTRATION) ILLUSTRATION 2 (SEE ILLUSTRATION) Unusual wear has not been a problem on naturally aspirated 3208 Engines or on turbocharged engines with no piston cooling jets. Some scuffing of the guide and plunger is normal. See Illustrations 3 and 4. ILLUSTRATION 3 (SEE ILLUSTRATION) ILLUSTRATION 4 (SEE ILLUSTRATION) Affected Engines And New Parts Needed Serial numbers of the affected engines are: Turbocharged Or Turbocharged Aftercooled 3208 Marine Engines 1Z2918-1Z3042, 3044-3072, 3074, 3076-3239, 3241, 3301, 3323-3521, 3523-3525, 3527, 3529-3538, 3540, 3541, 3543, 3544, 3546, 3548-3569, 3571-3582, 3584-3586, 3588, 3589, 3591, 3593, 3595-3601, 3603-3605, 3608, 3609, 3611, 3612, 3614, 3620-3622, 3624, 3628, 3630, 3631, 3634, 3635, 3641 Turbocharged 3208 Truck Engines 2Z4480-2Z4529, 4531-4343, 4546-4673, 4675, 4947, 4949-4951, 4954-5055, 5059-5061, 5063, 5067-5085, 5087, 5089, 5091-5094, 5100, 5104-5156, 5167-5278, 5286, 5303-5308, 5311-5318, 5324, 5325, 5328-5364, 5366-5371, 5377-5415, 5418-5422, 5430-5505, 5508-5517, 5519, 5525-5705, 5721, 5722, 5725-5764, 5766-5818, 5834-5846, 5851, 5852, 5854-5874, 5876, 5879-5922, 5945, 5951-5960, 5963-5967, 5972-5989, 5993-6064, 6069-6097, 6099-6130, 6136, 6138, 6140-6208, 6212-6223, 6238-6340, 6342, 6343, 6345-6349, 6353, 6355-6357, 6359-6437, 6439, 6442, 6444-6461, 6468-6474, 6476, 6478, 6488, 6490-6604, 6607-6609, 6611, 6612, 6618-6621, 6628, 6629, 6636-6662, 6664-6710, 6712-6718, 6720-6729, 6731-6735, 6737, 6739, 6740, 6750, 6752, 6767-6770, 6774-6783, 6799-6816, 6818-6825, 6827-6831, 6836, 6839, 6840, 6856, 6892-6901, 6904-6913, 6917, 6928-6930, 6934, 6941, 7011-7020, 7025, 7027-7030, 7034-7036, 7038, 7040, 7043, 7044, 7063, 7124, 7125, 7129-7132, 7141-7143, 7207, 7208, 7225, 7226, 7245-7248, 7263-7268, 7301, 7302, 7334, 7380, 7435-7439, 7443-7447 Turbocharged 3208 Industrial Engines 3Z2834-3Z2841, 2848-2855, 2862-2865, 2871-2878, 2890, 2892-2904, 2910-2913, 2920-2929, 2932, 2935, 2942, 2943, 2945, 2951, 2952, 2960, 2963, 2966-2974, 2984, 2987-2995, 3001-3026, 3029-3035, 3039, 3043-3045, 3050, 3051, 3055, 3060-3064, 3066-3068, 3070-3077, 3079, 3080, 3096-3103, 3105, 3107, 3115, 3117, 3122, 3126, 3130-3135, 3140-3167, 3169-3174, 3176, 3180, 3181, 3184, 3185, 3187-3193, 3197, 3199, 3200 Turbocharged 3208 Generator Sets 30A824-30A1087, 1090-1095, 1097-1106, 1110, 1112, 1114 Unusual wear of the valve guide has not been a problem on naturally aspirated 3208 Engines, nor has it been a problem on turbocharged 3208 Engines which do not have piston cooling jets installed. These engines use a different spring in the relief valve. These two types of engines can be easily identified by measuring the length of the oil cooler mounted on the side of the engine. It is approximately 254 mm (10") long on naturally aspirated engines. These engines use the smaller 8N9586 Oil Filter. Turbocharged engines with piston cooling jets have oil coolers that are approximately 356 mm (14") long. The larger 9N6007 Oil Filter is used on these engines. New Parts Needed: 1 - 7W239 Guide 1 - 9N241 Gasket (suction bell gasket) 1 - 9L8016 Gasket (oil pan) Action Requested (Parts Stock Action Required) 1. No action is necessary unless the oil pan of a listed engine is removed during other service or repair work. If the oil pan is removed for any reason, replace the former 2W4110 Oil Pump Relief Valve Guide with the new 7W239 Guide. Inspect the relief valve plunger. Light scuffing is normal and will not affect the operation of the plunger. However, replace the plunger (1N3165) if scoring or damage has occurred. Install a new 9L8016 Gasket between the oil pan and engine block and a new 9N241 Gasket between the suction bell flange and the oil pump housing. 2. If desired, dealers may rework any of the listed new engines currently in their inventory or in OEM inventory. 3. Stamp "S1" on the upper left hand corner of the engine information plate located on the valve cover of each engine reworked to indicate that the relief valve guide has been replaced. See Illustration 5. ILLUSTRATION 5 (SEE ILLUSTRATION) Labor in excess of the 1.0 hour allowed is for the dealer account. 4. Remove and scrap all former 2W4110 Oil Pump Relief Valve Guides in your parts stock. Warranty Allowance Submit one claim for all former relief valve guides in parts department stock that are replaced. The participation by Caterpillar and the suggested participation for dealers and customers is prorated in the following chart. This is a 0.5 hr job if the oil pan has been removed for other reasons. Caterpillar Dealers Users Parts Labor Parts Labor Parts Labor (C/L) 100% 1.0* 0% 0 0% 0 * The same labor allowance also applies for any new engines in dealer inventory that were reworked (i.e., engines in which the oil