2000/07/01 Caterpillar

Engines:

G3512 (S/N: 7NJ, 9FP, 5ZZ)

G3516 (S/N: 4EK, 8JZ)

G3524 (S/N: 7SZ)

G3532 (S/N: 8BZ)

Description of Change: Improvements have been made to the turbocharger water lines groups on these engines. These improvements will help prevent coolant leaks. O-ring fittings have replaced the former pipe thread fittings. New tube assemblies and related parts are also used. The new components provide improved fitup and resistance to vibration. The improvements to the water lines groups will also help eliminate entrapped air in the cooling system.

Adaptable To: The 121-7727 Water Lines Group (Turbocharger) has been modified. This change is effective with the following engines:

• G3512 (7NJ648-UP, 9FP228-UP and 5ZZ238-UP)

• G3516 (4EK2858-UP and 8JZ235-UP)

These improvements are adaptable to all engines that are listed in the subtitle. In order to update earlier engines, remove the parts that are listed in Table 1. These parts are shown in Illustrations 1 through 3. Then install the parts that are listed in Table 2. These parts are shown in Illustrations 4 through 6.

Table 1

Parts that Must Be Removed from the 121-7727 Water Lines Group (Turbocharger)
Item	Qty	Part Number	Description
1	2	1P-1441	Flare Nut
2	2	030-8144	Reducer
3	2	6S-5693	Tee
4	4	8N-0788	Cover
5	4	7N-7628	Gasket
6	2	2N-1288	Elbow
7	8	0S-1594	Bolt
8	2	8M-0755	Connector
9	1	140-9409	Tube
10	1	140-9410	Tube
11	1	140-9406	Tube
12	1	143-6858	Tube
13	1	140-9407	Tube
14	1	143-6857	Tube

Table 2

Parts that Are Necessary to Update the 121-7727 Water Lines Group (Turbocharger)
Item	Qty	Part Number	Description
5	4	7N-7628	Gasket
15	2	7D-9984	Elbow
16	2	8L-2786	O-Ring Seal
17	4	1A-2029	Bolt (1)
18	2	8S-5011	O-Ring Seal
19	2	180-5561	Junction Block
20	4	0S-1591	Bolt (1)
21	2	180-5044	Cover
22	4	8W-7478	Lug
23	1	180-6177	Tube
24	1	180-6176	Tube
25	1	180-6172	Tube
26	1	180-6174	Tube
27	1	180-6173	Tube
28	1	180-6175	Tube

( 1 )

Lubricate the threads and the seating surfaces with 5P-3931 Anti-Seize Compound before assembly.

Illustration 1	g00705640
LEFT SIDE VIEW OF ENGINE Remove these parts from the 121-7727 Turbocharger Water Lines Group .

Illustration 2	g00705641
REAR VIEW OF ENGINE Remove these parts from the 121-7727 Water Lines Group .

Illustration 3	g00705643
TOP VIEW OF ENGINE Remove these parts from the 121-7727 Water Lines Group .

Illustration 4	g00705654
LEFT SIDE VIEW OF ENGINE Install these parts in order to update the 121-7727 Turbocharger Water Lines Group .

Illustration 5	g00705656
REAR VIEW OF ENGINE Install these parts in order to update the 121-7727 Turbocharger Water Lines Group .

Illustration 6	g00705657
TOP VIEW OF ENGINE Install these parts in order to update the 121-7727 Turbocharger Water Lines Group .