Installation Procedure For The New Throttle Body Cooling Lines On Certain G3500 Engines{1380} Caterpillar


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Installation Procedure For The New Throttle Body Cooling Lines On Certain G3500 Engines{1380} [REHS9203]
COOLING SYSTEM
LINES GP-WATER
Installation Procedure For The New Throttle Body Cooling Lines On Certain G3500 Engines{1380}
1.1. Introduction
2.1. Safety Section
3.1. Required Parts
4.1. Group 1 Removal Procedures
5.1. Group 1 Installation Procedure
6.1. Group 2 Removal Procedure
7.1. Group 2 Installation Procedure
8.1. Group 3 Removal Procedure
9.1. Group 3 Installation Procedure
10.1. Group 4 Removal Procedure
11.1. Group 4 Installation Procedure
12.1. Group 5 Removal Procedure
13.1. Group 5 Installation Procedure
14.1. Group 6 Removal Procedure
15.1. Group 6 Installation Procedure
16.1. Group 7 Remove
17.1. Group 7 Installation Procedure
18.1. Group 8 Remove
19.1. Group 8 Installation Procedure
20.1. Group 9 Remove
21.1. Group 9 Installation Procedure
22.1. Group 10 Removal Procedure
23.1. Group 10 Installation Procedure
24.1. Group 11 Removal Procedure
25.1. Group 11 Installation Procedure
26.1. Group 12 Removal Procedure
27.1. Group 12 Installation Procedure
28.1. Group 13 Removal Procedure
29.1. Group 13 Installation Procedure
30.1. Group 14 Removal Procedure
31.1. Group 14 Installation Procedure
32.1. Group 15 Removal Procedure
33.1. Group 15 Installation Procedure
34.1. Group 16 Removal Procedure
35.1. Group 16 Installation Procedure
36.1. Group 17 Removal Procedure
37.1. Group 17 Installation Procedure
38.1. Group 18 Removal Procedure
39.1. Group 18 Installation Procedure
40.1. Group 19 Removal Procedure
41.1. Group 19 Installation Procedure
42.1. Group 20 Removal Procedure
43.1. Group 20 Installation Procedure
44.1. Group 21 Removal Procedure
45.1. Group 21 Installation Procedure
46.1. Group 22 Removal Procedure
47.1. Group 22 Installation Procedure
Engine:
G3512E (S/N: SSR1-UP; NGS1-UP)
G3516C (S/N: GSB1-UP; TJB1-UP; GZC1-UP; TJC1-UP; F6E1-UP; F6F1-UP; GZZ1-UP)
G3516E (S/N: F6G1-UP; GAS1-UP; SLY1-UP)
G3520C (S/N: GZA1-UP; GZB1-UP; MAD1-UP; GZJ1-UP; GZK1-UP; GZL1-UP; GZM1-UP; GZN1-UP; RLP1-UP; LGS1-UP; HAT1-UP; CWW1-UP; CWY1-UP)
G3520E (S/N: GZE1-UP; GZH1-UP)
Power Module:
PMG3516 (S/N: JKK1-UP)

Introduction

Table 1
Group     Serial Number Range    
1     (S/N: GZJ198,205-209,216,222-225,228,230,233,243,278-281,292-293,308,317-325,328,331-332,334,339,342,345,349,351-354,356-357,359,364,369-374,376-380,383,385,387,389,392,397-402,405,407-413,420-421,424-425,434-444,449,452-454,458-462,472-474,477-553,600-645)    
(S/N: GZK165,167,171-172,176)
(S/N: HAT204)
(S/N: LGS151-153,156-157,163-176)
2     (S/N: GSB115-116,124)    
(S/N: TJC817)
3     (S/N: F6E101)    
(S/N: GSB125-127)
4     (S/N: GZN216,218-220,226,228,243,282,293,304,307,310,312,315,317,320,324,326-328,335,342,350-351,354,360,362,372,374-377,381,388,390,392-393,412,414,417,426,429,431,435,440,443,446,458-459,461-462,469,471,474,476-478,481-482,493,495,508,511,514,521,527-535,541,548,551-552,557,566,568-569,580-582,588,591,597,601-602,605-606,610-611,637,639,641,648,674,677,682,685,692,702,704,708-709,715,717,732,737,742,744-745,748,753,767-768,775,781-782,790,798,815-816,820-821,828,830-831,849-853,858-860,867,870-872)    
5     (S/N: GZN873-874)    
6     (S/N: GZA193,217-249)    
(S/N: GZB201-202,206,209-210,222,230-231,235-249)
(S/N: GZM162,166,170,182-183,194-195,205-207,209-213)
(S/N: GZN806-814,817,825-827,829,835-848,861-866,868-869)
(S/N: RLP211-212,215-223,225,236)
7     (S/N: GZA250-260)    
(S/N: GZM214-217)
(S/N: GZN875-882)
8     (S/N: CWW102,235)    
(S/N: CWY200,207,211)
(S/N: MAD201)
(S/N: RLP150,153-155,162,165,168-169,172-174,185,189,191-192,195,197,201,204-205,207)
9     (S/N: GZL146)    
10     (S/N: SSR156)    
(S/N: GZC253,257)
(S/N: GZZ182,194,223,227,232,240-241,254-256,259,282,284,289-290,293,320,341-354,357-358,362)
(S/N: TJB106)
(S/N: F6G101)
(S/N: GAS136,139,141-146,148-149,151-157,159-167,173-178,181-182,184-187,189-193,196-198,200,202-208,210-211,214-217,220-223,225-226,228,231,234-237,239-242,247-253,255-260,262-268,270-280)
11     (S/N: GZZ118,142,146-147,149)    
(S/N: TJB103-104)
(S/N: GAS111-115,117,119-120,123-126,128-130,132-134)
(S/N: SLY108-109)
12     (S/N: GZC218,236-244,248-249)    
(S/N: GZZ217)
13     (S/N: F6F103-106)    
(S/N: GZC251-252,254-256)
(S/N: GZZ355-356,359-361)
(S/N: JKK100-126,128-129,131,133,135,138-139,145-147,149-161,163-166,168-171,173-175,177,179,181-183,194,197,202-205,208-211,213-214,216-218,220,222,224,226,228,231,234-235)
14     (S/N: CWW206-207,213,215-216,221,228-229,231,233,241,244,283,287-290,292-295)    
(S/N: RLP237-239)
(S/N: GZH111,114-115,117-126,128,130-132,134-139,141-143,146-149,151-155)
15     (S/N: GZN818-819,822-824,833-834,854-855,857)    
(S/N: GZE115,118,123-187,193,195-204,206-212,214-217,219-225)
(S/N: GZH156-157,163-167)
16     (S/N: RLP240-261)    
17     (S/N: NGS145-146)    
(S/N: SSR172,209,212-213,215)
18     (S/N: NGS135-144,147-157)    
(S/N: SSR162-171,173-208,210-211,214,216-217)
19     (S/N: GZE116-117,119-122,188-192,194,218)    
20     (S/N: GZE229-230,233-235,244,248,256)    
21     (S/N: GZE205,213)    
22     (S/N: SSR218-231)    

Safety Section


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.

Dispose of all fluids according to Local regulations and mandates.


Required Parts

Table 2
Group 1 Required Parts    
Qty     Part Number    
1     0L-2070 Bolt    
1     0S-1590 Bolt    
2     2A-2677 Spacers    
4     3H-8683 Clips    
3     5M-2894 Hard Washers    
6     6V-9746 O-ring Seals    
1     8M-9124 Washer    
1     9S-8752 Full Nut    
1     236-5182 Tube As  (1)    
1     265-5221 Tube As  (1)    
4     353-7953 Grommets    
2     365-0682 Connectors    
1     437-7369 Hose As    
1     439-0805 Hose As    
( 1 ) The original can be reused. Repair and/or replace as necessary.

Table 3
Group 2 Required Parts    
Qty     Part Number    
2     0L-2070 Bolts    
2     2A-2677 Spacers    
4     3H-8683 Clips    
2     5M-2894 Hard Washers    
4     6V-9746 O-ring Seals    
2     8M-9124 Washer    
2     8T-1919 O-ring Seals    
3     8T-6766 Pipe Plugs    
1     210-6274 Tube As  (1)    
1     215-4796 Tube As  (1)    
4     353-7953 Grommets    
2     365-0682 Connectors    
1     418-6827 Hose As    
1     418-6828 Hose As    
( 1 ) The original can be reused. Repair and/or replace as necessary.

Table 4
Group 3 Required Parts    
Qty     Part Number    
2     0L-2070 Bolts    
2     2A-2677 Spacers    
4     3H-8683 Clips    
2     5M-2894 Hard Washers    
4     6V-9746 O-ring Seals    
2     8M-9124 Washer    
1     210-6274 Tube As  (1)    
1     215-4796 Tube As  (1)    
4     353-7953 Grommets    
1     418-6827 Hose As    
1     418-6828 Hose As    
( 1 ) The original can be reused. Repair and/or replace as necessary.

Table 5
Group 4 Required Parts    
Qty     Part Number    
2     0L-2070 Bolts    
2     2A-2677 Spacers    
4     3H-8683 Clips    
2     5M-2894 Hard Washers    
7     6V-9746 O-ring Seals    
2     8M-9124 Washers    
1     200-6441 Tube As  (1)    
1     200-6442 Tube As  (1)    
4     353-7953 Grommets    
2     365-0682 Connectors    
1     437-7371 Hose As    
1     439-4508 Hose As    
( 1 ) The original can be reused. Repair and/or replace as necessary.

Table 6
Group 5 Required Parts    
Qty     Part Number    
2     0L-2070 Bolts    
2     2A-2677 Spacers    
4     3H-8683 Clips    
2     5M-2894 Hard Washers    
7     6V-9746 O-ring Seals    
2     8M-9124 Washers    
1     200-6441 Tube As  (1)    
1     200-6442 Tube As  (1)    
4     353-7953 Grommets    
2     365-0682 Connectors    
1     437-7371 Hose As    
1     439-4508 Hose As    
( 1 ) The original can be reused. Repair and/or replace as necessary.

Table 7
Group 6 Required Parts    
Qty     Part Number    
2     0L-2070 Bolts    
2     2A-2677 Spacers    
4     3H-8683 Clips    
2     5M-2894 Hard Washers    
7     6V-9746 O-ring Seals    
2     8M-9124 Washers    
1     200-6441 Tube As  (1)    
1     200-6442 Tube As  (1)    
4     353-7953 Grommets    
2     365-0682 Connectors    
1     437-7371 Hose As    
1     439-4508 Hose As    
( 1 ) The original can be reused. Repair and/or replace as necessary.

Table 8
Group 7 Required Parts    
Qty     Part Number    
2     0L-2070 Bolts    
2     2A-2677 Spacers    
4     3H-8683 Clips    
2     5M-2894 Hard Washers    
7     6V-9746 O-ring Seals    
2     8M-9124 Washers    
1     200-6441 Tube As  (1)    
1     200-6442 Tube As  (1)    
4     353-7953 Grommets    
2     365-0682 Connectors    
1     437-7371 Hose As    
1     439-4508 Hose As    
( 1 ) The original can be reused. Repair and/or replace as necessary.

Table 9
Group 8 Required Parts    
Qty     Part Number    
2     0L-2070 Bolts    
2     2A-2677 Spacers    
4     3H-8683 Clips    
2     5M-2894 Hard Washers    
9     6V-9746 O-ring Seals    
1     7X-7902 Elbow    
1     200-6441 Tube As  (1)    
1     200-6442 Tube As  (1)    
4     353-7953 Grommets    
2     365-0682 Connectors    
1     437-7371 Hose As    
1     439-4508 Hose As    
( 1 ) The original can be reused. Repair and/or replace as necessary.

Table 10
Group 9 Required Parts    
Qty     Part Number    
2     0L-2070 Bolts    
2     2A-2677 Spacers    
4     3H-8683 Clips    
2     5M-2894 Hard Washers    
7     6V-9746 O-ring Seals    
2     8M-9124 Washers    
1     200-6441 Tube As  (1)    
1     200-6442 Tube As  (1)    
4     353-7953 Grommets    
2     365-0682 Connectors    
1     437-7371 Hose As    
1     439-4508 Hose As    
( 1 ) The original can be reused. Repair and/or replace as necessary.

Table 11
Group 10 Required Parts    
Qty     Part Number    
1     0L-2070 Bolt    
1     1F-7958 Full Nut    
1     2A-2677 Spacer    
2     3H-8683 Clips    
1     5M-2894 Hard Washer    
2     5P-8245 Hard Washers    
6     6V-9746 O-ring Seals    
2     7X-7902 Elbows    
1     8M-9124 Washer    
1     9S-1366 Bolt    
2     353-7953 Grommets    
1     363-8651 Bracket As    
1     418-1233 Hose As    
1     418-1234 Hose As    

Table 12
Group 11 Required Parts    
Qty     Part Number    
1     0S-1591 Bolt    
1     1F-7958 Full Nut    
2     1L-2731 Tube Clamps    
1     5M-2894 Hard Washer    
2     5P-8245 Hard Washers    
2     6V-8733 Unions    
4     6V-9746 O-ring Seals    
2     7X-7902 Elbows    
1     8M-9124 Washer    
1     9S-1366 Bolt    
1     363-8651 Bracket As    
1     418-1233 Hose As    
1     418-1234 Hose As    

Table 13
Group 12 Required Parts    
Qty     Part Number    
2     0L-2070 Bolts    
2     2A-2677 Spacers    
4     3H-8683 Clips    
2     5M-2894 Hard Washers    
4     6V-9746 O-ring Seals    
2     8M-9124 Washers    
2     8T-1919 O-ring Seals    
3     8T-6766 Pipe Plugs    
1     210-6274 Tube As  (1)    
1     215-4796 Tube As  (1)    
4     353-7953 Grommets    
2     365-0682 Connectors    
1     418-6827 Hose As    
1     418-6828 Hose As    
( 1 ) The original can be reused. Repair and/or replace as necessary.

Table 14
Group 13 Required Parts    
Qty     Part Number    
2     0L-2070 Bolts    
2     2A-2677 Spacers    
4     3H-8683 Clips    
2     5M-2894 Hard Washers    
4     6V-9746 O-ring Seals    
2     8M-9124 Washers    
1     210-6274 Tube As  (1)    
1     215-4796 Tube As  (1)    
4     353-7953 Grommets    
1     418-6827 Hose As    
1     418-6828 Hose As    
( 1 ) The original can be reused. Repair and/or replace as necessary.

Table 15
Group 14 Required Parts    
Qty     Part Number    
1     0L-2070 Bolt    
1     1F-7958 Full Nut    
1     2A-2677 Spacer    
2     3H-8683 Clips    
1     5M-2894 Hard Washer    
2     5P-8245 Hard Washers    
2     6V-8733 Unions    
6     6V-9746 O-ring Seals    
2     7X-7902 Elbows    
1     8M-9124 Washer    
1     9S-1366 Bolt    
2     353-7953 Grommets    
1     363-8651 Bracket As    
1     418-1233 Hose As    
1     418-1234 Hose As    

Table 16
Group 15 Required Parts    
Qty     Part Number    
1     0L-2070 Bolt    
1     2A-2677 Spacer    
2     3H-8683 Clips    
1     5M-2894 Hard Washers    
2     6V-8733 Unions    
6     6V-9746 O-ring Seals    
2     7X-7902 Elbows    
1     8M-9124 Washer    
2     353-7953 Grommets    
1     418-1233 Hose As    
1     418-1234 Hose As    

Table 17
Group 16 Required Parts    
Qty     Part Number    
2     0L-2070 Bolts    
2     2A-2677 Spacers    
4     3H-8683 Clips    
2     5M-2894 Hard Washers    
9     6V-9746 O-ring Seals    
1     200-6441 Tube As  (1)    
1     200-6442 Tube As  (1)    
4     353-7953 Grommets    
2     365-0682 Connectors    
1     437-7371 Hose As    
1     439-4508 Hose As    
( 1 ) The original can be reused. Repair and/or replace as necessary.

Table 18
Group 17 Required Parts    
Qty     Part Number    
1     1S-1015 Clip    
4     6V-9746 O-ring Seals    
1     7X-7902 Elbow    
1     210-6274 Tube As  (1)    
1     215-4796 Tube As  (1)    
1     365-0682 Connector    
1     419-9843 Hose As    
1     419-9846 Hose As    
( 1 ) The original can be reused. Repair and/or replace as necessary.

Table 19
Group 18 Required Parts    
Qty     Part Number    
4     6V-9746 O-ring Seals    
1     365-0682 Connector    
1     419-9843 Hose As    
1     419-9846 Hose As    

Table 20
Group 19 Required Parts    
Qty     Part Number    
2     0L-2070 Bolts    
2     2A-2677 Spacers    
4     3H-8683 Clips    
2     5M-2894 Hard Washers    
7     6V-9746 O-ring Seals    
2     8M-9124 Washer    
1     200-6441 Tube As  (1)    
1     200-6442 Tube As  (1)    
4     353-7953 Grommets    
2     365-0682 Connectors    
1     437-7371 Hose As    
1     439-4508 Hose As    
( 1 ) The original can be reused. Repair and/or replace as necessary.

Table 21
Group 20 Required Parts    
Qty     Part Number    
2     0L-2070 Bolts    
2     2A-2677 Spacers    
4     3H-8683 Clips    
5     6V-9746 O-ring Seals    
2     8M-9124 Washer    
1     200-6441 Tube As  (1)    
1     200-6442 Tube As  (1)    
4     353-7953 Grommets    
1     437-7371 Hose As    
1     439-4508 Hose As    
( 1 ) The original can be reused. Repair and/or replace as necessary.

Table 22
Group 21 Required Parts    
Qty     Part Number    
1     0L-2070 Bolt    
1     2A-2677 Spacer    
2     3H-8683 Clips    
1     5M-2894 Hard Washers    
2     6V-8733 Unions    
6     6V-9746 O-ring Seals    
1     7X-7902 Elbows    
1     8M-9124 Washer    
2     353-7953 Grommets    
1     418-1233 Hose As    
1     418-1234 Hose As    

Table 23
Group 22 Required Parts    
Qty     Part Number    
1     449-1314 Hose As    

Group 1 Removal Procedures

Note: Refer to Table 1 for the serial number ranges for this group.




    Illustration 1g03521167

  1. Remove the tube assemblies, elbows, and mounting hardware.



    Illustration 2g03523278

  1. Inspect the welded bosses on the 236-5182 Tube As and 265-5221 Tube As . Repair and/or replace as necessary.

Group 1 Installation Procedure

Note: Refer to Table 1 for the serial number ranges for this group.




    Illustration 3g03521317

    (1) 6V-9746 O-ring Seal

    (2) 437-7369 Hose As

    (3) 439-0805 Hose As

    (4) 365-0682 Connector




    Illustration 4g03523279

    (1) 6V-9746 O-ring Seal

    (4) 365-0682 Connector

  1. Install four new O-rings (1) .

  1. Install hose assemblies (2) and (3) .



    Illustration 5g03521469

    (2) 437-7369 Hose As

    (3) 439-0805 Hose As

    (5) 353-7953 Grommet

    (6) 3H-8683 Clip

    (7) 0L-2070 Bolt

    (8) 5M-2894 Hard Washer

    (9) 2A-2677 Spacer

    (10) 8M-9124 Washer

    (11) 9S-8752 Full Nut

    (12) 0S1-590 Bolt

  1. Install four grommets (5) on to hose assemblies (2) and (3) .

  1. Install four clips (6) on to hose assemblies (2) and (3) .

  1. Attach the front clips to the aftercooler bracket using one bolt (7), one washer (8), one spacer (9), one washer (10) and one nut (11) .

  1. Attach the rear clips together using one bolt (12), two washers (8) one on each end of bolt (12), one spacer (9) and one nut (11) .

Group 2 Removal Procedure

Note: Refer to Table 1 for the serial number ranges for this group.




Illustration 6g03523778



Illustration 7g03525760

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 2 Installation Procedure

Note: Refer to Table 1 for the serial number ranges for this group.




    Illustration 8g03526136

    (1) 210-6274 Tube

    (2) 8T-1919 O-ring Seals

    (3) 215-4794 Elbows

    (4) 215-4796 Tube As

    (5) 0S-1594 Bolts

    (6) 5M-2894 Hard Washers

    (7) 4W-0531 Retainers

  1. Install one new O-ring (2) and one previously removed 4W-0530 Retaining Ring on to tube assembly (1). Attach tube assembly (1) to elbow (3) using two bolts (5), two washers (6) and two retainers (7) .

  1. Install one new O-ring (2) and one previously removed 4W-0530 Retaining Ring on to tube assembly (4). Attach tube assembly (4) to elbow (3) using two bolts (5), two washers (6) and two retainers (7) .



    Illustration 9g03526430

    (1) 210-6274 Tube

    (4) 215-4796 Tube As

    (8) 6V-9746 O-ring Seals

    (9) 365-0682 Connectors

  1. Install connectors (9) in to tube assemblies (1) and (4) .

  1. Install two O-rings (8) on adapters (9) .

  1. Install plugs (10) into elbows (3) .



    Illustration 10g03528258

    (9) 365-0682 Connectors

    (10) 418-6827 Hose As

    (11) 418-6828 Hose As

  1. Install hose assemblies (10) and (11) .



    Illustration 11g03523797

    (10) 418-6827 Hose As

    (11) 418-6828 Hose As

    (12) 353-7953 Grommets

    (13) 3H-8683 Clips

    (14) 0L-2070 Bolts

    (15) 5M-2894 Hard Washers

    (16) 2A-2677 Spacers

    (17) 8M-9124 Washers

  1. Install four grommets (12) onto hose assemblies (10) and (11), two on each hose.

  1. Install four clips (13) onto hose assemblies (10) and (11) .

  1. Attach clips (13) using two bolts (14), two washers (15), two spacers (16) and two washers (17) .

Group 3 Removal Procedure




    Illustration 12g03531093



    Illustration 13g03531096

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 3 Installation Procedure

Note: Refer to Table 1 for the serial number ranges for this group.




    Illustration 14g03526136

    (1) 210-6274 Tube

    (2) 8T-1919 O-ring Seals

    (3) 215-4794 Elbows

    (4) 215-4796 Tube As

    (5) 0S-1594 Bolts

    (6) 5M-2894 Hard Washers

    (7) 4W-0531 Retainers

  1. Install one new O-ring (2) and one previously removed 4W-0530 Retaining Ring on to tube assembly (1). Attach tube assembly (1) to elbow (3) using two bolts (5), two washers (6) and two retainers (7) .

  1. Install one new O-ring (2) and one previously removed 4W-0530 Retaining Ring on to tube assembly (4). Attach tube assembly (4) to elbow (3) using two bolts (5), two washers (6) and two retainers (7) .



    Illustration 15g03526430

    (1) 210-6274 Tube

    (4) 215-4796 Tube As

    (8) 6V-9746 O-ring Seals

    (9) 365-0682 Connectors

  1. Install connectors (9) in to tube assemblies (1) and (4) .

  1. Install two O-rings (8) on adapters (9) .

  1. Install plugs (10) into elbows (3) .



    Illustration 16g03528258

    (9) 365-0682 Connectors

    (10) 418-6827 Hose As

    (11) 418-6828 Hose As

  1. Install hose assemblies (10) and (11) .



    Illustration 17g03523797

    (10) 418-6827 Hose As

    (11) 418-6828 Hose As

    (12) 353-7953 Grommets

    (13) 3H-8683 Clips

    (14) 0L-2070 Bolts

    (15) 5M-2894 Hard Washers

    (16) 2A-2677 Spacers

    (17) 8M-9124 Washers

  1. Install four grommets (12) onto hose assemblies (10) and (11), two on each hose.

  1. Install four clips (13) onto hose assemblies (10) and (11) .

  1. Attach clips (13) using two bolts (14), two washers (15), two spacers (16) and two washers (17) .

Group 4 Removal Procedure




    Illustration 18g03531339



    Illustration 19g03531340

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 4 Installation Procedure




    Illustration 20g03534757

    (1) 200-6442 Tube As

    (2) 200-6441 Tube As

    (3) 365-0682 Connector

    (4) 6V-9746 O-Ring Seal

  1. Install connectors (3) into tube assemblies (1) and (2) .

  1. Install one O-ring (4) into each connector (1) .



    Illustration 21g03537600

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

  1. Install hose assemblies (5) and (6) .



    Illustration 22g03537617

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

    (7) 353-7953 Grommets

    (8) 3H-8683 Clips

    (9) 0L-2070 Bolts

    (10) 5M-2894 Hard Washers

    (11) 2A-2677 Spacers

    (12) 8M-9124 Washers

  1. Install four grommets (7) onto hose assemblies (5) and (6), two on each hose.

  1. Install four clips (8) onto hose assemblies (5) and (6) .

  1. Attach clips (8) using two bolts (9), two washers (10), two spacers (11) and two washers (12) .

Group 5 Removal Procedure




    Illustration 23g03531339



    Illustration 24g03531340

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 5 Installation Procedure




    Illustration 25g03534757

    (1) 200-6442 Tube As

    (2) 200-6441 Tube As

    (3) 365-0682 Connector

    (4) 6V-9746 O-ring Seal

  1. Install connectors (3) into tube assemblies (1) and (2) .

  1. Install one O-ring (4) into each connector (1) .



    Illustration 26g03537600

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

  1. Install hose assemblies (5) and (6) .



    Illustration 27g03537617

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

    (7) 353-7953 Grommets

    (8) 3H-8683 Clips

    (9) 0L-2070 Bolts

    (10) 5M-2894 Hard Washers

    (11) 2A-2677 Spacers

    (12) 8M-9124 Washers

  1. Install four grommets (7) onto hose assemblies (5) and (6), two on each hose.

  1. Install four clips (8) onto hose assemblies (5) and (6) .

  1. Attach clips (8) using two bolts (9), two washers (10), two spacers (11) and two washers (12) .

Group 6 Removal Procedure




    Illustration 28g03531339



    Illustration 29g03531340

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 6 Installation Procedure




    Illustration 30g03534757

    (1) 200-6442 Tube As

    (2) 200-6441 Tube As

    (3) 365-0682 Connector

    (4) 6V-9746 O-ring Seal

  1. Install connectors (3) into tube assemblies (1) and (2) .

  1. Install one O-ring (4) into each connector (1) .



    Illustration 31g03537600

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

  1. Install hose assemblies (5) and (6) .



    Illustration 32g03537617

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

    (7) 353-7953 Grommets

    (8) 3H-8683 Clips

    (9) 0L-2070 Bolts

    (10) 5M-2894 Hard Washers

    (11) 2A-2677 Spacers

    (12) 8M-9124 Washers

  1. Install four grommets (7) onto hose assemblies (5) and (6), two on each hose.

  1. Install four clips (8) onto hose assemblies (5) and (6) .

  1. Attach clips (8) using two bolts (9), two washers (10), two spacers (11) and two washers (12) .

Group 7 Remove




    Illustration 33g03531339



    Illustration 34g03531340

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 7 Installation Procedure




    Illustration 35g03534757

    (1) 200-6442 Tube As

    (2) 200-6441 Tube As

    (3) 365-0682 Connector

    (4) 6V-9746 O-ring Seal

  1. Install connectors (3) into tube assemblies (1) and (2) .

  1. Install one O-ring (4) into each connector (1) .



    Illustration 36g03537600

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

  1. Install hose assemblies (5) and (6) .



    Illustration 37g03537617

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

    (7) 353-7953 Grommets

    (8) 3H-8683 Clips

    (9) 0L-2070 Bolts

    (10) 5M-2894 Hard Washers

    (11) 2A-2677 Spacers

    (12) 8M-9124 Washers

  1. Install four grommets (7) onto hose assemblies (5) and (6), two on each hose.

  1. Install four clips (8) onto hose assemblies (5) and (6) .

  1. Attach clips (8) using two bolts (9), two washers (10), two spacers (11) and two washers (12) .

Group 8 Remove




    Illustration 38g03531339



    Illustration 39g03531340

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 8 Installation Procedure




    Illustration 40g03534757

    (1) 200-6442 Tube As

    (2) 200-6441 Tube As

    (3) 365-0682 Connector

    (4) 6V-9746 O-ring Seal

  1. Install connectors (3) into tube assemblies (1) and (2) .

  1. Install one O-ring (4) into each connector (1) .



    Illustration 41g03537600

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

  1. Install hose assemblies (5) and (6) .



    Illustration 42g03537617

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

    (7) 353-7953 Grommets

    (8) 3H-8683 Clips

    (9) 0L-2070 Bolts

    (10) 5M-2894 Hard Washers

    (11) 2A-2677 Spacers

    (12) 8M-9124 Washers

  1. Install four grommets (7) onto hose assemblies (5) and (6), two on each hose.

  1. Install four clips (8) onto hose assemblies (5) and (6) .

  1. Attach clips (8) using two bolts (9), two washers (10), two spacers (11) and two washers (12) .

Group 9 Remove




    Illustration 43g03531339



    Illustration 44g03531340

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 9 Installation Procedure




    Illustration 45g03534757

    (1) 200-6442 Tube As

    (2) 200-6441 Tube As

    (3) 365-0682 Connector

    (4) 6V-9746 O-ring Seal

  1. Install connectors (3) into tube assemblies (1) and (2) .

  1. Install one O-ring (4) into each connector (1) .



    Illustration 46g03537600

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

  1. Install hose assemblies (5) and (6) .



    Illustration 47g03537617

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

    (7) 353-7953 Grommets

    (8) 3H-8683 Clips

    (9) 0L-2070 Bolts

    (10) 5M-2894 Hard Washers

    (11) 2A-2677 Spacers

    (12) 8M-9124 Washers

  1. Install four grommets (7) onto hose assemblies (5) and (6), two on each hose.

  1. Install four clips (8) onto hose assemblies (5) and (6) .

  1. Attach clips (8) using two bolts (9), two washers (10), two spacers (11) and two washers (12) .

Group 10 Removal Procedure




    Illustration 48g03537677



    Illustration 49g03537676

  1. Remove the tube assemblies, elbows and mounting hardware.

Group 10 Installation Procedure




    Illustration 50g03538174

    (1) 7X-7902 Elbows

    (2) 6V-9746 O-ring Seals

  1. Install two O-rings (2) into elbows (1) .



    Illustration 51g03538175

    (2) 6V-9746 O-ring Seals

    (3) 418-1233 Hose As

    (4) 418-1234 Hose As

  1. Install hose assemblies (3) and (4) .



    Illustration 52g03538187

    (3) 418-1233 Hose As

    (4) 418-1234 Hose As

    (5) 353-7953 Grommets

    (6) 3H-8683 Clip

    (7) 0L-2070 Bolt

    (8) 5M-2894 Hard Washer

    (9) 2A-2677 Spacer

    (10) 8M-9124 Washer

    (11) 363-8651 Bracket As

  1. Install two new O-rings (2) .

  1. Install two grommets (5) onto hose assemblies (3) and (4), one on each hose.

  1. Install two clips (6) onto hose assemblies (3) and (4) .

  1. Attach clips (6) using one bolt (9), one washer (10), one spacer (11) and one washer (12) .

Group 11 Removal Procedure




    Illustration 53g03537677



    Illustration 54g03537676

  1. Remove the tube assemblies, elbows and mounting hardware.

Group 11 Installation Procedure




    Illustration 55g03538174

    (1) 7X-7902 Elbows

    (2) 6V-9746 O-ring Seals

  1. Install two O-rings (2) into elbows (1) .



    Illustration 56g03538175

    (2) 6V-9746 O-ring Seals

    (3) 418-1233 Hose As

    (4) 418-1234 Hose As

  1. Install hose assemblies (3) and (4) .



    Illustration 57g03538187

    (3) 418-1233 Hose As

    (4) 418-1234 Hose As

    (5) 353-7953 Grommets

    (6) 3H-8683 Clip

    (7) 0L-2070 Bolt

    (8) 5M-2894 Hard Washer

    (9) 2A-2677 Spacer

    (10) 8M-9124 Washer

    (11) 363-8651 Bracket As

  1. Install two new O-rings (2) .

  1. Install two grommets (5) onto hose assemblies (3) and (4), one on each hose.

  1. Install two clips (6) onto hose assemblies (3) and (4) .

  1. Attach clips (6) using one bolt (9), one washer (10), one spacer (11) and one washer (12) .

Group 12 Removal Procedure

Note: Refer to Table 1 for the serial number ranges for this group.




Illustration 58g03523778



Illustration 59g03525760

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 12 Installation Procedure

Note: Refer to Table 1 for the serial number ranges for this group.




    Illustration 60g03526136

    (1) 210-6274 Tube

    (2) 8T-1919 O-ring Seals

    (3) 215-4794 Elbows

    (4) 215-4796 Tube As

    (5) 0S-1594 Bolts

    (6) 5M-2894 Hard Washers

    (7) 4W-0531 Retainers

  1. Install one new O-ring (2) and one previously removed 4W-0530 Retaining Ring on to tube assembly (1). Attach tube assembly (1) to elbow (3) using two bolts (5), two washers (6) and two retainers (7) .

  1. Install one new O-ring (2) and one previously removed 4W-0530 Retaining Ring on to tube assembly (4). Attach tube assembly (4) to elbow (3) using two bolts (5), two washers (6) and two retainers (7) .



    Illustration 61g03526430

    (1) 210-6274 Tube

    (4) 215-4796 Tube As

    (8) 6V-9746 O-ring Seals

    (9) 365-0682 Connectors

  1. Install connectors (9) in to tube assemblies (1) and (4) .

  1. Install two O-rings (8) on adapters (9) .

  1. Install plugs (10) into elbows (3) .



    Illustration 62g03528258

    (9) 365-0682 Connectors

    (10) 418-6827 Hose As

    (11) 418-6828 Hose As

  1. Install hose assemblies (10) and (11) .



    Illustration 63g03523797

    (10) 418-6827 Hose As

    (11) 418-6828 Hose As

    (12) 353-7953 Grommets

    (13) 3H-8683 Clips

    (14) 0L-2070 Bolts

    (15) 5M-2894 Hard Washers

    (16) 2A-2677 Spacers

    (17) 8M-9124 Washers

  1. Install four grommets (12) onto hose assemblies (10) and (11), two on each hose.

  1. Install four clips (13) onto hose assemblies (10) and (11) .

  1. Attach clips (13) using two bolts (14), two washers (15), two spacers (16) and two washers (17) .

Group 13 Removal Procedure




    Illustration 64g03531093



    Illustration 65g03531096

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 13 Installation Procedure

Note: Refer to Table 1 for the serial number ranges for this group.




    Illustration 66g03526136

    (1) 210-6274 Tube

    (2) 8T-1919 O-ring Seals

    (3) 215-4794 Elbows

    (4) 215-4796 Tube As

    (5) 0S-1594 Bolts

    (6) 5M-2894 Hard Washers

    (7) 4W-0531 Retainers

  1. Install one new O-ring (2) and one previously removed 4W-0530 Retaining Ring on to tube assembly (1). Attach tube assembly (1) to elbow (3) using two bolts (5), two washers (6) and two retainers (7) .

  1. Install one new O-ring (2) and one previously removed 4W-0530 Retaining Ring on to tube assembly (4). Attach tube assembly (4) to elbow (3) using two bolts (5), two washers (6) and two retainers (7) .



    Illustration 67g03526430

    (1) 210-6274 Tube

    (4) 215-4796 Tube As

    (8) 6V-9746 O-ring Seals

    (9) 365-0682 Connectors

  1. Install connectors (9) in to tube assemblies (1) and (4) .

  1. Install two O-rings (8) on adapters (9) .

  1. Install plugs (10) into elbows (3) .



    Illustration 68g03528258

    (9) 365-0682 Connectors

    (10) 418-6827 Hose As

    (11) 418-6828 Hose As

  1. Install hose assemblies (10) and (11) .



    Illustration 69g03523797

    (10) 418-6827 Hose As

    (11) 418-6828 Hose As

    (12) 353-7953 Grommets

    (13) 3H-8683 Clips

    (14) 0L-2070 Bolts

    (15) 5M-2894 Hard Washers

    (16) 2A-2677 Spacers

    (17) 8M-9124 Washers

  1. Install four grommets (12) onto hose assemblies (10) and (11), two on each hose.

  1. Install four clips (13) onto hose assemblies (10) and (11) .

  1. Attach clips (13) using two bolts (14), two washers (15), two spacers (16) and two washers (17) .

Group 14 Removal Procedure




    Illustration 70g03539216



    Illustration 71g03539217

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 14 Installation Procedure




    Illustration 72g03539501

    (1) 7X-7902 Elbows

    (2) 6V-9746 O-Ring Seals

  1. Install two elbows (1) .

  1. Install two O-rings (2) into elbows (1) .



    Illustration 73g03539580

    (3) 418-1233 Hose As

    (4) 418-1234 Hose As

  1. Install hose assemblies (3) and (4) .



    Illustration 74g03538187

    (3) 418-1233 Hose As

    (4) 418-1234 Hose As

    (5) 353-7953 Grommets

    (6) 3H-8683 Clip

    (7) 0L-2070 Bolt

    (8) 5M-2894 Hard Washer

    (9) 2A-2677 Spacer

    (10) 8M-9124 Washer

    (11) 363-8651 Bracket As

  1. Install two new O-rings (2) .

  1. Install two grommets (5) onto hose assemblies (3) and (4), one on each hose.

  1. Install two clips (6) onto hose assemblies (3) and (4) .

  1. Attach clips (6) using one bolt (9), one washer (10), one spacer (11) and one washer (12) .

Group 15 Removal Procedure




    Illustration 75g03539216



    Illustration 76g03539217

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 15 Installation Procedure




    Illustration 77g03539501

    (1) 7X-7902 Elbows

    (2) 6V-9746 O-Ring Seals

  1. Install two elbows (1) .

  1. Install two O-rings (2) into elbows (1) .



    Illustration 78g03539580

    (3) 418-1233 Hose As

    (4) 418-1234 Hose As

  1. Install hose assemblies (3) and (4) .



    Illustration 79g03538187

    (3) 418-1233 Hose As

    (4) 418-1234 Hose As

    (5) 353-7953 Grommets

    (6) 3H-8683 Clip

    (7) 0L-2070 Bolt

    (8) 5M-2894 Hard Washer

    (9) 2A-2677 Spacer

    (10) 8M-9124 Washer

    (11) 363-8651 Bracket As

  1. Install two new O-rings (2) .

  1. Install two grommets (5) onto hose assemblies (3) and (4), one on each hose.

  1. Install two clips (6) onto hose assemblies (3) and (4) .

  1. Attach clips (6) using one bolt (9), one washer (10), one spacer (11) and one washer (12) .

Group 16 Removal Procedure




    Illustration 80g03531339



    Illustration 81g03531340

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 16 Installation Procedure




    Illustration 82g03534757

    (1) 200-6442 Tube As

    (2) 200-6441 Tube As

    (3) 365-0682 Connector

    (4) 6V-9746 O-Ring Seal

  1. Install connectors (3) into tube assemblies (1) and (2) .

  1. Install one O-ring (4) into each connector (1) .



    Illustration 83g03537600

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

  1. Install hose assemblies (5) and (6) .



    Illustration 84g03537617

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

    (7) 353-7953 Grommets

    (8) 3H-8683 Clips

    (9) 0L-2070 Bolts

    (10) 5M-2894 Hard Washers

    (11) 2A-2677 Spacers

    (12) 8M-9124 Washers

  1. Install four grommets (7) onto hose assemblies (5) and (6), two on each hose.

  1. Install four clips (8) onto hose assemblies (5) and (6) .

  1. Attach clips (8) using two bolts (9), two washers (10), two spacers (11) and two washers (12) .

Group 17 Removal Procedure




    Illustration 85g03539786



    Illustration 86g03539787

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 17 Installation Procedure




    Illustration 87g03540878

    (1) 210-6274 Tube

    (2) 215-4796 Tube As

    (3) 365-0682 Connector

    (4) 7X-7902 Elbow

    (5) 6V-9746 O-Ring Seals

  1. Install connector (3) onto tube (1) .

  1. Install elbow (4) onto tube (2) .

  1. Install one O-ring (5) in connector (3) and one in elbow (4) .



    Illustration 88g03541181

    (3) 365-0682 Connector

    (4) 7X-7902 Elbow

    (6) 419-9843 Hose As

    (7) 419-9846 Hose As

  1. Install hose assemblies (6) and (7) .

  1. Attach hose assembly (6) to connector (3).

  1. Attach hose assembly (7) to elbow (4) .



    Illustration 89g03541364

    (5) 6V-9746 O-Ring Seals

    (6) 419-9843 Hose As

    (7) 419-9846 Hose As

    (8) 1S-1015 Clip

  1. Install clip (8) onto hose assembly (7) .

  1. Install two new O-rings (5) .

Group 18 Removal Procedure




    Illustration 90g03541416

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 18 Installation Procedure




    Illustration 91g03541437

    (1) 365-0682 Connector

    (2) 7X-7902 Elbow

    (3) 6V-9746 O-Ring Seals

  1. Install connector (1) and elbow (2) .

  1. Install one O-ring (3) in connector (1) and one in elbow (3) .



    Illustration 92g03541516

  1. Install hose assemblies (4) and (5) .

  1. Attach hose (4) to connector (1) .

  1. Attach hose assembly (5) to elbow (2) .

  1. Install two new O-rings (3) .

Group 19 Removal Procedure




    Illustration 93g03531339



    Illustration 94g03531340

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 19 Installation Procedure




    Illustration 95g03534757

    (1) 200-6442 Tube As

    (2) 200-6441 Tube As

    (3) 365-0682 Connector

    (4) 6V-9746 O-Ring Seal

  1. Install connectors (3) into tube assemblies (1) and (2) .

  1. Install one O-ring (4) into each connector (1) .



    Illustration 96g03537600

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

  1. Install hose assemblies (5) and (6) .



    Illustration 97g03537617

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

    (7) 353-7953 Grommets

    (8) 3H-8683 Clips

    (9) 0L-2070 Bolts

    (10) 5M-2894 Hard Washers

    (11) 2A-2677 Spacers

    (12) 8M-9124 Washers

  1. Install four grommets (7) onto hose assemblies (5) and (6), two on each hose.

  1. Install four clips (8) onto hose assemblies (5) and (6) .

  1. Attach clips (8) using two bolts (9), two washers (10), two spacers (11) and two washers (12) .

Group 20 Removal Procedure




    Illustration 98g03541660



    Illustration 99g03541662

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 20 Installation Procedure




    Illustration 100g03534757

    (1) 200-6442 Tube As

    (2) 200-6441 Tube As

    (3) 365-0682 Connector

    (4) 6V-9746 O-Ring Seal

  1. Install connectors (3) into tube assemblies (1) and (2) .

  1. Install one O-ring (4) into each connector (1) .



    Illustration 101g03537600

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

  1. Install hose assemblies (5) and (6) .



    Illustration 102g03537617

    (5) 439-4508 Hose As

    (6) 437-7371 Hose As

    (7) 353-7953 Grommets

    (8) 3H-8683 Clips

    (9) 0L-2070 Bolts

    (10) 5M-2894 Hard Washers

    (11) 2A-2677 Spacers

    (12) 8M-9124 Washers

  1. Install four grommets (7) onto hose assemblies (5) and (6), two on each hose.

  1. Install four clips (8) onto hose assemblies (5) and (6) .

  1. Attach clips (8) using two bolts (9), two washers (10), two spacers (11) and two washers (12) .

Group 21 Removal Procedure




    Illustration 103g03541779



    Illustration 104g03541781

  1. Remove the tube assemblies, elbows, and mounting hardware.

Group 21 Installation Procedure




    Illustration 105g03538174

    (1) 7X-7902 Elbows

    (2) 6V-9746 O-ring Seals

  1. Install two O-rings (2) into elbows (1) .



    Illustration 106g03538175

    (2) 6V-9746 O-ring Seals

    (3) 418-1233 Hose As

    (4) 418-1234 Hose As

  1. Install hose assemblies (3) and (4) .



    Illustration 107g03538187

    (3) 418-1233 Hose As

    (4) 418-1234 Hose As

    (5) 353-7953 Grommets

    (6) 3H-8683 Clip

    (7) 0L-2070 Bolt

    (8) 5M-2894 Hard Washer

    (9) 2A-2677 Spacer

    (10) 8M-9124 Washer

    (11) 363-8651 Bracket As

  1. Install two new O-rings (2) .

  1. Install two grommets (5) onto hose assemblies (3) and (4), one on each hose.

  1. Install two clips (6) onto hose assemblies (3) and (4) .

  1. Attach clips (6) using one bolt (9), one washer (10), one spacer (11) and one washer (12) .

Group 22 Removal Procedure




    Illustration 108g03541943

    (1) 419-9843 Hose As

  1. Remove hose assembly (1) .

Group 22 Installation Procedure




    Illustration 109g03541945

    (1) 6V-9746 O-Ring Seals

  1. Install two O-rings (1) .



    Illustration 110g03541946

  1. Install hose assembly (2) .

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