Cat 3500B & 3500C Marine Engines Specifications Manual – PDF DOWNLOAD

RENR5077-11 July 2010

Specifications 3500B and 3500C Marine Engines M8A1-Up (Engine) S2A1-Up (Engine) M8B1-Up (Engine) S2B1-Up (Engine) S2D1-Up (Engine) S2E1-Up (Engine) S2F1-Up (Engine) B5G1-Up (Engine) MRG1-Up (Engine) PAG1-Up (Engine) S2G1-Up (Engine) MKH1-Up (Engine) S2H1-Up (Engine) S2J1-Up (Engine) S2K1-Up (Engine) S2L1-Up (Engine) S2M1-Up (Engine) S2N1-Up (Engine) S2P1-Up (Engine) S2R1-Up (Engine) S2S1-Up (Engine) S2T1-Up (Engine) S2W1-Up (Engine) S2X1-Up (Engine)

S2Y1-Up (Engine) S2Z1-Up (Engine)

SAFETY.CAT.COM

i03991620

Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

The warnings in this publication and on the product are, therefore, not all inclusive. You must not use this product in any manner different from that considered by this manual without first satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specific rules and precautions applicable to the worksite. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Cat dealers have the most current information available.

When replacement parts are required for this product Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material.

Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner's choosing.

RENR5077-11

Table of Contents Specifications Section Engine Design ....................................................... 5 Engine Design ....................................................... 5 Engine Design ....................................................... 6 Engine Design ....................................................... 7 Engine Design ....................................................... 7 Fuel Filter (Primary) ................................................ 8 Fuel Filter Base ...................................................... 9 Fuel Filter ............................................................. 10 Fuel Pressure Regulator ...................................... 10 Fuel Transfer Pump .............................................. 11 Fuel Injector Mechanism ....................................... 12 Fuel Injector .......................................................... 14 Camshaft ............................................................. 15 Camshaft ............................................................. 16 Camshaft ............................................................. 17 Camshaft ............................................................. 18 Camshaft ............................................................. 19 Camshaft ............................................................. 20 Valve Mechanism ................................................. 21 Cylinder Head ...................................................... 22 Cylinder Head Valves ........................................... 24 Turbocharger ........................................................ 26 Turbocharger ........................................................ 27 Turbocharger ........................................................ 28 Turbocharger ........................................................ 29 Turbocharger ........................................................ 30 Turbocharger ........................................................ 30 Turbocharger ........................................................ 31 Turbocharger ........................................................ 31 Turbocharger Support ........................................... 32 Accumulator ......................................................... 33 Exhaust Bypass Valve ......................................... 33 Exhaust Bypass Valve ......................................... 34 Exhaust Manifold ................................................. 35 Exhaust Manifold ................................................. 36 Exhaust Manifold ................................................. 36 Exhaust Manifold ................................................. 38 Exhaust Manifold ................................................. 39 Exhaust Flange .................................................... 40 Exhaust Flange .................................................... 40 Air Cleaner ........................................................... 41 Air Cleaner Adapter .............................................. 41 Air Cleaner Adapter .............................................. 42 Engine Air Cleaner Service Indicator .................... 42 Air Inlet and Exhaust Lines ................................... 43 Air Inlet and Exhaust Lines ................................... 44 Air Inlet and Exhaust Lines ................................... 47 Air Inlet and Exhaust Lines ................................... 49 Air Shutoff ............................................................. 51 Air Shutoff ............................................................. 52 Engine Oil Pump .................................................. 53 Engine Oil Pump .................................................. 55 Engine Oil Pump .................................................. 57 Engine Oil Pump .................................................. 59 Engine Oil Scavenge Pump ................................. 61 Engine Oil Cooler Bypass and Cooling Jet Sequence Valves ................................................................. 63

3 Table of Contents

Engine Oil Cooler Bypass and Cooling Jet Sequence Valves ................................................................. 64 Engine Oil Filter ................................................... 66 Engine Oil Filter ................................................... 67 Engine Oil Lines ................................................... 69 Engine Oil Lines (Front Mounted Engine Oil Filter) ................................................................... 70 Duplex Engine Oil Filters ..................................... 71 Engine Oil Filter Base .......................................... 73 Crankcase Breather ............................................. 73 Crankcase Breather ............................................. 75 Crankcase Breather ............................................. 76 Engine Oil Pan ..................................................... 76 Engine Oil Pan ..................................................... 78 Engine Oil Pan ..................................................... 80 Water Temperature Regulator .............................. 82 Water Lines ........................................................... 83 Engine Oil Sump Pump ........................................ 85 Water Pump ......................................................... 86 Auxiliary Water Pump .......................................... 87 Cooling System Pressure Cap ............................. 89 Cylinder Block ...................................................... 90 Cylinder Block ...................................................... 91 Cylinder Block ...................................................... 93 Cylinder Liner ....................................................... 95 Piston and Rings (One-Piece Piston) ................... 95 Piston and Rings (One-Piece Piston) ................... 97 Piston and Rings (Two-Piece Piston) ................... 99 Piston and Rings (Two-Piece Piston) ................. 101 Connecting Rod ................................................. 102 Connecting Rod and Main Bearing Journals ...... 104 Crankshaft ......................................................... 105 Crankshaft ......................................................... 106 Crankshaft Wear Sleeves and Seals ................. 108 Housing (Front) ................................................... 109 Housing (Front) .................................................... 110 Gear Group (Front) (Reverse Rotation) ............... 111 Gear Group (Front) (Reverse Rotation) ............... 113 Gear Group (Front) .............................................. 115 Gear Group (Front) .............................................. 116 Gear Group (Rear) ............................................... 117 Balancer Group (Front) ....................................... 119 Accessory Drive ................................................. 120 Accessory Drive ................................................. 122 Accessory Drive (Lower Left Hand) .................... 123 Accessory Drive (Lower Left Hand) .................... 124 Accessory Drive (Upper Right Hand) .................. 126 Accessory Drive (Upper Right Hand) .................. 128 Accessory Drive (Upper Right Hand) .................. 130 Accessory Drive (Upper Left Hand) .................... 131 Accessory Drive (Upper Left Hand, Reverse Rotation) ........................................................... 132 Flywheel ............................................................. 133 Flywheel Housing .............................................. 134 Flywheel Housing .............................................. 135 Flexible Coupling ................................................ 137 Engine Mount (Front) (Hydraulic Pump Drive or PTO Clutch) ............................................................... 138 Engine Trunnion .................................................. 139 Vibration Damper ............................................... 140 Vibration Damper ............................................... 141 Vibration Damper ............................................... 142 Vibration Damper Guard .................................... 143

4 Table of Contents

Stub Shaft (Front) ...............................................

Stub Shaft (Front) ...............................................

Stub Shaft (Front) ...............................................

Auxiliary Drive Pulley .........................................

Auxiliary Drive Shaft ..........................................

Belt Tension Chart .............................................

Belt Tension Chart .............................................

Alternator and Regulator ....................................

Alternator Mounting ...........................................

Electric Starting Motor .......................................

Air Starting Motor ...............................................

Air Starting Motor Pressure Regulating Valve ...

Jacket Water Heater ..........................................

Engine Harness (Rigid Wiring Harness) .............

Coolant Level Switch .........................................

Coolant Temperature Switch ...............................

Fuel Pressure Sensor ........................................

Magnetic Switch .................................................

Coolant Level Sensor .........................................

Engine Oil Pressure Sensor ...............................

Engine Oil Pressure Sensor ...............................

Turbocharger Inlet Pressure Sensor ...................

Turbocharger Outlet Pressure Sensor ................

Turbocharger Outlet Pressure Sensor ................

Aftercooler Coolant Temperature Sensor ...........

Engine Coolant Temperature Sensor ..................

Turbocharger Exhaust Temperature Sensor .......

Engine Speed/Timing Sensor .............................

Engine Speed/Timing Sensor .............................

Engine Speed/Timing Sensor .............................

Engine Speed/Timing Sensor .............................

Engine Speed/Timing Sensor .............................

Crankcase Pressure Sensor ...............................

Atmospheric Pressure Sensor ............................

Atmospheric Pressure Sensor ............................

Atmospheric Pressure Sensor ............................

Engine Speed Sensor .........................................

Engine Speed Sensor .........................................

RENR5077-11

143 144 145 146 147 148 149 150 151 152 153 154 155 155 158 158 159 159 160 160 161 161 162 163 163 163 164 164 165 166 166 167 168 168 169 169 170 170

Index Section Index ................................................................... 172

RENR5077-11

5 Specifications Section

Specifications Section

Reverse rotation CW .................. 1, 8, 7, 2, 6, 5, 4, 3 Valve lash i01939435

Engine Design

Inlet ......................................... 0.50 mm (0.020 inch) Exhaust ................................... 1.00 mm (0.040 inch)

SMCS Code: 1000

Note: The front end of the engine is opposite the flywheel end of the engine. The left and the right side of the engine are determined from the flywheel end.

The number 1 cylinder is the front cylinder on the right side. The number 2 cylinder is the front cylinder on the left side.

S/N: M8A1-Up S/N: S2A1-Up S/N: M8B1-Up S/N: S2B1-Up S/N: S2D1-Up

i01939560

Engine Design

S/N: S2E1-Up S/N: S2F1-Up

SMCS Code: 1000 S/N: S2G1-Up S/N: S2H1-Up S/N: S2K1-Up S/N: S2L1-Up S/N: S2M1-Up

Illustration 1

g00293348

Cylinder and valve location (A) Inlet valves (B) Exhaust valves

Number and arrangement of cylinders .............................................. 60 degree V-8 Valves per cylinder .................................................. 4 Illustration 2

Displacement .............................. 34.5 L (2105 cu in)

Cylinder and valve location

Bore ............................................. 170 mm (6.7 inch)

(A) Inlet valves (B) Exhaust valves

Stroke .......................................... 190 mm (7.5 inch) Compression ratio .............................................. 14:1 Combustion ........................................ Direct injection When the crankshaft is viewed from the flywheel end the crankshaft rotates in the following direction. ....................................... Counterclockwise Firing order (injection sequence) Standard rotation CCW ............... 1, 2, 7, 3, 4, 5, 6, 8

g00293349

Number and arrangement of cylinders ............................................ 60 degree V-12 Valves per cylinder .................................................. 4 Displacement .............................. 51.8 L (3158 cu in) Bore ............................................. 170 mm (6.7 inch) Stroke .......................................... 190 mm (7.5 inch) Compression ratio .............................................. 14:1 Combustion ........................................ Direct injection

6 Specifications Section

RENR5077-11

When the crankshaft is viewed from the flywheel end the crankshaft rotates in the following direction. ....................................... Counterclockwise

Bore ............................................. 170 mm (6.7 inch)

Firing order (injection sequence)

Compression ratio ........................................... 15.5:1

Standard rotation CCW ...................... 1, 12, 9, 4, 5, 8, 11, 2, 3, 10, 7, 6

Combustion ........................................ Direct injection

Stroke .......................................... 215 mm (8.5 inch)

Reverse rotation CW ......................... 1, 4, 9, 8, 5, 2, 11, 10, 3, 6, 7, 12

When the crankshaft is viewed from the flywheel end the crankshaft rotates in the following direction. ....................................... Counterclockwise

Valve lash

Firing order (injection sequence)

Inlet ......................................... 0.50 mm (0.020 inch)

Standard rotation CCW ...................... 1, 12, 9, 4, 5, 8, 11, 2, 3, 10, 7, 6

Exhaust ................................... 1.00 mm (0.040 inch) Note: The front end of the engine is opposite the flywheel end of the engine. The left and the right side of the engine are determined from the flywheel end.

The number 1 cylinder is the front cylinder on the right side. The number 2 cylinder is the front cylinder on the left side. i01443411

Engine Design SMCS Code: 1000 S/N: MRG1-Up S/N: MKH1-Up S/N: S2J1-Up S/N: S2N1-Up

Illustration 3

g00293349

Cylinder and valve location (A) Inlet valves (B) Exhaust valves

Number and arrangement of cylinders ............................................ 60 degree V-12 Valves per cylinder .................................................. 4 Displacement .............................. 58.5 L (3570 cu in)

Reverse rotation CW ......................... 1, 4, 9, 8, 5, 2, 11, 10, 3, 6, 7, 12 Valve lash Inlet ......................................... 0.50 mm (0.020 inch) Exhaust ................................... 1.00 mm (0.040 inch) Note: The front end of the engine is opposite the flywheel end of the engine. The left and the right side of the engine are determined from the flywheel end.

The number 1 cylinder is the front cylinder on the right side. The number 2 cylinder is the front cylinder on the left side.

RENR5077-11

7 Specifications Section

i01939608

Engine Design

Inlet ......................................... 0.50 mm (0.020 inch) Exhaust ................................... 1.00 mm (0.040 inch)

SMCS Code: 1000

Note: The front end of the engine is opposite the flywheel end of the engine. The left and the right side of the engine are determined from the flywheel end.

The number 1 cylinder is the front cylinder on the right side. The number 2 cylinder is the front cylinder on the left side.

S/N: S2P1-Up S/N: S2R1-Up S/N: S2S1-Up S/N: S2W1-Up

i01939644

S/N: S2Y1-Up

Engine Design SMCS Code: 1000 S/N: B5G1-Up S/N: PAG1-Up S/N: S2T1-Up S/N: S2X1-Up S/N: S2Z1-Up

Illustration 4

g00294285

Cylinder and valve location (A) Inlet valves (B) Exhaust valves

Number and arrangement of cylinders ............................................ 60 degree V-16 Valves per cylinder .................................................. 4 Displacement .............................. 69.1 L (4210 cu in) Bore ............................................. 170 mm (6.7 inch) Stroke .......................................... 190 mm (7.5 inch) Compression ratio .............................................. 14:1 Combustion ........................................ Direct injection

Illustration 5

g00294285

Cylinder and valve location (A) Inlet valves (B) Exhaust valves

Number and arrangement of cylinders ............................................ 60 degree V-16

When the crankshaft is viewed from the flywheel end the crankshaft rotates in the following direction. ....................................... Counterclockwise

Valves per cylinder .................................................. 4

Firing order (injection sequence)

Bore ............................................. 170 mm (6.7 inch)

Standard rotation CCW .. 1, 2, 5, 6, 3, 4, 9, 10, 15, 16, 11, 12, 13, 14, 7, 8

Stroke .......................................... 215 mm (8.5 inch)

Reverse rotation CW .. 1, 6, 5, 4, 3, 10, 9, 16, 15, 12, 11, 14, 13, 8, 7, 2 Valve lash

Displacement .............................. 78.0 L (4760 cu in)

Compression ratio ........................................... 15.5:1 Combustion ........................................ Direct injection When the crankshaft is viewed from the flywheel end the crankshaft rotates in the following direction. ....................................... Counterclockwise

8 Specifications Section

RENR5077-11

Firing order (injection sequence) Standard rotation CCW .. 1, 2, 5, 6, 3, 4, 9, 10, 15, 16, 11, 12, 13, 14, 7, 8

Part No.: 8N-6435 S/N: S2K1-Up Part No.: 8N-6435 S/N: S2L1-Up

Reverse rotation CW .. 1, 6, 5, 4, 3, 10, 9, 16, 15, 12, 11, 14, 13, 8, 7, 2

Part No.: 8N-6435 S/N: S2M1-Up

Valve lash

Part No.: 8N-6435 S/N: S2N1-Up

Inlet ......................................... 0.50 mm (0.020 inch) Exhaust ................................... 1.00 mm (0.040 inch) Note: The front end of the engine is opposite the flywheel end of the engine. The left and the right side of the engine are determined from the flywheel end.

The number 1 cylinder is the front cylinder on the right side. The number 2 cylinder is the front cylinder on the left side. i03657840

Fuel Filter (Primary)

Part No.: 8N-6435 S/N: S2P1-Up Part No.: 8N-6435 S/N: S2R1-Up Part No.: 8N-6435 S/N: S2S1-Up Part No.: 8N-6435 S/N: S2T1-Up Part No.: 8N-6435 S/N: S2W1-Up

SMCS Code: 1260

Part No.: 8N-6435 S/N: S2X1-Up

Part No.: 8N-6435 S/N: M8A1-Up

Part No.: 8N-6435 S/N: S2Y1-Up

Part No.: 8N-6435 S/N: S2A1-Up

Part No.: 8N-6435 S/N: S2Z1-Up

Part No.: 8N-6435 S/N: M8B1-Up Part No.: 8N-6435 S/N: S2B1-Up Part No.: 8N-6435 S/N: S2D1-Up Part No.: 8N-6435 S/N: S2E1-Up Part No.: 8N-6435 S/N: S2F1-Up Part No.: 8N-6435 S/N: MRG1-Up Part No.: 8N-6435 S/N: PAG1-Up Part No.: 8N-6435 S/N: S2G1-Up Part No.: 8N-6435 S/N: MKH1-Up Part No.: 8N-6435 S/N: S2H1-Up Part No.: 8N-6435 S/N: S2J1-Up

Illustration 6

g01561538

(1) Torque for the nut ..... 25 ± 5 N·m (221 ± 44 lb in) (2) Lubricate the bore and the shaft of the O-ring seal lightly with the clean engine oil.

(3) 7S-9323 Spring Length under test force ... 27.94 mm (1.100 inch) Test force ............... 27.7 to 32.3 N (6.2 to 7.3 lb) Free length after test ...... 42.67 mm (1.680 inch) Outside diameter ............ 17.32 mm (0.682 inch)

RENR5077-11

9 Specifications Section

i03083460

Fuel Filter Base

Part No.: 8N-3481 S/N: S2X1-Up

SMCS Code: 1262

Part No.: 8N-3481 S/N: S2Y1-Up

Part No.: 8N-3481 S/N: S2A1-Up

Part No.: 8N-3481 S/N: S2Z1-Up

Part No.: 8N-3481 S/N: S2B1-Up Part No.: 8N-3481 S/N: S2D1-Up Part No.: 8N-3481 S/N: S2E1-Up Part No.: 8N-3481 S/N: S2F1-Up Part No.: 8N-3481 S/N: B5G1-Up Part No.: 8N-3481 S/N: MRG1-Up Part No.: 8N-3481 S/N: PAG1-Up Part No.: 8N-3481 S/N: S2G1-Up Part No.: 8N-3481 S/N: MKH1-Up Part No.: 8N-3481 S/N: S2H1-Up Part No.: 8N-3481 S/N: S2J1-Up Part No.: 8N-3481 S/N: S2K1-Up Part No.: 8N-3481 S/N: S2L1-Up Part No.: 8N-3481 S/N: S2M1-Up Part No.: 8N-3481 S/N: S2N1-Up Part No.: 8N-3481 S/N: S2P1-Up Part No.: 8N-3481 S/N: S2R1-Up Part No.: 8N-3481 S/N: S2S1-Up Part No.: 8N-3481 S/N: S2T1-Up Part No.: 8N-3481 S/N: S2W1-Up

Illustration 7

g01563177

Typical example

(A) Length for applying 154-9731 Thread Lock Compound on the tapered end of the taperlock stud ................. 10.0 ± 1.5 mm (0.39 ± 0.06 inch) (1) Torque for the taperlock stud ............. 68 ± 7 N·m (50 ± 5 lb ft) i03609520

Fuel Filter SMCS Code: 1261 Part No.: 335-5612 S/N: M8A1-Up Part No.: 115-7842, 7W-9741 S/N: S2A1-Up Part No.: 335-5612 S/N: M8B1-Up Part No.: 115-7842, 7W-9741 S/N: S2B1-Up Part No.: 115-7842, 7W-9741 S/N: S2D1-Up Part No.: 115-7842, 7W-9741 S/N: S2E1-Up Part No.: 7W-9741 S/N: S2F1-Up Part No.: 7W-9741 S/N: B5G1-Up Part No.: 7W-9741 S/N: MRG1-Up

10 Specifications Section

RENR5077-11

Part No.: 7W-9741 S/N: PAG1-Up Part No.: 115-7842, 7W-9741 S/N: S2G1-Up Part No.: 7W-9741 S/N: MKH1-Up Part No.: 115-7842, 7W-9741 S/N: S2H1-Up Part No.: 115-7842, 7W-9741 S/N: S2J1-Up Part No.: 115-7842, 7W-9741 S/N: S2K1-Up Part No.: 115-7842, 7W-9741 S/N: S2L1-Up Part No.: 7W-9741 S/N: S2M1-Up Part No.: 115-7842, 7W-9741 S/N: S2N1-Up Part No.: 115-7842, 7W-9741 S/N: S2P1-Up Part No.: 115-7842, 7W-9741 S/N: S2R1-Up

Illustration 8

g01934499

Typical example (1) Manual valve assembly (3) Fuel filter element

Note: Lightly lubricate the bore of the O-ring seals with the lubricant that is being sealed or an approved equivalent.

(2) 1N-2895 Spring Length under test force ... 20.75 mm (0.817 inch) Test force ....................................... 222 N (50 lb) Free length after test ..... 62.48 mm (2.460 inch) Outside diameter ................ 88.9 mm (3.50 inch)

Part No.: 115-7842, 7W-9741 S/N: S2S1-Up

i02723705

Part No.: 115-7842, 7W-9741 S/N: S2T1-Up

Fuel Pressure Regulator

Part No.: 115-7842, 7W-9741 S/N: S2W1-Up

SMCS Code: 1277 Part No.: 114-5477

Part No.: 115-7842, 7W-9741 S/N: S2X1-Up Part No.: 7W-9741 S/N: S2Y1-Up Part No.: 115-7842, 7W-9741 S/N: S2Z1-Up

Illustration 9

g01366239

Typical example (1) Fuel manifold adapter (3) Valve plunger

(2) 9N-4053 Spring Length under test force ....... 28.5 mm (1.12 inch) Test force .................... 40.8 ± 2.1 N (9.2 ± 0.5 lb) Free length after test force .. 57.2 mm (2.25 inch)

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11 Specifications Section

Outside diameter ............ 15.24 mm (0.600 inch)

Part No.: 8N-6151 S/N: S2S1-Up

i03229222

Part No.: 8N-6151 S/N: S2T1-Up

Fuel Transfer Pump SMCS Code: 1256

Part No.: 8N-6151 S/N: S2W1-Up

Part No.: 313-7770 S/N: M8A1-Up

Part No.: 8N-6151 S/N: S2X1-Up

Part No.: 8N-6151 S/N: S2A1-Up

Part No.: 8N-6151 S/N: S2Y1-Up

Part No.: 313-7770 S/N: M8B1-Up

Part No.: 8N-6151 S/N: S2Z1-Up

Part No.: 8N-6151 S/N: S2B1-Up Part No.: 8N-6151 S/N: S2D1-Up Part No.: 8N-6151 S/N: S2E1-Up Part No.: 8N-6151 S/N: S2F1-Up Part No.: 8N-6151 S/N: B5G1-Up Part No.: 8N-6151 S/N: MRG1-Up Part No.: 8N-6151 S/N: PAG1-Up Part No.: 8N-6151 S/N: S2G1-Up Part No.: 8N-6151 S/N: MKH1-Up Part No.: 8N-6151 S/N: S2H1-Up Part No.: 8N-6151 S/N: S2J1-Up Part No.: 8N-6151 S/N: S2K1-Up Part No.: 8N-6151 S/N: S2L1-Up Part No.: 8N-6151 S/N: S2M1-Up Part No.: 8N-6151 S/N: S2N1-Up

Illustration 10

g01641861

(3) Check valve

When the fuel transfer pump group is viewed from the drive end, the drive gear rotates in the clockwise direction.

Minimum output .................... 21 L/min (5.5 US gpm) Minimum output is attained under the following conditions: Pump pressure ............................... 415 kPa (60 psi)

Part No.: 8N-6151 S/N: S2P1-Up

Pump speed ............................................... 2400 rpm

Part No.: 8N-6151 S/N: S2R1-Up

Minimum cracking pressure of bypass valve ............................................... 620 kPa (90 psi)

12 Specifications Section

RENR5077-11

Maximum pressure of fully open bypass valve ............................................. 965 kPa (140 psi)

Part No.: 224-9869 S/N: S2H1-Up

(1) Dimensions for terminal bushing

Part No.: 224-9869 S/N: S2J1-Up

Inside diameter of the terminal bushing for gear shaft ............................ 12.783 mm (0.5033 inch) Installation depth of terminal bushing ............. 1.5 ± 0.5 mm (0.06 ± 0.02 inch) (2) Dimensions for drive shaft assembly Diameter of the shaft ........ 12.700 to 12.675 mm (0.5000 to 0.4990 inch) Diameter of the gear ............ 29.801 ± 0.006 mm (1.1733 ± 0.0002 inch) Length of the gear ............... 25.347 ± 0.008 mm (0.9979 ± 0.0003 inch) (4) Dimensions for idler gear assembly Diameter of the gear ............ 29.801 ± 0.006 mm (1.1733 ± 0.0002 inch) Length of the gear ............... 25.347 ± 0.008 mm (0.9979 ± 0.0003 inch) i03601019

Part No.: 224-9869 S/N: S2K1-Up Part No.: 224-9869 S/N: S2L1-Up Part No.: 224-9869 S/N: S2M1-Up Part No.: 224-9869 S/N: S2N1-Up Part No.: 224-9869 S/N: S2P1-Up Part No.: 224-9869 S/N: S2R1-Up Part No.: 224-9869 S/N: S2S1-Up Part No.: 224-9869 S/N: S2T1-Up

Fuel Injector Mechanism

Part No.: 224-9869 S/N: S2W1-Up

SMCS Code: 1102; 1290

Part No.: 224-9869 S/N: S2X1-Up

Part No.: 332-9690 S/N: M8A1-Up Part No.: 224-9869 S/N: S2A1-Up Part No.: 332-9690 S/N: M8B1-Up

Part No.: 224-9869 S/N: S2Y1-Up Part No.: 224-9869 S/N: S2Z1-Up

Part No.: 224-9869 S/N: S2B1-Up Part No.: 224-9869 S/N: S2D1-Up Part No.: 224-9869 S/N: S2E1-Up Part No.: 224-9869 S/N: S2F1-Up Part No.: 224-9869 S/N: B5G1-Up Part No.: 224-9869 S/N: MRG1-Up Part No.: 224-9869 S/N: PAG1-Up Part No.: 224-9869 S/N: S2G1-Up Part No.: 224-9869 S/N: MKH1-Up

Illustration 11 (3) Timing pin

g01441231

RENR5077-11

13 Specifications Section

(A) Bore in the sleeve bearing for the rocker arm shaft after installation ........... 45.077 ± 0.015 mm (1.7747 ± 0.0006 inch) (1) Torque for the nut .... 120 ± 15 N·m (88 ± 11 lb ft) (B) Diameter of the rocker arm shaft ..................................... 45.000 ± 0.013 mm (1.7716 ± 0.0005 inch) (2) 100-3878 Injector Spring Length under test force ... 85.00 mm (3.346 inch) Test force .......................... 300 ± 25 N (67 ± 6 lb) Free length after test ...... 87.65 mm (3.451 inch) Outside diameter ............ 43.85 mm (1.726 inch) (C) Dimensions for the unit injector lifter assembly Diameter of the unit injector lifter assembly ............................. 34.950 ± 0.010 mm (1.3760 ± 0.0004 inch) Bore in the head for the unit injector lifter assembly ............................. 35.000 ± 0.025 mm (1.3779 ± 0.0010 inch)

Part No.: 250-1300 S/N: M8A1-Up Part No.: 256-3663 S/N: S2A1-Up Part No.: 250-1300 S/N: M8B1-Up Part No.: 256-3663 S/N: S2B1-Up Part No.: 256-3663 S/N: S2D1-Up Part No.: 256-3663 S/N: S2E1-Up Part No.: 256-3663 S/N: S2F1-Up Part No.: 248-8695, 256-3663 S/N: B5G1-Up Part No.: 248-8695, 256-3663 S/N: MRG1-Up Part No.: 256-3663 S/N: PAG1-Up Part No.: 256-3663 S/N: S2G1-Up Part No.: 248-8695, 256-3663 S/N: MKH1-Up Part No.: 256-3663 S/N: S2H1-Up Part No.: 256-3663 S/N: S2J1-Up

Illustration 12

g01925693

(4) Lubricate the bore of the O-ring seal lightly with clean engine oil.

Note: Start tightening the retainer nuts of the cap assembly by hand so that the terminal studs are not cross threaded.

(5) Torque for the retainer nuts of the cap assembly ............................... 2.500 ± 0.025 N·m (22.127 ± 0.221 lb in) (6) Apply 5P-3413 Pipe Sealant to the threads of the bolts, if the bolts are removed after initial installation. i02895694

Fuel Injector SMCS Code: 1290

Part No.: 256-3663 S/N: S2K1-Up Part No.: 256-3663 S/N: S2L1-Up Part No.: 256-3663 S/N: S2M1-Up Part No.: 256-3663 S/N: S2N1-Up Part No.: 256-3663 S/N: S2P1-Up Part No.: 256-3663 S/N: S2R1-Up Part No.: 256-3663 S/N: S2S1-Up Part No.: 256-3663 S/N: S2T1-Up Part No.: 256-3663 S/N: S2W1-Up

14 Specifications Section

RENR5077-11

Part No.: 256-3663 S/N: S2X1-Up

Part No.: 106-4586, 106-4595 S/N: S2A1-Up

Part No.: 256-3663 S/N: S2Y1-Up

Part No.: 106-4586, 106-4595 S/N: S2B1-Up

Part No.: 256-3663 S/N: S2Z1-Up

Part No.: 106-4586, 106-4595 S/N: S2D1-Up Part No.: 106-4586, 106-4595 S/N: S2E1-Up Part No.: 106-4586 S/N: S2F1-Up Part No.: 106-4595 S/N: B5G1-Up Part No.: 106-4586, 106-4595 S/N: MRG1-Up Part No.: 106-4595 S/N: PAG1-Up Part No.: 106-4586, 106-4595 S/N: S2G1-Up Part No.: 106-4586, 106-4595 S/N: MKH1-Up

Illustration 13

g01441567

Note: Prior to installation of the fuel injector group, lubricate the bore in the cylinder head with 1P-0808 Multipurpose Grease. Use the clamp to press the injector into the bore. Do not tap on the top surface of the injector.

(1) Torque for the bolt .......... 65 ± 7 N·m (48 ± 5 lb ft) (A) Timing dimension .................... 64.34 ± 0.20 mm (2.533 ± 0.008 inch) Note: Before assembly, lubricate the bore and the threads of valve assembly (2) with 1P-0808 Multipurpose Grease.

(2) Valve assembly Torque for valve assembly ............. 165 ± 10 N·m (120 ± 7 lb ft) Torque for terminal nuts ................. 2.4 ± 0.2 N·m (21 ± 2 lb in) (3) Torque for unit injector nozzle ........ 310 ± 20 N·m (230 ± 15 lb ft) i02874925

Part No.: 106-4586, 106-4595 S/N: S2H1-Up Part No.: 106-4586, 106-4595 S/N: S2J1-Up Part No.: 106-4586, 106-4595 S/N: S2K1-Up Part No.: 106-4586, 106-4595 S/N: S2L1-Up Part No.: 106-4586, 106-4595 S/N: S2M1-Up Part No.: 106-4586, 106-4595 S/N: S2N1-Up Part No.: 106-4586, 106-4595 S/N: S2P1-Up Part No.: 106-4586, 106-4595 S/N: S2R1-Up Part No.: 106-4586, 106-4595 S/N: S2S1-Up Part No.: 106-4586, 106-4595 S/N: S2T1-Up Part No.: 106-4586, 106-4595 S/N: S2W1-Up

Camshaft

Part No.: 106-4586, 106-4595 S/N: S2X1-Up

SMCS Code: 1210

Part No.: 106-4586, 106-4595 S/N: S2Y1-Up

RENR5077-11

15 Specifications Section

Part No.: 106-4586 S/N: S2Z1-Up

Illustration 15 Illustration 14

g01430676

(1) Left hand camshaft assembly (2) Right hand camshaft assembly

g01381515

Use the following procedure in order to determine the camshaft lobe lift: 1. Measure camshaft lobe height (H).

(A) Thickness of the groove in a new camshaft assembly .. 8.75 ± 0.05 mm (0.344 ± 0.002 inch)

2. Measure base circle (J).

(C) Extension of the dowel from the camshaft assembly ........ 12.0 ± 0.5 mm (0.47 ± 0.02 inch)

3. Subtract the base circle (J) from the camshaft lobe height (H). The difference is the actual camshaft lobe lift.

(D) Thickness of a new thrust washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)

(G) Specified camshaft lobe lift

(E) Journal surface Diameter of bearing journals for a new camshaft .. 91.88 ± 0.02 mm (3.617 ± 0.001 inch) Bore in camshaft bearing after installation ................................ 92.00 ± 0.06 mm (3.622 ± 0.002 inch) Note: End play for a new camshaft assembly is 0.15 to 0.35 mm (0.006 to 0.014 inch).

(3) Torque for 16 bolts ......... 55 ± 7 N·m (41 ± 5 lb ft) (F) Extension of the dowel from the end of the rear right hand camshaft and the front left hand camshaft ......... 22.0 ± 0.5 mm (0.87 ± 0.02 inch)

Inlet lobe ................. 12.7500 mm (0.50197 inch) Injector lobe ............ 13.7313 mm (0.54060 inch) Exhaust lobe ........... 13.2499 mm (0.52165 inch)

16 Specifications Section

RENR5077-11

i01390111

Camshaft SMCS Code: 1210 Part No.: 143-8726 S/N: S2A1-Up Part No.: 333-8957 S/N: M8B1-Up Part No.: 143-8726 S/N: S2D1-Up Illustration 17

g00290053

(6) Camshaft lobe height In order to determine the height, use the procedure that follows: 1. Measure camshaft lobe height (6).

2. Measure base circle (8).

Illustration 16

g00289972

Typical example

(1) Pin The pin extends from the camshaft by the following distance: ....................... 12.0 ± 0.5 mm (0.47 ± 0.02 inch) (2) New washer Thickness of a new washer ....... 8.50 ± 0.05 mm (0.335 ± 0.002 inch) Thickness of the groove in a new camshaft ... 8.75 ± 0.05 mm (0.344 ± 0.002 inch) End play for new camshafts ..... 0.15 to 0.35 mm (0.006 to 0.014 inch) (3) LH camshaft (4) RH camshaft (5) Journal surface Diameter of surface (journals) for new camshaft bearings .. 91.88 ± 0.02 mm (3.617 ± 0.001 inch) Bore in bearings for camshafts after assembly ................................. 92.00 ± 0.06 mm (3.622 ± 0.002 inch)

3. Subtract the base circle (Step 2) from the lobe height (Step 1). The difference is the actual lobe lift.

4. Specified camshaft lobe lift (7) Inlet lobe ...................... 13.250 mm (0.5217 inch) Injector lobe ................. 13.731 mm (0.5406 inch) Exhaust lobe ................ 13.250 mm (0.5217 inch)

RENR5077-11

17 Specifications Section

i02990771

Camshaft SMCS Code: 1210 Part No.: 332-7923 S/N: M8A1-Up Part No.: 106-4582 S/N: S2B1-Up Part No.: 106-4582 S/N: S2E1-Up Part No.: 106-4582 S/N: S2F1-Up

Illustration 19

g01460128

(E) Specified camshaft lobe lift Inlet lobe ................. 12.7500 mm (0.50197 inch) Injector lobe ............ 13.7313 mm (0.54060 inch) Exhaust lobe ........... 13.2500 mm (0.52165 inch)

Illustration 18

g01515757

(1) Left hand camshaft assembly (2) Right hand camshaft assembly

(A) Thickness of the groove for thrust washer in a new camshaft assembly ............ 8.75 ± 0.05 mm (0.344 ± 0.002 inch) (B) Extension of the dowel from the camshaft assembly ........ 12.0 ± 0.5 mm (0.47 ± 0.02 inch) (C) Thickness of a new thrust washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch) (D) Dimensions for the journal surface Diameter of bearing journal ..... 91.88 ± 0.02 mm (3.617 ± 0.001 inch) Bore in camshaft bearing after installation ................................ 92.00 ± 0.06 mm (3.622 ± 0.002 inch) Note: End play for a new camshaft assembly is 0.15 to 0.35 mm (0.006 to 0.014 inch).

Use the following procedure in order to determine the actual camshaft lobe lift: 1. Measure camshaft lobe height (F).

2. Measure base circle (G).

3. Subtract the base circle (G) from the camshaft lobe height (F). The difference is the actual camshaft lobe lift.

18 Specifications Section

RENR5077-11

i03021227

Camshaft SMCS Code: 1210

Bore in camshaft bearing after installation ................................ 92.00 ± 0.06 mm (3.622 ± 0.002 inch) Note: End play for a new camshaft assembly is 0.15 to 0.35 mm (0.006 to 0.014 inch).

Part No.: 143-8727 S/N: S2G1-Up

(3) Torque for 16 bolts ......... 55 ± 7 N·m (41 ± 5 lb ft)

Part No.: 143-8727 S/N: S2K1-Up

(F) Extension of the dowel from the end of the rear right hand camshaft and the front left hand camshaft ......... 22.0 ± 0.5 mm (0.87 ± 0.02 inch)

Part No.: 163-1419 S/N: S2N1-Up Part No.: 143-8728 S/N: S2P1-Up Part No.: 163-1451 S/N: S2T1-Up Part No.: 143-8728 S/N: S2W1-Up Part No.: 163-1451 S/N: S2Z1-Up

Illustration 21

g01447245

Use the following procedure in order to determine the actual camshaft lobe lift: 1. Measure camshaft lobe height (H).

2. Measure base circle (J).

Illustration 20

g01381231

(1) Left hand camshaft assembly (2) Right hand camshaft assembly

(A) Thickness of the groove in a new camshaft assembly .. 8.75 ± 0.05 mm (0.344 ± 0.002 inch) (C) Extension of the dowel from the camshaft assembly ........ 12.0 ± 0.5 mm (0.47 ± 0.02 inch) (D) Thickness of a new thrust washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch) (E) Dimensions for the journal surface Diameter of bearing journal ..... 91.88 ± 0.02 mm (3.617 ± 0.001 inch)

3. Subtract the base circle (J) from the camshaft lobe height (H). The difference is the actual camshaft lobe lift.

(G) Specified camshaft lobe lift Inlet lobe ..................... 13.250 mm (0.5217 inch) Injector lobe ................ 13.731 mm (0.5406 inch) Exhaust lobe ............... 13.250 mm (0.5217 inch)

RENR5077-11

19 Specifications Section

i03021222

Camshaft

(F) Extension of the dowel from the end of the rear right hand camshaft and the front left hand camshaft ......... 22.0 ± 0.5 mm (0.87 ± 0.02 inch)

SMCS Code: 1210 Part No.: 281-7848 S/N: B5G1-Up Part No.: 281-7848 S/N: MRG1-Up Part No.: 281-7848 S/N: PAG1-Up Part No.: 281-7849 S/N: MKH1-Up

Illustration 23

g01447245

Use the following procedure in order to determine the actual camshaft lobe lift: 1. Measure camshaft lobe height (H).

2. Measure base circle (J).

3. Subtract the base circle (J) from the camshaft lobe height (H). The difference is the actual camshaft lobe lift.

Illustration 22

g01381231

(1) Left hand camshaft assembly (2) Right hand camshaft assembly

(A) Thickness of the groove in a new camshaft assembly .. 8.75 ± 0.05 mm (0.344 ± 0.002 inch) (C) Extension of the dowel from the camshaft assembly ........ 12.0 ± 0.5 mm (0.47 ± 0.02 inch) (D) Thickness of a new thrust washer ...... 8.40 ± 0.05 mm (0.331 ± 0.002 inch) (E) Dimensions for the journal surface Diameter of bearing journal ..... 91.88 ± 0.02 mm (3.617 ± 0.001 inch) Bore in camshaft bearing after installation ................................ 92.00 ± 0.06 mm (3.622 ± 0.002 inch) Note: End play for a new camshaft assembly is 0.15 to 0.35 mm (0.006 to 0.014 inch).

(3) Torque for 16 bolts ......... 55 ± 7 N·m (41 ± 5 lb ft)

(G) Specified camshaft lobe lift Inlet lobe .................. 12.7300 mm (0.50118 inch) Injector lobe .............. 13.7313 mm (0.5406 inch) Exhaust lobe ........... 13.1000 mm (0.51575 inch)

20 Specifications Section

RENR5077-11

i03295700

Camshaft SMCS Code: 1210 Part No.: 231-9123 S/N: B5G1-Up Part No.: 231-9123 S/N: PAG1-Up

Illustration 25

g01447245

Use the following procedure in order to determine the actual camshaft lobe lift: 1. Measure camshaft lobe height (H).

2. Measure base circle (J).

Illustration 24

g01381231

(1) Left hand camshaft assembly (2) Right hand camshaft assembly

(A) Thickness of the groove in a new camshaft assembly .. 8.75 ± 0.05 mm (0.344 ± 0.002 inch) (C) Extension of the dowel from the camshaft assembly ........ 12.0 ± 0.5 mm (0.47 ± 0.02 inch)

3. Subtract the base circle (J) from the camshaft lobe height (H). The difference is the actual camshaft lobe lift.

(G) Specified camshaft lobe lift Inlet lobe ..................... 12.730 mm (0.5012 inch) Injector lobe ............ 13.7313 mm (0.54060 inch) Exhaust lobe ............... 13.100 mm (0.5157 inch) i03577164

(D) Thickness of a new thrust washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)

Valve Mechanism

(E) Dimensions for the journal surface

SMCS Code: 1102

Diameter of bearing journal ..... 91.88 ± 0.02 mm (3.617 ± 0.001 inch) Bore in camshaft bearing after installation ................................ 92.00 ± 0.06 mm (3.622 ± 0.002 inch) Note: End play for a new camshaft assembly is 0.15 to 0.35 mm (0.006 to 0.014 inch).

(3) Torque for 16 bolts ......... 55 ± 7 N·m (41 ± 5 lb ft) (F) Extension of the dowel from the end of the rear right hand camshaft and the front left hand camshaft ......... 22.0 ± 0.5 mm (0.87 ± 0.02 inch)

Part No.: 332-9690 S/N: M8A1-Up Part No.: 224-9869 S/N: S2A1-Up Part No.: 332-9690 S/N: M8B1-Up Part No.: 224-9869 S/N: S2B1-Up Part No.: 224-9869 S/N: S2D1-Up Part No.: 224-9869 S/N: S2E1-Up

RENR5077-11

21 Specifications Section

Part No.: 224-9869 S/N: S2F1-Up Part No.: 224-9869 S/N: B5G1-Up Part No.: 224-9869 S/N: MRG1-Up Part No.: 224-9869 S/N: PAG1-Up Part No.: 224-9869 S/N: S2G1-Up Part No.: 224-9869 S/N: MKH1-Up Part No.: 224-9869 S/N: S2H1-Up Part No.: 224-9869 S/N: S2J1-Up Part No.: 224-9869 S/N: S2K1-Up Part No.: 224-9869 S/N: S2L1-Up Part No.: 224-9869 S/N: S2M1-Up Part No.: 224-9869 S/N: S2N1-Up Part No.: 224-9869 S/N: S2P1-Up Part No.: 224-9869 S/N: S2R1-Up

Illustration 26

g01905795

Refer to Guideline for Reusable Parts and Salvage Operations, SEBF8172, “Visual Inspection of the 7N-4782 Lifter Guide Spring − 3500 Family of Engines” for lifter guide spring (2).

(1) Torque for two jam nuts ................... 70 ± 15 N·m (52 ± 11 lb ft)

Part No.: 224-9869 S/N: S2S1-Up

(A) Diameter of the rocker arm shaft assembly ............................. 45.000 ± 0.013 mm (1.7716 ± 0.0005 inch)

Part No.: 224-9869 S/N: S2T1-Up

(B) Dimensions for the valve lash

Part No.: 224-9869 S/N: S2W1-Up

Inlet ................................... 0.50 mm (0.020 inch) Exhaust ............................. 1.00 mm (0.039 inch)

Part No.: 224-9869 S/N: S2X1-Up

(C) Bore in the sleeve bearing for the rocker arm shaft assembly after installation ... 45.077 ± 0.015 mm (1.7747 ± 0.0006 inch)

Part No.: 224-9869 S/N: S2Y1-Up Part No.: 224-9869 S/N: S2Z1-Up

(D) Dimensions for the valve lifter assembly Diameter of the valve lifter assembly ............................. 29.900 ± 0.010 mm (1.1772 ± 0.0004 inch) Bore in the head for the valve lifter assembly ............................. 30.000 ± 0.025 mm (1.1811 ± 0.0010 inch)

22 Specifications Section

RENR5077-11

i03076672

Cylinder Head

Part No.: 101-0830 S/N: S2T1-Up

SMCS Code: 1100

Part No.: 101-0830 S/N: S2W1-Up

Part No.: 332-9694 S/N: M8A1-Up

Part No.: 101-0830 S/N: S2X1-Up

Part No.: 101-0830 S/N: S2A1-Up

Part No.: 101-0830 S/N: S2Y1-Up

Part No.: 332-9694 S/N: M8B1-Up

Part No.: 101-0830 S/N: S2Z1-Up

Part No.: 101-0830 S/N: S2B1-Up Part No.: 101-0830 S/N: S2D1-Up Part No.: 101-0830 S/N: S2E1-Up Part No.: 101-0830 S/N: S2F1-Up Part No.: 101-0830 S/N: B5G1-Up Part No.: 101-0830 S/N: MRG1-Up

Illustration 27

Part No.: 101-0830 S/N: PAG1-Up

(1) Locating pad

Part No.: 101-0830 S/N: S2G1-Up Part No.: 101-0830 S/N: MKH1-Up Part No.: 101-0830 S/N: S2H1-Up Part No.: 101-0830 S/N: S2J1-Up Part No.: 101-0830 S/N: S2K1-Up Part No.: 101-0830 S/N: S2L1-Up Part No.: 101-0830 S/N: S2M1-Up Part No.: 101-0830 S/N: S2N1-Up Part No.: 101-0830 S/N: S2P1-Up Part No.: 101-0830 S/N: S2R1-Up Part No.: 101-0830 S/N: S2S1-Up

g01429899

Typical example

NOTICE The pipe plug at location (2) is installed in the cylinder head for engines with dry exhaust manifolds. If the pipe plug is not installed into the water passage, the coolant will leak and engine damage will result. For engines with dry exhaust manifolds, make sure that the pipe plug is installed.

RENR5077-11

Illustration 28

23 Specifications Section

g01611158

Typical example Top view

(3) Before assembly, lubricate the thread of the pipe plug.

Use the following procedure to tighten the bolts of the cylinder head that is shown in Illustration 28: Note: Before assembly, coat the threads of the bolt with clean engine oil.

1. Tighten the bolt 1 through bolt 8 in the numerical sequence to 30 ± 5 N·m (22 ± 4 lb ft).

Illustration 29 Typical example

(A) Height of the new cylinder head ...... 142.00 ± 0.15 mm (5.591 ± 0.006 inch) Note: Before assembly, apply 6V-6640 Sealant to the bore of the ten cup plugs.

(B) Installation depth of two cup plugs from the top surface of the cylinder head .......... 9.0 ± 0.5 mm (0.35 ± 0.02 inch) (D) Installation depth of eight cup plugs from the top surface of the cylinder head .......... 1.0 ± 0.5 mm (0.04 ± 0.02 inch)

2. Tighten the bolt 1 through bolt 8 in the numerical sequence to 200 ± 15 N·m (150 ± 11 lb ft).

i03080402

3. Again tighten the bolt 1 through bolt 8 in the numerical sequence to 200 ± 15 N·m (150 ± 11 lb ft).

Cylinder Head Valves

4. Turn the bolt 1 through bolt 8 in the numerical sequence to an additional rotation of 180 ± 5 degrees.

Part No.: 332-9694 S/N: M8A1-Up

Note: Tighten the bolts (4) only after the cylinder head bolts have been given final torque.

(4) Torque for two bolts ..... 55 ± 10 N·m (41 ± 7 lb ft)

g01413732

SMCS Code: 1105

Part No.: 101-0830 S/N: S2A1-Up Part No.: 332-9694 S/N: M8B1-Up Part No.: 101-0830 S/N: S2B1-Up Part No.: 101-0830 S/N: S2D1-Up Part No.: 101-0830 S/N: S2E1-Up Part No.: 101-0830 S/N: S2F1-Up

24 Specifications Section

Part No.: 101-0830 S/N: B5G1-Up Part No.: 101-0830 S/N: MRG1-Up Part No.: 101-0830 S/N: PAG1-Up Part No.: 101-0830 S/N: S2G1-Up Part No.: 101-0830 S/N: MKH1-Up Part No.: 101-0830 S/N: S2H1-Up Part No.: 101-0830 S/N: S2J1-Up Part No.: 101-0830 S/N: S2K1-Up Part No.: 101-0830 S/N: S2L1-Up Part No.: 101-0830 S/N: S2M1-Up Part No.: 101-0830 S/N: S2N1-Up Part No.: 101-0830 S/N: S2P1-Up Part No.: 101-0830 S/N: S2R1-Up Part No.: 101-0830 S/N: S2S1-Up Part No.: 101-0830 S/N: S2T1-Up Part No.: 101-0830 S/N: S2W1-Up Part No.: 101-0830 S/N: S2X1-Up Part No.: 101-0830 S/N: S2Y1-Up Part No.: 101-0830, 335-6220 S/N: S2Z1-Up

RENR5077-11

RENR5077-11

25 Specifications Section

g01566713

Illustration 30 Typical example

Note: Before assembly, coat the inlet valve stems and the exhaust valve stems with clean engine oil.

(A) Height from the top of the cylinder head to the top of the valve guides ................. 26.0 ± 1.0 mm (1.02 ± 0.04 inch) (1) 316-5976 Spring Quantity ............................................................ 4 Length under test force ... 60.29 mm (2.374 inch) Test force .................. 460 ± 23 N (103.4 ± 5.2 lb) Free length after test .......... 74.8 mm (2.94 inch) Outside diameter ............. 43.47 mm (1.711 inch) (2) 316-5977 Spring Quantity ............................................................ 4 Length under test force ....... 57.5 mm (2.26 inch) Test force ............. 248.0 ± 12.4 N (55.8 ± 2.8 lb) Free length after test .......... 71.4 mm (2.81 inch) Outside diameter ................ 30.7 mm (1.21 inch) (3) Install the valve stem seal to the inlet valves.

(4) Install the washer to the exhaust valves.

(B) Dimension for the valves Diameter of the inlet valve stem .. 9.441 ± 0.010 mm (0.3717 ± 0.0004 inch)

Diameter of the exhaust valve stem ..................................... 12.464 ± 0.025 mm (0.4907 ± 0.0010 inch) (C) Bore in cylinder head for valve seat inserts Inlet .. 60.508 ± 0.025 mm (2.3822 ± 0.0010 inch) Exhaust ................................ 60.000 ± 0.025 mm (2.3622 ± 0.0010 inch) (5) Valve guide Bore of the inlet valve guide after installation .............................. 9.487 ± 0.025 mm (0.3735 ± 0.0010 inch) Bore of the exhaust valve guide after installation ............................ 12.619 ± 0.025 mm (0.4968 ± 0.0010 inch) (D) Valve face angles Inlet ................................... 19.40 ± 0.25 degrees Exhaust ............................. 44.40 ± 0.25 degrees (E) Diameter of the valve head ..... 56.00 ± 0.15 mm (2.205 ± 0.006 inch)

26 Specifications Section

RENR5077-11

i03670347

Turbocharger SMCS Code: 1052 Part No.: 333-2233 S/N: M8A1-Up Part No.: 145-7993 S/N: S2A1-Up Part No.: 333-8955 S/N: M8B1-Up Part No.: 145-7995 S/N: S2B1-Up Part No.: 145-7995 S/N: S2E1-Up Part No.: 145-7995 S/N: S2G1-Up Illustration 31

g01441032

Typical example

Part No.: 145-7995 S/N: S2K1-Up

(F) Diameter of the valve seat inserts Inlet .. 60.627 ± 0.015 mm (2.3869 ± 0.0006 inch) Exhaust ................................. 60.119 ± 0.015 mm (2.3669 ± 0.0006 inch) (G) Angle of the face of the valve seat inserts Inlet ................................... 20.00 ± 0.25 degrees Exhaust ............................. 45.00 ± 0.25 degrees (H) Depth of bore in the cylinder head for the valve seat insert ................................ 16.00 ± 0.15 mm (0.630 ± 0.006 inch) (J) Outside diameter of the face of the valve seat insert .................................... 53.6 mm (2.11 inch)

Illustration 32

g01616117

Note: Before assembly, lubricate the threads and the bearing surfaces of the bolts with 4C-5599 Anti-Seize Compound.

(1) Torque for the bolts ........ 54 ± 5 N·m (40 ± 4 lb ft)

RENR5077-11

27 Specifications Section

3. Again, tighten the clamp assemblies to 14 ± 3 N·m (124 ± 27 lb in). i03414341

Turbocharger SMCS Code: 1052 Part No.: 173-7676 S/N: S2H1-Up Part No.: 173-7676 S/N: S2L1-Up Part No.: 259-8431 S/N: S2M1-Up Part No.: 165-6678 S/N: S2T1-Up Illustration 33

g01619282

Rear view

Before assembly, lubricate the threads and the bearing surfaces of the bolts with 4C-5599 Anti-Seize Compound.

Use the following procedure in order to tighten the bolts of the half flange (2).

1. Tighten bolts 3 in any sequence to 54 ± 5 N·m (40 ± 4 lb ft).

2. Tighten bolts 4 in any sequence to 54 ± 5 N·m (40 ± 4 lb ft).

Illustration 35

g01616117

Note: Before assembly, lubricate the threads and the bearing surface of the bolts with 4C-5599 Anti-Seize Compound.

(1) Torque for the bolts to the exhaust manifold ......................... 54 ± 5 N·m (40 ± 4 lb ft)

Illustration 34

g01538253

Use the following procedure to tighten the clamp assembly (5) and turbine clamp assembly (6): 1. Tighten the clamp assemblies to 14 ± 3 N·m (124 ± 27 lb in).

2. Gently tap around the clamp assemblies with a soft faced hammer.

28 Specifications Section

RENR5077-11

i03411202

Turbocharger SMCS Code: 1052 Part No.: 159-8828 S/N: S2H1-Up Part No.: 159-8828 S/N: S2J1-Up Part No.: 176-3231 S/N: S2M1-Up Part No.: 159-8828 S/N: S2R1-Up Part No.: 159-8828 S/N: S2S1-Up Part No.: 159-8828, 250-6111 S/N: S2Z1-Up

Illustration 36

g01770114

Use the following procedure in order to tighten the bolts for the half flange (2): 1. Tighten bolts (3) in any sequence to 54 ± 5 N·m (40 ± 4 lb ft).

2. Tighten bolts (4) in any sequence to 54 ± 5 N·m (40 ± 4 lb ft).

(5) Cartridge's bolt torque ... 40 ± 2 N·m (30 ± 1 lb ft)

Illustration 37

g01616117

Note: Before assembly, lubricate the threads and the bearing surface of the bolts with 4C-5599 Anti-Seize Compound.

(1) Torque for the bolts ........ 54 ± 5 N·m (40 ± 4 lb ft)

RENR5077-11

29 Specifications Section

i03035044

Turbocharger SMCS Code: 1052 Part No.: 167-1762 S/N: S2H1-Up Part No.: 167-1762 S/N: S2J1-Up Part No.: 167-1762 S/N: S2R1-Up Part No.: 167-1762 S/N: S2S1-Up Part No.: 167-1762 S/N: S2Z1-Up

Illustration 38

g01753233

Use the following procedure in order to tighten the bolts for the half flange (2): 1. Tighten bolts (3) in any sequence to 54 ± 5 N·m (40 ± 4 lb ft).

2. Tighten bolts (4) in any sequence to 54 ± 5 N·m (40 ± 4 lb ft).

(5) Cartridge's bolt torque ... 40 ± 2 N·m (30 ± 1 lb ft) Illustration 39

g01538593

Note: Before assembly, apply 4C-5599 Anti-Seize Compound to the threads and to the bearing surface of the bolts.

(1) Torque for 20 bolts ......... 54 ± 5 N·m (40 ± 4 lb ft)

30 Specifications Section

RENR5077-11

Torque ............................ 40 ± 5 N·m (30 ± 4 lb ft) (2) Bolt Torque ............................ 65 ± 5 N·m (48 ± 4 lb ft) (3) Clamp Tighten each clamp in two places.

Torque ............................ 60 ± 5 N·m (44 ± 4 lb ft) i01909990

Turbocharger SMCS Code: 1052 Part No.: 4P-2581 S/N: S2R1-Up

Illustration 40

g01538619

(2) Torque for four bolts ....... 54 ± 5 N·m (40 ± 4 lb ft) (3) Torque for eight bolts for the turbine housing .......................... 40 ± 2 N·m (30 ± 1 lb ft) (4) Torque for eight bolts for the compressor housing. ......................... 40 ± 2 N·m (30 ± 1 lb ft) i02051385

Turbocharger SMCS Code: 1052 Part No.: 238-7771 S/N: B5G1-Up Part No.: 238-7774 S/N: MRG1-Up

Illustration 42

g00976451

(1) Bolt

Part No.: 238-7772 S/N: MKH1-Up

(2) Washers (3) Nut Lubricate the bearing surfaces of bolt (1), washers (2), and nut (3) and lubricate the threads of the bolt and the nut with 4C-5597 Anti-Seize Compound.

(4) Bolt Torque .......................... 55 ± 10 N·m (41 ± 7 lb ft) (5) Lock

Illustration 41

(1) Bolt

g01052152

After assembly, bend the short end of the lock against the bolt head. Bend the long end of the lock around the turbine clamp. Do not reuse an opened lock.

(6) Washer

RENR5077-11

31 Specifications Section

Lubricate the bearing surfaces of washer (6) with 4C-5597 Anti-Seize Compound.

(7) Bolt Lubricate the bolt's bearing surfaces and threads with 4C-5597 Anti-Seize Compound.

Torque .......................... 45 ± 10 N·m (33 ± 7 lb ft)

i03149240

Turbocharger SMCS Code: 1052 Part No.: 238-7769 S/N: PAG1-Up

(8) Bolt Torque .......................... 55 ± 10 N·m (41 ± 7 lb ft) i03140083

Turbocharger SMCS Code: 1052 Part No.: 159-8829 S/N: S2R1-Up Part No.: 159-8829 S/N: S2S1-Up

Illustration 44

g01619692

Rear view

Part No.: 159-8829 S/N: S2X1-Up

(1) Torque for two clamp assemblies ...... 60 ± 5 N·m (44 ± 4 lb ft) (2) Torque for 12 bolts ......... 40 ± 5 N·m (30 ± 4 lb ft) (3) Torque for 18 bolts ......... 65 ± 5 N·m (48 ± 4 lb ft)

Illustration 43

g01616497

Rear view

(1) Torque for four V-band clamp assemblies ..................... 60 ± 5 N·m (44 ± 4 lb ft)

32 Specifications Section

RENR5077-11

i03119342

Turbocharger Support SMCS Code: 1052 Part No.: 139-0600 S/N: S2G1-Up Part No.: 139-0600 S/N: S2H1-Up Part No.: 139-0600 S/N: S2P1-Up Part No.: 139-0600 S/N: S2R1-Up Part No.: 139-0600 S/N: S2Z1-Up

Illustration 45

(1) Torque for 21 bolts ... 120 ± 20 N·m (90 ± 15 lb ft) (2) Torque for 10 bolts .. 135 ± 20 N·m (100 ± 15 lb ft)

g01595655

RENR5077-11

33 Specifications Section

i02835300

i03341711

Accumulator

Exhaust Bypass Valve

SMCS Code: 1320

SMCS Code: 1057

S/N: S2Y1-Up

Part No.: 165-4406 S/N: PAG1-Up Part No.: 165-4406, 282-3015 S/N: MKH1-Up

Illustration 47

Illustration 46

g01433346

(1) Accumulator assembly Charging medium ............................ Dry nitrogen Internal volume of compartment for gas .......................................... 3786 mL (231 in3) Charged pressure ..................... 138 kPa (20 psi) Service pressure ....................... 138 kPa (20 psi) Bursting pressure ............. 34500 kPa (5000 psi)

g01414647

(1) Torque for the locknut .................. 12.5 ± 1.0 N·m (110 ± 9 lb in) (2) 7E-4677 Spring Free length ........................ 115.3 mm (4.54 inch) Outside diameter ............ 82.55 mm (3.250 inch) (3) 7E-4676 Spring Free length ........................ 115.3 mm (4.54 inch) Outside diameter ............ 62.48 mm (2.460 inch) (4) Torque for the nut ..... 14 ± 3 N·m (125 ± 27 lb in) (5) Torque for the five screws .............. 6.5 ± 1.0 N·m (60 ± 9 lb in) (6) Before assembly, lubricate the threads and the bearing surfaces of the setscrew with 4C-5599 Anti-Seize Compound.

34 Specifications Section

RENR5077-11

i03341316

Exhaust Bypass Valve SMCS Code: 1057 Part No.: 259-1436 S/N: B5G1-Up Part No.: 259-1436 S/N: PAG1-Up

Illustration 49

Illustration 48

g01717353

(7) Exhaust bypass valve (8) Locknut (9) Gasket

1. Clean the stud, the locknut, and the base of the locknut prior to assembly.

2. Apply 2P-2333 High Temperature Sealer to the threads of the stud that extend through the flange of the exhaust bypass valve and to the bottom of the mating face of each locknut.

3. Tighten two diagonal locknuts.

Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft) 4. Tighten the remaining locknuts.

Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft) 5. Tighten all four locknuts again.

Torque ............................. 47 ± 9 N·m (35 ± 7 lb ft)

g01414647

(1) Torque for the locknut .................. 12.5 ± 1.0 N·m (110 ± 9 lb in) (2) 259-1435 Spring Free length .......................... 127 mm (5.00 inch) Outside diameter ............ 82.55 mm (3.250 inch) (3) 259-1434 Spring Free length .......................... 127 mm (5.00 inch) Outside diameter ............ 62.48 mm (2.460 inch) (4) Torque for the nut ..... 14 ± 3 N·m (125 ± 27 lb in) (5) Torque for the five screws .............. 6.5 ± 1.0 N·m (60 ± 9 lb in) (6) Before assembly, lubricate the threads and the bearing surfaces of the setscrew with 4C-5599 Anti-Seize Compound.

RENR5077-11

35 Specifications Section

i03697281

Exhaust Manifold SMCS Code: 1059 Part No.: 334-7032 S/N: M8A1-Up Part No.: 334-7032 S/N: M8B1-Up

Illustration 50

g01717353

(7) Exhaust bypass valve (8) Locknut (9) Gasket Illustration 51

1. Clean the stud, the locknut, and the base of the locknut prior to assembly.

2. Apply 2P-2333 High Temperature Sealer to the threads of the stud that extend through the flange of the exhaust bypass valve and to the bottom of the mating face of each locknut.

3. Tighten two diagonal locknuts.

Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft) 4. Tighten the remaining locknuts.

Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft) 5. Tighten all four locknuts again.

Torque ............................. 47 ± 9 N·m (35 ± 7 lb ft)

g01988413

Note: Before assembly, lubricate the threads and the bearing surfaces of the bolts with 4C-5599 Anti-Seize Compound.

(1) Torque for the bolts ........ 65 ± 5 N·m (48 ± 4 lb ft)

36 Specifications Section

RENR5077-11

i03114083

i03114039

Exhaust Manifold

Exhaust Manifold

SMCS Code: 1059

SMCS Code: 1059

Part No.: 123-0324 S/N: S2A1-Up

Part No.: 129-5488, 161-2502 S/N: S2A1-Up

Part No.: 123-0324 S/N: S2B1-Up

Part No.: 129-5488, 161-2502 S/N: S2B1-Up

Part No.: 123-0324 S/N: S2D1-Up

Part No.: 129-5488, 161-2502 S/N: S2D1-Up

Part No.: 123-0324 S/N: S2E1-Up

Part No.: 129-5488, 161-2502 S/N: S2E1-Up

Part No.: 123-0324 S/N: S2F1-Up

Part No.: 129-5488, 161-2502 S/N: S2F1-Up Part No.: 129-5488, 161-2502 S/N: S2G1-Up Part No.: 129-5488, 161-2502 S/N: S2H1-Up Part No.: 129-5488, 161-2502 S/N: S2J1-Up Part No.: 129-5488, 161-2502 S/N: S2K1-Up Part No.: 129-5488, 161-2502 S/N: S2L1-Up

Illustration 52

g01592399

Top view of engine

Note: Apply 4C-5599 Anti-Seize Compound to the threads of the bolts and to the face of the washers.

Tighten diagonally opposite bolts simultaneously.

(1) Torque for the bolts ........ 55 ± 5 N·m (41 ± 4 lb ft)

Part No.: 129-5488, 161-2502 S/N: S2M1-Up Part No.: 129-5488, 161-2502 S/N: S2N1-Up Part No.: 129-5488, 161-2502 S/N: S2P1-Up Part No.: 129-5488, 161-2502 S/N: S2R1-Up Part No.: 129-5488, 161-2502, 161-2503, 167-1759 S/N: S2S1-Up Part No.: 129-5488, 161-2502, 167-1759 S/N: S2T1-Up Part No.: 129-5488, 161-2502 S/N: S2W1-Up Part No.: 129-5488, 161-2502, 161-2503 S/N: S2X1-Up

Illustration 53

g01592401

Note: Apply 4C-5599 Anti-Seize Compound to the threads of the bolts and to the face of the washers.

(2) Torque for the bolts ........ 65 ± 5 N·m (48 ± 4 lb ft)

Part No.: 129-5488, 161-2502, 161-2503 S/N: S2Y1-Up Part No.: 129-5488, 161-2502, 167-1759 S/N: S2Z1-Up

RENR5077-11

Illustration 54

37 Specifications Section

g01592366

Typical example Top view of engine

Illustration 55

g01592373

Rear view of engine

Note: Apply 4C-5599 Anti-Seize Compound to the threads of the bolts and to the face of the washers.

Tighten diagonally opposite bolts simultaneously.

(1) Torque for the bolts ........ 55 ± 5 N·m (41 ± 4 lb ft)

38 Specifications Section

RENR5077-11

i02051171

Exhaust Manifold SMCS Code: 1059 Part No.: 238-9120 S/N: PAG1-Up Part No.: 239-0731 S/N: MKH1-Up

Illustration 56

g01052090

(1) Clamp

Torque ............................ 35 ± 5 N·m (26 ± 4 lb ft)

Torque ............................ 25 ± 6 N·m (18 ± 4 lb ft) (2) Bolt Lubricate the washer face and the thread with 5P-3931 Anti-Seize Compound before assembly. Tighten diagonally opposite bolts simultaneously.

Torque ............................ 55 ± 5 N·m (41 ± 4 lb ft) (3) Bolt Lubricate the washer face and the thread with 5P-3931 Anti-Seize Compound before assembly.

(4) Bolt Lubricate the washer face and the thread with 5P-3931 Anti-Seize Compound before assembly.

(5) Stud

(6) Bolt Torque ............................ 55 ± 5 N·m (41 ± 4 lb ft)

RENR5077-11

39 Specifications Section

i03695742

Exhaust Manifold SMCS Code: 1059 Part No.: 240-0745 S/N: B5G1-Up Part No.: 239-0732 S/N: MRG1-Up

g01987274

Illustration 57 Typical example

(1) Before assembly, lubricate the threads and the bearing surfaces of the bolts with 4C-5599 Anti-Seize Compound.

Note: Before assembly, lubricate the threads and the bearing surfaces of the clamps with 4C-5599 Anti-Seize Compound.

Part No.: 7N-6962 S/N: M8A1-Up Part No.: 7N-6962 S/N: S2A1-Up Part No.: 7N-6962 S/N: M8B1-Up

(2) Torque for the clamps ........................ 25 ± 6 N·m (221 ± 53 lb in)

Part No.: 7N-6962 S/N: S2B1-Up

(3) Before assembly, lubricate the threads and the bearing surfaces of the locknuts with 4C-5599 Anti-Seize Compound.

Part No.: 7N-6962 S/N: S2D1-Up

Note: Before assembly, lubricate the threads and the bearing surfaces of the bolts with 4C-5599 Anti-Seize Compound. Tighten diagonally opposite bolts simultaneously.

Part No.: 7N-6962 S/N: S2E1-Up Part No.: 7N-6962 S/N: S2F1-Up

(4) Torque for the bolts ........ 55 ± 5 N·m (41 ± 4 lb ft)

Part No.: 7N-6962 S/N: S2G1-Up

i02953003

Part No.: 7N-6962 S/N: S2H1-Up

Exhaust Flange SMCS Code: 1061

Part No.: 7N-6962 S/N: S2J1-Up

40 Specifications Section

RENR5077-11

Part No.: 7N-6962 S/N: S2K1-Up

i02836282

Exhaust Flange

Part No.: 7N-6962 S/N: S2L1-Up

SMCS Code: 1061

Part No.: 7N-6962 S/N: S2M1-Up

Part No.: 103-6668 S/N: PAG1-Up

Part No.: 7N-6962 S/N: S2N1-Up

Part No.: 103-6668 S/N: MKH1-Up

Part No.: 7N-6962 S/N: S2P1-Up

Part No.: 103-6668 S/N: S2J1-Up

Part No.: 7N-6962 S/N: S2R1-Up

Part No.: 103-6668 S/N: S2K1-Up

Part No.: 7N-6962 S/N: S2S1-Up

Part No.: 103-6668 S/N: S2P1-Up

Part No.: 7N-6962 S/N: S2T1-Up

Part No.: 103-6668 S/N: S2R1-Up

Part No.: 7N-6962 S/N: S2W1-Up

Part No.: 103-6668 S/N: S2S1-Up

Part No.: 7N-6962 S/N: S2X1-Up

Part No.: 103-6668 S/N: S2T1-Up

Part No.: 7N-6962 S/N: S2Y1-Up

Part No.: 103-6668 S/N: S2W1-Up Part No.: 103-6668 S/N: S2X1-Up Part No.: 103-6668 S/N: S2Y1-Up Part No.: 103-6668 S/N: S2Z1-Up

Illustration 58

g01468407

Typical example

(1) Apply 4C-5599 Anti-Seize Compound to the threads of 12 bolts.

Illustration 59

g01414164

Typical example

(1) Apply 4C-5599 Anti-Seize Compound to the threads of the 16 bolts.

RENR5077-11

41 Specifications Section

i01659336

i02954024

Air Cleaner

Air Cleaner Adapter

SMCS Code: 1051

SMCS Code: 1051

Part No.: 5N-8728 S/N: S2A1-Up

Part No.: 7W-9828 S/N: M8A1-Up Part No.: 7W-9828 S/N: S2A1-Up Part No.: 7W-9828 S/N: M8B1-Up Part No.: 7W-9828 S/N: S2B1-Up Part No.: 7W-9828 S/N: S2D1-Up Part No.: 7W-9828 S/N: S2E1-Up Part No.: 7W-9828 S/N: S2F1-Up Part No.: 7W-9828 S/N: S2G1-Up

Illustration 60

g00856159

(1) Washer In order to align the precleaner with the air cleaner, use the 8T-4896 Hard Washers as spacers for the air cleaner.

(2) Bolt Torque .............................. 12 ± 4 N·m (9 ± 3 lb ft) (3) Washer In order to align the precleaner with the air cleaner, use the 8T-4122 Hard Washers as spacers for the precleaner.

Part No.: 7W-9828 S/N: S2K1-Up Part No.: 7W-9828 S/N: S2N1-Up Part No.: 7W-9828 S/N: S2P1-Up Part No.: 7W-9828 S/N: S2R1-Up Part No.: 7W-9828 S/N: S2W1-Up Part No.: 7W-9828 S/N: S2Z1-Up

Illustration 61

g01469799

(1) Torque for 48 locknuts ....................... 12 ± 4 N·m (105 ± 35 lb in)

42 Specifications Section

RENR5077-11

i02954022

Air Cleaner Adapter

i02894887

Engine Air Cleaner Service Indicator

SMCS Code: 1051

SMCS Code: 7452

Part No.: 4P-2013 S/N: MRG1-Up

Part No.: 213-1412, 7N-6782 S/N: S2A1-Up

Part No.: 4P-2013 S/N: S2G1-Up

Part No.: 213-1412, 7N-6782 S/N: S2B1-Up

Part No.: 4P-2013 S/N: S2H1-Up

Part No.: 213-1412, 7N-6782 S/N: S2G1-Up

Part No.: 4P-2013 S/N: S2J1-Up

Part No.: 213-1412, 7N-6782 S/N: S2H1-Up

Part No.: 4P-2013 S/N: S2L1-Up

Part No.: 213-1412, 7N-6782 S/N: S2P1-Up

Part No.: 4P-2013 S/N: S2M1-Up

Part No.: 213-1412, 7N-6782 S/N: S2R1-Up

Part No.: 4P-2013 S/N: S2R1-Up

Part No.: 213-1412, 7N-6782 S/N: S2Z1-Up

Part No.: 4P-2013 S/N: S2S1-Up Part No.: 4P-2013 S/N: S2T1-Up Part No.: 4P-2013 S/N: S2X1-Up Part No.: 4P-2013 S/N: S2Z1-Up

Illustration 63

g01440984

Rear view of engine Illustration 62

g01469798

(1) Torque for 28 locknuts ....................... 12 ± 4 N·m (105 ± 35 lb in)

(1) Air cleaner

Note: Install the air filter change indicator group with the filter side toward the air cleaner.

(2) Torque for the two air filter change indicator groups ....................... 2.0 ± 0.7 N·m (18 ± 6 lb in)

RENR5077-11

43 Specifications Section

i03688471

Air Inlet and Exhaust Lines SMCS Code: 1058; 1061 Part No.: 334-4668 S/N: M8A1-Up Part No.: 334-4668 S/N: M8B1-Up

Illustration 65

g01983494

Illustration 66

g01983495

Bolt tightening sequence

(2) Torque for the bolts .. 120 ± 20 N·m (89 ± 15 lb ft) Note: Before assembly, lubricate the threads of the plugs with 4C-5599 Anti-Seize Compound.

Illustration 64

g01983493

(1) Before assembly, lubricate the bore of the O-ring seals lightly with 5P-3975 Rubber Lubricant.

(3) Torque for the plugs .. 25 ± 5 N·m (221 ± 44 lb in) (4) Use the following procedure in order to tighten the bolts of the aftercooler assembly: 1. Assemble the seals to the aftercooler core.

2. Temporarily secure the bottom seal to the aftercooler with tape. Do not use an adhesive, a silicone lubricant, or any other lubricant for retention of the seal.

3. Assemble the aftercooler with seals to the inlet manifold.

4. Inspect the bottom seal in order to ensure that the seal is seating correctly in the recess.

44 Specifications Section

RENR5077-11

5. Install the aftercooler cover.

6. Inspect the upper seal in order to ensure that the seal is seating correctly in the recess.

Part No.: 173-2947 S/N: S2T1-Up Part No.: 173-2947 S/N: S2W1-Up

7. Install the cover bolts. Hand tighten the cover bolts.

Part No.: 173-2947 S/N: S2X1-Up

8. Tighten the bolts in the numerical sequence to 24 ± 6 N·m (212 ± 53 lb in). Refer to Illustration 66.

Part No.: 173-2947 S/N: S2Y1-Up

9. Again, tighten the bolts in the numerical sequence to 47 ± 9 N·m (35 ± 7 lb ft). Refer to Illustration 66.

Part No.: 173-2947 S/N: S2Z1-Up

10. Remove the tape. i03295780

Air Inlet and Exhaust Lines SMCS Code: 1058; 1061 Part No.: 173-2947 S/N: S2A1-Up Part No.: 173-2947 S/N: S2B1-Up Part No.: 173-2947 S/N: S2D1-Up Part No.: 173-2947 S/N: S2E1-Up Part No.: 173-2947 S/N: S2F1-Up Part No.: 173-2947 S/N: S2G1-Up Part No.: 173-2947 S/N: S2H1-Up Part No.: 162-5718, 173-2947 S/N: S2J1-Up Part No.: 173-2947 S/N: S2K1-Up Part No.: 173-2947 S/N: S2L1-Up Part No.: 173-2947 S/N: S2M1-Up Part No.: 162-5718, 173-2947 S/N: S2N1-Up Part No.: 173-2947 S/N: S2P1-Up Part No.: 173-2947 S/N: S2R1-Up Part No.: 173-2947 S/N: S2S1-Up

RENR5077-11

Illustration 67 Right side view

(1) Lubricate the bore for the O-ring seals with glycerin or an approved equivalent.

45 Specifications Section

g01679613

46 Specifications Section

Illustration 68

RENR5077-11

g01614754

Bolt tightening sequence

(2) Use the following procedure in order to tighten the bolts of the aftercooler assembly: 1. Assemble the seals to the aftercooler core.

2. Temporarily secure the bottom seal to the aftercooler with tape. Do not use an adhesive, a silicone lubricant, or any other lubricant for retention of the seal.

3. Assemble the aftercooler with seals to the inlet manifold.

4. Inspect the bottom seal in order to ensure that the seal is seating correctly in the recess.

5. Install the aftercooler cover.

6. Inspect the upper seal in order to ensure that the seal is seating correctly in the recess.

7. Install the cover bolts. Hand tighten the cover bolts.

8. Tighten the bolts in the numerical sequence to 24 N·m (18 lb ft).

9. Again, tighten the bolts in the numerical sequence to 47 N·m (35 lb ft).

10. Remove the tape.

Note: Lubricate the threads of the plugs with 4C-5599 Anti-Seize Compound before assembly.

(3) Torque for three plugs .... 20 ± 5 N·m (15 ± 4 lb ft)

RENR5077-11

47 Specifications Section

i03690160

Air Inlet and Exhaust Lines SMCS Code: 1058; 1061 Part No.: 107-0860 S/N: S2A1-Up Part No.: 107-0860 S/N: S2B1-Up Part No.: 107-0860 S/N: S2D1-Up Part No.: 107-0860 S/N: S2E1-Up Part No.: 107-0860 S/N: S2F1-Up

Illustration 69 Right side view of engine

g01984493

48 Specifications Section

Illustration 70

RENR5077-11

g01614673

Bolt tightening sequence

(1) Before assembly, lubricate the bore of the O-ring seals lightly with 5P-3975 Rubber Lubricant.

(2) Use the following procedure in order to tighten the bolts of the aftercooler assembly: 1. Assemble the seals to the aftercooler core.

2. Temporarily secure the bottom seal to the aftercooler with tape. Do not use an adhesive, a silicone lubricant, or any other lubricant for retention of the seal.

3. Assemble the aftercooler with seals to the inlet manifold.

4. Inspect the bottom seal in order to ensure that the seal is seating correctly in the recess.

5. Install the aftercooler cover.

6. Inspect the upper seal in order to ensure that the seal is seating correctly in the recess.

7. Install the cover bolts. Hand tighten the cover bolts.

8. Tighten the bolts in the numerical sequence to 24 ± 6 N·m (212 ± 53 lb in). Refer to Illustration 70.

9. Again, tighten the bolts in the numerical sequence to 24 ± 6 N·m (212 ± 53 lb in). Refer to Illustration 70.

10. Remove the tape.

Note: Before assembly, lubricate the threads of the plugs with 4C-5599 Anti-Seize Compound.

(3) Torque for the plugs .. 20 ± 5 N·m (177 ± 44 lb in) (4) Torque for the bolts .. 120 ± 20 N·m (89 ± 15 lb ft)

RENR5077-11

49 Specifications Section

i03137489

Air Inlet and Exhaust Lines SMCS Code: 1058; 1061 Part No.: 144-2885 S/N: S2P1-Up Part No.: 107-0862 S/N: S2R1-Up Part No.: 107-0862 S/N: S2S1-Up Part No.: 144-2885 S/N: S2W1-Up

g01614613

Illustration 71 Right side view of engine

Illustration 72

g01614614

View A-A

(1) Lubricate the bore for the O-ring seals with glycerin or an approved equivalent.

50 Specifications Section

RENR5077-11

g01614616

Illustration 73 Bolt tightening sequence

(2) Use the following procedure in order to tighten the bolts of the aftercooler assembly: 1. Assemble the seals to the aftercooler core.

2. Temporarily secure the bottom seal to the aftercooler with tape. Do not use an adhesive, a silicone lubricant, or any other lubricant for retention of the seal.

3. Assemble the aftercooler with seals to the inlet manifold.

4. Inspect the bottom seal in order to ensure that the seal is seating correctly in the recess.

Illustration 74

g01614623

5. Install the aftercooler cover.

View B-B

6. Inspect the upper seal in order to ensure that the seal is seating correctly in the recess.

Note: Lubricate the threads of the plugs with 4C-5599 Anti-Seize Compound before assembly.

7. Install the cover bolts. Hand tighten the cover bolts.

(4) Torque for two plugs ...... 20 ± 5 N·m (15 ± 4 lb ft)

8. Tighten the bolts in the numerical sequence to 24 N·m (18 lb ft).

9. Again, tighten the bolts in the numerical sequence to 47 N·m (35 lb ft).

10. Remove the tape.

(3) Torque for the bolts .. 120 ± 20 N·m (90 ± 15 lb ft)

RENR5077-11

51 Specifications Section

i03688482

Air Shutoff SMCS Code: 1078 Part No.: 335-1898 S/N: M8A1-Up Part No.: 335-1898 S/N: M8B1-Up

g01983517

Illustration 75

(1) Air shutoff group Maximum operating temperature of the valve .......................................... 204 °C (399 °F) Maximum operating pressure of the valve ......................................... 300 kPa (44 psi) Note: Before you assemble the limit switch assembly (2) in the shutoff valve, apply 4C-5599 Anti-Seize Compound to the threads of the plug.

(2) Torque for the limit switch assembly ..... 16.3 N·m (12.0 lb ft)

Illustration 76

g01927222

52 Specifications Section

RENR5077-11

Note: Apply 4C-5599 Anti-Seize Compound to the threads of the bolts (3) and to the threads of the bolts (7).

(3) Torque for the bolts ......... 7 ± 1 N·m (62 ± 9 lb in) (4) Apply 4C-5599 Anti-Seize Compound to the shaft of the air shutoff assembly.

Note: Before assembly, apply 4C-9614 Silicone Sealant between the body (5) and the cover (6).

(7) Torque for the bolts ........................ 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in)

Part No.: 214-5543 S/N: S2P1-Up Part No.: 214-5543 S/N: S2S1-Up Part No.: 214-5543 S/N: S2T1-Up Part No.: 214-5543 S/N: S2W1-Up Part No.: 214-5543 S/N: S2Z1-Up

(9) Solenoid assembly Operating voltage .......................... 18 to 32 VDC Resistance at 25 °C (77 °F) ................................ 1.485 to 1.815 Ohms Torque for the bolts (8) .................. 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in) i03601965

Air Shutoff SMCS Code: 1078 Part No.: 214-5543 S/N: S2A1-Up Part No.: 214-5543 S/N: S2B1-Up Part No.: 214-5543 S/N: S2D1-Up

Illustration 77

Part No.: 214-5543 S/N: S2E1-Up

(1) Air shutoff group

Part No.: 214-5543 S/N: S2F1-Up Part No.: 214-5543 S/N: S2G1-Up

g01927221

Rear view

Maximum operating temperature of the valve .......................................... 204 °C (399 °F) Maximum operating pressure of the valve ......................................... 300 kPa (44 psi)

Part No.: 214-5543, 274-5749 S/N: S2H1-Up

Note: Before you assemble the limit switch assembly (2) in the shutoff valve, apply 4C-5599 Anti-Seize Compound to the threads of the plug.

Part No.: 214-5543 S/N: S2J1-Up

(2) Torque for the limit switch assembly ..... 16.3 N·m (12.0 lb ft)

Part No.: 214-5543 S/N: S2K1-Up Part No.: 214-5543 S/N: S2L1-Up Part No.: 214-5543 S/N: S2M1-Up Part No.: 214-5543 S/N: S2N1-Up

RENR5077-11

53 Specifications Section

Part No.: 106-9872 S/N: S2F1-Up Part No.: 106-9872 S/N: B5G1-Up Part No.: 106-9872 S/N: MRG1-Up Part No.: 106-9872 S/N: PAG1-Up Part No.: 106-9872 S/N: S2G1-Up Part No.: 106-9872 S/N: MKH1-Up Part No.: 106-9872 S/N: S2H1-Up Part No.: 106-9872 S/N: S2J1-Up Illustration 78

g01927222

Note: Apply 4C-5599 Anti-Seize Compound to the threads of the bolts (3) and to the threads of the bolts (7).

(3) Torque for the bolts ......... 7 ± 1 N·m (62 ± 9 lb in) (4) Apply 4C-5599 Anti-Seize Compound to the shaft of the air shutoff assembly.

Note: Before assembly, apply 4C-9614 Silicone Sealant between the body (5) and the cover (6).

Part No.: 106-9872 S/N: S2K1-Up Part No.: 106-9872 S/N: S2L1-Up Part No.: 106-9872 S/N: S2M1-Up Part No.: 106-9872 S/N: S2N1-Up Part No.: 106-9872 S/N: S2P1-Up

(7) Torque for the bolts ........................ 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in)

Part No.: 106-9872 S/N: S2R1-Up

(9) Solenoid assembly

Part No.: 106-9872 S/N: S2S1-Up

Operating voltage .......................... 18 to 32 VDC Resistance at 25 °C (77 °F) ................................ 1.485 to 1.815 Ohms Torque for the bolts (8) .................. 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in) i03557502

Engine Oil Pump

Part No.: 106-9872 S/N: S2T1-Up Part No.: 106-9872 S/N: S2W1-Up Part No.: 106-9872 S/N: S2X1-Up

SMCS Code: 1304

Part No.: 106-9872 S/N: S2Y1-Up

Part No.: 106-9872 S/N: S2A1-Up

Part No.: 106-9872 S/N: S2Z1-Up

Part No.: 106-9872 S/N: S2B1-Up Part No.: 106-9872 S/N: S2D1-Up Part No.: 106-9872 S/N: S2E1-Up

54 Specifications Section

RENR5077-11

Diameter of new shaft .......... 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch) Bore in the sleeve bearing for the new shaft ...................................... 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch) (D) Extension of the hollow dowel from the oil pump cover ................. 6.0 ± 0.5 mm (0.24 ± 0.02 inch) (E) Distance from the end of the pump shaft assembly to the gear face ........... 34.0 ± 0.5 mm (1.34 ± 0.02 inch) (F) Dimensions for the pump drive shaft Illustration 79

g01554195

Note: The rotation of the drive gear is clockwise when you view the engine oil pump from the drive end.

Note: Before you install the pump, lubricate the moving parts with clean engine oil. Rotate the pump by hand in order to ensure that the pump rotates freely.

(1) 107-7175 Spring Length under test force ..................... 107.16 mm (4.219 inch) Test force ............ 555.6 ± 20.0 N (124.9 ± 4.5 lb) Free length after test ........ 144.5 mm (5.69 inch) Outside diameter ............ 27.00 mm (1.063 inch)

Illustration 80

g01883030

(B) Dimension for the gears Length of new gear ............. 110.000 ± 0.015 mm (4.3307 ± 0.0006 inch) Depth of the bore in the oil pump body for new gear ....... 110.15 ± 0.02 mm (4.337 ± 0.001 inch) (C) Dimensions for the idler shaft

Diameter of new pump drive shaft ..................................... 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch) Bore in the sleeve bearing for the pump drive shaft after assembly ............. 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch) (G) Distance from the gear face to the pump drive shaft assembly ............................. 47.0 ± 0.5 mm (1.85 ± 0.02 inch) (H) Installation depth of the sleeve bearing in the pump cover ....... 1.5 ± 0.5 mm (0.06 ± 0.02 inch) (J) Installation depth of the sleeve bearing in the oil pump body assembly ..................... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

Illustration 81

g01554196

RENR5077-11

55 Specifications Section

i03602902

Engine Oil Pump SMCS Code: 1304 Part No.: 7W-0053 S/N: M8A1-Up Part No.: 7N-8715 S/N: S2A1-Up Part No.: 7W-0053 S/N: M8B1-Up Illustration 82

g01554197

(K) Position of the bearing joints from the centerline through the bearing bores ........ 45 ± 15 degrees

Part No.: 7N-8715 S/N: S2B1-Up Part No.: 7N-8715 S/N: S2D1-Up Part No.: 7N-8715 S/N: S2E1-Up

Illustration 84

g01554195

Note: The rotation of the drive gear is clockwise when you view the engine oil pump from the drive end.

Illustration 83

g01881373

(L) Extension of the hollow dowel from the oil pump cover ................. 6.0 ± 1.0 mm (0.24 ± 0.04 inch)

Note: Before you install the pump, lubricate the moving parts with clean engine oil. Rotate the pump by hand in order to ensure that the pump rotates freely.

Bench test specifications

(1) 2S-2760 Spring

(2) Pump cover

Unrestricted flow rate per minute at 1000 rpm ....................................... 410 L (108 US gal) Pump pressure at 300 rpm with fully blocked outlet ..................... 570 to 630 kPa (83 to 91 psi)

Length under test force .. 117.14 mm (4.612 inch) Test force ........................ 499 ± 24 N (112 ± 5 lb) Approximate free length after test .... 152.91 mm (6.020 inch) Outside diameter ............ 27.00 mm (1.063 inch)

56 Specifications Section

Illustration 85

RENR5077-11

g01890213

Illustration 86

g01554196

Illustration 87

g01554197

(2) Before assembly, lubricate the O-ring seal lightly with 5P-3975 Rubber Lubricant.

(B) Dimensions for the gears Length of new gear .............. 54.000 ± 0.015 mm (2.1260 ± 0.0006 inch) Depth of the bore in the oil pump body for the new gear .. 54.15 ± 0.02 mm (2.132 ± 0.001 inch) (C) Dimensions for the pump shaft Diameter of the new shaft .... 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch) Bore in the sleeve bearing for the new shaft after assembly .............................. 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch) (D) Extension of the hollow dowel from the pump cover ................. 6.0 ± 0.5 mm (0.24 ± 0.02 inch) (E) Distance from the end of the idler shaft to the gear face ......... 34.0 ± 0.5 mm (1.34 ± 0.02 inch) (F) Dimensions for the pump drive shaft Diameter of new shaft .......... 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch) Bore in the sleeve bearing for the new shaft after assembly .............................. 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch) (G) Distance from the end of the shaft to the gear face ................. 47.0 ± 0.5 mm (1.85 ± 0.02 inch) (H) Installation depth of the sleeve bearing in the pump cover ....... 1.5 ± 0.5 mm (0.06 ± 0.02 inch) (J) Installation depth of the sleeve bearing in the oil pump body assembly ..................... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

(K) Position of bearing joints from the centerline through the bearing bores ........ 45 ± 15 degrees

RENR5077-11

57 Specifications Section

Part No.: 8N-6152 S/N: S2J1-Up Part No.: 8N-6152 S/N: S2K1-Up Part No.: 8N-6152 S/N: S2L1-Up Part No.: 8N-6152 S/N: S2M1-Up Part No.: 8N-6152 S/N: S2N1-Up Part No.: 8N-6152 S/N: S2P1-Up Part No.: 8N-6152 S/N: S2R1-Up Part No.: 8N-6152 S/N: S2S1-Up Illustration 88

g01927801

(3) Pump cover

Part No.: 8N-6152 S/N: S2T1-Up

(L) Extension of the hollow dowel from the oil pump cover ................. 6.0 ± 1.0 mm (0.24 ± 0.04 inch)

Part No.: 8N-6152 S/N: S2W1-Up

Bench test specifications

Part No.: 8N-6152 S/N: S2X1-Up

Unrestricted flow rate at 700 rpm ........... 135.0 L (35.7 US gal) Pump pressure at 300 rpm with fully blocked outlet ..................... 570 to 630 kPa (83 to 91 psi)

Part No.: 8N-6152 S/N: S2Y1-Up Part No.: 8N-6152 S/N: S2Z1-Up

i03560066

Engine Oil Pump SMCS Code: 1304 Part No.: 8N-6152 S/N: S2A1-Up Part No.: 8N-6152 S/N: S2B1-Up Part No.: 8N-6152 S/N: S2D1-Up Part No.: 8N-6152 S/N: S2E1-Up Part No.: 8N-6152 S/N: S2F1-Up Part No.: 8N-6152 S/N: S2G1-Up Part No.: 8N-6152 S/N: MKH1-Up Part No.: 8N-6152 S/N: S2H1-Up

Illustration 89

g01554195

Note: The rotation of the drive gear is clockwise when you view the engine oil pump from the drive end.

Note: Before you install the pump, lubricate the moving parts with clean engine oil. Rotate the pump by hand in order to ensure that the pump rotates freely.

(1) 2S-2760 Spring Length under test force .. 117.14 mm (4.612 inch) Test force .................. 499 ± 24 N (112.2 ± 5.4 lb)

58 Specifications Section

RENR5077-11

Approximate free length after test .... 152.91 mm (6.020 inch) Outside diameter ..................... 27 mm (1.1 inch)

Illustration 90

g01890213

(J) Installation depth of the sleeve bearing in the oil pump body assembly ..................... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

Illustration 91

g01883675

Illustration 92

g01883677

(2) Before assembly, lubricate the O-ring seal lightly with 5P-3975 Rubber Lubricant.

(B) Dimensions for the gears Length of new gear .............. 84.000 ± 0.015 mm (3.3071 ± 0.0006 inch) Depth of the bore in the oil pump body for the new gear .. 84.15 ± 0.02 mm (3.313 ± 0.001 inch) (C) Dimensions for the pump shaft Diameter of new shaft .......... 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch) Bore in the sleeve bearing for the new shaft after assembly .............................. 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch) (D) Extension of hollow dowel from the oil pump cover ................. 6.0 ± 1.0 mm (0.24 ± 0.04 inch) (E) Distance from the end of the idler shaft to the gear face ......... 34.0 ± 0.5 mm (1.34 ± 0.02 inch) (F) Dimensions for the pump drive shaft Diameter of new shaft .......... 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch) Bore in the sleeve bearing for the new shaft after assembly .............................. 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch) (G) Distance from the end of the shaft to the gear face ................. 47.0 ± 0.5 mm (1.85 ± 0.02 inch) (H) Installation depth of the sleeve bearing in the pump cover ....... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

(K) Position of bearing joints from the centerline through the bearing bores ........ 45 ± 15 degrees

RENR5077-11

59 Specifications Section

i02941571

Engine Oil Pump SMCS Code: 1304 Part No.: 244-8985 S/N: MRG1-Up Part No.: 244-8985 S/N: MKH1-Up

Illustration 94

Illustration 93

g01883017

(3) Pump cover

g01459732

(1) Lubricate the bore of the O-ring seal lightly with 5P-3975 Rubber Lubricant immediately before assembly of the engine oil pump.

(L) Extension of the hollow dowel from the oil pump cover ................. 6.0 ± 0.5 mm (0.24 ± 0.02 inch) Bench test specifications Unrestricted flow rate at 700 rpm ....... 220 L/min (58.1 US gpm) Pump pressure at 300 rpm with fully blocked outlet .................... 570 to 630 kPa (83 to 91 psi )

Illustration 95

g01459725

(2) 2S-2760 Spring Length under test force .. 117.14 mm (4.612 inch) Test force .................. 499 ± 24 N (112.2 ± 5.4 lb) Approximate free length after test .... 152.91 mm (6.020 inch) Outside diameter ............ 27.00 mm (1.063 inch)

60 Specifications Section

Illustration 96

RENR5077-11

g01459726

(B) Dimensions for the gears Length of new gear .............. 84.000 ± 0.015 mm (3.3071 ± 0.0006 inch) Depth of the bore in the oil pump body for the new gear .. 84.15 ± 0.02 mm (3.313 ± 0.001 inch) (C) Dimensions for the shafts Diameter of new shaft .......... 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch) Bore in the sleeve bearing for the new shaft ...................................... 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch)

Illustration 97

g01502139

(K) Extension of the dowel from the oil pump cover ................. 6.0 ± 1.0 mm (0.24 ± 0.04 inch)

(D) Extension of the hollow dowel from the oil pump cover ................. 6.0 ± 0.5 mm (0.24 ± 0.02 inch) (E) Distance from the end of the pump shaft assembly to the gear face ........... 34.0 ± 0.5 mm (1.34 ± 0.02 inch) (F) Dimensions for the pump drive shaft Diameter of new pump drive shaft ..................................... 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch) Bore in the sleeve bearing for the pump drive shaft ...................................... 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch) (G) Distance from the end of the pump drive shaft assembly to the gear face ........... 47.0 ± 0.5 mm (1.85 ± 0.02 inch) (H) Installation depth of the sleeve bearing in the pump cover ....... 1.5 ± 0.5 mm (0.06 ± 0.02 inch) (J) Installation depth of the sleeve bearing in the oil pump body assembly. .................... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

Illustration 98

g01459731

(L) Position of the bearing joints from the centerline through the bearing bores ........ 45 ± 15 degrees Bench test specifications Unrestricted flow rate at 700 rpm ....... 220 L/min (58 US gpm)

RENR5077-11

61 Specifications Section

Pump pressure at 300 rpm with fully blocked outlet ................. 710 to 770 kPa (105 to 110 psi) Note: Before you install the pump, lubricate the moving parts with clean engine oil. Rotate the pump by hand in order to ensure that the pump rotates freely. i02394919

Engine Oil Scavenge Pump SMCS Code: 1312 Part No.: 8N-9164 S/N: M8A1-Up Part No.: 8N-9164 S/N: M8B1-Up

g00118286

Illustration 99

NOTICE Before operation, the pump must be lubricated with clean engine oil and the pump must turn freely by hand or damage to parts can be the result.

When the oil scavenge pump is viewed from the drive end the drive rotates in the following direction. ....................................... Counterclockwise (1) Length of new gears 8N-9164 Pump Group ........ 84.000 ± 0.015 mm (3.3071 ± 0.0006 inch)

1W-8508 Pump Group ....... 110.000 ± 0.015 mm (4.3307 ± 0.0006 inch) 144-8267 Pump Group .... 145.000 ± 0.015 mm (5.7087 ± 0.0006 inch) Depth of bores for new gears 8N-9164 Pump Group ........ 84.150 ± 0.020 mm (3.3130 ± 0.0008 inch) 1W-8508 Pump Group ....... 110.150 ± 0.020 mm (4.3366 ± 0.0008 inch) 144-8267 Pump Group .... 145.150 ± 0.020 mm (5.7146 ± 0.0008 inch)

62 Specifications Section

RENR5077-11

(2) Diameter of new gear shafts .. 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch) Bore in bearings for new gear shafts after assembly .................................... 31.837 ± 0.070 mm (1.2534 ± 0.0028 inch) (3) Distance from the end of the shafts to the gear faces ............... 34.0 ± 0.5 mm (1.34 ± 0.02 inch) (4) The bearings are installed in the pump body at the following depth: ........................ 1.5 ± 0.5 mm (0.06 ± 0.02 inch) (5) Bolt Note: Before installing a gear onto the shaft, clean the shaft and clean the gear's bore with isopropyl alcohol.

1. Tap on gear in order to seat the taper on the shaft.

2. Tighten the bolt to the following torque: Torque for bolt ........... 100 ± 20 N·m (75 ± 15 lb ft) Repeat this procedure until the torque does not change.

Illustration 100 Typical example

g00118287

RENR5077-11

Illustration 101

63 Specifications Section

g00118288

(6) Position of bearing joints from the centerline through the bearing bores ........ 45 ± 15 degrees (7) The bearings are installed in the cover at the following depth: .. 1.5 ± 0.5 mm (0.06 ± 0.02 inch) (8) The dowels extend from the cover at the following distance: ........... 6.4 ± 0.5 mm (0.25 ± 0.02 inch) i03686767

Engine Oil Cooler Bypass and Cooling Jet Sequence Valves SMCS Code: 1314; 1331 Part No.: 335-3154, 335-3155 S/N: M8A1-Up Part No.: 335-3154, 335-3155 S/N: M8B1-Up

Illustration 102

(1) Lubricate the bore of the O-ring seals lightly with the clean engine oil.

g01982413

(2) Torque for the plug ... 100 ± 15 N·m (74 ± 11 lb ft)

64 Specifications Section

RENR5077-11

Note: The oil cooler bypass valve must open with a pressure difference of 180 ± 20 kPa (26.1 ± 2.9 psi).

Part No.: 115-7860 S/N: S2J1-Up

(3) 2W-1635 Spring for oil cooler bypass valve

Part No.: 115-7860 S/N: S2K1-Up

Length under test force ..... 102.0 mm (4.02 inch) Test force ........................ 518 ± 26 N (116 ± 6 lb) Free length after test ........ 143.4 mm (5.65 inch) Outside diameter ........ 37.251 mm (1.4666 inch) Note: The cooling jet sequence valves must start to open at a pressure difference of 130 ± 30 kPa (18.9 ± 4.4 psi).

Note: The cooling jet sequence valves must be fully open at a pressure difference of 200 ± 30 kPa (29.0 ± 4.4 psi).

(4) 6B-9202 Spring for the cooling jet sequence valve Length under test force ....... 68.3 mm (2.69 inch) Test force ............... 85 to 100 N (19.0 to 22.4 lb) Free length after test ......... 112.7 mm (4.44 inch) Outside diameter ............ 24.60 mm (0.969 inch) i03139927

Engine Oil Cooler Bypass and Cooling Jet Sequence Valves

Part No.: 115-7860 S/N: S2L1-Up Part No.: 115-7860 S/N: S2M1-Up Part No.: 115-7860 S/N: S2N1-Up Part No.: 115-7860 S/N: S2P1-Up Part No.: 115-7860 S/N: S2R1-Up Part No.: 115-7860 S/N: S2S1-Up Part No.: 115-7860 S/N: S2T1-Up Part No.: 115-7860 S/N: S2W1-Up Part No.: 115-7860 S/N: S2X1-Up

SMCS Code: 1314; 1331

Part No.: 115-7860 S/N: S2Y1-Up

Part No.: 115-7860 S/N: S2A1-Up

Part No.: 115-7860 S/N: S2Z1-Up

Part No.: 115-7860 S/N: S2B1-Up Part No.: 115-7860 S/N: S2D1-Up Part No.: 115-7860 S/N: S2E1-Up Part No.: 115-7860 S/N: S2F1-Up Part No.: 115-7860 S/N: B5G1-Up Part No.: 115-7860 S/N: MRG1-Up Part No.: 115-7860 S/N: PAG1-Up Part No.: 115-7860 S/N: S2G1-Up Part No.: 115-7860 S/N: MKH1-Up Part No.: 115-7860 S/N: S2H1-Up

RENR5077-11

65 Specifications Section

g01616336

Illustration 103 Right side view Typical example

Note: The cooling jet sequence valves must start to open at a pressure difference of 130 ± 30 kPa (19.0 ± 4.5 psi).

Note: The cooling jet sequence valves must be fully open at a pressure difference of 200 ± 30 kPa (29.0 ± 4.5 psi).

(5) 6B-9202 Spring for the cooling jet sequence valve Quantity ............................................................ 2 Length under test force ....... 68.3 mm (2.69 inch) Test force ..................... 85 to 102 N (19 to 23 lb) Free length after test ......... 112.7 mm (4.44 inch) Outside diameter ............ 24.60 mm (0.969 inch) Note: The oil cooler bypass valve must open with a pressure difference of 180 ± 20 kPa (26 ± 3 psi).

(6) 2W-1635 Spring for oil cooler bypass valve Illustration 104

g01616353

Front view Typical example

Use the following tightening sequence for the clamp bolts: 1. Snugly tighten the clamp assembly (3) to the tube (4).

2. Tighten two bolts (2) of the clamp assembly to the elbow (10) to 47 ± 9 N·m (35 ± 7 lb ft).

3. Tighten two bolts (1) of the clamp assembly to the tube (4) to 47 ± 9 N·m (35 ± 7 lb ft).

Length under test force ..... 102.0 mm (4.02 inch) Test force .................. 518 ± 26 N (115.0 ± 5.8 lb) Free length after test ........ 143.4 mm (5.65 inch) Outside diameter ........ 37.251 mm (1.4666 inch) (7) Lubricate the bore of the O-ring seals lightly with the clean engine oil.

(8) Lubricate the bore of two O-ring plugs lightly with the clean engine oil.

(9) Torque for the plug ... 100 ± 15 N·m (75 ± 11 lb ft)

66 Specifications Section

RENR5077-11

i03670352

Engine Oil Filter SMCS Code: 1318 Part No.: 112-4921

Illustration 105

g01445657

Front view

(1) Lubricate the bore of the O-ring seals lightly with clean engine oil.

(2) 2W-1635 Spring Length under test force ..... 102.0 mm (4.02 inch)

Test force ........................ 518 ± 26 N (116 ± 6 lb) Free length after test ........ 143.4 mm (5.65 inch) Outside diameter ........ 37.251 mm (1.4666 inch) Note: The bypass valve (3) must move freely in the bore.

RENR5077-11

67 Specifications Section

(3) Bypass valve Start to open pressure ..................... 287 ± 7 kPa (41.6 ± 1.0 psi) Fully open pressure ......................... 480 ± 7 kPa (69.6 ± 1.0 psi)

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2P1-Up Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2R1-Up

(4) Torque for the bolts ........ 55 ± 7 N·m (41 ± 5 lb ft)

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2S1-Up

i03742181

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2T1-Up

Engine Oil Filter SMCS Code: 1318 Part No.: 242-6278 S/N: M8A1-Up Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2A1-Up Part No.: 242-6278 S/N: M8B1-Up Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2B1-Up Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2D1-Up Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2E1-Up Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2F1-Up Part No.: 242-6278 S/N: B5G1-Up Part No.: 242-6278 S/N: MRG1-Up Part No.: 242-6278 S/N: PAG1-Up Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2G1-Up Part No.: 242-6278 S/N: MKH1-Up Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2H1-Up Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2J1-Up Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2K1-Up Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2L1-Up Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2M1-Up Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2N1-Up

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2W1-Up Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2X1-Up Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2Y1-Up Part No.: 115-7841, 147-3172, 242-6278, 4W-6874 S/N: S2Z1-Up

68 Specifications Section

Illustration 106 Front view

(1) Lubricate the bore of the O-ring seals lightly with clean engine oil.

(2) Torque for the bolts ........ 55 ± 7 N·m (41 ± 5 lb ft) (3) 2W-1635 Spring Length under test force ..... 102.0 mm (4.02 inch) Test force ........................ 518 ± 26 N (117 ± 6 lb) Free length after test force ................. 143.4 mm (5.65 inch) Outside diameter ........ 37.251 mm (1.4666 inch) Note: Bypass valve (4) must move freely in the bore.

(4) Bypass valve Start to open pressure: .. 287 ± 7 kPa (42 ± 1 psi) Fully open pressure: ..... 480 ± 7 kPa (70 ± 1 psi)

RENR5077-11

g01417897

RENR5077-11

69 Specifications Section

i03686744

Engine Oil Lines

i01906041

Engine Oil Lines (Front Mounted Engine Oil Filter)

SMCS Code: 1307 Part No.: 335-3157 S/N: M8A1-Up

SMCS Code: 1307

Part No.: 335-3157 S/N: M8B1-Up

Part No.: 242-6279 S/N: M8A1-Up Part No.: 107-7180, 242-6279 S/N: S2A1-Up Part No.: 242-6279 S/N: M8B1-Up Part No.: 107-7180, 242-6279 S/N: S2B1-Up Part No.: 107-7180, 242-6279 S/N: S2D1-Up Part No.: 107-7180, 242-6279 S/N: S2E1-Up Part No.: 107-7180, 242-6279 S/N: S2F1-Up Part No.: 107-7180, 242-6279 S/N: B5G1-Up Part No.: 107-7180, 242-6279 S/N: MRG1-Up Part No.: 107-7180, 242-6279 S/N: PAG1-Up Part No.: 107-7180, 242-6279 S/N: S2G1-Up

Illustration 107

g01982333

Typical example

Part No.: 107-7180, 242-6279 S/N: MKH1-Up

(1) Lubricate the bore of the O-ring seals lightly with the clean engine oil.

Part No.: 107-7180, 242-6279 S/N: S2H1-Up

Use the following tightening sequence to tighten the bolts of the clamp assembly (2):

Part No.: 107-7180, 242-6279 S/N: S2J1-Up

1. Snugly tighten the clamp assembly to the tube .

Part No.: 107-7180, 242-6279 S/N: S2K1-Up

2. Tighten the bolts of the clamp assembly to the elbow to 47 ± 9 N·m (35 ± 7 lb ft).

Part No.: 107-7180, 242-6279 S/N: S2L1-Up

3. Tighten the bolts of the clamp assembly to the tube to 47 ± 9 N·m (35 ± 7 lb ft).

Part No.: 107-7180, 242-6279 S/N: S2M1-Up Part No.: 107-7180, 242-6279 S/N: S2N1-Up Part No.: 107-7180, 242-6279 S/N: S2P1-Up Part No.: 107-7180, 242-6279 S/N: S2R1-Up

70 Specifications Section

RENR5077-11

Part No.: 107-7180, 242-6279 S/N: S2S1-Up

(1) Clamp bolts Torque ............................ 47 ± 9 N·m (35 ± 7 lb ft)

Part No.: 107-7180, 242-6279 S/N: S2T1-Up

Tightening sequence for the clamp bolts

Part No.: 107-7180, 242-6279 S/N: S2W1-Up

1. Snugly tighten the clamp assembly to the tube.

Part No.: 107-7180, 242-6279 S/N: S2X1-Up

2. Tighten the clamp assembly to the elbow.

3. Tighten the clamp assembly to the tube.

Part No.: 107-7180, 242-6279 S/N: S2Y1-Up

(2) O-rings

Part No.: 107-7180, 242-6279 S/N: S2Z1-Up

Lubricate the O-rings with clean engine oil prior to assembly. i03694821

Duplex Engine Oil Filters SMCS Code: 1318 Part No.: 120-4501 S/N: M8A1-Up Part No.: 120-4501 S/N: S2A1-Up Part No.: 120-4501 S/N: M8B1-Up Part No.: 120-4501 S/N: S2B1-Up Part No.: 120-4501 S/N: S2D1-Up Illustration 108

g00992667

Right side view

Part No.: 120-4501 S/N: S2E1-Up Part No.: 120-4501 S/N: S2F1-Up Part No.: 120-4501 S/N: B5G1-Up Part No.: 120-4501 S/N: MRG1-Up Part No.: 120-4501 S/N: PAG1-Up Part No.: 120-4501 S/N: S2G1-Up Part No.: 120-4501 S/N: MKH1-Up Part No.: 120-4501 S/N: S2H1-Up Part No.: 120-4501 S/N: S2J1-Up

Illustration 109 Front view (typical example)

g00992788

Part No.: 120-4501 S/N: S2K1-Up

RENR5077-11

Part No.: 120-4501 S/N: S2L1-Up Part No.: 120-4501 S/N: S2M1-Up Part No.: 120-4501 S/N: S2N1-Up Part No.: 120-4501 S/N: S2P1-Up Part No.: 120-4501 S/N: S2R1-Up Part No.: 120-4501 S/N: S2S1-Up Part No.: 120-4501 S/N: S2T1-Up Part No.: 120-4501 S/N: S2W1-Up Part No.: 120-4501 S/N: S2X1-Up Part No.: 120-4501 S/N: S2Y1-Up Part No.: 120-4501, 4W-9968 S/N: S2Z1-Up

71 Specifications Section

72 Specifications Section

RENR5077-11

g02002813

Illustration 110 Front view (2) Lever (3) Lever

(5) Tie rod (6) Ball plunger assembly

Note: Refer to Testing and Adjusting, “Duplex Oil Filter - Adjust” for correct adjustment procedures of the fluid control valve group (10).

(1) Lightly lubricate the O-ring seals with clean engine oil.

(4) Torque for the bolts ........ 55 ± 7 N·m (41 ± 5 lb ft) (8) 2W-1635 Spring Length under test force ..... 102.0 mm (4.02 inch) Test force ........................ 518 ± 26 N (116 ± 6 lb) Free length after test ........ 143.4 mm (5.65 inch) Outside diameter ........ 37.251 mm (1.4666 inch)

(7) Bracket (11) Cover

Note: The bypass valve (9) must move freely in the bore. The bypass valve must start to open at 287 ± 7 kPa (42 ± 1 psi). The bypass valve must be fully open at 480 ± 7 kPa (70 ± 1 psi).

RENR5077-11

73 Specifications Section

i02947466

Engine Oil Filter Base

Part No.: 124-5513 S/N: S2G1-Up Part No.: 124-5513 S/N: MKH1-Up

SMCS Code: 1306 Part No.: 151-9270, 8N-2001

Part No.: 124-5513 S/N: S2H1-Up Part No.: 124-5513 S/N: S2J1-Up Part No.: 124-5513 S/N: S2K1-Up Part No.: 124-5513 S/N: S2L1-Up Part No.: 124-5513 S/N: S2N1-Up Part No.: 124-5513, 247-4696 S/N: S2P1-Up Part No.: 124-5513, 247-4696 S/N: S2R1-Up Part No.: 124-5513, 247-4696 S/N: S2S1-Up

Illustration 111

g01460980

Typical example

(A) Length for applying 154-9731 Thread Lock Compound to the threads of the hollow stud ................. 10.2 ± 1.5 mm (0.40 ± 0.06 inch) (1) Torque for the hollow stud ............... 80 ± 14 N·m (60 ± 10 lb ft) i02895692

Crankcase Breather SMCS Code: 1317 Part No.: 124-5513 S/N: S2A1-Up Part No.: 124-5513 S/N: S2B1-Up Part No.: 124-5513 S/N: S2D1-Up Part No.: 124-5513 S/N: S2E1-Up Part No.: 124-5513 S/N: B5G1-Up Part No.: 124-5513 S/N: MRG1-Up Part No.: 124-5513 S/N: PAG1-Up

Part No.: 124-5513, 247-4696 S/N: S2T1-Up Part No.: 124-5513, 247-4696 S/N: S2W1-Up Part No.: 124-5513, 247-4696 S/N: S2X1-Up Part No.: 124-5513, 247-4696 S/N: S2Y1-Up Part No.: 247-4696 S/N: S2Z1-Up

74 Specifications Section

RENR5077-11

g01441554

Illustration 112 (2) Breather assembly

(4) Cover assembly

(1) Lubricate the bore of the four O-ring seals lightly with clean engine oil.

(3) Torque for the six hose clamps ...... 3.0 ± 0.5 N·m (27 ± 4 lb in)

RENR5077-11

75 Specifications Section

i03137363

Crankcase Breather SMCS Code: 1317 Part No.: 101-0838 S/N: M8A1-Up Part No.: 101-0838 S/N: S2A1-Up Part No.: 101-0838 S/N: M8B1-Up Part No.: 101-0838 S/N: S2B1-Up Part No.: 101-0838 S/N: S2D1-Up Part No.: 101-0838 S/N: S2E1-Up Part No.: 101-0838 S/N: S2F1-Up

g01614413

Illustration 113 (3) Breather assembly

(4) Cover assembly

(1) Lubricate the bore of two O-ring seals lightly with clean engine oil.

(2) Torque for three hose clamps ........ 3.0 ± 0.5 N·m (27 ± 4 lb in)

76 Specifications Section

RENR5077-11

i03117145

Crankcase Breather

Part No.: 8N-6164 S/N: S2A1-Up

SMCS Code: 1317

Part No.: 8N-6164 S/N: S2B1-Up

Part No.: 247-4696 S/N: S2P1-Up

Part No.: 8N-6164 S/N: S2D1-Up

Part No.: 247-4696 S/N: S2R1-Up

Part No.: 8N-6164 S/N: S2E1-Up

Part No.: 247-4696 S/N: S2S1-Up

Part No.: 8N-6164 S/N: S2F1-Up

Part No.: 247-4696 S/N: S2T1-Up

Part No.: 8N-6164 S/N: MRG1-Up

Part No.: 247-4696 S/N: S2W1-Up

Part No.: 8N-6164 S/N: PAG1-Up

Part No.: 247-4696 S/N: S2X1-Up

Part No.: 8N-6164 S/N: S2G1-Up

Part No.: 247-4696 S/N: S2Y1-Up

Part No.: 8N-6164 S/N: MKH1-Up

Part No.: 247-4696 S/N: S2Z1-Up

Part No.: 8N-6164 S/N: S2H1-Up Part No.: 8N-6164 S/N: S2J1-Up Part No.: 8N-6164 S/N: S2K1-Up Part No.: 8N-6164 S/N: S2L1-Up Part No.: 8N-6164 S/N: S2M1-Up Part No.: 8N-6164 S/N: S2N1-Up Part No.: 8N-6164 S/N: S2P1-Up Part No.: 8N-6164 S/N: S2R1-Up

Illustration 114

g01594054

(1) Lubricate the bore for the seal with clean engine oil.

(2) Torque for the hose clamps ........... 3.0 ± 0.5 N·m (27 ± 4 lb in) i02948560

Engine Oil Pan SMCS Code: 1302

Part No.: 8N-6164 S/N: S2S1-Up Part No.: 8N-6164 S/N: S2T1-Up Part No.: 8N-6164 S/N: S2W1-Up Part No.: 8N-6164 S/N: S2X1-Up Part No.: 8N-6164 S/N: S2Y1-Up

RENR5077-11

77 Specifications Section

Illustration 115

g01462912

Illustration 116

g01462767

Use the following procedure in order to tighten the bolts of the plate: 1. Tighten five bolts (12) to standard torque.

2. Tighten bolt (1) through bolt (10) in a numerical sequence that is shown in Illustration 115 to standard torque.

(11) As required, apply 4C-9614 Silicone Sealant, Permatex No. 2 or 138-8436 Liquid Gasket to the six joints of the gasket prior to assembly.

(13) Lubricate the bore of nine O-ring seals lightly with the lubricant that is being sealed or an approved equivalent.

(14) As required, apply 4C-9614 Silicone Sealant, Permatex No. 2 or 138-8436 Liquid Gasket on the sealing surface of the oil pan prior to assembly. The sealing surfaces are the following areas:

• Connecting joint of the flywheel housing (17) and the rear of the cylinder block

• Connecting joint of the front accessory drive

housing (18) and the front of the cylinder block

(15) As required, apply 4C-9614 Silicone Sealant, Permatex No. 2 or 138-8436 Liquid Gasket to the sealing surface of the integral seal prior to assembly.

78 Specifications Section

RENR5077-11

(16) As required, apply 4C-9509 Wicking Sealant to the open top end of the bolt holes after assembly of the oil pan.

(19) Torque for the oil drain plug ......... 145 ± 15 N·m (105 ± 11 lb ft) (20) Torque for the oil drain plug ............. 55 ± 7 N·m (41 ± 5 lb ft) i03139780

Engine Oil Pan SMCS Code: 1302 Part No.: 8N-7706 S/N: S2A1-Up Part No.: 8N-7706 S/N: S2B1-Up Part No.: 8N-7706 S/N: S2D1-Up Part No.: 8N-7706 S/N: S2E1-Up Part No.: 8N-7706 S/N: S2F1-Up Part No.: 8N-7706 S/N: MRG1-Up Part No.: 8N-7706 S/N: PAG1-Up Part No.: 8N-7706 S/N: S2G1-Up Part No.: 8N-7706 S/N: MKH1-Up Part No.: 8N-7706 S/N: S2H1-Up Part No.: 8N-7706 S/N: S2J1-Up Part No.: 8N-7706 S/N: S2K1-Up Part No.: 8N-7706 S/N: S2L1-Up Part No.: 8N-7706 S/N: S2M1-Up Part No.: 8N-7706 S/N: S2N1-Up Part No.: 8N-7706 S/N: S2P1-Up Part No.: 8N-7706 S/N: S2R1-Up

Part No.: 8N-7706 S/N: S2S1-Up Part No.: 8N-7706 S/N: S2T1-Up Part No.: 8N-7706 S/N: S2W1-Up Part No.: 8N-7706 S/N: S2X1-Up Part No.: 8N-7706 S/N: S2Y1-Up Part No.: 8N-7706 S/N: S2Z1-Up

RENR5077-11

79 Specifications Section

g01616154

Illustration 117

Use the following procedure in order to tighten the bolts of the plate: 1. Tighten five bolts (11) to a standard torque.

2. Tighten bolt 1 through bolt 10 in a numerical sequence that is shown in Illustration 117 to a standard torque.

(12) As required, apply 8T-9014 Silicone Sealant, Permatex No. 2 or 138-8436 Liquid Gasket to the joints of the gasket prior to assembly.

(13) Lubricate the bore of nine O-ring seals lightly with the lubricant that is being sealed.

(14) As required, apply 8T-9014 Silicone Sealant, Permatex No. 2 or 138-8436 Liquid Gasket on the sealing surface of the oil pan prior to assembly. The sealing surfaces are the following areas:

(15) As required, apply 4C-9509 Wicking Sealant to the open top end of the bolt holes after assembly of the oil pan.

(16) As required, apply 8T-9014 Silicone Sealant, Permatex No. 2 or 138-8436 Liquid Gasket to the sealing surface of the integral seal prior to assembly.

(19) Torque for the oil drain plug ......... 145 ± 15 N·m (105 ± 11 lb ft) (20) Torque for the oil drain plug ............. 55 ± 7 N·m (41 ± 5 lb ft) i03139762

Engine Oil Pan SMCS Code: 1302

• Connecting joint of the flywheel housing (17) and

Part No.: 335-3170, 7C-6887 S/N: M8A1-Up

• Connecting joint of the front accessory drive

Part No.: 7C-6887, 7C-7178, 7C-7185 S/N: S2A1-Up

the rear of the cylinder block

housing (18) and the front of the cylinder block

80 Specifications Section

Part No.: 335-3170, 7C-6887 S/N: M8B1-Up Part No.: 7C-6887, 7C-7178, 7C-7185, 7C-9938 S/N: S2B1-Up Part No.: 7C-6887, 7C-7178, 7C-7185, 7C-9938 S/N: S2D1-Up Part No.: 7C-6887, 7C-7178, 7C-7185, 7C-9938 S/N: S2E1-Up Part No.: 7C-6887, 7C-7185, 7C-9938 S/N: S2F1-Up Part No.: 7C-7178 S/N: B5G1-Up Part No.: 7C-7178, 7C-9938 S/N: MRG1-Up Part No.: 7C-7178, 7C-9938 S/N: PAG1-Up Part No.: 7C-7178, 7C-9938 S/N: S2G1-Up Part No.: 7C-7178, 7C-9938 S/N: MKH1-Up Part No.: 7C-7178, 7C-9938 S/N: S2H1-Up Part No.: 7C-7178, 7C-9938 S/N: S2J1-Up Part No.: 7C-7178, 7C-9938 S/N: S2K1-Up Part No.: 7C-7178, 7C-9938 S/N: S2L1-Up Part No.: 7C-9938 S/N: S2M1-Up Part No.: 7C-7178, 7C-9938 S/N: S2N1-Up Part No.: 7C-7178, 7C-9938 S/N: S2P1-Up Part No.: 7C-7178, 7C-9938 S/N: S2R1-Up Part No.: 7C-7178, 7C-9938 S/N: S2S1-Up Part No.: 7C-7178, 7C-9938 S/N: S2T1-Up Part No.: 7C-7178, 7C-9938 S/N: S2W1-Up Part No.: 7C-7178, 7C-9938 S/N: S2X1-Up Part No.: 7C-7178, 7C-9938 S/N: S2Y1-Up

RENR5077-11

Part No.: 7C-7178 S/N: S2Z1-Up

RENR5077-11

81 Specifications Section

g01448462

Illustration 118 Typical example

(1) Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate the bores of the O-ring seals.

i01957454

Water Temperature Regulator

(2) As required, apply 8T-9014 Silicone Sealant or 138-8436 Liquid Gasket to the joints of the gasket.

SMCS Code: 1355

(4) Torque for two oil drain plugs ......... 145 ± 15 N·m (105 ± 11 lb ft)

Part No.: 248-5513, 4W-4794 S/N: S2A1-Up

In order to prevent stress on the tube assembly (6), use the following tightening procedure during assembly:

Part No.: 248-5513 S/N: M8B1-Up

Part No.: 248-5513 S/N: M8A1-Up

1. Tighten two bolts (5) to 47 ± 9 N·m (35 ± 7 lb ft).

Part No.: 248-5513, 4W-4794 S/N: S2B1-Up

2. Tighten two bolts (3) to 47 ± 9 N·m (35 ± 7 lb ft).

Part No.: 248-5513, 4W-4794 S/N: S2D1-Up

82 Specifications Section

RENR5077-11

Part No.: 248-5513, 4W-4794 S/N: S2E1-Up Part No.: 248-5513, 4W-4794 S/N: S2F1-Up Part No.: 248-5513, 4W-4794 S/N: B5G1-Up Part No.: 248-5513, 4W-4794 S/N: MRG1-Up Part No.: 248-5513, 4W-4794 S/N: PAG1-Up Part No.: 248-5513, 4W-4794 S/N: S2G1-Up

Illustration 119

g00286978

Part No.: 248-5513, 4W-4794 S/N: MKH1-Up

Fully open temperature ...................... 92 °C (197 °F)

Part No.: 248-5513, 4W-4794 S/N: S2H1-Up

Minimum opening distance at 92 °C (197 °F) ..................................... 10.4 mm (0.41 inch)

Part No.: 248-5513, 4W-4794 S/N: S2J1-Up Part No.: 248-5513, 4W-4794 S/N: S2K1-Up Part No.: 248-5513, 4W-4794 S/N: S2L1-Up Part No.: 248-5513, 4W-4794 S/N: S2M1-Up Part No.: 248-5513, 4W-4794 S/N: S2N1-Up Part No.: 248-5513, 4W-4794 S/N: S2P1-Up Part No.: 248-5513, 4W-4794 S/N: S2R1-Up Part No.: 248-5513, 4W-4794 S/N: S2S1-Up Part No.: 248-5513, 4W-4794 S/N: S2T1-Up Part No.: 248-5513, 4W-4794 S/N: S2W1-Up Part No.: 248-5513, 4W-4794 S/N: S2X1-Up Part No.: 248-5513, 4W-4794 S/N: S2Y1-Up Part No.: 248-5513, 4W-4794 S/N: S2Z1-Up

i02636978

Water Lines SMCS Code: 1380 Part No.: 335-1845 S/N: M8A1-Up Part No.: 249-2846, 278-7527 S/N: S2A1-Up Part No.: 335-1845 S/N: M8B1-Up Part No.: 249-2846, 278-7527 S/N: S2B1-Up Part No.: 249-2846, 278-7527 S/N: S2D1-Up Part No.: 249-2846, 278-7527 S/N: S2E1-Up Part No.: 249-2846, 278-7527 S/N: S2F1-Up Part No.: 249-2846, 278-7527 S/N: B5G1-Up Part No.: 249-2846 S/N: MRG1-Up Part No.: 249-2846, 278-7527 S/N: S2G1-Up Part No.: 249-2846, 278-7527 S/N: MKH1-Up Part No.: 249-2846, 278-7527 S/N: S2H1-Up Part No.: 249-2846, 278-7527 S/N: S2J1-Up

RENR5077-11

Part No.: 249-2846, 278-7527 S/N: S2K1-Up Part No.: 249-2846, 278-7527 S/N: S2L1-Up Part No.: 249-2846, 278-7527 S/N: S2M1-Up Part No.: 249-2846, 278-7527 S/N: S2N1-Up Part No.: 249-2846, 278-7527 S/N: S2P1-Up Part No.: 249-2846, 278-7527 S/N: S2R1-Up Part No.: 249-2846, 278-7527 S/N: S2S1-Up Part No.: 249-2846, 278-7527 S/N: S2T1-Up Part No.: 249-2846, 278-7527 S/N: S2W1-Up Part No.: 249-2846, 278-7527 S/N: S2X1-Up Part No.: 249-2846, 278-7527 S/N: S2Y1-Up Part No.: 249-2846, 278-7527 S/N: S2Z1-Up

83 Specifications Section

84 Specifications Section

RENR5077-11

g01322263

Illustration 120 Zinc rod

Illustration 121

g01322268

Typical example of zinc rod assembly

1. Apply 9S-3263 Thread Lock Compound to shoulder (2) of a new zinc rod (1). Do not apply sealant to threads (3) of the rod.

2. Lightly lubricate the bores for the zinc rods and the plugs with liquid soap.

Torque for the zinc rod .. 2.25 ± .25 N·m (20 ± 2 lb in)

RENR5077-11

85 Specifications Section

i02843386

i03700561

Engine Oil Sump Pump

Water Pump

SMCS Code: 1324

SMCS Code: 1361

Part No.: 7W-9703 S/N: M8A1-Up

Part No.: 334-7865 S/N: M8A1-Up

Part No.: 7W-9703 S/N: M8B1-Up

Part No.: 212-8177 S/N: S2A1-Up Part No.: 334-7865 S/N: M8B1-Up Part No.: 212-8177 S/N: S2B1-Up Part No.: 212-8177 S/N: S2D1-Up Part No.: 212-8177 S/N: S2E1-Up Part No.: 212-8177 S/N: S2F1-Up Part No.: 212-8177 S/N: B5G1-Up Part No.: 212-8177 S/N: MRG1-Up Part No.: 212-8177 S/N: PAG1-Up Part No.: 212-8177 S/N: S2G1-Up Part No.: 212-8177 S/N: MKH1-Up

Illustration 122

g01434049

(1) Sump pump group

Use the following procedure to install the oil pickup assembly (2): Note: Coat the threads of the oil pickup assembly with 5P-3413 Pipe Sealant prior to assembly.

1. Keep nut (3) held against the oil pickup assembly and hand tighten the nut until the O-ring seal contacts the oil pan.

Part No.: 212-8177 S/N: S2H1-Up Part No.: 212-8177 S/N: S2J1-Up Part No.: 212-8177 S/N: S2L1-Up Part No.: 212-8177 S/N: S2M1-Up Part No.: 212-8177 S/N: S2N1-Up

2. Unscrew the oil pickup assembly until the word “UP” is at the 12 o'clock position.

Part No.: 212-8177 S/N: S2P1-Up

3. Hold the oil pickup assembly in position and tighten the nut to a torque of 150 ± 15 N·m (110 ± 11 lb ft).

Part No.: 212-8177 S/N: S2R1-Up Part No.: 212-8177 S/N: S2S1-Up Part No.: 212-8177 S/N: S2T1-Up

86 Specifications Section

RENR5077-11

Part No.: 212-8177 S/N: S2W1-Up Part No.: 212-8177 S/N: S2X1-Up Part No.: 212-8177 S/N: S2Y1-Up Part No.: 212-8177 S/N: S2Z1-Up

g01991398

Illustration 123 (2) Ring assembly

(3) Water pump seal group

(1) Do not lubricate the sealing lip of the lip type seal.

(4) Lubricate the bore of the O-ring seals with glycerin or an approved equivalent.

(5) Lubricate the shaft with a thin film of clean engine oil before pressing the impeller onto the shaft.

The end of the shaft must be flush with the face of the impeller within 0.15 mm (0.006 inch).

(E) Clearance between the impeller and the cover .................................. 0.5000 ± 0.4925 mm (0.01968 ± 0.01939 inch) (6) Torque for the taperlock studs ........... 35 ± 5 N·m (26 ± 4 lb ft) (7) Torque for the full nuts ....................... 27 ± 4 N·m (239 ± 35 lb in)

(B) Bore of the impeller for new shaft ..................................... 25.342 ± 0.013 mm (0.9977 ± 0.0005 inch)

Minimum leakage per minute for the lip type seal at 138 kPa (20 psi) of air pressure is less than 24 cc (1.5 cu in).

(C) Width of the groove for thrust washer ...... 8.75 ± 0.05 mm (0.344 ± 0.002 inch)

Minimum leakage per minute for the water pump seal assembly at 138 kPa (20 psi) of air pressure is less than 20 cc (1.2 cu in).

(D) Thickness of new thrust washer ............. 8.5 mm (0.33 inch)

RENR5077-11

87 Specifications Section

i03780690

Auxiliary Water Pump

Part No.: 9Y-8175 S/N: S2T1-Up

SMCS Code: 1371

Part No.: 9Y-8175 S/N: S2W1-Up

Part No.: 334-8471 S/N: M8A1-Up

Part No.: 9Y-8175 S/N: S2X1-Up

Part No.: 9Y-8175 S/N: S2A1-Up

Part No.: 9Y-8175 S/N: S2Y1-Up

Part No.: 334-8471 S/N: M8B1-Up

Part No.: 9Y-8175 S/N: S2Z1-Up

Part No.: 9Y-8175 S/N: S2B1-Up Part No.: 9Y-8175 S/N: S2D1-Up Part No.: 9Y-8175 S/N: S2E1-Up Part No.: 9Y-8175 S/N: S2F1-Up Part No.: 9Y-8175 S/N: B5G1-Up Part No.: 9Y-8175 S/N: MRG1-Up Part No.: 9Y-8175 S/N: PAG1-Up Part No.: 9Y-8175 S/N: S2G1-Up Part No.: 9Y-8175 S/N: MKH1-Up Part No.: 9Y-8175 S/N: S2H1-Up Part No.: 9Y-8175 S/N: S2J1-Up Part No.: 9Y-8175 S/N: S2K1-Up Part No.: 9Y-8175 S/N: S2L1-Up Part No.: 9Y-8175 S/N: S2M1-Up Part No.: 9Y-8175 S/N: S2N1-Up Part No.: 9Y-8175 S/N: S2P1-Up Part No.: 9Y-8175 S/N: S2R1-Up Part No.: 9Y-8175 S/N: S2S1-Up

88 Specifications Section

Illustration 124

RENR5077-11

g01486033

Typical example

(A) Width of groove in the shaft for thrust washer ...... 6.25 ± 0.05 mm (0.246 ± 0.002 inch) (B) Thickness of the new thrust washer ................................... 6.000 ± 0.025 mm (0.2362 ± 0.0010 inch) (C) Dimensions of the shaft Bore in the sleeve bearing for auxiliary drive shaft ..................................... 75.000 ± 0.055 mm (2.9528 ± 0.0022 inch) Diameter of new auxiliary drive shaft (not shown) ................................. 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) (D) Dimensions for the impeller Bore diameter of the impeller ........ 19.000 ± 0.013 mm (0.7480 ± 0.0005 inch) Diameter in the shaft for impeller ............................. 19.050 to 19.063 mm (0.7500 to 0.7505 inch)

(E) Installation depth of the sleeve bearing in the water pump housing ..................... 1.5 ± 0.5 mm (0.06 ± 0.02 inch) Note: Do not lubricate the sealing lip of the lip type seal (1).

Minimum leakage per minute for the lip type seal at 138 kPa (20 psi) of air pressure is less than 24 cc (1.5 cu in).

(3) Use the following procedure in order to assemble the water pump seal assembly.

1. Lubricate the outside diameter of ceramic ring and rubber seal (2) with clean water or with 207-1600 Rubber Lubricant.

2. Orient the polished face of the ceramic ring toward water pump seal assembly.

3. Use the installation tool and hand pressure to seat the ceramic ring and the rubber seal into the water pump housing.

RENR5077-11

4. Remove spring (4) from the water pump seal assembly.

5. Lubricate the inside diameter of the water pump seal assembly with clean water or with 207-1600 Rubber Lubricant.

89 Specifications Section

i01704040

Cooling System Pressure Cap SMCS Code: 1382; 1392 Part No.: 4N-3311

6. Use the seal installation tool and hand pressure to install the water pump seal assembly onto the shaft until the face of the water pump seal assembly makes light contact with the face of the ceramic ring and rubber seal.

7. Install spring (4) onto the water pump seal assembly.

Assembled length of the spring .. 17.45 ± 0.79 mm (0.687 ± 0.031 inch) Load on spring at assembled length ....................... 40.03 ± 4.45 N (9.0 ± 1.0 lb) Minimum leakage per minute for the water pump seal assembly at 138 kPa (20 psi) of air pressure is less than 20 cc (1.2 cu in).

(6) Lubricate the shaft with a thin film of clean engine oil before pressing the impeller (5) onto the shaft.

The end of the shaft must be flush with the face of the impeller within 0.15 mm (0.006 inch).

(7) Lubricate the bore of the O-ring seal lightly with sealant that is being sealed.

(8) Lubricate the bore of the O-ring seal with clean engine oil, glycerin or clean water.

Illustration 125

g00877286

Pressure that opens the cap relief valve ........ 48 kPa (7 psi) Maximum vacuum that opens the suction valve ..................................................... 7 kPa (1 psi)

90 Specifications Section

RENR5077-11

i03686680

Cylinder Block

(A) Extension of dowels from the surface of the cylinder block .. 20.0 ± 0.5 mm (0.79 ± 0.02 inch)

SMCS Code: 1201

(B) Thickness of the spacer plates ......... 12.363 mm (0.4867 inch)

Part No.: 350-5225 S/N: M8A1-Up

(C) Height of cylinder liner

Part No.: 350-5225 S/N: M8B1-Up

For the correct method of determining height of the liner, refer to Testing And Adjusting, “Cylinder Liner Projection”.

(D) Thickness of gasket between the cylinder block and spacer plates ................. 0.194 to 0.218 mm (0.0076 to 0.0086 inch) (E) Extension of dowels from the surface of the cylinder block .. 21.0 ± 0.5 mm (0.83 ± 0.02 inch) (F) Bore in the block for the camshaft bearings ............................... 98.000 ± 0.020 mm (3.8583 ± 0.0008 inch) (G) Oil holes must be positioned from horizontal at the following angle. ..................... 20 ± 5 degrees Note: All centerlines through oil holes in the camshaft bearings (G) and the camshaft bearing junctions (2) must be in the position that is shown for each side of the cylinder block.

Illustration 126

g01993533

(H) Main bearing cap width Width of main bearing ........ 340.030 ± 0.015 mm (13.3870 ± 0.0006 inch) Width of cylinder block for main bearing cap ..................................... 339.985 ± 0.015 mm (13.3852 ± 0.0006 inch) Tight press fit between the sides of the main bearing cap and the cylinder block ..... 0.075 mm (0.0030 inch) Loose press fit between the sides of the main bearing cap and the cylinder block ..... 0.015 mm (0.0006 inch)

Front view of cylinder block (2) Camshaft bearing junction

(J) New dimension from centerline of crankshaft bearing bore to the top of the block .. 586.00 mm (23.071 inch) (K) Bore in the block for the main bearings

Illustration 127

g01993594

Right side view

(1) Torque for the plugs .. 100 ± 15 N·m (74 ± 11 lb ft)

Standard, original new size .................................... 169.742 ± 0.020 mm (6.6827 ± 0.0008 inch) 0.63 mm (0.025 inch) larger than original size .................................... 170.372 ± 0.020 mm (6.7076 ± 0.0008 inch) (L) New dimension from centerline of crankshaft bearing bore to bottom of block (pan rails) .............................. 230.00 mm (9.055 inch) (3) Main bearing cap

RENR5077-11

91 Specifications Section

Use the following procedure to tighten the main bearing cap bolts:

Part No.: 240-6651, 240-6653 S/N: S2H1-Up

1. Install main bearing caps with the part number and FRONT toward the front of the block. Each cap has a number. Each cap must be installed in the same position as the correct number on the side of the cylinder block pan rail.

Part No.: 240-6651, 240-6653 S/N: S2J1-Up

2. Before assembly, apply clean engine oil to the threads of the bolts.

3. Tighten the bolts in the numerical sequence (4, 5, 6, 7) to 190 ± 14 N·m (140 ± 10 lb ft). Refer to Illustration 127 for the tightening sequence.

4. Again, tighten the bolts in the numerical sequence (4, 5, 6, 7) to an angle of 180 ± 5 degrees. Refer to Illustration 127 for the tightening sequence.

(M) Extension of dowels from the surface of the cylinder block .... 6.0 ± 0.5 mm (0.24 ± 0.02 inch) (N) Extension of dowels from the surface of the cylinder block .. 19.0 ± 0.5 mm (0.75 ± 0.02 inch) (P) Extension of dowels from the surface of the cylinder block .. 40.0 ± 0.5 mm (1.58 ± 0.02 inch) i03152764

Cylinder Block

Part No.: 240-6651, 240-6653 S/N: S2K1-Up Part No.: 240-6651, 240-6653 S/N: S2L1-Up Part No.: 240-6651 S/N: S2M1-Up Part No.: 240-6651, 240-6653 S/N: S2N1-Up Part No.: 240-6651, 240-6653 S/N: S2P1-Up Part No.: 240-6651, 240-6653 S/N: S2R1-Up Part No.: 240-6651, 240-6653 S/N: S2S1-Up Part No.: 122-5954, 240-6651, 240-6653 S/N: S2T1-Up Part No.: 240-6651, 240-6653 S/N: S2W1-Up Part No.: 122-5954, 240-6651, 240-6653 S/N: S2X1-Up

SMCS Code: 1201

Part No.: 240-6651, 240-6653 S/N: S2Y1-Up

Part No.: 240-6651, 240-6653 S/N: S2A1-Up

Part No.: 122-5954, 240-6651 S/N: S2Z1-Up

Part No.: 240-6651, 240-6653 S/N: S2B1-Up Part No.: 240-6651, 240-6653 S/N: S2D1-Up Part No.: 240-6651, 240-6653 S/N: S2E1-Up Part No.: 240-6651 S/N: S2F1-Up Part No.: 240-6653 S/N: B5G1-Up Part No.: 240-6651, 240-6653 S/N: MRG1-Up Part No.: 240-6653 S/N: PAG1-Up Part No.: 240-6651, 240-6653 S/N: S2G1-Up Part No.: 240-6651, 240-6653 S/N: MKH1-Up

92 Specifications Section

RENR5077-11

(1) Torque for four plugs ...................... 100 ± 15 N·m (75 ± 11 lb ft) (2) Lubricate the bore of the O-ring seals lightly with the lubricant that is being sealed.

(D) Height of the cylinder liner For the correct method of determining the height of the cylinder liner, refer to Testing And Adjusting, “Cylinder Liner Projection”.

(E) Bore in the block for the camshaft bearings ............................... 98.000 ± 0.020 mm (3.8583 ± 0.0008 inch) (F) The oil holes in the camshaft bearings must be positioned from horizontal at the following angle: .......................................... 20 ± 5 degrees Note: All centerlines through the oil holes in the camshaft bearings (F) and the camshaft bearing joints (3) must be in the position that is shown for each side of the cylinder block.

Illustration 128

g01417382

(G) New dimension from centerline of crankshaft bearing bore to the top of the block ....... 586 mm (23.1 inch) (H) New dimension from centerline of crankshaft bearing bore to bottom of block (pan rails) ....................................... 230 mm (9.1 inch)

Front view

(J) Bore in the block for the main bearings Standard, original new size .................................... 169.742 ± 0.020 mm (6.6827 ± 0.0008 inch) 0.63 mm (0.025 inch) larger than original size .................................... 170.372 ± 0.020 mm (6.7075 ± 0.0008 inch) (K) Dimension for crankshaft main bearing cap Illustration 129

g01434393

Right side view

Note: During assembly, the bottom of spacer plates, top of cylinder block and both sides of plate gasket must be free of fuel, oil, water, gasket adhesives, assembly compounds and any other contaminants.

(A) Thickness of the spacer plate .......... 12.313 mm (0.4848 inch) (B) Thickness of the plate gasket between the cylinder block and spacer plate ...................................... 0.194 to 0.218 mm (0.0076 to 0.0086 inch) (C) Extension of the dowel from the top face of the cylinder block .. 21.0 ± 0.5 mm (0.83 ± 0.02 inch)

Width of crankshaft main bearing cap ..................................... 340.030 ± 0.015 mm (13.3870 ± 0.0006 inch) Width of cylinder block for crankshaft main bearing cap ........................ 339.985 ± 0.015 mm (13.3852 ± 0.0006 inch) Tight press fit between the sides of the crankshaft main bearing cap and the cylinder block ............................. 0.075 mm (0.0030 inch) Loose press fit between the sides of the crankshaft main bearing cap and the cylinder block ............................. 0.015 mm (0.0006 inch) (4) Main bearing cap Use the following procedure to tighten the crankshaft main bearing cap bolts:

RENR5077-11

1. Install main bearing caps with the part number and “FRONT” toward the front of the block. Each cap has a number. Each cap must be installed in the same position as the correct number on the side of the cylinder block pan rail.

2. Before assembly, apply clean engine oil on the threads of the bolts.

3. Tighten bolt (5) through bolt (8) in the numerical sequence that is shown in Illustration 128 to a torque of 190 ± 14 N·m (140 ± 10 lb ft).

4. Tighten bolt (5) through bolt (8) again in the numerical sequence to a rotation of 180 ± 5 degrees.

(L) Extension of the dowel from the rear face of the cylinder block .... 6.0 ± 0.5 mm (0.24 ± 0.02 inch)

93 Specifications Section

i02674259

Cylinder Block SMCS Code: 1201 Part No.: 237-7957 S/N: S2A1-Up Part No.: 237-7957 S/N: S2B1-Up Part No.: 237-7957 S/N: S2D1-Up Part No.: 237-7957 S/N: S2E1-Up Part No.: 237-7957 S/N: S2F1-Up

(M) Extension of the dowel from the front face of the cylinder block .... 6.0 ± 0.5 mm (0.24 ± 0.02 inch) (N) Extension of the dowel from the rear face of the cylinder block .. 19.0 ± 0.5 mm (0.75 ± 0.02 inch) (P) Extension of the dowel from the front face of the cylinder block .. 40.0 ± 0.5 mm (1.57 ± 0.02 inch)

Illustration 130 Front view of cylinder block (1) Camshaft bearing junction

g01343555

94 Specifications Section

RENR5077-11

Width of cylinder block for main bearing cap ..................................... 339.985 ± 0.015 mm (13.3852 ± 0.0006 inch) Tight press fit between the sides of the main bearing cap and the cylinder block ..... 0.075 mm (0.0030 inch) Loose press fit between the sides of the main bearing cap and the cylinder block ..... 0.015 mm (0.0006 inch) (J) Bore in the block for the main bearings Standard, original new size .................................... 169.742 ± 0.020 mm (6.6827 ± 0.0008 inch) 0.63 mm (0.025 inch) larger than original size .................................... 170.372 ± 0.020 mm (6.7076 ± 0.0008 inch)

Illustration 131

g01343968

(A) Thickness of spacer plates ............... 12.313 mm (0.4848 inch) (B) Thickness of gasket between the cylinder block and spacer plates ................. 0.194 to 0.218 mm (0.0076 to 0.0086 inch) (C) All dowels extend above the face by the following distance. ......... 20.0 ± 0.5 mm (0.79 ± 0.02 inch) (2) Torque for plugs ....... 100 ± 15 N·m (75 ± 11 lb ft) (D) Height of Cylinder liner For the correct method of determining height of the liner, refer to Testing And Adjusting, “Cylinder Liner Projection”.

(E) Bore in the block for the camshaft bearings ............................... 98.000 ± 0.020 mm (3.8583 ± 0.0008 inch) (F) Oil holes must be positioned from horizontal at the following angle. ..................... 20 ± 5 degrees Note: All centerlines through oil holes in the camshaft bearings (F) and the camshaft bearing junctions (1) must be in the position that is shown for each side of the cylinder block.

(G) New dimension from centerline of crankshaft bearing bore to the top of the block .. 586.00 mm (23.071 inch) (H) Main bearing cap width Width of main bearing ........ 340.030 ± 0.015 mm (13.3870 ± 0.0006 inch)

(K) New dimension from centerline of crankshaft bearing bore to bottom of block (pan rails) .............................. 230.00 mm (9.055 inch) (3) Main bearing cap Use the following procedure to tighten the main bearing cap bolts: 1. Install main bearing caps with the part number and FRONT toward the front of the block. Each cap has a number. Each cap must be installed in the same position as the correct number on the side of the cylinder block pan rail.

2. Put clean engine oil on the bolts before assembly.

3. Tighten the bolts in the numerical sequence (4, 5, 6, 7) to the following torque.

Torque for bolts ....... 190 ± 14 N·m (140 ± 10 lb ft) 4. Tighten the bolts again in the numerical sequence to the following rotation.

Angle for bolts ............................ 180 ± 5 degrees (L) The dowel extends from the rear face of the block by the following distance. .............. 6.0 ± 0.5 mm (0.24 ± 0.02 inch) (M) The dowels extend from the front face of the block by the following distance. ..... 6.0 ± 0.5 mm (0.24 ± 0.02 inch) (N) The dowels extend from the rear face of the block by the following distance. ... 19.0 ± 0.5 mm (0.75 ± 0.02 inch) (P) The dowels extend from the front face of the block by the following distance. ... 40.0 ± 0.5 mm (1.58 ± 0.02 inch)

RENR5077-11

95 Specifications Section

i02871050

Cylinder Liner

i02872093

SMCS Code: 1216

Piston and Rings (One-Piece Piston)

Part No.: 211-7826

SMCS Code: 1214 Part No.: 332-7924 S/N: M8A1-Up Part No.: 332-7924 S/N: M8B1-Up

Illustration 132

g01399536

(A) Bore in new cylinder liner .. 170.025 ± 0.025 mm (6.6939 ± 0.0010 inch) (B) Thickness of flange (1) on cylinder liner ......... 12.65 ± 0.02 mm (0.498 ± 0.001 inch) Use the liner again with any used piston or any new piston if all the measurements are in the following range. Use a FLEX-HONE first. ..................................... 170.000 to 170.152 mm (6.6929 to 6.6989 inch) Use the liner again with the original piston if the measurements of the upper bore are in the following range. Use a FLEX-HONE first. ..................................... 170.000 to 170.229 mm (6.6929 to 6.7019 inch) Use the following procedure to install the cylinder liner: 1. Apply liquid soap on the cylinder block liner bore surfaces and the rubber seals that are on the lower end of the cylinder liner.

2. Dip the filler band (2) completely in clean engine oil for a moment.

3. Immediately install the filler band in the groove that is under the flange.

4. Immediately install the cylinder liner into the cylinder block before the expansion of the filler band.

Note: Refer to Reuse And Salvage Guidelines, SEBF8049, “Visual Inspection of the Piston” for more information. Also, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8068, “Cylinder Liners” for more information.

Illustration 133

g01430242

Note: Refer to Guideline for Reusable Parts for information on the pistons, the piston pins, and the retaining rings.

This piston has a square top piston ring. Use the 246-1176 Piston Ring Groove Gauge Gp for measuring the top piston ring groove.

This piston has a keystone type of intermediate piston ring. Use the 1U-6431 Piston Ring Groove Gauge Gp for measuring the intermediate piston ring groove. For correct use of the piston ring groove gauge group, refer to the instruction card that is with the piston ring groove gauge group.

Note: Prior to the installation of the piston rings, the ring grooves must be completely lubricated with clean engine oil. After assembly, the mating surfaces of the rings to the cylinder liner must be completely lubricated with clean engine oil.

Top Piston Ring (1) Install the top piston ring with the “UP-1” side toward the top of the piston.

96 Specifications Section

RENR5077-11

When the new top piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the following value. ............................ 0.625 ± 0.125 mm (0.0246 ± 0.0049 inch) Thickness of new top piston ring ................ 3.88 mm (0.153 inch)

Intermediate Piston Ring (2) Install the intermediate piston ring with the “UP-2” side toward the top of the piston.

When the new intermediate piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the following value. .......................... 1.00 ± 0.15 mm (0.039 ± 0.006 inch) Thickness of new intermediate piston ring ...................................... 3.785 mm (0.1490 inch)

Oil Control Piston Ring (3) The ends of the oil control piston ring should be a distance of 180 degrees from the ring end gap when the oil control piston ring is assembled. The white colored portion of the piston ring must be visible at the ring end gap.

Width of groove in new piston for the oil control piston ring ......... 4.04 mm to 4.07 mm (0.159 to 0.160 inch) Thickness of new oil control piston ring ................ 3.97 to 3.99 mm (0.156 to 0.157 inch) When the new oil control piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the following value. ...................... 0.5 mm to 0.8 mm (0.02 to 0.03 inch) Note: After the piston rings have been installed, rotate the piston rings so that the end gaps are 120 degrees from each other.

Illustration 134

g01446562

Note: Prior to assembly of the piston pin, the piston pin, the piston pin bore, the connecting rod eye, and the connecting rod pin bearing must be completely lubricated with clean engine oil.

Piston Pin Bore (4) (B) Angle of bushing locator on far side .. 45 degrees (C) Bore diameter of piston pin .................................... 70.0705 ± 0.0075 mm (2.75867 ± 0.00030 inch)

Piston Pin (5) Dimensions for piston pin Outside diameter of piston pin ... 69.930 ± 0.005 mm (2.7531 ± 0.0002 inch) Inside diameter of piston pin ........ 30.5 ± 0.5 mm (1.20 ± 0.02 inch) Length of piston pin ........... 102.0 + 0.0 - 0.3 mm (4.02 + 0.00 - 0.01) Note: The 263-8955 Piston Pin is not interchangeable with the former 197-0560 Piston Pin.

Pin Retainer (6) Assemble the pin retainer with the opening above section A-A. Refer to Table 1 for the part numbers of the tools that are used in servicing the piston.

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97 Specifications Section

Part No.: 223-6363 S/N: S2N1-Up

Table 1

Service Tools

(1) (2)

Part No.: 223-6363 S/N: S2P1-Up

Pt. No.

Description

271-0498

Expander Ring

1P-1861

Retaining Ring Pliers

1U-7616

Piston Ring Compressor Gp

246-1176

Piston Ring Groove Gauge Gp(1)

1U-6431

Piston Ring Groove Gauge Gp(2)

Part No.: 223-6363 S/N: S2R1-Up

Only for the top ring groove Only for the intermediate ring groove

i03661131

Piston and Rings (One-Piece Piston) SMCS Code: 1214 Part No.: 223-6363 S/N: S2A1-Up

Part No.: 223-6363 S/N: S2S1-Up Part No.: 223-6363 S/N: S2T1-Up Part No.: 223-6363 S/N: S2W1-Up Part No.: 223-6363 S/N: S2X1-Up Part No.: 223-6363 S/N: S2Y1-Up Part No.: 223-6363 S/N: S2Z1-Up

Part No.: 223-6363 S/N: S2B1-Up Part No.: 223-6363 S/N: S2D1-Up Part No.: 223-6363 S/N: S2E1-Up Part No.: 223-6363 S/N: S2F1-Up Part No.: 223-6363 S/N: B5G1-Up Part No.: 223-6363 S/N: MRG1-Up Part No.: 223-6363 S/N: PAG1-Up Part No.: 223-6363 S/N: S2G1-Up Part No.: 223-6363 S/N: MKH1-Up Part No.: 223-6363 S/N: S2H1-Up Part No.: 223-6363 S/N: S2J1-Up Part No.: 223-6363 S/N: S2K1-Up Part No.: 223-6363 S/N: S2L1-Up Part No.: 223-6363 S/N: S2M1-Up

Illustration 135

g01430242

Use the 246-1176 Piston Ring Groove Gauge Gp for measuring the top ring groove.

Use the 1U-6431 Piston Ring Groove Gauge Gp for measuring the intermediate ring groove. Refer to the instruction card that is with the gauge group.

Top Piston Ring (1) Install the top piston ring with the “UP-1” side toward the top of the piston.

When the new top piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the

98 Specifications Section

RENR5077-11

following value. ............................ 0.625 ± 0.125 mm (0.0246 ± 0.0049 inch) Thickness of new top piston ring ................ 3.88 mm (0.153 inch)

Intermediate Piston Ring (2) Install the intermediate piston ring with the “UP-2” side toward the top of the piston.

When the new intermediate piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the following value. .......................... 1.00 ± 0.15 mm (0.039 ± 0.006 inch) Thickness of new intermediate piston ring ...................................... 3.785 mm (0.1490 inch)

Oil Control Piston Ring (3) Orient the ends of the oil ring spring to 180 degrees from the gap. The white colored portion of the piston ring must be visible at the ring end gap.

Width of groove in new piston for the oil control piston ring ......... 4.04 mm to 4.07 mm (0.159 to 0.160 inch) Thickness of new oil control piston ring .......... 3.980 ± 0.010 mm (0.1567 ± 0.0004 inch) When the new oil control piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the following value. ............................. 0.5 to 0.8 mm (0.02 to 0.03 inch) Note: After the piston rings have been installed, rotate the piston rings so that the end gaps are 120 degrees from each other.

Illustration 136

g01446562

Note: Prior to assembly of the piston pin, the piston pin, the piston pin bore, the connecting rod eye, and the connecting rod pin bearing must be completely lubricated with clean engine oil.

Piston Pin Bore (4) Note: Measure the pin bore in two places. Take one measurement within the minor diameter. Move laterally and take another measurement within the minor diameter. Take the measurements close to the center of the pin bore. Do not take the measurements on the outside edges.

(B) Angle of bushing locator on far side .. 45 degrees (C) Bore diameter of piston pin ..................................... 70.060 to 70.075 mm (2.7583 to 2.7562 inch)

Piston Pin (5) Outside diameter ....................... 69.962 ± 0.005 mm (2.7544 ± 0.0002 inch) Inside diameter ..... 30.5 ± 0.5 mm (1.20 ± 0.02 inch) Length ......... 101.85 ± 0.15 mm (4.010 ± 0.006 inch) Note: The 197-0560 Piston Pin is not interchangeable with other pistons and connecting rods.

Pin Retainer (6) Assemble the retainer with the opening above line A-A.

RENR5077-11

99 Specifications Section

Refer to Table 2 for the part numbers of the tools that are used in servicing the piston.

Part No.: 101-0829 S/N: S2R1-Up

Table 2

Part No.: 101-0829 S/N: S2S1-Up

Service Tools

(1) (2)

Part No.: 101-0829 S/N: S2T1-Up

Pt. No.

Description

6V-4020

Piston Ring Expander Gp

6V-4023

Handle As

6V-4024

Guide Ring

1P-1861

Retaining Ring Pliers

1U-7616

Piston Ring Compressor Gp

246-1176

Piston Ring Groove Gauge Gp

(1)

1U-6431

Piston Ring Groove Gauge Gp

(2)

Part No.: 101-0829 S/N: S2W1-Up Part No.: 101-0829 S/N: S2X1-Up

Only for the top ring groove Only for the intermediate ring groove

Part No.: 101-0829 S/N: S2Y1-Up Part No.: 101-0829 S/N: S2Z1-Up

i03132941

Piston and Rings (Two-Piece Piston) SMCS Code: 1214 Part No.: 101-0829 S/N: S2A1-Up Part No.: 101-0829 S/N: S2B1-Up Part No.: 101-0829 S/N: S2D1-Up Part No.: 101-0829 S/N: S2E1-Up Part No.: 101-0829 S/N: S2F1-Up Part No.: 101-0829 S/N: S2G1-Up

Illustration 137

g01611477

Part No.: 101-0829 S/N: S2H1-Up

This piston has a Keystone top and Keystone intermediate rings. The 1U-6431 Piston Ring Groove Gauge is necessary for measuring the ring grooves in Keystone pistons. For correct use of the gauge group, see the instruction card that is with the gauge group.

Part No.: 101-0829 S/N: S2J1-Up

Top Piston Ring (1)

Part No.: 101-0829 S/N: S2K1-Up

Install the top ring with the “Up-1” side toward the top of the piston.

Part No.: 101-0829 S/N: S2L1-Up Part No.: 101-0829 S/N: S2M1-Up

Thickness of new top piston ring ................ 3.91 mm (0.154 inch)

Part No.: 101-0829 S/N: S2N1-Up

When the piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the following value. ...... 0.625 ± 0.125 mm (0.0246 ± 0.0049 inch)

Part No.: 101-0829 S/N: S2P1-Up

The increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch)

100 Specifications Section

increase in the cylinder liner bore size is the following value. ...................................... 0.08 mm (0.003 inch)

Intermediate Piston Ring (2)

RENR5077-11

Piston Pin (5) Measure the piston pin diameter on each end in a vertical and horizontal direction.

Install the intermediate ring with the “Up-2” side toward the top of the piston.

Inside diameter of the piston pin ........ 35.0 ± 0.5 mm (1.38 ± 0.02 inch)

Thickness of new intermediate piston ring ...................................... 3.785 mm (0.1490 inch)

Outside diameter of the piston pin ......... 69.962 ± 0.005 mm (2.7544 ± 0.0002 inch)

When the piston is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the following value. .............. 1.00 ± 0.15 mm (0.039 ± 0.006 inch)

Length of the piston pin ............... 133.00 ± 0.13 mm (5.236 ± 0.005 inch)

The increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch) increase in the cylinder liner bore size is the following value. ...................................... 0.08 mm (0.003 inch)

Assemble the retainer with the opening toward the top of the piston.

Oil Control Piston Ring (3) Width of groove in piston for the new piston ring .......... 5.050 ± 0.010 mm (0.1988 ± 0.0004 inch) Thickness of new piston ring ....... 4.954 ± 0.019 mm (0.1950 ± 0.0007 inch) Clearance between groove and new piston ring ........ 0.067 to 0.125 mm (0.0026 to 0.0049 inch) When the piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the following value. .............. 0.70 ± 0.19 mm (0.028 ± 0.007 inch) The increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch) increase in the cylinder liner bore size is the following value. ...................................... 0.08 mm (0.003 inch) Install the oil control ring so that the gap in the spring is 180 degrees away from the gap in the ring. The white portion of the spring must be visible at the ring gap.

After all of the piston rings have been installed, rotate the rings so that the end gaps are separated by 120 degrees. The ring gap for the oil ring must be aligned in the plane of the pin bore.

Piston Pin Bore (4) Measure the piston pin bore in the bushings in two places for each bushing in a vertical direction.

Bore diameter in the crown assembly for piston pin ......... 70.035 ± 0.005 mm (2.7573 ± 0.0002 inch) Bore diameter in the piston skirts for piston pin ......... 69.983 ± 0.005 mm (2.7552 ± 0.0002 inch)

Pin Retainer (6)

RENR5077-11

101 Specifications Section

i02674253

Piston and Rings (Two-Piece Piston)

(1) Top piston ring Install the piston ring with the “Up-1” side toward the top of the piston.

When the piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the following value. ................ 0.625 ± 0.125 mm (0.0246 ± 0.0050 inch) The increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch) increase in the cylinder liner bore size is the following value. ................. 0.08 mm (0.003 inch)

SMCS Code: 1214 Part No.: 249-5671 S/N: B5G1-Up Part No.: 249-5671 S/N: MRG1-Up Part No.: 160-5910 S/N: S2J1-Up

(2) Intermediate piston ring

Part No.: 160-5910 S/N: S2N1-Up

Install the piston ring with the “Up-2” side toward the top of the piston.

When the piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the following value. .................... 1.00 ± 0.15 mm (0.039 ± 0.006 inch) The increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch) increase in the cylinder liner bore size is the following value. ................. 0.08 mm (0.003 inch)

Part No.: 160-5910 S/N: S2T1-Up Part No.: 160-5910 S/N: S2X1-Up Part No.: 160-5910 S/N: S2Z1-Up

(3) Oil piston ring Width of groove in piston for the new oil piston ring .... 4.055 ± 0.015 mm (0.1596 ± 0.0006 inch) Maximum thickness of new oil piston ring .... 3.980 ± 0.010 mm (0.1570 ± 0.0004 inch) Clearance between groove and new oil piston ring .. 0.050 to 0.100 mm (0.0020 to 0.0039 inch) When the piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the following value. .................... 0.65 ± 0.15 mm (0.026 ± 0.006 inch) The increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch) increase in the cylinder liner bore size is the following value. ................. 0.08 mm (0.003 inch) Illustration 138

g01084998

Typical example

This piston has a Keystone top ring. This piston also has Keystone intermediate rings. The 204-8041 Piston Ring Groove Gauge Gp is necessary for measuring the ring grooves in the Keystone pistons.

For correct use of the gauge group, refer to the instruction card that is with the gauge group.

Note: Prior to the installation of the rings, the ring grooves must be completely lubricated with clean engine oil. After assembly, the mating surfaces of the rings to the cylinder liner must be completely lubricated with clean engine oil.

Note: Install the oil piston ring so that the gap in the spring is 180 degrees away from the gap in the piston ring. The white portion of the spring must be visible at the ring end gap.

Note: After all of the piston rings have been installed, rotate the piston rings so that the end gaps are separated by 120 degrees. The ring gap for the oil piston ring must be aligned in the plane of the pin bore.

(4) Piston pin bore Note: Prior to assembly of the piston pin, the piston pin, the piston pin bore, the connecting rod eye, and the connecting rod pin bearing must be completely lubricated with clean engine oil.

102 Specifications Section

RENR5077-11

Crown as Measure the pin bore in the bushings in two places for each bushing in a vertical direction.

Bore in bushing ................ 70.0525 ± 0.0075 mm (2.75796 ± 0.00029 inch) Piston skirt Measure the pin bore in a vertical direction.

Bore ..................................... 69.988 ± 0.005 mm (2.7554 ± 0.0002 inch) (5) Piston pin Measure the pin diameter on each end in a vertical and horizontal direction.

Outside diameter ................. 69.962 ± 0.005 mm (2.7544 ± 0.0002 inch) Inside diameter ............................ 33.0 ± 0.5 mm (1.30 ± 0.02 inch) Length ... 137.55 ± 0.15 mm (5.415 ± 0.006 inch) (6) Pin retainer ................ Assemble the pin retainer with the opening above line A-A. i03660673

Connecting Rod

Part No.: 144-0725 S/N: MKH1-Up Part No.: 101-0829, 144-0725, 161-2500 S/N: S2H1-Up Part No.: 101-0829, 144-0725, 161-2500 S/N: S2J1-Up Part No.: 101-0829, 144-0725, 161-2500 S/N: S2K1-Up Part No.: 101-0829, 144-0725, 161-2500 S/N: S2L1-Up Part No.: 101-0829, 144-0725, 161-2500 S/N: S2M1-Up Part No.: 101-0829, 144-0725, 161-2500 S/N: S2N1-Up Part No.: 101-0829, 144-0725, 161-2500 S/N: S2P1-Up Part No.: 101-0829, 144-0725, 161-2500 S/N: S2R1-Up Part No.: 101-0829, 144-0725, 161-2500 S/N: S2S1-Up Part No.: 101-0829, 144-0725, 161-2500 S/N: S2T1-Up

SMCS Code: 1218

Part No.: 101-0829, 144-0725, 161-2500 S/N: S2W1-Up

Part No.: 144-0725 S/N: M8A1-Up

Part No.: 101-0829, 144-0725, 161-2500 S/N: S2X1-Up

Part No.: 101-0829, 144-0725, 161-2500 S/N: S2A1-Up

Part No.: 101-0829, 144-0725, 161-2500 S/N: S2Y1-Up

Part No.: 144-0725 S/N: M8B1-Up

Part No.: 101-0829, 144-0725, 161-2500 S/N: S2Z1-Up

Part No.: 101-0829, 144-0725, 161-2500 S/N: S2B1-Up Part No.: 101-0829, 144-0725, 161-2500, 223-6363 S/N: S2D1-Up Part No.: 101-0829, 144-0725, 161-2500 S/N: S2E1-Up Part No.: 101-0829, 144-0725, 161-2500 S/N: S2F1-Up Part No.: 144-0725 S/N: B5G1-Up Part No.: 144-0725 S/N: MRG1-Up Part No.: 144-0725 S/N: PAG1-Up Part No.: 101-0829, 144-0725, 161-2500 S/N: S2G1-Up

RENR5077-11

103 Specifications Section

(D) Distance between the center of the bearings ............................... 380 mm (15.0 inch) (E) Protrusion of the dowel from the connecting rod cap .................... 4.0 ± 0.5 mm (0.16 ± 0.02 inch) (F) Bore in the connecting rod for the bearing for the crankshaft connecting rod journal after applying final torque to the connecting rod bolts ................................... 143.028 ± 0.015 mm (5.6310 ± 0.0006 inch) (G) Bore in the connecting rod bearing for crankshaft ..................... 135.133 to 135.194 mm (5.3202 to 5.3226 inch) (1) Etch the cylinder number on the connecting rod and the cap in this location. Mark the connecting rod and the cap with numbers. Mark the numbers on the same side of the connecting rod as the bearing retainer notch.

Note: Install the connecting rod in the engine with the part number to the rear of the engine.

Illustration 139

g01416660

(A) Angle above the centerline on either side of the bearing joint for the sleeve bearing for the piston pin. .................................................... 10 degrees Note: The connecting rod must be heated prior to installation of the sleeve bearing for the piston pin.

Do not use a torch to heat the connecting rod.

(B) The connecting rod may be heated from 175 to 260 °C (347 to 500 °F) for the installation of the sleeve bearing for the piston pin. Minimum length for heating the connecting rod .... 105 mm (4.1 inch) Note: Thoroughly lubricate the piston pin with clean engine oil prior to assembly of the piston and the connecting rod.

(C) Dimensions for the piston pin Bore in the sleeve bearing for the piston pin after installation of the sleeve bearing ................................. 70.000 ± 0.008 mm (2.7559 ± 0.0003 inch) Bore in the connecting rod for the sleeve bearing for the piston pin .................. 75.760 ± 0.015 mm (2.9827 ± 0.0006 inch)

Illustration 140

g01526418

View H-H (3) Location pin for correct installation of connecting rod caps

(2) The chamfer side must be adjacent to the crank pin thrust surface when the connecting rod and piston group is assembled in the engine.

Side clearance between two connecting rods on the same new crankshaft pin ............. 0.850 ± 0.332 mm (0.0335 ± 0.0131 inch) Use the following procedure for tightening the connecting rod bolts: Note: Bolt 1 and bolt 2 must be on the same end of the connecting rod cap that has bearing tabs and location pin (3).

1. Before assembly, apply 6V-4876 Lubricant on the bolt threads, the bolt shank and the bolt seat.

2. Tighten the bolt 1 and bolt 2 to 90 ± 5 N·m (66 ± 4 lb ft).

104 Specifications Section

RENR5077-11

3. Tighten the bolt 3 and bolt 4 to 90 ± 5 N·m (66 ± 4 lb ft).

4. Again, tighten the bolt 3 and bolt 4 to 90 ± 5 N·m (66 ± 4 lb ft).

5. Tighten all bolts for an additional 90 ± 5 degrees. i01359201

Connecting Rod and Main Bearing Journals SMCS Code: 1230 Part No.: 107-7330, 149-6031 Refer to Guidelines For Reusable Parts, SEBF8009, “Main Bearings And Connecting Rod Bearings” for more information.

Connecting Rod Bearing Journals Table 3

Diameter Of Crankshaft Journal (Bearing Surface) For Connecting Rod Bearings Original Size Journal

135.000 ± 0.025 mm (5.3150 ± 0.0010 inch)

Undersize Journal 0.63 mm (0.025 inch)

134.370 ± 0.025 mm (5.2902 ± 0.0010 inch)

Undersize Journal 1.27 mm (0.050 inch)

133.730 ± 0.025 mm (5.2650 ± 0.0010 inch)

Clearance between bearing and new journal ... 0.107 to 0.218 mm (0.0042 to 0.0086 inch) Main Bearing Journals Table 4

Diameter Of Crankshaft Journal (Bearing Surface) For Main Bearings Original Size Journal

160.000 ± 0.025 mm (6.2992 ± 0.0010 inch)

Undersize Journal 0.63 mm (0.025 inch)

159.370 ± 0.025 mm (6.2744 ± 0.0010 inch)

Undersize Journal 1.27 mm (0.050 inch)

158.730 ± 0.025 mm (6.2492 ± 0.0010 inch)

Clearance between bearing and new journal ... 0.122 to 0.241 mm (0.0048 to 0.0095 inch)

RENR5077-11

105 Specifications Section

i02871012

Crankshaft SMCS Code: 1202 Part No.: 152-7625 S/N: M8A1-Up Part No.: 152-7625 S/N: S2A1-Up Part No.: 152-7625 S/N: M8B1-Up Part No.: 152-7625 S/N: S2B1-Up Part No.: 152-7625 S/N: S2D1-Up Part No.: 152-7625 S/N: S2E1-Up Part No.: 152-7625 S/N: S2F1-Up

g01419944

Illustration 141 (1) Thrust plates

Refer to Specifications, “Connecting Rod And Main Bearing Journals” for more information.

(B) End play for the new crankshaft ................................. 0.17 to 0.63 mm (0.007 to 0.025 inch) (2) Torque for the plug ......... 50 ± 7 N·m (37 ± 5 lb ft)

Note: Do not reuse counterweight bolts.

(3) Use the following procedure to tighten the bolts: 1. Prior to assembly, lubricate the bolt threads, the bolt shank, the washer and the underside of the bolt head with 6V-4876 Lubricant.

106 Specifications Section

RENR5077-11

2. Torque the bolts evenly to 200 ± 5 N·m (145 ± 4 lb ft).

Part No.: 128-6786, 128-6788 S/N: S2R1-Up

3. Loosen the bolts.

Part No.: 128-6786, 128-6788 S/N: S2S1-Up

4. Again, torque the bolts evenly to 70 ± 5 N·m (50 ± 4 lb ft).

Part No.: 128-6786, 128-6788 S/N: S2T1-Up

5. Rotate each bolt for an additional 120 ± 5 degrees.

Part No.: 128-6786, 128-6788 S/N: S2X1-Up

i03062802

Part No.: 128-6786, 128-6788 S/N: S2Y1-Up

Crankshaft SMCS Code: 1202 Part No.: 128-6786, 128-6788 S/N: S2A1-Up Part No.: 128-6786, 128-6788 S/N: S2B1-Up Part No.: 128-6786, 128-6788 S/N: S2D1-Up Part No.: 128-6786, 128-6788 S/N: S2E1-Up Part No.: 128-6786 S/N: S2F1-Up Part No.: 128-6788 S/N: B5G1-Up Part No.: 128-6788 S/N: MRG1-Up Part No.: 128-6788 S/N: PAG1-Up Part No.: 128-6786, 128-6788 S/N: S2G1-Up Part No.: 128-6788 S/N: MKH1-Up Part No.: 128-6786, 128-6788 S/N: S2H1-Up Part No.: 128-6786, 128-6788 S/N: S2J1-Up Part No.: 128-6786, 128-6788 S/N: S2K1-Up Part No.: 128-6786, 128-6788 S/N: S2L1-Up Part No.: 128-6786 S/N: S2M1-Up Part No.: 128-6786, 128-6788 S/N: S2N1-Up Part No.: 128-6786, 128-6788 S/N: S2P1-Up

Part No.: 128-6786, 128-6788 S/N: S2Z1-Up

RENR5077-11

107 Specifications Section

g01419944

Illustration 142 (1) Thrust plates

Refer to Specifications, “Connecting Rod And Main Bearing Journals” for more information.

Part No.: 7W-3813 S/N: S2A1-Up

(B) Crankshaft end play ................. 0.17 to 0.63 mm (0.007 to 0.025 inch)

Part No.: 332-7911 S/N: M8B1-Up

(2) Torque for six plugs ....... 50 ± 7 N·m (37 ± 5 lb ft)

Part No.: 7W-3813 S/N: S2B1-Up

Note: Do not reuse counterweight bolts.

(3) Use the following procedure to tighten the bolts: 1. Before assembly, lubricate the threads of the bolts, the bolt shank, the washers and the contact surface under the bolt head with 6V-4876 Lubricant.

2. Tighten the bolts evenly to 70 ± 5 N·m (50 ± 4 lb ft).

Part No.: 7W-3813 S/N: S2D1-Up Part No.: 7W-3813 S/N: S2E1-Up Part No.: 7W-3813 S/N: S2F1-Up Part No.: 7W-3813 S/N: B5G1-Up

3. Rotate each bolt for an additional 120 ± 5 degrees.

Part No.: 7W-3813 S/N: MRG1-Up

i03350941

Part No.: 7W-3813 S/N: PAG1-Up

Crankshaft Wear Sleeves and Seals SMCS Code: 1160 Part No.: 332-7911 S/N: M8A1-Up

Part No.: 7W-3813 S/N: S2G1-Up Part No.: 7W-3813 S/N: MKH1-Up Part No.: 7W-3813 S/N: S2H1-Up

108 Specifications Section

RENR5077-11

Part No.: 7W-3813 S/N: S2J1-Up

Note: Make sure that the correct crankshaft seal group is installed on each end of the crankshaft.

Part No.: 7W-3813 S/N: S2K1-Up

(3) 113-8433 Crankshaft Seal Gp

• Install the crankshaft seal group in the flywheel

Part No.: 7W-3813 S/N: S2L1-Up

housing group on a standard rotation engine.

Part No.: 7W-3813 S/N: S2M1-Up

• Install thecrankshaft seal group in the front housing

Part No.: 7W-3813 S/N: S2N1-Up

(4) 113-8432 Crankshaft Seal Gp

group on a reverse rotation engine.

• Install the crankshaft seal group in the front

Part No.: 7W-3813 S/N: S2P1-Up

housing group on a standard rotation engine.

Part No.: 7W-3813 S/N: S2R1-Up

• Install the crankshaft seal group in the flywheel

Part No.: 7W-3813 S/N: S2S1-Up

(A) The crankshaft seal group is installed from both ends of the crankshaft at the following distance. ........... 8.0 ± 0.5 mm (0.31 ± 0.02 inch)

housing group on a reverse rotation engine.

Part No.: 7W-3813 S/N: S2T1-Up

(B) The wear sleeve is installed from both ends of the crankshaft at the following distance. ........... 0.5 ± 0.5 mm (0.02 ± 0.02 inch)

Part No.: 7W-3813 S/N: S2W1-Up Part No.: 7W-3813 S/N: S2X1-Up Part No.: 7W-3813 S/N: S2Y1-Up Part No.: 7W-3813 S/N: S2Z1-Up

Illustration 143

g01414669

(1) Flywheel housing group (2) Front housing group

Note: The crankshaft seal group cannot be used once the seal has been separated from the wear sleeve.

RENR5077-11

109 Specifications Section

i03671476

Housing (Front) SMCS Code: 1162 Part No.: 333-3712 S/N: M8A1-Up Part No.: 333-3712 S/N: M8B1-Up

g01971776

Illustration 144

Refer to table 5 for the correct position of the fasteners.

Note: Use a standard torque for the fasteners that are listed in table 5.

Table 5

Front Housing Bolt Installation Chart

Length

Diameter Inch

Location

Part Number

Quantity

mm

inch

1/2

1

9H-8260 Bolt

4

158.75

6.250

1/2

2

0S-1587 Bolt

4

44.45

1.750

1/4

4

8T-6765 Pipe Plug

7

14.2 ± 0.3

0.56 ± 0.01

5/8

5

1D-4593 Bolt

10

139.7

5.50

(A) Installation depth for the cup plugs .................. 1.25 ± 0.25 mm (0.050 ± 0.010 inch)

(3) Torque for six plugs .. 25 ± 5 N·m (221 ± 44 lb in) Note: Trim gasket (6) with face (7) after assembly.

110 Specifications Section

RENR5077-11

i02875170

Housing (Front)

Part No.: 4P-5426 S/N: S2X1-Up

SMCS Code: 1162

Part No.: 4P-5426 S/N: S2Y1-Up

Part No.: 4P-5426 S/N: S2A1-Up

Part No.: 4P-5426 S/N: S2Z1-Up

Part No.: 4P-5426 S/N: S2B1-Up Part No.: 4P-5426 S/N: S2D1-Up Part No.: 4P-5426 S/N: S2E1-Up Part No.: 4P-5426 S/N: S2F1-Up Part No.: 4P-5426 S/N: B5G1-Up Part No.: 4P-5426 S/N: MRG1-Up Part No.: 4P-5426 S/N: PAG1-Up Part No.: 4P-5426 S/N: S2G1-Up Part No.: 4P-5426 S/N: MKH1-Up Part No.: 4P-5426 S/N: S2H1-Up Part No.: 4P-5426 S/N: S2J1-Up Part No.: 4P-5426 S/N: S2K1-Up Part No.: 4P-5426 S/N: S2L1-Up Part No.: 4P-5426 S/N: S2M1-Up Part No.: 4P-5426 S/N: S2N1-Up Part No.: 4P-5426 S/N: S2P1-Up Part No.: 4P-5426 S/N: S2R1-Up Part No.: 4P-5426 S/N: S2S1-Up Part No.: 4P-5426 S/N: S2T1-Up Part No.: 4P-5426 S/N: S2W1-Up

RENR5077-11

111 Specifications Section

g01430989

Illustration 145

Refer to Table 6 for the correct position of the fasteners.

i03696090

Note: Use a standard torque for the fasteners that are listed in Table 6.

Gear Group (Front) (Reverse Rotation) SMCS Code: 1206

Table 6

Front Housing Bolt Installation Chart

Length

Diameter inch

Location

Part

mm

inch

1/4

1

8T-6765 Pipe Plug

14.2 ± 0.3

0.56 ± 0.01

1/2

2

9H-8260 Bolt

158.75

6.250

1/2

4

0S-1587 Bolt

44.45

1.750

5/8

5

1D-4593 Bolt

139.7

5.50

Part No.: 334-5314 S/N: M8A1-Up

(3) Torque for six plugs ....... 25 ± 5 N·m (18 ± 4 lb ft) Note: Trim gasket (6) with face (7) after assembly.

Illustration 146

g02019973

Front view (2) Crankshaft gear

(1) Thrust washer Thickness of new thrust washer .. 8.50 ± 0.05 mm (0.335 ± 0.002 inch)

112 Specifications Section

RENR5077-11

Width of groove in new pump drive shaft assembly. ............................... 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch)

g01988514

Illustration 147 (3) Water pump drive gear

(4) Auxiliary drive gear

(5) Lubricate the bore of the O-ring seals lightly with lubricant that is being sealed.

Note: Install the socket setscrew (9) to the bottom of the threaded hole.

(6) Shaft

(9) Torque for the socket setscrew for the pump drive shaft assembly ................ 6 ± 1 N·m (53 ± 9 lb in)

Diameter of the new shaft ........ 89.88 ± 0.02 mm (3.539 ± 0.001 inch) Bore in sleeve bearing for the idler gear assembly ............................. 90.000 ± 0.010 mm (3.5433 ± 0.0004 inch) Installation depth of the sleeve bearing .............. 2.3 ± 0.5 mm (0.09 ± 0.02 inch) (7) Auxiliary drive shaft Diameter of the new auxiliary drive shaft ..................................... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) Bore in the sleeve bearing after assembly ............................. 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch) (8) Pump drive shaft assembly Diameter of the new pump drive shaft assembly ............................. 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) Bore in the sleeve bearing after assembly ............................. 75.000 ± 0.055 mm (2.9527± 0.0022 inch)

(10) Thrust washer Thickness of new thrust washer .. 8.50 ± 0.05 mm (0.335 ± 0.002 inch) Width of groove in new pump drive shaft assembly. ............................... 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch)

RENR5077-11

113 Specifications Section

i03694527

Gear Group (Front) (Reverse Rotation) SMCS Code: 1206 Part No.: 334-5315 S/N: M8B1-Up

Illustration 148

g02019973

Front view (2) Crankshaft gear

(1) Thrust washer Thickness of new thrust washer .. 8.50 ± 0.05 mm (0.335 ± 0.002 inch) Width of groove in new pump drive shaft assembly. ............................... 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch)

114 Specifications Section

RENR5077-11

g01985973

Illustration 149 (3) Accessory drive gear

(4) Auxiliary drive gear

(5) Lubricate the bore of the O-ring seals lightly with lubricant that is being sealed.

(9) Torque for the socket setscrew for the pump drive shaft assembly ................ 6 ± 1 N·m (53 ± 9 lb in)

(6) Idler shaft

(10) Thrust washer

Diameter of the new idler shaft ...... 105.88 ± 0.02 mm (4.168 ± 0.001 inch) Bore in the sleeve bearing for the idler shaft ................................... 105.970 ± 0.010 mm (4.1720 ± 0.0004 inch)

Thickness of new thrust washer .. 8.50 ± 0.05 mm (0.335 ± 0.002 inch) Width of groove in new pump drive shaft assembly. ............................... 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch)

(7) Auxiliary drive shaft Diameter of the new auxiliary drive shaft ..................................... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) Bore in the sleeve bearing after assembly ............................. 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch) (8) Pump drive shaft assembly Diameter of the new pump drive shaft assembly ............................. 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) Bore in the sleeve bearing after assembly ............................. 75.000 ± 0.055 mm (2.9527± 0.0022 inch) Note: Install the socket setscrew (9) to the bottom of the threaded hole.

i03668141

Gear Group (Front) SMCS Code: 1206 Part No.: 122-9281 S/N: S2A1-Up Part No.: 334-5312 S/N: M8B1-Up Part No.: 122-9281 S/N: S2D1-Up Part No.: 122-9281 S/N: B5G1-Up Part No.: 122-9281 S/N: MRG1-Up

RENR5077-11

115 Specifications Section

Part No.: 122-9281 S/N: PAG1-Up Part No.: 122-9281 S/N: S2G1-Up Part No.: 122-9281 S/N: MKH1-Up Part No.: 122-9281 S/N: S2J1-Up Part No.: 122-9281 S/N: S2K1-Up Part No.: 122-9281 S/N: S2L1-Up Part No.: 122-9281 S/N: S2M1-Up Part No.: 122-9281 S/N: S2N1-Up Part No.: 122-9281 S/N: S2P1-Up Part No.: 122-9281 S/N: S2R1-Up Part No.: 122-9281 S/N: S2S1-Up Part No.: 122-9281 S/N: S2T1-Up Part No.: 122-9281 S/N: S2W1-Up Part No.: 122-9281 S/N: S2X1-Up Part No.: 122-9281 S/N: S2Y1-Up Part No.: 122-9281 S/N: S2Z1-Up

Illustration 150

g01428397

Typical example (5) Idler gear assembly (6) Water pump drive gear (7) Crankshaft gear

Note: Install the socket setscrew to the bottom of the threaded hole.

(1) Torque for the socket setscrew ............ 6 ± 1 N·m (53 ± 9 lb in) (2) Pump drive shaft assembly Bore in sleeve bearing after assembly ............................. 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch) Diameter of new pump drive shaft assembly. ............................. 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) (3) Lubricate the bore of the O-ring seals lightly with lubricant that is being sealed.

(4) Thrust washer Thickness of new thrust washer .. 8.50 ± 0.05 mm (0.335 ± 0.002 inch) Width of groove in new pump drive shaft assembly. ............................... 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch) End play for the pump drive shaft assembly .............................. 0.175 to 0.325 mm (0.0069 ± 0.0128 inch) (8) Idler shaft

116 Specifications Section

RENR5077-11

Diameter of the idler shaft ..... 105.88 ± 0.02 mm (4.168 ± 0.001 inch) Bore in the sleeve bearing for idler shaft ................................... 105.970 ± 0.010 mm (4.1720 ± 0.0004 inch) i03125700

Gear Group (Front) SMCS Code: 1206 Part No.: 334-5311 S/N: M8A1-Up Part No.: 8N-7174 S/N: S2A1-Up Part No.: 334-5311 S/N: M8B1-Up

Part No.: 8N-7174 S/N: S2R1-Up Part No.: 8N-7174 S/N: S2S1-Up Part No.: 8N-7174 S/N: S2T1-Up Part No.: 8N-7174 S/N: S2W1-Up Part No.: 8N-7174 S/N: S2X1-Up Part No.: 8N-7174 S/N: S2Y1-Up Part No.: 8N-7174 S/N: S2Z1-Up

Part No.: 8N-7174 S/N: S2B1-Up Part No.: 8N-7174 S/N: S2D1-Up Part No.: 8N-7174 S/N: S2E1-Up Part No.: 8N-7174 S/N: S2F1-Up Part No.: 8N-7174 S/N: B5G1-Up Part No.: 8N-7174 S/N: MRG1-Up Part No.: 8N-7174 S/N: PAG1-Up Part No.: 8N-7174 S/N: S2G1-Up Part No.: 8N-7174 S/N: MKH1-Up Part No.: 8N-7174 S/N: S2H1-Up Part No.: 8N-7174 S/N: S2J1-Up Part No.: 8N-7174 S/N: S2K1-Up Part No.: 8N-7174 S/N: S2L1-Up Part No.: 8N-7174 S/N: S2M1-Up Part No.: 8N-7174 S/N: S2N1-Up Part No.: 8N-7174 S/N: S2P1-Up

Illustration 151

g01428397

(5) Idler gear assembly (6) Water pump drive gear (7) Crankshaft gear

Note: Install the socket setscrew to the bottom of the threaded hole.

(1) Torque for the socket setscrew ............ 6 ± 1 N·m (55 ± 9 lb in) (2) Pump drive shaft assembly Bore in sleeve bearing after assembly ............................. 75.000 ± 0.055 mm (2.9528 ± 0.0022 inch)

RENR5077-11

117 Specifications Section

Diameter of new pump drive shaft assembly ............................. 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) (3) Lubricate the bore of four O-ring seals lightly with lubricant that is being sealed.

(4) Thrust washer Thickness of new thrust washer .. 8.50 ± 0.05 mm (0.335 ± 0.002 inch) Width of groove in new pump drive shaft assembly ............................... 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch) End play for the pump drive shaft assembly ............................... 0.250 ± 0.075 mm (0.0098 ± 0.0030 inch)

Part No.: 101-0835, 175-5203, 175-5204 S/N: PAG1-Up Part No.: 101-0835, 124-8395 S/N: S2G1-Up Part No.: 101-0835, 124-8395, 175-5203, 175-5204 S/N: MKH1-Up Part No.: 101-0835, 124-8395 S/N: S2H1-Up Part No.: 101-0835, 124-8395, 175-5204 S/N: S2J1-Up Part No.: 101-0835, 124-8395 S/N: S2K1-Up Part No.: 101-0835, 124-8395 S/N: S2L1-Up

(8) Shaft Bore in sleeve bearing after machining ............................ 90.000 ± 0.010 mm (3.5433 ± 0.0004 inch) Diameter of new shaft .............. 89.88 ± 0.02 mm (3.539 ± 0.001 inch)

Part No.: 124-8395 S/N: S2M1-Up Part No.: 101-0835, 124-8395 S/N: S2N1-Up

Note: After the sleeve bearing is installed in the gear the sleeve bearing must be machined to size.

Part No.: 101-0835, 124-8395 S/N: S2P1-Up

Maximum roughness average (Ra) .. 0.8 micrometer (32 microinch)

Part No.: 101-0835, 124-8395 S/N: S2R1-Up

i03125621

Part No.: 101-0835, 124-8395 S/N: S2S1-Up

Gear Group (Rear) SMCS Code: 1206

Part No.: 101-0835, 124-8395, 175-5203, 175-5204 S/N: S2T1-Up

Part No.: 334-5298 S/N: M8A1-Up

Part No.: 101-0835, 124-8395 S/N: S2W1-Up

Part No.: 101-0835, 124-8395 S/N: S2A1-Up

Part No.: 101-0835, 124-8395, 175-5203, 175-5204 S/N: S2X1-Up

Part No.: 334-5298 S/N: M8B1-Up Part No.: 101-0835, 124-8395 S/N: S2B1-Up Part No.: 101-0835, 124-8395 S/N: S2D1-Up Part No.: 101-0835, 124-8395 S/N: S2E1-Up Part No.: 124-8395 S/N: S2F1-Up Part No.: 101-0835, 175-5203, 175-5204 S/N: B5G1-Up Part No.: 101-0835, 175-5203, 175-5204 S/N: MRG1-Up

Part No.: 101-0835, 124-8395 S/N: S2Y1-Up Part No.: 101-0835, 124-8395 S/N: S2Z1-Up

118 Specifications Section

RENR5077-11

Illustration 153

g01256372

Vertical line

(9) Use the following procedure to tighten the bolt for the camshaft drive gears: Illustration 152

g01620759

(1) Ring (3) Idler gear assembly (13) Plate

Note: Before assembly, it is critical that the taper of the camshaft and the tapered bore of the camshaft drive gear are clean, dry, and free of residue.

Refer to Disassembly and Assembly for the installation procedure for the left camshaft drive gear (2).

1. Tighten the bolt for the camshaft drive gear to 360 ± 40 N·m (270 ± 30 lb ft).

2. Mark a vertical line on the head of the bolt for the camshaft drive gear. Refer to Illustration 153.

3. Place a driver against the retaining plate of the camshaft drive gear. Strike the driver solidly with a hammer 3 to 4 times.

4. Again, tighten the bolt for the camshaft drive gear to 360 ± 40 N·m (270 ± 30 lb ft).

(5) Torque for four bolts ....................... 140 ± 10 N·m (105 ± 7 lb ft) (6) Gear shaft Diameter of the gear shaft ... 74.990 ± 0.010 mm (2.9524 ± 0.0004 inch) Bore in the sleeve bearing for the gear shaft ..................................... 75.060 ± 0.010 mm (2.9551 ± 0.0004 inch) Maximum roughness average (Ra) ...................... 0.8 micrometer (32 microinch) Refer to Disassembly and Assembly for the installation procedure for the right camshaft drive gear (7).

(8) Idler shaft Diameter of the idler shaft ... 81.000 ± 0.010 mm (3.1890 ± 0.0004 inch) Bore in the sleeve bearing for the idler shaft ..................................... 81.060 ± 0.010 mm (3.1913 ± 0.0004 inch) Maximum roughness average (Ra) ...................... 0.8 micrometer (32 microinch)

Illustration 154

g01256393

5. Repeat Steps 3 and 4 until the mark on the bolt turns a minimum of 90 degrees. Refer to Illustration 154.

(10) Torque for four bolts ..................... 240 ± 20 N·m (175 ± 15 lb ft) (11) Torque for two bolts ..................... 240 ± 20 N·m (175 ± 15 lb ft)

RENR5077-11

119 Specifications Section

i03091223

Balancer Group (Front) SMCS Code: 1220 Part No.: 332-7916 S/N: M8A1-Up Part No.: 101-0833 S/N: S2A1-Up Part No.: 332-7916 S/N: M8B1-Up Illustration 155

g01620761

Rear view of engine

(14) The mark on the cluster gear assembly (4) must be in alignment with the mark on the crankshaft gear (12).

Part No.: 101-0833 S/N: S2B1-Up Part No.: 101-0833 S/N: S2D1-Up Part No.: 101-0833 S/N: S2E1-Up Part No.: 101-0833 S/N: S2F1-Up

Illustration 156

g01572454

(3) Balancer gear (4) Crankshaft gear

(1) Torque for four bolts ....................... 140 ± 10 N·m (105 ± 7 lb ft) (B) Dimensions for the gear shaft

120 Specifications Section

RENR5077-11

Diameter of the new gear shaft ..................................... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) Bore in the sleeve bearing after assembly ............................. 75.000 ± 0.053 mm (2.9528 ± 0.0021 inch) (C) Thickness of the thrust plate ..... 6.35 ± 0.25 mm (0.250 ± 0.010 inch) (2) The mark on the balancer gear must be in alignment with the mark on the crankshaft gear. i03742201

Accessory Drive SMCS Code: 1207 Part No.: 334-5306 S/N: M8A1-Up Part No.: 334-5306 S/N: M8B1-Up

Illustration 157 Front view

g02021255

RENR5077-11

Illustration 158

(1) Lightly lubricate the bore of the O-ring seals with the lubricant that is being sealed or with the approved equivalent.

Note: During assembly, align the hole in the sleeve bearing with the adapter assembly.

(2) Bore in the sleeve bearing of the adapter assembly after installation ... 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch) (3) Bore in the sleeve bearing of the adapter assembly after installation ... 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch) (4) Auxiliary drive shaft Diameter of new auxiliary drive shaft ..................................... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) Width of groove in the new auxiliary drive shaft .. 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch) (5) Thickness of the new thrust washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)

121 Specifications Section

g02021213

122 Specifications Section

RENR5077-11

i03742186

Accessory Drive SMCS Code: 1207 Part No.: 334-5320 S/N: M8B1-Up

Diameter of new idler gear assembly ............................. 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) Width of groove in new idler gear assembly for thrust washer ......................... 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch) Bore in the accessory drive gear ..................................... 74.980 ± 0.025 mm (2.9520 ± 0.0010 inch) (2) Thickness of new thrust washer .. 8.50 ± 0.05 mm (0.335 ± 0.002 inch) i03604440

Accessory Drive (Lower Left Hand) SMCS Code: 1207 Part No.: 7E-7647 S/N: S2A1-Up Part No.: 7E-7647 S/N: S2B1-Up Part No.: 7E-7647 S/N: S2D1-Up Illustration 159

g02021233

Front view

Part No.: 7E-7647 S/N: S2E1-Up Part No.: 7E-7647 S/N: S2F1-Up Part No.: 7E-7647 S/N: B5G1-Up Part No.: 7E-7647 S/N: MRG1-Up Part No.: 7E-7647 S/N: PAG1-Up Part No.: 7E-7647 S/N: S2G1-Up

Illustration 160

g02021234

Section A-A

(1) Lubricate the bore of the O-ring seal with the lubricant that is being sealed.

(B) Dimensions of the shaft Diameter of the new shaft .. 105.880 ± 0.020 mm (4.1685 ± 0.0008 inch) Bore in the bearing for idler gear for the shaft ................................... 105.970 ± 0.010 mm (4.1720 ± 0.0004 inch) (C) Dimensions of the idler gear assembly

Part No.: 7E-7647 S/N: MKH1-Up Part No.: 7E-7647 S/N: S2H1-Up Part No.: 7E-7647 S/N: S2J1-Up Part No.: 7E-7647 S/N: S2K1-Up Part No.: 7E-7647 S/N: S2L1-Up Part No.: 7E-7647 S/N: S2M1-Up

RENR5077-11

123 Specifications Section

Part No.: 7E-7647 S/N: S2N1-Up Part No.: 7E-7647 S/N: S2P1-Up Part No.: 7E-7647 S/N: S2R1-Up Part No.: 7E-7647 S/N: S2S1-Up Part No.: 7E-7647 S/N: S2T1-Up Part No.: 7E-7647 S/N: S2W1-Up Part No.: 7E-7647 S/N: S2X1-Up Part No.: 7E-7647 S/N: S2Y1-Up Illustration 162

Part No.: 7E-7647 S/N: S2Z1-Up

g01929454

Section B-B

(3) Diameter of the new shaft ........ 89.88 ± 0.02 mm (3.539 ± 0.001 inch) (4) Dimensions of the idler gear assembly Bore in the sleeve bearing of the idler gear assembly after installation ... 90.000 ± 0.010 mm (3.5433 ± 0.0004 inch) Maximum roughness average (Ra) ................... 0.8 micrometer (31.5 microinch) Note: After the bearing is installed in the gear the bearing must be machined to size.

(5) Dimensions of the auxiliary drive shaft

Illustration 161

g01929453

Front view (1) Water pump drive gear

(2) Lightly lubricate the bore of the O-ring seals with the lubricant that is being sealed.

Diameter of the new auxiliary drive shaft ..................................... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) Width of groove in the new auxiliary drive shaft for the thrust washer .............. 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch) End play for the auxiliary drive shaft ...................................... 0.175 to 0.325 mm (0.0069 to 0.0128 inch) (6) Thickness of the new thrust washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)

124 Specifications Section

RENR5077-11

Part No.: 179-1511 S/N: MRG1-Up Part No.: 179-1511 S/N: PAG1-Up Part No.: 179-1511 S/N: S2G1-Up Part No.: 179-1511 S/N: MKH1-Up Part No.: 179-1511 S/N: S2H1-Up Part No.: 179-1511 S/N: S2J1-Up Part No.: 179-1511 S/N: S2K1-Up Part No.: 179-1511 S/N: S2L1-Up Part No.: 179-1511 S/N: S2M1-Up Part No.: 179-1511 S/N: S2N1-Up Illustration 163

g01929474

Adapter assembly

(C) Installation depth of the sleeve bearing in the adapter assembly .......................... 1.5 ± 0.5 mm (0.06 ± 0.02 inch) (D) Bore in the sleeve bearing of the adapter assembly after installation ... 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch) i02889488

Accessory Drive (Lower Left Hand)

Part No.: 179-1511 S/N: S2P1-Up Part No.: 179-1511 S/N: S2R1-Up Part No.: 179-1511 S/N: S2S1-Up Part No.: 179-1511 S/N: S2T1-Up Part No.: 179-1511 S/N: S2W1-Up Part No.: 179-1511 S/N: S2X1-Up

SMCS Code: 1207

Part No.: 179-1511 S/N: S2Y1-Up

Part No.: 179-1511 S/N: S2A1-Up

Part No.: 179-1511 S/N: S2Z1-Up

Part No.: 179-1511 S/N: S2B1-Up Part No.: 179-1511 S/N: S2D1-Up Part No.: 179-1511 S/N: S2E1-Up Part No.: 179-1511 S/N: S2F1-Up Part No.: 179-1511 S/N: B5G1-Up

RENR5077-11

125 Specifications Section

(2) Diameter of new shaft ........ 105.880 ± 0.020 mm (4.1685 ± 0.0008 inch) (3) Bore in the sleeve bearing after assembly ............................. 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch) Note: After the bearing is installed in the idler gear the bearing must be machined to size.

(5) Bearing

Illustration 164

g01438742

Front view

Bore in the bearing after assembly ........................... 105.970 ± 0.010 mm (4.1720 ± 0.0004 inch) Maximum roughness average (Ra) ...................... 0.8 micrometer (32 microinch) (6) Auxiliary drive shaft Diameter of new auxiliary drive shaft ..................................... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) Width of groove in new auxiliary drive shaft .. 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch) (7) Thickness of new thrust washer .. 8.50 ± 0.05 mm (0.335 ± 0.002 inch) i03605121

Illustration 165

g01438748

Section A-A

(1) Lubricate the bore of the four O-ring seals with the lubricant that is being sealed.

Accessory Drive (Upper Right Hand) SMCS Code: 1207 Part No.: 166-4357 S/N: S2A1-Up Part No.: 166-4357 S/N: S2B1-Up Part No.: 166-4357 S/N: S2D1-Up Part No.: 166-4357 S/N: S2E1-Up Part No.: 166-4357 S/N: S2F1-Up Part No.: 166-4357 S/N: PAG1-Up Part No.: 166-4357 S/N: S2G1-Up Part No.: 166-4357 S/N: MKH1-Up

Illustration 166 Section B-B (4) Adapter assembly

g01438749

Part No.: 166-4357 S/N: S2H1-Up Part No.: 166-4357 S/N: S2J1-Up

126 Specifications Section

Part No.: 166-4357 S/N: S2K1-Up Part No.: 166-4357 S/N: S2L1-Up Part No.: 166-4357 S/N: S2M1-Up Part No.: 166-4357 S/N: S2N1-Up Part No.: 166-4357 S/N: S2P1-Up Part No.: 166-4357 S/N: S2R1-Up Part No.: 166-4357 S/N: S2S1-Up Part No.: 166-4357 S/N: S2T1-Up Part No.: 166-4357 S/N: S2W1-Up Part No.: 166-4357 S/N: S2X1-Up Part No.: 166-4357 S/N: S2Y1-Up Part No.: 166-4357 S/N: S2Z1-Up

RENR5077-11

RENR5077-11

127 Specifications Section

g01930053

Illustration 167

(1) Lightly lubricate the bore of the O-ring seals with the lubricant that is being sealed or with the approved equivalent.

(4) Bore in the sleeve bearing of the adapter assembly after installation ... 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch)

(2) Thickness of the new thrust washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)

(5) Bore in the sleeve bearing of the adapter assembly after installation ... 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch)

(3) Dimensions of the auxiliary drive shaft Diameter of new auxiliary drive shaft ..................................... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) Width of groove in the new auxiliary drive shaft .. 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch) Note: During assembly, align the hole in the sleeve bearing with the adapter.

i03604642

Accessory Drive (Upper Right Hand) SMCS Code: 1207 Part No.: 7N-4871 S/N: S2A1-Up Part No.: 7N-4871 S/N: S2B1-Up

128 Specifications Section

RENR5077-11

Part No.: 7N-4871 S/N: S2D1-Up Part No.: 7N-4871 S/N: S2E1-Up Part No.: 7N-4871 S/N: S2F1-Up Part No.: 7N-4871 S/N: B5G1-Up Part No.: 7N-4871 S/N: MRG1-Up Part No.: 7N-4871 S/N: PAG1-Up Part No.: 7N-4871 S/N: S2G1-Up Part No.: 7N-4871 S/N: MKH1-Up g01929617

Part No.: 7N-4871 S/N: S2H1-Up

Illustration 168

Part No.: 7N-4871 S/N: S2J1-Up

(1) Lightly lubricate the bore of the O-ring seals with the lubricant that is being sealed.

Part No.: 7N-4871 S/N: S2K1-Up Part No.: 7N-4871 S/N: S2L1-Up Part No.: 7N-4871 S/N: S2M1-Up Part No.: 7N-4871 S/N: S2N1-Up Part No.: 7N-4871 S/N: S2P1-Up Part No.: 7N-4871 S/N: S2R1-Up Part No.: 7N-4871 S/N: S2S1-Up Part No.: 7N-4871 S/N: S2T1-Up Part No.: 7N-4871 S/N: S2W1-Up Part No.: 7N-4871 S/N: S2X1-Up Part No.: 7N-4871 S/N: S2Y1-Up Part No.: 7N-4871 S/N: S2Z1-Up

Front view of engine

RENR5077-11

129 Specifications Section

(4) Thickness of the new thrust washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)

Illustration 170

g01929654

Adapter assembly

(D) Bore in the sleeve bearing of the adapter assembly after installation ... 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch) i02895664

Illustration 169

g01929618

Accessory Drive (Upper Right Hand)

Section A-A

Note: During assembly, align the hole in the sleeve bearing with the adapter.

SMCS Code: 1207 Part No.: 334-5304 S/N: M8A1-Up

(2) Bore in the sleeve bearing of the adapter assembly after installation ... 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch)

Part No.: 107-7361 S/N: S2A1-Up

(3) Dimensions of the auxiliary drive shaft

Part No.: 107-7361 S/N: S2B1-Up

Diameter of the new auxiliary drive shaft ..................................... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) Width of groove in the new auxiliary drive shaft for the thrust washer .............. 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch) End play for the auxiliary drive shaft ...................................... 0.175 to 0.325 mm (0.0069 to 0.0128 inch)

Part No.: 107-7361 S/N: S2D1-Up Part No.: 107-7361 S/N: S2E1-Up Part No.: 107-7361 S/N: S2F1-Up Part No.: 107-7361 S/N: B5G1-Up

130 Specifications Section

RENR5077-11

Part No.: 107-7361 S/N: MRG1-Up Part No.: 107-7361 S/N: PAG1-Up Part No.: 107-7361 S/N: S2G1-Up Part No.: 107-7361 S/N: MKH1-Up Part No.: 107-7361 S/N: S2H1-Up Part No.: 107-7361 S/N: S2J1-Up Part No.: 107-7361 S/N: S2K1-Up Part No.: 107-7361 S/N: S2L1-Up Part No.: 107-7361 S/N: S2M1-Up Part No.: 107-7361 S/N: S2N1-Up Part No.: 107-7361 S/N: S2P1-Up

Illustration 171

Part No.: 107-7361 S/N: S2R1-Up

(1) Lubricate the bore of the O-ring seal lightly with the lubricant that is being sealed.

g01441499

Part No.: 107-7361 S/N: S2S1-Up Part No.: 107-7361 S/N: S2T1-Up Part No.: 107-7361 S/N: S2W1-Up Part No.: 107-7361 S/N: S2X1-Up Part No.: 107-7361 S/N: S2Y1-Up Part No.: 107-7361 S/N: S2Z1-Up

Illustration 172

g01441501

Section A-A

(B) Dimensions for the sleeve bearing Bore in sleeve bearing before assembly ............................. 44.475 ± 0.025 mm (1.7510 ± 0.0010 inch)

RENR5077-11

131 Specifications Section

Diameter of accessory drive gear ..................................... 44.400 ± 0.015 mm (1.7480 ± 0.0006 inch) (C) Dimensions for the sleeve bearing Bore in sleeve bearing after assembly ............................. 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch) Diameter of accessory drive gear ..................................... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) i02960980

Accessory Drive (Upper Left Hand) SMCS Code: 1207 Part No.: 334-5328 S/N: M8A1-Up Part No.: 8N-9166 S/N: S2A1-Up Part No.: 334-5328 S/N: M8B1-Up Part No.: 8N-9166 S/N: S2B1-Up Part No.: 8N-9166 S/N: S2D1-Up Part No.: 8N-9166 S/N: S2E1-Up Part No.: 8N-9166 S/N: S2F1-Up Part No.: 8N-9166 S/N: PAG1-Up Part No.: 8N-9166 S/N: S2G1-Up Part No.: 8N-9166 S/N: MKH1-Up Part No.: 8N-9166 S/N: S2H1-Up Part No.: 8N-9166 S/N: S2J1-Up Part No.: 8N-9166 S/N: S2K1-Up Part No.: 8N-9166 S/N: S2L1-Up Part No.: 8N-9166 S/N: S2M1-Up Part No.: 8N-9166 S/N: S2N1-Up

Part No.: 8N-9166 S/N: S2P1-Up Part No.: 8N-9166 S/N: S2R1-Up Part No.: 8N-9166 S/N: S2S1-Up Part No.: 8N-9166 S/N: S2T1-Up Part No.: 8N-9166 S/N: S2W1-Up Part No.: 8N-9166 S/N: S2X1-Up Part No.: 8N-9166 S/N: S2Y1-Up Part No.: 8N-9166 S/N: S2Z1-Up

132 Specifications Section

RENR5077-11

g01479361

Illustration 173

(1) Lubricate the bore of six O-ring seals lightly with the lubricant that is being sealed.

(2) 127-5400 Sleeve Bearing Quantity ............................................................ 2 Bore in the sleeve bearing after assembly ............................. 75.000 ± 0.055 mm (2.9528 ± 0.0022 inch)

i02735559

Accessory Drive (Upper Left Hand, Reverse Rotation) SMCS Code: 1207 Part No.: 334-5322 S/N: M8B1-Up

(3) Dimensions for the auxiliary drive shaft Diameter of the new auxiliary drive shaft ..................................... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) Width of the groove in the new auxiliary drive shaft for the thrust washer ..... 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch) End play for the auxiliary drive shaft ...................................... 0.175 to 0.325 mm (0.0069 to 0.0128 inch) (E) Thickness of the new thrust washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)

Illustration 174

g01371445

(2) Accessory drive gear (5) Thrust washer (6) Idler gear

(1) Bore in the sleeve bearings after assembly ............................. 75.000 ± 0.055 mm (2.9528 ± 0.0022 inch)

RENR5077-11

133 Specifications Section

(3) Thickness of new thrust washer .. 8.50 ± 0.05 mm (0.335 ± 0.002 inch)

Part No.: 7N-4851, 7N-7784, 7W-0968 S/N: S2G1-Up

(4) Auxiliary drive shaft

Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: MKH1-Up

Diameter of new auxiliary drive shaft ..................................... 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch) Width of groove in new auxiliary drive shaft .. 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch) End play for auxiliary drive shaft ...................................... 0.175 to 0.325 mm (0.0069 to 0.0128 inch) (7) Sleeve bearing Bore in the sleeve bearing after assembly ............................. 90.000 ± 0.010 mm (3.5433 ± 0.0004 inch) Maximum roughness average (Ra) ...................... 0.8 micrometer (32 microinch)

Part No.: 7N-4851, 7N-7784, 7W-0968 S/N: S2H1-Up Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: S2J1-Up Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: S2K1-Up Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: S2L1-Up Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: S2M1-Up Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: S2N1-Up

Note: After the sleeve bearing is installed in the gear the sleeve bearing must be machined to size.

Part No.: 7N-4851, 7N-7784, 7W-0968 S/N: S2P1-Up

(8) Diameter of new shaft .......... 89.880 ± 0.020 mm (3.5386 ± 0.0008 inch)

Part No.: 7N-4851, 7N-7784, 7W-0968 S/N: S2R1-Up

i02869986

Flywheel SMCS Code: 1156 Part No.: 333-3742, 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: M8A1-Up Part No.: 7N-4851, 7N-7784, 7W-0968 S/N: S2A1-Up Part No.: 333-3742, 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: M8B1-Up Part No.: 7N-4851, 7N-7784, 7W-0968 S/N: S2B1-Up Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: S2D1-Up Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: S2E1-Up Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: S2F1-Up Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: B5G1-Up Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: MRG1-Up Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: PAG1-Up

Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: S2S1-Up Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: S2T1-Up Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: S2W1-Up Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: S2X1-Up Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038 S/N: S2Y1-Up Part No.: 7N-4851, 7N-7784, 7W-0968 S/N: S2Z1-Up

134 Specifications Section

RENR5077-11

Note: Before installation of the flywheel housing, inspect the front face of the flywheel housing and the rear face of the cylinder block. The components must be free of the following substances: oil, fuel, water, gasket adhesive, assembly compounds, and any other foreign material.

Tighten the bolts that hold the flywheel housing to the engine block evenly. Refer to Illustration 177 and Table 7 for the locations and for identification of the bolts.

Illustration 175

g01429511

Typical example (1) Flywheel gear (2) Crankshaft

Note: When the flywheel assembly is installed, align the dash mark on the flywheel assembly with the dash mark on the crankshaft.

Note: Before assembly, lubricate the threads of the bolts (3) with clean engine oil, molybdenum disulfide or graphite base lubricant.

Illustration 176

g01984633

Left side view

(1) To seal the joint between the flywheel housing and the cylinder block, apply 1U-8846 Gasket Sealant to the front face of the flywheel housing.

(2) Torque for the bolts ...... 55 ± 10 N·m (41 ± 7 lb ft)

(3) Torque for the 12 bolts ................. 1150 ± 60 N·m (840 ± 44 lb ft) i03690244

Flywheel Housing SMCS Code: 1157 Part No.: 333-7646 S/N: M8A1-Up Part No.: 333-7646 S/N: M8B1-Up For information on inspecting the flywheel housing, refer to the Testing and Adjusting, “Flywheel Housing - Inspect”.

Illustration 177

g02019674

RENR5077-11

135 Specifications Section

Table 7

Flywheel Housing Bolt Installation Chart

Bolt Length

Bolt

Diameter inch

Part Number

mm

inch

4

1/2

9X-8873

57.15

2.250

5

1/2

1D-4574

152.4

6.00

6

3/8

0S-1594

25.4

1.00

7

5/8

1D-4597

165.1

6.50

8

1/2

9X-8878

133.35

5.250

9

5/8

1D-4602

241.3

9.50

10

5/8

1D-4593

139.7

5.50

Note: Bond the entire surface with 6V-6640 Sealant to the flywheel housing cover assembly (3).

(4) Torque for the bolts ........................ 135 ± 20 N·m (100 ± 15 lb ft) (5) Torque for the bolts ........................ 135 ± 20 N·m (100 ± 15 lb ft) (6) Torque for the bolts ...... 55 ± 10 N·m (41 ± 7 lb ft) (7) Torque for the bolts ........................ 270 ± 40 N·m (199 ± 30 lb ft) (8) Torque for the bolts ........................ 135 ± 20 N·m (100 ± 15 lb ft) (9) Torque for the bolts ........................ 270 ± 40 N·m (199 ± 30 lb ft) (10) Torque for the bolts ...................... 270 ± 40 N·m (199 ± 30 lb ft) i02987334

Flywheel Housing SMCS Code: 1157 Part No.: 102-3540, 107-7177 S/N: S2A1-Up

Part No.: 102-3540, 107-7177 S/N: MRG1-Up Part No.: 102-3540, 107-7177 S/N: PAG1-Up Part No.: 102-3540, 107-7177 S/N: S2G1-Up Part No.: 102-3540, 107-7177 S/N: MKH1-Up Part No.: 102-3540, 107-7177 S/N: S2H1-Up Part No.: 102-3540, 107-7177 S/N: S2J1-Up Part No.: 102-3540, 107-7177 S/N: S2K1-Up Part No.: 102-3540, 107-7177 S/N: S2L1-Up Part No.: 102-3540, 107-7177 S/N: S2M1-Up Part No.: 102-3540, 107-7177 S/N: S2N1-Up Part No.: 102-3540, 107-7177 S/N: S2P1-Up Part No.: 102-3540, 107-7177 S/N: S2R1-Up Part No.: 102-3540, 107-7177 S/N: S2S1-Up Part No.: 102-3540, 107-7177 S/N: S2T1-Up Part No.: 102-3540, 107-7177 S/N: S2W1-Up Part No.: 102-3540, 107-7177 S/N: S2X1-Up Part No.: 102-3540, 107-7177 S/N: S2Y1-Up Part No.: 102-3540, 107-7177 S/N: S2Z1-Up

Part No.: 102-3540, 107-7177 S/N: S2B1-Up

For information on inspecting the flywheel housing, refer to Systems Operation/Testing and Adjusting.

Part No.: 102-3540, 107-7177 S/N: S2D1-Up

Note: Before installation of the flywheel housing, inspect the front face of the flywheel housing and the rear face of the cylinder block. The components must be free of the following substances: oil, fuel, water, gasket adhesive, assembly compounds, and any other foreign material.

Part No.: 102-3540, 107-7177 S/N: S2E1-Up Part No.: 102-3540, 107-7177 S/N: S2F1-Up Part No.: 102-3540, 107-7177 S/N: B5G1-Up

To seal the joint between the flywheel housing and the cylinder block, apply 1U-8846 Gasket Sealant to the mating surface of the flywheel housing.

136 Specifications Section

RENR5077-11

g01513774

Illustration 178 Rear view Table 8

Flywheel Housing Bolt Installation Chart

Bolt Length

Bolt

Diameter inch

Part Number

mm

inch

1

1/2

9X-8873

57.15

2.250

2

1/2

1D-4574

152.4

6.00

3

1/2

9X-8874

76.2

3.00

4

5/8

1D-4597

165.1

6.50

5 6

5/8 1/2

1D-4593 9X-8878

139.7 133.35

5.50 5.250

7

5/8

1D-4602

241.30

9.500

Tighten the bolts that hold the flywheel housing to the engine block evenly. Refer to Illustration 178 and Table 8 for the locations and for the identification of the bolts.

(1) Torque for eight bolts ..................... 135 ± 20 N·m (100 ± 15 lb ft) (2) Torque for six bolts ........................ 135 ± 20 N·m (100 ± 15 lb ft) (3) Torque for two bolts ....................... 135 ± 20 N·m (100 ± 15 lb ft) (4) Torque for two bolts ....................... 270 ± 40 N·m (200 ± 30 lb ft) (5) Torque for 12 bolts .. 270 ± 40 N·m (200 ± 30 lb ft)

RENR5077-11

137 Specifications Section

(6) Torque for four bolts ....................... 135 ± 20 N·m (100 ± 15 lb ft) (7) Torque for two bolts ....................... 270 ± 40 N·m (200 ± 30 lb ft)

i03606340

Flexible Coupling SMCS Code: 3279 Part No.: 5N-3765 S/N: S2A1-Up Part No.: 5N-3765 S/N: S2B1-Up Part No.: 5N-3765 S/N: S2G1-Up Part No.: 5N-3765 S/N: S2H1-Up Part No.: 5N-3765 S/N: S2P1-Up Part No.: 5N-3765 S/N: S2R1-Up

Illustration 179

g01513803

Left side view

(8) Apply 1U-8846 Gasket Sealant to the surface of the gasket before assembly.

Illustration 180

g01931073

Note: Before you install the outer coupling (1) the flywheel (6) must be clean and free from the following substances: oil, paint, dirt, and protective coating.

138 Specifications Section

RENR5077-11

Use the following procedure to install the flexible coupling:

Part No.: 7W-0284 S/N: S2P1-Up

1. Lubricate all the surfaces that will contact either the O-ring seals (2) or the rubber coupling boots (5) with 5N-5561 Silicone Lubricant except the plate (4).

Part No.: 7W-0284 S/N: S2R1-Up

2. Install the O-ring seals (2) in the outer coupling (1).

Part No.: 7W-0284 S/N: S2T1-Up

3. Center the drive coupling (3) inside the outer coupling (1).

4. Place the rubber coupling boots (5) between the drive coupling (3) and outer coupling (1).

5. Fill the cavities between the couplings and the rubber coupling boots (5) with the 5N-5561 Silicone Lubricant.

Part No.: 7W-0284 S/N: S2S1-Up

Part No.: 7W-0284 S/N: S2W1-Up Part No.: 7W-0284 S/N: S2X1-Up Part No.: 7W-0284 S/N: S2Z1-Up

6. Bolt the outer coupling (1) into the flywheel (6).

7. Bolt the drive coupling (3) to the shaft (7).

8. As needed, modify the assembly procedure for the installation of the flexible coupling in the field. i01691646

Engine Mount (Front) (Hydraulic Pump Drive or PTO Clutch) SMCS Code: 1152 Part No.: 7W-0284 S/N: S2A1-Up Part No.: 7W-0284 S/N: S2B1-Up Part No.: 7W-0284 S/N: S2D1-Up Part No.: 7W-0284 S/N: S2E1-Up Part No.: 7W-0284 S/N: S2G1-Up Part No.: 7W-0284 S/N: S2H1-Up Part No.: 7W-0284 S/N: S2J1-Up

Illustration 181

g00280831

(1) Damper (2) Adapter (3) Damper adapter Torque ................ 1125 ± 100 N·m (820 ± 75 lb ft)

Part No.: 7W-0284 S/N: S2K1-Up

(4) Coupling

Part No.: 7W-0284 S/N: S2L1-Up

Put a dash mark on the coupling in alignment with the marks on the damper adapter and the crankshaft.

Part No.: 7W-0284 S/N: S2N1-Up

RENR5077-11

139 Specifications Section

i02958521

Engine Trunnion SMCS Code: 1153

Part No.: 4P-3309 S/N: S2X1-Up Part No.: 4P-3309 S/N: S2Y1-Up

Part No.: 335-3181 S/N: M8A1-Up Part No.: 335-3181 S/N: M8B1-Up Part No.: 7N-1863 S/N: S2D1-Up Part No.: 7N-1863 S/N: S2E1-Up Part No.: 4P-3309 S/N: S2F1-Up Part No.: 4P-3309 S/N: B5G1-Up Part No.: 4P-3309 S/N: MRG1-Up Part No.: 4P-3309 S/N: PAG1-Up Part No.: 4P-3309 S/N: S2G1-Up

Illustration 182

g01475072

(1) Torque for 16 bolts .. 190 ± 30 N·m (140 ± 22 lb ft)

Part No.: 4P-3309 S/N: MKH1-Up

(2) Torque for 20 bolts .. 135 ± 20 N·m (100 ± 15 lb ft)

Part No.: 4P-3309 S/N: S2H1-Up

i02888713

Part No.: 4P-3309, 7N-1863 S/N: S2J1-Up

Vibration Damper SMCS Code: 1205

Part No.: 4P-3309, 7N-1863 S/N: S2K1-Up

Part No.: 247-0845 S/N: M8A1-Up

Part No.: 4P-3309, 7N-1863 S/N: S2L1-Up

Part No.: 146-3740 S/N: S2A1-Up

Part No.: 4P-3309 S/N: S2M1-Up

Part No.: 146-3740 S/N: M8B1-Up

Part No.: 4P-3309, 7N-1863 S/N: S2N1-Up

Part No.: 146-3740 S/N: S2B1-Up

Part No.: 4P-3309 S/N: S2P1-Up

Part No.: 146-3740 S/N: S2D1-Up

Part No.: 4P-3309 S/N: S2R1-Up

Part No.: 146-3740 S/N: S2E1-Up

Part No.: 4P-3309 S/N: S2S1-Up

Part No.: 146-3740 S/N: S2F1-Up

Part No.: 4P-3309 S/N: S2T1-Up

Part No.: 146-3740 S/N: B5G1-Up

Part No.: 4P-3309 S/N: S2W1-Up

Part No.: 146-3740 S/N: MRG1-Up

140 Specifications Section

RENR5077-11

Part No.: 146-3740 S/N: PAG1-Up Part No.: 146-3740 S/N: S2G1-Up Part No.: 146-3740 S/N: MKH1-Up Part No.: 146-3740 S/N: S2H1-Up Part No.: 146-3740 S/N: S2J1-Up Part No.: 146-3740 S/N: S2K1-Up Part No.: 146-3740 S/N: S2L1-Up Part No.: 146-3740 S/N: S2M1-Up Part No.: 146-3740 S/N: S2N1-Up Part No.: 146-3740 S/N: S2P1-Up Part No.: 146-3740 S/N: S2R1-Up

Illustration 183

Note: Apply 4C-4030 Thread Lock Compound to the threads of the bolts (1).

(1) Torque for the 48 bolts ... 55 ± 7 N·m (41 ± 5 lb ft) i03322541

Part No.: 146-3740 S/N: S2S1-Up

Vibration Damper

Part No.: 146-3740 S/N: S2T1-Up

SMCS Code: 1205

Part No.: 146-3740 S/N: S2W1-Up Part No.: 146-3740 S/N: S2X1-Up Part No.: 146-3740 S/N: S2Y1-Up Part No.: 146-3740 S/N: S2Z1-Up

g01438233

Part No.: 125-9749, 240-7762 S/N: S2A1-Up Part No.: 125-9749, 240-7762 S/N: S2B1-Up Part No.: 125-9749, 240-7762 S/N: S2D1-Up Part No.: 125-9749, 240-7762 S/N: S2E1-Up Part No.: 125-9749, 240-7762 S/N: S2F1-Up Part No.: 125-9749, 240-7762 S/N: B5G1-Up Part No.: 125-9749, 240-7762 S/N: MRG1-Up Part No.: 125-9749, 240-7762 S/N: PAG1-Up Part No.: 125-9749, 240-7762 S/N: S2G1-Up Part No.: 125-9749, 240-7762 S/N: MKH1-Up

RENR5077-11

141 Specifications Section

Part No.: 125-9749, 240-7762 S/N: S2H1-Up

Note: The alignment mark on the crankshaft (1) must be aligned with the alignment mark on the adapter (2). The mark on the damper group (3) must also be aligned with the mark on the adapter (2).

Part No.: 125-9749, 240-7762 S/N: S2J1-Up Part No.: 125-9749, 240-7762 S/N: S2K1-Up

Note: Before assembly, lubricate the threads of the bolts with molybdenum disulfide base lubricant.

Part No.: 125-9749, 240-7762 S/N: S2L1-Up

(4) Torque for six bolts ...................... 1150 ± 60 N·m (840 ± 44 lb ft)

Part No.: 125-9749, 240-7762 S/N: S2M1-Up

Note: Apply 4C-4030 Thread Lock Compound to the threads of the bolts.

Part No.: 125-9749, 240-7762 S/N: S2N1-Up

(5) Torque for 48 bolts ......... 55 ± 7 N·m (41 ± 5 lb ft)

Part No.: 125-9749, 240-7762 S/N: S2P1-Up

i03295581

Vibration Damper

Part No.: 125-9749, 240-7762 S/N: S2R1-Up

SMCS Code: 1205

Part No.: 125-9749, 240-7762 S/N: S2S1-Up

Part No.: 8N-7182 S/N: S2A1-Up

Part No.: 125-9749, 240-7762 S/N: S2T1-Up

Part No.: 8N-7182 S/N: S2B1-Up

Part No.: 125-9749, 240-7762 S/N: S2W1-Up

Part No.: 8N-7182 S/N: S2D1-Up

Part No.: 125-9749, 240-7762 S/N: S2X1-Up

Part No.: 8N-7182 S/N: S2E1-Up

Part No.: 125-9749, 240-7762 S/N: S2Y1-Up

Part No.: 8N-7182 S/N: S2F1-Up

Part No.: 125-9749, 240-7762 S/N: S2Z1-Up

Part No.: 8N-7182 S/N: B5G1-Up Part No.: 8N-7182 S/N: MRG1-Up Part No.: 8N-7182 S/N: PAG1-Up Part No.: 8N-7182 S/N: S2G1-Up Part No.: 8N-7182 S/N: MKH1-Up Part No.: 8N-7182 S/N: S2H1-Up Part No.: 8N-7182 S/N: S2J1-Up Part No.: 8N-7182 S/N: S2K1-Up

Illustration 184

g01412026

Part No.: 8N-7182 S/N: S2L1-Up Part No.: 8N-7182 S/N: S2M1-Up

142 Specifications Section

RENR5077-11

Part No.: 8N-7182 S/N: S2N1-Up

Part No.: 334-4642, 334-4644 S/N: M8B1-Up

Part No.: 8N-7182 S/N: S2P1-Up

Part No.: 197-9052, 8N-9639 S/N: S2B1-Up

Part No.: 8N-7182 S/N: S2R1-Up

Part No.: 102-8616, 197-9052, 8N-9639 S/N: S2D1-Up

Part No.: 8N-7182 S/N: S2S1-Up

Part No.: 102-8616, 197-9052, 8N-9639 S/N: S2E1-Up

Part No.: 8N-7182 S/N: S2T1-Up

Part No.: 102-8616, 197-9052, 8N-9639 S/N: S2F1-Up

Part No.: 8N-7182 S/N: S2W1-Up

Part No.: 102-8616, 197-9052, 8N-9639 S/N: B5G1-Up

Part No.: 8N-7182 S/N: S2X1-Up

Part No.: 102-8616, 197-9052, 8N-9639 S/N: MRG1-Up

Part No.: 8N-7182 S/N: S2Y1-Up

Part No.: 102-8616, 197-9052, 8N-9639 S/N: PAG1-Up

Part No.: 8N-7182 S/N: S2Z1-Up

Part No.: 197-9052, 8N-9639 S/N: S2G1-Up Part No.: 102-8616, 197-9052, 8N-9639 S/N: MKH1-Up Part No.: 197-9052, 8N-9639 S/N: S2H1-Up Part No.: 102-8616, 197-9052, 8N-9639 S/N: S2J1-Up Part No.: 102-8616, 197-9052, 8N-9639 S/N: S2K1-Up Part No.: 102-8616, 197-9052, 8N-9639 S/N: S2L1-Up

Illustration 185

g01515801

Note: The alignment mark on the crankshaft (1) must be aligned with the alignment mark on the damper adapter (2).

Note: Before assembly, lubricate the threads of the bolts with molybdenum disulfide base lubricant.

(3) Torque for six bolts ...................... 1150 ± 60 N·m (840 ± 44 lb ft) i03105503

Part No.: 102-8616, 197-9052, 8N-9639 S/N: S2M1-Up Part No.: 102-8616, 197-9052, 8N-9639 S/N: S2N1-Up Part No.: 197-9052, 8N-9639 S/N: S2P1-Up Part No.: 102-8616, 197-9052, 8N-9639 S/N: S2R1-Up Part No.: 102-8616, 197-9052, 8N-9639 S/N: S2S1-Up

Vibration Damper Guard

Part No.: 102-8616, 197-9052, 8N-9639 S/N: S2T1-Up

SMCS Code: 1205

Part No.: 102-8616, 197-9052, 8N-9639 S/N: S2W1-Up

Part No.: 334-4642, 334-4644 S/N: M8A1-Up

Part No.: 102-8616, 197-9052, 8N-9639 S/N: S2X1-Up

Part No.: 197-9052, 8N-9639 S/N: S2A1-Up

Part No.: 102-8616, 197-9052, 8N-9639 S/N: S2Y1-Up

RENR5077-11

143 Specifications Section

Part No.: 197-9052, 8N-9639 S/N: S2Z1-Up

Note: Before you tighten the bolts, apply a molybdenum disulfide grease to the threads of the bolts.

(2) Torque for the bolts ...................... 1150 ± 60 N·m (848 ± 44 lb ft)

Illustration 186

g01393058

Typical example

(1) Torque for the bolts ........ 15 ± 3 N·m (11 ± 2 lb ft) i03742222

Stub Shaft (Front) SMCS Code: 1237 Part No.: 334-0958 S/N: M8B1-Up

Illustration 187

g01744573

Typical example

Note: The alignment mark on the stub shaft (3) must be aligned with the mark on the adapter (1).

144 Specifications Section

RENR5077-11

i03879148

Stub Shaft (Front) SMCS Code: 1237 Part No.: 7W-5237 S/N: S2A1-Up Part No.: 334-0956 S/N: M8B1-Up Part No.: 7W-5237 S/N: S2B1-Up Part No.: 7W-5237 S/N: S2D1-Up Part No.: 7W-5237 S/N: S2E1-Up Part No.: 7W-5237 S/N: S2F1-Up Part No.: 7W-5237 S/N: S2Z1-Up

Illustration 188 Low kW (HP) attachments

g00278463

RENR5077-11

145 Specifications Section

g00278464

Illustration 189 High kW (HP) attachments

Part No.: 7W-3629 S/N: S2K1-Up

(1) Crankshaft (2) Adapter

Part No.: 7W-3629 S/N: S2L1-Up

(3) Bolts Apply a molybdenum disulfide grease under the bolt heads and to the threads before assembly.

Part No.: 7W-3629 S/N: S2M1-Up

Torque ......................... 1150 ± 60 N·m (850 ± 44)

Part No.: 7W-3629 S/N: S2N1-Up

(4) Alignment mark Align the alignment mark on the stub shaft with the alignment mark on the adapter. i03292468

Part No.: 7W-3629 S/N: S2P1-Up Part No.: 7W-3629 S/N: S2R1-Up

Stub Shaft (Front)

Part No.: 7W-3629 S/N: S2S1-Up

SMCS Code: 1237

Part No.: 7W-3629 S/N: S2T1-Up

Part No.: 7W-3629 S/N: S2E1-Up Part No.: 7W-3629 S/N: PAG1-Up Part No.: 7W-3629 S/N: S2G1-Up Part No.: 7W-3629 S/N: MKH1-Up Part No.: 7W-3629 S/N: S2H1-Up Part No.: 7W-3629 S/N: S2J1-Up

Part No.: 7W-3629 S/N: S2W1-Up Part No.: 7W-3629 S/N: S2X1-Up Part No.: 7W-3629 S/N: S2Y1-Up

146 Specifications Section

RENR5077-11

i03577893

Auxiliary Drive Pulley SMCS Code: 1205 Part No.: 334-5309 S/N: M8A1-Up Part No.: 334-5309 S/N: M8B1-Up

Illustration 190

g01676708

Before assembly, apply molybdenum disulfide grease to the shoulder of the bolt heads and to the threads of the bolt.

(1) Torque for 12 bolts ..................... 1150 ± 150 N·m (840 ± 110 lb ft)

Illustration 191

g01906433

(1) Lubricate the sealing lip of the lip type seal with the lubricant that is being sealed. i01940316

Auxiliary Drive Shaft SMCS Code: 1165; 1207 Part No.: 209-3562 S/N: M8A1-Up Part No.: 209-3559, 209-3560, 209-3561, 209-3562, 7N-8042 S/N: S2A1-Up

RENR5077-11

Part No.: 209-3562 S/N: M8B1-Up Part No.: 209-3559, 209-3560, 209-3561, 209-3562, 7N-8042 S/N: S2B1-Up Part No.: 209-3559, 209-3560, 209-3562, 7N-8042 S/N: S2D1-Up Part No.: 209-3559, 209-3560, 209-3562, 7N-8042 S/N: S2E1-Up Part No.: 209-3559, 209-3561, 209-3562 S/N: S2F1-Up Part No.: 209-3562 S/N: MRG1-Up

147 Specifications Section

Part No.: 209-3559, 209-3560, 209-3561, 209-3562, 7N-8042 S/N: S2T1-Up Part No.: 209-3559, 209-3560, 209-3561, 209-3562, 7N-8042 S/N: S2W1-Up Part No.: 209-3559, 209-3560, 209-3561, 209-3562, 7N-8042 S/N: S2X1-Up Part No.: 209-3559, 209-3561, 209-3562 S/N: S2Y1-Up Part No.: 209-3559, 209-3560, 209-3562, 7N-8042 S/N: S2Z1-Up

Part No.: 209-3559, 7N-8042 S/N: PAG1-Up Part No.: 209-3559, 209-3560, 209-3561, 209-3562, 7N-8042 S/N: S2G1-Up Part No.: 209-3559, 209-3562, 7N-8042 S/N: MKH1-Up Part No.: 209-3559, 209-3560, 209-3561, 209-3562, 7N-8042 S/N: S2H1-Up Part No.: 209-3559, 209-3560, 209-3562, 7N-8042 S/N: S2J1-Up Part No.: 209-3559, 209-3560, 209-3562, 7N-8042 S/N: S2K1-Up

Illustration 192

g00280784

Part No.: 209-3559, 209-3560, 209-3562, 7N-8042 S/N: S2L1-Up

(1) Bolt

Part No.: 209-3559, 209-3560, 209-3561, 209-3562 S/N: S2M1-Up

Install the seal as the seal is shown. Lubricate the sealing lip with the lubricant that is being sealed.

Part No.: 209-3559, 209-3560, 209-3562, 7N-8042 S/N: S2N1-Up Part No.: 209-3559, 209-3560, 209-3561, 209-3562, 7N-8042 S/N: S2P1-Up Part No.: 209-3559, 209-3560, 209-3561, 209-3562, 7N-8042 S/N: S2R1-Up Part No.: 209-3559, 209-3560, 209-3561, 209-3562, 7N-8042 S/N: S2S1-Up

Torque ............................ 47 ± 9 N·m (35 ± 6 lb ft)

148 Specifications Section

RENR5077-11

i03859469

Belt Tension Chart SMCS Code: 1357 Part No.: 7N-9693 S/N: S2A1-Up Part No.: 7N-9693 S/N: S2B1-Up Part No.: 7N-9693 S/N: S2G1-Up Part No.: 7N-9693 S/N: S2H1-Up Part No.: 7N-9693 S/N: S2R1-Up The new belt tension chart has been standardized.

The belt tension chart eliminates confusion about the correct belt tension to use. Studies were completed with different belt suppliers and the information that was gathered from the studies was developed into a new belt tension for each belt size.

Table 9

Belt Tension Chart SAE or RMA Belt SIze

Width of Belt (Top Reference)

Belt Tension “Initial”(1)

Belt Tension “Used”(2)(3)

IN

MM

IN

MM

LB

N

LB

N

3/8 (0.380)

10A

0.42

10.72

145±10

645±44

70±10

311±44

7/16 (0.440)

11A

0.46

11.68

155±10

689±44

75±10

333±44

1/2 (0.500)

13A

0.55

13.89

165±10

734±44

80±10

356±44

5V/5VX

5V

0.63

15.88

180±10

801±44

85±10

378±44

11/16 (0.600)

15A

0.69

17.48

180±10

801±44

85±10

378±44

3/4 (0.660)

17A

0.75

19.05

205±10

912±44

95±10

422±44

7/8 (0.790)

20A

0.88

22.23

205±10

912±44

95±10

422±44

15/16

N/A

0.98

23.83

205±10

912±44

95±10

422±44

4K

4PK

0.54

13.72

145±10

645±44

60±10

267±44

6K

6PK

0.82

20.94

215±10

956±44

90±10

400±44

8K

8PK

1.1

27.82

285±10

1179±44

115±10

511±44

10K

10PK

1.38

35.05

355±10

1579±44

145±10

645±44

12K

12PK

1.66

42.16

425±10

1891±44

175±10

778±44

14K

14PK

1.94

49.28

495±10

2202±44

205±10

912±44

15K

15PK

2.08

52.83

530±10

2358±44

215±10

956±44

(1) (2) (3)

Belt Tension“Initial ” is for a new belt.

Belt tension “Used” is for a belt that has operated for more than 30 minutes of operation at the rated speed..

If a belt falls below the “Used” belt tension, the belt should be tightened again to 80% of the “Initial” belt tension.

Note: The chart does not apply to belts that use a spring loaded tensioner.

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149 Specifications Section

For more accurate results, a Clavis frequency gauge should be used in order to measure the natural frequency of the belt. By the use of a formula, the natural frequency is converted into the belt tension force. If the Clavis frequency gauge can not be used, then use the appropriate Kent-Moore belt tension gauge to measure the belt tension force.

When matched sets of belts are used, check the tension of all the belts in order to verify that the lowest belt is in the acceptable tolerance range. Variations in tension between the belts can vary by as much as 65 pounds.

In order to determine the tension of a “banded” belt, refer to the chart above. Multiply the tension value of the belt by the number of belts that are banded together.Two 1/2 inch belts would require a used belt tension equal to twice the value of the used belt tension for one 1/2 inch belt (2 X 80 = 160 lb). i02899402

Belt Tension Chart SMCS Code: 1357 Part No.: 197-9087 Note: Do not use the belt tension chart for belts with tensioners that are spring loaded.

Table 10

Belt Tension Chart

Gauge Reading Size of Belt

8 - RIB POLY - RIB

Width of Belt

27.82 mm (1.095 inch)

Belt Tension (Force) “Initial”

Belt Tension (Force) “Used”

(1)

(2)(3)

800 ± 22 N (180 ± 5 lb)

489 ± 44 N (110 ± 10 lb)

Suggested Gauge (Force) Basic Gauge Number BT-33-109

Belt Tension (Frequency) “Initial”(1)

Belt Tension (Frequency) “Used”(2)(3)

Gauge Number 98 ± 10 HZ

76 ± 8 HZ

Measure the tension of the belt that is farthest from the engine.

(1) (2) (3)

Suggested Gauge (Frequency)

Belt tension “lnitial” is for a new belt.

Belt tension “Used” is for a belt that has operated for 30 minutes or more of operation at the rated speed.

If a belt falls below the “Used” belt tension, the belt should be tightened again to the high side of the “Used” belt tension.

Clavis Type 14

150 Specifications Section

RENR5077-11

i03879943

Alternator and Regulator SMCS Code: 1405 Part No.: 333-1184

Illustration 193

g02125953

Voltage ............................................................... 24 V Amperage ..................................................... 68 Amp Note: Load the battery with a carbon pile 4C-4911 Battery Load Tester in order to get the maximum alternator output.

Polarity ........................................... Insulated ground Rotation ............................................ Either direction Minimum full load current at 5000 rpm ......... 68 Amp Minimum full load current at 2000 rpm ......... 42 Amp

Illustration 194

g02125979

View A-A

(2) (B+) terminal. Final installation torque for the nut ....................... 6.2 ± 0.6 N·m (54.9 ± 5.3 lb in) Note: Use a 7/16 ring terminal for (B+) terminal.

(3) The peak voltage for (R) terminal must not be less than the output voltage for (B+) terminal.

(4) Final installation torque for the fastener .......................... 88 ± 7 N·m (65 ± 5 lb ft) (5) (S) terminal. Final installation torque for the nut ............... 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in)

Output voltage ............................................. 28 ± 1 V

(6) (B-) terminal. Final installation torque for the nut ....................... 6.2 ± 0.6 N·m (54.9 ± 5.3 lb in)

(1) Final installation torque for the flange nut ................................ 102 ± 7 N·m (75 ± 5 lb ft)

(7) Voltage regulator assembly Voltage setting ............................. No adjustment Permissible voltage range .................. 27 to 29 V i02899397

Alternator Mounting SMCS Code: 1405 Part No.: 335-4161, 7E-4836 S/N: M8A1-Up

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151 Specifications Section

Part No.: 7E-4836 S/N: S2A1-Up

Part No.: 7E-4836 S/N: S2Y1-Up

Part No.: 335-4161, 7E-4836 S/N: M8B1-Up

Part No.: 7E-4836 S/N: S2Z1-Up

Part No.: 7E-4836 S/N: S2B1-Up Part No.: 7E-4836 S/N: S2D1-Up Part No.: 7E-4836 S/N: S2E1-Up Part No.: 7E-4836 S/N: S2F1-Up Part No.: 7E-4836 S/N: B5G1-Up Part No.: 7E-4836 S/N: MRG1-Up Part No.: 7E-4836 S/N: PAG1-Up Part No.: 7E-4836 S/N: S2G1-Up Part No.: 7E-4836 S/N: MKH1-Up Part No.: 7E-4836 S/N: S2H1-Up Part No.: 7E-4836 S/N: S2J1-Up Part No.: 7E-4836 S/N: S2K1-Up Part No.: 7E-4836 S/N: S2L1-Up Part No.: 7E-4836 S/N: S2M1-Up Part No.: 7E-4836 S/N: S2N1-Up

Illustration 195

g01446906

Note: Maximum misalignment between pulley assembly (3) and pulley (1) is 0.4 degrees.

(2) Torque for the pulley retaining nut .. 110 ± 10 N·m (80 ± 7 lb ft) (4) Adjust the belt tension of the serpentine belt according to the 197-9087 Tension Chart.

(5) Lubricate the sealing lip of the lip type seal lightly with the lubricant that is being sealed. i02945902

Electric Starting Motor SMCS Code: 1453

Part No.: 7E-4836 S/N: S2P1-Up

Part No.: 207-1557, 207-1562 S/N: M8A1-Up

Part No.: 7E-4836 S/N: S2R1-Up

Part No.: 207-1557, 207-1562 S/N: S2A1-Up

Part No.: 7E-4836 S/N: S2S1-Up

Part No.: 207-1557, 207-1562 S/N: M8B1-Up

Part No.: 7E-4836 S/N: S2T1-Up

Part No.: 207-1557, 207-1562 S/N: S2B1-Up

Part No.: 7E-4836 S/N: S2W1-Up

Part No.: 207-1557, 207-1562 S/N: S2D1-Up

Part No.: 7E-4836 S/N: S2X1-Up

Part No.: 207-1557, 207-1562 S/N: S2E1-Up

152 Specifications Section

RENR5077-11

Part No.: 207-1557, 207-1562 S/N: S2F1-Up Part No.: 207-1557, 207-1562 S/N: PAG1-Up Part No.: 207-1557, 207-1562 S/N: S2G1-Up Part No.: 207-1557, 207-1562 S/N: MKH1-Up Part No.: 207-1557, 207-1562 S/N: S2H1-Up Part No.: 207-1557, 207-1562 S/N: S2J1-Up

Illustration 196

g01460088

Illustration 197

g01460089

Part No.: 207-1557, 207-1562 S/N: S2K1-Up Part No.: 207-1557, 207-1562 S/N: S2L1-Up Part No.: 207-1557, 207-1562 S/N: S2M1-Up Part No.: 207-1557, 207-1562 S/N: S2N1-Up Part No.: 207-1557, 207-1562 S/N: S2P1-Up Part No.: 207-1557, 207-1562 S/N: S2R1-Up Part No.: 207-1557, 207-1562 S/N: S2S1-Up Part No.: 207-1557, 207-1562 S/N: S2T1-Up Part No.: 207-1557, 207-1562 S/N: S2W1-Up Part No.: 207-1557, 207-1562 S/N: S2X1-Up

View A-A

When the electric starting motor is viewed from the drive end, the motor rotates in the following direction. ................................................... Clockwise No load conditions at 25 °C (77 °F) Speed ...................................... 7643 ± 1683 rpm Current draw ............................. 76.5 ± 14.5 Amp Voltage ......................................................... 23 V

Part No.: 207-1557, 207-1562 S/N: S2Y1-Up

(1) Final installation torque for the ground terminal nut ....................... 30.5 ± 3.5 N·m (270 ± 30 lb in)

Part No.: 207-1557, 207-1562 S/N: S2Z1-Up

(2) Final installation torque for the battery terminal nut ....................... 30.5 ± 3.5 N·m (270 ± 30 lb in) (3) Final installation torque for the ground terminal nut ......................... 2.25 ± 0.25 N·m (20 ± 2 lb in) (4) Final installation torque for the switch terminal nut ......................... 2.25 ± 0.25 N·m (20 ± 2 lb in) (5) Final installation torque for the motor terminal nut ....................... 30.5 ± 3.5 N·m (270 ± 30 lb in) (6) Final installation torque for the motor frame terminal nut ................... 8 ± 3 N·m (70 ± 27 lb in) Solenoid

RENR5077-11

153 Specifications Section

Current consumption at 20 V and 25 °C (77 °F) Pull in windings ....................................... 57 Amp Hold in windings ..................................... 16 Amp (B) Clearance between the pinion and the housing ................................. 9.1 mm (0.36 inch) i02787858

Tighten the bolts evenly in small increases until the following torque is reached: ............... 80 N·m (60 lb ft) (2) Bolt Torque ....................................... 36 N·m (27 lb ft) (3) Bolt Torque ....................................... 78 N·m (60 lb ft)

Air Starting Motor

(4) Bolt (pinion)

SMCS Code: 1451

Torque ...................................... 110 N·m (80 lb ft)

Part No.: 7C-3371, 8N-8477 S/N: S2A1-Up

(5) Rotor clamp nut

Part No.: 7C-3371, 8N-8477 S/N: S2B1-Up

Tighten the rotor clamp nut until the following clearance between the rear end plate and the rotor is reached: ........................ 0.03 to 0.08 mm (0.001 to 0.003 inch)

Part No.: 8N-8477 S/N: S2G1-Up Part No.: 8N-8477 S/N: S2H1-Up

Check the clearance again after the bolt for the rotor clamp nut is tightened.

Part No.: 8N-8477 S/N: S2J1-Up

(6) Rotor retainer bolt Torque ..................................... 120 N·m (90 lb ft)

Part No.: 8N-8477 S/N: S2M1-Up

i02817180

Part No.: 7C-3371, 8N-8477 S/N: S2P1-Up

Air Starting Motor Pressure Regulating Valve

Part No.: 7C-3371, 8N-8477 S/N: S2R1-Up

SMCS Code: 1462

Part No.: 7C-3371 S/N: S2W1-Up

Part No.: 1L-2073 S/N: M8A1-Up

Part No.: 8N-8477 S/N: S2X1-Up

Part No.: 1L-2073 S/N: S2A1-Up

Part No.: 7C-3371, 8N-8477 S/N: S2Z1-Up

Part No.: 1L-2073 S/N: M8B1-Up Part No.: 1L-2073 S/N: S2B1-Up Part No.: 1L-2073 S/N: S2D1-Up Part No.: 1L-2073 S/N: S2E1-Up Part No.: 1L-2073 S/N: S2F1-Up Part No.: 1L-2073 S/N: PAG1-Up

Illustration 198 Typical example

(1) Cover

g01392582

Part No.: 1L-2073 S/N: S2G1-Up Part No.: 1L-2073 S/N: S2H1-Up

154 Specifications Section

RENR5077-11

Part No.: 1L-2073 S/N: S2J1-Up

(3) Outlet pressure at outlet port ...... 620 to 750 kPa (90 to 110 psi)

Part No.: 1L-2073 S/N: S2K1-Up

i01668530

Jacket Water Heater

Part No.: 1L-2073 S/N: S2L1-Up

SMCS Code: 1383

Part No.: 1L-2073 S/N: S2M1-Up

Part No.: 7E-6247 S/N: M8A1-Up

Part No.: 1L-2073 S/N: S2N1-Up

Part No.: 7E-6247 S/N: S2A1-Up

Part No.: 1L-2073 S/N: S2P1-Up

Part No.: 7E-6247 S/N: M8B1-Up

Part No.: 1L-2073 S/N: S2R1-Up

Part No.: 7E-6247 S/N: S2B1-Up

Part No.: 1L-2073 S/N: S2S1-Up

Part No.: 7E-6247 S/N: S2D1-Up

Part No.: 1L-2073 S/N: S2T1-Up

Part No.: 7E-6247 S/N: S2E1-Up

Part No.: 1L-2073 S/N: S2W1-Up

Part No.: 7E-6247 S/N: PAG1-Up

Part No.: 1L-2073 S/N: S2X1-Up

Part No.: 7E-6247 S/N: S2G1-Up

Part No.: 1L-2073 S/N: S2Y1-Up

Part No.: 7E-6247 S/N: MKH1-Up

Part No.: 1L-2073 S/N: S2Z1-Up

Part No.: 7E-6247 S/N: S2H1-Up Part No.: 7E-6247 S/N: S2J1-Up Part No.: 7E-6247 S/N: S2K1-Up Part No.: 7E-6247 S/N: S2L1-Up Part No.: 7E-6247 S/N: S2M1-Up Part No.: 7E-6247 S/N: S2N1-Up Part No.: 7E-6247 S/N: S2P1-Up Part No.: 7E-6247 S/N: S2R1-Up

Illustration 199

g01392594

(1) Bolt

(2) Inlet port Inlet pressure ........................ 1700 kPa (250 psi) Maximum inlet pressure ....... 3100 kPa (450 psi)

Part No.: 7E-6247 S/N: S2S1-Up Part No.: 7E-6247 S/N: S2T1-Up Part No.: 7E-6247 S/N: S2W1-Up

RENR5077-11

155 Specifications Section

Part No.: 7E-6247 S/N: S2X1-Up

Part No.: 232-0013, 232-0014 S/N: MKH1-Up

Part No.: 7E-6247 S/N: S2Z1-Up

Part No.: 232-0014 S/N: S2H1-Up Part No.: 232-0013, 232-0014 S/N: S2J1-Up Part No.: 232-0013, 232-0014 S/N: S2K1-Up Part No.: 232-0013, 232-0014 S/N: S2L1-Up Part No.: 232-0013, 232-0014 S/N: S2M1-Up Part No.: 232-0013, 232-0014 S/N: S2N1-Up

Illustration 200

g00279581

Typical example

Power ...................................................... 3000 Watts Voltage ...................................................... 120/240 V (1) Hose Assemble the hose in order to maintain a gradual rise from the heater outlet to the engine.

(2) Jacket water heater (3) Reference dimension .. 60 ± 6 mm (2.4 ± .2 inch) (4) Thermostat (5) Coolant outlet (6) Coolant inlet i02053647

Engine Harness (Rigid Wiring Harness) SMCS Code: 1408 Part No.: 232-0013, 232-0014 S/N: MRG1-Up Part No.: 232-0014 S/N: S2G1-Up

156 Specifications Section

Illustration 201 Typical example

RENR5077-11

g01053142

RENR5077-11

157 Specifications Section

g01053143

Illustration 202 Typical example

(1) Nut Torque ...................................... 2.5 N·m (22 lb in) (2) Nut Torque ......................................... 8 N·m (70 lb in)

(6) Nut Torque ...................................... 2.5 N·m (22 lb in) (7) Nut Torque ...................................... 2.5 N·m (22 lb in)

(3) Nut Torque ...................................... 2.5 N·m (22 lb in) (4) Nut Torque ........................................ 15 N·m (11 lb ft) (5) Nut Torque ......................................... 10 N·m (7 lb ft)

i03292465

Coolant Level Switch SMCS Code: 1395; 7422 Part No.: 2N-9768 S/N: M8A1-Up Part No.: 2N-9768 S/N: S2A1-Up

158 Specifications Section

RENR5077-11

Part No.: 2N-9768 S/N: M8B1-Up Part No.: 2N-9768 S/N: S2B1-Up Part No.: 2N-9768 S/N: S2D1-Up Part No.: 2N-9768 S/N: S2E1-Up Part No.: 2N-9768 S/N: B5G1-Up Part No.: 2N-9768 S/N: MRG1-Up

Illustration 203

Part No.: 2N-9768 S/N: PAG1-Up

Note: The liquid level switch is shown in the high liquid level position.

Part No.: 2N-9768 S/N: S2G1-Up

g01676703

Part No.: 2N-9768 S/N: MKH1-Up

(A) When the liquid level switch activates, approximate travel distance of the liquid level switch is the following distance. .............. 6.4 mm (0.25 inch)

Part No.: 2N-9768 S/N: S2H1-Up

Operating temperature range ............. −53 to 107 °C (−63 to 225 °F)

Part No.: 2N-9768 S/N: S2J1-Up

Contact position ............................... Normally closed

Part No.: 2N-9768 S/N: S2K1-Up

i02995920

Part No.: 2N-9768 S/N: S2L1-Up Part No.: 2N-9768 S/N: S2N1-Up

Coolant Temperature Switch SMCS Code: 1395 Part No.: 3E-0264 S/N: S2Z1-Up

Part No.: 2N-9768 S/N: S2P1-Up Part No.: 2N-9768 S/N: S2R1-Up Part No.: 2N-9768 S/N: S2S1-Up Part No.: 2N-9768 S/N: S2T1-Up Part No.: 2N-9768 S/N: S2W1-Up Part No.: 2N-9768 S/N: S2X1-Up

Illustration 204

Part No.: 2N-9768 S/N: S2Z1-Up

(1) Final installation torque for the temperature switch group ............ 52.5 ± 7.5 N·m (39 ± 6 lb ft)

g01392736

Contact position .......................................... Normally closed below deactuation temperature Actuation temperature ....... 27.0 ± 2.8 °C (81 ± 5 °F)

RENR5077-11

159 Specifications Section

Minimum deactuation temperature ...... 20 °C (68 °F) Operating temperature ........................ −40 to 150 °C (−40 to 302 °F) i02869400

i02896484

Magnetic Switch SMCS Code: 7499 Part No.: 9X-8124

Fuel Pressure Sensor SMCS Code: 7414 Part No.: 161-1705

Illustration 205

g01135892

Illustration 206

(1) Final installation torque for the pressure sensor group .......................... 10 ± 2 N·m (90 ± 18 lb in) Operating temperature ........................ −40 to 125 °C (−40 to 257 °F) Operating voltage ........................... 5.00 ± 0.25 VDC

g01442059

(1) Final installation torque for the two nuts ........................... 5.5 ± 0.5 N·m (50 ± 4 lb in) Operating temperature range ............. −60 to 121 °C (−76 to 250 °F) Operating voltage ......................................... 24 VDC Contact position ................................. Normally open Maximum pull-in voltage at 25 °C (77 °F) ..... 16 VDC Maximum hold-in voltage at 25 °C (77 °F) ...... 8 VDC Resistance at 20 °C (68 °F) ........ 27.50 ± 0.28 Ohms Maximum current draw .............................. 1.25 Amp i02894836

Coolant Level Sensor SMCS Code: 7470 Part No.: 204-2518 S/N: M8A1-Up Part No.: 204-2518, 239-9957 S/N: S2A1-Up Part No.: 204-2518 S/N: M8B1-Up

160 Specifications Section

RENR5077-11

Part No.: 204-2518, 239-9957 S/N: S2B1-Up Part No.: 204-2518, 239-9957 S/N: S2D1-Up Part No.: 204-2518, 239-9957 S/N: S2E1-Up Part No.: 204-2518, 239-9957 S/N: S2F1-Up Part No.: 204-2518, 239-9957 S/N: B5G1-Up Part No.: 204-2518, 239-9957 S/N: MRG1-Up

Illustration 207

Part No.: 204-2518, 239-9957 S/N: PAG1-Up

(1) Final installation torque for the coolant level sensor group .................. 22 ± 3 N·m (16 ± 2 lb ft)

Part No.: 204-2518, 239-9957 S/N: S2G1-Up

g01440910

Operating temperature ........................ −40 to 125 °C (−40 to 257 °F)

Part No.: 204-2518, 239-9957 S/N: MKH1-Up

Operating voltage .................................. 7 to 32 VDC

Part No.: 204-2518, 239-9957 S/N: S2H1-Up

i02845092

Part No.: 204-2518, 239-9957 S/N: S2J1-Up Part No.: 204-2518, 239-9957 S/N: S2K1-Up

Engine Oil Pressure Sensor SMCS Code: 1924 Part No.: 194-6725

Part No.: 204-2518, 239-9957 S/N: S2L1-Up Part No.: 204-2518, 239-9957 S/N: S2M1-Up Part No.: 204-2518, 239-9957 S/N: S2N1-Up Part No.: 204-2518, 239-9957 S/N: S2P1-Up Part No.: 204-2518, 239-9957 S/N: S2R1-Up Part No.: 204-2518, 239-9957 S/N: S2S1-Up Part No.: 204-2518, 239-9957 S/N: S2T1-Up

Illustration 208

g01068621

(1) Final installation torque for the pressure sensor group .......................... 10 ± 2 N·m (90 ± 18 lb in)

Part No.: 204-2518, 239-9957 S/N: S2W1-Up

Operating temperature ........................ −40 to 125 °C (−40 to 257 °F)

Part No.: 204-2518, 239-9957 S/N: S2X1-Up

Operating voltage ........................... 5.00 ± 0.25 VDC

Part No.: 204-2518, 239-9957 S/N: S2Y1-Up Part No.: 204-2518, 239-9957 S/N: S2Z1-Up

RENR5077-11

161 Specifications Section

i02030238

Engine Oil Pressure Sensor

Part No.: 161-1703 S/N: S2E1-Up

SMCS Code: 1924

Part No.: 161-1703 S/N: S2F1-Up

Part No.: 103-6092, 143-9695, 161-9931 S/N: S2Z1-Up

Part No.: 161-1703 S/N: B5G1-Up Part No.: 161-1703 S/N: MRG1-Up Part No.: 161-1703 S/N: PAG1-Up Part No.: 161-1703 S/N: S2G1-Up Part No.: 161-1703 S/N: MKH1-Up Part No.: 161-1703 S/N: S2H1-Up

Illustration 209

g01046769

Typical example

Part No.: 161-1703 S/N: S2J1-Up Part No.: 161-1703 S/N: S2K1-Up

(1) Sensor assembly (2) Plug with socket A, socket B, and socket C

Part No.: 161-1703 S/N: S2L1-Up

(3) Port fitting

Part No.: 161-1703 S/N: S2M1-Up

Torque ........................ 10 ± 2 N·m (90 ± 18 lb in) Operating temperature ........................ −40 to 125 °C (−40 to 257 °F) Maximum input pressure (absolute pressure) ..................................... 1135 kPa (165 psi) Input supply voltage ............................. 5 ± 0.25 VDC

Part No.: 161-1703 S/N: S2N1-Up Part No.: 161-1703 S/N: S2P1-Up Part No.: 161-1703 S/N: S2R1-Up

Maximum supply current ................................. 20 mA

Part No.: 161-1703 S/N: S2S1-Up

Install the sensor so that the pressure port is lower than the wire end. Mount the sensor as close to vertical as possible.

Part No.: 161-1703 S/N: S2T1-Up

i02869431

Turbocharger Inlet Pressure Sensor

Part No.: 161-1703 S/N: S2W1-Up Part No.: 161-1703 S/N: S2X1-Up

SMCS Code: 1052

Part No.: 161-1703 S/N: S2Y1-Up

Part No.: 161-1703 S/N: S2A1-Up

Part No.: 161-1703 S/N: S2Z1-Up

Part No.: 161-1703 S/N: S2B1-Up Part No.: 161-1703 S/N: S2D1-Up

162 Specifications Section

RENR5077-11

i02847454

Turbocharger Outlet Pressure Sensor SMCS Code: 1052; 1917; 1919 Part No.: 161-1704 S/N: S2A1-Up Part No.: 161-1704 S/N: S2B1-Up Part No.: 161-1704 S/N: S2D1-Up Illustration 210

g01135892

(1) Final installation torque for the pressure sensor group .......................... 10 ± 2 N·m (90 ± 18 lb in) Operating temperature ........................ −40 to 125 °C (−40 to 257 °F) Operating voltage ........................... 5.00 ± 0.25 VDC i02847453

Turbocharger Outlet Pressure Sensor SMCS Code: 1052; 1917; 1919

Part No.: 161-1704 S/N: S2E1-Up Part No.: 161-1704 S/N: S2F1-Up Part No.: 161-1704 S/N: B5G1-Up Part No.: 161-1704 S/N: MRG1-Up Part No.: 161-1704 S/N: PAG1-Up Part No.: 161-1704 S/N: S2G1-Up Part No.: 161-1704 S/N: MKH1-Up

Part No.: 194-6724

Part No.: 161-1704 S/N: S2H1-Up Part No.: 161-1704 S/N: S2J1-Up Part No.: 161-1704 S/N: S2K1-Up Part No.: 161-1704 S/N: S2L1-Up Part No.: 161-1704 S/N: S2M1-Up Illustration 211

g01046622

(1) Final installation torque for the pressure sensor group .......................... 10 ± 2 N·m (90 ± 18 lb in)

Part No.: 161-1704 S/N: S2N1-Up Part No.: 161-1704 S/N: S2P1-Up

Operating temperature ........................ −40 to 125 °C (−40 to 257 °F)

Part No.: 161-1704 S/N: S2R1-Up

Operating voltage ........................... 5.00 ± 0.25 VDC

Part No.: 161-1704 S/N: S2S1-Up Part No.: 161-1704 S/N: S2T1-Up

RENR5077-11

163 Specifications Section

Part No.: 161-1704 S/N: S2W1-Up

Operating temperature ........................ −40 to 120 °C (−40 to 248 °F)

Part No.: 161-1704 S/N: S2X1-Up

Operating voltage .......................... 4.75 to 8.50 VDC

Part No.: 161-1704 S/N: S2Y1-Up

i02987360

Engine Coolant Temperature Sensor

Part No.: 161-1704 S/N: S2Z1-Up

SMCS Code: 1395 Part No.: 102-7532

Illustration 212

g01133887

(1) Final installation torque for the pressure sensor group .......................... 10 ± 2 N·m (90 ± 18 lb in)

Illustration 214

Operating temperature ........................ −40 to 125 °C (−40 to 257 °F)

(1) Final installation torque for the temperature sensor group .................. 20 ± 3 N·m (15 ± 2 lb ft)

Operating voltage ........................... 5.00 ± 0.25 VDC

Operating temperature ........................ −40 to 120 °C (−40 to 248 °F)

i02987333

Aftercooler Coolant Temperature Sensor SMCS Code: 1063; 1395 Part No.: 102-7532

Illustration 213

g01513773

(1) Final installation torque for the temperature sensor group .................. 20 ± 3 N·m (15 ± 2 lb ft)

g01513773

Operating voltage .......................... 4.75 to 8.50 VDC

164 Specifications Section

RENR5077-11

i02894896

i03911354

Turbocharger Exhaust Temperature Sensor

Engine Speed/Timing Sensor

SMCS Code: 1052; 1919

Part No.: 265-9034 S/N: M8A1-Up

SMCS Code: 1905; 1907

Part No.: 164-2441

Part No.: 265-9034 S/N: M8B1-Up

Illustration 215

g01441005

(2) Exhaust temperature sensor group

Note: Apply 4C-5599 Anti-Seize Compound to the threads of the adapter (1) before installation.

(1) Final installation torque for the adapter .......................... 45 ± 5 N·m (33 ± 4 lb ft)

Illustration 216

g02127933

(1) Final installation torque for the speed sensor group ............................. 40 ± 5 N·m (30 ± 4 lb ft) Operating voltage ............................ 7.5 to 14.0 VDC

Operating temperature ........................ −40 to 850 °C (−40 to 1562 °F)

Operating temperature ........................ −40 to 120 °C (−40 to 248 °F)

Operating voltage .............................. 7.5 to 8.5 VDC

Output frequency ................................ 9 to 10000 Hz

Output type ...................................................... PWM i02995988

Output frequency ................................. 500 ± 100 Hz

Engine Speed/Timing Sensor SMCS Code: 1905; 1907 Part No.: 102-9029 S/N: S2A1-Up Part No.: 102-9029 S/N: S2B1-Up Part No.: 102-9029 S/N: S2D1-Up Part No.: 102-9029 S/N: S2E1-Up Part No.: 102-9029 S/N: S2F1-Up Part No.: 102-9029 S/N: B5G1-Up Part No.: 102-9029 S/N: MRG1-Up

RENR5077-11

165 Specifications Section

Part No.: 102-9029 S/N: PAG1-Up

Note: Before installation, coat the sensor assembly's threads with 4c-5599 Anti-Seize Compound.

Part No.: 102-9029 S/N: S2G1-Up

(1) Final installation torque for the sensor assembly ....................... 40 ± 5 N·m (30 ± 4 lb ft)

Part No.: 102-9029 S/N: MKH1-Up

Operating temperature ........................ −40 to 121 °C (−40 to 250 °F)

Part No.: 102-9029 S/N: S2H1-Up

Operating voltage ..................................... 12 to 14 V

Part No.: 102-9029 S/N: S2J1-Up

(2) Sliphead Before installation, make sure that the sliphead is fully extended.

Part No.: 102-9029 S/N: S2K1-Up Part No.: 102-9029 S/N: S2L1-Up

i03535661

Engine Speed/Timing Sensor

Part No.: 102-9029 S/N: S2M1-Up

SMCS Code: 1905; 1907

Part No.: 102-9029 S/N: S2N1-Up

Part No.: 273-5041 S/N: S2A1-Up

Part No.: 102-9029 S/N: S2P1-Up

Part No.: 273-5041 S/N: S2B1-Up

Part No.: 102-9029 S/N: S2R1-Up

Part No.: 273-5041 S/N: S2D1-Up

Part No.: 102-9029 S/N: S2S1-Up

Part No.: 273-5041 S/N: S2E1-Up

Part No.: 102-9029 S/N: S2T1-Up

Part No.: 273-5041 S/N: B5G1-Up

Part No.: 102-9029 S/N: S2W1-Up

Part No.: 273-5041 S/N: MRG1-Up

Part No.: 102-9029 S/N: S2X1-Up

Part No.: 273-5041 S/N: PAG1-Up

Part No.: 102-9029 S/N: S2Y1-Up

Part No.: 273-5041 S/N: S2G1-Up

Part No.: 102-9029 S/N: S2Z1-Up

Part No.: 273-5041 S/N: MKH1-Up Part No.: 273-5041 S/N: S2H1-Up Part No.: 273-5041 S/N: S2J1-Up Part No.: 273-5041 S/N: S2K1-Up Part No.: 273-5041 S/N: S2L1-Up Part No.: 273-5041 S/N: S2N1-Up

Illustration 217

g01519083

Part No.: 273-5041 S/N: S2P1-Up

166 Specifications Section

RENR5077-11

Part No.: 273-5041 S/N: S2R1-Up

Part No.: 129-6628 S/N: B5G1-Up

Part No.: 273-5041 S/N: S2S1-Up

Part No.: 129-6628 S/N: MRG1-Up

Part No.: 273-5041 S/N: S2T1-Up

Part No.: 129-6628 S/N: PAG1-Up

Part No.: 273-5041 S/N: S2W1-Up

Part No.: 129-6628 S/N: S2G1-Up

Part No.: 273-5041 S/N: S2X1-Up

Part No.: 129-6628 S/N: MKH1-Up

Part No.: 273-5041 S/N: S2Z1-Up

Part No.: 129-6628 S/N: S2H1-Up Part No.: 129-6628 S/N: S2J1-Up Part No.: 129-6628 S/N: S2K1-Up Part No.: 129-6628 S/N: S2L1-Up Part No.: 129-6628 S/N: S2N1-Up Part No.: 129-6628 S/N: S2P1-Up g01441500

Part No.: 129-6628 S/N: S2R1-Up

(1) Final installation torque for the speed sensor group ............................. 40 ± 5 N·m (30 ± 4 lb ft)

Part No.: 129-6628 S/N: S2S1-Up

Operating temperature ........................ −40 to 120 °C (−40 to 248 °F)

Part No.: 129-6628 S/N: S2T1-Up

Operating voltage ................................ 12 to 14 VDC

Part No.: 129-6628 S/N: S2W1-Up

Output frequency ............................... 9 Hz to 10 kHz

Part No.: 129-6628 S/N: S2X1-Up

Illustration 218

Duty cycle ......................................................... 50 % i03291644

Part No.: 129-6628 S/N: S2Z1-Up

Engine Speed/Timing Sensor SMCS Code: 1905; 1907 Part No.: 129-6628 S/N: S2A1-Up Part No.: 129-6628 S/N: S2B1-Up Part No.: 129-6628 S/N: S2D1-Up Part No.: 129-6628 S/N: S2E1-Up

Illustration 219

g01706934

RENR5077-11

167 Specifications Section

Note: Before assembly, apply 4C-5599 Anti-Seize Compound on the threads of speed sensor group.

Part No.: 127-1008 S/N: S2T1-Up

(1) Torque for the speed sensor group .... 45 ± 5 N·m (33 ± 4 lb ft)

Part No.: 127-1008 S/N: S2W1-Up

Operating temperature ........................ −40 to 121 °C (−40 to 250 °F) Operating voltage ..................................... 12 to 14 V

Part No.: 127-1008 S/N: S2X1-Up Part No.: 129-6628 S/N: S2Z1-Up

i02788159

Engine Speed/Timing Sensor SMCS Code: 1905; 1907 Part No.: 127-1008 S/N: S2A1-Up Part No.: 127-1008 S/N: S2B1-Up Part No.: 127-1008 S/N: S2D1-Up g01046790

Part No.: 127-1008 S/N: S2E1-Up

Illustration 220

Part No.: 127-1008 S/N: B5G1-Up

(1) Sensor slip head

Part No.: 127-1008 S/N: MRG1-Up

1. Extend the sensor slip head to a minimum distance of 4 mm (.16 inch) prior to installation.

Part No.: 127-1008 S/N: PAG1-Up

(2) Control assembly

Part No.: 127-1008 S/N: S2G1-Up Part No.: 127-1008 S/N: MKH1-Up Part No.: 127-1008 S/N: S2H1-Up Part No.: 127-1008 S/N: S2J1-Up Part No.: 127-1008 S/N: S2K1-Up Part No.: 127-1008 S/N: S2L1-Up Part No.: 127-1008 S/N: S2N1-Up Part No.: 127-1008 S/N: S2P1-Up Part No.: 127-1008 S/N: S2R1-Up Part No.: 127-1008 S/N: S2S1-Up

Typical example

Put 4C-5599 Anti-Seize Compound on the threads.

Torque ............................ 40 ± 5 N·m (30 ± 4 lb ft) Operating temperature ............ −40 °C to 121 °C (−40 °F to 250 °F) Input supply voltage ....................... 12 to 14 VDC (3) Plug with socket A, socket B, and socket C.

168 Specifications Section

RENR5077-11

i02958537

Crankcase Pressure Sensor

Maximum input pressure (absolute pressure) ......................................... 116 kPa (17 psi) Operating voltage ........................... 5.00 ± 0.25 VDC

SMCS Code: 1916

Maximum supply current ................................. 20 mA

Part No.: 161-9926, 163-8492 S/N: S2D1-Up

Note: Install the pressure sensor group so that the pressure port is lower than the wire end. Mount the pressure sensor group as close to vertical as possible.

Part No.: 161-9926, 163-8492 S/N: S2E1-Up Part No.: 161-9926, 163-8492 S/N: S2F1-Up

i02845102

Part No.: 163-8492 S/N: B5G1-Up

Atmospheric Pressure Sensor

Part No.: 163-8492 S/N: MRG1-Up

SMCS Code: 1923 Part No.: 194-6722 S/N: M8A1-Up

Part No.: 163-8492 S/N: PAG1-Up

Part No.: 194-6722 S/N: M8B1-Up

Part No.: 163-8492 S/N: MKH1-Up Part No.: 163-8492 S/N: S2S1-Up Part No.: 163-8492 S/N: S2T1-Up Part No.: 163-8492 S/N: S2W1-Up Part No.: 163-8492 S/N: S2X1-Up Part No.: 163-8492 S/N: S2Y1-Up

Illustration 222

Part No.: 143-9696, 161-9926, 163-8492 S/N: S2Z1-Up

g01392045

(1) Final installation torque for the pressure sensor group .......................... 10 ± 2 N·m (90 ± 18 lb in) Operating voltage ........................... 5.00 ± 0.25 VDC Operating temperature ........................ −40 to 125 °C (−40 to 257 °F) i02847051

Atmospheric Pressure Sensor SMCS Code: 1923 Illustration 221

g01190345

(1) Final installation torque for the pressure sensor group .......................... 10 ± 2 N·m (90 ± 18 lb in) Operating temperature ........................ −40 to 125 °C (−40 to 257 °F)

Part No.: 161-1703 S/N: S2A1-Up Part No.: 161-1703 S/N: S2B1-Up Part No.: 161-1703 S/N: S2D1-Up

RENR5077-11

169 Specifications Section

Part No.: 161-1703 S/N: S2E1-Up Part No.: 161-1703 S/N: S2F1-Up Part No.: 161-1703 S/N: B5G1-Up Part No.: 161-1703 S/N: MRG1-Up Part No.: 161-1703 S/N: PAG1-Up Part No.: 161-1703 S/N: S2G1-Up

Illustration 223

Part No.: 161-1703 S/N: MKH1-Up

(1) Final installation torque for the pressure sensor group .......................... 10 ± 2 N·m (90 ± 18 lb in)

Part No.: 161-1703 S/N: S2H1-Up

g01133887

Operating temperature ........................ −40 to 125 °C (−40 to 257 °F)

Part No.: 161-1703 S/N: S2J1-Up

Operating voltage ........................... 5.00 ± 0.25 VDC

Part No.: 161-1703 S/N: S2K1-Up

i02958605

Part No.: 161-1703 S/N: S2L1-Up Part No.: 161-1703 S/N: S2M1-Up Part No.: 161-1703 S/N: S2N1-Up Part No.: 161-1703 S/N: S2P1-Up Part No.: 161-1703 S/N: S2R1-Up Part No.: 161-1703 S/N: S2S1-Up

Atmospheric Pressure Sensor SMCS Code: 1923 Part No.: 161-9926 S/N: S2D1-Up Part No.: 161-9926 S/N: S2E1-Up Part No.: 161-9926 S/N: S2F1-Up Part No.: 161-9926 S/N: S2Z1-Up

Part No.: 161-1703 S/N: S2T1-Up Part No.: 161-1703 S/N: S2W1-Up Part No.: 161-1703 S/N: S2X1-Up Part No.: 161-1703 S/N: S2Y1-Up Part No.: 161-1703 S/N: S2Z1-Up

Illustration 224

g01190345

(1) Final installation torque for the pressure sensor group .......................... 10 ± 2 N·m (90 ± 18 lb in) Operating temperature ........................ −40 to 125 °C (−40 to 257 °F)

170 Specifications Section

RENR5077-11

Maximum input pressure (absolute pressure) ......................................... 116 kPa (17 psi) Operating voltage ........................... 5.00 ± 0.25 VDC Maximum supply current ................................. 20 mA Note: Install the pressure sensor group so that the pressure port is lower than the wire end. Mount the pressure sensor group as close to vertical as possible. i03534581

i03001872

Engine Speed Sensor SMCS Code: 1907 Part No.: 189-5746 S/N: S2A1-Up Part No.: 189-5746 S/N: S2B1-Up Part No.: 189-5746 S/N: S2D1-Up

Engine Speed Sensor

Part No.: 189-5746 S/N: S2E1-Up

SMCS Code: 1907

Part No.: 189-5746 S/N: B5G1-Up

Part No.: 9X-5392 S/N: M8A1-Up

Part No.: 189-5746 S/N: MRG1-Up

Part No.: 9X-5392 S/N: M8B1-Up

Part No.: 189-5746 S/N: PAG1-Up Part No.: 189-5746 S/N: S2G1-Up Part No.: 189-5746 S/N: MKH1-Up Part No.: 189-5746 S/N: S2H1-Up Part No.: 189-5746 S/N: S2J1-Up Part No.: 189-5746 S/N: S2K1-Up

Illustration 225

g01448928

Operating temperature ........................ −40 to 150 °C (−40 to 320 °F) Clearance between the speed sensor group and the flywheel ring gear ............................ 0.50 to 0.75 mm (0.020 to 0.030 inch) Use the following procedure to install the speed sensor group (1): 1. Install the speed sensor group into the 5/8 threaded hole and turn until the magnetic core makes contact with a tooth of the flywheel ring gear.

2. Back out 180 degrees.

3. Tighten the nut to 25 ± 5 mm (221± 44 inch).

Part No.: 189-5746 S/N: S2L1-Up Part No.: 189-5746 S/N: S2N1-Up Part No.: 189-5746 S/N: S2P1-Up Part No.: 189-5746 S/N: S2R1-Up Part No.: 189-5746 S/N: S2S1-Up Part No.: 189-5746 S/N: S2T1-Up Part No.: 189-5746 S/N: S2W1-Up Part No.: 189-5746 S/N: S2X1-Up Part No.: 189-5746 S/N: S2Z1-Up

RENR5077-11

Illustration 226

171 Specifications Section

g01521632

(1) Final installation torque for locknut .... 25 ± 5 N·m (18 ± 4 lb ft) Operating temperature ........................ −40 to 120 °C (−40 to 248 °F) Resistance at 25 °C (77 °F) ............................. 142 Ω Minimum air gap ..................... 0.50 mm (0.035 inch) Screw the speed sensor into the hole by hand until the end of the sensor barely contacts the gear tooth.

Then, back out the sensor by a 1/2 turn (180 degrees in the counterclockwise direction).

172 Index Section

RENR5077-11

Index A Accessory Drive........................................... 120, 122 Accessory Drive (Lower Left Hand)............. 123–124 Accessory Drive (Upper Left Hand)..................... 131 Accessory Drive (Upper Left Hand, Reverse Rotation) ............................................................ 132 Accessory Drive (Upper Right Hand) .. 126, 128, 130 Accumulator........................................................... 33 Aftercooler Coolant Temperature Sensor ............ 163 Air Cleaner............................................................. 41 Air Cleaner Adapter ......................................... 41–42 Air Inlet and Exhaust Lines.................. 43–44, 47, 49 Air Shutoff........................................................ 51–52 Air Starting Motor................................................. 153 Air Starting Motor Pressure Regulating Valve ..... 154 Alternator and Regulator ..................................... 150 Alternator Mounting ............................................. 151 Atmospheric Pressure Sensor..................... 168–169 Auxiliary Drive Pulley........................................... 146 Auxiliary Drive Shaft ............................................ 147 Auxiliary Water Pump ............................................ 87 B Balancer Group (Front)......................................... 119 Belt Tension Chart ....................................... 148–149 C Camshaft ......................................................... 15–20 Connecting Rod................................................... 102 Connecting Rod and Main Bearing Journals ....... 104 Coolant Level Sensor .......................................... 160 Coolant Level Switch ........................................... 158 Coolant Temperature Switch ............................... 158 Cooling System Pressure Cap .............................. 89 Crankcase Breather................................... 73, 75–76 Crankcase Pressure Sensor................................ 168 Crankshaft .................................................. 105–106 Crankshaft Wear Sleeves and Seals................... 108 Cylinder Block............................................ 90–91, 93 Cylinder Head........................................................ 22 Cylinder Head Valves ............................................ 24 Cylinder Liner ........................................................ 95 D Duplex Engine Oil Filters ....................................... 71 E Electric Starting Motor ......................................... 152 Engine Air Cleaner Service Indicator..................... 42 Engine Coolant Temperature Sensor .................. 163 Engine Design ..................................................... 5–7

Engine Harness (Rigid Wiring Harness).............. 155 Engine Mount (Front) (Hydraulic Pump Drive or PTO Clutch) ............................................................... 138 Engine Oil Cooler Bypass and Cooling Jet Sequence Valves ............................................................ 63–64 Engine Oil Filter ............................................... 66–67 Engine Oil Filter Base............................................ 73 Engine Oil Lines .................................................... 69 Engine Oil Lines (Front Mounted Engine Oil Filter).................................................................... 70 Engine Oil Pan........................................... 76, 78, 80 Engine Oil Pressure Sensor ........................ 160–161 Engine Oil Pump.................................. 53, 55, 57, 59 Engine Oil Scavenge Pump................................... 61 Engine Oil Sump Pump ......................................... 85 Engine Speed Sensor.......................................... 170 Engine Speed/Timing Sensor ...................... 164–167 Engine Trunnion .................................................. 139 Exhaust Bypass Valve ..................................... 33–34 Exhaust Flange...................................................... 40 Exhaust Manifold ................................. 35–36, 38–39 F Flexible Coupling ................................................. 137 Flywheel .............................................................. 133 Flywheel Housing ........................................ 134–135 Fuel Filter............................................................... 10 Fuel Filter (Primary)................................................. 8 Fuel Filter Base ....................................................... 9 Fuel Injector........................................................... 14 Fuel Injector Mechanism ....................................... 12 Fuel Pressure Regulator........................................ 10 Fuel Pressure Sensor.......................................... 159 Fuel Transfer Pump................................................ 11 G Gear Group (Front)....................................... 115–116 Gear Group (Front) (Reverse Rotation)........ 111, 113 Gear Group (Rear) ............................................... 117 H Housing (Front)............................................. 109–110 I Important Safety Information ................................... 2 J Jacket Water Heater............................................ 155

RENR5077-11

M Magnetic Switch .................................................. 159 P Piston and Rings (One-Piece Piston) .............. 95, 97 Intermediate Piston Ring (2) ........................ 96, 98 Oil Control Piston Ring (3) ........................... 96, 98 Pin Retainer (6)............................................ 96, 98 Piston Pin (5) ............................................... 96, 98 Top Piston Ring (1) ...................................... 95, 97 Piston and Rings (Two-Piece Piston) ............ 99, 101 Intermediate Piston Ring (2) ............................ 100 Oil Control Piston Ring (3) ............................... 100 Pin Retainer (6)................................................ 100 Piston Pin (5) ................................................... 100 Piston Pin Bore (4)........................................... 100 Top Piston Ring (1) ............................................ 99 S Specifications Section ............................................. 5 Stub Shaft (Front) ........................................ 143–145 T Table of Contents..................................................... 3 Turbocharger ................................................... 26–31 Turbocharger Exhaust Temperature Sensor ....... 164 Turbocharger Inlet Pressure Sensor ................... 161 Turbocharger Outlet Pressure Sensor......... 162–163 Turbocharger Support ........................................... 32 V Valve Mechanism .................................................. 21 Vibration Damper......................................... 140–142 Vibration Damper Guard...................................... 143 W Water Lines ........................................................... 83 Water Pump........................................................... 86 Water Temperature Regulator ............................... 82

173 Index Section

174 Index Section

RENR5077-11

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175 Index Section

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