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Installation of the Dual Layered Shielded (DLS) Manifold System For Certain G3516 Engines {1052, 1059, 1063, 1067, 1071, 1380} Caterpillar


Installation of the Dual Layered Shielded (DLS) Manifold System For Certain G3516 Engines {1052, 1059, 1063, 1067, 1071, 1380}

Usage:

G3516B JEF
Engine
G3516B (S/N: N6E1-UP; JEF1-UP)
G3516J (S/N: N6W1-UP)

Introduction

Ensure that you read and understand the procedure that follows before ordering any parts or performing any of the procedure.

Safety Section

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NOTICE

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, NENG2500, "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.

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NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Parts Information

The tables below contain the information for the 505-9598 Installation Kit.

Table 1 contains the parts information for the 487-0653 Heat Shield Gp.

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Table 1
Qty  Part Number  Part Description 
73  5P-1075  Bolts 
67  5P-8167  Bolts 
6  5S-7379  Bolts 
1  474-2832  Shield As 
1  482-7027  Shield As 
1  482-7028  Bracket As 
1  482-7029  Bracket As 
1  482-7030  Shield As 
1  482-7031  Shield As 
1  485-5649  Bracket 
1  485-5650  Bracket As 
1  485-5651  Shield As 
1  485-5653  Shield As 
1  485-5654  Shield As 
1  485-5657  Shield As 
1  485-5663  Shield As 
1  485-5664  Shield As 
1  485-8835  Bracket As 
1  485-8836  Bracket As 
1  485-8837  Shield As 
1  485-8838  Shield As 
1  485-8839  Bracket 
1  485-8840  Bracket 
2  485-8841  Shield 
1  487-2087  Shield As 
1  487-2088  Shield As 
1  487-2089  Shield As 
1  500-1821  Shield As 
1  500-1822  Bracket 
1  500-1823  Bracket As 
1  500-1824  Bracket As 

Table 2 contains the parts information for the 487-0722 Turbocharger Gp and the 451-7005 Water Hose Assembly.

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Table 2
Qty  Part Number  Part Description 
4  0L-1351  Bolts 
9  0S-1594  Bolts 
1  1A-2029  Bolt 
1  2W-5331  Bracket 
1  3E-7403  Adapter 
4  3S-0127  Bolts 
1  4P-7233  Grommet 
12  5K-9090  O-Ring Seals 
18  5M-2894  Hard Washers 
2  5P-8245  Hard Washers 
1  6F-5282  Bolt 
2  6V-5064  O-Ring Seals 
4  6V-5138  O-Ring Seals 
2  6V-8556  Nuts 
2  6V-8942  Reducers 
1  6V-8946  Reducer 
1  6V-9169  Nut 
1  6V-9172  Nut 
2  6V-9837  Swivel Tees 
1  6V-9840  Swivel Tee 
2  6V-9853  Elbows 
1  6V-9854  Elbow 
1  7N-3297  Cover 
1  7N-3368  Gasket 
1  8C-6869  Connector 
1  8C-6871  Connector 
1  8C-6875  Connector 
2  8C-8989  Elbows 
1  8M-2518  Bolt 
1  8S-9089  Bolt 
1  8T-1685  Tee 
4  8T-1887  Clips 
4  8T-1888  Clips 
1  8T-1889  Clip 
1  8T-1890  Clip 
1  8T-6895  Union Tee 
23  9S-8752  Nuts 
1  9X-6458  Hard Washer 
1  039-8557  Washer 
1  053-2294  Bolt 
2  146-3342  Coupling As 
1  150-7158  Connector 
15  180-8424  O-Ring Seals 
1  190-4885  Spacer 
8  216-7485  O-Ring Seals 
1  241-6196  Tee 
3  272-1777  Hard Washers 
12  294-9072  O-Ring Seals 
3  301-7791  Clips 
3  301-7792  Clips 
1  309-5734  Spacer 
1  317-2845  Clip 
4  353-7953  Grommets 
2  353-7955  Grommets 
1  353-7957  Grommet 
1  450-9147  Line As 
1  451-0093  Bracket As 
1  451-7002  Line As 
1  451-7003  Line As 
1  451-7004  Line As 
1  451-7008  Bracket 
1  454-5513  Line As 
1  457-7922  Water Tube As 
1  457-7923  Bracket 
2  457-7924  Line As 
1  457-7925  Water Hose Assembly 
1  475-4049  Water Tube As 

Table 3 contains the parts information for the 451-7010 Water Lines Gp.

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Table 3
Qty  Part Number  Part Description 
1  0S-1588  Bolt 
2  5M-2894  Hard Washers 
3  6V-5064  O-Ring Seals 
1  6V-6609  O-Ring Seal 
1  6V-8557  Face Seal Nut 
2  6V-8635  Connectors 
1  6V-8944  Reducer 
1  6V-9008  Elbow 
1  6V-9847  Swivel Tee 
1  8T-1897  Clip 
1  8T-1898  Clip 
1  9S-4185  Plug 
1  180-8424  O-Ring Seal 
1  353-7952  Grommet 
1  451-7011  Hose As 
1  451-7012  Water Tube As 
1  451-7191  Hose As 

Table 4 contains the parts information for the 451-6367 Aftercooler Gp.

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Table 4
Qty  Part Number  Part Description 
4  1A-2029  Bolts 
8  5M-2894  Hard Washers 
1  7W-6492  Pipe Plug 
2  9X-6458  Hard Washers 
1  452-5783  Support As 

Table 5 contains the parts information for the 505-5905 Manifold Gp.

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Table 5
Qty  Part Number  Part Description 
32  0T-0055  Bolts 
8  3E-6916  Nuts 
64  5J-4715  Washers 
2  5N-2126  Connectors 
8  5P-7128  Bolts 
8  6V-3630  Bolts 
8  6V-3631  Nuts 
16  7E-4127  Gaskets 
32  8F-8544  Bolts 
1  9X-0262  Adapter 
8  110-8314  Washers 
4  165-3931  Bolts 
4  229-5333  Seals 
2  336-9259  Bellows As 
1  502-1107  Exhaust Manifold Gp 
1  502-1108  Exhaust Manifold Gp 

Table 6 contains the parts information for the 446-9262 Water Lines Gp.

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Table 6
Qty  Part Number  Part Description 
32  0S-1619  Bolts 
32  1B-7182  Bolts 
32  5P-7204  O-Ring Seals 
16  6V-9769  O-Ring Seals 
16  7E-8888  Elbows 
16  7E-8890  Collars 
16  179-2960  Integral Seals 
16  446-9261  Water Tube As 

Table 7 contains the parts information for the 449-6350 Exhaust Elbow Gp.

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Table 7
Qty  Part Number  Part Description 
2  0S-0509  Bolts 
4  1A-1460  Bolts 
3  1W-2430  Band Clamps 
2  2W-5713  Adapters 
2  3E-2331  Plugs 
18  5M-2894  Hard Washers 
4  5P-8245  Hard Washers 
4  6V-1943  Bolts 
3  7C-3920  Exhaust Seals 
3  7C-3921  Seal Rings 
2  8T-6762  Pipe Plugs 
2  9Y-6792  Spark Plug Gaskets 
4  110-8314  Washers 
2  121-5736  Gaskets 
8  165-3931  Bolts 
1  335-3377  Gasket 
1  345-1924  Gasket 
1  449-6352  Exhaust Elbow 
1  460-7186  Exhaust Gasket 

Table 8 contains the parts information for the 449-6353 Water Lines Gp.

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Table 8
Qty  Part Number  Part Description 
6  0S-1590  Bolts 
9  0S-1594  Bolts 
2  1A-5964  Bolts 
1  1W-8129  Support 
4  4L-3833  Gaskets 
1  4W-5782  Plug 
4  5M-2894  Hard Washers 
1  6V-1867  Clip 
1  6V-1868  Clip 
1  7X-0732  Hard Washer 
2  8T-1919  O-Ring Seals 
1  8T-6762  Pipe Plug 
10  9X-6458  Hard Washers 
1  9Y-8283  Elbow 
4  153-9481  Clamp As 
2  153-9963  Rings 
4  165-3931  Bolts 
1  193-2120  Grommets 
1  216-8579  O-Ring Seals 
1  375-5546  Tube As 

Table 9 contains the parts information for the 449-6354 Water Lines Gp.

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Table 9
Qty  Part Number  Part Description 
1  3E-7430  Pipe Plug 
2  5P-4255  Bolts 
2  6V-6809  O-Ring Seals 
3  6V-9027  O-Ring Seals 
2  7E-6016  Gaskets 
1  7E-6017  Cover 
8  8M-9024  Hard Washers 
1  9S-4182  Plug 
1  9Y-8540  Regulator Housing 
1  112-3231  Adapter 
1  119-6294  Cover 
1  153-1810  Integral Seal 
1  452-5375  Retainer As 

Table 10 contains the parts information for the 456-8223 Air Lines Gp.

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Table 10
Qty  Part Number  Part Description 
1  0S-1594  Bolt 
2  2P-4437  Clamps 
1  4P-7233  Grommet 
4  5M-2894  Hard Washers 
1  6V-6609  O-Ring Seal 
3  9X-6458  Hard Washers 
1  032-1268  Connector 
1  132-7551  Spacer 
1  165-3929  Bolt 
3  325-6994  Clips 
3  325-6995  Clips 
4  337-3363  Gaskets 
2  339-3175  Gaskets 
4  353-7956  Grommets 
1  452-9900  Hose As 

Table 11 contains the parts information for the 458-7310 Water Lines Gp.

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Table 11
Qty  Part Number  Part Description 
1  3J-7354  O-Ring Seal 
2  6V-3265  Clips 
1  6V-8628  Elbow 
2  121-4345  O-Ring Seals 

Removal Procedure

Use the procedure in this section to prepare the engine for installation of the new components.

  1. Remove all the exhaust manifold and the turbocharger components.

  2. Remove the water manifolds on both banks including the cylinder head adapters.

  3. Remove the exhaust manifold logs on both banks up to the turbine inlet.

  4. Remove the turbocharger support stand including the exhaust elbow and both turbochargers.

  5. Remove the air cleaners and the support brackets.

  6. Remove the aftercooler with the mounting pedestal, air inlet system, and water vent lines.

  7. Remove the front jacket water lower thermostat housing.

  8. Remove the right-hand side jacket water pressure switch and large fitting installed in the case elbow on the oil cooler.

  9. Remove the small jacket water plugs in the cylinder heads under the exhaust ports.

Manifold Installation Procedure

The installation order depends on the scenario. If the cylinder heads are already installed on the engine, leave the intake jumpers tightened in place. Install the water-cooled exhaust manifolds onto each bank with the exhaust jumper bolts. The bolt torque is 55 N·m (41 lb ft)for all 4 bolts per runner.

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    Illustration 1g06000135
    (1) 5M-2894 Hard Washers
    (2) 8F-8544 Bolts
    (3) 0T-0055 Bolts
    (4) 449-6337 Water Manifold (RH)
    (5) 449-6319 Water Manifold (LH)

  1. Install the water-cooled exhaust manifolds on the engine using 32 bolts (2) with 32 hard washers (1) in the top holes of the manifold. For the bottom holes of the manifold use 32 bolts (3) with 32 hard washers (1).
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    Illustration 2g06000143
    (6) 0S-1619 Bolts
    (7) 6V-9769 O-Ring Seals
    (8) 7E-8888 Elbows
    (9) 446-9261 Tubes
    (10) 1B-7182 Bolts
    (11) 7E-8890 Collars
    (12) 179-2960 Integral Seals
    (13) 5P-7204 O-Ring Seals

  2. Install the cylinder head to water-cooled exhaust manifold jumper tubes for each cylinder.

    1. Install o-ring seal (7) into elbow (8).

    2. Install two o-ring seals (13) on tube (9).

    3. Install tube (9) into elbow (8) and collar (11).

    4. Install the assembly using two bolts (6) on top and two bolts (10) with integral seal (12) on the bottom.
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      Illustration 3g06130813
      (6) 0S-1619 Bolts
      (47) 490-4199 Elbows
      (48) 2A-4639 Bolts

    5. On both sides of the aftercooler supports, install two elbows (47) with two bolts (6) and two bolts (48).
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    Illustration 4g06001446
    (14) 6V-6809 O-Ring Seals

  3. Install two o-ring seals (14) on the lower thermostat housing that gets installed on the front of the engine.
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      Illustration 5g06000153
      (15) 0S-1594 Bolts
      (16) 9X-6458 Hard Washers
      (17) 452-5375 Retainer As
      (18) 1A-2029 Bolts
      (19) 8M-9024 Hard Washers
      (36) 0S-1571 Bolts

    1. Install the thermostat housing using four bolts (15) with four hard washers (16) on top of the housing. Secure the bottom of the thermostat housing using four bolts (36) with four hard washers (16). Leave the bolts hand tight until the thermostat housing is installed.

    2. Install the lifting eye retainer assembly (17) using two bolts (18) with two hard washers (19).
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    Illustration 6g06000162
    (20) 112-3231 Adapter
    (21) 6V-6609 O-Ring Seal
    (22) 153-1810 Integral Seal

  4. Install the previous jacket water temperature sensor using adapter (20) with o-ring seal (21). Install the upper thermostat housing using integral seal (22).
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    Illustration 7g06000246
    (1) 5M-2894 Hard Washers
    (15) 0S-1594 Bolts
    (23) 0S-1590 Bolts
    (24) 7E-6017 Cover

  5. Install cover (24) using two bolts (23) with two hard washers (1) on the top. Use two bolts (15) with two hard washers (1) on the bottom of the cover. Leave the bolts hand tight until the thermostat housing is installed.
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    Illustration 8g06000249
    (1) 5M-2894 Hard Washers
    (15) 0S-1594 Bolts
    (23) 0S-1590 Bolts
    (25) 7W-6492 Pipe Plug
    (26) 119-6294 Cover
    (27) 3E-7430 Pipe Plug

  6. Install cover (26) using two bolts (23) with two hard washers (1) on the top holes. Use two bolts (15) with two hard washers (1) on the bottom holes of the cover. Leave the bolts hand tight until the thermostat housing is installed.

    1. Install pipe plugs (25) and (27) into cover (26).

    2. Tighten the bolts for the thermostat housing.
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    Illustration 9g06000291
    (1) 5M-2894 Hard Washers
    (15) 0S-1594 Bolts
    (28) 7N-3297 Cover
    (29) 7N-3368 Gasket

  7. Install cover (28) with gasket (29) using three bolts (15) with three hard washers (1) at the rear of the engine located between the water-cooled exhaust manifolds.
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    Illustration 10g06000414
    (1) 5M-2894 Hard Washers
    (30) 1W-2430 Band Clamps
    (31) 7C-3920 Exhaust Seals
    (32) 7C-3921 Seal Rings
    (33) 326-7931 Pipe As
    (34) 2W-5713 Adapters
    (35) 121-5736 Gaskets
    (36) 0S-1571 Bolts
    (37) 9S-8752 Full Nuts

  8. Install two adapters (34) on the end of each manifold using four bolts (36), four hard washers (1), four full nuts (37), and gasket (35).

  9. Install pipe assembly (33) as shown in Illustration 10 using two seal rings (32), two exhaust seals (31), and two band clamps (30).

Aftercooler and Water Lines Installation

Removal

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    Illustration 11g06000642
    (1) 005-4362 Elbow
    (2) 287-7261 Swivel Tee
    (3) 2T-2396 Elbow
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    Illustration 12g06000644
    (4) 353-7956 Grommet
    (5) 325-6994 Clip
    (6) 325-6995 Clip
    (7) 0S-1594 Bolt
    (8) 5M-2894 Hard Washer
    (9) 9S-8752 Full Nut
    (10) 396-0995 Bracket
    (11) 3S-0127 Bolt
    (12) 8T-1887 Clip
    (13) 8T-1888 Clip
    (14) 353-7955 Grommet

  1. Remove the water vent lines attached to the aftercooler. The parts shown in Illustrations 11 and 12 can be reused on the new lines.

Installation

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    Illustration 13g06000418
    (1) 121-5736 Support
    (45) 0L-1143 Bolts
    (46) 5M-2894 Hard Washers
    (47) 217-5449 Spacers

  1. Remove the previous aftercooler support and install support (1) using eight bolts (45), eight hard washers (46), and eight spacers (47).

    Note: The notch in the support will be on the left-hand side and rear facing when installed.

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    Illustration 14g06130867
    (39) 335-2279 Water Aftercooler Gp
    (40) 9X-6458 Hard Washers
    (41) 1A-2029 Bolts
    (42) 9M-1974 Hard Washers
    (43) 0S-1618 Bolts
    (44) 2B-2695 Bolts
    (49) 3B-1915 Bolts
    (50) 329-9301 Bracket As
    (51) 329-9302 Bracket As

  2. Install water aftercooler group (39) onto the previously installed supports.

    Note: This processes below must be completed on both sides of the engine.

    1. Install two bracket assemblies (51) to the engine using four bolts (43), four bolts (44), and eight hard washers (42).

    2. Install bracket assemblies (51) to bracket assembly (50) using four bolts (41) with four hard washers (40).

    3. Install water aftercooler group (39) to bracket assembly (50) using four bolts (49) with four hard washers (40).
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    Illustration 15g06000749
    (2) 2T-2396 Elbow
    (3) 180-8424 O-Ring Seal
    (4) 317-2845 Clip
    (5) 8T-1888 Clip
    (6) 8T-1887 Clip
    (7) 4P-7233 Grommet
    (8) 053-2294 Bolt
    (9) 5M-2894 Hard Washer
    (10) 1A-2029 Bolt
    (11) 9S-8752 Full Nut
    (12) 454-5513 Line As

  3. Install line assembly (12) as shown in Illustration 15.

    1. Install elbow (2) with o-ring seal (3).

    2. Install the line assembly.

    3. Install grommet (7) around the line assembly.

    4. Secure the line assembly using clips (4) (5), and (6). Secure the clips using bolt (8), bolt (10), hard washers (9), and full nut (11).
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    Illustration 16g06000884
    (5) 8T-1888 Clips
    (6) 8T-1887 Clips
    (7) 353-7955 Grommets
    (9) 5M-2894 Hard Washers
    (13) 272-1777 Spacer
    (14) 3S-0127 Bolts
    (15) 450-9147 Hose As
    (16) 309-5734 Spacer
    (17) 150-7158 Connector
    (18) 6V-5138 O-Ring Seal

  4. Install connector (17) with o-ring seal (18) in the location shown in Illustration 16.

  5. Install and secure hose assembly (15).

    1. Install grommets (7) on the hose assembly.

    2. Install clips (5) and (6) on the grommets.

    3. Secure the clips on the right using bolt (14), hard washer (9), hard washer (13), and spacer (13).

    4. Secure the clips on the left using bolt (14), hard washer (9), hard washer (13), and spacer (16).
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    Illustration 17g06000895
    (3) 180-8424 O-Ring Seal
    (9) 5M-2894 Hard Washers
    (13) 272-1777 Spacer
    (14) 3S-0127 Bolts
    (19) 475-4049 Hose As
    (20) 8C-6869 Connector
    (21) 3E-7403 Adapter
    (22) 6V-9837 Swivel Tee
    (23) 451-7008 Bracket As
    (24) 6V-9837 Swivel Tee
    (25) 8T-6895 Union Tee
    (26) 6V-9169 Nut

  6. Install hose assembly (19) and the associated hardware.

    1. Install connector (20) with o-ring seal (3), adapter (21), and swivel tee (22).

    2. Install bracket assembly (23) using two bolts (14), two spacers (13), and two hard washers (3).

    3. Install swivel tee (24) with o-ring seal (3).

    4. Install union tee (25) with nut (26) and o-ring seal (3).

    5. Attach the hose assembly.
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    Illustration 18g06000905
    (9) 5M-2894 Hard Washers
    (11) 9S-8752 Full Nut
    (27) 325-6994 Clips
    (28) 325-6995 Clips
    (29) 353-7956 Grommets
    (30) 0S-1608 Bolts
    (31) 9X-6458 Hard Washers
    (32) 7X-0732 Hard Washers
    (33) 0S-1594 Bolt
    (34) 396-0995 Bracket
    (35) 452-9900 Hose As
    (36) 2P-4437 Clamps
    (37) 4P-7233 Grommets
    (38) 0S-1591 Bolt

  7. Install hose assembly (35) and the associated hardware.

    1. Secure the hose assembly to the connections on both ends.

    2. Install grommet (37) and around the hose assembly. Install clamps (36) on the grommets.

    3. Secure the clamps using bolt (38) with two hard washers (9) and nut (11).

    4. Install grommets (29), clips (27), and clips (28) in the three top locations shown.

    5. Secure the top two locations using bolts (30) with hard washers (31) and (32).

    6. Secure the third set of clips using bolt (33) with hard washer (9), nut (11), and bracket (34).

Wastegate Fittings

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    Illustration 19g06000916
    (1) 8C-6871 Connector
    (2) 180-8424 O-Ring Seal
    (3) 032-1268 Connector
    (4) 345-1924 Gasket
    (5) 168-7800 Locknuts
    (6) 150-7158 Connector
    (7) 6V-5138 O-Ring Seal

  1. Install connector (1) with o-ring seal (2) into the location shown in Illustration 19.

  2. Install connector (3) into the location shown.

  3. Install connector (6) with o-ring seal (7) into the location shown in Illustration 19.

  4. Complete the wastegate assembly using gasket (4) with four locknuts (5).

  5. Install the wastegate assembly into the exhaust elbow between the turbochargers.

Turbocharger Fittings

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    Illustration 20g06000933
    (1) 8C-4424 Plugs
    (2) 216-7485 O-Ring Seals
    (3) 8T-7492 Connectors
    (4) 294-9072 O-Ring Seals
    (5) 6V-9853 Elbows
    (6) 3E-2331 Plugs
    (7) 9Y-6792 Spark Plug Gaskets

  1. Install plugs (1) with o-ring seals (2) into the top port shown in Illustration 20.

  2. Install connectors (3) with o-ring seals (4) into the bottom port in the turbochargers.

  3. Install elbows (5) with o-ring seals (4) into the connectors.

  4. Install plugs (6) with spark plug gaskets (7) into the NOx sensor flange.
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    Illustration 21g06000944
    (2) 216-7485 O-Ring Seals
    (3) 8T-7492 Connectors
    (4) 294-9072 O-Ring Seals
    (8) 5K-9090 O-Ring Seals
    (9) 6V-5064 O-Ring Seals
    (10) 6V-9008 Elbow
    (11) 6V-8635 Connector
    (12) 9S-4185 Plug
    (13) 6V-6609 O-Ring Seal
    (14) 444-1877 Exhaust Elbow

  5. Install connectors (3) with o-ring seals (2) and (4) into the turbocharger cartridge in the locations shown in Illustration 21.

  6. Install the adapters, connectors, and elbows into exhaust elbow (14).

    1. Install plug (12) with o-ring seal (13) into the upper exhaust elbow.

    2. Install elbow (10) with o-ring seals (8) and (9) into the upper port in the exhaust elbow.

    3. Install connector (11) with o-ring seals (8) and (9) into the lower port in the exhaust elbow.
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    Illustration 22g06000972
    (15) Heat Shield

  7. Install the previously used heat shield (15) on the exhaust elbow.

Turbocharger And Water Supply Line Installation

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    Illustration 23g06000981
    (1) 1W-2430 V Band Clamp
    (2) 7C-3920 Exhaust Seal
    (3) 7C-3921 Exhaust Seal Ring
    (4) 336-9259 Bellows As
    (5) 229-5333 Seals
    (6) 6V-3630 High Temperature Bolts
    (7) 6V-3631 Nuts

  1. Install v band clamp (1) with exhaust seal (2) and exhaust seal ring (3).

  2. Install two bellows assemblies (4) with two seals (5), eight high temperature bolts (6), and eight nuts (7).

    1. Install the bellows with the air flow indicator pointing in the correct direction.

    2. The curved side of the bellows goes on the top and bottom of the assembly. The flat sides of the bellows should be on the sides of the bellows.
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    Illustration 24g06001288
    (8) 457-7923 Bracket
    (9) 0L-1351 Bolts
    (10) 5M-2894 Hard Washers

  3. Install bracket (8) using two bolts (9) with two hard washers (10) onto the turbocharger stand.
    Show/hide table
    Illustration 25g06001298
    (9) 0L-1351 Bolts
    (10) 5M-2894 Hard Washers
    (11) 457-7923 Bracket

  4. Install bracket (11) using two bolts (9) with two hard washers (10) onto the turbocharger stand.
    Show/hide table
    Illustration 26g06001388
    (12) 1A-1460 Bolts
    (13) 5P-8245 Hard Washers
    (14) 6B-5072 Adapters

  5. Install adapters (14) between the bottom of the exhaust elbow and the turbocharger stand. Secure the exhaust elbow to the turbocharger stand using four bolts (12) with four hard washers (13).
    Show/hide table
    Illustration 27g06001397
    (15) 5P-7128 Bolts
    (16) 3E-6916 Full Nuts
    (17) 229-5333 Seals

  6. Install seals (17) between the bellows assemblies and the exhaust elbows. Secure the bellows assemblies to the manifolds using four bolts (15) with four hard washers (16) for each manifold.
    Show/hide table
    Illustration 28g06001412
    (18) 5P-2126 Adapters

  7. Install adapters (18) into the exhaust manifolds in the locations shown in Illustration 28.
    Show/hide table
    Illustration 29g03886704
    (19) 6V-8946 Reducer
    (20) 6V-9172 Nuts
    (21) 6V-9840 Swivel Tee
    (22) 5K-9090 O-Ring Seals
    (23) 241-6196 Tee

  8. Install tee (23) to the previously install bracket using nut (20).

    1. Install swivel tee (21) with two o-ring seals (22) to the tee.

    2. Install reducer (19) with two o-ring seals (22) to the tee.
    Show/hide table
    Illustration 30g03886755
    (22) 5K-9090 O-Ring Seal
    (24) 451-7012 Tube As

  9. Install tube assembly (24) with o-ring seal (22) for the supply to the exhaust elbow.
    Show/hide table
    Illustration 31g03886825
    (22) 5K-9090 O-Ring Seal
    (25) 457-7922 Water Tube As
    (26) 294-9072 O-Ring Seal

  10. Install water tube assembly (25) with o-ring seals (22) and (26).
    Show/hide table
    Illustration 32g03887204
    (25) 457-7922 Water Tube As
    (27) 353-7953 Grommets
    (28) 301-7791 Clips
    (29) 301-7792 Clips
    (30) 0S-1594 Bolt
    (31) 9X-6458 Hard Washer
    (32) 9X-8878 Bolt
    (33) 5P-8245 Hard Washer
    (34) 039-8557 Washer
    (35) 2W-5331 Bracket

  11. Secure water tube assembly (25) using the steps below.

    1. Install grommets (27) onto the water tube assembly in the locations shown in Illustration 32.

    2. Install clips (28) and (29) onto the grommets.

    3. Secure the clip assembly on the right using bolt (30) with hard washer (31).

    4. Secure the clip assembly on the left using bolt (32) with washer (34). Install bracket (35) under the clips under the clip assembly.
    Show/hide table
    Illustration 33g03887210
    (10) 5M-2894 Hard Washers
    (24) 451-7012 Tube As
    (25) 457-7922 Water Tube As
    (27) 353-7953 Grommet
    (28) 301-7791 Clips
    (29) 301-7792 Clips
    (36) 8T-1897 Clip
    (37) 8T-1898 Clip
    (38) 353-7952 Grommet
    (39) 0S-1588 Bolt
    (40) 9S-8752 Full Nut

  12. Secure the previously installed water tube assemblies together using the following steps.

    1. Install grommet (27), clip (28), and clip (29) on water tube assembly (25).

    2. Install grommet (38), clip (36), and clip (37) on water tube assembly (24).

    3. Secure the clips together using bolt (39), hard washers (10), and full nut (40).
    Show/hide table
    Illustration 34g03887327
    (26) 294-9072 O-Ring Seals
    (41) 457-7924 Hose As

  13. Install hose assembly (41) with o-ring seal (26) on each end for both sides of the engine
    Show/hide table
    Illustration 35g03887329
    (22) 5K-9090 O-Ring Seal
    (42) 457-7925 Water Hose Assembly
    (43) 6V-9854 Elbow
    (44) 8C-6875 Connector

  14. Install connector (44) into the end of the oil cooler.

  15. Install elbow (43) into the connector using an o-ring seal (22).

  16. Install water hose assembly (42) between the swivel tee and the elbow using an o-ring seal (22) on each end.

Vent Lines and Jacket Water Supply Installation

    Show/hide table
    Illustration 36g06004114
    (1) 8C-8989 Elbow
    (2) 180-8424 O-Ring Seal
    (3) 6V-8942 O-Ring Reducer
    (4) 6V-8556 Nut
    (5) 294-9072 O-Ring Seal
    (6) 8T-1685 Tee
    (7) 6V-5064 O-Ring Seal
    (9) 451-7003 Hose As

  1. Install tee (6) with o-ring seal (7) into the boss on the water manifold.

  2. Install o-ring reducer (3), with o-ring seal (5), and nut (4) into the tee.

  3. Install elbow (1) with o-ring seal (2) into the o-ring reducer.

  4. Install hose assembly (9).
    Show/hide table
    Illustration 37g03887995
    (2) 180-8424 O-Ring Seal
    (10) 451-7004 Hose As
    (11) 8M-2518 Bolt
    (12) 5M-2894 Hard Washer
    (13) 190-4885 Spacer
    (14) 8T-1887 Clip
    (15) 8T-1888 Clip
    (16) 353-7957 Grommet

  5. Install hose assembly (10) with o-ring (2) on each end.

    1. Install grommet (16), clip (14), and clip (15) around the hose assembly.

    2. Secure the clip assembly using bolt (11), spacer (13), and hard washer (12).
    Show/hide table
    Illustration 38g06004120
    (1) 8C-8989 Elbow
    (2) 180-8424 O-Ring Seal
    (5) 294-9072 O-Ring Seal
    (6) 8T-1685 Tee
    (7) 6V-5054 O-Ring Seal
    (17) 6V-8556 Nut
    (18) 6V-8942 O-Ring Reducer
    (19) 5K-9090 O-Ring Seals
    (20) 6V-8557 Face Seal Nut
    (21) 6V-8944 Reducer
    (22) 6V-9847 Swivel Tee
    (23) 8C-5723 Connector
    (24) 6V-5064 O-Ring Seal

  6. Install the fittings into the two bosses on the water manifold.

    1. Install tee (6) with o-ring seal (7) into the front boss.

    2. Install o-ring reducer (18), nut (17), and o-ring seal (5) into the tee.

    3. Install elbow (1) with o-ring seal (2) into the o-ring reducer.

    4. Install connector (23) with o-ring seal (24) into the rear boss.

    5. Install swivel tee (22) with o-ring seal (19) into the connector.

    6. Install reducer (21), face seal nut (20), and o-ring seal (19) into the swivel tee.
    Show/hide table
    Illustration 39g03888384
    (2) 180-8424 O-Ring Seal
    (25) 451-7191 Hose As

  7. Install hose assembly (25) with an o-ring seal (2) on each end.
    Show/hide table
    Illustration 40g03888395
    (2) 180-8424 O-Ring Seal
    (26) 451-7005 Hose As

  8. Install hose assembly (26) with an o-ring seal (2) on each end.
    Show/hide table
    Illustration 41g03888397
    (5) 294-9072 O-Ring Seal
    (12) 5M-2894 Hard Washer
    (27) 451-7002 Hose As
    (28) 8T-1889 Clip
    (29) 8T-1890 Clip
    (30) 353-7953 Grommet
    (31) 0S-1594 Bolt
    (32) 9S-8752 Full Nut

  9. Install hose assembly (27) with an o-ring seal (5) on each end.

  10. Install grommet (30), clip (28), and clip (29) on the hose assembly.

  11. Secure the clip assembly to the bracket using bolt (31), two hard washers (12), and full nut (32).
    Show/hide table
    Illustration 42g03888490
    (19) 5K-9090 O-Ring Seals
    (33) 451-7011 Hose As

  12. Install hose assembly (33) with an o-ring seal (19) on each end.
    Show/hide table
    Illustration 43g03888513

  13. Install the jacket water supply tube assembly to the aftercooler.
      Show/hide table
      Illustration 44g03888521
      (34) 375-5546 Tube As
      (35) 335-2477 Elbow
      (36) 0T-0573 Bolts
      (37) 5M-2894 Hard Washers
      (38) 8S-9191 Bolts
      (39) 153-9481 Clamps
      (40) 0S-1571 Bolts
      (41) 9X-6458 Hard Washers
      (42) 0S-1594 Bolts
      (43) 9S-8752 Nuts
      (44) 153-9963 Rings

    1. Install tube assembly (34) with ring (44) into elbow (35).

    2. Attach the elbow to the aftercooler using two bolts (36), two bolts (38), and four hard washers (37).

      Note: Leave the bolts to the aftercooler hand tight until the entire tube assembly is attached to the engine.

    3. Install two clamps (39) around the tube assembly.

    4. Secure the clamps using two bolts (42), four hard washers (41), and two nuts (43).

      Note: Leave the bolts hand tight until the other bolts are installed into the elbow.

    5. Secure the clamps to the elbow using two bolts (40) with two hard washers (41).
      Show/hide table
      Illustration 45g03888601
      (45) 1A-5964 Bolts
      (46) 1W-8129 Support
      (47) 0S-1590 Bolt
      (48) 9X-6458 Hard Washers
      (49) 9S-8752 Full Nut
      (50) 6V-1867 Clip
      (51) 6V-1868 Clip
      (52) 193-2120 Grommet

    6. Install grommet (52) on the tube assembly.

    7. Install clip (50) and clip (51) onto the grommet.

    8. Install support (46) using two bolts (45).

    9. Secure the clips to the support using bolt (47), two hard washers (48), and full nut (49).
      Show/hide table
      Illustration 46g03888626
      (39) 153-9481 Clamps
      (40) 0S-1571 Bolts
      (41) 9X-6458 Hard Washers
      (42) 0S-1594 Bolts
      (43) 9S-8752 Nuts
      (44) 153-9963 Rings
      (53) 2D-4534 Bolts
      (54) 189-5779 Elbow

    10. Install the tube assembly with o-ring seal (44) into elbow (54).

    11. Install the elbow using two bolts (53).

      Note: Leave the bolts hand tight until installation of the tube assembly is complete.

    12. Install two clamps (39) and secure using two bolts (42), four hard washers (41), and two nuts (43).

    13. Secure the clamps to the elbow using two bolts (40) with two hard washers (41). Tighten the rest of the bolts that were previously installed.

Fuel Heater Hose and Thermocouple Installation

    Show/hide table
    Illustration 47g06006986
    (1) 6V-8628 Elbow
    (2) 3J-7354 O-Ring Seal
    (3) 382-1407 Hose As
    (4) 121-4345 O-Ring Seal
    (5) 6V-3265 Clip
    (6) 0S-1594 Bolt
    (7) 9X-6458 Hard Washer
    (8) 5M-2894 Hard Washer
    (11) Thermocouples

  1. Install elbow (1) with o-ring seal (2) into the left-hand side water manifold.

  2. Install hose assembly (3) with o-ring seal (4).

  3. Secure the hose assembly using clip (5), bolt (6), hard washer (7), and hard washer (8). Reinstall the thermocouples (11) that were removed previously.
    Show/hide table
    Illustration 48g03888973
    (9) 9X-0262 Adapter
    (10) 6V-9027 O-Ring Seal

  4. Install adapter (9) with o-ring seal (10) into the left front water manifold. Reconnect the sensor.

Heat Shield Installation

    Show/hide table
    Illustration 49g06130224
    (1) 500-1822 Bracket
    (2) 8S-8909 Bolts

  1. Install bracket (1) using two bolts (2) onto the rear right side of the turbocharger support. Leave the bolts hand tight.
    Show/hide table
    Illustration 50g06130250
    (2) 8S-8909 Bolts
    (3) 500-1823 Bracket

  2. Install bracket (3) using two bolts (2) onto the rear left side of the turbocharger support. Leave the bolts hand tight.
    Show/hide table
    Illustration 51g03889131
    (4) 485-5649 Bracket
    (5) 5S-7379 Bolts
    (6) 5P-1075 Hard Washers

  3. Install bracket (4) onto the front of the exhaust elbow using two bolts (5) with two hard washers (6).
    Show/hide table
    Illustration 52g03889165
    (5) 5S-7379 Bolts
    (6) 5P-1075 Hard Washers
    (7) 485-5650 Bracket

  4. Install bracket (7) onto the bottom of the exhaust elbow using two bolts (5) with two hard washers (6).
    Show/hide table
    Illustration 53g03889541
    (8) 485-8841 Shields

  5. Install shields (8) onto the dry portion of the exhaust manifold logs.
    Show/hide table
    Illustration 54g06130267
    (6) 5P-1075 Hard Washers
    (10) 500-1821 Bracket As
    (11) 5P-8167 Bolts

  6. Install bracket assembly (10) using three bolts (11) with three hard washers (6).
    Show/hide table
    Illustration 55g06130274
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (14) 500-1824 Shield

  7. Install shield (14) using four bolts (11) with four hard washers (6). Leave the bolts hand tight.
    Show/hide table
    Illustration 56g03889552
    (9) 482-7028 Bracket As

  8. Install bracket assembly (9) behind the previously installed shield.
    Show/hide table
    Illustration 57g03889762
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (12) 482-7027 Shield

  9. Install shield (12) with three bolts (11) and three hard washers (6). Tighten the bolts left loose for Steps 1 and 2.
    Show/hide table
    Illustration 58g03890880
    (13) 482-7029 Shield

  10. Install shield (13) on the left-hand side in front of the seal for the manifold.
    Show/hide table
    Illustration 59g03890934
    (15) 482-7030 Shield

  11. Install shield (15) against the water manifold and under the shield that was installed in the previous step. Tighten the four bolts for the previously installed shield.
    Show/hide table
    Illustration 60g03890959
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (16) 485-8835 Bracket

  12. Install bracket (16) on the left water manifold in the front using two bolts (11) with two hard washers (11).
    Show/hide table
    Illustration 61g03891189
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (17) 485-8836 Bracket

  13. Install bracket (17) on the right water manifold in the front using two bolts (11) with two hard washers (11).
    Show/hide table
    Illustration 62g03891192
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (18) 485-8837 Shield

  14. Install shield (18) on the previously installed bracket (17) using bolt (11) with hard washer (6).
    Show/hide table
    Illustration 63g03891206
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (19) 485-8838 Shield

  15. Install shield (19) on the previously installed bracket using bolt (11) with hard washer (6).
    Show/hide table
    Illustration 64g03891240
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (20) 485-5651 Shield

  16. Install shield (20) between the previously installed shield and attached using four bolts (11) with four hard washers (6).
    Show/hide table
    Illustration 65g03891328
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (21) 487-2089 Shield

  17. Install shield (21) onto the front of the engine and fasten using eight bolts (11) with eight hard washers (6) on the backside of the shield.
    Show/hide table
    Illustration 66g03892458
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (22) 485-5657 Shield

  18. Install shield (22) on the bottom of the previously installed shield (21). Fasten the shield using eight bolts (11) with eight hard washers (6). Two bolts with two hard washers go on each side of shield (22).
    Show/hide table
    Illustration 67g03893599
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (23) 474-2832 Shield

  19. Install shield (23) using five bolts (11) with five hard washers (6). For the left side front of the shield, use the previous bolt and washer.

    Note: Route the thermocouple wires on the outside of the heat shield assembly.

    Show/hide table
    Illustration 68g03895795
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (24) 487-2087 Shield

  20. Install shield (24) on the right side using eight bolts (11) with eight hard washers (6).
    Show/hide table
    Illustration 69g03895850
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (25) 487-2088 Shield

  21. Install shield (25) on the left side using eight bolts (11) with eight hard washers (6).
    Show/hide table
    Illustration 70g03896012
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (26) 485-5663 Shield
    (27) 485-5664 Shield

  22. Install shield (26) first and then install shield (27). Secure the shields using six bolts (11) with six hard washers (6).
    Show/hide table
    Illustration 71g03896401
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (28) 485-5653 Shield

  23. Install shield (28) on the top right side of the shield assembly. Fasten the shield using seven bolts (11) with seven hard washers (6).
    Show/hide table
    Illustration 72g03896442
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (29) 485-5654 Shield

  24. Install shield (29) on the top left side of the shield assembly. Fasten the shield using seven bolts (11) with seven hard washers (6).
    Show/hide table
    Illustration 73g03896450
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (30) 485-8339 Shield

  25. Install shield (30) using two bolts (11) with two hard washers (6).
    Show/hide table
    Illustration 74g03896456
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (31) 485-8340 Shield

  26. Install shield (31) using two bolts (11) with two hard washers (6) on the right side of the engine. Leave the bolts hand tight until the next step.
    Show/hide table
    Illustration 75g03896464
    (6) 5P-1075 Hard Washers
    (11) 5P-8167 Bolts
    (32) 482-7031 Shield

  27. Install shield (32) using two bolts (11) with two hard washers (6). The bolts shown in the bottom of the shield are from the previous step, these bolts can now be tightened.
    Show/hide table
    Illustration 76g03896469
    (33) 372-1186 Nitrogen Oxide Sensor As
    (34) 330-5405 Shield
    (35) 335-3377 Gasket
    (36) 9I-2295 Bolts
    (37) 110-8314 Washers
    (38) 2B-2694 Bolts
    (39) 9N-0869 Hard Washers
    (40) 0S-0509 Bolt
    (41) 5M-2894 Hard Washers
    (42) 4P-8134 Clip
    (43) 9X-6772 Cable Strap
    (44) 9S-1350 Clip
    (45) 0S-1594 Bolt
    (46) 9S-8752 Full Nut

  28. Install nitrogen oxide sensor assembly (33) to the front of the shield assembly using four bolts (38) with four hard washers (39).

  29. Install gasket (35) behind shield (34) and fasten using four bolts (36) with four hard washers (37).

  30. Install clip (42) using bolt (40) with hard washer (41). Secure the sensor wire to the clip using cable strap (43).

  31. Install the sensor wire through clip (44). Fasten the clip to the shield using bolt (45) with two hard washers (41) and full nut (46).

Register the Retrofit

Because retrofits to a prime product will change the configuration of the product, updating the configuration in SIMSi and AIMS is important. If the retrofit information is not provided, Caterpillar will not be able to provide important product updates.

  1. When performing a retrofit installation, record the vital information in Table 12.

    Note: If the procedure is performed by the customer, ask the customer to record the proper information.

    Show/hide table
    Table 12
    Repair Date   
    Product Serial Number   
    Service Hours or Service Meter Units   
    Removed Component Part Number(1)   
    Removed Component Serial Number(1)   
    Installed Component Part Number(2)   
    Installed Component Serial Number(3)   
    Show/hide table
    (1) Only applies if a component is replaced by a retrofit component. If the product is an engine, and the product retrofit is a kit for upgrading the engine, disregard the "Removed Component" information.
    (2) Record the highest level retrofit kit, arrangement, or group part number.
    (3) Most retrofits will not have a serial number. Exceptions include emissions repower engines and diesel particulate filters.

  2. Update the product configuration by entering the information from Table 12 into SIMSi and AIMS.

    Note: For retrofits that have a Caterpillar serial number, the AIMS application is "JIZ111-08". For retrofits that do not have a Caterpillar serial number, the AIMS application is "JIZ111-07".

  3. For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit".

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