3838282 Volvo.Penta Flange

Introduction
This Special Instruction describes the installation of the Caterpillar Ignition System (CIS) on G3612 and G3616 Engines. The CIS replaces mechanical parts that are prone to wear. The CIS improves the ignition system's precision and reliability. The CIS also provides self-diagnostics and diagnostics for the ignition system.The CIS was designed to operate with the Caterpillar Timing Control Module (TCM) in the Engine Supervisory System. The function of the TCM remains unchanged. No reprogramming is required.For information on the operation of the CIS, refer to Systems Operation/Testing and Adjusting, RENR2255, "Ignition System".A brief overview provides a summary of the installation procedure. The actual installation procedure provides more detailed identification of the parts.Do not perform any procedure in this Special Instruction until you read this information and you understand this information.Reference: The following reference materials may be necessary for this procedure:
Disassembly and Assembly, SENR5535, "G3612 and G3616 Engines"
Operation and Maintenance Manual, SEBU6496, "G3612 and G3616 Engines"
Systems Operation/Testing and Adjusting, RENR2255, "G3612 and G3616 Engines"
Troubleshooting, SENR6510, "G3600 Engines"
Special Instruction, REHS0190, "System Operation Testing And Adjusting For The Caterpillar Ignition System (CIS)"
Special Instruction, SEHS9122, "Using the 7X-1400 Digital Diagnostic Tool (DDT) Group"
For engines that were built before October 1998, refer to the 3E-9348 Wiring Diagram that was shipped in the engine mounted terminal box.
For later engines, refer to the 128-3198 Wiring Diagram that was shipped in the engine mounted terminal box.Overview
Illustration 1 g00905483
Typical example (in-line engine) (1) Magneto (2) Magneto interface box (3) Ignition harnessMagneto (1), magneto interface box (2), and the related wiring harnesses are removed. The original ignition harness (3) is removed.Note: The oil mister pump is not necessary on G3600 Engines. For more information, refer to Engine News April, "Oil Mister Pump and Lines Group No Longer Used".
Illustration 2 g00905503
(4) Oil mister pump (5) AdapterOil mister pump (4), the oil lines, adapter (5), and the oil mister pump's drive are removed. A plate with a magnet for the camshaft position sensor is bolted to the camshaft in place of the pump drive's components.
Illustration 3 g00905488
Camshaft position sensorA new adapter is installed over the camshaft and a camshaft position sensor is installed.
Illustration 4 g00905504
CIS Programming ControlThe CIS Programming Control and a new ignition harness are installed. A wiring harness is routed from the camshaft position sensor to the programming control.
Illustration 5 g00905493
Terminal boxWiring harnesses for the programming control's communication with the TCM and for the programming control's electrical power are connected to the engine's terminal box.
Illustration 6 g00905355
CIS Programming DisplayThe CIS Programming Display is connected to the programming control. The programming display provides an interface between the service technician and the CIS. The installation is tested for proper operation.Required Parts
Table 1 includes parts that are required for installation of the CIS.
Table 1
Required Parts for the CIS    
Pt. No.    Description    Qty    Function    
G3612 Engine    G3616 Engine    G3612 Engine G3616 Engine    
172-0062     172-0063     CIS Programming Control     1     Ignition control, mounting plate, mounting bracket, and mounting hardware
The lockwasher is for the control's ground strap.    
145-8462     Plate     1    
122-3360     Bracket     1    
0S-1588     Bolt     2    
3V-3308     Hard Washer     4    
9S-8752     Full Nut     2    
7H-3937     Lockwasher     1    
146-1802     146-1803     Wiring Harness     1     Ignition harness    
175-1495     175-1496     Plate     1   &nbs