- Engine:
- G3612 (S/N: 1YG1-UP)
- G3616 (S/N: 4CG1-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 G3612 and G3616 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 parameters. Cat ET provides real-time monitoring of the engine during operation and comprehensive display of diagnostics.
Machine Information and 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 MIDS 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 components meet the certification for CSA. If your engine requires certification for CSA, 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 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 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 submit the three items that are listed above. The prompt submission 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, REHS0385, "Installation of the Hydraulic Actuator System (Hydrax)"
CIS
Disassembly and Assembly, SENR5535
Schematic, SENR5082, "G3612 and G3616 Engine Electrical System"
Systems Operation/Testing and Adjusting, RENR2255
Troubleshooting, SENR6510
ADEM 3
Disassembly and Assembly, SENR5535
Operation and Maintenance Manual, SEBU7563
Schematic, RENR5911, "G3612 Electrical System"
Schematic, RENR5912, "G3616 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, SENR5528, "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, SEBU6496, "Cooling System Coolant - Change".
Remove the Existing Components and Systems
Remove the ESS Panel
- At the ESS panel, identify each connection from the customer wiring. Label each connection.
- Disconnect the wiring from the ESS panel and remove the panel.
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 cable (1) that runs between the transformer and the combustion buffer.
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| Illustration 2 | g01066614 |
Left side view (1) Cable (2) Connector for the detonation sensor (3) Harness (4) Tie strap (5) Tie strap (6) Harness (7) Junction box (8) Clips | |
- Disconnect the remaining connectors at each combustion buffer.
- Cut all of the tie straps (4) between the combustion buffers and the junction box for the combustion buffers and detonation sensors.
- Remove harnesses (3) that run between each combustion buffer and the junction box for the combustion buffer and detonation sensors.
- Disconnect connectors (2) at each detonation sensor.
- Cut all of the tie straps (5) between the detonation sensors and the junction box for the combustion buffers and detonation sensors.
- Remove harnesses (6) that run between the detonation sensors and the junction box for the combustion buffers and detonation sensors.
- Remove clips (8) that were used to secure the harness for the combustion buffers to the brackets.
- Remove junction box (7) 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 wiring harnesses (1) for the hydrax actuators and the position sensors.
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| Illustration 3 | g01066655 |
(1) Harnesses (2) Clip (3) Junction box (4) Harness | |
- Remove clips (2) that were used to support the wiring harnesses.
- Remove the wiring harness (4) that runs between the junction box for the hydrax driver modules and the engine junction box.
- Remove junction box (3) for the hydrax driver modules.
- Remove the bracket that attached the junction box to the engine.
- Remove each position sensor (1) and mounting hardware (2). Be sure to remove the coupling (3) from each shaft (4) .
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| Illustration 4 | g01066666 |
Typical position sensor and mounting hardware (1) Position sensor (2) Mounting hardware (3) Coupling (4) Shaft | |
Remove the Components for the Magneto or the CIS
If the engine is equipped with a magneto, perform the following procedure:
- Disconnect connector (6) and harness (4) from magneto (5) .
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| Illustration 5 | g01066731 |
Left side of the rear of the engine (1) Ground strap (2) Interface box (3) Connector for the interface harness (4) Harness (5) Magneto (6) Connector for the ignition harness | |
- Disconnect interface harness (3) from interface box (2) .
- Remove ground strap (1), interface box (2), and harness (4) as a unit.
- Remove three bolts (8) and three washers (9) in order to remove magneto (5) from the flywheel housing. Do not remove the magneto drive coupling (7). Keep bolts (8) and washers (9) for later use.
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| Illustration 6 | g01066777 |
Left side view of the magneto (5) Magneto (7) Drive coupling (8) Bolt (9) Washer | |
- Install gasket (10) and plate (11) 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 7 | g01066792 |
Left side of the rear of the engine (10) 147-6549 Gasket (11) 147-6548 Plate | |
If the engine is equipped with CIS, perform the following procedure:
- Remove harnesses (12), (13), and (14) from the engine.
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| Illustration 8 | g01066842 |
Rear view (12) Harness (13) Harness (14) Harness | |
- Disconnect connector (17) .
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| Illustration 9 | g01066851 |
Rear view (15) Plate (16) Programming control (17) Connector (18) Ground strap | |
- Remove ground strap (18), programming control (16), and plate (15) .
Remove the Ignition Wiring and the Detonation Sensors
- Remove all of the ignition wiring (1) and all of the mounting brackets (2) from the engine.
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| Illustration 10 | g01066892 |
Right side view (1) Ignition wiring (2) Mounting brackets | |
- Remove all of the detonation sensors from the engine.
Remove the Switches for the Inlet Air Restriction
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| Illustration 11 | g01066961 |
Rear view (1) Air hose (2) Switches for the inlet air restriction | |
Remove the switches for the inlet air restriction (2) and the associated hardware. Do not disconnect hoses (1) that are connected to the turbochargers. The hoses will be connected to the new switches.
Remove Some of the Engine 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 12 | g01066971 |
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 13 | g01066980 |
Front view (4) Unfiltered oil pressure sensor | |
- Remove tubing (4) and prelube pressure switch (5) .
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| Illustration 14 | g01066992 |
Prelube pressure switch (4) Tubing (5) Prelube pressure switch | |
Remove the Engine Mounted Junction Box
Disconnect the connectors from the following components:
- All of the engine 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 junction box. Remove the engine mounted junction 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 15 | g01067017 |
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 16 | g01048238 |
Section view of the end of the camshaft (2) Magnet (3) Plate (4) Bolt (5) Washer | |
- Install gasket (6) and cover (7) by using eight washers (8) and eight bolts (9) .
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| Illustration 17 | g01067023 |
Front view (6) 1W-2334 Gasket (7) 206-6583 Cover (8) 3V-3308 Hard Washers (9) 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 (1) .
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| Illustration 18 | g01067049 |
Removal of the accumulator (1) Tee (2) Line (3) Accumulator | |
| 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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. |
- Remove accumulator (3) and mounting hardware.
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 19 | g01062888 |
Right side view The 12 cylinder engine is shown. The 16 cylinder engine is similar. (1) 116-0118 Clip (2) 3V-3308 Hard Washer (3) 4F-4879 Bolt (4) 128-8831 Bracket (5) 9X-3495 Clip Assembly (6) 0S-1590 Bolt (7) 0S-1571 Bolt (8) 4P-7581 Clip (9) 3V-3308 Hard Washer | |
- For 12 cylinder engines, perform the following procedure:
- For cylinder 11, install bracket (4) and clip (5) to the upper left corner of the cover plate.
- For cylinder 11, install clip (1) to bracket (4) by using washer (2) and bolt (3) .
- For the remaining cylinders, install clip (5), washer (2), and bolt (7) to the upper left corner of each cover plate.
- For 16 cylinder engines, perform the following procedure:
- For cylinder 15, install bracket (4) and clip (5) to the upper left corner of the cover plate.
- For cylinder 15, install clip (1) to bracket (4) by using washer (2) and bolt (3) .
- For the remaining cylinders, install clip (5), washer (2), and bolt (7) in cylinders 1 through 7. Install the parts to the upper left corner of each cover plate.
- 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 New Orifice Plates
- Remove the 18 mm orifice plates. Discard the plates.
- Install a 122-2083 Orifice into the fuel line for each cylinder.
Install the Speed/Timing Sensor and the Speed-Timing Wheel
- Remove the rear cam cover.
- Lubricate the speed/timing sensor 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 20 | g01067159 |
Rear view and section view (1) 154-8716 Spacer (2) 154-2709 Wheel (3) 5P-8245 Hard Washer (4) 1D-4569 Bolt (5) Direction of the camshaft 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 washers (3) and four bolts (4) in order to enable the speed-timing wheel to be moved.
- Rotate the speed-timing wheel in the direction of the camshaft rotation (5). Rotate the wheel 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 head and the extra tooth. The distance must be between 0.6 mm (0.024 inch) and 1.6 mm (0.063 inch). 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 two washers (2) and two bolts (3) .
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| Illustration 21 | g01067184 |
Right side of the rear housing (1) 196-9484 Bracket As (2) 5P-8245 Hard Washers (3) 0S-1595 Bolts | |
- Attach two shock mounts (15) to box (8). Use one bolt (12), one washer (4), two washers (13) and one nut (16) for each mount.
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| Illustration 22 | g01067285 |
Installation of the terminal box (4) 3V-3308 Hard Washer (5) 4D-1326 Lockwasher (6) 127-0594 Wire (7) 0S-0509 Bolt (8) 195-6244 Control Panel Box Gp (9) 5P-0537 Hard Washer (10) 9S-8750 Nut (11) 167-9430 Isolator (12) 0L-2070 Bolt (13) 9Y-9481 Washer (14) 0S-1615 Bolt (15) 9Y-9480 Shock Mount (16) 9S-8752 Full Nut | |
- 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 (9), and four nuts (10) for each shock mount.
- Remove the paint near the mounting locations for ground wire (6). Install the ground wire by using two lockwashers (5), two washers (4) and two bolts (7) .
- Place two isolators (11) into position. Attach each isolator with one washer (9) and one nut (10). Torque each nut to 6 N·m (53 lb in).
- Open the box door and install one washer (9) and one nut (10) onto each shock mount. Torque each nut to 6 N·m (53 lb in).
Install the Hardware for the Combustion Sensing System
- Install the top of bracket (3) to the side of the engine by using two bolts (1), two spacers (6), and two washers (2). Install lockwasher (5) and ground wire (4) in the upper right-hand location.
Note: On 12 cylinder engines, the brackets are mounted at cylinders 6 and 7. On 16 cylinder engines, the brackets are mounted at cylinders 8 and 9.
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| Illustration 23 | g01067421 |
Bracket (1) 0L-2070 Bolt (2) 3V-3308 Hard Washer (3) 198-0112 Bracket As (4) 127-0594 Wire (5) 7H-3937 Lockwasher (6) 4S-5719 Spacer (7) 0S-1571 Bolt | |
- Install the bottom of bracket (3) to the side of the engine by using two bolts (7) and two washers (2) .
- Install bracket (8) by using two bolts (8) and two washers (9) .
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| Illustration 24 | g01067425 |
Bracket (8) 0S-1617 Bolt (9) 9M-1974 Hard Washer | |
- Install module (10) by using four mounts (13), eight washers (9), and eight nuts (12). Be sure to attach the ground wire to the module by using lockwasher (11) .
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| Illustration 25 | g01067443 |
Installation of the ICSM (10) 176-1287 Electronic Control Module (11) 7H-3937 Lockwasher (12) 5S-0003 Nut (13) 141-6380 Flexible Mount | |
- For 12 cylinder engines, install the wiring harnesses and the thermocouple for the turbocharger inlet according to the following procedure:
- Install clips (4) and harnesses (5-10) for each combustion sensor.
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Illustration 26 g01069541
Left side view and right side view of a 12 cylinder engine
The arrows indicate the locations for the 9X-6772 Cable Straps .
(1) 6B-5072 Terminal Bushing
(2) 116-2649 Temperature Sensor Gp
(3) 6K-8179 Clip
(4) 5P-9297 Clip
(5) 194-6864 Sensor Harness As
(6) 194-6863 Sensor Harness As
(7) 194-6862 Sensor Harness As
(8) 194-6866 Sensor Harness As
(9) 194-6867 Sensor Harness As
(10) 194-6868 Sensor Harness As
(11) 195-6055 Sensor Harness As
(12) 116-0118 Clip
(13) 3V-3308 Hard Washer
(14) 0S-1594 Bolt
(15) 4P-7581 Clip
(16) 0S-1571 Bolt
(17) 9X-6772 Cable Strap
(18) 192-4329 Bracket
(19) 9L-9132 Washer
(20) 195-6055 Sensor Harness As
(21) 0S-1620 Bolt
(22) 5P-8245 Hard Washer
(23) 4P-7428 Clip
- Install harnesses (11) and (20) for the thermocouples.
- Use 9X-6772 Cable Straps in order to secure the harnesses to the clips and to the side cover for each cylinder.
- Install ten brackets (18) at the appropriate locations.
- Thread caps (24) onto the L4 and R4 terminals on each ICSM.
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Illustration 27 g01068325
Caps and plate for the ICSM
(24) 234-5895 Cap
(25) 198-0114 Plate
(26) 0S-1614 Bolt
(27) 5P-0537 Hard Washer
- Install two plates (25) by using four bolts (26) and four washers (27) for each plate.
- For 16 cylinder engines, install the wiring harnesses and the thermocouple for the turbocharger inlet according to the following procedure:
- Install clips (4) and harnesses (5-12) for each combustion sensor.
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Illustration 28 g01069599
Left side view and right side view of a 12 cylinder engine
The arrows indicate the locations for the 9X-6772 Cable Straps .
(1) 6B-5072 Terminal Bushing
(2) 116-2649 Temperature Sensor Gp
(3) 6K-8179 Clip
(4) 5P-9297 Clip
(5) 194-6865 Sensor Harness As
(6) 194-6864 Sensor Harness As
(7) 194-6863 Sensor Harness As
(8) 194-6862 Sensor Harness As
(9) 194-6866 Sensor Harness As
(10) 194-6867 Sensor Harness As
(11) 194-6868 Sensor Harness As
(12) 194-6869 Sensor Harness As
(13) 195-6060 Sensor Harness As
(14) 116-0118 Clip
(15) 3V-3308 Hard Washer
(16) 0S-1594 Bolt
(17) 4P-7581 Clip
(18) 9X-6772 Cable Strap
(19) 192-4329 Bracket
(20) 9L-9132 Washer
(21) 195-6059 Sensor Harness As
(22) 0S-1620 Bolt
(23) 5P-8245 Hard Washer
(24) 4P-7428 Clip
- Install harnesses (13) and (21) for the thermocouples.
- Use 9X-6772 Cable Straps in order to secure the harnesses to the clips and to the side cover for each cylinder.
- Install 14 brackets (19) at the appropriate locations.
Replace the Engine 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:
- On an engine that is equipped with a TPS57 turbocharger, install the air inlet restriction switches (1) according to Illustration 30.
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Illustration 30 g01068385
Air inlet restriction switch on an engine that is equipped with a TPS57 turbocharger
The right side is shown. The left side is similar.
(1) 211-3504 Pressure Switch
(2) 5D-9231 Connector
(3) 5L-3233 Fitting
(4) 4P-7581 Clip
(5) 3S-2093 Cable Strap
(6) 9X-3495 Clip As
- On an engine that is equipped with a VTC254 turbocharger, install the air inlet restriction switches (1) according to Illustration 31.
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Illustration 31 g01068393
Air inlet restriction switch on an engine that is equipped with a VTC254 turbocharger
The right side is shown. The left side is similar.
(1) 9X-6772 Cable Strap
(2) 4P-7581 Clip
(3) 211-3504 Pressure Switch
(4) 5D-9231 Connector
(5) 5L-3233 Fitting
(6) 4P-7581 Clip
(7) 3S-2093 Cable Strap
(8) 9X-3495 Clip As
- 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:
- Install the switch for the inlet pressure of the jacket water by using the following components:
Tighten the switch to the appropriate torque.
Note: Refer to the engine 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 33 | g01056942 |
Right side view | |
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 wires.
- Prepare the ends of each wire for soldering.
- Slide gasket (1) onto both of the wires.
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| Illustration 34 | 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, if necessary.
Install the Wiring Harness to the Right Side of the Engine
- For a 12 cylinder engine, connect the 70-pin connector for the 195-6051 Harness to the J5 connector on the bottom of the terminal box. For a 16 cylinder engine, connect the 70-pin connector for the 195-6056 Harness to the J5 connector on the bottom of the terminal box.
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| Illustration 35 | g01051298 |
J5 connector on the bottom of the terminal box | |
- For a 12 cylinder engine, loosely position the harness across the right side of the engine. Attach the harness according to Illustration 36.
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| Illustration 36 | g01068744 |
Right side view of a 12 cylinder engine (1) 116-0118 Clip (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 (17) 6K-0806 Cable Strap (18) 213-6304 Harness or 219-9941 Harness (1) 5P-5006 Flared Reducer | |
- For a 16 cylinder engine, loosely position the harness across the right side of the engine. Attach the harness according to Illustration 36. There are nine locations for attaching the harness across the side of the engine. Refer to Illustration 37.
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| Illustration 37 | g01069061 |
Right side view of a 16 cylinder engine | |
Install the Wiring Harness to the Front of the Engine
- Install plug (3) and O-Ring Seal (4) .
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| Illustration 38 | g01069124 |
Front view (1) 3V-3308 Hard Washer (2) 5B-9603 Bolt (3) 9S-4191 Plug (4) 6V-5049 O-Ring Seal (5) 4N-5756 Bracket (6) 9X-3495 Clip (7) 9S-8752 Full Nut (8) 0S-1594 Bolt (9) 0S-1588 Bolt (10) 9X-6772 Cable Strap (11) 4P-8134 Clip (12) 5P-8245 Hard Washer (13) 4P-7428 Clip | |
- Install bolt (2) and washer (1) .
- Loosely position the harness across the front of the engine. Attach the harness according to Illustration 38.
Install the Wiring Harness to the Rear of the Engine
- For a 12 cylinder engine, connect the 70-pin connector for the 195-6053 Harness to the J5 connector on the bottom of the terminal box. For a 16 cylinder engine, connect the 70-pin connector for the 195-6058 Harness to the J5 connector on the bottom of the terminal box.
 | |
| Illustration 39 | g01062996 |
J6 connector on the bottom of the terminal box | |
- Loosely position the harness across the rear of the engine. Attach the harness according to Illustration 40.
 | |
| Illustration 40 | g01069301 |
Rear view (1) 9X-6772 Cable Straps (2) 3V-3308 Hard Washers (3) 0S-1594 Bolt (4) 4P-7581 Clip (5) 9X-3495 Clip As (6) 0S-1591 Bolt (7) 4P-8134 Clips | |
Install the Wiring Harness to the Left Side of the Engine
- For a 12 cylinder engine, loosely position the harness across the right side of the engine. Attach the harness according to Illustration 41.
 | |
| Illustration 41 | g01069332 |
Left side view (1) 4P-7428 Clip (2) 5P-8245 Hard Washer (3) 0S-1620 Bolt (4) 9X-6772 Cable Strap (5) 4P-7581 Clip (6) 4P-8134 Clip | |
- For a 16 cylinder engine, loosely position the harness across the right side of the engine. Attach the harness according to Illustration 41. There are five locations for attaching the harness across the side of the engine. Refer to Illustration 42.
 | |
| Illustration 42 | g01069605 |
Left side view of a 16 cylinder engine | |
Install the Ignition Harnesses
- For a 12 cylinder engine, perform the following procedure:
- Connect conduit (2) to the end of harness (1). Connect conduit (9) to the end of harness (8) .
Show/hide table
Illustration 43 g01069408
Rear view
(1) 191-5008 Harness
(2) 207-4555 Conduit
(3) 1B-4971 Spacer
(4) 8T-7529 Clip
(5) 3v-3308 Hard Washer
(6) 0L-2070 Bolt
(7) 9X-6772 Cable Strap
(8) 191-5007 Harness
(9) 207-4556 Conduit
- Secure each harness to the brackets by using the 3V-3308 Hard Washers and 0S-1594 Bolts that are provided with each rail.
- Install a 127-0594 Wire between each rail and the engine block. Use a 0S-0509 Bolt in order to secure each ground wire to the block.
- Attach conduit (2) to the engine.
- Connect each ignition transformer to the ignition harness.
- Connect each detonation sensor to the ignition harness.
- Connect the engine harness to the ignition harness.
Note: Handle the rails carefully. Otherwise, the rails may be damaged.
- For a 16 cylinder engine, perform the following procedure:
- Connect conduit (2) to the end of harness (1). Connect conduit (9) to the end of harness (8) .
Show/hide table Illustration 44 g01069408
Rear view
(1) 198-2941 Harness
(2) 207-4555 Conduit
(3) 1B-4971 Spacer
(4) 8T-7529 Clip
(5) 3v-3308 Hard Washer
(6) 0L-2070 Bolt
(7) 9X-6772 Cable Strap
(8) 198-2938 Harness
(9) 207-4556 Conduit
- Secure each harness to the brackets by using 3V-3308 Hard Washers and 0S-1594 Bolts that are provided with each rail.
- Install a 127-0594 Wire between each rail and the engine block. Use a 0S-0509 Bolt in order to secure each ground wire to the block.
- Connect each ignition transformer to the ignition harness.
- Connect each detonation sensor to the ignition harness.
- Connect the engine harness to the ignition harness.
- Connect the end of each conduit to the hole on the bottom of the terminal box.
 | |
| Illustration 45 | g01069438 |
Holes for the conduits 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.
 | |
| Illustration 46 | g01051860 |
Harness side of the P2 connector | |
Note: The appropriate location for each terminal is identified on the end of each wire.
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 Wiring to the MIDS
Connect the customer 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 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 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.