Coolant Line Upgrade for the Exhaust System Components on G3516B Engine.{1050, 1059, 1061, 1380} Caterpillar

Engine:

G3516B (S/N: JEF1-UP)

Introduction

This Special Instruction can be used to update the G3516B Engines with new waterlines, exhaust manifold bellows, exhaust elbows, and exhaust heat shielding.

Because of ongoing design changes, some of the updates apply to certain serial numbers

The serial number breaks are defined in table 1.

Before performing this procedure shutdown the engine. Drain the coolant from both the Jacket Water and Separate Circuit Aftercooler (SCAC) waterlines. Both circuits will be modified.

Group 1: Initial Updating of the 341-8736 Water Lines Gp

Note: The following engine serial numbers apply for the removal procedure: (S/N: JEF00101-00107,00109-00131,00135,00149-00162,00165-00171,00174-00189,01001-01035)

Show/hide table



Illustration 1	g03275397
(1) 361-2216 Hose As (2) 6V-5064 O-Ring Seal (3) 250-2343 O-Ring Seal (4) 162-3122 Elbow

1. Remove the original hose assembly, elbow, and O-Ring seal on the left bank turbocharger. Install new hose assembly (1), O-Ring Seal (2), O-Ring Seal (3), and elbow (4) .

Show/hide table



Illustration 2	g03276996
(5) 5G-3676 Grommet (6) 7S-3916 Clip (7) 7S-3919 Clip (8) 0S-1588 Bolt (9) 9X-6458 Hard Washer (10) 9S-8752 Full Nut (11) 341-8719 Bracket

2. Remove the original grommet (5), clip (6), clip (7), bolt (8), hard washer (9), full nut (10), and bracket (11).
   Show/hide table

   Table 3

   Item	Qty	New Part	Original Part
   12	1	416-1326 Hose As	341-8717 Hose As
   13	1	6V-9810 Union	6V-8733 Union
   14	2	250-2343 O-Ring Seal

Show/hide table



Illustration 3	g03277617
(12) 416-1326 Hose As (13) 6V-9810 Union (14) 250-2343 O-Ring Seal

3. Remove the original hose assembly, union, and O-Ring seal on the left bank turbocharger. Install a new union (13), hose assembly (12), and O-Ring seal (14) .

Group 2: Initial 341-8736 Water Lines Gp Procedure

Note: The following engine serial numbers apply to the removal procedure: (S/N: JEF01036-01107,01109-01137,01140-01148,01150-01165,01167-01168,01170-01298,01300-01351,01353-01408)

Show/hide table



Illustration 4	g03278436
(1) 361-2216 Hose As (2) 180-8424 O-Ring Seal (3) 6V-9851 Elbow

1. Remove the original hose assembly, O-Ring seal, and swivel tee from the left bank turbocharger. Then install a new hose assembly (1), O-Ring seal (2), and swivel tee (3).
   Show/hide table

   Table 5

   Item	Qty	New Part	Original Part
   4	1	416-1326 Hose As	341-8717 Hose As
   5	1	6V-9810 Union	6V-8733 Union
   6	2	250-2343 O-Ring Seal

Show/hide table



Illustration 5	g03281236
(4) 416-1326 Hose As (5) 6V-9810 Union (6) 250-2343 O-Ring Seal

2. Remove the original hose assembly, union, and O-Ring Seal from the right bank turbocharger. Then install new hose assembly (4), O-Ring seal (6), and union (5).

All Engines 341-8736 Water Lines Gp Procedure

Note: All the engine serial numbers in table 1 apply to this removal procedure.

Illustration 6	g03283057
(1) 361-2217 Hose As (2) 330-4024 Tube As (3) 330-6788 Tube As (4) 330-6789 Tube As (5) 341-8715 Hose As (6) 8C-6871 Connector (7) 6V-9837 Swivel Tee (8) 330-4015 Tube As (9) 330-7151 Hose As (10) 330-4019 Tube As (11) 6V-8782 Tee

Remove the original parts in the following order:

1. Remove the (8) 330-4015 Tube As .

2. Remove the (10) 330-4019 Tube As .

3. Remove the (2) 330-4024 Tube As .

4. Remove the (3) 330-6788 Tube As .

5. Remove the (4) 330-6789 Tube As .

6. Remove the (5) 341-8715 Hose As .

7. Remove the (1) 361-2217 Hose As .

8. Remove the (11) 6V-8782 Tee .

9. Remove the (9) 330-7151 Hose As .

10. Remove the (7) 6V-9837 Swivel Tee .

11. Remove the (6) 8C-6871 Connector .
    Show/hide table

    Table 7

    Item	Qty	Original Part
    12	1	330-4023 Tube As
    6	1	8C-6871 Connector

Show/hide table



Illustration 7	g03284456
(12) 330-4023 Tube As (6) 8C-6871 Connector

Note: The engine is shown with the original lines and fittings.

12. Remove tube assembly (12) and connector (6).
    Show/hide table

    Table 8

    Item	Qty	Original Part
    13	1	8T-1576 Connector

Show/hide table



Illustration 8	g03284760
(13) 8T-1576 Connector

13. Remove the connector (13).
    Show/hide table

    Table 9

    Item	Qty	New Part
    14	1	5P-8196 Plug
    15	1	6V-3251 O-Ring Seal

Show/hide table



Illustration 9	g03284876
(14) 5P-8196 Plug (15) 6V-3251 O-Ring Seal

14. Install the new plug (14) and O-Ring Seal (15).
    Show/hide table

    Table 10

    Item	Qty	Original Part
    16	1	9S-4185 O-Ring Plug
    17	1	114-5277 Elbow

Show/hide table



Illustration 10	g03284964
(16) 9S-4185 O-Ring Plug (17) 114-5277 Elbow

15. Remove the original elbow (17) and plug (16) from the aftercooler.

Group 1: 339-3788 Exhaust Shield Gp Procedure

Note: The following engine serial numbers apply for the procedure: (S/N: JEF00101-00107,00109-00131,00135,00149-00162,00165-00171,00174-00189,01001-01035)

Illustration 11	g03286358

1. Remove all the exhaust shielding from the exhaust manifold and the turbochargers.

Group 2: 339-3788 Exhaust Shield Gp Procedure

Note: The following engine serial numbers apply for the procedure: (S/N: JEF01036-01107,01109-01137,01140-01148,01150-01165,01167-01168,01170-01298,01300-01351,01353-01408)

Illustration 12	g03286537

Illustration 13	g03286577

1. Remove all the exhaust shielding from the exhaust adapters and turbochargers.

Group 1,2,3: Exhaust Bellows, and Elbows Procedure

Note: The following engine serial numbers in table 11 apply for this removal and installation procedure:

Illustration 14	g03288776
(1) 6V-3630 High Temperature Bolt (2) 1W-2430 V Band Clamp (3) 382-6091 Elbow (4) 382-6095 Elbow (5) 5P-7128 High Temperature Bolt (6) 229-5333 Exhaust Seal (7) 110-8314 Washer (8) 3E-6916 Full Nut (9) 336-9259 Bellows As (10) 6V-3631 Full Nut

1. Remove the existing bellows and elbows. Refer to Exhaust Manifold Remove, KENR8147.

2. Install the new bellows (9) and elbows (3), and (4). Refer to Exhaust Manifold Install, KENR8147.

All Engines 259-1436 Exhaust Bypass Procedure

Note: All the engine serial numbers in table 1 apply to this removal procedure.

Illustration 15	g03290416
(1) 3S-5849 Gasket (2) 9S-4205 Plug (3) 320-8921 Setscrew (4) 1B-2578 Nut (5) 146-0751 Cover As (6) 113-1572 Diaphragm (7) 7S-7816 Locknut (8) 3B-4504 Lockwasher (9) 7C-9721 Screw

1. Remove the exhaust bypass valve from the engine. Refer to Exhaust Bypass Valve Remove and Install, KENR8147.

Show/hide table

Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened.

2. Remove the plug (2), then loosen the nut (4) to relieve tension on the springs. Once the tension is removed, carefully loosen the screws (9) that connect the valve body to the cover (5) and remove the cover (5). There will still be some spring tension on the cover (5) after the adjustment screw is loosened. Remove bolts evenly to prevent the valve spring tension from pushing the cover (5) off.

3. Loosen locknut (7) .

4. Replace diaphragm (6), and gasket (1) with new diaphragm (6), and gasket (1) .

   Note: Ensure that the diaphragm (6) is installed correctly.

5. Install nut (7), springs, and cover (5). Then reassemble the exhaust bypass valve. Refer to Exhaust Bypass Valve, KENR6891.

6. Replace the screws (9), and lockwashers (8) with new screws (9), and lockwashers (8).
   Show/hide table

   Table 14

   Item	Qty	New Part	Original Part
   10	1	416-0058 Plate
   11	2	0S-0509 Bolt
   12	2	5M-2894 Hard Washer
   13	1	168-7800 Locknut
   14	1	7C-9710 Gasket

Show/hide table



Illustration 16	g03290539
(10) 416-0058 Plate (11) 0S-0509 Bolt (12) 5M-2894 Hard Washer (13) 168-7800 Locknut (14) 7C-9710 Gasket

7. Install plate (10) with bolts (11) and hard washers (12) .

8. Install a new gasket (14) then install the exhaust bypass valve with locknut (13) and refer to Exhaust Bypass Valve Remove and Install, KENR8147.

All Engines 341-8736 Water Lines Gp Procedure

Note: All the engine serial numbers in table 1 apply to this installation procedure. Remove any metal part number tags from the water lines.

Illustration 17	g03291677
(1) 9X-8873 Bolt (2) 127-1958 Spacer (3) 5P-8245 Hard Washer (4) 7S-3916 Clip (5) 7S-3919 Clip (6) 5G-3676 Grommet (7) 1F-7958 Full Nut (8) 396-0994 Bracket As (9) 5M-2894 Hard Washer (10) 0S-1594 Bolt

1. Install the bracket assembly (1) with bolts (10) , and hard washers (9) .

2. Then install clips (4) and (5) on the coolant line. Attach the clip (4) and (5) to the bracket assembly (8) with bolt (1), spacer (2), hard washer (3), full nut (7), and grommet (6).
   Show/hide table

   Table 16

   Item	Qty	New Part
   11	1	114-5277 Elbow
   12	1	5G-1442 Gasket
   13	1	0S-1594 Bolt
   14	1	0S-1619 Bolt

Show/hide table



Illustration 18	g03297645
(11) 114-5277 Elbow (12) 5G-1442 Gasket (13) 0S-1594 Bolt (14) 0S-1619 Bolt

3. Install elbow (10) with gasket (11) , bolt (12), and bolt (13).
   Show/hide table

   Table 17

   Item	Qty	Original Part
   15	1	8T-6765 Pipe Plug

Show/hide table



Illustration 19	g03299961
(15) 8T-6765 Pipe Plug

4. Make sure that there are two pipe plugs (15) on the rear housing of the aftercooler.
   Show/hide table

   Table 18

   Item	Qty	New Part
   16	1	8T-1715 Adapter
   17	1	6V-6609 O-Ring Seal

Show/hide table



Illustration 20	g03300137
(16) 8T-1715 Adapter (17) 6V-6609 O-Ring Seal

5. Install adapter (16) with O-Ring Seal (17) on the front of the aftercooler.
   Show/hide table

   Table 19

   Item	Qty	New Part
   18	3	180-8424 O-Ring Seal
   19	1	157-2348 Elbow
   20	2	6V-5138 O-Ring Seal
   21	1	032-1268 Connector
   22	2	8C-6871 Connector
   23	1	6V-9851 Elbow

Show/hide table



Illustration 21	g03300339
(18) 180-8424 O-Ring Seal (19) 157-2348 Elbow (20) 6V-5138 O-Ring Seal (21) 032-1268 Connector (22) 8C-6871 Connector (23) 6V-9851 Elbow

6. Install elbow (19) onto the wastegate with O-Ring Seal (18), and O-Ring Seal (20) .

7. Install connector (21), and connector (22) onto the wastegate.

8. Install elbow (23) onto the wastegate with O-Ring Seal (18).
   Show/hide table

   Table 20

   Item	Qty	New Part
   24	1	2T-2396 Elbow
   25	1	287-7261 Swivel Tee
   26	2	6v-5138 O-Ring Seal
   27	1	150-7158 Connector
   28	1	8C-7563 Elbow

Show/hide table



Illustration 22	g03300569
(24) 2T-2396 Elbow (25) 287-7261 Swivel Tee (25) 6v-5138 O-Ring Seal (27) 150-7158 Connector (28) 8C-7563 Elbow

9. Install elbow (24) on top of the cast elbow (11) .

10. Install swivel tee (25) with O-Ring Seal (26) onto the connector (27) .

11. Install elbow (28) onto swivel tee (25).
    Show/hide table

    Table 21

    Item	Qty	New Part
    29	3	180-8424 O-Ring Seal
    30	1	6V-9837 Swivel Tee
    31	1	8C-6871 Connector

Show/hide table



Illustration 23	g03300861
(29) 180-8424 O-Ring Seal (30) 6V-9837 Swivel Tee (31) 8C-6871 Connector

12. Install connector (31) with O-Ring Seal (39) on the right side of the aftercooler.

13. Install swivel tee (30) with O-Ring Seal (29) to connector (20).
    Show/hide table

    Table 22

    Item	Qty	New Part
    32	1	053-2294 Bolt
    33	2	5M-2894 Hard Washer
    34	2	4B-9302 Clip
    35	2	138-1490 Spacer
    36	2	6V-5138 O-Ring Seal
    37	1	394-9753 Tube As
    38	1	394-9928 Tube As
    39	2	180-8424 O-Ring Seal
    40	1	5M-2894 Hard Washer
    41	1	053-2294 Bolt
    42	1	0S-0509 Bolt
    43	1	5K-6438 Clip
    44	1	3S-7189 Bracket

Show/hide table



Illustration 24	g03302537
(32) 053-2294 Bolt (33) 5M-2894 Hard Washer (34) 4B-9302 Clip (35) 138-1490 Spacer (36) 6V-5138 O-Ring Seal (37) 394-9753 Tube As (38) 394-9928 Tube As (39) 180-8424 O-Ring Seal (40) 5M-2894 Hard Washer (41) 053-2294 Bolt (42) 0S-0509 Bolt (43) 5K-6438 Clip (44) 3S-7189 Bracket

14. Install tube assembly (37) with bolt (32), hard washer (33), clip (34), spacer (35) and O-Ring Seal (36) .

15. Install tube assembly (38) with O-Ring Seal (39), hard washer (40), bolt (41), bolt (42), clip (43), and bracket (44).
    Show/hide table

    Table 23

    Item	Qty	New Part
    45	1	6V-9851 Elbow
    46	1	180-8424 O-Ring Seal
    47	1	9X-2539 Elbow

Show/hide table



Illustration 25	g03310456
(45) 6V-9851 Elbow (46) 180-8424 O-Ring Seal (47) 9X-2539 Elbow

16. Install elbow (45) with O-Ring Seal (46) on elbow (47).
    Show/hide table

    Table 24

    Item	Qty	New Part
    48	2	6V-5064 O-Ring Seal
    49	1	173-0064 Elbow
    50	1	8T-1685 Tee
    51	2	250-2343 O-Ring Seal
    52	1	6V-8556 Nut
    53	1	6V-8942 O-Ring Reducer
    54	1	180-8424 O-Ring Seal
    55	1	6V-9851 Elbow

Show/hide table



Illustration 26	g03310976
(48) 6V-5064 O-Ring Seal (49) 173-0064 Elbow (50) 8T-1685 Tee (51) 250-2343 O-Ring Seal (52) 6V-8556 Nut (53) 6V-8942 O-Ring Reducer (54) 180-8424 O-Ring Seal (55) 6V-9851 Elbow

17. Install elbow (49) with O-Ring Seal (48) onto the engine right side water manifold.

18. Install tee (50) with O-Ring Seal (48) to elbow (49) .

19. Install O-Ring Seal (51), nut (52), and O-Ring Reducer (53) onto tee (50) .

20. Install elbow (55) with O-Ring Seal (54) onto O-Ring Reducer (53).
    Show/hide table

    Table 25

    Item	Qty	New Part
    56	1	395-0326 Tube As
    57	2	180-8424 O-Ring Seal
    58	1	1A-5183 Bolt
    59	1	5M-2894 Hard Washer
    60	1	138-1490 Spacer
    61	1	4B-0418 Clip

Show/hide table



Illustration 27	g03312185
(56) 395-0326 Tube As (57) 180-8424 O-Ring Seal (58) 1A-5183 Bolt (59) 5M-2894 Hard Washer (60) 138-1490 Spacer (61) 4B-0418 Clip

21. Install tube assembly (56) with O-Ring Seal (57) .

22. Install clip (61) on tube assembly (56) with bolt (58), hard washer (59), and spacer (60).
    Show/hide table

    Table 26

    Item	Qty	New Part
    62	1	180-8424 O-Ring Seal
    63	1	8C-8989 Elbow
    64	1	6V-8789 Tee

Show/hide table



Illustration 28	g03312480
(62) 180-8424 O-Ring Seal (63) 8C-8989 Elbow (64) 6V-8789 Tee

23. Install elbow (63) with O-Ring Seal (62), then install tee (64) with O-Ring Seal (62).
    Show/hide table

    Table 27

    Item	Qty	New Part
    62	4	180-8424 O-Ring Seal
    65	1	395-0274 Tube As

Show/hide table



Illustration 29	g03312596
(62) 180-8424 O-Ring Seal (65) 395-0274 Tube As

24. Install tube assembly (65) with O-Ring Seal (62).
    Show/hide table

    Table 28

    Item	Qty	New Part
    66	1	053-2294 Bolt
    67	2	5M-2894 Hard Washer
    68	2	9C-5336 Spacer
    69	1	4B-0418 Clip
    70	1	5M-8429 Clip
    71	1	395-0272 Tube As

Show/hide table



Illustration 30	g03313018
(66) 053-2294 Bolt (67) 5M-2894 Hard Washer (68) 9C-5336 Spacer (69) 4B-0418 Clip (70) 5M-8429 Clip (71) 395-0272 Tube As

25. Install tube assembly (71) with clip (69), clip (70), bolt (66), hard washer (67), and spacer (68). Tube assembly (71) is not straight, but has a slight angle. Carefully install tube assembly (71) so there is no contact with the aftercooler.
    Show/hide table

    Table 29

    Item	Qty	New Part
    72	1	6V-6609 O-Ring Seal
    73	1	005-4362 Elbow
    74	1	395-0330 Tube As
    75	1	0L-1352 Bolt
    76	1	138-1490 Spacer
    77	2	9X-6458 Hard Washer
    78	2	5M-1198 Clip
    79	2	5P-9297 Clip
    80	1	396-0995 Bracket
    81	2	9S-8752 Full Nut
    82	3	0L-1351 Bolt
    83	3	5M-2894 Hard Washer

Show/hide table



Illustration 31	g03313657
(72) 6V-6609 O-Ring Seal (73) 005-4362 Elbow (74) 395-0330 Tube As (75) 0L-1352 Bolt (76) 138-1490 Spacer (77) 9X-6458 Hard Washer (78) 5M-1198 Clip (79) 5P-9297 Clip (80) 396-0995 Bracket (81) 9S-8752 Full Nut (82) 0L-1351 Bolt (83) 5M-2894 Hard Washer

26. Install elbow (73) with O-Ring Seal (72) on top of the aftercooler.

27. Install tube assembly (74) with bolt (75), spacer (76), hard washer (77), and clip (78). Also the tube assembly (74) is supported by clip (79), bracket (80), full nut (81), bolt (82), and hard washer (83).
    Show/hide table

    Table 30

    Item	Qty	New Part
    85	1	0S-1591 Bolt
    86	1	6W-2928 Boss
    87	1	353-7956 Grommet
    88	1	4P-7233 Grommet
    89	1	2P-4437 Clip

Show/hide table



Illustration 32	g03515125
(74) 395-0330 Tube As (81) 9S-8752 Full Nut (83) 5M-2894 Hard Washer (85) 0S-1591 Bolt (86) 6W-2928 Boss (87) 353-7956 Grommet (88) 4P-7233 Grommet (89) 2P-4437 Clip

28. Install grommet (87) around the boost sensing line.

    Note: Grommet (87) is installed around the smaller line.

29. Install grommet (88) around the water line.

30. Install two clips (89) around grommets (87) and (88) use one boss (86), one bolt (85), two washers (83), and one nut (81).
    Show/hide table

    Table 31

    Item	Qty	New Part
    90	1	6V-8625 Elbow
    91	1	180-8424 O-Ring Seal
    92	1	6V-6609 O-Ring Seal

Show/hide table



Illustration 33	g03515165
(90) 6V-8625 Elbow (91) 180-8424 O-Ring Seal (92) 6V-6609 O-Ring Seal

31. Install elbow (90) with O-Ring Seal (91) and O-Ring Seal (92) onto the left side water manifold.

Group 1: 339-3788 Exhaust Shield Gp Update Procedure

Note: The following engine serial numbers apply for the removal procedure: (S/N: JEF00101-00107,00109-00131,00135,00149-00162,00165-00171,00174-00189,01001-01035)

Show/hide table



Illustration 34	g03315544
(1) 383-2306 Shield As (2) 383-2313 Shield As (3) 383-2316 Shield As (4) 383-2310 Shield As (5) 383-2304 Shield As (7) 383-2308 Shield As (8) 383-2319 Shield As (9) 342-4814 Exhaust Shield (10) 342-4816 Exhaust Shield (11) 342-4815 Exhaust Shield (12) 342-4813 Exhaust Shield (13) 5P-4116 Hard Washer (14) 5K-0906 Bolt (15) 383-2318 Shield As (16) 342-4817 Bracket (17) 4M-0061 Bolt (18) 417-8520 Shield As (19) 383-2315 Shield As

1. For the exhaust manifold the following parts will need to be installed. Install the shield assembly (8), shield assembly (9), exhaust shield (10), exhaust shield (11), and exhaust shield (12). Also install hard washer (13), bolt (14), shield assembly (15), bracket (16), and bolt (17) .

2. For the turbocharger and wastegate the following parts will need to be installed. Install the shield assembly (5), shield assembly (18), and shield assembly (19). Also for the turbocharger install shield assembly (1), shield assembly (2), shield assembly (3), shield assembly (4), shield assembly (6), and shield assembly (7).
   Show/hide table

   Table 33

   Item	Qty	New Part
   20	1	383-2305 Shield As
   21	1	383-2303 Shield As
   22	1	383-2309 Shield As
   23	1	383-2307 Shield As
   24	1	383-2312 Shield As
   25	1	383-2314 Shield As

Show/hide table



Illustration 35	g03316119
(20) 383-2305 Shield As (21) 383-2303 Shield As (22) 383-2309 Shield As (23) 383-2307 Shield As (24) 383-2312 Shield As (25) 383-2314 Shield As

3. For the turbocharger install shield assembly (20), shield assembly (21), shield assembly (22), shield assembly (23), shield assembly (24), and shield assembly (25) .

Group 2: 339-3788 Exhaust Shield Gp Procedure

Note: The following engine serial numbers apply to the installation procedure: (S/N: JEF01036-01107,01109-01137,01140-01148,01150-01165,01167-01168,01170-01298,01300-01351,01353-01408)

Show/hide table



Illustration 36	g03316499
(1) 383-2306 Shield As (2) 383-2313 Shield As (3) 383-2316 Shield As (4) 383-2310 Shield As (5) 383-2304 Shield As (6) 383-2311 Shield As (7) 383-2308 Shield As (8) 417-8520 Shield As (9) 383-2315 Shield As

1. Install the turbocharger shield assembly (1), shield assembly (2), shield assembly (3), shield assembly (4). Also install shield assembly (5), shield assembly (6), shield assembly (7), shield assembly (8), and shield assembly (9).
   Show/hide table

   Table 35

   Item	Qty	New Part
   10	1	383-2305 Shield As
   11	1	383-2303 Shield As
   12	1	383-2309 Shield As
   13	1	383-2307 Shield As
   14	1	383-2312 Shield As
   15	1	383-2314 Shield As

Show/hide table



Illustration 37	g03316642
(10) 383-2305 Shield As (11) 383-2303 Shield As (12) 383-2309 Shield As (13) 383-2307 Shield As (14) 383-2312 Shield As (15) 383-2314 Shield As

2. Install shield assembly (10), shield assembly (11), shield assembly (12), shield assembly (13), shield assembly (14), and shield assembly (15) around the turbochargers.

Group 3 and 4: 339-3788 Exhaust Shield Gp

Note: The following engine serial numbers apply for this removal and installation procedure:

Show/hide table



Illustration 38	g03316669
(1) 417-8520 Shield As

1. Install the shield assembly (1) next to the wastegate.