Generac 2.4L Diesel Generator Kia 96954 Parts Manual PB24000D

Page 1


“O/S” OVERSIZE “U/IS” UNDERSIZE

NOTICE!

THE INFORMATION IN THIS MANUAL IS KNOWN TO BE ACCURATE AS OF THE DATE OF RELEASESHOWNON THE COVER.HOWEVER,ENGINEERINGCHANGESCAN OCCURWITHOUTNOTICE.TOOBTAINTHEPROPERPARTS,PLEASEBESURETOUSE THEMODELNUMBEROFTHEUNITBEINGSERVICEDWHENORDERINGFROMTHIS MANUAL.

CRANKCASEOILCAPACITY:

COOLING SYSTEM CAPACITY: 2.8 U.S. GALLONS (11.1 LITERS)

RECOMMENDED FLUIDS:

COOLANT

USEA50/50MIXTUREOFLOWSILICATEETHYLENEGLYCOLBASEANTI-FREEZEANDSOFTWATER.(IFDESIRED,AHIGHQUALITY RUSTINHIBITORMAYBEADDEDTOTHERECOMMENDEDCOOLANTMIXTURE.)WHENADDINGCOOLANT,ALWAYSADDTHERECOM-

MENDED 50/50 MIXTURE.

ENGINE OIL: Lo USE A HIGH QUALITY DETERGENT OIL CLASSIFIED *FOR SERVICE SC, SD, SE, OR SF." DETERGENT OILS KEEP THE ENGINE CLEANER ANDREDUCECARBONDEPOSITS.USEOILHAVINGTHEFOLLOWINGSAEVISCOSITYRATINGBASEDONTHEAMBIENTTEMPERATURE RANGEANTICIPATEDBEFORETHENEXTOILCHANGE.

AFTER FIRST 30 HOURS OF OPERATION. CHANGE ENGINE CRANKCASE OIL AND OIL FILTER.

EVERY SIX MONTHS

CHANGE ENGINE OIL AND FILTER SERVICE ENGINE AIR CLEANER REPLACE ALL RUBBER HOSES SERVICE ENGINE FUEL FILTER » REPLACE ENGINE FAN BELTS DRAIN, FLUSH, AND REFILL COOLING SYSTEM

INSPECT FAN BELTS CHECK ENGINE COOLANT LEVEL INSPECT ENGINE COOLING SYSTEM HOSES

Engine parts contact: Phone: 269 673 1638 Text: 269 760 8652 email: EngineParts@HeavyEquipmentRestorationParts.com alternate email: EngineParts2@gmail.com www.Generac-Generator-Engine-Parts.com

101-96954

4107-96954 138-55441

118-96954

4119-96954

4127-96954 4130-96954 131-96954 ©

132-96954

133-96954 346-96954 347-96954

348-96954

349-96954

52408

350-96954

351-96954

352-96954

353-96954

406-96954

DESCRIPTION

HEAD, CYLINDER

PIPE, SEAL

STUD, ROCKER BRACKET

INSERT, COMBUSTION CHAMBER

CAP, SEALING

WASHER, WELCH

PLUG, OIL HOSE

BOLT, CYLINDER HEAD

BOLT, CYLINDER HEAD

WASHER, PLAIN

STUD, EXHAUST MANIFOLD STUD, EXHAUST MANIFOLD

CASE, THERMOSTAT

BOLT

SEAL, VALVE

GASKET, THERMOSTAT CASE COVER, REAR END

GASKET, BLIND COVER

HANGER, ENGINE COVER, CYLINDER HEAD

GASKET,CYLINDERHEADCOVER|:

WASHER, SEALING CAP, OIL FILLER

PIPE, BREATHER HOSE, BREATHER HOSE, BREATHER

GASKET, CYLINDER HEAD

BOLT

BOLT

HOSE CLAMP

WASHER

BOLT

CAP, SEALING

WASHER, SPRING STUD

WASHER

BOLT

BOLT

2.4L DIESEL CYLINDER BLOCK

138-5544 1 110-96954

359-96954 52411

361-96954

BOLT

WASHER, PLAIN

STUD

BLOCK, CYLINDER

PLUG , PLUG, CAMSHAFT

PLUG, OIL PUMP

PLUG, CYLINDER BLOCK LINER, CYLINDER

PLUG, WATER DRAIN

PLUG, BLIND

PIN, DOWEL

STUD, IDLE GEAR

BOLT, BEARING CAP

CAP, SEALING

CAP, SEALING

CAP, SEALING STUD

PIN

CAP, SEALING STUD

PLUG, BLIND PIN

2.4LDIESELOILPANANDENGINECOVERS

PART NUMBER

2.4L DIESELOIL PANAND ENGINECOVERS

DESCRIPTION

i

150-96954 OIL PAN

4152-96954 PLUG : 153-96954

GASKET,OILPAN(INCLUDES4,5,&6) (INCL. IN #3 ) | (INCL.IN#3 ) (INCL. IN #3 )

4157-96954

STIFFENER(LH),FRONT 4158-96954

STIFFENER(RH),FRONT 4159-96954 STIFFENER(LH),REAR 4160-96954

STIFFENER(RH),REAR 161-96954 BOLT

4140-67057

HOLDER,OILGAUGEPIPE 163-96954 PIPE, OIL GAUGE 164-96954 GAUGE,OILLEVEL 165-96954 CASE ASSY, TIMING GEAR 168-96954 GASKET, TIMING CASE TO BLOCK

4167-96954

COVER,TIMINGCASE : 168-96954 SEAL,OIL 169-96954 STUD,GEARCOVER 4170-96954 PIN 171-96954 GASKET, TIMING CASE COVER 172-96954

COVER,FUELPUMP 4170-57778 JOINT,GEARCOVER 4173-96954 PLATE,END 174-96954 BOLT

226-96954 BOLT 348-96954 WASHER, SPRING 362-96954 BOLT

363-96954 BOLT 364-96954 BOLT

365-96954 NUT 366-96954 NUT 367-96954 WASHER _ 368-96954 BOLT

151-67057 PACKING 347-96954 HOSE CLAMP 371-96954 BOLT

Engine parts contact: Phone: 269 673 1638 Text: 269 760 8652 email: EngineParts@HeavyEquipmentRestorationParts.com alternate email: EngineParts2@gmail.com

www.Generac-Generator-Engine-Parts.com

179-96954

180-96954

4193-67057 182-96954

183-96954

185-96954

186-96954

188-96954

190-96954

182-57778

192-96954

193-96954 194-96954

195-96954

199-96954 97369 201-96954

206-5544 1

203-96954 204-96954

205-96954

206-96954 207-96954

217-96954

218-96954

219-96954

220-96954

221-96954

222-96954

223-96954

224-96954

225-96954

362-96954

348-96954

DESCRIPTION

ROD, CONNECTING

BOLT, CONN ROD

NUT, CONN ROD

CRANKSHAFT

CAP, OIL SEAL ' GEAR, CRANKSHAFT

GASKET, OIL SEAL CAP

SPRING, FRICTION GEAR

GEAR, FRICTION

DEFLECTOR, OIL

KEY, CRANK GEAR

BOLT, CRANKSHAFT

WASHER

OIL SEAL

PULLEY, CRANKSHAFT

FLYWHEEL

BOLT, LOCK

WASHER, FLYWHEEL

PISTON SET (STD)

PISTON SET (0.50 O.S)

PISTON SET (1.00 O.S.)

RING SET, PISTON (STD)

RING SET, PISTON (0.50 O.S.)

RING SET, PISTON (0.50 O.S.)

RING SET, PISTON (0.75 O.S.)

RING SET, PISTON (1.00 O.S.)

CONN. ROD BEARING (STD)

CONN. ROD BEARING (0.25 U.S.)

CONN. ROD BEARING (0.50 U.S.)

CONN. ROD BEARING (0.75 U.S.)

CONN. ROD BEARING (1.00 U.S.)

MAIN BEARING SET (STD)

MAIN BEARING SET (0.25 U.S)

MAIN BEARING SET (0.50 U.S.)

MAIN BEARING SET (0.75 U.S)

MAIN BEARING SET (1.00 U.S.)

THRUST BEARING SET (STD)

THRUSTBEARINGSET(0.25U.S.) |

THRUSTBEARINGSET(0.50U.S.) .

THRUST BEARING SET (0.75 U.S.)

THRUST BEARING SET (1.00 U.S.) |

BOLT

WASHER, SPRING

PART NUMBER

262-96954

263-96954

264-96954

DESCRIPTION

SPACER

MANIFOLD, INTAKE

GASKET, INTAKE MANIFOLD

375-96954 CLIP

348-96954 WASHER, SPRING ©

376-96954

WASHER,SPRING

365-96954 NUT

377-96954 BOLT

265-96954

267-96954

WASHER, PLAIN

MANIFOLD, EXHAUST

268-96954 STUD, EXHAUST PIPE

269-96954

GASKET,EXHAUSTMANIFOLD

270-96954 NUT

PART NUMBER

271-96954

272-96954

273-96954 274-96954

251-67057

269-5544 1

270-55441

278-96954

279-96954

254-67057 282-96954

283-96954 284-96954

285-96954

287-96954

252-57778

290-96954

292-96954

293-96954

294-96954 254-57778

298-96954 256-57778

300-96954 301-96954

302-96954 98110 263-57778

308-96954

310-96954

260-67057

379-96954

380-96954

381-96954

348-96954

382-96954

383-96954

DESCRIPTION

GEAR, FRICTION NUT

HOLDER, NOZZLE

HOLDER, NOZZLE

WASHER, NOZZLE

GASKET

GASKET

HEAT SHIELD, NOZZLE

PIPE, LEAK

GASKET

PIPE, FUEL #1

PIPE, FUEL #2

PIPE, FUEL #3

PIPE, FUEL #4

CLIP, INJECTION PIPE

CHANNEL, PIPE CLIP

BOLT

CLIP, INJECTION PIPE

CHANNEL, PIPE CLIP

PUMP, FUEL INJECTION

NUT

STAY, INJECTION PUMP

GASKET, FUEL INJECTION PUMP

WASHER, PLAIN

GEAR, FUEL INJECTION PUMP

WASHER, PLAIN

FILTER, FUEL

CLIP

HOSE

CLIP, INJECTION PIPE

BOLT

WASHER

NUT

KEY, WOODRUFF

WASHER, SPRING

BOLT

CLIP

312-96954 PUMP,OIL |

313-96954 PLUG, SPRING

314-96954 COVER, OIL PUMP

315-96954 SHAFT, OIL PUMP

316-96954 PIN, DOWEL

317-96954 GEAR, DRIVE

318-96954 PLUNGER

319-96954 SCREW SET

320-96954

STRAINER, OIL

321-96954 PIPE, OIL

443-57778

323-96954

GASKET, OIL PIPE

GASKET, OIL STRAINER

324-96954 OIL FILTER ASSY

324-55441

GASKET,OILFILTERSUPPORT 99600 CARTRIDGE, OIL FILTER

312-55441 SPRING,PRESSURE

387-96954 NUT

388-96954 WASHER,SPRING

389-96954 BOLT

390-96954 BOLT

391-96954

WASHER, SPRING

392-96954 BOLT

PART NUMBER

96954

DESCRIPTION

ENGINE,2.4LDIESEL 97253

50618

50619

57771

97921

MOUNT, ENGINE RH

.ALTERNATOR, DC (DELCO-REMY)

FAN, DC ALTERNATOR

PULLEY,DCALTERNATOR

ADAPTER, EXHAUST MANIFOLD

GASKET, EXHAUST MANIFOLD

SUPPORT,COOLINGSENDER(SQUARESHAPED)

PIPE PLUG, 3/8 SOCKET 53667

SENDER, WATER TEMPERATURE

SWITCH, WATER TEMPERATURE 57522

SWITCH, WATER LEVEL 57750 GASKET, THERMOSTAT

SPACER, COOLING FAN

TEE PIPE, 1/8 NPT BRASS

SENDER, OIL PRESSURE

PART NUMBER

96954

DESCRIPTION

(VERSION 2 WITH DELCO ALTERNATOR)

ENGINE,2.4LDIESEL 97253 MOUNT, ENGINE LH

50618

MOUNT,ENGINERH

ALTERNATOR, DC (DELCO-REMY)

50619 FAN, DC ALTERNATOR 57771

97921

PULLEY,DCALTERNATOR

ADAPTER,EXHAUSTMANIFOLD 97256

GASKET, EXHAUST MANIFOLD

SUPPORT,COOLINGSENDER ( HEXAGONALSHAPED )

PIPE PLUG, 3/8 SOCKET 53667 SENDER, WATER TEMPERATURE

SWITCH,WATERTEMPERATURE |

SWITCH, WATER LEVEL

GASKET,THERMOSTAT (FOR HEXAGONAL COOLING SENDER SUPPORT)

SPACER, COOLING FAN

TEE PIPE, 1/8 NPT BRASS

SENDER,OILPRESSURE

DIESEL

PART NUMBER ; DESCRIPTION

96954

ENGINE. 2.4L DIESEL 97253 MOUNT, ENGINE LH 97254

A1354

MOUNT,ENGINERH

ALTERNATOR, DC (GENERAC) 33437 SPACER

97921

ADAPTER,EXHAUSTMANIFOLD 97256

GASKET,EXHAUSTMANIFOLD 20856

SUPPORT,COOLINGSENDER(HEXAGONALSHAPED ) 31919

PIPE PLUG, 3/8 SOCKET

53667

SENDER, WATER TEMPERATURE 35606 : SWITCH, WATER TEMPERATURE 57522 SWITCH, WATER LEVEL

GASKET, THERMOSTAT (FOR HEXAGONAL COOLING SENDER SUPPORT)

SPACER, COOLING FAN -

TEE PIPE, 1/8 NPT BRASS 53666 SENDER, OIL PRESSURE

OIL PRESSURE

LOCKWASHER

HEX HEAD CAP SCREW

LOCKWASHER, M12

HEXHEADCAPSCREW

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