Retrofitting the Dynamic Gas Blending Capability for Certain 3512B Off-Highway Truck Engines {1000, 1250, 7000}
- Off-Highway Truck/Tractor
- 785C (S/N: 8BR1-UP; APX1-UP)
Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.
Note: The air conditioner compressor update in Service Magazine, SEPD1715 must be installed on the engine prior to making this update.
Note: The 457-5994 Chassis Wiring Gp Must be installed before the engine and cooling package.
Note: The intake manifold temperature sensor must be installed after the engine is installed in the truck. If the temperature sensor is installed, the lifting bale will smash the temperature sensor while lifting the engine. Alternatively to eliminate the potential for this to occur, the port on the intake manifold can be drilled and tapped to a 3/4"-16 port prior to kit assembly. This will eliminate the requirement for a 353-5440 Adapter (3/4" to 1/2"), which eliminates the potential for the lifting bale to damage the temperature sensor.
Safety Section
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Removing the engine from the truck with the body of the truck in the UP position will change the balance point of the truck. The shift in the balance point could allow the front of the truck to unexpectedly raise off the ground. This unexpected movement could cause injury or death. To stabilize the truck, always install the specified tooling to stabilize the truck before removing the engine and torque converter. |
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Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove filler cap slowly to relieve pressure only when engine is stopped and radiator cap is cool enough to touch with your bare hand. Cooling System Conditioner contains alkali. Avoid contact with skin and eyes. |
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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
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| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
References
Reference: Disassembly and Assembly, SENR1126, "3500 and 3500B High Displacement Engines for Caterpillar Built Machines"
Reference: Disassembly and Assembly, SENR1486, "3512B and 3516B Engine Supplement for 784C, 785C, and 785C HAA Off-Highway Truck/Tractors"
Reference: Reuse and Salvage Guidelines, SEBF9011, "Dynamometer Testing of Caterpillar Engines"
Reference: Schematic, UENR8455, "785C Off-Highway Truck Dynamic Gas Blend (DGB) Conversion Electrical System, 462-8302"
Reference: Special Instruction, M0079018, "Installation and Removal of the 443-5682 Pressure Sensor Gp (In Cylinder Pressure Sensor)"
Reference: Operation and Maintenance Manual, M0091539, "785C Off-Highway Trucks Equipped with Dynamic Gas Blending (DGB)"
Reference: Systems Operation and Testing and Adjusting, M0083188, "3512B Engines for 785C Off-Highway Trucks with Dynamic Gas Blending"
Reference: Troubleshooting, M0083187, "3512B Engines for 785C Off-Highway Trucks with Dynamic Gas Blending"
Engine Parts
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| 7E-9220 Water Lines Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 48 | |
| O-Ring Seal | 12 | |
| Integral Seal | 12 | |
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| 9Y-1595 Accessory Drive Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| O-Ring Seal | 1 | |
| O-Ring Seal | 1 | |
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| 298-0478 Flywheel Housing Cover Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Cover Gasket | 1 | |
| O-Ring Seal | 1 | |
| Copper Gasket | 1 | |
| Gasket | 2 | |
| Gasket | 2 | |
| Gasket | 1 | |
| Integral Seal | 1 | |
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| 332-7911 Crankshaft Seal Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Crankshaft Seal | 1 | |
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| 332-9695 Cylinder Head Plug Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Pipe Plug | 12 | |
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| 351-9062 Flywheel Housing Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 1 | |
| Bolt | 7 | |
| Bolt | 1 | |
| Bolt | 8 | |
| Bolt | 11 | |
| Bolt | 2 | |
| Hard Washer | 14 | |
| Hard Washer | 12 | |
| Hard Washer | 2 | |
| Hard Washer | 2 | |
| Pipe Plug | 5 | |
| Pipe Plug | 1 | |
| Flywheel Housing As | 1 | |
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| 369-9365 Rear Gear Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 1 | |
| Hard Washer | 1 | |
| Ring | 1 | |
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| 370-9889 Valve Mechanism Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Seal | 12 | |
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| 381-3901 Oil Pan Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Oil Pan Gasket | 1 | |
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| 383-2091 Cylinder Block Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| O-Ring Seal | 1 | |
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| 393-4996 Camshaft Cover Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 18 | |
| Hard Washer | 18 | |
| Seal | 3 | |
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| 398-0924 Flywheel Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Hard Washer | 12 | |
| Bolt | 12 | |
| Flywheel As | 1 | |
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| 430-2697 Fumes Disposal Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 2 | |
| Bolt | 4 | |
| Boot | 2 | |
| Hose Clamp | 2 | |
| Clip | 2 | |
| Clip | 2 | |
| Grommet | 2 | |
| Full Nut | 2 | |
| Hard Washer | 4 | |
| Hose Clamp | 2 | |
| Tube | 2 | |
| Bracket | 1 | |
| Bracket | 1 | |
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| 445-8603 Block Spacer Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 24 | |
| Hard Washer | 24 | |
| O-Ring Seal | 24 | |
| Cylinder Head Fastener Gp | 72 | |
| Cylinder Head Fastener Gp | 24 | |
| Plate Gasket | 12 | |
| Cylinder Head Gasket | 12 | |
| Water Seal Assembly | 48 | |
| Water Seal Assembly | 48 | |
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| 453-4105 Exhaust Manifold Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Exhaust Manifold Gasket | 12 | |
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| 463-0919 Cylinder Head Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Cylinder Head Gp | 12 | |
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| 463-7674 Air Lines Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 48 | |
| Hard Washer | 48 | |
| O-Ring Seal | 12 | |
| Connector Plug | 12 | |
| Manifold Gasket | 12 | |
| Air Inlet Elbow | 10 | |
| Air Inlet Elbow | 2 | |
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| 464-9825 Fuel Priming Lines Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 1 | |
| Bracket | 1 | |
| Hard Washer | 2 | |
| Connector | 1 | |
| O-Ring Adapter | 1 | |
| Clip | 2 | |
| Clip | 2 | |
| Full Nut | 1 | |
| O-Ring Seal | 1 | |
| O-Ring Seal | 1 | |
| O-Ring Seal | 4 | |
| Elbow | 1 | |
| Grommet | 2 | |
| Plug | 2 | |
| 1 | ||
| 1 | ||
| 1 | ||
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| 464-9826 Fuel Injection Lines Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 2 | |
| Bolt | 1 | |
| Bolt | 1 | |
| Bolt | 1 | |
| Bolt | 1 | |
| Bolt | 1 | |
| Spacer | 1 | |
| Tube As | 1 | |
| Tube As | 1 | |
| Clamp As | 10 | |
| Clamp As | 8 | |
| Bracket | 1 | |
| Flared Elbow | 1 | |
| Bolt | 1 | |
| Bolt | 1 | |
| Hard Washer | 4 | |
| Swivel Tee | 1 | |
| Hard Washer | 1 | |
| Flared Cap | 1 | |
| Fuel Manifold Adapter | 1 | |
| Fuel Manifold Adapter | 1 | |
| Clamp | 1 | |
| Pipe | 2 | |
| Flared Elbow | 1 | |
| Hard Washer | 2 | |
| Connector | 1 | |
| Spring | 1 | |
| Full Nut | 2 | |
| Cap | 1 | |
| Hard Washer | 6 | |
| Union Tee | 1 | |
| Elbow | 3 | |
| Elbow | 1 | |
| Flared Union | 1 | |
| Valve Plunger | 1 | |
| Bolt | 2 | |
| O-Ring Seal | 5 | |
| Grommet | 2 | |
| Bracket As | 1 | |
| Fuel Tube | 1 | |
| Fuel Tube | 1 | |
| Fuel Tube | 1 | |
| Fuel Tube | 1 | |
| Fuel Tube | 1 | |
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| 465-3214 Oil Level Gauge Gp (Dipstick) | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 2 | |
| Shaft Gasket | 1 | |
| Bolt | 1 | |
| Clamp As | 6 | |
| Hard Washer | 2 | |
| Nut | 1 | |
| Hard Washer | 4 | |
| Bolt | 1 | |
| Spacer | 1 | |
| Oil Gauge Tube As | 1 | |
| Oil Level Gauge As | 1 | |
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| 466-3233 Engine Cover Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 3 | |
| Gasket | 1 | |
| Cover | 1 | |
| Hard Washer | 3 | |
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| 466-3762 Valve Mechanism Cover Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 48 | |
| Hard Washer | 48 | |
| Valve Cover Seal | 12 | |
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| 466-8154 Fuel Filter Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 1 | |
| O-Ring Seal | 2 | |
| Bolt | 10 | |
| Hard Washer | 10 | |
| Hard Washer | 1 | |
| Filter Base Cover | 1 | |
| Bolt | 1 | |
| Pipe Plug | 3 | |
| Hard Washer | 1 | |
| Plug | 1 | |
| Hard Washer | 1 | |
| Gasket | 1 | |
| Plug | 1 | |
| Pump Adapter | 1 | |
| O-Ring Seal | 1 | |
| O-Ring Seal | 1 | |
| O-Ring Seal | 1 | |
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| 467-2785 Breather Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Hose Clamp | 3 | |
| Hose Clamp | 3 | |
| O-Ring Seal | 3 | |
| Elbow Hose | 1 | |
| Tee Hose | 1 | |
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| 468-5925 Turbocharger Oil Lines Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 2 | |
| Gasket | 2 | |
| Bolt | 7 | |
| Hard Washer | 6 | |
| O-Ring Seal | 4 | |
| Clip | 2 | |
| Clip | 2 | |
| Full Nut | 1 | |
| Hard Washer | 2 | |
| O-Ring Seal | 4 | |
| Oil Tube As | 1 | |
| Oil Tube As | 1 | |
| Elbow | 2 | |
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| 469-5663 Water Lines Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 2 | |
| Bolt | 2 | |
| Bolt | 2 | |
| Hard Washer | 4 | |
| O-Ring Seal | 1 | |
| Gasket | 1 | |
| Full Nut | 2 | |
| Clamp As | 2 | |
| Ring | 1 | |
| Elbow | 1 | |
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| 474-4546 Pump Mounting Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Hard Washer | 4 | |
| Bolt | 4 | |
| Pump Bracket As | 1 | |
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| 476-4213 Oil Filler Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Locknut | 1 | |
| Clip | 2 | |
| Hard Washer | 2 | |
| Hard Washer | 1 | |
| Bolt | 4 | |
| Nut | 3 | |
| Bolt | 3 | |
| Hard Washer | 1 | |
| Hard Washer | 6 | |
| Bolt | 2 | |
| Special Bolt | 1 | |
| Hasp | 1 | |
| Spacer | 1 | |
| Front Support | 1 | |
| Front Support | 1 | |
| Engine Oil Filler Cap As | 1 | |
| Block | 1 | |
| O-Ring Seal | 1 | |
| Bracket As | 1 | |
| Oil Filler Tube | 1 | |
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| 476-5478 Oil Filler Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Gasket | 1 | |
| Bolt | 3 | |
| Hard Washer | 3 | |
| Elbow | 1 | |
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| 495-7573 Fuel Lines Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 16 | |
| Bolt | 86 | |
| Bolt | 12 | |
| Bolt | 3 | |
| Bolt | 4 | |
| Bolt | 48 | |
| Spacer | 2 | |
| O-Ring Seal | 12 | |
| Hard Washer | 56 | |
| O-Ring Seal | 2 | |
| Connector | 20 | |
| Connector | 2 | |
| Elbow | 2 | |
| Clip | 10 | |
| Clip | 10 | |
| Clip | 2 | |
| Clip | 2 | |
| Full Nut | 12 | |
| Hard Washer | 79 | |
| O-Ring Seal | 6 | |
| O-Ring Seal | 12 | |
| Spacer | 48 | |
| O-Ring Seal | 22 | |
| O-Ring Seal | 4 | |
| O-Ring Seal | 24 | |
| Grommet | 2 | |
| Grommet | 10 | |
| Cover | 2 | |
| Gas Control Valve | 12 | |
| Bracket | 2 | |
| Bracket As | 8 | |
| Bracket As | 4 | |
| Bracket | 10 | |
| Manifold | 4 | |
| Manifold | 2 | |
| Manifold | 2 | |
| Hose and Tube As | 10 | |
| Hose As | 2 | |
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| 496-0842 Engine Wiring Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 7 | |
| Bolt | 4 | |
| Bolt | 1 | |
| Full Nut | 1 | |
| Stud | 2 | |
| Clip | 2 | |
| Clip | 1 | |
| Hard Washer | 5 | |
| Clip | 3 | |
| Clip | 3 | |
| Clip | 2 | |
| Clip | 11 | |
| Clip | 9 | |
| Grommet | 1 | |
| Hard Washer | 2 | |
| Grommet | 5 | |
| Nut | 2 | |
| Spacer | 1 | |
| Grommet | 2 | |
| Grommet | 3 | |
| Grommet | 3 | |
| Grommet | 1 | |
| Cable Strap | 46 | |
| Clip | 1 | |
| Clip | 1 | |
| Grommet | 1 | |
| Clip | 1 | |
| Clip | 1 | |
| Grommet | 12 | |
| Hard Washer | 2 | |
| Full Nut | 11 | |
| Hard Washer | 26 | |
| Spacer | 4 | |
| Grommet | 3 | |
| Grommet | 1 | |
| Clip | 1 | |
| Bracket | 2 | |
| Bracket | 1 | |
| Cable Tie Mounting | 5 | |
| Mounting Saddle | 2 | |
| Stud | 2 | |
| Grommet | 2 | |
| Bracket As | 1 | |
| Pressure Sensor Gp | 12 | |
| Sensor Harness As | 12 | |
| Engine Harness As | 1 | |
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| 497-2280 Fuel Priming Pump Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 1 | |
| Bolt | 2 | |
| Isolation Mount | 8 | |
| Hard Washer | 6 | |
| Spacer | 1 | |
| Spacer | 2 | |
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| 512-2636 Engine Electronic Control and Mounting Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 8 | |
| Bolt | 4 | |
| Bolt | 4 | |
| Bolt | 4 | |
| Bolt | 6 | |
| Bolt | 3 | |
| Bolt | 4 | |
| Bolt | 2 | |
| Spacer | 4 | |
| Hard Washer | 3 | |
| Hard Washer | 22 | |
| Hard Washer | 4 | |
| Nut | 3 | |
| Spacer | 16 | |
| Cable Strap | 3 | |
| Isolation Mount | 32 | |
| Hard Washer | 16 | |
| Bracket | 1 | |
| Stud | 4 | |
| Hard Washer | 8 | |
| Stud | 1 | |
| Plate As | 1 | |
| Bracket As | 4 | |
| Clip | 3 | |
| Stud | 2 | |
| Inductor Assembly | 3 | |
| Bracket As | 2 | |
| Bracket As | 2 | |
| Electronic Control Module | 2 | |
| Electronic Control Gp | 1 | |
| Electronic Control Module | 1 | |
| Gasket | 1 | |
| Control Harness As | 1 | |
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| 519-3166 Fuel Lines Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 3 | |
| Bolt | 1 | |
| Bolt | 5 | |
| Bolt | 11 | |
| Bolt | 1 | |
| Bolt | 4 | |
| Bolt | 4 | |
| Bolt | 4 | |
| Bolt | 2 | |
| O-Ring Seal | 1 | |
| Bolt | 4 | |
| Grommet | 1 | |
| Band Clamp | 1 | |
| Hard Washer | 11 | |
| Hard Washer | 8 | |
| Stud | 4 | |
| O-Ring Seal | 4 | |
| O-Ring Seal | 1 | |
| Connector | 1 | |
| Elbow | 1 | |
| O-Ring Seal | 1 | |
| O-Ring Seal | 1 | |
| Bolt | 2 | |
| Nut | 8 | |
| Swivel Adapter | 1 | |
| O-Ring Seal | 2 | |
| Connector | 1 | |
| Elbow | 1 | |
| Clip | 1 | |
| Clip | 1 | |
| Clip | 1 | |
| Clip | 1 | |
| Hard Washer | 14 | |
| Plug | 1 | |
| Full Nut | 4 | |
| Full Nut | 9 | |
| Plug | 1 | |
| Hard Washer | 38 | |
| Spacer | 4 | |
| Ball Valve | 1 | |
| Grommet | 1 | |
| Elbow | 1 | |
| Plug As | 1 | |
| Bolt | 4 | |
| Bolt | 1 | |
| Hose | |
|
| Bolt | 6 | |
| O-Ring Seal | 1 | |
| O-Ring Seal | 1 | |
| O-Ring Seal | 3 | |
| O-Ring Seal | 1 | |
| Elbow As | 1 | |
| Drain Valve Gp | 1 | |
| Seal | 4 | |
| Elbow As | 1 | |
| O-Ring Seal | 1 | |
| Clip | 1 | |
| Bracket | 1 | |
| Gas Pressure Regulator Gp | 1 | |
| Bracket | 1 | |
| Bracket | 1 | |
| Bracket | 1 | |
| Check Valve | 1 | |
| Solenoid Valve Gp | 1 | |
| Fuel Tube | 1 | |
| Fuel Tube | 1 | |
| Plate | 1 | |
| Adapter | 1 | |
| Hose and Tube As | 1 | |
| Bracket As | 1 | |
| Bracket | 1 | |
| Bracket | 1 | |
| Plate | 1 | |
| Adapter | 1 | |
| Adapter | 1 | |
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| 526-2561 Alternator Wiring Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 2 | |
| Clip | 2 | |
| Hard Washer | 4 | |
| Clip | 2 | |
| Clip | 2 | |
| Grommet | 2 | |
| Grommet | 1 | |
| Cable Strap | 15 | |
| Grommet | 9 | |
| Full Nut | 3 | |
| Hard Washer | 2 | |
| Mounting Stud | 1 | |
| Bracket | 1 | |
| Mount | 4 | |
| Grommet | 2 | |
| Power Harness As | 1 | |
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| 539-1906 Engine Wiring Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 16 | |
| Bolt | 2 | |
| Bolt | 10 | |
| Bolt | 9 | |
| Bolt | 3 | |
| Bolt | 2 | |
| Bolt | 4 | |
| Bolt | 1 | |
| Bolt | 5 | |
| Full Nut | 1 | |
| Stud | 1 | |
| Bolt | 2 | |
| Spacer | 1 | |
| O-Ring Seal | 1 | |
| Pipe Elbow | 1 | |
| Clip | 2 | |
| Hard Washer | 4 | |
| Hard Washer | 1 | |
| Washer | 1 | |
| Washer | 2 | |
| Fitting | 1 | |
| Bolt | 1 | |
| Grommet | 1 | |
| Clip | 1 | |
| Clip | 1 | |
| Clip | 16 | |
| Clip | 7 | |
| Grommet | 1 | |
| Hard Washer | 50 | |
| Adapter | 1 | |
| Clip | 3 | |
| Clip | 3 | |
| Clip | 9 | |
| Clip | 9 | |
| Hard Washer | 2 | |
| Nut | 7 | |
| Bolt | 2 | |
| Spacer | 1 | |
| Circuit Breaker As | 1 | |
| Grommet | 11 | |
| Grommet | 3 | |
| Grommet | 1 | |
| Grommet | 3 | |
| O-Ring Seal | 1 | |
| O-Ring Seal | 3 | |
| O-Ring Seal | 1 | |
| Nut | 7 | |
| Screw | 2 | |
| Cover | 1 | |
| Gasket | 1 | |
| Cable Strap | 82 | |
| Stud | 1 | |
| Clip | 1 | |
| Clip | 1 | |
| Grommet | 3 | |
| Pipe Plug | 1 | |
| Adapter | 1 | |
| Clip | 1 | |
| Hard Washer | 4 | |
| Clip | 1 | |
| Clip | 1 | |
| Grommet | 4 | |
| Hard Washer | 2 | |
| Hard Washer | 2 | |
| Pipe Plug | 2 | |
| Grommet | 5 | |
| Breather As | 1 | |
| Full Nut | 16 | |
| Hard Washer | 30 | |
| Elbow | 1 | |
| Spacer | 5 | |
| Bar | 2 | |
| Sensor Mounting Block | 1 | |
| Elbow | 1 | |
| Hex Socket Screw | 4 | |
| Mounting Stud | 1 | |
| Clip | 10 | |
| Spacer | 2 | |
| Toggle Switch Gp | 1 | |
| Connector | 1 | |
| Bolt | 1 | |
| Stud | 1 | |
| Spacer | 4 | |
| Bracket | 2 | |
| Bracket | 1 | |
| Clip | 1 | |
| Cable Tie Mounting | 5 | |
| Mounting Saddle | 3 | |
| O-Ring Seal | 2 | |
| O-Ring Seal | 1 | |
| O-Ring Seal | 1 | |
| Elbow | 1 | |
| O-Ring Seal | 1 | |
| O-Ring Seal | 10 | |
| O-Ring Seal | 1 | |
| Temperature Sensor Gp | 1 | |
| O-Ring Seal | 4 | |
| Stud | 3 | |
| Temperature Sensor | 3 | |
| Bracket As | 1 | |
| Adapter | 2 | |
| Clip | 1 | |
| Grommet | 4 | |
| Hose As | 1 | |
| Speed Sensor Gp | 1 | |
| Pressure Sensor Gp | 5 | |
| Pressure Sensor Gp | 1 | |
| Pressure Sensor Gp | 2 | |
| Pressure Sensor Gp | 1 | |
| Plate | 2 | |
| Adapter | 1 | |
| Elbow | 1 | |
| Connector | 1 | |
| Bracket | 2 | |
| Bracket | 2 | |
| Clip | 1 | |
| Clip | 2 | |
| Connector | 3 | |
| Adapter | 1 | |
| Elbow Adapter | 1 | |
| Grommet | 1 | |
| Grommet | 3 | |
| Stud | 1 | |
| Bracket As | 1 | |
| Adapter | 2 | |
| Exhaust Temperature Sensor Gp | 2 | |
| Pressure Sensor Gp | 1 | |
| Stud | 2 | |
| Liquid Level Sensor Gp | 1 | |
| Sensor Guard As | 1 | |
| Stud | 1 | |
| Bracket As | 1 | |
| Bracket | 12 | |
| Speed Sensor Gp | 2 | |
| Bracket | 1 | |
| Engine Harness As | 1 | |
| Bracket | 1 | |
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| 554-9988 Fuel Filter Mounting Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 3 | |
| Hard Washer | 8 | |
| Bolt | 1 | |
| Nut | 2 | |
| Bolt | 5 | |
| Bolt | 7 | |
| Hard Washer | 3 | |
| Spacer | 7 | |
| Bracket | 1 | |
| Bracket As | 1 | |
| Block | 1 | |
| Plate As | 1 | |
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| 558-9984 Camshaft Cover Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 4 | |
| Hard Washer | 4 | |
| Seal | 1 | |
| Camshaft Cover | 1 | |
Truck Parts
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| 455-2340 Fuel Lines Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 2 | |
| Bolt | 1 | |
| Hard Washer | 6 | |
| Swivel Tee | 1 | |
| Swivel Tee | 2 | |
| Clip | 2 | |
| Clip | 2 | |
| Nut | 1 | |
| Swivel Tee | 1 | |
| Hard Washer | 4 | |
| Bolt | 4 | |
| Grommet | 2 | |
| Elbow | 1 | |
| Elbow | 1 | |
| Hex Nut | 8 | |
| Bracket | 1 | |
| Washer | 16 | |
| O-Ring Seal | 1 | |
| Elbow | 1 | |
| Connector As | 2 | |
| Bolt | 8 | |
| Heat Shield | 1 | |
| Plate As | 1 | |
| Hose As | 1 | |
| Hose As | 1 | |
| Hose As | 1 | |
| Hose As | 1 | |
| 2 | ||
| Tee Adapter | 1 | |
| Plate As | 1 | |
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| 455-2341 Water Lines Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 1 | |
| Plate | 1 | |
| Half Clamp | 2 | |
| Clip | 10 | |
| Full Nut | 8 | |
| Bolt | 1 | |
| Bolt | 4 | |
| Boss | 1 | |
| O-Ring Seal | 1 | |
| Bolt | 4 | |
| Clip | 1 | |
| Clip | 1 | |
| Grommet | 1 | |
| Hard Washer | 20 | |
| Gasket | 3 | |
| Bolt | 1 | |
| Bolt | 1 | |
| Plate | 1 | |
| Clip | 1 | |
| Clip | 1 | |
| Nut | 2 | |
| Bolt | 2 | |
| Bolt | 12 | |
| Gasket | 1 | |
| Gasket | 1 | |
| Bolts | 4 | |
| Hard Washer | 8 | |
| Bolt | 8 | |
| Hard Washer | 2 | |
| Hard Washer | 10 | |
| Hose Clamp | 16 | |
| Hose Clamp | 8 | |
| Bolt | 4 | |
| Boss | 1 | |
| Connector As | 1 | |
| Boss | 1 | |
| Plate | 1 | |
| Half Clip | 2 | |
| Hose | 4 | |
| Hose | 1 | |
| Connector As | 2 | |
| Vaporizer | 1 | |
| Tube As | 1 | |
| Hose As | 1 | |
| Hose As | 1 | |
| Spacer | 1 | |
| Plate As | 1 | |
| Plate As | 1 | |
| Housing and Regulator Gp | 1 | |
| Bracket As | 1 | |
| Bracket As | 1 | |
| Bracket As | 1 | |
| Tube As | 1 | |
| Tube As | 1 | |
| Tube As | 1 | |
| Tube | 1 | |
| Tube As | 1 | |
| Bracket As | 1 | |
| Plate As | 1 | |
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| 455-2342 Fuel Lines Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Primary Fuel Filter Gp | 1 | |
| Bolt | 1 | |
| Clip | 1 | |
| Bolt | 1 | |
| Clip | 1 | |
| Check Valve As | 1 | |
| Bolt | 3 | |
| Hard Washer | 5 | |
| Elbow | 2 | |
| Elbow | 1 | |
| Hose As | 1 | |
| Manual Valve As | 1 | |
| Elbow As | 1 | |
| Plate As | 1 | |
| Hose As | 1 | |
| Hose As | 1 | |
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| 455-2343 Fuel Tank Vent Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 1 | |
| Clip | 1 | |
| Clip | 1 | |
| Bolt | 1 | |
| Adapter | 1 | |
| Boss | 3 | |
| Boss | 1 | |
| Bolt | 8 | |
| Clip | 2 | |
| Clip | 2 | |
| Face Seal Nut | 1 | |
| Nut | 1 | |
| Boss | 2 | |
| Boss | 1 | |
| Clip | 11 | |
| Washer | 1 | |
| Union | 1 | |
| Fitting As | 1 | |
| Hard Washer | 3 | |
| Bolt | 2 | |
| Bolt | 2 | |
| Bolt | 1 | |
| Hard Washer | 2 | |
| Hard Washer | 11 | |
| Grommet | 2 | |
| Boss | 2 | |
| Flared Union | 1 | |
| Plug Bushing | 1 | |
| Pipe Nipple | 1 | |
| Connector | 1 | |
| Flared Elbow | 1 | |
| Connector | 1 | |
| Elbow | 2 | |
| Bracket As | 2 | |
| Adapter | 1 | |
| Cable Strap | 3 | |
| O-Ring Seal | 4 | |
| O-Ring Seal | 2 | |
| O-Ring Seal | 1 | |
| O-Ring Seal | 1 | |
| Elbow | 1 | |
| Manifold | 1 | |
| Cable Tie | 7 | |
| Reducer As | 1 | |
| Reflective Sleeve | |
|
| Nut | 1 | |
| Tee As | 1 | |
| Ball Valve | 1 | |
| Hose As | 2 | |
| Hose As | 1 | |
| Tube As | 1 | |
| Connector As | 1 | |
| Adapter | 1 | |
| Adapter | 1 | |
| Relief Valve | 1 | |
| Tube As | 1 | |
| Hose As | 1 | |
| Hose As | 1 | |
| Adapter | 1 | |
| Tag | 1 | |
| Tag | 1 | |
| Tag | 1 | |
| Tube As | 1 | |
| Valve As | 1 | |
| Tube As | 1 | |
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| 457-5994 Chassis Wiring Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 14 | |
| Taperlock Stud | 1 | |
| Hard Washer | 3 | |
| Screw | 2 | |
| Grommet | 1 | |
| Bolt | 1 | |
| Nut | 9 | |
| Link | 5 | |
| Grommet | 1 | |
| Bolt | 2 | |
| Boss | 6 | |
| Hard Washer | 6 | |
| Bolt | 3 | |
| Bolt | 2 | |
| Bolt | 1 | |
| Hard Washer | 24 | |
| Spacer | 2 | |
| Lockwasher | 2 | |
| Bolt | 1 | |
| Boss | 1 | |
| Boss | 1 | |
| O-Ring Seal | 1 | |
| Plate As | 2 | |
| Clip | 11 | |
| Spacer | 1 | |
| Horn | 1 | |
| Hard Washer | 1 | |
| Mount | 2 | |
| Cable Strap | 98 | |
| Cable Tie Mounting | 27 | |
| O-Ring Seal | 1 | |
| Temperature Sensor Gp | 1 | |
| Plate As | 1 | |
| Taperlock Stud | 8 | |
| Pressure Sensor Gp | 1 | |
| Grommet | 1 | |
| Indicator Lamp Gp | 1 | |
| Indicator Lamp Gp | 1 | |
| Pressure Sensor Gp | 1 | |
| Plate As | 1 | |
| Control Harness As | 1 | |
| Control Harness As | 1 | |
| Chassis Harness As | 1 | |
| Plate | 1 | |
| Control Harness As | 1 | |
| Sensor Harness As | 1 | |
| Sensor Harness As | 1 | |
| Sensor Harness As | 1 | |
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| 457-6005 Film Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Film | 3 | |
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| 457-6006 Cab Ar | ||
|---|---|---|
| Part Number | Description | Qty |
| Bracket | 1 | |
| Bracket As | 1 | |
| Wiring Harness | 1 | |
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| 458-0433 Fuel Tank Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Fuel Tank | 1 | |
| Receptacle | 1 | |
| Pressure Gauge | 1 | |
| Flow Control Valve | 1 | |
| Check and Relief Valve Gp | 1 | |
| Receptacle | 1 | |
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| 461-7190 Bottom Guard Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Nut | 4 | |
| Washer | 14 | |
| Plate | 2 | |
| Hard Washer | 74 | |
| Bolt | 16 | |
| Bolt | 6 | |
| Bolt | 58 | |
| Plated Washer | 4 | |
| Screw | 4 | |
| Washer | 2 | |
| Plate | 8 | |
| Connector | 2 | |
| Plate | 2 | |
| Plate | 8 | |
| Hard Washer | 4 | |
| Nut | 6 | |
| Plate | 8 | |
| Chain | 1 | |
| Support As | 4 | |
| Mud Deflector | 1 | |
| Mud Deflector | 1 | |
| Mud Deflector | 1 | |
| Plate As | 1 | |
| Mud Deflector | 1 | |
| Magnet | 4 | |
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| 482-3914 Fuel Tank Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Vent As | 1 | |
| Hose As | 1 | |
| Fuel Tank Mounting Gp | 1 | |
| Fuel Tank As | 1 | |
| Tube As | 1 | |
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| 492-3644 Water Lines Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 1 | |
| O-Ring Seal | 2 | |
| O-Ring Seal | 1 | |
| Grommet | 1 | |
| Connector | 1 | |
| Spacer | 1 | |
| Clip | 1 | |
| Clip | 1 | |
| Hard Washer | 1 | |
| Full Nut | 1 | |
| Hard Washer | 1 | |
| Bolt | 2 | |
| Water Tube As | 1 | |
| Bracket | 1 | |
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| 500-3897 Air Lines Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 48 | |
| Hard Washer | 48 | |
| Manifold Gasket | 12 | |
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| 507-6501 Fuel Lines Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 16 | |
| Bolt | 86 | |
| Bolt | 2 | |
| Bolt | 12 | |
| Bolt | 3 | |
| Bolt | 24 | |
| Bolt | 4 | |
| Bolt | 48 | |
| Spacer | 2 | |
| O-Ring Seal | 12 | |
| Hard Washer | 56 | |
| O-Ring Seal | 12 | |
| O-Ring Seal | 2 | |
| Clip | 12 | |
| Clip | 12 | |
| Hard Washer | 24 | |
| Full Nut | 12 | |
| Hard Washer | 79 | |
| O-Ring Seal | 6 | |
| O-Ring Seal | 12 | |
| Hard Washer | 48 | |
| Connector As | 12 | |
| Grommet | 12 | |
| Cover | 2 | |
| Gas Control Valve | 12 | |
| Bracket As | 8 | |
| Bracket As | 4 | |
| Bracket | 12 | |
| Manifold | 4 | |
| Manifold | 2 | |
| Manifold | 2 | |
| Hose and Tube As | 12 | |
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| 509-7934 Valve Mechanism Gp | ||
|---|---|---|
| Part Number | Description | Qty |
| Bolt | 2 | |
| Hard Washer | 2 | |
Engine and Parts Removal
- Using a suitable lifting device, remove the engine and torque converter from the truck. The engine and torque converter weigh approximately
7031 kg (15500 lb) .Show/hide table
Illustration 1 g03784204 (A) 451-4587 Bracket As - Install tool (A) onto the torque converter.
- Using a suitable lifting device and tool (A), remove the torque converter. The torque converter weighs approximately
839 kg (1850 lb) . - Remove and discard the 177-9060 Engine Wiring Gp and sensors.
- Remove and set aside the 220-6131 Fuel Filter Gp for partial reuse.
- Remove and set aside the 475-8918 Fuel Priming Pump Gp for partial reuse.
- Remove and discard the 384-9204 Fumes Disposal Gp.
- Remove and set aside the turbochargers for reuse. Each turbocharger weighs approximately
50 kg (110 lb) . - Remove and set aside the 394-8116 Breather Gp for reuse.
- Remove and set aside the 109-8081 Turbocharger Oil Lines Gp for partial reuse.
- Remove and discard the 465-5886 Engine Oil Filler Gp.
- Remove and set aside the 220-6135 Fuel Injection Lines Gp for partial reuse.
- Remove and discard the 107-9513 Engine Electronic Control and Mounting Gp (A2 ECM).
- Remove and set aside the 394-8036 Valve Mechanism Cover Gp and the 394-8039 Valve Mechanism Cover Gp for reuse.
- Remove the 370-9889 Valve Mechanism Gp.
- Remove and set aside 180-7424 Shield Gp for reuse.
- Remove and set aside the 7E-9220 Water Lines Gp for reuse. Leave the thermostat housing attached.
- Remove and set aside the 376-0510 Fuel Injection Pump Gp (Fuel Injectors) for reuse.
- Remove and set aside the 133-5950 Manifold Shield Gp for reuse.
- Disconnect the elbow flanges from the air inlet manifold and pry the elbow flanges away from the air inlet manifold.
- Using a suitable lifting device, remove the left bank of cylinder heads and exhaust manifold. The left bank of cylinder heads and exhaust manifold weighs approximately
290 kg (640 lb) . - Using a suitable lifting device, remove the right bank of cylinder heads and exhaust manifold. The right bank of cylinder heads and exhaust manifold weighs approximately
290 kg (640 lb) . - Using a suitable lifting device, remove and set aside the exhaust manifold for reuse. The exhaust manifold weighs approximately
67 kg (148 lb) per side. - Remove and set aside the 445-8603 Block Spacer Gp for reuse.
- Using a suitable lifting device, remove and set aside the aftercooler assembly for reuse. The aftercooler assembly weighs approximately
143 kg (315 lb) . - Using a suitable lifting device, remove and set aside the oil pan and associated hardware for reuse. The oil pan weighs approximately
295 kg (650 lb) . - Using a suitable lifting device, remove and discard the flywheel. The flywheel weighs approximately
109 kg (239 lb) . - Remove and set aside the cam gears and associated hardware for reuse.
- Remove and set aside the 9Y-1595 Accessory Drive Gp for reuse.
- Using a suitable lifting device, remove the flywheel housing. The flywheel housing weighs approximately
229 kg (505 lb) . - Remove the 2W-6057 Elbow from the 177-9073 Water Lines Gp.
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Illustration 2 g06230235 (1) 8N-9993 Camshaft Cover
(2)8N-9992 Camshaft Cover - Remove the camshaft covers from cylinders 9 and 11.
- Reinstall camshaft cover (1) onto cylinder 11 with the original hardware.
- Reinstall camshaft cover (2) onto cylinder 9 with the original hardware.
Installing the
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| Illustration 3 | g06101403 |
|
(1) (2) (3) (4) (5) (6) (7) | |
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| Illustration 4 | g06101377 |
|
(1) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) | |
- Install the original 7N-2865 Drive Gear and shaft assembly into flywheel housing (1). Use the original 4 bolts (8) and 4 washers (9).
- Install 1 O-ring (4) onto the original 7N-3005 Idler Shaft. Lubricate the O-ring with engine oil.
- Install the original 7N-2909 Cluster Gear Assembly, 7N-3006 Thrust Washer, and 7N-3005 Idler Shaft into flywheel housing (1). Use the original 2 washers (10) and 2 nuts (11). Refer to Disassembly and Assembly, SENR1126 for additional information.
- Install the original plug (2) and copper gasket (3) into the top right-hand hole of flywheel housing (1). Refer to Illustration 3 for the correct location.
- Attach the original 4B-3140 Cover to flywheel housing (1) with 1 gasket (5) and the original 2 bolts (6) and 2 washers (7).
- Attach the original 2P-2772 Cover to flywheel housing (1) with 1 integral seal (15) and the original spacer (16), 1 bolt (6), 2 washers (7), and 1 bolt (17). Refer to Illustration 4 for the correct location of the bolts.
- Attach 2 original 1W-5454 Covers to flywheel housing (1) with 1 gasket (12) and the original 3 bolts (6), and 3 washers (7) per cover.
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Illustration 5 g06250415 (9) 5P-8245 Hard Washer
(18)3F-5792 O-Ring Seal
(19)1F-7958 Full Nut - Install the original 288-8960 Adapter As onto flywheel housing (1) with 1 O-ring (18) and the original 4 washers (9) and 4 nuts (19).
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Illustration 6 g06114511 - Install the original 5T-1009 Yoke onto the original 315-3096 Shaft As with the original hardware.
Installing the
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| Illustration 7 | g06100093 |
|
(1) (2) (3) (4) (5) (6) (7) (8) | |
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| Illustration 8 | g06100097 |
|
(1) (3) (4) (9) | |
- Using a suitable lifting device, attach flywheel housing (1) to the engine with the original 8 bolts (2), 14 washers (3), 8 bolts (4), 11 bolts (5), 12 washers (6), 2 bolts (7), 2 washers (8), and 1 bolt (9). The flywheel housing weighs approximately
229 kg (505 lb) . Refer to Illustrations 7 and 8 for the correct locations of the bolts.Show/hide table
Illustration 9 g06100104 (1) 351-1776 Flywheel Housing
(11)8T-6763 Pipe Plug
(12)436-1479 Crankshaft SealNote: Use Loctite 567® on all pipe threads.
- Install 2 pipe plugs (11) into flywheel housing (1).
- Install crankshaft seal (12) into flywheel housing (1).
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Illustration 10 g06100109 (1) 351-1776 Flywheel Housing
(11)8T-6763 Pipe Plug
(13)8T-6765 Pipe Plug - Install 3 pipe plugs (11) into flywheel housing (1).
- Install 1 pipe plug (13) into flywheel housing (1).
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Illustration 11 g06101776 The callout 14 is from the 298-0478 Flywheel Housing Cover Gp.
(1)351-1776 Flywheel Housing
(14)2J-6274 O-Ring Seal - Install 1 O-ring (14) into flywheel housing (1).
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Illustration 12 g06101762 The callouts 15 through 17 are from the 298-0478 Flywheel Housing Cover Gp.
(1)351-1776 Flywheel Housing
(15)1W-4954 Cover Gasket
(16)0S-1594 Bolt
(17)5M-2894 Hard Washer - Install the original 7N-3170 Cover onto flywheel housing (1) with 1 gasket (15) and the original 20 bolts (16) and 20 washers (17).
Installing the
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| Illustration 13 | g06101804 |
|
(1) (2) (3) (4) | |
- If the flywheel has the dowel installed and the crankshaft is not drilled for the dowel, remove the dowel before installation.
Note:
Using a suitable lifting device, attach flywheel (2) to the crankshaft with 12 bolts (3) and 12 washers (4). The flywheel weighs approximately
108 kg (238 lb) . - Pin both camshafts and the flywheel. Refer to Disassembly and Assembly, SENR1126 for additional information.
- Attach ring (1) and the original camshaft drive gear to the left-hand camshaft with the original hardware.
- Attach the original camshaft drive gear to the right-hand camshaft with the original hardware.
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Illustration 14 g06101814 The following parts are from the 298-0478 Flywheel Housing Cover Gp.
(5)7N-4320 Gasket
(6)0S-1591 Bolt
(7)5M-2894 Hard Washer
(8)0S-1594 Bolt - Attach the 1 original 7N-4319 Cover to the left-hand side of the flywheel housing with 1 gasket (5) and the original 2 bolts (6), and 10 washers (7), and 8 bolts (8).
- Attach the 1 original 7N-4319 Cover to the right-hand side of the flywheel housing with 1 gasket (5) and the original 2 bolts (6), and 10 washers (7), and 8 bolts (48).
Installing the
- Install 1 plate gasket (1) per cylinder onto the cylinder block.
- Install 1 O-ring (2) onto each of the 197-7008 Dowels.
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Illustration 16 g06114589 (3) 362-9677 Spacer Plates - Install 1 original spacer plates (3) per cylinder onto the cylinder block.
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Illustration 17 g06114601 (2) 5P-0840 O-Ring Seal
(4)420-0652 Water Seal Assembly
(5)420-0653 Water Seal Assembly - Install 4 water seals (4) per cylinder onto the cylinder block.
- Install 4 water seals (5) per cylinder onto the cylinder block.
- Install 1 O-ring (2) onto each of the 197-7008 Dowels.
Note: Make sure that an O-ring is installed on both sides of the 362-9677 Spacer Plates.
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Illustration 18 g06114594 (6) 362-8264 Cylinder Head Gasket - Install 1 cylinder head gasket (6) per cylinder onto the cylinder block.
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| Illustration 15 | g06114571 |
|
(1) (2) | |
Installing the Oil Pan Group and the Engine Oil Filter Group
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| Illustration 19 | g06231636 |
- Using a suitable lifting device, install the oil pan onto the engine use 1 7E-2630 Oil Pan Gasket and the original hardware. The oil pan weighs approximately
295 kg (650 lb) .Show/hide table
Illustration 20 g06231640 - Attach the engine oil filter group to the engine with the original hardware. The engine oil filter group weighs approximately
50 kg (110 lb) .Show/hide table
Illustration 21 g06238759 Show/hide table
Illustration 22 g06238762 - Install the 304-8067 Oil Tube and the 105-4299 Tube As with the original hardware.
Installing the
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| Illustration 23 | g06180429 |
|
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) | |
- Install elbows (3) and (7) onto the cylinder heads use 1 gasket (10), 4 bolts (8), and 4 washers (5) per elbow.
Note: Elbow (3) is installed on cylinders 1 and 12.
- Install 1 O-ring (6) per elbow onto elbows (3) and (7).
Note: Lubricate the bore of flange (2) lightly with glycerin.
- Install original flange (2) onto elbows (3) and (7). Make sure to push the flanges back against the stops.
Note: Lubricate the O-ring groove of flange (2) lightly with glycerin to hold O-ring in place.
- Install 1 O-ring (1) into each flange (2).
- Install 1 plug (11) and 1 O-ring (12) into elbows (3) and (7).
- Install 1 plug (9) into each cylinder head (13).
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Illustration 24 g06230197 The following parts are from the 495-7573 Fuel Lines Gp (Gas).
(7)461-5752 Air Inlet Elbow
(14)6V-8638 Connector
(15)238-5081 O-Ring Seal
(16)228-7090 O-Ring Seal - Install 1 connector (14) and 1 O-ring (15) into each elbow (7). The connectors go on cylinders 2 through 11.
- Install 1 O-ring (16) into each connector (14).
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Illustration 25 g06231649 The following parts are from the 495-7573 Fuel Lines Gp (Gas).
(3)461-5753 Air Inlet Elbow
(15)238-5081 O-Ring Seal
(16)228-7091 O-Ring Seal
(17)6V-9003 Elbow - Install 1 elbow and 1 O-ring into each elbow (3). The elbows go on cylinders 1 and 12.
- Install 1 O-ring (16) into each elbow (17).
Installing the
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| Illustration 26 | g06147949 |
|
(1) | |
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| Illustration 27 | g06148758 |
|
(1) | |
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| Illustration 28 | g06155342 |
|
(A) Area around the sensor
(B) Port threads (C) Port surface (D) Sensor seat | |
- Inspect area around the sensor port (A) to ensure that the area is free of debris that could fall into the combustion chamber.
- If using previously removed cylinder heads, remove the 9U-7067 Tapered Cap/Plug from the sensor port.
- Inspect port threads (B) to ensure that the threads are free of any debris. If cylinder heads were delivered with Tarp or Tarp-B applied, clean per the Engine News, SEBD9204, Uses, Characteristics, And Removal of Castrol Tarp®, Tarp-B®, And 4164® prior to installing on the engine. If the heads were delivered with a different rest preventer applied, clean appropriately prior to installing on the engine.
Note: If the engine and DGB retrofit kit is going to be painted, ensure that all sensors, actuators, and wiring harnesses are installed and connected or ensure that any open holes or exposed connectors are fully masked. Paint in port threads will affect the sensor's tightening torque. Paint inside connectors may prevent a good electrical connection.
- Clean port threads (B) and port surfaces (C) with the 264-4355 Nylon Brush to ensure that cleaning agent removes tarp in the cylinder pressure sensor threads. Do not use metal brushes. Any tarp left in the threads will affect the cylinder pressure sensor's tightening torque.
- Clean sensor seat (D) with the 266-2281 Nylon Brush to ensure that cleaning agent removes tarp from the cylinder pressure sensor seat. Do not use metal brushes. Any tarp left on the seat may cause premature sensor failure because of combustion gas leakage.
- Inspect sensor seat (D) to ensure that the seat is free of debris. It is important for the sensor seat to be clean so the sensor seals to the cylinder head. A poor seal at this location may cause premature sensor failure because of combustion gas leakage.
- Use shop air to blow out the port in the cylinder head.
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Illustration 29 g06155337 (A) Area around the sensor
(1)443-5682 Pressure Sensor Gp (In Cylinder Pressure Sensor)
(2)478-3965 Sensor Harness As - Clean the threads of pressure sensor (1) with nylon brush. Do not use steel or brass brushes.
- Inspect pressure sensor (1). Ensure all surfaces and the connector are free of debris, liquid, or damage.
- Lightly apply anti-seize to pressure sensor threads. Use Loctite C5-A / Loctite 8008 or equivalent copper-based anti-seize.
- Hand-tighten sensor into port until seated. Use caution to avoid cross-threading. Do not use an impact wrench. Use caution to keep the pressure sensor tip from contacting any hard surfaces during installation.
- If sensor resists hand-tightening, chase port threads (B) in the cylinder head with a 4C-5894 Tap (M10 x 1). Contain metal debris using a small magnet and/or vacuum. Repeat steps 4 through 12.
- Tighten sensor to
11.5 ± 1 N·m (102 ± 9 lb in) using a torque wrench, a 12mm 6-Point Deep Socket, and solid extensions (if necessary). Do not use an impact wrench. Do not use flexible/universal wrenches or extensions because they reduce the torque applied to the sensor. Applying too much torque to the sensor may cause premature sensor failure.Note: There will be a gap between the sensor and the cylinder head because the sensor seats at the bottom of the port.
Installing the
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| Illustration 30 | g06230995 |
- Using a suitable lifting device, install the exhaust manifold onto the right bank cylinder heads with 6 320-8974 Exhaust Manifold Gasket and the original hardware. The exhaust manifold weighs approximately
67 kg (148 lb) per side. - Using a suitable lifting device, install the exhaust manifold onto the left bank cylinder heads with 6 320-8974 Exhaust Manifold Gasket and the original hardware. The exhaust manifold weighs approximately
67 kg (148 lb) per side.Show/hide table
Illustration 31 g06231003 - Using a suitable lifting device, install the right bank of cylinder heads and exhaust manifold onto the cylinder block. The right bank of cylinder heads and exhaust manifold weighs approximately
290 kg (640 lb) . - Using a suitable lifting device, install the left bank of cylinder heads and exhaust manifold onto the cylinder block. The left bank of cylinder heads and exhaust manifold weighs approximately
290 kg (640 lb) .Show/hide table
Illustration 32 g06231085 - Using a suitable lifting device, install the aftercooler assembly onto the cylinder block. The aftercooler assembly weighs approximately
143 kg (315 lb) . - Attach the 461-5752 Air Inlet Elbow and the 461-5753 Air Inlet Elbow to the original 283-9599 Manifold (Snake Coffin).
Note: Make sure that the O-rings are in place.
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Illustration 33 g06231089 - Install the original 133-5950 Manifold Shields onto the exhaust manifolds.
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Illustration 34 g06231106 - Install 1 fuel injector into each cylinder head.
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Illustration 35 g06231108 - Install 2 original valve bridges onto each cylinder head.
- Install 3 original pushrods into each cylinder head.
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Illustration 36 g06231221 - Install 1 original valve mechanism onto each cylinder head.
- Adjust the fuel injectors and valves, refer to the Testing and Adjusting, 3512C Engines for 785C Off-Highway Trucks with Dynamic Gas Blending for additional information.
- Attach the original wiring harnesses to the fuel injectors.
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Illustration 37 g06239513 Right-hand side of the engine
(1)486-3150 Bracket
(2)465-7601 BracketShow/hide table
Illustration 38 g06231223 Left-hand side of the engine
(1)486-3150 Bracket
(2)465-7601 Bracket - Attach brackets (1) and (2) and the valve covers to the valve cover bases with the original hardware. Refer to Illustration 37 and 38 for the correct location of the brackets and valve covers.
Note: Cylinders 2 and 11 do not have brackets installed on the valve covers.
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Illustration 39 g06231232 - Attach the original 7E-9220 Water Lines Gp to the thermostat housing and cylinder heads with the original hardware.
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Illustration 40 g06231520 - Attach the right 187-4586 Plate As to the thermostat housing and water manifold with the original hardware.
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Illustration 41 g06231522 - Attach the left 187-4586 Plate As to the thermostat housing and water manifold with the original hardware.
- Install 2 7W-2122 Port Connectors and 2 214-7568 O-Ring Seals into each cylinder head.
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Illustration 42 g06231552 - Attach the right fuel line to the water manifold with the original hardware.
- Attach the fuel tube assemblies to the fittings in the cylinder heads.
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Illustration 43 g06231556 - Attach the left fuel line to the water manifold with the original hardware.
- Attach the fuel tube assemblies to the fittings in the cylinder heads.
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Illustration 44 g06238845 - Attach each turbochargers. Each turbocharger weighs approximately
50 kg (110 lb) .Show/hide table
Illustration 45 g06238827 - Attach each elbow assembly to the 155-0437 Cover and turbocharger with the original hardware.
Installing the
Note: If you prefer to install the oil filler group at the Component Repair Center (CRC), the parts must be pulled from the chassis kit and routed to the appropriate location.
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| Illustration 46 | g06355896 |
|
(1) (2) (3) (4) | |
- Attach elbow (1) and 1 gasket (2) to with 3 bolts (3) and 3 washers (4) to the camshaft cover on cylinder 8.
Installing the
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| Illustration 47 | g06373109 |
|
(1) (2) (3) (4) | |
- Remove the original camshaft cover from cylinder 4.
- Install seal (2) into camshaft cover (1).
- Attach camshaft cover (1) to cylinder 4 with 4 bolts (3) and 4 washers (4).
Note: The top middle and rear holes of the camshaft cover will be used during the installation of the 495-7573 Fuel Lines Gp (Gas Lines).
Installing the
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| Illustration 48 | g06239370 |
|
(1) (2) (3) (4) (5) (6) (7) (8) (9) | |
- Install one O-ring (7) and one O-ring (8) into each manifold (9).
- Attach 1 gas control valve (1) to each manifold (9) with 4 bolts (2) and 4 washers (3) per gas control valve.
- Install 1 O-ring (5) into each connector (4).
- Install 1 O-ring (6) onto each connector (4).
- Install 1 connector (4) into each manifold (9).
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Illustration 49 g06239376 (1) 463-0220 Gas Control Valve
(2)1D-4541 Bolt
(3)214-1048 Spacer
(4)6V-8638 Connector
(5)228-7090 O-Ring Seal
(6)238-5081 O-Ring Seal
(7)3E-6788 O-Ring Seal
(8)144-7338 O-Ring Seal
(10)495-6438 Manifold - Install 2 O-rings (7) and 2 O-rings (8) into each manifold (10).
- Attach 2 gas control valves (1) onto each manifold (10) with 4 bolts (2) and 4 washers (3) per gas control valve.
- Install 1 O-ring (5) into each connector (4).
- Install 1 O-ring (6) onto each connector (4).
- Install 2 connectors (4) into each manifold (10).
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Illustration 50 g06239379 (1) 463-0220 Gas Control Valve
(2)1D-4541 Bolt
(3)214-1048 Spacer
(6)238-5081 O-Ring Seal
(7)3E-6788 O-Ring Seal
(8)144-7338 O-Ring Seal
(11)6V-8642 Connector
(12)228-7091 O-Ring Seal
(13)495-6440 Manifold - Install 1 O-ring (7) and 1 O-ring (8) into each manifold (13).
- Attach 1 gas control valve (1) onto each manifold (13) with 4 bolts (2) and 4 washers (3) per gas control valve.
- Install 1 O-ring (12) into each connector (11).
- Install 1 O-ring (6) onto each connector (11).
- Install 1 connector (11) into each manifold (13).
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Illustration 51 g06239389 (9) 495-6439 Manifold
(10)495-6438 Manifold
(13)495-6440 Manifold
(14)061-9457 O-Ring Seal
(15)0S-1588 Bolt
(16)5M-2894 Hard Washer - Attach one manifold (10) to manifold (9) with 1 O-ring (14), 5 bolts (15), and 5 washers (16).
- Attach one manifold (10) to manifold (10) with 1 O-ring (14), 5 bolts (15), and 5 washers (16).
- Attach one manifold (13) to manifold (10) with 1 O-ring (14), 5 bolts (15), and 5 washers (16).
- Repeat Steps 16 through 17 for the remaining manifolds.
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Illustration 52 g06239452 (13) 495-6440 Manifold
(17)165-3931 Bolt
(18)9X-6458 Hard Washer
(19)431-8900 Bracket As
(20)462-9101 Cover
(21)6J-2244 O-Ring Seal - Attach bracket (19), cover (20), and 1 O-ring (21) to manifold (13) with 2 bolts (17) and 2 washers (18).
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Illustration 53 g06239461 (15) 0S-1588 Bolt
(16)5M-2894 Hard Washer - Attach the manifold assembly to the right-hand side cylinder heads with 12 bolts (15) and 12 washers (16).
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Illustration 54 g06239473 (9) 495-6439 Manifold
(16)5M-2894 Hard Washer
(20)462-9101 Cover
(21)6J-2244 O-Ring Seal
(22)165-3929 Bolt - Attach cover (20) and 1 O-ring (21) to manifold (9) with 2 bolts (22) and 2 washers (16).
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Illustration 55 g06239419 (15) 0S-1588 Bolt
(16)5M-2894 Hard Washer - Attach the manifold assembly to the left-hand side cylinder heads with 12 bolts (15) and 12 washers (16).
- Install the turbocharger drain lines.
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Illustration 56 g06239558 (18) 9X-6458 Hard Washer
(23)501-3772 Hose and Tube As
(24)501-3806 Hose As
(25)353-7957 Grommet
(26)8T-1887 Clip
(27)8T-1888 Clip
(28)0S-1594 Bolt
(29)9S-8752 Full Nut
(30)353-7954 Grommet
(31)8T-1889 Clip
(32)8T-1890 Clip - Attach 1 hose (24) to the 6V-9003 Elbow and the 6V-8642 Connector on cylinder 1.
- Install 1 grommet (30) around hose (24).
- Install 1 clip (31) and 1 clip (32) around grommet (30). Refer to Illustration 56 for the correct orientation of the clips.
- Attach clips (31) and (32) to the 465-7601 Bracket with 1 bolt (28), 2 washers (18), and 1 nut (29).
- Attach 1 hose (23) to the 6V-9003 Elbow and the 6V-8642 Connector on cylinders 1, 3, 5, 7, and 9.
- Install 1 grommet (25) around hose (23).
- Install 1 clip (26) and 1 clip (27) around grommet (25). Refer to Illustration 56 for the correct orientation of the clips.
- Attach clips (26) and (27) to the 486-3150 Bracket with 1 bolt (28), 2 washers (18), and 1 nut (29).
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Illustration 57 g06239551 (18) 9X-6458 Hard Washer
(23)501-3772 Hose and Tube As
(24)501-3806 Hose As
(25)353-7957 Grommet
(26)8T-1887 Clip
(27)8T-1888 Clip
(28)0S-1594 Bolt
(29)9S-8752 Full Nut
(30)353-7954 Grommet
(31)8T-1889 Clip
(32)8T-1890 Clip - Attach 1 hose (24) to the 6V-9003 Elbow and the 6V-8642 Connector on cylinder 12.
- Install 1 grommet (30) around hose (24).
- Install 1 clip (31) and 1 clip (32) around grommet (30). Refer to Illustration 57 for the correct orientation of the clips.
- Attach clips (31) and (32) to the 465-7601 Bracket with 1 bolt (28), 2 washers (18), and 1 nut (29).
- Attach 1 hose (23) to the 6V-9003 Elbow and the 6V-8642 Connector on cylinders 4, 6, 8, 10, and 12.
- Install 1 grommet (25) around hose (23).
- Install 1 clip (26) and 1 clip (27) around grommet (25). Refer to Illustration 57 for the correct orientation of the clips.
- Attach clips (26) and (27) to the 486-3150 Bracket with 1 bolt (28), 2 washers (18), and 1 nut (29).
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Illustration 58 g06239595 (15) 0S-1588 Bolt
(18)9X-6458 Hard Washer
(33)474-5362 Bracket As
(34)474-5361 Bracket As
(35)2V-2209 Spacer
(36)0S-1608 Bolt
(37)1A-5964 Bolt
(38)0L-1143 Bolt - Remove all camshaft cover bolts as needed.
- Attach 1 bracket (34) to cylinders 1, 7, and 9 with 2 bolts (15), 2 bolts (38), and 4 washers (18) per bracket.
- Attach 1 bracket (34) to cylinder 5 with 4 bolts (15), 2 bolts (38), and 6 washers (18) per bracket.
- Attach 1 bracket (33) to cylinder 3 with 1 bolt (36), 1 bolt (37), and 2 washers (18).
- Attach 1 bracket (33) to cylinder 11 with 1 spacer (35), 1 bolt (36), 1 bolt (37), and 2 washers (18).
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Illustration 59 g06239573 (15) 0S-1588 Bolt
(18)9X-6458 Hard Washer
(33)474-5362 Bracket As
(34)474-5361 Bracket As
(35)2V-2209 Spacer
(36)0S-1608 Bolt
(37)1A-5964 Bolt
(38)0L-1143 Bolt - Remove all camshaft cover bolts as needed.
- Attach 1 bracket (34) to cylinders 2 and 12 with 4 bolts (15), 2 bolts (38), and 6 washers (18) per bracket.
- Attach 1 bracket (34) to cylinders 4 and 10 with 2 bolts (15), 2 bolts (38), and 4 washers (18) per bracket.
- Attach 1 bracket (33) to cylinder 6 with 1 bolt (37) and 1 washer (18).
- Attach 1 bracket (33) to cylinder 8 with 1 spacer (35), 1 bolt (36), 1 bolt (37), and 2 washers (18).
Installing the
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| Illustration 60 | g06373534 |
|
(1) (2) (3) (4) (5) | |
- Install 2 O-rings (2) onto oil tube (1).
- Lubricate the O-rings with engine oil.
- Install one end oil tube (1) into the 9Y-5814 Drain Elbow.
- Install 1 elbow (3) onto the other end of oil tube (1).
- Attach elbow (3) and 1 gasket (4) to the camshaft cover of cylinder 3 with 3 bolts (5).
Note: The top front hole uses a bolt from the 495-7573 Fuel Lines Gp (Gas Lines).
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Illustration 61 g06373539 (2) 112-3540 O-Ring Seal
(3)468-5751 Elbow
(4)2W-0752 Gasket
(5)3B-1915 Bolt
(6)468-5749 Tube As - Install 2 O-rings (2) onto oil tube (6).
- Lubricate the O-rings with engine oil.
- Install one end oil tube (6) into the 9Y-5814 Drain Elbow.
- Install 1 elbow (3) onto the other end of oil tube (6).
- Attach elbow (3) and 1 gasket (4) to the camshaft cover of cylinder 6 with 3 bolts (5).
Note: The top rear hole uses a bolt from the 495-7573 Fuel Lines Gp (Gas Lines).
Installing the
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| Illustration 62 | g06252267 |
|
(1) (2) (3) (4) (5) | |
- Attach solenoid valve (4) and 1 O-ring (5) to adapter (1) with 4 bolts (2) and 4 washers (3).
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Illustration 63 g06252298 (6) 517-1689 Plate
(7)5V-8840 Stud - Install 4 studs (7) into plate (6).
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Illustration 64 g06381701 (1) 533-0071 Adapter
(3)5P-0537 Hard Washer
(4)516-8290 Solenoid Valve Gp
(5)7X-4744 O-Ring Seal
(6)517-1689
(7)5V-8840 Stud
(8)9S-8750 Full Nut
(9)9S-4181 Plug
(10)7M-8485 O-Ring Seal - Attach plate (6) to the solenoid valve (4) with 4 washers (3) and 4 nuts (8).
- Install plug (9) and 1 O-ring (10) into adapter (1).
Note: The plug is for keeping the lines clean during assembly and will be removed when connected to the lines from the truck.
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Illustration 65 g06381702 (1) 533-0071 Adapter
(11)502-7088 Bracket
(12)347-3880 Bracket
(13)0T-0573 Bolt
(14)9X-6458 Hard Washer
(15)9S-8752 Full Nut - Attach Adapter (1) and bracket (12) to bracket (11) with 2 bolts (13), 4 washers (14), and 2 nuts (15). Refer to Illustration 65 for the correct orientation of bracket (11).
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Illustration 66 g06381705 (14) 9X-6458 Hard Washer
(15)9S-8752 Full Nut
(16)541-5923 Bracket
(17)541-5924 Bracket
(18)1A-2029 Bolt - Attach bracket (16) loosely to bracket (17) with 2 bolts (18), 4 washers (14), and 2 nuts (15).
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Illustration 67 g06381716 Callouts 19 through 22 are from the 539-1906 Engine Wiring Gp.
(16)541-5923 Bracket
(19)183-4274 Bracket
(20)4M-6425 Bolt
(21)8T-4224 Hard Washer
(22)5S-0003 Nut - Attach bracket (19) to bracket (16) with 1 bolt (20), 2 washers (21), and 1 nut (22). Refer to Illustration 67 for the correct orientation of bracket (19).
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Illustration 68 g06381790 (14) 9X-6458 Hard Washer
(23)536-3677 Bracket As
(24)0S-1594 Bolt
(25)502-7087 Bracket - Attach bracket (23) to bracket (25) with 1 bolt (24) and 1 washer (14).
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Illustration 69 g06381794 (26) 422-2065 Elbow As
(27)238-5080 O-Ring Seal
(28)6V-8625 Elbow
(29)228-7090 O-Ring Seal
(30)7X-3164 Swivel Adapter
(31)109-0897 Ball Valve
(32)9S-8005 Plug - Install elbow (28) and 1 O-ring (27) into elbow (26).
- Install 1 O-ring (29) into elbow (28).
- Install swivel adapter (30) onto elbow (28).
- Install 1 O-ring (27) onto swivel adapter (30).
- Install ball valve (31) onto swivel adapter (30).
- Install plug (32) and 1 O-ring (27) into ball valve (31).
Note: The plug is for keeping the lines clean during assembly and will be removed when connected to the lines from the truck.
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Illustration 70 g06381804 (14) 9X-6458 Hard Washer
(26)422-2065 Elbow As
(33)549-4442 Plate
(34)0L-1351 Bolt - Install elbow (26) to bracket (33) with 3 bolts (34) and 3 washers (14).
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Illustration 71 g06381810 Callouts 12, 35, 36, and 37 are from the 539-1906 Engine Wiring Gp.
(12)347-3880 Bracket
(26)422-2065 Elbow As
(35)5S-7379 Bolt
(36)8T-4896 Hard Washer
(37)132-5789 Clip - Attach bracket (12) to elbow (26) with 1 bolt (35) and 1 washer (36). Refer to Illustration 71 for the correct orientation of bracket.
- Attach clip (37) to elbow (26) with 1 bolt (35) and 1 washer (36). Refer to Illustration 71 for the correct orientation of clip.
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Illustration 72 g06352918 (11) 502-7088 Bracket
(14)9X-6458 Hard Washer
(16)541-5923 Bracket
(17)541-5924 Bracket
(38)0S-1619 Bolt
(39)3B-1915 Bolt
(40)165-3929 Bolt - Attach bracket (11) to the flywheel housing with 3 bolts (38) and 3 washers (14).
- Attach brackets (16) and (17) to the flywheel housing with 2 bolts (39), 2 bolts (40), and 4 washers (14). Refer to Illustration 72 for the correct location of the bolts.
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Illustration 73 g06352924 (14) 9X-6458 Hard Washer
(15)9S-8752 Full Nut
(19)183-4274 Bracket
(25)502-7087 Bracket
(33)517-1687 Bracket
(38)0S-1619 Bolt
(39)3B-1915 Bolt
(40)165-3929 Bolt
(41)091-9035 Spacer
(42)0L-2070 Bolt
(43)0L-1352 Bolt
(44)5M-2894 Hard Washer
(45)493-0919 Bracket
(46)7N-1637 Stud - Attach bracket (25) and bracket (45) loosely to the flywheel housing with 1 bolt (38), 2 bolts (40), 1 bolt (43) 2 washers (14), and 2 washers (44). Refer to Illustration 73 for the correct location of the bolts.
- Attach bracket (33) loosely to the flywheel housing with 4 spacers (41), 3 bolts (42), 1 stud (46), and 4 washers (14). Refer to Illustration 73 for the correct location of the bolts.
- Install bracket (19) onto stud (46) with 1 washer (44) and 1 nut ().
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Illustration 74 g06352925 (47) 517-1684 Fuel Tube
(48)452-8389 Clip - Install clip (48) around tube assembly (47).
Note: This clip is difficult to open and close. Prior to the tube assembly install, off engine, open the clip using a vice and/or vice grips, loosely install the clip on the tube, close the clip using the vice and/or vice grips. The bolt provided for this clip is long enough to help close the clip while tightening.
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Illustration 75 g06352926 (26) 422-2065 Elbow As
(44)5M-2894 Hard Washer
(47)517-1684 Fuel Tube
(49)6J-2244 O-Ring Seal
(50)0S-1588 Bolt - Install 1 O-ring (49) into each end of tube assembly (47).
- Attach tube assembly (47) to the 495-6440 Manifold with 2 bolts (50) and 2 washers (44).
- Attach tube assembly (47) to elbow (26) with 2 bolts (50) and 2 washers (44).
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Illustration 76 g06352928 (26) 422-2065 Elbow As
(44)5M-2894 Hard Washer
(49)6J-2244 O-Ring Seal
(50)0S-1588 Bolt
(51)517-1685 Fuel Tube - Install 1 O-ring (49) into each end of tube assembly (51).
- Attach tube assembly (51) to the 495-6439 Manifold with 2 bolts (50) and 2 washers (44).
- Attach tube assembly (51) to elbow (26) with 2 bolts (50) and 2 washers (44).
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Illustration 77 g06383955 (52) 561-3487 Adapter
(53)7D-1195 O-Ring Seal
(54)425-2519 O-Ring Seal
(55)507-7807 Check Valve - Install 1 O-ring (54) onto check valve (55).
- Install 1 O-ring (53) into the end of check valve (55).
- Install check valve (55) into adapter (52).
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Illustration 78 g06383981 (6) 517-1689 Plate
(25)536-3675 Support
(26)422-2065 Elbow As
(52)516-3487 Tube As
(56)490-7541 Gas Pressure Regulator Gp
(57)389-8389 Seal
(58)561-4340 AdapterShow/hide table
Illustration 79 g06352929 (13) 0T-0573 Bolt
(14)9X-6458 Hard Washer
(15)9S-8752 Full Nut
(42)0L-2070 Bolt
(59)201-7354 Bolt
(60)8T-4122 Hard Washer
(61)7X-0448 Nut
(62)7X-0347 Bolt - Attach gas pressure regulator (56) and 1 O-ring (57) to plate (6) and the 541-5924 Bracket with 2 bolts (59), 2 bolts (62), 8 washers (60), and 4 nuts (61).
- Install 1 O-ring (57) into each end of tube assembly (52).
- Attach one end of tube assembly (52) to gas pressure regulator (56) and the 541-5924 Bracket with 4 bolts (59), 8 washers (60), and 4 nuts (61).
- Install 1 O-ring (57) into adapter (58).
- Attach the other end of tube assembly (52) and adapter (58) to elbow (26) with 2 bolts (13), 1 bolt (42) , 5 washers (14), and 2 nuts (15).
- Tighten all brackets that were left loose during assembly.
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Illustration 80 g06384057 (13) 9X-6458 Hard Washer
(14)9S-8752 Full Nut
(23)536-3677 Bracket As
(37)132-5789 Clip
(48)452-8389 Clip
(56)490-7541 Gas Pressure Regulator Gp
(63)165-3931 Bolt
(64)6V-8715 Connector
(65)2M-9780 O-Ring Seal
(66)6V-8397 O-Ring Seal - Attach clips (37) and (48) to bracket (23) with 1 bolt (63), 2 washers (13), and 1 nut (14).
- Install connector (64) and 1 O-ring (65) into gas pressure regulator (47).
- Install 1 O-ring (66) into connector (64).
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Illustration 81 g06352930 (14) 9X-6458 Hard Washer
(15)9S-8752 Full Nut
(44)5M-2894 Hard Washer
(50)0S-1588 Bolt
(64)6V-8715 Connector
(67)8C-6870 Connector
(68)533-0072 Hose and Tube As
(69)4P-7233 Grommet
(70)8T-1887 Clip
(71)8T-1888 Clip
(72)8C-8988 Elbow
(73)228-7089 O-Ring Seal - Install connector (67) into the 283-9599 Manifold (Snake Coffin).
- Attach the 90 degree end of hose (68) to connector (67).
- Install 1 O-ring (73) into elbow (72).
- Attach elbow (72) to connector (64).
- Attach the straight end of hose (68) to elbow (72).
- Install grommet (69) around hose (68).
- Install 1 clip (70) and 1 clip (71) around grommet (69).
- Attach clips (70) and (71) to the 493-0919 Bracket with 1 bolt (50), 1 washer (14), 1 washer (44), and 1 nut (15).
Note: Install washer (14) against the 493-0919 Bracket.
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Illustration 82 g06384088 (13) 0T-0573 Bolt
(14)9X-6458 Hard Washer
(56)490-7541 Gas Pressure Regulator Gp
(74)129-2327 Elbow
(75)238-5081 O-Ring Seal
(76)463-6640 Bracket
(77)353-4364 Drain Valve Gp - Install elbow (74) and 1 O-ring (75) into gas pressure regulator (56).
- Install drain valve (77) into elbow (74).
- Attach bracket (76) to the left-hand rear cam cover with 1 bolt (13) and 1 washer (14).
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Illustration 83 g06384095 (13) 0T-0573 Bolt
(14)9X-6458 Hard Washer
(15)9S-8752 Full Nut
(76)463-6640 Bracket
(77)353-4364 Drain Valve Gp
(78)5D-1026 Band Clamp
(79)190-9770 Hose
(80)122-0450 Grommet
(81)8T-1897 Clip
(82)8T-1898 Clip - Attach hose (79) to drain valve (77) with 1 band clamp (78).
- Install grommet (80) around hose (79).
- Install 1 clip (81) and 1 clip (82) around grommet (80).
- Attach clips (81) and (82) to bracket (76) with 1 bolt (13), 2 washers (14), and 1 nut (15).
Inspect the Gas Rail for Leaks
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| Illustration 84 | g06371065 |
- Connect a hose from a Nitrogen bottle or compressed shop air (requires a filter and drier) to the ball valve.
- Supply maximum
700 kPag (100 psi) and then open the manual ball valve on the rail. Leave the ball valve open throughout the entire test. - Spray the rear gas rail components at each joint with leak detect solution. If the leak detect solution is not available, soapy water may be used.
- Continue the same process on each bank of the engine gas rail components.
- If an external leak is present at the joint, visible bubbles and spraying of the solution will be observed.
Note: Each gas admission valve has a specification for maximum allowable 1 slpm (2.2 acfh) internal leak rate. That means during this process there potentially will be the sound of gas flowing from the gas rail into the intake air system of the engine. This is normal. If desired, an alternative troubleshooting method could be applied to install a 6V-9830 Cap (ORFS) at each gas admission valve outlet for cylinders 2 through 11, and a 6V-9831 Cap (ORFS) on cylinders 1 and 12. That would prevent any flow of gas into the engine intake air system during troubleshooting.
Installing the
Note: If you prefer to install the oil filler group at the Component Repair Center (CRC), the parts must be pulled from the chassis kit and routed to the appropriate location.
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| Illustration 85 | g06384165 |
|
(1) (2) (3) (4) (5) | |
- Attach support (4) loosely to block (1) with 1 bolt (2) and 1 washer (3).
- Attach support (5) loosely to block (1) with 1 bolt (2) and 1 washer (3).
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Illustration 86 g06384166 (4) 117-0041 Front Support
(5)117-0042 Front Support
(6)9B-7237 Bolt
(7)5P-1075 Hard Washer
(8)112-6032 Spacer - Attach support (5) to the 154-1618 Front Manifold on cylinder 4 with 1 bolt (6) and washer (7).
- Attach support (4) to the 4P-3897 Manifold on cylinder 6 with 1 spacer (8), 1 bolt (6) and washer (7).
Note: Install the spacer in between the support and the manifold.
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Illustration 87 g06384167 (7) 5P-1075 Hard Washer
(9)476-5452 Bracket As
(10)8T-2502 Bolt
(11)6V-8801 Nut - Attach bracket (9) loosely to each 474-5362 Bracket As on cylinders 8 and 10 with 1 bolt (10), 2 washers (7), and 1 nut (11) per bracket.
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Illustration 88 g06384172 (1) 178-6388 Block
(2)5S-7379 Bolt
(3)8T-4896 Hard Washer
(9)476-5452 Bracket As
(12)476-5461 Tube As
(13)237-7623 O-Ring Seal
(14)4H-7993 Clip - Install tube (12) and 1 O-ring (13) into the 472-1181 Elbow.
- Attach tube (12) to block (1) with 1 clip (14), 1 bolt (2), and 1 washer (3).
- Attach tube (12) to bracket (9) with 1 clip (14), 1 bolt (2), and 1 washer (3).
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Illustration 89 g06384174 (3) 8T-4896 Hard Washer
(10)8T-2502 Bolt
(11)6V-8801 Nut
(12)476-5461 Tube As
(15)313-6839 Deflector
(16)133-5946 Engine Oil Filler Cap As - Attach deflector (15) to tube (12) with 1 bolt (10), 2 washers (3), and 1 nut (11).
- Install oil filler cap (16) into tube (12).
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Illustration 90 g06384958 (3) 8T-4896 Hard Washer
(17)4P-0707 Clamp As
(18)4L-6459 Bolt
(19)465-3177 Oil Gauge Tube As
(20)4F-3765 Shaft Gasket
(21)0S-1588 Bolt
(22)5M-2894 Hard Washer - Slide oil gauge tube (19) up trough the hole in the 313-6839 Deflector.
- Attach oil gauge tube (19) to the oil pan with 1 gasket (20), 2 bolts (21), and 2 washers (22).
- Attach oil gauge tube (19) to the 476-5452 Bracket As with 2 clamps (17), 1 bolt (18), and 1 washer (3).
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Illustration 91 g06385001 (3) 8T-4896 Hard Washer
(11)6V-8801 Nut
(17)4P-0707 Clamp As
(19)465-3177 Oil Gauge Tube As
(23)9G-8140 Spacer
(24)8T-8915 Bolt
(25)8T-7008 Bolt - Attach oil gauge tube (19) to the 178-6388 Block with 2 clamps (17), 1 bolt (25), and 1 washer (3).
- Attach oil gauge tube (19) to the 313-6839 Deflector and the 476-5461 Tube As with 2 clamps (17), 1 spacer (23), 1 bolt (2), and 2 washers (3), and 1 nut (11).
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Illustration 92 g06385015 (19) 465-3177 Oil Gauge Tube As
(26)465-3213 Oil Level Gauge As (Dipstick) - Insert oil level gauge (26) into oil gauge tube (19).
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Illustration 93 g06384175 The oil level gauge and oil level tube was removed to show parts.
(15)313-6839 Deflector
(27)100-5372 Hasp
(28)5P-8501 Padlock
(29)039-6937 Special Bolt
(30)8T-4121 Hard Washer
(31)5P-4115 Hard Washer
(32)2D-6235 Locknut - Attach hasp (27) to deflector (15) with 1 bolt (29), 1 washer (30), 1 washer (31), and 1 nut (32).
Note: Install washer (20) in between the hasp and the head of the bolt.
- Lock hasp (27) to deflector (15) with 1 padlock (28).
Installing the
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| Illustration 94 | g06253562 |
|
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) | |
- Install 3 pipe plugs (2) into the original pump adapter (1).
- Attach cover (5) and 1 gasket (6) onto pump adapter (1) with 1 bolt (3), 1 washer (4), 1 bolt (9), and 1 washer (10).
- Install plug (7) and 1 O-ring (8) into the pump adapter (1).
- Install plug (11), 1 O-ring (12), and 1 O-ring (13) into the pump adapter (1).
- Install the original elbow (14) and 1 O-ring (13) into the pump adapter (1). The elbow and O-ring are from the 464-9826 Fuel Injection Lines Gp.
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Illustration 95 g06253584 (1) 171-8944 Pump Adapter
(15)2K-8198 O-Ring Seal
(16)3B-1915 Bolt
(17)5M-2894 Hard Washer - Attach pump adapter (1) and 2 O-rings (15) to the 1W-7559 Fuel Filter Base As with 4 bolts (16) and 4 washers (17).
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Illustration 96 g06256368 (8) 238-5080 O-Ring Seal
(18)1P-7625 Elbow - Install the original elbow (18) and 1 O-ring (8) into the 1W-7559 Fuel Filter Base As. The elbow and O-ring are from the 464-9826 Fuel Injection Lines Gp.
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Illustration 97 g06253800 (19) 554-4630 Block
(20)165-3931
(21)298-6389 Spacer
(22)283-8650 Hard Washer
(23)555-1546 Plate As - Attach block (19) to the 418-1263 Camshaft Cover on cylinder 4 with 4 bolts (20) and 4 spacers (21).
- Attach plate (23) to the 100-4818 Support As with 3 bolts (20) and 3 washers (22).
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Illustration 98 g06253819 (19) 554-4630 Block
(21)298-6389 Spacer
(23)555-1546 Plate As
(24)554-4628 Bracket As
(25)165-3929 Bolt
(26)1A-2029 Bolt
(27)5M-2894 Hard Washer - Attach bracket (24) to block (19) with 3 bolts (25) and 3 spacers (21).
- Attach bracket (24) to plate (23) with 3 bolts (26) and 3 washers (27).
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Illustration 99 g06313190 (23) 555-1546 Plate As
(27)5M-2894 Hard Washer
(28)3B-1915 Bolt - Attach the 1W-7559 Fuel Filter Base Assemblies to plate (23) with the original 3 bolts (28) and the original 3 washers (27) per fuel filter base assembly.
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Illustration 100 g06253845 (25) 165-3929 Bolt
(27)5M-2894 Hard Washer
(29)8S-9191 Bolt
(30)465-1349 Bracket
(31)9S-8752 Full NutNote: The 507-3577 Fuel Tube may be easier to install before installing bracket (24).
- Attach bracket (30) to the cam cover of cylinder 6 with 1 bolt (29) and 1 washer (27).
- Attach bracket (30) to 1W-7559 Fuel Filter Base As with 2 bolts (25), 4 washers (27), and 2 nuts (31).
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Illustration 101 g06381691 (32) 557-8315 Bracket
(33)6V-7345 Screw
(34)4B-4863 Washer
(35)6T-3642 Circuit Breaker As
(36)146-0240 Toggle Switch GpNote: The shield will not be installed until the 539-1453 Wiring Harness is connected to the circuit breaker and toggle switch.
- Attach circuit breaker (35) to bracket (32) with 2 bolts (33) and 2 washers (34).
- Attach toggle switch (36) to bracket (32) with the nut that comes with the toggle switch.
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Illustration 102 g06381696 (24) 554-4628 Bracket As
(32)557-8315 Bracket
(37)0S-0509 Bolt
(38)9X-6458 Hard Washer - Attach bracket (32) to bracket (24) with 2 bolts (37) and 2 washers (38).
Installing the
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| Illustration 103 | g06258296 |
|
(1) (2) (3) (4) | |
- Install the original elbow (2) and 1 O-ring (3) into manifold (1).
- Install connector (4) and 1 O-ring (3) into manifold (1).
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Illustration 104 g06258755 (3) 238-5081 O-Ring Seal
(5)4W-1807 Flared Elbow
(6)9N-4053 Spring
(7)114-5477 Valve Plunger
(8)7C-7682 Fuel Manifold Adapter - Install valve plunger (7) into manifold (8).
- Install spring (6) into manifold (8).
- Install elbow (5) and 1 O-ring (3) into manifold (8).
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Illustration 105 g06258307 (2) 250-1497 Elbow
(3)238-5081 O-Ring Seal
(5)4W-1807 Flared Elbow
(8)7C-7682 Fuel Manifold Adapter
(9)9S-4182 Plug
(10)214-7566 O-Ring Seal
(11)6M-7476 Elbow - Install the original elbow (2) and 1 O-ring (3) into manifold (8).
- Install the original plug (9) and 1 O-ring (10) into manifold (8).
- Install the original elbow (11) and 1 O-ring (3) into manifold (8).
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Illustration 106 g06258317 (1) 7C-7683 Fuel Manifold Adapter
(12)7N-6806 Rectangular Seal
(13)1D-4539 Bolt
(14)9M-1974 Hard Washer - Attach manifold (1) and 2 seals (12) to the 156-9754 Fuel Manifold Gp with 1 bolt (13) and 1 washer (14).
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Illustration 107 g06258322 (8) 7C-7682 Fuel Manifold Adapter
(12)7N-6806 Rectangular Seal
(14)9M-1974 Hard Washer
(15)1D-4541 Bolt - Attach manifold (8) and 2 seals (12) to the 156-9753 Fuel Manifold Gp with 1 bolt (15) and 1 washer (14).
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Illustration 108 g06258765 (3) 238-5081 O-Ring Seal
(16)9S-8896 Cap
(17)5P-3264 Elbow - Install the original elbow (17) and 1 O-ring (3) into the fuel transfer pump.
- Install cap (16) onto the original elbow (17).
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Illustration 109 g06258353 (18) 420-1796 Check Valve
(19)238-5080 O-Ring Seal
(20)5P-3166 Swivel Tee
(21)8K-2396 Flared Elbow - Install the original check valve (18) and 1 O-ring (19) into the fuel transfer pump.
- Install tee (20) onto check valve (18).
- Install elbow (21) onto tee (20).
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Illustration 110 g06258330 (4) 9M-4584 Connector
(11)6M-7476 Elbow
(22)463-0325 Fuel Tube - Attach tube (22) to connector (4) and the original elbow (11).
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Illustration 111 g06258281 (2) 250-1497 Elbow
(23)2W-3973 Tube As
(24)003-8581 Union Tee
(25)507-3577 Fuel Tube
(26)1P-7625 Elbow
(27)463-0326 Fuel Tube
(28)061-8248 Flared Union
(29)463-0328 Fuel Tube - Attach tube (27) to the original elbow (2).
- Attach union (28) to tube (27).
- Attach tube (29) to union (28).
- Attach tube (25) to the original elbow (26).
- Attach tee (24) to tube (25).
- Attach tube (23) to tee (24).
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Illustration 112 g06258282 (2) 250-1497 Elbow
(5)4W-1807 Flared Elbow
(21)8K-2396 Flared Elbow
(23)2W-3973 Tube As
(29)463-0328 Fuel Tube
(30)463-0330 Fuel Tube - Attach tube (23) to the original elbow (2).
- Attach tube (29) to elbow (21).
- Attach tube (30) to elbow (5).
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Illustration 113 g06258612 (2) 250-1497 Elbow
(22)463-0325 Fuel Tube
(23)2W-3973 Tube As
(24)003-8581 Union Tee
(27)463-0326 Fuel Tube
(31)196-5052 Clip
(32)196-5053 Clip
(33)2W-0598 Tube As
(34)7K-3377 Pipe
(35)5F-4899 Bolt
(36)5M-2894 Hard Washer
(37)4P-0692 Clamp As
(38)4P-0693 Clamp As
(39)030-7972 Elbow - Install elbow (39) onto tee (24).
- Attach tube (33) to the original elbow (2) and elbow (39).
- Install 2 clamps (37) around tube (22).
- Install 2 clamps (38) around tubes (23) and (27).
- Install the original clips (31) and (32) around the 119-6349 Tube. The clips are part of the 453-4968 Water Lines Gp.
- Secure the original clips (31) and (32) and clamps (37) and (38) to the front housing with 1 pipe (34), 1 bolt (35), and 1 washer (36).
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Illustration 114 g06258418 (25) 507-3577 Fuel Tube
(27)463-0326 Fuel Tube
(36)5M-2894 Hard Washer
(37)4P-0692 Clamp As
(40)353-7954 Grommet
(41)7D-4108 Clamp
(42)1W-8793 Spacer
(43)1A-1460 Bolt
(44)5P-8245 Hard Washer
(45)0L-2070 Bolt - Attach tube (25) to the camshaft cover of cylinder 2 with 2 clamps (37), 1 bolt (45), and 1 washer (36).
- Install 1 grommet (40) around tubes (25) and (27).
- Attach tubes (25) and (27) to the front housing with 2 clamps (41), 1 spacer (42), 1 bolt (43), and 1 washer (44).
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Illustration 115 g06258436 (18) 463-0325 Fuel Tube
(19)2W-3973 Tube As
(25)463-0328 Fuel Tube
(26)463-0330 Fuel Tube
(30)7K-3377 Pipe
(32)5M-2894 Hard Washer
(33)4P-0692 Clamp As
(34)4P-0693 Clamp As
(42)0T-0573 Bolt
(43)9X-6458 Hard Washer
(44)5B-2638 Bolt - Install 2 clamps (33) around tube (18).
- Install 2 clamps (34) around tubes (19) and (26).
- Secure clamps (33) and (34) to the front housing with 1 pipe (30), 1 bolt (44), and 1 washer (32).
- Install 2 clamps (34) around tubes (25) and (26).
- Secure clamps (33) and (34) to the 431-8900 Bracket As with 1 bolt (42) and 1 washer (43).
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Illustration 116 g06258391 (36) 5M-2894 Hard Washer
(45)0S-1590 Bolt
(46)4P-3485 Bracket
(47)101-3120 Spacer
(48)0S-1591 Bolt - Attach bracket (46) to the 1W-1475 Lines Adapter with the original 2 bolts (45) and 2 washers (36).
- Attach the 501-6696 Alternator Guard As to bracket (46) with the original 1 spacer (47) and 1 bolt (48).
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Illustration 117 g06258386 (25) 463-0328 Fuel Tube
(26)463-0330 Fuel Tube
(37)4P-0692 Clamp As
(38)4P-0693 Clamp As
(43)9X-6458 Hard Washer
(45)0L-2070 Bolt
(49)0T-0055 Bolt
(50)6J-7366 Flared Cap
(51)9S-8752 Full Nut - Install cap () onto tube (26).
- Install 2 clamps (33) around each tube (25) and (26).
- Secure clamps (33) to bracket with 1 bolt (45) and 1 washer (43).
- Install 2 clamps (34) around each tube (25) and (26).
- Secure clamps (34) to bracket with 1 bolt (41), 2 washers (43), and 1 nut ().
Installing the
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| Illustration 118 | g06256756 |
|
(1) (2) (3) | |
- Attach bracket (1) to the 474-5361 Bracket As and the 474-5362 Bracket As with 2 bolts (2) and 2 washers (3) per bracket assembly.
Note: The bracket assemblies are on cylinder 1 and 3.
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Illustration 119 g06373593 (1) 474-4547 Bracket As
(4)191-1782 Spacer
(5)1D-4539 Bolt
(6)9N-0869 Hard Washer
(7)191-1783 Spacer
(8)3H-5932 Bolt - Attach the original 235-8725 Filter and Fuel Transfer Pump Gp to bracket (1) with 1 spacer (4), 2 spacers (7), 1 bolt (5), 2 bolts (8), and 6 washers (6).
Note: Washers go against each 8T-9655 Isolation Mount.
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Illustration 120 g06373596 (9) 268-1530 Elbow
(10)238-5081 O-Ring Seal
(11)360-3681 Plug
(12)6K-3607 Connector
(13)420-1796 Check Valve
(14)238-5080 O-Ring Seal - Install plug (11) and 1 O-ring (10) into the lower left-hand port of the 235-8725 Filter and Fuel Transfer Pump Gp.
- Install elbow (9) and 1 O-ring (10) into upper left-hand port of the 235-8725 Filter and Fuel Transfer Pump Gp.
- Install check valve (13) and 1 O-ring (14) into elbow (9).
- Install plug (11) and 1 O-ring (10) into the upper right-hand port of the 235-8725 Filter and Fuel Transfer Pump Gp.
- Install connector (12) and 1 O-ring (10) into the lower right-hand port of the 235-8725 Filter and Fuel Transfer Pump Gp.
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Illustration 121 g06373600 (15) 4P-7048 Bracket
(16)8M-0506 O-Ring Adapter
(17)214-7568 O-Ring Seal - Remove the cover bolt and washer from the 7C-9217 Elbow.
- Attach bracket (15) to the 7C-9217 Elbow with the original bolt and washer.
- Install adapter (16) and 1 O-ring (17) into the fuel transfer pump.
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Illustration 122 g06373606 (3) 5M-2894 Hard Washer
(12)6K-3607 Connector
(13)420-1796 Check Valve
(15)4P-7048 Bracket
(16)8M-0506 O-Ring Adapter
(18)495-1360 Hose As
(19)0S-1594 Bolt
(20)9S-8752 Full Nut
(21)353-7952 Grommet
(22)8T-1897 Clip
(23)8T-1898 Clip
(24)533-5388 Hose As - Attach the straight end of hose (18) to check valve (13).
- Attach the 90 degree end of hose (18) to the 5P-3166 Swivel Tee.
- Install grommet (21) around hose (18).
- Install 1 clip (22) and 1 clip (23) around grommet (21).
- Attach clips (22) and 23 to bracket (15) with 1 bolt (19), 2 washers (3), and 1 nut (20).
- Attach the 90 degree end of hose (24) to connector (12).
- Attach the straight end of hose (24) to adapter (16).
- Remove the hardware from the 4P-0692 Clamp Assemblies of the 464-9826 Fuel Injection Lines Gp.
- Install grommet (21) around hose (24).
- Install 1 clip (22) and 1 clip (23) around grommet (21).
- Attach clips (22) and (23) to the 4P-0692 Clamp Assemblies with the original hardware.
Installing the
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| Illustration 123 | g06354073 |
|
(1) (2) (3) (4) (5) (6) (7) | |
- Install 1 O-ring (2) onto connector (1).
- Install 1 O-ring (3) into connector (1).
- Install connector (1) into the 488-5793 Elbow.
- Remove the bolt from the bottom rear hole of the 1N-3007 Bracket.
- Attach bracket (7) to the engine block with 1 spacer (4), 1 bolt (5), and 1 washer (6).
Note: The spacer goes in between the bracket and the 1N-3007 Bracket.
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Illustration 124 g06354983 (1) 6V-8635 Connector
(3)5K-9090 O-Ring Seal
(8)492-3645 Water Tube As
(9)6V-9833 Cap As - Install 1 O-ring (3) into water tube assembly (8).
- Install cap (9) onto water tube assembly (8).
- Attach water tube assembly (8) to connector (1).
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Illustration 125 g06355037 (7) 492-3646 Bracket
(8)492-3645 Water Tube As
(10)6V-7359 Grommet
(11)3B-1915 Bolt
(12)9X-6458 Hard Washer
(13)9S-8752 Full Nut
(14)8T-1899 Clip
(15)8T-1900 Clip - Install grommet (10) around water tube assembly (8).
- Install 1 clip (14) and 1 clip (15) around grommet (10). Refer to Illustration 125 for the correct orientation of the clips.
- Attach clips (14) and (15) to bracket (7) with 1 bolt (11), 2 washers (12), and 1 nut (13).
Installing the
Left-Hand Side ECM
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| Illustration 126 | g06253973 |
|
(1) (2) (3) (4) (5) (6) (7) (8) (9) | |
- Attach bracket (4) to bracket (1) with 2 bolts (6) and 2 washers (3).
- Attach bracket (1) to the 495-6438 Manifold with 4 bolts (2) and 4 washers (3).
- Attach bracket (4) to the camshaft cover of cylinder 10 with 2 bolts (5) and 2 washers (3).
- Attach plate assembly (9) to the cylinder block over the side cover of cylinder 8 with 4 bolts (7) and 4 washers (8).
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Illustration 127 g06255769 (1) 474-4544 Bracket As
(10)8T-9655 Isolation Mount
(11)6I-1418 Spacer
(12)198-4777 Hard Washer
(13)1D-4539 Bolt
(14)9N-0869 Hard Washer
(15)488-4875 Electronic Control Module
(16)127-1570 Stud
(17)285-6395 Clip
(18)3E-4352 Hard Washer
(19)5S-0003 Nut - Install 2 isolation mounts (10) and 1 spacer (11) into the each corner of ECM (14).
- Attach ECM (15) to bracket (1) with 3 hard washers (12), 2 bolts (13), 1 stud (16), and 3 washers (14). Refer to Illustration 127 for the correct location of the bolts and stud.
- Install clip (17) onto stud (16) with 1 washer (18) and 1 nut (19).
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Illustration 128 g06255809 (10) 8T-9655 Isolation Mount
(11)6I-1418 Spacer
(12)198-4777 Hard Washer
(13)1D-4539 Bolt
(14)9N-0869 Hard Washer
(20)458-2971 Inductor Assembly
(21)7K-1181 Cable Strap
(22)528-0412 Control Harness As
(23) Original ground strap screw - Remove and discard the ground strap from the ECM. Set aside the screw for reuse.
- Plug control harness (22) into inductor (20).
- Attach the large eyelet of control harness (22) and the ECM to the 474-4544 Bracket As with 1 hard washer (12), 1 bolt (13) and 1 washer (14).
Note: Install the eyelet of the control harness behind the washer.
- Attach the little eyelet of control harness (22) to the ECM with the original ground strap screw (23.).
- Secure inductor (20) to the 285-6395 Clip with 1 cable strap (21).
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Illustration 129 g06255838 (9) 230-1078 Plate As
(10)8T-9655 Isolation Mount
(11)6I-1418 Spacer
(14)9N-0869 Hard Washer
(24)224-9907 Stud
(25)1B-9575 Bolt
(26)491-6842 Electronic Control Module - Install 2 isolation mounts (10) and 1 spacer (11) into the each corner of ECM (26).
- Attach ECM (26) to plate assembly (9) with 1 stud (24), 3 bolts (25), and 4 washers (14). Refer to Illustration 129 for the correct location of the stud and bolts.
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Illustration 130 g06255853 (15) 488-4875 Electronic Control Module
(27)233-0891 Bracket As
(28)232-1693 Bolt - Attach 2 bracket assemblies (27) to ECM (15) with 1 bolt (28) per bracket.
Note: Bolt (28) is part of bracket assembly (27).
Front ECM
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| Illustration 131 | g06255834 |
|
(3) (29) (30) (31) (32) | |
- Attach bracket (31) and 1 gasket (32) to the 381-0680 Front Housing Gp with 1 stud (29), 6 bolts (30), and 7 washers (3).
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Illustration 132 g06256606 (10) 8T-9655 Isolation Mount
(11)6I-1418 Spacer
(14)9N-0869 Hard Washer
(17)285-6395 Clip
(18)3E-4352 Hard Washer
(19)5S-0003 Nut
(33)2V-4387 Spacer
(34)1D-4540 Bolt
(35)488-9091 Electronic Control Gp
(36)344-0346 Stud - Install 2 isolation mounts (10) and 1 spacer (11) into the each corner of ECM (35).
- Attach ECM (35) to the 110-2760 Bracket with 3 spacers (33), 2 bolts (34), 1 stud (36), and 3 washers (14). Refer to Illustration for the correct location of the stud and bolts.
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Illustration 133 g06256591 (10) 8T-9655 Isolation Mount
(11)6I-1418 Spacer
(13)1D-4539 Bolt
(14)9N-0869 Hard Washer
(20)458-2971 Inductor Assembly
(21)7K-1181 Cable Strap
(22)528-0412 Control Harness As
(23) Original ground strap screw
(33)2V-4387 Spacer
(36)344-0346 Stud - Remove and discard the ground strap from the ECM. Set aside the screw for reuse.
- Plug control harness (22) into inductor (20).
- Attach the large eyelet of control harness (22) and the ECM to the 110-2760 Bracket with 1 spacer (33), 1 stud (36), and 1 washer (14).
Note: Install the eyelet of the control harness behind the washer.
- Attach the little eyelet of control harness (22) to the ECM with the original ground strap screw (23.).
- Secure inductor (20) to the 285-6395 Clip with 1 cable strap (21).
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Illustration 134 g06256626 (27) 233-0891 Bracket As
(28)232-1693 Bolt
(35)488-9091 Electronic Control Gp - Attach 2 bracket assemblies (27) to ECM (35) with 1 bolt (28) per bracket.
Note: Bolt (28) is part of bracket assembly (27).
Right-Hand Side ECM
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| Illustration 135 | g06256672 |
|
(1) (2) (3) (4) (5) (6) | |
- Attach bracket (4) to bracket (1) with 2 bolts (6) and 2 washers (3).
- Attach bracket (1) to the 495-6438 Manifold with 4 bolts (2) and 4 washers (3).
- Attach bracket (4) to the camshaft cover of cylinder 7 with 2 bolts (5) and 2 washers (3).
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Illustration 136 g06256694 (1) 474-4544 Bracket As
(10)8T-9655 Isolation Mount
(11)6I-1418 Spacer
(12)198-4777 Hard Washer
(13)1D-4539 Bolt
(14)9N-0869 Hard Washer
(15)488-4875 Electronic Control Module
(16)127-1570 Stud
(17)285-6395 Clip
(18)3E-4352 Hard Washer
(19)5S-0003 Nut - Install 2 isolation mounts (10) and 1 spacer (11) into the each corner of ECM (14).
- Attach ECM (15) to bracket (1) with 3 hard washers (12), 2 bolts (13), 1 stud (16), and 3 washers (14). Refer to Illustration for the correct location of the bolts and stud.
- Install clip (17) onto stud (16) with 1 washer (18) and 1 nut (19). Refer to Illustration for the correct location of the clip.
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Illustration 137 g06256742 (10) 8T-9655 Isolation Mount
(11)6I-1418 Spacer
(12)198-4777 Hard Washer
(14)9N-0869 Hard Washer
(16)127-1570 Stud
(20)458-2971 Inductor Assembly
(21)7K-1181 Cable Strap
(22)528-0412 Control Harness As
(23) Original ground strap screw - Remove and discard the ground strap from the ECM. Set aside the screw for reuse.
- Plug control harness (22) into inductor (20).
- Attach the large eyelet of control harness (22) and the ECM to the 474-4544 Bracket As with 1 hard washer (12), 1 stud (16), and 1 washer (14).
Note: Install the eyelet of the control harness behind the washer.
- Attach the little eyelet of control harness (22) to the ECM with the original ground strap screw (23.).
- Secure inductor (20) to the 285-6395 Clip with 1 cable strap (21).
Installing the
Note: Some of the original mounting hardware can be reused at your discretion.
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| Illustration 138 | g06313282 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) | |
- Attach wiring harness (1) to the engine electronic control module (ECM).
- Remove the bolt and washer from the to the top outer hole of the 106-4685 Cover.
- Attach bar (10) and clip (11) to the top outer hole of the 106-4685 Cover with 1 bolt (12) and 1 washer (13).
Note: The clip is installed on top of the bar.
- Install 1 grommet (3) around wiring harness (1).
- Install 1 clip (4) and 1 clip (5) around grommet (3).
- Attach clips (4) and (5) to bar (10) with 1 stud (6), 2 washers (7), 1 spacer (8), and 1 nut (9).
Note: The spacer is installed between the clips and the bar.
- Secure wiring harness (1) to clip (11) with 1 cable strap (2).
- Secure excess wiring harness (1) with cable straps (2) as needed.
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Illustration 139 g06313285 (1) 563-8617 Harness
(2)7K-1181 Cable Strap
(4)5P-7468 Clip
(5)5P-7469 Clip
(6)423-0909 Stud
(7)9X-6458 Hard Washer
(8)145-5181 Spacer
(9)9S-8752 Full Nut
(10)098-9852 Bar
(11)4P-7581 Clip
(12)0S-1588 Bolt
(13)5M-2894 Hard Washer
(14)8T-7087 Grommet
(15)129-3172 Mounting Stud
(16)5S-0003 Nut
(17)353-7953 Grommet
(18)8T-1889 Clip
(19)8T-1890 Clip
(20)3E-4352 Hard Washer - Remove the bolt and washer from the to the top outer hole of the 106-4685 Cover.
- Install 1 stud (15) and 1 washer (13) into the to the top outer hole of the 106-4685 Cover.
- Attach bar (10) to stud (15) with 1 washer (13) and 1 nut (15).
- Install 1 grommet (14) around wiring harness (1).
- Install 1 clip (4) and 1 clip (5) around grommet (14).
- Attach clips (4) and (5) to bar (10) with 1 stud (6), 2 washers (7), 1 spacer (8), and 1 nut (9).
Note: The spacer is installed between the clips and the bar.
- Install 2 grommets (17) around wiring harness (1).
- Install 1 clip (18) and 1 clip (19) around each grommet (17).
- Attach each set of clips (18) and (19) onto the 344-0346 Stud with 1 washer (20) and 1 nut (16).
- Secure excess wiring harness (1) with cable straps (2) as needed.
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Illustration 140 g06313292 (1) 563-8617 Harness
(2)7K-1181 Cable Strap
(11)4P-7581 Clip
(21)4P-8134 Clip - Attach 2 clips (11) to the left-hand 154-1619 Front Manifold with the original hardware.
- Attach 2 clips (11) to the right-hand 154-1619 Front Manifold with the original hardware.
- Attach 2 clips (21) to the bottom 2 bolts on the left-hand side of the 141-7117 Regulator Housing with the original hardware.
- Attach 2 clips (11) to the front 2 bolts on the left-hand side of the 9Y-4090 Regulator Housing with the original hardware.
- Attach 1 clip (21) to the top front bolt on the right-hand side of the 9Y-4090 Regulator Housing with the original hardware.
- Secure wiring harness (1) to clips (11) and (21) with 1 cable strap (2) per clip.
- Secure excess wiring harness (1) with cable straps (2) as needed.
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Illustration 141 g06313298 (1) 563-8617 Harness
(2)7K-1181 Cable Strap
(4)5P-7468 Clip
(5)5P-7469 Clip
(7)9X-6458 Hard Washer
(9)9S-8752 Full Nut
(11)4P-7581 Clip
(13)5M-2894 Hard Washer
(14)8T-7087 Grommet
(21)4P-8134 Clip
(22)8T-2920 Grommet
(23)5P-7464 Clip
(24)5P-7465 Clip
(25)204-8000 Cable Tie Mounting
(26)355-4656 Stud
(27)5P-8245 Hard Washer
(28)1F-7958 Full Nut
(29)323-9928 Plate
(30)0S-1594 Bolt
(31)091-9035 Spacer
(32)0L-2070 Bolt
(33)352-3964 Clip
(34)0S-0509 Bolt
(35)8C-4985 Adapter
(36)330-9741 Elbow
(37)6V-3250 O-Ring Seal
(38)416-6999 Pressure Sensor Gp
(39)216-8579 O-Ring Seal - Attach plate (29) to the 4P-0693 Clamp As of the 464-9826 Fuel Injection Lines Gp with the original hardware.
- Install 1 grommet (14) around wiring harness (1).
- Install 1 clip (4) and 1 clip (5) around grommet (14).
- Attach clips (4) and (5) to plate (29) with 1 stud (26), 2 washers (27), and 1 nut (28).
- Attach cable tie mount (25) to the 474-5361 Bracket As on cylinder 1 with 1 spacer (31), 1 bolt (32), 2 washers (7), and 1 nut (9).
- Install 1 grommet (22) around wiring harness (1).
- Secure grommet (22) to cable tie mount (25) with 1 cable strap (2).
- Install 1 grommet (22) around wiring harness (1).
- Install 1 clip (4) and 1 clip (5) around grommet (22).
- Attach clips (4) and (5) to the 474-5361 Bracket As on cylinder 3 with 1 spacer (31), 1 bolt (32), 2 washers (7), and 1 nut (9).
- Plug wiring harness (1) into the fuel injector wiring harnesses on cylinders 1 and 3.
- Secure wiring harness (1) to the 496-9936 Bracket on cylinders 1 and 3 with 1 cable strap (2) per bracket.
- Attach 1 clip (11) to the 474-5361 Bracket As on cylinder 1 with 1 bolt (30) and washer (13).
- Secure wiring harness (1) to clip (11) with 1 cable strap (2).
- Attach 1 clip (33) to the 474-5361 Bracket As on cylinder 1 with the original hardware from the 495-7573 Fuel Lines Gp.
- Secure wiring harness (1) to clip (33) with 2 cable straps (2).
- Plug wiring harness (1) into the 235-8724 Fuel Transfer Pump Gp.
- Attach 1 clip (21) to the 353-2464 Alternator Support with 1 bolt (34) and 1 washer (13).
- Install adapter (35) into the 1W-1475 Lines Adapter.
- Install elbow (36) and 1 O-ring (37) into adapter (35).
- Install pressure sensor (38) and 1 O-ring (39) into elbow (36).
- Plug wiring harness (1) into pressure sensor (38).
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Illustration 142 g06313336 (1) 563-8617 Harness
(2)7K-1181 Cable Strap
(7)9X-6458 Hard Washer
(9)9S-8752 Full Nut
(13)5M-2894 Hard Washer
(22)8T-2920 Grommet
(23)5P-7464 Clip
(24)5P-7465 Clip
(25)204-8000 Cable Tie Mounting
(31)091-9035 Spacer
(40)415-2431 Exhaust Temperature Sensor Gp
(41)261-6847 Adapter
(42)352-3968 Clip
(43)132-5789 Clip
(44)1A-2029 Bolt
(45)3A-3692 Clip
(46)6V-1249 Grommet
(47)6V-0683 Grommet
(48)206-2423 Mounting Saddle
(49)0S-1590 Bolt - Install 1 grommet (22) around wiring harness (1).
- Install 1 grommet (46) around wiring harness (1).
- Attach 1 cable tie mount (25) to the 474-5361 Bracket As on cylinders 5 and 7 with 1 spacer (31), 1 bolt (49), and 1 washer (7) per bracket.
- Secure grommets (22) and (46) to cable tie mount (25) with 1 cable strap (2) per cable tie mount.
- Install 1 grommet (46) around wiring harness (1).
- Install 1 clip (23) and 1 clip (24) around grommet (46).
- Attach clips (23) and (24) to the 474-5361 Bracket As on cylinders 9 with 1 spacer (31), 1 bolt (49), and 1 washer (7).
- Install 1 grommet (47) around wiring harness (1).
- Attach 1 mounting saddle (48) to grommet (47) with 1 cable strap (2).
- Plug wiring harness (1) into the fuel injector wiring harnesses on cylinders 5, 7, and 9.
- Secure wiring harness (1) to the 496-9936 Bracket on cylinders 5, 7, and 9 with 1 cable strap (2) per bracket.
- Attach 1 clip (43) to the 474-5361 Bracket As on cylinders 5 and 7 with 1 bolt (44), 2 washers (13), and 1 nut (9) per bracket.
- Secure wiring harness (1) to clips (43) with 1 cable strap (2) per clip.
- Install adapter (41) into the 115-0556 Exhaust Manifold.
- Install exhaust temperature sensor (40) into adapter (41).
- Plug exhaust temperature sensor (40) into wiring harness (1).
- Install 1 clip (45) around exhaust temperature sensor (40).
- Attach clip (45) to the 474-5361 Bracket As on cylinders 5 with the original hardware from the 468-5925 Turbocharger Oil Lines Gp.
- Attach clips (42) to the water manifold with the original hardware.
- Secure exhaust temperature sensor (40) to clips (42) with 1 cable strap (2) per clip.
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Illustration 143 g06315394 (1) 563-8617 Harness
(2)7K-1181 Cable Strap
(11)4P-7581 Clip
(43)132-5789 Clip
(47)6V-0683 Grommet
(50)353-5439 Connector
(51)228-7100 O-Ring Seal
(52)216-4596 Elbow
(53)320-3063 Pressure Sensor Gp
(54)170-0610 Stud
(55)522-1641 Speed Sensor Gp - Install 2 grommets (47) around wiring harness (1).
- Attach 2 clips (43) to the 474-5361 Bracket As on cylinder 11 with the original hardware from the 495-7573 Fuel Lines Gp.
- Secure grommets (47) to clips (43) with 1 cable strap (2) per clip.
- Install connector (50) and 1 O-ring (51) into the 4P-7850 Cover on cylinder 11.
- Install elbow (52) and 1 O-ring (51) into connector (50).
- Install pressure sensor (53) and 1 O-ring (51) into elbow (52).
- Plug wiring harness (1) into pressure sensor (53).
- Install speed sensor (55) into the flywheel housing.
- Plug wiring harness (1) into speed sensor (55).
- Remove the rear bolt and washer from the 488-5793 Elbow. Set aside the washer for reuse.
- Reattach 108-6170 Clamp As to the 488-5793 Elbow with 1 stud (54) and the original washer.
- Attach 1 clip (11) to the 108-6170 Clamp As with 1 stud (54), 1 washer (13), and 1 nut (9).
- Secure wiring harness (1) to clip (11) with 1 cable strap (2).
- Attach 1 clip (43) to the 492-3644 Water Lines Gp with the original hardware.
- Secure speed sensor (55) to clip (43) with 1 cable strap (2).
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Illustration 144 g06316516 (1) 563-8617 Harness
(2)7K-1181 Cable Strap
(21)4P-8134 Clip
(51)228-7100 O-Ring Seal
(56)353-5440 Adapter
(57)256-6453 Temperature Sensor
(58)238-5080 O-Ring Seal
(59)306-8526 Grommet
(60)7V-6571 Grommet
(61)5G-3676 Grommet
(62)366-4683 Adapter
(63)320-3060 Pressure Sensor Gp - Plug wiring harness (1) into the fuel injector wiring harness on cylinder 11.
- Install 1 grommet (61) around wiring harness (1).
- Secure grommet (61) to the 496-9936 Bracket on cylinder 11 with 1 cable strap (2).
- Install adapter (56) into the 283-9599 Manifold.
- Install temperature sensor (57) and 1 O-ring (58) into adapter (56).
- Install adapter (62) and 1 O-ring (58) into the 391-5001 Elbow.
- Install pressure sensor (63) and 1 O-ring (51) into adapter (62).
- Install temperature sensor (57) and 1 O-ring (58) into the 391-5001 Elbow.
- Plug wiring harness (1) into pressure sensor (63) and temperature sensors (57).
- Install clip (21) to the 7N-3170 Cover with the original hardware.
- Install 3 grommets (60) around wiring harness (1).
- Secure grommets (60) to the 132-5789 Clip, 183-4274 Bracket, and clip (21) with 1 cable strap (2) per bracket and clip.
- Install 3 grommets (59) around wiring harness (1).
- Secure grommets (59) to the 132-5789 Clip, 183-4274 Bracket, and 347-3880 Bracket with 1 cable strap (2) per bracket and clip.
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Illustration 145 g06318088 (1) 563-8617 Harness
(2)7K-1181 Cable Strap
(51)228-7100 O-Ring Seal
(64)353-7957 Grommet
(65)4P-7233 Grommet
(66)238-0112 Temperature Sensor Gp
(67)5P-1318 Adapter
(68)214-7567 O-Ring Seal
(69)320-3065 Pressure Sensor Gp
(70)214-7568 O-Ring Seal - Install temperature sensor (66) and 1 O-ring (51) into the 533-0071 Adapter.
- Install adapter (67) and 1 O-ring (68) into the 516-8290 Solenoid Valve Gp.
- Install pressure sensor (69) and 1 O-ring (70) into adapter (67).
- Plug wiring harness (1) into the 516-8290 Solenoid Valve Gp, temperature sensor (66), and pressure sensor (69).
- Install 1 grommet (64) and 1 grommet (65) around wiring harness (1).
- Secure grommets (64) and (65) to the 347-3880 Bracket with 1 cable strap (2) per grommet.
- Secure wiring harness (1) to the 516-8290 Solenoid Valve Gp with 1 cable strap (2).
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Illustration 146 g06313339 (1) 563-8617 Harness
(2)7K-1181 Cable Strap
(3)6V-0545 Grommet
(4)5P-7468 Clip
(5)5P-7469 Clip
(7)9X-6458 Hard Washer
(9)9S-8752 Full Nut
(12)0S-1588 Bolt
(25)204-8000 Cable Tie Mounting
(29)323-9928 Plate
(40)415-2431 Exhaust Temperature Sensor Gp
(41)261-6847 Adapter
(57)256-6453 Temperature Sensor
(71)6V-6609 O-Ring Seal
(72)330-9739 Adapter
(73)6V-5048 O-Ring Seal
(74)320-3061 Pressure Sensor Gp
(75)228-7101 O-Ring Seal
(76)451-2253 Stud - Install temperature sensor (57) and 1 O-ring (71) into the 7E-5326 Cover.
- Plug wiring harness (1) into temperature sensor (57).
- Install adapter (72) and 1 O-ring (73) into the 117-0069 Sensor Mounting Block
- Install pressure sensor (74) and 1 O-ring (75) into adapter (72).
- Plug wiring harness (1) into pressure sensor (75).
- Attach plate (29) to the 474-5361 Bracket As on cylinder 2 with 1 bolt (12) and 1 washer (7).
- Install 1 grommet (3) around wiring harness (1).
- Install 1 clip (4) and 1 clip (5) around grommet (3).
- Attach clips (4) and (5) to plate (29) with 1 stud (76), 2 washers (7), and 1 nut (9).
- Install 2 grommets (3) around wiring harness (1).
- Attach cable tie mount (25) to the 474-5361 Bracket As on cylinders 4 and 6 with 1 bolt (12) and 1 washer (7) per bracket.
- Secure grommets (3) to cable tie mounts (25) with 1 cable strap (2) per mount.
- Plug wiring harness (1) into the fuel injector wiring harnesses on cylinders 2, 4, and 6.
- Secure wiring harness (1) to the 496-9936 Bracket on cylinders 2, 4, and 6 with 1 cable strap (2) per bracket.
- Install adapter (41) into the 115-0554 Exhaust Manifold.
- Install exhaust temperature sensor (40) into adapter (41).
- Plug exhaust temperature sensor (40) into wiring harness (1).
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Illustration 147 g06315542 (1) 563-8617 Harness
(2)7K-1181 Cable Strap
(3)6V-0545 Grommet
(4)5P-7468 Clip
(5)5P-7469 Clip
(7)9X-6458 Hard Washer
(9)9S-8752 Full Nut
(12)0S-1588 Bolt
(13)5M-2894 Hard Washer
(25)204-8000 Cable Tie Mounting
(40)415-2431 Exhaust Temperature Sensor Gp
(41)261-6847 Adapter
(43)132-5789 Clip
(45)3A-3692 Clip
(48)206-2423 Mounting Saddle
(77)303-4649 Clip
(78)2B-0941 Spacer
(79)1W-1038 Stud
(80)249-2943 Stud - Install 2 grommets (3) around wiring harness (1).
- Install 1 clip (4) and 1 clip (5) around each grommet (3).
- Attach clips (4) and (5) to the 474-5362 Bracket As on cylinder 8 with 1 spacer (78) and 1 stud (79).
- Plug exhaust temperature sensor (40) into wiring harness (1).
- Install 1 clip (45) around exhaust temperature sensor (40).
- Attach clip (45) onto stud (79), 1 washers (7), and 1 nut (9).
- Secure exhaust temperature sensor (40) to clip (77) with 1 cable strap (2).
- Attach clips (4) and (5) to the 474-5362 Bracket As on cylinder 10 with 1 stud (80) and 1 washer (7).
- Install 1 grommet (3) around wiring harness (1).
- Attach 1 mounting saddle (48) to grommet (3) with 1 cable strap (2).
- Plug wiring harness (1) into the fuel injector wiring harnesses on cylinders 8, 10, and 12.
- Secure wiring harness (1) to the 496-9936 Bracket on cylinders 8, 10, and 12 with 1 cable strap (2) per bracket.
- Attach 1 clip (43) to the 474-5361 Bracket As on cylinder 8 with 1 bolt (12), 2 washers (13), and 1 nut (9) per bracket.
- Secure wiring harness (1) to clip (43) with 1 cable strap .
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Illustration 148 g06313353 (1) 563-8617 Harness
(2)7K-1181 Cable Strap
(7)9X-6458 Hard Washer
(11)4P-7581 Clip
(13)5M-2894 Hard Washer
(22)8T-2920 Grommet
(34)0S-0509 Bolt
(64)353-7957 Grommet
(80)249-2943 Stud
(81)123-0707 Hex Socket Screw
(82)8T-0328 Hard Washer
(83)563-8619
(84)187-3301 Bracket
(85)465-1028 Bracket As
(86)5V-9221 Spacer
(87)1A-1460 Bolt
(88)3H-7654 Hard Washer - Attach bracket (83) to the camshaft cover of cylinder 12 with 2 bolts (34) and 2 washers (13).
- Attach wiring harness (1) to bracket (83).
- Attach bracket (83) to the 474-5361 Bracket As with the original hardware.
- Attach wiring harness (1) to bracket assembly (85) with 4 screws (81) and 4 washers (82).
- Attach bracket assembly (85) to the 7N-4319 Cover with the original hardware.
- Install 2 grommets (64) around wiring harness (1).
- Secure grommets (64) to bracket assembly (85) with 1 cable strap (2) per grommet.
- Attach clip (11) to the 474-4544 Bracket As with 1 stud (80) and 1 washer (7).
- Install 1 grommet (22) around wiring harness (1).
- Secure grommet (22) to clip (11) with 1 cable strap (2).
- Attach wiring harness (1) to the cylinder block with 1 spacer (86), 1 bolt (87), and 1 washer (88).
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Illustration 149 g06313342 (1) 563-8617 Harness
(2)7K-1181 Cable Strap
(11)4P-7581 Clip
(89)318-1181 Speed Sensor Gp - Install speed sensor (89) into the flywheel housing.
- Plug wiring harness (1) into speed sensor (89).
- Secure wiring harness (1) to clips (11) with 1 cable strap (2) per clip.
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Illustration 150 g06313346 (1) 563-8617 Harness
(2)7K-1181 Cable Strap
(4)5P-7468 Clip
(5)5P-7469 Clip
(7)9X-6458 Hard Washer
(9)9S-8752 Full Nut
(11)4P-7581 Clip
(12)0S-1588 Bolt
(13)5M-2894 Hard Washer
(14)8T-7087 Grommet
(34)0S-0509 Bolt
(43)1A-2029 Bolt
(48)206-2423 Mounting Saddle
(55)522-1641 Speed Sensor Gp - Install 2 grommets (14) around wiring harness (1).
- Attach 1 mounting saddle (48) to grommet (14) with 1 cable strap (2).
- Install 1 clip (4) and 1 clip (5) around each grommet (14).
- Attach clips (4) and (5) to the 187-3301 Bracket on cylinder 12 with 1 bolt (12), 2 washers (7), and 1 nut (9).
- Install speed sensor (55) into the flywheel housing.
- Plug wiring harness (1) into speed sensor (55).
- Secure wiring harness (1) to speed sensor (55) with 1 cable strap (2).
- Attach 1 clip (11) to the camshaft cover on cylinder 12 with 1 bolt (34) and 1 washer (13).
- Attach 1 clip (11) to the 7N-3298 Block Cover with 1 bolt (34) and 1 washer (13).
- Secure wiring harness (1) to clips (11) with 1 cable strap (2) per clip.
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Illustration 151 g06319093 (1) 563-8617 Harness
(2)7K-1181 Cable Strap
(7)9X-6458 Hard Washer
(13)5M-2894 Hard Washer
(21)4P-8134 Clip
(23)5P-7464 Clip
(24)5P-7465 Clip
(34)0S-0509 Bolt
(46)6V-1249 Grommet
(50)353-5439 Connector
(51)228-7100 O-Ring Seal
(58)238-5080 O-Ring Seal
(62)366-4683 Adapter
(63)320-3063 Pressure Sensor Gp
(70)214-7568 O-Ring Seal
(80)249-2943 Stud
(90)0L-1351 Bolt
(91)365-5173 Bracket As
(92)320-3060 Pressure Sensor Gp
(93)214-7566 O-Ring Seal
(94)4P-7428 Clip
(95)4H-0553 Fitting
(96)2N-1931 Pipe Elbow
(97)9G-5127 Breather
(98)155-2078 Connector
(99)335-3999 Connector - Install fitting (95) into the front side 230-1078 Plate As.
- Install pipe elbow (96) into fitting (95).
- Install breather (97) into pipe elbow (96).
- Install connector (98) into the top side 230-1078 Plate As.
- Install connector (99) and 1 O-ring (70) into connector (98).
- Install pressure sensor (63) and 1 O-ring (51) into connector (99).
- Install connector (50) and 1 O-ring (93) into the 133-5915 Elbow.
- Install pressure sensor (92) and 1 O-ring (51) into connector (50).
- Install adapter (62) and 1 O-ring (58) into the 8N-3481 Fuel Filter Base As.
- Install pressure sensor (92) and 1 O-ring (51) into adapter (62).
- Attach 1 clip (21) to each camshaft cover on cylinders 4 and 6 with 1 bolt (90) and 1 washer (13) per clip.
- Attach bracket assembly (91) to the camshaft cover on cylinder 8 with 1 bolt (34) and 1 washer (13) per clip.
- Install 1 grommet (46) around wiring harness (1).
- Install 1 clip (23) and 1 clip (24) around grommet (46).
- Attach clips (4) and (5) to bracket assembly (91) with 1 stud (80) and 1 washer (7).
- Attach 1 clip (94) to the 100-4818 Support As with the original hardware.
- Plug wiring harness (1) into pressure sensors (63) and (92).
- Secure wiring harness (1) to clips (21) and (94) with 1 cable strap (2) per clip.
- Secure excess wiring harness (1) to itself with 1 cable strap (2).
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Illustration 152 g06351306 (1) 563-8617 Harness
(2)7K-1181 Cable Strap
(43)132-5789 Clip
(50)353-5439 Connector
(51)228-7100 O-Ring Seal
(73)6V-5048 O-Ring Seal
(92)320-3060 Pressure Sensor Gp
(93)214-7566 O-Ring Seal
(100)202-2762 Clip
(101)353-5441 Elbow Adapter - Install connector (50) and 1 O-ring (93) into the 186-4192 Elbow.
- Install pressure sensor (92) and 1 O-ring (51) into connector (50).
- Install elbow (101) and 1 O-ring (73) into the 171-8944 Pump Adapter.
- Install pressure sensor (92) and 1 O-ring (51) into elbow (101).
- Attach 1 clip (43) to the 4P-0692 Clamp As with the original hardware.
- Plug wiring harness (1) into pressure sensors (92).
- Secure wiring harness (1) to clip (43) with 1 cable strap (2).
- Install clip (100) around wiring harness (1).
- Attach clip (100) to the top rear bolt of the 230-1080 Elbow with the original hardware.
- Secure excess wiring harness (1) to itself with 1 cable strap (2).
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Illustration 153 g06313349 (1) 563-8617 Harness
(11)4P-7581 Clip
(13)5M-2894 Hard Washer
(34)0S-0509 Bolt
(102)4P-7429 Clip
(103)430-9455 Liquid Level Sensor Gp
(104)2M-9780 O-Ring Seal
(105)8M-2772 Clip
(106)443-3869 Sensor Guard As - Install liquid level sensor (103) and 1 O-ring (104) into the oil pan.
- Plug wiring harness (1) into liquid level sensor (103).
- Attach sensor guard (106) to the oil pan with 2 bolts (34) and 2 washers (13).
- Install clip (105) around the wiring harness of liquid level sensor (103).
- Attach clip (105) to sensor guard (106) with 1 bolt (34) and 1 washer (13).
- Attach clip (102) to the oil pan with the original hardware.
- Attach clip (11) to the top front bolt of the 205-4776 Cover As with the original hardware.
- Secure wiring harness (1) to clips (11) and (102) with 1 cable strap (2) per clip.
Installing the
Note: Install the 478-3965 Sensor Harness As onto each 443-5682 Pressure Sensor Gp before installing the 496-0842 Engine Wiring Gp.
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| Illustration 154 | g06373409 |
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(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) | |
- Attach wiring harness (1) to the 491-6842 Electronic Control Module and the 289-1525 Engine Electronic Control Gp.
- Secure wiring harness (1) to each 233-0891 Bracket As with 1 cable straps (3) per bracket.
- Attach wiring harness (1) to the 563-8617 Engine Harness As.
- Install 1 grommet (9) around wiring harness (1).
- Install 1 clip (5) and 1 clip (6) around grommet (9).
- Secure clips (5) and (6) to the 249-2943 Stud with 2 washers (7) and 1 nut (8).
- Install 1 grommet (4) around wiring harness (1).
- Install 1 clip (5) and 1 clip (6) around grommet (4).
- Secure clips (5) and (6) to the 249-2943 Stud with 2 washers (7) and 1 nut (8).
- Install 1 grommet (12) around wiring harness (1).
- Install 1 clip (13) and 1 clip (14) around grommet (12).
- Attach clips (5) and (6) to the 230-1078 Plate As with 1 bolt (15) and 1 washer (7).
- Install 1 grommet (10) and 1 grommet (11) around wiring harness (1).
- Secure grommet (10) to grommet (11) with 1 cable strap (3).
- Install 1 grommet (2) around wiring harness (1).
- Secure grommet (2) to the 206-2423 Mounting Saddle with 1 cable strap (3).
- Secure wiring harness (1) with cable straps (3) as needed.
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Illustration 155 g06373492 (1) 563-8618 Engine Harness As - Attach wiring harness (1) to the engine block with the original hardware.
- Attach wiring harness (1) to the 563-8617 Engine Harness As.
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Illustration 156 g06380768 (1) 563-8618 Engine Harness As
(3)7K-1181 Cable Strap
(5)5P-7467 Clip
(6)5P-7468 Clip
(7)9X-6458 Hard Washer
(8)9S-8752 Full Nut
(9)5P-8444 Grommet
(16)204-8000 Cable Tie Mounting
(17)0S-1588 Bolt
(18)6V-0826 Grommet
(19)4P-7581 Clip
(20)5P-7469 Clip
(21)6B-2882 SpacerShow/hide table
Illustration 157 g06380795 (1) 563-8618 Engine Harness As
(6)5P-7468 Clip
(9)5P-8444 Grommet
(20)5P-7469 Clip
(21)6B-2882 Spacer - Attach wiring harness (1) to the 488-4875 Electronic Control Module and the 491-6842 Electronic Control Module.
- Plug wiring harness (1) into the 478-3965 Sensor Harness As and the 463-0220 Gas Control Valves on cylinders 6, 8, 10, and 12.
- Attach bracket (19) to the 495-6440 Manifold with the original hardware.
- Secure wiring harness (1) to bracket (19) and the 496-9936 Brackets with 1 cable strap (3).
- Secure wiring harness (1) to the 496-9936 Brackets with 1 cable strap (3) per bracket.
- Install 1 grommet (9) around wiring harness (1).
- Install 1 clip (5) and 1 clip (6) around grommet (9).
- Install clips (5) and (6) onto the 249-2943 Stud on cylinder 10 with 1 washer (7) and 1 nut (8).
- Install 1 grommet (18) around wiring harness (1).
- Secure grommet (18) to the 206-2423 Mounting Saddle with 1 cable strap (3).
- Remove the 1W-1038 Stud and associated hardware from the 563-8617 Engine Harness As
- Install 1 grommet (9) around wiring harness (1).
- Install 1 clip (6) and 1 clip (20) around grommet (9).
- Install clips (6) and (20) onto the 474-5362 Bracket As on cylinder 8 with 1 spacer (21) and the original hardware.
- Attach cable tie mount (16) to the 474-5362 Bracket As on cylinder 6 with 1 bolt (17) and 1 washer (7).
- Install 1 grommet (9) around wiring harness (1).
- Secure grommet (9) to cable tie mount (16) with 1 cable strap (3).
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Illustration 158 g06380863 (1) 563-8618 Engine Harness As
(3)7K-1181 Cable Strap
(4)6V-0545 Grommet
(6)5P-7468 Clip
(7)9X-6458 Hard Washer
(8)9S-8752 Full Nut
(9)5P-8444 Grommet
(16)204-8000 Cable Tie Mounting
(17)0S-1588 Bolt
(20)5P-7469 Clip
(22)8T-7087 Grommet - Plug wiring harness (1) into the 478-3965 Sensor Harness As and the 463-0220 Gas Control Valves on cylinders 2 and 4.
- Secure wiring harness (1) to bracket (19) and the 496-9936 Brackets with 1 cable strap (3) per bracket.
- Attach cable tie mount (16) to the 474-5361 Bracket As on cylinder 4 with 1 bolt (17) and 1 washer (7).
- Install 1 grommet (9) around wiring harness (1).
- Secure grommet (9) to cable tie mount (16) with 1 cable strap (3).
- Install 1 grommet (22) around wiring harness (1).
- Install 1 clip (6) and 1 clip (20) around grommet (22).
- Install clips (6) and (20) onto the 451-2253 Stud with 2 washers (7) and 1 nut (8).
Note: Install 1 washer against the head of the stud before installing the clips.
- Install 1 grommet (4) around the 563-8617 Engine Harness As.
- Install 1 grommet (22) around wiring harness (1).
- Secure grommet (4) to grommet (22) with 1 cable strap (3).
- Install 1 grommet (22) around wiring harness (1).
- Install 1 clip (6) and 1 clip (20) around grommet (22).
- Install clips (6) and (20) onto the 423-0909 Stud with 2 washers (7) and 1 nut (8).
Note: Install 1 washer against the head of the stud before installing the clips.
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Illustration 159 g06380924 (1) 563-8618 Engine Harness As
(6)5P-7468 Clip
(7)9X-6458 Hard Washer
(8)9S-8752 Full Nut
(17)0S-1588 Bolt
(20)5P-7469 Clip
(22)8T-7087 Grommet
(24)132-6782 Bracket
(25)5M-2894 Hard Washer
(26)249-2943 Stud - Remove the 2 original 0L-2070 Bolts holding the 7C-2199 Clamps. Set aside the washer for reuse.
- Install 2 studs (23) and the original washers to hold the 7C-2199 Clamps.
- Install 1 bracket (24) onto each stud (23) with 1 washer (25) and 1 nut (8) per stud.
- Install 2 grommets (22) around wiring harness (1).
- Install 1 clip (6) and 1 clip (20) around each grommet (22).
- Attach each set of clips (6) and (20) to bracket (24) with 1 stud (26), 1 washer (7), 1 washer (25) and, 1 nut (8) per bracket.
Note: Install washer (8) against the head of the stud.
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Illustration 160 g06380942 (1) 563-8618 Engine Harness As
(6)5P-7468 Clip
(7)9X-6458 Hard Washer
(8)9S-8752 Full Nut
(17)0S-1588 Bolt
(20)5P-7469 Clip
(22)8T-7087 Grommet - Install 2 grommets (22) around the 563-8617 Engine Harness As.
- Install 1 clip (6) and 1 clip (20) around each grommet (22).
- Install each set of clips (6) and (20) to each stud (26) with 2 washer (7) and 1 nut (8) per stud.
Note: Install 1 washer against the head of the stud before installing the clips.
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Illustration 161 g06380970 (1) 563-8618 Engine Harness As
(3)7K-1181 Cable Strap
(4)6V-0545 Grommet
(6)5P-7468 Clip
(7)9X-6458 Hard Washer
(8)9S-8752 Full Nut
(17)0S-1588 Bolt
(20)5P-7469 Clip
(22)8T-7087 Grommet
(27)5P-8245 Hard Washer
(28)1F-7958 Full Nut
(29)206-2423 Mounting Saddle - Install 1 grommet (22) around wiring harness (1).
- Install 1 clip (6) and 1 clip (20) around each grommet (22).
- Install clips (6) and (20) onto the 423-0909 Stud with 2 washers (7) and 1 nut (8).
Note: Install 1 washer against the head of the stud before installing the clips.
- Install 2 grommets (22) around wiring harness (1).
- Attach 1 mounting saddle (29) each grommet (22) with 1 cable strap (3) per mounting saddle.
- Install 1 grommet (22) around the 563-8617 Engine Harness As.
- Attach grommet (22) to mounting saddle (29) with 1 cable strap (3).
- Install 1 grommet (4) around the 563-8617 Engine Harness As.
- Attach grommet (4) to mounting saddle (29) with 1 cable strap (3).
- Install 1 grommet (22) around wiring harness (1).
- Install 1 clip (6) and 1 clip (20) around each grommet (22).
- Install clips (6) and (20) onto the 355-4656 Stud with 2 washers (27) and 1 nut (28).
Note: Install 1 washer against the head of the stud before installing the clips.
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Illustration 162 g06381250 (1) 563-8618 Engine Harness As
(3)7K-1181 Cable Strap
(6)5P-7468 Clip
(7)9X-6458 Hard Washer
(17)0S-1588 Bolt
(18)6V-0826 Grommet
(19)4P-7581 Clip
(20)5P-7469 Clip
(22)8T-7087 Grommet
(30)6V-1249 Grommet
(31)091-9035 Spacer
(32)0S-1590 Bolt
(33)5P-8112 Grommet
(34)8T-1889 Clip
(35)8T-1890 Clip - Plug wiring harness (1) into the 478-3965 Sensor Harness As and the 463-0220 Gas Control Valves on cylinders 1, 3, 5, and 7.
- Secure wiring harness (1) to the 496-9936 Brackets with 1 cable strap (3) per bracket.
- Attach cable tie mount (16) to the 474-5361 Bracket As on cylinder 1 with 1 spacer (31), 1 bolt (32), and 1 washer (7).
Note: Install the spacer behind the cable tie mount.
- Install 1 grommet (22) around wiring harness (1).
- Secure grommet (22) to cable tie mount (16) with 1 cable strap (3).
- Install 1 grommet (22) around wiring harness (1).
- Install clip (6) and clip (20) around grommet (22).
- Attach clips (6) and (20) to the 474-5362 Bracket As on cylinder 3 with 1 spacer (31), 1 bolt (32), and 1 washer (7).
- Attach cable tie mount (16) to the 474-5361 Bracket As on cylinder 5 with 1 bolt (17) and 1 washer (7).
- Install 1 grommet (33) around wiring harness (1).
- Secure grommet (33) to cable tie mount (16) with 1 cable strap (3).
- Attach 1 clip (19) to the 474-5361 Bracket As on cylinder 5 with the original hardware.
- Secure wiring harness (1) to clip (19) with 1 cable strap (3).
- Attach cable tie mount (16) to the 474-5361 Bracket As on cylinder 7 with 1 spacer (31), 1 bolt (32), and 1 washer (7).
Note: Install the spacer behind the cable tie mount.
- Install 1 grommet (30) around wiring harness (1).
- Secure grommet (30) to cable tie mount (16) with 1 cable strap (3).
- Install 1 grommet (18) around wiring harness (1).
- Install clip (34) and clip (35) around grommet (18).
- Attach clips (34) and (35) to the 474-4544 Bracket As with 1 bolt (17) and 1 washer (7).
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Illustration 163 g06381337 (1) 563-8618 Engine Harness As
(2)118-2950 Grommet
(3)7K-1181 Cable Strap
(7)9X-6458 Hard Washer
(13)5P-7464 Clip
(14)5P-7465 Clip
(17)0S-1588 Bolt
(18)6V-0826 Grommet
(25)5M-2894 Hard Washer
(30)6V-1249 Grommet
(31)091-9035 Spacer
(32)0S-1590 Bolt
(36)187-3301 Bracket
(37)9M-1974 Hard Washer
(38)5S-0003 Nut
(39)355-4677 Bracket As - Attach wiring harness (1) to the 488-4875 Electronic Control Module.
- Secure the 344-2466 Cover As to the 127-1570 Stud with 1 washer (37) and 1 nut (38).
- Plug wiring harness (1) into the 478-3965 Sensor Harness As and the 463-0220 Gas Control Valves on cylinders 9 and 11.
- Secure wiring harness (1) to the 496-9936 Brackets with 1 cable strap (3) per bracket.
- Install 1 grommet (30) around wiring harness (1).
- Install clip (13) and clip (14) around grommet (30).
- Attach clips (13) and (14) to the 474-5361 Bracket As with 1 spacer (31), 1 bolt (32), and 1 washer (7).
- Install 1 grommet (18) around wiring harness (1).
- Secure grommet (18) to the 206-2423 Mounting Saddle with 1 cable strap (3).
- Install 2 grommets (2) around wiring harness (1).
- Secure grommet (2) to each 132-5789 Clip and 6V-0683 Grommet on cylinder 11 with 1 cable strap (3) per clip and grommet.
- Attach bracket (36) to the 474-4544 Bracket As with 1 bolt (17) and 1 washer (7).
- Attach bracket (39) to the 127-1570 Stud with 1 washer (25), 1 washer (37), and 1 nut (38).
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Illustration 164 g06381361 (1) 563-8618 Engine Harness As
(7)9X-6458 Hard Washer
(8)9S-8752 Full Nut
(13)5P-7464 Clip
(14)5P-7465 Clip
(17)0S-1588 Bolt
(30)6V-1249 Grommet
(40)7V-6571 Grommet
(41)7S-3916 Clip
(42)7S-3919 Clip - Install 1 grommet (30) around wiring harness (1).
- Install clip (13) and clip (14) around grommet (30).
- Attach clips (13) and (14) to the 187-3301 Bracket with 1 bolt (17), 1 washer (7), and 1 nut (8).
Note: The install clips with the bracket on one side and the washer on the other side.
- Install 1 grommet (40) around wiring harness (1).
- Install clip (41) and clip (42) around grommet (40).
- Attach clips (41) and (42) to the 355-4674 Bracket with 1 bolt (17) and 1 washer (7).
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Illustration 165 g06381425 (1) 563-8618 Engine Harness As
(3)7K-1181 Cable Strap
(43)4P-8134 Clip - Attach clip (43) to the 495-6440 Manifold on cylinder 1 with the original hardware.
- Secure wiring harness (1) to clip (43) with 1 cable strap (3).
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Illustration 166 g06381446 (1) 563-8618 Engine Harness As
(3)7K-1181 Cable Strap
(44)132-5789 Clip - Attach clip (44) to the 463-0220 Gas Control Valve on cylinder 11 with the original hardware.
- Secure wiring harness (1) to clip (44) with 1 cable strap (3).
Installing the
- Remove and discard the ground cable and associated hardware.
- Remove the battery + terminal and cable strap back to the wiring harness.
Note: Cable strapping the wiring harness back will prevent damage to other components.
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Illustration 167 g06276179 (1) 183-4274 Bracket
(2)129-3172 Mounting Stud
(3)5M-2894 Hard Washer
(4)9S-8752 Full Nut - Remove the original 1A-2029 Bolt from the 166-8455 Elbow.
- Install 1 mounting stud (2) and 1 washer (3) into the 166-8455 Elbow.
- Install 1 bracket (1) onto mounting stud (2) with 1 washer (3) and 1 nut (4).
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Illustration 168 g06276188 (3) 5M-2894 Hard Washer
(4)9S-8752 Full Nut
(5)290-5562 Mount
(6)7K-1181 Cable Strap
(7)4P-7581 Clip
(8)1A-2029 Bolt
(9)6V-1574 Grommet
(10)6V-1572 Clip
(11)6V-1573 Clip - Attach 3 mounts (5) to the 105-4299 Tube As with 1 cable strap (6) per mount.
- Install 2 grommets (9) around the 105-4299 Tube As.
- Install 1 clip (10) and 1 clip (11) around each grommet (9).
- Attach 1 clip (7) to each set of clips (10) and (11) with 1 bolt (8), 2 washers (3), and 1 nut (5).
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Illustration 169 g06276195 (6) 7K-1181 Cable Strap
(12)526-2560 Power Harness As
(13)8T-2920 Grommet - Attach battery - of wiring harness (12) to the alternator.
- Attach battery + of wiring harness (12) to the alternator.
- Attach wiring harness (12) to the 4P-8134 Clip on the bottom of the alternator bracket with 1 grommet (13) and 1 cable strap (6).
- Attach wiring harness (12) to the 183-4274 Bracket with 2 grommets (13) and 2 cable straps (6).
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Illustration 170 g06276209 (6) 7K-1181 Cable Strap
(12)526-2560 Power Harness As
(13)8T-2920 Grommet - Attach wiring harness (12) to the 290-5562 Mounts with 1 grommet (13) and 1 cable strap (6) per mount.
- Attach wiring harness (12) to the 4P-7581 Clips with 1 grommet (13) and 1 cable strap (6) per clip.
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Illustration 171 g06276225 (5) 290-5562 Mount
(6)7K-1181 Cable Strap
(12)526-2560 Power Harness As
(13)8T-2920 Grommet
(14)306-8526 Grommet
(15)6V-1874 Grommet - Attach wiring harness (12) to the 496-0838 Wiring Harness with 1 grommet (13), 1 grommet (5), 1 mount (5), and 2 cable straps (6).
- Attach the ground terminal of wiring harness (12) to the existing ground boss with the original hardware.
- Attach wiring harness (12) to the 465-1028 Bracket As with 2 grommets (14) and 2 cable straps (6) per clip.
Chassis Rework
With the engine out of the chassis, weld the following bosses and links.
Note: Most easily done with rear hood at ground level, before engine installation.
Note: Weld a
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| Illustration 172 | g06038558 |
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Bottom of rear hood (A) (B) (C) (1) | |
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| Illustration 173 | g06232374 |
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Bottom of rear hood (D) (1) | |
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| Illustration 174 | g06038552 |
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Bottom of rear hood (E) (F) (G) (H) (1) (2) | |
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| Illustration 175 | g06232388 |
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Bottom of rear hood (J) (1) | |
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| Illustration 176 | g06038581 |
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Bottom of rear hood (K) (L) (M) (N) (P) (R) (S) (T) (3) | |
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| Illustration 177 | g06227476 |
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(U) (V) (4) | |
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| Illustration 178 | g06227484 |
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(W) (X) (5) | |
Installing the
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| Illustration 179 | g06061073 |
Note: The 465-9489 Control Harness As must be installed down the left-hand side frame before installing the radiator shroud.
- Attach the original VIMS (4) to plate assembly (1) with the original 3 washers (2) and 3 nuts (3).
- Install green lamp (5) into plate assembly (1).
- Install red lamp (6) into plate assembly (1).
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Illustration 181 g06038048 (1) 465-9487 Plate As
(6)442-1341 Indicator Lamp Gp
(7)174-7875 Horn
(8)8T-4196 Bolt
(9)8T-4121 Hard Washer
(10)483-2443 Control Harness As - Attach horn (7) to plate assembly (1) with 1 bolt (8) and 1 washer (9).
- Plug wiring harness (10) into red lamp (6) and horn (7).
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Illustration 182 g06038084 (1) 465-9487 Plate As
(5)443-2975 Indicator Lamp Gp
(9)8T-4121 Hard Washer
(10)483-2443 Control Harness As
(11)204-8000 Cable Tie Mounting
(12)8T-4136 Bolt
(13)204-2281 Cable Strap - Attach 2 cable mounts (11) to plate assembly (1) with 1 bolt (12) and 1 washer (9) per cable mount.
- Secure the wire of green lamp (5) to cable mount (11) with 1 cable strap (13).
- Secure wiring harness to cable mount (11) with 1 cable strap (13).
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Illustration 183 g06038112 (1) 465-9487 Plate As
(14)7X-0291 Bolt
(15)5P-1075 Hard Washer
(16)8W-1152 Spacer
(17)130-5300 ClipNote: After the radiator is installed, attach the VIMS light and warning horn to the bumper.
- Attach plate assembly (1) to the truck bumper with 2 bolts (14), 2 washers (15), 2 spacers (16), and 1 clip (17). Refer to Illustration 183 for the correct location of the clip.
- Attach the connector of green lamp (5) to clip (17).
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Illustration 184 g06038169 Top of bumper on the left-hand side
(5)443-2975 Indicator Lamp Gp
(10)483-2443 Control Harness As
(11)204-8000 Cable Tie Mounting
(15)5P-1075 Hard Washer
(17)130-5300 Clip
(18)465-9489 Control Harness As
(19)313-9550 Taperlock Stud
(20)6V-8801 Nut
(21)125-8534 Plate As - Plug wiring harness (18) into green lamp (5) and wiring harness (10).
- Plug the VIMS wiring harness into the original wiring harness.
- Install 1 taperlock stud (19) into the 8B-1910 Boss.
- Install plate assembly (21), clip (17), and cable mount (11) onto taperlock stud (19) with 1 washer (15) and 1 nut (20).
- Attach the connector of wiring harness (18) to clip (17).
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Illustration 185 g06038187 Top of bumper on the left-hand side
(5)443-2975 Indicator Lamp Gp
(9)8T-4121 Hard Washer
(10)483-2443 Control Harness As
(11)204-8000 Cable Tie Mounting
(13)204-2281 Cable Strap
(15)5P-1075 Hard Washer
(17)130-5300 Clip
(18)465-9489 Control Harness As
(21)125-8534 Plate As
(22)8T-4195 Bolt - Attach cable mount (11) and clip (17) to plate assembly (21) with 1 bolt (22) and 1 washer (9).
- Attach the connector of red lamp (6) to clip (17).
- Secure wiring harness of red lamp (6) to cable mount (11) with 1 cable strap (13).
- Secure wiring harness (10) to cable mount (11) with 1 cable strap (13).
- Secure wiring harness (18) to the original wiring harness as needed with cable straps (13).
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Illustration 186 g06037559 Rear of bumper on the left-hand side
(11)204-8000 Cable Tie Mounting
(13)204-2281 Cable Strap
(17)130-5300 Clip
(18)465-9489 Control Harness As
(19)313-9550 Taperlock Stud
(20)6V-8801 Nut
(23)8T-4896 Hard Washer
(24)5S-7379 Bolt
(25)465-9495 Chassis Harness AsNote: The 465-9495 Chassis Harness As is more easily installed before re-installation of the belly guards.
- Remove the original hardware from the original wiring harness.
Note: Leave the clips on the wiring harness.
- Attach the original clip and cable mount (11) to the 9D-5659 Boss with 1 taperlock stud (19), 1 washer (23), and 1 nut (20).
- Attach clip (17) to the 9D-6166 Boss with 1 bolt (24) and 1 washer (23).
- Attach the original clip and cable mount (11) to the 9D-6166 Boss with 1 taperlock stud (19), 1 washer (23), and 1 nut (20).
- Plug wiring harness (25) into wiring harness (18).
- Attach the connector of wiring harness (25) to clip (17).
- Secure wiring harness (18) to the original wiring harness as needed with cable straps (13).
- Secure wiring harness (18) to cable mount (11) with 1 cable strap (13).
- Secure wiring harness (25) to cable mount (11) with 1 cable strap (13).
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Illustration 187 g06037455 Rear of bumper on the right-hand side
(11)204-8000 Cable Tie Mounting
(13)204-2281 Cable Strap
(19)313-9550 Taperlock Stud
(20)6V-8801 Nut
(23)8T-4896 Hard Washer
(25)465-9495 Chassis Harness As
(26)353-7956 Grommet
(27)7V-6571 Grommet
(28)200-6345 Mount - Attach wiring harness (25) to the ground lug.
- Attach the original clips and 2 cable mounts (11) to the 9D-5659 Boss with 1 taperlock stud (19), 1 washer (23), and 1 nut (20) per boss.
- Attach the original clips and 2 cable mounts (11) to the 9D-6166 Bosses with 1 taperlock stud (19), 1 washer (23), and 1 nut (20) per boss.
- Secure wiring harness (25) to cable mounts (11) with 1 cable strap (13) per cable mount.
- Install grommet (26) around wiring harness (25).
- Install grommet (27) around the original wiring harness.
- Attach mount (28) to grommets (26) and (27) with 1 cable strap (13) per grommet.
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Illustration 188 g06037827 Left-hand front corner of the engine compartment.
(13)204-2281 Cable Strap
(18)465-9489 Control Harness As - Secure wiring harness (18) to the original wiring harness as needed with cable straps (13).
Note: The wiring harness must be installed down the left-hand side frame before installing the radiator shroud.
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Illustration 189 g06037833 Upper left-hand front corner of the engine compartment, near the ROPs tube mount
(13)204-2281 Cable Strap
(18)465-9489 Control Harness As - Secure wiring harness (18) to the original wiring harness as needed with cable straps (13).
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Illustration 190 g06037840 (13) 204-2281 Cable Strap
(18)465-9489 Control Harness As - Secure wiring harness (18) to the original wiring harness as needed with cable straps (13).
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Illustration 191 g06037852 (13) 204-2281 Cable Strap
(17)130-5300 Clip
(18)465-9489 Control Harness As
(19)313-9550 Taperlock Stud
(20)6V-8801 Nut
(23)8T-4896 Hard Washer
(29)133-6934 Spacer
(30)517-2818 Sensor Harness AsShow/hide table
Illustration 192 g06038937 The arrow points to the correct location of the wiring harness.
(30)517-2818 Sensor Harness As - Relocate the 24 V wiring harness. Sensor harness (30) will go inside the cab at that location.
- Remove the original hardware from the original wiring harness.
Note: Leave the clip on the wiring harness.
- Attach 1 clip (17) to each connector of sensor harness (30).
- Attach the original clip and clips (17) to the 9D-5659 Boss with 1 spacer (29), 1 taperlock stud (19), 1 washer (23), and 1 nut (20).
Note: The spacer goes in between the original clip and clips (17).
- Plug sensor harness (30) into control harness (18).
Note: The loose connector plugs into the 465-9490 Control Harness As for the 465-0623 Pressure Sensor Gp.
- Secure wiring harnesses (18) and (30) to the original wiring harness as needed with cable straps (13).
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Illustration 193 g06037859 (13) 204-2281 Cable Strap
(30)517-2818 Sensor Harness As - Secure wiring harness (30) to the original wiring harness as needed with cable straps (13).
Note: It is IMPERATIVE that there be no contact between the engine mounted wiring harnesses and the chassis mounted wiring harnesses as this will cause failure. Clips may need to be removed and reoriented.
Note: The loose connector plugs into the 463-0870 Wiring Harness on the engine.
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Illustration 194 g06037890 (13) 204-2281 Cable Strap
(30)517-2818 Sensor Harness As - Secure wiring harness (30) to the original wiring harness as needed with cable straps (13).
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Illustration 195 g06061666 Rear left-hand frame rail
(13)204-2281 Cable Strap
(30)517-2818 Sensor Harness As
(31)517-2817 Sensor Harness As - Secure wiring harness (30) to the original wiring harness as needed with cable straps (13).
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Illustration 196 g06038460 (17) 130-5300 Clip
(19)313-9550 Taperlock Stud
(20)6V-8801 Nut
(21)125-8534 Plate As
(23)8T-4896 Hard Washer
(30)517-2818 Sensor Harness As
(31)517-2817 Sensor Harness As - Attach 1 clip (17) to each connector of wiring harness (31).
- Attach clips (17) and plate assembly (21) to the 9D-5659 Boss with 1 taperlock stud (19), 1 washer (23), and 1 nut (20). Refer to Illustration for the correct orientation of the plate assembly.
- Plug wiring harness (30) into wiring harness (31).
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Illustration 197 g06037916 (11) 204-8000 Cable Tie Mounting
(13)204-2281 Cable Strap
(21)125-8534 Plate As
(23)8T-4896 Hard Washer
(31)517-2817 Sensor Harness As
(32)4L-6454 Bolt - Attach cable mount (11) to plate assembly (21) with 1 bolt (32) and 1 washer (23).
- Secure wiring harness (31) to cable mount (11) with 1 cable strap (13).
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Illustration 198 g06037939 (11) 204-8000 Cable Tie Mounting
(13)204-2281 Cable Strap
(23)8T-4896 Hard Washer
(31)517-2817 Sensor Harness As
(32)4L-6454 Bolt - Attach cable mount (11) to the 461-7161 Mounting Plate Gp with 1 bolt (32) and 1 washer (23).
- Secure wiring harness (31) to cable mount (11) with 1 cable strap (13).
Note: This wiring harness plugs into 457-5995 on the fuel tank.
Note: Complete Steps 56 through 62 after the engine has been re-installed and the hoods are in place.
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Illustration 199 g06039503 (11) 204-8000 Cable Tie Mounting
(13)204-2281 Cable Strap
(17)130-5300 Clip
(23)8T-4896 Hard Washer
(32)4L-6454 Bolt
(33)465-9490 Control Harness As - Attach clip (17) to wiring harness (33).
Note: This wiring harness plugs into 517-2817 Control Harness As after the hood is installed.
- Attach clip (17) to the 8D-3508 Boss with 1 bolt (32) and 1 washer (23).
- Attach 5 cable mounts (11) to the 8D-3508 Bosses with 1 bolt (32) and 1 washer (23) per cable mount and boss.
- Secure wiring harness (33) to cable mounts (11) with 1 cable strap (13) per cable mount.
- Secure wiring harness (33) to the 7T-1099 Links with 1 cable strap (13) per link.
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Illustration 200 g06039528 (13) 204-2281 Cable Strap
(34)465-0623 Pressure Sensor Gp
(35)5P-8394 Screw
(36)9B-7233 Lockwasher - Attach pressure sensor (34) to the 465-9505 Plate with 2 screws (35) and 2 washers (36).
- Secure wiring harness (33) to the 7T-1099 Links with 1 cable strap (13) per link.
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| Illustration 180 | g06038024 |
|
(1) (2) (3) (4) (5) (6) | |
Three Main Areas of Concern While Installing the Engine
Left Rear Wiring Harness
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| Illustration 201 | g06244411 |
- Loosen and adjust clips on the engine.
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Illustration 202 g06244412 - Relocate the clips for the wiring harness on the chassis to adjust for clearance.
Right Center Transmission Cooler and Fuel Water Separator
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| Illustration 203 | g06391038 |
Right Rear Steering Suction Line
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| Illustration 204 | g06244399 |
Note: The steering suction hose will rub on the gas tube at the right rear of the engine.
- Remove the clip to pull the steering suction hose out of harms way during the engine install.
- Re-clip the steering suction hose to existing block higher on the frame with the original hardware. When clipped in new location, and adjusted, there will be no interference between the hose and the tube.
Installing the Engine and Torque Converter
- Using a suitable lifting device and tool (A), attach the torque converter to the engine with the original hardware. The torque converter weighs approximately
839 kg (1850 lb) .Note: The 457-5994 Chassis Wiring Gp must be installed before the engine and cooling package is installed.
- Install the engine and torque converter into the truck. The engine and torque converter weigh approximately
7031 kg (15500 lb) .
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| Illustration 205 | g03784204 |
|
(A) | |
Installing the
Note: The 457-6006 Cab Ar (Wiring Harness) can be installed at any time in the process.
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| Illustration 206 | g06061615 |
- Remove the rear panel from the cab.
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Illustration 208 g06046853 (1) 570-7683 Wiring Harness
(2)3S-2093 Cable Strap - Attach wiring harness (1) to the 517-2817 Sensor Harness As.
Note: The little wire going toward the rear of the cab runs up the corner into the cab.
- Secure wiring harness (1) to the main cab wiring harness as needed with cable straps (2).
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Illustration 209 g06227516 (1) 570-7683 Wiring Harness
(2)3S-2093 Cable Strap
(A) Wire 150-RD
(B) Wire 151-GN
(C) Supercomm connector
(D) Wire Y956-GN
(E) Wire Y957-YL - Cut a hole out of the fuse plate to locate Supercomm connector (C) next to the service port.
- Attach Supercomm connector (C) to the fuse plate.
- Connect wire (D) to position G of the existing 9 pin communication adapter connector.
- Connect wire (E) to the CE-C7 connector position F.
- Connect wire (A) to position G6 of the existing fuse panel.
- Insert the 15 A fuse (spare) into position F26.
- Connect wire (B) to the T-C4 into position A1.
- Insert the 10 A fuse (spare) into position F1.
- Secure wiring harness (1) to the main cab wiring harness as needed with cable straps (2).
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Illustration 210 g06046880 (1) 570-7683 Wiring Harness
(2)3S-2093 Cable Strap
(F) Connector GC-C10
(G) Connector GC-C11 - Disconnect the T-C2 connector of the fuse block wiring harness from the 20A power converter.
- Connect connector (F) of wiring harness (1) to the 20A power converter in place of the T-C2 connector of the fuse block wiring harness.
- Connect connector (G) of wiring harness (1) to the T-C2 connector of the fuse block wiring harness.
- Secure wiring harness (1) to the main cab wiring harness as needed with cable straps (2).
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Illustration 211 g06046906 (1) 570-7683 Wiring Harness
(2)3S-2093 Cable Strap
(3)5S-7349 Bolt
(4)8T-4205 Hard Washer
(5)3E-5239 Relay As - Attach relay (5) to the cab with 1 bolt (3) and 1 washer (4).
- Secure wiring harness (1) to the main cab wiring harness as needed with cable straps (2).
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Illustration 212 g06046846 - Remove the 3 center panels from the bottom of the cab.
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Illustration 213 g06047676 (1) 570-7683 Wiring Harness
(2)3S-2093 Cable Strap - Run wiring harness (1) from the back of the cab to the front of the cab.
- Secure wiring harness (1) to the main cab wiring harness as needed with cable straps (2).
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Illustration 214 g06048182 - Remove the front panel from the cab.
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Illustration 215 g06048882 (1) 570-7683 Wiring Harness
(2)3S-2093 Cable Strap - Run wiring harness (1) from the front of the cab to the dash panel.
- Secure wiring harness (1) to the main cab wiring harness as needed with cable straps (2).
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Illustration 216 g06048894 (1) 570-7683 Wiring Harness
(6)160-6382 Grommet
(7)285-6393 Clip
(8)132-1829 Alarm Gp - Cut a hole out in the dash panel next to the hole for the main cab harness.
Note: Instead of having 2 separate holes, the original hole can be modified to single hole with a suitable grommet.
- Remove the cabin air filter to access either a through hole or a weld nut. Refer to Illustration 216 for the correct location.
- Attach the clip (7) and alarm (8) to the dash panel with the original hardware. Refer to Illustration 216 for the correct location.
- Plug alarm (8) into wiring harness (1).
- Secure wiring harness (1) to clip (7) with 1 cable strap. The cable strap is not shown in Illustration 216.
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Illustration 217 g06048910 (1) 570-7683 Wiring Harness
(2)3S-2093 Cable Strap
(9)492-8156 Bracket As
(10)363-7544 Service Meter
(11)468-1945 Methane Detector Gp
(12)7Y-7389 Screw
(13)8T-0328 Hard Washer - Attach bracket (9) to the 300-3582 Mounting Bracket Gp with 4 screws (12) and 4 washers (13).
- Install service meter (10) into bracket (9).
- Install display (11) into bracket (9).
- Plug service meter (10) and (11) into wiring harness (1).
- Secure the connector of display (11) to wiring harness (1) with 1 cable strap (2).
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Illustration 218 g06048922 - Remove the 3 trim panels from around the window.
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Illustration 219 g06048927 (1) 570-7683 Wiring Harness - Run wiring harness (1) up the corner of the cab.
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Illustration 220 g06048984 (14) 465-0623 Pressure Sensor Gp
(15)492-8155 Bracket
(16)121-4405 Bolt
(17)244-2331 Washer
(18)5C-8312 Nut - Attach pressure sensor (14) to bracket (15) with 2 bolts (16), 4 washers (17), and 2 nuts (18).
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Illustration 221 g06048954 (15) 492-8155 Bracket - Reinstall the bottom and rear trim pieces with the original hardware.
Note: Make sure that the 570-7683 Wiring Harness is installed behind the trim pieces.
- Attach bracket (15) and the top trim piece to the cab with the original hardware.
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| Illustration 207 | g06046838 |
Installing the
Note: The fuel tank group should come preassembled.
Note: Apply Loctite® 567 thread sealant to all pipe threads.
- Install connector (1) and 1 O-ring (2) into valve assembly (3).
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Illustration 223 g06031406 (2) 5P-2618 Connector
(4)492-9025 Hose As - Attach hose (4) to connector (2).
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Illustration 224 g06250173 (5) 486-4571 Plate
(6)8X-8443 Cover
(7)4H-9027 Pipe Plug - Remove plate (5) the from the 482-3931 Fuel Tank As. Set aside the plate and associated hardware for reuse.
- Remove and discard cover (6) the from the 482-3931 Fuel Tank As. Set aside the associated hardware for reuse.
- Remove and discard pipe plug (7) the from the 482-3931 Fuel Tank As.
- Run a string through the pipe plug (7) hole to the hole in the end of the 482-3931 Fuel Tank As.
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Illustration 225 g06032218 (3) 252-5806 Shutoff Valve Assembly
(8)9X-7287 O-Ring Seal
(9)8T-4196 Bolt
(10)8T-4121 Hard Washer - Attach a string to the 492-9025 Hose As. Pull the hose assembly through the 482-3931 Fuel Tank As up to the pipe plug hole.
- Attach valve assembly (3) and 1 O-ring (8) to the 482-3931 Fuel Tank As with 6 bolts (9) and 6 washers (10).
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Illustration 226 g06250185 320-9175 Vent As - Remove the 2 roll pins and cap from the vent assembly.
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Illustration 227 g06250192 (1) 5P-2618 Connector
(2)3J-1907 O-Ring Seal
(11)320-9175 Vent As - Install connector (1) and 1 O-ring (2) into vent assembly (11).
- Attach the 492-9025 Hose As to connector (1).
- Remove the string from the 492-9025 Hose As.
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Illustration 228 g06031416 (1) 320-9175 Vent As - Install vent assembly (11) into the 482-3931 Fuel Tank As.
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Illustration 229 g06250185 320-9175 Vent As - Reinstall the cap and 2 roll pins onto the vent assembly.
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Illustration 230 g06032232 (3) 252-5806 Shutoff Valve Assembly
(12)471-8198 Receiver
(13)4J-0527 O-Ring Seal
(14)388-4327 Dust Cap
(15)1P-4582 Half Flange
(16)8T-4184 Bolt
(17)8T-4223 Hard Washer - Attach receiver (12) and 1 O-ring (13) to valve assembly (3) with 2 half flanges (15), 4 bolts (16), and 4 washers (17).
- Install dust cap (14) onto receiver (12).
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Illustration 231 g06031124 (5) 486-4571 Plate
(18)0S-1594 Bolt
(19)486-4559 Tube As
(20)416-4772 Level Sender As
(21)6C-3060 Gasket or363-4122 Gasket
(22)8T-4138 Bolt
(23)9X-8256 Washer - Attach tube assembly (19) and level sender (20) to the 482-3931 Fuel Tank As with 1 gasket (21), 6 bolts (22), and 6 washers (23).
- Reinstall plate (5) onto the 482-3931 Fuel Tank As with 6 bolts (18).
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Illustration 232 g06031474 (24) 360-9055 Hose As
(25)7D-1553 Clip
(26)8T-4137 Bolt
(27)8T-4121 Hard Washer
(28)5M-3062 Bolt
(29)5P-1075 Hard Washer
(30) Clamp - Attach hose assembly (27) to the 6G-7803 Vent As with 1 clamp (30).
- Secure hose assembly (27) to the 482-3931 Fuel Tank As with 2 clips (25), 1 bolt (26), 1 washer (27), 1 bolt (28), and 1 washer (29).
Note: Adjust clips for the breather hose to ensure that hose does not rub against anything.
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| Illustration 222 | g06032224 |
|
(1) (2) (3) | |
Installing the
Note: Before installing the LNG fuel tank, the tank pressure needs to be checked to confirm that there are no leaks. Tanks are pressurized with Nitrogen prior to shipment to prevent moisture from entering the tank. This is critical because any moisture in the tank will freeze and form ice when LNG is filled. Any ice in the tank has a potential to create a blockage in the outlet line and stop flow of fuel to the engine. The tank pressure should be between
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| Illustration 233 | g06030375 |
|
The following parts are from the (1) (2) (3) (4) | |
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| Illustration 234 | g06025584 |
|
The following parts are from the (1) (2) (3) (4) | |
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| Illustration 235 | g06025588 |
|
The following parts are from the (1) (2) (3) (4) | |
- Using a suitable lifting device, install fuel tank (1) onto fuel tank (4). The fuel tank weighs approximately
1025 kg (2260 lb) .Note: Install the top bolts first.
Note: Use the 550-5345 Shims and the 550-5348 Shims as needed.
- Secure fuel tank (1) to fuel tank (4) with 16 bolts (2) and 32 washers (3). Each bolt uses 2 washers.
Torque bolts ...
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Illustration 236 g06025637 The following parts are from the 461-7190 Bottom Guard Gp.
(6)8T-4121 Hard Washer
(7)492-8765 Mud Deflector
(8)428-5380 Plate
(9)8T-4195 Bolt
(10)134-0165 Washer - Attach the top of mud deflector (7) to the 482-3931 Fuel Tank As (Diesel) with 4 plates (8), 8 bolts (9), and 8 washers (6).
- Attach the bottom of mud deflector (7) to the 482-3931 Fuel Tank As (Diesel) with 2 bolts (9) and 2 washers (6).
Installing Sub Assembled Groups onto the
The sub assemblies contain parts from the following groups:
- 455-2340 Fuel Lines Gp (Gas System)
- 455-2341 Water Lines Gp
- 455-2342 Fuel Lines Gp (Diesel System)
- 455-2343 Fuel Tank Vent Gp
Note: Apply Loctite® 567 thread sealant to all pipe threads.
Note: Apply Lox-8® paste to the face of all cryogenic flare fittings.
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| Illustration 237 | g06025748 |
|
The following parts are from the (1) (2) (3) (4) | |
- Using a suitable lifting device, install vaporizer (1) onto fuel tank (4). The vaporizer weighs approximately
133 kg (293 lb) . - Secure vaporizer (1) to fuel tank (4) with 8 bolts (2) and 8 washers (3).
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Illustration 238 g06031901 The following parts are from the 455-2341 Water Lines Gp.
(1)554-3064 Vaporizer
(5)9S-4191 Plug
(6)3J-1907 O-Ring Seal
(7)421-6206 Connector As - Install plug (5) and 1 O-ring (6) into the vaporizer (1).
- Install 2 connectors (7) into the vaporizer (1).
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Illustration 239 g06031913 The following parts are from the 455-2342 Fuel Lines Gp (Diesel System).
(8)001-6301 Elbow
(9)2W-6071 Primary Fuel Filter Gp - Install 2 elbows (8) into primary fuel filter (9). Refer to Illustration 239 for the correct orientation of the elbows.
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Illustration 240 g06031984 The following parts are from the 455-2342 Fuel Lines Gp (Diesel System).
(4)482-3931 Fuel Tank As (Diesel)
(9)2W-6071 Primary Fuel Filter Gp
(10)8T-2502 Bolt
(11)8T-4896 Hard Washer
(12)304-7982 Manual Valve As
(13)7D-6936 Check Valve As
(14)032-1269 Elbow - Attach primary fuel filter (9) to fuel tank (4) with 2 bolts (10) and 2 washers 11.
- Remove the 3J-5389 Plug and the 9S-4183 Plug fuel tank (4).
- Install manual valve (12) into the fuel tank (4).
- Install check valve (13) into the fuel tank (4).
- Install elbow (14) into check valve (13). Refer to Illustration 240 for the correct orientation of the elbow.
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Illustration 241 g06032005 The following parts are from the 455-2342 Fuel Lines Gp (Diesel System).
(8)001-6301 Elbow
(12)304-7982 Manual Valve As
(15)357-4619 Elbow As
(16)466-6944 Hose As - Install elbow (15) into manual valve (12). Refer to Illustration 241 for the correct orientation of the elbow.
- Attach the 90 degree end of hose (16) to elbow (8).
- Attach the straight end of hose (16) to elbow (15).
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Illustration 242 g06032072 The following parts are from the 455-2343 Fuel Tank Vent Gp.
(17)459-0623 Ball Valve
(18)119-0572 Adapter
(19)215-4639 O-Ring Seal
(20)030-7935 Connector
(21)326-5136 Manifold
(22)030-7951 Flared Elbow
(23)4S-6797 Adapter
(24)228-7096 O-Ring Seal
(25)8K-6898 Fitting AsNote: Make sure that no oil or water is in the LNG lines.
- Install adapter (18) and 1 O-ring (19) into manifold (21).
- Install connector (20) and 1 O-ring (19) into manifold (21).
- Install elbow (22) and 1 O-ring (19) into manifold (21).
- Install adapter (23) and 1 O-ring (24) into manifold (21).
- Install elbow (25) and 1 O-ring (19) into manifold (21).
- Attach ball valve (17) to elbow (25).
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Illustration 243 g06038989 Ball valve rubbing on the 482-1995 Hose As. - Adjust the ball valve to avoid rubbing on the 482-1995 Hose As, refer to Illustration 243.
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Illustration 244 g06032292 The following parts are from the 455-2343 Fuel Tank Vent Gp.
(26)507-8357 Adapter
(27)514-2369 Relief Valve
(28)514-2368 Adapter
(29)002-6454 ConnectorNote: Do not over tighten the relief valve.
- Install adapter (26) onto relief valve (27).
- Install relief valve (27) onto adapter (28).
- Install adapter (28) onto connector (29).
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Illustration 245 g06032302 The following parts are from the 455-2343 Fuel Tank Vent Gp.
(30)030-8307 Connector
(31)9Y-2238 Plug Bushing
(32)238-5080 O-Ring Seal
(33)553-0293 Valve As
(34)551-4179 Adapter
(35)031-5744 Elbow - Install adapter (30) into plug bushing (31).
- Install plug bushing (31) and 1 O-ring (32) into valve assembly (33).
- Install valve assembly (33) into adapter (34).
- Install adapter (34) into elbow (35).
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Illustration 246 g06032100 The following parts are from the 455-2343 Fuel Tank Vent Gp.
(18)119-0572 Adapter
(23)4S-6797 Adapter
(29)002-6454 Connector
(35)031-5744 Elbow
(36)8C-4065 Union - Install pipe nipple (29) into adapter (18).
- Install union (36) onto adapter (23).
- Install elbow (35) onto union (36). Refer to Illustration 246 for the correct orientation of the elbow.
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Illustration 247 g06032081 The following parts are from the 455-2343 Fuel Tank Vent Gp.
(21)326-5136 Manifold
(37)8T-4176 Bolt
(38)8T-4223 Hard Washerd - Attach manifold (21) to the 482-3931 Fuel Tank As (Diesel) with 2 bolts (37) and 2 washers (38).
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Illustration 248 g06312558 (17) 459-0623 Ball Valve
(27)514-2369 Relief Valve
(33)553-0293 Valve As
(39)551-6115 Tag
(40)123-3202 Cable Strap
(41)551-6117 Tag
(42)551-6116 Tag - Attach tag (39) to relief valve (27) with 1 cable strap (40).
- Attach tag (41) to ball valve (17) with 1 cable strap (40).
- Attach tag (42) to valve assembly (27) with 1 cable strap (40).
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Illustration 249 g06032340 The following parts are from the 455-2340 Fuel Lines Gp (Gas).
(43)455-2349 Plate As
(44)4L-6454 Bolt
(45)5P-1075 Hard Washer - Attach plate assembly (43) to the 482-3931 Fuel Tank As (Diesel) with 2 bolts (44) and 2 washers (55).
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Illustration 250 g06032395 The following parts are from the 455-2340 Fuel Lines Gp (Gas).
(46)398-5610 Connector As
(47)465-3352 Gas Filter Assembly - Install 2 fittings (46) into gas filter (47).
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Illustration 251 g06032351 The following parts are from the 455-2340 Fuel Lines Gp (Gas).
(3)8T-4121 Hard Washer
(43)455-2349 Plate As
(47)465-3352 Gas Filter Assembly
(48)8T-4136 Bolt - Attach gas filter (47) to plate assembly (43) with 4 bolts (48) and 4 washers (3).
Note: Ensure that the flow arrow points from the vaporizer toward the manifold block.
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Illustration 252 g06032406 The following parts are from the 455-2340 Fuel Lines Gp (Gas).
(49)183-6780 Connector
(50)5P-2242 Swivel Tee
(51)550-8582 Hose As - Install 2 connector (49) into the top of the 554-3064 Vaporizer.
Note: Install a 3R-6789 Flared Cap onto the flange to protect the threads during installation.
- Install swivel tee (50) onto the 030-8307 Connector.
- Attach hose (51) to swivel tee (50) and the 398-5610 Connector As.
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Illustration 253 g06032451 The following parts are from the 455-2340 Fuel Lines Gp (Gas).
(45)5P-1075 Hard Washer
(51)550-8582 Hose As
(52)9B-7237 Bolt
(53)6V-8801 Nut
(54)144-6302 Bracket
(55)5M-3062 Bolt
(56)8T-7087 Grommet
(57)5P-7468 Clip
(58)5P-7469 Clip - Attach bracket (54) to the 482-3931 Fuel Tank As with 1 bolt (55) and 1 washer (45).
- Install grommet (56) around hose (51).
- Install clips (57) and (58) around grommet (56). Refer to Illustration 253 for the correct orientation of the clips.
- Attach clips (57) and (58) to bracket (54) with 1 bolt (52), 2 washers (45), and 1 nut (53).
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Illustration 254 g06032466 The following parts are from the 455-2340 Fuel Lines Gp (Gas).
(35)031-5744 Elbow
(59)5P-4494 Swivel Tee
(60)463-9872 Hose As - Install swivel tee (56) onto the 183-6780 Connector closest to the 458-0433 Fuel Tank Gp.
- Install swivel tee (59) onto swivel tee (59).
- Install elbow (35) onto the 398-5610 Connector As.
- Attach hose (60) to elbow (35) and swivel tee (59).
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Illustration 255 g06033474 The following parts are from the 457-5994 Chassis Wiring Gp.
(11)8T-4896 Hard Washer
(44)4L-6454 Bolt
(61)545-7289 Coaxial Cable As
(62)204-8000 Cable Tie Mounting
(63)204-2281 Cable Strap
(64)508-3310 Liquid Level Sensor As
(65)153-8003 Bolt - Attach liquid level sensor (64) to the 550-9115 Plate As of the 458-0433 Fuel Tank Gp with 2 bolts (65).
- Plug coaxial cable (61) into the 458-0433 Fuel Tank Gp.
- Plug coaxial cable (61) into liquid level sensor (64).
- Attach 2 cable tie mounts (62) to the 482-3931 Fuel Tank As with 1 bolt (44) and 1 washer (11) per cable tie mount.
- Secure coaxial cable (61) to the 2 cable tie mounts (62) with 1 cable strap (63) per cable tie mount.
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Illustration 256 g06033488 The following parts are from the 457-5994 Chassis Wiring Gp.
(11)8T-4896 Bolt
(44)4L-6454 Hard Washer
(62)204-8000 Cable Tie Mounting
(63)204-2281 Cable Strap
(64)508-3310 Liquid Level Sensor As
(66)483-4287 Plate
(67)130-5300 Clip
(68)483-2445 Sensor Harness As
(69)517-2817 Sensor Harness As - Attach 1 cable mount (62), 1 plate (66), and 1 clip (67) to the 482-3931 Fuel Tank As (Diesel) with 1 bolt (44) and 1 washer (11).
Note: Cable mount and clip face downward and plate faces upward.
- Attach 1 cable mount (62) and 1 clip (67) to the 482-3931 Fuel Tank As (Diesel) with 1 bolt (44) and 1 washer (11).
Note: The clip is install in between the cable tie mount and the fuel tank assembly.
- Attach 2 cable mount (62) to the 482-3931 Fuel Tank As (Diesel) with 1 bolt (44) and 1 washer (11).
Note: The cable tie mounts need to be left loose until after the tank is installed is installed onto the chassis. The cable tie mounts will contact the bottom mount during installation if not removed.
- Plug sensor harness (68) into the connector of the 416-4772 Level Sender As.
- Attach sensor harness (68) to clips (67).
- Plug sensor harness (69) into liquid level sensor (64).
- Secure sensor harness (69) to cable tie mount (62) and plate (66) with 1 cable strap (63) per mount and plate..
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Illustration 257 g06033661 The following parts are from the 455-2343 Fuel Tank Vent Gp (Gas).
(35)031-5744 Elbow
(70)463-9873 Hose As
(71)463-8929 Hose As - Attach elbow (35) to the bottom port of the 520-2983 Fuel Tank Gp (LNG).
- Attach the 90 degree end of hose (70) to the 030-7935 Connector.
- Attach the straight end of hose (70) to elbow (35).
- Attach the 90 degree end of hose (71) to the 459-0623 Ball Valve.
- Attach the straight end of hose (71) to the 5P-4494 Swivel Tee.
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Illustration 258 g06036308 The following parts are from the 455-2343 Fuel Tank Vent Gp (Gas).
(56)8T-7087 Grommet
(57)5P-7468 Clip
(58)5P-7469 Clip
(70)463-9873 Hose As
(72)8T-4186 Bolt
(73)7X-7729 Washer
(74)344-5675 Nut - Install grommet (56) around hose 70.
- Install clips (57) and (58) around grommet (56).
- Attach clips (57) and (58) to the 554-3064 Vaporizer with 1 bolt (72), 2 washers (73), and 1 nut (74).
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Illustration 259 g06033695 The following parts are from the 455-2343 Fuel Tank Vent Gp (Gas).
(35)031-5744 Elbow
(75)463-9876 Hose As - Attach elbow (35) to the 5P-4494 Swivel Tee.
- Attach the 90 degree end of hose (75) to the 507-8357 Adapter.
- Attach the straight end of hose (75) to elbow (35).
Installing the
- Using a suitable lifting device, attach mounting plate (1) to the truck frame with 6 bolts (2) and 6 washers (3). The bracket weighs approximately
35 kg (77 lb) .Show/hide table
Illustration 261 g06030445 (1) 461-7161 Mounting Plate Gp
(4)7N-5656 Sleeve
(5)8N-1214 Mount As - Install 2 sleeves (4) and 4 mount assemblies (5) onto mounting plate (1).
Note: Make sure that a 3R-6789 Flared Cap was installed onto the 183-6780 Connector to protect the threads during installation.
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Illustration 262 g06030424 Note: Use the threaded hole on the 482-3931 Fuel Tank As and the 2 outside lifting eyes for lifting the fuel tank assembly.
- Using a suitable lifting device, lift the fuel tank assembly at a 73 degree angle for installation adjust accordingly. The tank assembly weighs approximately
1866 kg (4114 lb) .Show/hide table
Illustration 263 g06039020 - Install the fuel tank assembly onto the 6G-7439 Bracket As with the rear pin flush with the bracket.
Note: There must be a gap between the fuel tank assembly and bracket.
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Illustration 264 g06030472 (3) 8T-4994 Hard Washer
(6)6G-5294 Cap
(7)8X-3332 Plate
(8)1D-4610 Bolt - Secure the fuel tank assembly to the 6G-7439 Bracket As with 2 caps (6), 4 plates (7), 4 bolts (8), and 4 washers (3). Refer to Special Instruction, REHS2325 for information on shimming the fuel tank.
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Illustration 265 g06030479 (1) 461-7161 Mounting Plate Gp
(5)8N-1214 Mount As
(9)8C-8478 Bolt
(10)198-4781 Hard Washer - Secure the fuel tank assembly to bracket (1) with 2 mount assemblies (5), 2 bolts (9), and 4 washers (10).
Note: 1 washer (10) goes on each side of mount assembly (5).
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Illustration 266 g06233006 The following parts are from the 455-2343 Fuel Lines Gp.
(11)553-5960 Hose As
(12)281-5892 Elbow - Attach the 45 degree end of hose (11) to elbow (12).
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Illustration 267 g06233012 The following parts are from the 455-2343 Fuel Lines Gp.
(11)553-5960 Hose As
(13)455-2346 Heat Shield - Slide heat shield (13) over hose (11).
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Illustration 268 g06233019 The following parts are from the 455-2343 Fuel Lines Gp.
(11)553-5960 Hose As
(12)281-5892 Elbow
(13)455-2346 Heat Shield - Attach the straight end of hose (11) to the LNG tank.
Note: It is IMPERATIVE that no rubbing occurs between the fuel lines and any of the other truck components.
- Attach elbow (12) to the 183-6780 Connector.
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| Illustration 260 | g06030439 |
|
(1) (2) (3) | |
Installing the
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| Illustration 269 | g06061033 |
|
| |
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| Illustration 270 | g06035790 |
|
(A) (B) (1) | |
- Weld boss (1) to the truck chassis.
Note: Weld a
3 mm (0.12 inch) fillet weld around the boss.Show/hide table
Illustration 271 g06036462 The following parts are from the 482-3914 Fuel Tank Gp (Diesel).
(2)1R-0755 Fuel Filter
(3)305-0589 Bracket As
(4)9B-7237 Bolt
(5)5P-1075 Hard Washer
(6)148-8373 Elbow As - Attach bracket assembly (3) to the truck chassis with 2 bolts (4) and 2 washers (5).
- Install fuel filter (2) onto bracket assembly (3).
- Install elbow (6) into bracket assembly (3).
Using the existing breather and mounting assembly is acceptable.
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Illustration 272 g06040074 (6) 148-8373 Elbow As
(7)7S-0530 Clip
(8)552-3218 Tube As
(9)7D-3898 Boss
(10)5M-3062 Bolt
(11)8T-4896 Hard Washer
(12)486-4577 Hose As
(13)103-0010 Bracket As
(14)8T-4136 Bolt
(15)8T-4121 Hard Washer
(16)9S-7754 Flared Union - Remove the original hardware from the wiring harness.
- Attach tube (8) and the wiring harness loosely to the existing bosses on the truck chassis with 2 clips (7) and the original hardware.
- Install clip (7) around tube (8).
- Attach clip (7) to boss (9) with 1 bolt (10) and 1 washer (11).
Note: The boss will be welded to the truck chassis after the 455-2343 Fuel Tank Vent Gp is assembled.
- Attach bracket (13) to the original boss on the truck frame with 1 bolt (10) and 1 washer (11).
- Install clip (7) around tube (8).
- Attach clip (7) to bracket (13) with 1 bolt (14) and 1 washer (15).
- Attach flared union (16) to tube (8).
- Install diesel vent hose (12) onto elbow (6). The diesel vent hose may need trimmed depending on where the diesel fuel tank vent filter is located on the frame behind the cab.
Note: Make sure that the O-ring is in the elbow.
Note: The diesel vent hose may need to be cut to length.
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Illustration 273 g06036500 (11) 8T-4896 Hard Washer
(12)486-4577 Hose As
(16)9S-7754 Flared Union
(17)8T-7087 Grommet
(18)5P-7468 Clip
(19)5P-7469 Clip
(20)7D-1553 Clip
(21)0S-1594 Bolt
(22)550-8582 Hose As
(23)030-7951 Flared Elbow - Attach hose (22) to flared union (16) and flared elbow (23).
- Install 1 grommet (17) around hose (22).
- Install 1 clip (18) and 1 clip (19) around grommet (17).
- Install 1 clip (20) around hose (12).
- Attach clips (18), (19), and (20) loosely to the 5F-7845 Boss with 1 bolt (21) and 1 washer (11).
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Illustration 274 g06040204 (8) 552-3218 Tube As
(24)352-6510 Tee As
(25)6V-8557 Face Seal Nut
(26)330-9720 Reducer As - Attach tee (24) loosely to tube assembly (8).
- Attach reducer (26) to the bottom of tee (24) with nut (25).
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Illustration 275 g06040298 (7) 7S-0530 Clip
(9)7D-3898 Boss
(10)5M-3062 Bolt
(11)8T-4896 Hard Washer
(24)352-6510 Tee As
(27)5D-9077 Boss
(28)463-9878 Tube As - Attach tube assembly (28) loosely to tee (24).
- Install 3 clips (7) around tube assembly (28). Refer to Illustration 275 for the correct orientation of the clip.
- Attach 1 clip (7) to each boss (27) with 1 bolt (10) and 1 washer (11) per clip and boss. Refer to Illustration 275 for the correct location of the boss.
Note: The boss will be welded to the truck chassis after the 455-2343 Fuel Tank Vent Gp is assembled.
- Attach 1 clip (7) to boss (9) with 1 bolt (10) and 1 washer (11). Refer to Illustration 275 for the correct location of the boss.
Note: The boss will be welded to the truck chassis after the 455-2343 Fuel Tank Vent Gp is assembled.
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Illustration 276 g06049776 (7) 7S-0530 Clip
(10)5M-3062 Bolt
(11)8T-4896 Hard Washer
(28)463-9878 Tube As
(29)7D-5135 Boss
(30)555-7124 Tube As
(31)228-7093 O-Ring Seal - Slide tube assembly (30) under the 5T-1049 Air Tank.
Note: The fire suppression and/or the grease canister may need to be loosened or removed in order to feed the tube under the air tank.
- Attach tube assembly (30) and 1 O-ring (31) loosely to tube assembly (28).
- Install clip (7) around tube assembly (30). Refer to Illustration 276 for the correct orientation of the clip.
- Attach clip (7) to boss (29) with 1 bolt (10) and 1 washer (11).
Note: The boss will be welded to the truck chassis after the 455-2343 Fuel Tank Vent Gp is assembled.
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Illustration 277 g06049800 (7) 7S-0530 Clip
(10)5M-3062 Bolt
(11)8T-4896 Hard Washer
(31)228-7093 O-Ring Seal
(32)4L-6454 Bolt
(33)6V-8801 Nut
(34)549-6957 Tube As
(35)3E-6915 Clip
(36)8X-4549 Boss - Attach tube assembly (34) and 1 O-ring (31) to tube assembly (30).
Note: The two 8X-4549 Bosses may need to be relocated to accommodate the routing past the fire suppression and other components.
- Install 1 clip (7) around tube assembly (30). Refer to Illustration 277 for the correct orientation of the clip.
Note: The two 8X-4549 Bosses may need to be relocated to accommodate the routing past the fire suppression and other components.
- Install 2 clips (7) around tube assembly (34). Refer to Illustration 277 for the correct orientation of the clips.
- Install 1 clip (35) around the 311-3362 Handrail As. Refer to Illustration 277 for the correct orientation of the clip.
- Attach clip (7) loosely to clip (35) with 1 bolt (32), 2 washers (11), and 1 nut (33). Refer to Illustration 277 for the correct orientation of the clips.
- Attach clip (7) to each boss (36) with 1 bolt (10) and 1 washer (11) per clip and boss.
- Make sure that the 455-2343 Fuel Tank Vent Gp is not rubbing on anything.
- Tighten all loose connectors and hardware.
- Weld all loose bosses to the truck chassis.
Note: Weld a
3 mm (0.12 inch) fillet weld around the bossesShow/hide table
Illustration 278 g06049904 (28) 463-9878 Tube As
(37)326-4516 Cable Tie
(38)333-0971 Reflective Sleeve - Install 2 sleeves (38) around tube assembly (28).
- Secure each sleeve (38) to tube assembly (28) with 2 cable ties (37).
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Illustration 279 g06233147 (10) 5M-3062 Bolt
(11)8T-4896 Hard Washer
(13)103-0010 Bracket As
(14)8T-4136 Bolt
(15)8T-4121 Hard Washer
(25)6V-8557 Face Seal Nut
(26)330-9720 Reducer As
(39)1S-1015 Clip
(40)550-8583 Hose As
(41)507-8354 Connector As - Install connector assembly (41) into the 109-0897 Ball Valve.
- Attach the 90 degree end of hose (40) to connector assembly (41).
- Attach the straight end of hose (40) to reducer (26).
- Install bracket (13) to the truck frame with 1 bolt (10) and 1 washer (11).
- Install clip (39) around hose (40).
- Attach clip (40) to bracket (13) with 1 bolt 14 and 1 washer (15).
Installing the
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| Illustration 280 | g06233125 |
- Install elbow (1) and 1 O-ring (2) into the 464-8532 Adapter. The adapter is attach to the rear of the engine.
- Attach the straight end of hose assembly (3) to elbow (1).
Note: It is IMPERATIVE that no rubbing occurs between the hose and any of the other truck components.
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Illustration 282 g06049913 (3) 551-4081 Hose As
(4)5P-2242 Swivel Tee - Attach the end of hose assembly (3) to swivel tee (4).
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Illustration 283 g06049946 (5) 490-1014 Plate As - Remove the bolts from the 2 2V-0600 Half Clamps and the 344-3596 Plate. Set aside the associated hardware for reuse.
- Attach plate assembly (5) to the 2 2V-0600 Half Clamps and the 344-3596 Plate with the original hardware.
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Illustration 284 g06049935 (3) 551-4081 Hose As
(5)490-1014 Plate As
(6)4L-6454 Bolt
(7)5P-1075 Hard Washer
(8)8T-7087 Grommet
(9)5P-7468 Clip
(10)5P-7469 Clip - Install grommet (8) around hose assembly (3).
- Install clips (9) and (10) around grommet (8).
- Attach clips (9) and (10) to plate assembly (5) with 1 bolt (6) and 1 washer (7).
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| Illustration 281 | g06049917 |
|
(1) (2) (3) | |
Installing the
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| Illustration 285 | g06061606 |
- Remove and discard the original fuel supply hose assembly. Set aside the associated hardware for reuse.
Note: Now is a good time to change out the fuel return hose assembly if necessary.
Note: It may be easier to install the lines before engine installation (clip and bolt access).
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Illustration 286 g06049842 (1) 468-8884 Hose As
(2)001-6301 Elbow - Attach hose assembly (1) to elbow (2).
- Attach hose assembly (1) to the fuel transfer pump.
- Secure hose assembly (1) and the fuel return hose assembly to the truck chassis with the original hardware.
Installing the
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| Illustration 287 | g06061610 |
- Attach hose assembly (1) to the 421-6206 Connector As at the top of the vaporizer.
- Attach hose assembly (2) to the 421-6206 Connector As at the bottom of the vaporizer.
Note: Hose assembly (2) runs on the inside of hose assembly (1).
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Illustration 289 g06050020 (1) 482-1996 Hose As
(2)482-1995 Hose As
(3)2V-0600 Half Clamp
(4)4L-6454 Bolt
(5)8T-4896 Hard Washer
(6)6V-8801 Nut
(7)4D-7388 Clip
(8)0S-1588 Bolt
(9)492-5239 Plate As
(10)8C-4436 Bolt
(11)8T-4223 Hard Washer - Install 2 half clamps (3) around the 8X-6235 Tube As.
- Attach plate assembly (9) to the 2 half clamps (3) with 2 bolts (10) and 2 washers (11).
- Install 1 clip (7) around hose assembly (1). Refer to Illustration for the correct orientation of the clip.
- Install 1 clip (7) around hose assembly (2). Refer to Illustration for the correct orientation of the clip.
- Attach clip (7) to clip (7) with 1 bolt (4), 2 washers (5), and 1 nut (6).
- Install 1 clip (7) around hose assembly (1). Refer to Illustration for the correct orientation of the clip.
- Install 1 clip (7) around hose assembly (2). Refer to Illustration for the correct orientation of the clip.
- Attach clips (7) to plate assembly (9) with 1 bolt (10) and 1 washer (11).
- Cap off hose assembly (2) to keep dirt and debris out until the engine is installed.
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Illustration 290 g06050116 (1) 482-1996 Hose As
(5)8T-4896 Hard Washer
(7)4D-7388 Clip
(12)491-7726 Plate As
(13)5S-7379 Bolt
(14)483-7800 Spacer
(15)5S-7383 Bolt - Install 2 clips (7) around hose assembly (1). Refer to Illustration for the correct orientation of the clips.
- Attach 1 clip (7) to the truck chassis with 1 spacer (14), 1 bolt (15), and 1 washer (5).
- Attach plate assembly (12) to the truck chassis with 1 bolt (13) and 1 washer (5).
- Attach 1 clip (7) to plate assembly (12) with 1 bolt (13) and 1 washer (5).
- Cap off hose assembly (1) to keep dirt and debris out until the engine is installed.
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Illustration 291 g06050045 (2) 482-1995 Hose As
(5)8T-4896 Hard Washer
(6)6V-8801 Nut
(7)4D-7388 Clip
(16)5P-8112 Grommet
(17)5P-7466 Clip
(18)5P-7467 Clip
(19)8T-2502 Bolt - Attach hose assembly (2) to the 492-3645 Tube As.
Note: Make sure that the O-ring is installed.
- Install clip (7) around the 423-6691 Hose As.
- Install grommet (16) around hose assembly (2)
- Install clip (17) and clip (18) around grommet (16).
- Attach clips (17) and (18) to clip (7) with 1 bolt (19), 2 washers (5), and 1 nut (6).
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Illustration 292 g06050481 Right-hand side of the radiator
(20)5C-6565 Bolt
(21)8M-7066 Gasket
(22)148-8335 Connector As
(23)466-2151 Tube As
(24)8N-3248 Gasket - Attach tube assembly (23) to the radiator with 1 gasket (24) and 4 bolts (20).
- Attach the 8M-7057 Plug Adapter to tube assembly (23) with 1 gasket (22) and the original hardware.
- Install connector (21) into tube assembly (23).
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Illustration 293 g06050150 (1) 482-1996 Hose As
(5)8T-4896 Hard Washer
(7)4D-7388 Clip
(13)5S-7379 Bolt
(19)8T-2502 Bolt
(22)148-8335 Connector As
(25)5F-7845 Boss
(26)204-9746 Boss
(27)127-0960 Boss - Install 3 clips (7) around hose assembly (1). Refer to Illustration for the correct orientation of the clips.
- Attach clip (7) to boss (25) with 1 bolt (13) and 1 washer (5).
- Attach clip (7) to boss (26) with 1 bolt (19) and 1 washer (5).
- Attach clip (7) to boss (27) with 1 bolt (19) and 1 washer (5).
Note: Ensure that hose assembly (1) is not in contact or rubbing on any components.
- Weld all loose bosses to the truck chassis.
Note: Weld a
3 mm (0.12 inch) fillet weld around the bosses - Tighten all loose hardware.
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Illustration 294 g06050544 Left-hand side of the radiator
(28)8T-4986 Hose Clamp ()
(29)8T-4985 Hose Clamp
(30)324-2601 Hose
(31)493-8160 Tube As - Install tube assembly (31) into the 5D-6005 Hose and the 317-6426 Hose.
- Secure tube assembly (31) to the 5D-6005 Hose and the 317-6426 Hose with 2 hose clamps (28) per hose.
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Illustration 295 g06050570 (29) 8T-4985 Hose Clamp
(30)324-2601 Hose
(32)493-7986 Tube As
(33)494-0729 Bracket As
(34)270-9283 Half Clip - Install tube assembly (32) into hose (30).
- Secure tube assembly (32) loosely to hose (30) with 2 hose clamps.
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Illustration 296 g06050603 (5) 8T-4896 Hard Washer
(10)8C-4436 Bolt
(11)8T-4223 Hard Washer
(13)5S-7379 Bolt
(32)493-7986 Tube As
(33)494-0729 Bracket As
(34)270-9283 Half Clip
(35)3G-9190 Plate - Attach bracket assembly (33) to plate (35) with 2 bolts (13) and 2 washers (5).
Note: Plate (35) will be welded to the truck chassis.
- Install 2 half clips (34) around tube assembly (32).
- Attach half clips (34) loosely to bracket assembly (33) with 2 bolts (10) and 2 washers (11).
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Illustration 297 g06384160 (A) Supply
(B) Bypass (bottom radiator)
(C) Cooler (top of radiator)
(10)8C-4436 Bolt
(11)8T-4223 Hard Washer
(29)8T-4985 Hose Clamp
(30)324-2601 Hose
(32)493-7986 Tube As
(36)493-7985 tube
(37)494-5741 Plate As
(38)6V-5039 Clip
(39)6V-5040 Clip
(40)493-7905 Bracket As
(41)8T-8917 Bolt
(42)493-7901 Bracket As
(43)5P-2228 Bolt
(44)7X-0350 Bolt
(45)267-8821 Washer
(46)7X-0448 Nut
(47)513-7165 Housing and Regulator Gp
(48)5R-9779 Gasket
(49)6G-9554 Plate
(50)493-7903 Bracket AsShow/hide table
Illustration 298 g06052315 513-7165 Housing and Regulator Gp
(A) Supply
(B) Bypass (bottom radiator)
(C) Cooler (top of radiator)Show/hide tableNOTICE Port C must be routed to the top of the radiator and Port B must be routed to the pump inlet or the machine may overheat and damage may occur.
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Illustration 299 g06050656 (49) 6G-9554 Plate
(D)35.00 mm (1.378 inch)
(E)8.99 mm (0.354 inch) - Tack weld plate (49) to the truck chassis.
Note: Weld an
8 mm (0.315 inch) weld around the plate after fitting up coolant lines.Note: Caterpillar recommends following Step 39 through Step 47 to ensure the correct placement of the plate before welding the plate.
- Attach bracket assembly (42) to plate (49) with 4 bolts (43) and 4 washers (11).
- Attach bracket assembly (40) loosely to plate assembly (42) with 2 bolts (41) and 2 washers (11).
- Attach bracket assembly (50) loosely to plate assembly (42) with 2 bolts (41) and 2 washers (11).
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NOTICE Port C must be routed to the top of the radiator and Port B must be routed to the pump inlet or the machine may overheat and damage may occur.
- Attach tube assembly (36) and housing and regulator group (47) to bracket assembly (40) with 1 gasket (48), 2 bolts (44), 4 washers (45), and 2 nuts (46).
Note: Make sure that the gasket is installed between the tube assembly and housing and regulator group.
Note: The nuts may need to be ground down to resolve interference.
- Attach tube assembly (36) and housing and regulator group (47) to bracket assembly (50) with 1 gasket (48), 2 bolts (44), 4 washers (45), and 2 nuts (46).
- Install hose (30) onto tube assembly (36).
- Secure hose (30) to tube assembly (36) with 2 hose clamps (29).
- Using a suitable lifting device, install the pre-assembled parts. The pre-assembled parts weigh approximately
50 kg (110 lb) . - Install hose (30) onto the 8M-3011 Elbow of the radiator.
- Secure hose (30) to the 8M-3011 Elbow of the radiator with 2 hose clamps (29).
- Attach tube assembly (32) to housing and regulator group (47) with 1 gasket (48), 4 bolts (44), 8 washers (45), and 4 nuts (46).
- Install 1 clip (38) and 1 clip (39) around tube assembly (36).
- Attach clips (38) and (39) to plate assembly (37) with 1 bolt (10) and 1 washer (11).
- Attach plate assembly (37) to the truck chassis with the original hardware of the hood assembly.
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Illustration 300 g06050690 (35) 3G-9190 Plate - Tack weld plate (35) the truck chassis.
Note: Weld a
5 mm (0.197 inch) weld around the plate after fitting up coolant lines.Show/hide table
Illustration 301 g06384159 (29) 8T-4985 Hose Clamp
(30)324-2601 Hose
(44)7X-0350 Bolt
(45)267-8821 Washer
(46)7X-0448 Nut
(47)513-7165 Housing and Regulator Gp
(48)5R-9779 Gasket
(51)493-7988 Tube
(52)493-7987 Tube As - Attach tube assembly (52) to housing and regulator group (47) with 1 gasket (48), 4 bolts (44), 8 washers (45), and 4 nuts (46).
- Install 2 hoses (30) onto tube assembly (51).
- Install 8 hose clamps (29) onto tube assembly (51).
- Install hose (30) of the short end of tube assembly (51) onto tube assembly (52).
- Install hose (30) of the long end of tube assembly (51) onto the brake oil cooler.
- Secure 1 hose (30) to tube assemblies (51) and (52) with 4 hose clamps (29).
- Secure 1 hose (30) to tube assembly (51) the brake oil cooler with 4 hose clamps (29).
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| Illustration 288 | g06049990 |
|
(1) (2) | |
Installation of the
- Attach plate (1) to the 458-0431 Fuel Tank with 4 bolts (2) and 4 washers (3).
- Attach mud deflector (4) to plate (1) with 2 plates (5), 4 bolts (2), 8 washers (3), and 4 nuts (6).
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Illustration 303 g06388515 (3) 8T-4121 Hard Washer
(7)461-7191 Support As
(8)8T-4137 Bolt - Attach 2 support assemblies (7) to the 458-0431 Fuel Tank with 4 bolts (8) and 4 washers (3) per support assembly.
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Illustration 304 g06025680 Top section of the 461-7195 Mud Deflector
(2)8T-4195 Bolt
(3)8T-4121 Hard Washer
(9)149-1926 Plate
(10)340-3616 Plate
(11)428-5380 Plate - Attach the top of the 461-7195 Mud Deflector to the 2 461-7191 Support As with 2 plates (9), 2 plates (10), 2 plates (11), 14 bolts (2), and 14 washers (3).
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Illustration 305 g06388519 Bottom section of the 461-7195 Mud Deflector
(2)8T-4121 Hard Washer
(3)8T-4195 Bolt
(9)149-1926 Plate - Attach the bottom of the 461-7195 Mud Deflector to the 482-3931 Fuel Tank As with 3 plates (9), 6 bolts (2), and 6 washers (3).
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Illustration 306 g06388511 (3) 8T-4121 Hard Washer
(7)461-7191 Support As
(8)8T-4137 Bolt - Attach 2 support assemblies (7) to the 458-0431 Fuel Tank with 4 bolts (8) and 4 washers (3) per support assembly.
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Illustration 307 g06025733 Top section of the 461-7196 Mud Deflector
(2)8T-4195 Bolt
(3)8T-4121 Hard Washer
(9)149-1926 Plate
(10)340-3616 Plate
(11)428-5380 Plate - Attach the top of the 461-7196 Mud Deflector to the 2 461-7191 Support As with 2 plates (9), 2 plates (10), 2 plates (11), 14 bolts (2), and 14 washers (3).
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Illustration 308 g06025738 Bottom section of the 461-7196 Mud Deflector
(2)8T-4195 Bolt
(3)8T-4121 Hard Washer
(9)149-1926 Plate
(12)275-3525 Plate
(13)8T-4222 Plated Washer - Attach the bottom of the 461-7196 Mud Deflector to the 482-3931 Fuel Tank As with 1 plate (9), 2 plates (12), 6 bolts (2), 2 washers (3), and 4 washers (13).
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Illustration 309 g06388529 (14) 340-3616 Plate
(15)161-8900 Connector
(16)448-1266 Chain
(17)8T-4182 Bolt
(18)7X-7729 Washer
(19)344-5675 Nut - Attach 2 plates (14) to the 461-7195 Mud Deflector with 2 bolts (17), 4 washers (18), and 2 nuts (19).
Note: The center hole is used with the 448-1266 Chain.
- Attach 2 plates (14) to the 461-7196 Mud Deflector with 2 bolts (17), 4 washers (18), and 2 nuts (19).
Note: The center hole is used with the 448-1266 Chain.
- Attach 1 connector (15) to the 461-7195 Mud Deflector 1 bolt (17), 3 washers (18), and 1 nut (19).
Note: A washer is installed on each side of the connector.
- Attach 1 connector (15) to the 461-7196 Mud Deflector 1 bolt (17), 3 washers (18), and 1 nut (19).
Note: A washer is installed on each side of the connector.
- Attach chain (16) to each connector (15).
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Illustration 310 g06388599 (20) 8T-7585 Screw
(21)342-0606 Hard Washer
(22)5C-8312 Nut
(23)563-7639 Magnet - Attach 4 magnets (23) to the 572-4477 Mud Deflector with 1 screw (20), 1 washer (21), and 1 nut (22) per magnet.
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| Illustration 302 | g06388496 |
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(1) (2) (3) (4) (5) (6) | |
Installing the
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| Illustration 311 | g06384459 |
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(1) | |
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| Illustration 312 | g06384480 |
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(2) | |
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| Illustration 313 | g06384472 |
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(2) (3) (4) (5) | |
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| Illustration 314 | g06384490 |
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(1) (2) (6) (7) (8) | |
Dimension References
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| Illustration 315 | g06389393 |
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Front bumper (D1) (D2) (D3) (1) | |
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| Illustration 316 | g06389366 |
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Front side of the fuel tank (D7) (D8) (2) | |
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| Illustration 317 | g06384677 |
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Rear side of the fuel tank (D9) (D10) (D11) (D12) (D13) (D14) (2) (4) (5) | |
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| Illustration 318 | g06384679 |
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Inside end of the fuel tank (D15) (D16) (3) | |
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| Illustration 319 | g06384502 |
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Top outside end of the fuel tank (D17) (D18) (D19) (D20) (D21) (1) (6) | |
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| Illustration 320 | g06384523 |
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Bottom outside end of the fuel tank (D22) (D23) (D24) (D25) (D26) (D27) (D28) (D29) (2) (7) (8) | |
Low-Pressure Warm Leak Check
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| NOTICE |
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The hoses must not have oil in the lines due to use for charging the struts. |
- Connect a Nitrogen gas cylinder with a pressure regulator to the truck tank vent to station valve. Make new hoses and connect directly to the regulator as shown in picture:
- Open the truck LNG tank vent to station valve.
- Ensure that the regulator on the Nitrogen cylinder is completely closed.
- Open the main shutoff valve on the Nitrogen cylinder.
- Slowly dial the Nitrogen gas regulator up to approximately
552 to 689 kPa (80 to 100 psi) . - Observe truck LNG tank and plumbing for any obvious leaks.
- Close the main shutoff valve on the Nitrogen cylinder.
- Close the truck LNG tank vent to station valve.
- Open the ball valve on the nitrogen charging tooling to release the pressure in the lines.
- Monitor the truck LNG tank pressure for obvious drop.
Note: Small changes in pressure could be a result of temperature change of the Nitrogen gas as it warms or cools after coming in contact with the truck LNG tank. The concern is a steady and continuous leak causing a measurable pressure drop.
- Use a soap and water solution or other gas leak detection solution to check all truck tank and LNG pump plumbing.
- If pressure in the truck tank holds and no leaks are detected, open the vent valve and drain the truck tank pressure down to approximately
69 kPa (10 psi) . If storing the tank/truck in a warm condition, the tank/truck should be stored with69 to 138 kPa (10 to 20 psi) dry nitrogen to keep system dry (no humid air in system). - If a leak is found outside of the tank shroud, attempt to tighten the fitting.
- If tightening the fitting does not seal the leak, close the "Tank Isolation Valve". Open the manual vent to relieve the system pressure and install Lock Out Tag Out (LOTO) on the manual vent to prevent pressure buildup.
- Disconnect the leaking fitting and clean both sides of fitting. Inspect for damage, reapply LOX-8 or thread tape as needed, and reassemble.
- If leak is found inside the shroud, vent back to the station so the truck tank pressure lowers to 0 psi. Open the system vent valve and install LOTO.
- Disconnect the leaking fitting, clean both sides of fitting. Inspect for damage, reapply LOX-8 or thread tape as needed, and reassemble.
- Reinitiate the warm tank fill. During the 10 minute wait, inspect for leaks.
Preparing to Start on Diesel
- Connect to Cat Electronic Technician (ET).
Note: Must have Cat ET 2017A or newer.
- The Product Status Report (PSR) for the following ECMs:
- Transmission
- VIMS
- Brake
- Engine
- In Cylinder Pressure Sensor
- Gaseous Fuel Actuation #1
- Gaseous Fuel Actuation #2
- Flash the new software for the following ECMs:
- In Cat ET turn gas system installation status – set to installed. Will require factory password.
- In Cat ET turn gas system enable status – set to enabled.
- Check for codes and troubleshoot/resolve.
- Prime Diesel.
- Crank and start the engine
- Check for new codes.
- Engine is now idling in "Diesel" only mode.
- Move truck to fuel island and proceed to the"First/Warm Fill (General)".
First/Warm Fill (General)
Fueling station first fill procedures must be established and well known for both off loading and dispensing. In general, LNG is
The initial cooling of the storage tank is a manual process will take approximately 60 minutes. Extreme caution and diligence should be used when performing initial tank cool-down. Tanks can be a significant investment and have a long lead time for purchase and installation. A tank rupture can be catastrophic.
When an LNG vehicle fuel tank is filled for the first time, the inner vessel must be cooled to the temperature of LNG. The first fill procedure should be followed when a tank is returned to service after maintenance.
- Fueler prepares LNG vehicle for refueling.
- Don the proper PPE.
- Attach the LNG filling station ground cable to the LNG truck grounding stud.
- Remove the caps covering the fill and vent receptacles.
- Inspect the valves, fittings, and tubes on the vehicle fuel tank.
Note: DO NOT attempt to fill a truck with a damaged tank, missing components, or leaks
- Make sure that tank has been purged of all nitrogen prior to filling with LNG.
- Dispensing
- Prior to engaging fill or vent nozzles, clean with pressurized air and cloth to avoid contamination.
- Engage the station vent nozzle with the vehicle fuel tank.
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NOTICE DO NOT fill the tank with the vent valve open. This may fill the expansion volume with LNG and cause early venting of fuel during operation.
- Observe the LNG vehicle tank pressure on the external pressure gauge. If the vehicle fuel tank pressure is above
1034 kPa (150 psi) , it may be necessary to vent the vehicle fuel tank back to the station tank to prevent false fills and decrease fill time. Consult the LNG fuel station manual for this procedure. The vehicle tank vent valve must be opened to vent. Close the vent valve once the desired pressure reaches less than34 kPa (5 psi) . - Engage the filling station fill nozzle with the truck fuel tank fill receptacle. Be sure that the fill nozzle is firmly attached and completely engaged.
- Begin filling the vehicle tank per the LNG fuel station manual. Fill the vehicle fuel tank with 10 gallons of LNG. If the truck tank pressure gauge exceeds
1448 kPa (210 psi) open the vent to station valve to maintain pressure less than1448 kPa (210 psi) .If this is a first fill after assembly or maintenance, as the tank cools, utilize snoop/soap and water and methane gas detector to inspect all joints for leaks.
- If a leak is found outside of the tank shroud, attempt to tighten the fitting.
- If tightening the fitting does not seal the leak, close the"Tank Isolation Valve". Open the manual vent to relieve the system pressure and install Lock Out Tag Out (LOTO) on the manual vent to prevent pressure buildup.
- Disconnect the leaking fitting and clean both sides of fitting. Inspect for damage, reapply LOX-8 or thread tape as needed, and reassemble.
- If leak is found inside the shroud, vent back to the station so the truck tank pressure lowers to 0 psi. Open the system vent valve and install LOTO.
- Disconnect the leaking fitting, clean both sides of fitting. Inspect for damage, reapply LOX-8 or thread tape as needed, and reassemble.
- Reinitiate the warm tank fill. During the 10 minute wait, inspect for leaks.
- Wait 10 minutes to allow the tank to cool. If the truck tank pressure gauge exceeds
1448 kPa (210 psi) , open the vent to station valve to maintain pressure less than1448 kPa (210 psi) . - After the 10 minutes, vent the tank to the station to bring the pressure below
862 kPa (125 psi) . It will be necessary to relieve tank pressure to continue filling the tank. - For the second time….Begin filling the vehicle tank per the LNG fuel station manual. Fill the vehicle fuel tank with 10 gallons of LNG.
- Wait 10 minutes to allow the tank to cool. If the truck tank pressure gauge exceeds
1448 kPa (210 psi) , open the vent to station valve to maintain pressure less than1448 kPa (210 psi) . - After the 10 minutes, vent the tank to the station to bring the pressure below
862 kPa (125 psi) . It will be necessary to relieve tank pressure to continue filling the tank. - For the third time…..Begin filling the vehicle tank per the LNG fuel station manual. Fill the vehicle fuel tank with 10 gallons of LNG.
- Wait 10 minutes to allow the tank to cool. If the truck tank pressure gauge exceeds
1448 kPa (210 psi) , open the vent to the station valve to maintain pressure less than1448 kPa (210 psi) . - After the 10 minutes, vent the tank to the station to bring the pressure below
862 kPa (125 psi) . It will be necessary to relieve tank pressure to continue filling the tank - Restart the filling station pump and observe the truck tank pressure gauge. If the pressure remains below
1448 kPa (210 psi) continue filling. Completely fill the vehicle fuel tank per the fuel station manufacturer instructions. Depending on the filling station design, it may be necessary to vent tank to below 150 psi several times during the fill.
- Exiting the fueling station
- Check the truck fuel gauge to verify that the tank has been completely filled. It may be necessary to vent tank to below
1034 kPa (150 psi) to complete the fill. - Disconnect the vent nozzle and the fill nozzle from the vehicle fuel tank. Be sure to reinstall all caps and close door flap. Be sure that the vent to station valve is closed.
- Disconnect the ground cable from the truck.
- Check the truck fuel gauge to verify that the tank has been completely filled. It may be necessary to vent tank to below
- After first fill, run truck during normal Commissioning shake-down.
- After running several hours, double check for leaks.
- Use the snoop or soap and water solution to verify that no lines have come loose due to thermal expansion or vibration. Tighten all loose hoses or fittings.
If necessary to reapply Lox-8, the system must be properly vented and isolated. Use caution not to allow any contamination inside the hoses or fittings.
- Double check all clipping points for the hoses to insure they are secure.
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