6487 Mercury JET, Main (.060), IDLE AIR BLEED

06Sep2011
(Revised 30Apr2012)
U-371
A-308
D-330
O-323
TM-21
Before/After
PRODUCT SUPPORT PROGRAM FOR REPLACING FUEL INJECTORS ON CERTAIN C32 MARINE ENGINES
1251 1290 PS43362
This Program must be administered either before or after failure.In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS43362" as the Part Numberand "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code.If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
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 Revised Service Letter replaces the 06Sep2011 Service Letter. Changes have been made to the Action Required and Service Claim Allowances.
TERMINATION DATE
30Sep2013
PROBLEM
The existing fuel injectors can experience internal body cracks due to material inclusions and variability in the factory tightening procedure and/or the poppet sticking as a result of body and valve tolerancing on certain C32 marine engines. If the existing fuel injector fails it can result in complaints of misfire and/or low power.
AFFECTED PRODUCT
Model Identification Number
C32 RND00276-00339
RNE00126-00140
RNX00104-00110, 112, 115-136, 140, 145, 148-158, 162-165, 169-202, 206, 209-212, 214-217, 219-220, 222, 224-228, 232-238, 240-247, 250, 252-253, 257, 263, 265, 267-282, 284-285, 288-289, 291-305, 307, 310, 312-317, 320, 323, 325-329, 334-339, 341-343
RNY00102-00107, 119-120, 123-129, 135, 137, 154, 156-162, 171, 173, 183, 190-192, 196-200, 202-203, 205, 210-211, 213, 220-222, 225-226, 228-236, 238-242, 244-246, 248-249, 253-258, 260, 263-266, 269, 276, 280, 282, 285-286, 289-300, 302-305, 308-309, 312-315, 317-318, 327, 333-335, 337-349, 352, 356-358, 360-361, 363-366, 368, 370, 386, 391, 398-403, 406-408, 411-414, 417-419, 421-428, 443-448, 452-453, 456-457, 459-471, 474, 476, 478-489, 491-492, 497, 499-500, 502-507, 511-513, 516, 518-519, 521, 529-539, 541-542, 544, 546, 549, 551-554, 556-558, 571, 579-581, 585, 600-602, 606, 609-610, 613, 617-619, 621, 624-642, 644-665, 667, 672, 674, 676-677, 686-687, 695, 697-698, 700-702, 707-709, 711-728, 731-734, 737, 741, 746-748, 751-752, 755, 763, 765, 767, 777-782, 786-787, 794, 796, 798-799, 802, 804-820, 826, 829, 836, 842, 848, 859, 862, 866-867, 872-875, 886, 890-891, 894, 896-903, 909-910, 913-919, 925, 927, 929, 931, 934, 938, 952-954, 959-960, 973
RNZ00101-00158, 160, 162-181, 183-189, 191-220, 222-223, 225-231, 233-250, 252-253, 255-261, 263-270, 272-274, 276-294, 296-304, 306-447, 449-450, 452-456, 459-491, 493-496, 498-499, 502, 512-514
T3T00103-00104, 114, 134, 144-145, 147-150, 154-160, 164-213, 215-381, 383
PARTS NEEDED
Qty
Part Number Description
12 8S9191 BOLT
12 10R7231 FUEL INJECTOR GP
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 7% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Take the following actions only after a failure occurs on one or more injectors in any of the engines listed in the Affected Product. A fuel injector is considered a failure if the following troubleshooting procedure is completed and the problem is not resolved.
1. Update the ECM software.
2. If still unable to produce advertised power, use publication SEBD9408 to determine if a change to FLS/FTS is required.
3. If still unable to produce advertised power, test the injector solenoid per RENR9326.
4. If still unable to produce advertised power, test the unit i