Procedure for Replacing the 339-3161 Water Lines Group on G3508B Engines {1355, 1380, 1393} Caterpillar

Procedure for Replacing the 339-3161 Water Lines Group on G3508B Engines {1355, 1380, 1393}

Usage:

Engine:: G3508B (S/N: RBK1-UP)

Introduction

This Special Instruction outlines the steps needed to rework the water lines group for the G3508B engines.

Do not perform any procedure contained in this publication or order any parts until you have read and understand the directions in this publication.

Procedure for Replacing the 339-3161 Water Lines Gp

Remove the Original Parts

Note: Retain all removed parts until the installation procedure is complete, some parts may be reused.

Drain the cooling system to a level beneath the engine oil cooler.

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Table 1
Required Parts to Remove from Engine
Item	Part	Qty
1	0L-1143 Bolt	1
2	1A-2029 Bolts	2
3	5G-3676 Grommets	2
4	6V-3251 O-Ring Seals	3
5	6V-5064 O-Ring Seal	1
6	6V-6609 O-Ring Seal	1
7	6V-8556 Nut	1
8	6V-8716 Connector	1
9	6V-8942 O-Ring Reducer	1
10	6V-9837 Swivel Tees ⁽¹⁾	2
11	6V-9839 Swivel Tee	1
12	6V-9841 Connector	1
13	7S-3916 Clips	3
14	7S-3919 Clips	3
15	9S-8752 Full Nut	2
16	9X-6458 Hard Washers	4
17	104-9054 Connector	1
18	180-8424 O-Ring Seals	14
19	250-2343 O-Ring Seals	5
20	318-0820 Grommet	1
21	339-3171 Tube As	1
22	341-8719 Bracket	1
23	345-6735 Bracket	1
24	345-6736 Hose As	1
25	345-6738 Tube As	1
26	345-6739 Hose As	1
27	345-6740 Hose As	1
28	6V-9851 Elbow ⁽¹⁾	1

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^( 1 )

Retain this part for the installation procedure.

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Table 2
Line Group Parts that Stay Installed
Item	Part	Qty
1	0S-1590 Bolts	3
2	6V-8640 Connector	1
3	6V-8775 Face Seal Tee	1
4	6V-9830 Cap As	1
5	6V-9837 Swivel Tee	1
6	7E-7547 Spacer	1
7	7N-3368 Gasket	1
8	8C-4424 Plugs	2
9	8C-6871 Connectors	3
10	8T-7492 Connectors	2
11	9S-4190 O-Ring Plug	1
12	9X-6458 Hard Washer	1
13	144-2980 Housing	1
14	216-7485 O-Ring Seals	4
15	250-2343 O-Ring Seals	2
16	339-3169 Hose As	1

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Illustration 1	g03403957

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Illustration 2	g03403966

Remove the water lines group as shown in Illustration 1 and 2

Installation Procedure

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Table 3
Item	Qty	New Part
1	2	6V-8639 Connectors
2	2	180-8424 O-Ring Seals
3	1	434-7490 Adapter
4	1	5P-8924 Union
5	2	6V-5064 O-Ring Seals

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Illustration 3	g03403976
(1) 6V-8639 Connector (2) 180-8424 O-Ring Seal (3) 434-7490 Adapter (4) 5P-8924 Union (5) 6V-5064 O-Ring Seal

Assemble the parts listed in table 3 and install the tee on the right side water manifold.

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Table 4
Item	Qty	New Part
6	1	6V-9837 Swivel Tee
7	1	434-7488 Tube As
8	1	3S-0127 Bolt
9	1	5M-2894 Hard Washer
10	1	8T-1887 Clip
11	1	4P-7233 Grommet
12	1	8T-1888 Clip
13	1	205-6716 Spacer

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Illustration 4	g03403977
(6) 6V-9837 Swivel Tee (7) 434-7488 Tube As (8) 3S-0127 Bolt (9) 5M-2894 Hard Washer (10) 8T-1887 Clip (11) 4P-7233 Grommet (12) 8T-1888 Clip (13) 205-6716 Spacer

Remove the 1T-0720 Bolt before installing the tube assembly.

Attach tube assembly (7) to the tee (6) that should still be on the engine.

Attach the other end of the tube assembly to (3) to tee that was installed in step 1.

Install grommet (11), clip (10), and clip (12) around tube assembly (7) .

Attach clips (10) and clip (12) to the aftercooler with the new bolts supplied.

Now secure the tube assembly (7) to the top and bottom tees (3) and (6). The vent line connection is now 13/16" size fitting.

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Table 5
Item	Qty	New Part
14	1	434-7487 Tube As
15	2	6V-7543 Bolts
16	2	5M-2894 Hard Washers
17	2	8T-1887 Clips
18	2	4P-7233 Grommets
19	2	8T-1888 Clips
20	2	199-7854 Spacers
21	1	6V-8775 Face Seal Tee
22	1	180-8424 O-Ring Seal
23	1	6V-9830 Cap As

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Illustration 5	g03403978
(14) 434-7487 Tube As (15) 6V-7543 Bolt (16) 5M-2894 Hard Washer (17) 8T-1887 Clip (18) 4P-7233 Grommet (19) 8T-1888 Clip (20) 199-7854 Spacer (21) 6V-8775 Face Seal Tee (22) 180-8424 O-Ring Seal (23) 6V-9830 Cap As

Remove the 1T-0720 Bolt before installing the tube assembly.

Attach one side of the tube assembly (3) to the tee that was installed in step 1.

Install grommet (18), clip (17), and clip (19) around tube assembly

Repeat process on the second set of clips. Install grommet (18), clip (17), and clip (19) around tube assembly

Install O-Ring (22) on the bottom side of the tee (21) and secure cap (23) to the bottom side of tee (21). The tee (21) is only used on engines in group 1 and not group 2.

Secure all bolts and fittings that was installed.

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Table 6
Item	Qty	New Part
24	1	6V-5063 O-Ring Seal
25	1	6V-9007 Elbow
26	1	250-2343 O-Ring Seal
27	1	434-7486 Hose As
28	1	3B-1915 Bolt
29	2	9X-6458 Hard Washer
30	1	5P-7464 Clip
31	1	6V-1249 Grommet
32	1	5P-7465 Clip
33	1	437-6980 Bracket
34	2	9X-6458 Hard Washer
35	1	9S-8752 Full Nut
36	1	250-2343 O-Ring Seal

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Illustration 6	g03403980
(24) 6V-5063 O-Ring Seal (25) 6V-9007 Elbow (26) 250-2343 O-Ring Seal (27) 434-7486 Hose As (28) 3B-1915 Bolt (29) 9X-6458 Hard Washer (30) 5P-7464 Clip (31) 6V-1249 Grommet (32) 5P-7465 Clip (33) 437-6980 Bracket (34) 9X-6458 Hard Washer (35) 9S-8752 Full Nut (36) 250-2343 O-Ring Seal

Install elbow (25) with O-Ring (24) to the tee (3) that was installed in Step 1.

Install hose assembly (26) with O-Ring Seal (24) to elbow (25) .

Install clip (30), grommet (31), clip (32) on tube assembly (27) with bolt (28), washer (29), bracket (33), washer (34), full nut (35).

When securing the clips and connectors, make sure the hose assembly (27) does not kink.

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Table 7
Item	Qty	New Part
37	1	5G-1442 Gasket
38	1	130-7224 Adapter
39	1	8C-6869 Connector
40	1	8L-2779 O-Ring Seal
41	1	3E-2333 Elbow
42	3	180-8424 O-Ring Seals
43	1	444-2619 Hose As
44	2	3S-0127 Bolts
45	4	5M-2894 Hard Washers
46	2	205-6716 Spacers
47	1	1A-2029 Bolt
48	1	8T-1887 Clip
49	1	100-3237 Grommet
50	1	8T-1888 Clip
51	1	437-8491 Bracket
52	1	9S-8752 Full Nut

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Illustration 7	g03677363
(37) 5G-1442 Gasket (38) 130-7224 Adapter (39) 8C-6869 Connector (40) 8L-2779 O-Ring Seal (41) 3E-2333 Elbow (42) 180-8424 O-Ring Seal (43) 444-2619 Hose As (44) 3S-0127 Bolt (45) 5M-2894 Hard Washer (46) 205-6716 Spacer (47) 1A-2029 Bolt (48) 8T-1887 Clip (49) 100-3237 Grommet (50) 8T-1888 Clip (51) 437-8491 Bracket (52) 9S-8752 Full Nut

Remove two 1T-0720 Bolts from the aftercooler will be replaced by new bolts (44) as shown in Illustration 7.

Install adapter (38) with gasket (37) .

Install straight adapter (39) on elbow (41) with O-Rings (40) and (42) .

Attach hose assembly (43) to elbow (41) and exhaust bypass connection.

Install bracket assembly (51) with new bolts (44), washers (45), and spacers (46 ) to the aftercooler.

Install clip (48), grommet (49), and clip (50) on the hose assembly. Attach the clip (48) and (50) to the bracket assembly (51) with bolt (47), two washers (45) and nut (52).

Secure all bolts and fittings that were installed.

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Table 8
Item	Qty	New Part
53	1	7W-3448 Elbow
54	1	5G-1442 Gasket
55	1	2T-1925 Elbow
56	1	8L-2779 O-Ring Seal
57	1	3E-7403 Adapter
58	5	180-8424 O-Ring Seals
59	1	6V-9830 Cap As
60	1	6V-9837 Swivel Tee
61	1	456-6982 Hose and Tube As
62	2	1N-7284 Bolts
63	2	5M-2894 Hard Washers
64	2	8T-1887 Clips
65	2	4P-7233 Grommets
66	2	8T-1888 Clips
67	2	133-6934 Spacers
68	1	6V-9851 Elbow
69	1	8C-6871 Connector

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Illustration 8	g03664879
(53) 7W-3448 Elbow (54) 5G-1442 Gasket (55) 2T-1925 Elbow (56) 8L-2779 O-Ring Seals (57) 3E-7403 Adapter (58) 180-8424 O-Ring Seal (59) 6v-9830 Cap As (60) 6V-9837 Swivel Tee (61) 456-6982 Hose and Tube As

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Illustration 9	g03664893
(61) 456-6982 Hose and Tube As (62) 1N-7284 Bolt (63) 5M-2894 Hard Washer (64) 8T-1887 Clip (65) 4P-7233 Grommet (66) 8T-1888 Clip (67) 133-6934 Spacer (68) 6V-9851 Elbow (69) 8C-6871 Connector

Install elbow (53) and gasket (54) with the previously installed bolts.

Install elbow (55) with O-Ring (56) onto elbow (53) .

Install straight adapter (57) with O-Ring (56) onto elbow (55) .

Assemble the tee adapter with O-Rings (58) in each opening and secure the cap (59) to the tee (60). Attach the assembled tee adapter (60) to the straight adapter (57) and to the tube assembly (61) .

Install clip (64), grommet (65), and clip (66) onto the tube assembly. Attach the clips (64) and (66), spacer (67) and washer (63) to the aftercooler with bolt (62) .

Remove straight adapter (69) in order to install new O-Ring (58) onto the wastegate, if necessary.

Note: Elbow (68) will be removed from the engine in Step 33 and reused in the location shown in Illustration 9.

Connector (69) should already be installed on the wastegate. Install the elbow (68) with O-Ring (58) to the tube assembly (61) and connector (69).

Secure all bolts and fittings that was installed.
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Table 9
Item Qty New Part

71 1 9S-4190 Plug

72 1 6V-3251 O-Ring Seal

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Illustration 10	g03407592
(71) 9S-4190 Plug (72) 6V-3251 O-Ring Seal

Remove the tube assembly and the 6V-9851 Elbow and retain, the elbow will be installed in Step 31. Replace with plug (72) and O-Ring (71) as shown in Illustration 10.

Procedure for Replacing the 339-3157 Air Lines Group

Removal of the Old Lines Group

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Illustration 11	g03407594

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Table 10
Item	Qty	Remove Old Parts
1	1	2T-2305 Elbow
2	1	345-2239 Tube As
3	1	8L-2786 O-Ring Seal
4	1	6V-8723 Elbow
5	1	9S-4185 Plug
6	1	8L-2786 O-Ring Seal

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Illustration 12	g03407595
(1) 2T-2305 Elbow (2) 345-2239 Tube As (3) 8L-2786 O-Ring Seal (4) 6V-8723 Elbow

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Illustration 13	g03407601
(5) 9S-4185 Plug (6) 8L-2786 O-Ring Seal

Remove elbow (1), tube assembly (2), elbow (4), and O-Ring (3). After removing elbow (4) install a plug (5) and O-Ring seal (6) in place.
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Table 11
Item Qty New Part

7 1 005-4362 Elbow

8 2 6V-6609 O-Ring Seals

9 1 8T-1715 Adapter

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Illustration 14	g03407597
(7) 005-4362 Elbow (8) 6V-6609 O-Ring Seals (9) 8T-1715 Adapter

Remove the plug 9S-4185 and O-Ring 3K-0360 on the far left port of the aftercooler.

Assemble the straight adapter (9) with O-Rings (8) and (8), elbow (7) and install the assembled adapter in the far left port of the aftercooler.

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Table 12
Item	Qty	New Part
10	1	032-1268 Connector
11	1	434-7483 Tube As
12	2	1A-2029 Bolts
13	2	5M-2894 Hard Washers
14	2	5P-9297 Clips
15	2	7X-0732 Spacers

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Illustration 15	g03407599
(10) 032-1268 Connector (11) 434-7483 Tube As (12) 1A-2029 Bolts (13) 5M-2894 Hard Washers (14) 5P-9297 Clips (15) 7X-0732 Spacers

Install the elbow (10) to the wastegate.

Install tube assembly (11) to wastegate elbow (10) and attach the other end to the assembled adapter (5) from the previous step.

Install clips (14) onto the tube assembly and attach clips to the aftercooler with bolts (12), washers (13), and spacers (15).

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Table 13
Item	Qty	New Part
16	2	0S-1594 Bolts
17	6	5M-2894 Hard Washers
18	4	234-0216 Clamps
19	2	353-7956 Grommets
20	2	4P-7233 Grommets
21	2	9S-8752 Full Nut

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Illustration 16	g03407603
(16) 0S-1594 Bolts (17) 5M-2894 Hard Washers (18) 234-0216 Clamps (19) 353-7956 Grommets (20) 4P-7233 Grommets (21) 9S-8752 Full Nut

Install grommets (19) and (20), clamps (18) with one washer (17) placed between the clamps to separate the clamps slightly, and clamps around both tube assembly.

Secure the bolts (16), washers (17), and nut (21) on the bottoms of the clamps (18).

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Table 14
Item	Qty	New Part
22	1	8T-9101 Bolt
23	1	9X-6458 Hard Washer
24	1	5P-7464 Clip
25	1	6V-1249 Grommet
26	1	5P-7465 Clip
27	1	7E-7547 Spacer