- Engine:
- G3606 (S/N: 3XF1-UP)
- G3608 (S/N: 4WF1-UP)
Introduction
Do not perform any procedure that is outlined in this Special Instruction or order any parts until the entire instruction has been read and understood.
This Special Instruction describes the procedures for ordering and installing the ADEM 3 control system for the G3606 and G3608 Engines.
Whenever questions arise about this product or this Special Instruction, consult your local Caterpillar dealer for the latest available information.
System Description
The ADEM 3 control system replaces the Caterpillar Ignition System (CIS). Upgrading an engine to the ADEM 3 control system provides the following improvements and enhancements:
Increased Reliability - The simplified design of the system has fewer control modules and wiring harnesses.
Improved Control of Detonation - The ADEM 3 control system provides control of the detonation level for each cylinder. This results in improved protection for the engine, reduced exhaust emissions, and improved performance.
Improved Control of the Choke - Engine wear is reduced through better control of the choke during warm-up and during light load operation.
Pyrometer - The exhaust temperature is monitored at the exhaust port of each cylinder, at the inlet of each turbocharger, and at the outlet of each turbocharger.
Caterpillar Electronic Technician (Cat ET) - The Cat ET provides an interface for the programming of the engine's parameters. Cat ET also provides real time monitoring of the engine during operation and comprehensive display of diagnostics.
Machine Information Display System (MIDS) - The MIDS is a device which enables the operator to monitor engine operation. The MIDS receives information from the Electronic Control Module (ECM). The device cannot be used for programming. A screen display and a keypad provide the interface for the operator.
Requirements Before Starting the Conversion
Hydraulic Actuator System (Hydrax System)
The engine must be equipped with the Hydrax system. The Hydrax system replaces the electronic actuators that control the fuel, the wastegate, and the choke. Refer to Special Instruction, REHS0147 for information on installation of the Hydrax system.
Canadian Standards Association (CSA)
All of the kit's components meet the certification for CSA. If your engine requires certification for CSA you must contact the CSA and arrange for an inspection by a CSA auditor.
Engine Operation
The engine must be mechanically sound.
The engine must be tuned prior to performing this upgrade.
Performance Data Sheet
Illustration 1 is the "Performance Data Sheet" for the Engine Supervisory System (ESS). Use the sheet in order to record the engine data from these systems:
- Digital Diagnostic Tool (DDT)
- Caterpillar Monitoring System (CMS)
- Status Control Module (SCM)
- ECM
- Pyrometer
This information serves as a reference in order to ensure that engine performance is maintained after installation of the ADEM 3 control system. This information will also be used to determine the requirements of the new software.
Use an emission analyzer tool in order to test the engine's emissions. Record the results on the sheet.
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| Illustration 1 | g01056776 |
Request for New Software
New software will be required in order to make the engine compatible with the customer's requirements. The following items are required in order to determine the software requirements:
- "G3600 ESS Performance Data Sheet"
- Current fuel analysis
- Software Request Form
These items must be submitted to the Service Center at Caterpillar Diversified Power Products in order to determine the requirements of the new software. The Service Center will respond with the appropriate part number that can be downloaded by the Caterpillar dealer via the Service Information System.
If the appropriate software is not available, on-site mapping by a Caterpillar performance engineer will be required. On-site mapping will add approximately four days to the time that is required for the conversion.
Be sure to promptly submit the three items that are listed above. This will provide sufficient time in order to determine the software requirements. Submit the request for new software before you order any parts. Fax the request to the following number:
(765) 448-5586References
Special Instruction, REHS0147, "Installation of the Hydraulic Actuator System (Hydrax)"
CIS
Disassembly and Assembly, SENR4259
Schematic, SENR5083, "G3606 and G3608 Engine Electrical System"
Systems Operation/Testing and Adjusting, RENR2254
Troubleshooting, SENR6510
ADEM 3
Disassembly and Assembly, SENR4259
Operation and Maintenance Manual, SEBU7563
Schematic, RENR5966, "G3606 Electrical System"
Schematic, RENR5967, "G3608 Electrical System"
Systems Operation/Testing and Adjusting, RENR5908
Troubleshooting, RENR5910
Special Instruction, REHS1336, "Installation and Initial Start-Up Procedure for G3600 Engines"
Preparation of the Engine
- Ensure that all of the new parts are available.
- Operate the prelube pump and the barring device in order to put the number 1 cylinder in the top center position on the compression stroke. Pin the camshaft. For instructions, refer to Systems Operation/Testing and Adjusting, RENR2254, "Finding the Top Center Compression Position for No. 1 Cylinder".
- Lock out the gas and the electrical power.
- Drain the coolant from the engine. Refer to Operation and Maintenance Manual, SEBU6278, "Cooling System Coolant - Change".
Remove the Existing Components and Systems
Remove the ESS Panel
- At the ESS panel, identify each connection from the customer's wiring. Label each connection.
- Disconnect the wiring from the ESS panel and remove the panel.
Remove the Main Fuel Line and Other Components for the Fuel System
- Remove the fuel lines that run between the main fuel line and the needle valves.
Note: Do not remove the needle valves.
- Remove the fuel lines that run between the main fuel line and each cylinder. Discard the 18 mm orifice plates.
- Remove the main fuel line.
- Remove all of the brackets that attached the main fuel line to the engine.
Remove the Thermocouples, If Necessary
Note: Do not remove the thermocouples for the outlets of the turbochargers.
Each thermocouple for the cylinders must have a round 3-pin connector. If the thermocouples are incorrect, remove the thermocouples and replace the thermocouples with 152-0807 Temperature Sensor Gp .
Remove the harness for the thermocouples. Remove any clips and brackets that attached the harness to the engine.
Remove the Combustion Sensing System
Perform the following steps in order to remove the combustion sensing system:
- For each cylinder, remove the cable that runs between the transformer and the combustion buffer.
- Disconnect the remaining connectors at each combustion buffer.
- Cut all of the tie straps between the combustion buffers and the junction box for the combustion buffers and detonation sensors.
- Remove the harnesses that run between each combustion buffer and the junction box for the combustion buffer and detonation sensors.
- Disconnect the connectors at each detonation sensor.
- Cut all of the tie straps between the detonation sensors and the junction box for the combustion buffers and detonation sensors.
- Remove the harnesses that run between the detonation sensors and the junction box for the combustion buffers and detonation sensors.
- Remove the clips that were used to secure the harness for the combustion buffers to the brackets for the main fuel line.
- Remove the junction box for the combustion buffers and detonation sensors. Remove the brackets that attached the junction box to the engine.
Remove Some of the Components for the Hydrax System, If Necessary
Remove the following components for the hydrax system:
- Remove the wiring harnesses for the hydrax actuators and the position sensors.
- Remove the clips that were used to support the wiring harness.
- Remove the wiring harness that runs between the junction box for the hydrax driver modules and the engine junction box.
- Remove the junction box for the hydrax driver modules.
- Remove the bracket that attached the junction box to the engine.
- Remove the position sensors and the mounting hardware for the sensors. Be sure to remove the couplings from the shafts.
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| Illustration 2 | g01047834 |
Position sensor and mounting hardware | |
Remove the Components for the Magneto or the CIS
If the engine is equipped with a magneto, perform the following procedure:
- Disconnect ignition harness (1) and harness (5) from magneto (2) .
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| Illustration 3 | g01048052 |
Rear view and right side view (1) Ignition harness (2) Magneto (3) Mounting plate (4) Interface box (5) Harness (6) Ground strap (7) Interface harness | |
- Disconnect interface harness (7) from interface box (4) .
- Remove the bolts and washers from mounting plate (3). Keep the bolts and washers for later use. Remove the mounting plate, interface box (4), and harness (5) as a unit. Keep ground strap (6) for later use.
- Remove magneto (2) from the flywheel housing. Do not remove the magneto's drive coupling. Keep the magneto's mounting bolts and washers for later use.
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| Illustration 4 | g01048059 |
Right side section view of the magneto's drive coupling (2) Magneto | |
- Install gasket (8) and plate (9) in place of the magneto. Use the mounting bolts and washers that were removed from the magneto in Step 4.
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| Illustration 5 | g01048064 |
Rear view (1) Ignition harness (8) 147-6549 Gasket (not shown) (9) 147-6548 Plate | |
- Remove ignition harness (1) from the engine.
- Remove interface harness (7) .
If the engine is equipped with CIS, perform the following procedure:
- Remove harnesses (10), (11), and (12) from the engine.
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| Illustration 6 | g01048047 |
Right side view (10) Harness (11) Harness (12) Harness | |
- Disconnect connector (16) .
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| Illustration 7 | g01048079 |
Right side view (13) Plate (14) Programming control (15) Ground strap (16) Connector | |
- Remove ground strap (15), programming control (14), and plate (13) .
Remove the Ignition Wiring and the Detonation Sensors
- Remove ignition wiring (2) and all of the mounting brackets (1) from the engine.
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| Illustration 8 | g01048088 |
Right side view (1) Mounting brackets (2) Ignition wiring | |
- Remove the detonation sensors.
Remove the Switch for the Inlet Air Restriction
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| Illustration 9 | g01062882 |
Switch for the inlet air restriction | |
Remove the switch for the inlet air restriction and the associated hardware. Do not disconnect the hose that is connected to the turbocharger. The hose will be connected to the new switch.
Remove Some of the Engine's Sensors
Remove the following sensors:
- Remove crankcase pressure sensor (1) and hose (2). The new sensor will be installed into the port on the side cover for the crankshaft.
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| Illustration 10 | g01048115 |
Right side view (1) Crankcase pressure sensor (2) Hose (3) Junction box for the switches for the oil level and the water level | |
- Remove junction box (3) and the associated mounting hardware.
- Remove unfiltered oil pressure sensor (4) and associated mounting hardware. Use a 9S-4191 Plug and a 6V-5049 O-Ring Seal in order to seal the opening.
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| Illustration 11 | g01048133 |
Front view (4) Unfiltered oil pressure sensor | |
- Remove the prelube pressure switch and the associated hardware.
Remove the Engine Junction Box
Disconnect the connectors from the following components:
- All of the engine's sensors
- Air start solenoid valve
- Solenoid valve for prelubrication
- Hydrax actuators
- CIS module or magneto interface box
The individual conduits may be left attached to the bottom of the engine mounted junction box.
Attach a suitable lifting device to the engine mounted terminal box. Remove the engine mounted terminal box and the brackets from the engine.
Replace the Front Camshaft Cover
- Remove camshaft cover (1) from the front of the engine.
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| Illustration 12 | g01048236 |
Front view (1) Camshaft cover | |
- Remove bolts (4) and washers (5) in order to remove plate (3) and magnet assembly (2) .
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| Illustration 13 | g01048238 |
Section view of the end of the camshaft (2) Magnet (3) Plate (4) Bolt (5) Washer | |
- Install the 1W-2334 Gasket and 206-6583 Cover by using eight 3V-3308 Hard Washers and eight 0S-1594 Bolts .
Remove the Accumulator for the Hydrax System
The ADEM 3 control system does not require an accumulator for the hydrax system. If the hydrax system has an accumulator, the accumulator may be removed. Leaving the accumulator installed does not adversely affect the operation of the engine. Perform the following procedure in order to remove the accumulator:
- Disconnect line (2) from tee (3) .
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| Illustration 14 | g01048191 |
Left side view (1) Accumulator (2) Line (3) Tee | |
- Remove the mounting hardware and accumulator (1) .
Remove the Side Covers
- Remove the ignition transformers and the extenders.
- Remove the side covers.
Note: The extension tubes may come out of the cylinder head when the side covers are removed. Keep the extension tubes for later use.
Install the New Components and the New Systems
Install the Components for the Ignition
- Inspect the O-Ring Seals on both ends of each extension tube. Look for cracks or other damage. Replace the O-Ring Seals, if necessary. Insert an extension tube into each cylinder head.
- For each cylinder, place a 9X-7688 O-Ring Seal into position. Place all of the 145-8634 Covers into position.
- Install clips (8), washers (9), and bolts (7) for all of the cylinders.
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| Illustration 15 | g01062888 |
Right side view The six cylinder engine is shown. The eight cylinder engine is similar. (1) 116-0118 Clip (2) 3V-3308 Hard Washers (3) 4F-4879 Bolt (4) 128-8831 Bracket (5) 9X-3495 Clip Assemblies (6) 0S-1590 Bolt (7) 0S-1571 Bolt (8) 4P-7581 Clips (9) 3V-3308 Hard Washer (10) 145-8634 Cover | |
- For six cylinder engines, perform the following procedure:
- Install clip (5), washer (2), and bolt (7) in cylinders 1 through 5.
- Install bracket (4) and clip (5) to the upper left corner of the cover plate for cylinder 6.
- Install clip (1) to bracket (4) by using washer (2) and bolt (3) .
- For eight cylinder engines, perform the following procedure:
- Install clip (5), washer (2), and bolt (7) in cylinders 1 through 7.
- Install bracket (4) and clip (5) to the upper left corner of the cover plate for cylinder 8.
- Install clip (1) to bracket (4) by using washer (2) and bolt (3) .
- Install new spark plugs.
- Thread an extender onto each transformer hand tight.
- Install a 6V-3834 O-Ring Seal onto the side cover for each cylinder.
- Install a transformer into each cylinder by using four 9M-1974 Hard Washers and four 4B-3388 Bolts .
Install the Speed/Timing Sensor and the Speed-Timing Wheel
- Remove the rear cam cover.
- Lubricate the speed/timing sensor's O-Ring Seal with clean engine oil.
- Install sensor (7) into the counterbore on the rear housing. Make sure that the sensor is properly seated and that the bracket is flush with the mounting surface. Use the bolt in order to secure the bracket to the rear housing.
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| Illustration 16 | g01048301 |
Rear view and section view (1) 196-6043 Spacer (2) 154-2709 Wheel (3) 5P-8245 Hard Washer (4) 1D-4569 Bolt (5) Direction of the camshaft's rotation (6) Extra tooth (7) 194-5338 Speed Sensor | |
- Install spacer (1) and speed-timing wheel (2) .
- Orient extra tooth (6) near the sensor. Loosely install four bolts (4) and washer (3) in order to enable the speed-timing wheel to be moved.
- Rotate the speed-timing wheel in the direction of the camshaft's rotation (5) until the first tooth that follows the extra tooth is aligned with the centerline of the sensor.
- Tighten four bolts (4) .
- Measure the gap between the sensor's head and the speed-timing wheel. The distance must be between 0.6 mm (0.024 inches) and 1.6 mm (0.063 inches). If the gap is too large, remove material from the housing in order to attain the correct gap. If the gap is too small, use 119-9738 Shims in order to attain the correct gap.
- Install the cover for the speed-timing wheel.
Install the Terminal Box
Note: Do not install the terminal box until the speed-timing wheel and the cover are installed.
- Install bracket (1) to the right side of the rear housing by using four washers (2) and four bolts (3) .
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| Illustration 17 | g01048666 |
Right side of the rear housing (1) 213-6283 Bracket As (2) 5P-8245 Hard Washers (3) 0S-1595 Bolts | |
- Attach two shock mounts (15) to terminal box (8) by using two washers (4), four washers (13) and two nuts (16) for each shock mount.
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| Illustration 18 | g01048761 |
Installation of the terminal box (4) 3V-3308 Hard Washers (5) 4D-1326 Lockwashers (6) 0S-0509 Bolts (7) 127-0594 Wire (8) 213-6284 Control Panel Box Gp (9) 0L-2070 Bolt (10) 5P-0537 Hard Washers (11) 9S-8750 Nuts (12) 167-9430 Isolators (13) 9Y-9481 Washers (14) 0S-1615 Bolts (15) 9Y-9480 Shock Mounts (16) 9S-8752 Full Nuts | |
- Place the terminal box onto the bracket. Align the holes in the shock mounts with the holes on the bracket. Attach the shock mounts to the bracket by using four bolts (14), eight washers (10), and four nuts (11) for each shock mount.
- Remove the paint near the mounting locations for wire (7). Install the wire by using two lockwashers (5), two washers (4) and two bolts (6) .
- Place two isolators (12) into position. Attach each isolator with two washers (11) and two nuts (10). Torque each nut to 6 N·m (53 lb in).
- Open the door and install two washers (11) and two nuts (10) to each shock mount. Torque each nut to 6 N·m (53 lb in).
Install the Hardware for the Combustion Sensing System
- Attach four flexible mounts (1) to bracket (4) by using a washer (2) and nut (3) for each shock mount.
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| Illustration 19 | g01051920 |
Bracket and shock mounts (1) 209-3413 Flexible Mount (2) 9M-1974 Hard Washers (3) 5S-0003 Nuts (1) 213-6287 Bracket As | |
- Install bracket (4) to the side of the engine by using two bolts (5), two bolts (9), and four washers (6). Install lockwasher (7) and wire (8) in the upper right hand location.
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| Illustration 20 | g01048880 |
Right side view (5) 0L-2070 Bolts (6) 3V-3308 Hard Washers (7) 4D-1326 Lockwasher (8) 127-0594 Wire (9) 3B-1915 Bolts | |
Note: On six cylinder engines, the bracket is mounted at cylinder 3. On eight cylinder engines, the bracket is mounted at cylinder 4.
- Place bracket (10) onto the shock mounts. Secure the bracket with four washers (11) and four nuts (12) .
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| Illustration 21 | g01048946 |
Right side view (10) 213-6287 Bracket As (11) 9M-1974 Hard Washer (12) 5S-0003 Nut | |
- Install bracket (13) by using a washer (6) and a bolt (14) .
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| Illustration 22 | g01048948 |
Right side view (13) 213-6302 Bracket (14) 0T-0102 Bolt (15) 7H-3937 Lockwasher (16) 176-1287 Electronic Control Module | |
- Install module (16) by using three washers (11) and three nuts (12). Attach the ground strap to the module by using a lockwasher (15), a washer (11) and a nut (12) .
- For six cylinder engines, install the wiring harnesses and the thermocouple for the turbocharger inlet according to the following procedure:
- Install the wiring (18-23) for each sensor.
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Illustration 23 g01049134
Right side view
The arrows indicate the locations for the 9X-6772 Cable Straps .
(17) 213-6289 Harness
(18) 213-6300 Wire
(19) 213-6299 Wire
(20) 213-6298 Wire
(21) 213-6297 Wire
(22) 213-6296 Wire
(23) 213-6295 Wire
(X) Locations for the attachment of the wires
- Install harness (17) for the thermocouples.
- Use 9X-6772 Cable Straps in order to secure the harnesses to the bracket for the Integrated Combustion Sensing Module (ICSM) and to the side cover for each cylinder.
- Attach each harness to the clips at locations (X) .
- For eight cylinder engines, install the wiring harnesses and the thermocouple for the turbocharger inlet according to the following procedure:
- Install the wiring (27-34) for each sensor.
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Illustration 25 g01050516
Right side view
The arrows indicate the locations for the 9X-6772 Cable Straps .
(26) 219-9939 Sensor Harness As
(27) 213-6301 Sensor Wiring Gp
(28) 213-6300 Wire
(29) 213-6299 Wire
(30) 213-6298 Wire
(31) 213-6297 Wire
(32) 213-6296 Wire
(33) 213-6295 Wire
(34) 213-6294 Wire
(X) Locations for the attachment of the wiring
- Install harness (26) for the thermocouples.
- Use 9X-6772 Cable Straps in order to secure the harnesses to the bracket for the ICSM and to the side cover for each cylinder.
- Attach each harness to the clips at locations (X) .
Replace the Engine's Sensors
- Remove the following components:
- Sensor for the inlet manifold air temperature
- Sensor for the outlet pressure of the jacket water
- Sensor for the jacket water coolant temperature
- Filtered engine oil pressure sensor
- Engine oil temperature sensor
- Detonation sensors
- Sensor for the inlet manifold air temperature
- The pressure module for inlet air and fuel must be part number 211-6713. If the module is the incorrect part number, replace the module.
- Install the following components:
- Install the air inlet restriction switch by using the following components:
- Install the sensor for the inlet manifold air temperature by using a 8L-2786 O-Ring Seal and 130-8299 Temperature Sensor Gp . Tighten the sensor to the appropriate torque.
- Install the sensor for the outlet pressure of the jacket water by using the following components:
- Install the sensor for the jacket water coolant temperature by using the following components:
Tighten the sensor to the appropriate torque.
- Install the sensor for the filtered engine oil pressure by using the following components:
- 6V-5048 O-Ring Seal
- 8L-2779 O-Ring Seal
- 6V-9872 Connector
- 6V-5049 O-Ring Seal
- 8T-0788 Elbow
- 163-8523 Pressure Sensor Gp
Tighten the sensor to the appropriate torque.
- 6V-5048 O-Ring Seal
- Install the sensor for the unfiltered engine oil pressure by using the following components:
Tighten the sensor to the appropriate torque.
- Install the engine oil temperature sensor by using the following components:
Tighten the sensor to the appropriate torque.
- Install the crankcase pressure sensor by using the following components:
Note: Refer to the engine's Specifications manual for the appropriate torque value for each sensor.
- Install a 195-2431 Knock Sensor Group between every two cylinders. Tighten each detonation sensor to the appropriate torque.
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| Illustration 27 | g01056942 |
Right side view | |
Install the Brackets for the Fuel Manifold
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| Illustration 28 | g01050751 |
Right side view (1) 0S-1594 Bolts (2) 9L-9132 Washers (3) 213-6288 Brackets (4) 214-9421 Brackets | |
Install brackets (3 and 4) for the fuel manifold.
Modify the Solenoids for the Prelube and the Air Start
Note: If there is enough room, you may perform this procedure while the solenoids are installed on the engine. Otherwise, remove the solenoids from the engine.
- Cut the ends off the solenoid's wires.
- Prepare the ends of each wire for soldering.
- Slide gasket (1) onto both of the wires.
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| Illustration 29 | g01050783 |
Valve (1) 4P-9477 Gasket (2) 9Y-6993 Adapter (3) 033-4926 Screws | |
- Slide a piece of heat shrink tube onto each wire.
- Solder the wires onto the terminals of adapter (2). The polarity of the wires is not important.
- Secure each connection with the heat shrink tube.
- Slide the wires into the body of the valve.
- Attach the adapter to the body with four screws (3) .
- Reinstall the solenoids if the solenoids were removed from the engine.
Install the Wiring Harness to the Right Side of the Engine
- For a 6 cylinder engine, connect the 70-pin connector for the 213-6304 Harness to the J5 connector on the bottom of the terminal box. For a 8 cylinder engine, connect the 70-pin connector for the 219-9941 Harness to the J5 connector on the bottom of the terminal box.
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| Illustration 30 | g01051298 |
J5 connector on the bottom of the terminal box | |
- Slide the boot onto the 70-pin connector. Secure the top of the boot to the connector by using cable strap (6). Secure the bottom of the boot to the trunk of the harness by using cable strap (7) .
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| Illustration 31 | g01050912 |
Right side view (1) 5P-5006 Flared Reducer (2) 2M-9780 O-Ring Seal (3) 030-7949 Flared Elbow (4) 9X-3495 Clip (5) 5L-3233 Fitting (6) 4P-8134 Clip (7) 9X-6772 Cable Strap (8) 148-0170 Hose As (9) 4P-7581 Clip (10) 3S-2093 Cable Strap (11) 0S-0509 Bolt (12) 3V-3308 Hard Washer (13) 4P-7428 Clip (14) 5D-9231 Connector (15) 211-3504 Pressure Switch (16) 116-0118 Clip (17) 6K-0806 Cable Strap | |
- For six cylinder engines, loosely position the harness across the right side of the engine. Attach the harness according to Illustration 31.
- For eight cylinder engines, loosely position the harness across the right side of the engine. Attach the harness according to Illustration 31. There are nine locations for attaching the harness across the side of the engine. Refer to Illustration 32.
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| Illustration 32 | g01051997 |
Right side view of an eight cylinder engine | |
Install the Wiring Harness to the Front of the Engine
- Install plug (1) and O-Ring Seal (2) .
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| Illustration 33 | g01050934 |
Front view (1) 9S-4191 Plug (2) 6V-5049 O-Ring Seal (3) 3V-3308 Hard Washers (4) 5B-9603 Bolt (5) 9X-6772 Cable Straps (6) 4P-7429 Clip (7) 9X-3495 Clips (8) 0S-1594 Bolt (9) 9S-8752 Full Nut (10) 4N-5756 Bracket (11) 4P-8134 Clips (12) 4P-7428 Clips | |
- Install bolt (4) and washer (3) .
- Loosely position the harness across the front of the engine. Attach the harness according to Illustration 33.
Install the Wiring Harness to the Rear of the Engine
- For engines that are equipped with a TPS57 turbocharger, perform the following procedure:
- Connect the 70-pin connector for the 213-6305 Harness to the J6 connector on the bottom of the terminal box.
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Illustration 34 g01062996
J6 connector on the bottom of the terminal box
- Slide boot (4) onto the 70-pin connector. Secure the top of the boot to the connector by using cable strap (3). Secure the bottom of the boot to the trunk of the harness by using cable strap (2) .
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Illustration 35 g01063029
Rear view of an engine that is equipped with a TPS57 turbocharger
(1) 4P-8134 Clips
(2) 9X-6772 Cable Straps
(3) 6K-0806 Cable Strap
(4) Boot
(5) 9S-8752 Full Nut
(6) 3V-3308 Hard Washers
(7) 0S-1594 Bolt
(8) 213-6305 Engine Harness As
- Loosely position the harness across the rear of the engine. Attach the harness according to Illustration 35.
- For engines that are equipped with a VTC254 turbocharger, perform the following procedure:
- Connect the 70-pin connector for the 219-9942 Harness to the J6 connector on the bottom of the terminal box.
Show/hide table Illustration 36 g01062996
J6 connector on the bottom of the terminal box
- Slide boot (4) onto the 70-pin connector. Secure the top of the boot to the connector by using cable strap (3). Secure the bottom of the boot to the trunk of the harness by using cable strap (2) .
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Illustration 37 g01063037
Rear view of an engine that is equipped with a VTC254 turbocharger
(1) 4P-8134 Clips
(2) 9X-6772 Cable Straps
(3) 6K-0806 Cable Strap
(4) Boot
(5) 9S-8752 Full Nut
(6) 3V-3308 Hard Washers
(7) 0S-1594 Bolt
(8) 219-9942 Engine Harness As
- Loosely position the harness across the rear of the engine. Attach the harness according to Illustration 37.
Install the Wiring Harness to the Left Side of the Engine
- For engines that are equipped with a TPS57 turbocharger, loosely position the harnesses across the left side of the engine. Attach the harnesses according to Illustration 38.
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| Illustration 38 | g01051229 |
Left side view of an engine that is equipped with a TPS57 turbocharger (1) 9X-3495 Clips (2) 5N-2840 Clip (3) 9X-6772 Cable Straps (4) 4P-7581 Clip (5) 0S-1594 Bolt (6) 3V-3308 Hard Washers (7) 9S-8752 Full Nut (8) 8T-1887 Clip (9) 8T-1888 Clip (10) 5P-9299 Clip (11) 4P-8134 Clips (12) 4P-7582 Clip | |
- For engines that are equipped with a VTC254 turbocharger, loosely position the harnesses across the left side of the engine. Attach the harnesses according to Illustration 39.
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| Illustration 39 | g01057039 |
Left side view of an engine that is equipped with a VTC254 turbocharger (1) 9X-3495 Clips (2) 5N-2840 Clip (3) 9X-6772 Cable Straps (4) 4P-7581 Clip (5) 0S-1594 Bolt (6) 3V-3308 Hard Washers (7) 9S-8752 Full Nut (8) 8T-1887 Clip (9) 8T-1888 Clip (10) 5P-9299 Clip (11) 4P-8134 Clips (12) 4P-7582 Clip | |
Install the Ignition Harness
- Connect the 207-4556 Conduit to the end of the rail.
Note: Handle the rail carefully. Otherwise, the rail may be damaged.
- Install a 127-0594 Wire between the rail and the engine block. Use a 0S-0509 Bolt in order to secure the ground wire to the block.
- Connect the end of the conduit to the hole on the bottom of the terminal box.
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| Illustration 40 | g01063039 |
Hole for the conduit on the bottom of the terminal box | |
- Insert each terminal into the appropriate hole in the P2 connector. Pull on each wire in order to verify that the terminal is fully inserted into the connector.
Note: You do not need to disconnect the P2 connector in order to install the terminals.
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| Illustration 41 | g01051860 |
Harness side of the P2 connector | |
Note: The appropriate location for each terminal is identified on the end of each wire.
Install the Components for the Fuel
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| Illustration 42 | g01051341 |
Right side view (1) 8L-2779 O-Ring Seal (2) 8C-6868 Connector (3) 6J-2244 O-Ring Seal (4) 0S-1588 Bolt (5) 3V-3308 Hard Washer (6) 122-2083 Orifice (7) 210-5639 Tube As (8) 5P-8211 O-Ring Seal (9) 210-5638 Tube As (10) 124-9633 Clip (11) 6V-5049 O-Ring Seal (12) 6V-8636 Connector (13) 6V-8002 O-Ring Seal (14) 210-5637 Tube As (15) 9S-8752 Full Nut (16) 8M-7145 Washer (17) 0S-1591 Bolt (18) 6V-5039 Clip (19) 6V-5040 Clip (20) 9S-4191 Plug (21) 0S-1590 Bolt (22) 9D-6196 Clip (23) 9D-6197 Clip | |
Install the components for the fuel according to Illustration 42.
Install the Fuel Temperature Sensor
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| Illustration 43 | g01051402 |
Right side view (1) 130-8299 Temperature Sensor Gp (2) 8L-2786 O-Ring Seal | |
Install O-Ring Seal (2) and fuel temperature sensor (1). Tighten the sensor to the value in the engine's Specifications manual.
Install the MIDS and the Interconnect Harness (If Applicable)
Install the MIDS at the appropriate location. Refer to Special Instruction, REHS1336 for information on installation of the panel.
Connect the Customer's Wiring to the MIDS
Connect the customer's wiring to the MIDS. Refer to Special Instruction, REHS1336 for information on the connections for the customer.
Flash the Modules
- Verify that all of the engine's electrical connectors are connected. Verify that all of the harnesses are securely attached to the engine.
- Apply electrical power to the engine.
- Flash the following modules, if necessary:
- ECM
- ICSM
- MIDS
- ECM
Note: For procedures on flashing the modules, refer to Troubleshooting, RENR5910.
Prepare the Engine for Initial Start-Up
- Check for diagnostic codes. Correct any codes before you continue.
- Check the level of the coolant according to the engine's Operation and Maintenance Manual. Fill the system with coolant, as needed. Check for any coolant leaks and correct any coolant leaks.
- Remove the crankshaft timing pin. Return the pin to the storage location.
- Restore the fuel supply to the engine.
Initial Start-Up of the Engine
Perform the Initial start-up procedure according to Special Instruction, REHS1336.