4045AFM85 and 4045SFM85

Marine Engine Installation

Instructions for Double
Wall Fuel LineDZ117600
Kit

INSTALLATION INSTRUCTIONS
DZ118318
DZ118318 21FEB20 (ENGLISH)

4045AFM85 and 4045SFM85

John Deere Power Systems

DZ118318 (21FEB20)
PRINTED IN U.S.A.
COPYRIGHT © 2020
DEERE & COMPANY
Moline, Illinois
All rights reserved.
A John Deere ILLUSTRUCTION ™ Manual
Previous Editions
Copyright © 2019
DZ118318-19-21FEB20
 DZ117600

RG32037 —UN—13JAN20
Reference Video
NOTE: This video is for reference only. Components
shown are for a 6068 engine. Some components
will not be used on 4045 engines.

Fuel Line Installation Video

BF67790,0001E53 -19-14JAN20-1/1

Note kit at the same time while it is necessary to

replace an exhaust manifold gasket (available
IMPORTANT: It is recommended to install both in the double wall fuel line kit).
insulation blanket and double wall fuel line
BF67790,0000036 -19-14MAR16-1/1

Live With Safety

Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.

TS231 —19—07OCT88
RG19661,0000006 -19-27AUG13-1/1

DZ118318 (21FEB20) 1 022120

PN=3
 DZ117600

Parts List for DZ117600 Kit

RG31663A —UN—30JAN20
Double Wall Fuel Line Kit

Number Part Number Description Quantity

1 DZ10419 Straight Adapter with O-Ring 1
2 DZ108891 Double Wall Fuel Line, Injector #1 1
3 DZ113841 Fuel Supply Line (AFM engine only) 1
4 DZ114031 O-Ring (SFM engine only) 1
5 DZ118079 Double Wall Fuel Line 1
6 DZ118084 Spray Shield Cast Bracket 1
7 DZ118085 Top Spray Shield Cover 1
8 DZ118086 Front Spray Shield Cover 1
9 R521158 Turbocharger Oil Drain Line Gasket 1
10 R523069 Washer 4
11 R543538 Banjo Bolt 2
12 RE528054 Hose 1
13 RE528059 Alarm Tank Assembly 1
14 RE528060 Alarm Tank Mounting Kit 1
15 RE551765 Exhaust Manifold Gasket 1
16 RE566438 Double Wall Fuel Line 1
17 RE566440 Common Rail Adapter with O-Ring 1
18 RE566441 Fuel Return Line 1
19 RE566442 Spray Shield Support Bracket 1
20 RE566443 Drain Line 1
21 RE566445 2-Pipe Clamp 1
Continued on next page BF67790,0001CC2 -19-28JAN20-1/3

DZ118318 (21FEB20) 2 022120

PN=4
 DZ117600

Number Part Number Description Quantity

22 RE566447 Double Wall Fuel Line, Injector #2 1
23 RE566448 Double Wall Fuel Line, Injector #3 1
24 RE566449 Double Wall Fuel Line, Injector #4 1
25 RE502655 3-Pipe Clamp 1
26 RE502654 2-Pipe Clamp 2
27 RE568649 2-Pipe Clamp (AFM engine only) 1
28 19M8320 M10 x 45 mm Cap Screw 2
DZ118318 Assembly Instructions 1
BF67790,0001CC2 -19-28JAN20-2/3

IMPORTANT: If 4045SFM85 engine was manufactured

before 11/21/2019, the following additional
part will need to be ordered. Parts can be
ordered through the John Deere Production
Distribution Center (PDC).

RG32034 —UN—09JAN20
Additional Part

Number Part Number Description Quantity

1 DZ118162 Fuel Supply Line 1
BF67790,0001CC2 -19-28JAN20-3/3

DZ118318 (21FEB20) 3 022120

PN=5
 DZ117600

Remove Engine Components

Remove Exhaust Manifold and Turbocharger
Assembly (For 4045AFM85 Engine Only)
NOTE: For 4045SFM85 Engines, skip this section.

IMPORTANT: Avoid damage to fittings and/or fuel

lines. ALWAYS use a backup wrench.

IMPORTANT: Avoid component failure. Immediately

plug or cover ports to prevent dirt form
entering the fuel system.

NOTE: To avoid spills, use a drip tray when fuel, oil, or

RG31697 —UN—23OCT19
coolant connections are disconnected.

1. Disconnect wiring harness connectors (A, B, D, and E).

2. Remove flanged nut (F).
3. Using a backup wrench, remove flange nut (G).
NOTE: Retain hardware for reinstallation. Wiring Harness Removal

A—Suction Control Valve E—Fuel Rail Pressure Sensor

Connector Connector
B—Camshaft Position Sensor F— Flange Nut
Connector G—Flange Nut
C—High-Pressure
Common-Rail
D—Fuel Temperature Sensor
Connector

BF67790,0001CC3 -19-01NOV19-1/20

4. Disconnect the coolant temperature sensor connector

(D).
5. Using a backup wrench, remove flange nuts (B) from
the CCV mounting bracket (A) and double ended stud
(E).
6. Remove double ended stud from the exhaust manifold
(C).
7. Remove wiring harness and harness bracket (F). Set
aside to access the high-pressure common-rail.
NOTE: Retain hardware for reinstallation.

A—CCV Mounting Bracket D—Coolant Temperature

RG31698 —UN—13SEP19

B—Flange Nuts Sensor Connector

C—Exhaust Manifold E—Double Ended Stud
F— Harness Bracket

Wiring Harness Removal

Continued on next page BF67790,0001CC3 -19-01NOV19-2/20

DZ118318 (21FEB20) 4 022120

PN=6
 DZ117600

8. Using a backup wrench, disconnect charge air cooler

(CAC) coolant return line end nut (A).
9. Remove clamp cap screw (B), and end cap side hose
clamp (C).
NOTE: O-ring should remain on O-ring face seal
of straight adapter (D).

10. Remove coolant return line with P-clamp and hose

RG30097 —UN—15FEB18
at the end.

A—End Nut C—Endcap Side Hose Clamp

B—Clamp Cap Screw D—Straight Adapter

Coolant Return Line Removal

BF67790,0001CC3 -19-01NOV19-3/20

11. Loosen hose clamps (A) and remove cap screws (B).
12. Disconnect hoses (C) at thermostat cover (D) and
heat exchanger cover (E).

A—Hose Clamp D—Thermostat Cover

B—Cap Screw E—Heat Exchanger Cover
C—Hose

RG30098 —UN—10OCT19
Hose Clamp Removal
Continued on next page BF67790,0001CC3 -19-01NOV19-4/20

DZ118318 (21FEB20) 5 022120

PN=7
 DZ117600

13. Using a backup wrench, loosen turbocharger oil drain

line end nut (A).
14. Remove cap screws (F) and oil drain line (G).
15. Using a backup wrench, loosen turbocharger end oil
supply line end nut (B) and coolant supply line end
nut (C).
16. Loosen compressor end hose clamps (D) at air inlet
and outlet ports. Disconnect hoses.
NOTE: O-ring should remain on O-ring face
seal of fittings (E).

A—Oil Drain Line End Nut E—Fitting

B—Oil Supply Line End Nut F— Cap Screw
C—Coolant Supply Line End G—Oil Drain Line
Nut
D—Hose Clamp

RG30099 —UN—10OCT19
Line Removal
BF67790,0001CC3 -19-01NOV19-5/20

CAUTION: Avoid possible injury, assembly is

heavy. Plan a proper handling procedure
to avoid injury.

NOTE: Use guide pins if appropriate.

NOTE: Retain hardware for reinstallation.

NOTE: If turbocharger is removed separately, a NEW

RG30100 —UN—11OCT19
gasket is needed. Gasket is NOT included in the kit.

17. Loosen exhaust manifold mount cap screws

and remove complete assembly (A) of exhaust
manifold with thermostat cover, exhaust elbow, and
turbocharger from engine (B).

A—Exhaust Manifold B—Engine Exhaust Manifold Assembly Removal

Assembly

Continued on next page BF67790,0001CC3 -19-01NOV19-6/20

DZ118318 (21FEB20) 6 022120

PN=8
 DZ117600

18. Remove cap screws (B and H) and P-clamps (A).

19. Using a backup wrench, remove fuel supply line (C)
end nuts between the high-pressure fuel pump (E) and
the secondary fuel filter (F).
20. Using a backup wrench, remove elbow fitting (D).

RG31665 —UN—10OCT19
21. Install cap screw (B) onto bracket once the fuel supply
line is removed.
22. Go to removal of high-pressure fuel lines and
high-pressure common-rail section.

A—P-Clamp E—High-Pressure Fuel Pump Remove Fuel Supply Line

B—Cap Screw F— Secondary Fuel Filter
C—Fuel Supply Line H—Cap Screw
D—Elbow Fitting

RG31860 —UN—05NOV19
Remove Fuel Supply Line
BF67790,0001CC3 -19-01NOV19-7/20

Remove Left Hand Side Service Oil Filter Header

Assembly (For 4045SFM85 Engines Only)
NOTE: For right hand side service oil filter header
engines, skip this section.

NOTE: To avoid spills, use a drip tray when fuel, oil, or

coolant connections are disconnected.

1. Using a backup wrench, loosen oil inlet and outlet

lines (A) at oil filter header end (B).

A—Oil Inlet and Outlet Lines B—Oil Filter Header End

RG30109 —UN—05FEB18

Oil Inlet and Outlet Lines

Continued on next page BF67790,0001CC3 -19-01NOV19-8/20

DZ118318 (21FEB20) 7 022120

PN=9
 DZ117600

2. Remove cap screw (A).

3. Loosen bracket mount cap screw (B) and bolt (F) with
washer (E) from exhaust manifold (C).
4. Remove oil filter header assembly from the engine.

A—Cap Screw D—Oil Filter

B—Cap Screw E—Washer

RG31667 —UN—05SEP19
C—Exhaust Manifold F— Bolt

Remove Oil Filter Header

BF67790,0001CC3 -19-01NOV19-9/20

5. Reinstall and tighten cap screw (A) on fuel filter

bracket through front plate to specification.
Specification
Cap Screw—Torque....................................................... 35 N·m (26 lb·ft)

A—M8x40 Cap Screw

RG30047 —UN—05FEB18
Cap Screw
Continued on next page BF67790,0001CC3 -19-01NOV19-10/20

DZ118318 (21FEB20) 8 022120

PN=10
 DZ117600

Remove Heat Exchanger, Exhaust Manifold,

and Turbocharger Assembly (For 4045SFM85
Engines Only)
IMPORTANT: Avoid damage to fittings and/or fuel
lines. ALWAYS use a backup wrench.

IMPORTANT: Avoid component failure. Immediately

plug or cover ports to prevent dirt form
entering the fuel system.

RG30013 —UN—12JAN18
NOTE: To avoid spills, use a drip tray when fuel, oil, or
coolant connections are disconnected.

1. Disconnect harness connector (A).

2. Remove coolant tube mount P-clamp cap screw (E)
3. Loosen heat exchanger (B) side of the hose clamps 4045SFM85 Engine
(C). Disconnect hoses.
4. Loosen heat exchanger side vent line (D) end nut. A—Harness Connector D—Vent Line
B—Heat Exchanger E—P-Clamp Cap Screw
C—Hose Clamp

BF67790,0001CC3 -19-01NOV19-11/20

5. Loosen heat exchanger mount cap screws (A) and (C)

from the exhaust manifold and remove heat exchanger
(B) from the engine.
NOTE: Retain hardware for reinstallation.

A—M10 x 35 mm Cap Screw C—M10 x 170 mm Cap Screw

B—Heat Exhanger

RG30014 —UN—12JAN18
Heat Exchanger Removal
Continued on next page BF67790,0001CC3 -19-01NOV19-12/20

DZ118318 (21FEB20) 9 022120

PN=11
 DZ117600

6. Remove FIR-tree clip (K).

7. Disconnect wiring harness connectors (A, B, D, and E)
8. Remove cap screws (F) from the exhaust manifold
(C) and bracket (G).
9. Remove nut (H) from high-pressure common-rail stud.
10. Using a backup wrench, remove cap screw (J) from
stud (L).
NOTE: Retain hardware for reinstallation.

A—Suction Control Valve G—Bracket

Connector H—Nut
B—Camshaft Position Sensor I— P-Clamp

RG31668 —UN—10OCT19
Connector J— Cap Screw
C—Exhaust Manifold K—FIR-Tree Clip
D—Fuel Temperature Sensor L— Stud
Connector
E—Fuel Rail Pressure Sensor
Connector
F— Cap Screws

Remove Wiring Harness

BF67790,0001CC3 -19-01NOV19-13/20

11. Disconnect connectors (C and D).

12. Remove wiring harness mounting bracket cap screws
(A).
13. Set aside disconnected portion of wiring harness
with bracket (B) for clearance to remove the exhaust
manifold.
NOTE: Retain hardware for reinstallation.

A—Cap Screw C—Fuel Pressure Sensor

B—Harness Bracket Connector
D—Low-Pressure Fuel Pump
Connector

RG30051 —UN—10OCT19

Harness Bracket Mount

Continued on next page BF67790,0001CC3 -19-01NOV19-14/20

DZ118318 (21FEB20) 10 022120

PN=12
 DZ117600

14. Using a backup wrench, remove two fuel lines (A and

B).
NOTE: To avoid spills, use a drip tray when fuel, oil, or
coolant connections are disconnected.

15. Remove fuel filter mounting bracket cap screw (C).

A—Fuel Line to Secondary C—Cap Screw

B—Fuel Line Between Fuel
Filters

RG30016 —UN—10OCT19
Fuel Line Removal
BF67790,0001CC3 -19-01NOV19-15/20

16. Using a backup wrench, loosen turbocharger oil drain

line end nut (A) at oil pan.
17. Remove cap screws (J) from turbocharger oil drain
line. Remove turbocharger oil drain line.
18. Loosen compressor air inlet and outlet end hose
clamps (D). Disconnect hoses.
19. Using a backup wrench, loosen turbocharger oil
supply line end nut (B) at turbocharger.
NOTE: O-ring should remain on O-ring face
seal of fitting (E).

A—Oil Drain Line End Nut F— Turbocharger Oil Drain Line

B—Oil Supply Line End Nut G—Drain Line Gasket
D—Hose Clamps J— Cap Screws
E—Fitting

RG31834 —UN—10OCT19

Oil Drain Line

Continued on next page BF67790,0001CC3 -19-01NOV19-16/20

DZ118318 (21FEB20) 11 022120

PN=13
 DZ117600

CAUTION: Avoid possible injury, assembly is

heavy. Plan a proper handling procedure
to avoid injury.

NOTE: Use guide pins if appropriate.

NOTE: Retain hardware for reinstallation.

RG30020 —UN—10OCT19
NOTE: If turbocharger is removed separately, a NEW
gasket is needed. Gasket is NOT included in the kit.

20. Loosen exhaust manifold mount cap screws (A) and

remove complete assembly (B) of exhaust manifold,
turbocharger, and exhaust elbow with hose from the
engine.
Exhaust Manifold Assembly Removal
A—Cap Screw (11 used) B—Exhaust Manifold
Assembly

BF67790,0001CC3 -19-01NOV19-17/20

21. Remove cap screw (A) and P-clamp (B).

A—Cap Screw C—Fuel Supply Line

B—P-Clamp

RG31830 —UN—10OCT19
Remove Fuel Supply Line
BF67790,0001CC3 -19-01NOV19-18/20

22. Using a backup wrench,disconnect fuel supply line (A)

end nut at the high-pressure fuel pump (B). Remove
fuel supply line.

A—Fuel Supply Line B—High-Pressure Fuel Pump RG31831 —UN—10OCT19

Remove Fuel Supply Line

Continued on next page BF67790,0001CC3 -19-01NOV19-19/20

DZ118318 (21FEB20) 12 022120

PN=14
 DZ117600

High-Pressure Common Rail and High Pressure

Fuel Lines — Removal

CAUTION: Escaping diesel fuel under pressure

can have sufficient force to penetrate the skin,
causing serious injury. Before disconnecting
lines, be sure to relieve pressure. Before
applying pressure to the system, be sure that ALL
connections are tight and lines, pipes and hoses
are not damaged. Keep hands and body away
from pinholes and nozzles which eject fluid under
pressure. Use a piece of cardboard or wood,
rather than hands, to search for suspected leaks.

RG31669 —UN—10OCT19
If ANY fluid is injected into the skin, it must
be surgically removed within a few hours by
a doctor familiar with this type of injury or
gangrene may result. Doctors unfamiliar with
this type of injury may call the Deere & Company
Medical Department in Moline, Illinois, or another
knowledgeable medical source. Remove Fuel Lines

CAUTION: Fuel in the high-pressure common A—Starter E—Elbow Fitting

rail is under extremely high pressure. Do NOT B—High-Pressure Fuel Lines F— Common-Rail Mounting
C—High-Pressure Bracket
start this procedure until the engine has been Common-Rail G—Fuel Rail Pressure Sensor
turned OFF for at least 5 minutes. D—Fuel Return Line

IMPORTANT: ALWAYS use a backup wrench when

removing and/or installing fittings and/or
2. Using a backup wrench, remove fuel return lines (D)
fuel lines to avoid damage.
and elbow fitting (E).
IMPORTANT: Immediately plug or cover ports to 3. Using a backup wrench, remove all high-pressure fuel
prevent dirt from entering the fuel system. If lines (B).
any dirt, paint chips, or debris enters the fuel
system, component failure will occur. 4. Remove fuel rail pressure sensor (G).
5. Remove high-pressure common-rail (C) and
IMPORTANT: While removing the fuel line fitting, common-rail mounting bracket (F).
do not allow the inlet connector to turn. If
the inlet connector is allowed to turn, galling NOTE: Retain hardware for reinstallation.
might occur on the injector sealing surface.
This could case fuel leaks. NOTE: Retain fuel rail pressure sensor for reinstallation.

1. Remove cap screws and nut securing starter motor

(A) to flywheel housing. Remove starter.
BF67790,0001CC3 -19-01NOV19-20/20

DZ118318 (21FEB20) 13 022120

PN=15
 DZ117600

Install Double Wall Fuel Lines Kit

Components
Install Double Wall Fuel Lines
NOTE: Clean the sealing surfaces of cylinder head and

RG31832 —UN—10OCT19
exhaust manifold before installing new gasket.

1. Install new exhaust manifold gasket (A), available in

the kit.
2. Using a backup wrench, install fuel leak-off line (C)
between T-fitting (D) and straight adapter (E). Tighten
to specification.
Install Exhaust Manfold Gasket
Specification
End Nut—Torque..........................................................16 N·m (142 lb·in)
A—Exhaust Manifold Gasket D—T-Fitting
(RE551765) E—Straight Adapter
B—Guide Pins
C—Fuel Leak-Off Line

Continued on next page BF67790,0001CC4 -19-09JAN20-1/50

DZ118318 (21FEB20) 14 022120

PN=16
 DZ117600

3. Install spray shield cast bracket (A) onto cylinder block

using two existing M10 cap screws (B). Tighten cap
screws to specification.
Specification
M10 Cap
Screws—Torque............................................................. 69 N·m (51 lb·ft)

4. Install common-rail into spray shield cast bracket

using two M10 x 45 mm cap screws (D) available in
kit. Do not tighten cap screws at this time.

A—Spray Shield Cast Bracket C—High-Pressure

RG31546 —UN—05AUG19
(DZ118084) Common-Rail
B—M10 Cap Screws D—M10 x 45 mm Cap Screws
(19M8320)

Spray Shield Cast Bracket

RG31548 —UN—01OCT19
Common-Rail into Spray Shield Cast Bracket
Continued on next page BF67790,0001CC4 -19-09JAN20-2/50

DZ118318 (21FEB20) 15 022120

PN=17
 DZ117600

5. Install top spray shield cover (B) onto cast bracket (C)
with three M6 x 10 mm button head cap screws (A)
and tighten to specification.
Specification
M6X10 Button Head Cap
Screws—Torque...............................................................6 N·m (53 lb·in)

A—M6 x 10 mm Button Head C—Spray Shield Cast Bracket

Cap Screws
B—Top Spray Shield Cover
(DZ118085)

RG31550 —UN—10OCT19
Spray Shield Cover
Continued on next page BF67790,0001CC4 -19-09JAN20-3/50

DZ118318 (21FEB20) 16 022120

PN=18
 DZ117600

IMPORTANT: To avoid contamination, thoroughly

clean all fuel lines, fittings, components,
and chamfered area. If any direct paint
chips or debris enters the fuel system,
injector failure will occur.

RG31246 —UN—26MAR19
IMPORTANT: Avoid damage to fittings and/or fuel
lines. ALWAYS use a backup wrench.

IMPORTANT: Avoid fuel leaks. While tightening

the fuel delivery line nut, do not allow the
inlet connector to turn. If the inlet connector
is allowed to turn, galling might occur on
the injector sealing surface. High-Pressure Fuel Line Installation

IMPORTANT: High-pressure injection lines are

one time use only. If any sets of lines are
removed, discard and replace.

6. Install high-pressure double wall fuel line (A) onto

high-pressure common-rail and high-pressure fuel
pump. Do not tighten at this time.

RG31670A —UN—09JAN20
7. Install high-pressure double wall fuel line (B) onto
high-pressure common-rail. Then install onto the fuel
feed tube. Do not tighten at this time.
8. Pre-assemble three-pipe clamp (F) onto high-pressure
fuel lines (C, D, and E). Tighten clamp bolts so lines
are held in place.
High-Pressure Fuel Line Installation
NOTE: Fuel line (E) should be placed over line
(D) at location (G).

9. Install fuel line assembly onto the common-rail. Then

install onto the side feed tubes. Do not tighten at this
time.

RG31671A —UN—09JAN20
A—High-Pressure Fuel Line E—High-Pressure Fuel Line
(DZ118079) (RE566447)
B—High-Pressure Fuel Line F— Three-Pipe Clamp
(RE566448) (RE502655)
C—High-Pressure Fuel Line G—Orientation Location
(RE566449)
D—High-Pressure Fuel Line
(DZ108891)
High-Pressure Fuel Line Installation

RG32035 —UN—09JAN20

High-Pressure Fuel Line Installation

Continued on next page BF67790,0001CC4 -19-09JAN20-4/50

DZ118318 (21FEB20) 17 022120

PN=19
 DZ117600

10. Install two-pipe clamps (B) onto high-pressure fuel

lines. Do not tighten at this time.
11. Using a backup wrench, tighten all high-pressure fuel
line end fittings to specification.
Specification

RG31672A —UN—09JAN20
High-Pressure Fuel Lines
End Fittings—Torque...................................................... 40 N·m (30 lb·ft)

12. Tighten all pipe clamps to specification.

Specification
Fuel Line
Clamps—Torque...............................................................5 N·m (44 lb·in)
Install High-Pressure Fuel Lines
A—Three-Pipe Clamp B—Two-Pipe Clamp
(RE502655) (RE502654)

BF67790,0001CC4 -19-09JAN20-5/50

13. Install drain line (E) onto the spray shield drain port (B)
with the banjo bolt (D) through the washers (C) and
line banjo to the spray shield cast bracket (A). Do not
tighten at this time.

A—Spray Shield Cast Bracket D—Banjo Bolt (R543538)

RG31553A —UN—09JAN20
B—Spray Shield Drain Port E—Fuel Drain Line (RE566443)
C—Sealing Washers (R523069)

Drain Line Installation

Continued on next page BF67790,0001CC4 -19-09JAN20-6/50

DZ118318 (21FEB20) 18 022120

PN=20
 DZ117600

14. Install the fuel line (A) fitting at common-rail.

A—Fuel Line (RE566438)

RG31554 —UN—10OCT19
Fuel Line Installation
BF67790,0001CC4 -19-09JAN20-7/50

15. Rotate the line until two-pipe clamp is installed.

RG31555 —UN—01OCT19

Rotate Fuel Line

Continued on next page BF67790,0001CC4 -19-09JAN20-8/50

DZ118318 (21FEB20) 19 022120

PN=21
 DZ117600

16. Install the two-pipe clamp (B) between two lines as

shown. Tighten banjo bolt (A) to specification.
Specification
Banjo Bolt—Torque......................................................20 N·m (177 lb·in)

A—Banjo Bolt (R543538) B—Two-Pipe Clamp

(RE566445)

RG31808 —UN—02OCT19
Two-Pipe Clamp
BF67790,0001CC4 -19-09JAN20-9/50

17. Rotate the fuel line (C) back to the previous position.
Using a backup wrench, tighten the line end fitting to
high-pressure fuel pump fitting (B). Tighten both end
of line fittings to specification.
Specification
Fuel Line
Fittings—Torque............................................................. 40 N·m (30 lb·ft)

18. Tighten two-pipe clamp (A) to specification.

RG31557 —UN—01OCT19
Specification
Two-Pipe
Clamp—Torque................................................................7 N·m (62 lb·in)

A—Two-Pipe Clamp C—Fuel Line (RE566438)

(RE566445)
B—High-Pressure Fuel Pump
Re-Rotate and Install Fuel Line (RE566438)
Fitting

BF67790,0001CC4 -19-09JAN20-10/50

19. Using a backup wrench, install a common-rail adapter

(A) with O-ring (available in kit) on the common rail
pressure limiter (B). Tighten to specification.
Specification
Common Rail Adapter to
RG31675A —UN—09JAN20

Common Rail Pressure

Limiter—Torque............................................................15 N·m (133 lb·in)

A—Common-Rail Adapter B—Common-Rail Pressure

(RE566440) Limiter

Common-Rail Adapter Installation

Continued on next page BF67790,0001CC4 -19-09JAN20-11/50

DZ118318 (21FEB20) 20 022120

PN=22
 DZ117600

20. Install fuel return line (D) onto the common-rail using
banjo bolt (A) and sealing washers (B).
21. Install fuel line end nut (E) to fitting (F).
22. Using a backup wrench, tighten the banjo bolt and fuel
line end nut to specification.

RG31676A —UN—09JAN20
Specification
Banjo Bolt—Torque......................................................20 N·m (177 lb·in)
Line Fitting End
Nut—Torque.................................................................16 N·m (142 lb·in)

A—Banjo Bolt (R543538) D—Fuel Return Line

B—Sealing Washers (R523069) (RE566441) Fuel Return Line
C—Common Rail Adapter with E—Fuel Return Line End Nut
O-Ring (RE566440) F— T-Fitting

BF67790,0001CC4 -19-09JAN20-12/50

23. Tighten two M10 cap screws to specification.

Specification
M10 Cap
Screws—Torque............................................................. 69 N·m (51 lb·ft)

RG31677A —UN—09JAN20
A—High-Pressure B—M10 Cap Screw
Common-Rail

Torque Common-Rail
BF67790,0001CC4 -19-09JAN20-13/50

24. Reinstall the pressure sensor (A) onto the

high-pressure common-rail (B) and tighten to
specification.
Specification
Pressure Sensor to
Common-Rail—Torque................................................. 100 N·m (74 lb·ft)

RG31833 —UN—15OCT19
A—Common-Rail Pressure B—High-Pressure
Sensor Common-Rail

Reinstall Pressure Sensor

Continued on next page BF67790,0001CC4 -19-09JAN20-14/50

DZ118318 (21FEB20) 21 022120

PN=23
 DZ117600

25. Install front spray shield cover (A) onto spray shield
cast bracket (D) by sliding it into the top spray shield
cover (C).
26. Tighten button head cap screws (B) to specification.
Specification

RG31678 —UN—05SEP19
M6 Button Head Cap
Screw—Torque.................................................................6 N·m (53 lb·in)

A—Front Spray Shield Cover C—Top Spray Shield Cover

(DZ118086) (DZ118085)
B—M6 x 10 mm Button head D—Spray Shield Cast Bracket
Cap Screws (DZ118084)
Spray Shield Cover Installation
BF67790,0001CC4 -19-09JAN20-15/50

Fuel Line Reinstallation (For 4045AFM85 Engine Only)

NOTE: For 4045SFM85 engines, skip this section.

NOTE: Fuel supply line is ONLY compatible with the

Racor fuel filter. Racor fuel filter assembly is

RG31679 —UN—13SEP19
available in a different kit.

1. Using a backup wrench, temporarily remove

low-pressure fuel line (A) to access the fuel injection
pump fuel supply port (B).

A—Low-Pressure Fuel Line B—Injection Pump Fuel Supply

Port Low-Pressure Fuel Line Removal

BF67790,0001CC4 -19-09JAN20-16/50

2. Install adapter (A) at injection pump supply port (B).

Specification
Adapter—Torque............................................................ 40 N·m (30 lb·ft)

A—Adapter (DZ10419) B—Injection Pump Fuel Supply

Port

RG31680 —UN—13SEP19

Install Adapter
Continued on next page BF67790,0001CC4 -19-09JAN20-17/50

DZ118318 (21FEB20) 22 022120

PN=24
 DZ117600

3. Install fuel supply line (B) between adapters. Clamp

(C) the line on spray shield cast bracket (D). Tighten
clamp to specification.
Specification
Clamps to Spray Shield
Bracket—Torque...............................................................7 N·m (62 lb·in)

RG31681 —UN—05SEP19
4. Install two 2-pipe clamps (E) at rear side of the fuel
supply line and tighten clamp cap screws to air filter
mount bracket (F). Tighten to specification.
Specification
Clamp Cap Screws to
Bracket—Torque............................................................. 69 N·m (51 lb·ft) Fuel Supply Line (4045AFM85 engines only)

A—High-Pressure Fuel Pump D—Spray Shield Cast Bracket

B—Fuel Supply Line E—Pipe Clamp
(DZ113841) F— Air Filter Mounting Bracket
C—Clamp

BF67790,0001CC4 -19-09JAN20-18/50

5. Using a backup wrench, tighten fuel supply line (C)

end fittings to specification.
Specification
Fuel Supply Line
Fitting—Torque.............................................................24 N·m (212 lb·in)

C—Fuel Supply Line F— Secondary Fuel Filter

(DZ113841) Assembly

RG31909 —UN—05NOV19
Install Fuel Supply Line
BF67790,0001CC4 -19-09JAN20-19/50

6. Clamp fuel supply line (C) with turbocharger oil

supply line (A) using a two-pipe clamp (B). Tighten
to specification.
Specification
Hose Clamp—Torque.......................................................7 N·m (62 lb·in)
RG31683 —UN—10OCT19

A—Turbocharger Oil Supply C—Fuel Supply Line

Line (DZ113841)
B—Two-Pipe Clamp
(RE568649)

Install Pipe Clamp

Continued on next page BF67790,0001CC4 -19-09JAN20-20/50

DZ118318 (21FEB20) 23 022120

PN=25
 DZ117600

7. Reinstall the low-pressure fuel line (A) between elbow

fitting (B) and tee fitting (C).
8. Using a backup wrench, tighten fuel line end nuts to
specification.
Specification

RG31684 —UN—05SEP19
Low-Pressure Fuel Line
End Nuts—Torque........................................................16 N·m (142 lb·in)

9. Go to Alarm Tank Installation Section.

A—Low-Pressure Fuel Line C—Tee Fitting

B—Elbow Fitting
Install Low-Pressure Fuel Line
BF67790,0001CC4 -19-09JAN20-21/50

Fuel Line Reinstallation (For 4045SFM85 Engine Only)

NOTE: For 4045AFM85 engines, skip this section.

1. Using a backup wrench, temporarily remove

low-pressure fuel line (A) to access the fuel injection

RG31840 —UN—16OCT19
pump fuel supply port (B).

A—Low-Pressure Fuel Line B—Injection Pump Fuel Supply

Port

Low-Pressure Fuel Line Removal

BF67790,0001CC4 -19-09JAN20-22/50

2. Install fuel supply line (A) onto straight adapter (B)

on the high-pressure fuel pump (C). Do not tighten
at this time.

A—Fuel Supply Line C—High-Pressure Fuel Pump

B—Adapter

RG31841 —UN—11OCT19

Install Adapter
Continued on next page BF67790,0001CC4 -19-09JAN20-23/50

DZ118318 (21FEB20) 24 022120

PN=26
 DZ117600

3. Install P-clamp (A) and cap screw (B). Do not tighten

at this time.
4. Using a backup wrench, tighten fuel supply line end
nut to specification.
Specification

RG31842 —UN—11OCT19
Line End Nut—Torque..................................................24 N·m (212 lb·in)

A—P-Clamp B—Cap Screw

Install Fuel Line

BF67790,0001CC4 -19-09JAN20-24/50

5. Reinstall the low-pressure fuel line (A) between elbow

fitting (B) and T-fitting (C).
6. Using a backup wrench, tighten fuel line end nuts to
specification.
Specification

RG31843 —UN—11OCT19
Low-Pressure Fuel Line
End Nuts—Torque........................................................16 N·m (142 lb·in)

A—Low-Pressure Fuel Line C—T-Fitting

B—Elbow Fitting

Install Low-Pressure Fuel Line

Continued on next page BF67790,0001CC4 -19-09JAN20-25/50

DZ118318 (21FEB20) 25 022120

PN=27
 DZ117600

Install Alarm Tank Assembly

NOTE: A complete double wall fuel line kit is supplied
with an alarm tank. The alarm tank should
be connected to either the engine electronic
management system or to an audible or visual

RG31685 —UN—05SEP19
alarm to indicate a failure in the fuel system.

1. Mount the alarm tank vertically with the inlet

connections at the bottom.
2. Depending on engine access, mount the tank at
either end of the engine using mounting kit hardware.
Tighten cap screws to specification.
Alarm Tank Assembly
Specification
M8 x 40 Cap
A—Alarm Tank Assembly C—Flexible Hose (RE528054)
Screw—Torque............................................................... 32 N·m (24 lb·ft) (RE528059) D—Drain Line (RE566443)
B—Alarm Tank Mounting Kit
NOTE: Be sure hose connecting the alarm tank to the (RE528060)
drain line meets applicable regulatory requirements.

3. Connect the alarm tank to the drain line using the

supplied blue hose. Using a backup wrench, tighten IMPORTANT: DO NOT block the vent pipe at any time.
end fittings to specification.
NOTE: If the vent or overflow pipe is routed to a suitable
Specification collection tank, the collection tank must be vented
Hose End to atmospheric pressure. Failure to do this may
Fitting—Torque.............................................................16 N·m (142 lb·in) result in an air lock preventing fuel from entering
4. The vent pipe may be left open to allow for spills to the alarm tank and setting the alarm.
drip into a tray below the alarm tank or routed to a
suitable collection tank.
Continued on next page BF67790,0001CC4 -19-09JAN20-26/50

DZ118318 (21FEB20) 26 022120

PN=28
 DZ117600

A N/O E
Alarm
L Float N
C Switch
D F

RG27919 —UN—08MAR16

RG27920 —UN—08MAR16
B N/C E
Alarm
L Float N
C Switch
D F

Wiring Diagram
Alarm Tank
5. Connect float switch to alarm system. Refer to the
electrical details.
Tank Body: Cast Aluminum
Float Assembly: Stainless Steel Body and Buna-n Float
Tank Weight: 750 grams
Tank Dimensions: 140 mm x 50 mm Diameter
Electrical: Connection by Terminal Block
Maximum Voltage: 300 V AC/DC
Maximum Current: 0.5 A
Temperature Range: -10°C to 100°C
Continued on next page BF67790,0001CC4 -19-09JAN20-27/50

DZ118318 (21FEB20) 27 022120

PN=29
 DZ117600

NOTE: The alarm tank float switch is shipped in the

normally closed configuration. Refer to the following
instructions to change the switch to normally open.

6. If alarm tank is already in use, drain any fuel from

the tank. Loosen the cap nut (E) to drain fuel from
alarm tank.
7. If loosened, retighten cap nut to specification.
Specification
Cap Nut—Torque..........................................................16 N·m (142 lb·in)

8. Remove bottom cap of alarm tank.

9. Remove retainer clip from the stem.

RG27921 —UN—08MAR16
10. Remove the float. Invert the float and replace it on
the stem.
11. Install retainer clip onto the stem.
12. Reassemble the bottom cap. Tighten to specification.
Specification
Bottom Cap—Torque......................................................45 N·m (33 lb·in) Configuring Float Switch

NOTE: Maintenance should be done on a regular basis:

A—Stem D—Alarm Tank Cap
• Weekly — Visual inspection of all bracketing B—Float
C—Retainer Clip
E—Cap Nut
and connections.
• Monthly — Check alarm tank switching by raising
float and monitoring signal. Always clean fuel pipe
mating surfaces before disconnecting any parts. intervals. Fill engine with proper amount of
engine oil and engine coolant as specified
IMPORTANT: Check engine oil and coolant levels. in the Operator’s Manual.
Run the engine multiple times for short
BF67790,0001CC4 -19-09JAN20-28/50

13. Install support bracket (C) using M8 cap screw (B)

and M14 cap screw (D). Tighten cap screws to
specification.
Specification
M8 Cap Screw to Cast
Bracket—Torque............................................................. 32 N·m (24 lb·ft)

RG31686 —UN—05SEP19
M14 Cap Screw to
Cylinder Block—Torque.............................................. 174 N·m (128 lb·ft)

A—Common-Rail Enclosure D—M14 Cap Screw

B—M8 Cap Screw E—Cylinder Block
C—Support Bracket
(RE566442)
Install Bracket
Continued on next page BF67790,0001CC4 -19-09JAN20-29/50

DZ118318 (21FEB20) 28 022120

PN=30
 DZ117600

Reinstall Starter Motor

NOTE: This kit is compatible with insulated
ground started only.

NOTE: Ground cable is not provided in the kit.

RG31687 —UN—05NOV19
1. Attach ground cable (D) to stater before installing.
2. Reinstall the starter motor (A) on the engine using
existing M10 cap screws (C) and nut (B). Tighten to
specification.
Specification
Starter to Stater Motor Installation
Engine—Torque.............................................................. 69 N·m (51 lb·ft)
A—Starter Motor C—Cap Screw
B—Nut D—Ground Cable

BF67790,0001CC4 -19-09JAN20-30/50

Reinstall Exhaust Manifold Assembly,

Turbocharger, and Exhaust Elbow Assembly
(For 4045AFM85 Engines Only)
NOTE: For 4045SFM85 Engines, skip this section.

CAUTION: Assembly is heavy. Avoid possible

injury, plan a proper lifting procedure.

NOTE: Guide pins can be used to aid with installation.

RG30103 —UN—10OCT19
1. Reinstall complete assembly (B) of exhaust
manifold with thermostat cover, exhaust elbow, and
turbocharger on the engine (C).

A—Exhaust Manifold Gasket C—Engine

B—Exhaust Manifold
Assembly Reinstall Exhaust Manifold

BF67790,0001CC4 -19-09JAN20-31/50

2. Tighten cap screws to specification per torque

sequence.
Specification
Exhaust Manifold
Assembly Cap Screws to
Cylinder Head—Torque.................................................. 69 N·m (51 lb·ft)
RG30104 —UN—01FEB18

• M10 x 100 mm Cap Screw (4 used)

• M10 x 180 mm Cap Screw (7 used)

Torque Sequence
Continued on next page BF67790,0001CC4 -19-09JAN20-32/50

DZ118318 (21FEB20) 29 022120

PN=31
 DZ117600

3. Connect hoses (C) at thermostat cover (D) and heat

exchanger cover (E). Tighten hose clamps (B) to
specification.
Specification
Hose Clamp—Torque.......................................................7 N·m (62 lb·in)

4. Tighten cap screws (F) to specification.

Specification
Cap Screw—Torque....................................................... 35 N·m (26 lb·ft)

5. Tighten coolant pump tube mount cap screw (A) to

specification.
Specification
Tube Cap Screw to
Cylinder Block—Torque................................................ 100 N·m (74 lb·ft)

A—M16 x 25 mm Cap Screw D—Thermostat Cover

B—Hose Clamp E—Heat Exchanger Cover
C—Hose F— M10 x 30 mm Cap Screws

RG30105 —UN—10OCT19
Hose Clamp Reinstallation
Continued on next page BF67790,0001CC4 -19-09JAN20-33/50

DZ118318 (21FEB20) 30 022120

PN=32
 DZ117600

6. Install drain line (F) with new gasket (G) (available in

the kit) onto the turbocharger. Tighten cap screws (J)
to specification.
Specification
Cap Screws—Torque..................................................... 35 N·m (26 lb·ft)

7. Using a backup wrench, tighten the turbocharger oil

drain line end nut (A) and coolant supply line end nut
(C) to specification.
Specification
Line End Nuts—Torque................................................ 102 N·m (75 lb·ft)

8. Using a backup wrench, tighten the turbocharger oil

supply line end nut (B) to specification.
Specification
Line End Nut—Torque..................................................24 N·m (212 lb·in)

9. Tighten the compressor end hose clamps (D) at air

inlet and outlet ports to specification.
Specification
End Hose

RG31688 —UN—16OCT19
Clamps—Torque...............................................................7 N·m (62 lb·in)

NOTE: O-ring should remain on O-ring face

seal of fittings (E).

A—Oil Drain Line End Nut E—Fitting

B—Oil Supply Line End Nut F— Turbocharger Drain Line
C—Coolant Supply Line End G—Gasket (R521158)
Nut J— Cap Screws Reinstall Oil Lines
D—Hose Clamps

BF67790,0001CC4 -19-09JAN20-34/50

10. Reinstall charge air cooler (CAC) coolant return line

between thermostat cover (A) and CAC end cap (B).
11. Install P-clamp (H) on coolant return line. Tighten cap
screw (C) on bracket (D) to specification.
Specification

RG31689 —UN—10OCT19
P-Clamp Cap
Screw—Torque............................................................... 69 N·m (51 lb·ft)

12. Using a backup wrench. tighten line end nut (E) to

specification.
Specification
Line End Nut—Torque.................................................. 102 N·m (75 lb·ft)
Reinstall Coolant Return Line
13. Tighten hose clamp (F) to specification.
Specification A—Thermostat Cover E—Line End Nut
Hose Clamp—Torque.......................................................6 N·m (53 lb·in) B—CAC End Cap F— Hose Clamp
C—Cap Screw G—Straight Adapter
NOTE: O-ring should remain on O-ring face seal D—Bracket H—P-Clamp
of straight adapter (G).

Continued on next page BF67790,0001CC4 -19-09JAN20-35/50

DZ118318 (21FEB20) 31 022120

PN=33
 DZ117600

14. Reinstall harness bracket (A) on exhaust manifold (B)

and CCV mounting bracket (E) with double ended
stud (C) and nut (D).
15. Tighten double ended stud to specification.
Specification
Double Ended
Stud—Torque................................................................. 35 N·m (26 lb·ft)

16. Using a backup wrench, tighten nut (D) to specification.

Specification
Nut—Torque................................................................... 69 N·m (51 lb·ft)

17. Install harness with P-clamp (F) onto double ended

stud.

RG31690 —UN—05SEP19
18. Using a backup wrench, tighten nut (H) to specification.
Specification
Nut—Torque................................................................... 35 N·m (26 lb·ft)

19. Reconnect coolant temperature sensor connector (G).

A—Harness Bracket E—CCV Mounting Bracket Reinstall Wiring Harness

B—Exhaust Manifold F— Harness P-Clamp
C—M8 Double Ended Stud G—Coolant Temperature
D—M10 Nut Sensor Connector
H—M8 Nut

BF67790,0001CC4 -19-09JAN20-36/50

20. Install P-clamp and nut (D). Using a backup wrench,

tighten to specification.
Specification
Nut—Torque................................................................... 35 N·m (26 lb·ft)

21. Install P-clamp and button head cap screw (F). Tighten

RG31691 —UN—05SEP19
to specification.
Specification
Button Head Cap
Screw—Torque.................................................................7 N·m (62 lb·in)

22. Reconnect suction control valve connector (A).

23. Reconnect camshaft position sensor connector (B). Reinstall Wiring Harness

24. Reconnect fuel rail pressure sensor connector (E).

A—Suction Control Valve D—Nut
25. Reconnect fuel temperature sensor connector (C). Connector E—Fuel Rail Pressure Sensor
B—Camshaft Position Sensor Connector
Connector F— Button Head Cap Screw
C—Fuel Temperature Sensor
Connector

Continued on next page BF67790,0001CC4 -19-09JAN20-37/50

DZ118318 (21FEB20) 32 022120

PN=34
 DZ117600

Reinstall Exhaust Manifold Assembly,

Turbocharger, and Exhaust Elbow Assembly
(For 4045SFM85 Engines Only)

CAUTION: Avoid possible injury, assembly is

heavy. Plan a proper handling procedure
to avoid injury.

NOTE: Use guide pins if appropriate.

1. Reinstall complete assembly (B) of exhaust manifold,

turbocharger, and exhaust elbow with hose on the
engine.

RG31847 —UN—16OCT19
A—Exhaust Manifold Gasket C—M10 x 190 mm Cap Screw
(RE551765)
B—Exhaust Manifold
Assembly

Exhaust Manifold Installation

BF67790,0001CC4 -19-09JAN20-38/50

2. Tighten cap screws (C) to specification per torque

sequence.
Specification
Exhaust Manifold
Assembly Cap Screws to
Cylinder Head—Torque.................................................. 69 N·m (51 lb·ft)

RG30030 —UN—12JAN18
Torque Sequence
Continued on next page BF67790,0001CC4 -19-09JAN20-39/50

DZ118318 (21FEB20) 33 022120

PN=35
 DZ117600

3. Install gasket (G) (available in the kit) and turbocharger

oil drain line (F) onto the turbocharger. Tighten cap
screws (J) to specification.
Specification
Cap Screws—Torque..................................................... 35 N·m (26 lb·ft)

4. Using a backup wrench, tighten the turbocharger oil

drain line end nut (A) to specification.
Specification
Line End Nut—Torque.................................................. 102 N·m (75 lb·ft)

5. Using a backup wrench, tighten the turbocharger oil

supply line end nut (B) to specification.
Specification
Line End Nut—Torque..................................................24 N·m (212 lb·in)

6. Tighten the compressor end hose clamps (D) at air

inlet and outlet ports to specification.
Specification
Line End Nut—Torque......................................................7 N·m (62 lb·in)

NOTE: O-ring should remain on O-ring face

RG31834 —UN—10OCT19
seal of fitting (E).

A—Oil Drain Line End Nut F— Turbocharger Oil Drain Line

B—Oil Supply Line End Nut G—Gasket (R521158)
D—Hose Clamps J— M8 x 25 mm Cap Screws
E—Fitting

Oil Supply and Drain Line

Continued on next page BF67790,0001CC4 -19-09JAN20-40/50

DZ118318 (21FEB20) 34 022120

PN=36
 DZ117600

7. Tighten cap screw (A) to exhaust manifold through

fuel filter mount bracket (B) to specification.
Specification
Cap Screw Through Filter
Bracket—Torque............................................................. 69 N·m (51 lb·ft)

8. Tighten cap screws (C and E) to exhaust manifold

through harness bracket (D) to specification.
Specification
Cap Screw
Through Harness
Bracket—Torque............................................................. 35 N·m (26 lb·ft)

9. Tighten cap screws (F) to fan support through harness

bracket (D). Tighten cap screws to specification.

RG31835 —UN—10OCT19
Specification
Cap Screw Through Fan
Support—Torque............................................................ 69 N·m (51 lb·ft)

10. Reconnect fuel pressure sensor connector (G) and

low-pressure fuel pump connector (H).
Bracket Installation
A—M10 x 55 mm Cap Screw E—M8 x 65 mm Cap Screw
B—Fuel Filter Mount Bracket F— M10 x 20 mm Cap Screw
C—M8 x 90 mm Cap Screw G—Fuel Pressure Sensor
D—Harness Bracket Connector
H—Low-Pressure Fuel Pump
Connector

Continued on next page BF67790,0001CC4 -19-09JAN20-41/50

DZ118318 (21FEB20) 35 022120

PN=37
 DZ117600

IMPORTANT: Avoid damage to fittings and/or fuel

lines. ALWAYS use a backup wrench.

NOTE: For front left-hand side service oil filter options,

install fuel line (C) after oil filter is reinstalled.

11. Reinstall fuel line (A) between secondary fuel filter

fuel outlet port (D) and injection pump connected fuel
supply line (B).
12. Using a backup wrench, tighten supply line end nuts
to specification.
Specification
Fuel Line End
Nuts—Torque...............................................................24 N·m (212 lb·in)

RG31848 —UN—16OCT19
13. Tighten P-clamp (E) mounting cap screw (F) to
specification.
Specification
Cap Screw—Torque....................................................... 35 N·m (26 lb·ft)

14. Reinstall fuel line (C) between both fuel filters. Tighten
line end nuts to specification. Fuel Lines Installation

Specification
Fuel Line End A—Fuel Line to Secondary D—Fuel Outlet Port
Filter E—P-Clamp
Nuts—Torque...............................................................24 N·m (212 lb·in)
B—Fuel Supply Line F— Cap Screw
C—Fuel Line Between Fuel
Filters

Continued on next page BF67790,0001CC4 -19-09JAN20-42/50

DZ118318 (21FEB20) 36 022120

PN=38
 DZ117600

15. Install harness P-clamp with cap screw (H) on stud (I).
Using a backup wrench, tighten to specification.
Specification
Cap Screw—Torque.....................................................24 N·m (212 lb·in)

16. Install harness P-clamps with cap screws (J) on the

bottom of the exhaust manifold (K) and bracket (D).
Tighten cap screws to specification.
Specification
Cap Screw—Torque.....................................................24 N·m (212 lb·in)

17. Install FIR-tree clip (G).

18. Install P-clamp and button head cap screw (F). Tighten
to specification.

RG31692 —UN—10OCT19
Specification
Button Head Cap
Screw—Torque.................................................................7 N·m (62 lb·in)

19. Reconnect suction control valve connector (A).

20. Reconnect camshaft position sensor connector (B).
Reinstall Wiring Harness
21. Reconnect fuel rail pressure sensor connector (E).
22. Reconnect fuel temperature sensor connector (C). A—Suction Control Valve G—FIR-Tree Clip
Connector H—M8 Cap Screw
B—Camshaft Position Sensor I— Stud
Connector J— M8 Cap Screw
C—Fuel Temperature Sensor K—Exhaust Manifold
Connector
D—Bracket
E—Fuel Rail Pressure Sensor
Connector
F— Button Head Cap Screw

BF67790,0001CC4 -19-09JAN20-43/50

Reinstall Heat Exchanger Assembly (For

4045SFM85 Engines Only)
1. Replace the O-ring (A) (available in the kit) on the
exhaust manifold (B).

A—O-Ring (DZ114031) B—Exhaust Manifold

RG30037 —UN—05FEB18

O-Ring
Continued on next page BF67790,0001CC4 -19-09JAN20-44/50

DZ118318 (21FEB20) 37 022120

PN=39
 DZ117600

2. Reinstall heat exchanger assembly (F) on exhaust

manifold by tightening cap screws (D and I) while
inserting end cap port in seawater inlet hose (E) and
thermostat cover port in coolant tube end hose (B).
3. Tighten coolant tube P-clamp cap screw (A) to
specification.
Specification
P-clamp Cap
Screw—Torque............................................................... 63 N·m (46 lb·ft)

4. Insert exhaust elbow end hose (H) over heat

exchanger end cap outlet port.
5. Torque heat exchanger end hose clamps (C) to
specification.

RG31693 —UN—10OCT19
Specification
Hose Clamps—Torque.....................................................7 N·m (62 lb·in)

6. Reconnect coolant temperature connector (G).

A—M10 x 20 mm P-Clamp Cap F— Heat Exchanger Assembly

Screw G—Coolant Temperature Reinstall Heat Exchanger
B—Coolant Tube End Hose Connector
C—Heat Exchanger End Hose H—Exhaust Elbow End Hose
Clamp I— M10 x 35 mm Cap Screw
D—M10 x 170 mm Cap Screw
E—Seawater Inlet Hose

Continued on next page BF67790,0001CC4 -19-09JAN20-45/50

DZ118318 (21FEB20) 38 022120

PN=40
 DZ117600

7. Tighten all cap screws to specification per torque

sequence.
Specification
Cap Screws to Exhaust
Manifold—Torque........................................................... 69 N·m (51 lb·ft)

RG30040 —UN—05FEB18
RG30041 —UN—12JAN18
Heat Exchanger Cap Screw Torque Sequence
BF67790,0001CC4 -19-09JAN20-46/50

8. Using a backup wrench, tighten coolant vent line

(B) end fitting to adapter at heat exchanger (A) to
specification.
Specification
Line End Nut—Torque....................................................10 N·m (89 lb·in)

A—Heat Exchanger B—Coolant Vent Line RG30039 —UN—12JAN18

Coolant Vent Line

Continued on next page BF67790,0001CC4 -19-09JAN20-47/50

DZ118318 (21FEB20) 39 022120

PN=41
 DZ117600

Reinstall Left hand Service Oil Filter Header Assembly

(For 4045SFM85 Engines Only)
NOTE: For right-hand side service oil filter engines,
skip this section.

1. Remove cap screw (A).

A—Cap Screw

RG30048 —UN—05FEB18
Cap Screw Removal
BF67790,0001CC4 -19-09JAN20-48/50

2. Reinstall complete assembly of bracket with oil filter

header and canister (E) on the exhaust manifold using
cap screw (B) and bolt (C) with washer (D). Tighten
cap screws to specification.
Specification
Cap Screws to Exhaust
Manifold—Torque........................................................... 69 N·m (51 lb·ft)

3. Reinstall and tighten cap screw (A) on fuel filter bracket

through oil filter bracket and front plate to specification.
Specification
Cap Screws to Fuel Filter
Bracket—Torque............................................................. 35 N·m (26 lb·ft)

RG31695 —UN—05SEP19
A—Cap Screw E—Oil Filter Header and
B—M10 x 30 mm Cap Screw Canister Assembly
C—M10 x 35 mm Bolt F— Fuel Filter Bracket
D—Washer G—Oil Filter Bracket
H—Front Plate

Reinstall Oil Filter Header

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4. Reinstall oil inlet line (A) at oil filter header end (C).
5. Using a backup wrench, tighten line (A) end fitting to
specification.
Specification
Line End
Fitting—Torque............................................................... 69 N·m (51 lb·ft)

6. Reinstall oil inlet line (B) at oil filter header end (C).
7. Using a backup wrench, tighten line (B) end fitting to
specification.
Specification
Line End
Fitting—Torque............................................................... 69 N·m (51 lb·ft)

RG31696 —UN—06NOV19
A—Oil Inlet Line C—Fittings
B—Oil Outlet Line

Reinstall Oil Lines

BF67790,0001CC4 -19-09JAN20-50/50

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