Fuel Lines Rework on Certain D11T Tier 2 Track-Type Tractors{1274} Caterpillar

Track-Type Tractor:

D11N (S/N: 74Z1-UP)

D11R (S/N: 7PZ1-UP)

D11T (S/N: GEB1-UP; TPB1-UP)

Introduction

Before you attempt the procedures documented in this Special Instruction, make sure that you have read and understand the information in this document. Inventory and inspect all parts before performing this procedure. Replace any missing or damaged parts.

Safety Section

Before performing any of the following procedure, ensure that the machine has been properly locked out/ tagged out.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Required Tools

In addition to the standard mechanics toolkit, ensure that you have the following special tools:

• 463-1899 Wrench

• Clean drum or container to contain coolant to be reused

Machine Preparation

Before beginning the service letter installation, prepare the machine by doing the following:

1. Remove shields and doors required to access the engine compartment. Refer to the Disassembly and Assembly Manual for more information.

2. Drain the coolant into clean drum or container. This coolant will be reused, do not discard.

3. Prevent siphoning of residual fuel in the system.

   1. Shut off fuel supply.

   2. Remove and drain secondary fuel filter.

   3. Reinstall secondary fuel filter.

Part Required

Table 1 below contains the parts for the 454-3170 Fuel Lines Kit .

Table 1

Item	Qty	Part Number	Part Description
1	4	0L-1143	Bolt
2	4	0L-1351	Bolt
3	2	0L-2070	Bolt
4	3	0S-1571	Bolt
5	4	0S-1594	Bolt
6	2	0S-1595	Bolt
7	6	1A-5183	Bolt
8	2	1B-3057	Clip
9	4	1P-1376	Port Connector
10	1	1P-7625	Elbow
11	1	2B-0941	Spacer
12	3	2P-3213	Bolt
13	2	2R-6806	Adapter
14	2	3B-1915	Bolt
15	5	3E-4352	Hard Washer
16	1	3E-4353	Hard Washer
17	2	4B-0418	Clip
18	2	4P-0692	Clamp As
19	4	4P-0693	Clamp As
20	4	4P-0983	Stud
21	1	4P-8134	Clip
22	18	4P-8525	Spacer
23	4	4W-7627	Spacer
24	2	5B-9603	Bolt
25	18	5M-2894	Hard Washer
26	8	5P-1075	Hard Washer
27	1	5P-2228	Bolt
28	4	5P-4116	Hard Washer
29	2	5P-8211	O-Ring Seal
30	2	5P-8245	Hard Washer
31	1	5P-9617	Adapter
32	3	5S-0003	Nut
33	1	6V-3250	O-Ring Seal
34	2	6V-5217	Bolt
35	1	6V-5230	Bolt
36	2	6V-6609	O-Ring Seal
37	3	6V-8189	Nut
38	1	6V-8639	Connector
39	4	6V-8801	Nut
40	1	6V-9027	O-Ring Seal
41	2	7G-1239	Spacer
42	1	7K-1181	Cable Strap
43	1	7W-0534	Washer
44	15	7X-0440	Bolt
45	1	8C-3089	O-Ring Seal
46	1	8K-2396	Flared Elbow
47	3	8T-1887	Clip
48	3	8T-1888	Clip
49	2	8T-1897	Clip
50	2	8T-1898	Clip
51	1	8T-4121	Hard Washer
52	1	8T-4185	Bolt
53	1	8T-4223	Hard Washer
54	8	8T-4224	Hard Washer
55	4	8T-8912	Bolt
56	3	9M-1974	Hard Washer
57	1	9S-8005	O-Ring Plug
58	1	9X-2492	O-Ring Tee
59	13	9X-6458	Hard Washer
60	1	030-7949	Elbow
61	1	030-7972	Elbow
62	4	126-0559	Bolt
63	1	132-7551	Spacer
64	1	133-6934	Spacer
65	1	154-9023	Valve
66	1	157-0670	Dust Cap
67	3	165-3931	Bolt
68	4	180-8424	O-Ring Seal
69	4	198-4776	Hard Washer
70	6	214-7568	O-Ring Seal
71	3	224-9907	Stud
72	3	237-3759	Stud
73	2	238-5080	O-Ring Seal
74	1	238-5081	O-Ring Seal
75	2	305-2452	Bracket As
76	1	327-4448	Check Valve Gp
77	4	341-9211	Gasket
78	2	346-6981	Bracket As
79	2	353-7952	Grommet
80	3	353-7957	Grommet
81	1	369-9380	Fuel Manifold
82	3	387-9526	Seal
83	1	391-2993	Bracket As
84	1	393-8968	Bracket As
85	1	393-9283	Bracket As
86	8	433-7014	Saddle Assembly
87	1	436-5801	Hose and Tube As
88	1	436-5802	Hose and Tube As
89	1	436-5803	Hose As
90	1	436-7326	Guard
91	1	436-7327	Guard
92	1	436-7552	Water Tube As
93	1	436-7553	Water Tube As
94	1	437-0127	Cover
95	2	437-0128	Cover As
96	1	444-6978	Guard
97	1	444-6979	Guard
98	1	445-1246	Bracket As
99	1	456-9156	Hose and Tube As
100	1	456-9157	Hose and Tube As
101	1	456-9158	Hose and Tube As
102	1	456-9159	Hose and Tube As

Installation Procedure

Note: With removal of any component, ensure that any opening is covered to prevent contamination. Contamination can cause early wear or failure of components and/or systems.

Note: Remove the metal identification tags from the fuel lines after installation is completed to prevent any rubbing or wear of the lines.

Exhaust and Intake Piping Removal

Table 2

Removed Components
Item	Qty	Part Number	Part Description
1	1	239-5609 (1)	Clamp
2	1	267-5215 (1)	Tube
3	1	268-8665 (1)	Hose
4	2	271-7377 (1)	Tube As
5	1	274-7911 (1)	Tube As
6	1	275-0860 (1)	Elbow
7	4	9X-2201 (1)	Hose Clamp

( 1 )

Retain the part for reuse during the installation process.

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Illustration 1	g03736674

1. Remove upper exhaust tube assembly (5) .

2. Remove intake tube assembly (4) unfastening the air filter and clamp (1) at the compressor elbow.

3. Remove the Air to Air Aftercooler (ATAAC) piping by removing elbow (6), tube (2), hose (3), and hose clamps (7).
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   Table 3

   Removed Components
   Item	Qty	Part Number	Part Description
   8	1	239-5609 (1)	Clamp
   9	1	267-5215 (1)	Tube
   10	1	268-8665 (1)	Hose
   11	2	271-7377 (1)	Tube As
   12	1	274-7911 (1)	Tube As
   13	1	275-0860 (1)	Elbow
   14	4	9X-2201 (1)	Hose Clamp

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   ( 1 )

   Retain the part for reuse during the installation process.

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Illustration 2	g03736942

4. Remove upper exhaust tube assembly (12) .

5. Remove intake tube assembly (11) unfastening the air filter and clamp (8) at the compressor elbow.

6. Remove the Air to Air Aftercooler (ATAAC) piping by removing elbow (13), tube (9), hose (10), and hose clamps (14).
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   Table 4

   Removed Components
   Item	Qty	Part Number	Part Description
   15	1	5P-0597 (1)	Hose Clamp
   16	1	265-5210 (1)	Clamp As
   17	1	277-4858 (1)	Air Cleaner Gp

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   ( 1 )

   Retain the part for reuse during the installation process.

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Illustration 3	g03736947

7. Remove hose clamp (15) that holds the fumes line disposal in place. Remove the fumes disposal line.

8. Unbolt clamp assembly (16) that holds air cleaner group (17) in place. Remove the air cleaner group.
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   Table 5

   Removed Components
   Item	Qty	Part Number	Part Description
   18	1	5P-0597 (1)	Hose Clamp
   19	1	265-5210 (1)	Clamp As
   20	1	277-4858 (1)	Air Cleaner Gp

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   ( 1 )

   Retain the part for reuse during the installation process.

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Illustration 4	g03736954

9. Remove hose clamp (18) that holds the fumes line disposal in place. Remove the fumes disposal line.

10. Unbolt clamp assembly (19) that holds air cleaner group (20) in place. Remove the air cleaner group.
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    Table 6

    Removed Components
    Item	Qty	Part Number	Part Description
    21	1	263-5494 (1)	Cover Support

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    ( 1 )

    Retain the part for reuse during the installation process.

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Illustration 5	g03736969

11. Remove cover support (21) by unfastening the bolts that hold the support in place.
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    Table 7

    Removed Components
    Item	Qty	Part Number	Part Description
    22	1	133-6934 (1)	Spacer
    23	1	8T-4181 (1)	Bolt
    24	1	8T-4185 (1)	Bolt

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    ( 1 )

    Retain the part for reuse during the installation process.

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Illustration 6	g03736977

12. Remove bolts (24), hard washers (23), and spacer (22) at the cable strap location shown in Illustration 6.

Fuel System Preparation

1. Ensure that the fuel supply from the tank is shut off.

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Illustration 7	g03736984
(1) Fuel supply outlet hose

2. Disconnect fuel supply outlet hose (1) from the primary fuel filter to prevent draining the filter.
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   Table 8

   Removed Components
   Item	Qty	Part Number	Part Description
   2	2	1B-3057	Clip
   3	2	4B-0418	Clip
   4	2	5P-4116	Hard Washer
   5	2	8T-8912	Bolt
   6	2	198-4776	Hard Washer

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Illustration 8	g03736988

3. Remove clips (2) and (3) by removing bolts (5) with hard washers (4) and (6) .

   Note: Leave the isolation assemblies that are located under the hard washers.

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   Table 9

   Removed Components
   Item	Qty	Part Number	Part Description
   7	1	0L-1143	Bolt
   8	1	0S-1594	Bolt
   9	1	4W-7627	Spacer
   10	2	5M-2894	Hard Washer
   11	1	7N-7628	Gasket
   12	1	272-2946	Tube As

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Illustration 9	g03737000

4. Unfasten the swivel nut for tube assembly (12) .

5. Remove bolt (7), bolt (8), spacer (9), hard washers (10), and gasket (11) from the turbocharger flange.

6. Once the connections are loose, remove tube assembly (12) from the engine.
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   Table 10

   Removed Components
   Item	Qty	Part Number	Part Description
   13	1	0L-1143	Bolt
   14	1	0S-1594	Bolt
   15	1	4W-7627	Spacer
   16	2	5M-2894	Hard Washer
   17	1	7N-7628	Gasket
   18	1	272-2947	Tube As

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Illustration 10	g03737032

7. Unfasten the swivel nut for tube assembly (18) .

8. Remove bolt (13), bolt (14), spacer (15), hard washers (16), and gasket (17) from the turbocharger flange.

9. Once the connections are loose, remove tube assembly (18) from the engine.

Right Side Turbocharger Water Lines Disassembly

Table 11

Removed Components
Item	Qty	Part Number	Part Description
1	2	1B-3057	Clip
2	2	4B-0418	Clip
3	2	5P-4116	Hard Washer
4	2	8T-8912	Bolt
5	2	198-4776	Hard Washer

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Illustration 11	g03737042

1. Remove clips (1) and (2) by removing bolts (4), hard washers (3), and (5) .

   Note: Leave the isolation assemblies that are located under the hard washers.

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   Table 12

   Removed Components
   Item	Qty	Part Number	Part Description
   6	1	0L-1143	Bolt
   7	1	0S-1594	Bolt
   8	1	4W-7627	Spacer
   9	2	5M-2894	Hard Washer
   10	1	7N-7628	Gasket
   11	1	272-2945	Tube As

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Illustration 12	g03737123

2. Unfasten the swivel nut for tube assembly (11) .

3. Remove bolt (6), bolt (7), spacer (8), hard washers (9), and gasket (10) from the turbocharger flange.

4. Once the connections are loose, remove tube assembly (11) from the engine.
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   Table 13

   Removed Components
   Item	Qty	Part Number	Part Description
   12	1	0L-1143	Bolt
   13	1	0S-1594	Bolt
   14	1	4W-7627	Spacer
   15	2	5M-2894	Hard Washer
   16	1	7N-7628	Gasket
   17	1	272-2945	Tube As

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Illustration 13	g03737151

5. Unfasten the swivel nut for tube assembly (17) .

6. Remove bolt (12), bolt (13), spacer (14), hard washers (15), and gasket (16) from the turbocharger flange.

7. Once the connections are loose, remove tube assembly (17) from the engine.
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   Table 14

   Removed Components
   Item	Qty	Part Number	Part Description
   18	1	0S-1585	Bolt
   19	1	1S-1015	Clip
   20	1	5P-8245	Hard Washer
   21	1	8T-1897	Clip
   22	1	8T-1898	Clip
   23	1	353-7952	Grommet

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Illustration 14	g03737159

8. Remove bolt (18) with hard washer (20) in order to unfasten clips (19), (21), and (22) from the bracket.
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   Table 15

   Removed Components
   Item	Qty	Part Number	Part Description
   24	1	0L-2070	Bolt
   25	1	5M-2894	Hard Washer
   26	1	9G-7101	Spacer
   27	1	8T-1889	Clip
   28	1	8T-1890	Clip
   29	1	310-7177	Bracket As
   30	1	353-7954	Grommet

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Illustration 15	g03737163

9. Remove bolt (24) with hard washer (25) from bracket assembly (29) .

10. Once the bracket assembly has been removed, remove clips (27) and (28).
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    Table 16

    Removed Components
    Item	Qty	Part Number	Part Description
    31	1	0S-1585	Bolt
    32	1	1S-1015	Clip
    33	1	1V-8230	Spacer
    34	1	5P-8245	Hard Washer

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Illustration 16	g03737599

11. Remove clip (32) by removing bolt (31), spacer (33), and hard washer (34) from the fuel filter bracket.
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    Table 17

    Removed Components
    Item	Qty	Part Number	Part Description
    35	1	346-5755	Hose As

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Illustration 17	g03737632

12. Unfasten the swivel nuts on each end of hose assembly (35) and remove the hose assembly from the engine.
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    Table 18

    Removed Components
    Item	Qty	Part Number	Part Description
    36	1	6V-9169	Nut
    37	1	7X-7715	Tee

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Illustration 18	g03737648

13. Remove tee (37) by removing nut (36) that tightens against the mounting bracket.

Center Fuel Line Disassembly

Table 19

Removed Components
Item	Qty	Part Number	Part Description
1	1	0S-1595	Bolt
2	1	5P-8245	Hard Washer
3	1	8T-1897	Clip
4	1	8T-1898	Clip
5	1	353-7952	Grommet

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Illustration 19	g03737662

1. Remove bolt (1) with hard washer (2) in order to remove clip (3), clip (4), and grommet (5) from the fuel line.
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   Table 20

   Removed Components
   Item	Qty	Part Number	Part Description
   6	6	0T-0320	Bolt
   7	3	3G-8047	Grommet
   8	3	3G-8054	Clip
   9	3	3G-8057	Clip
   10	6	5P-8244	Hard Washer

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Illustration 20	g03737675

2. Remove bolt (6) with hard washer (10) in order to remove clip (8), clip (9), and grommet (7) from the fuel line.
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   Table 21

   Removed Components
   Item	Qty	Part Number	Part Description
   11	6	0T-0320	Bolt
   12	3	3G-8047	Grommet
   13	3	3G-8054	Clip
   14	3	3G-8057	Clip
   15	6	5P-8244	Hard Washer

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Illustration 21	g03737693

3. Remove bolts (11) with hard washers (15) from clips (14) and (15). Once the clips are removed, take grommet (12) off the fuel lines.
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   Table 22

   Removed Components
   Item	Qty	Part Number	Part Description
   16	1	361-7206	Hose As
   17	1	361-7208	Hose As

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Illustration 22	g03737710

4. Unfasten the swivel nuts at each end of hose assembly (16) and (17). Remove the hose assemblies from the engine.
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   Table 23

   Removed Components
   Item	Qty	Part Number	Part Description
   18	1	8M-0547	Flared Elbow

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Illustration 23	g03737717

5. Remove flared elbow (18) from the straight adapter coming off the primary fuel filter base. Leave the straight adapter on the primary fuel filter base.
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   Table 24

   Removed Components
   Item	Qty	Part Number	Part Description
   19	2	1A-5183	Bolt
   20	2	5M-2894	Hard Washer
   21	1	320-6723	Bracket As

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Illustration 24	g03737721

6. Remove bolts (19) with hard washers (20) in order to remove bracket assembly (21) .

   1. If the wiring harness is attached to the bracket assembly with cable straps. Remove the straps and attach the wiring harness to the existing ladder clip.
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      Table 25

      Removed Components
      Item	Qty	Part Number	Part Description
      22	1	275-2426	Hose As

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Illustration 25	g03737735

7. Remove hose assembly (22) by unfastening the swivel nuts at each end. Remove the hose assembly from the engine.

Right Rear Fuel Line Disassembly

Table 26

Removed Components
Item	Qty	Part Number	Part Description
1	1	322-7617	Hose As
2	2	353-7954	Grommet
3	2	8T-1889	Clip
4	2	8T-1890	Clip
5	1	375-4326	Bracket As
6	2	0S-1594	Bolt
7	2	9X-6458	Hard Washer
8	2	7W-9094	Spacer
9	2	5M-2894	Hard Washer
10	2	0S-1571	Bolt

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Illustration 26	g03737783

1. Remove bolts (6) with hard washers (7) in order to remove clip (3), clip (4), and grommet (2) from hose assembly (1) .

2. Unfasten the swivel nuts on each end of hose assembly (1) and remove the hose assembly from the engine.

3. Remove bolt (10) with hard washer (9) in order to remove bracket assembly (5) from the engine.

Fuel Transfer Pump Fitting Replacement

Table 27

Removed Components
Item	Qty	Part Number	Part Description
1	1	331-3635	Fuel Transfer Pump Gp
2	2	5M-2894	Hard Washer
3	2	3B-1915	Bolt

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Illustration 27	g03737787

1. Remove fuel transfer pump group (1) by removing bolt (3) with hard washer (2).
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   Table 28

   Removed Components
   Item	Qty	Part Number	Part Description
   4	1	118-4728	Elbow
   5	1	238-5080	O-Ring Seal
   6	1	9M-4584	Connector
   7	1	238-5081	O-Ring Seal

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Illustration 28	g03737792

2. Remove elbow (4) with o-ring seal (5) from the fuel transfer pump assembly.

3. Remove connector (6) with o-ring seal (7) from the fuel transfer pump assembly.
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   Table 29

   Installed Components
   Item	Qty	Part Number	Part Description
   8	1	1P-7625	Elbow
   9	1	238-5080	O-Ring Seal
   10	1	030-7949	Elbow
   11	1	238-5081	O-Ring Seal
   12	1	030-7972	Elbow

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Illustration 29	g03737798
(A) 30 degrees (B) 15 degrees

4. Install elbow (8) with o-ring seal (9) into the top port of the fuel transfer pump assembly. Orient the elbow at 30 degrees as shown in Illustration29.

5. Install elbow (10) with o-ring seal (11) into the front port of the fuel transfer pump assembly. Orient the elbow at 15 degrees as shown in Illustration29.

6. Install elbow (12) into elbow (10) and orient facing forward.
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   Table 30

   Installed Components
   Item	Qty	Part Number	Part Description
   13	2	3B-1915	Bolt
   14	2	5M-2894	Hard Washer
   15	1	8C-3089	O-Ring Seal

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Illustration 30	g03737801

7. Replace o-ring seal (15) on the back of the fuel transfer pump housing.

8. Install the fuel transfer pump group into the rear housing using bolts (13) with hard washers (14) .

Left Rear Fuel Line Disassembly

Table 31

Removed Components
Item	Qty	Part Number	Part Description
1	1	0S-1590	Bolt
2	1	0T-0320	Bolt
3	1	5P-8244	Hard Washer
4	1	9X-6458	Hard Washer
5	1	8T-1889	Clip
6	1	8T-1890	Clip
7	1	127-5447	Spacer
8	1	314-3174	Bracket As
9	1	353-7954	Grommet

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Illustration 31	g03737802

1. Remove clips (5) and (6) by removing bolt (2) with hard washer (3) .

2. Remove bracket assembly (8) by removing bolt (1), hard washer (4), and spacer (7).
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   Table 32

   Removed Components
   Item	Qty	Part Number	Part Description
   10	1	322-7615	Hose As

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Illustration 32	g03737803

3. Unfasten the swivel nuts on each end of hose assembly (10) and remove the hose assembly from the engine.

Fuel Manifold Replacement

Table 33

Removed Components
Item	Qty	Part Number	Part Description
1	3	8S-9191	Bolt
2	3	9X-6458	Hard Washer

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Illustration 33	g03737804

1. Disconnect the fuel supply line from the tank.

2. Remove bolts (1) with hard washers (2) in order to remove the fuel manifold from the engine.
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   Table 34

   Installed Components
   Item	Qty	Part Number	Part Description
   3	2	2R-6806	Adapter
   4	2	214-7568	O-Ring Seal
   5	1	327-4448	Check Valve Gp
   6	1	9S-8005	O-Ring Plug
   7	1	238-5080	O-Ring Seal
   8	1	369-9380	Fuel Manifold

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Illustration 34	g03737901

3. Install check valve group (5) into fuel manifold (8). Lubricate the o-rings seals prior to installation. Torque the check valve group to 21 ± 2 N·m (15 ± 1.5 lb ft).

4. Install o-ring plug (6) with o-ring seal (7) into the side of the fuel manifold.

5. Install adapters (3) with o-ring seals (4) into the locations shown in Illustration 34.

6. Remove the fuel supply fitting from the previous fuel manifold in the top port.
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   Table 35

   Installed Components
   Item	Qty	Part Number	Part Description
   9	3	1A-5183	Bolt
   10	3	9X-6458	Hard Washer

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Illustration 35	g03737927

7. Install the fuel manifold using bolts (9) with hard washers (10) .

8. Install the fuel return line from the tank. Inspect the line for any signs of rubbing or damage. If there is damage, replace the line. If there is rubbing, secure the line away from other components.

Left Rear Valve Cover Disassembly

Table 36

Removed Components
Item	Qty	Part Number	Part Description
1	6	7X-0440	Bolt
2	6	8T-4224	Hard Washer
3	6	212-7728	Isolator As
4	1	224-7506	Valve Cover Seal
5	1	345-2010	Cover

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Illustration 36	g03737940

1. Remove bolts (1), hard washers (2), and isolation assemblies (3) from the valve cover.

2. Remove valve cover (5) from the engine and remove valve cover seal (4) .

   Note: Leave the breather attached to the valve cover until the cover is removed.

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   Table 37

   Removed Components
   Item	Qty	Part Number	Part Description
   6	2	126-0559 (1)	Bolt
   7	1	5P-8211	O-Ring Seal

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   ( 1 )

   Retain part for reuse in installation procedure.

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Illustration 37	g03737951

3. Remove the breather assembly by removing bolts (6). Remove o-ring seal (7) from the bottom of the breather assembly.

Left Rear Valve Cover Assembly

Table 38

Installed Components
Item	Qty	Part Number	Part Description
1	1	387-9526	Seal
2	1	437-0128	Cover As

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Illustration 38	g03879772

1. Install seal (1) into cover (2) using the orientation shown in Illustration 38.

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Illustration 39	g03879884

2. Remove 444-2472 Bracket As or 444-2473 Bracket As so the bracket does not interfere with the valve cover. Cut the plastic straps from the injector harness and remove the nut, washer, and bracket from the valve cover base.

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Illustration 40	g03879887

3. Use 123-3202 Cable Strap to connect the harness to the valve cover base as shown above. Ensure that the harness cannot move into any moving parts.

   Note: Verify that no damage has occurred to the harness or the mating surface of the valve cover.

   Show/hide table

   Table 39

   Installed Components
   Item	Qty	Part Number	Part Description
   3	1	5P-8211	O-Ring Seal
   4	2	126-0559	Bolt

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Illustration 41	g03737968

4. Install o-ring seal (3) on the backside of the breather assembly.

5. Install the breather assembly onto the valve cover using bolts (4). Torque the bolts to 25 ± 6 N·m (18 ± 4 lb ft).
   Show/hide table

   Table 40

   Installed Components
   Item	Qty	Part Number	Part Description
   5	5	7X-0440	Bolt
   6	6	4P-8525	Spacer
   7	1	224-9907	Stud

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Illustration 42	g03737982

6. Install the valve cover on the valve cover base using bolts (5), stud (7), and spacers (6) as shown in Illustration 42.

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Illustration 43	g03686156

7. Torque the bolts and stud in the sequence shown in Illustration 43 to 25 ± 6 N·m (18 ± 4 lb ft).

Left Rear Fuel Line Assembly

Table 41

Installed Components
Item	Qty	Part Number	Part Description
1	1	126-0559	Bolt
2	1	5M-2894	Hard Washer
3	1	132-7551	Spacer
4	1	393-8968	Bracket As

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Illustration 44	g03738043

1. Install bracket assembly (4) to the rear support using bolt (1), hard washer (2), and spacer (3). Orient the bracket assembly as shown in Illustration 44.
   Show/hide table

   Table 42

   Installed Components
   Item	Qty	Part Number	Part Description
   5	1	1P-1376	Port Connector
   6	1	214-7568	O-Ring Seal

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Illustration 45	g03738068

2. Replace the fuel adapter in the cylinder head with connector (5) and o-ring seal (6).
   Show/hide table

   Table 43

   Installed Components
   Item	Qty	Part Number	Part Description
   7	1	4P-0983	Stud
   8	1	9X-6458	Hard Washer
   9	1	456-9159	Hose and Tube As
   10	2	433-7014	Saddle Assembly

3. Inspect hose and tube assembly (9) for damage. The hose should have uniform diameter throughout. If the hose has specific locations of larger or smaller diameter, do not use the hose and tube assembly. Obtain a new part and proceed to the following step.

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Illustration 46	g03738075

4. Install hose and tube assembly (9) by threading the swivel nuts connections finger tight on both ends.

5. Place saddle assembly (10) around the hose and tube assembly.

6. Fasten the saddle assembly using stud (7) with hard washer (8) and thread into the weld nut. Tighten the saddle assembly.

7. Torque the connection at the fuel manifold to 30 ± 5 N·m (22 ± 4 lb ft).

8. Torque the connection at the cylinder head to 30 ± 5 N·m (22 ± 4 lb ft) while using a back-up wrench to prevent hose twisting.

9. If using a new hose and tube assembly, remove the metal part number tag.

   Note: Failure to remove the part number tag can result in hose failure.

   Show/hide table

   Table 44

   Installed Components
   Item	Qty	Part Number	Part Description
   11	1	436-7327	Guard
   12	1	6V-8801	Nut
   13	2	5P-1075	Hard Washer
   14	1	6V-8189	Nut
   15	2	8T-4224	Hard Washer

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Illustration 47	g03738084

10. Install guard (11) over the upper stud at the fuel line clamp with hard washer (13) on each side of the guard. Install nut (12) finger tight on the upper stud.

11. Install guard (11) over the lower stud at the valve cover with hard washer (15) on each side of the guard. Install nut (14) finger tight on the lower stud.

12. Inspect the guard for any fouling against any other component. All components should be above the guard.

Do not attach anything to the guard or the fuel line except for the parts called out in this Special Instruction.

Right Rear Valve Cover Disassembly

Table 45

Removed Components
Item	Qty	Part Number	Part Description
1	6	7X-0440	Bolt
2	6	8T-4224	Hard Washer
3	6	212-7728	Isolator As
4	1	224-7506	Valve Cover Seal
5	1	345-2010	Cover

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Illustration 48	g03738099

1. Remove bolts (1), hard washers (2), and isolation assemblies (3) from valve cover (5) .

2. Remove the valve cover and valve cover seal (4) .

   Note: Leave the breather assembly attached to the valve cover until the cover is removed.

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   Table 46

   Removed Components
   Item	Qty	Part Number	Part Description
   6	2	126-0559	Bolt
   7	1	5P-8211	O-Ring Seal

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Illustration 49	g03737951

3. Remove the breather assembly by removing bolts (6). Remove o-ring seal (7) from the bottom of the breather assembly.

Right Rear Valve Cover Assembly

Table 47

Installed Components
Item	Qty	Part Number	Part Description
1	1	387-9526	Seal
2	1	437-0128	Cover As

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Illustration 50	g03737956

1. Install seal (1) into cover (2) using the orientation shown in Illustration 50.
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   Table 48

   Installed Components
   Item	Qty	Part Number	Part Description
   3	1	5P-8211	O-Ring Seal
   4	2	126-0559	Bolt

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Illustration 51	g03737968

2. Install o-ring seal (3) on the backside of the breather assembly.

3. Install the breather assembly onto the valve cover using bolts (4). Torque the bolts to 25 ± 6 N·m (18 ± 4 lb ft).
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   Table 49

   Installed Components
   Item	Qty	Part Number	Part Description
   5	5	7X-0440	Bolt
   6	6	4P-8525	Spacer
   7	1	224-9907	Stud

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Illustration 52	g03738335

4. Install the valve cover on the valve cover base using bolts (5), stud (7), and spacers (6) as shown in Illustration 52.

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Illustration 53	g03686156

5. Torque the bolts and stud in the sequence shown in Illustration 53 to 25 ± 6 N·m (18 ± 4 lb ft).

Right Rear Fuel Line Assembly

Table 50

Installed Components
Item	Qty	Part Number	Part Description
1	2	0S-1571	Bolt
2	2	5M-2894	Hard Washer
3	2	7G-1239	Spacer
4	1	393-9283	Bracket As

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Illustration 54	g03738349

1. Install bracket assembly (4) using bolts (1), hard washers (2), and spacers (3). The spacers should be placed behind the bracket assembly. Orient the bracket assembly as shown in Illustration 54.
   Show/hide table

   Table 51

   Installed Components
   Item	Qty	Part Number	Part Description
   5	1	1P-1376	Port Connector
   6	1	214-7568	O-Ring Seal

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Illustration 55	g03738068

2. Replace the fuel adapter in the cylinder head with connector (5) and o-ring seal (6).
   Show/hide table

   Table 52

   Installed Components
   Item	Qty	Part Number	Part Description
   7	1	4P-0983	Stud
   8	1	9X-6458	Hard Washer
   9	1	456-9157	Hose and Tube As
   10	2	433-7014	Saddle Assembly

3. Inspect hose and tube assembly (9) for damage. The hose should have uniform diameter throughout. If the hose has specific locations of larger or smaller diameter, do not use the hose and tube assembly. Obtain a new part and proceed to the following step.

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Illustration 56	g03738364

4. Install hose and tube assembly (9) by threading the swivel nuts connections finger tight on both ends.

5. Place saddle assembly (10) around the hose and tube assembly.

6. Fasten the saddle assembly using stud (7) with hard washer (8) and thread into the weld nut. Tighten the saddle assembly.

7. Torque the connection at the fuel manifold to 30 ± 5 N·m (22 ± 4 lb ft).

8. Torque the connection at the cylinder head to 30 ± 5 N·m (22 ± 4 lb ft) while using a back-up wrench to prevent hose twisting.

9. If using a new hose and tube assembly, remove the metal part number tag.

   Note: Failure to remove the part number tag can result in hose failure.

   Show/hide table

   Table 53

   Installed Components
   Item	Qty	Part Number	Part Description
   11	1	444-6979	Guard
   12	1	6V-8801	Nut
   13	2	5P-1075	Hard Washer
   14	1	6V-8189	Nut
   15	2	8T-4224	Hard Washer

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Illustration 57	g03738369

10. Install guard (11) over the upper stud at the fuel line clamp with hard washer (13) on each side of the guard. Install nut (12) finger tight on the upper stud.

11. Install guard (11) over the lower stud at the valve cover with hard washer (15) on each side of the guard. Install nut (14) finger tight on the lower stud.

12. Inspect the guard for any fouling against any other component. All components should be above the guard.

Do not attach anything to the guard or the fuel line except for the parts called out in this Special Instruction.

Right Front Fuel Line Disassembly

Table 54

Removed Components
Item	Qty	Part Number	Part Description
1	1	0S-1571	Bolt
2	2	5M-2894	Hard Washer
3	1	8T-1889	Clip
4	1	8T-1890	Clip
5	1	9S-8752	Full Nut
6	1	353-7954	Grommet

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Illustration 58	g03738422

1. Remove nut (5) and hard washer (2) from the back of the bracket.

2. Remove bolt (1) with hard washer (2) in order to remove clips (3) and (4) .

   Note: Let the ladder clip that was held with bolt (1) hang freely. The wire will be transfer to the bracket installed in the next section.

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   Table 55

   Removed Components
   Item	Qty	Part Number	Part Description
   7	1	0L-1352	Bolt
   8	1	5M-2894	Hard Washer
   9	1	352-7474	Bracket

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Illustration 59	g03738444

3. Remove bolt (7) with hard washer (8) in order to remove bracket assembly (9) from the front support.
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   Table 56

   Removed Components
   Item	Qty	Part Number	Part Description
   10	1	322-7616	Hose As

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Illustration 60	g03738451

4. Remove hose assembly (10) by unfastening the swivel nuts on each end of the hose assembly.

Right Front Fuel Line Assembly

Table 57

Installed Components
Item	Qty	Part Number	Part Description
1	2	0L-1351	Bolt
2	2	9X-6458	Hard Washer
3	1	445-1246	Bracket As

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Illustration 61	g03738457

1. Install bracket assembly (3) by installing two bolts (1) with two hard washers (2) into the holes shown in Illustration 61.

2. Remove the wire from the ladder clip that was left hanging in the previous section. Install the wire to the lower section of bracket assembly (3) using a cable strap.
   Show/hide table

   Table 58

   Installed Components
   Item	Qty	Part Number	Part Description
   5	1	1P-1376	Port Connector
   6	1	214-7568	O-Ring Seal

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Illustration 62	g03738461

3. Replace the fuel adapter in the cylinder head with connector (4) and o-ring seal (5).
   Show/hide table

   Table 59

   Installed Components
   Item	Qty	Part Number	Part Description
   6	1	4P-0983	Stud
   7	1	9X-6458	Hard Washer
   8	1	456-9156	Hose and Tube As
   9	2	433-7014	Saddle Assembly

4. Inspect hose and tube assembly (8) for damage. The hose should have uniform diameter throughout. If the hose has specific locations of larger or smaller diameter, do not use the hose and tube assembly. Obtain a new part and proceed to the following step.

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Illustration 63	g03738465

5. Install hose and tube assembly (8) by threading the swivel nuts connections finger tight on both ends.

6. Place saddle assembly (9) around the hose and tube assembly.

7. Fasten the saddle assembly using stud (6) with hard washer (7) and thread into the weld nut. Tighten the saddle assembly.

8. Torque the connection at the fuel manifold to 30 ± 5 N·m (22 ± 4 lb ft).

9. Torque the connection at the cylinder head to 30 ± 5 N·m (22 ± 4 lb ft) while using a back-up wrench to prevent hose twisting.

10. If using a new hose and tube assembly, remove the metal part number tag.

    Note: Failure to remove the part number tag can result in hose failure.

    Show/hide table

    Table 60

    Installed Components
    Item	Qty	Part Number	Part Description
    10	1	444-6978	Guard
    11	1	6V-8801	Nut
    12	2	5P-1075	Hard Washer
    13	1	6V-8189	Nut
    14	2	8T-4224	Hard Washer

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Illustration 64	g03738479

11. Install guard (10) over the upper stud at the fuel line clamp with hard washer (12) on each side of the guard. Install nut (11) finger tight on the upper stud.

12. Install guard (10) over the lower stud at the valve cover with hard washer (14) on each side of the guard. Install nut (13) finger tight on the lower stud.

13. Inspect the guard for any fouling against any other component. All components should be above the guard.

Do not attach anything to the guard or the fuel line except for the parts called out in this Special Instruction.

Left Front Fuel Line Disassembly

Table 61

Removed Components
Item	Qty	Part Number	Part Description
1	1	322-7616	Hose As
2	2	353-7954	Grommet
3	2	8T-1889	Clip
4	2	8T-1890	Clip
5	1	352-7474	Bracket
6	1	0L-1352	Bolt
7	1	0L-1571	Bolt
8	3	5M-2894	Hard Washer
9	1	9S-8752	Full Nut
10	1	0S-1594	Bolt
11	1	9X-6458	Hard Washer

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Illustration 65	g03738515

1. Remove bolts (6), bolts (7), bolts (10), hard washers (8), hard washer (11), and nut (9) .

2. After fastener hardware has been removed, remove bracket (5), clips (3), and clips (4) .

3. Unfasten the swivel nuts on both ends of hose assembly (1). Remove the hose assembly from the engine.

Left Front Valve Cover Disassembly

Table 62

Removed Components
Item	Qty	Part Number	Part Description
1	6	7X-0440	Bolt
2	6	8T-4224	Hard Washer
3	6	212-7728	Isolator As
4	1	224-7506	Valve Cover Seal
5	1	345-2010	Cover

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Illustration 66	g03738528

1. Remove bolts (1), hard washers (2), and isolation assemblies (3) from valve cover (5) .

2. Remove the valve cover and valve cover seal (4) .

Left Front Valve Cover Assembly

Table 63

Installed Components
Item	Qty	Part Number	Part Description
1	1	387-9526	Seal
2	1	437-0127	Cover As

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Illustration 67	g03737956

1. Install seal (1) into cover (2) using the orientation shown in Illustration 67.
   Show/hide table

   Table 64

   Installed Components
   Item	Qty	Part Number	Part Description
   2	1	437-0127	Cover As
   3	5	7X-0440	Bolt
   4	6	4P-8525	Spacer
   5	1	224-9907	Stud

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Illustration 68	g03738604

2. Place cover assembly (2) onto the valve cover base. Install spacers (4) onto bolts (3) and stud (5) .

3. Install the bolts and stud in the locations shown in Illustration 68. Torque the bolts and stud to 25 ± 6 N·m (18 ± 4 lb ft).

Left Front Fuel Lines Assembly

Table 65

Installed Components
Item	Qty	Part Number	Part Description
1	2	0L-1351	Bolt
2	2	9X-6458	Hard Washer
3	1	391-2993	Bracket As

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Illustration 69	g03738626

1. Install bracket assembly (3) on the left front corner of the engine.

2. Install and tighten bolts (1) with hard washers (2) into the top and side holes of the bracket assembly.
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   Table 66

   Installed Components
   Item	Qty	Part Number	Part Description
   4	1	1P-1376	Port Connector
   5	1	214-7568	O-Ring Seal

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Illustration 70	g03738631

3. Replace the fuel adapter in the cylinder head with connector (4) and o-ring seal (5).
   Show/hide table

   Table 67

   Installed Components
   Item	Qty	Part Number	Part Description
   6	1	4P-0983	Stud
   7	1	9X-6458	Hard Washer
   8	2	433-7014	Saddle Assembly
   9	1	456-9158	Hose and Tube As

4. Inspect hose and tube assembly (9) for damage. The hose should have uniform diameter throughout. If the hose has specific locations of larger or smaller diameter, do not use the hose and tube assembly. Obtain a new part and proceed to the following step.

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Illustration 71	g03738636

5. Install hose and tube assembly (9) at the connections to the fuel manifold and the cylinder head. Leave the connections finger tight.

6. Place saddle assembly (8) around the hose and tube assembly in the location shown in Illustration 71.

7. Fasten the saddle assembly by using bolt (6) with hard washer (7). Tighten the bolt into the weld nut.

8. Torque the connection at the fuel manifold to 30 ± 5 N·m (22 ± 4 lb ft).

9. Torque the connection at the cylinder head to 30 ± 5 N·m (22 ± 4 lb ft) using a back-up wrench to prevent hose twisting.

10. If using a new hose and tube assembly, remove the metal part number tag.

    Note: Failure to remove the part number tag can result in hose failure.

    Show/hide table

    Table 68

    Installed Components
    Item	Qty	Part Number	Part Description
    10	1	436-7326	Guard
    11	1	6V-8801	Nut
    12	2	5P-1075	Hard Washer
    13	1	6V-8189	Nut
    14	2	8T-4224	Hard Washer

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Illustration 72	g03738662

11. Install guard (10) over the upper stud at the fuel lines clamp with hard washer (12) on each side of the guard. Install nut (11) onto the stud finger tight.

12. Install the guard over the lower stud at the valve cover with hard washer (14) on each side of the guard. Install nut (13) and tighten.

13. Tighten nut (11) and inspect for fouling of any component. All components should be above the guard.

Do not attach anything to the guard or the fuel line except for the parts call out in this Special Instruction.

Center Fuel Lines Assembly

Table 69

Installed Components
Item	Qty	Part Number	Part Description
1	1	8K-2396	Flared Elbow

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Illustration 73	g03738671

1. Install flared elbow (1) in the primary fuel filter and leave finger tight. Orient the fitting as shown in Illustration 73 at 20 degrees.
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   Table 70

   Installed Components
   Item	Qty	Part Number	Part Description
   2	1	1A-5183	Bolt
   3	1	2P-3213	Bolt
   4	1	5M-2894	Hard Washer
   5	1	2B-0941	Spacer
   6	1	346-6981	Bracket As

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Illustration 74	g03739127

2. Install bracket assembly (6) with spacer (5) underneath and using bolt (2) with hard washer (4) .

3. Install the ladder clip with the wiring harness from the previous step using bolt (3) .

4. Torque both of the bolts to 47 ± 9 N·m (35 ± 7 lb ft).
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   Table 71

   Removed Components
   Item	Qty	Part Number	Part Description
   7	2	1A-5183	Bolt
   8	2	5M-2894	Hard Washer
   9	1	350-6722	Cable As

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Illustration 75	g03739147

5. Remove bracket assembly (9) by removing bolt (7) with hard washer (9).
   Show/hide table

   Table 72

   Installed Components
   Item	Qty	Part Number	Part Description
   10	2	2P-3213	Bolt

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Illustration 76	g03739170

6. Install bolts (10) into the intake manifold and torque to 47 ± 9 N·m (35 ± 7 lb ft).
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   Table 73

   Removed Components
   Item	Qty	Part Number	Part Description
   11	2	1A-5183	Bolt
   12	2	5M-2894	Hard Washer
   13	1	320-6724 (1)	Bracket As

   Show/hide table

   ( 1 )

   Leave the part in location after removing fasteners.

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Illustration 77	g03739188

7. Remove bolts (11) with hard washers (12) from bracket assembly (13) .

   Note: Leave the bracket assembly in the same location after removing the fasteners.

   Show/hide table

   Table 74

   Removed Components
   Item	Qty	Part Number	Part Description
   14	2	0T-0102 (1)	Bolt
   15	2	8M-2770 (1)	Clip
   16	2	8T-4896 (1)	Hard Washer

   Show/hide table

   ( 1 )

   Retain parts for reuse in the installation procedure.

Note: If the ether lines are flexible enough to fit a spacer underneath the new bracket assembly, skip this step.

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Illustration 78	g03739200

8. Remove bolts (14), hard washers (16), and clips (15) from the bracket.
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   Table 75

   Installed Components
   Item	Qty	Part Number	Part Description
   13	1	320-6724 (1)	Bracket As
   17	2	5B-9603	Bolt
   18	2	5M-2894	Hard Washer
   19	1	7W-0534	Washer
   20	1	346-6981	Bracket As

   Show/hide table

   ( 1 )

   Reused from previous removal step.

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Illustration 79	g03739215

9. Place bracket assembly (20) with spacer (19) under bracket assembly (13) .

10. Install bolts (17) with hard washers (18) into the holes of the bracket assembly and torque to 47 ± 9 N·m (35 ± 7 lb ft).

11. If the ether lines had to be removed, reinstall the line using the retained hardware.
    Show/hide table

    Table 76

    Installed Components
    Item	Qty	Part Number	Part Description
    21	1	436-5801	Hose and Tube As
    22	1	436-5802	Hose and Tube As

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Illustration 80	g03739226

12. Install hose and tube assembly (22) from the primary fuel filter to the lower fitting of the fuel transfer pump. Leave the swivel nuts at each end finger tight.

13. Install hose and tube assembly (21) from the secondary and tertiary filter port to the upper transfer pump fitting. Leave the swivel nuts at each end finger tight.

14. Torque the connections left loose in the previous step at the fuel transfer pump.

    1. Torque the top elbow adapter to 80 ± 12 N·m (59 ± 9 lb ft).

    2. Torque the bottom adapter to 110 ± 17 N·m (81 ± 13 lb ft).

    3. Torque the fitting at the fuel filter base to 80 ± 12 N·m (59 ± 9 lb ft).
       Show/hide table

       Table 77

       Installed Components
       Item	Qty	Part Number	Part Description
       23	2	0L-2070	Bolt
       24	4	4P-0693	Clamp As
       25	2	9X-6458	Hard Washer

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Illustration 81	g03739240

15. Place clamp assemblies (24) around the fuel lines as shown in Illustration 81.

16. Fasten the clamp assemblies using bolts (23) with hard washers (25) into the weld nut on the bracket assemblies. Leave the bolts finger tight.
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    Table 78

    Installed Components
    Item	Qty	Part Number	Part Description
    26	1	0S-1595	Bolt
    27	1	3E-4353	Hard Washer
    28	2	4P-0692	Clamp As
    29	1	5P-8245	Hard Washer
    30	1	6V-5230	Bolt
    31	1	8T-1897	Clip
    32	1	8T-1898	Clip
    33	1	353-7952	Grommet

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Illustration 82	g03739249

17. Install clamps (28) in the location shown in the left part of Illustration 82. Fasten the clamp using bolt (30) with hard washer (27) .

18. Install grommet (33) around the fuel line.

19. Install clips (31) and (32) around the grommet. Use bolt (26) with hard washer (29) to fasten the clips. Leave the bolt finger tight.
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    Table 79

    Installed Components
    Item	Qty	Part Number	Part Description
    34	1	0S-1595	Bolt
    35	1	5P-8245	Hard Washer
    36	1	8T-1897	Clip
    37	1	8T-1898	Clip
    38	1	353-7952	Grommet

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Illustration 83	g03739259

20. Place grommet (38) around the fuel line.

21. Install clips (36) and (37) around the grommet. Use bolt (34) with hard washer (35) to fasten the clips.

22. Torque the hose and tube assemblies that were installed in Step 12 of this section.

    1. Torque the swivel nuts at the fuel transfer pump to 90 ± 13 N·m (66 ± 10 lb ft).

    2. Torque the connections at the primary fuel filter to 90 ± 13 N·m (66 ± 10 lb ft).

    3. Torque the connection at the secondary fuel filter to 60 ± 9 N·m (44 ± 7 lb ft). Tighten the rest of the clips and clamps on the fuel lines.
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       Table 80

       Installed Components
       Item	Qty	Part Number	Part Description
       39	1	436-5803	Hose As

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Illustration 84	g03739262

23. Install hose assembly (39) in the location that the previous hose was removed.

24. Torque the swivel nut at the elbow to 60 ± 9 N·m (44 ± 7 lb ft).

25. Torque the connection at the fuel filter base to 60 ± 9 N·m (44 ± 7 lb ft).

Left Side Turbocharger Water Line Assembly

Table 81

Removed Components
Item	Qty	Part Number	Part Description
1	1	353-5126	Plug As

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Illustration 85	g03739267

1. Remove plug (1) from the cylinder head.
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   Table 82

   Installed Components
   Item	Qty	Part Number	Part Description
   2	1	6V-8639	Connector
   3	1	180-8424	O-Ring Seal
   4	1	6V-6609	O-Ring Seal

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Illustration 86	g03739276

2. Install connector (2) into the port where the plug was previously removed. Install o-ring seals (3) and (4) on the connector before installation.
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   Table 83

   Installed Components
   Item	Qty	Part Number	Part Description
   5	1	0L-1143	Bolt
   6	1	0S-1594	Bolt
   7	1	4W-7627	Spacer
   8	2	5M-2894	Hard Washer
   9	1	341-9211	Gasket
   10	1	436-7552	Water Tube As

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Illustration 87	g03739282

3. Install water tube assembly (10) by attaching to the turbocharger first.

   1. Place gasket (9) between the turbocharger housing and the flange.

   2. Place hard washer (8) and spacer (7) onto bolt (5). Install the bolt into the top hole of the flange and leave finger tight.

   3. Install bolt (6) with hard washer (8) into the bottom hole of the flange and leave finger tight.

   4. Fasten the swivel nut onto the fitting installed in the previous step. Leave the swivel nut finger tight.
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      Table 84

      Removed Components
      Item	Qty	Part Number	Part Description
      11	1	1A-9579	Bolt
      12	1	9M-1974	Hard Washer

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Illustration 88	g03739288

4. Remove bolt (11) with hard washer (12) from the valve cover base.
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   Table 85

   Installed Components
   Item	Qty	Part Number	Part Description
   2	1	9M-1974	Hard Washer
   3	1	237-3759	Stud

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Illustration 89	g03739291

5. Install stud (14) with hard washer (13) in the valve cover base where the previous bolt was removed.
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   Table 86

   Installed Components
   Item	Qty	Part Number	Part Description
   15	2	3E-4352	Hard Washer
   16	1	5S-0003	Nut
   17	1	6V-5217	Bolt
   18	1	8T-1887	Clip
   19	1	8T-1888	Clip
   20	1	305-2452	Bracket As
   21	1	353-7957	Grommet

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Illustration 90	g03739427

6. Place bracket assembly (20) onto the stud from the previous step and fasten with hard washer (15) and nut (16) .

7. Install grommet (21) around the tube assembly.

8. Install clips (18) and (19) around the grommet.

9. Install bolt (17) with hard washer (15) through the clips and into the weld nut of the bracket assembly.

10. Torque the bolts at the turbocharger housing to 47 ± 9 N·m (35 ± 7 lb ft). Torque the swivel nut to 65 ± 10 N·m (48 ± 7 lb ft). Tighten the clips to the bracket assembly.
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    Table 87

    Installed Components
    Item	Qty	Part Number	Part Description
    22	1	272-2946 (1)	Tube As
    23	1	341-9211	Gasket
    24	2	5M-2894	Hard Washer
    25	1	4W-7627	Spacer
    26	1	0S-1594	Bolt
    27	1	0L-1143	Bolt
    28	1	180-8424	O-Ring Seal

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    ( 1 )

    Reused from previous step.

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Illustration 91	g03739509

11. Reinstall tube assembly (22) by first attaching the tube to the turbocharger housing.

    1. Place gasket (23) between the turbocharger housing and the flange.

    2. Install bolt (27), hard washer (24), and spacer (25) into the bottom hole of the flange. Leave the bolt finger tight.

    3. Install bolt (26) with hard washer (24) into the top hole of the flange. Leave the bolt finger tight.

    4. Fasten the swivel nut on tube assembly (22) onto the tee fitting in the center of the engine. Replace o-ring seal (28) before installation.
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       Table 88

       Installed Components
       Item	Qty	Part Number	Part Description
       29	1	1B-3057	Clip
       30	1	4B-0418	Clip
       31	2	5P-4116	Hard Washer
       32	2	8T-8912	Bolt
       33	2	198-4776	Hard Washer

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Illustration 92	g03739525

12. Install clips (29) and (30) onto the tube as shown in Illustration 92.

    Note: Ensure that the clips are installed in the correct location as shown in Illustration 92.

13. Fasten clips to the valve cover using bolt (32), hard washer (31), and hard washer (33). Hard washer (33) underneath the clips as shown in Illustration 92.

Right Side Turbocharger Water Line Assembly

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Illustration 93	g03739534
(1) Tee fitting assembly

1. Remove tee fitting assembly (1) attached to the inlet port of the water line.
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   Table 89

   Installed Components
   Item	Qty	Part Number	Part Description
   2	1	6V-6609	O-Ring Seal
   3	1	9X-2492	O-Ring Tee
   4	1	157-0670	Dust Cap
   5	1	5P-9617	Adapter
   6	1	154-9023	Valve
   7	1	6V-9027	O-Ring Seal
   8	1	6V-3250	O-Ring Seal

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Illustration 94	g03739567

2. Subassemble the components shown above on a bench before installation.

   1. Install o-ring seal (2) into the bottom of o-ring tee (3) .

   2. Install adapter (5) with o-ring seal (8) into the top of o-ring tee (3) .

   3. Install valve (6) with o-ring seal (7) into adapter (5) .

   4. Install dust cap (4) onto the top of the assembly.

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Illustration 95	g03739577
(1) Tee fitting assembly

3. Install the new tee fitting assembly (1) into the port where the previous fitting was removed. Leave the fitting loose.
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   Table 90

   Installed Components
   Item	Qty	Part Number	Part Description
   9	1	0L-1143	Bolt
   10	1	0S-1594	Bolt
   11	1	4W-7627	Spacer
   12	2	5M-2894	Hard Washer
   13	1	341-9211	Gasket
   14	1	180-8424	O-Ring Seal
   15	1	436-7553	Water Tube As

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Illustration 96	g03739580

4. Install tube assembly (15) by attaching the tube to the turbocharger housing first.

   1. Place gasket (13) between the turbocharger housing and the flange.

   2. Install bolt (9), hard washer (12), and spacer (11) into the top hole of the flange. Leave the bolt finger tight.

   3. Install bolt (10) with hard washer (12) into the top hole of the flange. Leave the bolt finger tight.

   4. Install o-ring seal (14) and fasten the swivel nut to the tee fitting assembly.
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      Table 91

      Installed Components
      Item	Qty	Part Number	Part Description
      16	2	9M-1974	Hard Washer
      17	2	237-3759	Stud

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Illustration 97	g03739587

5. Replace the existing bolts with bolts (17) and hard washers (16) as shown in Illustration 97. Tighten the bolts.
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   Table 92

   Installed Components
   Item	Qty	Part Number	Part Description
   18	3	3E-4352	Hard Washer
   19	2	5S-0003	Nut
   20	1	6V-5217	Bolt
   21	2	8T-1887	Clip
   22	2	8T-1888	Clip
   23	1	305-2452	Bracket As
   24	2	353-7957	Grommet

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Illustration 98	g03739590

6. Install grommets (24) around the tube assembly.

7. Install clips (21) and (22) around the grommet in the left location.

8. Place nut (19) with hard washer (18) onto the previously installed stud and leave finger tight.

9. Place bracket assembly (23) over the top of the previously stud and secure with nut (19) and hard washer (18) .

10. Install clips (21) and (22) around the grommet in the right location. Install bolt (20) with hard washer (18) through the clips and thread into the weld nut on bracket assembly (23) .

11. Torque the tube connection at the swivel nut and tee fitting to 65 ± 10 N·m (48 ± 7 lb ft).

12. Torque the tee fitting to 100 ± 15 N·m (74 ± 11 lb ft).

13. Torque the bolts at the turbocharger housing tp 47 ± 9 N·m (35 ± 7 lb ft).

14. Tighten all of the clips, bracket assemblies, and stud connections.
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    Table 93

    Installed Components
    Item	Qty	Part Number	Part Description
    25	1	272-2943	Tube As
    26	1	341-9211	Gasket
    27	2	5M-2894	Hard Washer
    28	1	4W-7627	Spacer
    29	1	0S-1594	Bolt
    30	1	0L-1143	Bolt
    31	1	180-8424	O-Ring Seal

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Illustration 99	g03739594

15. Reinstall tube assembly (25) by first attaching the tube to the turbocharger housing.

    1. Place gasket (26) between the turbocharger housing and the flange.

    2. Install bolt (30), hard washer (27), and spacer (28) into the bottom hole of the flange. Leave the bolt finger tight.

    3. Install bolt (29) with hard washer (27) into the top hole of the flange. Leave the bolt finger tight.

    4. Fasten the swivel nut on tube assembly (25) onto the tee fitting in the center of the engine. Replace o-ring seal (31) before installation.
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       Table 94

       Installed Components
       Item	Qty	Part Number	Part Description
       32	1	1B-3057	Clip
       33	1	4B-0418	Clip
       34	2	5P-4116	Hard Washer
       35	2	8T-8912	Bolt
       36	2	198-4776	Hard Washer

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Illustration 100	g03739600

16. Install clips (32) and (33) onto the tube as shown in Illustration 100.

    Note: Ensure that the clips are installed in the correct location as shown in Illustration 100.

17. Fasten clips to the valve cover using bolt (35), hard washer (34), and hard washer (36). Hard washer (36) underneath the clips as shown in Illustration 100.

Wiring Harness Clipping

Table 95

Installed Components
Item	Qty	Part Number	Part Description
1	1	133-6934	Spacer
2	1	4P-8134	Clip
3	1	8T-4121	Hard Washer
4	1	8T-4185	Bolt

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Illustration 101	g03739615

1. Install clip (3) using bolt (4), hard washer (3), and spacer (1).
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   Table 96

   Installed Components
   Item	Qty	Part Number	Part Description
   5	1	7K-1181	Cable Strap

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Illustration 102	g03739616

2. Use cable strap (5) to attach wiring harness to the top of the ladder clip installed in previous step.

Exhaust and Intake Piping Install

Table 97

Installed Components
Item	Qty	Part Number	Part Description
1	1	263-5494 (1)	Cover Support

( 1 )

Reused part from previous removal.

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Illustration 103	g03739620

1. Install cover support (1) by fastening the bolts that hold the support in place.
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   Table 98

   Installed Components
   Item	Qty	Part Number	Part Description
   2	1	5P-0597 (1)	Hose Clamp
   3	1	265-5210 (1)	Clamp As
   4	1	277-4858 (1)	Air Cleaner Gp

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   ( 1 )

   Reused part from previous removal.

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Illustration 104	g03739621

2. Bolt clamp assembly (3) that holds air cleaner group (4) in place. Install the air cleaner group.

3. Install hose clamp (2) that holds the fumes line disposal in place. Install the fumes disposal line.
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   Table 99

   Installed Components
   Item	Qty	Part Number	Part Description
   5	1	5P-0597 (1)	Hose Clamp
   6	1	265-5210 (1)	Clamp As
   7	1	277-4858 (1)	Air Cleaner Gp

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   ( 1 )

   Reused part from previous removal.

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Illustration 105	g03739626

4. Install the air cleaner group. Bolt clamp assembly (6) that holds air cleaner group (7) in place.

5. Install the fumes disposal line. Install hose clamp (5) that holds the fumes line disposal in place.
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   Table 100

   Installed Components
   Item	Qty	Part Number	Part Description
   8	1	239-5609 (1)	Clamp
   9	1	267-5215 (1)	Tube
   10	1	268-8665 (1)	Hose
   11	2	271-7377 (1)	Tube As
   12	1	274-7911 (1)	Tube As
   13	1	275-0860 (1)	Elbow
   14	4	9X-2201 (1)	Hose Clamp

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   ( 1 )

   Reused part from previous removal.

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Illustration 106	g03739627

6. Install the Air to Air Aftercooler (ATAAC) piping by installing elbow (13), tube (9), hose (10), and hose clamps (14) .

7. Install intake tube assembly (11) by fastening the air filter and clamp (8) at the compressor elbow.

8. Install upper exhaust tube assembly (12).
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   Table 101

   Removed Components
   Item	Qty	Part Number	Part Description
   15	1	239-5609 (1)	Clamp
   16	1	267-5215 (1)	Tube
   17	1	268-8665 (1)	Hose
   18	2	271-7377 (1)	Tube As
   19	1	274-7911 (1)	Tube As
   20	1	275-0860 (1)	Elbow
   21	4	9X-2201 (1)	Hose Clamp

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   ( 1 )

   Reused part from previous removal.

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Illustration 107	g03739631

9. Install the Air to Air Aftercooler (ATAAC) piping by installing elbow (20), tube (16), hose (17), and hose clamps (21) .

10. Remove intake tube assembly (18) unfastening the air filter and clamp (15) at the compressor elbow.

11. Remove upper exhaust tube assembly (19) .

Starting Procedure

Illustration 108	g03731345

Use the following procedure to test for leaks with the fuel and coolant components that were replaced. If a leak is found. repair the leak and related components immediately.

1. Inspect all the installed components are tighten and torqued properly. Clean the engine of any debris.

2. Refill the coolant back to operating capacity.

3. Turn the fuel supply to the "ON" position.

4. Prime the fuel system without starting the engine and check all of the fuel line connections for leaks.

5. If no leaks are identified, start and idle the machine for 5 minutes. Shutdown engine and check again for any possible fuel leaks.

6. If no leaks are identified, restart the engine. Operate the machine bringing the coolant to operating temperature for 5 to 10 minutes.

7. Shut off the engine and immediately check for fuel and coolant leaks.

8. If no fuel leaks were found, reinstall the side panels.