Installing the Air To Air Aftercooler (ATAAC) on 3512C and 3516C Generator Set Engines{1063} Caterpillar

Generator Set:

3516C (S/N: SBK1-UP)

Engine:

3512C (S/N: YBD1-UP; SBG1-UP)

3516C (S/N: SKC1-UP; SBJ1-UP; SCJ1-UP; SFJ1-UP; SCK1-UP; SEK1-UP; SFK1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

This Special Instruction describes the procedures that are required in order to install the Air To Air Aftercooler (ATAAC) onto 3512C and 3516C Generator Set Engines. The ATAAC in this Special Instruction was installed on a 3516C Generator Set Engine. Some part numbers may not be the same for other generator sets.

Installation of the Stub Shaft onto the Engine

The stub shaft is mounted onto the damper of the engine. Use the following procedure to mount the stub shaft. Do not install the stub shaft over the existing bolts.

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Illustration 1	g01357241
(1) Vibration damper guard

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Illustration 2	g01357314
(2) Bolts

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Illustration 3	g01357342
Guard (1) is removed.

1. Remove the four bolts (2) that secure guard (1) to the engine.

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Illustration 4	g01357352
(3) 8S-4757 Bolts

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Illustration 5	g01357370
(4) Bolts are removed.

2. Remove bolts (3) .

   The two bolts must be 180 degrees apart. Refer to Illustration 4.

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Illustration 6	g01357381
(5) Guide stud 1 - 14 by 10 inch

3. Install guide studs (5) into holes at location (4) .

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Illustration 7	g01357390

4. Remove the remaining bolts (3) .

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Illustration 8	g01357391

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Illustration 9	g01357743

5. Clean the paint from the damper surface. The stub shaft cannot be installed correctly without removing the paint.

   The paint must be removed from the edges of the damper and from the surface of the damper.

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Illustration 10	g01357771
(6) Index mark on the flange

6. Locate index mark (6) that is located on the flange of the stub shaft.

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Illustration 11	g01357773
(7) Index mark on the damper

7. Locate index mark (7) that is located on the vibration damper.

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Illustration 12	g01357780
Correct alignment of the index marks

8. Line up index mark (6) and index mark (7) .

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Illustration 13	g01357781
(8) Stub shaft

9. Use guide studs (5) in order to install stub shaft (8) .

   Ensure that index marks (6) and index mark (7) are aligned.

10. Ensure that stub shaft (8) is seated correctly in the damper.

11. Apply a molybdenum disulfide grease under the shoulder of the bolt heads and to the threads before assembly.

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Illustration 14	g01357864

12. Install four 9F-8122 Bolts with 5P-8250 Washers .

    Do not tighten the bolts.

13. Remove guide studs (5) .

14. Install the remaining two 9F-8122 Bolts with 5P-8250 Washers .

    Do not tighten the bolts.

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Illustration 15	g01358110

15. Tighten the 9F-8122 Bolts .

    Refer to Illustration 15 for the tightening sequence of the bolts.

    9F-8122 Bolts

    Torque ... 1150 ± 150 N·m (850 ± 110 lb ft)

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Illustration 16	g01358115

16. Measure the run out of stub shaft (8) .

    129-2288 Shaft

    Run out must be less than ... 0.254 mm (0.0100 inch)

17. Install guard (1) .

Installation of the Radiator onto the Engine

Pulleys

Illustration 17	g01893938
(1) Guard for the pulleys for serial number S/N:SBG is shown.

1. Remove guard (1) .
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   Illustration 18	g01329127
   (2) Bolts that secure the sides of guard

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   Illustration 19	g03211738

   1. Remove all of the bolts (2) from the guard. If your engine is equipped with a guard in three parts, remove all parts of the guard.

   2. Remove the seven bolts that mount guard (1) to the frame of the ATAAC.
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   Illustration 20	g01329128
   Typical example of the assembly with guard (1) removed

   3. Remove both sides of guard (1) .

      Remove the belts from the inside of the guard.

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Illustration 21	g01329139
(3) 129-2288 Shaft (4) 288-0833 Idler Pulley for (S/N: SBJ; SBK), 288-0830 Idler Pulley for (S/N: SBG), 297-3154 Idler Pulley for (S/N: SBJ), 296-6666 Fan Drive Pulley As for (S/N: SCK), 374-0180 Pulley As for (S/N: SCK).

2. Install pulley (4) onto stub shaft (3) .

   Stub shaft (3) is installed on the end of the crankshaft.

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   Illustration 22	g01329169
   Typical example of stub shaft (3)

   1. Ensure that the end of stub shaft (3) is clean.
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   Illustration 23	g01329165
   (5) 287-8585 Bushing Kit (6) Keys

   Note: Bushing installed on the engine side of the stub shaft.

   2. Install bushing (5) .

   3. Install keys (6) .

   4. Tighten the set screw on the side of bushing (5) .
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   Illustration 24	g01329182

   5. Install pulley (4) .

      Note: The pulley can protrude up to 12.7 mm (0.50 inch) from the end of the stub shaft for proper alignment.

   6. Install the three bolts that secure pulley (4) onto bushing (5) .

Installation of the 286-2444 Radiator Mounting Group

Illustration 25	g01329599
Top view of the connection points for the ATAAC assembly (A) Location of the 286-2445 Plate (B) Location of the 289-0222 Plate (C) Location of the 289-0223 Plate

Install the 286-2445 Plate

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Illustration 26	g03217116
(7) Rail of the Generator Set (8) 286-2445 Plate (9) 7X-0369 Bolt (10) 5P-6652 Washer (11) 198-4782 Hard Washer (12) 6V-8182 Nut

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Illustration 27	g01329223
Order of assembly for the mounting hardware for the joint between plate (8) and rail (7)

1. Use bolts (9), washers (10), hard washers (11) and nuts (12) in order to install plate (8). Install the plates onto location (A) onto both rails (7) of the generator set.

   7X-0369 Bolt

   Torque ... 370 ± 50 N·m (275 ± 37 lb ft)

2. Move the ATAAC assembly into the final mounting position at the front of the generator set.

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Illustration 28	g03217236
(13) 7X-0371 Bolt (14) Frame of the ATAAC assembly

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Illustration 29	g01329494
Order of assembly for the mounting hardware for the joint between plate (8) and frame (14)

3. Use bolts (13), washers (10), hard washers (11) and nuts (12) in order to install plate (8) onto both sides of frame (14) .

   7X-0371 Bolt

   Torque ... 370 ± 50 N·m (275 ± 37 lb ft)

Install the 289-0222 Plate

Illustration 30	g03217623
(15) 289-0222 Plate

1. Use bolts (9), washers (10), hard washers (11) and nuts (12) in order to install plate (15). Install the plates onto locations (B) on both rails (7) of the generator set.

   7X-0369 Bolt

   Torque ... 370 ± 50 N·m (275 ± 37 lb ft)

   For the order of assembly, refer to Illustration 27.

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Illustration 31	g03218797
(16) 251-5715 Bolt (17) 289-0223 Plate

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Illustration 32	g03218859
(17) 289-0223 Plate

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Illustration 33	g01329586
Order of assembly for the hardware for the joint between plate (15) and frame (14)

2. Use bolts (16), plate (17), washers (10), hard washers (11) and nuts (12) in order to install plate (15) onto both sides of frame (14) .

   251-5715 Bolt

   Torque ... 370 ± 50 N·m (275 ± 37 lb ft)

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Illustration 34	g03219056
(18) 289-0272 Bolt (22) 366-9470 Plate As

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Illustration 35	g03219680

3. Use bolts (18), washers (10), hard washers (11) and plate (22) in order to attach frame (14) onto rails (7) of the generator set. Refer to Illustration 34.

Installation of the Drive Belts for the Fan Drive

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Illustration 36	g03219117

1. Verify that the fan pulley, the idler pulley, and the drive pulley are properly aligned.

   1. Use a straight edge in order to check the alignment of the pulleys.

      The straight edge must contact both edges of each pulley.

   2. If the alignment of the pulleys is correct, proceed to Step 2.

   3. If the alignment of the pulleys is incorrect, adjust pulley (4) that is attached to shaft (3) .

   4. Verify that the alignment of the pulleys is correct.

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Illustration 37	g01329762
(19) Retaining bolts (20) Tensioner

2. Adjust the idler pulley in order to install the belts.

   1. Apply 4C-5597 Anti-Seize Compound to the threads of tensioner (20) .

   2. Loosen the four retaining bolts (19) at the base of the idler pulley assembly. There are two bolts on each side of the idler pulley.

   3. Use the tensioner in order to move the idler pulley assembly in the direction of the fan pulley.

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Illustration 38	g01329767
(21) Drive Belts

3. Install belts (21) .

4. Adjust the tension of belts (21) .

   1. Use the tensioner in order to move the idler pulley assembly in the opposite direction of the fan pulley.

      Belts (21)

      Tension ... 712 ± 111 N (160 ± 25 lb)

   2. Tighten the four retaining bolts (19) at the base of the idler pulley assembly.

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Illustration 39	g01329780

5. Reinstall guard (1) .

   Ensure that guard (1) is not in contact with the water lines group that is located at the front of the engine. Ensure that guard (1) is not in contact with any rotating part.

Note: Recheck the tension of the belts after 30 minutes of operation.

Install the Coolant Lines

Install the Coolant Outlet Tubes

Illustration 40	g01329786
(1) 274-1746 Tubes (S/N: SBK), 273-3544 Tubes (S/N: SBG), 274-1732 Tubes (S/N: SBJ) (2) 5P-0054 Tube Joints

1. Install tube joints (2) .
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   Illustration 41	g01329798
   (3) Ports in the water temperature regulator housing

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   Illustration 42	g01329799
   Parts of the 5P-0054 Tube Joint (4) Clamp (5) Bolt (6) Nut (7) Seal (8) Collar (9) Body

   1. Install collar (8) onto port (3) .

   2. Install seal (7) onto port (3) .

      Ensure that the steel insert is properly seated in the seal.

      The angled face of seal (7) faces collar (8) .

   3. Install body (9) .
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   Illustration 43	g01329818

   4. Use bolts (5) and nuts (6) in order to install clamp (4) .

      Ensure that the clamp is even on all sides before you tighten the clamp.

   5. Tighten the bolts on the clamp to a torque of 28 ± 0.5 N·m (20.65 ± 0.37 lb ft).
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   Illustration 44	g01329823

   6. Repeat Step 1.a through Step 1.d on the upper ports of the ATAAC assembly. Refer to Illustration 44.

   7. Install collars (8) onto tubes (1) .

   8. Install seals (7) onto tubes (1) .

      Ensure that the steel insert is properly seated in the seal.

      The angled face of seal (7) faces collar (8) .

   9. Install tubes (1) into bodies (9) .

      Ensure that tubes (1) are level.

   10. Tighten the bolts on the clamp to a torque of 28 ± 0.5 N·m (20.65 ± 0.37 lb ft).

Install the 126-5957 Elbow

Illustration 45	g01329870
(10) 126-5957 Elbow

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Illustration 46	g01329938
Orientation of elbow (10)

1. Use 0S-1588 Bolts and 4F-0411 Bolts in order to install elbow (10) and the 6V-3835 O-Ring Seal onto the inlet of the water pump.

   Refer to Illustration 46 for the correct orientation of elbow (10) .

Install the 274-1742 Tube

Illustration 47	g01329945
(10) 126-5957 Elbow (11) 274-1742 Tube (12) Outlet of the ATAAC assembly (13) 216-2783 Tube Joint

Illustration 48	g03219176

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Illustration 49	g01329961
(14) Seal (15) Clamp (16) Bolt (17) Nut (18) Collar (19) Body

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Illustration 50	g01329963

1. Install collar (18), seal (14), and body (19) onto each end of tube (11) .

   Apply 207-1600 Rubber Lubricant to the outside face of seal (14) .

   The angled face of seal (14) faces collar (18) .

   Do not install clamps (15) .

2. Install collar (18) and seal (14) onto elbow (10) .

   Apply 207-1600 Rubber Lubricant to the outside face of seal (14) .

   The angled face of seal (14) faces collar (18) .

3. Install collar (18) and seal (14) onto outlet (12) .

   Apply 207-1600 Rubber Lubricant to the outside face of seal (14) .

   The angled face of seal (14) faces collar (18) .

4. Position the assembled tube (11) between elbow (10) and outlet (12) .

   Ensure that the parts are properly aligned.

5. Use bolts (16) and nuts (17) in order to install all of clamps (15) .

   Verify that all of the parts are properly aligned.

6. Tighten the bolts to a torque of 34 ± 0.5 N·m (25.1 ± 0.37 lb ft).

Install the Air Lines

Install the 273-3540 Tube

Install the Clamps for the 273-3540 Tube

Illustration 51	g03219996

Illustration 52	g01329995
(1) 282-6680 Strap (2) 5P-2566 Bolt (3) 8T-4223 Hard Washer (4) 6V-8801 Nut (5) 135-6261 Clamp (6) Inlet for air of the ATAAC assembly (7) 273-3538 Hose (8) 282-6679 Clamp (9) 273-3540 Tube

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Illustration 53	g01330028

1. Use bolts (2), washers (3), and nuts (4) in order to install clamps (8), and straps (1) on inlets (6) of the ATAAC.

2. Use clamps (5) in order to install hoses (7), onto inlets (6) of the ATAAC.

   Apply 207-1600 Rubber Lubricant to the mating surface on the inside of hoses (7) .

   Do not tighten clamps (5) .

   Do not install tube (9) yet.

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Illustration 54	g01330107
(10) 274-1737 Bracket

3. Use 7X-0345 Bolts , 8T-4122 Hard Washers , and 7X-0448 Nuts in order to mount brackets (10) .

4. Install tube (9) .
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   Illustration 55	g03220077
   (10) 274-1737 Bracket

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   Illustration 56	g01330377
   (9) 273-3540 Tube (10) 274-1737 Bracket (11) 136-4190 Two-Piece Clip (12) 136-4191 Two-Piece Clip (13) 8T-2501 Bolt (14) 8T-4896 Hard Washer (15) 5P-1075 Hard Washer (4) 6V-8801 Nut

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   Illustration 57	g01330390
   Order of assembly

   1. Use bolts (13), washers (14), washers (15), and nuts (4) in order to install clips (11) and clips (12) onto brackets (10) .

      Do not tighten bolts (13) .

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   Illustration 58	g01330401

   2. Use bolts (2), washers (3), and nuts (4) in order to install clamps (8), and straps (1) onto tube (9) .

   3. Tighten all the bolts to a torque of 47 ± 9 N·m (34.7 ± 6.6 lb ft). Tighten the clamps to a torque of 7.5 ± 1 N·m (5.5 ± 0.74 lb ft).

Install left side and right side air tubes

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Illustration 59	g01330510
(16) 8T-9379 Bolt (17) 7N-6986 Support (14) 8T-4896 Hard Washer

1. Use bolts (16) and washer (14) in order to install support (17) onto cylinder number 1 and onto cylinder number 2. Tighten the bolts to a torque of 47 ± 9 N·m (34.7 ± 6.6 lb ft).

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Illustration 60	g01330513
(18) 294-5249 Bracket and 294-5250 Bracket (19) 9B-7237 Bolt (15) 5P-1075 Hard Washer (14) 8T-4896 Hard Washer (4) 6V-8801 Nut

2. Use bolts (19), washers (15), washers (14), and nuts (4) in order to install brackets (18). Tighten the bolts to a torque of 47 ± 9 N·m (34.7 ± 6.6 lb ft).

   Note: Install the 294-5249 Bracket on the left side of the engine. Install the 294-5250 Bracket on the right side of the engine.

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Illustration 61	g01341833
(20) Air Inlet Tube

3. Install tubes (20).
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   Table 1

   Inlet Air Tubes
   Engine Prefix	Left Side (20)	Right Side
   S/N:SBG	276-3043	276-3044
   S/N:YBD
   S/N:SBG (50C)	297-5564	297-5563
   S/N:YBD (50C)
   S/N:SBJ	276-3041	276-3042
   S/N:SFJ
   S/N:SBJ (50C)	297-3151	297-3153
   S/N:SFJ (50C)
   S/N:SCJ	276-3041	276-3042
   S/N:SKC
   S/N:SCJ (50C)	282-9917	282-9918
   S/N:SKC (50C)
   S/N:SBK
   S/N:SCK
   S/N:SEK
   S/N:SFK
   S/N:SBK (50C)
   S/N:SCK (50C)
   S/N:SEK (50C)
   S/N:SFK (50C)

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   Illustration 62	g01330649

   1. Use clamps (5) in order to install hose (7) onto tube (9) .

      Do not tighten clamps (5). Do not install tubes (20) .

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   Illustration 63	g01345552
   (21) 294-5248 Elbow

   2. Use clamps (5) in order to install hoses (7) onto elbows (21) .

      Apply 207-1600 Rubber Lubricant to the inside mating surface of hoses (7) .

      Do not tighten clamps (5) .

   3. Insert tubes (20) into hoses (7) that are installed on tubes (9) .

      Apply 207-1600 Rubber Lubricant to the inside surface of hoses (7) .

      Do not tighten clamps (5) .

   4. Insert tubes (20) into hoses (7) that are installed on elbows (21) .

      Apply 207-1600 Rubber Lubricant to the inside mating surface of hoses (7) .

      Do not tighten clamps (5) .

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   Illustration 64	g01330675
   (10) 274-1737 Bracket (13) 8T-2501 Bolt (14) 8T-4896 Hard Washer (15) 5P-1075 Hard Washer (4) 6V-8801 Nut (11) 136-4190 Two-Piece Clip (12) 136-4191 Two-Piece Clip (20) 282-9917 Tube and 282-9918 Tube

   5. Use bolts (13), washers (14), washers (15), and nuts (4) in order to install clips (11) and clips (12) onto brackets (10) .

      Do not tighten bolts (13) .

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   Illustration 65	g01345691
   (22) 293-9810 Clip (23) 293-9809 Clip (24) 295-2847 Bracket (25) 8T-2502 Bolt

   6. Use bolts (25), washers (14), washers (15), and nuts (4) in order to install brackets (24) onto brackets (18) .

      Do not tighten bolts (25) .

   7. Use bolts (13), washers (14), washers (15), and nuts (4) in order to install clips (22) and clips (23) onto brackets (24) .

      Do not tighten bolts (13) .

   8. Ensure that tubes (20) are level.

   9. Tighten all bolts and clamps.

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Illustration 66	g01345700
(26) 315-5341 Clamp (27) 315-5344 Clamp (28) 315-5338 Strap

4. Install the clamps and straps for the connections of joint between tube (20) and elbow (21) .
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   Illustration 67	g01345710
   (26) 315-5341 Clamp (27) 315-5344 Clamp (28) 315-5338 Strap (29) 7X-0311 Bolt (30) 8T-5360 Washer (31) 6V-4430 O-Ring Seal (32) 1S-4305 Washer (33) 7X-0447 Nut

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   Illustration 68	g01345715

   1. Use bolts (29), washers (30), seals (31), washers (32), and nuts (33) in order to install straps (28), clamps (26), and clamps (27) onto tube (20) .
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   Illustration 69	g01345730
   (34) 8T-8916 Bolt (35) 266-5360 Washer

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   Illustration 70	g01345732

   2. Use bolts (34), washers (35), seals (31), and washers (32), in order to install straps (28) onto elbow (21). Tighten the bolts to a torque of 70 ± 15 N·m (51.6 ± 11.1 lb ft).

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Illustration 71	g03223519
(1) 282-6680 Strap (2) 5P-2566 Bolt (3) 8T-4223 Hard Washer (4) 6V-8801 Nut (5) 135-6261 Clamp (8) 282-6679 Clamp (9) 273-3540 Tube (20) 282-9917 Tube and 282-9918 Tube

5. Install clamps (8) and straps (1) for the connections of joint between tube (9) and tube (20) .

   1. Use bolts (2), washers (3), and nuts (4) in order to install clamps (8), and straps (1) onto tube (9), and tube (20) .

   2. Position clamps (5) as clamps (5) are shown in Illustration 69. Tighten the bolts to a torque of 105 ± 20 N·m (77 ± 14.8 lb ft). Tighten the clamps to a torque of 7.5 ± 1 N·m (5.5 ± 0.7 lb ft).

Install the Support for the Return Air Lines

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Illustration 72	g03220538
Return air line support

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Illustration 73	g01345857
(3) 8T-4223 Hard Washer (36) Refer to table 2 for the part number for the support. (38) 6V-8188 Nut (39) 8T-8919 Bolt (44) 8T-4835 Bolt

1. Install supports (36).
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   Table 2

   Return Air Supports
   Prefix	Vertical (36) SBG	Horizontal (41) SBJ	Angular (42) SBK
   S/N:SBG	300-7354	283-2543	282-2542
   S/N:YBD
   S/N:SBG (50C)	297-5574	276-3039	297-5575
   S/N:YBD (50C)
   S/N:SBJ	276-3033	276-3039	267-3040
   S/N:SFJ
   S/N:SBJ (50C)	282-6666	282-6670	282-6669
   S/N:SFJ (50C)
   S/N:SCJ	276-3033	276-3039	388-6912
   S/N:SKC
   S/N:SCJ (50C)	282-6666	282-6670	389-0713
   S/N:SKC (50C)
   S/N:SBK	282-6666	282-6670	282-6669
   S/N:SEK
   S/N:SBK (50C)	295-6342	295-9254	295-9255
   S/N:SEK (50C)
   S/N:SCK	282-6666	282-6670	389-0713
   S/N:SFK
   S/N:SCK (50C)	295-6342	295-9254	363-2828
   S/N:SFK (50C)

   Use bolts (44), bolts (39), washers (3), and nuts (38) in order to install support (36) .

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Illustration 74	g01345866
(3) 8T-4223 Hard Washer (38) 6V-8188 Nut (40) 5P-1076 Hard Washer (41) Refer to table 2 for the part number for the support. (45) 8C-4436 Bolt

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Illustration 75	g01345873
Order of assembly

2. Install the support (41) .

   Use bolts (45), washers (3), washers (40), and nuts (38) in order to install support (41) onto support (36) .

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Illustration 76	g01331559
(42) Support

3. Install support (42). Refer to table 2 for the part number for the support.
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   Illustration 77	g03221900
   (41) Refer to table 2 for the part number for the support. (42) Support

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   Illustration 78	g01345900
   (38) 6V-8188 Nut (40) 5P-1076 Hard Washer (41) Refer to table 2 for the part number for the support. (42) Support

   1. Use bolts (45), washers (40), and nuts (38) in order to install supports (42) onto support (41) .
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   Illustration 79	g03223738

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   Illustration 80	g01331590
   (43) 5P-2228 Bolt

   2. Use bolts (43), and washers (3) in order to install supports (42) onto the ATAAC assembly.

4. Install the support for the belt guard.

   Note: S/N:SCJ, ; S/N:SKC, ; S/N:SCK, and ; S/N:SFK do not use bracket (63).

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   Table 3

   Brackets for the Belt Guard
   Prefix	Part Number
   S/N:SBG	330-4363
   S/N:YBD
   S/N:SBJ	330-4361
   S/N:SFJ
   S/N:SBK	330-4114
   S/N:SEK

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   Illustration 81	g01895921
   (61) Bolts for the guard (62) Belt guard (63) Bracket (64) Bolts for the bracket

   1. Remove the bolts (61) on the top section of the guard. The bolts hold the two halves together.

   2. Use the same bolts in order to install the bracket on the top of the guard.

   3. Install 8T-8916 Bolts , 7X-0589 Hard Washers (radiator side), 8T-5360 Washers and 7X-0447 Nuts in order to fasten the bracket to the angle support.

   4. Tighten the bolts to a torque of 70 ± 15 N·m (51.6 ± 11.1 lb ft).

Install the Return Air Lines

Illustration 82	g01925036
(46) 282-6664 Bellows (47) Tube (48) Adapter (65) 318-4305 Spacers

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Illustration 83	g03234457
(48) Adapter (49) 7X-0440 Bolt or 5S-7383 Bolt (14) 8T-4224 Hard Washer or 8T-4896 Hard Washer (4) 6V-8189 Nut or 6V-8801 Nut

1. Install adapter (48) .

   Use bolts (49), washers (14), and nuts (4) in order to install the gasket and adapter (48) onto the engine.

   SBG and YBD require the following hardware to install adapter (48) :

   • 7X-0440 Bolt

   • 8T-4224 Hard Washer

   • 6V-8189 Nut

   SBK, SKC, SBJ, SCJ, SFJ, SCK, SEK, and SFK require the following hardware to install adapter (48) :

   • 5S-7383 Bolt

   • 8T-4896 Hard Washer

   • 6V-8801 Nut

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Illustration 84	g03234616
(50) 7X-0368 Bolt (51) 8T-4994 Hard Washer (52) 1K-6870 Locknut

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Illustration 85	g01331765
Tightening sequence

2. Install bellows (46) onto adapter (48) with the 318-4305 Spacers inserted between the rubber lip and the adapter.

   Use bolts (50), washers (51), and nuts (52) in order to install bellows (46). Tighten the bolt to a torque of 370 ± 50 N·m (273 ± 37 lb ft).

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Illustration 86	g01331789

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Illustration 87	g01345966
(59) 7X-0370 Bolt

3. Install bellows (46) onto the ATAAC assembly with the 318-4305 Spacer inserted between the rubber lip and the adapter.

   Use bolts (59), washers (51), and nuts (52) in order to install bellows (46). Hand tighten bolts (59) .

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Illustration 88	g01331834

4. Use a suitable lifting device in order to install tube (47) .

   Tube (47)

   Weight ... 28 kg (62 lb)

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   Illustration 89	g03234696
   (53) 282-8532 Bracket

   1. Use bolts (45) and washers (3) in order to install bracket (53) .

      Use bolts (50), washers (51), and nuts (52) in order to install tube (47). Hand tighten bolts (50) .

   2. Use bolts (50), washers (51), and nuts (52) in order to install tube (47). Hand tighten bolts (50) .

      Note: Intake bellows (46) may require compression to fit in between the inlet pipes. Do not damage or puncture the rubber in the bellows.

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   Illustration 90	g03234797

   3. Use bolts (50), washers (51), and nuts (52) in order to install tube (47). Follow the tightening sequence that is shown in Illustration85. Hand tighten bolts (50) .

   4. Follow the tightening sequence that is shown in Illustration 85. Tighten all bolts (50) and (59) to a torque of 370 ± 50 N·m (273 ± 37 lb ft).

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Illustration 91	g03234878
(54) 282-6678 Bracket (57) 282-6684 Bracket

5. Install bracket (54) and bracket (57) .
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   Illustration 92	g03235039
   (55) 8T-8917 Bolt (56) 5P-1076 Hard Washer (3) 8T-4223 Hard Washer (38) 6V-8188 Nut

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   Illustration 93	g01331926
   Order of assembly

   1. Use bolts (55), washers (56), washers (3), and nuts (38) in order to install bracket (54) onto support (41) .
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   Illustration 94	g03235576

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   Illustration 95	g01332066
   Order of assembly

   2. Use bolts (55), washers (56), washers (3), and nuts (38) in order to install bracket (57) onto bracket (54) .
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   Illustration 96	g01332068
   (58) 282-8535 U-Bolt

   3. Use washers (56) and nuts (38) in order to install U-bolts (58) onto bracket (57) .

Install the ATAAC Lines Soft Wrap Heat Shield Group

Illustration 97	g03231480
(1) Top left-hand thermal wraps (2) Top right-hand thermal wraps (3) Bottom right and left-hand thermal wraps

Install the Thermal Wrap

Illustration 98	g03231196

Illustration 99	g03231249
Left-hand thermal wrap installed.

Illustration 100	g03231250
Right-hand thermal wrap installed.

Thermal wrap (1) is installed on the left side of the engine. Thermal wrap (2) is installed on the right side of the engine.

Install the Clip for the Fuel Lines

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Illustration 101	g01333029
(1) 1W-2858 Strap (2) 092-7385 Clip (3) 8T-8917 Bolt (4) 8T-4223 Hard Washer (5) 6V-8188 Nut (6) 285-5971 Hose As (7) 285-5970 Hose As

1. Use bolts (3), washers (4), and nuts (5) in order to install strap (1) and clip (2) onto the frame of the ATAAC assembly.

Install the Fluid Level Sensor and the Sensor Harness

Install the 239-9957 Liquid Level Sensor Gp

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Illustration 102	g01332725
(1) Plug

1. Remove plug (1) .

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Illustration 103	g01332751
(2) 239-9957 Liquid Level Sensor Gp

2. Install sensor (2) .

   Sensor (2)

   Torque ... 20 ± 3 N·m (15 ± 2 lb ft)

Install the 121-3369 Sensor Harness As

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Illustration 104	g01332762
(3) 121-3369 Sensor Harness As (4) 4D-7794 Clip (5) 7K-1181 Cable Strap

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Illustration 105	g01332846
(4) 4D-7794 Clip (5) 7K-1181 Cable Strap

1. Connect harness (3) to sensor (2) .

2. Install clips (4) and straps (5) .

   1. Use existing hardware in order to install clips (4) .

   2. Install straps (5) onto clips (4) .

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Illustration 106	g01332856

3. Install straps (5) onto the ATAAC assembly.

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Illustration 107	g01332876
(6) 274-1746 Tube

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Illustration 108	g01333010

4. Install straps (5) onto tube (6) .

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Illustration 109	g01333007

5. Install strap (5) .

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Illustration 110	g01332887
(7) Straps (8) Engine harness

6. Remove the straps (7) that secure engine harness (8) .

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Illustration 111	g01333021

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Illustration 112	g01332891

7. Install straps (5). Start with the strap closest to the connector on sensor harness (3). Connect engine harness (8) to sensor harness (3). Install the rest of straps (5) .