01560-08757 Suzuki BOLT

This Revised Service Letter replaces the January 12, 1989 Service Letter. Changes have been made to the Affected Product, Parts Needed, Action Required, and Service Claim Allowances.
Problem
The turbocharger oil lines may crack and allow oil to leak into the vee of the engine between the heat shields and exhaust manifolds on some D11N Tractors; 776B Tractors; 777B and 785 Trucks; and 3508 and 3512 Engines.
Affected Product
Check the list of identification numbers under both Group A and Group B. Some of the Affected Product are included in both groups. When possible, all applicable portions of this Program should be administered at the same time.
Model & Identification Number
Group A - Turbocharger Oil Drain Lines
D11N (74Z1-593)
776B (6JC1-73)
777B (4YC1-871, 4YC873-935, 4YC937-939, 4YC943-947, 4YC949, 4YC956; 3NF1-15, 3NF17-26)
785 (8GB1-331, 8GB333-336)
3508 (99W308, 99W493, 99W495, 99W497, 99W555, 99W556, 99W558, 99W566, 99W590, 99W592, 99W618, 99W636, 99W637, 99W654, 99W670, 99W677, 99W678, 99W702, 99W712, 99W719, 99W748, 99W778, 99W783, 99W784, 99W790, 99W794, 99W797, 99W802, 99W808, 99W815, 99W825, 99W826, 99W836, 99W861, 99W882, 99W883, 99W900, 99W903, 99W905, 99W916, 99W921, 99W927, 99W982, 99W989, 99W1005, 99W1031, 99W1033, 99W1036, 99W1037, 99W1053, 99W1059, 99W1071, 99W1084, 99W1087, 99W1095, 99W1100, 99W1101, 99W1137, 99W1187, 99W1190, 99W1192, 99W1199, 99W1200, 99W1240, 99W1241, 99W1275, 99W1276, 99W1277, 99W1280, 99W1368, 99W1407, 99W1436, 99W1437, 99W1464, 99W1470, 99W1493, 99W1495, 99W1564, 99W1584, 99W1599, 99W1602, 99W1605)
3512 (96Z225, 96Z231, 96Z232, 96Z244, 96Z276, 96Z277, 96Z292, 96Z335, 96Z338, 96Z341, 96Z349, 96Z350, 96Z371, 96Z381, 96Z391, 96Z396, 96Z399, 96Z403, 96Z411, 96Z417, 96Z421, 96Z422, 96Z429, 96Z430, 96Z439, 96Z442, 96Z443)
If a spare engine has been installed in any of the Affected Product, the engine that was removed needs to be reworked.
Group B - Turbocharger Oil Supply Lines
D11N (74Z258, 74Z281-284, 74Z286-390, 74Z392-535, 74Z537-539, 74Z552)
776B (6JC62-69)
777B (4YC298, 4YC362, 4YC364, 4YC365, 4YC367, 4YC368, 4YC378-447, 4YC449-803, 4YC805-807, 4YC809-819, 4YC821, 4YC826, 4YC827, 4YC829, 4YC830, 4YC863; 3NF1-12)
785 (8GB211-216, 8GB218-301, 8GB303-309)
3508 (99W618, 99W636, 99W637, 99W654, 99W670, 99W677, 99W678, 99W702, 99W712, 99W719, 99W748, 99W778, 99W783, 99W784, 99W790, 99W794, 99W797, 99W802, 99W808, 99W815, 99W825, 99W826, 99W836, 99W861, 99W882, 99W883, 99W900, 99W903, 99W905, 99W916, 99W921, 99W927, 99W982, 99W989, 99W1005, 99W1031, 99W1033, 99W1036, 99W1037, 99W1053, 99W1059, 99W1071, 99W1084, 99W1087, 99W1095, 99W1100, 99W1101, 99W1137, 99W1187, 99W1190, 99W1192, 99W1199, 99W1200, 99W1240, 99W1241, 99W1275, 99W1276, 99W1277, 99W1280, 99W1368, 99W1407, 99W1436, 99W1437)
3512 (96Z335, 96Z338, 96Z341, 96Z349, 96Z350, 96Z371, 96Z381, 96Z391, 96Z396, 96Z399, 96Z403, 96Z411, 96Z417, 96Z421, 96Z422, 96Z429)
If a spare engine has been installed in any of the Affected Product, the engine that was removed needs to be reworked.
Parts Needed
Dealers will need to order parts for this Program. Order parts from the list or lists that apply to the Affected Product.
Group A - Turbocharger Oil Drain Lines
2 - 7N7559 Gasket - Elbow4 - 5P9890 Seal - Drain LIne2 - 5S7382 Bolt - Elbow2 - 2W0752 Gasket - Drain Line2 - 7X0291 Bolt - Elbow2 - 9Y5814 Elbow - Drain LineGroup B - Turbocharger Oil Supply Lines
8 - 7C2199 Clamp - Tube4 - 7C3036 Grommet - Clamp2* - 1D4541 Bolt - Plate4 - 0L2070 Bolt - Clamp4 - 5M2894 Washer - Clamp2 - 7N8875 Gasket - Tube1 - 6V4589 Seal - Tee1* - 1W2635 Plate1* - 2W1954 Plate1 - 9Y9887 Tube Assembly (LH)1 - 9Y9888 Tube Assembly (RH)1 - 314136 Tee - Tube to block*Use as required to attach oil line clamps to R.H. fuel manifold.Action Required
Parts Stock
Remove the following parts from dealer parts stock:
1W7991 Elbow7W8612 Tube Assembly7W8918 Tube Assembly7W8619 Tube AssemblyAffected Product
Remove the existing turbocharger oil lines and install the new parts as shown in the following illustrations.
Illustration 1 - Front View D11N, 776B, 777B, and 785
Illustration 2 - L.H. View D11N, 776B, 777B, and 785
Illustration 3 - R.H. View D11N Only
Illustration 4 - R.H. View 776B, 777B, and 785Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
This is a 1-hour job for Group A and a 1-hour job for Group B.
When filing a claim for a spare engine use the following serial numbers as the vehicle serial number:
U.S. and Canadian Dealers - 99Z21CofA Dealers - 99Z121CACO Dealers - 99Z621COSA Dealers - 99Z421Submit one claim for all 7W8612 Tube Assemblies, 7W8619 Tube Assemblies, 7W8918 Tube Assemblies, and 1W7991 Elbows removed from parts stock.
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)Copy Of Owner Notification For U.S. And Canadian Owners