Volvo Penta 5.7GiPHUS Marine Gasoline Engine Parts Manual PDF

Maintenance Parts, 5.7L

200 5.7GiPHUS

5

1

8

9

6

7

2

7

10

3 12 11 13

14

4

Upd:6/30/2022

53145

7797018_G6A -200 -54161847 5.7GiPHUS

Maintenance Parts, 5.7L

200

5.7GiPHUS REF PART NO. QTY 1 21951346 1 Impeller kit 2 3862228 1 Fuel filter 3 835440 1 Oil filter 4 6 Oil X 21681794 6 Oil 21681795 1 Oil 21681796 1 Oil 21681797 Oil 3847302 6 Oil 3847303 1 Oil 3847304 1 Oil 3847305 1 Oil X Oil 3840002 6 Oil 3840003 1 Oil 3840004 1 Oil 3840005 1 Oil 5 3856961 1 Thermostat 6 3852071 1 O-ring 7 3852111 1 Gasket 8 3831426 1 Thermostat kit 9 416033 1 Sealing ring 10 3851861 2 Spark plug kit 11 3854548 1 Distributor cap 12 3862014 1 Rotor 13 3888326 1 Ignition cable kit 14 1141674 1 Coolant, green 21646481 1 Coolant, green 1141647 1 Coolant, green

7797018_G6A- 200- 54161847 5.7GiPHUS

DESCRIPTION

NOTES

Fill level is determined by dipstick USA Synthetic, quart Synthetic, gallon Synthetic, 5 gal Synthetic, 55 gal Mineral, quart Mineral, gallon Mineral, 5 gal Mineral, 55 gal Europe and other markets Mineral, 1L Mineral, 4L Mineral, 20L Mineral, 208L, barrel For seawater cooled engine

For freshwater cooled engine

5L, ready-mixed 210L, ready-mixed 210L, full strength

53145

Upd:6/30/2022

Crankcase

210 5.7GiPHUS

Upd:6/30/2022

54577

7797018_G6A -210 -54142769 5.7GiPHUS

Crankcase

210

5.7GiPHUS REF PART NO. QTY 1 3850848 1 Longblock 2 (3854219) 8 Piston, standard (3854221) 8 Piston kit, 0.030 in. os 3 (3854171) 1 Piston ring kit, standard 3854172 1 Piston ring kit, 0.030 in. os 4 (3853113) 2 Locating pin, transmission line-up 5 3853210 1 Bearing, camshaft, #1 6 3853211 2 Bearing, camshaft, #2, #5 7 3853212 2 Bearing, camshaft, #3, #4 8 3852100 8 Core plug, water jacket 9 3853209 1 Core plug, camshaft brg., rear 10 3852471 10 Plug, oil gallery 11 3853208 3 Cap plug, oil gallery, front 12 3853114 8 Locating pin, cylinder head 13 3853213 4 Pin, front cover & brg. cap 14 3853221 1 Bearing, rear, standard 3853224 1 Bearing, rear, 0.010 in. U.S. 3853225 1 Bearing, rear, 0.020 in. U.S. 15 (3853163) 5 Stud, bearing cap 16 3853214 5 Bolt, crankshaft, brg. cap 17 3853215 4 Bearing, #1, 2, 3, & 4 standard (3853218) 4 Bearing, #1, 2, 3, & 4, 0.010 in. U.S. (3853220) 4 Bearing, #1, 2, 3, & 4, 0.020 in. U.S. 18 3853201 1 Retainer, crankshaft seal 19 3853202 2 Stud, oil pan 20 3852656 1 Gasket, seal retainer 21 3852657 1 Seal, crankshaft, rear 22 3853203 2 Bolt, seal retainer 23 3853204 1 Bolt, seal retainer 24 3853206 1 Nut, rear seal retainer 25 3853205 1 Stud, rear seal retainer 26 3853149 8 Bearing, rod, standard 3853152 8 Bearing, rod,0.010 in. U/S (3853153) 8 Bearing, rod,0.020 in. U/S 27 3853957 8 Connecting rod 28 3853413 16 Nut, rod bolt 29 3853162 16 Bolt, connecting rod 30 (3853156) 1 Crankshaft 31 3853200 1 Pin, flywheel 32 3852219 1 Valve 33 (3852694) 1 Retainer, oil pan drain 34 3852133 2 Screw, adapter 35 (3853194) 1 Timing gear casing, c'case front end 36 (3853341) 1 Seal, front cover 37 3852654 1 Gasket, front cover 38 (3853159) 1 Camshaft 39 3853213 1 Pin, camshaft gear 40 3852685 1 Chain, camshaft timing 41 3852441 10 Screw, front cover 42 3853161 1 Reinforcement, starboard 3853160 1 Reinforcement, port 43 3855112 1 Fitting, oil drain pan 44 3852689 1 Sprocket, camshaft 45 3853958 1 Flywheel 46 3853207 1 Gear, flywheel 47 3851981 1 Washer, fitting to oil pan 48 3852489 1 Adapter, petcock 49 3852007 1 Washer, retainer to fitting 50 3853168 4 Nut, oil pan 51 3852968 1 Fitting, oil sender 52 3853674 1 O-ring, Retainer 53 3854023 1 Oscillation damper 54 855656 1 Oscillation damper, flywheel 7797018_G6A- 210- 54142769 5.7GiPHUS

DESCRIPTION

54577

Upd:6/30/2022

Crankcase

210

5.7GiPHUS REF PART NO. QTY 55 3852663 2 Woodruff key, crankshaft 56 835482 3 Screw, damper to flywheel 57 3852690 1 Sprocket, crankshaft 58 940097 3 Washer, damper to flywheel 59 942336 3 Spring washer, damper 60 3854494 2 Drain cock, water drain 61 3853173 2 Bolt, oil pan front 62 3852744 1 Baffle, oil pan 63 3852664 1 Gasket, oil pan 64 3853197 1 Oil strainer 65 3853195 1 Indicator 66 3853800 1 Pressure sensor 67 3852595 1 Bolt, oil pan 68 3853173 3 Bolt, camshaft sprocket 69 3850249 1 Tube, oil drain 70 3852686 1 Oil pan 71 3853199 1 Retainer, oil pump shaft 72 3853198 1 Shaft, oil pump to shaft & gear 73 3853134 5 Nut, oil pan baffle 74 3853234 1 Bolt, pump to bloc 75 3850474 1 Gauge, oil level 76 3853851 1 Oil pump 77 835440 1 Oil filter 78 3850660 1 Fitting, oil pressure switch 79 3850490 1 Fitting, drain & knock sensor 80 3850418 1 Cap, fuel pump flange 81 3852113 1 Gasket 82 3852053 2 Flange screw, fuel pump flange 83 (3853419) 2 Flange screw, fuel pump flange 84 3852215 1 Sensor 85 3852503 Elbow, oil pres. sender to adapter 86 941909 6 Spring washer, flywheel to crank 87 835439 6 Screw, Fi wheel to crank

7797018_G6A- 210- 54142769 5.7GiPHUS

DESCRIPTION

54577

Upd:6/30/2022

Cylinder Head

211 5.7GiPHUS

19

24

23

20

17

16 15

14 26 13 2

7 6 9 8 10 27 12

5 18

1

25 22 3 11

4

21

Upd:6/30/2022

52681

7797018_G6A -211 -54142808 5.7GiPHUS

Cylinder Head

211

5.7GiPHUS REF PART NO. QTY 1 (3853852) 2 Head 2 3856115 16 Stud, rocker arm, standard (3853147) 1 Stud, rocker arm, 0.013 os 3 (3852451) 8 Valve, intake, standard (3852449) 1 Valve, intake, 0.015 os (3852450) 1 Valve, intake, 0.030 os 4 (3853164) 8 Valve, exhaust, standard (3853166) 1 Valve, exhaust, 0.015 os 5 (3853311) 1 Bracket, port, rear 6 3853228 16 Valve spring washer, Valve Spring (3853229) 8 Rotator, valve, exhaust 7 3853131 32 Valve cotter, valve stem 8 3853132 16 Valve stem seal, valve stem 9 (3853145) 16 Shield, valve stem 10 (3853227) 16 Spring 11 3853954 16 Valve tappet 12 3853230 14 Bolt, cylinder head, 3.75 in 3853231 4 Bolt, cylinder head, 3.00 in 3853232 16 Bolt, cylinder head, 1.75 in 13 3853157 16 Push rod 14 3853158 16 Arm 15 3853193 16 Ball 16 (3853004) 16 Nut 17 3854009 2 Valve cover 18 (3853557) 1 Flange screw, lift bracket to engine 19 3852688 8 Screw, valve cover 20 3852104 2 Elbow, valve cover 21 3853380 2 Cylinder head gasket, cylinder head 22 3851861 2 Spark plug kit, spark plug, 4-pack 23 3854008 2 Oil filler cap, oil 24 3852103 1 Grommet, valve cover 25 3852471 1 Plug, cylinder head 26 3852687 2 Gasket, valve cover 27 3853226 8 Seal, valve stem, intake, standard 3853645 8 Seal, valve stem, inlet, 0.015 in os (3853646) 8 Seal, valve stem, inlet, 0.030 in os

7797018_G6A- 211- 54142808 5.7GiPHUS

DESCRIPTION

NOTES

Front, stbd

52681

Upd:6/30/2022

Remote Oil Filter

217 5.7GiPHUS

5

1 7

10

8

9

1 6

2

3 2 9 4

1

Upd:6/30/2022

52683

7797018_G6A -217 -54142909 5.7GiPHUS

Remote Oil Filter

217

5.7GiPHUS REF PART NO. QTY 1 (3850884) 1 Filter, 5.7 liter 3852011 4 O-ring, oil hose 2 (3854591) 1 Hose, engine oil to filter 3 3852089 1 O-ring, adapter retainer 4 3853495 1 Retainer, oil filter adapter 5 3852470 1 O-ring, adapter to engine 6 (3852837) 1 Clamp, oil hoses to manifold 7 (3852838) 1 Adapter, remote oil filter 3852015 1 Connector 8 3853246 1 Adapter, engine oil 9 (3854590) 1 Hose, engine oil from filter 10 835440 1 Oil filter

7797018_G6A- 217- 54142909 5.7GiPHUS

DESCRIPTION

NOTES Not shown

52683

Upd:6/30/2022

Flywheel Housing and Mounts

218 5.7GiPHUS

20

1

10 13

15 18

15

14

11

12 2

19 8

17 16

3

4

6

7

27 27

28

9 22 26

5

21

23 25 24 30 29

Upd:6/30/2022

52489

7797018_G6A -218 -54160659 5.7GiPHUS

Flywheel Housing and Mounts

218

5.7GiPHUS REF PART NO. QTY DESCRIPTION 1 3851017 1 Flywheel housing 2 873013 1 Primary shaft 3 958859 1 Sealing ring, primary shaft 4 3851019 1 Ball bearing, primary shaft 5 914533 2 Snap ring, primary shaft 6 914462 1 Snap ring, primary shaft 7 958860 1 Sealing ring, primary shaft 8 854939 1 Cover plate, flywheel housing 9 947224 5 Hexagon screw, flywheel cover to housing 10 3853547 1 Flange screw 11 3850753 3 Flange screw, flywheel housing to engine 12 3860697 1 Bushing, primary shaft to crankshaft 13 3850571 2 Stud, flywheel housing to engine 14 3852058 2 Washer 3852002 2 Tab washer 15 (3852065) 4 Nut 16 854315 1 Clamping ring kit, flywheel housing 17 806624 3 Striker plate, clamp ring 18 191844 6 Hexagon screw 19 804190 2 Rubber ring, clamp ring 20 (3852070) 2 Washer 21 3853805 2 Rubber cushion, engine front 22 3852760 2 Bracket, front, port and starboard 23 3853326 6 Flange screw, front mount bracket to engine 24 3852566 2 Bolt, front mount 25 3852090 2 Tab washer, bolt, front mount, engine 26 3852433 2 Washer, front mount 27 3852021 6 Nut, bolt, mount bracket 28 3852428 2 Washer, front mount 29 (3852146) 1 Clamp, starter leads to stbd bracket 30 3852092 1 Attaching clamp, engine harness

7797018_G6A- 218- 54160659 5.7GiPHUS

52489

NOTES

Ground

Not shown

Port and starboard

Front Upper Front Lower

Upd:6/30/2022

Fuel System

230 5.7GiPHUS

15 14

6

8

13

7

10

5

75

11

9

12

16 13

4

74

17 3

76

73 72

2

82

18

1 77

22

78 79

71

19 20

21

23

81 80

24

26 27 28 29 30

70 25

69 61 5

58 60

10

67

55 51

66

31

41

32

46

54

53

42 45

56 68

41

57

59

43

44

40

47

33

34

39

50 52

65

38 36

48

64

35

37 62

49

63

Upd:6/30/2022

52671

7797018_G6A -230 -54160682 5.7GiPHUS

Fuel System

230

5.7GiPHUS REF PART NO. QTY DESCRIPTION 1 3854280 1 Fuel pump, electric, high pressure (3853605) 1 Seal 2 3850424 1 O-ring, 0.375 in (9.54 mm), fuel line to TBI 3 3852481 1 Grommet, fuel pump to cover, reservoir assy 4 (3850277) 1 Fuel pipe, HP pump to TBI 5 3850820 1 O-ring, fitting 6 3853494 1 Fitting, fuel line 7 (3853573) 1 Bracket, fuel pump grommet 8 (3850278) 1 Fuel pipe, tBI to reservoir 9 3850423 1 O-ring, 0.312 in (7.94 mm), fuel line to TBI 10 3852158 2 Cable tie, cable assy to fuel pump assy 11 3852017 1 Adapter, fuel line 12 3852462 1 Fitting, tBI to reservoir (3852453) 1 Fitting, fuel pump outlet 13 3852529 2 Hose clamp, hose, pulse limiter 14 3852225 1 Impulse limiter, reservoir to TBI adapter 15 3852503 1 Elbow, pulse limiter to TBI adapter 16 (3850689) 1 Hose, reservoir to pulse limiter 17 3853597 1 Elbow, vent, reservoir to intake 18 (3853616) 1 Protective cap, pressure valve 19 (3854152) 1 Valve, reservoir assy 20 (3853606) 8 Screw, cover to reservoir 21 (3854405) 1 Cap, reservoir assy 22 (3853577) 1 Gasket, float needle seat 23 (3853576) 1 Spring seat, float needle 24 (3853578) 1 Needle, float 25 (3852034) 1 Retainer, float pin 26 3853642 2 O-ring, retainer, fuel pump 27 (3853572) 1 Retainer, fuel pump to cover 28 3853579 1 Clip, needle to float 29 3853622 1 Pin, float hinge, reservoir 30 (3853575) 1 Float 31 3853574 1 Gasket, cover 32 (3854149) 1 Reservoir 33 3852052 1 Split pin 34 (3853580) 1 Hose, reservoir assy to oil cooler 35 (3853558) 2 Screw, reservoir to bracket 36 (3850657) 1 Nut, reservoir to bracket 37 3853547 1 Flange screw, vapor separator & bracket 38 3856449 1 Fitting, reservoir, port nipple 39 (3850271) 1 Bracket, reservoir to flywheel hsg 40 (3852480) 1 Elbow, reservoir to thermostat hsg 41 (3852196) 3 Hose clamp 42 (3852167) 1 Plug, reservoir drain 43 (3850653) 1 Hose 44 (3854925) 2 Hose clamp 45 (3850666) 1 Nipple 46 (3850633) 1 Hose 47 3853326 1 Flange screw, lift & fuel filter bracket to engine 48 (3853310) 1 Bracket, fuel filter 49 (3850374) 1 Kit, fuel reservoir 50 3853620 2 Hexagon screw, circuit breaker to bracket 51 (3853544) 1 Bracket, fuel pump & relay mounting 52 (3852210) 1 Bracket 53 (3852208) 2 Screw, relay & cable assy 54 3850403 1 Relay, fuel pump 55 3852481 1 Grommet, fuel pump to bracket 56 3854163 1 Automatic fuse, 20A, fuel pump 57 (3852231) 1 Attaching clamp, fuel line 58 3852115 1 Flange screw, fuel line clamp to bracket 59 (3852001) 1 Tab washer 60 (3852064) 2 Nut, circuit breaker terminals 61 3852029 1 Sensor, water temperature 7797018_G6A- 230- 54160682 5.7GiPHUS

52671

NOTES

Reservoir assy Return

Return

Reservoir assy Reservoir assy Reservoir assy

Reservoir assy Reservoir assy

Reservoir assy

Fuel pump

Upd:6/30/2022

Fuel System

230

5.7GiPHUS REF PART NO. QTY DESCRIPTION 62 (3850861) 1 Kit 63 3851218 1 Fuel filter 64 3853266 2 Flange screw, fuel pump, support bracket, fuel filter 65 (3852013) 1 Elbow, inlet, fuel filter cover 66 3853493 1 Fitting, fuel pump to fuel filter cover 67 3850819 1 O-ring, fitting 68 3854902 1 Fuel pump, low pressure 69 3853494 1 Fitting, fuel line 70 3850405 1 Gasket, adapter to intake manifold 71 (3850270) 1 Adapter, TBI to intake manifold 3850740 1 Plug, adapter, TBI to intake manifold 72 3850355 1 Gasket, TBI to adapter 73 (3850354) 1 Throttle body 74 3852160 3 Stud, TBI to adapter 75 3852142 3 Nut, stud, TBI to adapter 76 (3850297) 1 Bracket, throttle cable to throttle body assy 77 3853399 1 Flange screw, lever & pin assy to throttle body 78 3852420 1 Nut retainer, shoulder screw, throttle lever to TBI 79 3850411 1 Shoulder screw, lever & pin assy to throttle body 80 3850276 1 Fuel pipe, lp pump to reservoir 81 (3850275) 1 Bracket, fuel iine & hose to intake manifold 82 3856766 1 Cap, nipple, throttle body

7797018_G6A- 230- 54160682 5.7GiPHUS

52671

NOTES

Not shown

Upper Lower

Front; not shown

Upd:6/30/2022

Exhaust and Cooling

250 5.7GiPHUS

Upd:6/30/2022

54552

7797018_G6A -250 -54142773 5.7GiPHUS

Exhaust and Cooling

250

5.7GiPHUS REF PART NO. QTY DESCRIPTION 1 3852046 1 Tab washer, pulley 2 3850214 2 Exhaust pipe 3 3852742 2 Hose, exhaust pipe, lower 4 3852604 8 Hose clamp, hose to exhaust pipe 5 3853401 1 Flange screw, housing to manifold 6 3852002 8 Tab washer, high rise to manifold 7 3852830 8 Screw, high rise to manifold 8 3850496 2 Gasket, elbow 9 3852374 2 Manifold 10 3852476 2 Cap, manifold 11 3850363 Hose 12 3852602 2 Hose clamp, manifold cap 13 3852220 1 Pulley, water pump 14 3852137 1 Pulley, crankshaft 15 3852336 1 V-belt, water pump 16 (3852110) 1 Washer, harmonic balancer 17 3852131 1 Screw, harmonic balancer 18 (3852284) 1 Bracket, water pump 19 3852507 3 Stud, water pump 20 3853539 1 Bolt, water pump, lower (rh) 21 3855472 4 Flange screw, pipe to gimbal 22 3853404 12 Nut, manifold stud to engine 23 3851000 1 Exhaust pipe 24 3852467 12 Stud, manifold to engine 25 3852111 1 Gasket, thermostat housing 26 3853850 1 Circulation pump 27 3850802 2 Plug, 1 inch 28 3852477 2 Gasket, pump to block 29 (3852135) 1 Plug, ¾ in 30 3850595 1 Gasket, water pump cover 31 (3852054) 2 Washer, water pump 32 (3850361) 1 Hose, transom to water pump 33 3852098 2 Hose clamp, Hose 34 3852288 1 Hose, water pump to thermostat 35 3852602 3 Hose clamp, Hose 36 3853390 1 Screw, pulley to pump 37 3852216 1 Thermostat 38 (3853418) 3 Screw, crankshaft pulley 39 3850422 1 Hose clamp, water hose, inlet 40 3852746 2 Hose, thermostat to manifold* 41 3853368 1 V-belt, alternator 42 (3852649) 1 Bracket, center lift 43 3853860 8 Hose clamp, hose, high rise 44 3855270 2 Exhaust pipe 3850740 2 Plug 45 3852468 2 Gasket, manifold to engine 46 3852696 2 Hose, high rise to elbow 47 3853391 1 Flange screw, housing to manifold 48 3852071 1 O-ring, thermostat 49 3850360 1 Housing 50 3851623 1 Seawater pump 51 3852505 1 Pulley, water pump 52 (3853397) 2 Screw, water pump to bracket 53 3853326 2 Flange screw, bracket to engine 54 3850362 1 Hose, raw water pump to reservoir 55 3853786 1 Hose clamp, water pump, outlet 56 3853780 2 Hose clamp, Hose 57 3852058 5 Washer 58 3853598 1 Elbow, thermostat housing 59 (857045) 1 Attaching clamp, water hose, cooler to thermostat

7797018_G6A- 250- 54142773 5.7GiPHUS

54552

Upd:6/30/2022

Exhaust, 3'' Risers

251 5.7GiPHUS

3

1

2

Upd:6/30/2022

52495

7797018_G6A -251 -54142854 5.7GiPHUS

Exhaust, 3'' Risers

251

5.7GiPHUS REF PART NO. QTY 1 3850497 1 Manifold 2 3850496 2 Gasket 3 3853427 2 Exhaust riser

7797018_G6A- 251- 54142854 5.7GiPHUS

DESCRIPTION

52495

Upd:6/30/2022

Intake Manifold

251 5.7GiPHUS

3 27

2

4

1

5 26

25

6

20

21 23

8 7 22

24

10

14 11 18

19

17

9 12 13 14

16

Upd:6/30/2022

15

52680

7797018_G6A -251 -54160683 5.7GiPHUS

Intake Manifold

251

5.7GiPHUS REF PART NO. QTY DESCRIPTION 1 (3854532) 1 Manifold 2 3852008 4 Screw, TBI adapter to manifold 3 3856129 1 Bolt, distributor clamp 4 3852108 1 Clamp, distributor 5 3852109 1 Gasket, distributor 6 (3854269) 1 Intake gasket kit, manifold 7 3852007 1 Washer, nut, flame arrestor cover 8 3852749 1 Nut, flame arrestor cover 9 (3850510) 1 Cover, flame arrestor (3850458) 2 Pad, cover, flame arrestor 10 (3853561) 1 Nut, flame arrestor 11 (3852695) 2 Connector, hose to flame arrester 12 (3850280) 1 Flame shield 13 (3850274) 1 Stud, flame arrestor 14 3852435 1 Hose, flame arrestor to valve cover (3852668) 1 Hose, flame arrestor to valve cover 15 (3850228) 1 Bracket, throttle cable to intake manifold 16 (3852019) 1 Retainer, throttle cable 17 (3850266) 1 Anchor, throttle cable 18 (3852048) 1 Screw, anchor, throttle cable to bracket 19 3852193 1 Washer 20 (3850653) 1 Hose, antisiphon valve to reservoir 21 (3854925) 2 Hose clamp, hose, antisiphon valve 22 (3850666) 1 Nipple, hoses, thermostat hsg to reservoir 23 (3852196) 3 Hose clamp, hose, antisiphon valve 24 (3850633) 1 Hose, antisiphon valve to thermostat hsg 25 3856132 8 Bolt 3856131 4 Bolt 26 (3854980) 1 Decal, cover, flame arrestor 27 3855085 1 Decal, cover, flame arrestor

7797018_G6A- 251- 54160683 5.7GiPHUS

52680

NOTES

L=35mm L=38mm Volvo Penta 5.7Gi

Upd:6/30/2022

Throttle Body Repair Kits

256 5.7GiPHUS

Upd:6/30/2022

48954

7797018_G6A -256 -54160488 5.7GiPHUS

Throttle Body Repair Kits

256

5.7GiPHUS REF PART NO. QTY 1 (3850354) 1 Throttle body 1 Fuel press regulator 2 1 Cover, fuel meter 3 3 Screw, long 4 5 Screw, short 5 1 Throttle body 6 2 O-ring, fuel injector 7 2 Injector, fuel 8 2 Filter, fuel injector 9 2 Filter 10 (3855188) 1 Repair kit, fuel meter 11 1 Gasket 12 1 Gasket 13 1 Nut, fuel line 14 1 Gasket, fuel meter 15 (3855183) 1 Throttle body, base 16 1 Position sensor, throttle 17 2 Screw 18 1 Seal 19 1 O-ring 20 1 Iac valve 21 2 Screw 22 3 Screw 23 1 Nut, fuel line 24 1 Gasket 25 4 Screw 26 (3855179) 1 Repair kit, 5, 6, 8, 9, 11, 14, 19, 24 (3855180) 1 Repair kit, 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 (3855181) 1 Repair kit, 1, 2, 5, 14 3855182 1 Injector, 5, 6, 7, 8, 9, 11, 14 (3855184) 1 Repair kit, 16, 18 3855185 1 Control valve, 19, 20 (3855186) 1 Repair kit, 12, 13, 23, 24 (3855187) 1 Repair kit, 3, 4, 17, 21, 22 (3855189) 1 Repair kit, 5, 6, 8, 9, 14

7797018_G6A- 256- 54160488 5.7GiPHUS

DESCRIPTION

48954

Upd:6/30/2022

Freshwater Cooling

261 5.7GiPHUS

Upd:6/30/2022

52480

7797018_G6A -261 -54142922 5.7GiPHUS

Freshwater Cooling

261

5.7GiPHUS REF PART NO. QTY DESCRIPTION 1 (3851539) 1 Radiator 2 961672 2 Hose clamp 3 (857500) 1 Hose 4 861105 1 Expansion tank 5 968145 1 Plug 968147 1 Plug 3851384 1 Thermostat housing 6 (3851383) 1 Thermostat housing, lower 479977 1 Plug 7 943268 1 Hose nipple 8 942700 1 Hose 9 875788 1 Thermostat kit 416033 1 Sealing ring 10 943369 1 Rubber hose 11 944386 1 Rubber hose 12 945444 2 Flange screw 13 945652 2 Hose clamp 14 946173 4 Flange screw 15 948645 6 Flange lock nut 16 (180254) 1 Elbow nipple 17 961666 14 Hose clamp 18 961667 2 Hose clamp 19 961670 2 Hose clamp 20 1357775 1 Pressure cap 21 (3851363) 1 Bracket 22 (3851393) 1 Bracket 23 (3851396) 1 Bar 24 (3851413) 2 Connection pipe 25 (3851530) 1 Bracket 26 (3851586) 1 Heat exchanger 192134 2 Plug (841063) 1 Zinc anode (841068) 2 Bolt 841911 2 Cap 841912 2 Gasket 861551 1 Plug 925054 2 O-ring 27 961611 1 Hose nipple 28 3851414 1 Connection pipe 29 3851591 1 Hose 30 3851592 1 Hose 31 3851762 1 Hose 32 3851594 1 Connection pipe 33 3851395 1 Brace 34 3852111 2 Gasket 35 3853391 1 Flange screw 36 3853401 2 Flange screw 37 961669 2 Hose clamp 38 (3851598) 1 Fitting 943367 1 Rubber hose, to vapor separator 961663 2 Hose clamp 3853598 1 Elbow

7797018_G6A- 261- 54142922 5.7GiPHUS

NOTES 4.3 GL / GS / Gi, 5.7 GL / Gi

See no. 23, FWC installation instructions (P/N 7736034) See no. 23, FWC installation instructions (P/N 7736034) See no. 23, FWC installation instructions (P/N 7736034)

52480

Upd:6/30/2022

Seawater Pump Parts

266 5.7GiPHUS

1 5

6

4 4

3

2

Upd:6/30/2022

52481

7797018_G6A -266 -54160597 5.7GiPHUS

Seawater Pump Parts

266

5.7GiPHUS REF PART NO. QTY DESCRIPTION 1 3851623 1 Seawater pump 3855778 1 Seawater pump 3858847 1 Seawater pump 2 3855546 1 Repair kit, impeller 3856039 1 Impeller 3862281 1 Impeller kit 1 Gasket 21951346 1 Impeller kit 3 3851702 1 Gasket, plate to body 4 (841693) 4 Screw 21951334 1 Screw kit 5 3851697 1 End cover 6 3851698 1 Cam, impeller

NOTES 165mm pulley, 5/16'' mounting bolt, replaced by next part number 165mm pulley, 5/16'' mounting bolt, replaced by next part number See ''Seawater Pump, New Service Kits'' for parts replaced by next part number replaced by next part number replaced by next part number

7797018_G6A- 266- 54160597

52481

5.7GiPHUS

See ''Seawater Pump, New Service Kits'' for parts replaced by next part number 6 screws

Upd:6/30/2022

Seawater Pump, New Service Kits

266 5.7GiPHUS

2

6

5 9

8 4

7 3

11

10

1

12 13

Upd:6/30/2022

52478

7797018_G6A -266 -54162974 5.7GiPHUS

Seawater Pump, New Service Kits

266

5.7GiPHUS REF PART NO. QTY 1 3858847 1 Seawater pump 2 21951346 1 Impeller kit 3 (825940) Impeller 4 (3855782) 1 Gasket, plate to body 5 21951372 1 Wear kit 6 3851697 1 End cover 7 (3858086) 1 Cam, impeller 8 (3855782) 1 Gasket 9 (841693) 1 Screw 10 1 O-ring 11 827247 1 Sealing ring 12 21951334 1 Screw kit 13 (841693) 6 Screw

7797018_G6A- 266- 54162974 5.7GiPHUS

DESCRIPTION

NOTES 165mm pulley, 5/16'' mounting bolt

52478

Upd:6/30/2022

Ignition

280 5.7GiPHUS

34

38

35

33

32 37 36 3

32

35

31 2

18

1 17

4

11

39

21

20 13 5

14 12 15 16

19 23 22

6 7 26

8 9 25

29 10

Upd:6/30/2022

24

27

48911

30

28

7797018_G6A -280 -54160551 5.7GiPHUS

Ignition

280

5.7GiPHUS REF PART NO. QTY 1 3850399 1 Distributor 2 3854548 1 Distributor cap 3 3853318 2 Screw 4 3862014 1 Rotor 5 3855596 1 Spindle 6 3853317 1 Retainer 7 3854001 1 Coil 8 3853316 1 Locating pin 9 3854552 1 Shield 10 3854309 1 Pole shoe 11 1 Housing 12 (3854557) 1 Repair kit 13 1 Washer 14 1 Washer 15 1 Gear 16 1 Plug kit 17 3854003 1 Module 18 3853319 2 Screw 19 3852109 1 Gasket 20 3852108 1 Clamp 21 (3853557) 1 Flange screw 22 3854002 1 Coil 23 3857448 2 Cross recessed screw 24 3852051 2 Nut 25 3850429 1 Bracket 26 3853266 1 Flange screw 27 980933 2 Washer 28 3852002 1 Tab washer 29 1 Stud 30 (3852065) 1 Nut 31 3851861 2 Spark plug kit 3851860 1 Spark plug kit 32 3851819 1 Ignition cable kit 3857167 1 Cable kit 33 3856052 2 Bracket 34 980933 1 Washer 35 3852619 2 Retainer 36 (3853557) 2 Flange screw 37 (3856053) 2 Bracket 38 (3852491) 1 Retainer (3852492) 1 Retainer 39 3854084 1 Cable

7797018_G6A- 280- 54160551 5.7GiPHUS

DESCRIPTION

NOTES

not sold separately not sold separately not sold separately not sold separately not sold separately

4 pack 24 pack

4 wire 3 wire, Not shown

48911

Upd:6/30/2022

Alternator

321 5.7GiPHUS

22

12 11

15

8

18

2 1 3 17 13 3 6

9 5

20 16

14

7 19 4

23 10 16

Upd:6/30/2022

21

53157

7797018_G6A -321 -54142801 5.7GiPHUS

Alternator

321

5.7GiPHUS REF PART NO. QTY 1 3854809 1 Alternator (3853756) 1 Fan 2 (3853755) 1 Pulley 3 (3852643) 2 Bearing 4 (3852642) 1 Retainer, rear bearing 5 (3852641) 1 Diode 6 (3853836) 1 Rectifier 7 (3853835) 1 Brush 8 (3852639) 1 Spacer, fan 9 (3852637) 1 Gasket 10 (3853834) 1 Cap 11 (3852625) 1 Washer, pulley 12 (3852630) 1 Nut, pulley 13 (3853833) 1 Governor, voltage 14 (3854225) 1 Stator, alternator bracket to engine 15 (3852054) 1 Washer, brace to alternator 16 3853883 1 Bracket 17 3853396 1 Flange screw, brace to alternator 18 (3852761) 1 Brace, alternator 19 3852058 1 Washer, alternator to bracket 20 (3853367) 1 Flange screw, alternator to bracket 21 3852051 2 Nut, alternator to bracket 22 3853403 1 Nut retainer, stud, brace to water pump 23 3853547 2 Flange screw, alternator bracket to engine

7797018_G6A- 321- 54142801 5.7GiPHUS

DESCRIPTION

53157

Upd:6/30/2022

Starter

331 5.7GiPHUS

2

1

8 6 5

7

3

4

Upd:6/30/2022

48922

7797018_G6A -331 -54160661 5.7GiPHUS

Starter

331

5.7GiPHUS REF PART NO. QTY 1 3854751 1 Starter motor, engine 2 3850216 1 Solenoid 3 3854496 2 Washer 4 3854752 2 Screw, starter motor to engine 5 3852487 1 Trunk, battery cable 6 3852520 2 Washer 7 3852518 2 Nut, starter solenoid 8 3853714 1 Nut, battery cable to starter solenoid

7797018_G6A- 331- 54160661 5.7GiPHUS

DESCRIPTION

48922

Upd:6/30/2022

Engine Harness

371 5.7GiPHUS

34

23 5 25 6 7 8 24

4

5 27 28 29 2

38 30

33

18 19 20 23 35

1 39

31

8 36 37 38

32

27 21 22

40 41

3 18 19 20 8 17

26 14 16 15 6 7 13

11 8 10 9 10

42

12 14 14

9 14

Upd:6/30/2022

52674

7797018_G6A -371 -54142770 5.7GiPHUS

Engine Harness

371

5.7GiPHUS REF PART NO. QTY DESCRIPTION 1 (3850364) 1 Wiring harness 2 (3852527) 2 Terminal, 3/8 in 3 (3852229) 4 Terminal 4 (3853565) 2 Connector, 2-pin 5 3853679 4 Terminal 6 (3855021) 2 Connector housing 7 (3853681) 2 Trunk 8 (3852233) 5 Terminal, #10 9 (3852107) 2 Terminal, ¼ in 10 (3852130) 1 Rubber cap 11 (3852036) 1 Terminal, #10 12 (3854192) 1 Relay 13 (3852254) 4 Terminal 14 (3852235) 5 Terminal, #10 15 3850403 2 Relay 16 (3852210) 1 Bracket, relay 17 (3855022) 1 Terminal, 3/8 in 18 (3855023) 5 Terminal 19 (3853478) 9 Seal 20 (3853480) 2 Terminal casing 21 3855024 1 Terminal 22 3855025 1 Cable sleeve, terminal 23 3855026 2 Connector 24 (3852084) 1 Terminal, side receptacie 25 (3853320) 1 Cap 26 3855027 9 Terminal 27 (3854244) 1 Cable 28 (3852246) 5 Terminal, receptacle 29 (3852247) 3 Terminal, receptacle 30 (3850272) 1 Bracket, knock module 31 3850273 1 Bracket, PCM & MAP sensor 32 (3850356) 1 Module, knock sensor 33 3854463 1 Engine control modul, electronic control module 34 3852115 4 Flange screw, knock sensor bracket 35 3852115 2 Flange screw, ECM bracket 36 3852115 2 Flange screw, map sensor bracket 37 3852115 2 Flange screw, ECM & MAP adapter 38 3852115 2 Flange screw, knock module bracket 39 3850357 1 Knock sensor 40 3850397 1 Switch 41 3850396 1 Sensor 42 (3850688) 1 Hose, MAP sensor to TBI

7797018_G6A- 371- 54142770 5.7GiPHUS

52674

Upd:6/30/2022

Engine Harness Bracket

371 5.7GiPHUS

Upd:6/30/2022

52676

7797018_G6A -371 -54142775 5.7GiPHUS

Engine Harness Bracket

371

5.7GiPHUS REF PART NO. QTY 1 3854162 1 Automatic fuse, 12.5 amp 2 3853620 4 Hexagon screw 3 3854186 1 Automatic fuse, 60 amp 4 (3852064) 6 Nut, circuit breaker terminals 5 (3852001) 6 Tab washer, circuit breaker 6 (3852825) 1 Retainer 7 (3852208) 1 Screw, engine harness 8 3854138 1 Relay, starter 9 3850234 1 Rubber cushion, starter relay 10 3852118 1 Nut, starter relay 11 3854164 1 Automatic fuse, 50 amp 12 3853620 2 Hexagon screw 13 (3850455) 1 Bracket, engine cable

7797018_G6A- 371- 54142775 5.7GiPHUS

DESCRIPTION

52676

Upd:6/30/2022

Steering

645 5.7GiPHUS

Upd:6/30/2022

52477

7797018_G6A -645 -54160689 5.7GiPHUS

Steering

645

5.7GiPHUS REF PART NO. QTY DESCRIPTION 1 3850491 1 Steering pump, P/S pump to engine 2 3852512 1 Bracket 3 3852162 1 Washer 4 3852162 2 Washer, stud, water pump & steering pump 5 3852464 1 V-belt, P/S pump 6 3854168 1 Hose assembly, cylinder to oil cooler, P/S 7 3852497 1 O-ring, pressure hose to steering pump 8 (3850644) 1 Hose, oil cooler to pump, return 9 (3853580) 1 Hose, reservoir to cooler 10 (3853804) 1 Pulley 11 3853967 1 Hose assembly, steering pump to pressure valve 12 (3852079) 1 Nut, oil cooler & bracket assy 13 3853236 1 Spacer, oil cooler, P/S 14 (3852126) 1 Screw, oil cooler & bracket assy 15 (3853315) 1 Fitting, steering hoses 16 3852158 2 Cable tie 17 3852840 1 Oil cooler, P/S 18 (3852177) 1 Nut, P/S cooler clamp to reservoir 3853326 1 Flange screw, P/S cooler clamp to flywheel hsg 19 (3852218) 1 Clamp, engine oil cooler, P/S 20 3853405 3 Screw, steering pump bracket 21 3852507 1 Stud, water/steering pump bracket to engine 22 (3853557) 1 Flange screw, plug lead retainer bracket to cyl head 23 (3852837) 1 Clamp, hoses to cylinder head 24 3852093 1 Stud, oil cooler clamp to reservoir 25 3853403 1 Nut retainer, stud, P/S pump bracket 26 3853403 1 Nut retainer, stud, P/S pump bracket 27 (3853557) 1 Flange screw, lift bracket/clamp, P/S hoses to head 28 3852490 1 Attaching clamp, steering pump hoses to front mount 29 3852602 2 Hose clamp, hose, oil cooler, bypass pipe 30 (3852196) 2 Hose clamp, hose, P/S pump to oil cooler 31 3853786 1 Hose clamp, hose, water to gimbal hsg 32 3850363 1 Hose, cooler to thermostat 33 (3853402) 1 Stud, P/S pump bracket to engine 34 (3852054) 1 Washer, stud, P/S pump bracket 35 3852058 1 Washer, oil cooler clamp to reservoir

7797018_G6A- 645- 54160689 5.7GiPHUS

52477

NOTES

Rear, starboard power steering pump

Port, rear, lower Port Return

To engine block

Upd:6/30/2022

Engine Information, General

200

Maintenance Parts, 5.7L

DESCRIPTION

SEE SEC. NOTES 54161847 5.7GiPHUS

7797018_G6A- 200- 200

Upd:6/30/2022

5.7GiPHUS

General, Engine with Mounting and Equipment

REF 200 Engine Information, General

7797018_G6A- 20- 20 5.7GiPHUS

DESCRIPTION

20 SEE SEC. 200

Upd:6/30/2022

Engine Repair Parts

210 DESCRIPTION

Crankcase

7797018_G6A- 210- 210 5.7GiPHUS

SEE SEC. NOTES 54142769 5.7GiPHUS

Upd:6/30/2022

Engine

REF 210 211 217 218

21 DESCRIPTION

Engine Repair Parts Cylinder Head Oil Pan Engine Mounting

7797018_G6A- 21- 21 5.7GiPHUS

SEE SEC. 210 211 217 218

Upd:6/30/2022

Cylinder Head

211 DESCRIPTION

Cylinder Head

7797018_G6A- 211- 211 5.7GiPHUS

SEE SEC. NOTES 54142808 5.7GiPHUS

Upd:6/30/2022

Oil Pan

217 DESCRIPTION

Remote Oil Filter

7797018_G6A- 217- 217 5.7GiPHUS

SEE SEC. NOTES 54142909 5.7GiPHUS

Upd:6/30/2022

Engine Mounting

218 DESCRIPTION

Flywheel Housing and Mounts

7797018_G6A- 218- 218 5.7GiPHUS

SEE SEC. NOTES 54160659 5.7GiPHUS

Upd:6/30/2022

Fuel System, General

230 DESCRIPTION

Fuel System

7797018_G6A- 230- 230 5.7GiPHUS

SEE SEC. NOTES 54160682 5.7GiPHUS

Upd:6/30/2022

Fuel System

REF 230 Fuel System, General

7797018_G6A- 23- 23 5.7GiPHUS

23 DESCRIPTION

SEE SEC. 230

Upd:6/30/2022

General, Inlet and Exhaust Systems

DESCRIPTION Exhaust and Cooling

7797018_G6A- 250- 250 5.7GiPHUS

250 SEE SEC. NOTES 54142773 5.7GiPHUS

Upd:6/30/2022

Inlet and Exhaust System

REF 250 General, Inlet and Exhaust Systems 251 Inlet and Exhaust Manifolds 256 Air Filter, Throttle Housing

7797018_G6A- 25- 25 5.7GiPHUS

25 DESCRIPTION

SEE SEC. 250 251 256

Upd:6/30/2022

Inlet and Exhaust Manifolds

251 DESCRIPTION

Exhaust, 3'' Risers Intake Manifold

7797018_G6A- 251- 251 5.7GiPHUS

SEE SEC. NOTES 54142854 5.7GiPHUS 54160683 5.7GiPHUS

Upd:6/30/2022

Air Filter, Throttle Housing

256

Throttle Body Repair Kits

DESCRIPTION

SEE SEC. NOTES 54160488 5.7GiPHUS

7797018_G6A- 256- 256

Upd:6/30/2022

5.7GiPHUS

Cooling System

REF DESCRIPTION 261 Radiator and Connections, Coolant Filter, Expansion Tank 266 Sea Water System, Sea Water Pump

7797018_G6A- 26- 26 5.7GiPHUS

26 SEE SEC. 261 266

Upd:6/30/2022

Radiator and Connections, Coolant Filter, Expansion Tank

DESCRIPTION Freshwater Cooling

7797018_G6A- 261- 261 5.7GiPHUS

261 SEE SEC. NOTES 54142922 5.7GiPHUS

Upd:6/30/2022

Sea Water System, Sea Water Pump

DESCRIPTION Seawater Pump Parts Seawater Pump, New Service Kits

7797018_G6A- 266- 266 5.7GiPHUS

266 SEE SEC. NOTES 54160597 5.7GiPHUS 54162974 5.7GiPHUS

Upd:6/30/2022

General, Ignition and Control System

DESCRIPTION Ignition

7797018_G6A- 280- 280 5.7GiPHUS

280 SEE SEC. NOTES 54160551 5.7GiPHUS

Upd:6/30/2022

Ignition and Control Systems

REF 280 General, Ignition and Control System

7797018_G6A- 28- 28 5.7GiPHUS

28 DESCRIPTION

SEE SEC. 280

Upd:6/30/2022

Alternator, Charging, Electric Motor, Electric Drives

REF 321 Alternator

7797018_G6A- 32- 32 5.7GiPHUS

DESCRIPTION

32 SEE SEC. 321

Upd:6/30/2022

Alternator

321 DESCRIPTION

Alternator

7797018_G6A- 321- 321 5.7GiPHUS

SEE SEC. NOTES 54142801 5.7GiPHUS

Upd:6/30/2022

Starting System

REF 331 Starter Motor

7797018_G6A- 33- 33 5.7GiPHUS

33 DESCRIPTION

SEE SEC. 331

Upd:6/30/2022

Starter Motor

331 DESCRIPTION

Starter

7797018_G6A- 331- 331 5.7GiPHUS

SEE SEC. NOTES 54160661 5.7GiPHUS

Upd:6/30/2022

Cables and Fuses

REF 371 Cables

7797018_G6A- 37- 37 5.7GiPHUS

37 DESCRIPTION

SEE SEC. 371

Upd:6/30/2022

Cables

371

Engine Harness Engine Harness Bracket

DESCRIPTION

SEE SEC. NOTES 54142770 5.7GiPHUS 54142775 5.7GiPHUS

7797018_G6A- 371- 371

Upd:6/30/2022

5.7GiPHUS

Steering

REF 645 Hydralic equipment including pump

7797018_G6A- 64- 64 5.7GiPHUS

64 DESCRIPTION

SEE SEC. 645

Upd:6/30/2022

Hydralic equipment including pump

DESCRIPTION Steering

7797018_G6A- 645- 645 5.7GiPHUS

645 SEE SEC. NOTES 54160689 5.7GiPHUS

Upd:6/30/2022

5.7GiPHUS

REF 20 21 23 25 26 28 32 33 37 64

DESCRIPTION General, Engine with Mounting and Equipment Engine Fuel System Inlet and Exhaust System Cooling System Ignition and Control Systems Alternator, Charging, Electric Motor, Electric Drives Starting System Cables and Fuses Steering

7797018_G6A- - TOC 5.7GiPHUS

SEE SEC. 20 21 23 25 26 28 32 33 37 64

Upd:6/30/2022