| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | - | Loctite C5-A Copper Anti-Seize Lubricant | - |
| B | 195-4609 | Seal Pick | 1 |
| C | - | Isopropyl Alcohol | - |
| D | 5P-4996 | Plug | 2 |
Start By:
- Remove the exhaust elbow.
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Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the start switch off when changing fuel filters or water separator elements. Clean up fuel spills immediately. |
| NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool. |
- Turn the fuel supply to the OFF position and turn the power disconnect switch to the OFF.
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Illustration 1 g02848517 - Disconnect clamp assemblies (1) and remove hose (2).
- Remove bolts (4), tube assembly (3), and the gasket. Discard the gasket.
Note: Cap all hose assemblies, with Tooling (D), and fittings that are disconnected o prevent fluid loss. This action will also keep contaminants out of the systems.
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Illustration 2 g02848516 - Remove bolt (5) and disconnect harness assembly (6).
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Illustration 3 g02848515 - Disconnect hose assemblies (7) and hose assembly (8).
- Remove allen bolt (9) and the clamp assembly. Position cable assembly (10) out of the way.
- Disconnect flame detection temperature sensor (11).
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Illustration 4 g02153382 - Remove nuts (16) and combustion head (15).
- Remove gasket (14), tube assembly (13), and gasket (12). Discard the gaskets.
Note: The gaskets are for one time use only. Replace with new gaskets upon installation.
- If required, remove studs (17).
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Illustration 5 g03686649 - Remove fittings (18) and (19).
- Remove spark plug (20) and fittings (21).
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Illustration 6 g02481277 - Use Tooling (B) to remove O-ring seals (22) and (23) from cable assembly (10). Discard the O-ring seals.
- Install combustion head (15) in reverse order of removal.
- Apply Tooling (A) to the threads of studs (17). Tighten studs (17) to a torque of
17 ± 2 N·m (150 ± 18 lb in) . - Apply Tooling (A) to the threads of the studs and nuts (16). Tighten nuts (16) in a crisscross pattern to a torque of
23 ± 3 N·m (204 ± 27 lb in) . Tighten nuts (16) again in a crisscross pattern to a torque of28 ± 3 N·m (21 ± 2 lb ft) . Tighten nuts (16) again in a crisscross pattern to a torque of28 ± 3 N·m (21 ± 2 lb ft) .Show/hide tableUse caution when you are using isopropyl alcohol. Avoid prolonged skin contact with isopropyl alcohol.
Vapors may be harmful if inhaled. Use only in a well ventilated area. Do not smoke while using isopropyl alcohol.
Isopropyl alcohol is flammable. Do not use near an open flame or near welding operations. Keep isopropyl alcohol away from heated surfaces exceeding
482°C (900°F) .Note: This connection is an electrical connection and cannot be lubricated with a petroleum-based lubricant. Isopropyl alcohol is the only approved lubrication for this connection.
- Lubricate new O-ring seals (22) and (23) with Tooling (C) prior to installation.
- Tighten fitting (21) to a torque of
60 ± 6 N·m (44 ± 4 lb ft) . - Tighten fittings (19) and (18) to a torque of
30 ± 2 N·m (266 ± 18 lb in) . - Tighten spark plug (20) to a torque of
57.5 ± 4 N·m (42 ± 3 lb ft) . - Apply Tooling (A) to the threads of flame detection temperature sensor (11) and install the sensor. Tighten flame detection temperature sensor (11) to a torque of
45 ± 5 N·m (33 ± 3 lb ft) . - Check the coolant level. If necessary, refer to Operation and Maintenance Manual, "Coolant - Change" for the proper filling procedures.
- Apply Tooling (A) to the threads of studs (17). Tighten studs (17) to a torque of
- Perform the ARD ignition test. Refer to Troubleshooting Manual, "ARD Ignition - Test".