PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL LINES ON CERTAIN C32 MARINE ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL LINES ON CERTAIN C32 MARINE ENGINES

Usage:

REBE6561-02

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01Dec2010

(Revised 26May2011)

U-484

A-396

D-424

O-424

TM-29

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL LINES ON CERTAIN C32 MARINE ENGINES
1274 1261 1712		PI10831

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10831" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code.
Exception: If the repair is done after failure, use "PI10831" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:	This Revised Service Letter replaces the 01 December 2010 (Revised 09 March 2011) Service Letter. Changes have been made to Rework Procedure.

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PROBLEM

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The fuel lines need to be replaced on certain C32 Marine Engines. The existing fuel lines can develop leaks which can become a potential fire hazard and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C32	RNR00102-00103, 105, 107, 110-111, 113, 115 RNZ00124, 140-141, 146-153, 156-158, 160, 164, 166-168, 170-171, 174-175, 179, 183, 185, 188, 196-199, 201, 203-206, 208-209, 211-212, 215, 217-218, 222, 226, 228-229, 231, 235, 237-240, 242-243, 246, 248, 252-253, 257-258, 264, 269, 274, 278-280, 282, 286-287, 289, 291, 293-294, 296, 298-299, 306-309, 316-321, 324, 326, 328-330, 332, 335, 337, 344-345, 347, 350-354

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*****Group 2*****
C32	RNZ00102, 104, 106, 108-110, 113, 115-116, 118-120, 126-127, 143-144

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*******Group 3*******

C32

RNR00100-00101, 104, 106, 108-109, 112, 114

RNZ00101, 103, 105, 107, 111-112, 114, 117, 121-123, 125, 128-139, 142, 145, 154-155, 162-163, 165, 169, 172-173, 176-178, 180-181, 184, 186-187, 189, 191-195, 200, 202, 207, 210, 213-214, 216, 219-220, 223, 225, 227, 230, 233-234, 236, 241, 244-245, 247, 249-250, 255-256, 259-261, 263, 265-268, 270, 272-273, 276-277, 281, 283-285, 288, 290, 292, 297, 300-302

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*****Group 4*****
C32	RNZ00303-00304, 310-315, 322-323, 325, 327, 331, 333-334, 336, 338-343, 346, 348-349, 355

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
6	1P1376	CONNECTOR-STOR
4	4L6454	BOLT
3	4L6459	BOLT
11	5P1075	WASHER-HARD
4	5P4116	WASHER-HARD
4	5S7379	BOLT
1	5V9221	SPACER
1	6D3479	CLIP
4	6V8189	NUT-FULL
16	6V8801	NUT
2	7V6571	GROMMET
3	7X0288	BOLT
1	7X0732	WASHER-HARD
1	8C3089	SEAL-O-RING
1	8M0505	ADAPTER-STR
1	8T0315	SEAL-O-RING-ORFS
1	8T1686	ADAPTER-ELBOW
5	8T1887	CLIP
5	8T1888	CLIP
2	8T1889	CLIP-2 PIECE
2	8T1890	CLIP-2 PIECE
1	8T2502	BOLT
20	8T4896	WASHER-HARD
2	9B7237	BOLT
1	9M4136	SPACER
2	9S8005	PLUG-STOR
1	0908635	SPACER
1	1279258	CONNECTOR
1	1293172	STUD-BOLT
1	1700610	STUD-BOLT
6	2147568	SEAL-O-RING-STOR
2	2287090	SEAL-O-RING-ORFS
2	2287091	SEAL-O-RING-ORS
1	2314708	SEAL-O-RING
4	2373759	STUD-BOLT
5	2385080	SEAL-O-RING-STOR
1	2971456	BRACKET
2	3256994	CLIP-HALF SLOT
2	3256995	CLIP-HALF TAB
2	3274448	VALVE GP-CHECK-A
1	3394983	KIT-SPRING
2	3537956	GROMMET
5	3537957	GROMMET
1	3644034	MANIFOLD-FUEL
1	3645893	HOSE AS-FUEL
1	3645898	HOSE AS-FUEL
2	3645899	HOSE AS-FUEL
1	3645900	BRACKET AS
1	3645901	BRACKET AS-(LH)
1	3648552	TUBE AS-FUEL
1	3648675	HOSE AS-FUEL
1	3648676	HOSE AS-FUEL
1	3648677	HOSE AS-FUEL
1	3648678	TUBE AS-FUEL
1	3672066	HOSE AS-FUEL
1	3678542	BRACKET AS
1	3678637	HOSE AS-FUEL
1	3679987	BRACKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
6	1P1376	CONNECTOR-STOR
8	4L6454	BOLT
3	4L6459	BOLT
11	5P1075	WASHER-HARD
4	5P4116	WASHER-HARD
4	5S7379	BOLT
1	5V9221	SPACER
1	6D3479	CLIP
4	6V8189	NUT-FULL
18	6V8801	NUT
1	6V8982	ADAPTER-ELBOW
1	6V9170	NUT-BULKHEAD
2	7V6571	GROMMET
3	7X0288	BOLT
1	7X0732	WASHER-HARD
1	8C3089	SEAL-O-RING
1	8M0505	ADAPTER-STR
1	8T0315	SEAL-O-RING-ORFS
1	8T1686	ADAPTER-ELBOW
5	8T1887	CLIP
5	8T1888	CLIP
2	8T1889	CLIP-2 PIECE
2	8T1890	CLIP-2 PIECE
1	8T2502	BOLT
28	8T4896	WASHER-HARD
2	9B7237	BOLT
1	9M4136	SPACER
4	9S8005	PLUG-STOR
1	0908635	SPACER
1	1279258	CONNECTOR
1	1293172	STUD-BOLT
1	1700610	STUD-BOLT
6	2147568	SEAL-O-RING-STOR
2	2287090	SEAL-O-RING-ORFS
3	2287091	SEAL-O-RING-ORS
1	2314708	SEAL-O-RING
4	2373759	STUD-BOLT
5	2385080	SEAL-O-RING-STOR
1	2971456	BRACKET
2	3256994	CLIP-HALF SLOT
2	3256995	CLIP-HALF TAB
2	3274448	VALVE GP-CHECK-A
1	3309385	BRACKET
1	3394983	KIT-SPRING
2	3537956	GROMMET
5	3537957	GROMMET
1	3644034	MANIFOLD-FUEL
1	3645893	HOSE AS-FUEL
1	3645898	HOSE AS-FUEL
2	3645899	HOSE AS-FUEL
1	3645900	BRACKET AS
1	3645901	BRACKET AS-(LH)
1	3648552	TUBE AS-FUEL
1	3648675	HOSE AS-FUEL
1	3648676	HOSE AS-FUEL
1	3648677	HOSE AS-FUEL
1	3648678	TUBE AS-FUEL
1	3672066	HOSE AS-FUEL
1	3678542	BRACKET AS
1	3678637	HOSE AS-FUEL
1	3679987	BRACKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 3*****
6	1P1376	CONNECTOR-STOR
4	4L6454	BOLT
3	4L6459	BOLT
4	4L9337	BOLT
9	5P1075	WASHER-HARD
1	5P2424	BOLT
4	5P4116	WASHER-HARD
4	5S7379	BOLT
1	5V9221	SPACER
1	6D3479	CLIP
4	6V8189	NUT-FULL
1	6V8722	ADAPTER-ELBOW
13	6V8801	NUT
2	7V6571	GROMMET
3	7X0288	BOLT
1	7X0732	WASHER-HARD
1	8C3089	SEAL-O-RING
1	8M0505	ADAPTER-STR
1	8S0023	CLIP
1	8S0024	CLIP
1	8T0315	SEAL-O-RING-ORFS
3	8T1887	CLIP
3	8T1888	CLIP
2	8T1889	CLIP-2 PIECE
2	8T1890	CLIP-2 PIECE
1	8T2502	BOLT
1	8T4223	WASHER-HARD
22	8T4896	WASHER-HARD
1	9B7237	BOLT
1	9M4136	SPACER
2	9S8005	PLUG-STOR
1	0908635	SPACER
4	0910081	SPACER
1	1220450	GROMMET
1	1293172	STUD-BOLT
1	1700610	STUD-BOLT
6	2147568	SEAL-O-RING-STOR
1	2287090	SEAL-O-RING-ORFS
1	2287091	SEAL-O-RING-ORS
1	2314708	SEAL-O-RING
4	2373759	STUD-BOLT
4	2385080	SEAL-O-RING-STOR
2	2385081	SEAL-O-RING-STOR
1	2971456	BRACKET
1	3083003	BRACKET AS
2	3256994	CLIP-HALF SLOT
2	3256995	CLIP-HALF TAB
2	3274448	VALVE GP-CHECK-A
1	3394983	KIT-SPRING
2	3537956	GROMMET
3	3537957	GROMMET
1	3644034	MANIFOLD-FUEL
1	3645891	HOSE AS-FUEL
1	3645892	HOSE AS-FUEL
1	3645893	HOSE AS-FUEL
1	3645895	HOSE AS-FUEL
1	3645897	TUBE AS-FUEL
1	3645898	HOSE AS-FUEL
2	3645899	HOSE AS-FUEL
1	3645900	BRACKET AS
1	3645901	BRACKET AS-(LH)
1	3673930	HOSE AS-FUEL
1	3678542	BRACKET AS
1	3678637	HOSE AS-FUEL
1	3679987	BRACKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 4*****
6	1P1376	CONNECTOR-STOR
4	4L6454	BOLT
3	4L6459	BOLT
9	5P1075	WASHER-HARD
1	5P2424	BOLT
4	5P4116	WASHER-HARD
4	5S7379	BOLT
1	5V9221	SPACER
1	6D3479	CLIP
4	6V8189	NUT-FULL
1	6V8722	ADAPTER-ELBOW
13	6V8801	NUT
2	7V6571	GROMMET
3	7X0288	BOLT
1	7X0732	WASHER-HARD
1	8C3089	SEAL-O-RING
1	8M0505	ADAPTER-STR
1	8S0023	CLIP
1	8S0024	CLIP
1	8T0315	SEAL-O-RING-ORFS
3	8T1887	CLIP
3	8T1888	CLIP
2	8T1889	CLIP-2 PIECE
2	8T1890	CLIP-2 PIECE
1	8T2502	BOLT
1	8T4223	WASHER-HARD
18	8T4896	WASHER-HARD
1	9B7237	BOLT
1	9M4136	SPACER
2	9S8005	PLUG-STOR
1	0908635	SPACER
1	1220450	GROMMET
1	1293172	STUD-BOLT
1	1700610	STUD-BOLT
6	2147568	SEAL-O-RING-STOR
1	2287090	SEAL-O-RING-ORFS
1	2287091	SEAL-O-RING-ORS
1	2314708	SEAL-O-RING
4	2373759	STUD-BOLT
4	2385080	SEAL-O-RING-STOR
2	2385081	SEAL-O-RING-STOR
1	2971456	BRACKET
2	3256994	CLIP-HALF SLOT
2	3256995	CLIP-HALF TAB
2	3274448	VALVE GP-CHECK-A
1	3394983	KIT-SPRING
2	3537956	GROMMET
3	3537957	GROMMET
1	3644034	MANIFOLD-FUEL
1	3645891	HOSE AS-FUEL
1	3645892	HOSE AS-FUEL
1	3645893	HOSE AS-FUEL
1	3645895	HOSE AS-FUEL
1	3645897	TUBE AS-FUEL
1	3645898	HOSE AS-FUEL
2	3645899	HOSE AS-FUEL
1	3645900	BRACKET AS
1	3645901	BRACKET AS-(LH)
1	3673930	HOSE AS-FUEL
1	3678542	BRACKET AS
1	3678637	HOSE AS-FUEL
1	3679987	BRACKET
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Replace the existing fuel lines with the new fuel lines. Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 15.0-hour job for Group 1
This includes all preparation work, parts handling, and an additional 1.0 hour to paint fuel lines and touch up. There is a $30 miscellaneous allowance for purchase of paint to match the engine.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 15.0-hour job for Group 2
This includes all preparation work, parts handling, and an additional 1.0 hour to paint fuel lines and touch up. There is a $30 miscellaneous allowance for purchase of paint to match the engine.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 15.0-hour job for Group 3
This includes all preparation work, parts handling, and an additional 1.0 hour to paint fuel lines and touch up. There is a $30 miscellaneous allowance for purchase of paint to match the engine.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 15.0-hour job for Group 4
This includes all preparation work, parts handling, and an additional 1.0 hour to paint fuel lines and touch up. There is a $30 miscellaneous allowance for purchase of paint to match the engine.

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL LINES

MODELS INVOLVED - C32 Marine Engines

Dear Caterpillar Product Owner:

The fuel lines need to be replaced on the products listed below. The existing fuel lines can develop leaks which can become a potential fire hazard and may, in conjunction with other factors or circumstances, result in a risk of personal injury or death. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 01Dec2010 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 01Dec2010 Service Letter

Rework Procedure

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Group Number 1

This rework procedure is for updating Left Hand Service Pleasure Craft Engines built with "rounded" style front housing as shown in Image 1.1.1. This procedure will outline the conversion to the new 364-5890 Main Fuel Lines Group, 364-6614 Simplex Fuel Filter Group, and 364-6620 Fuel Cooler Group. If you encounter a front housing dissimilar to the images in this service letter please contact your Marine Customer Service Representative or DSN for guidance. For torque specifications reference media number SENR3130.

Note: It is critical that the correct rework group is identified by engine serial number and that the rework is followed step by step to ensure that incorrect assembly does not occur.

Image1.1.1

Caution:
Ensure the engine is shut down and steps have been taken to prevent any attempt to start the engine while fuel hoses are being updated.

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, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Step 1: To allow access to the fuel system, remove both the right and left hand air cleaner assemblies from the turbochargers.

Step 2: To allow access to the fuel transfer pump, remove the 276-7628 Air Tube as seen in Image 1.2.1 which connects the turbocharger to the aftercooler.

NOTE: The 8C-3089 O-Ring is required to re-install the air tube.

Step 3: Remove the 275-0190 Coolant Tube which connects the turbocharger to the cylinder head shown in Image 1.2.1. The 8T-0833 Service Tool can be used to aid the removal of the 275-0190 Coolant Tube.

NOTE: The 231-4708 O-Ring is required to reinstall the 275-0190 Coolant Tube. The 275-0191 Tube may also need to be moved for additional clearance. To reinstall the 275-0191 Tube the 8T-0315 O-Ring may be required.

Image1.2.1

Step 4: To allow access to the fuel fittings that connect the left front head to the fuel lines, the 237-9311 Fuel Filter Base Assembly, 330-9385 Fuel Filter Bracket, and 269-6440 Fuel Filter Mounting Bracket will need to be removed.

Step 5: Remove the old fuel lines called out in Image 1.3.1.

Image1.3.1

Step 6: Remove the four 030-7937 Stand-off Connectors and 214-7568 O-Rings that are located on all four outer corners of the engine cylinder heads.

NOTE: Use of the appropriate crowfoot wrench from the 5P-0336 Wrench Set will aid in the removal and installation of fuel system fittings and lines.

Step 7: Remove the existing fuel pressure regulating valves located in the fuel pressure regulating blocks at the front of each side of the engine above the front valve covers.

Step 8: Install two new 327-4448 Check Valves. Ensure these fuel pressure regulating valves are tightened to a torque of 28 Nm (20.6 ft-lb). Refer to Special Instruction, REHS5025.

Step 9: Remove the existing fuel transfer pump spring kit and install the new 339-4983 Spring Kit to convert the existing fuel transfer pump to the higher pressure 331-3635 Pump. The new spring is shown in Image 1.4.1.

Step 10: Remove the washers from beneath the stud bolts that mount the 297-1458 Brackets from both sides of the engine shown in Image 1.4.2 (Arrows).

Step 11: Reinstall the mounting stud bolts and 297-1458 Brackets.

Image1.4.1

Image1.4.2

NOTES:
- To install the new fuel lines reference Images 1.5.1 though 1.5.5. For more detailed images reference the fuel lines groups in SIS WEB. When installing fuel lines that incorporate a hose assembly, a back-up wrench must be used to prevent any hose twisting and undo stress to the fuel lines.

- When installing these new fuel lines the wiring harness will need to be re-routed in some areas to prevent interference.

- Fuel line installation best practices should be followed. All fuel line connections should first be installed hand tight, all clips and clamps should then be installed, and finally all fuel connections should be tightened to the correct torque value.

- All of the fuel lines metal surfaces and mounting hardware must be painted to match the engine prior to installation to prevent rusting. Ensure that all ends of the fuel lines are capped during the handling and paint process to prevent fuel system contamination.

Image1.5.1

Image1.5.2

Image1.5.3

Image1.5.4

Image1.5.5

Step 12: Install four 1P-1376 Stand-off Connectors with four 214-7568 O-Rings located on all four outer corners of the cylinder heads. See the example at Detail G on Image 1.5.3.

Step 13: Install the 364-8552 Tube Assembly to the fuel transfer pump inlet and the 364-8678 Tube Assembly to the fuel transfer pump outlet. Tighten both connections at the transfer pump to a torque of 55 Nm (40.6 ft-lb) as shown in Image 1.5.1.

Step 14: Install the 364-5893 Hose Assembly and the 364-5898 Hose Assembly ensuring to properly tighten this connection as shown in Detail G on Image 1.5.3.

Step 15: Install two of the previously removed fuel line clamp assemblies from the old fuel lines at locations shown in Detail C and Detail D in Image 1.5.1 and 1.5.3. Installation of these fuel line clamp assemblies will require two 4L-6459 Bolts, four 8T-4896 Washers, two 5P-4116 Washers, two 6V-8189 Nuts, two 237-3759 Stud Bolts, and two 6V-8801 Nuts for both of the clamp assemblies. The old 297-1456 Brackets that are already on the engine should be swapped with the bolts in this location.

Step 16: Install the 364-8675 Hose Assembly as shown in Image 1.5.1. The 228-7090 O-Ring is required between the 364-8552 Tube Assembly and the 364-8675 Hose Assembly.

Step 17: To secure the 364-5893 Hose Assembly install the 5P-4116 Washer, 6V-8189 Nut, 367-9987 Bracket, 8T-4896 Washer, 6V-8801 Nut, 4L-6454 Bolt, 5P-1075 Washer, 325-6994 Half Clip, 325-6995 Half Clip, 237-3759 Stud Bolt, and 353-7956 Grommet as shown at Item 1 on Detail E (Left hand side of engine).

Step 18: To secure the 364-8678 Tube Assembly to the 367-9987 Bracket install the P-clip at Item 2 on Detail E. Installation will require the 7X-0288 Bolt, 5P-1075 Washer, 8T-4896 Washer, 6V-8801 Nut, 8T-1887 Clip, 8T-1888 Clip, 353-7957 Grommet, and 9M-4136 Spacer.

Step 19: Install a fuel line clamp assembly previously removed from the old lines as shown in Detail B on Image 1.5.1 and 1.5.3.

Step 20: To secure the 364-5898 Hose Assembly shown in Detail F (Right hand side of the engine) on Image 1.5.1 and Image 1.5.3, install the 5P-4116 Washer, 6V-8189 Nut, 297-1456 Bracket, 325-6994 Half Clip, 325-6995 Half Clip, 353-7956 Grommet, 6V-8801 Nut, two 8T-4896 Washers, 237-3759 Stud Bolt, and 8T-2502 Bolt.

Step 21: Install a fuel line clamp assembly previously removed from the old lines as shown in Detail A on Image 1.5.1 and 1.5.3.

Step 22: Install the 364-5900 Bracket to the right hand front housing support with two 5S-7379 Bolts and two 5P-1075 Washers shown as Item 1 in Detail L.

Step 23: Install the 364-5901 Bracket to the left hand front housing support with two 5S-7379 Bolts and two 5P-1075 Washers shown as Item 1 in Detail I.

Step 24: Install the 170-0610 Stud Bolt (Item 2 in Detail J) and the 367-8542 Bracket (Item 1 in Detail J) with two 6V-8801 Nuts and two 8T-4896 Washers.

Step 25A: Sub assemble the 364-4034 Manifold Block by installing the two 1P-1376 Connectors with two 214-7568 O-Rings (see Item 4 in Detail J) to the manifold and tighten to a torque of 48 Nm (35.4 ft-lb).

Step 25B: Install the 8M-0505 Adapter with 238-5080 O-Ring (Item 5 in Detail J) to the manifold and tighten to a torque of 55 Nm (40.5 ft-lb).

Step 25C: In the remaining two ports (not shown) install two 9S-8005 Plugs with two 238-5080 O-Rings and tighten to a torque of 70 Nm (51.6 ft-lb).

Step 25D: Install the 364-4034 Manifold to the 367-8542 Bracket using two 7X-0288 Bolts and two 8T-4896 Washers (see Item 6 in Detail J).

Step 26: Install the 367-8637 Hose Assembly shown in Image 1.5.1.

Note: The fuel pressure regulating manifolds located on both sides of the front of the engine may need to be repositioned to allow the 367-8637 Hose Assembly to have adequate clearance to avoid interference.

Step 27: Step 25: To secure the 367-8637 Hose Assembly to the 367-8542 Bracket, install the 6V-8801 Nut, 4L-6459 Bolt, 7X-0732, two 8T-4896 Washers, 353-7957 Grommet, 8T-1887 Clip, and 8T-1888 Clip as (see Item 3 in Detail J in Image 1.5.4 and Image 1.5.5).

Step 28: Install the two 364-5899 Hose Assemblies that connect the front 1P-1376 Connectors to the 364-4034 Manifold Block and tighten to a torque of 27 Nm (19.9 ft-lb) shown in Image 1.5.1.

Step 29: To secure the 364-5899 Hose Assemblies to the 364-5901 Bracket on the left hand side of the engine and the 364-5900 Bracket on the right hand side of the engine shown in Images 1.5.1 and 1.5.4, install the 4L-6454 Bolt, 8T-4896 Washer, 7V-6571 Grommet, 6V-8801 Nut, two 8T-4896 Washers, 8T-1889 Clip, 8T-1890 Clip (see Item 2 in Detail I and Item 2 in Detail L).

Step 30: Reinstall the 269-6440 Fuel Filter Mounting Bracket, 330-9385 Fuel Filter Bracket, and 237-9311 Fuel Filter Base Assembly.

Step 31A: On the fuel filter base install the 127-9258 Connector, 228-7091 O-Ring, and 238-5080 O-Ring (see Item 2 on Detail H). Tighten to a torque of 27.5 Nm (20.2 ft-lb), see Item 2 Detail H shown in Image 1.5.1 and 1.5.3.

Step 31B: Install the 228-7090 O-Ring, 8T-1686 Elbow, and 238-5080 O-Ring. Tighten to a torque of 27.5 Nm (20.2 ft-lb) shown at Item 1 on Detail H in Image 1.5.1 and 1.5.3.

Step 32: Install the 364-8676 Hose Assembly between the 364-8678 Tube Assembly and fuel filter base as shown in Image 1.5.1. The 228-7091 O-Ring is required between the 364-8676 Hose Assembly and the 364-8678 Tube Assembly.

Step 33: Install the 367-2066 Hose Assembly between the 364-4034 Manifold Block, see Detail J on Image 1.5.4, and the fuel filter base as shown in Image 1.5.1.

Step 34: Finish connecting the 364-8675 Hose Assembly to the fuel filter base as shown in Image 1.5.1.

Step 35: Install the 364-8677 Hose Assembly as shown in Image 1.5.1.

Step 36: To secure the 364-8677 Hose Assembly to the heat exchanger, install the 5V-9221 Spacer, 5P-2424 Bolt, and 8T-4223 Washer with the existing bracket and clamp as shown in Detail K in Images 1.5.1 and 1.5.3

Step 37: To secure the 364-8675 Hose Assembly to the 364-5900 Bracket as shown at Item 3 in Detail L on Images 1.5.1 and 1.5.4, install two 5P-1075 Washers, 6V-8801 Nut, 9B-7237 Bolt, 353-7957 Grommet, 8T-1887 Clip, and 8T-1888 Clip.

Step 38: To secure the 367-2066 Hose Assembly to the 364-5901 Bracket shown at Item 3 in Detail I, install the 4L-6454 Bolt, 5P-1075 Washer, 6V-8801 Nut, 8T-4896 Washer, 090-8635 Spacer, 353-7957 Grommet, 8T-1887 Clip, and 8T-1888 Clip.

Step 39: To secure the 364-8675 Hose Assembly to the 364-5901 Bracket shown at Item 4 on Detail I, install two 5P-1075 Washers, 8T-1887 Clip, 8T-1888 Clip, 353-7957 Grommet, 6V-8801 Nut, and 9B-7237 Bolt.

Step 40: The turbocharger cooling vent line will need to be re-routed and secured to the 364-5901 Bracket on the left hand side of the engine using the 129-3172 Stud Bolt, 6D-3479 Clip, two 6V-8801 Nuts and two 8T-4896 Washers as shown at Item 5 on Detail I on Images 1.5.1 and 1.5.4.

Step 41: Reinstall the 275-0190 Coolant Tube which connects the turbocharger to the cylinder head shown in Image 1.2.1. The 8T-0833 Service Tool can be used to aid the installation of the 275-0190 Coolant Tube.

NOTE: The 231-4708 O-Ring is required to reinstall the 275-0190 Coolant Tube. Reinstall the 275-0191 Tube if necessary. To reinstall the 275-0191 Tube, the 8T-0315 O-Ring may be required.

Step 42: Reinstall the 276-7628 Air Tube as seen in Image 1.2.1 which connects the turbocharger to the aftercooler.

NOTE: The 8C-3089 O-Ring is required to reinstall.

Step 43: Reinstall the air cleaners.

Step 44: These new fuel lines can cause the engines fuel pressure to
raise above the alarm limits. If required flash the ECM to the
latest flash file is SISweb to correct alarm set point.

Group Number 2

This rework procedure is similar to the Group 1 update, but requires replacement of the 296-3691 Bracket with the new 330-9385 Fuel Filter Bracket used on certain Left Hand Service Pleasure Craft Engines ordered with the 297-1144 Commercial Filter Group, built with "rounded" style front housing as shown in Image 2.1.1. This procedure will outline the conversion to the new 364-5890 Main Fuel Lines Group, 364-6614 Simplex Fuel Filter Group, and 364-6620 Fuel Cooler Group. If you encounter a front housing dissimilar to the images in this service letter please contact your Marine Customer Service Representative or DSN for guidance. For torque specifications reference media number SENR3130.

Note: It is critical that the correct rework group is identified by engine serial number and that the rework is followed step by step to ensure that incorrect assembly does not occur.

Image2.1.1

Caution:
Ensure the engine is shut down and steps have been taken to prevent any attempt to start the engine while fuel hoses are being updated.

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, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Step 1: To allow access to the fuel system, remove both the right and left hand air cleaner assemblies from the turbochargers.

Step 2: To allow access to the fuel transfer pump, remove the 276-7628 Air Tube as seen in Image 2.2.1 which connects the turbocharger to the aftercooler.

NOTE: The 8C-3089 O-Ring is required to reinstall the air tube.

Step 3: Remove the 275-0190 Coolant Tube which connects the turbocharger to the cylinder head shown in Image 2.2.1. The 8T-0833 Service Tool can be used to aid the removal of the 275-0190 Coolant Tube.

NOTE: The 231-4708 O-Ring is required to reinstall the 275-0190 Coolant Tube. The 275-0191 Tube may also need to be moved for additional clearance. To reinstall the 275-0191 Tube the 8T-0315 O-Ring may be required.

Image2.2.1

Step 4: To allow access to the fuel fittings that connect the left front head to the fuel lines, the 237-9311 Fuel Filter Base Assembly, 296-3691 Fuel Filter Bracket, and 269-6440 Fuel Filter Mounting Bracket will need to be removed.

Step 5: Remove the old fuel lines called out in Image 2.3.1.

Image2.3.1

Step 6: Remove the four 030-7937 Stand-off Connectors and 214-7568 O-Rings that are located on all four outer corners of the engine cylinder heads.

NOTE: Use of the appropriate crowfoot wrench from the 5P-0336 Wrench Set will aid in the removal and installation of fuel system fittings and lines.

Step 7: Remove the existing fuel pressure regulating valves located in the fuel pressure regulating blocks at the front of each side of the engine above the front valve covers.

Step 8: Install two new 327-4448 Check Valves. Ensure the fuel pressure regulating valves are tightened to a torque of 28 Nm (20.6 ft-lb). Refer to Special Instruction, REHS5025.

Step 9: Remove the existing fuel transfer pump spring kit and install the new 339-4983 Spring Kit to convert the existing fuel transfer pump to the higher pressure 331-3635 Pump. The new spring is shown in Image 2.4.1.

Step 10: Remove the washers from beneath the stud bolts that mount the 297-1458 Brackets from both sides of the engine shown in Image 2.4.2(Arrows).

Step 11: Reinstall the mounting stud bolts and 297-1458 Brackets.

Image2.4.1

Image2.4.2

Note:
- To install the new fuel lines reference Images 2.5.1 though 2.5.5. For more detailed images reference the fuel lines groups in SIS WEB.

- When installing fuel lines that incorporate a hose assembly, a back-up wrench must be used to prevent any hose twisting and undo stress to the fuel lines.

- When installing these new fuel lines the wiring harness will need to be re-routed in some areas to prevent interference.

- Fuel line installation best practices should be followed. All fuel line connections should first be installed hand tight, all clips and clamps should then be installed, and finally all fuel connections should be tightened to the correct torque value.

- All of the fuel lines metal surfaces and mounting hardware must be painted to match the engine prior to installation to prevent rusting. Ensure that all ends of the fuel lines are capped during the handling and paint process to prevent fuel system contamination.

Image2.5.1

Image2.5.2

Image2.5.3

Image2.5.4

Image2.5.5

Step 12: Install four 1P-1376 Stand-off Connectors with four 214-7568 O-Rings located on all four outer corners of the cylinder heads. See the example at Detail G on Image 2.5.3.

Step 13: Install the 364-8552 Tube Assembly to the fuel transfer pump inlet and the 364-8678 Tube Assembly to the fuel transfer pump outlet. Tighten both connections at the transfer pump to a torque of 55 Nm (40.6 ft-lb) as shown in Image 2.5.1.

Step 14: Install the 364-5893 Hose Assembly and the 364-5898 Hose Assembly ensuring to properly tighten this connection as shown in Detail G on Image 2.5.3.

Step 15: Install two of the previously removed fuel line clamp assemblies from the old fuel lines at locations shown in Detail C and Detail D in Images 2.5.1 and 2.5.3. Installation of these fuel line clamp assemblies will require two 4L-6459 Bolts, four 8T-4896 Washers, two 5P-4116 Washers, two 6V-8189 Nuts, two 237-3759 Stud Bolts, and two 6V-8801 Nuts for both of the clamp assemblies. The old 297-1456 Brackets that are already on the engine should be swapped with the bolts in this location.

Step 16: Install the 364-8675 Hose Assembly as shown in Image 2.5.1. The 228-7090 O-Ring is required between the 364-8552 Tube Assembly and the 364-8675 Hose Assembly.

Step 17: To secure the 364-5893 Hose Assembly install the 5P-4116 Washer, 6V-8189 Nut, 367-9987 Bracket, 8T-4896 Washer, 6V-8801 Nut, 4L-6454 Bolt, 5P-1075 Washer, 325-6994 Half Clip, 325-6995 Half Clip, 237-3759 Stud Bolt, and 353-7956 Grommet as shown at Item 1 on Detail E (Left hand side of engine).

Step 18: To secure the 364-5897 Tube Assembly to the 367-9987 Bracket install the P-clip at Item 2 on Detail E. Installation will require the 7X-0288 Bolt, 5P-1075 Washer, 8T-4896 Washer, 6V-8801 Nut, 8T-1887 Clip, 8T-1888 Clip, 353-7957 Grommet, 9M-4136 Spacer.

Step 19: Install a fuel line clamp assembly previously removed from the old lines as shown in Detail B on Images 2.5.1 and 2.5.3.

Step 20: To secure the 364-5898 Hose Assembly shown in Detail F (Right hand side of the engine) on Image 2.5.1 and Image 2.5.3, install the 5P-4116 Washer, 6V-8189 Nut, 297-1456 Bracket, 325-6994 Half Clip, 325-6995 Half Clip, 353-7956 Grommet, 6V-8801 Nut, two 8T-4896 Washers, 237-3759 Stud Bolt, and 8T-2502 Bolt.

Step 21: Install a fuel line clamp assembly previously removed from the old lines as shown in Detail A on Image 2.5.1 and 2.5.3.

Step 22: Install the 364-5900 Bracket to the right hand front housing support with two 5S-7379 Bolts and two 5P-1075 Washers shown as Item 1 in Detail L.

Step 23: Install the 364-5901 Bracket to the left hand front housing support with two 5S-7379 Bolts and two 5P-1075 Washers shown as Item 1 in Detail I.

Step 24: Install the 170-0610 Stud Bolt (Item 2 in Detail J) and the 367-8542 Bracket (Item 1 in Detail J) with two 6V-8801 Nuts and two 8T-4896 Washers.

Step 25A: Sub assemble the 364-4034 Manifold Block by installing the two 1P-1376 Connectors with two 214-7568 O-Rings (see Item 4 in Detail J) to the manifold and tighten to a torque of 48 Nm (35.4 ft-lb).

Step 25B: Install the 8M-0505 Adapter with 238-5080 O-Ring (Item 5 in Detail J) to the manifold and tighten to a torque of 55 Nm (40.5 ft-lb).

Step 25C: In the remaining two ports (not shown) install two 9S-8005 Plugs with two 238-5080 O-Rings and tighten to a torque of 70 Nm (51.6 ft-lb).

Step 25D: Install the 364-4034 Manifold to the 367-8542 Bracket using two 7X-0288 Bolts and two 8T-4896 Washers (see Item 6 in Detail J).

Step 26: Install the 367-8637 Hose Assembly shown in Image 2.5.1.

Note: The fuel pressure regulating manifolds located on both sides of the front of the engine may need to be repositioned to allow the 367-8637 Hose Assembly to have adequate clearance to avoid interference.

Step 27: To secure the 367-8637 Hose Assembly to the 367-8542 Bracket, install the 6V-8801 Nut, 4L-6459 Bolt, 7X-0732, two 8T-4896 Washers, 353-7957 Grommet, 8T-1887 Clip, and 8T-1888 Clip as (see Item 3 in Detail J in Image 2.5.4 and Image 2.5.5).

Step 28: Install the two 364-5899 Hose Assemblies that connect the front 1P-1376 Connectors to the 364-4034 Manifold Block and tighten to a torque of 27 Nm (19.9 ft-lb) shown in Image 2.5.1.

Step 29: To secure the 364-5899 Hose Assemblies to the 364-5901 Bracket on the left hand side of the engine and the 364-5900 Bracket on the right hand side of the engine shown in Images 2.5.1 and 2.5.4, install the 4L-6454 Bolt, 8T-4896 Washer, 7V-6571 Grommet, 6V-8801 Nut, two 8T-4896 Washers, 8T-1889 Clip, 8T-1890 Clip (see Item 2 in Detail I and Item 2 in Detail L).

Step 30: Reinstall the 269-6440 Fuel Filter Mounting Bracket.

Step 31: Install the new style 330-9385 Fuel Filter Bracket replacing the commercial bracket with four 4L-6454 Bolts and four 8T-4896 Washers shown as Item 1 in Image 2.7.1.

Image2.7.1

Step 32A: Install the existing fuel filter base with two 5S-7383 Bolts, four 8T-4896 Washers, and two 6V-8801 Nuts shown as Item 2 in Image 2.6.1 ensure that the 4P-8134 Clip is installed (Item 5 Image 2.7.1) at this time.

Step 32B: Install two 9S-8005 Plugs with two 238-5080 O-Rings shown in Item 3 in Image 2.6.1. Install the 6V-8982 Adapter, 228-7091 O-Ring, and 6V-9170 Nut shown in Item 4 in Image 2.7.1.

Step 32C: Install the 127-9258 Connector, 228-7091 O-Ring, and 238-5080 O-Ring (see Item 2 on Detail H) and tighten to a torque of 27.5 Nm (20.2 ft-lb), see Item 2 Detail H shown in Images 2.5.1 and 2.5.3.

Step 32D: Install the 228-7090 O-Ring, 8T-1686 Elbow, and 238-5080 O-Ring and tighten to a torque of 27.5 Nm (20.2 ft-lb) shown at Item 1 on Detail H in Images 2.5.1 and 2.5.3.

Step 33: Install the 364-8676 Hose Assembly between the 364-8678 Tube Assembly and fuel filter base as shown in Image 2.5.1. The 228-7091 O-Ring is required between the 364-8676 Hose assembly and the 364-8678 Tube Assembly.

Step 34: Install the 367-2066 Hose Assembly between the 364-4034 Manifold Block, see Detail J on Image 2.5.4, and the fuel filter base as shown in Image 2.5.1.

Step 35: Finish connecting the 364-8675 Hose Assembly to the fuel filter base as shown in Image 2.5.1.

Step 36: Install the 364-8677 Hose Assembly as shown in Image 2.5.1.

Step 37: To secure the 364-8677 Hose Assembly to the heat exchanger, install the 5V-9221 Spacer, 5P-2424 Bolt, and 8T-4223 Washer with the existing bracket and clamp as shown in Detail K in Images 2.5.1 and 2.5.3.

Step 38: To secure the 364-8675 Hose Assembly to the 364-5900 Bracket as shown at Item 3 in Detail L on Images 2.5.1 and 2.5.4, install two 5P-1075 Washers, 6V-8801 Nut, 9B-7237 Bolt, 353-7957 Grommet, 8T-1887 Clip, and 8T-1888 Clip.

Step 39: To secure the 367-2066 Hose Assembly to the 364-5901 Bracket shown at Item 3 in Detail I, install the 4L-6454 Bolt, 5P-1075 Washer, 6V-8801 Nut, 8T-4896 Washer, 090-8635 Spacer, 353-7957 Grommet, 8T-1887 Clip, and 8T-1888 Clip.

Step 40: To secure the 364-8675 Hose Assembly to the 364-5901 Bracket shown at Item 4 in Detail I, install two 5P-1075 Washers, 8T-1887 Clip, 8T-1888 Clip, 353-7957 Grommet, 6V-8801 Nut, and 9B-7237 Bolt.

Step 41: The turbocharger cooling vent line will need to be re-routed and secured to the 364-5901 Bracket on the left hand side of the engine using the 129-3172 Stud Bolt, 6D-3479 Clip, two 6V-8801 Nuts and two 8T-4896 Washers as shown at Item 5 on Detail I on Images 2.5.1 and 2.5.4.

Step 42: Reinstall the 275-0190 Coolant Tube which connects the turbocharger to the cylinder head shown in Image 2.2.1. The 8T-0833 Service Tool can be used to aid the installation of the 275-0190 Coolant Tube.

NOTE: The 231-4708 O-Ring is required to reinstall the 275-0190 Coolant Tube. Reinstall the 275-0191 Tube if necessary. To reinstall the 275-0191 Tube the 8T-0315 O-Ring may be required.

Step 43: Reinstall the 276-7628 Air Tube as seen in Image 2.2.1 which connects the turbocharger to the aftercooler.

Note: The 8C-3089 O-Ring is required to reinstall the air tube.

Step 44: Reinstall the air cleaners.

Step 45: These new fuel lines can cause the engines fuel pressure to
raise above the alarm limits. If required flash the ECM to the
latest flash file is SISweb to correct alarm set point.

Group Number 3

This rework procedure is similar to the procedure outlined for Group 4, but requires the replacement of the existing 308-3003 Fuel Filter Bracket with a new updated 308-3003 Fuel Filter Bracket used on certain Right Hand Service Pleasure Craft Engines built with "rounded" style front housing as shown in Image 3.1.1. This procedure will outline the conversion to the new 364-5890 Main Fuel Lines Group, 364-6613 Simplex Fuel Filter Group, and the 364-6619 Fuel Cooler Group. If you encounter a front housing dissimilar to the images in this service letter please contact your Marine Customer Service Representative or DSN for guidance. For torque specifications reference media number SENR3130.

Note: It is critical that the correct rework group is identified by engine serial number and that the rework is followed step by step to ensure that incorrect assembly does not occur.

Caution:
Ensure the engine is shut down and steps have been taken to prevent any attempt to start the engine while fuel hoses are being updated.

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, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Image3.1.1

Step 1: To allow access to the fuel system, remove both the right and left hand air cleaner assemblies from the turbochargers.

Step 2: To allow access to the fuel transfer pump, remove the 276-7628 Air Tube as seen in Image 3.2.1 which connects the turbocharger to the aftercooler.

NOTE: The 8C-3089 O-Ring is required to reinstall the air tube.

Step 3: Remove the 275-0190 Coolant Tube which connects the turbocharger to the cylinder head shown in Image 3.2.1. The 8T-0833 Service Tool can be used to aid the removal of the 275-0190 Coolant Tube.

NOTE: The 231-4708 O-Ring is required to reinstall the 275-0190 Coolant Tube. The 275-0191 Tube may also need to be moved for additional clearance. To reinstall the 275-0191 Tube the 8T-0315 O-Ring may be required.

Image3.2.1

Step 4: To allow access to the fuel fittings that connect the right front head to the fuel lines, the 237-9311 Fuel Filter Base Assembly, 296-3691 Fuel Filter Bracket, and 269-6440 Fuel Filter Mounting bracket will need to be removed.

Step 5: Remove the old fuel lines called out in Image 3.3.1.

Image3.3.1

Step 6: Remove the four 030-7937 Stand-off Connectors and 214-7568 O-Rings that are located on all four outer corners of the engine cylinder heads.

NOTE: Use of the appropriate crowfoot wrench from the 5P-0336 Wrench Set will aid in the removal and installation of fuel system fittings and lines.

Step 7: Remove the existing fuel pressure regulating valves located in the fuel pressure regulating blocks at the front of each side of the engine above the front valve covers.

Step 8: Install new 327-4448 Check Valves. Ensure the fuel pressure regulating valves are tightened to a torque of 28 Nm (20.6 ft-lb). Refer to Special Instruction, REHS5025.

Step 9: Remove the existing fuel transfer pump spring kit and install the new 339-4983 Spring Kit to convert the existing fuel transfer pump to the higher pressure 331-3635 Pump. The new spring is shown in Image 3.4.1.

Step 10: Remove the washers from beneath the stud bolts that mount the 297-1458 Brackets from both sides of the engine shown in Image 3.4.2 (Arrows).

Step 11: Reinstall the mounting stud bolts and 297-1458 Brackets.

Image3.4.1

Image3.4.2

NOTE:
- To install the new fuel lines reference Images 3.5.1 though 3.5.5. For more detailed images reference the fuel lines groups in SIS WEB.

- When installing fuel lines that incorporate a hose assembly, a back-up wrench must be used to prevent any hose twisting and undo stress to the fuel lines.

- When installing these new fuel lines the wiring harness will need to be re-routed in some areas to prevent interference.

- Fuel line installation best practices should be followed. All fuel line connections should first be installed hand tight, all clips and clamps should then be installed, and finally all fuel connections should be tightened to the correct torque value.

- All of the fuel lines metal surfaces and mounting hardware must be painted to match the engine prior to installation to prevent rusting. Ensure that all ends of the fuel lines are capped during the handling and paint process to prevent fuel system contamination.

Image3.5.1

Image3.5.2

Image3.5.3

Image3.5.4

Image3.5.5

Step 12: Install four 1P-1376 Stand-off Connectors with 214-7568 O-Rings located on all four outer corners of the cylinder heads, see the example at Detail G on Image 3.5.3.

Step 13: Install the 367-3930 Tube Assembly to the fuel transfer pump inlet and the 364-5897 Tube Assembly to the fuel transfer pump outlet. Tighten both connections for the transfer pump to a torque of 55 Nm (40.6 ft-lb) as shown in Image 3.5.1.

Step 14: Install the 364-5893 Hose Assembly and the 364-5898 Hose Assembly ensuring to properly tighten this connection as shown in Detail G on Image 3.5.4.

Step 15: Install two of the previously removed fuel line clamp assemblies from the old fuel lines at locations shown in Detail C and Detail D in Images 3.5.1 and 3.5.3. Installation of these fuel line clamp assemblies will require two 4L-6459 Bolts, four 8T-4896 Washers, two 5P-4116 Washers, two 6V-8189 Nuts, two 237-3759 Stud Bolts, and two 6V-8801 Nuts for both of the clamp assemblies. The old 297-1456 Brackets that are already on the engine should be swapped with the bolts in this location.

Step 16: Install the 364-5891 Hose Assembly shown in Images 3.5.1 and 3.5.2. The 228-7090 O-Ring is required between the 364-5891 Tube Assembly and the 364-5897 Hose Assembly.

Step 17: To secure the 364-5897 Hose Assembly as seen on Images 3.5.1 and 3.5.3, install the 5P-4116 Washer, 6V-8189 Nut, 367-9987 Bracket, 8T-4896 Washer, 6V-8801 Nut, 4L-6454 Bolt, 5P-1075 Washer, 325-6994 Half Clip, 325-6995 Half Clip, 237-3759 Stud Bolt, and 353-7956 Grommet as shown at Item 1 on Detail E (Left hand side of engine).

Step 18: To secure the 364-5897 Tube Assembly to the 367-9987 Bracket install the P-clip at Item 2 on Detail E. Installation will require the 7X-0288 Bolt, 5P-1075 Washer, 8T-4896 Washer, 6V-8801 Nut, 8T-1887 Clip, 8T-1888 Clip, 353-7957 Grommet, 9M-4136 Spacer.

Step 19: Install fuel line clamp assembly previously removed from the old lines as shown in Detail B on Images 3.5.1 and 3.5.3.

Step 20: To secure the 364-5898 Hose Assembly as shown in Detail F (Right hand side of the engine) on Images 3.5.1 and 3.5.3 install the 5P-4116 Washer, 6V-8189 Nut, 297-1456 Bracket, 325-6994 Half Clip, 325-6995 Half Clip, 353-7656 Grommet, 6V-8801 Nut, two 8T-4896 Washers, 237-3759 Stud Bolts, and 8T-2502 Bolt.

Step 21: Install a fuel line clamp assembly previously removed from the old lines as shown in Detail A on Images 3.5.1 and 3.5.3.

Step 22: Install the 364-5900 Bracket to the right hand front housing support with two 5S-7379 Bolts and two 5P-1075 Washers as shown as Item 1 in Detail I.

Step 23: Install the 364-5901 Bracket to the left hand front housing support with two 5S-7379 Bolts and two 5P-1075 Washers as shown as Item 1 in Detail L.

Step 24: Install the 170-0610 Stud Bolt (Item 2 in Detail J) and the 367-8542 Bracket (Item 1 in Detail J) with two 6V-8801 Nuts and two 8T-4896 Washers.

Step 25A: Sub assemble the 364-4034 Manifold Block by installing the two 1P-1376 Connectors with two 214-7568 O-Rings (see Item 4 in Detail J) to the manifold and tighten to a torque of 48 Nm (35.4 ft-lb).

Step 25B: Install the 8M-0505 Adapter with 238-5080 O-Ring (Item 6 in Detail J) to the manifold and tighten to a torque of 55 Nm (40.5 ft-lb).

Step 25C: Install two 9S-8005 Plugs with two 238-5080 O-Rings and tighten to a torque of 70 Nm (51.6 ft-lb) (see Item 5 Detail J).

Step 25D: Install the 364-4034 Manifold to the 367-8542 Bracket using two 7X-0288 Bolts and two 8T-4896 Washers (see Item 7 in Detail J).

Step 26: Install the 367-8637 Hose Assembly shown in Image 3.5.1.

Note: The fuel pressure regulating manifolds located on both sides of the front of the engine may need to be repositioned to allow the 367-8637 Hose Assembly to have adequate clearance to avoid interference.

Step 27: To secure the 367-8637 Hose Assembly to the 367-8542 Bracket, install the 6V-8801 Nut, 4L-6459 Bolt, 7X-0732, two 8T-4896 Washers, 353-7957 Grommet, 8T-1887 Clip, and 8T-1888 Clip as (see Item 3 in Detail J in Image 3.5.4 and Image 3.5.5).

Step 28: Install the two 364-5899 Hose Assemblies that connect the front 1P-1376 Connectors to the 364-4034 Manifold and tighten to a torque of 27 Nm (19.9 ft-lb) as shown in Image 3.5.1.

Step 29: To secure the 364-5899 Hose Assemblies to the 364-5901 Bracket on the left hand side of the engine and the 364-5900 Bracket on the right hand side of the engine shown Images 3.5.1 and 3.5.4, install two 4L-6454 Bolts, two 7V-6571 Grommets, two 6V-8801 Nuts, four 8T-4896 Washers, two 8T-1889 Clips, and two 8T-1890 Clips (see Item 3 in Detail I and Item 2 in Detail L).

Step 30: Reinstall the 269-6440 Fuel Filter Mounting Bracket.

Step 29: A new style 308-3003 Fuel Filter Bracket must be installed replacing the old style 308-3003 Filter Bracket, for differences see Image 4.6.1. The new style 308-3003 Bracket should be installed with four 091-0081 Spacers, four 4L-9337 Bolts, and four 8T-4896 Washers (see Image 3.7.1).

Image3.7.1

Step 31: Reinstall the 237-9311 Fuel Filter Base. A new 6V-8722 Adapter with 228-7091 and 238-5080 O-Rings is required on the fuel filter base as shown as Item 1 in Detail H on Image 3.5.3.

Step 33: Install the 364-5892 Hose Assembly between the 364-4034 Manifold and the fuel filter base as shown in Images 3.5.1 and 3.5.2.

Step 34: Finish connecting the 364-3691 Hose Assembly to the fuel filter base as shown in Images 3.5.1 and 3.5.2.

Step 35: To secure the 364-5891 Hose Assembly to the 364-5900 Bracket as shown in Item 3 in Detail I on Image 3.5.4, install two 5P-1075 Washers, 6V-8801 Nut, 9B-7237 Bolt, 353-7957 Grommet, 8T-1887 Clip, and 8T-1888 Clip.

Step 36: To secure the 364-5892 Hose Assembly to the 364-5900 Bracket as shown in Item 4 in Detail I on Image 3.5.4, install 090-8635 Spacer, 4L-6454 Bolt, 5P-1075 Washer, 122-0450 Grommet, 8S-0023 Clip, and 8S-0024 Clip.

Step 37: The turbocharger cooling vent line will need to be re-routed and secured to the 364-5901 Bracket on the left hand side of the engine using the 129-3172 Stud Bolt, 6D-3479 Clip, two 6V-8801 Nuts and two 8T-4896 Washers as shown as Item 5 on Detail I on Image 3.5.1 and 3.5.4.

Step 38: Install the 364-5895 Hose Assembly as shown in Images 3.5.1 and 3.5.2.

Step 39: To secure the 364-5895 Hose Assembly to the heat exchanger install the 5V-9221 Spacer, 5P-2424 Bolt, 8T-4223 Washer with the existing bracket and clamp as shown in Detail K in Images 3.5.1 and 3.5.3.

Step 40: Reinstall the 275-0190 Coolant Tube which connects the turbocharger to the cylinder head shown in Image 3.2.1. The 8T-0833 Service Tool can be used to aid the installation of the 275-0190 Coolant Tube.

NOTE: The 231-4708 O-Ring is required to reinstall the 275-0190 Coolant Tube. Reinstall the 275-0191 Tube if necessary. To reinstall the 275-0191 Tube the 8T-0315 O-Ring may be required.

Step 41: Reinstall the 276-7628 Air Tube as seen in Image 3.2.1 which connects the turbocharger to the aftercooler.

NOTE: The 8C-3089 O-Ring is required to reinstall the air tube.

Step 42: Reinstall the air cleaners.

Step 43: These new fuel lines can cause the engines fuel pressure to
raise above the alarm limits. If required flash the ECM to the
latest flash file is SISweb to correct alarm set point.

Group Number 4

This rework procedure is for updating Right Hand Service Pleasure Craft Engines built with "rounded" style front housing as shown in Image 4.1.1. This procedure will outline the conversion to the new 364-5890 Main Fuel Lines Group, 364-6613 Simplex Fuel Filter Group, and the 364-6619 Fuel Cooler Group. If you encounter a front housing dissimilar to the images in this service letter please contact your Marine Customer Service Representative or DSN for guidance. For torque specifications reference media number SENR3130.

Note: It is critical that the correct rework group is identified by engine serial number and that the rework is followed step by step to ensure that incorrect assembly does not occur.

Caution:
Ensure the engine is shut down and steps have been taken to prevent any attempt to start the engine while fuel hoses are being updated.

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, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Image4.1.1

Step 1: To allow access to the fuel system, remove both the right and left hand air cleaner assemblies from the turbochargers.

Step 2: To allow access to the fuel transfer pump, remove the 276-7628 Air Tube as seen in Image 4.2.1 which connects the turbocharger to the aftercooler.

NOTE: The 8C-3089 O-Ring is required to reinstall the air tube.

Step 3: Remove the 275-0190 Coolant Tube which connects the turbocharger to the cylinder head shown in Image 4.2.1. The 8T-0833 Service Tool can be used to aid the removal of the 275-0190 Coolant Tube.

NOTE: The 231-4708 O-Ring is required to reinstall the 275-0190 Coolant Tube. The 275-0191 Tube may also need to be moved for additional clearance. To reinstall the 275-0191 Tube the 8T-0315 O-Ring may be required.

Image4.2.1

Step 4: To allow access to the fuel fittings that connect the right front head to the fuel lines, the 237-9311 Fuel Filter Base Assembly, 296-3691 Fuel Filter Bracket, and 269-6440 Fuel Filter Mounting Bracket will need to be removed.

Step 5: Remove the old fuel lines called out in Image 4.3.1.

Image4.3.1

Step 6: Remove the four 030-7937 Stand-off Connectors and 214-7568 O-Rings that are located on all four outer corners of the engine cylinder heads.

NOTE: Use of the appropriate crowfoot wrench from the 5P-0336 Wrench Set will aid in the removal and installation of fuel system fittings and lines.

Step 7: Remove the existing fuel pressure regulating valves located in the fuel pressure regulating blocks at the front of each side of the engine above the front valve covers.

Step 8: Install new 327-4448 Check Valves. Ensure the fuel pressure regulating valves are tightened to a torque of 28 Nm (20.6 ft-lb). Refer to Special Instruction, REHS5025.

Step 9: Remove the existing fuel transfer pump spring kit and install the new 339-4983 Spring Kit to convert the existing fuel transfer pump to the higher pressure 331-3635 Pump. The new spring is shown in Image 4.4.1.

Step 10: Remove the washers from beneath the stud bolts that mount the 297-1458 Brackets from both sides of the engine shown in Image 4.4.2 (Arrows).

Step 11: Reinstall the mounting stud bolts and 297-1458 Brackets.

Image4.4.1

Image4.4.2

NOTE:

- To install the new fuel lines reference Images 4.5.1 though 4.5.5. For more detailed images reference the fuel lines groups in SIS WEB.

- When installing fuel lines that incorporate a hose assembly, a back-up wrench must be used to prevent any hose twisting and undo stress to the fuel lines.

- When installing these new fuel lines the wiring harness will need to be re-routed in some areas to prevent interference.

- Fuel line installation best practices should be followed. All fuel line connections should first be installed hand tight, all clips and clamps should then be installed, and finally all fuel connections should be tightened to the correct torque value.

- All of the fuel lines metal surfaces and mounting hardware must be painted to match the engine prior to installation to prevent rusting. Ensure that all ends of the fuel lines are capped during the handling and paint process to prevent fuel system contamination.

Image4.5.1

Image4.5.2

Image4.5.3

Image4.5.4

Image4.5.5

Step 12: Install four 1P-1376 Stand-off Connectors with 214-7568 O-Rings located on all four outer corners of the cylinder heads, see the example at Detail G on Image 4.5.3.

Step 13: Install the 367-3930 Tube Assembly to the fuel transfer pump inlet and the 364-5897 Tube Assembly to the fuel transfer pump outlet. Tighten both connections for the transfer pump to a torque of 55 Nm (40.6 ft-lb) as shown in Image 4.5.1.

Step 14: Install the 364-5893 Hose Assembly and the 364-5898 Hose Assembly ensuring to properly tighten this connection as shown in Detail G on Image 4.5.4.

Step 15: Install two of the previously removed fuel line clamp assemblies from the old fuel lines at locations shown in Detail C and Detail D in Images 4.5.1 and 4.5.3. Installation of these fuel line clamp assemblies will require two 4L-6459 Bolts, four 8T-4896 Washers, two 5P-4116 Washers, two 6V-8189 Nuts, two 237-3759 Stud Bolts, and two 6V-8801 Nuts for both of the clamp assemblies. The old 297-1456 Brackets that are already on the engine should be swapped with the bolts in this location.

Step 16: Install the 364-5891 Hose Assembly shown in Images 4.5.1 and 4.5.2. The 228-7090 O-Ring is required between the 364-5891 Tube Assembly and the 364-5897 Hose Assembly.

Step 17: To secure the 364-5893 Hose Assembly as seen on Images 4.5.1 and 4.5.3, install the 5P-4116 Washer, 6V-8189 Nut, 367-9987 Bracket, 8T-4896 Washer, 6V-8801 Nut, 4L-6454 Bolt, 5P-1075 Washer, 325-6994 Half Clip, 325-6995 Half Clip, 237-3759 Stud Bolt, and 353-7956 Grommet as shown at Item 1 on Detail E (Left hand side of engine).

Step 18: To secure the 364-8678 Tube Assembly to the 367-9987 Bracket install the P-clip at Item 2 on Detail E. Installation will require the 7X-0288 Bolt, 5P-1075 Washer, 8T-4896 Washer, 6V-8801 Nut, 8T-1887 Clip, 8T-1888 Clip, 353-7957 Grommet, 9M-4136 Spacer.

Step 19: Install fuel line clamp assembly previously removed from the old lines as shown in Detail B on Image 4.5.1 and 4.5.3.

Step 20: To secure the 364-5898 Hose Assembly as shown in Detail F (Right hand side of the engine) on Images 3.5.1 and 3.5.3 install the 5P-4116 Washer, 6V-8189 Nut, 297-1456 Bracket, 325-6994 Half Clip, 325-6995 Half Clip, 353-7656 Grommet, 6V-8801 Nut, two 8T-4896 Washers, 237-3759 Stud Bolts, and 8T-2502 Bolt.

Step 21: Install a fuel line clamp assembly previously removed from the old lines as shown in Detail A on Images 4.5.1 and 4.5.3.

Step 22: Install the 364-5900 Bracket to the right hand front housing support with two 5S-7379 Bolts and two 5P-1075 Washers as shown as Item 1 in Detail I.

Step 23: Install the 364-5901 Bracket to the left hand front housing support with two 5S-7379 Bolts and two 5P-1075 Washers as shown as Item 1 in Detail L.

Step 24: Install the 170-0610 Stud Bolt (Item 2 in Detail J) and the 367-8542 Bracket (Item 1 in Detail J) with two 6V-8801 Nuts and two 8T-4896 Washers.

Step 25A: Sub assemble the 364-4034 Manifold Block by installing the two 1P-1376 Connectors with two 214-7568 O-Rings (see Item 4 in Detail J) to the manifold and tighten to a torque of 48 Nm (35.4 ft-lb).

Step 25B: Install the 8M-0505 Adapter with 238-5080 O-Ring (Item 6 in Detail J) to the manifold and tighten to a torque of 55 Nm (40.5 ft-lb).

Step 25C: Install two 9S-8005 Plugs with two 238-5080 O-Rings and tighten to a torque of 70 Nm (51.6 ft-lb) (see Item 5 Detail J).

Step 25D: Install the 364-4034 Manifold to the 367-8542 Bracket using two 7X-0288 Bolts and two 8T-4896 Washers (see Item 7 in Detail J).

Step 26: Install the 367-8637 Hose Assembly shown in Image 4.5.1.

Note: The fuel pressure regulating manifolds located on both sides of the front of the engine may need to be repositioned to allow the 367-8637 Hose Assembly to have adequate clearance to avoid interference.

Step 27: Step 25: To secure the 367-8637 Hose Assembly to the 367-8542 Bracket, install the 6V-8801 Nut, 4L-6459 Bolt, 7X-0732, two 8T-4896 Washers, 353-7957 Grommet, 8T-1887 Clip, and 8T-1888 Clip as (see Item 3 in Detail J in Image 4.5.4 and Image 4.5.5).

Step 28: Install the two 364-5899 Hose Assemblies that connect the front 1P-1376 Connectors to the 364-4034 Manifold and tighten to a torque of 27 Nm (19.9 ft-lb) as shown in Image 4.5.1.

Step 29: To secure the 364-5899 Hose Assemblies to the 364-5901 Bracket on the left hand side of the engine and the 364-5900 Bracket on the right hand side of the engine shown Images 4.5.1 and 4.5.4, install two 4L-6454 Bolts, two 7V-6571 Grommets, two 6V-8801 Nuts, four 8T-4896 Washers, two 8T-1889 Clips, and two 8T-1890 Clips (see Item 3 in Detail I and Item 2 in Detail L).

Step 30: Reinstall the 269-6440 Fuel Filter Mounting Bracket, the 308-3003 Fuel Filter Bracket, and the 237-9311 Fuel Filter Base Assembly.

Step 31: A new 6V-8722 Adapter with 228-7091 and 238-5080 O-Rings is required on the fuel filter base as shown as Item 1 in Detail H on Image 4.5.3.

Step 32: Install the 364-5892 Hose Assembly between the 364-4034 Manifold and the fuel filter base as shown in Images 4.5.1 and 4.5.2.

Step 33: Finish connecting the 364-3691 Hose Assembly to the fuel filter base as shown in Images 4.5.1 and 4.5.2.

Step 34: To secure the 364-5891 Hose Assembly to the 364-5900 Bracket as shown at Item 3 in Detail I on Image 4.5.4, install two 5P-1075 Washers, 6V-8801 Nut, 9B-7237 Bolt, 353-7957 Grommet, 8T-1887 Clip, and 8T-1888 Clip.

Step 35: To secure the 364-5892 Hose Assembly to the 364-5900 Bracket as shown in Item 4 in Detail I on Image 4.5.4, install 090-8635 Spacer, 4L-6454 Bolt, 5P-1075 Washer, 122-0450 Grommet, 8S-0023 Clip, and 8S-0024 Clip.

Step 36: The turbocharger cooling vent line will need to be re-routed and secured to the 364-5901 Bracket on the left hand side of the engine using the 129-3172 Stud Bolt, 6D-3479 Clip, two 6V-8801 Nuts and two 8T-4896 Washers as show as Item 5 on Detail I on Images 4.5.1 and 4.5.4.

Step 37: Install the 364-5895 Hose Assembly as shown in Images 4.5.1 and 4.5.2.

Step 38: To secure the 364-5895 Hose Assembly to the heat exchanger install the 5V-9221 Spacer, 5P-2424 Bolt, 8T-4223 Washer with the existing bracket and clamp as shown in Detail K in Images 4.5.1 and 4.5.3.

Step 39: Reinstall the 275-0190 Coolant Tube which connects the turbocharger to the cylinder head shown in Image 4.2.1. The 8T-0833 Service Tool can be used to aid the installation of the 275-0190 Coolant Tube.

- The 231-4708 O-Ring is required to reinstall the 275-0190 Coolant Tube. Reinstall the 275-0191 Tube if necessary. To reinstall the 275-0191 Tube the 8T-0315 O-Ring may be required.

Step 40: Reinstall the 276-7628 Air Tube as seen in Image 4.2.1 which connects the turbocharger to the aftercooler.

NOTE: The 8C-3089 O-Ring is required to reinstall the air tube.

Step 41: Reinstall the air cleaners.

Step 42: These new fuel lines can cause the engines fuel pressure to
raise above the alarm limits. If required flash the ECM to the
latest flash file is SISweb to correct alarm set point.