Installation of 3516B High Displacement Engines in 793C Off-Highway Trucks{1000, 7960} Caterpillar

Off-Highway Truck:

793C (S/N: 4AR1-UP; 4GZ1-UP)

Introduction

This publication describes the procedures that are necessary in order to install a 3516B high displacement engine in a 793C Off-Highway Truck. This publication only concerns items that are unique to the installation of the high displacement engine. Refer to the disassembly and assembly module for the procedures that are necessary in order to install the engine in the truck. Inspect all components for wear. Replace all components that are damaged, worn or broken.

Illustration 1	g00686681
3516B High Displacement Engine

The 3516B high displacement engine provides increased machine performance with less fuel consumption in certain applications. The 3516B high displacement engine uses four identical single stage turbochargers that eliminate the need for a wastegate. There are two pairs of turbochargers on the standard engine. Each pair of turbochargers has a low pressure turbocharger and a high pressure turbocharger. The low pressure turbocharger and the high pressure turbocharger are connected in series. The series arrangement turbochargers require a wastegate in order to regulate the boost pressure. The separate turbochargers of the 3516B high displacement engine do not require a wastegate. The installation of the 3516B high displacement engine requires changes to the parts groups that follow: air inlet tubes, coolant return lines for the turbochargers, tubes for the Separate Circuit Aftercooler (SCAC), air line for the wastegate and VIMS software.

Note: If the standard engine is not equipped with a Tu-Flo 1000 air compressor, modifications are required. Refer to Special Instruction, REHS0521, "Converting Off-Highway Trucks from a Tu-Flo 750 Air Compressor to a Tu-Flo 1000 Air Compressor" in order to make the required modifications.

References

Disassembly and Assembly, SENR1461, "3516B Engine Supplement for 793C Off-Highway Truck"

Disassembly and Assembly, RENR2533, "3516B Engine Supplement for 793C Off-Highway Truck"

Disassembly and Assembly, SENR1463, "793C Off-Highway Truck Machine Systems"

Disassembly and Assembly, RENR2535, "793C Off-Highway Truck Machine Systems"

Disassembly and Assembly, RENR2535, "793C Off-Highway Truck Machine Systems"

Special Instruction, REHS0521, "Converting Off-Highway Trucks from a Tu-Flo 750 Air Compressor to a Tu-Flo 1000 Air Compressor"

Read the entire special instruction. Understand the information before you perform any procedures. Understand the information before you order any parts.

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Personal injury or death can result from improper assembly procedures. Do not attempt any assembly until you have read and understand the assembly instructions.

The photos and illustrations are for illustrative purposes. The illustrations may not be drawn to scale. THE PHOTOS MAY NOT BE FROM AN ACTUAL INSTALLATION PROCEDURE.

Important Safety Information

The following information is an explanation of various labels that are found in this document.

Warnings

The warning label informs the technician that an injury or death can occur as a result of a condition that may exist.

Notices

A notice informs the technician that component damage can occur as a result of a condition that exists.

Notes

A note contains general information for the technician about the operation that is being performed.

Proper repair is important to the safe operation and the reliable operation of this machine. This document outlines basic recommended procedures. Some of the procedures require special tools, devices, or work methods.

Before you perform any repairs or before you perform any maintenance, read all safety information. Understand all safety information before you perform any repairs or before you perform any maintenance.

Safety information is provided in this document and on the machine. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons.

The Safety Alert Symbol that is followed by a Signal Word identifies a hazard. "DANGER", "WARNING", and "CAUTION" are "Signal Words". Illustration 2 shows the Safety Alert Symbol and the signal word "WARNING".

Illustration 2	g00008666

The signal word "WARNING" has the following meanings:

• Pay Attention !

• Become Alert !

• Your Safety Is Involved !

The message that appears under the safety alert symbol explains the hazard.

Operations or conditions that may cause product damage are identified by "NOTICE" labels on the machine and in the service information.

The person that services the machine may be unfamiliar with many of the systems on the machine. Use caution when you perform service work. Special knowledge of the systems and of the components is important. Before you remove any component or before you disassemble any component obtain knowledge of the system and knowledge of the component.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. You must determine that the tools, procedures, work methods, and operating techniques are safe. You must determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

Basic Precautions

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Always observe the list of basic precautions that follows:

Safety Signs

Safety signs include the items that follow: signs, information plates and decals. Read all "Safety" signs on the machine before operating, lubricating or repairing the machine. Understand all "Safety" signs on the machine before operating, lubricating or repairing the machine. Replace any safety signs that are in the conditions that follow: damage, unreadable and missing.

Protective Equipment

When you work around the machine, always wear protective equipment that is required by the job conditions. Protective equipment includes the items that follow: hard hat, protective glasses and protective shoes. In particular, wear protective glasses when you use a hammer or when you use a sledge hammer. When you weld use the appropriate protective equipment that is required by the job conditions. Protective equipment for welding includes the items that follow: gloves, welding hood, goggles and apron. Do not wear loose clothing or jewelry that can catch on parts of the machine.

Mounting and Dismounting

Use steps and handholds when you mount a machine. Also, use steps and handholds when you dismount a machine. Before you mount the machine, clean any mud or debris from steps, walkways, or work platforms. Always face the machine when you use steps, handholds and walkways. When you can not use the accesses on the machine, use ladders, scaffolds, or work platforms to perform safe repair operations.

Procedures for Lifting

In order to avoid back injury, use a hoist when you lift heavy components. Make sure that all chains, hooks, and slings are in good condition. Ensure that all chains, hooks, and slings are of the correct capacity. Be sure that the hooks are positioned correctly. Ensure that the hooks are equipped with a safety latch. Do not place a side load on the lifting eyes during a lifting operation.

Hot Fluids and Parts

To avoid burns, be alert for hot parts on machines which have just been stopped and hot fluids in lines, tubes and compartments.

Be careful when you remove filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug in order to prevent being sprayed by pressurized liquids. When the machine has just been stopped, the danger of hot fluids is greater.

Corrosion Inhibitor

Corrosion inhibitor contains alkali. Avoid contact with the eyes. Do not allow corrosion inhibitor to contact the skin for extended periods of time. Avoid repeated contact with the skin. Do not drink corrosion inhibitor. In case of contact, immediately wash skin with soap and water. For contact with the eyes, flush the eyes with large amounts of water for at least 15 minutes. Seek medical attention.

Batteries

Do not smoke when an inspection of the battery electrolyte level is made. Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit is operating. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Do not allow battery electrolyte to make contact with the skin or with the eyes. Battery electrolyte is an acid. In case of contact with battery electrolyte, immediately wash the skin with soap and water. For contact with the eyes, flush the eyes with large amounts of water for at least 15 minutes. Seek medical attention.

Pressurized Items

1. Always use a board or a piece of cardboard when you check for a leak. Leaking fluid under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If fluid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

2. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure that all raised components are blocked correctly. Be alert for possible pressure when you disconnect any device from a system that utilizes pressure.

3. Fuel lines that are damaged and fuel lines that are loose can cause fires. Lubrication lines that are damaged and lubrication lines that are loose can cause fires. Hydraulic lines, tubes, and hoses that are damaged can cause fires. Hydraulic lines, tubes, and hoses that are loose can cause fires. Do not bend or strike high pressure lines. Do not install lines which have been bent or damaged. Check lines, tubes and hoses carefully. Do not use your bare hand to check for leaks. If fluids are injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

4. Pressure air or water can cause personal injury. When pressure air or water is used for cleaning, wear a protective face shield, protective clothing, and protective shoes. The maximum air pressure for cleaning purposes must be below 205 kPa (30 psi). When you use a pressure washer, keep in mind that the nozzle pressures are very high. The nozzle pressures are frequently above 13790 kPa (2000 psi). Follow all of the recommended practices that are provided by the manufacturer of the pressure washer.

Repair

1. Before you start to work on the machine, disconnect the battery. Attach a Warning Tag, SEHS7332 to the start switch for the engine.

2. When possible, make all repairs with the machine parked on a level, hard surface. When you work on the machine or when you work under the machine, block the machine in order to prevent the machine from rolling.

3. Do not work on any machine that is supported only by lift jacks or a hoist. Always use hardwood blocks or jack stands to support the machine before performing any service or disassembly. Always make sure that the maximum load capacity of the jack stands is greater than the weight of the machine.

4. Make sure that the work area around the machine is made safe. Become aware of hazardous conditions that may exist. If an engine is started inside an enclosure, make sure that the engine exhaust is properly vented.

5. Before you start a repair, be sure that all protective devices are properly installed and that all protective devices function correctly. When a guard must be removed or a shield must be removed in order to perform the repair work, use extra caution.

6. Always use tools that are in good condition. Before you perform any service work, understand the intended use of the tools.

7. Replace all fasteners with fasteners of the same part number. Do not use a lesser quality fastener if replacements are necessary.

8. Prepare to stop an engine that has had a recent overhaul. Prepare to stop an engine that has a fuel system that has recently been worked on. If the engine has not been assembled correctly, the engine can possibly overspeed. If the fuel settings are not correct, the engine can possibly overspeed. Overspeeding can cause bodily injury, death or property damage. Prepare to shut off the fuel and the air supply to the engine in order to stop the engine.

9. Be careful when you remove cover plates. Gradually back off the last two bolts or the last two nuts that are located at opposite sides of the cover or the device. Pry the cover loose in order to relieve any spring or other pressure, before you completely remove the last two bolts or the last two nuts.

10. When you make repairs that require welding, have appropriate reference information. Welding should only be performed by personnel that are adequately trained. Personnel should be knowledgeable in welding procedures. Make sure that all repairs that require welding comply with the ANSI/AWS standards.

11. Do not damage wiring during removal operations. When you install the wiring, do not damage the wiring. The wiring can be damaged in operation by the conditions that follow: contact with sharp corners, rubbing against objects and contact with hot surfaces. Do not connect the wiring to a line that contains fluid.

12. Tighten connections to the correct torque. Make sure that all heat shields, clamps and guards are installed correctly in order to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust components in the event of a line, tube or seal failure must be installed correctly.

13. Do not operate a machine if any rotating part is damaged or if any rotating part contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing. Before you start the engine, make sure that all protective devices are properly installed. Before you operate the machine, make sure that all protective devices are functioning correctly.

14. Use extra caution when you service the rubber belts. Follow all safety instructions in the appropriate manuals. Wear protective glasses. Block the machine in order to prevent the machine from moving.

Prepare the Work Area

Select an appropriate site in order to install the engine. Select an area that is flat, smooth, and well drained. Make sure that there is sufficient space for the items that follow: machine, components, tools and lifting devices.

Illustration 3	g00686682
Engine and shipping crate

Illustration 4	g00686683
Shipping crate and components

Illustration 5	g00686684
Components that are organized for assembly

When you unload the engine and the components, place the engine and the components near the machine. Leave enough space around the machine in order to maneuver lifting devices. When possible, place the engine and components in front of the machine. Open the shipping crate. Carefully remove the parts for inspection. Refer to the charts in this special instruction in order to ensure that all parts are present. Ensure that all parts are undamaged. Organize the parts for assembly.

Note: Do not open bags of hardware for inspection. Open the bags when the hardware is needed in order to prevent lost hardware. The part numbers of the hardware are marked on the outside of the bags.

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NOTICE
Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation.

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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 product. 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 Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

The weight of the 3516B high displacement engine is 7790 kg (17174 lb).

Note: The weight does not include the torque converter.

The installation of the new engine will be easier if the machine is clean. Use a steam cleaner to clean the truck. Be careful with the steam cleaner. Do not damage electrical wiring or cab windows.

Components

Table 1

Required Components from 170-1139 Air Lines
Quantity	Part Number	Description
2	8X-6132 (1)	Block
12	8T-4136	Bolt
16	8T-4121	Hard Washer
4	188-4782	Support
2	7E-7790	Hose
4	141-7148	Clamp
2	157-2804	Tube As
2	9X-6605	U-Bolt
2	8X-3635	Strip
4	6V-7744	Locknut
2	156-6255	Plate
2	7N-5008	Hump Hose
6	137-8292	Clamp
2	147-0815	Tube As
4	9X-2494	U-Bolt
4	4W-1211	Strip
8	2K-4973	Locknut
8	8T-4896	Hard Washer
2	7C-2985	Elbow
10	133-5940	Clamp
2	147-0839	Tube As
4	4P-5104	Elbow
4	119-6298	Clamp
2	1W-6903	Hump Hose
2	147-0814	Tube As
1	030-7951	Flared Elbow
2	7M-8485	O-Ring Seal
1	2V-0508	Hose As
1	9L-4007	Flared Elbow
1	9S-4181	Straight Thread Plug

( 1 )

This part is nonserviceable. You must fabricate this part.

Table 2

Required Components from 171-4614 Water Lines
Quantity	Part Number	Description
1	195-2334	Bracket
1	5S-7379	Bolt
11	8T-4896	Hard Washer
2	8T-9043	Bolt
2	8T-4224	Hard Washer
4	9B-7237	Bolt
1	156-6275	Bracket
1	157-2802	Tube As
1	137-8213	Flange
1	2H-3928	O-Ring Seal
1	9M-2092	O-Ring Seal
2	313-2506	Clamp As
1	153-9964	Ring
2	8T-7008	Bolt
2	8T-4195	Bolt
8	8T-4121	Hard Washer
4	8T-4133	Nut
6	6V-6782	Clip
6	6V-6783	Clip
2	8T-4196	Bolt
1	8T-1919	O-Ring Seal
1	156-6239	Tube As
1	4W-0530	Retaining Ring
1	7C-9597	Flange
2	4W-0531	Retainer
1	6J-2680	O-Ring Seal
1	5P-1262	Hose
2	8T-6675	Hose Clamp
2	3J-1907	O-Ring Seal
1	6V-8774	Tee
1	3J-7354	O-Ring Seal
1	6V-9200	Elbow
4	6V-8397	O-Ring Seal
1	190-0117	Hose As
1	190-0116	Hose As
2	8T-9377	Bolt

Table 3

Required Components from 171-4615 Water Lines
Quantity	Part Number	Description
2	3B-1915	Bolt
2	9X-6458	Hard Washer
1	156-6254	Plate As
1	141-9813	Hose
6	8T-6703	Hose Clamp
1	156-6249	Tube
2	7S-8920	Clip
2	7S-8921	Clip
2	8T-4133	Nut
2	7X-7729	Washer
1	8T-6466	Bolt
1	039-9892	Spacer
2	8T-4121	Hard Washer
1	8T-4195	Bolt
1	127-0796	Hose
1	156-6276	Tube As
1	126-9036	Hose
1	190-3728	Tube As
8	8T-4194	Bolt
8	4B-4280	Washer
2	1P-3705	Rectangular Seal

Table 4

Required Components from 170-1140 Exhaust Pipe Gp
Quantity	Part Number	Description
1	7E-9153	Sleeve
4	6V-3822	Bolt
4	6V-5839	Washer
1	156-6247	Elbow
2	2W-8851	Seal Ring
1	2W-9078	Pipe
1	156-6237	Elbow
1	1W-4161	C-Clamp

Table 5

Required Components from 174-9370 Exhaust Pipe Gp
Quantity	Part Number	Description
4	8T-4183	Bolt
8	5P-1076	Hard Washer
4	8T-4244	Nut
1	156-6257	Bracket
1	7E-8452	Clamp
1	155-0528	Elbow
1	4P-9981	Strap
2	8T-4172	Bolt
2	7X-7729	Washer
2	2W-8851	Seal Ring
1	2W-9078	Pipe
1	7C-3337	Elbow
1	1W-4161	C-Clamp

Table 6

Required Components from 190-6112 Radiator
Quantity	Part Number	Description
2	156-6277	Hose As
1	6K-8420	Locknut
1	061-8827	Flared Tee
1	157-2797	Bracket
1	0L-1351	Bolt
1	5M-2894	Hard Washer
4	8T-4195	Bolt
4	8T-4121	Hard Washer
1	6I-3996	Gasket
1	133-5988	Elbow
1	8T-6767	Pipe Plug
1	030-7945	Elbow
1	7M-8485	O-Ring Seal
1	190-6440	Hose As
1	030-7965	Elbow
4	7S-5833	Hose
8	9X-2201	Hose Clamp
1	133-5988	Elbow
1	155-1214	Tube

Table 7

Required Components from 163-2633 Platform
Quantity	Part Number	Description
4	8T-8917	Bolt
4	7D-1649	Hard Washer
1	160-9853	Platform

Table 8

Required Components from 170-1141 Pressure Sensor and Mounting Gp
Quantity	Part Number	Description
4	6V-5048	O-Ring Seal
2	9X-0262	Adapter
2	161-9926	Pressure Sensor
8	0S-0509	Bolt
8	5M-2894	Hard Washer
4	4P-8134	Clip
14	9X-6772	Cable Strap
4	4P-7581	Clip

Table 9

Required Electrical Components
Quantity	Part Number	Description
2	204-2603	Wire Assembly
1	118-7226 (2)	Temperature Sensor Gp

( 2 )

This part may be reused for the old engine.

Remove the Engine

Table 10

Required Components from 190-6112 Radiator
Item	Qty	Part Number	Description
1	1	3J-1907	O-Ring Seal
2	1	6V-9507	Face Seal Plug

Refer to the Disassembly and Assembly Manual for the standard removal procedures. After you remove the standard engine, you must remove some additional components in order to accommodate the high displacement engine.

Note: Remove 118-7226 Temperature Sensor Gp and retain 118-7226 Temperature Sensor Gp . The temperature sensor is needed in order to prevent diagnostic errors.

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Illustration 6	g00686203
Left side exhaust flange

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Illustration 7	g00686204
Crossbeam without the exhaust flange

1. Remove the exhaust flange from the crossbeam.

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Illustration 8	g00686205
Lower right side exhaust elbow

2. Remove the lower right side exhaust elbow.

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Illustration 9	g00686206
Support bracket for the right side exhaust elbow

3. Remove the bracket that supports the lower right side exhaust elbow.

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Illustration 10	g00794482
Upper right side exhaust elbow

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Illustration 11	g00686207
Muffler without the right side exhaust elbow

4. Remove the upper right side exhaust elbow that connects to the muffler.

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Illustration 12	g00686208
Right side air inlet tubes

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Illustration 13	g00686209
Engine compartment without right side air inlet tubes

5. Remove the right side air inlet tubes.

6. Remove the support assemblies that held the air inlet tube from the frame.

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Illustration 14	g00686355
tube for the Separate Circuit Aftercooler (SCAC)

7. Remove the tube for the Separate Circuit Aftercooler (SCAC) on the left side of the engine compartment.

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Illustration 15	g00695167
Air line connection for the wastegate

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Illustration 16	g00686368
Air line connection that is plugged

8. Remove the air line for the turbo wastegate actuator.

   Note: Use a 5M-6213 Pipe Plug to plug the fitting at the cab.

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Illustration 17	g00695177
Vent line at the tee at the expansion tank

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Illustration 18	g00695180
Vent line that is below the platform

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Illustration 19	g00695217
Tee that is capped at the expansion tank

9. Remove the turbocharger coolant return tube from the tee at the right side of the expansion tank.

   Note: Use a 6V-9831 Cap and a 7J-9108 O-Ring Seal to cap the tee at the expansion tank.

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Illustration 20	g00695224
Vent line for the aftercooler

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Illustration 21	g00695232
Port for the vent line for the aftercooler that is plugged

10. Use 3J-1907 O-Ring Seal (1) and 6V-9507 Face Seal Plug (2) to plug the port in the tube assembly at the upper left side of the radiator. The port was for the coolant return line of the turbocharger.

Prepare the High Displacement Engine for Installation

In order to make the installation easier, install some components on the new engine before you install the new engine in the truck. Refer to the disassembly and assembly procedure for the installation of the standard components.

Install the Components from 171-4615 Water Lines

Table 11

Required Components from 171-4615 Water Lines
Item	Quantity	Part Number	Description
1	2	3B-1915	Bolt
2	2	9X-6458	Hard Washer
3	1	156-6254	Plate As
4	1	156-6249	Tube
5	6	8T-6703	Hose Clamp
6	1	141-9813	Hose
7	2	7S-8920	Clip
8	2	7S-8921	Clip
9	2	8T-4133	Nut
10	2	7X-7729	Washer
11	1	8T-6466	Bolt
12	1	039-9892	Spacer
13	2	8T-4121	Hard Washer
14	1	8T-4195	Bolt
15	1	127-0796	Hose
16	1	156-6276	Tube As
17	1	126-9036	Hose
18	1	190-3728	Tube As

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Illustration 22	g00687585

1. Use two 3B-1915 Bolts (1) and two 9X-6458 Hard Washers (2) to install 156-6254 Plate As (3) on the front of the engine.

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Illustration 23	g00687624

2. Use the following components to connect 156-6249 Tube (4) to the existing 166-8428 Tube As (not shown): two 8T-6703 Hose Clamps (5) and 141-9813 Hose (6) .

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Illustration 24	g00794556

3. Secure 156-6249 Tube (4) to the fuel filter bracket with the items that follow: 7S-8920 Clip (7), 7S-8921 Clip (8), 8T-4133 Nut (9), two 7X-7729 Hard Washers (10), 8T-6466 Bolt (11) and 039-9892 Spacer (12) .

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Illustration 25	g00687626

4. Secure 156-6249 Tube (4) to 156-6254 Plate As (3) with the items that follow: 7S-8920 Clip (7), 7S-8921 Clip (8), 8T-4133 Nut (9), two 8T-4121 Hard Washers (13) and 8T-4195 Bolt (14) .

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Illustration 26	g00687627

5. Use 127-0796 Hose (15) and two 8T-6703 Hose Clamps (5) to connect 156-6276 Tube As (16) to 156-6249 Tube (4) .

   Note: Leave the hose clamps loose until the final assembly.

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Illustration 27	g00687893

6. Use 126-9036 Hose (17) and two 8T-6703 Hose Clamps (5) to connect 190-3728 Tube (18) to the coolant bypass tube at front right side of the engine.

   Note: Leave the hose clamps loose until the final assembly.

Install the Components from 171-4614 Water Lines

Table 12

Required Components from 171-4614 Water Lines
Item	Quantity	Part Number	Description
1	1	195-2334	Bracket
2	1	5S-7379	Bolt
3	11	8T-4896	Hard Washer
4	2	8T-9043	Bolt
5	2	8T-4224	Hard Washer
6	4	9B-7237	Bolt
7	1	156-6275	Bracket
8	1	157-2802	Tube As
9	1	137-8213	Flange
10	1	2H-3928	O-Ring Seal
11	1	9M-2092	O-Ring Seal
12	2	313-2506	Clamp As
13	1	153-9964	Ring
14	2	8T-7008	Bolt
15	2	8T-4195	Bolt
16	8	8T-4121	Hard Washer
17	4	8T-4133	Nut
18	6	6V-6782	Clip
19	6	6V-6783	Clip
20	2	8T-4196	Bolt
21	1	8T-1919	O-Ring Seal
22	1	156-6239	Tube As
23	1	4W-0530	Retaining Ring
24	1	7C-9597	Flange
25	2	4W-0531	Retainer
26	1	6J-2680	O-Ring Seal
27	1	5P-1262	Hose
28	2	8T-6675	Hose Clamp
29	2	3J-1907	O-Ring Seal
30	1	6V-8774	Tee
31	1	3J-7354	O-Ring Seal
32	1	6V-9200	Elbow
33	4	6V-8397	O-Ring Seal
34	1	190-0117	Hose As
35	1	190-0116	Hose As
36	2	8T-9377	Bolt

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Illustration 28	g00793230

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Illustration 29	g00687586

1. Use the following components to install 195-2334 Bracket (1) on the left side of the engine: 5S-7379 Bolt (2), 8T-4896 Hard Washer (3), two 8T-9043 Bolts (4) and two 8T-4224 Hard Washers (5) .

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Illustration 30	g00687590

2. Use four 9B-7237 Bolts (6) and four 8T-4896 Hard Washers (3) to install 156-6275 Bracket (7) on rear of the engine.

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Illustration 31	g01730459

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Illustration 32	g01730473

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Illustration 33	g01730474

3. Install O-ring seal (10) to flange (9). Install O-ring seal (11) to tube (8). Position flange (9) and tube (8) to the outlet tube of the coolant pump. Secure flange (9) and tube (8) to the outlet tube of the coolant pump on the front left side of the engine with the following items: two clamps (12), one ring (13), two bolts (14), two bolts (15), four washers (16), two nuts (17) and two washers (3) .

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Illustration 34	g01730593

4. Secure 157-2802 Tube As (8) to 195-2334 Bracket (1) with the items that follow: 6V-6782 Clip (18), 6V-6783 Clip (19), 8T-4196 Bolt (20), 8T-4133 Nut (17) and two 8T-4121 Hard Washers (16) .

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Illustration 35	g01730594

5. Secure 157-2802 Tube As (8) to 156-6275 Bracket (7) with the items that follow: 6V-6782 Clip (18), 6V-6783 Clip (19), 8T-4196 Bolt (20), 8T-4133 Nut (17) and two 8T-4121 Hard Washers (16) .

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Illustration 36	g01730595

6. Install 8T-1919 O-Ring Seal (21) on the flange of 156-6239 Tube As (22) .

7. Slide 4W-0530 Retaining Ring (23) over 156-6239 Tube As (22). Slide 7C-9597 Flange (24) over the flange of 156-6239 Tube As (22) .

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Illustration 37	g01730597

8. Secure 156-6239 Tube As (22) and 7C-9597 Flange (24) to the back of the engine at the aftercooler with the items that follow: two 8T-9377 Bolts (36), two 8T-4896 Hard Washers (3), two 4W-0531 Retainers (25) and 6J-2680 O-Ring Seal (26) .

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Illustration 38	g01730598

9. Use 5P-1262 Hose (27) and two 8T-6675 Hose Clamps (28) to connect 156-6239 Tube As (22) and 157-2802 Tube As (8). Install 102-2240 Temperature Sensor and 3K-0360 O-Ring Seal .

   Note: The 102-2240 Temperature Sensor is tied to the harness.

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Illustration 39	g01730600

10. Install 3J-1907 O-Ring Seal (29) and 6V-8774 Tee (30) in 157-2802 Tube As (9) .

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Illustration 40	g01730601

11. Install 3J-7354 O-Ring Seal (31) and 6V-9200 Elbow (32) at the aftercooler at the rear of the engine. Install 6V-8397 O-Ring Seal (33) and 190-0117 Hose As (34) to 6V-9200 Elbow (32) at the aftercooler.

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Illustration 41	g01730602

12. Install 6V-8397 O-Ring Seal (33) in 6V-8774 Tee (30). Connect the opposite end of 190-0117 Hose As (34) to 6V-8774 Tee (30) .

13. Install 6V-8397 O-Ring Seal (33) in 6V-8774 Tee (30). Connect 190-0116 Hose As (35) to the opposite side of 6V-8774 Tee (30) .

Install the Electrical Components

Table 13

Required Electrical Components
Quantity	Part Number	Description
2	204-2603	Wire
1	118-7226 (2)	Temperature Sensor Gp

( 2 )

This part may be reused for the old engine.

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Illustration 42	g00899714

1. Replace each jumper with one 204-2603 Wire jumper (not shown) for circuits "K983A" and "799A".

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Illustration 43	g00899719

2. Connect 118-7226 Temperature Sensor Gp (not shown) to the connector. Tie the sensor to the harness.

   Note: The 118-7226 Temperature Sensor Gp is not used, but the sensor must be installed in order to prevent diagnostic errors.

Install the Components from 190-6112 Radiator

Table 14

Required Components from 190-6112 Radiator
Item	Quantity	Part Number	Description
1	2	156-6277	Hose As
2	1	6K-8420	Locknut
3	1	061-8827	Flared Tee
4	1	157-2797	Bracket

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Illustration 44	g00688232

1. Connect 156-6277 Hose As (1) to the coolant return line for the turbochargers on each side of the engine.

2. Use 6K-8420 Locknut (2) to connect 061-8827 Flared Tee (3) to 157-2797 Bracket (4) .

   Note: Do not bolt the bracket to the engine. You must move the bracket in order to gain access to the lifting eye for the engine.

3. Connect the unsecured ends of 156-6277 Hose As (1) to the sides of 061-8827 Flared Tee (3) .

4. Refer to Special Instruction, REHS0521, "Converting Off-Highway Trucks from a Tu-Flo 750 Air Compressor to a Tu-Flo 1000 Air Compressor".

Replace the Bonnet on the Front Brake Oil Cooler

ReferenceDisassembly and Assembly, SENR1463, "793C Off-Highway Truck Machine Systems"

Table 15

Required Components from 171-4614 Water Lines
Item	Qty	Part Number	Description
1	1	166-6043	Bonnet
2	1	121-5746	Gasket

1. Refer to the disassembly and assembly procedures for the standard steps that are necessary in order to remove the cooler from the truck.

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Illustration 45	g00761752

2. Replace the bonnet with 166-6043 Bonnet (1). Use a new 121-5746 Gasket (2) .

3. Refer to the disassembly and assembly procedures for the standard steps that are necessary in order to install the cooler in the truck.

Install the 3516B High Displacement Engine in the 793C Off-Highway Truck

Refer to the disassembly and assembly procedures for the standard steps that are necessary in order to install the engine in the truck. After the new high displacement engine is placed in the chassis, continue with the steps that follow.

Connect the switch for the Transmission Charge Filter on 793C (S/N: 4AR) Off-Highway Trucks

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Illustration 46	g00899765

1. Connect the switch for the transmission charge filter.

Install the Components from 171-4614 Water Lines

Table 16

Required Components from 171-4614 Water Lines
Item	Quantity	Part Number	Description
1	2	142-2333	Hose
2	6	8T-4986	Hose Clamp
3	1	183-8000	Tube As
4	2	8T-4194	Bolt
5	6	6V-6782	Clip
6	6	6V-6783	Clip
7	4	8T-4223	Hard Washer
8	4	8T-4244	Nut
9	1	6V-8724	Elbow
10	2	3J-1907	O-Ring Seal
11	4	6V-8397	O-Ring Seal
12	2	7X-3342	Locking Stud
13	1	190-2880	Tube
14	1	9Y-6886	Bracket
15	3	5P-1076	Hard Washer
16	1	8T-4139	Bolt
17	1	151-6284	Hose

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Illustration 47	g00689359

1. Use 142-2333 Hose (1) and two 8T-4986 Hose Clamps (2) to connect the 183-8000 Tube As (3) to the tube for the outlet of the front brake oil cooler.

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Illustration 48	g00794789

2. Use the following components to install 183-8000 Tube As (3) on the upper left side of the engine compartment: 8T-4194 Bolt (4), 6V-6782 Clip (5), 6V-6783 Clip (6), two 8T-4223 Hard Washers (7) and 8T-4244 Nut (8) .

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Illustration 49	g00911729

3. Install 6V-8724 Elbow (9), 3J-1907 O-Ring Seal (10), and 6V-8397 O-Ring Seal (11) into 183-8000 Tube As (3). Connect 190-0116 Hose As (A) to 6V-8724 Elbow (9) .

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Illustration 50	g00793360

4. Use the following components to install 183-8000 Tube As (3) on the upper left side of the engine compartment: 6V-6782 Clip (5), 6V-6783 Clip (6), 7X-3342 Locking Stud (12), 8T-4223 Hard Washer (7) and 8T-4244 Nut (8) .

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Illustration 51	g00689357

5. Use 142-2333 Hose (1) and two 8T-4986 Hose Clamps (2) to connect 183-8000 Tube As (3) to 190-2880 Tube (13) .

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Illustration 52	g00762163

6. Use the following components to install 190-2880 Tube (13) on the upper left side of the engine compartment: 9Y-6886 Bracket (14), 5P-1076 Hard Washer (15), 8T-4139 Bolt (16), 8T-4194 Bolt (4), 6V-6782 Clip (5), 6V-6783 Clip (6), two 5P-1076 Hard Washer (7) and 8T-4244 Nut (8) .

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Illustration 53	g00797659

7. Use the following components to install 190-2880 Tube (13) on the upper left side of the engine compartment: 6V-6782 Clip (5), 6V-6783 Clip (6), 7X-3342 Locking Stud (12), 8T-4223 Hard Washer (7) and 8T-4244 Nut (8) .

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Illustration 54	g00689376

8. Use 151-6284 Hose (17) and two 8T-4986 Hose Clamps (2) to connect 157-2802 Tube As (not shown) to the tube that is for the inlet of the front brake oil cooler.

Refer to the disassembly and assembly procedures for the steps that are necessary to complete the installation of the engine. Follow the procedures in the 793C Off-Highway Truck assembly procedure for the engine commissioning.

Load the new VIMS configuration software for the 3516B engine control system. Refer to Special Instruction, SENR6059, "Vital Information Management System".

Note: Contact 1-800-882-7221 or, 1-217-475-5527 for help in determining the needed software. The following information should be provided in order to ensure that compatible software is chosen accordingly:

• Chassis Serial Number

• Current part number for the VIMS configuration software

Install the Components from 170-1139 Air Lines

Table 17

Required Components from 170-1139 Air Lines
Item	Quantity	Part Number	Description
1	2	8X-6132 (1)	Block
2	12	8T-4136	Bolt
3	16	8T-4121	Hard Washer
4	4	188-4782	Support
5	2	7E-7790	Hose
6	4	141-7148	Clamp
7	2	157-2804	Tube As
8	2	9X-6605	U-Bolt
9	2	8X-3635	Strip
10	4	6V-7744	Locknut
11	2	156-6255	Plate
12	2	7N-5008	Hump Hose
13	6	137-8292	Clamp
14	2	147-0815	Tube As
15	4	9X-2494	U-Bolt
16	4	4W-1211	Strip
17	8	2K-4973	Locknut
18	8	8T-4896	Hard Washer
19	2	7C-2985	Elbow
20	10	133-5940	Clamp
21	2	147-0839	Tube As
22	4	4P-5104	Elbow
23	4	119-6298	Clamp
24	2	1W-6903	Hump Hose
25	2	147-0814	Tube As
26	2	7M-8485	O-Ring Seal
27	1	9S-4181	Straight Thread Plug
28	1	030-7951	Flared Elbow
29	1	2V-0508	Hose As
30	1	9L-4007	Flared Elbow

( 1 )

This part is nonserviceable. You must fabricate this part.

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Illustration 55	g00761423

1. Four 8X-6132 Blocks (1) are needed in order to install the air lines group. Refer to Illustration 55 and Table 18 in order to fabricate four 8X-6132 Blocks (1). Fabricate the blocks from structural steel that has a minimum yield strength of 207 MPa (30000 psi).
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   Table 18

   Fabrication Dimensions
   Item	Dimension
   A	185 mm (7.3 inch)
   B	153 mm (6.0 inch)
   C	15 mm (0.59 inch)
   D	16 mm (0.6 inch)
   E	8.7 mm (0.34 inch) diameter M10 X 1.5-6H THD 2 Holes
   F	20 mm (0.8 inch)
   G	30 mm (1.2 inch)

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Illustration 56	g00689397
(H) 224 ± 5 mm (8.82 ± 0.20 inch) (J) 300 ± 5 mm (11.81 ± 0.20 inch) (K) 677 ± 5 mm (26.65 ± 0.20 inch)

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Illustration 57	g00689399

2. Refer to Illustration 56 in order to weld two 8X-6132 Blocks (1) to the bottom of the superstructure below the cab.

3. Weld two 8X-6132 Blocks (1) to the right side of the superstructure.

   Note: After you install 8X-6132 Blocks (1), paint 8X-6132 Blocks (1) and the welds that are on the bottom of the superstructure.

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Illustration 58	g00689400

4. Use four 8T-4136 Bolts (2) and four 8T-4121 Hard Washers (3) to install two 188-4782 Supports (4) on 8X-6132 Blocks (1) .

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Illustration 59	g00689403

5. Use 7E-7790 Hose (5) and two 141-7148 Clamps (6) to connect 157-2804 Tube As (7) to the left side elbow for the air inlet from the air cleaners.

   Note: Do not tighten the clamps until the final assembly.

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Illustration 60	g00795198

6. Use 9X-6605 U-Bolt (8), 8X-3635 Strip (9), two 6V-7744 Locknuts (10), and two 8T-4121 Hard Washers (3) to secure 156-6255 Plate (11) on 157-2804 Tube As (7) .

   Note: Do not tighten the U-bolts until the final assembly.

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Illustration 61	g00795203

7. Bolt 156-6255 Plate (11) to the crossbeam with two 8T-4136 Bolts (2) and two 8T-4121 Hard Washers (3) .

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Illustration 62	g00689406

8. Use 7N-5008 Hump Hose (12) and two 137-8292 Clamps (13) to join 147-0815 Tube As (14) to 157-2804 Tube As (7) on the left side of the machine.

   Note: Do not tighten the clamps until the final assembly.

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Illustration 63	g00689407

9. Use two 9X-2494 U-Bolts (15), two 4W-1211 Strips (16), four 2K-4973 Locknuts (17), and four 8T-4896 Hard Washers (18) to secure 147-0815 Tube As (14) to two 188-4782 Supports (4) at the left side of the machine.

   Note: Do not tighten the U-bolts until the final assembly.

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Illustration 64	g00689408

10. Use 7C-2985 Elbow (19), 133-5940 Clamp (20) and 137-8292 Clamp (13) to connect 147-0839 Tube As (21) to 147-0815 Tube As (14) .

    Note: Do not tighten the clamps until the final assembly.

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Illustration 65	g00689410

11. Use 4P-5104 Elbow (22), 133-5940 Clamp (20), and 119-6298 Clamp (23) to connect 147-0839 Tube As (21) and the left rear turbocharger.

    Note: Do not tighten the clamps until the final assembly.

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Illustration 66	g00689478

12. Use 1W-6903 Hump Hose (24) and two 133-5940 Clamps (20) to connect 147-0814 Tube As (25) to 157-2804 Tube As (7) .

    Note: Do not tighten the clamps until the final assembly.

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Illustration 67	g00689487

13. Use 4P-5104 Elbow (22), 133-5940 Clamp (20), and 119-6298 Clamp (23) to connect 147-0814 Tube As (25) and the left front turbocharger.

    Note: Do not tighten the clamps until the final assembly.

14. Position the tube assemblies and fully tighten all the clamps.

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Illustration 68	g00689479

15. Use four 8T-4136 Bolts (2) and four 8T-4121 Hard Washers (3) to install two 188-4782 Supports (4) on the frame at the right side of the truck.

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Illustration 69	g00796996

16. Install 7M-8485 O-Ring Seal (26) and 9S-4181 Straight Thread Plug (27) into 157-2804 Tube As (7) .

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Illustration 70	g00689482

17. Use 7E-7790 Hose (5) and two 141-7148 Clamps (6) to connect 157-2804 Tube As (7) to the right side elbow for the air inlet from the air cleaners.

    Note: Do not tighten the clamp until the final assembly.

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Illustration 71	g00797005

18. Use 9X-6605 U-Bolt (8), 8X-3635 Strip (9), two 6V-7744 Locknuts (10), and two 8T-4121 Hard Washers (3) to secure 156-6255 Plate (11) on the 157-2804 Tube As (7) .

    Note: Do not tighten the clamps until the final assembly.

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Illustration 72	g00797012

19. Bolt 156-6255 Plate (11) to the crossbeam with two 8T-4136 Bolts (2) and two 8T-4121 Hard Washers (3) .

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Illustration 73	g00689494

20. Use 7N-5008 Hump Hose (12) and two 137-8292 Clamps (13) to join 147-0815 Tube As (14) to 157-2804 Tube As (7) on the right side of the machine.

    Note: Do not tighten the clamps until the final assembly.

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Illustration 74	g00689499

21. Use two 9X-2494 U-Bolts (15), two 4W-1211 Strips (16), four 2K-4973 Locknuts (17), and four 8T-4896 Hard Washers (18) to secure 147-0815 Tube As (14) to two 188-4782 Supports (4) at the right side of the machine.

    Note: Do not tighten the U-bolts until the final assembly.

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Illustration 75	g00689501

22. Use 7C-2985 Elbow (19), 133-5940 Clamp (20), and 137-8292 Clamp (13) to connect 147-0839 Tube As (21) to 147-0815 Tube As (14) .

    Note: Do not tighten the clamps until the final assembly.

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Illustration 76	g00689507

23. Use 4P-5104 Elbow (22), 133-5940 Clamp (20), and 119-6298 Clamp (23) to connect 147-0839 Tube As (23) and the right rear turbocharger.

    Note: Do not tighten the clamp until the final assembly.

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Illustration 77	g00689510

24. Use 1W-6903 Hump Hose (24) and two 133-5940 Clamps (20) to connect 147-0814 Tube As (25) to 157-2804 Tube As (7) .

    Note: Do not tighten the clamps until the final assembly.

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Illustration 78	g00689519

25. Use 4P-5104 Elbow (22), 133-5940 Clamp (20), and 119-6298 Clamp (23) to connect 147-0814 Tube As (25) and the right front turbocharger.

    Note: Do not tighten the clamps until the final assembly.

26. Position the tube assemblies and fully tighten all the clamps.

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Illustration 79	g00689523

27. Use the following parts to connect the air compressor to 157-2804 Tube As (7) at the left side of the machine: 030-7951 Flared Elbow (28), 7M-8485 O-Ring Seal (26), 2V-0508 Hose As (29) and 9L-4007 Flared Elbow (30) .

    Note: Lubricate the bore of 030-7951 Flared Elbow (28) with glycerin or with an approved lubricant.

Install the Components from 170-1141 Pressure Sensor and Mounting Gp

Table 19

Required Components from 170-1141 Pressure Sensor and Mounting Gp
Item	Quantity	Part Number	Description
1	4	6V-5048	O-Ring Seal
2	2	9X-0262	Adapter
3	2	161-9926	Pressure Sensor
4	8	0S-0509	Bolt
5	8	5M-2894	Hard Washer
6	4	4P-8134	Clip
7	14	9X-6772	Cable Strap
8	4	4P-7581	Clip

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Illustration 80	g00911732

1. Use two 6V-5048 O-Ring Seals (1) and 9X-0262 Adapter (2) to install 161-9926 Pressure Sensor (3) in 147-0815 Tube As (A) at the left side of the engine compartment. Use two 0S-0509 Bolts (4), two 5M-2894 Washers (5), two 4P-8134 Clips (6), and two 9X-6772 Cable Straps (7) to secure the wiring harness of 161-9926 Pressure Sensor to 147-0815 Tube As (A) .

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Illustration 81	g00911736

2. Use two 0S-0509 Bolts (4), two 5M-2894 Washers (5), two 4P-7581 Clips (8), and two 9X-6772 Cable Straps (7) to secure the wiring harness of 161-9926 Pressure Sensor to 157-2804 Tube As (B) .

3. Use three 9X-6772 Cable Straps (7) to secure the wiring harness to the ROPS tube.

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Illustration 82	g00911737

4. Use two 6V-5048 O-Ring Seals (1) and 9X-0262 Adapter (2) to install 161-9926 Pressure Sensor in the 147-0815 Tube As (A) at the right side of the engine compartment. Use two 0S-0509 Bolts (4), two 5M-2894 Washers (5), two 4P-8134 Clips (6), and two 9X-6772 Cable Straps (7) to secure the wiring harness of 161-9926 Pressure Sensor to 147-0815 Tube As (A) .

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Illustration 83	g00911738

5. Use two 0S-0509 Bolts (4), two 5M-2894 Washers (5), two 4P-7581 Clips (8), and two 9X-6772 Cable Straps (7) to secure the wiring harness of 161-9926 Pressure Sensor to 157-2804 Tube As (B) .

Install the Components from 170-1140 Exhaust Pipe Gp

Table 20

Required Component from 170-1140 Exhaust Pipe Gp
Item	Quantity	Part Number	Description
1	1	7E-9153	Sleeve
2	4	6V-3822	Bolt
3	4	6V-5839	Washer
4	1	156-6247	Elbow
5	2	2W-8851	Seal Ring
6	1	2W-9078	Pipe
7	1	156-6237	Elbow
8	1	1W-4161	C-Clamp

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Illustration 84	g00689531

1. Insert 7E-9153 Sleeve (1) into the opening for the exhaust at the crossbeam.

2. Use four 6V-3822 Bolts (2) and four 6V-5839 Washers (3) to install 156-6247 Elbow (4) to the crossbeam.

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Illustration 85	g00689534

3. Install 2W-8851 Seal Ring (5) on 2W-9078 Pipe (6). Insert the pipe and the seal in 156-6247 Elbow (4) .

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Illustration 86	g00689542

4. Install 2W-8851 Seal Ring (5) on 156-6237 Elbow (6). Insert the elbow and the seal into 2W-9078 Pipe (6). Use 1W-4161 C-Clamp (8) to secure 156-6237 Elbow (7) to the left side exhaust outlet of the engine.

Install the Components from 174-9370 Exhaust Pipe Gp

Table 21

Required Components from 174-9370 Exhaust Pipe Gp
Item	Quantity	Part Number	Description
1	4	8T-4183	Bolt
2	8	5P-1076	Hard Washer
3	4	8T-4244	Nut
4	1	156-6257	Bracket
5	1	7E-8452	Clamp
6	1	155-0528	Elbow
7	1	4P-9981	Strap
8	2	8T-4172	Bolt
9	2	7X-7729	Washer
10	2	2W-8851	Seal Ring
11	1	2W-9078	Pipe
12	1	7C-3337	Elbow
13	1	1W-4161	C-Clamp

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Illustration 87	g00689550

1. Use four 8T-4183 Bolts (1), eight 5P-1076 Washers (2), and four 8T-4244 Nuts (3) to secure 156-6257 Bracket (4) to the right side of the frame.

2. Use 7E-8452 Clamp (5) to secure 155-0528 Elbow (6) to the muffler.

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Illustration 88	g00689552

3. Use 4P-9981 Strap (7), two 8T-4172 Bolts (8), and two 7X-7729 Washers (9) to secure 155-0528 Elbow (6) to 156-6257 Bracket (4) .

4. Install 2W-8851 Seal Ring (10) on 2W-9078 Pipe (11). Insert the pipe and the seal in 155-0528 Exhaust Pipe (6) .

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Illustration 89	g00689558

5. Install 2W-8851 Seal Ring (10) on 7C-3337 Elbow (12). Insert the elbow and the seal into 2W-9078 Pipe (11). Use 1W-4161 C-Clamp (13) to secure 7C-3337 Elbow (12) to the right side exhaust outlet of the engine.

Install Components from 190-6112 Radiator

Table 22

Required Components from 190-6112 Radiator
Item	Quantity	Part Number	Description
1	1	0L-1351	Bolt
2	1	5M-2894	Hard Washer
3	4	8T-4195	Bolt
4	4	8T-4121	Hard Washer
5	1	6I-3996	Gasket
6	1	133-5988	Elbow
7	1	8T-6767	Pipe Plug
8	1	030-7945	Elbow
9	1	7M-8485	O-Ring Seal
10	1	190-6440	Hose As
11	1	030-7965	Elbow
12	4	7S-5833	Hose
13	8	9X-2201	Hose Clamp
14	1	133-5988	Elbow
15	1	155-1214	Tube

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Illustration 90	g00911789

1. Use 0L-1351 Bolt (1), and 5M-2894 Hard Washer (2) to secure 157-2797 Bracket (A). Use the bolt and the washer in the regulator housing to secure 157-2797 Bracket (A) .

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Illustration 91	g00695404

2. Use four 8T-4195 Bolts (3), four 8T-4121 Hard Washers (4), and 6I-3996 Gasket (5) to install a new 133-5988 Elbow (6) at the upper center of the radiator. Ensure that there is a 8T-6767 Pipe Plug (7) that is installed in 133-5988 Elbow (6) .

3. Install 030-7945 Elbow (8) to 133-5988 Elbow (6). Use 7M-8485 O-Ring Seal (9) to connect 190-6440 Hose As (10) to 030-7945 Elbow (8) .

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Illustration 92	g00695412

4. Install 030-7965 Elbow (11) in 061-8827 Flared Tee . Connect the opposite end of 190-6440 Hose As (9) to the 030-7965 Elbow (11) .

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Illustration 93	g00695427

5. Use the existing tube, two 7S-5833 Hoses (12), and four 9X-2201 Hose Clamps (13) to connect 133-5988 Elbow (14) to the outlet for the center regulator housing on the engine.

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Illustration 94	g00695433

6. Use 155-1214 Tube (15), two 7S-5833 Hoses (11), and four 9X-2201 Hose Clamps (13) to connect the elbow at the right side of the radiator to the regulator housing on the engine.

Install the Components from 171-4614 Water Lines

Table 23

Required Components from 171-4614 Water Lines
Item	Quantity	Part Number	Description
1	1	142-2333	Hose
2	2	8T-4986	Hose Clamp

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Illustration 95	g00695391

1. Use 142-2333 Hose (1) and two 8T-4986 Hose Clamps (2) to connect the 184-4255 Tube As to the elbow assembly at the left side of the radiator.

Install the Components from 163-2633 Platform Gp

Table 24

Required Components from 163-2633 Platform Gp
Item	Quantity	Part Number	Description
1	4	8T-8917	Bolt
2	4	7D-1649	Hard Washer
3	1	160-9853	Platform

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Illustration 96	g00695438

1. Use four 8T-8917 Bolts (1) and four 7D-1649 Hard Washers (2) to install 160-9853 Platform (3) .

Install the Components of 171-4615 Water Lines

Table 25

Required Components from 171-4615 Water Lines
Item	Quantity	Part Number	Description
1	8	8T-4194	Bolt
2	8	4B-4280	Washer
3	2	1P-3705	Rectangular Seal

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Illustration 97	g00911746

1. After you install the expansion tank, use four 8T-4194 Bolts (1), four 4B-4280 Washers (2), and 1P-3705 Rectangular Seal (3) to install 190-3728 Tube (A) on the right side at the bottom of the expansion tank. Tighten two 8T-6703 Hose Clamps (not shown) on 126-9036 Hose (not shown) that connects 190-3728 Tube (not shown) and the coolant bypass line.

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Illustration 98	g00911747

2. Use four 8T-4194 Bolts (1), four 4B-4280 Washers (2), and 1P-3705 Rectangular Seal (3) to install 156-6276 Tube (B) on the left side at the bottom of the expansion tank. Tighten two 8T-6703 Hose Clamps (C) on 127-0796 Hose (D) that connects 156-6276 Tube (B) and the 156-6249 Tube (not shown).