REPAIR KIT-SEAL 5W7601 - Caterpillar

PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
1. Disconnect the positive battery connection before performing this rework procedure.
2. Remove the air inlet heater relay, the cable assembly connected to the heating element, and the relay isolation bracket assembly. These parts will not be re-used. Refer to Image1.1.1
Image1.1.1
3. Disconnect the cable connected to the starter from the air inlet heater relay. Refer to Image1.2.1
Image1.2.1
4. Relocate the air inlet heater relay to the firewall on the driver side of the engine compartment.
Refer to Image1.3.1 and Image1.3.2
Image1.3.1
Image1.3.2
5. Locate the bottom bolt of the radiator support bracket on the driver side of the engine compartment. This bolt will be used to secure the left side of the 283-1226 Relay Isolation Bracket Assembly.
6. Use the 283-1226 Relay Isolation Bracket Assembly as a template to mark the right side mounting hole. Drill a 5/16" hole for the mounting hole. Take care not to damage any components located behind the location where you are drilling the 5/16" hole. Refer to Image1.4.1
Image1.4.1
7. Use three 8T-4121 Washers on the right side of the relay isolation bracket and one 8T-4121 Washers on the left side to shim the bracket away from the firewall. Use one 8T-4182 Bolt, one 8T-4121 Washer, and one 8T-4133 Nut to secure the right side of the isolation bracket to the firewall.
Refer to Image1.5.1 and Image1.5.2
Image1.5.1
Image1.5.2
8. Remove paint or debris from the terminal lug (if necessary) then re-connect the cable connected to the starter to the 5/16" stud (2)on the right side of the 208-5581 Air Inlet Heater Relay. Use the 345-9109 Cable Assembly to re-connect the heater element to remaining 5/16" stud (1) on left side of the Air Inlet Heater Relay. Refer to Image1.6.1 and Image1.6.2
Image1.6.1
Image1.6.2
9. Reconnect relay pigtail to ECM harness connection (J501/P501).
refer to Image1.7.1
Image1.7.1
10. Secure cables as shown using the cable straps and the 177-2215 Strap Dual Clamp. The routing of the power cable should not create a force on the isolation mount on the relay. Provide relief for any items that inhibit the ability of the mounts to isolate the relay from vibration or shock. This may require additional mounting points at the relay or near the relay. A longer wire from the relay to the heater element will also remedy the issue. Power leads must be supported within six to eight inches of the terminal connection at the relay. Also, the wire must not be attached to a fuel line.
Refer to Image1.8.1
11. Reconnect the positive battery connection for the vehicle.
Image1.8.1
Torque requirements:
Wire terminal nuts and locking washers are supplied with the relay.
Note: Not meeting the specified torque limit may cause electrical arcing due to a mechanical failure of the stud on the relay or a loose connection.
Tighten nut (2) to 9 +/- 1 N.m (7 +/- 1 lb ft). Hold nut (6) with an additional wrench as you are applying torque to nut (2) .
Tighten isolation mount (5) to 12 +/- 1 N.m (9 +/- 1 lb ft).
Tighten mounting hardware (1) to