20460945 Volvo.Penta Turbocharger

Problem
Rod bearing failures have occurred in both new engines from the factory and in rebuilt engines. These failures resulted in seizure of connecting rods. The bearing failures have been traced back to a lead tin overlay delamination. The delamination is large enough that the oil film has been disrupted. This leads to adhesive failure of the bearing.
Table 1
3500 Affected Bearings.    
Part Numbers     Description    
107-7330     Connecting Rod Bearing    
107-7331     Connecting Rod Bearing    
107-7332     Connecting Rod Bearing    
107-7333     Connecting Rod Bearing    
107-7334     Connecting Rod Bearing    
107-7335     Connecting Rod Bearing    
230-2520     Connecting Rod Bearing    
283-2579     Connecting Rod Bearing    
283-2580     Connecting Rod Bearing    
283-2581     Connecting Rod Bearing    
283-2582     Connecting Rod Bearing    
283-2584     Connecting Rod Bearing    
149-6031     Main Bearing As    
149-6032     Main Bearing    
149-6033     Main Bearing    
149-6034     Main Bearing    
149-6035     Main Bearing    
Table 2
G3600 Affected Bearings.    
Part Numbers     Description    
192-7870     Connecting Rod Bearing    The affected bearings were plated from July 2008 through January 2009. Refer to Illustration 1 for the location of date codes.
Illustration 1 g01993413
(1) Year code (2) Month codeThe root cause was a interruption to the electrical current during the plating process. This resulted in a poor adhesion of the lead and tin. This condition caused a loss of the bond.The supplier has identified the following range of date codes that are affected:
For the year 2008, the year code is "NO" with the month codes "UG", "UH", "UI", "UJ", "UK", and "UL".
For the year 2009, the year code is "ND" with the month code "UA".Note: Not all of the bearings that are in the affected date codes will cause a seizure of the connecting rod.Solution
The oil pump's suction screen must be inspected in order to determine if the lamination of the lead tin overlay has deteriorated.Note: Also, if you have an engine that has a bearing failure, inspect the remaining connecting rods and main bearings for deterioration of the lamination.
Inspect the oil pump's suction screen.If nonferrous material is found in the suction screen, clean the screen and reinstall the screen.
Allow the engine to run for 72 hours of normal operation.
Inspect the oil pump's suction screen for a second time.If nonferrous material is found, the material must be tested in order to determine whether the material is lead.
Test the material in order to determine if the material is lead.
If lead is found remove the connecting rod bearings first and inspect the connecting rod bearings. If deterioration of the lamination is found, replace the connecting rod bearings and the main bearings with acceptable bearings. If no deterioration is found on the connecting rod bearings, inspect the main bearings for deterioration of the lamination.Note: If there are any bearings that have deterioration of the lamination, replace the bearings and use the Dealer Solution Network (DSN) to notify the product group. If there are any bearings that have the suspect date codes replace the bearings regardless of the condition.
Take photographs of the bearing surfaces and of the date codes. Submit an entry to the DSN.The entry must contain the following items:
Photos of all the bearings in the engine that include the date codes
Photos of all damaged components
Engine serial number
Bearing hours of operation
Engine oil filter element
Results of the five latest S O S oil analyses
History of the engine's rebuilds
For electronic engines, an "ECM Summary" of the engine's Electronic Control Module from Caterpillar Electronic Technician (ET)Note: If you are working on an engine that requires separation of a connecting rod or main bearing joint and if you see a bearing that has lost the bond as shown in Illustration 2, submit an entry to the DSN that includes the information listed above.
Illustration 2 g01993416
(1) Area that has lost the bondBearings that are currently in the parts system with the following markings are approved for use:
A handwritten "2009" on the back of the bearing
An ink stamped "09" on the back of the bearing
Newly manufactured bearings with a permanently stamped numeric indicator of the year
Illustration 3 g02024051
(3) Handwritten "2009"
Illustration 4 g02024054
(4) Ink stamped "09"