Procedure for Updating the C27 Engines in Certain O;K Shovel Excavators{1000} Caterpillar

Industrial Engine:

C27 (S/N: TWM1-UP)

Introduction

This Special Instruction is used for updating the C27 Engines in certain O&K Shovel Excavators.

Updating the Right-Hand Engine

Removing the 238-8294 Engine Electronic Wiring Gp

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Illustration 1	g02770256
(1) Wiring harness connectors (2) Clips (3) Clips (4) Clip

1. Disconnect wiring harness connectors (1) .

2. Remove clips (2) one at a time. Discard the clips and replace the hardware. Torque the bolts to 47 ± 9 N·m (35 ± 7 lb ft).

3. Remove clips (3) one at a time. Discard the clips and replace the hardware. Torque the bolts to 47 ± 9 N·m (35 ± 7 lb ft).

4. Remove clip (4) and discard.

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Illustration 2	g02770356
(5) ECM connector (6) Wiring harness connectors (7) Clips

5. Disconnect wiring harness connectors (6) .

6. Remove clips (7) one at a time. Discard the clips and replace the hardware. Torque the bolts to 47 ± 9 N·m (35 ± 7 lb ft).

7. Loosening the bolt that holds ECM connector (5) in place.

8. Remove any tie straps connecting the wiring harness and remove the harness.

Removing the 269-6434 Fuel Lines Gp

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Illustration 3	g02770443
(8) 200-2285 Hose As , 8M-0547 Flared Elbow , and the supporting clips (9) 322-7616 Hose As , 1P-1376 Port Connector , and the supporting clips (10) 322-7616 Hose As , 1P-1376 Port Connector , and the supporting clips

1. Remove hose, elbow, and clips (8) and cap both openings on the engine.

2. Remove hose, connector, and clips (9) and cap both openings on the engine.

3. Remove hose, connector, and clips (10) and cap both openings on the engine.

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Illustration 4	g02770556
(11) 170-1833 Hose As (12) 233-6148 Hose As (13) 170-1833 Hose As (14) 269-6438 Hose As

4. Remove hose assembly (14) and the adapters for the control group only. Cap or plug both openings on the engine.

   Note: Do not remove the adapter on the fuel filter group.

5. Remove hose assembly (12) and the adapter on the manifold only. Cap or plug both openings on the engine.

   Note: Do not remove the adapter on the fuel filter group.

6. Remove hose assembly (11) and the adapter from the fuel transfer group only. Cap or plug both openings on the engine.

   Note: Do not remove the adapter on the fuel filter group.

7. Remove hose assembly (13) and the adapter from the fuel transfer group only. Cap or plug both openings on the engine.

   Note: Do not remove the adapter on the fuel filter group.

8. Remove all retaining clips and brackets that supported the hose assemblies.

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Illustration 5	g02770937
(15) 322-7617 Hose As (16) 322-7616 Hose As (17) Brackets and clamp assemblies

9. Remove hose assembly (15) and the adapter from the 314-3173 Manifold and the 2R-6806 O-Ring Connector .

   Note: Cap both openings on the engine.

10. Remove hose assembly (16) from the 1P-1376 Port Connector and the 2R-6806 O-Ring Connector .

    Note: Cap both openings on the engine.

11. Removed all remaining brackets and clamp assemblies (17) .

Removing the 269-6437 Fuel Filter Gp

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Illustration 6	g02773090
(18) 160-1744 Bracket (19) 239-2396 Pressure Sensor Gp and 237-9309 Base As (20) 213-4740 Fuel Priming Pump and Water Separator

1. Remove pressure sensor group and filter base (19) and all attached components from the filter mounting group.

   Note: Leave the removed components attached to the filter base and store for potential reuse.

2. Remove fuel priming pump (20) and the attached components (such as the switch) from the fuel filter mounting group.

   Note: Leave the removed components attached to the filter base and store for potential reuse.

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Illustration 7	g02776837
(21) Wiring group

3. Leave wiring group (21) connected to the engine and leave all of the clips in place.

Removing the 269-6432 Fuel Filter Mounting Gp

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Illustration 8	g02781451
(22) 269-6432 Fuel Filter Mounting Gp

1. Remove filter mounting group (22) from the engine and discard.

Removing the 241-0072 Engine Electronic Control and Mounting Gp

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Illustration 9	g02781459
(23) 239-7904 Engine Electronic Control Gp (24) Four existing bolts

1. Remove the mounting for engine electronic control group (23) .

2. Replace existing bolts (24) with the standard 7X-0440 Bolts and 8T-4224 Hard Washers .

Removing the 347-3256 Aftercooler Support Gp

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Illustration 10	g02781731
(25) 347-3256 Aftercooler Support Gp

1. Remove support group (25) from the engine and discard.

Removing the 282-6854 Turbocharger Oil Lines Gp

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Illustration 11	g02781758
Right side view (26) 282-6856 Tube As and 148-8315 Connector (27) Oil drain tube

1. Remove tube assembly and connector (26) from the engine and discard.

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Illustration 12	g02781799
Left side view (28) 282-6858 Tube As and 148-8315 Connector (29) Oil drain tube

2. Remove tube assembly and connector (28) from the engine and discard.

3. Do not disturb the existing oil drain tubes.

Installing the 362-8721 Turbocharger Oil Lines Gp

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Illustration 13	g02783118
Right side view (30) 155-3504 Elbow As (31) 362-8722 Hose and Tube As

1. Install elbow assembly (30). Torque the jam nut on the elbow to 140 ± 21 N·m (103 ± 15 lb ft).

2. Install hose and tube assembly (31) using the following parts: one 7N-8875 Gasket , two 1A-2029 Bolts and two 5M-2894 Hard Washers .

   Torque for the 1A-2029 Bolts ... 47 ± 9 N·m (35 ± 7 lb ft)

   Torque for the nut on the 362-8722 Hose and Tube As ... 110 ± 17 N·m (81 ± 13 lb ft)

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Illustration 14	g02783236
Left side view (32) 155-3504 Elbow As (33) 363-0382 Hose and Tube As

3. Install elbow assembly (32). Torque the jam nut on the elbow to 140 ± 21 N·m (103 ± 15 lb ft).

4. Install hose and tube assembly (33) using the following parts: one 7N-8875 Gasket , two 1A-2029 Bolts and two 5M-2894 Hard Washers .

   Torque for the 1A-2029 Bolts ... 47 ± 9 N·m (35 ± 7 lb ft)

   Torque for the nut on the 363-0382 Hose and Tube As ... 110 ± 17 N·m (81 ± 13 lb ft)

Installing the 360-3436 Filter Mounting Gp

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Illustration 15	g02783244
(34) 360-3436 Filter Mounting Gp

1. Install bracket assembly (34) which consists of the following parts: 360-3439 Bracket As , six 0S-1566 Bolts and six 5P-8247 Hard Washers

   Torque for the 0S-1566 Bolts ... 215 ± 40 N·m (159 ± 30 lb ft)

Component Removal on the 269-6437 Fuel Filter Gp

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Illustration 16	g02784203
(35) Adapters

1. Remove adapters (35) from the fuel filter base.

Assembly and Installation of the 359-9143 Fuel Filter Gp

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Illustration 17	g02784356

1. Attach adapters (35) in location (36) and install two 307-2673 Plug As into the ports that the adapters were removed from.

   Torques for the fittings and plugs ... 80 ± 12 N·m (59 ± 9 lb ft)

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Illustration 18	g02784796
237-9309 Base As (36) 2A-4639 Bolts (37) 9X-6458 Hard Washers (38) 3S-2093 Cable Strap (39) 4P-7581 Clip

2. Install the previously removed 237-9309 Base As using the hardware referenced in Illustration 18.

   Torque for the 2A-4639 Bolts ... 47 ± 9 N·m (35 ± 7 lb ft)

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Illustration 19	g02785619
213-4740 Fuel Priming Pump and Water Separator (40) Reuse the 160-1744 Bracket (41) 0S-1594 Bolt (42) Three 5M-2894 Hard Washers (43) 0L-1351 Bolt (44) 5P-9085 Clip (45) 4P-7581 Clip (46) 9S-8752 Full Nut (47) Two 8T-9655 Isolation Mounts (48) 191-1752 Spacer (49) 1D-4539 Bolt (50) 9N-0869 Hard Washer (51) Reuse 232-1374 Bracket (52) Reuse 165-5970 Toggle Switch Gp (53) Two 4F-3508 Bolts (54) Two 9N-0869 Hard Washers (55) Six 8T-9655 Isolation Mounts (56) Two 232-1376 Spacers

3. Install the previously removed 213-4740 Fuel Priming Pump and Water Separator using the hardware referenced in Illustration 19.

   Install isolators (55) in the following locations: one under washer (54), one between the support and the filter base and one between the base and the bracket with spacers (56) through the casting.

   Torque for the 5/16 inch bolts ... 25 ± 6 N·m (18 ± 4 lb ft)

   Torque for the 3/8 inch bolts ... 47 ± 9 N·m (35 ± 7 lb ft)

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Illustration 20	g02788641
(57) 360-0484 Hose As (58) 360-1873 Hose As (59) 360-1873 Hose As (60) 249-5294 Sensor Harness As (61) 269-6436 Sensor Harness As

4. Install hose assemblies (57), (58), and (59) .

   Plug the exposed ends of the hose assemblies.

   Torque for the hose assemblies 7/8 inch JIC ... 80 ± 12 N·m (59 ± 9 lb ft)

   Torque for the hose assemblies 3/4 inch JIC ... 55 ± 8 N·m (41 ± 6 lb ft)

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Illustration 21	g02788702
(62) 160-1744 Bracket (63) 0T-0102 Bolt (64) Three 5M-2894 Hard Washers (65) 0L-1351 Bolt (66) 5P-9297 Clip (67) 9S-8752 Full Nut

5. Install the following parts according to Illustration 21: bracket (62), bolt (63), washers (64), bolt (65), clip (66) and nut (67) .

Installing the 357-9694 Aftercooler Support Gp

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Illustration 22	g02791175
(68) 224-3158 Brace (69) Three 3B-1915 Bolts and three 9X-6458 Hard Washers

1. Install brace (68) using bolts and washers (69) in the locations shown.

   Note: Finger tighten the bolts only, do not torque the bolts.

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Illustration 23	g02791181
(70) 219-6923 Brace (69) Three 3B-1915 Bolts and three 9X-6458 Hard Washers

2. Install brace (70) using bolts and washers (69) in the locations shown.

   Note: Finger tighten the bolts only, do not torque the bolts.

Installing the 354-1474 Fuel Lines Gp

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Illustration 24	g02791239
(71) 1A-0291 Shaft Cover (72) 353-1840 Bracket (73) Location for 2P-1282 Union and 7F-2060 Locknut connected to the hose from the fuel priming pump (74) Location for 2P-1282 Union and 7F-2060 Locknut that is capped (75) Location for 2P-1282 Union and 7F-2060 Locknut connected to the hose to the fuel filter base (76) Location for 2P-1282 Union and 7F-2060 Locknut connected to the hose from the fuel filter base

1. Remove cover (71) and reinstall the cover with bracket (72) over the cover. Use the following hardware to mount the cover and bracket: 226-4753 Gasket , two 1A-2029 Bolts and two 9X-6458 Hard Washer .

   Torque for the 3/8 inch bolts ... 47 ± 9 N·m (35 ± 7 lb ft)

2. Install the 2P-1282 Union and 7F-2060 Locknut in location (73). Connect the fuel hose assembly coming from the fuel priming pump to the bottom of the 2P-1282 Union .

   Torque for the 7F-2060 Locknut ... 100 ± 15 N·m (74 ± 11 lb ft)

   Torque for the hose assemblies 7/8 inch JIC ... 80 ± 12 N·m (59 ± 9 lb ft)

3. Install the 2P-1282 Union and 7F-2060 Locknut in location (74). Cap the bottom of the 2P-1282 Union .

   Torque for the 7F-2060 Locknut ... 100 ± 15 N·m (74 ± 11 lb ft)

   Torque for the hose assemblies 7/8 inch JIC ... 80 ± 12 N·m (59 ± 9 lb ft)

4. Install the 2P-1282 Union and 7F-2060 Locknut in location (75). Connect the fuel hose assembly going to the fuel filter base to the bottom of the 2P-1282 Union .

   Torque for the 7F-2060 Locknut ... 100 ± 15 N·m (74 ± 11 lb ft)

   Torque for the hose assemblies 7/8 inch JIC ... 80 ± 12 N·m (59 ± 9 lb ft)

5. Install the 2P-1282 Union and 7F-2060 Locknut in location (76). Connect the fuel hose assembly coming from the fuel filter base to the bottom of the 2P-1282 Union .

   Torque for the 7F-2060 Locknut ... 100 ± 15 N·m (74 ± 11 lb ft)

   Torque for the hose assemblies 7/8 inch JIC ... 80 ± 12 N·m (59 ± 9 lb ft)

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Illustration 25	g02791523
(77) Existing 0L-1143 Bolts and 5M-2894 Hard Washers (78) 335-3732 Bracket

6. Remove bolts and washers (77) from the flywheel housing.

7. Install bracket (78) and reinstall bolts and washers (77) .

   Torque for the 3/8 inch bolts ... 47 ± 9 N·m (35 ± 7 lb ft)

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Illustration 26	g02791763
(79) 356-4834 Fuel Line (80) 353-2158 Clamp As (81) 356-3315 Fuel Line (82) 356-3316 Fuel Line (83) 357-9676 Fuel Line

8. Install fuel line (79) in the location shown in Illustration 26. Attach a 061-8248 Flared Union to the other end of the fuel line.

   Torque for the hose assemblies 7/8 inch JIC ... 80 ± 12 N·m (59 ± 9 lb ft)

9. Install fuel line (82). Attach the fuel line to the 314-3173 Manifold using a new 1P-7625 Elbow and 238-5080 O-Ring Seal .

10. Install fuel line (81). Attach the fuel line to the fuel transfer pump using a new 6M-7476 Elbow and 238-5081 O-Ring Seal .

11. Install fuel line (83). Leave the opposite end of the fuel line free for now.

12. Secure the fuel lines using clamp assembly (80). The following parts are required to secure the fuel lines with clamp assembly (80) : two 4P-0693 Clamp As , two 9X-6458 Hard Washers , 0T-0065 Bolt and 9S-8752 Full Nut .

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Illustration 27	g02793220
(84) 357-9677 Fuel Line (85) Clamp assembly (86) Clamp assemblies (87) 353-1836 Fuel Line

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Illustration 28	g02793230
(84) 357-9677 Fuel Line (88) Clipping point

13. Install fuel line (84) at the transfer pump using a new 1P-7625 Elbow and 238-5080 O-Ring Seal .

14. Install the following parts at clipping point (88) : one 332-0011 Clip , one 353-9663 Spacer , one 5M-2894 Hard Washer and one 1A-5183 Bolt .

15. Attach fuel line (87) as shown to the 2P-7213 Bulkhead Tee at the front of the engine.

16. Secure the fuel line at location (85) using the following hardware: one 8T-1889 Clip , one 8T-1890 Clip , one 7V-6571 Grommet , one 172-4211 Spacer , one 5M-2894 Hard Washer and one 0T-0065 Bolt .

    Note: Finger tighten the bolt only, do not torque.

17. Secure the fuel line at locations (86) using the following hardware: two 4P-0692 Clamp As , one 353-1841 Bracket , two 9X-6456 One-Piece Flanges , one 0L-1143 Bolt and one 9S-8752 Full Nut .

    Note: Finger tighten the bolts only, do not torque.

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Illustration 29	g02802337
(89) Clamp assembly (90) 361-1997 Fuel Line (91) 256-2211 Hose As (92) Clamp assembly

18. Connect fuel line (90) to the 314-3173 Manifold using a 2R-6806 O-Ring Connector and a 214-7568 O-Ring Seal . Connect the other end of the fuel line to the existing adapter on the cylinder head.

19. Secure fuel line (90) at location (89) using the following hardware: two 090-8635 Spacers , one 354-1478 Bracket As , two 5M-2894 Hard Washers , two 0S-1571 Bolts , one 8T-1889 Clip , one 8T-1890 Clip , one 7V-6571 Grommet , one 9X-6458 Hard Washer and one 0L-1351 Bolt .

20. Connect fuel line (91) to the 314-3173 Manifold using a 2R-6806 O-Ring Connector and a 214-7568 O-Ring Seal . Connect the other end of the fuel line to the existing adapter on the cylinder head.

21. Secure fuel line (91) at location (92) using the following hardware: two 090-8635 Spacers , one 355-5896 Bracket As , two 5M-2894 Hard Washers , two 0S-1571 Bolts , one 8T-1889 Clip , one 8T-1890 Clip , one 7V-6571 Grommet , two 9X-6458 Hard Washers , one 0S-1588 Bolt and one 9S-8752 Full Nut .

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Illustration 30	g02802936
(93) Two 324-3357 Hose As (94) Clamping locations (95) Clamping locations

22. Install one hose assembly (93) onto the right side of the engine. Connect the hose to the 2P-7213 Bulkhead Tee at the front of the engine. Connect the other end of the hose to the adapter at the cylinder head.

23. Secure the hose assembly at location (94) using the following hardware: one 5M-2894 Hard Washer , one 0L-1352 Bolt , one 7V-6571 Grommet , one 8T-1889 Clip , one 8T-1890 Clip , two 5M-2894 Hard Washers , one 2A-4639 Bolt and one 9S-8752 Full Nut .

24. Secure the hose assembly at location (95) using the following hardware: one 7V-6571 Grommet , one 8T-1889 Clip , one 8T-1890 Clip , one 5M-2894 Hard Washer and one 0S-1594 Bolt .

25. Install one hose assembly (93) onto the left side of the engine. Connect the hose to the 2P-7213 Bulkhead Tee at the front of the engine. Connect the other end of the hose to the adapter at the cylinder head.

26. Secure the hose assembly at location (94) using the following hardware: one 5M-2894 Hard Washer , one 0L-1352 Bolt , one 7V-6571 Grommet , one 8T-1889 Clip , one 8T-1890 Clip , two 5M-2894 Hard Washers , one 2A-4639 Bolt and one 9S-8752 Full Nut .

27. Secure the hose assembly at location (95) using the following hardware: one 7V-6571 Grommet , one 8T-1889 Clip , one 8T-1890 Clip , one 5M-2894 Hard Washer and one 0S-1594 Bolt .

Component Removal of the 241-0072 Engine Electronic Control and Mounting Gp

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Illustration 31	g02803237
(96) 225-6309 Bracket (97) 233-0891 Bracket As

1. Remove bracket (96) and retain the hardware for reuse. Discard the rubber isolators, the isolators will be replaced.

2. Remove both bracket assemblies (97) and discard.

Assembly and Installation of the 357-8958 Engine Electronic Control and Mounting Gp

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Illustration 32	g02803257
(98) 239-7904 Engine Electronic Control Gp (99) 357-8961 Bracket

1. Install electronic control group (98) on to bracket (99) using the retained hardware from the removal. Install eight new 8T-9655 Isolation Mounts with one under each washer and one between the control group and the bracket.

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Illustration 33	g02803277
(83) 357-9676 Fuel Line (84) 357-9677 Fuel Line (100) 357-8958 Engine Electronic Control and Mounting Gp

2. Attach control and mounting group (100) as shown using the following hardware: four 6V-4249 Bolts , four 6V-5839 Washers and four 9N-4685 Blocks .

3. Attach fuel line (83) to the control group using a new 141-2375 Elbow and a 238-5080 O-Ring Seal .

4. Attach fuel line (84) to the control group using a new 2P-7636 Connector and a 238-5080 O-Ring Seal .

Installation of the 357-0448 Engine Sensor Gp

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Illustration 34	g02803357
(101) Two 341-8364 Adapters (102) 326-4514 Cable Tie (103) Tie strap location (104) Tie strap location (105) Tie strap location (106) Tie strap location (107) 343-6890 Temperature Sensor Gp

1. Install adapters (101) .

   Torque for adapters (101) ... 45 ± 5 N·m (33 ± 4 lb ft)

2. Attach sensor group (107) to adapters (101) .

   Note: The outer wire on the sensor group installs in the front of the exhaust manifold.

3. Secure the sensor group using cable tie (102) as shown above.

4. Secure the harness assembly at location (103) using a 3S-2093 Cable Strap on the existing 132-5789 Clip .

5. Secure the harness assembly at location (104) using a 3S-2093 Cable Strap on the existing 132-5789 Clip .

6. Secure the harness assembly at location (105) using the following hardware: one 3S-2093 Cable Strap , one 352-3967 Clip , one 5P-8245 Hard Washer and one 6H-1717 Bolt .

7. Secure the harness assembly at location (106) using the following hardware: one 3S-2093 Cable Strap , one 178-1781 Clip , one 5M-2894 Hard Washer and one 0S-0509 Bolt .

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Illustration 35	g02803639
(101) Two 341-8364 Adapters (102) Two 326-4514 Cable Tie (107) 343-6890 Temperature Sensor Gp (108) Tie strap location (109) Tie strap location

8. Install adapters (101) .

   Torque for adapters (101) ... 45 ± 5 N·m (33 ± 4 lb ft)

9. Attach sensor group (107) to adapters (101) .

   Note: The outer wire on the sensor group installs in the front of the exhaust manifold.

10. Secure the sensor group using cable tie (102) as shown above.

11. Secure the harness assembly at location (108) using the following hardware: one 3S-2093 Cable Strap , one 132-5789 Clip , one 5P-2894 Hard Washer and one 0S-0509 Bolt .

12. Secure the harness assembly at location (109) using the following hardware: one 3S-2093 Cable Strap , one 178-1781 Clip , one 5P-2894 Hard Washer and one 0S-0509 Bolt .

Installing the 353-1551 Engine Wiring Gp

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Illustration 36	g02804817
(110) Existing 4P-7581 Clip (111) Existing 132-5789 Clip

1. Install clips (110) and clips (111) in the locations specified in Illustration 36

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Illustration 37	g02804981
(112) 353-1551 Engine Wiring Gp (113) Clipping location (114) Clipping location

2. Attach wiring group (112) to the 357-8958 Engine Electronic Control and Mounting Gp .

3. Install the following hardware at location (113) : one 4P-8134 Clip , one 5M-2894 Hard Washer and one 0S-0509 Bolt .

4. Install the following hardware at location (114) : one 197-6453 Clip , one 5M-2894 Hard Washer and one 0S-0509 Bolt .

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Illustration 38	g02805238
(115) Tie strap locations (116) Engine speed/timing sensor (117) Tie strap location (118) Temperature sensor

5. Locate the existing 4P-7581 Clips at locations (115) .

6. At location (117) install the following hardware: one 132-5789 Clip , one 5M-2894 Hard Washer and one 0S-0509 Bolt

7. Secure the wiring harness with 7K-1181 Cable Straps at location (115), location (116), and location (117) .

8. Plug connector "EN-C11" into the engine speed/timing sensor at location (116)

9. Plug connector "EN-C4" into the temperature sensor at location (118) .

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Illustration 39	g02805417
(119) Tie strap locations (120) Right side exhaust temperature sensor (121) Mounting locations for 316-9351 Cable Tie Mounting (122) Fuel pressure sensor connection

10. Locate the existing 4P-7581 Clips at locations (119) .

11. Install two 316-9351 Cable Tie Mountings in locations (121) .

12. Secure the wiring harness at locations (119) and locations (121) using 7K-1181 Cable Straps .

13. Plug connector "EN-C2" into the right side exhaust temperature sensor at location (120) .

14. Plug connector "EN-C6" into the fuel pressure sensor at location (122) .

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Illustration 40	g02805896
(123) Location of the coolant temperature sensor (124) Location of the fuel pressure sensor (125) Location of the start speed sensor (126) Location to use 316-9351 Cable Tie Mounting

15. Plug connector "EN-C15" into the coolant temperature sensor at location (123) .

16. Plug connector "EN-C7" into the fuel pressure sensor at location (124) .

17. Plug connector "EN-C12" into the start speed sensor at location (125) .

18. Secure the wiring harness at location (126) using a 316-9351 Cable Tie Mounting .

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Illustration 41	g02806177
(127) Inlet air temperature sensor (128) Fuel pressure sensor +5V (129) Fuel pressure sensor *5V (130) 12V return (131) Left bank injector connector

19. Plug connector "EN-C13" into the inlet air temperature sensor at location (127) .

20. Plug connector "EN-C8" into the fuel pressure sensor +5V at location (128) .

21. Plug connector "EN-C9" into the fuel pressure sensor *5V at location (129) .

22. Plug connector "EN-C18" into the 12V return at location (130) .

23. Plug connector "EN-C5" into the left bank injector connector at location (131) .

24. Plug connector "EN-C3" into the right bank injector connector.

Updating the Left-Hand Engine

Removing the 238-8294 Engine Electronic Wiring Gp

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Illustration 42	g02770256
(1) Wiring harness connectors (2) Clips (3) Clips (4) Clip

1. Disconnect wiring harness connectors (1) .

2. Remove clips (2) one at a time. Discard the clips and replace the hardware. Torque the bolts to 47 ± 9 N·m (35 ± 7 lb ft).

3. Remove clips (3) one at a time. Discard the clips and replace the hardware. Torque the bolts to 47 ± 9 N·m (35 ± 7 lb ft).

4. Remove clip (4) and discard.

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Illustration 43	g02770356
(5) ECM connector (6) Wiring harness connectors (7) Clips

5. Disconnect wiring harness connectors (6) .

6. Remove clips (7) one at a time. Discard the clips and replace the hardware. Torque the bolts to 47 ± 9 N·m (35 ± 7 lb ft).

7. Loosening the bolt that holds ECM connector (5) in place.

8. Remove any tie straps connecting the wiring harness and remove the harness.

Removing the 269-6434 Fuel Lines Gp

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Illustration 44	g02770443
(8) 200-2285 Hose As , 8M-0547 Flared Elbow , and the supporting clips (9) 322-7616 Hose As , 1P-1376 Port Connector , and the supporting clips (10) 322-7616 Hose As , 1P-1376 Port Connector , and the supporting clips

1. Remove hose, elbow, and clips (8) and cap both openings on the engine.

2. Remove hose, connector, and clips (9) and cap both openings on the engine.

3. Remove hose, connector, and clips (10) and cap both openings on the engine.

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Illustration 45	g02770556
(11) 170-1833 Hose As (12) 233-6148 Hose As (13) 170-1833 Hose As (14) 269-6438 Hose As

4. Remove hose assembly (14) and the adapters for the control group only. Cap or plug both openings on the engine.

   Note: Do not remove the adapter on the fuel filter group.

5. Remove hose assembly (12) and the adapter on the manifold only. Cap or plug both openings on the engine.

   Note: Do not remove the adapter on the fuel filter group.

6. Remove hose assembly (11) and the adapter from the fuel transfer group only. Cap or plug both openings on the engine.

   Note: Do not remove the adapter on the fuel filter group.

7. Remove hose assembly (13) and the adapter from the fuel transfer group only. Cap or plug both openings on the engine.

   Note: Do not remove the adapter on the fuel filter group.

8. Remove all retaining clips and brackets that supported the hose assemblies.

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Illustration 46	g02770937
(15) 322-7617 Hose As (16) 322-7616 Hose As (17) Brackets and clamp assemblies

9. Remove hose assembly (15) and the adapter from the 314-3173 Manifold and the 2R-6806 O-Ring Connector .

   Note: Cap both openings on the engine.

10. Remove hose assembly (16) from the 1P-1376 Port Connector and the 2R-6806 O-Ring Connector .

    Note: Cap both openings on the engine.

11. Removed all remaining brackets and clamp assemblies (17) .

Removing the 269-6437 Fuel Filter Gp

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Illustration 47	g02773090
(18) 160-1744 Bracket (19) 239-2396 Pressure Sensor Gp and 237-9309 Base As (20) 213-4740 Fuel Priming Pump and Water Separator

1. Remove pressure sensor group and filter base (19) and all attached components from the filter mounting group.

   Note: Leave the removed components attached to the filter base and store for potential reuse.

2. Remove fuel priming pump (20) and the attached components (such as the switch) from the fuel filter mounting group.

   Note: Leave the removed components attached to the filter base and store for potential reuse.

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Illustration 48	g02776837
(21) Wiring group

3. Leave wiring group (21) connected to the engine and leave all of the clips in place.

Removing the 269-6432 Fuel Filter Mounting Gp

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Illustration 49	g02781451
(22) 269-6432 Fuel Filter Mounting Gp

1. Remove filter mounting group (22) from the engine and discard.

Removing the 241-0072 Engine Electronic Control and Mounting Gp

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Illustration 50	g02781459
(23) 239-7904 Engine Electronic Control Gp (24) Four existing bolts

1. Remove the mounting for engine electronic control group (23) .

2. Replace existing bolts (24) with the standard 7X-0440 Bolts and 8T-4224 Hard Washers .

Removing the 347-3256 Aftercooler Support Gp

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Illustration 51	g02781731
(25) 347-3256 Aftercooler Support Gp

1. Remove support group (25) from the engine and discard.

Removing the 282-6854 Turbocharger Oil Lines Gp

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Illustration 52	g02781758
Right side view (26) 282-6856 Tube As and 148-8315 Connector (27) Oil drain tube

1. Remove tube assembly and connector (26) from the engine and discard.

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Illustration 53	g02781799
Left side view (28) 282-6858 Tube As and 148-8315 Connector (29) Oil drain tube

2. Remove tube assembly and connector (28) from the engine and discard.

3. Do not disturb the existing oil drain tubes.

Installing the 362-8721 Turbocharger Oil Lines Gp

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Illustration 54	g02783118
Right side view (30) 155-3504 Elbow As (31) 362-8722 Hose and Tube As

1. Install elbow assembly (30). Torque the jam nut on the elbow to 140 ± 21 N·m (103 ± 15 lb ft).

2. Install hose and tube assembly (31) using the following parts: one 7N-8875 Gasket , two 1A-2029 Bolts and two 5M-2894 Hard Washers .

   Torque for the 1A-2029 Bolts ... 47 ± 9 N·m (35 ± 7 lb ft)

   Torque for the nut on the 362-8722 Hose and Tube As ... 110 ± 17 N·m (81 ± 13 lb ft)

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Illustration 55	g02783236
Left side view (32) 155-3504 Elbow As (33) 363-0382 Hose and Tube As

3. Install elbow assembly (32). Torque the jam nut on the elbow to 140 ± 21 N·m (103 ± 15 lb ft).

4. Install hose and tube assembly (33) using the following parts: one 7N-8875 Gasket , two 1A-2029 Bolts and two 5M-2894 Hard Washers .

   Torque for the 1A-2029 Bolts ... 47 ± 9 N·m (35 ± 7 lb ft)

   Torque for the nut on the 363-0382 Hose and Tube As ... 110 ± 17 N·m (81 ± 13 lb ft)

Installing the 360-3438 Fuel Filter Mounting Gp

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Illustration 56	g02807572
(34) 360-3438 Filter Mounting Gp

1. Install bracket assembly (34) which consists of the following parts: 360-3440 Bracket As , six 0S-1566 Bolts and six 5P-8247 Hard Washers

   Torque for the 0S-1566 Bolts ... 215 ± 40 N·m (159 ± 30 lb ft)

Component Removal on the 269-6437 Fuel Filter Gp

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Illustration 57	g02807740
(35) 9S-8005 O-Ring Plug (36) Adapters

1. Remove plugs (35) from the fuel filter base.

2. Remove adapters (36) from the fuel filter base.

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Illustration 58	g02807822
(37) Adapter locations (38) 9S-8006 O-Ring Plug (39) 6K-3607 Connector (40) 5P-1404 Adapter

3. Remove the components specified in Illustration 58.

Assembly and Installation of the 359-9142 Fuel Filter Gp

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Illustration 59	g02808977

1. Attach plugs (35), connector (39), and adapter (40) in the locations shown in Illustration 59.

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Illustration 60	g02809078
(41) New 307-2673 Plug As

2. Install plug (38) and plugs (41) in the locations shown in Illustration 60.

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Illustration 61	g02809097
(42) Fuel filter group harness

3. Route the harness assembly along the right side of the engine using the clips left in place from the previous harness.

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Illustration 62	g02809237
(43) Clip locations (44) Clip location

4. Install the following hardware at locations (43) : one 132-5789 Clip and one 3S-2093 Cable Strap .

5. Install the following hardware at location (44) : one 4P-7048 Bracket , one 6V-3265 Clip , one 0S-0509 Bolt , one 5M-2894 Hard Washer and one 9S-8752 Full Nut .

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Illustration 63	g02809356
237-9309 Base As (45) 0S-1591 Bolt (46) 9X-6458 Hard Washers (47) 3S-2093 Cable Strap (48) 4P-7581 Clip (49) 2A-4639 Bolt

6. Install the previously removed 237-9309 Base As using the hardware referenced in Illustration 63.

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Illustration 64	g02809362
213-4740 Fuel Priming Pump and Water Separator (50) Two 8T-9655 Isolation Mounts (51) 191-1752 Spacer (52) 1D-4539 Bolt (53) 9N-0869 Hard Washer (54) Reuse 232-1374 Bracket (55) Reuse 165-5970 Toggle Switch Gp (56) Two 4F-3508 Bolts (57) Two 9N-0869 Hard Washers (58) Six 8T-9655 Isolation Mounts (59) Two 232-1376 Spacers

7. Install the previously removed 213-4740 Fuel Priming Pump and Water Separator using the hardware referenced in Illustration 19.

   Install isolators (58) in the following locations: one under washer (57), one between the support and the filter base and one between the base and the bracket with spacers (59) through the casting.

   Torque for the 5/16 inch bolts ... 25 ± 6 N·m (18 ± 4 lb ft)

   Torque for the 3/8 inch bolts ... 47 ± 9 N·m (35 ± 7 lb ft)

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Illustration 65	g02809396
(60) 130-5300 Clip (61) 4P-7581 Clip (62) 3S-2093 Cable Strap (63) 0S-0509 Bolt (64) 5M-2894 Hard Washer (65) 9S-8752 Full Nut (66) 160-1744 Bracket (67) 0S-1594 Bolt (68) 9X-6458 Hard Washer (69) 249-5294 Sensor Harness As

8. Install and secure harness assembly (69) as shown in Illustration 65.

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Illustration 66	g02809480
(70) 360-0484 Hose As (71) 360-0486 Hose As (72) 360-0485 Hose As

9. Install hose assemblies (70), (71), and (72) .

   Plug the exposed ends of the hose assemblies.

   Torque for the hose assemblies 7/8 inch JIC ... 80 ± 12 N·m (59 ± 9 lb ft)

   Torque for the hose assemblies 3/4 inch JIC ... 55 ± 8 N·m (41 ± 6 lb ft)

Installing the 357-9752 Aftercooler Support Gp

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Illustration 67	g02809657
(73) 224-3158 Brace (74) Three 3B-1915 Bolts and three 9X-6458 Hard Washers

1. Install brace (73) using bolts and washers (74) in the locations shown.

   Note: Finger tighten the bolts only, do not torque the bolts.

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Illustration 68	g02809676
(75) 219-6923 Brace (74) Three 3B-1915 Bolts and three 9X-6458 Hard Washers

2. Install brace (75) using bolts and washers (74) in the locations shown.

   Note: Finger tighten the bolts only, do not torque the bolts.

Installing the 354-1474 Fuel Lines Gp

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Illustration 69	g02809679
(76) Location for 2P-1282 Union and 7F-2060 Locknut connected to the hose from the fuel filter base (77) Location for 2P-1282 Union and 7F-2060 Locknut connected to the hose to the fuel filter base (78) Location for 2P-1282 Union and 7F-2060 Locknut connected to the hose from the fuel priming pump (79) Location for 2P-1282 Union and 7F-2060 Locknut that is capped (80) 353-1840 Bracket (81) 1A-0291 Shaft Cover

1. Remove cover (81) and reinstall the cover with bracket (80) over the cover. Use the following hardware to mount the cover and bracket: 226-4753 Gasket , two 1A-2029 Bolts and two 9X-6458 Hard Washer .

   Torque for the 3/8 inch bolts ... 47 ± 9 N·m (35 ± 7 lb ft)

2. Install the 2P-1282 Union and 7F-2060 Locknut in location (78). Connect the fuel hose assembly coming from the fuel priming pump to the bottom of the 2P-1282 Union .

   Torque for the 7F-2060 Locknut ... 100 ± 15 N·m (74 ± 11 lb ft)

   Torque for the hose assemblies 7/8 inch JIC ... 80 ± 12 N·m (59 ± 9 lb ft)

3. Install the 2P-1282 Union and 7F-2060 Locknut in location (79). Cap the bottom of the 2P-1282 Union .

   Torque for the 7F-2060 Locknut ... 100 ± 15 N·m (74 ± 11 lb ft)

   Torque for the hose assemblies 7/8 inch JIC ... 80 ± 12 N·m (59 ± 9 lb ft)

4. Install the 2P-1282 Union and 7F-2060 Locknut in location (77). Connect the fuel hose assembly going to the fuel filter base to the bottom of the 2P-1282 Union .

   Torque for the 7F-2060 Locknut ... 100 ± 15 N·m (74 ± 11 lb ft)

   Torque for the hose assemblies 7/8 inch JIC ... 80 ± 12 N·m (59 ± 9 lb ft)

5. Install the 2P-1282 Union and 7F-2060 Locknut in location (76). Connect the fuel hose assembly coming from the fuel filter base to the bottom of the 2P-1282 Union .

   Torque for the 7F-2060 Locknut ... 100 ± 15 N·m (74 ± 11 lb ft)

   Torque for the hose assemblies 7/8 inch JIC ... 80 ± 12 N·m (59 ± 9 lb ft)

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Illustration 70	g02809736
(82) 355-5556 Fuel Injection Line As (83) 355-5552 Fuel Injection Line As (84) 355-5551 Fuel Injection Line As (85) 357-9448 Fuel Line (86) 353-2158 Clamp As

6. Install fuel line (82) in the location shown in Illustration 26. Attach a 061-8248 Flared Union to the other end of the fuel line.

   Torque for the hose assemblies 7/8 inch JIC ... 80 ± 12 N·m (59 ± 9 lb ft)

7. Install fuel line (84). Attach the fuel line to the 314-3173 Manifold using a new 1P-7625 Elbow and 238-5080 O-Ring Seal .

8. Install fuel line (83). Attach the fuel line to the fuel transfer pump using a new 6M-7476 Elbow and 238-5081 O-Ring Seal .

9. Install fuel line (85). Leave the opposite end of the fuel line free for now.

10. Secure the fuel lines using clamp assembly (86). The following parts are required to secure the fuel lines with clamp assembly (80) : two 4P-0693 Clamp As , two 9X-6458 Hard Washers , 0T-0065 Bolt and 9S-8752 Full Nut .

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Illustration 71	g02809760
(87) 357-4449 Elbow As (88) Clamp assembly (89) Clamp assemblies (90) 355-5554 Fuel Line

11. Install fuel line (87) at the transfer pump using a new 2P-7636 Connector and 238-5080 O-Ring Seal .

12. Install the following parts at clipping point (88) : two 4P-0692 Clamp As , one 353-9853 Spacer , one 9X-6458 Hard Washer and one 1A-5183 Bolt .

    Note: Finger tighten the bolt only, do not torque.

13. Attach fuel line (90) as shown to the 2P-7213 Bulkhead Tee at the front of the engine.

14. Secure the fuel line at location (89) using the following hardware: two 4P-0692 Clamp As , one 353-1841 Bracket , two 9X-6458 Hard Washers , one 9S-8752 Full Nut and one 0L-1143 Bolt .

    Note: Use the existing manifold group hardware to attach the bracket to the manifold.

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Illustration 72	g02809821
(91) Clamp assembly (92) 361-1997 Fuel Line (93) 256-2211 Hose As (94) Clamp assembly

15. Connect fuel line (92) to the 314-3173 Manifold using a 2R-6806 O-Ring Connector and a 214-7568 O-Ring Seal . Connect the other end of the fuel line to the existing adapter on the cylinder head.

16. Secure fuel line (92) at location (91) using the following hardware: two 090-8635 Spacers , one 354-1478 Bracket As , two 5M-2894 Hard Washers , two 0S-1571 Bolts , one 8T-1889 Clip , one 8T-1890 Clip , one 7V-6571 Grommet , one 9X-6458 Hard Washer and one 0L-1351 Bolt .

17. Connect fuel line (93) to the 314-3173 Manifold using a 2R-6806 O-Ring Connector and a 214-7568 O-Ring Seal . Connect the other end of the fuel line to the existing adapter on the cylinder head.

18. Secure fuel line (93) at location (94) using the following hardware: two 090-8635 Spacers , one 355-5896 Bracket As , two 5M-2894 Hard Washers , two 0S-1571 Bolts , one 8T-1889 Clip , one 8T-1890 Clip , one 7V-6571 Grommet , two 9X-6458 Hard Washers , one 0S-1588 Bolt and one 9S-8752 Full Nut .

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Illustration 73	g02809838
(95) Two 324-3357 Hose As (96) Clamping locations (97) Clamping locations

19. Install one hose assembly (95) onto the right side of the engine. Connect the hose to the 2P-7213 Bulkhead Tee at the front of the engine. Connect the other end of the hose to the adapter at the cylinder head.

20. Secure the hose assembly at location (96) using the following hardware: one 5M-2894 Hard Washer , one 0L-1352 Bolt , one 7V-6571 Grommet , one 8T-1889 Clip , one 8T-1890 Clip , two 5M-2894 Hard Washers , one 2A-4639 Bolt and one 9S-8752 Full Nut .

21. Secure the hose assembly at location (97) using the following hardware: one 7V-6571 Grommet , one 8T-1889 Clip , one 8T-1890 Clip , one 5M-2894 Hard Washer and one 0S-1594 Bolt .

22. Install one hose assembly (95) onto the left side of the engine. Connect the hose to the 2P-7213 Bulkhead Tee at the front of the engine. Connect the other end of the hose to the adapter at the cylinder head.

23. Secure the hose assembly at location (96) using the following hardware: one 5M-2894 Hard Washer , one 0L-1352 Bolt , one 7V-6571 Grommet , one 8T-1889 Clip , one 8T-1890 Clip , two 5M-2894 Hard Washers , one 2A-4639 Bolt and one 9S-8752 Full Nut .

24. Secure the hose assembly at location (97) using the following hardware: one 7V-6571 Grommet , one 8T-1889 Clip , one 8T-1890 Clip , one 5M-2894 Hard Washer and one 0S-1594 Bolt .

Component Removal of the 241-0072 Engine Electronic Control and Mounting Gp

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Illustration 74	g02809840
(98) 225-6309 Bracket (99) 233-0891 Bracket As

1. Remove bracket (98) and retain the hardware for reuse. Discard the rubber isolators, the isolators will be replaced.

2. Remove both bracket assemblies (99) and discard.

Assembly and Installation of the 357-8958 Engine Electronic Control and Mounting Gp

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Illustration 75	g02809856
(100) 239-7904 Engine Electronic Control Gp and 357-8961 Bracket

1. Install electronic control group (100) on to bracket (101) using the retained hardware from the removal. Install eight new 8T-9655 Isolation Mounts with one under each washer and one between the control group and the bracket.

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Illustration 76	g02809859
(85) 357-9677 Fuel Line (87) 357-9676 Fuel Line (100) 357-8958 Engine Electronic Control and Mounting Gp

2. Attach control and mounting group (100) as shown using the following hardware: four 6V-4249 Bolts , four 6V-5839 Washers and four 9N-4685 Blocks .

3. Attach fuel line (87) to the control group using a new 141-2375 Elbow and a 238-5080 O-Ring Seal .

4. Attach fuel line (85) to the control group using a new 2P-7636 Connector and a 238-5080 O-Ring Seal .

Installation of the 357-0448 Engine Sensor Gp

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Illustration 77	g02803357
(101) Two 341-8364 Adapters (102) 326-4514 Cable Tie (103) Tie strap location (104) Tie strap location (105) Tie strap location (106) Tie strap location (107) 343-6890 Temperature Sensor Gp

1. Install adapters (101) .

   Torque for adapters (101) ... 45 ± 5 N·m (33 ± 4 lb ft)

2. Attach sensor group (107) to adapters (101) .

   Note: The outer wire on the sensor group installs in the front of the exhaust manifold.

3. Secure the sensor group using cable tie (102) as shown above.

4. Secure the harness assembly at location (103) using a 3S-2093 Cable Strap on the existing 132-5789 Clip .

5. Secure the harness assembly at location (104) using a 3S-2093 Cable Strap on the existing 132-5789 Clip .

6. Secure the harness assembly at location (105) using the following hardware: one 3S-2093 Cable Strap , one 352-3967 Clip , one 5P-8245 Hard Washer and one 6H-1717 Bolt .

7. Secure the harness assembly at location (106) using the following hardware: one 3S-2093 Cable Strap , one 178-1781 Clip , one 5M-2894 Hard Washer and one 0S-0509 Bolt .

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Illustration 78	g02803639
(101) Two 341-8364 Adapters (102) Two 326-4514 Cable Tie (107) 343-6890 Temperature Sensor Gp (108) Tie strap location (109) Tie strap location

8. Install adapters (101) .

   Torque for adapters (101) ... 45 ± 5 N·m (33 ± 4 lb ft)

9. Attach sensor group (107) to adapters (101) .

   Note: The outer wire on the sensor group installs in the front of the exhaust manifold.

10. Secure the sensor group using cable tie (102) as shown above.

11. Secure the harness assembly at location (108) using the following hardware: one 3S-2093 Cable Strap , one 132-5789 Clip , one 5P-2894 Hard Washer and one 0S-0509 Bolt .

12. Secure the harness assembly at location (109) using the following hardware: one 3S-2093 Cable Strap , one 178-1781 Clip , one 5P-2894 Hard Washer and one 0S-0509 Bolt .

Installing the 353-1551 Engine Wiring Gp

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Illustration 79	g02804817
(110) Existing 4P-7581 Clip (111) Existing 132-5789 Clip

1. Install clips (110) and clips (111) in the locations specified in Illustration 36

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Illustration 80	g02804981
(112) 353-1551 Engine Wiring Gp (113) Clipping location (114) Clipping location

2. Attach wiring group (112) to the 357-8958 Engine Electronic Control and Mounting Gp .

3. Install the following hardware at location (113) : one 4P-8134 Clip , one 5M-2894 Hard Washer and one 0S-0509 Bolt .

4. Install the following hardware at location (114) : one 197-6453 Clip , one 5M-2894 Hard Washer and one 0S-0509 Bolt .

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Illustration 81	g02805238
(115) Tie strap locations (116) Engine speed/timing sensor (117) Tie strap location (118) Temperature sensor

5. Locate the existing 4P-7581 Clips at locations (115) .

6. At location (117) install the following hardware: one 132-5789 Clip , one 5M-2894 Hard Washer and one 0S-0509 Bolt

7. Secure the wiring harness with 7K-1181 Cable Straps at location (115), location (116), and location (117) .

8. Plug connector "EN-C11" into the engine speed/timing sensor at location (116)

9. Plug connector "EN-C4" into the temperature sensor at location (118) .

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Illustration 82	g02805417
(119) Tie strap locations (120) Right side exhaust temperature sensor (121) Mounting locations for 316-9351 Cable Tie Mounting (122) Fuel pressure sensor connection

10. Locate the existing 4P-7581 Clips at locations (119) .

11. Install two 316-9351 Cable Tie Mountings in locations (121) .

12. Secure the wiring harness at locations (119) and locations (121) using 7K-1181 Cable Straps .

13. Plug connector "EN-C2" into the right side exhaust temperature sensor at location (120) .

14. Plug connector "EN-C6" into the fuel pressure sensor at location (122) .

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Illustration 83	g02805896
(123) Location of the coolant temperature sensor (124) Location of the fuel pressure sensor (125) Location of the start speed sensor (126) Location to use 316-9351 Cable Tie Mounting

15. Plug connector "EN-C15" into the coolant temperature sensor at location (123) .

16. Plug connector "EN-C7" into the fuel pressure sensor at location (124) .

17. Plug connector "EN-C12" into the start speed sensor at location (125) .

18. Secure the wiring harness at location (126) using a 316-9351 Cable Tie Mounting .

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Illustration 84	g02806177
(127) Inlet air temperature sensor (128) Fuel pressure sensor +5V (129) Fuel pressure sensor *5V (130) 12V return (131) Left bank injector connector

19. Plug connector "EN-C13" into the inlet air temperature sensor at location (127) .

20. Plug connector "EN-C8" into the fuel pressure sensor +5V at location (128) .

21. Plug connector "EN-C9" into the fuel pressure sensor *5V at location (129) .

22. Plug connector "EN-C18" into the 12V return at location (130) .

23. Plug connector "EN-C5" into the left bank injector connector at location (131) .

24. Plug connector "EN-C3" into the right bank injector connector.