PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE AFTERTREATMENT REGENERATION DEVICE (ARD) COMBUSTION BODY ON CERTAIN C15 ON-HIGHWAY TRUCK ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE AFTERTREATMENT REGENERATION DEVICE (ARD) COMBUSTION BODY ON CERTAIN C15 ON-HIGHWAY TRUCK ENGINES

Usage:

REBE4750-02

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07Jan2009

(Revised 25Nov2009)

U-4

A-4

O-4

TT-1

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*Safety*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE AFTERTREATMENT REGENERATION DEVICE (ARD) COMBUSTION BODY ON CERTAIN C15 ON-HIGHWAY TRUCK ENGINES
108B 108M 108E		PI10732

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10732" as the Part Number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code.
Exception: If the repair is done after failure, use "PI10732" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:	This Revised Service Letter replaces the 07Jan2009 (Revised 28Jan2009) Service Letter. Changes have been made to the Affected Product, Parts Needed, and Rework Procedure.

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PROBLEM

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This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act and the requirements of the Canadian Motor Vehicle Act. Caterpillar has decided that a defect which relates to motor vehicle safety exists in 2008 and 2009 model year trucks equipped with certain Caterpillar C15 diesel engines.

The Aftertreatment Regeneration Device (ARD) body may develop a hole and heat and flame may escape during a regeneration of the Diesel Particulate Filter, which may result in a fire hazard. The ARD body will be replaced and software updated. You will not be charged for the service performed. It is a violation of US Federal Law for a dealer to deliver a new motor vehicle or new or used engine covered by this Safety PIP until the PIP has been completed.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
C15	SDP00532-00533, 535, 546, 633, 638, 704, 778, 780, 860, 863, 869, 1113-1114, 1117-1118, 1134-1136, 1144, 1153, 1160, 1167, 1254, 1258, 1264, 1268, 1270, 1273, 1275-1277, 1282, 1285, 1293, 1300, 1312, 1320-1321, 1327, 1477, 1516, 1522, 1529, 1539, 1559, 1569, 1571, 1574, 1590, 1625-1626, 1769, 1785, 1808, 1878, 1976, 1989, 2051, 2068, 2083, 2085, 2095, 2108, 2120, 2134, 2146, 2186, 2194, 2198, 2211, 2339, 2350, 2496, 2580, 2670, 2840, 2877, 2885, 2887, 2901, 2903, 2905, 2909, 2916-2917, 2928, 2931, 2933-2934, 2936-2937, 2940, 2942-2945, 2947, 2949-2951, 2957, 2965, 2973, 2976, 2978-2980, 2982, 2988-2990, 2992, 3181, 3199, 3215, 3221, 3224-3225, 3383, 3425, 3428, 3466, 3470, 3482, 3516, 3524, 3536, 3543, 3565-3566, 3578, 3589, 3596, 3613, 3616, 3621, 3628, 3640, 3802, 3824, 3856, 3869, 3878, 3891, 3904-3905, 3911, 3917, 3921, 4465, 4823, 4937, 4942, 4985, 5000, 5022, 5024, 5112, 5156, 5193, 5262, 5278, 5287, 5292, 5294, 5305, 5318, 5381, 5383, 5405-5406, 5428, 5438, 5440-5441, 5470, 5473, 5478, 5488, 5515, 5517, 5520, 5529, 5578, 5585, 5726, 5805, 5819, 5824, 5832, 5837, 5878, 5886, 5890, 5911, 5924, 5929, 5942, 5953, 5964-5965, 5967, 6183, 6214, 6304, 6536, 6554-6555, 6557, 6610, 6792, 6833, 6836-6837, 6850, 6854-6856, 6860, 6868-6870, 6881, 6885-6886, 6889, 6892, 6895, 6900-6901, 6904, 6906, 6908, 6910, 6913, 6916-6917, 6924, 6927-6928, 6931, 6940, 6944, 6948, 6960, 7029, 7037, 7049, 7059, 7062, 7069, 7076, 7079, 7090, 7100, 7114, 7117, 7130, 7151-7152, 7239, 7320, 7326, 7379-7380, 7402, 7646, 7666, 7720, 7734, 7743, 7745, 7756, 7759, 7765-7766, 7769, 7771, 7773, 7777, 7781, 7784, 7788, 7792, 7795, 7800, 7806, 7808, 7812, 7824, 7832, 7838, 7845, 7849, 7919, 8133, 8145, 8172, 8185, 8191, 8209, 8213, 8215, 8226, 8248, 8250, 8262, 8267, 8273, 8292, 8297, 8299, 8307, 8343, 8350, 8359, 8371, 8376, 8385, 8389, 8408, 8419, 8440, 8470, 8489, 8529, 8538, 8551, 8580, 8620, 8625, 8648, 8652, 8673, 8683, 8688, 8691, 8701, 8709, 8711, 8718, 8727, 8729, 8737, 8757, 8769, 8781, 8789, 8811, 8835-8836, 8841, 8844-8845, 8847, 8852, 8857, 8865, 8870, 8874, 8925, 8930, 8934-8936, 8951-8952, 8957, 8959, 8978, 8983, 9001, 9007, 9014-9015, 9024-9026, 9032, 9040-9041, 9046, 9149, 9155, 9159, 9163-9164, 9166-9167, 9174, 9222, 9245, 9251, 9253, 9255-9256, 9263, 9278, 9287, 9289, 9298, 9303-9304, 9307, 9313, 9321, 9324, 9331, 9341, 9351, 9355, 9360-9361, 9369, 9378-9379, 9382, 9389-9390, 9400, 9410, 9416, 9462, 9465, 9468-9469, 9471-9472, 9474, 9476-9477, 9575, 9587, 9589-9590, 9598, 9616, 9627, 9642, 9650, 9659, 9706, 9724, 9726, 9737, 9745, 9754, 9769-9770, 9777, 9780, 9783, 9790-9791, 9805, 9816, 9828, 9841, 9860, 9863, 9865, 9877, 9880, 9884, 9887, 9902, 9914, 9921, 9927, 9958, 9970, 9982-9983, 9991, 9993, 10001, 10003, 10043, 10045-10047, 10061, 10068, 10078, 10083-10084, 10087-10088, 10091, 10112, 10116-10117, 10121-10122, 10124, 10135, 10207, 10237, 10271, 10273, 10275, 10308, 10312, 10322-10324, 10330, 10335, 10341, 10343, 10346-10348, 10351, 10353-10354, 10356-10362, 10364-10366, 10368, 10371-10372, 10374-10375, 10378, 10384, 10388, 10390, 10392-10393, 10395, 10399, 10406, 10412, 10418-10419, 10421, 10423, 10426, 10433, 10437, 10443, 10447-10448, 10450, 10452-10453, 10459, 10462, 10466, 10470, 10472, 10475-10476, 10478, 10482-10484, 10486-10487, 10492, 10494-10495, 10499-10501, 10503, 10505, 10507, 10522-10523, 10528-10530, 10532, 10537-10538, 10544-10546, 10548, 10560-10562, 10572, 10576, 10580, 10587, 10592, 10594, 10596-10601, 10604, 10608-10611, 10614, 10617-10618, 10621-10624, 10626, 10629-10631, 10633, 10643, 10645, 10652, 10656-10657, 10663, 10685, 10694, 10700, 10704-10707, 10711, 10725, 10743, 10747, 10749, 10760, 10762, 10766, 10769, 10777, 10788, 10792-10793, 10821, 10837, 10840, 10847, 10850, 10852, 10854, 10858-10859, 10861, 10868, 10879, 10882, 10885-10889, 10894-10895, 10899, 10903-10904, 10907, 10910-10911, 10917-10918, 10921, 10925, 10930, 10945, 10952, 10955, 10971, 10984-10985, 10987, 10990, 10993, 10998, 11018, 11020, 11022, 11025-11026, 11028, 11031, 11037, 11046-11047, 11057, 11065, 11067, 11090-11091, 11094, 11098-11101, 11103, 11105-11108, 11110-11111, 11116, 11118-11119, 11121, 11123, 11143, 11161, 11203, 11217, 11231, 11234, 11245, 11594, 11634, 11643-11645, 11650, 11658, 11665-11666, 11672, 11687-11688, 11694-11695, 11697, 11700, 11731, 11760-11762, 11764, 11771, 11774, 11785-11786, 11805, 11809-11810, 11816, 11819, 11839, 11900, 11902, 11904, 11909, 11912, 11918, 11923, 11925, 11927, 11930, 11990, 11992, 12036, 12046, 12137, 12142, 12145, 12171, 12173, 12179-12180, 12230, 12247, 12258, 12284, 12313, 12329, 12575, 12595, 12732, 12824, 12852, 12855, 12868, 12895-12896, 12898-12899, 12901, 12931, 12936, 12939-12940, 12944-12945, 12954, 12971, 12975, 12986, 12998, 13012-13013, 13016, 13040, 13056, 13060, 13064, 13100, 13106, 13144, 13325, 13373, 13384, 13393, 13445, 13453, 13467, 13472, 13486, 13501, 13505, 13510, 13524, 13559, 13561, 13565, 13595, 13632, 13644, 13683, 13689-13690, 13697, 13707, 13717, 13723, 13725-13726, 13736, 13738, 13743-13744, 13746, 13748, 13752, 13771, 13775, 13785-13786, 13812, 13817, 13819, 13821, 13826-13827, 13832-13833, 13865, 13883, 13905, 13919, 13936, 13942, 13954, 13962, 13965, 13977, 13981, 13986, 13989, 14001, 14047, 14059, 14063, 14079, 14087, 14120, 14141, 14148, 14157, 14217, 14219, 14224, 14255, 14293, 14302, 14312, 14319-14320, 14327, 14355, 14381, 14399, 14403-14404, 14409, 14427, 14430-14431, 14456, 14487, 14501, 14536, 14840, 14870, 14923, 14976, 15008, 15080, 15140, 15261, 15322, 15342, 15398, 15401, 15410, 15418, 15424, 15432, 15442, 15444, 15450, 15464, 15466, 15494, 15590, 15617, 15622, 15642, 15693, 15698, 15717, 15725, 15728, 15742, 15745-15746, 15758, 15792, 15806, 15817, 15863, 15877, 15881, 15891, 15898, 15902, 15983, 16131, 16249, 16307, 16384, 16406, 16447, 16469, 16482, 16487, 16516, 16539, 16557, 16595, 16605, 16607, 16613, 16624, 16664, 16690, 16694, 16701, 16738, 16750, 16757, 16788-16790, 16795, 16798-16800, 16802, 16806, 16808, 16811-16813, 16815, 16819, 16821, 16823, 16827, 16830-16836, 16838, 16845-16846, 16849, 16851, 16853-16855, 16896-16897, 16904, 16945, 16949, 17002, 17005, 17009, 17014, 17059, 17062-17063, 17067-17068, 17079, 17098, 17116, 17134, 17148, 17167, 17241, 17318, 17452, 17516, 17564, 17582, 17836, 17838, 17878, 17904, 18099, 18110, 18123, 18135, 18153, 18156, 18159, 18188, 18222, 18263, 18271, 18273, 18285, 18291, 18296, 18307, 18312, 18323, 18329, 18334, 18339, 18384, 18387, 18407, 18411, 18436, 18457, 18462, 18487, 18493, 18500, 18515, 18524, 18528, 18532, 18535-18536, 18539, 18541, 18549, 18551, 18586, 18588, 18591, 18593, 18596, 18602, 18651, 18678, 18696-18697, 18704, 18718, 18722, 18844, 18862, 18872, 18914, 18974, 19008, 19019, 19057, 19068, 19125, 19142, 19145, 19159, 19174, 19190, 19220, 19226, 19256, 19275, 19279, 19285, 19288, 19297, 19312, 19316, 19319, 19334, 19336, 19368, 19384, 19387, 19397, 19402, 19410, 19517, 19522, 19524, 19526, 19528, 19534, 19539, 19541, 19554, 19645-19646, 19648, 19650-19651, 19653-19660, 19663-19664, 19666-19667, 19673-19674, 19676, 19679, 19701, 19746, 19780, 19793-19794, 19822, 19835-19836, 19839, 19843-19844, 19846, 19848, 19850, 19857-19859, 19861, 19866, 19870, 19878, 19887, 19890, 19899, 19908, 19913, 19928, 19939, 19941, 19943, 19965, 20021, 20114, 20132, 20141, 20153, 20164-20165, 20171-20175, 20184, 20187, 20191, 20196, 20199, 20205, 20207-20208, 20212, 20243, 20251-20252, 20263, 20281, 20296, 20333, 20380, 20409, 20435, 20506, 20508, 20511, 20546, 20558, 20744, 20757, 20784, 20811, 20835, 20927, 20959, 21009, 22068, 22081, 22180, 22209, 22427-22428, 22472, 22491

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*****Group 2*****
C15	SDP13395, 13404, 13588, 13734, 13918, 14874, 14912, 14960, 14975, 15090, 15113, 15147, 15187, 15194, 15291, 15296, 15520, 16154-16155, 16158, 16161, 16167, 16169-16170, 16181, 16186, 16188, 16191, 16197, 16458, 20090, 20121, 20152, 20780

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*******Group 3*******

C15

SDP13787, 15724, 16193, 16446, 16454, 16456, 16460-16461, 16468, 16485, 16489, 16501, 16814, 16816, 17048, 17066, 17141, 17155, 17388, 17594, 17739, 17745, 17837, 17848, 17965, 17992, 17998, 18013, 18029, 18032, 18050, 18069, 18079, 18090, 18102, 18109, 18119, 18122, 18126, 18134, 18137, 18149, 18157, 18362, 18475-18476, 18485, 18489, 18512, 18869, 18890, 18899-18900, 18908, 18953, 18960, 18982, 18998, 19003, 19007, 19026, 19045, 19138, 19157, 19474, 19478, 19483-19484, 19486, 19498, 19509, 19513, 19560, 19566, 19571-19572, 19574, 19580, 19583, 19587-19588, 19593-19594, 19598, 19879, 19915, 19966, 19980, 20053, 20071, 20073, 20078, 20080, 20083-20085, 20088-20089, 20091, 20093, 20097, 20099, 20102-20103, 20108-20110, 20117, 20120, 20124, 20126-20127, 20129, 20131, 20133, 20136-20137, 20148, 20154, 20157, 20162, 20195, 20221, 20226, 20228, 20247, 20249-20250, 20310, 20345, 20769, 20773, 20775, 20783, 20785, 20787-20790, 20793, 20799, 20802-20803, 20805, 20807, 20810, 20812, 20816-20817, 20819, 20821-20822, 20828-20830, 20832, 20834, 20836-20837, 20842, 20849, 20853, 20862, 20866, 20877, 20925, 20929, 20931-20932, 20937-20938, 20941-20943, 20945, 20949, 20953, 20955, 20957-20958, 20962, 20964, 20967-20968, 21033, 21069, 21091, 21139, 21146, 21166, 21171, 21173, 21212, 21240, 21244, 21258, 21265, 21294, 21318, 21324, 21330, 21342-21344, 21347, 21356, 21358, 21360, 21363, 21412-21413, 21418, 21420, 21429, 21542, 21652, 21666, 21686, 21703, 21705, 21712, 21723, 21738-21744, 21752, 21756, 21760, 21765, 21768, 21778, 21783-21785, 21790, 22073, 22152, 22155-22156, 22159, 22162-22163, 22166, 22168, 22170-22171, 22175-22176, 22188, 22264, 22270, 22272

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
1	0S1619	BOLT
1	5M2894	WASHER-HARD
1	2886036	TUBE AS.-AIR
1	2893107	GASKET
2	2967780	GASKET
1	3239486	BODY-MACHINED
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
1	0S1619	BOLT (Before Failure Only)
1	5M2894	WASHER-HARD (Before Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 3*****
1	0S1619	BOLT
1	5M2894	WASHER-HARD
1	2886036	TUBE AS.-AIR
1	2893107	GASKET
2	2967780	GASKET
1	3239486	BODY-MACHINED
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 45% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Replace the Aftertreatment Regeneration Device (ARD) body.

Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 4.0-hour job for Group 1
4.0 hours will be allowed to replace the parts listed in the required parts list. Note: Heat shields are not listed in the required parts list therefore should not be replaced

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 0.5-hour job for Group 2
0.5 hour will be allowed to replace 0T-0573 Bolt with a 0S-1619 Bolt and second 5M-2894 Washer for the combustion body support bracket. No ECM Download is required for this repair. A maximum of $49.50 US Dollars will be allowed for shipping the OEM owned engines that have not yet been installed. Parts have been supplied to the dealer and are not to be claimed for Group 2.

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 2.0-hour job for Group 3
2.0 hours will be allowed to replace the parts listed in the required parts list. No ECM Download is required for this repair. A maximum of $49.50 US Dollars will be allowed for shipping the OEM owned engines that have not yet been installed. Parts have been supplied to the dealer and are not to be claimed for Group 3.

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PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - RECALL- REPLACEMENT OF THE AFTERTREATMENT REGENERATION DEVICE BODY

MODELS INVOLVED - C15 On-Highway Truck Engines

Dear Caterpillar Product Owner:

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. This notice is also in accordance with the requirements of the Canadian Motor Vehicle Safety Act. Caterpillar has decided that a defect which relates to motor vehicle safety exists in 2008 & 2009 model year trucks equipped with certain Caterpillar C15 truck engines.

The Aftertreatment Regeneration Device (ARD) body may develop a hole and heat and flame may escape during a regeneration of the Diesel Particulate Filter, which may result in a fire hazard. The ARD body will be replaced and the software updated. You will not be charged for the service performed.

If you are a lessor of these vehicles, you must forward this letter to your lessee within ten days.

If you have had your vehicle repaired for this condition prior to receipt of this notice and incurred any costs, you may be eligible for reimbursement. Please contact Caterpillar at this toll free number (800) 447-4986.

If you no longer own the truck with this engine, please contact Caterpillar at this toll free number (800) 447-4986.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

If the dealer is unable to have the inspection and repair made, please contact:

Caterpillar Inc.
PO Box 610
Mossville, IL 61552-610
Attn: Engine Products Division
Truck Engine Call Center
Telephone: (800) 447-4986

If you are unable to have the inspection and repair made within 60 days or without charge, you may submit a complaint to:

In the U.S.
Administrator
National Highway Traffic Safety Administration
1200 New Jersey Avenue, S.E.
Washington, D.C. 20590
Telephone: 1-888-327-4236 (TTY:1-800-424-9153)or go to http://www.safercar.gov

In Canada
Transport Canada
Road Safety and Motor Vehicle Regulation
Ottawa, Ontario KIA 0N5
Telephone: (613) 993-9851
Caterpillar Inc.

Please refer the dealer to their Service Letter dated 07Jan2009 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 07Jan2009 Service Letter

Rework Procedure

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Group Number 1

1. Perform an ECM warranty download using Cat ET.

2. Remove combustion head group (ARD). Refer to RENR9706 "Combustion Head Group (ARD) ? Removal Procedure".

3. Loosen the OEM band clamp at the bottom of the combustion body and remove the extension pipe attached to the combustion body.

4. Disconnect the temperature sensor located at the bottom of the combustion body. Refer to Image 1.1.1

Image1.1.1

Image1.1.2

5. Remove the two bolts that attach the combustion body to the support bracket. Refer to Image 1.1.2

6. Disconnect the temperature sensor located on the back of the combustion body near the top.

7. Remove the clamp that attaches the combustion body to the turbocharger and remove the combustion body.

8. Remove the bolts and washer used to attach heat shield to the combustion body, and remove heat shield. Retain hardware for reuse.

9. Use the hardware retained from Step 8 to attach the heat shield removed in Step 8 to the new combustion body.

10. Install the new combustion body. Apply anti-seize compound to the threads of the clamp assembly. Position combustion body and tighten clamp assembly to a torque of 11 +/- 2 N.m (98 +/- 18 lb in).

11. Install the two bolts that attach the combustion body to the support bracket. Refer to Image 1.2.1

12. Apply anti-seize compound to the threads of the temperature sensor located at the bottom of the combustion body and install. Refer to Image 1.1.1

13. Attach the OEM extension pipe to the bottom of the combustion body and tighten the band clamp.

14. Apply anti-seize compound onto the threads of the temperature sensor located on the back of the combustion body near the top. Tighten sensor to a torque of 45 +/- 5 N.m (33 +/- 4 lb ft).

15. Apply anti-seize compound to the threads of studs (19). Install studs (19) with the end that is marked "X" in the Up position. Tighten studs (19) to a torque of 17 +/- 2 N.m (12.5 +/- 1.5 lb ft). Install tube (18). Refer to Image 1.2.1 and Image 1.2.2

Image1.2.1

Image1.2.2

16. Install combustion head group (ARD). Refer to RENR9706 "Combustion Head Group (ARD) ? Installation Procedure".

17. Install a new 289-3107 gasket (not pictured) between the 288-6036 tube assembly (1) and ARD Head. Tighten clamp (6). Refer to Image 1.3.1

Image1.3.1

18. Fill the cooling system with coolant. Refer to Operation and Maintenance, "Refill Capacities" for the cooling system capacity.

19. Perform the ARD ignition test. Refer to Troubleshooting Manual, "ARD Ignition - Test".

20. Perform an after repair ECM warranty report.

Group Number 2

Replace the 0T0573 Bolt (4) located in the top mounting hole for the combustion body support bracket (3) with the 0S1619 Bolt and a second 5M2894 Washer (5).

Image2.1.1

Group Number 3

1. Remove bolts (2). Disconnect tube assembly (1) and remove the gasket (not shown). Loosen clamp assembly (4) and remove tube assembly (1). Refer to Image 3.1.1 and 3.1.2.

Image3.1.1

Image3.1.2

2. Remove nuts (12) and spacers (13). Remove combustion head (14) and remove gasket 15). Remove flanged tube (16) and remove gasket (17). Remove studs (19). Refer to Image 3.2.1.

Image3.2.1

3. Disconnect the temperature sensor located at the bottom of the combustion body. Refer to Image 3.3.1.

Image3.3.1

4. Remove the two bolts (1) that attach the combustion body to the support bracket (2). Remove the top mounting bolt (3) and washer (4) for the support bracket (2). Refer to Image 3.4.1.

Image3.4.1

5. Disconnect the temperature sensor located on the back of the combustion body near the top.

6. Remove the clamp that attaches the combustion body to the turbocharger and remove the combustion body.

7. Remove the bolts and washer used to attach heat shield to the combustion body, and remove heat shield. Retain hardware for reuse.

8. Use the hardware retained from Step 7 to attach the heat shield removed in Step 7 to the new combustion body.

9. Install the new combustion body. Apply anti-seize compound to the threads of the clamp assembly. Position combustion body and tighten clamp assembly to a torque of 11 +/- 2 N.m (98 +/- 18 lb in).

10. Install the two bolts that attach the combustion body to the support bracket (1). Install the new 0S-1619 Bolt (2) and second 5M-2894 Washer (3). Refer to Image 3.5.1.

Image3.5.1

11. Apply anti-seize compound to the threads of the temperature sensor located at the bottom of the combustion body and install. Refer to Image 3.3.1.

12. Apply anti-seize compound onto the threads of the temperature sensor located on the back of the combustion body near the top. Tighten sensor to a torque of 45 +/- 5 N.m (33 +/- 4 lb ft).

13. Apply anti-seize compound to the threads of studs (19). Install studs (19) with the end that is marked "X" in the Up position. Tighten studs (19) to a torque of 17 +/- 2 N.m (12.5 +/- 1.5 lb ft). Refer to Image 3.6.1 and Image 3.6.2.

Image3.6.1

Image3.6.2

14. Install gasket (17) and install flanged tube (16). Install gasket (15) and install combustion head (14). Apply anti-seize compound onto the threads of the studs and nuts (19) and (12). Install spacers (13) and nuts (12) . Tighten nuts (12) in a crisscross pattern to a torque of 23 +/- 3 N.m (17 +/- 2 lb ft). Tighten nuts (12) again in a crisscross pattern to a torque of 28 +/- 7 N.m (21 +/- 5 lb ft). Tighten nuts (12) again in a crisscross pattern to a torque of 28 +/- 7 N.m (21 +/- 5 lb ft). Refer to Image 3.6.1.

15. Install a new 289-3107 Gasket (not pictured) between the 288-6036 Tube Assembly (1) and ARD Head. Tighten clamp (6). Refer to Image 3.1.2.