13119-96J00 Suzuki GASKET, INTAKE MANIFOLD

January 3, 2005
(Revised June 2005)
U-1
A-1
D-1
O-1
SafetyParts stock action needed PRODUCT IMPROVEMENT PROGRAM FOR REPLACINGTURBOCHARGER HOUSINGS ON CERTAIN 3500 SERIES ENGINES.
1052 PI10333
This Program must be administered assoon as possible. When reporting the repair, use "PI10333" as the Partnumber and "7751" as the Group Number, "56" as the Warranty Claim DescriptionCode and "T" as the SIMS Description Code. Exception: If the repair isdone after failure, use "PI10333" as the Part Number, "7751" as the GroupNumber, "96" as the Warranty Claim Description Code, and "Z" as the SIMSDescription Code. This Revised Service Letter replacesthe January 3, 2005 (Revised January 2005) Service Letter. Changes havebeen made to the Parts Needed and Problem Discription Sections.PROBLEM
All Caterpillar turbochargers are designed andtested to ensure turbo wheel fragments do not exit the turbo housings shoulda turbo failure occur. Loose turbo parts exiting a turbo during a turbofailure present a potential safety hazard. Recent tests have indicatedthe 1135181, 1989916, and reman 0R7719 turbos on the above engines canfail to contain some loose turbo fragments should a turbo failure occur. This service letter is issued to addressa hardness problem with the housing. Other types of turbo damage are notcovered in this service letter.AFFECTED PRODUCT
Model Identification Number
3512B 6GW141, 147,192, 195, 202-203, 214, 219, 243, 317-318, 353-354, 395, 397, 400-403,647, 660-661, 667, 693-694, 725, 740-743, 753-754, 761-764,766, 831, 835-836, 838-839,844-847,853, 10426WN76-98, 102-112, 116-117, 121-125,127-132, 134-140, 142-150, 152, 154, 159, 161-167, 169-186, 189-197, 199-210,212, 214-254, 256-263, 265-277, 279-292, 294-387, 391-411, 413-432, 435-449,451, 453, 455-464, 467-543, 545, 547, 549-561,563-586,589-608, 611-712, 715-738, 740-8028RM1, 107, 109-112, 130-131, 138-140,148-150, 153-154, 156-158, 175, 189-190, 199-200, 203-208, 211, 217-218,220-221, 235-237, 240-243, 251-252, 254, 262, 272-274, 277, 279, 284-285,291-292, 294, 296, 302, 306, 309, 311-314, 316-317, 321-322, 324, 326-330,333-334, 337, 339-341, 347, 349-350, 352-354, 360, 366-367, 371-385, 393-394,397-398, 401-408, 410-431, 433-436, 438, 440, 442-452, 456-459, 462-464,469, 471, 474-475, 481, 491-492, 499, 501, 504, 507, 509, 513-514, 517,519-522, 526, 529, 533, 535, 538-541, 544, 546, 548-549, 553-554, 556,565, 569-570, 578, 583, 586-587, 597, 599, 606, 608, 612, 614, 624-625,630, 632, 636-638, 653, 656-657, 659, 661-662, 665, 667, 669, 671-672,675-678, 680-692, 694-695, 697, 699-701, 704,709-710, 712-713, 717, 731-732,735-740,749, 754, 757, 759BNR311-313CMC112-113, 115-117, 121, 124-126,128-139, 141-145, 147-149, 152-154, 158, 161-162, 164, 173, 177, 179-185,187-188, 190-193, 198-205, 208-210, 212-222, 224, 226-228, 231, 234, 237-240,242-243, 246-263, 267-277, 283, 286-287, 296-301, 303-304, 306-311, 320,322, 325-327, 332-336, 340-345, 348-360, 362-367, 369, 372-378, 390-391,394-395, 397-404, 406, 410-411, 413-414, 416-418, 420-424, 439-440, 442,448, 450-451, 453-459, 463, 465-467, 469-475, 480-485, 487, 489-492, 494,499, 501-503, 512-513, 515-516, 520, 527-529, 531-538, 540-541, 544-554,556, 561-568, 573-580, 582-586, 588-589, 591-594, 596-626, 629-633, 637-642,644, 646-651, 658, 661, 663-665, 667-678, 680-682, 684-685, 687-688, 691-692,694, 697-703, 707-717, 719-720, 729-735, 741, 743-747, 751-758, 760, 762-764,767-775, 777-780, 782-783, 786-790, 792-804, 808-810, 813-823, 825-827,837-839, 843-854, 860, 869-870, 872-873, 876-877, 880-884, 887, 890, 892-893,895-899, 908-912, 923-927, 931-935, 944, 950-953, 955-959, 964, 968-974,979, 982, 989-997, 1002-1005, 1010, 1015-1016, 1020-1022, 1025-1026, 1028-1029,1036-1041, 1044-1046, 1056-1058, 1064-1066,1071-1076, 1080-1081, 1086, 1088-1089,1095-1096,1098-1105PARTS NEEDED
Qty
Part Number Description
1 2631452 TURBO-KIT There are 4 turbine housings per kit.Only 1 kit is required per engine.ACTION REQUIRED
***** Parts Stock *****Rework all 1135181, 1989916, and 0R7719 TURBOGROUPS in parts stock.In order to remove a turbine housing from anexisting turbocharger, place the turbocharger compressor side down andfollow steps 3 through 7 in the "affected product" section below. Makesure the turbo impellers spin freely.After the rework has been completed use a 1/8"stamp to stamp a "W" on the end of the turbocharger part number. The nameplateis located on the turbocharger cartridge as shown below: Please keep in mind this stamping method isonlyfor the turbocharger part numbers listed above.***** Affected Product *****
Follow the removal procedure within publication"Turbocharger - Remove - Center Mounted Turbocharger", SENR6564 to removethe turbocharger from the engine.
After the turbocharger is removed, place the turbochargeron a bench top with the compressor side down.
Loosen the turbine housing band clamp.
Carefully lift the turbine housing from the turbo.
Install the new turbine housing.
Carefully install the band clamp.
Tighten the band clamp, but leave it loose enoughto turn the housing.
Install turbo on exhaust manifold and tightenbolts to 55 newton-meters.
Be sure to apply anti-seize to bolts.
Tighten the oil supply line, the turbo drain,and the compressor housing to the after-cooler to 47 newton-meters.
Then tighten band clamp on turbine housing to14 newton-meters and tap on band clamp.
Then retighten to 14 newton-meters.
Make sure turbo impellers spin freely.
Install air intake tube and tighten hardware.
After the rework has been completed use a 1/8"stamp to stamp a "W" on the end of the turbocharger part number. The nameplateis located on the turbocharger cartridge as shown below: Please keep in mind this stamping method isonlyfor the turbochargers shown below effected by this rework.OWNER NOTIFICATION
U.S. and Canadian owners will receive the attachedOwner Notification.SERVICE CLAIM ALLOWANCES
***** Parts Stock *****Submit one claim for all TURBO GROUPS reworkedin parts stock.***** Affected Product *****