875584 Volvo.Penta Repair kit

Introduction
This Special Instruction is used for the installation of the optional migration kits on C15 and C18 China On-Highway Stage IV.Read the entire Special Instruction and understand the information before you perform any procedures.Fuel System Conversion
Required Parts
Table 1
Sales Model Plug and O-Ring for Diverter Valve
C15
C18 360-3693 Plug
033-6028 O-Ring Seal Conversion Procedure - Fuel System
Illustration 1 g03887760
(1) Fuel Diverter Valve
(2) Fuel Outlet Port Fitting
Remove fuel diverter valve (1) from the ARD fuel pump.
Plug the diverter valve port with a 360-3693 Plug and 033-6028 O-Ring Seal.
Fuel lines do not need to be connected to aftertreatment module.
Fuel outlet port fitting should be plugged (from factory configuration). If needed plug with 389-3708 or 6V-9828.Note: The fuel pump will remain operational to prime the engine fuel system.
Illustration 2 g03888062
(3) ARD Fuel Manifold Inlet Fitting
(4) 6V-9829 Cap
Inlet fitting and cap assembly in Illustration 2 should be present on DPF module.
If not present, or were previously removed will need to cap with 6V-9829.Exhaust System Conversion
Required Parts
Table 2
Sales Model Part Number
C15
C18 509-9290 Discard: 6V-9027, 6V-9828, 6V-9829, 9S-8002, and discard software part number 507-8936.Conversion Procedure
Illustration 3 g03890235
(1) Diesel Particulate Filter (DPF) Straps
(2) DPF Center Section
Illustration 4 g06074938
Incorrect Alignment
Illustration 5 g06074942
Correct Alignment
Put identification marks on both sides of clamp assemblies (1) for installation purposes.
Disconnect exhaust stack with outlet assembly.
Disconnect straps (1) to remove the diesel particulate filter group.
Attach a suitable lifting device to the DPF.
Remove the DPF center section.
Install new muffler kit specified in Table 2 in place of the DPF center section. Be sure to fully engage the pin and slot on both sides of the muffler.
Position the muffler assembly and tighten the new strap groups (1) to a torque of 15 3/-0 N m (11 2/-0 lb ft) after aligning the new straps with the identification marks on the inlet and outlet sections.Coolant Lines and Fuel Lines
DPF module will not be regenerating so coolant lines, fuel lines, and DPF interconnect harness do not need to be connected between the engine and DPF.Engine Software
Table 3
Sales Model Software Part Number
C15 540-0789-00
C18 540-0790-00 Note: Factory passwords are required to install the decertification flash file.
Download the decertification flash file from Service Information (SIS). Refer to Table 3 for part numbers.
Factory passwords will be issued utilizing Factory password system.
Requires Cat Electronic Technician (ET) release 2017C to flash software file. If 2017C is not available, please contact Caterpillar to obtain a Beta Release version of Cat ET to support this Special Instruction.Note: Once deregulation software is flashed on the engine, it cannot be flashed back to a regulated software. Deregulation films must be applied immediately to engine to accurately reflect unregulated emissions for the engine.
Install/update Migration Kit.
Key-ON.
Use Cat ET 2017C Latest Beta version.
Using Cat ET, connect to ECM to check for baseline SW.
Using Winflash, Flash-over the T4i C15/C18 App Test file per Table 3.
After the flash-over, Cat ET will pop up with 'Personality Module Mismatch'.
Use supplied FPS process/codes to apply FPS.
Upon successful application of the FPS, the Cat ET will be able to access the ECM configuration scree.
Perform first-time calibrations/installations procedure.
This will clear all the diagnostic codes.
Follow Additional Steps If Installing/Running Engine Immediately, if not follow through at later date when engine is installed in chassis.
If PWM throttle capability exists, Install Throttle using the attached throttle procedure. Power-cycle for throttle to take effect.
Review supplied pin-out for application I/Os. Make sure that remote shutdown/over speed shutdown switch are configured and wired correctly.
Electric Fuel Priming.
Make sure that no Fuel priming related diagnostics are present.
Keep the engine speed zero. Make sure the fuel priming switch J1-14 is OFF.
In Cat ET status screen, the parameter Fuel pump relay command will be OFF under Miscellaneous II group.
Confirm the fu