Procedure to Convert the Marine Auxiliary Diesel Electric Power (DEP) C280-16 Engine to a Main Propulsion Conversion C280-16 Engine {1051, 1052, 108D, 1152, 1205, 1302, 1307, 1308, 1319, 1326, 1403, 1901, 7490} Caterpillar

Engine

C280-16 (S/N: S4M100-107)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

This Special Instruction provides the following information for C280-16 Engine:

• Replacement of the dry sump oil pan with the standard marine propulsion wet sump oil pan.

• Replacement of the front engine crankshaft damper.

• Replacement of the jacket water engine outlet water connection to RH side (for half of the engines) and the gaskets.

• Replacement the ECM panel.

• Replacement of the PD box.

• Addition of J1939 cable to RH wiring harness assembly.

• Addition of turbocharger oil monitoring sensors, lines, and associated harnessing.

• Replacement of supervisory display panel.

• Installation of dual SCR system harness.

• Installation and marking of oil gauge group.

• Removal of flywheel guard.

• Addition of air cleaner adapter.

• Reconfigure of pre-lubrication system.

• Replacement of engine mounting feet.

• Addition of engine lifting eyes (for previously packaged gensets).

Safety Section

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide"for tools and supplies to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations.

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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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.

Replacement of the Oil Pan

Replace Oil Pan

Reference: Disassembly and Assembly, UENR0127, Engine Oil Pan-Remove and Install

Remove Existing Dry Pan

1. Drain all the oil from the pan if required.

2. Remove 501-6552 Engine Oil Lines Gp.

3. Remove 381-4041 Engine Oil Lines Gp.

4. Remove 465-1333 Oil Pan Gp.

Install New Wet Pan

Required Parts

Table 1

Qty	Part Number	Part Name
1	392-2899	Oil Pan Gp.
1	460-4215	Engine Oil Lines Gp.
1	493-7534	Cover Gp. (Engine Oil Lines Gp)
1	500-6475	Fastener Gp (Oil Pan Gp.)
1	396-1902	Fastener Gp (Oil Pan Gp.)
1	389-6219	Drain Gp-Oil Pan
1	389-6220	Plug Gp.
1	419-4369	Oil Pain Drain Gp.
1	419-4372	Plug Gp.

Installation Procedure

1. Install 392-2899 Oil Pan Gp along with 500-6475 Oil Pan Fastener Gp and 396-1902 Oil Pan Fastener Gp.

2. Install 460-4215 Engine Oil Lines Gp.

3. Install 493-7534 Engine Oil Line Cover Gp.

4. On the rear side of the oil pan, install 389-6219 Engine Oil Drain Gp and 389-6220 Engine Fastener Gp.

5. On the front of the oil pan, install 419-4369 Engine Oil Drain Gp and 419-4372 Engine Fastener Gp.

Replacement of the Damper

Replace the Damper

Reference: Disassembly and Assembly, UENR0127, Vibration Damper-Remove and Install

Remove Existing Damper

1. Remove 1W-0920 Damper Guard Gp and 456-7776 Gear Fastener Gp.

2. Remove 449-1833 Damper Gp.

Install New Damper

Table 2

Required Parts
Qty	Part Number	Part Name
1	392-2909	Damper Gp.
1	419-4382	Damper Guard Gp.
1	419-4384	Fastener Gp.

1. Install 392-2909 Damper Gp.

2. Install 419-4382 Damper Guard Gp and 419-4384 Damper Fastener Gp.

Replacement of the Water Connection on Right Side of Engine

Disassembly and Assembly, UENR0127

1. Mover the 462-1859 Air Separator Group to the opposite side as shown for engine serial numbers (S/N: S4M00101-00101,00103-00103,00105-00105,00107-00107).

2. Move both 7W-3271 Cover and 7C-9332 Cover As and the 502-0134 Jacket Water Engine Sensor Gp to the opposite side for the same four engines.

3. Replace all four 7W-3269 Gaskets.

Illustration 1	g06144528
Movement of Water Connection to Left.

Replacement of the ECM Panels

Replace ECM

Reference: Disassembly and Assembly, UENR0127

Remove Existing ECM

1. Remove 493-4308 Control Box Gp.

Install New ECM

Table 3

Required Parts
Qty	Part Number	Part Name
1	519-8043	Box GP-Cont

1. Install 519-8043 Control Box Gp.

Replacement of the PD Box

Replace PD Box

Reference: Disassembly and Assembly, UENR0127

Remove Existing PD Box

1. Remove 354-2819 Circuit Breaker Panel Gp.

Install New PD Box

Table 4

Required Parts
Qty	Part Number	Part Name
1	522-0256	Mounting Gp

1. Install 522-0256 Mounting Gp.

Addition of CAN C-J1939 Cable to the Right-Hand Harness

Add J1939 Cable (CAN C Wires)

Table 5

Required Parts
Qty	Part Number	Part Name
1 (623 mm)	235-2765	Conduit-Bulk
1	239-5374	Connector
1	239-5375	Nut-M32
1	291-1960	Adapter

Reference: Disassembly and Assembly, UENR0127

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Illustration 2	g06144556
Removal of Right-Hand Wiring Harness Tray Cover (1) Wiring Harness Tray Cover Removed (2) SCR System Connector (3) ECM System Connector

1. Remove the wiring harness tray cover as shown in Illustration 2.

2. Remove connector back-shells on the right-hand harness ECM panel connector and SCR system connector.
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   Illustration 3	g06144561
   Pin Out of SCR Panel Connector

3. Remove all wires from SCR system connector to allow for removal of the plastic conduit, note the wiring marking according to the pinout shown in Illustration 3.

4. Remove plastic conduit and fittings.

5. Pull the wire bundle back into the tray and increase the hole size to 35 mm on the bottom harness tray.
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   Illustration 4	g06158587
   New Conduit and Fittings for SCR Connector (4) 239-5375 Nut (5) 239-5374 Connector (6) 235-2765 Flexible Conduit (623 MM) PMA_N29 (7) 297-3218 Clips (8) 7K-1181 Cable Straps (9) 291-1960 Adapter

6. Reinstall wires through back shell to back of the connector and install larger size 235-2765 Flexible Conduit of 625 mm length (approximately) showing in Illustration 4 including a new J1939 cable (Can C Wire) 153-2707 Electrical Cable between the SCR system connector and the ECM panel connector.
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   Illustration 5	g06144573
   Pin Out for ECM and SCR Connector

7. Use Caterpillar 9X-3401 Connector Pins and 9X-3402 Connector Socket and 133-0969 Socket Connector to terminate the wire ends to the connectors as shown in Illustration 5 for the CANC Wires.

8. Reinstall the SCR system connector using the pinout in the Illustration 3 and secure the back shell.

9. Resecure harness to the engine as shown in Illustration 4.

10. Reinstall tray cover.

Addition of the Turbocharger Oil Monitoring Sensor, Lines, and Associated Harnessing

Reconfigure Turbocharger Oil Supply and Drain Lines

Table 6

Required Parts
Qty	Part Number	Part Name
1	520-8137	Elbow-Turbo
1	201-9897	Cross-37 Degree
1	030-7965	Adapter Elbow
1	030-6936	Reducer-Flared
1	8M-0744	Nut-Flared
1	8T-2909	Union-Adapter
1	521-8360	Sensor Gp-Engine
1	520-0761	Wiring Gp

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Illustration 6	g06158594
(1) 520-8137 Elbow-Turbo (2) 201-9897 Cross (3) 030-7965 Elbow (4) 030-6936 Flared Reducer (5) 8M-0744 Flared Nut (6) 8T-2909 Adapter Union

1. Reconfigure turbocharger oil lines group to 519-7315 Lines GP-Turbo.

   1. Replace 4W-7323 Cast Elbow with 520-8137 Elbow-Turbo.

   2. Replace 7D-0978 Adapter-Tee with 201-9897 Cross.

   3. Add 030-7965 Elbow, 030-6936 Flared Reducer, 8M-0744 Flared Nut, and 8T-2909 Adapter Union.
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   Illustration 7	g06144607
   Turbocharger Sensors and Harness

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   Illustration 8	g06158598
   Detail A (Turbocharger Sensors and Harness) Route with Existing Wiring Harness and Straps) (7) 522-2418 Temperature Sensor (8) 521-3356 Harness Assembly (9) 7K-1181 Tie Strap

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   Illustration 9	g06158607
   Detail B (Turbocharger Sensors and Harness) Detail C (Turbocharger Sensors and Harness) (9) 7K-1181 Cable Strap (10) 522-1732 Check Valve (11) 520-7335 Pressure Sensor (12) 132-5789 Bracket (13) 277-1873 Ladder Clip (14) 4P-7581 Ladder Clip

2. Install new 521-8360 Sensor Gp-Engine (temperature sensors on the cast elbows and pressure sensor on the union adapter) and 520-0761 Wiring Gp.

Replacement of Display Panel

Install New Display Panel

Table 7

Required Parts
Qty	Part Number	Part Name
1(1)	521-1560	Panel GP-ELEK (RH)
1(1)	521-1570	Panel GP-ELEK (LH)
1(1)	520-0760	Wiring Harness EXT

(1)	This is going to half (four) of the engines only.

1. Replace current 444-1272 Electronic Panel Gp (Qty-8) with a new 521-1560 Panel Gp-Elek (Qty-4) and 521-1570 Panel Gp-Elek (Qty-4).

   1. The panels will include the following options - local throttle group 521-1561, telematics 521-1561, wiring group 521-1561, OMD override 521-1561, and relay module (MK-14) 521-1561.

   2. Use extension wiring harness 520-0760 to connect ECM and display panel.

Installation of Dual SCR System Harness

Cat Clean Emission Module Application & Installation Guide

Reference: Application and Installation Guide, LEBM0023

Installation of New Dosing Cabinet and CEM

Table 8

Required Parts
Qty	Part Number	Part Name
2(1)	498-3600	Module Ar-DEF
2	476-5501	Conversion Gp
1	520-0758	Wiring GP
2(1)	437-4238	Wiring GP
2(1)	434-3160	Wiring Kit

(1)	Can use the one existing harness and Module AR-DEF supplied on serial numbers S/N:S4M00100-00107.

1. Update 518-1556 Software in SIS web in the previously shipped 447-7158 Diesel Exhaust Fluid Module Ar.

2. Connect two 498-3600 DEF Module Ar. or 447-7158 Diesel Exhaust Fluid Module Ar and two 476-5501 Conversion Gp (SCR) for every engine.
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   Illustration 10	g06158612
   ECM Split for Two SCR (Dosing Cabinet) Connection. (1) Right-Hand Harness (2) 520–0758 SCR Split Interconnect Wiring Group and 521–2827 Harness

3. Use the 520-0758 Jumper Harness for connection of two dosing cabinets to the engine wiring harness.
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   Illustration 11	g06158619
   SCR Connection Detail Diagram (A) 520-0758 ECM Split (B) 437-4238 Harness (C) 498-3600 Dosing Cabinet (D) 434-3160 Harness Kit (E) 399-9971 SCR Module

4. Use two 437-4238 Harnesses to connect the engine to the dosing cabinets.

5. Use 434-3160 Harness Kit to connect each SCR system.

Relocation of the Oil Level Switch

Table 9

New Parts
Qty	Part Number	Part Name
2	0L-1143	Bolt
2	1B-4971	Spacer
2	3V-3308	Hard Washer
2	8F-8513	Clip
N/A	237-3860	Tape
1	369-6622	Tube As
1	529-6119	Cover
1	529-7213	Plate As
1	533-3046	Tube As

Illustration 12	g06190484

1. Remove small lines to centrifugal oil filters.

2. Disconnect the wiring harness from the crankcase pressure.

3. Remove the oil fill cover with the switch and oil gauge installed from cylinder 3.

4. Remove the centrifugal oil filter cover from cylinder 7.

5. Remove the side cover with from cylinder 13.
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   Illustration 13	g06190488
   The original plate assembly and cover.

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   Illustration 14	g06190497
   The original plate assembly and cover. (1) 169-9517 Plate As (2) 169-9519 Cover

6. Remove plate assembly (1) and cover (2).
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   Illustration 15	g06190499
   The new plate assembly and cover. (3) 529-7213 Plate As (4) 529-6119 Cover

7. Install plate assembly (3) and cover (4).
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   Illustration 16	g06190476
   The original location of the side covers.

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   Illustration 17	g06190480
   The new location of the side covers.

8. Reinstall the oil fill cover, the centrifugal oil filter cover, and the side cover with the original hardware and seals. Refer to Illustration 17 for the correct location of the covers.

9. Reconnect wiring harness to the crankcase pressure sensor. Reroute wiring harness as needed.
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   Illustration 18	g06190523
   (5) 8F-8513 Clip (6) 0L-1143 Bolt (7) 3V-3308 Hard Washer (8) 1B-4971 Spacer (9) 369-6622 Tube As (10) 533-3046 Tube As

10. Use 237-3860 Tape on all joints.

    Note: Reuse the tube assemblies and hardware in blue.

11. Install the centrifugal oil filter supply lines.

Installation and Marking of Oil Gauge Group

Marking Oil Gauge Group

Reference: Disassembly and Assembly, UENR0127

Remove Existing cover Assembly

1. Remove the existing 483-7462 Crankcase Cover As installed on cylinder number three.

Installation of New Cover Group

Table 10

Required Parts
Qty	Part Number	Part Name
1	9Y-9924	Cover-Cyl Block
1	4P-5304	Tube As.
1	6V-4314	Seal-O-Ring
1	9Y-6874	Elbow-Oil-Ring
4	3V-3308	Washer-Hard
4	0S-1590	Bolt
1	6I-4545	Seal-O-Ring
1	7E-1659	Cap GP-Oil
1	396–1906	Fastener GP
1	474–9098	Gauge GP-O Level

1. Assemble new 9Y-9924 Cylinder Block Cover, 4P-5304 Oil Fill Tube As, 6V-4314 O-Ring Seal group, and 9Y-6874 Oil Filler Elbow using four 3V-3308 Hard Washers and four 0S-1590 Bolts.

2. Install above assembly and 6I-4545 O-Ring Seal Group.

3. Install 7E-1659 Engine Oil Filler Cap Gp.

4. Assemble 396-1906 Oil Level Gauge Fastener Gp with 474-9098 Oil Level Gauge Gp (Dipstick) and mark and install oil level gauge as follows:

Illustration 19	g06158636

Illustration 20	g06158640

Mark Oil Level Gauge

Reference: LEBV4830Marine Analyst Service Handbook

Refer to Operation and Maintenance Manuals for dipstick marking base on installed tilt angles or use the following procedure.

Procedure

1. Drain engine crankcase and remove oil filter elements.

2. Install new oil filter elements.

3. Fill crankcase with a given volume of oil. (Vf) which can be determined as follows.

   (Vf)=Vr-Vm

   Where:

   Vr = Volume of oil required to refill Full mark with filter change.

   Vm = volume of oil between add mark and Full mark for level operation.

   Note: Both Vr and Vm values for a specific engine model are published in the current Technical Marketing Information (TMIWEB) on Marine Engine Systems data, or consult physical data for the oil pan to get the Oil Capacity.

   Add to this any additional oil volume required for special filters, oil lines, or coolers which are additions to the standard engine or unique to the installation.

4. Inset the dipstick to make certain that the oil shows on the dipstick. Be certain that the correct dipstick is used and that it does not hit the bottom of the sump or is otherwise improperly installed.

5. Start the engine and operate it at one half rated rpm until the oil has reached normal operating temperature. Reduce engine speed to low idle and mark the level indicated on the dipstick. This is the add oil or low mark.

6. Add additional oil equivalent to Vm as shown in the Technical Marketing Information (TMIWEB) and let the engine operate at least another five minutes to bring all the oil up to temperature. Mark the new oil level on the dipstick. This is the full mark.

Illustration 21	g06158663
(1) 7H-3986 Screw (2) 7X-0620 Hard Washer (3) 166-7718 Nut (4) 6Y-6815 Gasket Assembly (5) 166-7658 Gasket (6) 166-7656 Socket Connector (7) 166-7657 Plug Connector (8) 3V-3308 Hard Washer (9) 0S-0509 Bolt (10) 8B-8679 Spacer (11) 6V-9168 Nut (12) 6V-8397 O-Ring Seal (13) 8C-6915 Bulkhead Adapter (14) 174-1821 Liquid Level Switch

Illustration 22	g06158677
(8) 3V-3308 Hard Washer (9) 0S-0509 Bolt (12) 6V-8397 O-Ring Seal (15) 163-0936 Enclosure (16) 6V-8636 Connector (17) 3J-1907 O-Ring Seal (18) 169-9517 Plate As (19) 8B-6127 Clip (20) 169-9519 Cover (21) 9Y-6877 Tube As (22) 0S-1591 Bolt

Illustration 23	g06158682
(8) 3V-3308 Hard Washer (23) 2W-0544 Oil Level Gauge As (24) 0S-1588 Bolt (25) 1W-1415 Gasket (26) 9Y-4871 Tube As (27) 8T-1886 Clip (28) 8T-1885 Clip

Illustration 24	g06158690
(8) 3V-3308 Hard Washer (22) 0S-1591 Bolt (29) 6E-4545 Valve (30) 9Y-9924 Cylinder Block Cover

Illustration 25	g06158700
(8) 3V-3308 Hard Washer (31) 7E-5304 Fan Guard (32) 9Y-6874 Oil Filler Elbow (33) 6V-4314 O-Ring Seal (34) 0S-1590 Bolt (35) 4P-5304 Tube As

Illustration 26	g06158709
(36) 207-6859 Pressure Sensor Gp (37) 8T-2353 Adapter (38) 214-7568 O-Ring Seal

Removal of the Flywheel Guard

Remove Flywheel Guard

Reference: Disassembly and Assembly, UENR0127

Remove Existing Flywheel Guard

1. Remove existing 465-8996 Coupling Guard Support.

2. Remove 464-6731 Coupling Guard Gp.

3. Remove 464-6729 Coupling Guard Gp.

4. Remove flywheel 466-7150 Flywheel Guard Gp.

Addition of the Air Cleaner Adapter

Add Air Cleaner Adapter

Reference: Disassembly and Assembly, UENR0127

Install Air Cleaner Adapter

Table 11

Required Parts
Qty	Part Number	Part Name
2	238-9380	Adapter Gp-ACL

1. Install one 238-9380 Air Cleaner Adapter before each turbocharger.

Reconfiguration of Pre-Lube System

Remove Existing Pre-Lube System

Illustration 27	g06144743
Items that need removed (in red).

1. Remove 464-7667 Centrifugal Filter Lines.

2. Remove 464-7669 Oil Line Adapter Gp.

3. Remove 462-3257 Oil Lines Gp.

4. Remove 469-0016 Air Lines Gp.

Installation of New Intermittent Pre-Lube System

Table 12

Required Parts
Qty	Part Number	Part Name
1	460-2294	Lines Gp-Prelube
1	503-6004	Adapter Gp
1	504-6980	Cover Gp
1	392-2900	Cover Gp
1	460-4217	Cover Gp
1	477-5997	Elbow Gp-Oil
1	458-9848	Lines Gp-Filter
1	463-3108	Sensor Gp-Air

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Illustration 28	g06144746
Items that need to be added.

1. Install 460-2294 Prelubrication Lines Gp, 503-6004 Oil Line Adapter Gp, 204-6980 Tube As, 392-2900 Gear Inspection Cover Gp, 460-4217 Engine Oil Line Cover Gp, 477-5997 Engine Oil Lines Gp, 458-9848 Oil Filter Lines, and 463-3108 Pressure Switch Gp.

Replacement of Engine Mounting Feet

Add Engine Mounting

Reference: Disassembly and Assembly, UENR0127

Remove Existing Engine Mounting

1. Remove 392-2890 Engine Mounting Gp.

Installation of Engine Mounting

Table 13

Required Parts
Qty	Part Number	Part Name
1	522-3912	Mounting Gp-Engine

1. Install new 522-3912 Mounting Gp-Engine.

Addition of Lifting Eyes

Install Lifting Eyes

Table 14

Required Parts
Qty	Part Number	Part Name
1	383-1764	Lifting Gp

1. Install 383-1764 Engine Lifting Gp to the four engines that were previously packaged gensets.

Dosing Cabinet Updates

Removal of the Air Manifold Assembly

Illustration 29	g06190261

1. Remove and set aside the access door and associated hardware for reuse.
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   Illustration 30	g06190302

2. Cut and discard the cable ties that secure the wiring harness.

3. Disconnect the air manifold wiring harnesses from the sensor and solenoid valve.
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   Illustration 31	g06190268

4. Remove and set aside the four air manifold bolts for reuse.

5. Remove the air manifold from the dosing cabinet.
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   Illustration 32	g06190315

6. Remove the following parts from the air manifold for reuse:

   • 320-3061 Pressure Sensor Gp and 6V-6560 O-Ring Seal

   • 352-6503 Plug As

   • 376-7736 Solenoid Valve Gp

   • 361-3082 Regulator

   • 1P-1669 Seal Plug

   • 4P-7581 Clip

   • 5C-9553 Bolt

   • 5P-4115 Hard Washer

Installation of the Air Manifold Assembly

Table 15

New Parts
Qty	Part Number	Part Name
1	481-0392	Manifold
1	481-0395	Strainer

Illustration 33	g06190323
(1) 320-3061 Pressure Sensor Gp (2) 6V-6560 O-Ring Seal (3) 352-6503 Plug As (4) 376-7736 Solenoid Valve Gp (5) 4P-7581 Clip (6) 5C-9553 Bolt (7) 5P-4115 Hard Washer (8) 361-3082 Regulator (9) 481-0392 Manifold (10) 1P-1669 Seal Plug

Note: Clip (5), bolt (6), and washer (7) are not shown in Illustration 33.

1. Install the parts from the original air manifold onto the new air manifold (9).
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   Illustration 34	g06190328
   (6) 481-0392 Manifold (8) 481-0395 Strainer

2. Install strainer (8) into air manifold (6).

3. Install air manifold (6) into the dosing cabinet. Use the original hardware.

4. Reconnect the wiring harnesses to the sensor and solenoid valve.

5. Secure the wiring harness to the 4P-7581 Clip with a 7K-1181 Cable Strap.

Removal of the DEF Manifold Assembly

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Illustration 35	g06190346

1. Cut and discard the cable ties that secure the wiring harness.

2. Disconnect the DEF manifold wiring harnesses from the sensors and solenoid valves.
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   Illustration 36	g06190351

3. Disconnect the hoses from the DEF manifold.
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   Illustration 37	g06190361

4. Remove and set aside the eight DEF manifold bolts for reuse.

5. Remove the DEF manifold from the dosing cabinet.
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   Illustration 38	g06190373

6. Remove the following parts from the DEF manifold for reuse:

   • 195-2150 Temperature Sensor Gp and 6V-3250 O-Ring Seal

   • 5M-6213 Pipe Plug

   • 376-7350 Adapter and 3K-0360 O-Ring Seal

   • 114-0840 Plug and 3K-0360 O-Ring Seal

   • 376-7737 Solenoid Valve Gp
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   Illustration 39	g06190379

7. Remove the following parts from the DEF manifold for reuse:

   • 298-6488 Pressure Sensor Gp and 6V-3250 O-Ring Seal

   • 345-4080 Connector and 6V-3250 O-Ring Seal

   • 352-6503 Plug As

   • 477-0474 Solenoid Valve Gp

Installation of the DEF Manifold Assembly

Table 16

New Parts
Qty	Part Number	Part Name
1	481-0392	Manifold
1	481-0396	Strainer

Illustration 40	g06184561
(1) 376-7737 Solenoid Valve Gp (2) 298-6488 Pressure Sensor Gp (3) 6V-3250 O-Ring Seal (4) 345-4080 Connector (5) 195-2150 Temperature Sensor Gp (6) 5M-6213 Pipe Plug (7) 376-7350 Adapter (8) 3K-0360 O-Ring Seal (9) 114-0840 Plug (10) 481-0394 Manifold (11) 477-0474 Solenoid Valve Gp (12) 352-6503 Plug As

1. Install the parts from the original DEF manifold onto the new DEF manifold (10).
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   Illustration 41	g06190390
   (8) 3K-0360 O-Ring Seal (13) 481-0396 Strainer

2. Install DEF manifold (10) into the dosing cabinet. Use the original hardware.

3. Install strainer (13) into DEF manifold (10).
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   Illustration 42	g06190346

4. Reconnect the wiring harnesses to the sensors and solenoid valves.

5. Secure the wiring harness to the clips on the dosing cabinet with a 7K-1181 Cable Straps as needed.
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   Illustration 43	g06190351

6. Reconnect the hoses to the DEF manifold.
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   Illustration 44	g06190261

7. Reinstall the dosing cabinet cover with the original hardware.

Terminal Strip Box Updates

Converting a 433-8208 Box Wiring Gp to a 516-3971 Box Wiring Gp

Removal Procedure

Illustration 45	g06184590

Illustration 46	g06184600

Illustration 47	g06184611

1. Disassemble the box wiring group.

2. Remove the terminal strip rail.

3. Remove the wires from terminal blocks.

Installation Procedure

Table 17

New Parts
Qty	Part Number	Part Name
1	133-6623	Wire As
2	314-9086	Terminal Block
4	314-9090	Terminal Cover
2	419-4954	Gasket
1	438-9639	Film
1	520-9215	Junction Box As
1	524-7247	Terminal Marker

Illustration 48	g06190445
520-9215 Junction Box As

1. Install the terminal strip rail in the new junction box.

2. Install the button plugs and harness nuts in the new junction box.
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   Illustration 49	g06190413

3. Replace terminal blocks 1, 2, 10, and 11 with new 314-9086 Terminal Block and 314-9090 Terminal Cover.
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   Illustration 50	g06190439
   (1) 419-4954 Gaskets

4. Route harnesses through the two exterior gaskets (1) and the nuts (interior) and land in terminal blocks.
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   Illustration 51	g06190441

5. Install the terminal markers on new terminals 1, 2, 10, and 11.
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   Illustration 52	g06190442
   (2) 438-9639 Film (3) 133-6623 Wire As

6. Attach ground wire (3) to the junction box and the door of the junction box.

7. Attach film (2) to the junction box door.

8. Check the continuity from terminal blocks to connector.

Converting a 438-0996 Box Wiring Gp/ 438-0992 Box Wiring Gp to a 521-2975 Box Wiring Gp/ 521-2976 Box Wiring Gp

Removal Procedure

Illustration 53	g06184633

Illustration 54	g06184635

Illustration 55	g06184638

1. Disassemble the box wiring group.

2. Remove the terminal strip rail.

3. Remove the wires from terminal blocks.

Installation Procedure

Table 18

New Parts
Qty	Part Number	Part Name
1	133-6623	Wire As
1	419-4954	Gasket
1	450-9656(1)	Film
1	450-9658(2)	Film
1	520-9217	Junction Box As

(1)	The 450-9656 Film is for the 521-2976 Box Wiring Gp outlet of the CEM.
(2)	The 450-9658 Film is for the 521-2975 Box Wiring Gp inlet of the CEM.

Illustration 56	g06190450
(1) 520-9217 Junction Box As

1. Install the terminal strip rail in the new junction box.

2. Install the button plug and harness nut in the new junction box.
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   Illustration 57	g06190453
   (1) Cover plate (2) 419-4954 Gasket

3. Route harness through the one exterior gasket (2) and the nut (interior) and land in terminal blocks.

4. Relocate the cover plate (1) from the top to the bottom.
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   Illustration 58	g06190462
   (3) 133-6623 Wire As (4) 438-9639 Film

5. Attach ground wire (3) to the junction box and the door of the junction box.

6. Attach film (4) to the junction box door.

7. Check the continuity from terminal blocks to connector.