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:

REBE6635-03

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19Jan2011

(Revised 26May2011)

U-26

A-19

D-26

O-26

TM-2

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE FUEL LINES ON CERTAIN C32 MARINE ENGINES
1274 1261 1712		PI10839

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10839" 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 "PI10839" 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 19 January 2011 (Revised 09 March 2011) Service Letter. Changes have been made to Rework Procedure.

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PROBLEM

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The existing fuel lines on certain C32 marine engines 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	RNZ00356-00357, 360, 362-365, 367, 369, 371, 373, 375, 377-378, 382-383, 385, 389-391, 395-396, 399, 401-402, 404, 407, 410, 412-413, 415, 418-419, 421, 427-432, 434-438, 440, 447, 450, 454-455, 463-465, 470-473, 475-480, 482, 486-487, 491, 493-494, 502-506, 508-509, 514-515, 524-526, 532, 535, 538, 540-541, 544, 548, 557

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*****Group 2*****
C32	RNZ00358-00359, 361, 366, 368, 370, 372, 374, 376, 379-381, 384, 386-388, 392-394, 397-398, 400, 403, 405-406, 408-409, 411, 414, 416-417, 420, 422-426, 433, 439, 441-446, 449, 452-453, 456, 459-462, 466-469, 474, 481, 483-485, 488-490, 495-500, 507, 510-513, 516, 518, 521, 527-530, 534, 542, 545-547

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
6	1P1376	CONNECTOR-STOR
7	4L6454	BOLT
3	4L6459	BOLT
4	4L9337	BOLT
11	5P1075	WASHER-HARD
1	5P2424	BOLT
4	5P4116	WASHER-HARD
1	5P6944	ADAPTER-STR
4	5S7379	BOLT
3	5S7383	BOLT
1	5V9221	SPACER
2	6D3479	CLIP
4	6V8189	NUT-FULL
1	6V8625	ADAPTER-ELBOW
1	6V8782	ADAPTER-TEE
24	6V8801	NUT
1	6V8982	ADAPTER-ELBOW
1	6V9844	ADAPTER-TEE
2	6V9873	ADAPTER-STR
2	7V6571	GROMMET
3	7X0288	BOLT
1	7X0732	WASHER-HARD
1	7X2501	BOLT
1	8C6561	BOLT
1	8M0505	ADAPTER-STR
1	8T1686	ADAPTER-ELBOW
5	8T1887	CLIP
5	8T1888	CLIP
2	8T1889	CLIP-2 PIECE
2	8T1890	CLIP-2 PIECE
1	8T2502	BOLT
1	8T4205	WASHER-HARD
2	8T4224	WASHER-HARD
44	8T4896	WASHER-HARD
1	8T6870	BOLT
2	8T6876	ADAPTER-ELBOW
2	9B7237	BOLT
1	9M4136	SPACER
2	9S8005	PLUG-STOR
1	9X8256	WASHER
1	0908635	SPACER
1	1279258	CONNECTOR
1	1293172	STUD-BOLT
1	1700610	STUD-BOLT
7	2147568	SEAL-O-RING-STOR
11	2287090	SEAL-O-RING-ORFS
5	2287091	SEAL-O-RING-ORS
4	2373759	STUD-BOLT
7	2385080	SEAL-O-RING-STOR
2	2385081	SEAL-O-RING-STOR
1	2971456	BRACKET
4	3072673	PLUG AS
2	3256994	CLIP-HALF SLOT
2	3256995	CLIP-HALF TAB
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	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	3678542	BRACKET AS
1	3678637	HOSE AS-FUEL
1	3679987	BRACKET
1	3689036	HOSE AS-FUEL
1	3689038	BRACKET AS
1	3689039	BRACKET AS
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
3	4L6454	BOLT
3	4L6459	BOLT
1	4L9337	BOLT
9	5P1075	WASHER-HARD
1	5P2424	BOLT
4	5P4116	WASHER-HARD
4	5S7379	BOLT
1	5S7383	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	1220450	GROMMET
1	1293172	STUD-BOLT
1	1542302	SPACER
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	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	3673930	HOSE AS-FUEL
1	3678542	BRACKET AS
1	3678637	HOSE AS-FUEL
1	3679987	BRACKET
1	3689038	BRACKET AS
1	3689039	BRACKET AS
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. A $30 miscellaneous allowance will be allowed 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. A $30 miscellaneous allowance will be allowed 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.

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

Please refer the dealer to their Service Letter dated 19Jan2011 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 19Jan2011 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 a front housing that incorporates a "mounting pad" as shown in Image 1.1.1. This procedure will outline the conversion to the new 368-8870 Main Fuel Lines Group, 368-8874 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 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 reinstall 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 washers from beneath the stud bolts that mount the 297-1458 Brackets from both sides of the engine shown in Image 1.4.1. (Arrows)

Step 8: Reinstall the mounting stud bolts and 297-1458 Brackets.

Image1.4.1

NOTES:
- To install the new fuel lines reference Images 1.5.1 though 1.5.4. 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 9: 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 10: 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 11: 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 12: 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 13: 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 14: 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 15: 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 16: 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 17: 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 18: 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 19: Install the 368-9038 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 20: Install the 364-9039 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 21: 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 22A: 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 22B: 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 22C: 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 22D: 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 23: 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 24: To secure the 367-8637 Hose Assembly to the 367-8542 Bracket, install the 6V-8801 Nut, 4L-6459 Bolt, two 8T-4896 Washers, 353-7957 Grommet, 7X-0732 Washer, 8T-1887 Clip, and 8T-1888 Clip (see Item 3 in Detail J in Image 1.4.1 and Image 1.5.5).

Step 25: 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 26: To secure the 364-5899 Hose Assemblies to the 368-9039 Bracket on the left hand side of the engine and the 368-9038 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 27: Reinstall the 269-6440 Fuel Filter Mounting Bracket, 330-9385 Fuel Filter Bracket, and 237-9311 Fuel Filter Base Assembly.

Step 28A: 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 28B: 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 29: 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 30: Install the 368-9036 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 31: Finish connecting the 364-8675 Hose Assembly to the fuel filter base as shown in Image 1.5.1.

Step 32: Install the 364-8677 Hose Assembly as shown in Image 1.5.1.

Step 33: 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 34: To secure the 364-8675 Hose Assembly to the 368-9038 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 35: To secure the 368-9036 Hose Assembly to the mounting pad on the left hand side of the front housing 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 36: To secure the 364-8675 Hose Assembly to the 368-9039 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 37: The turbocharger cooling vent line will need to be re-routed and secured to the 368-9039 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 38: 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 39: 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 40: Reinstall the air cleaners.

Step 41: 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 for updating Right Hand Service Pleasure Craft Engines built with front housing that incorporates a "mounting pad" as shown in Image 2.1.1. This procedure will outline the conversion to the new 368-8870 Main Fuel Lines Group, 368-8873 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 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.

Image2.1.1

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 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 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 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 washers from beneath the stud bolts that mount the 297-1458 Brackets from both sides of the engine shown in Image 2.4.1. (Arrows)

Step 8: Reinstall the mounting stud bolts and 297-1458 Brackets.

Image2.4.1

NOTE:

- To install the new fuel lines reference Images 2.5.1 though 2.5.4. 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 9: 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 2.5.3.

Step 10: 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 2.5.1.

Step 11: 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 2.5.4.

Step 12: 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 13: Install the 364-5891 Hose Assembly shown in Images 2.5.1 and 2.5.2. The 228-7090 O-Ring is required between the 364-5891 Tube Assembly and the 364-5897 Hose Assembly.

Step 14: To secure the 364-5893 Hose Assembly as seen on Images 2.5.1 and 2.5.3, 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 15: 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 16: Install fuel line clamp assembly previously removed from the old lines as shown in Detail B on Image 2.5.1 and 2.5.3.

Step 17: 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 18: Install a fuel line clamp assembly previously removed from the old lines as shown in Detail A on Images 2.5.1 and 2.5.3.

Step 19: Install the 368-9038 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 20: Install the 368-9039 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 21: 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 22A: 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 22B: 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 22C: 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 22D: 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 23: 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 24: To secure the 367-8637 Hose Assembly to the 367-8542 Bracket shown as Item 3 in Detail J on Image 2.5.4 and on Image 2.5.5, install the 6V-8801 Nut, 4L-6495 Bolt, two 8T-4896 Washers, 353-7957 Grommet, 7X-0732 Washer 8T-1887 Clip, and 8T-1888 Clip.

Step 25: 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 2.5.1.

Step 26: To secure the 364-5899 Hose Assemblies to the 368-9039 Bracket on the left hand side of the engine and the 368-9038 Bracket on the right hand side of the engine shown Images 2.5.1 and 2.5.4, 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 27: Reinstall the 269-6440 Fuel Filter Mounting Bracket, the 308-3003 Fuel Filter Bracket, and the 237-9311 Fuel Filter Base Assembly.

Step 28: 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 2.5.3.

Step 29: Install the 364-5892 Hose Assembly between the 364-4034 Manifold and the fuel filter base as shown in Images 2.5.1 and 2.5.2.

Step 30: Finish connecting the 364-5891 Hose Assembly to the fuel filter base as shown in Images 2.5.1 and 2.5.2.

Step 31: To secure the 364-5891 Hose Assembly to the 368-9038 Bracket as shown at Item 3 in Detail I on Image 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 32: To secure the 364-5892 Hose Assembly to the mounting pad of the right hand side of the front housing shown in Item 4 in Detail I on Image 2.5.4, install 154-2302 Spacer, 4L-9337 Bolt, 5P-1075 Washer, 122-0450 Grommet, 8S-0023 Clip, and 8S-0024 Clip.

Step 33: The turbocharger cooling vent line will need to be re-routed and secured to the 368-9039 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 2.5.1 and 2.5.4.

Step 34: Install the 364-5895 Hose Assembly as shown in Images 2.5.1 and 2.5.2.

Step 35: 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 2.5.1 and 2.5.3.

Step 36: 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.

- 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 37: 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 38: Reinstall the air cleaners.

Step 39: 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.