BLOCK 3V6909 - Caterpillar

Introduction
This Special Instruction details the procedure to fabricate new CGI lines on certain C15 Truck Engines. These engines are experiencing condensation in the lines freezing when the truck is shut down in severe temperatures. The Engine Control Module (ECM) will log a "3487-7 Air Pressure Control Not Responding" fault code and will not allow a manual regeneration. Refer to the procedure below in order to correct this issue.Required Parts
Table 1
New Part Number     Description     Quantity    
1P-4278     Hose Clamp     6    
238-5079     O-Ring Seal     2    
337-4178     Hose     Bulk hose cut to size    
341-0098     Elbow     2    
368-6475     Bracket     1    
9W-4216     Spacer     2    Installation Procedure
Remove all necessary engine and chassis components needed in order to be able to access the CGI lines and sensor assembly.
Illustration 1 g02470377
(1) Sensor block assembly (2) Clamp assembly (3) CGI lines (4) Fittings
Disconnect lines (3) from fittings (4) .
Remove the sensor block assembly.
Remove the sensor block from the mounting bracket.
Remove fittings (4) from the sensor block.
Illustration 2 g02474476
(2) Clamp assembly (5) Location to cut the CGI lines
Remove clamp (2) in order to cut both CGI lines at location (5). A tubing cutter must be used to cut the CGI lines in order to prevent debris from entering the sensor lines.Note: Do not use a cut-off wheel or a hacksaw to cut the CGI lines.
Illustration 3 g02475247
Sensor block with new 341-0098 Elbows installed
Install the new 341-0098 Elbows used two 238-5079 O-Ring Seal in the sensor block in place of fittings (4) .
Install the sensor block onto the new 368-6475 Bracket using the existing mounting hardware.
Mount the sensor block assembly to the cylinder block using two 9W-4216 Spacers between the bracket and each of the existing mounting bolts.
Illustration 4 g02474656
CGI line cut with the paint removed
Remove the paint from the end of the CGI lines. This area will give the hose a better surface to seal on.
Cut the 337-4178 Hose to length that will replace the section of tubing that was cut from the CGI lines.Note: Blow out the cut sections of 337-4178 Hose with compressed air to ensure cleanliness.
Illustration 5 g02475079
Sensor block assembly and newly fabricated lines installed
Install the two 337-4178 Hoses and secure the hose with four 1P-4278 Hose Clamps .Note: Torque the clamps to standard torque.
Reinstall all necessary engine and chassis components that were removed in order to be able to access the CGI lines and sensor assembly.
Perform a manual regeneration to ensure that the "CGI Mass Air Flow" reading is correct.