COMPLAINTS OF EXCESSIVE OIL CONSUMPTION ON 3208 NATURALLY ASPIRATED (NA) ENGINES - MAILED WORLDWIDE EXCEPT BRAZIL Caterpillar

Complaints Of Excessive Oil Consumption on 3208 Naturally Aspirated (NA)
Engines, 1300,
U-85
A-34
AU-46
E-35
O-42
NOTE: This Service Letter applies only during the applicable stated
warranty period for the Affected Product.

Some 3208 DINA Engines have experienced excessive oil consumption: Several
improved parts used in production are the new oil pump suction bell assembly,
intake valve stem seals, new oil level gauges, and positive crankcase
ventilation (PCV) valve changes. This Service Letter provides:
Guidance for verifying whether or not a 3208 Engine exceeds Caterpillar
guidelines for oil consumption;
The recommended repair procedure, including the improved parts which are
adaptable to the Affected Product;
Instructions for proper claim procedure.
NOTE: The standard warranty terms, instructions and claim procedures apply,
including the use of the Time Requirement Guide in those applications where
labor is authorized by the stated warranty.
Warranty repairs relating to excessive oil consumption require acceptable
documentation of actual oil and fuel usage that exceeds published Caterpillar
guidelines. This documentation must be submitted by the user as explained in
Attachment A, "Method Of Verification".

Original Equipment Engine Serial Number
51Z1 - 68764 29A225 - 1693
90N52894 - 69296 75V7390 - 9412
99R1 - 1527 79V8492 - 16002
NOTE: Claims for naturally aspirated engines in Caterpillar Product must
include the engine serial number.
Caterpillar Remanufactured Engines
62W1 - 40700 93Z1 - 3601
NOTE: For remanufactured engines, the "Reference Serial Number" will also be
needed to determine whether the improved suction bell is needed.
Remanufactured engines with Ref. Serial No. 40S1-Up, 32Y1-68440, and 90N1-52893
have the former type oil pump relief valve which bypasses internally to the
suction side of the oil pump. These engines do NOT require the new suction
bell assembly with the relief valve spray shield feature (new tube).
VERIFICATION OF OIL CONSUMPTION
The user should record his oil and fuel usage and mileage or hours on a daily
basis so that average oil consumption can be determined. No repairs should
be made for oil consumption until accurate daily records are obtained, and the
average oil use determined. For a verification procedure and guidelines, refer
to Attachment A, "Method Of Verification".

Step One Repairs
1 7C6351 PCV Valve Sleeve
1 9L8837 PCV Valve Cover Gasket
1 7W7965 PCV Valve Element
1 7C4085 Oil Capacity Film (Decal)
1 9L7873 PCV Valve Diaphragm (if needed)
4 9M1974 Washer (replace sheet metal locks on  suction
bell bolts)
8 7W9143 Intake Valve Seal
2 9L8020 Valve Cover Gasket
1 9L8016 Oil Pan Gasket
1 9N241 Suction Bell Gasket
1 See Chart A Suction Bell Assembly
1 See Chart B Oil Level Gauge (dipstick)
2 7C3472 Temp. Regulator (190 deg. F) Low Leakage
(optional)
1 9N5429 Gasket (Regulator Housing)
1/870613/01/001  CHART B - OIL LEVEL GAUGE ADAPTABILITY
New Former New Former
Part No. Part No. Part No. Part No.
7C9395 5N7109 7C9207 9N6165
7C6271 5N8193 7C9205 9N6167
7C6584 5N8194 7C6355 9N6647
7C6408 8N8020 7C6269 9N6648
7C6271 8N8023 7C6277 9N6650
7C6584 8N8026 7C6279 9N6651
7C6279 8N8031 7C6275 2W1500
7C6355 9N6157 7C6273 4W4254
7C9396 9N6159 7C6583 4W4422
7C6277 9N6161
7C6269 9N6163
7C5795 Gauge (unmarked, "T" handle type).
4N4542 Gauge (unmarked, cane-handle type).
The 7C5795 and 4N4542 Gauges are used in circumstances where calibration and
remarking are required. See the topic, "Lubrication System Calibration".
The oil capacities of naturally aspirated engines with center-sump oil pans did
not change. Therefore, some of the former gauges are still available for use
in other applications.
Use the engine serial number and arrangement number to determine which parts
are needed. Do not schedule an engine for repair until all the parts needed
are received.
Step Two Repairs (Only if needed)
Order eight sets of piston rings for each engine that is reworked. Verify bore
size of engine before ordering part numbers from Chart C.
CHART C - PISTON RING PARTS
0.51 mm 1.02 mm
Piston Ring Description Standard (.020") (.040")
and Application Size Oversize Oversize
Counterbored Compression Ring 2W2178 4W8260 4W8268
(Not for turbocharged engines)
Oil Ring  2W8045 2W8416 2W8417
ACTION REQUESTED:
Action is required only for the Affected Product which have a verified
excessive oil consumption complaint as described in Attachment A, "Method of
Verification".
For Affected Product which have verified excessive oil consumption, perform
repairs outlined in Attachment B, "Step One Repairs Procedure". Some Affected
Product already have intake valve stem seals installed at the factory effective
with 51Z68442, 90N68921, 79V15389, 75V9255, 29A1602, 99R1528, 62W38966,
93Z3203.
If oil consumption continues to be excessive after Step One repairs are
completed, perform repairs outlined in Attachment C, "Step Two Repairs
Procedure".
WARRANTY ALLOWANCES AND CLAIM PROCEDURE:
The stated warranty terms and claim procedures apply and depend upon the
specific engine application. The Time Requirement Guide must be used in
applications where labor is claimable.
In applications where labor is claimable, the total labor allowed for Step One
repairs is actual repair time, up to a maximum of 7.5 hours. For the Affected
Product that already have the intake valve seals, labor up to 5.0 hours is
allowed. The total labor allowed for Step Two repairs (if required) is the
actual repair time up to a maximum of 20.0 hours. Any additional labor claimed
due to unusual engine installations, attachments, cab types, etc. must be
supported by a written explanation.
The claim must include the average fuel-to-oil ratio (Liters of fuel per
Liter of oil or gallons of fuel per quart of oil), as well as the total
amount of fuel and oil consumed which was used to compute the ratio, and the
kilometers (miles) or hours accumulated during the "verification" period. The
dealer must keep a copy of the actual Daily Log or user's records in the work
order file.
When reporting all oil consumption repairs for either claims forms or SIMS
Reports, use 9L6233 Piston Ring as Part Number, even if the piston rings
weren't replaced, and enter 1225 as the substitute Group Number. In the
Optional Comments field enter "Step One Repairs" or "Step Two Repairs". See
the attached example SIMS Report.
Attach. (A-Method Of Verification)
(B-Step One Repairs Procedure)
(C-Step Two Repairs Procedure)
(SEE ILLUSTRATION) ATTACHMENT A
METHOD OF VERIFICATION
Reference Publication: Listed under General Information Section; Warranty
Bulletin #16; "Excessive Oil Consumption"; Form SEBF5115-03 (2-87).
Verification of oil use is required before any warranty repair for excessive
oil consumption is performed. When a user contacts a dealer and registers a
complaint about excessive oil use, the dealer must request that the user
substantiate the oil consumption or participate in an oil consumption test.
The dealer or user must complete an Oil Consumption Test Report, Form No.
01-081227 (shown on Pages 3 and 4 of this attachment). Such reports are
required to substantiate warranty claims.
Prior to completing an Oil Consumption Test Report, the dealer should:
1. Inspect the product to determine if the complaint is the result of some
external problem.
2. Question the user to determine that there is nothing unusual about his
particular application which could cause high oil consumption.
The dealer should then proceed with the test:
1. The user must complete the Oil Consumption Daily Log portion of the "Oil
Consumption Test Report" (see Page 4 of this attachment) or make available
equivalent documentation. For warranty purposes, the dealer must keep a
copy of these records in the dealer's work order files for the Affected
Product.
2. The dealer calculates average oil consumption on a basis of Liters (gal) of
fuel consumed (fuel/oil ratio) on the Oil Consumption Test Report.
Total Liters (gal) fuel / Total Liters (qt) oil = Liters (gal) fuel per Liter
(qt) oil.
3. After the report is completed, the fuel to oil ratio must be compared to the
oil consumption graphs shown on Page 5 of this attachment. These graphs are
for use only by dealer personnel and are not intended for users.
Both graphs clearly have two distinct areas. The top areas show the typical
operating ranges for the engines. The lower areas (shaded portion) show
investigative ranges. A plotted graph and the following points will determine
if an engine has an oil consumption problem that requires repairs.
1. If the average oil consumption is in the "Investigative Range" shown in the
attached oil consumption graph, and is also more than 1 Liter (one quart)
per shift, perform repairs under "Action Required" on Page 4 of the Service
Letter.
2. If the average oil consumption is not in the "Investigative Range", then
a repair is not recommended and is not covered by warranty, even if oil
consumption is more than 1 Liter (one quart) per shift.
3. Due to engine break-in, no repairs should be made prior to 8000 kilometers
(5000 miles) or 150 hours. If the engine is used in an agricultural
application, the break-in period is one season.
4. Other factors also need to be considered. For example, low engine operating
temperature can contribute to excessive oil consumption.
5. Oil consumption repairs should be made only after an engine is confirmed to
have an oil consumption problem.
NOTICE
The graphs are not intended to be extrapolated beyond 160,000 km (100,000
miles) or 3000 hours.
1/870613/01/003 OIL CONSUMPTION DAILY LOG
(FOR OWNER/OPERATOR USE)
Complete each entry for oil consumption verification. Record odometer reading
each day (mileage) even if no fuel or oil additions are made. Both odometer
and hourmeter readings should be recorded if unit is so equipped. Oil
additions should be made only when oil reaches the "ADD" level on the engine
dipstick.
(SEE ILLUSTRATION)
(SEE ILLUSTRATION) ATTACHMENT B
STEP ONE REPAIRS PROCEDURE
This Procedure is not to be used for repairs to 3208 Turbocharged Engines.
(Perform all the items listed below during the same repair.)
1. Inspect the engine for external oil leaks such as crankshaft seals, valve
covers, etc. Repair as needed.
2. Check the entire "clean" side of intake system for evidence of dirt entry.
NOTE: Oil consumption caused by dirt entry is not Caterpillar's
responsibility.
3. Check the air compressor clean air supply line (if connected to the engine
air intake system) to see if the air compressor is "pumping oil" back into the
intake system when the compressor is running "unloaded". Also, check the air
tank drains to see if the compressor is pumping oil into the air tanks.
4. Remove the valve covers. Check the cylinder head and block oil drain-back
passages. See Illustration 2 in the topic, "Checking Oil Drain Passages," for
locations.
5. Install the 7W9143 Seals on the intake valve guides only. (These seals will
not fit turbocharged engines.)
6. Disassemble the PCV (Positive Crankcase Ventilation) valve. Remove and
discard the former 9L8836 Sleeve and element, if equipped.
7. Compare the underside of the valve cover with the PCV housing attached. The
valve cover opening may not match the PCV valve opening. Mark the area of the
valve cover which partly obstructs the opening of the PCV valve. Grind or cut
away the excess valve cover material so the openings will match. An air
powered, high-speed pencil grinder works well. The larger flow area will
reduce the amount of oil mist being carried into the PCV valve. Clean the
valve cover and PCV housing to remove metal particles. See Illustration 1 for
the location of the excess material.
Illustration 1
(SEE ILLUSTRATION) 8. Check the diaphragm and replace, if necessary.
Reassemble the PCV using the new 7C6351 Sleeve and 7W7965 Element. The new
sleeve has more shield area at the bottom to protect against direct oil spray
from the PCV opening.
NOTE: After the PCV is cleaned and reassembled with the new parts listed, hold
the PCV in a vertical position (PCV outlet up) and apply a slight suction. The
PCV should be closed against suction with only a slight leakage, if any. If
the PCV is not closed, remove the PCV cover and stretch the spring slightly.
Reassemble the PCV and check again. If the parts which hold the diaphragm are
installed backwards, the valve will not seal.
9. Remove the standard 9N5121 Water Temperature Regulators, 82 deg. C. (180
deg. F), and install two 7C3472 Regulators, 87 deg. C. (190 deg. F, low
leakage). The new regulators are not used in most production engines.
NOTE: If the unit is equipped with coolant temperature alarms or shutdown
systems, thermostatically-controlled fan clutch and/or radiator shutters, it
may be necessary to install a different temperature sensor with a setting
approximately 6 deg. C. (10 deg. F) higher to correspond to the higher opening
temperature of the new thermostats. The sensors are not for Caterpillar's
account. In these situations, using the 7C3472 temperature regulators is
optional.
10. Remove the oil pan, oil filters, and the former suction bell assembly.
Install the appropriate new suction bell assembly, using new 9M1974 Washers
(instead of sheet metal bolt locks).
11. Install the appropriate, new oil level gauge (dipstick) to provide the new
(reduced) oil capacity ?reduced by 2 L (2 U.S. qt)!. The new gauges are marked
for 2 L (2 U.S. qt) between "Add" and "Full". Some former gauges were marked
for 4 L (4 U.S. qt) between "Add" and "Full".
a. Use Chart A in the Parts Needed list to determine the correct new oil level
gauge part number to be used.
b. Install two new oil filters.
c. Install the correct amount of oil for the new, reduced refill capacity
(includes filters) as shown in Chart B in the topic, "Lubrication System
Calibration".
d. Start the engine and allow it to operate for 5-10 minutes. Stop the engine
and allow 10-15 minutes for the oil to drain back into the oil pan.