Retrofitting for the Dynamic Gas Blending Capability on Certain 3512C Oil Well Service Engines{1250, 1280} Caterpillar

Engine:

3512C (S/N: WF31-UP; WF51-UP)

Petroleum Engine:

3512C (S/N: R1A1-UP; R1S1-UP)

Pumper:

SPF343C (S/N: RTX1-UP; R2A1-UP)

Introduction

Note: Make sure that your engine is in proper running order and up to date on all maintenance activities prior to installation or operation of Dynamic Gas Blending Capability (DGB). Check customer speed sensing and direct rack (if applicable) connections for quality connectivity and proper grounding.

Note: Make sure to copy the Product Status Report before starting the following procedure.

This Special Instruction provides the procedure in order to install an upgrade fuel kit for a 3512C Diesel Engine. Refer to following Tables for the upgrade fuel kit part numbers.

Refer to Systems Operation/Testing and Adjusting, UENR4321.

Refer to Troubleshooting, UENR0572.

Parts Needed

Table 1

282-8422 Exhaust Manifold Gp
Qty	Part
8	5M-2894 Hard Washer
8	6V-1943 High Temperature Bolt

Table 2

283-2447 Turbocharger Gp S/N:(R1A, R2A, RTX, and WF3)
Qty	Part
16	2N-2765 High Temperature Bolt
16	2N-2766 Locknut
4	121-5736 Gasket

Table 3

357-2151 Turbocharger Gp S/N:(R1S and WF5)
Qty	Part
16	2N-2765 High Temperature Bolt
16	2N-2766 Locknut
4	121-5736 Gasket

Table 4

371-9531 Proximity Sensor Gp S/N:(R1S and WF5)
Qty	Part
2	371-9531 Proximity Sensor Gp

Table 5

394-3670 Cylinder Block Cover Gp S/N:(R1S and WF5)
Qty	Part
4	0S-1588 Bolt
30	1A-2029 Bolt
6	1C-2251 Bolt
5	2W-0752 Gasket
6	5L-5840 Washer
40	5M-2894 Hard Washer
6	277-5833 Seal
4	349-6052 Camshaft Cover
2	374-1513 Camshaft Cover

Table 6

394-3671 Air Lines Gp S/N:(R1S and WF5)
Qty	Part
8	2K-4973 Locknut
8	5G-4313 Spacer
4	5P-0600 Hose Clamp
4	5P-3860 Hose Clamp
4	5P-4869 Hose Clamp
4	5S-0003 Nut
2	7E-8224 Reducer Hose
4	7M-1599 Taperlock Stud
4	8N-5254 Reducer Hose
4	9M-1974 Hard Washer
8	9X-6458 Hard Washer
4	197-9732 U-Bolt
1	394-0406 Tube As
1	394-0407 Tube As

Table 7

394-3677 Aftercooler Water Lines Gp S/N:(R1S and WF5)
Qty	Parts
8	0L-1351 Bolt
9	0S-1571 Bolt
1	0S-1590 Bolt
2	0S-1594 Bolt
4	0S-1621 Bolt
4	1A-2029 Bolt
2	3B-1915 Bolt
29	5M-2894 Hard Washer
4	5P-8245 Hard Washer
6	6V-1867 Clip
6	6V-1868 Clip
4	8T-1919 O-Ring Seal
14	9S-8752 Full Nut
10	9X-6458 Hard Washer
8	153-9481 Clamp As
4	153-9963 Ring
6	193-2120 Grommet
2	261-7951 Tube Joint
1	272-1777 Hard Washer
4	272-8176 Clamp
1	357-5400 Bracket As
2	394-3669 Bracket
1	394-3673 Tube
1	394-3674 Tube As
1	394-3675 Tube
1	394-3676 Tube

Table 8

395-2974 Air Shutoff Gp S/N:(R1S and WF5)
Qty	Part
2	2A-4639 Bolt
5	4J-5477 O-Ring Seal
1	6V-8641 Connector
1	6V-9842 Swivel Tee
2	7X-5331 Elbow
2	145-5181 Spacer
1	214-7568 O-Ring Seal
4	388-2134 Bracket
1	395-2972 Tube As
1	395-2973 Tube As

Table 9

396-9740 Engine Wiring Gp S/N:(R1S and WF5)
Qty	Part
1	0L-1143 Bolt
2	0S-0509 Bolt
14	0S-1571 Bolt
2	0S-1594 Bolt
10	1A-2029 Bolt
2	3A-3692 Clip
3	4P-7429 Clip
25	4P-7581 Clip
32	4P-8134 Clip
28	5M-2894 Hard Washer
12	5N-2126 Connector
2	6V-9028 O-Ring Seal
2	6V-9330 Elbow
1	6W-6672 Spacer
71	7K-1181 Cable Strap
14	9C-5344 Spacer
1	9X-0262 Adapter
3	126-1774 Connector Cover
5	132-5789 Clip
6	195-2431 Detonation Sensor Gp
1	211-6807 Connector Cover
7	214-7566 O-Ring Seal
2	214-7568 O-Ring Seal
8	228-7100 O-Ring Seal
1	228-7101 O-Ring Seal
3	238-5080 O-Ring Seal
3	256-6453 Temperature Sensor
2	261-6847 Adapter
2	261-6848 Exhaust Temperature Sensor Gp
2	273-5041 Speed Sensor Gp
1	305-6873 Pressure Sensor Gp
2	318-1181 Speed Sensor Gp
4	320-3060 Pressure Sensor
1	320-3061 Pressure Sensor
4	320-3063 Pressure Sensor
1	330-9739 Adapter
2	335-3999 Connector
5	353-5439 Connector
1	353-5440 Adapter
3	353-5441 Elbow Adapter
12	383-2990 Temperature Sensor Gp
1	396-9743 Engine Harness As
1	447-0902 Sensor Harness As

Table 10

416-5258 Engine Oil Filler Gp S/N:(R1S and WF5)
Qty	Part
4	1A-9579 Bolt
1	2B-2695 Bolt
1	4P-9226 Bracket
5	9M-1974 Hard Washer
1	9N-0869 Hard Washer
1	031-4155 Locknut
1	101-4199 Cover As
1	262-6104 Engine Oil Filler Cap As
1	272-0760 Valve Cover Seal

Table 11

417-6750 Jacket Water Heater Lines Gp
Qty	Part
3	0S-1571 Bolt
3	0S-1588 Bolt
5	0S-1619 Bolt
2	0T-0055 Bolt
3	2A-4639 Bolt
2	1W-8129 Support
3	2M-7077 Spacer
3	3B-6555 Elbow
3	4P-0916 Spacer
5	5K-9090 O-Ring Seal
12	5M-2894 Hard Washer
1	5P-0492 Adapter
1	6V-9649 Elbow
3	7J-0728 Clip
3	7J-0729 Clip
1	7M-8485 O-Ring Seal
3	8C-6875 Connector
10	9S-8752 Full Nut
10	9X-6458 Hard Washer
2	196-9420 Ball Valve
1	417-6743 Hose As
1	417-6744 Hose As
1	417-6745 Bracket
1	417-6746 Hose As
1	417-6747 Tube As
1	417-6748 Tube As
3	417-6749 Bracket
1	426-3515 Bracket

Table 12

419-1886 Electronic Control and Mounting Gp
Qty	Part
7	1A-2029 Bolt
4	1B-9575 Bolt
4	1D-4540 Bolt
4	2V-4387 Spacer
7	5M-2894 Hard Washer
8	6I-1418 Spacer
1	8N-9885 Cover Gasket
8	8T-9655 Isolation Mount
2	9M-1974 Hard Washer
8	9N-0869 Hard Washer
1	110-2760 Bracket
8	155-0576 Isolation Mount
1	353-8089 Electronic Control Module
1	417-6011 Electronic Control Module

Table 13

419-5447 Air Lines Gp
Qty	Part
48	1T-0720 Bolt
24	2A-4639 Bolt
12	4S-5898 O-Ring Seal
72	5M-2894 Hard Washer
12	6V-5101 O-Ring Seal
12	7C-8199 Flange
24	153-8455 Manifold Gasket
10	370-7335 Air Inlet Elbow
2	370-7336 Air Inlet Elbow
12	371-5211 Flame Arrestor As

Table 14

420-4639 Water Lines Gp
Qty	Part
1	0S-1588 Bolt
2	0S-1594 Bolt
3	1A-5964 Bolt
1	1L-4031 Service Tee
1	2A-4639 Bolt
2	4F-7391 O-Ring Seal
3	4J-5477 O-Ring Seal
4	4L-6454 Bolt
10	5M-2894 Hard Washer
5	5P-9297 Clip
1	6B-1628 Reducing Bushing
1	6V-1581 Clip
1	6V-1582 Clip
1	6V-8397 O-Ring Seal
1	7W-9094 Spacer
2	7X-5331 Elbow
1	8C-6867 Connector
1	8C-6870 Connector
4	8T-4896 Hard Washer
1	8T-6761 Pipe Plug
7	9S-8752 Full Nut
4	9X-6458 Hard Washer
1	196-9420 Ball Valve
2	265-5254 Plate
1	318-2484 Orifice
1	318-2485 Gasket
1	397-9377 Bracket
1	416-6524 Bracket
1	420-4637 Hose As
1	420-4638 Hose As

Table 15

421-8500 Air Lines Gp S/N:(R1A, R2A, RTX, and WF3)
Qty	Part
8	2K-4973 Locknut
8	5G-4313 Spacer
4	5P-0600 Hose Clamp
4	5P-3860 Hose Clamp
4	5P-4869 Hose Clamp
4	5S-0003 Nut
2	7E-8224 Reducer Hose
4	7M-1599 Taperlock Stud
4	8N-5254 Reducer Hose
4	9M-1974 Hard Washer
8	9X-6458 Hard Washer
4	197-9732 U-Bolt
1	394-0406 Tube As
1	394-0407 Tube As

Table 16

424-5885 Cylinder Block Cover Gp S/N:(R1A, R2A, RTX, and WF3)
Qty	Part
30	1A-2029 Bolt
6	1C-2251 Bolt
6	2W-0752 Gasket
6	5L-5840 Washer
36	5M-2894 Hard Washer
6	277-5833 Seal
3	349-6052 Camshaft Cover
3	374-1513 Camshaft Cover

Table 17

424-7719 Electronic Actuator Gp
Qty	Part
1	424-7719 Electronic Actuator Gp

Table 18

426-0075 Cylinder Block Cover Gp S/N:(R2A and RTX)
Qty	Part
30	1A-2029 Bolt
6	1C-2251 Bolt
6	2W-0752 Gasket
6	5L-5840 Washer
36	5M-2894 Hard Washer
6	277-5833 Seal
2	349-6052 Camshaft Cover
3	374-1513 Camshaft Cover
1	426-0074 Camshaft Cover

Table 19

426-3518 Fumes Disposal Gp
Qty	Part
1	0S-1591 Bolt
2	0S-1594 Bolt
2	6V-3378 Clip
3	9S-8752 Full Nut
6	9X-6458 Hard Washer
2	426-3526 Tube
1	426-3602 Bracket As

Table 20

435-0428 Engine Wiring Gp S/N:(R2A and RTX)
Qty	Part
1	0L-1143 Bolt
2	0S-0509 Bolt
14	0S-1571 Bolt
2	0S-1594 Bolt
10	1A-2029 Bolt
2	3A-3692 Clip
3	4P-7429 Clip
25	4P-7581 Clip
32	4P-8134 Clip
28	5M-2894 Hard Washer
12	5N-2126 Connector
2	6V-9028 O-Ring Seal
2	6V-9330 Elbow
1	6W-6672 Spacer
71	7K-1181 Cable Strap
14	9C-5344 Spacer
2	9M-1974 Hard Washer
1	9X-0262 Adapter
5	132-5789 Clip
6	195-2431 Detonation Sensor Gp
6	214-7566 O-Ring Seal
2	214-7568 O-Ring Seal
8	228-7100 O-Ring Seal
1	228-7101 O-Ring Seal
3	238-5080 O-Ring Seal
3	256-6453 Temperature Sensor
2	261-6847 Adapter
2	261-6848 Exhaust Temperature Sensor Gp
2	273-5041 Speed Sensor Gp
1	305-6873 Pressure Sensor Gp
2	318-1181 Speed Sensor Gp
4	320-3060 Pressure Sensor
1	320-3061 Pressure Sensor
4	320-3063 Pressure Sensor
1	330-9739 Adapter
5	353-5439 Connector
2	353-5440 Adapter
3	353-5441 Elbow Adapter
2	371-9531 Proximity Sensor Gp
12	383-2990 Temperature Sensor Gp
1	435-0427 Engine Harness As

Table 21

435-0900 Gas Pressure Regulator Gp
Qty	Part
10	0S-1585 Bolt
2	0S-1587 Bolt
2	0S-1588 Bolt
4	0S-1590 Bolt
4	0S-1591 Bolt
1	1A-2029 Bolt
4	1A-5183 Bolt
1	1A-5822 Bolt
4	1A-9579 Bolt
1	1B-7182 Bolt
10	1F-7958 Full Nut
8	2A-4639 Bolt
6	3B-1915 Bolt
5	3E-4352 Hard Washer
8	4K-0367 Full Nut
1	4P-7233 Grommet
24	5M-2894 Hard Washer
8	5P-8245 Hard Washer
16	5P-8247 Hard Washer
2	6K-5290 Clip
2	6K-5291 Clip
2	6V-8398 O-Ring Seal
23	7D-1649 Hard Washer
6	8S-9092 Bolt
1	8T-1887 Clip
1	8T-1888 Clip
2	8W-8909 Sleeve
1	9S-1366 Bolt
17	9S-8752 Full Nut
22	9X-6458 Hard Washer
6	9X-8873 Bolt
2	9X-8882 Bolt
1	105-8180 Gasket
1	122-8905 Elbow
1	211-5237 Connector
2	293-4056 Gasket
1	293-8396 Core
1	397-8632 Bracket
1	419-0893 Solenoid Valve Gp
2	420-8789 Gasket
3	425-3549 Gasket
1	435-0888 Gas Pressure Regulator Gp
1	436-0490 Bracket As
1	436-0492 Tube As
1	436-0493 Tube As
1	436-0494 Tube As
1	436-0495 Bracket
2	436-0496 Bracket
1	436-0497 Tube As
1	442-2010 Bracket
1	460-0915 Bracket
1	460-7069 Bracket
1	469-8876 Bracket As
1	469-8878 Flange

Table 22

435-3147 Solenoid Harness As S/N:R1A and WF3
Qty	Part
1	435-3147 Solenoid Harness As

Table 23

435-4642 Fuel Lines Gp S/N:(R1S and WF5)
Qty	Part
4	2A-4639 Bolt
2	3B-1915 Bolt
12	5M-2894 Hard Washer
2	6V-4368 O-Ring Seal
2	8C-5098 Tube Joint
6	9S-8752 Full Nut
4	9X-6458 Hard Washer
1	105-8180 Gasket
2	255-6464 Joint
2	381-3558 Tube As
1	394-2431 Tube As
1	436-0498 Tube As
1	436-0499 Tube

Table 24

435-4645 Fuel Lines Gp S/N:(R1A, R2A, RTX, and WF3)
Qty	Part
1	0S-1591 Bolt
1	0S-1621 Bolt
2	0T-0055 Bolt
4	2A-4639 Bolt
5	3B-1915 Bolt
16	5M-2894 Hard Washer
1	5P-8245 Hard Washer
2	6V-1581 Clip
2	6V-1582 Clip
2	6V-4368 O-Ring Seal
1	7N-6986 Support
1	8C-5098 Tube Joint
10	9S-8752 Full Nut
4	9X-6458 Hard Washer
1	105-8180 Gasket
2	255-6464 Joint
2	381-3558 Tube As
1	421-9082 Bracket
1	421-9083 Bracket
1	436-0503 Tube As
1	436-0504 Tube As

Table 25

437-2782 Engine Parts Kit
Qty	Part
8	5K-5552 Locking Bolt
2	5P-0600 Hose Clamp
2	5P-4869 Hose Clamp
8	6V-0717 Self-Locking Bolt
2	7E-8224 Reducer Hose
16	9X-6458 Hard Washer
2	425-1743 Plate
2	425-1752 Plate

Table 26

437-2783 Engine Parts Kit
Qty	Part
21	0S-1571 Bolt
2	0S-1587 Bolt
13	0S-1588 Bolt
18	0S-1591 Bolt
2	1F-7958 Full Nut
8	2A-4639 Bolt
5	3B-1915 Bolt
2	6V-1581 Clip
2	6V-1582 Clip
4	7D-1649 Hard Washer
2	7K-1401 Clip
2	7K-1402 Bracket
78	8M-9124 Washer
29	9S-8752 Full Nut
16	9X-6458 Hard Washer
2	132-5789 Clip
1	363-8104 Bracket
1	363-8106 Bracket
1	364-1620 Bracket As
1	364-1621 Bracket
1	364-1622 Bracket
1	364-1628 Bracket
2	393-9373 Bracket
1	399-6205 Bracket
2	422-8942 Bracket
1	422-8943 Bracket

Table 27

437-2784 Engine Parts Kit
Qty	Part
35	0S-1571 Bolt
2	0S-1587 Bolt
7	0S-1588 Bolt
18	0S-1591 Bolt
24	1D-4539 Bolt
2	1F-7958 Full Nut
8	2A-4639 Bolt
5	3B-1915 Bolt
24	5S-0003 Nut
2	6V-1581 Clip
2	6V-1582 Clip
4	7D-1649 Hard Washer
2	7K-1401 Clip
2	7K-1402 Bracket
100	8M-9124 Washer
8	8T-4990 Hose Clamp
48	9M-1974 Hard Washer
43	9S-8752 Full Nut
16	9X-6458 Hard Washer
2	113-1323 Gasket
2	132-5789 Clip
2	251-6235 Hose
1	363-8104 Bracket
1	363-8106 Bracket
1	364-1620 Bracket As
1	364-1621 Bracket
1	364-1622 Bracket
1	364-1628 Bracket
2	371-0346 Bracket
2	393-9373 Bracket
1	399-6205 Bracket
2	422-8942 Bracket
1	422-8943 Bracket

Table 28

437-4401 Catalytic Converter Gp
Qty	Part
1	437-4401 Catalytic Converter Gp

Table 29

440-4302 Engine Parts Kit
Qty	Part
32	2K-4973 Locknut
4	5L-3773 Exhaust Elbow Gasket
32	8T-2501 Bolt
64	8T-4896 Hard Washer
2	214-6045 Bellows As

Table 30

440-4303 Engine Parts Kit
Qty	Part
2	0S-1588 Bolt
2	0S-1621 Bolt
2	1L-8181 Clip
1	3B-1915 Bolt
3	5M-2894 Hard Washer
5	5P-7854 Clip
2	5P-8245 Hard Washer
1	8M-7065 Gasket
1	8T-6762 Pipe Plug
1	9M-0397 Adapter
1	9S-7296 Flared Elbow
1	030-8307 Connector
1	164-0228 Elbow
1	438-5670 Hose As

Table 31

441-5248 Exhaust Shield Gp
Qty	Part
1	441-6637 Exhaust Shield
1	441-6638 Exhaust Shield

Table 32

441-5948 Film (Emission Certified Engines)
Qty	Part
1	449-0090 Film
1	444-0543 Film

Table 33

443-1074 Film (Non-Emission Certified Engines)
Qty	Part
1	443-5866 Film
1	444-0543 Film

Table 34

445-9283 Engine Parts Kit
Qty	Part
32	2K-4973 Locknut
4	5L-3773 Exhaust Elbow Gasket
32	8T-2501 Bolt
64	8T-4896 Hard Washer
2	438-2037 Bellows As

Table 35

Software
Qty	Part
1	433-6418 Engine Ratings Electronic Software Gp (ISM)
1	455-9202 Engine Ratings Electronic Software Gp (ECM) 1864 kW (2500 hp) 7 percent Torque Rise ATAAC
1	455-9537 Engine Ratings Electronic Software Gp (ECM) 1678 kW (2250 hp) 1.6 percent Torque Rise ATAAC
1	455-9538 Engine Ratings Electronic Software Gp (ECM) 1678 kW (2250 hp) 7 percent Torque Rise ATAAC
1	455-9198 Engine Ratings Electronic Software Gp (ECM) 1864 kW (2500 hp) 7 percent Torque Rise SCAC
1	456-0314 Engine Ratings Electronic Software Gp (ECM) 1678 kW (2250 hp) 7 percent Torque Rise SCAC
1	456-0315 Engine Ratings Electronic Software Gp (ECM) 1678 kW (2250 hp) 1.6 percent Torque Rise SCAC

Copying the Product Status Report and the Injector Trim Codes

Copying the Product Status Report

1. Connect Cat Electronic Technician (ET) 2012C or newer to the Electronic Control Module (ECM).

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Illustration 1	g03285257

2. Click on the "Information" tab and select the "Product Status Report", or click the "Product Status Report" button.

   The Product Status Report is for reference only.

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Illustration 2	g03285338

3. Click on the "Create Report" button.

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Illustration 3	g03285341

4. Click on the "Continue" button.

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Illustration 4	g03285343

5. Wait for the report to download.

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Illustration 5	g03285345

6. Click on the "Save As" button.

7. Save the file in a convenient location.

8. Click on the "Close Report" button.

Copying the Injector Trims Codes

Illustration 6	g03285599

1. Click on the "Service" tab.

2. Select "Calibrations".

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Illustration 7	g03285600

3. Click on "Injector Codes Calibration".

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Illustration 8	g03285601

4. Click on the "File" tab.

5. Select "Print To File".

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Illustration 9	g03285603

6. Change the file type to HTML.

7. Save the file in a convenient location.

8. Disconnect Cat ET from the ECM.

Verification of the Flame Arrestors

Illustration 10	g03612336
Typical engine with flame arrestors (1) 153-8455 Manifold Gasket (2) 371-5211 Flame Arrestor As

Illustration 11	g03646122
Typical engine without flame arrestors (3) 7N-5080 Manifold Gaskets (Paper Gaskets)

1. Verify if the flame arrestors are installed from the factory.

   If the flame arrestors are installed in the ATAAC engines from the factory, proceed to Steps 20 through 22 of ""Installing the 419-5447 Air Lines on a S/N:R1A, ; S/N:R2A, ; S/N:RTX, or ; S/N:WF3 Engine" ".

   If the flame arrestors are installed in the SCAC engines from the factory, proceed to Steps 23 through 25 of ""Installing the 419-5447 Air Lines on a S/N:R1S or ; S/N:WF5 Engine" ".

   Note: The 153-8455 Manifold Gaskets (Metal Gaskets) are used on engines with the flame arrestors.

   If the flame arrestors are not installed in the ATAAC engines from the factory, proceed to Step 1 of ""Installing the 419-5447 Air Lines on a S/N:R1A, ; S/N:R2A, ; S/N:RTX, or ; S/N:WF3 Engine" ".

   If the flame arrestors are not installed in the SCAC engines from the factory, proceed to Step 1 of ""Installing the 419-5447 Air Lines on a S/N:R1S or ; S/N:WF5 Engine" ".

   Note: The 7N-5080 Manifold Gaskets (Paper Gaskets) are used on engines without the flame arrestors.

Installing the 419-5447 Air Lines

Installing the 419-5447 Air Lines on a S/N:R1A, ; S/N:R2A, ; S/N:RTX, or ; S/N:WF3 Engine

Illustration 12	g03141417

1. Drain coolant from cooling system into a suitable container for storage or for disposal. Set the following components and associated hardware aside for reuse:
   • Air cleaners

   • Air inlet pipes

   • Air inlet manifold assembly

   • Air compressor pipes

   • Air shutoff valve oil line

   • Compressor pipes

   • Exhaust crossover manifold

   • Exhaust Elbows

   • Turbochargers

   • Turbocharger oil supply and drain lines

   • Turbocharger water lines

2. Remove the compressor pipes.

3. Remove the inlet air pipes from the turbochargers.

4. Remove the ataac pipe from the ataac to the air shutoff valve.

5. Remove the coolant lines from the turbochargers.

6. Remove the oil supply lines and oil drain lines from the turbochargers.

7. Remove the exhaust bellows from the turbochargers.

8. Using a suitable lifting device, remove the turbochargers from the exhaust manifolds. The turbochargers weigh approximately 34 kg (75 lb) apiece.

9. Remove the exhaust elbows from the exhaust manifold.

10. Remove the exhaust crossover manifold from the exhaust manifolds.

11. Disconnect the air shutoff oil supply line.

12. Disconnect the elbow flanges from the air inlet manifold and pry the elbow flanges away from the air inlet manifold.

13. Using a suitable lifting device, remove the air inlet manifold assembly. The air inlet manifold assembly weighs approximately 110 kg (243 lb).

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Illustration 13	g03141419
(1) 4S-5898 O-Ring Seal (2) 7C-8199 Flange (3) 6V-5101 O-Ring Seal (4) 370-7336 Air Inlet Elbow (5) 2A-4639 Bolt (6) 5M-2894 Hard Washer (7) 370-7335 Air Inlet Elbow (8) 1T-0720 Bolt (9) 153-8455 Manifold Gasket (10) 371-5211 Flame Arrestor As

14. Remove the 7C-7909 Elbows , 7C-7910 Elbow per each head.

15. Install one flame arrestor (10) with cylindrical side toward the air inlet elbow (4) and air inlet elbow (7). Use two gaskets (9), four bolts (8), and four washers (6) per each head.

16. Install one O-ring (3) per elbow onto elbows (4) and (7) .

Note: Lubricate the bore of flange (2) lightly with glycerin.

17. Install flange (2) onto elbows (4) and (7). Make sure to push the flanges back against the stops.

Note: Lubricate the O-ring groove of flange (2) lightly with glycerin to hold O-ring in place.

18. Install one O-ring (1) into flange (2) .

19. Install two bolts (5) and two washers (6) into the bolt holes of flange (2). The thread end of the bolts will be flush with the flanges.

20. Remove the pipe plug from the exhaust outlet port per cylinder head.

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Illustration 14	g03141437
The following parts are from the 396-9740 Engine Wiring Gp . (11) 5N-2126 Connector (12) 243-5752 Temperature Sensor Gp

21. Install connector (11) into exhaust outlet port of each cylinder head.

22. Install temperature sensor gp (12) into connector (11) .

    Tighten the temperature sensor ... 12 ± 3 N·m (9 ± 2 lb ft)

23. Using a suitable lifting device, install the air inlet manifold assembly. The air inlet manifold assembly weighs approximately 110 kg (243 lb).

24. Attach the air inlet elbow flanges to the air inlet manifold.

25. Connect the air shutoff oil supply line.

26. Install the exhaust crossover manifold onto the exhaust manifolds use the original hardware.

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Illustration 15	g03421285
(6) 5M-2894 Hard Washer (13) 6V-1943 High Temperature Bolt

27. Attach the exhaust elbows to the exhaust manifolds with four bolts (13) and four washers (6) per exhaust elbow.

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Illustration 16	g03371598
(14) 121-5736 Gasket (15) 2N-2765 High Temperature Bolt (16) 2N-2766 Locknut

28. Install the turbochargers onto the exhaust manifolds use one gasket (14), four bolts (15), and four nuts (16) per turbocharger.

29. Attach the exhaust bellows to the turbochargers use the original hardware.

30. Install the oil supply lines use the original hardware per turbocharger.

    Note: The oil drain lines are installed after the installation of the 424-5885 Cylinder Block Cover Gp or the 426-0075 Cylinder Block Cover Gp .

31. Install the turbochargers water lines.

32. Attach the ataac pipe to the ataac and the air shutoff valve.

Installing the 419-5447 Air Lines on a S/N:R1S or ; S/N:WF5 Engine

Illustration 17	g03141422

1. Drain coolant from cooling system into a suitable container for storage or for disposal. Set the following components and associated hardware aside for reuse:
   • Air cleaners

   • Air inlet pipes

   • Air shutoff valves

   • Aftercooler assembly

   • Compressor pipes

   • Exhaust crossover manifold

   • Exhaust Elbows

   • Turbochargers

   • Turbocharger oil supply and drain lines

2. Remove the compressor pipes from the aftercooler and the turbochargers.

3. Disconnect the water lines from the aftercooler core.

4. Remove the exhaust crossover manifold from the exhaust manifolds.

5. Remove the oil supply lines and oil drain lines from the turbochargers.

6. Remove the exhaust bellows from the turbochargers.

7. Remove the exhaust elbows from the exhaust manifolds.

8. Using a suitable lifting device, remove the turbochargers from the exhaust manifolds. The turbochargers weigh approximately 34 kg (75 lb) apiece.

9. Disconnect the elbow flanges from the air inlet manifold and pry the elbow flanges away from the air inlet manifold.

10. Using a suitable lifting device, remove the aftercooler assembly. The aftercooler assembly weighs approximately 300 kg (661 lb).

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Illustration 18	g03141424
(1) 4S-5898 O-Ring Seal (2) 7C-8199 Flange (3) 6V-5101 O-Ring Seal (4) 370-7336 Air Inlet Elbow (5) 2A-4639 Bolt (6) 5M-2894 Hard Washer (7) 370-7335 Air Inlet Elbow (8) 1T-0720 Bolt (9) 153-8455 Manifold Gasket (10) 371-5211 Flame Arrestor As

11. Remove the 7C-7909 Elbows , 7C-7910 Elbow per each head.

12. Install one flame arrestor (10) with cylindrical side toward the air inlet elbow (4) and air inlet elbow (7). Use two gaskets (9), four bolts (8), and four washers (6) per each head.

13. Install one O-ring (3) per elbow onto elbows (4) and (7) .

Note: Lubricate the bore of flange (2) lightly with glycerin.

14. Install flange (2) onto elbows (4) and (7). Make sure to push the flanges back against the stops.

Note: Lubricate the O-ring groove of flange (2) lightly with glycerin to hold O-ring in place.

15. Install one O-ring (1) into flange (2) .

16. Install two bolts (5) and two washers (6) into the bolt holes of flange (2). The thread end of the bolts will be flush with the flanges.

17. Remove the pipe plug from the exhaust outlet port per cylinder head.

18. Install one flame arrestor (10) with cylindrical side toward the air inlet elbow (4) and air inlet elbow (7). Use two gaskets (9), four bolts (8), and four washers (6) per each head.

19. Install one O-ring (3) per elbow onto elbows (4) and (7) .

Note: Lubricate the bore of flange (2) lightly with glycerin.

20. Install flange (2) onto elbows (4) and (7). Make sure to push the flanges back against the stops.

Note: Lubricate the O-ring groove of flange (2) lightly with glycerin to hold O-ring in place.

21. Install one O-ring (1) into flange (2) .

22. Install two bolts (5) and two washers (6) into the bolt holes of flange (2). The thread end of the bolts will be flush with the flanges.

23. Remove the pipe plug from the exhaust outlet port per cylinder head.

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Illustration 19	g03141457
The following parts are from the 396-9740 Engine Wiring Gp . (11) 5N-2126 Connector (12) 243-5752 Temperature Sensor Gp

24. Install connector (11) into exhaust outlet port of each cylinder head.

25. Install temperature sensor gp (12) into connector (11) .

    Tighten the temperature sensor ... 12 ± 3 N·m (9 ± 2 lb ft)

26. Using a suitable lifting device, install the aftercooler assembly. The aftercooler assembly weighs approximately 300 kg (661 lb).

27. Attach the air inlet elbow flanges to the air inlet manifold use the original hardware.

28. Install the exhaust crossover manifold onto the exhaust manifolds use the original hardware.

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Illustration 20	g03421285
(6) 5M-2894 Hard Washer (13) 6V-1943 High Temperature Bolt

29. Attach the exhaust elbows to the exhaust manifolds with four bolts (13) and four washers (6) per exhaust elbow.

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Illustration 21	g03371610
(14) 121-5736 Gasket (15) 2N-2765 High Temperature Bolt (16) 2N-2766 Locknut

30. Install the turbochargers onto the exhaust manifolds use one gasket (14), four bolts (15), and four nuts (16) per turbocharger.

31. Attach the exhaust bellows to the turbochargers use the original hardware.

32. Install the oil supply lines and the original hardware per turbocharger.

    Note: The oil drain lines are installed after the installation of the 394-3670 Cylinder Block Cover Gp .

33. Attach the compressor pipes to the aftercooler and the turbochargers use the original hardware.

Installing the Cam Covers

Installing the 394-3670 Cylinder Block Cover Gp on a S/N:R1S or ; S/N:WF5 Engine

Illustration 22	g03070899
(1) 2W-0752 Gasket (2) 1C-2251 Bolt (3) 5M-2894 Hard Washer (4) 374-1513 Camshaft Cover (5) 5L-5840 Washer (6) 1A-2029 Bolt (7) 277-5833 Seal (8) 349-6052 Camshaft Cover

1. Install seal (7) into camshaft covers (4) and (8) .

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Illustration 23	g03151201
Typical left-side engine view (4) 374-1513 Camshaft Cover (8) 349-6052 Camshaft Cover

Note: Washer (5) is installed under washer (3) on bolt (2) .

2. Remove the 8N-9992 Camshaft Cover and the 8N-9993 Camshaft Cover from cylinders 2, 6, and 10.

3. Install camshaft cover (4) onto cylinder 2. Use one bolt (2), five bolts (6), one washer (5), and six washers (3) .

4. Install camshaft cover (8) onto cylinders 6 and 10. Use one bolt (2), five bolts (6), one washer (5), and six washers (3) per cover.

5. Remove the 117-0066 Mounting Bracket from the 8N-9993 Camshaft Cover .

6. Attach the 117-0066 Mounting Bracket onto camshaft cover (4) of cylinder 2 with one gasket (1) and the original hardware.

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Illustration 24	g03151203
Typical right-side engine view (4) 374-1513 Camshaft Cover (8) 349-6052 Camshaft Cover

Note: Washer (5) is installed under washer (3) on bolt (2) .

7. Remove the 8N-9992 Camshaft Cover and the 8N-9993 Camshaft Cover from cylinders 3, 7, and 11.

8. Install camshaft cover (8) onto cylinders 3 and 11. Use one bolt (2), five bolts (6), one washer (5), and six washers (3) per cover.

9. Install camshaft cover (4) onto cylinder 7. Use one bolt (2), five bolts (6), one washer (5), and six washers (3) .

10. Remove the 7N-5094 Drain Elbow from the 8N-9993 Camshaft Cover .

11. Install the 7N-5094 Drain Elbow onto camshaft cover (4) of cylinder 7 use one gasket (1) and the original hardware.

Installing the 424-5885 Cylinder Block Cover Gp on a S/N:R1A, ; S/N:R2A, ; S/N:RTX, or ; S/N:WF3 Engine

Illustration 25	g03070899
(1) 2W-0752 Gasket (2) 1C-2251 Bolt (3) 5M-2894 Hard Washer (4) 374-1513 Camshaft Cover (5) 5L-5840 Washer (6) 1A-2029 Bolt (7) 277-5833 Seal (8) 349-6052 Camshaft Cover

1. Install seal (7) into camshaft covers (4) and (8) .

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Illustration 26	g03193738
Typical left-side engine view (4) 374-1513 Camshaft Cover (8) 349-6052 Camshaft Cover

Note: Washer (5) is installed under washer (3) on bolt (2) .

2. Remove the 8N-9992 Camshaft Cover and the 8N-9993 Camshaft Cover from cylinders 2, 6, and 10.

3. Install seal (7) into camshaft covers (4) and (8) .

4. Install camshaft cover (4) onto cylinders 2 and 10. Use one bolt (2), five bolts (6), one washer (5), and six washers (3) per cover.

5. Install camshaft cover (8) onto cylinder 6 use one bolt (2), five bolts (6), one washer (5), and six washers (3) .

6. Remove the 117-0066 Mounting Bracket from the 8N-9993 Camshaft Cover .

7. Install the 117-0066 Mounting Bracket onto camshaft cover (4) of cylinder 2 use one gasket (1) and the original hardware.

8. Remove the 7N-1875 Engine Oil Filler Gp from the 8N-9993 Camshaft Cover .

9. Install the 7N-1875 Engine Oil Filler Gp onto camshaft cover (4) of cylinder 10 use gasket (1) and the original hardware.

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Illustration 27	g03151203
Typical right-side engine view (4) 374-1513 Camshaft Cover (8) 349-6052 Camshaft Cover

Note: Washer (4) is installed under washer (5) on bolt (2) .

10. Remove the 8N-9992 Camshaft Cover and the 8N-9993 Camshaft Cover from cylinders 3, 7, and 11.

11. Install camshaft cover (8) onto cylinders 3 and 11. Use five bolts (1), one bolt (2), one washer (3), and six washers (4) per cover.

12. Install camshaft cover (4) onto cylinder 7 use five bolts (1), one bolt (2), one washer (3), and six washers (4) .

13. Remove the 7N-5094 Drain Elbow from the 8N-9993 Camshaft Cover .

14. Install the 7N-5094 Drain Elbow onto camshaft cover (4) of cylinder 7 use one gasket (1) and the original hardware.

Installing the 426-0075 Cylinder Block Cover Gp on a S/N:R2A or ; S/N:RTX Engine

Note: This camshaft cover group is used on engines with an air shut-off. The oil from the air shut-off drains back into the camshaft cover.

Illustration 28	g03375031
(1) 2W-0752 Gasket (2) 1C-2251 Bolt (3) 5M-2894 Hard Washer (4) 374-1513 Camshaft Cover (5) 5L-5840 Washer (6) 1A-2029 Bolt (7) 277-5833 Seal (8) 349-6052 Camshaft Cover (9) 426-0074 Camshaft Cover

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Illustration 29	g03374987
Typical left-side engine view (4) 374-1513 Camshaft Cover (8) 349-6052 Camshaft Cover

Note: Washer (5) is installed under washer (3) on bolt (2) .

1. Remove the 8N-9992 Camshaft Cover and the 8N-9993 Camshaft Cover from cylinders 2, 6, and 10.

2. Install seal (7) into camshaft covers (4), (8), and (9) .

3. Install camshaft cover (4) onto cylinders 2 and 10. Use one bolt (2), five bolts (6), one washer (5), and six washers (3) per cover.

4. Install camshaft cover (8) onto cylinder 6 use one bolt (2), five bolts (6), one washer (5), and six washers (3) .

5. Remove the 117-0066 Mounting Bracket from the 8N-9993 Camshaft Cover .

6. Install the 117-0066 Mounting Bracket onto camshaft cover (4) of cylinder 2 use one gasket (1) and the original hardware.

7. Remove the 7N-1875 Engine Oil Filler Gp from the 8N-9993 Camshaft Cover .

8. Install the 7N-1875 Engine Oil Filler Gp onto camshaft cover (4) of cylinder 10 use gasket (1) and the original hardware.

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Illustration 30	g03374988
Typical right-side engine view (4) 374-1513 Camshaft Cover (8) 349-6052 Camshaft Cover (9) 426-0074 Camshaft Cover

Note: Washer (4) is installed under washer (5) on bolt (2) .

9. Remove the 8N-9992 Camshaft Cover , the 8N-9993 Camshaft Cover , and the 237-5656 Cover from cylinders 3, 7, and 11.

10. Install camshaft cover (8) onto cylinder 3 use five bolts (1), one bolt (2), one washer (3), and six washers (4) per cover.

11. Install camshaft cover (4) onto cylinder 7 use five bolts (1), one bolt (2), one washer (3), and six washers (4) .

12. Install camshaft cover (9) onto cylinder 11 use five bolts (1), one bolt (2), one washer (3), and six washers (4) .

13. Remove the 7N-5094 Drain Elbow from the 8N-9993 Camshaft Cover .

14. Install the 7N-5094 Drain Elbow onto camshaft cover (4) of cylinder 7 use one gasket (1) and the original hardware.

Installing the 416-5258 Engine Oil Filler Gp on a S/N:R1S or ; S/N:WF5 Engine

Illustration 31	g03193756
(1) 4P-9226 Bracket (2) 2B-2695 Bolt (3) 9M-1974 Hard Washer (4) 9N-0869 Hard Washer (5) 031-4155 Locknut (6) 262-6104 Engine Oil Filler Cap As

1. Attach cap assembly (6) to bracket (1) with one bolt (2), one washer (3), one washer (4), and one locknut (5) .

   Note: Washer (4) goes on top of the cable.

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Illustration 32	g03197576

2. Remove the bolt and washer from the fuel rail support bracket over the valve cover of cylinder four.

3. Attach the assembled parts to the fuel rail bracket use the original hardware.

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Illustration 33	g03193757
(7) 101-4199 Cover As (8) 272-0760 Valve Cover Seal

4. Install seal (8) into the valve cover (7) .

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Illustration 34	g03193759
(3) 9M-1974 Hard Washer (9) 1A-9579 Bolt

5. Remove the original valve cover from cylinder 4.

6. Install valve cover (7) onto the valve cover base use four bolts (9) and four washers (3) .

Installing the Engine Wiring Gp

Note: There are two different engine wiring groups, but the engine wiring groups are installed with the same sensors and hardware.

• 396-9740 Engine Wiring Gp

• 435-0428 Engine Wiring Gp

The 396-9740 Engine Wiring Gp is used on S/N:R1S and ; S/N:WF5 engines.

The 396-9740 Engine Wiring Gp , 435-3147 Solenoid Harness As , and the 447-0902 Sensor Harness As are used on S/N:R1A and ; S/N:WF3 engines.

The 435-0428 Engine Wiring Gp is used on S/N:R2A, ; S/N:RTX, and ; S/N:WF5 engines.

1. Remove the original wiring harness from the original mounting hardware.

   Note: Some of the original mounting hardware can be reused at your discretion.

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Illustration 35	g03241978
Typical left-hand side view of the engine. (1) 396-9743 Engine Harness As (2) 7K-1181 Cable Strap (3) 9C-5344 Spacer (4) 4P-8134 Clip (5) 0S-1571 Bolt (6) 5M-2894 Hard Washer

2. Install one spacer (3) and one clip (4) to the front bolt hole of each left-hand cylinder head. Use one bolt (5) and one washer (6) per cylinder head.

3. Install one spacer (3) and one clip (4) to the rear bolt hole of cylinder head 12 use one bolt (5) and one washer (6) .

4. Secure engine wiring harness (1) to clip (4). Use one cable strap (2) per clip.

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Illustration 36	g03247561
Typical left-hand rear view of the engine. (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (7) 4P-7429 Clip

5. Remove the bolts from the left-hand rear cam cover and flywheel housing. Refer to Illustration 36 for the correct bolts.

6. Attach one clip (7) to the flywheel housing use the original bolt.

7. Attach one clip (4) to the left-hand rear cam cover use the original bolt and washer.

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Illustration 37	g03244420
Typical left-hand front view of the engine. (1) 396-9743 Engine Harness As (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (8) 0S-0509 Bolt (9) 132-5789 Clip (10) 4P-7581 Clip

8. Install one clip (4) onto the left-hand side of the 111-0349 Module Bracket use one bolt (8) and one washer (6) .

9. Install one clip (9) onto the top of the 111-0349 Module Bracket use one bolt (8) and one washer (6) .

10. Install one clip (10) onto the right-hand side of the 111-0349 Module Bracket use one bolt (8) and one washer (6) .

11. Secure engine wiring harness (1) to clips (4), (9), and (10). Use one cable strap (2) per clip.

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Illustration 38	g03247579
Typical right-hand front view of the engine. (1) 396-9743 Engine Harness As (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (7) 4P-7429 Clip (8) 0S-0509 Bolt (9) 132-5789 Clip

12. Remove two bolts from the front housing. Refer to Illustration 38 for the correct bolts.

13. Attach two clips (7) to the front housing with the original bolts.

14. Attach one clip (4) to the top of the 110-2760 Bracket with one bolt (8) and one washer (6) .

15. Attach two clips (9) during the installation of the 353-8088 Electronic Control Module .

16. Secure the engine wiring harness to clips (4), (7), and (9). Use one cable strap (2) per clip.

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Illustration 39	g03241980
Typical right-hand side view of the engine. (1) 396-9743 Engine Harness As (2) 7K-1181 Cable Strap (3) 9C-5344 Spacer (4) 4P-8134 Clip (5) 0S-1571 Bolt (6) 5M-2894 Hard Washer

17. Install one spacer (3) and one clip (4) to the rear bolt hole of each right-hand cylinder head. Use one bolt (5) and one washer (6) per cylinder head.

18. Install one spacer (3) and one clip (4) to the front bolt hole of cylinder head 1 use one bolt (5) and one washer (6) .

19. Secure engine wiring harness (1) to clip (4). Use one cable strap (2) per clip.

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Illustration 40	g03241984
Typical left-hand front view of the engine. (1) 396-9743 Engine Harness As (11) 330-9739 Adapter (12) 214-7566 O-Ring Seal (13) 320-3061 Pressure Sensor (14) 228-7101 O-Ring Seal (15) 353-5439 Connector (16) 320-3063 Pressure Sensor (17) 228-7100 O-Ring Seal

20. Remove the adapter and pressure sensor from the inside port of the 111-0349 Module Bracket .

21. Install adapter (11) and one O-ring (12) into the inside port of the 111-0349 Module Bracket .

22. Install pressure sensor (13) and one O-ring into (14) adapter (11) .

    Tighten the pressure sensor ... 10 ± 2 N·m (7 ± 1 lb ft)

23. Remove the adapter and pressure sensor from the outside port of the 111-0349 Module Bracket .

24. Install connector (15) and one O-ring (12) into the outside port of the 111-0349 Module Bracket .

25. Install pressure sensor (16) and one O-ring (17) into connector (15) .

    Tighten the pressure sensor ... 10 ± 2 N·m (7 ± 1 lb ft)

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Illustration 41	g03156296
(1) 396-9743 Engine Harness As (18) 256-6453 Temperature Sensor (19) 238-5080 O-Ring Seal

26. Remove the jacket water temperature sensor from the 111-9375 Housing .

27. Install temperature sensor (18) and one O-ring (19) into the 111-9375 Housing .

    Tighten the temperature sensor ... 20 ± 3 N·m (15 ± 2 lb ft)

28. Remove the air inlet manifold temperature sensor from the 283-9599 Manifold .

29. Install temperature sensor (18) and one O-ring (19) into the 283-9599 Manifold .

    Tighten the temperature sensor ... 20 ± 3 N·m (15 ± 2 lb ft)

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Illustration 42	g03156318
(1) 396-9743 Engine Harness As (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (10) 4P-7581 Clip (20) 383-2990 Temperature Sensor Gp

30. Remove the original bolt and washer from the upper left corner of each valve cover.

31. Install one clip (10) onto upper left corner of the valve cover use the original hardware per each valve cover.

32. Remove the original bolt and washer from the lower left corner of the valve cover base.

33. Install one clip (4) onto lower left corner of the valve cover base use the original hardware per each valve cover base.

34. Secure temperature sensor gp (20) and wiring harness (1) to clips (7). Use one cable strap (2) per clip.

35. Secure engine wiring harness (1) to clips (8) use one cable strap (2) per clip.

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Illustration 43	g03156299
Typical left-hand side view of the engine. (1) 396-9743 Engine Harness As (2) 7K-1181 Cable Strap (6) 5M-2894 Hard Washer (10) 4P-7581 Clip (21) 195-2431 Detonation Sensor Gp (22) 1A-2029 Bolt

36. Attach detonation sensors (21) to the engine under the camshaft covers on cylinders 2, 6, and 10.

    Tighten the detonation sensors ... 15 ± 3 N·m (11 ± 2 lb ft)

37. Attach one clip (10) to the camshaft covers on cylinders 4, 8, and 12 with one bolt (22) and one washer (6) .

38. Secure engine wiring harness (1) and detonation sensors (21) to clips (10) use one cable strap (2) per clip.

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Illustration 44	g03156302
Typical right-hand side view of the engine. (1) 396-9743 Engine Harness As (2) 7K-1181 Cable Strap (6) 5M-2894 Hard Washer (10) 4P-7581 Clip (21) 1A-2029 Bolt (22) 195-2431 Detonation Sensor Gp

39. Attach detonation sensors (21) to the engine under the camshaft covers on cylinders 3, 7, and 11.

    Tighten the detonation sensors ... 15 ± 3 N·m (11 ± 2 lb ft)

40. Attach one clip (10) to the camshaft covers on cylinders 1, 5, and 9 use one bolt (22) and one washer (6) .

41. Secure engine wiring harness (1) and detonation sensors (21) to clips (10) use one cable strap (2) per clip.

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Illustration 45	g03156316
Typical left-hand side view of the engine. (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (10) 4P-7581 Clip (23) 261-6847 Adapter (24) 261-6848 Exhaust Temperature Sensor Gp

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Illustration 46	g03156329
Typical left-hand side view of the engine. (1) 396-9743 Engine Harness As (2) 7K-1181 Cable Strap (6) 5M-2894 Hard Washer (10) 4P-7581 Clip (24) 261-6848 Exhaust Temperature Sensor Gp (25) 0S-1594 Bolt (26) 3A-3692 Clip

42. Remove the adapter and exhaust temperature sensor gp from the 115-0554 Exhaust Manifold .

43. Install adapter (23) into the 115-0554 Exhaust Manifold .

44. Lubricate the exhaust temperature sensor gp (24) with Loctite Nickel Anti Seize.

45. Install exhaust temperature sensor gp (24) into adapter (23)

    Tighten the exhaust temperature sensor gp ... 45 ± 5 N·m (33 ± 4 lb ft)

46. Install the exhaust temperature sensor gp (24) onto the cylinder head of cylinder 2 use one bolt (25), one washer (6), and one clip (26) .

47. Remove the top right rear bolt from the 117-0066 Mounting Bracket .

48. Attach clip (10) to the 117-0066 Mounting Bracket use the original bolt.

49. Secure exhaust temperature sensor gp (24) to clips (4) and (10) use one cable strap (2) per clip. Refer to Illustrations 45 and 46.

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Illustration 47	g03156319
Typical right-hand side view of the engine. (1) 396-9743 Engine Harness As (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (10) 4P-7581 Clip (22) 1A-2029 Bolt (23) 261-6847 Adapter (24) 261-6848 Exhaust Temperature Sensor Gp (25) 0S-1594 Bolt (26) 3A-3692 Clip

50. Remove the adapter and exhaust temperature sensor gp from the 115-0554 Exhaust Manifold .

51. Install adapter (23) into the 115-0554 Exhaust Manifold .

52. Lubricate the exhaust temperature sensor gp (24) with Loctite Nickel Anti Seize.

53. Install exhaust temperature sensor gp (24) into adapter (23)

    Tighten the exhaust temperature sensor gp ... 45 ± 5 N·m (33 ± 4 lb ft)

54. Install one clip (26) around exhaust temperature sensor gp (24) .

55. Attach clip (26) and one clip (10) onto the camshaft cover of cylinder 11 with one bolt (25) and one washer (6). Clip (10) is installed on top of clip (26) .

56. Attach one clip (10) to the cam cover of cylinder 9 use one bolt (22) and one washer (6) .

57. Secure exhaust temperature sensor gp (24) to clips (4) and (10) use one cable strap (2) per clip.

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Illustration 48	g03156321
Typical right-hand side view of the engine. (12) 214-7566 O-Ring Seal (15) 353-5439 Connector (17) 228-7100 O-Ring Seal (27) 320-3060 Pressure Sensor

58. Remove the connector and the pressure sensor from the front filter port (block inlet) of the oil filter base.

59. Install connector (15) and one O-ring (12) into the front filter port (block inlet) of the oil filter base.

60. Install pressure sensor (27) and one O-ring (17) into connector (15) .

    Tighten the pressure sensor ... 10 ± 2 N·m (7 ± 1 lb ft)

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Illustration 49	g03156323
Typical high-mount oil filter base (12) 214-7566 O-Ring Seal (17) 228-7100 O-Ring Seal (27) 320-3060 Pressure Sensor (28) 353-5441 Elbow Adapter

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Illustration 50	g03671055
Typical mid-mount oil filter base (12) 214-7566 O-Ring Seal (17) 228-7100 O-Ring Seal (27) 320-3060 Pressure Sensor (28) 353-5441 Elbow Adapter (29) 447-0902 Sensor Harness As (30) 8C-6427 Adapter

Note: Callouts 29 and 30 are only used on the mid-mount oil filter base.

61. Remove the elbow and the pressure sensor from the rear unfiltered port (filter inlet) of the oil filter base.

62. Install elbow (28) and one O-ring (12) into the rear unfiltered port (filter inlet) of the oil filter base.

63. Install pressure sensor (27) and one O-ring (17) into elbow (28) .

    Tighten the pressure sensor ... 10 ± 2 N·m (7 ± 1 lb ft)

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Illustration 51	g03156325
(12) 214-7566 O-Ring Seal (17) 228-7100 O-Ring Seal (27) 320-3060 Pressure Sensor (28) 353-5441 Elbow Adapter

64. Remove the elbows and the pressure sensors from the 118-6678 Adapter on the fuel filter base.

65. Install two elbow adapters (28) and one O-ring (12) per elbow into the 118-6678 Adapter .

66. Install one pressure sensor (27) and one O-ring (17) per pressure sensor into each elbow adapter (28) .

    Tighten the pressure sensor ... 10 ± 2 N·m (7 ± 1 lb ft)

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Illustration 52	g03679845
Typical high-mount oil temperature sensor (1) 396-9743 Engine Harness As (2) 7K-1181 Cable Strap (9) 132-5789 Clip (18) 256-6453 Temperature Sensor (19) 238-5080 O-Ring Seal (31) 353-5440 Adapter

Note: For mid-mount oil temperature sensor, move to Step 73.

67. Remove the adapter and the temperature sensor from the 359-4123 Adapter .

68. Install adapter (31) into the 359-4123 Adapter .

    Note: Use Loctite 567 on all pipe thread joints.

69. Install temperature sensor (18) and one O-ring (19) into adapter (31) .

    Tighten the temperature sensor ... 20 ± 3 N·m (15 ± 2 lb ft)

70. Remove the bolt and washer from the front outside corner of the 7N-3170 Cover .

71. Attach one clip (9) onto the 7N-3170 Cover with the original bolt and washer.

72. Secure wiring harness (1) to clip (9) use one cable strap (2) .

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Illustration 53	g03675554
Typical mid-mount oil temperature sensor (1) 396-9743 Engine Harness As (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (18) 256-6453 Temperature Sensor (19) 238-5080 O-Ring Seal (29) 447-0902 Sensor Harness As (31) 353-5440 Adapter

73. Remove the adapter and the temperature sensor from the 121-5734 Base Adapter .

74. Install adapter (31) into the 121-5734 Base Adapter .

    Note: Use Loctite 567 on all pipe thread joints.

75. Install temperature sensor (18) and one O-ring (19) into adapter (31) .

    Tighten the temperature sensor ... 20 ± 3 N·m (15 ± 2 lb ft)

76. Attach three clips (4) to the 4P-2533 Plate As with the original bolts.

77. Attach sensor harness assembly (29) to engine wiring harness (1) .

78. Secure wiring harness (29) to clips (4). Use one cable strap (2) per clip.

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Illustration 54	g03145117
(12) 214-7566 O-Ring Seal (15) 353-5439 Connector (16) 320-3063 Pressure Sensor (17) 228-7100 O-Ring Seal

79. Remove the connector and crankcase pressure sensor from the 117-0066 Mounting Bracket on cylinder 2.

80. Install connector (15) and one O-ring (12) into the 117-0066 Mounting Bracket .

81. Install pressure sensor (16) and one O-ring (17) into connector (15) .

    Tighten the pressure sensor ... 10 ± 2 N·m (7 ± 1 lb ft)

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Illustration 55	g03675579
(32) 318-1181 Speed Sensor Gp (33) 273-5041 Speed Sensor Gp

82. Remove the speed sensor gp from the top of the flywheel housing.

83. Install one speed sensor gp (32) into the top of the flywheel housing.

    Note: The minimum clearance between the sensor and the teeth of the flywheel is 0.5 mm (0.020 inch).

    Tighten speed sensor jam nut ... 25 N·m (18 lb ft)

84. Remove the two speed sensor gps from the left-hand side of the flywheel housing.

85. Install two speed sensor gps (33) into the left-hand side of the flywheel housing.

    Note: The minimum clearance between the sensor and the teeth of the flywheel is 0.5 mm (0.020 inch).

    Tighten speed sensor gp ... 40 ± 0.5 N·m (29.5 ± 0.4 lb ft)

    Note: The lower speed sensor gp (33) is the primary speed sensor.

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Illustration 56	g03675580
(32) 318-1181 Speed Sensor Gp

86. Remove the speed sensor gp from the lower right-hand side of the flywheel housing.

87. Install speed sensor (32) into the flywheel housing.

    Note: The minimum clearance between the sensor and the teeth of the flywheel is 0.5 mm (0.020 inch).

    Tighten speed sensor jam nut ... 25 N·m (18 lb ft)

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Illustration 57	g03675581
Typical left-hand side view of the engine. (1) 396-9743 Engine Harness As (2) 7K-1181 Cable Strap (4) 4P-8134 Clip (6) 5M-2894 Hard Washer (34) 305-6873 Pressure Sensor Gp (35) 6W-6672 Spacer (36) 9X-0262 Adapter (37) 6V-9028 O-Ring Seal (38) 0L-1143 Bolt

88. Install two O-rings (37) onto adapter (36) .

89. Install adapter (36) into the 436-0492 Tube As .

90. Install pressure sensor (34) onto adapter (36) .

    Tighten the pressure sensor ... 10 ± 2 N·m (7 ± 1 lb ft)

91. Remove the upper rear bolt and washer from the side cover of cylinder 8.

92. Attach one clip (4) to the side cover of cylinder 8 with one spacer (35), one bolt (38), and one washer (6) .

93. Secure engine wiring harness (1) to clip (4). Use one cable strap (2) .

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Illustration 58	g03647483
(1) 396-9743 Engine Harness As (2) 7K-1181 Cable Strap (4) 4P-8134 Clip

94. Attach one clip (4) to the 436-0492 Tube As and the 436-0496 Bracket with the original 3B-1915 Bolt , 9X-6458 Hard Washers , and the 9S-8752 Full Nut . Refer to Illustration 58 for the correct location.

95. Secure engine wiring harness (1) to clip (4). Use one cable strap (2) .

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Illustration 59	g03675583
The 435-3147 Solenoid Harness As is only used on S/N:R1A or ; S/N:WF3 engines. (39) 435-3147 Solenoid Harness As

96. Attach solenoid harness assembly (39) to the air shutoff (if applicable).

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Illustration 60	g03675582
The 435-0428 Engine Wiring Gp is only used on S/N:R2A, ; S/N:RTX, and ; S/N:WF5 engines. (40) 435-0427 Engine Harness As

97. Attach engine harness assembly (40) to the customer connection (if applicable).

Installing the 419-1886 Electronic Control and Mounting Gp

Illustration 61	g03144087
(1) 417-6011 Electronic Control Module

Illustration 62	g03023698
(2) 9M-1974 Hard Washer (3) 9N-0869 Hard Washer (4) 8T-9655 Isolation Mount (5) 6I-1418 Spacer (6) 2V-4387 Spacer (7) 1D-4540 Bolt

1. Remove the original engine electronic control module from the 111-0349 Module Bracket .

   Note: The original mounting hardware will be reused except isolation mounts.

2. Install electronic control module (1) onto the 111-0349 Module Bracket . Use four bolts (7), one washer (2), four washers (3), eight isolation mounts (4), four spacers (5), and four spacers (6) .

   Note: The corner with ground wire will use washer (2) .

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Illustration 63	g03144436

3. Remove the front right-hand camshaft cover. Set the original hardware aside for reuse.

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Illustration 64	g03144460
(8) 110-2760 Bracket (9) 8N-9885 Cover Gasket (10) 1A-2029 Bolt (11) 5M-2894 Hard Washer

4. Attach bracket (9) to front housing with one gasket (8), seven bolts (10), and seven washers (11) .

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Illustration 65	g03144517
(2) 9M-1974 Hard Washer (3) 9N-0869 Hard Washer (5) 6I-1418 Spacer (8) 110-2760 Bracket (12) 1B-9575 Bolt (13) 155-0576 Isolation Mount (14) 353-8089 Electronic Control Module

5. Attach electronic control (14) to bracket (8) use four bolts (12), four washers (3), four spacers (5), and eight isolation mounts (13) .

   Note: The corner with ground wire will use washer (2) .

Installing the Inlet Air Pipes

Installing the 394-3671 Air Lines Gp on a S/N:R1S or ; S/N:WF5 Engine

Illustration 66	g03146497
(1) 394-0407 Tube As (2) 394-0406 Tube As (3) 7M-1599 Taperlock Stud (4) 9M-1974 Hard Washer (5) 5S-0003 Nut

1. Install four studs (3) into tube assemblies (1) and (2)

   Note: For kits shipped after June 2014, the kits will utilize four 2B-2695 Bolts and four 9M-1974 Hard Washers for this procedure.

2. Install one washer (4) and one nut (5) loosely per stud onto studs (3). The nuts and washers will be used with the 381-3558 Tube As from the 435-4642 Fuel Lines Gp .

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Illustration 67	g03370566
(1) 394-0407 Tube As (2) 394-0406 Tube As (6) 8N-5254 Reducer Hose (7) 5P-4869 Hose Clamp (8) 5P-3860 Hose Clamp

3. Install two reducer hoses (6) per tube assembly onto tube assemblies (1) and (2) use one hose clamp per reducer hose.

4. Attach tube assemblies (1) and (2) to turbochargers with one reducer hose (6) and one hose clamp (8) per turbocharger.

5. Install the original heat shields.

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Illustration 68	g03377475
(1) 394-0407 Tube As (2) 394-0406 Tube As (9) 2K-4973 Locknut (10) 9X-6458 Hard Washer (11) 5G-4313 Spacer (12) 197-9732 U-Bolt

6. Install two U-bolts (12) per tube assembly around tube assemblies (1) and (2) .

7. Attach U-bolts (12) to the 191-6015 Bracket with two spacers (11), two washers (10), and two nuts (9) per U-bolt.

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Illustration 69	g03377513
(1) 394-0407 Tube As (2) 394-0406 Tube As (13) 5P-0600 Hose Clamp (14) 7E-8224 Reducer Hose

8. Install one reducer hose (14) onto tube assemblies (1) and (2) with one hose clamp (13) per tube assembly.

   Note: Extra hose clamp (13) will be used during the installation of the air cleaners.

9. Install the compressor pipes use the original hardware.

Installing the 421-8500 Air Lines Gp on a S/N:R1A, ; S/N:R2A, ; S/N:RTX, or ; S/N:WF3 Engine

Illustration 70	g03176181
(1) 394-0407 Tube As (2) 394-0406 Tube As (3) 7M-1599 Taperlock Stud (4) 9M-1974 Hard Washer (5) 5S-0003 Nut

1. Install four studs (3) into tube assemblies (1) and (2) .

   Note: For kits shipped after June 2014, the kits will utilize four 2B-2695 Bolts and four 9M-1974 Hard Washers for this procedure.

2. Install one washer (4) and one nut (5) loosely per stud onto studs (3). The nuts and washers will be used with the 381-3558 Tube As from the 435-4645 Fuel Lines Gp .

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Illustration 71	g03370627
(1) 394-0407 Tube As (2) 394-0406 Tube As (6) 8N-5254 Reducer Hose (7) 5P-4869 Hose Clamp (8) 5P-3860 Hose Clamp

3. Install two reducer hoses (6) per tube assembly onto tube assemblies (1) and (2) use one hose clamp per reducer hose.

4. Attach tube assemblies (1) and (2) to turbochargers with one reducer hose (6) and one hose clamp (8) per turbocharger.

5. Install the original heat shields.

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Illustration 72	g03176178
(1) 394-0407 Tube As (2) 394-0406 Tube As (9) 2K-4973 Locknut (10) 9X-6458 Hard Washer (11) 5G-4313 Spacer (12) 197-9732 U-Bolt

6. Install two U-bolts (12) per tube assembly around tube assemblies (1) and (2) .

7. Attach U-bolts (12) to the 191-6015 Bracket with two spacers (11), two washers (10), and two nuts (9) per U-bolt.

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Illustration 73	g03377515
(1) 394-0407 Tube As (2) 394-0406 Tube As (13) 5P-0600 Hose Clamp (14) 7E-8224 Reducer Hose

8. Install one reducer hose (14) onto tube assemblies (1) and (2) with one hose clamp (13) per tube assembly.

   Note: Extra hose clamp (13) will be used during the installation of the air cleaners.

9. Install the compressor pipes use the original hardware.

Installing the 435-0900 Gas Pressure Regulator Gp

Illustration 74	g03796769
(1) 436-0494 Tube As (2) 425-3549 Gasket (3) 0S-1590 Bolt (4) 5M-2894 Hard Washer (5) 469-8876 Bracket As (6) 469-8878 Flange (7) 293-8396 Fuel Cooler Core (8) 0S-1591 Bolt

1. Attach long elbow (1) to core (7) with one gasket (2), four bolts (8), and four washers (4) .

2. Attach short elbow (5) and flange (6) to core (7), with two gaskets (2), one placed on each side of the flange (6), using four bolts (3), and four washers (4) .

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Illustration 75	g03796842
(4) 5M-2894 Hard Washer (9) 397-8632 Bracket (10) 0S-1585 Bolt (11) 7D-1649 Hard Washer (12) 1A-5183 Bolt (13) 9S-8752 Full Nut (14) 2A-4639 Bolt (15) 9X-6458 Hard Washer

3. Attach assembled parts to bracket (9) loosely with four bolts (14) and four washers (15) .

4. Remove the four bolts and four washers from the oil pan below the side cover of cylinder 8.

5. Using a suitable lifting device, attach the bracket (9) to the engine below the side cover of cylinder 8 and to the oil pan with two bolts (10), two washers (11), four bolts (12), eight washers (4), and four nuts (13). The assembled parts weigh approximately 91 kg (202 lb).

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Illustration 76	g03796871
(9) 397-8632 Bracket (10) 0S-1585 Bolt (13) 9S-8752 Full Nut (15) 9X-6458 Hard Washer (16) 436-0490 Bracket As (17) 3B-1915 Bolt (18) 436-0496 Bracket (19) 5P-8245 Hard Washer

6. Attach the bracket (16) to bracket (9) with eight bolts (10) and eight washers (19) .

7. Attach brackets (18) to bracket (16) loosely with four bolts (17), eight washers (15), and four nuts (13) .

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Illustration 77	g03796888
(11) 7D-1649 Hard Washer (16) 436-0490 Bracket As (20) 1F-7958 Full Nut (21) 0S-1587 Bolt (22) 436-0495 Bracket

8. Attach bracket (22) to bracket (16) loosely with two bolts (21), four washers (11), and two nuts (20) .

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Illustration 78	g03797507
(23) 435-0888 Gas Pressure Regulator Gp (24) 122-8905 Elbow (25) 6V-8398 O-Ring Seal

Note: Use Loctite 567 on all pipe thread joints.

9. Install elbow (24) into the side port of gas regulator (23) .

10. Install one O-ring (25) into elbow (24) .

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Illustration 79	g03798965
(13) 9S-8752 Full Nut (15) 9X-6458 Hard Washer (23) 435-0888 Gas Pressure Regulator Gp (27) 3E-4352 Hard Washer (33) 8W-8909 Sleeve (34) 6K-5290 Clip (35) 6K-5291 Clip (51) 0S-1588 Bolt (54) 460-7069 Bracket (55) 1B-7182 Bolt

11. Attach bracket (54) to gas regulator (23) with one bolt (55) and one washer (27) .

12. Install sleeve (33) around the tube assembly of the gas regulator (23) .

13. Install one clip (34) and one clip (35) around sleeve (33) .

14. Attach clips (34) and (35) to bracket (30) with one bolt (51), two washers (15), and one nut (13) .

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Illustration 80	g03798218
(1) 436-0494 Tube As (11) 7D-1649 Hard Washer (16) 436-0490 Bracket As (20) 1F-7958 Full Nut (23) 435-0888 Gas Pressure Regulator Gp (26) 9X-8873 Bolt (27) 3E-4352 Hard Washer (28) 1A-9579 Bolt (29) 1A-5822 Bolt (30) 442-2010 Bracket (31) 293-4056 Gasket

15. Attach gas regulator (23) to bracket (16) with four bolts (28) and four washers (27) .

16. Attach gas regulator (23) to elbow (1) with one gasket (31), one bracket (30), one bolt (29), one bolt (26), four washers (11), and two nuts (20). Refer to Illustration 80 for the correct location for the bracket and bolts.

    Note: Remaining fasteners will be attached in a later step.

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Illustration 81	g03798310
(13) 9S-8752 Full Nut (15) 9X-6458 Hard Washer (23) 435-0888 Gas Pressure Regulator Gp (30) 442-2010 Bracket (32) 1A-2029 Bolt (33) 8W-8909 Sleeve (34) 6K-5290 Clip (35) 6K-5291 Clip

17. Install sleeve (33) around the tube assembly of the gas regulator (23) .

18. Install one clip (34) and one clip (35) around sleeve (33) .

19. Attach clips (34) and (35) to bracket (30) with one bolt (32), two washers (15), and one nut (13) .

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Illustration 82	g03798335
(1) 436-0494 Tube As (11) 7D-1649 Hard Washer (20) 1F-7958 Full Nut (23) 435-0888 Gas Pressure Regulator Gp (26) 9X-8873 Bolt (36) 9S-1366 Bolt (37) 460-0915 Bracket

20. Attach gas regulator (23) to elbow (1) with one bracket (37), one bolt (36), one bolt (26), four washers (11), and two nuts (20). Refer to Illustration 82 for the correct location for the bracket and bolts.

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Illustration 83	g03798478
(11) 7D-1649 Hard Washer (13) 9S-8752 Full Nut (15) 9X-6458 Hard Washer (17) 3B-1915 Bolt (18) 436-0496 Bracket (20) 1F-7958 Full Nut (23) 435-0888 Gas Pressure Regulator Gp (26) 9X-8873 Bolt (31) 293-4056 Gasket (39) 436-0493 Tube As (40) 436-0492 Tube As

21. Attach elbow (39) to gas regulator (23) loosely with one gasket (31), four bolts (26), eight washers (11), and four nuts (20) .

22. Attach elbow (40) to bracket (18) loosely with two bolts (17), four washers (15), and two nuts (13) .

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Illustration 84	g03798501
(22) 436-0495 Bracket (39) 436-0493 Tube As (40) 436-0492 Tube As (41) 8S-9092 Bolt (42) 5P-8247 Hard Washer (43) 4K-0367 Full Nut (44) 420-8789 Gasket (45) 419-0893 Solenoid Valve Gp (46) 9X-8882 Bolt

23. Attach solenoid valve gp (45) to elbow (39) loosely with one gasket (44), four bolts (41), eight washers (42), and four nuts (43) .

24. Attach solenoid valve gp (45) to bracket (22) and elbow (40) loosely. Use one gasket (44), two top bolts (41), two bottom bolts (46), eight washers (42), and four nuts (43) .

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Illustration 85	g03798551
(11) 7D-1649 Hard Washer (13) 9S-8752 Full Nut (24) 122-8905 Elbow (25) 6V-8398 O-Ring Seal (37) 460-0915 Bracket (39) 436-0493 Tube As (47) 211-5237 Connector (48) 4P-7233 Grommet (49) 8T-1887 Clip (50) 8T-1888 Clip (51) 0S-1588 Bolt (52) 436-0497 Tube As

Note: Use Loctite 567 on all pipe thread joints.

25. Install connector (47) into elbow (39) .

26. Attach tube assembly (52) and one O-ring (25) to connector (47) .

27. Attach tube assembly (52) to elbow (24) .

    Note: Make sure that the O-ring is in the elbow.

28. Install sleeve (48) around the tube assembly (52) .

29. Install one clip (49) and one clip (50) around sleeve (48) .

30. Attach clips (49) and (50) to bracket (37) with one bolt (51), two washers (11), and one nut (13) .

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Illustration 86	g03798612
(4) 5M-2894 Hard Washer (13) 9S-8752 Full Nut (14) 2A-4639 Bolt (18) 436-0496 Bracket (40) 436-0492 Tube As (53) 105-8180 Gasket

31. Tighten all the hardware that was left loose for installation except for outside bracket (18) .

Note: The remaining parts called out are used for installing 424-7719 Electronic Actuator Gp .

32. Refer to Illustration 87.

Installing the 424-7719 Electronic Actuator Gp

Illustration 87	g03137643
(1) 424-7719 Electronic Actuator Gp

1. Attach actuator (1) to the 436-0492 Tube As with one 105-8180 Gasket , four 2A-4639 Bolts , eight 5M-2894 Hard Washers , and four 9S-8752 Full Nuts .

   Note: The actuator must be oriented correctly with respect to gas flow.

Installing the 394-3677 Aftercooler Water Lines Gp on a S/N:R1S or ; S/N:WF5 Engine

Illustration 88	g03158142
Typical left-hand side engine view. (1) 394-3669 Bracket (2) 1A-2029 Bolt (3) 9X-6458 Hard Washer

1. Remove the original separate circuit aftercooler tube assemblies, the brackets, and all the hardware. Leave the 358-6313 Elbow and the 358-6677 Elbow on the aftercooler.

2. Install brackets (1) onto the camshaft covers of cylinders 6 and 10 use two bolts (2) and two washers (3) per bracket.

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Illustration 89	g03158143
(4) 0L-1351 Bolt (5) 5M-2894 Hard Washer (6) 9S-8752 Full Nut (7) 0S-1571 Bolt (8) 153-9963 Ring (9) 8T-1919 O-Ring Seal (10) 153-9481 Clamp As (11) 394-3673 Tube (12) 394-3674 Tube As

3. Install O-ring seal (9) onto tube assembly (11). Lubricate the O-ring seal with 1U-6395 O-Ring Assembly Compound .

4. Install ring (8) around tube assembly (11).

5. Install two clamp assemblies (10) loosely around tube assembly (11) use two bolts (4), four washers (5), and two nuts (6) .

6. Install tube assembly (11) into the 357-6196 Elbow use two bolts (7) and two washers (5) .

7. Tighten all the bolts that were left loose.

8. Install O-ring seal (9) onto tube assembly (12). Lubricate the O-ring seal with 1U-6395 O-Ring Assembly Compound .

9. Install ring (8) around tube assembly (12).

10. Install two clamp assemblies (10) loosely around tube assembly (12) use two bolts (4), four washers (5), and two nuts (6) .

11. Install tube assembly (12) into the 214-0729 Adapter use two bolts (7) and two washers (5) .

12. Tighten all the bolts that were left loose.

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Illustration 90	g03158145
(1) 394-3669 Bracket (3) 9X-6458 Hard Washer (5) 5M-2894 Hard Washer (6) 9S-8752 Full Nut (11) 394-3673 Tube (12) 394-3674 Tube As (13) 3B-1915 Bolt (14) 193-2120 Grommet (15) 6V-1867 Clip (16) 6V-1868 Clip (17) 272-8176 Clamp (18) 0S-1594 Bolt

13. Install two grommets (14) around tube assembly (11) .

14. Install one clip (15) and one clip (16) per grommet around grommets (17) .

15. Attach clips (15) and (16) to brackets (1) use one bolt (13), two washers (3), and one nut (6) per bracket.

16. Attach tube assemblies (11) and (12) use two clamps (17), one bolt (18), two washers (5), and one nut (6) .

17. Refer to Illustration 90 for the correct clamp position.

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Illustration 91	g03158139
(4) 0L-1351 Bolt (5) 5M-2894 Hard Washer (6) 9S-8752 Full Nut (7) 0S-1571 Bolt (8) 153-9963 Ring (9) 8T-1919 O-Ring Seal (10) 153-9481 Clamp As (19) 394-3676 Tube (20) 394-3675 Tube

18. Install O-ring seal (9) onto tube assembly (20). Lubricate the O-ring seal with 1U-6395 O-Ring Assembly Compound .

19. Install retaining ring (8) around tube assembly (20) .

20. Install two clamp assemblies (10) loosely around tube assembly (20) use two bolts (4), four washers (5), and two nuts (6) .

21. Install tube assembly (20) into the 358-6313 Elbow use two bolts (7) and two washers (5) .

22. Tighten all the bolts that were left loose.

23. Install O-ring seal (9) onto tube assembly (19). Lubricate the O-ring seal with 1U-6395 O-Ring Assembly Compound .

24. Install retaining ring (8) around tube assembly (19) .

25. Install two clamp assemblies (10) loosely around tube assembly (19) use two bolts (4), four washers (5), and two nuts (6) .

26. Install tube assembly (19) into the 358-6677 Elbow use two bolts (7) and two washers (5) .

27. Tighten all the bolts that were left loose.

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Illustration 92	g03158147
(11) 394-3673 Tube (12) 394-3674 Tube As (19) 394-3676 Tube (20) 394-3675 Tube (21) 261-7951 Tube Joint

28. Attach tube assembly (11) to tube assembly (20) with one tube joint (21) .

    Tighten the tube joint ... 12 ± 0.5 N·m (106 ± 4 lb in)

29. Attach tube assembly (12) to tube assembly (19) with one tube joint (19) .

    Tighten the tube joint ... 12 ± 0.5 N·m (106 ± 4 lb in)

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Illustration 93	g03158138
(22) 357-5400 Bracket As (23) 0S-1621 Bolt (24) 5P-8245 Hard Washer

30. Install bracket (22) onto the top left-hand side of the flywheel housing use four bolts (23) and four washers (24) .

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Illustration 94	g03158141
(5) 5M-2894 Hard Washer (6) 9S-8752 Full Nut (14) 193-2120 Grommet (15) 6V-1867 Clip (16) 6V-1868 Clip (19) 394-3676 Tube (20) 394-3675 Tube (22) 357-5400 Bracket As (25) 272-1777 Hard Washer (26) 0S-1590 Bolt

31. Install grommet (14) around tube assemblies (19) and (20) .

32. Install one clip (15) and one clip (16) per grommet around grommets (14) .

33. Refer to Illustration 94 for the correct clamp position.

34. Attach clips (15) and (16) to bracket (22) with one spacer (25), one bolt (26), two washers (5), and one nut (6) .

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Illustration 95	g03160956
(3) 9X-6458 Hard Washer (6) 9S-8752 Full Nut (14) 193-2120 Grommet (15) 6V-1867 Clip (16) 6V-1868 Clip (19) 394-3676 Tube (20) 394-3675 Tube (27) 0S-1571 Bolt

Note: The following steps will proceed after the installation of the 422-8945 Air Cleaner Mounting .

35. Install one grommet (14) around tube assemblies (19) and (20) .

36. Install one clip (15) and one clip (15) per grommet around grommets (14) .

37. Refer to Illustration 95 for the correct clamp position.

38. Attach clips (15) and (16) to the 399-6205 Bracket use one bolt (27), two washers (3), and one nut (6) .

Installing the Air Cleaner Mounting Brackets

Installing the 437-2782 Engine Parts Kit (if applicable)

Note: Refer to 425-1754 Air Cleaner Mounting for more detailed information.

Illustration 96	g03295576
(1) 5K-5552 Locking Bolt (2) 9X-6458 Hard Washer (3) 6V-0717 Self-Locking Bolt

Illustration 97	g03191067
(4) 425-1743 Plate (5) 425-1752 Plate

1. Remove the original 338-5741 Bracket As from the left-hand rear camshaft cover.

2. Attach the original 338-5741 Bracket As to the left rear camshaft cover. Use one plate (4), one plate (5), four bolts (1), four bolts (3), and eight washers (2). Refer to Illustration 96 for the correct bolt location.

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Illustration 98	g03295581
(1) 5K-5552 Locking Bolt (2) 9X-6458 Hard Washer (3) 6V-0717 Self-Locking Bolt

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Illustration 99	g03295579
(4) 425-1743 Plate (5) 425-1752 Plate

3. Remove the original 338-5742 Bracket As from the right-hand rear camshaft cover.

4. Attach the original 338-5742 Bracket As to the left rear camshaft cover. Use one plate (4), one plate (5), four bolts (1), four bolts (3), and eight washers (2). Refer to Illustration 98 for the correct bolt location.

Installing the 437-2783 Engine Parts Kit (if applicable)

Note: Refer to 422-8944 Air Cleaner Mounting for more detailed information.

Illustration 100	g03195719
(1) 364-1620 Bracket As (2) 364-1621 Bracket (3) 364-1622 Bracket

Illustration 101	g03195721
(1) 364-1620 Bracket As (3) 364-1622 Bracket (4) 132-5789 Clip (5) 0S-1571 Bolt (6) 8M-9124 Washer (7) 9S-8752 Full Nut (8) 363-8104 Bracket

1. Attach bracket (3) to bracket (1) with five bolts (5), ten washers (6), and five nuts (7) .

   Note: Ladder clip (4) goes under washer (6). Refer to Illustration 101 for location.

2. Attach bracket (8) to bracket (3) with three bolts (5), six washers (6), and three nuts (7) .

3. Attach bracket (8) to bracket (1) with one bolt (5), two washers (6), and one nut (7) .

   Note: The bolt goes in the rear hole.

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Illustration 102	g03195720
(1) 364-1620 Bracket As (2) 364-1621 Bracket (4) 132-5789 Clip (5) 0S-1571 Bolt (6) 8M-9124 Washer (7) 9S-8752 Full Nut (9) 363-8106 Bracket

4. Attach bracket (2) to bracket (1) with five bolts (5), ten washers (6), and five nuts (7) .

   Note: Ladder clip (4) goes under washer (6). Refer to Illustration 102 for location.

5. Attach bracket (9) to bracket (2) with three bolts (5), six washers (6), and three nuts (7) .

6. Attach bracket (9) to bracket (1) with one bolt (5), two washers (6), and one nut (7) .

   Note: The bolt goes in the rear hole.

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Illustration 103	g03195818
(1) 364-1620 Bracket As (5) 0S-1571 Bolt (6) 8M-9124 Washer (7) 9S-8752 Full Nut (10) 364-1628 Bracket

7. Attach bracket (10) loosely to bracket (1) with three bolts (5), six washers (6), and three nuts (7) .

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Illustration 104	g03195836
(1) 364-1620 Bracket As (6) 8M-9124 Washer (11) 393-9373 Bracket (12) 0S-1591 Bolt (13) 0S-1588 Bolt

8. Attach brackets (11) to bracket (1) with three bolts (12) and three washers (6) per bracket.

   Note: The two inside bolts go into the rear hole.

   The callouts (6) and (13) are used for mounting the air cleaners.

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Illustration 105	g03196199
(1) 364-1620 Bracket As (6) 8M-9124 Washer (11) 393-9373 Bracket (12) 0S-1591 Bolt

9. Attach brackets (11) to bracket (1) with four bolts (12) and four washers (6) per bracket.

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Illustration 106	g03197579
(2) 364-1621 Bracket (6) 8M-9124 Washer (10) 364-1628 Bracket (13) 0S-1588 Bolt (14) 2A-4639 Bolt

10. Using a suitable lifting device, attach bracket (10) to the top of the flywheel housing with eight bolts (14) and eight washers (6). The mounting bracket assembly weighs approximately 126 kg (278 lb).

11. Attach bracket (2) to the upper right-hand corner of the flywheel housing with four bolts (13) and four washers (6) .

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Illustration 107	g03198056
(3) 364-1622 Bracket (6) 8M-9124 Washer (12) 0S-1591 Bolt (13) 0S-1588 Bolt (15) 399-6205 Bracket

12. Attach bracket (3) and bracket (15) to the upper left-hand corner of the flywheel housing. Use one bolt (12), three bolts (13), and four washers (6) .

    Note: Bracket (15) is installed on top of bracket (3) and uses bolts (13) .

13. Tighten all the bolts that were left loose.

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Illustration 108	g03198057
(7) 9S-8752 Full Nut (11) 393-9373 Bracket (16) 422-8942 Bracket (17) 3B-1915 Bolt (18) 9X-6458 Hard Washer

14. Attach brackets (16) to brackets (11) with two bolts (17), four washers (18), and two nuts (7) per bracket.

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Illustration 109	g03200577
(7) 9S-8752 Full Nut (11) 393-9373 Bracket (13) 0S-1588 Bolt (18) 9X-6458 Hard Washer (19) 422-8943 Bracket

15. Attach bracket (9) to bracket (11) with two bolts (13), four washers (18), and two nuts (7) .

    Note: The following steps will be performed after the installation of the 435-4642 Fuel Lines Gp .

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Illustration 110	g03200559
(7) 9S-8752 Full Nut (16) 422-8942 Bracket (20) 7K-1401 Clip (21) 7K-1402 Bracket (22) 0S-1587 Bolt (23) 7D-1649 Hard Washer (24) 1F-7958 Full Nut

16. Install two clips (20) and two brackets (21) around the 394-2431 Tube As .

17. Attach one clip (20) and one bracket (21) to each bracket (16) with one bolt (22), two washers (23), and one nut (24) .

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Illustration 111	g03200557
(7) 9S-8752 Full Nut (17) 3B-1915 Bolt (18) 9X-6458 Hard Washer (19) 422-8943 Bracket (25) 6V-1581 Clip (26) 6V-1582 Clip

18. Install one clip (25) and one clip (26) around the 436-0499 Tube .

19. Attach clips (25) and (26) to bracket (19) with one bolt (17), two washers (18), and one nut (7) .

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Illustration 112	g03240996
(7) 9S-8752 Full Nut (12) 0S-1591 Bolt (15) 399-6205 Bracket (18) 9X-6458 Hard Washer (25) 6V-1581 Clip (26) 6V-1582 Clip

20. Install one clip (25) and one clip (26) around the 436-0499 Tube .

21. Attach clips (25) and (26) to bracket (25) with one bolt (15), two washers (18), and one nut (7) .

Installing the 437-2784 Engine Parts Kit (if applicable)

Note: Refer to 422-8945 Air Cleaner Mounting for more detailed information.

Illustration 113	g03154396
(1) 364-1620 Bracket As (2) 364-1621 Bracket (3) 364-1622 Bracket

Illustration 114	g03195721
(1) 364-1620 Bracket As (3) 364-1622 Bracket (4) 132-5789 Clip (5) 0S-1571 Bolt (6) 8M-9124 Washer (7) 9S-8752 Full Nut (8) 363-8104 Bracket

1. Attach bracket (3) to bracket (1) with five bolts (5), ten washers (6), and five nuts (7) .

   Note: Ladder clip (4) goes under washer (6). Refer to Illustration 101 for location.

2. Attach bracket (8) to bracket (3) with three bolts (5), six washers (6), and three nuts (7) .

3. Attach bracket (8) to bracket (1) with one bolt (5), two washers (6), and one nut (7) .

   Note: The bolt goes in the rear hole.

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Illustration 115	g03195720
(1) 364-1620 Bracket As (2) 364-1621 Bracket (4) 132-5789 Clip (5) 0S-1571 Bolt (6) 8M-9124 Washer (7) 9S-8752 Full Nut (9) 363-8106 Bracket

4. Attach bracket (2) to bracket (1) with five bolts (5), ten washers (6), and five nuts (7) .

   Note: Ladder clip (4) goes under washer (6). Refer to Illustration 102 for location.

5. Attach bracket (9) to bracket (2) with three bolts (5), six washers (6), and three nuts (7) .

6. Attach bracket (9) to bracket (1) with one bolt (5), two washers (6), and one nut (7) .

   Note: The bolt goes in the rear hole.

7. Attach bracket (9) to bracket (2) with three bolts (5), six washers (6), and three nuts (7) .

8. Attach bracket (9) to bracket (1) with one bolt (5), two washers (6), and one nut (7) .

   Note: The bolt goes in the rear hole.

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Illustration 116	g03195818
(1) 364-1620 Bracket As (5) 0S-1571 Bolt (6) 8M-9124 Washer (7) 9S-8752 Full Nut (10) 364-1628 Bracket

9. Attach bracket (10) loosely to bracket (1) with three bolts (5), six washers (6), and three nuts (7) .

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Illustration 117	g03195836
(1) 364-1620 Bracket As (6) 8M-9124 Washer (11) 393-9373 Bracket (12) 0S-1591 Bolt (13) 0S-1588 Bolt

10. Attach brackets (11) to bracket (1) with three bolts (12) and three washers (6) per bracket.

    Note: The two inside bolts go into the rear hole.

    The callouts (6) and (13) are used for mounting the air cleaners.

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Illustration 118	g03196199
(1) 364-1620 Bracket As (6) 8M-9124 Washer (11) 393-9373 Bracket (12) 0S-1591 Bolt

11. Attach brackets (11) to bracket (1) with four bolts (12) and four washers (6) per bracket.

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Illustration 119	g03197597
(5) 0S-1571 Bolt (6) 8M-9124 Washer (7) 9S-8752 Full Nut (11) 393-9373 Bracket (14) 371-0346 Bracket

12. Attach one bracket (14) to each bracket (11) with seven bolts (5), fourteen washers (6), and seven nuts (7) per bracket.

    Note: Brackets (14) go on the inside of brackets (11) .

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Illustration 120	g03198846
(2) 364-1621 Bracket (6) 8M-9124 Washer (10) 364-1628 Bracket (13) 0S-1588 Bolt (15) 2A-4639 Bolt

13. Using a suitable lifting device, attach bracket (10) to the top of the flywheel housing with eight bolts (15) and eight washers (6). The mounting bracket assembly weighs approximately 148 kg (326 lb).

14. Attach bracket (2) to the upper right-hand corner of the flywheel housing with four bolts (13) and four washers (6) .

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Illustration 121	g03198847
(3) 364-1622 Bracket (6) 8M-9124 Washer (12) 0S-1591 Bolt (13) 0S-1588 Bolt (16) 399-6205 Bracket

15. Attach bracket (3) and bracket (16) to the upper left-hand corner of the flywheel housing. Use one bolt (12), three bolts (13), and four washers (6) .

    Note: Bracket (16) is installed on top of bracket (3) and uses bolts (13) .

16. Tighten all the bolts that were left loose.

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Illustration 122	g03201376
(7) 9S-8752 Full Nut (11) 393-9373 Bracket (17) 422-8942 Bracket (18) 3B-1915 Bolt (19) 9X-6458 Hard Washer

17. Attach brackets (17) to brackets (11) with two bolts (18), four washers (19), and two nuts (7) per bracket.

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Illustration 123	g03201379
(7) 9S-8752 Full Nut (11) 393-9373 Bracket (13) 0S-1588 Bolt (19) 9X-6458 Hard Washer (20) 422-8943 Bracket

18. Attach bracket (20) to bracket (11) with two bolts (13), four washers (19), and two nuts (7) .

    Note: The following steps will be performed after the installation of the 435-4642 Fuel Lines Gp .

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Illustration 124	g03197598
(17) 422-8942 Bracket (21) 7K-1401 Clip (22) 7K-1402 Bracket (23) 0S-1587 Bolt (24) 7D-1649 Hard Washer (25) 1F-7958 Full Nut

19. Install two clips (21) and two brackets (22) around the 394-2431 Tube As .

20. Attach one clip (21) and one bracket (22) to each bracket (17) with one bolt (23), two washers (24), and one nut (25) .

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Illustration 125	g03200579
(7) 9S-8752 Full Nut (18) 3B-1915 Bolt (19) 9X-6458 Hard Washer (20) 422-8943 Bracket (26) 6V-1581 Clip (27) 6V-1582 Clip

21. Install one clip (26) and one clip (27) around the 436-0499 Tube .

22. Attach clips (26) and (27) to bracket (20) with one bolt (18), two washers (19), and one nut (7) .

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Illustration 126	g03241018
(7) 9S-8752 Full Nut (12) 0S-1591 Bolt (16) 399-6205 Bracket (19) 9X-6458 Hard Washer (26) 6V-1581 Clip (27) 6V-1582 Clip

23. Install one clip (26) and one clip (27) around the 436-0499 Tube .

24. Attach clips (26) and (27) to bracket (16) with one bolt (12), two washers (19), and one nut (7) .

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Illustration 127	g03201059
(14) 371-0346 Bracket (28) 113-1323 Gasket (29) 1D-4539 Bolt (30) 9M-1974 Hard Washer (31) 5S-0003 Nut (32) Original tube assemblies

25. Attach original tube assemblies (32) to bracket (14) and the 395-2974 Air Shutoff Gp . Use two gaskets (28), twelve bolts (29), twenty-four washers (30), and twelve nuts (31) per tube assembly.

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Illustration 128	g03202065
(32) Original tube assemblies (33) 8T-4990 Hose Clamp (34) 251-6235 Hose

26. Install hose (34) onto tube assembly (32) use two hose clamps (33) per hose.

    Note: Extra hose clamps (33) will be used to connect hoses (34) to the air system of the customer.

Installing the Fuel Lines

Installing the 435-4642 Fuel Lines Gp on a S/N:R1S or ; S/N:WF5 Engine

Illustration 129	g03145176
(1) 381-3558 Tube As (2) 6V-4368 O-Ring Seal

Note: The two sets of mixing tubes provided are intended for use with specific ranges of gas quality. Installation is the same for both tube assemblies. The proper mixing tube to be used for optimal substitution performance should be determined by the Lower Heating Value (LHV) of the supply gas as calculated from a gas analysis. The LHV of a gas analysis can be calculated using Caterpillar Gas Engine Rating Pro (GERP). Once an LHV is determined, install the correct mixing tubes listed in reference to Table 36.

Table 36

LHV Range British Thermal Unit (BTU) / Standard Cubic Foot (SCF)	Part
450-1400 BTU / SCF	381-3558 Tube As
1300-2300 BTU / SCF	399-3105 Tube As

1. Install tube assembly (1) into air inlet tube assemblies. Use one O-ring (2), two 9M-1974 Hard Washers and two 5S-0003 Nuts per tube assembly (1) .

   Note: For kits shipped after June 2014, the kits will utilize four 2B-2695 Bolts and four 9M-1974 Hard Washers for this procedure.

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Illustration 130	g03145177
(1) 381-3558 Tube As (3) 255-6464 Joint (4) 394-2431 Tube As

2. Attach tube assembly (4) to tube assemblies (1) with two joints (3) .

   Tighten the joints ... 12 ± 0.5 N·m (106 ± 4 lb in)

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Illustration 131	g03145178
(5) 105-8180 Gasket (6) 2A-4639 Bolt (7) 5M-2894 Hard Washer (8) 9S-8752 Full Nut (9) 436-0498 Tube As (10) 3B-1915 Bolt (11) 9X-6458 Hard Washer

3. Attach tube assembly (9) to the actuator with one gasket (5), four bolts (6), eight washers (7), and four nuts (8) .

4. Attach tube assembly (9) to the 436-0496 Bracket with two bolts (10), four washers (11), and two nuts (8) .

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Illustration 132	g03145181
(4) 394-2431 Tube As (9) 436-0498 Tube As (12) 8C-5098 Tube Joint (13) 436-0499 Tube

5. Attach tube assembly (13) to tube assembly (4) with one tube joint (12) .

   Tighten the tube joint ... 16 ± 0.5 N·m (142 ± 4 lb in)

6. Attach tube assembly (13) to tube assembly (9) with one tube joint (12) .

   Tighten the tube joint ... 16 ± 0.5 N·m (142 ± 4 lb in)

Installing the 435-4645 Fuel Lines Gp on a S/N:R1A, ; S/N:R2A, ; S/N:RTX, or ; S/N:WF3 Engine

Illustration 133	g03160958
(1) 381-3558 Tube As (2) 6V-4368 O-Ring Seal

Note: The two sets of mixing tubes provided are intended for use with specific ranges of gas quality. Installation is the same for both tube assemblies. The proper mixing tube to be used for optimal substitution performance should be determined by the Lower Heating Value (LHV) of the supply gas as calculated from a gas analysis. The LHV of a gas analysis can be calculated using Caterpillar Gas Engine Rating Pro (GERP). Once an LHV is determined, install the correct mixing tubes listed in reference to Table 36.

Table 37

LHV Range British Thermal Unit (BTU) / Standard Cubic Foot (SCF)	Part
450-1400 BTU / SCF	381-3558 Tube As
1300-2300 BTU / SCF	399-3105 Tube As

1. Install tube assembly (1) into air inlet tube assemblies. Use one O-ring (2), two 9M-1974 Hard Washers and two 5S-0003 Nuts per tube assembly (1) .

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Illustration 134	g03370482
(3) 105-8180 Gasket (4) 2A-4639 Bolt (5) 5M-2894 Hard Washer (6) 9S-8752 Full Nut (7) 436-0503 Tube As (8) 3B-1915 Bolt (9) 9X-6458 Hard Washer

2. Attach tube assembly (7) to the actuator with one gasket (3), four bolts (4), eight washers (5), and four nuts (6) .

3. Attach tube assembly (7) to the 436-0496 Bracket with two bolts (8), four washers (9), and two nuts (5) .

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Illustration 135	g03160960
(1) 381-3558 Tube As (7) 436-0503 Tube As (10) 255-6464 Joint (11) 436-0504 Tube As (12) 8C-5098 Tube Joint

4. Install two joints (10) and tube joint (12) loosely onto tube assembly (11) .

5. Install two joints (10) onto tube assemblies (1) .

   Tighten the joints ... 12 ± 0.5 N·m (106 ± 4 lb in)

6. Install one tube joint (12) onto tube assembly (7) .

   Tighten the tube joint ... 16 ± 0.5 N·m (142 ± 4 lb in)

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Illustration 136	g03160961
(13) 0T-0055 Bolt (14) 7N-6986 Support

7. Remove the bolts and the washers from the bottom two holes of the valve cover base of cylinder 12.

8. Attach support (14) to the cylinder head use two bolts (13) .

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Illustration 137	g03175638
(5) 5M-2894 Hard Washer (6) 9S-8752 Full Nut (8) 3B-1915 Bolt (14) 7N-6986 Support (15) 421-9083 Bracket

9. Attach bracket (15) to support (14) use two bolts (8), four washers (5), and two nuts (6) .

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Illustration 138	g03175639
(6) 9S-8752 Full Nut (8) 3B-1915 Bolt (9) 9X-6458 Hard Washer (11) 436-0504 Tube As (15) 421-9083 Bracket (16) 6V-1581 Clip (17) 6V-1582 Clip

10. Install one clip (16) and one clip (17) around tube assembly (17) .

11. Attach clips (16) and (17) to bracket (15) with one bolt (8), two washers (9), and one nut (6) .

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Illustration 139	g03175640
(6) 9S-8752 Full Nut (9) 9X-6458 Hard Washer (11) 436-0504 Tube As (16) 6V-1581 Clip (17) 6V-1582 Clip (18) 0S-1621 Bolt (19) 5P-8245 Hard Washer (20) 0S-1591 Bolt (21) 421-9082 Bracket

12. Install bracket (21) onto the 8N-9211 Flywheel Housing Cover Assembly use one bolt (18) and one washer (19)

13. Install one clip (16) and one clip (17) around tube assembly (11) .

14. Attach clip (16) and clip (17) to bracket (21) use one bolt (20), two washers (9), and one nut (6) .

Installing the 395-2974 Air Shutoff Gp on a S/N:R1S or ; S/N:WF5 Engine

Illustration 140	g03191056

1. Remove the original brackets, oil fittings, pressure fittings, and proximity sensors from the air shutoff. Set air cleaners, air shutoff valves, and all associated hardware aside for reuse.

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Illustration 141	g03191057
(1) 388-2134 Bracket

2. Install brackets (1) loosely use the original hardware.

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Illustration 142	g03191059
The callouts 4 through 8 are from the 396-9740 Engine Wiring Gp (2) 7X-5331 Elbow (3) 371-9531 Proximity Sensor Gp (4) 335-3999 Adapter (5) 214-7568 O-Ring Seal (6) 6V-9330 Elbow (7) 320-3063 Pressure Sensor (8) 228-7100 O-Ring Seal

Note: Use Loctite 567 on all pipe thread joints.

3. Install elbow (2) into the 358-7807 Hydraulic Cylinder .

4. Remove the original bottom outer pipe plug from the air shutoff valve.

5. Install the original outer pipe plug into the inner bottom port of the air shutoff valves.

6. Install elbow (6) into the bottom outer port of the air shutoff valve.

7. Install adapter (4) and one O-ring (5) into elbow (6) .

8. Install pressure sensor (7) and one O-ring (8) into adapter (4) .

9. Install proximity sensor (3) into the air shutoff valve.

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Illustration 143	g03191060
The callouts 4 through 8 are from the 396-9740 Engine Wiring Gp (2) 7X-5331 Elbow (3) 371-9531 Proximity Sensor Gp (4) 335-3999 Adapter (5) 214-7568 O-Ring Seal (6) 6V-9330 Elbow (7) 320-3063 Pressure Sensor (8) 228-7100 O-Ring Seal

Note: Use Loctite 567 on all pipe thread joints.

10. Install elbow (2) into the 358-7807 Hydraulic Cylinder .

11. Remove the original bottom outer pipe plug from the air shutoff valve.

12. Install the original outer pipe plug into the inner bottom port of the air shutoff valves.

13. Install elbow (6) into the bottom outer port of the air shutoff valve.

14. Install adapter (4) and one O-ring (5) into elbow (6) .

15. Install pressure sensor (7) and one O-ring (8) into adapter (4) .

16. Install proximity sensor (3) into the air shutoff valve.

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Illustration 144	g03372407
(1) 388-2134 Bracket (9) 3B-1915 Bolt (10) 5M-2894 Hard Washer (11) 0S-1588 Bolt (12) 8M-9124 Washer

17. Attach the air cleaner and the air shutoff valve to the 393-9373 Bracket with three bolts (11) and three washers (12) .

18. Attach brackets (1) to the 393-9373 Bracket with two bolts (9) and two washers (10) per bracket.

19. Tighten all the hardware that was left loose for installation.

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Illustration 145	g03191061
(2) 7X-5331 Elbow (13) 395-2973 Tube As (14) 4J-5477 O-Ring Seal (15) 145-5181 Spacer (16) 2A-4639 Bolt

20. Attach tube assembly (13) and one O-ring (14) to elbow (2) .

21. Install the original 7M-8322 Clips around tube assembly (13) .

22. Attach the outside 7M-8322 Clip to the 364-1620 Bracket As use the original bolt and spacer (15) .

    The original spacer is not reused.

23. Attach the inside 7M-8322 Clip to the 364-1620 Bracket As using the original hardware and bolt (16) .

    The original bolt is not reused.

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Illustration 146	g03372410
(1) 388-2134 Bracket (9) 3B-1915 Bolt (10) 5M-2894 Hard Washer (11) 0S-1588 Bolt (12) 8M-9124 Washer

24. Attach the air cleaner and the air shutoff valve to the 393-9373 Bracket with three bolts (11) and three washers (12) .

25. Attach brackets (1) to the 393-9373 Bracket with two bolts (9) and two washers (10) per bracket.

26. Tighten the nuts that were left loose for installation.

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Illustration 147	g03191063
(2) 7X-5331 Elbow (14) 4J-5477 O-Ring Seal (15) 145-5181 Spacer (16) 2A-4639 Bolt (17) 395-2972 Tube As

27. Attach tube assembly (17) and one O-ring (14) to elbow (2) .

28. Install the original 7M-8322 Clips around tube assembly (17) .

29. Attach the outside 7M-8322 Clip to the 364-1620 Bracket As use the original hardware and spacer (15) .

    The original spacer is not reused.

30. Attach the inside 7M-8322 Clip to the 364-1620 Bracket As use the original hardware and bolt (16) .

    The original bolt is not reused.

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Illustration 148	g03191065

31. Install the original 381-0676 Air Shutoff Valve and Mounting use the original hardware.

32. Remove the 005-9129 Tee from the top port.

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Illustration 149	g03191064
(10) 4J-5477 O-Ring Seal (14) 6V-9842 Swivel Tee (15) 6V-8641 Connector (16) 214-7568 O-Ring Seal

33. Install connector (15) and one O-ring (16) into the top port of the original 381-0676 Air Shutoff Valve and Mounting .

34. Install swivel tee (14) and one O-ring (10) onto connector (15) .

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Illustration 150	g03191066
(9) 395-2973 Tube As (10) 4J-5477 O-Ring Seal (13) 395-2972 Tube As (14) 6V-9842 Swivel Tee

35. Attach tube assembly (9) and one O-ring (10) to swivel tee (14) .

36. Attach tube assembly (13) and one O-ring (10) to swivel tee (14) .

Installing the 420-4639 Water Lines Gp

Illustration 151	g03177211
(1) 7X-5331 Elbow (2) 4J-5477 O-Ring Seal (3) 4L-6454 Bolt (4) 8T-4896 Hard Washer (5) 265-5254 Plate (6) 318-2484 Orifice (7) 4F-7391 O-Ring Seal (8) 318-2485 Gasket

Note: Use Loctite 567 on all pipe thread joints.

1. Install one O-ring (7) per plate into bottom of plates (5) .

2. Attach plate (5) and orifice (6) to front port of 293-8396 Core with one gasket (8), two bolts (3), and two washers (4) .

3. Attach plate (5) to rear port of 293-8396 Core with two bolts (3) and two washers (4) .

4. Install one elbow (1) per plate into plates (5) .

5. Install one O-ring (2) per elbow into elbows (5) .

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Illustration 152	g03177212
(9) 6B-1628 Reducing Bushing (10) 8C-6867 Connector (11) 1L-4031 Service Tee (12) 196-9420 Ball Valve (13) 8T-6761 Pipe Plug

6. Remove pipe plug from the 7N-3298 Block Cover on the front left corner of the engine.

7. Install service tee (11) into the 7N-3298 Block Cover .

8. Install pipe plug (13) into the bottom port of service tee (11) .

9. Install ball valve (12) into the center port of service tee (11) .

10. Install reducer bushing (9) into ball valve (12) .

11. Install connector (10) into reducer bushing (9) .

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Illustration 153	g03177213
(1) 7X-5331 Elbow (2) 4J-5477 O-Ring Seal (10) 8C-6867 Connector (14) 420-4637 Hose As (15) 1A-5964 Bolt (16) 5M-2894 Hard Washer (17) 9S-8752 Full Nut (18) 397-9377 Bracket (19) 416-6524 Bracket (20) 5P-9297 Clip (21) 0S-1594 Bolt

12. Attach hose (14) and one O-ring (2) to and connector (10) .

13. Attach hose (14) to elbow (1)

    Note: Make sure that the O-ring is in elbow (1)

14. Install bracket (19) to the engine below the side cover of cylinder four use one bolt (15), two washers (16), and one nut (17). Refer to Illustration 153 for the correct location.

15. Install bracket (18) to the engine below the side cover of cylinder six use two bolts (15), four washers (16), and two nuts (17). Refer to Illustration 153 for the correct location.

16. Install two clips (20) around hose (14) .

17. Attach clips (20) to brackets (18) and (18) with one bolt (21), two washers (16), and one nut (17) per clip.

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Illustration 154	g03177309
(17) 9S-8752 Full Nut (20) 5P-9297 Clip (22) 8C-6870 Connector (23) 6V-8397 O-Ring Seal (24) 420-4638 Hose As (25) 0S-1588 Bolt (26) 9X-6458 Hard Washer

18. Remove the pipe plug the rear top port of the 111-8276 Manifold .

19. Install connector (22) into the 111-8276 Manifold .

20. Attach hose (24) and one O-ring (23) to connector (22) .

21. Attach hose (24) to elbow (1) on the rear port of the 293-8396 Core .

    Note: Make sure that the O-ring is in the elbow (1) .

22. Remove the original hardware from the 278-9544 Tube brackets.

23. Install one clip (20) around hose (24) .

24. Attach clip (20) to the 278-9544 Tube brackets with one bolt (25), two washers (26), and one nut (17) .

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Illustration 155	g03177313
(1) 7X-5331 Elbow (17) 9S-8752 Full Nut (20) 5P-9297 Clip (24) 420-4638 Hose As (26) 9X-6458 Hard Washer (27) 6V-1581 Clip (28) 6V-1582 Clip (29) 7W-9094 Spacer (30) 2A-4639 Bolt

25. Attach hose (24) to elbow (1) .

    Note: Make sure that the O-ring is in the elbow (1) .

26. Remove the top front bolt from the 7N-5094 Drain Elbow .

27. Install one clip (20) around hose (24) .

28. Attach clip (20) to the 7N-5094 Drain Elbow with the original hardware.

29. Install one clip (20) around hose (24) .

30. Install one clip (27) and one clip (28) around the 436-0498 Tube As or the 436-0503 Tube As .

31. Attach clips (20), (27), and (28) using one spacer (29), one bolt (30), two washers (26), and one nut (17) .

Installing the 417-6750 Jacket Water Heater Lines Gp

Installing the Jacket Water Heater Lines Gp on Engines with Transmission Coolers (if applicable)

Illustration 156	g03179820
(1) 417-6745 Bracket

Note: Pay close attention to the bolt hole orientation of the bracket.

Illustration 157	g03179837
(1) 417-6745 Bracket (2) 2M-7077 Spacer (3) 2A-4639 Bolt (4) 5M-2894 Hard Washer (5) 9S-8752 Full Nut (6) 0S-1619 Bolt (7) 1W-8129 Support (8) 4P-0916 Spacer

1. Attach support (7) to the top of bracket (1) with three spacers (2), three bolts (3), six washers (4), and three nuts (5) .

2. Attach support (7) to the bottom of bracket (1) with three spacers (8), three bolts (6), six washers (4), and three nuts (5) .

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Illustration 158	g03179841
(6) 0S-1619 Bolt (7) 1W-8129 Support (9) 0T-0055 Bolt

3. Remove the lower valve cover base bolts from cylinder 6.

4. Attach supports (7) onto cylinder head and valve cover base of cylinder 6 use two bolts (6) and two bolts (9). Refer to Illustration 158 for the correct bolt locations.

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Illustration 159	g03418788
(5) 9S-8752 Full Nut (10) 426-3602 Bracket As (11) 0S-1591 Bolt (12) 9X-6458 Hard Washer (13) 0S-1571 Bolt (14) 426-3515 Bracket

5. Remove the original hardware from the 191-6015 Bracket on cylinder 10.

6. Attach brackets (10) and (14) to the 191-6015 Bracket with one bolt (11), one bolt (13), four washers (12), and two nuts (5). Refer to Illustration 159 for the correct bolt locations.

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Illustration 160	g03177971

7. Attach the jacket water heater to bracket (1) with the original hardware.

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Illustration 161	g03179843
Jacket water heater gp with the short solenoid valve. (15) 3B-6555 Elbow (16) 8C-6875 Connector (17) 5K-9090 O-Ring Seal (18) 417-6743 Hose As (19) 196-9420 Ball Valve

Note: Use Loctite 567 on all pipe thread joints.

8. Proceed to Step 16 for jacket water heater gp with the long solenoid valve.

9. Remove the pipe plug from the bottom of the service tee.

10. Install elbow (15) into the bottom of the service tee.

11. Install elbow (15) into elbow (15) .

12. Install ball valve (19) into elbow (15) .

13. Install connector (16) into ball valve (19) .

14. Attach hose assembly (18) and one O-ring (17) to connector (16) .

15. Attach hose assembly (18) to the bottom of the solenoid valve.

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Illustration 162	g03182177
Jacket water heater gp with the long solenoid valve. (15) 3B-6555 Elbow (16) 8C-6875 Connector (17) 5K-9090 O-Ring Seal (19) 196-9420 Ball Valve (20) 417-6744 Hose As

Note: Use Loctite 567 on all pipe thread joints.

16. Remove the pipe plug from the bottom of the service tee.

17. Install elbow (15) into the bottom of the service tee.

18. Install elbow (15) into elbow (15) .

19. Install ball valve (19) into elbow (15) .

20. Install connector (16) into ball valve (19) .

21. Install connector (16) into the bottom of the solenoid valve.

22. Attach hose assembly (20) and one O-ring (17) per connector to connectors (16) .

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Illustration 163	g03179844
(5) 9S-8752 Full Nut (12) 9X-6458 Hard Washer (14) 426-3515 Bracket (16) 8C-6875 Connector (17) 5K-9090 O-Ring Seal (21) 0S-1588 Bolt (22) 417-6748 Tube As (23) 7J-0728 Clip (24) 7J-0729 Clip

Note: Use Loctite 567 on all pipe thread joints.

23. Install connector (16) into the end of the jacket water heater.

24. Attach tube assembly (22) one O-ring (17) and loosely to connector (16) .

25. Install one clip (23) and one clip (24) around tube assembly (22) .

26. Attach clip (23) and clip (24) loosely to bracket (14) with one bolt (21), two washers (12), and one nut (5) .

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Illustration 164	g03179856
(5) 9S-8752 Full Nut (12) 9X-6458 Hard Washer (13) 0S-1571 Bolt (21) 0S-1588 Bolt (22) 417-6748 Tube As (23) 7J-0728 Clip (24) 7J-0729 Clip (25) 417-6749 Bracket

27. Remove the original bolt and washer from each of the rear camshaft covers. Refer to Illustration 164 for bolt and washer location.

28. Attach brackets (25) to the rear camshaft covers with one bolt (13) and one washer (12) per bracket.

29. Install two clips (23) and two clips (24) around tube assembly (22) .

30. Attach clips (23) and clips (24) to brackets (25) with one bolt (21), two washers (12), and one nut (5) per bracket.

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Illustration 165	g03179857
(15) 3B-6555 Elbow (16) 8C-6875 Connector (17) 5K-9090 O-Ring Seal (19) 196-9420 Ball Valve (22) 417-6748 Tube As (26) 6V-9649 Elbow (27) 417-6746 Hose As (28) 5P-0492 Adapter (29) 7M-8485 O-Ring Seal

Note: Use Loctite 567 on all pipe thread joints.

31. Attach elbow (26) and one O-ring (17) loosely to tube assembly (22) .

32. Remove the O-ring plug from the 384-3701 Tube As .

33. Install adapter (28) and one O-ring (29) into the 384-3701 Tube As .

34. Install elbow (15) into adapter (28) .

35. Install ball valve (19) into elbow (15) .

36. Install connector (16) into ball valve (19) .

37. Attach hose assembly (27) and one O-ring (17) loosely to elbow (26) .

38. Attach hose assembly (27) and one O-ring (17) loosely to connector (16) .

39. Tighten all the brackets that were left loose.

40. Tighten all the hose and tube assembly joints that were left loose.

Installing the Jacket Water Heater Lines Gp on Engines without Transmission Coolers (if applicable)

Illustration 166	g03179820
(1) 417-6745 Bracket

Note: Pay close attention to the bolt hole orientation of the bracket.

Illustration 167	g03179837
(1) 417-6745 Bracket (2) 2M-7077 Spacer (3) 2A-4639 Bolt (4) 5M-2894 Hard Washer (5) 9S-8752 Full Nut (6) 0S-1619 Bolt (7) 1W-8129 Support (8) 4P-0916 Spacer

1. Attach support (7) to the top of bracket (1) with three spacers (2), three bolts (3), six washers (4), and three nuts (5) .

2. Attach support (7) to the bottom of bracket (1) with three spacers (8), three bolts (6), six washers (4), and three nuts (5) .

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Illustration 168	g03179841
(6) 0S-1619 Bolt (7) 1W-8129 Support (9) 0T-0055 Bolt

3. Remove the lower valve cover base bolts from cylinder 6.

4. Attach supports (7) onto cylinder head and valve cover base of cylinder 6 use two bolts (6) and two bolts (9). Refer to Illustration 158 for the correct bolt locations.

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Illustration 169	g03418788
(5) 9S-8752 Full Nut (10) 426-3602 Bracket As (11) 0S-1591 Bolt (12) 9X-6458 Hard Washer (13) 0S-1571 Bolt (14) 426-3602 Bracket As

5. Remove the original hardware from the 191-6015 Bracket on cylinder 10.

6. Attach brackets (10) and (14) to the 191-6015 Bracket with one bolt (11), one bolt (13), four washers (12), and one nut (5). Refer to Illustration 169 for the correct bolt locations.

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Illustration 170	g03177971

7. Attach the jacket water heater to bracket (1) with the original hardware.

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Illustration 171	g03179843
Jacket water heater gp with the short solenoid valve. (15) 3B-6555 Elbow (16) 8C-6875 Connector (17) 5K-9090 O-Ring Seal (18) 417-6743 Hose As (19) 196-9420 Ball Valve

Note: Use Loctite 567 on all pipe thread joints.

8. Proceed to step 16 for jacket water heater gp with the long solenoid valve.

9. Remove the pipe plug from the bottom of the service tee.

10. Install elbow (15) into the bottom of the service tee.

11. Install elbow (15) into elbow (15) .

12. Install ball valve (19) into elbow (15) .

13. Install connector (16) into ball valve (19) .

14. Attach hose assembly (18) and one O-ring (17) to connector (16) .

15. Attach hose assembly (18) to the bottom of the solenoid valve.

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Illustration 172	g03182177
Jacket water heater gp with the long solenoid valve. (15) 3B-6555 Elbow (16) 8C-6875 Connector (17) 5K-9090 O-Ring Seal (19) 196-9420 Ball Valve (20) 417-6744 Hose As

Note: Use Loctite 567 on all pipe thread joints.

16. Remove the pipe plug from the bottom of the service tee.

17. Install elbow (15) into the bottom of the service tee.

18. Install elbow (15) into elbow (15) .

19. Install ball valve (19) into elbow (15) .

20. Install connector (16) into ball valve (19) .

21. Install connector (16) into the bottom of the solenoid valve.

22. Attach hose assembly (20) and one O-ring (17) per connector to connectors (16) .

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Illustration 173	g03179844
(5) 9S-8752 Full Nut (12) 9X-6458 Hard Washer (14) 426-3515 Bracket (16) 8C-6875 Connector (17) 5K-9090 O-Ring Seal (21) 0S-1588 Bolt (22) 417-6748 Tube As (23) 7J-0728 Clip (24) 7J-0729 Clip

Note: Use Loctite 567 on all pipe thread joints.

23. Install connector (16) into the end of the jacket water heater.

24. Attach tube assembly (22) one O-ring (17) and loosely to connector (16) .

25. Install one clip (23) and one clip (24) around tube assembly (22) .

26. Attach clip (23) and clip (24) loosely to bracket (14) with one bolt (21), two washers (12), and one nut (5) .

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Illustration 174	g03177745
(5) 9S-8752 Full Nut (12) 9X-6458 Hard Washer (13) 0S-1571 Bolt (21) 0S-1588 Bolt (22) 417-6748 Tube As (23) 7J-0728 Clip (24) 7J-0729 Clip (25) 417-6749 Bracket

27. Remove the original bolt and washer from each of the rear camshaft covers. Refer to Illustration 174 for bolt and washer location.

28. Attach brackets (25) to the rear camshaft covers with one bolt (12) and one washer (13) per bracket.

29. Install two clips (23) and two clips (24) around tube assembly (22) .

30. Attach clips (23) and clips (24) to brackets (25) with one bolt (21), two washers (12), and one nut (5) per bracket.

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Illustration 175	g03177746
(15) 3B-6555 Elbow (16) 8C-6875 Connector (17) 5K-9090 O-Ring Seal (19) 196-9420 Ball Valve (22) 417-6748 Tube As (26) 6V-9649 Elbow (30) 417-6747 Tube As

Note: Use Loctite 567 on all pipe thread joints.

31. Attach elbow (26) and one O-ring (17) loosely to tube assembly (22) .

32. Remove the pipe plug from the 7N-4944 Elbow .

33. Install elbow (15) into the 7N-4944 Elbow .

34. Install ball valve (19) into elbow (15) .

35. Install connector (16) into ball valve (19) .

36. Attach tube assembly (30 ) and one O-ring (17) loosely to elbow (26) .

37. Attach tube assembly (30 ) and one O-ring (17) loosely to connector (16) .

38. Tighten all the brackets that were left loose.

39. Tighten all the hose and tube assembly joints that were left loose.

Installing the 426-3518 Fumes Disposal Gp

Illustration 176	g03418799
(1) 426-3526 Tube (2) 6V-3378 Clip (3) 426-3602 Bracket As (4) 0S-1594 Bolt (5) 9X-6458 Hard Washer (6) 9S-8752 Full Nut

1. Attach tubes (1) to the 217-6692 Tee Hose with the original clamps.

2. Install one clip (2) around each tube (1) .

3. Attach clips (2) to bracket assembly (3) with one bolt (4), two washers (5), and one nut (6) per clip.

Installing the 441-5248 Exhaust Shield Gp

Illustration 177	g03418731
(1) 441-6638 Exhaust Shield (2) 441-6637 Exhaust Shield (3) 437-4401 Catalytic Converter Gp

1. Install exhaust shield (2) onto the bottom of catalytic converter gp (3) .

2. Install exhaust shield (1) onto the top of catalytic converter gp (3) .

3. Attach exhaust shield (1) and exhaust shield (2) with the spring kits attached to the exhaust shields.

Installing the 388-3916 Muffler and Mounting Gp and the 437-4401 Catalytic Converter Gp (if applicable)

Illustration 178	g03386261
(1) 437-4401 Catalytic Converter Gp (2) 214-6045 Bellows As (3) 236-1161 Elbow

Illustration 179	g03386265
(1) 437-4401 Catalytic Converter Gp (2) 214-6045 Bellows As (3) 236-1161 Elbow (4) 5L-3773 Exhaust Elbow Gasket (5) 8T-2501 Bolt (6) 8T-4896 Hard Washer (7) 2K-4973 Locknut

Note: The structure that holds up the 437-4401 Catalytic Converter Gp is supplied by the Original Equipment Manufacturer (OEM).

1. Attach one bellow (2) to exhaust elbows (3) with one gasket (4), eight bolts (6), sixteen washers (7), and eight locknuts (7) per elbow.

2. Attach one bellow (2) to the flanges of the catalytic converter gp (1) with one gasket (4), eight bolts (6), sixteen washers (7), and eight locknuts (7) per flange.

Installing the 445-9283 Engine Parts Kit and the 437-4401 Catalytic Converter Gp (if applicable)

Illustration 180	g03386261
(1) 437-4401 Catalytic Converter Gp (2) 438-2037 Bellows As (3) 236-1161 Elbow

Illustration 181	g03386265
(1) 437-4401 Catalytic Converter Gp (2) 214-6045 Bellows As (3) 236-1161 Elbow (4) 5L-3773 Exhaust Elbow Gasket (5) 8T-2501 Bolt (6) 8T-4896 Hard Washer (7) 2K-4973 Locknut

Note: The structure that holds up the 437-4401 Catalytic Converter Gp is supplied by the Original Equipment Manufacturer (OEM).

1. Attach one bellow (2) to exhaust elbows (3) with one gasket (4), eight bolts (6), sixteen washers (7), and eight locknuts (7) per elbow.

2. Attach one bellow (2) to the flanges of the catalytic converter gp (1) with one gasket (4), eight bolts (6), sixteen washers (7), and eight locknuts (7) per flange.

3. Attach the 441-5948 Film to the valve cover next to the engine certification film.

   Note: Do not obstruct the view of any other film.

Installing the 436-0500 Air Compressor Lines Gp (if applicable)

Illustration 182	g03386641
(1) 438-5670 Hose As (2) 9M-0397 Adapter (3) 8M-7065 Gasket (4) 164-0228 Elbow (5) 030-8307 Connector

Note: Use Loctite 567 on all pipe thread joints.

1. Remove one end of the 7W-1839 Hose As and the 9L-5254 Elbow from the engine air intake manifold.

2. Install the 8T-6762 Pipe Plug into the engine air intake manifold.

3. Remove one end of the 7W-1839 Hose As from the 061-6717 Flared Elbow on the air compressor.

4. Remove the 7W-9834 Regulator Valve and the 061-6717 Flared Elbow from the air compressor.

5. Install adapter (2) onto the air compressor with one gasket (3) and the original hardware.

6. Install elbow (4) into adapter (2) .

7. Install connector (5) into elbow (4) .

8. Install the 9S-7296 Flared Elbow into the new boss provided by the customer.

   Note: The flared elbow must be install in the inlet air pipes upstream of the 381-3558 Tube As or the 399-3105 Tube As .

9. Attach hose (1) to connector (5) and the 9S-7296 Flared Elbow .

   Note: The clipping points and routing of hose (1) will be determined during the installation. The clips and associated hardware are supplied in the kit.

Software Flash Instructions

Two software files need downloaded and installed by the dealer prior to beginning operation with Dynamic Gas Blending kits.

1. Download the 433-6418 Engine Ratings Electronic Software Gp free from the Service Information System (SIS).

   Note: All 3500 DGB engine ratings use the same Integrated Sensing Module (ISM) software.

2. Install the 433-6418 Engine Ratings Electronic Software Gp on a blank ISM (A3).

3. Download one of the following engine Electronic Control Module (ECM) software free from the SIS:
   • The 455-9202 Engine Ratings Electronic Software Gp is for the 1864 kW (2500 hp) 7 percent Torque Rise ATAAC

   • The 455-9537 Engine Ratings Electronic Software Gp is for the 1678 kW (2250 hp) 1.6 percent Torque Rise ATAAC

   • The 455-9538 Engine Ratings Electronic Software Gp is for the 1678 kW (2250 hp) 7 percent Torque Rise ATAAC

   • The 455-9198 Engine Ratings Electronic Software Gp is for the 1864 kW (2500 hp) 7 percent Torque Rise SCAC

   • The 456-0314 Engine Ratings Electronic Software Gp is for the 1678 kW (2250 hp) 7 percent Torque Rise SCAC

   • The 456-0315 Engine Ratings Electronic Software Gp is for the 1678 kW (2250 hp) 1.6 percent Torque Rise SCAC

4. Install the correct software onto a blank ECM (A4).

   After the software is installed, it will be possible to run the engine as a diesel engine, but gas blending will not be available or functional.

Installing the Injector Trim Codes and Setting the FLS/FTS

Illustration 183	g03285604

1. Connect Cat ET to the ECM

2. Click on the "Service" tab.

3. Select "Calibrations".

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Illustration 184	g03286182

4. Click on "Injector Codes Calibration".

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Illustration 185	g03286196

5. Select the "Injector".

6. Click the "Change" button.

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Illustration 186	g03286198

7. Enter the correct Injector Code that was previously saved.

8. Click the "OK" button.

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Illustration 187	g03286199

9. Click the "Yes" button.

10. Continue the previous procedures until all Injector Trim Codes are calibrated to match the values saved from the original ECM.

11. Set both the FLS/FTS to zero. Refer to the engine information label.

Setting the Air Shutoffs Configuration and Calibration of the Engine Timing

Setting the Air Shutoffs Configuration

Illustration 188	g03357967
Default air shutoff not installed

Illustration 189	g03357984
Air shutoffs installed

1. Enable the air shutoffs.

Calibration of the Speed Timing

Note: The engine has to be out of Cold Mode in order to calibrate the speed timing.

Illustration 190	g03286158

1. Click on the "Service" tab.

2. Select "Calibrations".

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Illustration 191	g03286176

3. Click on "Timing Calibration".

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Illustration 192	g03286178

4. Follow the Prompts.

5. Click the "Continue" button.

Software Enabled Attachments (SEA)

Illustration 193	g03342855
SEA not installed

Note: There is a significant charge for enabling the Gas Substitution SEA 441-7475 Premium Configuration feature. The charge will be billed to the license holder of the Cat ET performing the switch.

Note: The Gas Substitution SEA can only be enabled when the Direct Fuel Control Mode is set to Disabled. The Direct Fuel Control Mode can be re-enabled after the Gas Substitution SEA is installed.

Illustration 194	g03342857
SEA installed

1. Refer to Information Release Memo, PELJ0138, "Electronics & Electrical Systems" and Information Release Memo, PELJ1357, "Cat Electronics" for more information.

2. Disconnect CAT ET from the ECM

Installing the 441-5948 Film or the 443-1074 Film

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Illustration 195	g03427538
Typical 449-0090 Film (Emission Certified Engines)

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Illustration 196	g03814974
Typical 443-5866 Film (Non-Emission Certified Engines)

1. Write in the correct information on the 449-0090 Film if applicable.

   Note: Caterpillar provides warranty for the alternative fuel conversion system of your kit for regulatory terms of 5 years/3000 hours, whichever comes first, in the U.S. and 12 months Caterpillar New Parts terms for rest of world provided there has been no abuse, neglect, or improper maintenance of the kit or your engine.

2. Clean off the valve cover next to the valve cover with the engine certification film.

Note: Do not obstruct the view of any other film.

3. Attach the 449-0090 Film or the 443-5866 Film to the valve cover.

4. Attach the 444-0543 Film to the valve cover on top of the 449-0090 Film or the 443-5866 Film .

   Note: The 444-0543 Film is a protective film for the 449-0090 Film or the 443-5866 Film .

Startup Checklist

The following retrofit checklist is used before the dynamic gas blending is activated.

Table 38

Step	Description	Complete/Measured Values	Dealer sign-off	Customer sign-off
1	Confirm the air filter covers are removed.
2	Power on engine, check for any fault codes.
3	Check customer Input / Output connections, proper operation (direct rack, secondary gas shutoff valve).
4	Diesel-only startup, ensure proper engine function.
5	Check voltage / current for each phase.
6	Check for leaks (cooling, lube, manifold area, exhaust).
7	Operate engine through as much load range as possible.
8	Confirm no excessive exhaust restriction (including catalyst).
9	Pull a Product Status Report.
10	Measure exhaust Diesel Oxidation Catalyst inlet temperature.
11	Check all temperatures.
12	Check all pressures.
13	Confirm E-stop works.
14	Supply gas system checks.
-	Clean, dry gas per Application and Installation Guide, LEBW4977, "Gaseous Fuels".
-	<4 ppm H2S present in gas (<50 ppm with a stainless steel aftercooler).
-	Gas pressure is (12 to 35 psig).
-	Meets required gas flow (per web calculator tool).
15	Regulator pressure is set properly (engine loaded and running) per procedure. Refer to Testing and Adjusting, "Fuel Pressure (Gas System)".
16	Check gas system for leaks.
17	Confirm Software Enabled Attachment works, blending enabled.
18	Enable Dynamic Gas Blending mode.
19	Set desired substitution percentage and check for fault codes (pressure within range, gas valves performance, etc.).
20	Inspect supply gas equipment for proper operation while gas is flowing.

Register the Retrofit

Because retrofits to a prime product will change the configuration of the product, updating the configuration in SIMSi and AIMS is important. If the retrofit information is not provided, Caterpillar will not be able to provide important product updates.

The following information includes instructions on registering the updates and retrofits.

1. When performing a retrofit installation, record the vital information in Table 39.

   Note: If the procedure is performed by the customer, ask the customer to record the proper information.

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   Table 39

   Repair Date
   Product Serial Number
   Service Hours or Service Meter Units
   Removed Component Part Number (1)
   Removed Component Serial Number (1)
   Installed Component Part Number (2)
   Installed Component Serial Number (3)

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   ( 1 )	Only applies if a component is replaced by a retrofit component. If the product is an engine, and the product retrofit is a kit for upgrading the engine, disregard the "Removed Component" information. Refer to detailed instructions in Step 1 for more information.
   ( 2 )	Record the highest level retrofit kit, arrangement, or group part number.
   ( 3 )	Most retrofits will not have a serial number. Exceptions include emissions repower engines and diesel particulate filters.

2. Update the product configuration by entering the information from Table 39 into SIMSi and AIMS.

   Note: For retrofits that have a Caterpillar serial number, the AIMS application is "JIZ111-08". For retrofits that do not have a Caterpillar serial number, the AIMS application is "JIZ111-07".

3. For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit".