Speccifications 1

RENR9362-08
CATERPILLAR' January 2011
Specifi cations
35OOC Engines
LLAl-Up (Engine)
R1A1-Up (Engine)
LLBl-Up (Engine)
LLGl-Up (Engine)
GBEl-Up (Engine)
LLEl-Up (Engine)
LLFl-Up (Engine)
SBGl -Up (Generator Set)
SBJ1 -Up (Generator Set)
C8Kl-Up (Engine)
SBKl -Up (Generator Set)
SBMl -Up (Generator Set)
PESl-Up (Engine)
RlSl-Up (Engine)
RMSl -Up (Generator Set)
RTX1-Up (Pumper)
T2X1-Up (Engine)
i0399 1 620
lmportant 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.
lmproper 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, untilyou have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. lf 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. lf 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 seruice 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 re-
placement parts or parts with equivalent speci-
fications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture 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.
RENR9362-08 3
Table of Contents
Table of Contents Air Cleaner Adapter ........ 52

Ensine Air creaner s"rili'iiilji;;6; :.:.:::.:: .......... s2
Lines)
Air Lines (Air Starting ............, 53
Lines)
Air Lines (Air Starting .............. 54
Lines)
Air Lines (Air Starting .............. 55
Air Lines ....... 55
Air Lines ..,.... 56
Air lnlet and Exhaust Lines ............,... 60
Air lnlet and Exhaust Lines ................ 62
Air lnlet and Exhaust Lines ................ 63
Air Inlet and Exhaust Lines ................ 64
Air Inlet and Exhaust Lines ................ 65
Air lnlet and Exhaust Lines ............... 66
o Air Inlet and Exhaust Lines

Air lnlet and Exhaust Lines
Air Inlet and Exhaust Lines
................ 67
................ 67
............... 69
................ 70
Air Shutoff ....................... 71
Air Shutoff ....-.................. 72
AirShutoff 73
AirShutoff 74
AirShutoff 76
AirShutoff ................... 77
Engine Oil Pump 78
Engine Oil Pump 80
Engine Oil Pump 82
?n Engine Oil Pump 84
Engine Oil Pump 85
31
Engine Oil Scavenge Pump 87
32
Engine Oil Scavenge Pump 90
33
Engine Oil Scavenge Pump .............. 92
34
Engine Oil Cooler Bypass and Cooling Jet Sequence
35
36
Valves ........ 94
38
3B
Valves ........95
39
Exhaust Manifold ........... 40
Valves ........ 97
Valves ........ 99
Valves ...... 101
Exhaust Manifold Engine Oil Filter ........... 102
........... 43
Engine Oil Filter ........... 104
Exhaust Manifold Duplex Engine Oil Filters ................ 105
........... 45
Engine Oil Filter Base ......... ............ 107
Engine Oil Cooler ......... 107
Exhaust Manifold 46
Exhaust Shield Crankcase Breather ..... 108
47
Exhaust Flange Crankcase Breather ..... 109
................. 48
Exhaust Flange Crankcase Breather ...... 110
................. 48
Exhaust Flange Crankcase Breather ......111
49
Exhaust Flange Crankcase Breather ......112
49
Exhaust Franle : ::: :::. :::::.::.::::: :: ::
Engine Oil Pan .............112
50
Engine Oil Pan
:
Exhaust Fitting .............114

50
Air Cleaner F,1
Engine Oil Pan .............. 116
Air Cleaner Adapter Engine Oil Pan .............. 118
51
Air Cleaner Adapter Engine Oil Pan .............. 119
52
Engine Oil Pan ............. 120
4 RENR9362-08
Tab e of Contents
Water Temperatu re Regulator 121 Vibration Damper ........ 194

Water Temperature Regulator tzz Vibration Damper ......... 195
Water Lines ......,... 123 Vibration Damper ........ 196
Water Lines .......... 124 Vibration Damper ........ 1go
Water Lines .......,.. 124 Vibration Damper .....,,. 197
Water Lines .....,.... 125 Vibration DamperGuard ................. 198
Water Lines .......... 125 Vibration Damper Guard ................ 199
Water Lines ...,. 126 Stub Shaft (Front) ......... 200
Water Lines .......... 127 Stub Shaft (Front) ........ 201
Water Lines (Aftercooler) 128 Stub Shaft (Front) ........ 202
Thermostatic Valve 128 Stub Shaft (Front) ........ 202
Thermostatic Valve 129 Stub Shaft (Rear) ......... 203
Thermostatic Valve 130 Auxiliary Drive Pulley ..,................... 203
Water Connection Group 130 Auxiliary Drive Pulley ...................... 204
Fan Drive 130 Belt Tension Chart ........ ................. 204
Engine Oil Sump Pump ........ 132 Belt Tension Chart ........ ................. 206
Water Pump ........ 133 Alternator and Regulator ............. ... 208
Water Pump ........ 136 Alternator and Regulator ............. ... 209
Auxiliary Water Pump 138 Alternator and Regulator ............. ... 210
Auxiliary Water Pump 139 Alternator and Regulator .............
Auxiliary Water Pump
Cylinder B|ock ........
142
143
Alternator Mounting
Electric Starting Motor ..::...:
jjl^
Cylinder 81ock ........ 144 Motor
Electric Starting .................... 213
Cylinder Block 146 Electric Starting Motor....... ............ 214
Cylinder Block ........ 148 Electric Starting Motor....... ............ 215
Cylinder Liner ......... 149 Air Starting Motor ........ 216
Piston and Rings (One-Piece Piston) 150 Air Starting Motor ........ 217
Piston and Rings (Two-Piece Piston) 151 Air Starting Valve....,.... .................... 217
Piston and Rings (One-Piece Piston) 153 Switches (StarUStop) ... 218
Piston and Rings (Two-Piece Piston) 154 Engine Oil Level Switch ................... 218
Piston and Rings (Two-Piece Piston) 155 Fuel Pressure Sensor ..................... 2ig
Connecting Rod ........... 157 Fuel Pressure Sensor ..................... 219
Connecting Rod ...,....... 158 Coofant Level Sensor ................ ..... 220
Connecting Rod and Main Bearing Journals ..,... 160 Coolant Level Sensor ................. .... 220
Crankshaft 161 Engine Oil Pressure Sensor ........... 221
Crankshaft 162 Engine Oil Pressure Sensor ........... 222
Crankshaft 163 Turbocharger f nlet Pressure Sensor ................... 222
Crankshaft 164 Turbocharger I nlet Pressure Sensor ................... 229
Crankshaft Wear Sleeves and Seals ......... ....... 165 Turbocharger Outlet Pressure Sensor ................ 223
Housing (Front) 166 Turbocharger Outlet Pressure Sensor ................ 224
Housing (Front) 167 Engine Coolant Temperature Sensor 224:
Housing (Front) 168 Engine. Coolant Temperature Sensor ................., Z2O
Cover Group (Front Housing) 169 Turbocharger Exhaust Temperature Sensor ....... 225 -
Gear Group (Front) 170 Engine Speed/Timing Sensor ......... 226
Gear Group (Front) 171 Engine Speed/Timing Sensor ......... 227
Gear Group (Rear) 172 Engine Speed/Timing Sensor ......... 227
Balancer Group (Front) 174 Crankcase Pressure Sensor ........... 228
Accessory Drive ......... 174 Crankcase Pressure Sensor ........... 228
Accessory Drive ......... 176 Atmospheric Pressure Sensor ........ 229
Accessory Drive (Lower Left Hand) 176 Atmospheric Pressure Sensor ...,.... 229
Accessory Drive (Lower Left Hand) 178 Engine Speed Sensor ...................... 230
Accessory Drive (Upper Right Hand) 180 Tachometer Drive ......... .................." 231
Accessory Drive (Upper Right Hand) 182 Thermocouple ............... ................... 232
Accessory Drive (Upper Right Hand) 183 Thermocouple ............... ................... 232
Flywheel 184
Flywheel Housing 185 Index Section
Flywheel Housing 187
Flywheel
Flywheel
Housing
Housing
189 Index......... .................... 233
191
Flywheel Housing Cover 193
Flexible Coupling 194
RENR9362-08 5
Specifications Section
Specifications Section 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.
i02414042 The number 1 cylinder is the front cylinder on the
right side. The number 2 cylinder is the front cylinder
Engine Design on the left side.
SMCS Gode: 1000
io2415723
S/N: LLC1-Up
Engine Design
S/N: C8E1-Up
SMCS Code: 1000
S/N: LLE1-Up
S/N: LLA1-Up
S/N: CBK1-Up
S/N: LLBl-Up
S/N: SBG1-Up
S/N: RMSl-Uo
S/N: RTXI-Up
i /
a
lllustration 1 900293348
Cylinder and valve location

(A) Inlet valves
(B) Exhaust valves
Number and arrangement of

cylinders ........ 60 degree V-8 lllustration 2 900293349

Valves per cylinder ............ 4
(A) Inlet valves
(B) Exhaust valves
Displacement ............... 34.5 L (2105 cu in)
Bore .......... 170 mm (6.7 inch) cylinders ...... 60 degree V-12
Stroke .... 190 mm (7.5 inch) Valves per cylinder ............ 4
Compression ratio ..... 14.7:1 Displacement ............... 51.8 L (3158 cu in)
Combustion .. Direct injection Bore .......... 170 mm (6.7 inch)
When the crankshaft is viewed from the flywheel Stroke .... 190 mm (7.5 inch)
end the crankshaft rotates in the following
direction. . Counterclockwise Gompression ratio ..... 14.7'.1
Firing order (injection sequence)

Combustion .. Direct injection
Standard rotation CCW............... 1, 2, 7, 3, 4,5, 6, B
When the crankshaft is viewed from the flywheel
Valve lash direction. . Counterclockwise
..........,
Inlet 0.50 mm (0.020 inch) Firing order (injection sequence)
Exhaust 1.00 mm (0.040 inch)
RENR9362-08
Standard rotation Firing order (injection sequence)

ccw ......... 1,12,9,4, 5, B, 11,2,3,,10, 7, 6
Standard rotation
Valve lash ccw ......... 1,12,9,4, 5, g, 11,2,3,10, 7, 6
...........
Inlet 0.50 mm (0.020 inch) Valve lash
Exhaust 1.00 mm (0.040 inch) ...........

Inlet 0.50 mm (0.020 inch)
Note: The front end of the engine is opposite the Exhaust 1.00 mm (0.040 inch)
of the engine are determined from the flywheel end. Note: The front end of the engine is opposite the
The number 1 cylinder is the front cylinder on the flywheel end of the engine. The left and the right side
right side. The number 2 cylinder is the front cylinder of the engine are determined from the flywheel end.
on the left side. The number 1 cylinder is the front cylinder on the
on the left side.
i0241 5956
Engine Design 19699'l
SMCS Code: 1000

S/N: R141-Uo
Engine Design o
SMCS Code: 1000
S/N: LLF'I-Up Part No.: 329 - 3355, 336 - 2026, 368 - 9070
S/N: R151-Up
12_f 0_E_6_4_2
oo
t/ ,/
A'B //
oa
A, B.

(A) Inlet valves Cylinder and valve location
(B) Exhaust valves
(A) Inlet valves
(B) Exhaust valves
cylinders ...... 60 degree V-12 Number and arrangement of
Valves per cylinder ............ 4
cylinders ......60 degree V-'12
Vafves per cylinder ............ 4

Bore .......... 170 mm (6.7 inch)
Bore .......... 170 mm (6.7 inch)
Stroke ....215 mm (8.5 inch)
Gompression ratio ..... 14.7:1
Stroke .... 215 mm (8.5 inch)
Compression ratio ....

Combustion ..................... Direct injection 14.7:1
When the crankshaft is viewed from the flywheel

Gombustion .. Direct injection
direction. . Counterclockwise
RENR9362-08 I
Specifications Sect on
When the crankshaft is viewed from the flywheel ratio

Comoression ..... 14.7:1
end, the crankshaft rotates in the following
direction. Counterclockwise Combustion .. Direct injection
Firing order (injection sequence) When the crankshaft is viewed from the flywheel
Standard rotation direction. Counterclockwise
ccw......... 1,2,9,10,5,6,11,12,3,4,7,8
Valve lash
Standard rotation
...........
lnlet 0.50 mm (0.020 inch) ccw .. 1,2,5,6,3,4,9, 10, 15, 16, 11 ,12,13,14,7,8
Exhaust 1.00 mm (0.040 inch) Valve lash
Note: The front end of the engine is opposite the ............

Inlet 0.50 mm (0.020 inch)
of the engine are determined from the flywheel end. Exhaust 1.00 mm (0.040 inch)
The number 1 cylinder is the front cylinder on the
right side. The number 2 cylinder is the front cylinder Note: The front end of the engine is opposite the
on the left side. flywheel end of the engine. The left and the right side
i0241 5900
Engine Design on the left side.
SMCS Gode: 1000 i02415764
S/N: SBK1-Up Engine Design

S/N: SBMl-Up
SMCS Code: 1000
S/N: PES1-Up
S/N: SBJl-Up
S/N: T2X1-Uo
r2_10_8_6_4_2
6\ /o-\ /t\ /51/t\ /t\
RJ/49\.9\J/qy \.y
/.-n /'-\ d\ p-\ /5\ /t\
RJ/ \J/ \.y qy RJ/ qJ/
d.-\ 16\ f"-\ 6"-\
\r9 \.9 6"-\
\9\y \.y 1f"-\ ca
15-13-1r-9-7-5-J-
6\ 6"-\ 6-d\ 6\ f--\ 6--\
\J/ \9 \y \.9 \J/ Ca
r5-13-1r-9-7-5-J-
o/r/
lllustration 5 900294285 o/r/
(A) Inlet valves lllustration 6 900294285
(B) Exhaust valves Cylinder and valve location
(A) Inlet valves
Number and arrangement of (B) Exhausl valves
cylinders ..... 60 degree V-16
Valves per cylinder ........... 4 cylinders 60 degree V-16
Displacement ............... 78.0 L (4760 cu in) Valves per cylinder 4
Bore .......... 170 mm (6.7 inch) 69.1 L (4210 cu in)

Stroke ...215 mm (8.5 inch) 170 mm (6.7 inch)
8 RENR9362-08
Stroke .... 190 mm (7.5 inch) Part No.: 8N-6435

S/N: SBMl-Up
Compression ratio .... 14.7:1
Part No.: 8N-6435
Combustion Direct injection S/N: PES1-Up
When the crankshaft is viewed from the flywheel Part No.: 8N-6435
end the crankshaft rotates in the following S/N: RlSl-Uo
direction. . Counterclockwise Part No.: 8N-6435
S/N: RMS1-Up
Part No.: 8N-6435
Standard rotation S/N: T2X1-Up
ccw .. 1,2,5,6,3,4,9, 10, 15, 16, 11 ,12,13,14,7,9
Valve lash
lnlet 0.50 mm (0.020 inch)
Exhaust 1.00 mm (0.040 inch)
Note: The front end of the engine is opposite the

on the left side.
i03657840
Fuel Filter (Primary) (1) Torque for the nut ..... 25 t 5 N.m (221 t 44 tb in)
SMCS Code: 1260

(2) Lubricate the bore and the shaft of the O-ring
seal lightly with the clean engine oil.
Part No.: 8N-6435
S/N: LLA1-Up (3) 75-9s23 Spring
Part No.: 8N-6435 Length under test force... 27.94 mm(1.100 inch)
S/N: R141-Uo Testforce 27.7 to 32.3 N (6.2 to 7.3lb)
Free length aftertest ...... 42.67 mm (1.680 inch)
Part No.: BN-6435 Outside diameter 17.32 mm (0,682 inch)
S/N: LLBl-Up ^
Part No.: BN-6435 -
S/N: LLCl-Up
Part No.: BN-6435
S/N: C8E1-Up
Part No.: 8N-6435
S/N: LLEl-Up
Part No.: BN-6435
S/N: LLFl-Up
Part No.: 8N - 6435
S/N: SBGl-Up
Part No.: BN-6435
S/N: SBJl-Uo
Part No.: 8N-6435
S/N: C8K1-Uo
Part No.: 8N-6435
S/N: SBK1-Up
RENR9362-08 o
Specifications Sect on
i04010911 i02723705
Fuel Filter Base Fuel Pressure Regulator

(Spin-on Filter) SMCS Code:1277
SMCS Code:1262 Part No.: 114-5477
Part No.: 1W-7559
S/N: RlAl-Up
Part No.: 1W-7559
S/N: LLBl-Up
Part No.: 1W-7559
S/N: LLF1-Up
Part No.: 1W- 7559
S/N: SBGl-Up
Part No.: 1W-7559
S/N: SBJl-Up
Part No.: 1W-7559
S/N: SBK1-Up lllustration I s01366239
Typical example
Part No.: 1W-7559 (1) Fuel manifold adapter
S/N: SBMl-Up (3) Valve plunger
Part No.: 1W-7559 (2) 9N-4053 Spring

S/N: PESl-Up
Length undertestforce .......28.5 mm ('1.12 inch)
Part No.: 1W-7559 Test force .40.8 ! 2.1 N (9.2 t 0.5 lb)
S/N: R151-Uo Free length after test force .. 57.2 mm (2.25 inch)
Part No.: 1W- 7559 Outside diameter 15.24 mm (0.600 inch)
S/N: RTX1-Uo
Fuel Transfer Pump

SMCS Code: 1256
Part No.: 8N-6151
S/N: LLA1-Up
Part No.: 8N - 61 51
S/N: RlAl-Up
Part No.: 8N-6151
S/N: LLBl-Up
Part No.: 8N - 61 51
lllustration I 902183574 S/N: LLCl-Up
Note: Apply red Loctite 271 on the last 10.0 t 1.5 mm Part No.:8N-6151
(0.39 t 0.06 inch) of the threads at the base end of S/N: C8E1-Up
the taperlock stud.
Part No.: 8N-6151
(1) Torque for the taperlock stud ............. 68 t 7 N'm S/N: LLEl-Up
(50r5|bft) Part No.:8N-6151
S/N: LLFl-Uo
Part No.: 8N-6151
S/N: SBGl-Up
Part No.: BN - 6151
S/N: SBJl-Uo
RENR9362-OB
Part No.: 8N - 6151 Minimum cracking pressure of bypass

S/N: C8K1-Up valve ......... 620 kPa (90 psi)
Part No.: BN-6151 Maximum pressure of fully open bypass
S/N: SBK1-Up valve ......... 965 kPa (1a0 psi)
Part No.: 8N-6151
S/N: PESl-Up (1) Dimensions for terminal bushing
Part No.: 8N-6151 Inside diameter of the terminal bushing for gear
S/N: R1S1-Uo shaft........... 12.783 mm (0.5033 inch)
Installation depth of terminal
Part No.:8N-6151 bushing 1.5 i 0.5 mm (0.06 t 0.02 inch)
S/N: RMS1-Up
(2) Dimensions for drive shaft assembly
Part No.: 8N - 61 51
S/N: RTX1-Up Diameter of the shaft ........ 12.700 to 12.675 mm
(0.5000 to 0.4990 inch)
Part No.: 8N - 61 51 Diameter of thegear 29.801 + 0.006 mm
S/N: T2X1-Up t
(1.1733 0.0002 inch)
Length of the gear 25.347 r 0.008 mm
(0.9979 r 0.0 oo3 inci!
A
(4) Dimensions for idler gear assembly
Diameter of thegear 29.801t 0.006 mm
(1.1733 t 0.0002 inch)
Length of the gear 25.347t 0.008 mm
(, (0.9979 t 0.0003 inch)
L-l
lllustration 10 901641 861
(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 2l Llmin (5.5 US gpm)
Minimum output is attained under the following

conditions:
Pump pressure ............ 415 kPa (60 psi)
Pump speed 2400 rpm

RENR9362-08 11
Soecifications Section
i031 47530 lnside diameter of the terminal

Fuel Transfer Pump bushing .... 12.783 mm (0.5033 inch)
Installation depth of terminal
bushing 1.5 t 0.5 mm (0.06 t 0.02 inch)
SMCS Gode: 1256
(2) Dimensions for drive shaft assembly
Part No.: 207 -1349
S/N: SBK1-Up Diameter of the shaft ........ 12.700 to 12.675 mm
(0.5000 to 0.4990 inch)
Part No.: 207 -1349
S/N: SBMl-Up Diameter of the gear 29.801 t 0.006 mm
(1.1733 t 0.0002 inch)
Length of the gear 35.347 i 0.008 mm

(1.3916 t 0.0003 inch)
(4) Dimensions for idler gear assembly
Diameter of thegear 29.801 t 0.006 mm

(1.1733 t 0.0002 inch)
Length of the gear 35.347 t 0.008 mm
(1.3916 t 0.0003 inch)
i03601 01 I
Fuel Injector Mechanism
SMCS Code: 1102',1290
Part No.: 224-9869
S/N: LLA1-Up
Part No.: 224-9869
S/N: R141-Up
Part No.: 224-9869
S/N: LLBl-Up
Part No.: 224-9869
S/N: LLCl-Up
lllustration 11 901 641 857
(3) Check valve

Part No.: 224 -9869. 332 - 9690
S/N: C8E1-Up
When the fuel transfer pump group is viewed from Part No.: 224-9869
the drive end, the drive gear rotates in the clockwise S/N: LLEl-Up
direction.
Part No.: 224-9869
Minimum output 28 L/min (7.a US gpm) S/N: LLF1-Up
Minimum output is attained under the following Part No.: 224-9869

conditions: S/N: SBGI-Up
Part No.: 224-9869
Pump pressure 415 kPa (60 psi)
S/N: SBJ1-Up
Pump speed ........ 2400 rpm Part No.: 224 - 9869. 332 - 9690
S/N: G8K1-Up
Minimum cracking pressure of bypass
valve ......... 620 kPa (90 psi) Part No.: 224-9869
S/N: SBK1-Up
Maximum pressure of fully open bypass
valve ......... 965 kPa (1a0 psi) Part No.: 224-9869
S/N: SBMl-Up
(1) Dimensions for terminal bushing Part No.: 224-9869
S/N: PESl-Up
12 RENR9362-08
Part No.: 224-9869

S/N: R1S1-Up
Part No.: 224-9869
S/N: RMS1-Up
Part No.: 224-9869
S/N: RTX1-Up
Part No.: 224-9869
S/N: T2X1-Uo
g0'1925693
lllustration 1 3
(4) Lubricate the bore of the O-ring seal lightly with

clean engine oil.
]g':ffi rT,i'fl :i"lii,'[1ffi 5[il]lTiJ,ii:",::?"o

cross threaded.
(5) Torque for the retainer nuts of the cap

assembly 2.500 r 0.025 N'm
(22.127 t 0.221 lb in)
(6) Apply 5P - 341 3 Pipe Sealant to the threads of

the bolts, if the bolts are removed after initial
installation.
lllustration '12 901441231
(3) Timing pin i02895028
(A) Bore in the sleeve bearing for the rocker arm

Fuel Injector Mechanism
shaft after installation 45.077 t 0.015 mm SMCS Code: 1102:1290
(1.7747 t 0.0006 inch)
Part No.:281-6160
(1) Torque for the nut .... 120 r 15 N'm (88 + 11 lb ft) S/N: LLA1-Up
(B) Diameter of the rocker arm Part No.: 281 -6160, 286 -5723
shaft 45.000 t 0.013 mm S/N: R1A1-Up
(1 !
7716 0.0005 inch)
Part No.:281-6160
S/N: LLBl-Up
(2) 100 - 3878 Injector Spring
Part No.:281-6160
Length undertest force... 85.00 mm (3.346 inch)
S/N: LLC1-Up
Test force ....... 300 r 25 N (67 r 6 tb)
Free length after test ...... 87.65 mm (3.451 inch) Part No.:281-6160
Outside diameter 43.85 mm (1.726 inch) SIN: LLE1-Up
(C) Dimensions for the unit injector lifter assembly Part No.: 281 -6160
S/N: LLF1-Up
Diameter of the unit injector lifter
assembly 34.950 t 0.010 mm Part No.: 281 - 61 60
t
(1.3760 0.0004 inch) S/N: SBG1-Up
Bore in the head for the unit injector lifter
assembly 35.000 + 0.025 mm Part No.:281-6160
S/N: SBJl-Up
(1.3779 t 0.0010 inch)
Part No.:281 -6160
S/N: SBK1-Up
RENR9362-08 13
Part No.: 281 -6160

S/N: SBMl-Up
Part No.: 281-6160
S/N: PESl-Up
Part No.: 281 -6160
S/N: RMS'1-Up
Pad No.: 281-6160
S/N: RTX1-Up
Part No.: 281 -6160
S/N: T2X1-Up

clean engine oil.
Note: Start the retainer nuts of the cap assembly

by hand so that the terminal studs are not cross
threaded.
(5) Torque for the cap assembly ..... 2.50 t 0.25 N.m
(22 x 2lb in)
i02895694
Fuel Injector
SMCS Code: 1290
Part No.: 246 - 1854, 254 - 1 417, 256- 3663
9O1441231
S/N: LLA1-Up
lllustration 14
(3) Timing pin Part No.: 252-0064, 253 - 2636
S/N: R1A1-Up
(A) Bore in the sleeve bearing for the rocker arm shaft
assembly after installation ... 45,077 + 0.015 mm Part No.: 246-1854, 254- 1 41 7, 256-3663
(1.7747 t 0.0006 inch) S/N: LLBl-Up
Part No.: 246-1854, 254- 1417, 256-3663
(1) Torque for the nut .... 120 + 15 N.m (90 r 11 tb ft) S/N: LLCl-Up
(B) Diameter of the rocker arm Part No.: 246-1854. 256-3663
shaft.......... .,...... 45.000 i 0.013 mm S/N: C8E1-Up
(1.7716 t 0.0005 inch)
Part No.: 246 - 1854, 254 - 1 417, 256-3663,
(2) 1 00 - 3878 Injector Spring 269-31 52,282-6903
S/N: LLEl-Up
Length under test force ... 85.00 mm (3.346 inch)
Test force i
300 25 N (67.4 t 5.6 tb) Part No.: 246 - 1 854, 254 - 1 417, 256-3663,
Free length aftertest ...... 87.65 mm (3.451 inch) 269-3152,282-6903
Outside diameter 43.85 mm (1.726 inch) S/N: LLF1-Up
(C) Dimensions for the unit injector lifter assembly Part No.: 1 44 - 0726, 256 -3663, 27 4 - OO53
S/N: SBGI-Uo
Diameter of the unit injector lifter
assembly 34.950 t 0.010 mm Part No.: 256-3663, 274 - OO53
S/N: SBJl-Up
(1.3760 t 0.0004 inch)
Bore in the head for the unit injector lifter Part No.: 256-3663, 269-3152
assembly 35.000 + 0.025 mm S/N: C8K1-Up
(1.3779 t 0.0010 inch)
14 RENR9362-OB
Part No.: 231 -7845, 256-3663 (3) Torque for unit injector nozzle........ 310 t 20 N'm
S/N: SBK1-Up (230 r 15 tb ft)
Part No.: 253-2636
S/N: SBMl-Up i02945981
Part No.: 269-31 52, 282-6903 Camshaft

S/N: PESl-Up
SMCS Code: 1210
Part No.: 282-5076
S/N: RlSl-Up Part No.: 261 -4683
S/N: LLC1-Up
Part No.: 246 - 1854, 254 - 1 417, 256-3663
S/N: RMS1-Up Part No.: 333-2238
S/N: C8E1-Up
Part No.: 252 -0064, 253 - 2636, 27 4 -O0Sg
S/N: RTX1-Up Part No.: 261 -4683
S/N: LLEl-Up
Part No.: 252 - 0064, 256 - 3663
S/N: T2X1-Uo Part No.: 333-2238
S/N: C8K1-Up
(1) Left hand camshaft assembly

(2) Right hand camshaft assembly
(A) Thickness of the groove for thrust washer in a

g0'1441567 new camshaft assemblv 8.75 r 0.05 mm
lllustration 16
(0.344 t 0.002 inc,nO
Note: Prior to installation of the fuel injector group, (B) Extension of the dowel from the camshaft
lubricate the bore in the cylinder head with 1 P - 0B0g
assembly ........ 12.0 i 0.5 mm (0.47 t 0.02 inch)
Multipurpose Grease. Use the clamp to press the
injector into the bore. Do not tap on the top surface (C) Thickness of a new thrust
of the injector.
washer ...... 8.50 t 0.05 mm (0.335 t 0.002 inch)
(1) Torque for the bo|t.......... 65 r 7 N.m (48 t 5 lb ft) (D) Dimensions for the journal surface
(A) Timing dimension 64.34 t 0.20 mm Diameter of bearing journal ..... 91.88 t 0.02 mm
(2.533 t 0.008 inch) (3.617 r 0.001 inch)
Bore in camshaft bearing after
Note: Before assembly, lubricate the bore and installation 92.00 r 0.06 mm
the threads of valve assembly (2) with 1P-0808 (3.622 t 0.002 inch)
Multipurpose Grease.
Note: End play for a new camshaft assembly is
(2) Valve assembly 0.15 to 0.35 mm (0.006 to 0.014 inch).
Torque for valve assembly 165 t 10 N.m
(120 ! 7 tb ft)
Torque for terminal nuts ............ .....2.4 t 0.2 N.m
(21 t2lbin)
RENR9362-08 15
i03021227
Gamshaft
SMCS Gode: 1210
Part No.: 163 - 1419
S/N: LLA1-Up
Part No,: 163 - 1419
S/N: LLBl-Up
Part No.: 163 - 141 9
S/N: LLF1-Up
Part No.: 163 - 1 41 I
S/N: RMSl-Up
(E) Specified camshaft lobe lift

lnletlobe ...... 13.25 mm (0.522 inch)
Injector lobe ............ 13.8065 mm (0.54356 inch)
Exhaust lobe ................... 13.25 mm (0.522 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 lllustration 19 901 381 231
camshaft lobe lift. (1) Left hand camshafl assembly
(A) Thickness of the groove in a new camshaft

assembly .. 8.75 t 0.05 mm (0.344 t 0.002 inch)
(C) Extension of the dowel from the camshaft

assembly ........ 12.0 t 0.5 mm (0.47 t 0.02 inch)
(D) Thickness of a new thrust

washer ...... 8.50 t 0.05 mm (0.335 t 0.002 inch)
(E) Dimensions for the journal surface

Diameter of bearing journal ..... 91.88 t 0.02 mm
t
(3.617 0.001 inch)
installation 92.00 f 0.06 mm
t
(3.622 0.002 inch)

0.15 to 0.35 mm (0.006 to 0.014 inch).
(3) Torque for 16 bolts ......... 55 i 7 N.m (4'1 r 5 lb ft)

16 RENR9362-08
(F) Extension of the dowel from the end of the i03021231

rear right hand camshaft and the front left hand
camshaft .........22.0 t 0.5 mm (0,87 r 0.02 inch) Camshaft
SMCS Code: 1210
Part No.: 283-7639
S/N: LLA1-Up
Part No.: 283 - 7639
S/N: LLBl-Up
Part No.: 283 - 7639
S/N: LLF1-Up
Part No.: 285 - 3785
S/N: PESI-Up
Part No.: 283-7639
S/N: RMSl-Up
lllustration 20 9O1447245

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.
(G) Specified camshaft lobe lift

B.B
lnlet lobe . 13.250 mm (0.5217 inch)
Injector lobe .............,.. 13.731mm (0.5406 inch)
Exhaust lobe ...,........... 13.250 mm (0.5217 inch) (1) Left hand camshaft assembly

assembly .. 8.75 r 0.05 mm (0.344 t 0.002 inch)

assembly ........ 12.0 t 0.5 mm (0.47 t 0.02 inch)

washer ...... 8.50 t 0.05 mm (0.335 t 0.002 inch)

Diameter of bearing journal ..... 91.88 r 0.02 mm
(3.617 t 0.001 inch)
installation 92.00 r 0.06 mm
(3.622 t 0.002 inch)

0.15 to 0.35 mm (0.006 to 0.014 inch).
RENR9362-08 17
(3) Torque for the 16 bolts ... 55 t 7 N'm (41 t 5 lb ft) 103021222
(F) Extension of the dowel from the end of the Gamshaft

t t
camshaft ......... 22.0 0.5 mm (0.87 0.02 inch) SMCS Gode: 1210
Part No.: 281-7849
S/N: RlAl-Up
Part No.: 281-7849
S/N: SBGl-Up
Part No.: 281-7848
S/N: SBJl-Up
Part No.: 281-7848
S/N: SBKI-Up
Part No.: 281-7849
S/N: RTXI-Up
lllustration 22 9o1447245


lobe lift.
(G) Specified camshaft lobe lift lllustration 23 901 381 231
lnlet lobe .. 13.250 mm (0.5217 inch) (1) Left hand camshaft assembly
Injector lobe ................ 13.806 mm (0.5435 inch)
Exhaust lobe ............... 13.250 mm (0.5217 inch)
assembly .. 8.75 t 0.05 mm (0.344 t 0.002 inch)

assembly ........ 12.0 t 0.5 mm (0.47 ! 0.02 inch)

washer ...... 8.40 t 0.05 mm (0.331 t 0.002 inch)

Diameter of bearing journal ..... 91.88 t 0.02 mm
(3.617 t 0.001 inch)
installation 92.00 t 0.06 mm
(3.622 t 0.002 inch)

0.15 to 0.35 mm (0.006 to 0.014 inch).
18 RENR9362-08
(3) Torque for 16 bo|ts..,......55 r 7 N.m (41 r 5 lb ft) i02758767
(F) Extension of the dowel from the end of the Camshaft

camshaft ......... 22.0 t 0.5 mm (0.87 r 0.02 inch) SMCS Gode: 1210
Part No.: 273 -57 12. 273 - 57 13
S/N: RlAl-Up
Part No.: 273-5712
S/N: SBGI-Up
Part No.: 273-5713
S/N: SBJl-Up
Part No.: 273-5713
S/N: SBK1-Up
Part No.: 273-5713
S/N: SBMl-Up
Part No.: 308-5361
S/N: RlSl-Up
Part No.: 273 -57 12. 273 - 57 13
S/N: RTXI-Up
Part No.: 273-5713
S/N: T2X1-Up
lllustration 24 9o144724s


height (H). The difference is the actual camshaft -D
lobe lift.

lnlet lobe 12.7300 mm (0.50118 inch)
lnjector lobe ........... ... 13.7313 mm (0.5406 inch)
Exhaust lobe ........... 13.1000 mm (0.S,1b75 inch)
(1) Left hand camshaft assembly


assembly .. 8.75 r 0.05 mm (0.344 t 0.002 inch)

assembly ........ 12.0 + 0.5 mm (0.47 t 0.02 inch)

washer ...... 8.40 r 0.05 mm (0.331 t 0.002 inch)

RENR9362-08 19
t 0.02 mm
Diameter of bearing journal ..... 91.88 Part No.: 224-9869,281 -6160, 286 -5723
(3.617 t 0.001 inch) S/N: R1A1-Uo
installation 92.00 t 0.06 mm Part No.: 224 -9869, 281 - 61 60
(3.622 t 0.002 inch) S/N: LLBl-Up
Part No.: 224 -9869, 281 - 61 60
S/N: LLC1-Up
0.15 to 0.35 mm (0.006 to 0.014 inch).
Part No.: 224 -9869, 332 - 9690
(3) Torque for the 16 bolts ...55 t 7 N.m (41 t 5 lb ft) S/N: C8E1-Up
(F) Extension of the dowel from the end of the Part No.: 224 -9869, 281 - 61 60
rear right hand camshaft and the front left hand S/N: LLE1-Up
camshaft ......... 22.0 t 0.5 mm (0.87 t 0.02 inch)
Part No.: 224 - 9869, 281 - 61 60
S/N: LLFI-Uo
Part No.: 224 -9869, 281 - 61 60
S/N: SBGl-Up
Part No.: 224 -9869, 281 - 61 60
S/N: SBJl-Up
Part No.: 224 - 9869, 332 - 9690
S/N: C8K1-Up
Part No.: 224 -9869, 281 - 61 60
S/N: SBK1-Up
Part No.: 224 -9869, 281 - 61 60
S/N: SBMl-Uo
Part No.: 224-9869, 281-6160
S/N: PES1-Up
Part No.: 224-9869
S/N: R1S1-Up
lllustration 26 9o1447245 Part No.: 224 -9869, 281 - 61 60
S/N: RMS1-Up
actual camshaft lobe lift: Part No.: 224-9869.281 -6160
S/N: RTX1-Up
Part No.: 224 -9869. 281 - 61 60
S/N: T2X1-Uo
lobe lift.

fnlet lobe 12.7300 mm (0.50118 inch)
Injector lobe ............ 13.8065 mm (0.54356 inch)
Exhaust lobe ........... 13.1000 mm (0.51575 inch)
i035771 64
Valve Mechanism
SMCS Gode: 1102
Part No.: 224-9869,281 -6160
S/N: LLA1-Up
20 RENR9362-08
i04104193
Cylinder Head
SMCS Gode: 1100
Part No.: 1 01 -0830, 274 -8568, 299-3521
S/N: LLAI-Up
Part No.: 101 -0830, 274-8568,299-3521
S/N: RlAl-Up
Part No.: 101 -0830, 274-8568, 299-3521
S/N: LLBl-Up
Part No.: 101 -0830, 274-8568,299-3521
S/N: LLC1-Up
Part No.: 1 01 - 0830, 332 - 9693
S/N: GBE1-Up
Part No.: 101 -0830, 274-8568, 299-3521
S/N: LLE1-Up
Part No.: 1 01 -0830, 27 4 -8568, 299 - 3521
S/N: LLFl-Up
Part No.: 101 -0830, 274-8568,299-3521
S/N: SBG1-Up

Part No.: 101 -0830, 274-8568,299-3521
S/N: SBJl-Up
Refer to Guideline for Reusable Parts and Salvage Part No.: 101 -0830,332-9693
Operations, SEBFS'172, "Visual Inspection of the S/N: C8K1-Up
7N-4782 Lifter Guide Spring - 3500 Famity of
Engines" for lifter guide spring (2). Part No.: 1 01 -0830, 27 4 -8568, 299-3521
S/N: SBK1-Up
(1) Torque for two jam nuts 70 t 15 N.m Part No.: 101 -0830,299-3521
(52 r 11 tb ft) S/N: SBMl-Up
(A) Diameter of the rocker arm shaft
Part No.: 1 01 -0830, 274 -8568, 299-3521
assembly 45.000 t 0.013 mm
S/N: PES1-Up
t
(1.7716 0.0005 inch)
Part No.: 299-3521
(B) Dimensions for the valve lash S/N: R1S1-Up
In|et........... ..... 0.50 mm (0.020 inch) Part No.: 1 01 -0830, 27 4 -8568, 299 -3521
Exhaust 1.00 mm (0.039 inch) S/N: RMSl-Up
(C) Bore in the sleeve bearing for the rocker arm shaft Part No.: 101 -0830, 274-8568,299-3521
assembly after installation ... 45.077 r 0.015 mm S/N: RTX1-Up
(1.7747 t 0.0006 inch) Part No.: 101-0830
(D) Dimensions for the valve lifter assembly S/N: T2X1-Up
Diameter of the valve lifter

t
(1.1772 0.0004 inch)
Bore in the head for the valve lifter
t
(1.1811 0.0010 inch)
RENR9362-OB 21
@
/\
\J
o
g0 1 429899
lllustration 28
Typical example
('l )Locating pad
NOTICE
The pipe plug at location (2) is installed in the cylinder
901413732
head for engines with dry exhaust manifolds. lf the lllustration 30
pipe plug is not installed into the water passage, the Typical example
coolant will leak and engine damage will result. For
engines with dry exhaust manifolds, make sure that (A) Height of the new cylinder
the pipe plug is installed. head ...... 142.00 r 0.15 mm (5.591 t 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 t 0.5 mm
(0.35 r 0.02 inch)
(D) Installation depth of eight cup plugs from the top
surface of the cylinder head 1.0 t 0.5 mm
(0.04 r 0.02 inch)
Bolt Tightening Procedure

The cylinder head bolt tightening procedure
depends on which cylinder head gasket is
used. Refer to one of the following bolt tightening
procedures based on your cylinder head gasket.
Bolt Tightening with the 110-6991

Gylinder Head Gasket
Typical example (top view) Use the following procedure when the 110 - 6991
(3) Pipe plug Cylinder Head Gasket is installed.
(3) Before assembly, lubricate the threads of the pipe 1. Coat the threads of the bolts with clean enoine oil,
plug.with 5P - 393 1 Anti-Seize Compound.
22 RENR9362-08
10
2. Tighten bolt (1)through bolt (8) in the numerical 2. Tighten bolt (1) through bolt (B) in the numerical
sequence to 30 t 5 N.m (22 t 4 lb ft). sequence to a torque of 30 t 5 N'm (22 t 4lb ft).
3. Tighten bolt (1) through bolt (8) in the numerical 3. Tighten bolt (1) through bolt (B) in the numericat
sequence to 200 t 15 N.m (150 r 11 tb ft). sequence to 100 t 15 N'm (75 r 11 tb ft).
4. Again tighten bolt (1) through bolt (8) in 4. Tighten bolt (1) through bolt (8) in the numerical
the numerical sequence to 200 t 15 N.m sequence to 450 t 15 N'm (330 r 11 lb ft).
(150 i 11 tb ft).
5. Loosen bolt (1) through bolt (B) in the numerical
5. Turn bolt (1) through bolt (8) in the numerical sequence for an angle of 90 t 5 degrees.
sequence to an additional rotation of 180 r 5
degrees. 6. Tighten bolt (1) through bolt (8) in the numerical
sequence to 490 t 15 N.m (360 r 11 tb ft).
Note: Tighten bolts (9) and (10) only after bott (1)
through bolt (B) have been given the final torque. Note: Tighten bolts (9) and (10) only after bott (1)
through bolt (8) have been given finaltorque.
6. Tighten bolts (9) and (10) to 55 t 10 N.m
(40r7rbf0. 7. Tighten bolts (9) and (10) to 55 r 10 N.m
(40t7tbft).
Bolt Tightening with the 362-8264
Cylinder Head Gasket
Use the following procedure when the 962-8264
Cylinder Head Gasket is installed.
1. Coat the threads of the bolts with clean enoine oil.

RENR9362-08 23
io4104192
Cylinder Head
SMCS Gode: 1100
Part No.: 291-1463
S/N: R1,A1-Up
Part No.:285-3086
S/N: T2X1-Up (e/
,n
V
O
901 429899
lllustration 33
Typical example
(1) Locating pad 901 430598
lllustration 34
(2) Pipe plug
Typical example
NOTICE Note: Apply 6V- 6640 Sealant to the bores of the

The pipe plug at location (2) is installed in the cylinder cup plugs before assembly.
head for engines with dry exhaust manifolds. lf the
pipe plug is not installed into the water passage, the (A) Depth of the cup plugs in the top of the cylinder
coolant will leak and engine damage will result. For head ............;..... 9.0 t 0.5 mm (0.35 r 0.02 inch)
engines with dry exhaust manifolds, make sure that
the pipe plug is installed. (B) Height of new cylinder head .. 142.00 + 0.15 mm
(5.591 t 0.006 inch)
(C) Depth of the cup plugs in the cylinder head below

the bottom of the chamfer.............. 1.0 t 0.5 mm
(0.04 t 0.02 inch)
Bolt Tightening Procedure

The cylinder head bolt tightening procedure
depends on which cylinder head gasket e is
used. Refer to one of the following bolt tightening
procedures based on your cylinder head gasket.
Bolt Tightening with the 1 10 - 6991

Cylinder Head Gasket
Use the following procedure when the 110 - 6991
1. Coat the threads of the bolts with clean engine oil.

24 RENR9362-08
10
lllustration 35 go23o885s
sequence to 30 t 5 N.m (22 t 4 lb ft). sequence to a torque of 30 t !
5 N.m (22 4lb ft).
sequence to 200 t 15 N.m (150 r 11 lb ft). sequence to 100 t 15 N.m (75 i 11 lb ft).
4. Again tighten bolt (1) through bolt (8) in 4. Tighten bolt (1) through bolt (8) in the numerical
the numerical sequence to 200 t 15 N'm sequence to 450 t 15 N'm (330 r 11 lb ft).
(150 r 11 tb ft).
5. Loosen bolt (1) through bolt (8) in the numerical
5. Turn bolt (1) through bolt (8) in the numerical sequence for an angle of 90 t 5 degrees.
sequence to an additional rotation of 180 r 5
degrees. 6. Tighten bolt (1) through bolt (8) in the numerical
sequence to 490 t 15 N.m (360 t 11 lb ft).
Note: Tighten bolts (9) and (10) only after bott (1)
through bolt (B) have been given the final torque. Note: Tighten bolts (9) and (10) only after bolt (1)
through bolt (8) have been given final torque.
6. Tighten bolts (9) and (10) to 55 r 10 N.m
(40r7rbft). 7. Tighten bolts (9) and (10) to 55 t 10 N.m
(40f7rbft).
Boft Tightening with the 362-8264
Cylinder Head Gasket i03080402
Use the following procedure when the 362-8264 Cylinder Head Valves
SMCS Gode: 1105
l. Coat the threads of the bolts with clean enoine oil.
Part No.: 101 -0830, 299-3521, 335-6220
S/N: LLA1-Up
Part No.: 101 -0830, 299-3521, 335-6220
S/N: RlAl-Up
Part No.: 101 -0830, 299-3521,335-6220
S/N: LLBl-Up
Part No.: 101 -0830, 299-3521,335-6220
S/N: LLC1-Up
Part No.: 101 -0830, 335-6220
S/N: C8E1-Up
RENR9362-OB 25
Part No.: 1 01 - 0830, 299-3521, 335-6220

S/N: LLE1-Up
Part No.: 1 01 - 0830, 299 - 3521 335 - 6220
,
S/N: LLF1-Up
Part No.: 1 01 - 0830, 299 - 3521 335 - 6220
,
S/N: SBG1-Up
Part No.: 101 -0830, 299-3521, 335 - 6220
S/N: SBJl-Up
Part No.: 101-0830. 335 - 6220
S/N: CBK1-Up
Part No.: 1 01 - 0830, 299-3521, 335 - 6220
S/N: SBK1-Up
Part No.: 1 01 - 0830, 299-3521, 335 - 6220
S/N: SBMl-Up
Part No.: 101 - 0830, 299-3521
S/N: PES1-Up
Part No.: 299-3521, 335 - 6220
S/N: R'1S1-Up
Part No.: 101 -0830, 299-3521, 335 - 6220
S/N: RMS1-Up
Part No.: 1 01 - 0830, 299-3521, 335 - 6220
S/N: RTX1-Up
Part No.: 101 -0830, 285 - 3086
S/N: T2X1-Up
Typical example
26 RENR9362-08
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 t 1.0 mm
(1.02 ! 0.04 inch)
(1) 316-5976 Sprrng
Quantity ...................... 4
Length under test force ... 60.2t mm (2.374 inch)
Test force 460 t 23 N (103.4 i 5.2 tb)
Free length after test 74.8 mm (2.94 inch)
Outside diameter 43.47 mm (1.711 inch)
(2) 316-5977 Spnng

Quantity ...................... 4
Length under test force ....... 57.5 mm (2.26 inch)
Test force 248.0 t 12.4 N (55.8 I 2.8 tb)
Free length after test 71.4 mm (2.8,| inch)
(3) Install the valve stem seal to the inlet valves. Typical example
(4) Install the washer to the exhaust valves. (F) Diameter of the valve seat inserts
(B) Dimension for the valves lnlet .. 60.627 t 0,015 mm (2.3869 r 0.0006 inch)
Exhaust 60.119 + 0.015 mm
Diameter of the inlet valve (2 3669 t 0.0006 inch)
stem ,. 9.441 1 0.010 mm (0.3717 t 0.0004 inch)
Diameter of the exhaust valve (G) Angle of the face of the valve seat inserts
stem 12.464 r 0.025 mm
(0.4907 r 0.0010 inch) Inlet 20.00 t 0.25 degrees
Exhaust 45.00 t 0.25 degrees
(c) Bore in cylinder head for valve seat inserts
(H) Depth of bore in the cylinder head for the valve
lnlet .. 60.508 t 0.025 mm (2.3822 t 0.0010 inch) seat insert 16.00 r 0.15 mm
Exhaust 60.000 r 0.025 mm (0.630 t 0.006 inch)
(2.3622 t 0.0010 inch)
(J) Outside diameter of the face of the valve seat
(5) Valve guide 53.6 mm (z tt incf
Bore of the inlet valve guide after
installation 9.487 ! 0.025 mm
(0.3735 r 0.0010 inch)
Bore of the exhaust valve guide after
installation ......... 12.619 r 0.025 mm
(0.4968 t 0.0010 inch)
(D) Valve face angles

..,.........
Inlet t 0.25 degrees
.... 19.40
Exhaust t 0.2b degrees
44.40
(E) Diameter of the valve head ..... 56.00 t 0.15 mm

(2.205 t 0.006 inch)
RENR9362-08 27
i03022679
Turbocharger Oil Lines

SMCS Code: 1052;1307
Part No.: 162-5719
S/N: LLA1-Up
----lJ-.J-l-r{-
Part No.: 162-5719
S/N: LLB1-Up
Part No.: 162-5719
S/N: LLC1-Up
Part No.: 162-5719
S/N: C8E1-Up
Part No.: 162-5719
S/N: LLEI-Uo
Part No.: 162-5719
S/N: LLF1-Up
Part No.: 162-5719
S/N: CBK1-Up Right side view of engine
Part No.: 162-5719 (1) Apply 4C-5599 Anti-Seize Compound to the

S/N: PESl-Up threads and the bearing surface of eight bolts.
Part No.: 162-5719 (2) Lubricate the bore of the seven O-ring seals
S/N: RMSI-Up lightly with clean engine oil or with an approved
equivalent lubricant.
Part No.: 162-5719
S/N: T2X1-Up
(3) Lubricate the bore of the elbow assembly
lightly with clean engine oil or with an approved
Rear view of engine

28 RENR9362-08
i03022677
Turbocharger Oil Lines

SMCS Code: 1052;1307
Part No.: 111-3424
S/N: LLB1-Up
PartNo.:101-1255
S/N: SBG1-Up
Part No.: 101 - 1255, 1 11-3424
S/N: SBJl-Uo
Part No.: 101 - 1 255, 272-6983
S/N: SBK1-Up
Part No.: 272-6983
S/N: SBMl-Up
Part No.: 101 - 1255
S/N: T2X1-Up
Typical example
Rear view of engine
(1) Apply 4C-5599 Anti-Seize Compound to the

threads and the bearing surface of 32 bolts.
(2) Lubricate the bore of the eight O-ring seals lightly

with the lubricant that is beino sealed.
Typical example
Front view of engine
RENR9362-08 29
i03022661 i03022663
Turbocharger Oil Lines Turbocharger Oil Lines

SMCS Code: 1052;1307 SMCS Gode: 1052',1307
Part No.: 261 -6791, 286-0615, 294-0092, Part No.: 282-8782
295 - 0657 S/N: T2X1-Up
S/N: RlAl-Up
Part No.: 261 -6791
S/N: R151-Up
Part No.: 261-6791
S/N: RTX1-Up
(1) Lubricate the seven O-ring seals with glycerin or

with an equivalent lubricant.

(3) Lubricate the bore of eight O-ring seals lightly

with the lubricant that is being sealed or with 901528421
lllustration 45
Rear view of engine
(1) Lubricate the five O-ring seal lightly with glycerin

or with an approved equivalent lubricant.

30 RENR9362-08
(3) Lubricate the bore of the eight O-ring seals lightly

with the lubricant that is being sealed or with an
approved equivalent lubricant.
i03034841
Turbocharger
SMCS Code: 1052
Part No.: 333-2242
S/N: C8E1-Up
Part No.: 268-0009
S/N: LLE1-Up
Part No.: 333-2235
S/N: CBK1-Up
Note: Before assembly, lubricate the threads of

the bolts and the bearing surfaces 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 t 5 N.m

(40r4tbft).
2. Tighten bolts (4) in any sequence to 54 r 5 N.m
(40r4tbft).
Illustration 46 901 6161 1 7
Note: Before assembly, lubricate the threads of

the bolts and the bearing surfaces with 4C-5599
(1) Torque for eight bolts ..... 54 I 5 N.m (40 r 4 tb ft)
Use the following procedure to tighten the clamp

assembly (5) and turbine clamp assembly (6):
1. Tighten the clamp assemblies to 13.6 t 1.0 N.m

(120 ! 9 lb in).
2. Gently tap around the clamp assemblies with a

soft faced hammer.
RENR9362-08 31
3. Again, tighten the clamp assemblies to

13.6 + 1.0 N.m (120 ! 9 lb in).
i03577280
Turbocharger
SMCS Code: 1052
Part No.: 261-7279
S/N: LLC1-Up
Part No.: 261-7279
S/N: LLE1-Up
Typical example
Use the following procedure to tighten two band

clamps (3) :
1. Tighten two band clamps to 9.5 t 1.0 N.m

(84.1 t 8.9 lb in).
2. Gently tap around the band clamps with a soft

faced hammer.
3. Again tighten two band clamps to 9.5 t 1.0 N.m

901 905875
(84.1 ! 8.9 lb in).
lllustration 49
Typical example Use the following procedure to tighten two turbine
clamp assemblies (4) and two clamp assemblies (5):
(1) Torque for eight locknuts 54t5N.m
(40r4rbft) 1. Tighten four clamp assemblies to 14.0 t 1.5 N'm
(123.9 t 13.3 lb in).
(2) Lubricate the threads of the bolts and the bearing
surfaces with the lubricant 4C - 5599 Anti-Seize 2. Gently tap around the clamp assemblies with a
Compound before assembly. soft faced hammer.
3. Again tighten the four clamp assemblies to

t
14.0 1.5 N.m (123.9 t
13.3 lb in).
32 RENR9362-08
i03411202
Turbocharger
SMGS Code: 1052
Part No.: 250-6111
S/N: LLAI-Uo
Part No.: 159-8828, 250-6111
S/N: LLBl-Uo
Part No.: 250-6111
S/N: LLFI-Up
Part No.: 159 - 8828
S/N: PESI-Up
Part No.: 250-6111
S/N: RMSI-Up
A-A B-B

bolts for the half flange (2):
1. Tighten bolts (3) in any sequence to 54 t 5 N'm

(40t4rbft)
2. Tighten bolts (4) in any sequence to 54 t 5 N'm
(40r4rbft).
901616117
(5) Cartridge's bolt torque ...40 r 2 N'm (30 r 1 lb ft)
lllustration
o
51
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 r 5 N.m (40 r 4 tb ft)

RENR9362-OB 33
i03034522 1. Tighten the eight clamp assemblies to

Turbocharger 14.0 !'1.5 N'm (125 t 13 lb in).
SMCS Gode: 1052 soft faced hammer.
Part No.: 274-3879
S/N: SBGl-Up 3. Again tighten the eight clamp assemblies to
14.0 ! 1.5 N.m (125 ! 13 lb in).
Front View
(1) Before assembly, apply 4C-5599 Anti-Seize

Compound to the threads and to the bearing
surface of the 16 bolts.
g0 I 446530
lllustration 54
Use the following procedure to tighten the four turbine

clamp assemblies (2) and the four compressor clamp
assemblies (3):
34 RENR9362-08
Use the following procedure to tighten the four band i03577308

clamps (4):
Turbocharger
1. Tighten the four band clamps to 9.5 t 1.0 N'm
(85r9rbin). SMCS Code: 1052
2. Gently tap around the band clamps with a soft Part No.: 280-2938
faced hammer. S/N: LLF1-Up
3. Again tighten the four band clamps to 9.5 t 1.0 N.m

(85t9lbin).
(1) Torque for eight locknuts 54 r 5 N.m

(40r4tbft)
(2) Lubricate the threads of the bolts and the bearing
surfaces with the lubricant 4C - 5599 Anti-Seize
Compound before assembly.
RENR9362-08
i03037223
Turbocharger
SMCS Code: 1052
Part No.: 283-2447
S/N: R1A1-Up
Part No.: 357 -2151
S/N: R1S1-Up
Part No.: 283-2447
S/N: RTX1-Up
Typical example
Use the following procedure to tighten two turbine

clamp assemblies (3) and two clamp assemblies (4):
1. Tighten four clamp assemblies to 14.0 t 1.5 N'm

(123.9 t 13.3 lb in).

soft faced hammer.
3. Again tighten four clamp assemblies to

14.0 ! 1.5 N'm (123.9 t 13.3 lb in). lllustration 58 901541115
Front view
(1) Before assembly, apply 4C-5599 Anti-Seize

Compound to the threads and to the bearing
surface of the 16 bolts.
901 446530
lllustration 59
36 RENR9362-08
Use the following procedure to tighten clamp i03468903

assemblies (2) and (3)for the cartridges:
Turbocharger
1. Tighten the eight clamp assemblies to
14.0 r 1,5 N.m (125 t 13 tb in). SMCS Gode: 1052
2. Gently tap around the clamp assemblies with a Part No.: 268 - 4027, 27 4 - 3881
soft faced hammer. S/N: SBJl-Up
Part No.: 267 - 14O1, 274 - 3883
3. Again tighten the eight clamp assemblies to S/N: SBKI-Uo
14.0 t 1.5 N.m (125 ! 13 lb in).
Part No.: 296-5671
S/N: SBMl-Up
lllustration 60 901 5411 1 6
Right side view

g0 440892
lllustration 61 1
Use the following procedure to tighten the four band Front view
clamps (4):
Note: Before assembly, apply 4C - 5599 Anti-Seize
1. Tighten the four band clamps to 20 r 1 N.m Compound to the threads and to the bearing surface
(15r1tbft). of the bolts.
2. Gently tap around the band clamps with a soft (1) Torque for 16 bolts ....... 55 t 10 N.m (41 t7b O
faced hammer.
3. Again tighten the four band clamps to 20 r 1 N'm

(15t1rbft).
37
RENR9362-08
901 446530
lllustration 62
Use the following procedure to tighten the four turbine

clamp assemblies (2) and the four compressor clamp
assemblies (3):
1. Tighten the eight clamp assemblies to

14.0 t 1.5 N'm (125 x 13 lb in).

soft faced hammer.
3. Again tighten the eight clamp assemblies to

14.0 ! 1.5 N'm (125 t 13 lb in).
901 440900
lllustration 63
Right side view
Use the following procedure to tighten the four band 1. Tighten the four band clamps to 9'5 t 1.0 N'm
clamps (4): (85t9lbin).
3B RENR9362-08
2. Gently tap around the band clamps with a soft io3414341

faced hammer.
Turbocharger
3. Again tighten the four band clamps to 9.5 t 1.0 N.m
(85t9lbin). SMCS Code: 1052
Part No.: 307-7553
i03577562 S/N: PES1-Up
Turbocharger
SMCS Code: 1052
Part No.:255-9141
S/N: T2X1-Uo
lllustration 64 901 9061 34 lllustration 65 901616117
Use the following procedure to tighten the clamps ('1) Note: Before assembly, lubricate the threads and the
on the bellows assembly: bearing surface of the bolts with 4C - 5599 Anti-Seize
Compound.
1. Tighten the clamps to 20 t 5 N'm (17T t44 tb in).
('1) Torque for the bolts to the exhaust
2. Gently tap around the clamps with a soft faced manifold ...... 54 r 5 N.m (40 r 4 tb ft)
hammer.
3. Again, tighten the clamps to 20 t 5 N.m

(177 ! 44 lb in).
Use the following procedure to tighten the turbine

clamp assemblies (2) and the compressor clamp
assemblies (5):
1. Tighten the clamp assemblies to 14.0 t 1.5 N.m

(123.9 t 13.3 tb in).

soft faced hammer.
3. Again, tighten the clamp assemblies to

14.0 ! 1.5 N.m (123.9 t 13.3 lb in).
Note: Before assembly, apply 4C-5599 Anti-Seize

Compound to the washer face and threads of the
bolts (3).
(4) Torque for the locknuts . b5 t 10 N.m

(41 r7tbft)
RENR9362-08 39
i03670320
Exhaust Manifold
SMCS Gode: 1059
Part No.: 334-7039
S/N: CBEI-Up
Part No.: 334-7039
S/N: C8K1-Up
B-B

bolts for the half flange (2):
1. Tighten bolts (3) in any sequence to 54 t 5Nm

(40r4rbft). Note: Before assembly, lubricate the threads and
the bearing surfaces of the bolts with 4C-5599
2. Tighten bolts (4) in any sequence to 54 t 5 N'm Anti-Seize Compound.
(40 14 rb ft).
(1) Torque for the bolts ........ 50 r 5 N.m (37 t 4 lb ft)
(5) Cartridge's bolt torque ...40 t 2 N.m (30 r 1 lb ft)
40 RENR9362-OB
i03670285 i03114039
Exhaust Manifold Exhaust Manifold

SMCS Code: 1059 SMCS Code: 1059
Part No.: 334-7036 Part No.: 161 -2502
S/N: C8E1-Up S/N: LLAI-Uo
Part No.:334-7036 Part No.: 161-2502
S/N: CBKI-Up S/N: LLBl-Up
Part No.: 161-2502
S/N: LLC1-Up
Part No.: 161-2502
S/N: C8E1-Up
Part No.: 161-2502
S/N: LLEl-Up
Part No.: 161-2502
S/N: LLF1 -Up
Part No.: 161 -2502
S/N: CBKI-Uo
Part No.: 167-1759
S/N: PESl-Up
Part No.: 161-2502
S/N: RMSl-Up
Part No.: 161-2502
901 970475
S/N: T2X1-Up
lllustration 6B
Note: Before assembly, lubricate the threads and

(1) Torque for the bolts ........55 r 5 N.m (41 t 4 tb ft)
(2) Torque for the bolts ........ 50 r 5 N.m (37 r 4 tb ft)
Typical example
Top view of engine
41
RENR9362-08
i03601 824
Exhaust Manifold
SMCS Gode: 1059
Part No.: 172-0921
S/N: LLAI-Up
Part No.: 172-0921
S/N: LLB1-Up
Part No.: 172-0921
S/N: LLC1-Up
Part No.: 172-0921
901 592373 S/N: C8E1-Up
lllustration 70
Rear view of engine Part No.: 172-0921
S/N: LLE'1-Up
Note: Apply 4C-5599 Anti-Seize Compound to the
threads of the bolts and to the face of the washers. Part No.: 172-0921
Tighten diagonally opposite bolts simultaneously' S/N: LLF1-Up
(1) Torque for the bolts ......., 55 t 5 N'm (41 r 4 lb ft) Part No.: 172-0921
S/N: C8K1-Up
Part No.: 172-0921
S/N: RMSl-Up
Part No.: 172-0921
S/N: T2X1-UP
9o1927073
lllustration 71

Compound to the threads and the bearing surfaces
of the bolts.
(1) Torque for the bolts ........ 55 t i 4 lb ft)

5 N'm (41
(2) Torque for the bolts ........ 50 t 5 N'm (37 i 4 lb ft)

42 RENR9362-08
i03664360
Exhaust Manifold
SMCS Gode: 1059
Part No.: 1 44 -2876. 283 - 1557. 288-5986
S/N: LLC1-Up
Part No.: 144 -2876, 1 91 - 8391 , 283 - 155Z
S/N: LLE1-Up
Note: Before assembly, lubricate the threads and

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

(2) Torque for the bolts ........ 50 t 5 N.m (37 r 4 tb ft)
43
RENR9362-08
i03080401
Exhaust Manifold
SMCS Gode: 1059
Part No.: 265 - 6794, 270 - 9300
S/N: SBGI-Up
901 5631 59
lllustration 74
901 5631 63
lllustration 73
(4) Torque for nine bolts ...... 55 t 5 N'm (41 t 4 lb ft)
Front view
Note: Before assembly, apply 4C-5599 Anti-Seize i0'1967429
Compound to the threads and the bearing surfaces

of the plugs. Exhaust Manifold
(1) Torque for four p1u9s......20 t 5 N'm (15 t 4 lb ft) SMCS Code: 1059
Use the following procedure in order to tighten the Part No.: 297 -6327
bolts (2) :
S/N: LLF1-Up
1. Opposite bolts of each exhaust manifold are

snug diagonally in order to seat the exhaust seal
uniformly.
2. Tighten 24 bolts to 55 t 5 N'm (41 t 4 lb ft).

(3) Torque for 48 bolts ......... 50 t 5 N'm (37 t 4 lb ft)
Reor View
900952099
lllustration 75
44 RENR9362-08
(1) Bolt
Apply 5P-3931 Anti-Seize Compound to the
threads and the bearing surfaces.
Torque ......... 55 t 5 N.m (41 r 4 tb ft)
(2) Bolt
Put 5P-3931 Anti-seize Compound on the
threads of the bolts and washer face that hold
exhaust manifolds to the cylinder head.
Torque ......... 50 t 5 N.m (37 r 4 tb ft)
i02940996
Exhaust Manifold
SMCS Gode: 1059
Part No.: 282-8422
S/N: RlAl-Up
Part No.: 282-8422
S/N: RlSl-Up
Part No.: 282-8422
S/N: RTXI-Up
Top view of engine
Use the following procedure to tighten the bolts (2):

Compound to the threads and to the bearing surface
of the bolts (2).
1. Opposite bolts of each exhaust manifold are

snug diagonally in order to seat the exhaust seal
uniformly.
2. Tighten 32 bolts to 55 t 5 N.m (41 i 4 tb ft).
Front view of engine Note: Before assembly, apply 4C-5599 Anti-Seize
Note: Before assembly, apply 4C-5599 Anti-Seize of the bolts (3).
of the plugs (1). (3) Torque for48 bolts .........50 t 5 N'm (37 r 4 tb ft)
(1) Torque forfour plugs......20tS N.m (1S r 4 tb ft) (4) Torque for five bolts ..... 55 t 10 N.m (41 !7 tbft)
RENR9362-08 45

threads of the plug.
(1) Torque forthe plug.... 20 t 5 N.m (177 t44 lb in)

threads of the bolts.
(2) Torque for the bolts ......., 50 t 5 N.m (37 r 4 lb ft)
Right side view of engine

of the bolts (5).
(5) Torque for eight bolts ... 55 r 10 N.m (41 r 7 lb ft)
lllustration B0 901 98461 4

i03690280
Exhaust Manifold
(3) Torque for the clamp ..25 ! 5 N'm (221 t 44 lb in)
SMCS Code: 1059
Part No.: 282-8423 threads of the bolts.
S/N: RIA1-Up
(4) Torque forthe bolts ...... 55 f 10 N.m (41 t 7 lbft)
Part No.: 282-8423
S/N: R151-Up
Part No.: 282-8423
S/N: RTX1-Up
901 98461 3
lllustration 79
46 RENR9362-08
03468922 Note: Before assembly, apply 4C-5599 Anti-Seize

Exhaust Manifold of the bolts (2).
SMCS Gode: 1059 (2) Torque for 64 bolts ,........ 50 t 5 N.m (37 r 4 lb ft)
Part No.: 264-7866
S/N: SBJl-Up
Part No.: 264-7866
S/N: SBK1-Up
Part No.: 264-7866
S/N: SBMl-Up
lllustration B3
Right side view

of the bolts (3).
(3) Torque for eight bolts ..... 55 r 5 N.m (41 r 4 lb ft)
i02549877
Exhaust Manifold
SMGS Code: 1059
lllustration B1 901440496
Front view Part No.; 281 -6063

S/N: T2X1-Up
_t
I
o
I
t
Top view

of the bolts.
(1) Torque for 48 bolts .......55 t 10 N'm (41 t 7 lb ft) lllustration 84 901 276369
(1) Plug
47
RENR9362-OB
i02659920
threads.
Exhaust Shield
Torque ........,20 t 5 N'm (15 t 4 lb ft)
SMCS Gode: 1067
(2) Bolt
Part No.: 1 48 -6854, 235 -7 173, 321 -3848
Torque ...25 t 6 N'm (18.5 t 4'5 lb ft) S/N: LLBl-Up
(3) Bolt Part No.: 148 - 6854

S/N: PESl-Up
threads. Tighten the bolts that hold the exhaust
manifolds to the cYlinder head.
Torque ......... 50 t 5 N'm (37 t 4 lb ft)
901 336344
lllustration 86
Right side view
(1) 5/16 Bolt

901276382
lllustration B5
(2) 3/B Bolt
(4) Bolt
Apply 4C - 5599 Anti-Seize Compound to.th.e threads
Apply 5P-3931 Anti-Seize Compound to the and ifre bearing surfaces for bolts (1) and (2).
threads. Tighten the bolts that hold the exhaust
manifolds to the cYlinder head.
Torque ......... 50 t 5 N'm (37 t 4 lb ft)
48 RENR9362-08
i02953003 i03530163
Exhaust Flange Exhaust Flange

Part No.: 7N-6962 Part No.: 2W-7756
S/N: RlAl-Up S/N: LLAI-Up
S/N: LLB1-Up S/N: RlAl-Up
S/N: LLC1-Up S/N: LLBl-Up
S/N: C8E1-Up S/N: SBG1-Up
S/N: LLE1-Up S/N: SBJl-Up
Part No.: 7N-6962 Paft No.: 2W-7756
S/N: SBGl-Up S/N: SBK1-Up
S/N: C8K1-Up S/N: SBMl-Up
S/N: R151-Up S/N: PESl-Up
S/N: T2X1-Up S/N: RMSl-Up
Part No.: 2W-7756
S/N: T2X1-Up
901468407
lllustralion B7
-.------
Typical example
lllustration 8B 901 858820

threads of 12 bolts. Typical example

49
RENR9362-08
i026541 81
i02952998
Exhaust Flange Exhaust Flange

SMCS Code: 1061 SMCS Gode: 1061

S/N: SBGl-Up S/N: LLAI-Up

S/N: SBJ1-Up S/N: R141-Up
Part No.: 7N - 6961 Part No.: 1W-9488

S/N: SBK1-Up S/N: LLBl-Up
Part No.: 7N-6961 Part No.: 1W-9488, 295-0739

S/N: R1S1-UP S/N: SBJl-UP

S/N: T2X1-Up S/N: SBK1-UP
g0 1 468348 901 332839

lllustration B9 lllustration 90
(1) Apply 4C-5599 Anti-Seize Compound to the (1) Bolt

threads of eight bolts.
Apply 4C-5599 Anti-Seize Compound to the bolts'
50 RENR9362-08
i02952392
Exhaust Flange Exhaust Fitting

SMCS Gode: 1061 SMCS Code: 1061-X6
Part No.: 2W-7871 Part No.: 1W-9487, 7N-6967
S/N: LLA1-Up S/N: LLA1-Up
Part No.: 2W-7871 Part No.: 7N-6968
S/N: LLBl-Up S/N: RlAl-Up
Part No.: 2W-7871 Part No.: 1W-9487, 4P-3363, 7N-6967, 7N-6969
S/N: LLFI-Up S/N: LLBl-Up
S/N: SBJl-Up S/N: LLCl-Uo
S/N: PES1-Up S/N: C8E1-Up
S/N: R151-Up S/N: LLEl-Up
S/N: T2X1-Uo S/N: LLF'1-Up
Part No.: 7N-6968
S/N: SBG1-Up
Part No.: 137-5555, 7N-6967
S/N: SBJl-Up
Part No.: 7N - 6968
S/N: C8K1-Up
Part No.: 1 37 - 5555
S/N: SBK1-Up
Part No.: 1W-9487, 4P-3363, 7N-6967
S/N: PESl-Up

Part No.: 7N-6968
S/N: R151-Up
Typical example
Part No.: 1W-9487, 7N-6967
(1) Apply anti-seize compound to the threads of the S/N: RMS1-Up
bolts.
Part No.: 4P-3363, 7N-6967, 7N-6968
S/N: T2X1-Uo
RENR9362-08 51
(1) Bolts i02954024
Apply 4C-5597 Anti-Seize Compound to the bolts. Air Gleaner Adapter

SMCS Code: 1051
i0 1 659336
Part No.: 7W-9828
Air Cleaner S/N: LLA1-Up
SMCS Code: 1051 Part No.:7W-9828

S/N: R1A1-UP
Part No.: 5N-8728
S/N: LLC'1-Up Part No.: 7W-9828
S/N: LLBl-Up
Part No.:5N-8728
S/N: LLE1-Up Part No.: 7W-9828
S/N: LLCl-Up
Part No.: 5N-7904
S/N: LLF1-Up Part No.: 7W-9828
S/N: C8E1-Up
Part No.: 7W-9828
S/N: PES'1-Up
Part No.: 7W-9828
S/N: RMSl-Up
901 469799
9008561 59 lllustration 94
lllustration 93
(1) Washer (1) Torque for 48 locknuts ............. 12r4N'm

(105 t 35 lb in)
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 t 4 N'm (9 t 3 lb ft)
(3) Washer
ln order to align the precleaner with the air cleaner,

use the 8T - 41 22 Hard Washers as spacers for the
precleaner.
52 RENR9362-08
io2954o22 io2B94B87
Air Cleaner Adapter Engine Air Cleaner Service

SMCS Code: 1051 Indicator
Part No.: 4P -2013 SMCS Code=7452
S/N: LLB1-Up
Part No.: 213 - 1 412. 7N -6782
Part No.: 4P -2013 S/N: LLA1-Up
S/N: PES1-Up
Part No.: 213 - 1 412, 286-5736, 7N - 6782
S/N: R141-Up
Part No.: 213 - 1 412, 7N-6782
S/N: LLBl-Up
Part No.: 213 - 1 412. 7N -6782
S/N: LLC1-Up
Part No.: 335 - 1 903, 335 - 551 6
S/N: C8E1-Uo
Part No.: 213 - 1 412, 7N -6782
S/N: LLE1-Up
Part No.: 213 - 1 412, 7N-6782
901469798
S/N: LLFl-Up
lllustration 95
Part No.: 7N-6782
(1) Torque for 28 locknuts ............... ........ 12 r 4 N.m S/N: SBGl-Up
(105 t 35 lb in)
Part No.: 7N-6752
S/N: SBJl-Uo
i03114005
Part No.: 335 - 1 903, 335 - 551 6
Air Cleaner Adapter S/N: C8K1-Uo
SMCS Gode: 1051 Part No.:7N-6782
S/N: SBKl-Up
Part No.: 115-3612
S/N: SBJl-Up Part No.: 7N-6782
S/N: SBMl-Up
Part No.: 115-3612
S/N: SBK1-Up Part No.: 213 -'l 412, 7N -6782
S/N: PES1-Up
Part No.: 115-3612
S/N: T2X1-Up Part No.: 7N-6782
S/N: R151-Up
Part No.: 213 -'l 41 2, 7N - 6782
S/N: RMS1-Up
Part No.: 7N-6782
S/N: RTX1-Up
Part No.: 7N-6782
S/N: T2X1-Up
g0'1592329
lllustration 96
(1) Torque for 32 bolts .... 12 t 4 N.m (105 r 35 tb in)

RENR9362-08 53
i0401 3955
Air Lines
(Air Starting Lines)
SMCS Gode: 1058; 1071
Part No.: 8N-8481
S/N: LLAI-Up
Part No.: 8N - B4B1 , 8N - 8489
S/N: LLBI-Uo
Part No.: 8N-8481
S/N: LLC1-Up
Part No.: 8N - 8481
S/N: LLEl-Up
Part No.: 8N-8481
S/N: LLFI-Up
g0 1 440984 Part No.:8N-8481
lllustration 97
S/N: PES1-Up
Rear view of engine
(1) Air cleaner Part No.: BN-8481
S/N: RMSl-Up
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 t 0.7 N'm (18 t 6 lb in)
Right side view
(1) Apply Loctite 574to the threads of the fittings that

is mounting on the relay valve group (4) end.
(2) Apply white Loctite Low Breakloose PST to the

threads of the fittings.

threads of the elbow
54 RENR9362-08
i0401 4069
Air Lines
(Air Starting Lines)
SMCS Gode: 1058: 1071
Part No.: 7W-9269
S/N: LLA1-Up
Part No.:7W-9269
S/N: R141-Up
Part No.: 7W-9269
S/N: LLBl-Up
Part No.: 7W-9269
S/N: LLC1-Up
Part No.: 7W-9269
S/N: LLEl-Up
Part No.: 7W-9269
S/N: LLF1-Up
Fronl view
Part No.: 7W-9269
(5) Apply white Loctite Low Breaktoose PST to the S/N: PES1-Up
threads of the pipe nipples.

threads of the pipe coupling.
,o
lllustration 100
Apply white Loctite Low Breakloose PST to the

threads of the reducing bushing (1), flared elbow (2),
pipe nipple (3), elbows (4) and fittings (5).
This system is designed to operate between 620 kPa

(90 psi) and 1034 kPa (150 psi) of air pressure. tf the
air pressure exceeds 1034 kPa (150 psi), a regulator
must be used.
Do not use this system with natural gas that has more
than 0.1 percent hydrogen sulfide.
RENR9362-08 55
i04014132 i03690345
Air Lines Air Lines

(Air Starting Lines) SMCS Code: 1058; 1071
SMCS Gode: 1058; 1071 Part No.: 250-4642
S/N: SBGl-Up
Part No.: 207 - 4476
S/N: SBGl-Up
Part No.: 207 -4476
S/N: SBJl-Up
Part No.: 2O7 -4476
S/N: SBKI-Up
Part No.: 207 - 4476
S/N: RMS1-Up
g0'1984653
lllustration 102
Top view of engine
(1) Torque for the U-bolts ..... 15t2Nm

(133 r 18 tb in)
9021 90233
lllustration 101
Lefl side view
(1) Apply Loctite 574 to the threads of the fitting that

is mounting on the relay valve group end (5).

threads of the fittings.

threads of the elbow.
(4) Apply Loctite 574 to the threads of the elbow that

is mounting on the relay valve group end (5).
This system is designed to operate between 620 kPa

(90 psi) and 1034 kPa (150 psi). lf the pressure
exceeds 1034 kPa (150 psi), a regulator must be
used.
Do not use this system with natural gas that has more
than 0.1 percent hydrogen sulfide.
56 RENR9362-08
i03717526
Air Lines
SMCS Gode: 1058; 1071
Part No.: 2W-9595
S/N: LLBl-Up

Top view of engine
o
A.A

(1) Lubricate the bore of the O-ring seats lightly with (2) Torque for the pipe plugs 20t 5 N.m
glycerin or an approved equivalent. (177 ! 44 lb in)
of the pipe plugs.
57
RENR9362-08
i03577501
Air Lines
SMCS Gode: 1058; 1071
Part No.: 286-0638
S/N: RlAl-Up
g0 1 4 57949
lllustration 106

of the bolts (4).
901 457940
(4) Torque for eight bolts 10 N.m (41 i 7lb ft)
lllustration 105
Top view of engine
i03991 830
.... 15t2N'm
(1) Torque for four U-bolts
(133 I 18 lb in) Air Lines
SMCS Code: 1058; 1071
Use the following procedure to tighten 16 clamps (2):
Part No.: 356 - 3314
1. Center the clamps within the marking on the hose. S/N: R1S'1-Up
2. Orient the clamps so that the T-bolts are separated
by 90 degrees.
3. Tighten the clamps to 1O t 2 N'm (88 t 18 lb in).
(3) Lubricate the bore of the O-ring seals with

glycerin or an approved equivalent.
902171094
lllustration 107
Top view of engine
58 RENR9362-08
(1) Torque forthe U-bolts 15t2N.m

(133 t 18lb in)
(2) Do not crush the insulation shied assembly
during assembly. Assemble the insulation shield
assembly with springs and hooks at the top of
the hose reducer.
i03991 890
!,TE-[_IT"TD
Air Lines
SMCS Code: 1058; 1071
Part No.: 353-7974
S/N: R1S1-Up lllustration 109 902171133
(3) Torque for bolts 50 r 10 N.m (37 r 7 tb ft)
Air Lines
SMCS Code: 1058; 1071
Part No.: 1 15-3613, 208-0821 ,278-3525
S/N: SBJl-Up
Part No.: 2Og - 0821, 278 - 3526
S/N: SBK1-Up
Part No.: 278-3526
S/N: SBMl-Up
Part No.: 285-4161
S/N: T2X1-Up
Use the following procedure to tighten the clamp (1):
L Center the clamps within the markings on the

hose.

by 90 degrees.
3. Tighten the clamp to 9 t 2 N.m (80 t 18 lb in)
(2) Lightly lubricate the bore of the O-ring seals with lllustration 110 900954951
5P - 3975 Rubber Lubricant.
(1) Nuts for U-bolts ,
Torque 15 t2 N.m (11 i 1 lb ft)

59
RENR9362-OB
i02656371 Tighten the bolts in the sequence in lllustration

112.
Air Lines Torque ,....90 r 20 N'm (66 t '15 lb ft)
SMCS Gode: 1058; 1071
i03532280
Part No.: 281 -0585, 293-2059
S/N: RTXI-UP Air Lines
SMCS Code: 1058; 1071
Part No.: 284-6868
S/N: RTX1-Up
901 334549
lllustration 111
s018623e5
lllustration 11 3
Left side view
(1) Coupling AssemblY

Minimum depth for insertion of both the
ends..........
Torque for the Coupling assembly "...20 t 2 N'm
(177 ! 18 lb in)
(2) Torque for four clamPs 3.5 to 4.0 N'm

(31.0 to 35.4 lb in)
901 334567
lllustration 112
Detail A
Bolt tightening sequence
(1) Bolts
RENR9362-08
i03685300

SMCS Gode: 1058; 1061
Part No.: 334-4667
S/N: CBE1-Up
Part No.: 334-4666
S/N: C8K1-Up
Itr
19u
.tr - r
[." lutf, l.l ,I
l
(1) Lubricate the bore for the O-ring seals tightty *itJ
lllustration 114 90.1984513 Note: Before assembly, lubricate the threads of the
Typical example
plugs with 4C- 5599 Anti-Seize Compound.
(2) Torque forthe plugs .. 25 t 5 N'm (221 t 44 tb in)
(3) Use the following procedure in order to assemble

the aftercooler assembly and tighten the bolts:
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. lnstall the aftercooler cover.
6. Inspect the upper seal in order to ensure that the

7. Install the cover bolts. Hand tighten the cover

bolts.
8. Tighten the bolts in a numerical sequence that is

shown in lllustration 116 to 24 N'm (212lbin).
9. Again, tighten the bolts in a numerical sequence

tn-at is shown in lllustration 116 to 47 N'm (35 lb ft).
10. Remove the taPe.

RENR9362-OB

SMCS Code: 1058; 1061
Part No.: 261-7281
S/N: LLCl-Up
Part No.: 261 -7281, 268 - 001 5
S/N: LLE1-Up
ol- -lo
lllustration 'l17 901614656

RENR9362-08 63
i02438646

SMCS Code: 1058; 1061
IF
19u ls
.tr - r Part No.: 244-1856
S/N: LLAI-Up
JtiH, ,t:
I
Part No.: 244-1856

il; S/N: LLBl-Uo
Part No.: 244- 1856, 268 - 0010
S/N: LLFl-Up
Part No.: 244-1856
lllustration 118 901614673 S/N: RMSl-Up
(1) Lubricate the bore for the O-ring seals lightly with

the aftercooler assembly and tighten the bolts:
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.
901 21 8564
lllustration 119
3. Assemble the aftercooler with seals to the inlet
manifold. Typical example
4. Inspect the bottom seal in order to ensure that the (1) Plus
Apply 4C-5598 High Temperature Anti-Seize to
the threads of the plug.
Torque .........20 i 5 N'm (15 f 4 lb ft)
7. Install the cover bolts. Hand tighten the cover

bolts.
8. Tighten the bolts in a numerical sequence that is

shown in illustration 118 to 24 N'm (18 lb ft).
900280590
lllustration 120
9. Again, tighten the bolts in a numerical sequence Bolt tightening sequence (3512)
that is shown in illustration 118 to 47 N'm (35 lb ft).
(2) Bolt
10. Remove the tape.
Use the following procedure to tighten the bolts for
Note: Before assembly, lubricate the threads of the the aftercooler:
plugs with 4C-5599 Anti-Seize Compound.
1. Assemble seals to the aftercooler core.
(3) Torque for two plugs ...... 25 i 5 N.m (18 ! 4 lb ft)
2. Temporarily secure the bottom sealwith tape. Do
not use an adhesive, a silicone lubricant, or any
other lubricant for retention of the seal.
3. Assemble the aftercooler with the seals to the

inlet manifold.
64 RENR9362-08
4. Inspect the bottom seal in order to ensure that the i0265411 I

seating in the recess is correct.
5. Install the aftercooler cover.
SMCS Gode: 1058: 1061
seating in the recess is correct. Part No.: 283 -2546, 286 - 3045, 297 -5562
S/N: SBGl-Up
7. lnstall the cover bolts and hand tighten the bolts. Part No.: 276-2449,282-8315, 286 -9047,
295 - 6337
8. Tighten the bolts according to the numerical S/N: SBJl-Uo
sequence to the following torque.
Part No.: 282-8315, 295-6337
Torque . 24 N.m (18 tb ft) S/N: SBK1-Up
9. Tighten the bolts again according to the numerical Part No.: 282-8315, 295 - 6337
sequence to the following torque. S/N: SBMl-Uo
Torque . 47 N.m (35 tb ft)

10. Remove the taoe.
.b

AF
RENR9362-08
(1) Bolt
Tighten the bolts in the sequence in I llustration
122.
Torque 88 t 20 N.m (65 r 15 lb ft)
io2444420
Air lnlet and Exhaust Lines lllustration 124

Bolt tightening sequence (3512)
900280590
SMCS Gode:1058; 1061

Part No.: 27 1 - 0559, 272 - 2895, 272- 31 92
S/N: SBG1-Up
Part No.: 272-3501
S/N: SBJl-Up
Part No.: 272-3501
900280589
S/N: T2X1-Up lllustration 125
Bolt tightening sequence (3516)
(3) Bolt
Use the following procedure to tighten the bolts for

the aftercooler:

other lubricant for retention of the seal,

inlet manifold.
lllustration 123 so1221357
Right side (typical example) 4. Inspect the bottom seal in order to ensure that the
(1) Hose clamp assembly
1. Center the clamps within the markings on the
hose. 6. Inspect the upper seal in order to ensure that the
2. Ensure that the T-bolts are spread apart by a
minimum of 90 degrees. 7. Install the cover bolts and hand tighten the bolts.
3. Tighten the clamps. 8. Tighten the bolts according to the numerical

sequence to the following torque.
Torque ....... 10 t 2 N'm (89 r 18 lb in)
Torque .. 24 N'm (18 lb ft)
(2) O-ring
9. Tighten the bolts again according to the numerical
Apply 1 U - 6396 O-Ring Assembly Compound to all sequence to the following torque.
the O-rings.
Torque .. 47 N'm (35 lb ft)
10. Remove the tape.

66 RENR9362-08
i03991 930 2. Orient the clamps so that the T-bolts are separated
Air Inlet and Exhaust Lines by 90 degrees.
3. Tighten the clamps to 10 r 2 N.m (89 t 1B tb in)

SMCS Code: 1058; 1061
Part No,: 288 - 141 9, 289-2861 (2) Do not crush the insulation shield assembly
S/N: RlAl-Up during assembly. Assemble the shield assembly
with the springs and the hooks are at the top of
Part No.: 353-2778 the reducer hose.
S/N: R151-Up
(3) Lightly lubricate the bore of the O-ring seats with
glycerine or approved equivalent.
rL+l
I
"' I'-tlr'i
rll
rll
Itr
\ft=
Top view of engine

Section A-A

-l-ri'-
F..--. ,..-- (4) Torque for high temperature bolts ... SS r 10
lt ttt. N m
(41 !7 tb
b
Rear view of engine
Use the following procedure to tighten the clamp (1): '
1. Center the clamps within the marking on the hose.

67
RENR9362-08
io3534422
i02438923
Air Inlet and Exhaust Lines Air Inlet and Exhaust Lines
SMCS Gode: 1058; '1061 SMCS Gode: 1058; 1061
Part No.: 247 -3012 Part No.: 262-7577

S/N: R1A1-UP S/N: R141-UP
Part No.: 247 -3012 Part No.: 262-7577

S/N: RTX1-Up S/N: RTXI-UP
901 21 8731
lllustration 129
(1) Stud
Torque. ....... 35 r 5 N'm (26 i 4 lb ft)
901 457940
lllustration 130
Top view of engine
(1) Torque for four U-bolts 15t2N'm

('133 t '18 lb in)
Use the following procedure to tighten 16 clamps (2):
1. Center the clamps within the marking on the hose'

by 90 degrees.
3. Tighten the clamps to 10 t 2 N'm (88 t 18lb in).
' Lubricate the bore of the O-ring seals with

(3)
68 RENR9362-08

of the bolts (4).
(4) Torque for eight bolts .,.55 r 10 N.m (41 r 7 tb ft)

RENR9362-08
i02896426

SMCS Code:1058; 1061
Part No.: 272-2894
S/N: SBJl-Up
Part No.: 272-2894
S/N: SBK1-Up
Part No.: 272-2894
S/N: SBMl-Up
lllustration 132
Front view
70 RENR9362-08
lllustration 133
Right side view
(1) Lubricate the bore of the 1B O-ring seals with

i03577421

SMCS Gode: 1058; '1061
Part No.: 286-4392

S/N: PESl-Up
lllustration 135
Use the following procedure to tighten the bolts (2)

for the aftercooler:

other lubricant for retention of the seal.

Note: Before assembly, apply 4C-5599 Anti-Seize inlet manifold.
Compound to the threads of the plug (1).
4. Inspect the bottom seal in order to ensure that the
(1) Torque forthe plugs .. 20 t 5 N.m (177 t44tbin) seating in the recess is correct.
5. Install the aftercooler cover.

seating in the recess is correct,
7. Install the cover bolts and hand tighten the bolts.

RENR9362.08 71
8. Tighten the bolt 1 through bolt 12 to 24 N'm

(18 lb ft) in the numerical sequence.
9. Again, tighten the bolt 1 through bolt 12 to 47 N'm

(35 lb ft) in the numerical sequence.
{0. Remove the tape.
i03688482
Air Shutoff
SMCS Gode: 1078
Part No.: 335 - 1898
S/N: C8E1-UP
Part No.: 335 - 1898
S/N: C8K1-Up
901 98351 7
lllustration 136
(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 rb ft)
72 RENR9362-08
i03601 965
Air Shutoff
SMCS Code: 1078
Part No.: 214-5543
S/N: LLA1-Up
Part No.: 214-5543
S/N: LLB1-Up
Part No.: 214-5543
S/N: LLCl-Uo
Part No.: 214-5543
S/N: LLE1-Up
Part No.: 214-5543
S/N: LLF1-Up
Part No.: 214-5543
S/N: PES1-Uo
Part No.: 214-5543
Note: Apply 4C-5599 Anti-Seize Compound to the S/N: RMSI-Uo
threads of the bolts (3) and to the threads of the bolts
(7).
(3) Torque for the bolts ......... 7 t 1 N'm (62 t 9 tb in)

shaft of the air shutoff assembly.
Note: Before assembly, apply 4C-9614 Silicone

Sealant between the body (5) and the cover (6).
(7) Torque forthe bolts........... 9.5 t 1.5 N.m

(84.1 i 13.3 lb in)
(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 (B) 9.5 r 1.5 N.m
i
(84.1 13.3 tb in)
Rear view
(1) Air shutoff group

Maximum operating temperature of the
valve ,........ 204"C (3gg'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 tb ft)
RENR9362-08 73
i01 957468
Air Shutoff
SMCS Code: 1078
Part No.: 1 12-6597, 27 4 - 57 49
S/N: LLA1-UP
Part No,: 112-6597
S/N: RlAl-Up
Part No.: 112-6597, 274-5749
S/N: LLBl-Up
Part No.: 112-6597, 274-5749
S/N: LLC1-Up
Part No.: 112-6597, 274-5749
S/N: LLEl-Up
Part No.: 1 12 - 6597, 27 4 - 57 49
S/N: LLF1-Up
9O1927222
lllustration 139
Part No.: 112-6597
S/N: SBGl.UP
threads bi fne notts (3) and to the threads of the bolts Part No.: 112-6597
(7). S/N: SBJl-Up
(3) Torque for the bolts ......... 7 t 1 N'm (62 r 9 lb in) Part No.: 112-6597
S/N: SBK'1-Up
shaft of the air shutoff assemblY. Part No.: 112-6597, 274-5749
S/N: PESl-Up
Note: Before assembly, apply 4C-9614 Silicone Part No.: 112-6597, 274-5749
Sealant between the body (5) and the cover (6). S/N: RMSl-Up
(7) Torque for the bolts ........... t
9.5 1.5 N'm
t
(84.1 13.3 lb in)
(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) t
9.5 1.5 N'm
I
(84.1 13.3 lb in)
9009561 04
lllustration 140
74 RENR9362-08
i03602343
Air Shutoff
SMCS Code: 1078
Part No.: 278-7724, 286-5791, 286-5739,
291 - 1 495
S/N: RlAl-Up
Part No.: 287 -7866
S/N: SBG1-Up
Part No.: 284-0621
S/N: SBJl-Uo
Part No.: 284-0621
S/N: SBK1-Up
Part No.: 278-7724
S/N: RTXI-Uo
lllustration 14'l 900986704
(1) Switch assembly

Lubricate the threads of the capscrews with
4C-5598 High Temperature Anti-Seize prior to
assembly.
Torque 12 N.m (106 tb in)
(2) Capscrew
Lubricate the threads of the capscrews with
4C-5598 High Temperature Anti-Seize prior to
assembly.
Torque .........7 r 1 N.m (60 t 9 tb in)
(3) Shaft
Lubricate the shaft with 4C-5598 High Temperature
Anti-Seize prior to assembly.
lllustration 142 s01s50687
(4) Cover Typical example
(1) Air shutoff valve and mounting
Apply aC-9614 Silicone Sealant between the body
and the cover of the air shutoff prior to assembly.
(5) Capscrew
Lubricate the threads of the capscrew with
5598 High Temperature Anti-Seize prior to
4C -
assembly.
Torque ...,.. 10 t 2 N.m (84 t 13 tb in)
(6) Capscrew
Torque ...... 10 + 2 N.m (84 t 13 lb in)
RENR9362-08 75
901 950678
lllustration 143
Rear view of engine
(2) Nominal actuation pressure of the air shutoff

group ........ 117 kPa (17 Psi)
(3) Lightly lubricate the bore of the O-ring seals with lllustration 144 901 927553
glycerin or with an approved equivalent.
Detailed view of air shutoff valve and mounting
(6) Valve manifold
Air shutoff group must not actuate at 14 kPa (2 psi) or
below 14 kPa (2 psi). Air shutoff group must actuate
at 172 kPa (25 psi) or above 172 kPa (25 psi). (5) Solenoid valve group
Fressure should not exceed 690 kPa (100 psi). Nominalvoltage 24VDC
Resistance at 25 t 5 "C
(77 t 9 "F) ............. .32.6 x'1.6 Ohms
Final installation torque for the nut
(4) .. ..... ... 9.0 r 0.5 N'm (79.7 r 4.4 lb in)
Final installation torque for the solenoid valve
group ........ 108 J 7 N'm (80 i 5lb ft)
76 RENR9362-OB
i02662588
Air Shutoff
SMCS Code: 1078
Part No.: 172-0258
S/N: LLB1-Up
Torque 8.0 N.m (71 lb in)
(B) Elbow
(e) Elbow
(1) Elbow
Torque 8.0 N'm (71 tb in)
(2) Connector
Torque 8.0 N.m (71 tb in)
(3) Connector
Torque 8.0 N.m (71 tb in)
(4) Plug
Torque 8.0 N.m (71 tb in) (10) Bolts

(5) Elbow Torque 3t 1N'm(27t9tbin)
Torque 8.0 N.m (71 tb in) (11 ) Apply 6V - 6652 Sealant to the surface of the
gasket.
(6) Elbow

RENR9362-OB
Specification, s..till
i03991 970
Air Shutoff
SMCS Code: 1078
Part No.: 352-8583
S/N: R151-Up
90217 1234
lllustration 148
Top view of engine
s02186533
lllustration 150
Air shutoff valve and mounting
(5) Valve manifold
(1) Lightly lubricate the bore of the O-ring seals with

5P - 3975 Rubber Lubricant.
(4) Solenoid valve group

Nominalvoltage 24VDC
Resistance at 25 t 5 "C
(77 tg "F) ............. 32.6 t 1.6 Ohms
Final installation torque for the nut
(3) ..... .. .... 9.0 t 0.5 N m (79.7 t 4'4 lb in)
Final installation torque for the solenoid valve
group ........ 108 t 7 N'm (80 + 5 lb ft)
Nominal actuation pressure of the air shutoff

lllustration 149
902171235 group......... 117 kPa (17 Psi)
Rear view of engine a (2 Psi)or

(2) Air shutoff valve and mounting st actuate
psl).
psi).
78 RENR9362-08
i03557502 Note: Before you install the pump, lubricate the

moving parts with clean engine oil. Rotate the pump
Engine Oil Pump by hand in order to ensure that the pump rotates
freely.
SMCS Gode:1304
Part No.: 106-9872 (1) 107-7175 Spring
S/N: LLA1-Up Length under test force .. . .. .... . 1 07. 1 6 mm
Part No.: 106 - 9872 (4.219 inch)

S/N: RlAl-Up Test force 555.6 r 20.0 N (124.9 r 4.5 tbi
Free length aftertest ........ 144.5 mm (5.69 inch)
Part No.: 106 - 9872 Outside diameter 27.00 mm (1.063 inchi
S/N: LLBI-Up
Part No.: 106 - 9872
S/N: LLCl-Up
Part No,: 106-9872
S/N: LLEI-Uo
Part No.: '106-9872
S/N: LLF1-Up
Part No.: 106-9872
S/N: SBGl-Up
Part No.: 1 06 - 9872
S/N: SBJl-Up
Part No.: 1 06 - 9872
S/N: SBK1-Up
Part No.: 1 06 - 9872
S/N: PESl-Up
Part No.: 1 06 - 9872
S/N: RMSl-Up
Part No.: 1 06 - 9872 (B) Dimension for the gears
S/N: RTX1-Up
Length of new gear............. 110.000 t 0.015 mm
Part No.: 106-9872 (4.3307 t 0.0006 inch)
S/N: T2X1-Up Depth of the bore in the oil pump body for new
gear ....... 110.15 t 0.02 mm (4.337 t 0.001 inch)
(C) Dimensions for the idler shaft

Diameter of new shaft .......... 31.742 t 0.008 mm
(1.2497 t 0.0003 inch)
Bore in the sleeve bearing for the new
shaft........... ........31.811 r 0.013 mm
(1.2524 t 0.0005 inch)
(D) Extension of the hollow dowel from the oil pump

cover................. 6.0 t 0.b mm (0.24 t 0.02 inch)
(E) Distance from the end of the pump shaft
assembly to the gear face ........... 34.0 r 0.5 mm
lllustration 151 9015541 95 (1.34 f 0.02 inch)
Note: The rotation of the drive gear is clockwise when (F) Dimensions for the pump drive shaft
you view the engine oil pump from the drive end.
Diameter of new pump drive
shaft.......... ........ 31 .742 ! 0,008 mm
(1.2497 t 0.0003 inch)
79
RENR9362-08
Bore in the sleeve bearing for the pump drive

shaft after assemblv
- 31'811 t 0'013 mm
(1 .2524 t 0.0005 inch)
(G) Distance from the gear face to the pump drive

shaft assemblY 47.0 ! 0'5 mm
(1.85 f 0.02 inch)
(H) Installation depth of the sleeve bearing in the

pump cover ....... 1.5 t 0.5 mm (0.06 + 0.02 inch)
(J) Installation depth of the sleeve bearing in the oil

pump body assembly .... .. ......... 1.5 t 0.5 mm
(0.06 t 0.02 inch)
901 881 373

lllustration 155
(2) Pump cover
(L) Extension of the hollow dowel from the oil pump

cover 6.0 t 1.0 mm (0.24! 0.04 inch)
. ol-tit
b o/1l5.o Jo
Bench test specifications
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)
901 5541 96
lllustration 153
Y'\Y
gl-/ g
901 5541 97
lllustration 154
(K) Position of the bearing joints from the centerline

through the bearing bores ........ 45 ! 15 degrees
RENR9362-08
i03602902
Engine Oil Pump

SMCS Gode: 1304
Part No.: 7N - 871 5
S/N: LLCl-Up
Part No.: 7W-0053
S/N: CBE1-Up
Part No.: 7N-8715
S/N: LLEl-Up
Part No.: 7W-0053
S/N: C8K1-Up
(2) Before assembly, lubricate the O-ring seal lighily

with 5P - 3975 Rubber Lubricant.
(B) Dimensions for the gears

Length of new gear .............. 54.000 t 0.015 mm
t
(2.1260 0.0006 inch)
Depth of the bore in the oil pump body for the
new gear .. 54.15 r 0.02 mm (2.132 t 0.001 inch)
Note: The rotation of the drive gear is clockwise when
you view the engine oil pump from the drive end. (C) Dimensions for the pump shaft
Diameter of the new shaft .... 31742 r 0.008 mm
Note: Before you install the pump, lubricate the (1.2497 t 0.0003 inch)
moving parts with clean engine oil. Rotate the pump Bore in the sleeve bearing for the new shaft after
by hand in order to ensure that the pump rotates
freely.
(1.2524 t 0.0005 inch)
(1) 23 -2760 Spring ( o)
Length undertestforce .. 117.14 mm (4.612 inch) ff':i ::i :l :T [:J "=-,fH* isT.'f.'Ji,l",o
Test force ..... 499 r 24 N (112 r S tb)
Approximate free length aftertest .... i52.91 mm (E) Distance from the end of the idler shaft to the
(6.020 inch)
gear face ......... 34.0 t 0.5 mm (1.34 r 0.02 inch)
(F) Dimensions for the pump drive shaft
Diameter of new shaft.......... 31.7421 0.009 mm
(1.2497 t 0.0003 inch)
Bore in the sleeve bearing for the new shaft after
assembly 31.81i t 0.013 mm
(1.2524 t 0.0005 inch)
(G) Distance from the end of the shaft to the gear

face ........... ...... 47.0 + 0.5 mm (1.8b i 0.02 inch)

pump cover....... 1.5 r 0.5 mm (0.06 t 0.02 inch)

pump body assembly .. 1.5 i 0.S mm
(0.06 t 0.02 inch)
B1
RENR9362-08
6 olti,
" / ll- l"
o o
901 927801
901 5541 96 lllustration 160
lllustration 158
(3) Pump cover
(L) Extension of the hollow dowel from the oil plmP

cover ....,............ 6.0 t 1.0 mm (0.24 t 0'04 inch)

Unrestricted flow rate at 700 rpr 135'0 L
YIY
(35.7 US gal)
outlet,........ 570 to 630 kPa (83 to 91 psi)
CVO
901 5541 97
lllustration 159
(K) Position of bearing joints from the centerline

through the bearing bores ........ 45 ! 15 degrees
82 RENR9362-OB
i03560066 Length under test force.. 117.14 mm (4.612 inch)

Engine Oil Pump Test force 499 t 24 N (112.2 r S.4 lbi
Approximate free length after test .,. tSZ.gt mm
(6.020 inch)
SMCS Gode: 1304
Outside diameter .. 27 mm (1.1 inch)
Part No.: 8N - 6152
S/N: LLA1-Up
Part No.: 8N-6152
S/N: R141-Uo
Part No.: BN-6152
S/N: LLBl-Uo
Part No.: 8N - 6152
S/N: LLCl-Uo
Part No.: 8N - 6152
S/N: LLEl-Up
Part No.: 8N - 6152
S/N: LLFl-Up
Part No.: BN-6152
S/N: SBGl-Up
Part No.: 8N-6152
S/N: SBJl-Uo
Part No.: 8N-6152
S/N: SBK1-Uo (2) Before assembly, lubricate the O-ring seal lighfly
Part No.: 8N - 61 52 with 5P - 3975 Rubber Lubricant.
S/N: RMS1-Uo
Part No.: 8N - 6152
S/N: RTXI-Uo Length of new gear .............. 84.000 t 0.015 mm
t
(3.3071 0.0006 inch)
Part No.: BN-6152 Depth of the bore in the oil pump body for the
S/N: T2X1-Uo new gear .. 84.15 r 0.02 mm (3.313 t 0.001 inch)
(C) Dimensions for the pump shaft

Diameter of new shaft .......... 31.742 t 0.008 mm
0"",i n s t'.2frtJ ,,i,?. :3 3i Xh"n

(1.2524 r 0,0005 inch)
(D) Extension of hollow dowel from the oil purnp

cover................. 6.0 + 1.0 mm (0.24 r 0.04 inch)
(E) Distance from the end of the idler shaft to the

gear face .......,. 34.0 + 0.5 mm (1.34 r 0.02 inch)
lllustration 161 901 5541 95 (F) Dimensions for the pump drive shaft
Diameter of new shaft.......... 31.742 t 0.008 mm
Note: The rotation of the drive gear is clockwise when
you view the engine oil pump from the drive end. (1.2497 t 0.0003 inch)
Bore in the sleeve bearing for the new shaft after
Note: Before you install the pump, lubricate the
(1.2524 r 0.0005 inch)
by hand in order to ensure that the pump rotates (G) Distance from the end of the shaft to the gear
freely.
face ........... ...... 47 .O + 0.5 mm (1.8S r 0.02 inch)
(1) 2S-2760 Spring
B3
RENR9362-OB

pump cover ....... 1.5 r 0.5 mm (0.06 t 0.02 inch)

pump body assembly .................'... 1.5 t 0'5 mm
(0.06 I 0.02 inch)
b o" ol_tit
/ ll_.
/o o
901 883675 g0 1 88301 7

lllustration 163 lllustration 165
(3) Pump cover
(L) Extension of the hollow dowel from the oil pump

cover ...........,..... 6.0 t 0.5 mm (0'24 ! 0'02 inch)
Unrestricted flow rate at 700 rpm ......' 220 Llmin
Yr\Y (58.1 US gPm)

olJ o outlet ......... 570 to 630 kPa (83 to 91 psi )
901 883677
lllustration 164
(K) Position of bearing joints from the centerline

through the bearing bores ........ 45 t 15 degrees
84 RENR9362-08
i04 1 05450
Engine Oil Pump

SMCS Code: 1304
Part No.: 244-898s
S/N: R141-Uo
Part No.: 244-8985
S/N: RlSl-Up
Part No.: 244-8985
S/N: RTXI-Uo

Length of new gear .............. 84.000 t 0.015 mm
(3.3071 t 0.0006 inch)
new gear .. 84.15 ! 0.02 mm (3.313 t 0.001 inch)
(1) Lubricate the bore of the O-ring seal lighfly with (C) Dimensions for the shafts
5P - 3975 Rubber Lubricant immediatelv before
assembly of the engine oil pump. Diameter of new shaft.......... 31.742 t 0.008 mm
tn0'0003 inch)
Bore in the steeve n""r,njtro"o97
shaft ........... ........ 31.811 t 0.0'13 mm
(1.2524 t 0.0005 inch)

cover........,........ 6.0 + 0.5 mm (0.24 ! 0.02 inch)
(
=) 3J::XTiu lril Ji"":i*:j ll: ::' gol81no
(1.34 t t
u
-f
lllustration 167 9O1459725 shaft 31.742 t 0.008 mm
(1.2497 t 0.0003 inch)
(2) 2S -2760 Spring Bore in the sleeve bearing for the pump drive
shaft.......... .........31.811 r 0.013 mm
Length under test force .. 117.14 mm (4.612 inch) (1.2524 t 0.0005 inch)
Test force 499 t 24 N (112.2 r S.4 tb)
Approximate free length aftertest .... 152.g1 mm (G) Distance from the end of the pump drive shaft
(6.020 inch) assembly to the gear face ........... 47.0 t 0.5 mm
Outside diameter 27.00 mm (1.063 inch) (1.85 i 0.02 inch)

pump cover ....... 1.5 r 0.5 mm (0.06 t 0,02 inch)

pump body assembly. . 1.5 t 0.5 mm
(0.06 r 0.02 inch)
RENR9362-08 85

outlet ......... ........ 710 to770 kPa (105 to 110 psi)

freely.
i041 05311
Engine Oil Pump

SMCS Gode: 1304
Part No.: 231 -4915
S/N: SBK1-Up
Part No.: 231-4915
S/N: SBMl-Up
+K
9015021 39
lllustration 169
(K) Extension of the dowel from the oil pump

cover ................. 6.0 t 1.0 mm (0.24 x 0.04 inch)
901 4s9732
lllustration 171

5P - 3975 Rubber Lubricant immediately before
assembly of the engine oil pump.
o\-/ o
901 459731 901 459725

lllustration 170 lllustration 172
(L) Position of the bearing joints from the centerline (2) 1o7-7175 Spring
Length under test force.......... 107.16 mm
Bench test specifications (4.219 inch)
Test force 555.6 t 20.0 N (124.9 t 4.5 lb)
Unrestricted flow rate at 700 rpm ....... 220 Llmin Free length after test ........ 144.5 mm (5.69 inch)
(58 US gpm) Outside diameter 27.00 mm (1.063 inch)
86 RENR9362-08

pump body assembly. . 1.5 0.5 mm t
(0.06 r 0.02 inch)

Length of new gear............. 110.000 f 0.0,15 mm
(4.3307 t 0.0006 inch)
new gear 110.150 t 0.020 mm
(4.3366 t 0.0008 inch)
(c) Dimensions for the shafts lllustration 174 901 5021 39
Diameter of new shaft ......,... 31.742 t 0.008 mm (K) Extension of the dowel from the oil pump
(1.2497 t 0.0003 inch)
Bore n the sleeve bearing for the new
cover ................. 6.0 t 1.0 mm (0.24 t 0.04 inch)
shaft 31,811 t 0.013 mm
(1.2524 t 0.0005 inch)

cover................. 6.0 t 0.5 mm (0.24 t 0.02 inch)
(E) Distance from the end of the pump shaft
assembly to the gear face ........... 34.0 r 0.5 mm
(1.34 0.02 inch) t

shaft 31.742f 0.008 mm o f 'lf-. o o
(1.2497 t
0.0003 inch)
Bore in the sleeve bearing for the pump drive
shaft .......... ......... 31.811 r 0.013 mm
(1.2524 t 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 t 0.02 inch) lllustration 175 9023091 53

pump cover ....... 1.5 r 0.5 mm (0.06 t 0.02 inch)
RENR9362-OB 87
Part No.: 8N-9164

S/N: SBJl-Uo
Part No.: 8N - 91 64
S/N: C8K'1-Uo
Part No.: 8N-9164
S/N: SBK1-Up
YlY
c-o
Part No.: 8N - 91 64
S/N: RMSI-Up
Part No.: 8N-9164
S/N: RTX1-Uo
Part No.: 8N-9164
lllustration 176 9023091 73 S/N: T2X1-Up
(L) Position of bearing joints from the centerline

through the bearing bores ........ 45 x15 degrees
When the engine oil pump is viewed from the

drive end, the drive gear rotates in the following
direction. Clockwise

Unrestricted flow rate at 1000 rpm ..... 410 L/min
(108 US gpm)
out|et......... 750 t 30 kPa (109 t 4.5 psi )

freely.
i0239491 9
Engine Oil Scavenge Pump

SMGS Code:1312
Part No.: 8N - 9164
S/N: LLA1-Up
Part No.:8N-9164
S/N: R141-Up
Part No.: 8N - 9164
S/N: LLB1-Up
Part No.: 8N - 9164
S/N: LLC1-Up
Part No.:8N-9164
S/N: C8E1-Up
Part No.: 8N-9164
S/N: LLEI-Up
Part No.: 8N - 9164
S/N: LLF1-Up
Part No.: 8N - 9164
S/N: SBGl-Uo
88 RENR9362-08
Bore in bearings for new gear shafts after

NOTICE assembly 31.837 r 0.070 mm
Before operation, the pump must be lubricated with t
(1.2534 0.0028 inch)
clean engine oiland the pump mustturn freely by hand
or damage to parts can be the result. (3) Distance from the end of the shafts to the gear
t
faces ............... 34.0 + 0.5 mm (1.34 0.02 inch)
When the oil scavenge pump is viewed from (4) The bearings are installed in the pump body at
the drive end the drive rotates in the following the following depth: ..... 1.5 r 0.5 mm
direction. . Counterclockwise t
(0.06 0.02 inch)
(1) Length of new gears (5) Bolt
8N-9164 Pump Group ........ 84.000 r 0.015 mm Note: Before installing a gear onto the shaft, clean
(3.3071 t 0.0006 inch)
1W-8508 Pump Group ....... 110.000 t 0,015 mm the shaft and clean the gear's bore with isopropyl
(4.3307 t 0.0006 inch) alcohol,
144-8267 Pump Group .... 145.000 t 0.0'15 mm
(5.7087 t 0.0006 inch) 1. Tap on gear in order to seat the taper on the shaft.
Depth of bores for new gears 2. Tighten the bolt to the following torque:
8N-9164 Pump Group ........ 84.150 t

0.020 mm Torque for bolt 100 t 20 N.m (75 r 15 tb ft)
(3.3130 t 0.0008 inch)
1W-8508 Pump Group .......110,150 t 0.020 mm Repeat this procedure until the torque does not
(4.3366 r 0.0008 inch) change.
144-8267 Pump Group .... 145.150 0.020 mmi
(5.7146 t 0.0008 inch)
(2) Diameter of new gear shafts .. 31 142 t 0.008 mm

(1.2497 t 0.0003 inch)
RENR9362-08 B9
Typical example
(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 t 0.5 mm (0.06 t 0.02 inch)
(B) The dowels extend from the cover at the following

distance: 6.4 r 0.5 mm (0.25 t 0.02 inch)
90 RENR9362-OB
i02956557

SMCS Gode: 1312
Part No.: 144-8267
(C) Distance from the end of the idler shaft assembly

NOTICE to the gear face ............ 34.0 1 0.5 mm
Before operation, the pump must be lubricated with (1.34 t 0.02 inch)
clean engine oil and the pump must turn freely by hand
or damage to parts can be the result. (")
:::il';J.:: ffi3il, :: ": :l:::: :::1"8 i%i?",",.O
When the oil scavenge pump is viewed from
( .06 r 0.02 inch)
the drive end the drive rotates in the following (E) Dimensions for the idler shaft
direction Counterclockwise
Diameter of new idler shaft .. 31.742 r 0.008 mm
(A) Dimensions for the gears (1.2497 r 0.0003 inch)
Bore in the sleeve bearing for the new idler
Length of new gear ............ 145.000 r 0.015 mm ..........
shaft ........ 31.837 r 0.070 mm
t
(5.7087 0.0006 inch) t
(1.2534 0.0028 inch)
Depth of the bore in the scavenge oil body for the
new gear ......... 145.150 t 0.020 mm (1) Use the following procedure in order to tighten
t
(5.7146 0.0008 inch) the bolt:
(B) Dimensions for the drive shafts Note: Before installing the drive gear onto the drive
Diameter of new drive shaft ..31.742 t 0.008 mm shaft assembly, clean the shaft and clean the bore of
the gear with isopropyl alcohol.
t
(1.2497 0.0003 inch)
Bore in the sleeve bearing for the new drive
shaft.. 3't.837 t 0.070 mm
1. Tap on the drive gear in order to seat the taper
t
(1.2534 0.0028 inch) of the drive gear.
2. Tighten the bolt to '100 r 20 N.m (75 r 15 tb ft).

RENR9362-OB 91
3. Repeat this procedure until the torque does not

change,
Typical example
(F) Position of bearing joints from the centerline

through the bearing bores ........ 45 r 15 degrees
(G) Extension of two hollow dowels from the cover of

the scavenge pump .... 6.4 i 0.5 mm
(0.25 t 0.02 inch)

scavenge pump cover 1.5 t 0.5 mm
(0.06 t 0.02 inch)
92 RENR9362-08
i02945798

SMCS Gode: 1312
Part No.: 1W-8508
Bottom view of engine
(1) Lubricate the bore of two O-ring seals lightly with Rotation . Counterclockwise
clean engine oil.
Length of new gear............. '110.000 t 0.015 mm
t
(4.3307 0.0006 inch)
Depth of the bore in the scavenge oil body for the
new gear 110.15 r 0.02 mm
t
(4.337 0.00'1 inch)
(C) Dimensions for the drive shafts

Diameter of new drive shaft ..31.742 t 0.008 mm
t
(1.2497 0.0003 inch)
Bore in the sleeve bearing for the new drive
shaft 3'1.837t 0.070 mm
(1.2534 t 0.0028 inch)
(D) Installation depth of the sleeve bearing in the
scavenge oil body ...,.. 1.5 r 0.5 mm
(0.06 f 0.02 inch)
(E) Distance from the end of the idler shaft assembly

to the gear face ............ 34.0 0.5 mm t
t
(1.34 0.02 inch)
Section A-A
(F) Dimensions for the idler shaft
NOTICE Diameter of new idler shaft .. 31.742 t 0.008 mm
Before operation, the pump must be lubricated with (1.2497 t 0.0003 inch)
clean engine oil and the pump must turn freely by hand Bore in the sleeve bearing for the new idler
or damage to parts can be the result. shaft .......... ........ 31.837 I 0.070 mm
(1.2534 t 0.0028 inch)
RENR9362-08 93
(2) Use the following procedure in order to tighten

the bolt:
Note: Before installing the drive gear onto the drive

shaft assembly, clean the shaft and clean the bore of
the gear with isopropyl alcohol.
1. Tap on the drive gear in order to seat the taper

of the drive gear.
2. Tighten the bolt to 100 t 20 N.m (75 t 15 lb ft).

3. Repeat this procedure until the torque does not
change.
(G) Position of the bearing joints from the centerline


scavenge pump cover 1.5 t 0.5 mm
(0.06 r 0.02 inch)
(J) Extension of two hollow dowels from the cover of

the scavenge pump .... 6.4 t 0.5 mm
(0.25 t 0.02 inch)
94 RENR9362-08
i03686767
Engine Oil Cooler Bypass and

Gooling Jet Sequence Valves
SMCS Code: 1314,1331
Part No.:335-3154
S/N: C8E1-Up
Part No.:335-3154
S/N: C8K1-Up
(1) Lubricate the bore of the O-ring seals lighfly with Free length after test .........112.7 mm (4.44 inch)
the clean engine oil. Outside diameter 24.60 mm (0.969 inch)
(2) Torque for the plug ... 100 r 15 N.m (74 r 11 lb ft)
Note: The oil cooler bypass valve must open with a
pressure difference of 180 r 20 kPa (26.1 t 2.9 psi).
(3) 2W- 1635 Spring for oil cooler bypass valve

Length undertest force..... 102.0 mm (4.02 inch)
Test force .... S18 r 26 N (116 t 6 tb)
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 t 30 kpa
(18.9 r 4.4 psi).
Note: The cooling jet sequence valves must be

fully open at a pressure difference of 200 t 30 kpa
(29.0 t 4.4 psi).
(4) 68 -9202 Spring for the cooling jet sequence

valve
Length under test force....... 68.3 mm (2.69 inch)
Testforce 85 to 100 N (19.0 to 22.4 lb\
RENR9362-08 95
i03139927

SMCS Gode: 1314:1331
PartNo.:115-7860
S/N: LLA1-Up
Part No.: 1 15 - 7860
S/N; LLB1-Up
Part No.: 1 15 - 7860
S/N: LLC1-Up
Part No.: 1 15 - 7860
S/N: LLE1-Up
Part No.: 1 15 - 7860
S/N: LLF1-Up
Part No.: 1 15 - 7860
S/N: SBGl-Up
Part No.: 1 15 - 7860
S/N: SBJl-Up
PartNo.:115-7860
S/N: SBKl-Up
Part No.: 1 15 - 7860
S/N: RMS1-Up
Part No.: 115-7860
S/N: T2X1-Up
lllustration 'lB7 90 1 61 6336
Right side view

Typical example
96 RENR9362-08
(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 f 15 N'm (75 t 11 lb ft)
lllustration 1BB 901616353
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 tg N.m (35 r 7 tb ft).
3. Tighten two bolts (1) of the clamp assembly to the

tube (4) to 47 t g N.m (35 t 7 lb ft).
Note: The cooling jet sequence valves must start
to open at a pressure difference of 130 + 30 kPa
('19.0 r 4.5 psi).
Note: The cooling jet sequence valves must be
fully open at a pressure difference of 200 t 30 kPa
(29.0 r 4.5 psi).
(5) 68 -9202 Spring for the cooling jet sequence

valve
Quantity ...................... 2
Test force . 85 to 102 N (19 to 23 lb)
Free length after test ......... 112.7 mm (4.44 inch)
Note: The oil cooler bypass valve must open with a

pressure difference of 180 t 20 kPa (26 t 3 psi).
(6) 2W- 1635 Spring for oil cooler bypass valve
Length under test force ..... 102.0 mm (4.02 inch)

Test force 518 + 26 N (115.0 r 5.8 tb)
Outside diameter ........ 37.251 mm ('1.4666 inch)
RENR9362-08 ^1
i02617932

Cooling Jet Sequence Valves
SMCS Gode: 1314;1331
Part No.: 273-7582
S/N: RlAl-Up
Part No.: 273-7582
S/N: RTX1-Up
98 RENR9362-08

The oil cooler bypass valve must open with the

following pressuredifference: 180 r 20 kpa
t
(26 3 psi)
Section B-B
(1) Plug
Lubricate the bore lightly with glycerin or clean

engine oil.
Torque ... 100 t 15 N.m (7S t 11 tb ft)
(2) 68 - 9202 Spring for the cooling jet sequence

valve
There is a spring at each end of the block.
Test force 85 to 100 N (19.0 to 22.4 tb)
Free length after test .........112.8 mm (4.44 inch)
Both of the cooling jet sequence valves

must start to open at the following pressure
difference: ..... 130 t 30 kPa (19 t 4 psi)

must be fully open at the following pressure
difference: ...... 200 t 30 kPa (29 t 4 psi)
(3) Clamp bolts

Torque .........47 r g N.m (35 r 7 tb ft)
Tightening sequence for the clamp bolts
1. Snugly tighten the clamp assembly to the tube.
2. Tighten the clamp assembly to the elbow.
3. Tighten the clamp assembly to the tube.

(4) 2W - 1 635 Spring for oil cooler bypass valve
Length undertestforce..... 102.0 mm (4.02 inch)
Testforce ... 492 to 544 N (1 I 0 to 1 20 tb)
RENR9362-08 99
i02945958

SMCS Gode: 1314; 1331
Part No.: 262-7578
S/N: R151-Uo
4
F
1n 11
A.A c-c

(8) Rear face of block (11) Front face of block
(1) Lubricate the bore of two O-ring seals of the filter (7) 6B -9202 Spring for the cooling jet sequence
tube lightly with the lubricant that is being sealed. valve
Use the following procedure to tighten the bolts of Quantity ...................... 2

the clamp assembly: Length under test force ... 68.28 mm (2.688 inch)
Test force .. 85 to 100 N (19 to 22 lb)
1. Snugly tighten the clamp assembly (5) to the tube Free length after test .....112.73 mm (4 438 inch)
assembly (6). Outside diameter 24.61 mm (0.969 inch)
2. Tighten two bolts (3) of the clamp assembly to the Note: Both of the cooling jet sequence valves must
elbow (\ b a7 + 9 N.m (35 r 7 lb ft). start to open at a pressure difference of 130 + 30 kPa
(19.0 t 4.5 psi) and both the cooling jet sequence
3. Tighten two bolts (4) of the clamp assembly to the valves must be fully open at a pressure difference of
tube assembly (6) to 47 t 9 N.m (351 7 tb ft). 200 t 30 kPa (29,0 t 4,5 psi).
100 RENR9362-08
(9) Lubricate the bores of three O-ring seals lighfly (17) 2W - 1 635 Spring for the oil cooler bypass valve
with glycerin or an approved equivalent.
Length under test force..... 102.0 mm (4.02 inch)
(10) Lubricate the bore of two O-ring seals of the Test force 518 r 26 N (116.b r S.8 tb)
tube lightly with the lubricant that is being sealed. Free length after test ........ 143.4 mm (5.65 inch)
Outside diameter ........ 37.251mm (1.4666 inch)
(12) Lubricate the bore of two O-ring seats lighfly
with the lubricant that is being sealed.
Note: The plunger of the engine oil filter bypass

valves (13) must move freely in the bore.
(13) During engine operation, the engine oilfilter

bypass valves must starl to open at a pressure
difference of 203 t 20 kPa (29.5 r 3.0 psi).
(14) 7G-6713 Spring

Quantity ...................... 3
Test force ... 109 r 5 N (24.5 r 1.1 tb)
Approximate free length after test ........ 99.7 mm
outside diameter 21.23 mm,Ji33 iffiRl
Note: Lubricate the bore of the O-ring seal lighfly with

(15) Torque for the plug .. 100 r 15 N'm (75 t 11 tb ft)

(16) The oil cooler bypass valve must open with a
pressure difference of '180 r 20 kPa (26 t 3 psi).
RENR9362-08 10'1
i026 1 7863

SMCS Gode:1314; 1331
Part No.: 202-2657
S/N: SBK1-Up
Part No.: 202-2657
S/N: SBMl-Up
JITI
VIEW A-A
I rlywrn
\
\
900277849
lllustration 193
Typical example
(1) Clamp bolts 2. Tighten the clamp assembly to the elbow.

Torque .........47 t 9 N m (35 t 7lb ft) 3. Tighten the clamp assembly to the tube.
Tightening sequence for the clamp bolts (2) Plus

102 RENR9362-08
Lubricate the bore lightly with clean engine oil. Part No.: 112-4921
Torque ... 100 r 15 N.m (75 r 11 tb ft) S/N: SBK1-Up
(3) 68-9202 Spring for the cooling jet sequence Part No.: 112-4921
S/N: SBMl-Up
valve
There is a spring at each end of the block.
Part No.: 112-4921
S/N: PES1-Uo
Length under test force....... 68.3 mm (2.69 inch)
Test force 85 to 100 N (19.0 to 22.4 tb) Part No.: 112-4921
Free length aftertest ........,112.8 mm (4.44 inch) S/N: R1S1-Up
Part No.: 112-4921
Both of the cooling jet sequence valves S/N: RMSl-Up
must start to open at the following pressure Part No.: 112-4921
difference: ...... 130 t 30 kpa (19 r 4 psi) S/N: T2X1-Up
must be fully open at the following pressure
difference: ...... 200 r 30 kPa (29 r 4 psi)
(4) 2W - 1 635 Spring for oil cooler bypass valve

Test force .. 518 i 26 N (115 i 5.8 tb)
Free length after test ........ 143.4 mm (5.65 inch)
The oil cooler bypass valve must open with the

following pressure difference: 180 t 20 kpa
(26 t 3 psi)
i03670352
Engine Oil Filter

SMCS Gode:1318
Part No.: 112-4921
S/N: LLA1-Up
Part No.: 112-4921
S/N: LLBI-Up
Part No.: 112-4921
S/N: LLCl-Uo
Part No.: 1 12- 4921, 335 -31 52
S/N: C8E1-Uo
Part No.: 112-4921
S/N: LLE1-Up
Part No.: 112-4921
S/N: LLFl-Up
Part No.: 112-4921
S/N: SBGl-Up
Part No.: 112-4921
S/N: SBJl-Up
Part No.: 112-4921, 335-3152
S/N: CBKI-Up
RENR9362-08 103
B
I
o o) - -to o I
g0 1 445657
lllustration 194
Front view
(1) Lubricate the bore of the O-ring seals lightly with (3) Bypass valve
clean engine oil.
Start to open pressure .....................287 t 7 kPa
(2) 2W- 1635 Spring (41.6 r 1.0 psi)
Fully open pressure ...... 480 t 7 kPa
Length under test force ...., 102.0 mm (4.02 inch) (69.6 t '1.0 psi)
Test force ..... 518 r 26 N (116 r 6 tb)
Free length aftertest ........ 143.4 mm (5.65 inch) 55t7N.m(41 t5lbft)
Note: The bypass valve (3) must move freely in the

oore.
104 RENR9362-08
Engine Oil Filter

SMCS Code: 1318
Part No.: 115-7841
S/N: LLA1-Up
Part No.: 1 15 -7841, 242-6278
S/N: LLBl-Uo
Part No.: 115-7841
S/N: LLCl-Up
Part No.: 115-7841
S/N: C8E1-Up
Part No.: 115-7841
S/N: LLEl-Up
Part No.: 115 -7841 , 242-6278
S/N: LLFI-Uo
Part No.: 115-7841
S/N: C8K1-Uo
Part No.: 242-6278
S/N: PESl-Up
Part No.: 115-7841
S/N: RMS1-Up
Part No.: 115-7841
S/N: T2X1-Up

Front view
RENR9362-08 105
(1) Lubricate the bore of the O-ring seals lightly with Part No.: 120-4501
the clean engine oil. S/N: SBK1-Up
(2) Bypass valve Part No.: 120-4501

S/N: SBMl-Up
Start to open pressure: ..287 t7 kPa (42 t 1 psi)
Fully open pressure: ..... 480 t7 kPa (70 r 1 psi) Part No.: 1 20 - 450'l
S/N: PES1-Up
Note: Bypass valve (2) must move freely in the bore.
(3) 2W-1635 Spring

Test force .....518 r 26 N (116 r 6 tb)
Free length aftertest ........ 143.4 mm (5,65 inch)
Left side view
Use the following tightening sequence for the clamp

assembly (4):

2. Tighten the bolts of the clamp assembly to the
elbow to 47 t 9 N.m (35 r 7 lb ft).
3. Tighten the bolts of the clamp assembly to the
tube to 47 !9 N.m (35 r 7 lb ft).
(5) Torque for the bolts ........ 55 r 7 N'm (41 r 5 tb ft)
i03694821
Duplex Engine Oil Filters

SMCS Gode: 1318
Part No.: 120 - 4501 , 4W- 9968
S/N: LLB1-Up
Part No.: 120-4501
S/N: LLF1-Up
Part No.: 120-4501
S/N: SBG1-Up
Part No.: 120-4501
S/N: SBJ1-Up
106 RENR9362-OB
qoJ10 loo
lllustration 197 Str00re

Front view
(2) Lever (5) Tie rod (7) Bracket
(3) Lever (6) Ball plunger assembly (11) Cover
Note: Refer to Testing and Adjusting, "Duplex Oil Note: The bypass valve (9) must move freely in
Filter - Adjust" for correct adjustment procedures of the bore. The bypass valve must start to open at
the fluid control valve group (10). t
287 t7 kPa (42 1 psi). The bypass valve must be
fully open at 480 t 7 kPa (70 t 1 psi).
(1) Lightly lubricate the O-ring seals with ctean
engine oil.
i0401 6578
(4) Torque for the bolts ...,.... 55 r 7 N'm (41 r S tb ft) Engine Oil Filter Base
(8) 2W-1635 Spring
SMCS Code: 1306
Length undertestforce..... 102.0 mm (4.02 inch)
Part No.: 151 -9270,8N - 2001
Test force .... 518 r 26 N (1i6 t 6 tb)
S/N: LLA1-Up
Outside diameter ........ 37.251 mm (1.4666 inch) Part No.: 151-9270, 8N-2001
S/N: R141-Up
RENR9362-08 107
Part No.: 151 -9270.8N - 2001 (1) Torque for the hollow stud ....,..,....... 80 r 14 N.m
S/N: LLBl,Up (60 r 10 tb ft)
Part No.: 151-9270, BN-2001
S/N: LLCl-Up
Part No.: 15'l -9270, 8N - 2001 Engine Oil Cooler
S/N: LLE1-Up
SMCS Gode: 1378
Part No.: 151 -9270,8N - 2001
S/N: LLF1-Up Part No.: 273-7587
S/N: RlAl-Up
Part No.: 151 -9270,8N - 2001
S/N: SBGl-Up Part No.: 273-7587
S/N: R151-Up
Part No.: 151 -9270, 8N - 2001
S/N: SBJ'1-Up Part No.: 273-7587
S/N: RTX1-Uo
Part No.: 151 -9270, 8N - 2001
S/N: SBK1-Up
Part No.: 151 -9270, 8N - 2001
S/N: SBMl-Up
Part No.: 151 -9270,8N - 2001
S/N: PESl-Up
Part No.: 151 -9270,8N - 2001
S/N: RlSl-Uo
Part No.: 151-9270, BN-2001
S/N: RMS1-Up
Part No.: 151 -9270,8N - 2001
S/N: RTX1-Up
f llustration 1 99 svz It
Part No.: 151 -9270, BN - 2001 Left side view

S/N: T2X1-Up
(1) Lubricate bore of the O-ring seals lightty with
clean engine oil.
io2947522
Grankcase Breather
SMCS Gode: 1317
Part No.: 124-5512
S/N: LLA1-Up
Part No.: 124-5512
S/N: RlAl-Up
Part No.: 124-5512
S/N: LLBl-Up
Part No.: 124-5512
S/N: LLC1-Up
Part No.: 124-5512
lllustration 198 901460980 S/N: LLEl-Up
Typical example Part No.: 124-5512
S/N: LLF1-Up
(A) Apply Loctite 271 on the tapered end of the
hollow stud to a distance of 10.2 t 1.5 mm Part No.: 124-5512
(0.40 r 0.06 inch) S/N: SBGl-Up
108 RENR9362-OB
Part No.: 124-5512

S/N: SBJ1-Up
Part No.: 124-5512
S/N: SBKI-Up
Part No.: 357 -7061
S/N: RIS'1-Up
Part No,: 124-5512
S/N: RMS1-Up
Part No.: 124-5512
S/N: RTX1-Up
Part No.: 124-5512
S/N: T2X1-Uo
JA
A-A
lllushation 200 g01461017
(3) Cover assembly
(1) Lubricate the bore of three O-ring seats lighfly

with clean engine oil.
(2) Torque forfive hose clamps 3.0 r 0.b N.m

(27 t4tbin)
RENR9362-OB 109
i031 37363
Crankcase Breather
SMCS Gode: 1317
Part No.: 101 -0838
S/N: LLA1-Up
Part No.: 101-0838
S/N: LLCI-Uo
Part No.: 101 -0838
S/N: C8E1-Up
Part No.: 101-0838
S/N: LLEl-Up
Part No.: 101 -0838
S/N: C8K1-Uo
JA
A-A

(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 t 0.5 N.m
(27 t 4lb in)
110 RENR9362-OB
Grankcase Breather
SMCS Code: 1317
Part No.: 124-5513
S/N: LLB1-Up
Part No.: 1 24 - 551 3
S/N: SBJ'1-Up
Part No.: 124-5513
S/N: SBK1-Up
Part No.: 124-5513
S/N: T2X1-Up
-lo
JA

(1) Lubricate the bore of the four O-ring seals lighfly

with clean engine oil.
(3) Torque for the six hose clamps ...... 3.0 t 0.5 N,m
(27 t4tbin)
RENR9362-08 111
i027 12900
Crankcase Breather
SMCS Code: 1317
Part No.: 265-8050
S/N: RlAl-Up
Part No.: 273-9806, 276-8258
S/N: SBJ1-Up
Part No.: 273-9806, 276-8258
S/N: SBK1-Up
Part No.: 276-8258
S/N: SBMl-Uo
Part No.: 273-9806
S/N: T2X1-Up
Typical example
(1) Breather assembly
(2) Cover assembly
(3) Torque for the hose clamps 3.0 t 0.5 N.m

t
(27 4lb in)
112 RENR9362-08
i031 37380
Crankcase Breather
SMCS Gode:1317
Part No.: 284-4153
S/N: PESl-Up
JA
A-A
(1) Lubricate the bore of six O-ring seals lightly with Part No.: BN - 61 64
clean engine oil. S/N: SBJl-Up
(2) Torque for ten hose clamps 3.0 t 0.5 N.m Part No.: 8N-6164
(27 t4tbin) S/N: SBK1-Up
Part No.: BN-6164
S/N: R151-Up
Engine Oil Pan Part No.: 8N - 61 64
S/N: RMSl-Up
SMCS Code: 1302
Part No.: BN-6164
Part No.: 8N-6164 S/N: RTX1-Up
S/N: LLAI-Up
Part No.: 8N-6164
Part No.: 8N - 61 64 S/N: T2X1-Up
S/N: RlAl-Up
Part No.: 8N-6164
S/N: LLB1-Uo
Part No.: 8N - 6164
S/N: LLC1-Up
Part No.: 8N - 6164
S/N: LLEI-Uo
Part No.: 8N - 6164
S/N: LLF1-Up
Part No.: BN - 6164
S/N: SBG1-Up
RENR9362-08 113
C B-B
lllustration 206 g0'1462767
Use the following procedure in order to tighten the (1a) As required, apply 4C-9614 Siticone Seatant,
bolts of the plate: Permatex No.2 or 138-8436 Liquid Gasket
on the sealing surface of the oil pan prior to
{. Tighten five bolts (12) to standard torque. assembly. The sealing surfaces are the following
areas:
2. Tighten bolt (1) through bott (10) in a numerical
sequence that is shown in lllustration 205 to . Connecting joint of the flywheel housing (17) and
standard torque. the rear of the cylinder block
(11) As required, apply 4C-9614 Silicone Seatant, . Connecting joint of the front accessory drive
Permatex No. 2 or 138-9436 Liquid Gasket to housing ('18) and the front of the cylinder block
the six joints of the gasket prior to assembly.
(15) As required, apply 4C-9614 Silicone Seatant,
(13) Lubricate the bore of nine O-ring seals tighfly Permatex No, 2 or 138-9496 Liquid Gasket to
with the lubricant that is being sealed or an the sealing surface of the integral seal prior to
approved equivalent. assembly.
114 RENR9362-08
(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 i 1S N,m
(105 r 11 tb ft)
(20) Torque for the oil drain plug ............. SS r 7 N.m

(41 r5tbft)
i031 39780
Engine Oil Pan

SMGS Code: 1302
Part No.: 8N-7706
S/N: LLA1-Up
Part No.: 8N-7706
S/N: LLB1-Uo
Part No.: BN - 7706
S/N: LLCl-Up
Part No.: BN-7706
S/N: LLEI-Uo
Part No,: 8N-7706
S/N: LLF1-Up
Part No.:8N-7706
S/N: SBG1-Uo
Part No.: BN - 7706
S/N: SBJl-Up
Part No,: 8N-7706
S/N: SBK1-Up
Part No.: 8N-7706
S/N: RMS1-Up
Part No.: BN-7706
S/N: RTXI-Up
Part No.: 8N-7706
S/N: T2X1-Uo
RENR9362-08 115
B-B
Use the following procedure in order to tighten the (15) As required, apply 4C-9509 Wicking Sealantto
bolts of the plate: the open top end of the bolt holes after assembly
of the oil pan.
1. Tighten five bolts (11) to a standard torque.
(16) As required, apply 8T-9014 Silicone Sealant,
2. Tighten bolt 1 through bolt 10 in a numerical Permatex No. 2 or 138-8436 Liquid Gasket to
seouence that is shown in lllustration 207 Io a the sealing surface of the integral seal prior to
standard torque. assembly.
(12) As required, apply 8T-9014 Silicone Sealant, (19) Torque forthe oildrain plug ......... 145 t 15 N m
Permatex No. 2 or 138-8436 Liouid Gasket to (105 r 11 rb ft)
the joints of the gasket prior to assembly.
(20) Torque for the oil drain plug ............. 55 + 7 N'm
('13) Lubricate the bore of nine O-ring seals lightly (41 r5rbft)
i031 39762
(1a) As required, apply BT-9014 Silicone Sealant,
Permatex No. 2 or 138-8436 Liquid Gasket
on the sealing surface of the oil pan prior to
Engine Oil Pan
assembly. The sealing surfaces are the following SMCS Code: 1302
areas:
Part No.: 7C - 6752, 7C - 9938
Connecting joint of the flywheel housing (17) and S/N: LLA1-Up
the rear of the cylinder block
Part No.: 7C-6752, 7C- 9938
Connecting joint of the front accessory drive S/N: R1A1-Up
housing (18) and the front of the cylinder block
116 RENR9362-08
Part No.: 7C - 4711, 7C-6752, 7C-7 178, 7C-9938

S/N: LLBl-Up
Part No.: 7C - 6752, 7C-6887, 7C- 9938
S/N: LLCl-Up
Part No.: 335 -31 70, 7C-6887
S/N: C8E1-Up
Part No.: 7C - 6752, 7C -6887, 7C -9938
S/N: LLEl-Uo
Part No.: 7C-6752, 7C - 9938
S/N: LLFl-Up
Part No.r 7C-6752, 7C - 9938
S/N: SBGl-Up
Part No.: 7C- 471 1, 7C -6752, 7C -7178, 7C-9938
S/N: SBJl-Up
Part No.: 335 -31 70, 7C-6887
S/N: C8K1-Up
Part No.: 7C- 471 1, 7C-6752, 7C -7178, 7C-9938
S/N: SBKI-Up
Part No.: 7C - 471 1 , 7C -7178
S/N: SBMl-Up
Part No.: 7C - 4711 , 7C -7178
S/N: PESl-Uo
Part No.: 7C - 6752, 7C - 9938
S/N: RMSl-Up
Part No.: 7C-6752, 7C - 9938
S/N: RTX1-Up
Part No.: 7C- 471 1, 7C-6752, 7C-7178, 7C-9938
S/N: T2X1-Uo
RENR9362-08 117
Typical example
(1) Before assembly, apply 1 P - 0808 Multipurpose

Grease in order to lubricate the bores of the
O-ring seals.
(2) As required, apply BT-9014 Silicone Sealant

or 138 - 8436 Liquid Gasket to the joints of the
gasket.
(4) Torque for two oil drain plugs ......... 145 t 15 N.m
(105 t 11 tb ft)
In order to prevent stress on the tube assembly
(6), use the following tightening procedure during
assembly:
1. Tighten two bolts (5)to 47 t 9 N'm (35 t 7lb ft).
2. Tighten two bolts (3) to 47 t g N.m (35 r 7 lb ft).

118 RENR9362-08
(4) Bolts
Engine Oil Pan In order to prevent stress to the tube assembly,

tighten the bolts on the flange before you tighten
SMCS Gode: 1302 the bolts on the housing.
Part No.: 284-5124 Torque .........47 t 9 N'm (35 t 6 lb ft)
S/N: LLB1-Up
Part No.: 284-5124
S/N: SBJl-Up
Part No.: 284-5124
S/N: SBK1-Up
Part No.: 284-5124
S/N: SBMl-Up
Part No.: 204 - 5153, 284 -5124
S/N: PESI-Up
Part No.: 284-5124
S/N: T2X1-Up
1A
<rA
View B-B View A-A Section C-C
Typical example
(1) Gasket joint

Apply one of the following sealants to the gasket
joints prior to assembly:
. 4C-9613 Silicone Sealant

. 138-8436 Liquid Gasket
(2) Plugs
Torque ..145 t 15 N.m (1071 11 tb ft)
(3) Seals
Apply 1 P - 0808 Multipurpose Grease to the bores

prior to assembly.
RENR9362-OB 119
i03694522
Engine Oil Pan

SMCS Code: 1302
Part No.: 158 - 0604
S/N: RlAl-Up
Use the following procedure in order to tighten the (1a) As required, apply BT-9014 Silicone Sealant,
bolts of the plate: Permatex No. 2 or 138-8436 Liquid Gasket to
the sealing surface of the oil pan. The sealing
1. Tighten five bolts (11)to a standard torque. surfaces are the following areas:
2. Tighten bolt 1 through bolt 10 in a numerical . Connecting joint of the flywheel housing (17) and
sequence that is shown in lllustration 210 to a the rear of the cylinder block
standard torque.
. Connecting joint of the front accessory drive
(12) Before assembly, apply 8T-9014 Silicone housing (18) and the front of the cylinder block
Sealant, Permatex No.2 or 138-8496 Liquid
Gasket to the joints of the gasket prior to (15) As required, apply 8T-9014 Silicone Sealant,
assembly. Permatex No. 2 or 138 - 8436 Liquid Gasket to
the sealing surface of the integral seal prior to
(13) Lubricate the bore of the O-ring seals lightly with assembly.
the lubricant that is being sealed or an approved .
equivalent. (16) As required, apply 4C'9509 Wicking Sealantto
the open top end of the bolt holes after assembly
of the oil pan.
120 RENR9362-08
(19) Torque for the oil drain plug .........145 t 15 N'm

(107 t 11 rb ft)
(20) Torque for the oil drain plug ......... 110 t 15 N'm
(81 r 11 rb ft)
i031 31461
Engine Oil Pan

SMCS Gode: '1302
Part No.: 127 -4462
S/N: RlAl-Up
Part No.: 127 -4462
S/N: R151-Up
tc
130
17
13
Use the following procedure in order to tighten the (11) As required, apply 4C-9614 Silicone Sealant,
bolts of the olate: Permatex No. 2 or 138-8436 Liquid Gasket to
eight joints of the gasket before assembly.
1. Tighten five bolts (12) to standard torque.
(13) Lubricate the bore of nine O-ring seals lightly
2. Tighten the bolt (1)through the bolt (10) in a with the lubricant that is being sealed or an
numerical sequence that is shown in lllustration approved equivalent.
211 to standard torque.
RENR9362-OB 121
(1a) As required, apply 4C-9614 Silicone Sealant, Part No.: 6I -4950

Permatex No. 2 or 138-8436 Liquid Gasket S/N: Rl51-Up
on the sealing surface of the oil pan before
assembly. The sealing surfaces are the following Part No.: 6I -4950
areas: S/N: RMSl-Up
Part No.: 6I -4950
. Connecting joint of the front accessory drive S/N: RTX1-Up
housing (17) and the front of the cylinder block
Part No.: 6I -4950
. Connecting joint of the flywheel housing (18) and S/N: T2X1-Up
the rear of the cylinder block
(15) As required, apply 4C-9509 Wicking Sealant

to the sealing surface of the integral seal after
assembly of the oil pan.
(16) As required, apply 4C-9614 Silicone Sealant,

Permatex No. 2 or 138-8436 Liquid Gasket to
the sealing surface of the integral seal before
assembly.
(19) Torque for the oil drain plug ......... 145 ! 15 N'm
(105 i 11 lb ft)
(20) Torque for the oil drain plug ...........,. 55 t 7 N m

(41 r5lbft)
i03295643
Water Tem perature Regulator

SMCS Code: 1355 lllustration 212 901 449799
Part No.: 6I -4950

S/N: LLAI-Uo
Start to open temperature ......... 81 to 84 "C
(178 to 183 'F)
Part No.: 6I -4950
S/N: R1A1-Up Fully open temperature ...92"C (198'F)
Part No.: 6I -4950 (A) Minimum opening distance at fully open
S/N: LLBl-Up temperature ..... 10.4 mm (0.41 inch)
Part No.: 6I -4950 Maximum opening time from closed position at
S/N: LLCI-Up 79'C (174'F) to fully open position at 94 'C
Part No.: 6I -4950 (201 "F) 3 minutes
S/N: LLE1-Up
Maximum closing time from fully open position
Part No.: 6I -4950 at 94 'C (201 'F) to closed position at 79 "C
S/N: LLFI-Up (174'F) 6 minutes
Part No.: 6I -4950

S/N: SBGl-Up
Part No.: 6I -4950
S/N: SBJl-Up
Part No.: 6I -4950
S/N: SBK1-Up
Part No.: 6I -4950
S/N: SBMl-Up
Part No.: 6I -4950
S/N: PESl-Up
122 RENR9362-08
i04 1 66093
Water Temperature Regulator

SMCS Code: 1355
Part No.: 248 - 551 3
Start to open temperature .... 81 to 84 .C

(178 to '183 "F)
Fully open temperature ...92"C (198 "F)
(A) Minimum opening distance at fully open

temperature ..... 10.4 mm (0.41 inch)
Air leakage at 138 kPa (20 psi).... 0 cc (0 cubic inch)
RENR9362-08 123
Water Lines
SMCS Gode: 1380
Part No.: 249 - 2846, 278 -7527
S/N: LLB1-Up
Part No.: 278-7527
S/N: LLEI-Up
Part No.: 278-7527
S/N: LLF1-Up
Part No.: 278-7527
S/N: PESl-Up
lllustration 214
Zinc rod
124 RENR9362-OB
lllustration 215 901322268 lllustration 217 9o2174108

Typical example of zinc rod assembly View A-A
1. Apply 95-3263 Thread Lock Compound to (2) Torque for pipe plug ............ ..... 110 N.m (81 tb ft)
shoulder (2) of a new zinc rod (1). Do not appty
sealant to threads (3) of the rod. Use the following procedure in order to tighten the
bolts (3) :
2. Lightly lubricate the bores for the zinc rods and

the plugs with liquid soap. 1. Tighten the clamp assembly to the tube until the
clamp is snug fit.
Torque for the zinc rod ..2.25 r .25 N.m (20 t 2 lb in)
2. Tighten the clamp assembly to the elbow.
i03996298
3. Tighten the clamp assembly to the tube
Water Lines
4. Tighten the bolts to 47 t 9 N.m (35 r 7 tb ft)
SMCS Gode: 1380
Part No.: 273 -7585, 286 - 0623 i03992052
S/N: RlAl-Up
Water Lines
Part No.: 273 -7585, 358 - 3839
S/N: RlSl-Up SMCS Gode: 1380
Part No.: 273-7585 Part No.: 261-7286

S/N: RTX1-Up S/N: RlAl-Up
Part No.: 261-728G
S/N: R1S1-Up
Part No.: 261-7286
S/N: RTX1-Up
Ar-
(1) Lubricate the bore of the O-ring seats lighfly with

Fronl view of engine

RENR9362-08 125
lllustration 219 902173426 lllustration 221 901 336589
(1) Lubricate the bore of the O-ring seals lightly with (3) O-ring seal ............ Lubricate the O-ring sealwith
glycerin or an approved equivalent. glycerin or with an equivalent lubricant.
i02660447 i02661 01 9
Water Lines Water Lines

Part No.: 158 - 6603 Part No.: 286-0627
S/N: RlAl-Up S/N: R141-Uo
Part No.: 158-6603
S/N: RTX1-Up
(1) Bolt
Apply aC-5599 Anti-Seize Compound to the

(1) O-ring seal ............ Lubricate the O-ring sealwith threads of the bolt.
glycerin or with an equivalent lubricant.
Torque .......55 t 10 N.m (41 i 7 lb ft)
(2) Plug
(2) O-ring seal ............ Lubricate the O-ring sealwith
Torque 110 N'm (80 lb ft) glycerin or with an equivalent lubricant.
126 RENR9362-08

threads and the bearing surface of the bolts.
i03996341
Water Lines
SMCS Code: 1380
Part No.:355-2313
S/N: RlSl-Up
Note: Before assembly, lubricate the threads and the (1) Torque for high temperature bolts.... 55 r 10 N.m
bearing surface of the bolts with 4C - 5599 Anti-Seize (41 r7tbft)
Compound
RENR9362-08 127
i03686721
Water Lines
SMCS Gode: 1380
Part No.: 9Y - 91 73
S/N: R151-Uo
(2) Before assembly, lubricate the threads and

the bearing surface of the bolts with 4C - 5599
Typical example

glycerin.
128 RENR9362-08
i03991 989 (2) Torque for the tube joint 12.0 ! 0.5 N.m
(106.2 r 4.4 lb in)
Water Lines
(Aftercooler) i01 540245
SMCS Code: 1380 Thermostatic Valve

Part No.: 353 - 2478, 353 - 2683 SMCS Code: 1355
S/N: R1S1-Up
Part No.: 1 28 - 2063
S/N: LLBl-Up
Part No.: 1 28 - 2063
S/N: LLCI-Uo
Part No.: 128 - 2063
S/N: SBG1-Up
Part No.: 1 28 - 2063
S/N: SBJl-Uo
Part No.: 128-2063
S/N: SBK1-Up
Part No.: 128-2063
S/N: PES1-Up
Part No.: 128 - 2063
S/N: T2X1-Uo
Typical example
Fronl view of engine
(1) Lightly lubricate bore of the O-ring seals for the

tube with 5P - 3975 Rubber Lubricant.
(1) Thermostatic valve group
Install the thermostatic valve. Orient the markings

and "C" as the sections are shown in the
illustration.
(2) Bolt
t 2 N'm
Tighten the bolt to the following torque: ...20
(15r1tbft)
(3) Temperature regulator assembly
Openingtemperature .. 29 'C (84 "F)
lllustration 228 90217124o temperature 4'1 "C (106 "F)
Fully open
Typical example Minimum opening distance at fully open
Right side view of engine temperature ...7.87 mm (0.3'10 inch)
RENR9362-08 129
Thermostatic Valve
SMCS Code: 1355
Part No.: 216 - 6217, 292-6969
S/N: LLA1-Up
Part No.: 216 -6217, 282- 8537, 292-6969
S/N: LLB1-Up
Part No.: 216 - 6217 , 282 - 8537, 292 - 6969
S/N: LLC1-Up
Part No.:292-6969
S/N: C8E1-Up
Part No.: 216 - 6217, 282- 8537, 292 - 6969
S/N: LLE1-Up
Part No.: 216 - 6217, 292- 6969
S/N: LLF'1-Up
Part No.: 2'16-6217
S/N: SBGl-Up
Part No.: 216-6217
S/N: SBJl-Up
Part No.: 292-6969 g0 1 428095
S/N: C8K1-Up lllustration 230
Part No.: 216-6217 (1) Water temperature regulator

S/N: SBK1-Up
Start to open temperature ................. 18 to 23 'C
Part No.: 216-6217 (64 to 73 'F)
S/N: PES1-Up Fully open temperature 33'C (9'1 "F)
Part No.: 216-6217 (2) Apply glycerin or an approved equivalent to the

S/N: RlSl-Uo bore of the two O-ring seals.
Part No.: 216 -6217, 292- 6969 (A) Minimum opening distance at fully open
S/N: RMS1-Up t
temperature ...... 9.0 0.5 mm (0.35 r 0.02 inch)
Part No.: 216-6217
S/N: T2X1-Up
130 RENR9362-08
i02866901 Start to open temperature .............. 27 'C (81 "F)

Thermostatic Valve temperature
Fully open 35'C (95'F)
Minimum opening distance at fully open
SMCS Gode: 1355
temperature ... 9.48 mm (0.373 inch)
Part No.: 7E-4711 i03823534
S/N: LLA1-Up
Part No.: 7E-4711
Water Connection Group
S/N: LLBI-Uo SMCS Gode: 1355
Part No.: 7E-4711 Part No.: 284 - 8013
S/N: LLCl-Up
Part No.: 7E-4711
S/N: LLE'1-Up
Part No.: 7E-4711
S/N: LLF1-Up
Part No.: 7E-4711 A
S/N: SBGl-Up
Part No.: 7E-4711
S/N: SBJl-Up
o
A
Part No.: 7E-4711
S/N: SBK1-Up
Part No.: 7E-4711
S/N: PESl-Up
Part No.: 7E-4711
S/N: RMS1-Up
Part No.: 7E-4711
S/N: T2X1-Uo
(1) Lightly lubricate the bore of the O-ring sealwith

Fan Drive
SMCS Code: 1359
Part No.: 7W-3953
S/N: LLA1-Up
Part No.: 7W-3953
S/N: LLB1-Up
Part No.: 7W-3953
S/N: LLC1-Up
Part No.: 7W-3953
S/N: LLE1-Up
Part No.: 7W-3953
S/N: LLF1-Up
(1) Torque for the two bolts .. 20 t 2 N'm (15 r 1 lb ft)
Part No.: 7W-3953
(2) Water temperatu re reg ulator S/N: RMSl-Up
Quantity .....................2
RENR9362-08 131
lllustralion 233 901417759
Typical example
Note: Fill the bearing cavity with 1P-0808

Multipurpose Grease.

the lubricant that is being sealed.
(2) Lubricate the sealing lip of the lip type seal lightly
(3) Apply red Loctite 271 to the threads of the bolts.

(4) Apply grease into the grease fitting in order to
adjust the belt tension. Do not apply grease
during the assembly of the fan drive group.
132 RENR9362-08
i040 1 4370
Engine Oil Sump Pump

SMCS Code: 1324
Part No.: 7W-9704
S/N: LLA1-Up
Part No.: 7W-9703, 7W-9704
S/N: LLBl-Uo
Part No.: 7W-9704
S/N: PES1-Up
(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 white Loctite Breakloose PST 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.
2. Unscrew the oil pickup assembly until the word

"UP" is at the 12 o'clock position.
3. Hold the oil pickup assembly in position and

tighten the nut to a torque of 150 t 15 N.m
(110 r 11 rb ft).
,| ??
RENR9362-08
i01 980486
Water Pump
SMCS Code: 1361
Part No.: 212-8176
S/N: C8E1-Up
Part No.: 212-8176
S/N: CBK1-Up
Type 1
A-A
Typical example
(1) Oil seal 1. Install ring assembly (2) and oil seal (1) into
the pump housing. Install the oil seal dry. Do
(2) Ring assembly not lubricate the sealing lip. Use the correct
installation tool and use a slow, even motion to
(3) Ceramic ring and rubber seal press the seal into the pump housing.
(4) Seal assembly 2. lnstall shaft (6) through the oil seal.
(5) Spring 3. Install the shaft's thrust washer (7).
Follow these recommendations for installation of the 4. Lubricate the outside diameter of the ceramic rino
seals: and rubber seal (3) with clean water.
Note: The seal installation tool is part of the 5. Orient the polished face of the ceramic ring toward
replacement seal assembly. seal assembly (4). Use the installation tool and
hand pressure to seat the ceramic ring and the
rubber seal into the pump housing.
134 RENR9362-08
6. Remove spring (5) from the seal assembly,

Lubricate the inside diameter of the seal assemblv
with clean water.
7. Use the seal installation tool and hand pressure

to install the seal assembly onto the shaft until the
face of the seal assembly makes light contact with
the face of the ceramic ring and rubber seal.
8. Install the spring onto the seal assembly.
(6) Shaft
Width of shaft's groove for thrust
washer ...... 8.75 t 0.05 mm (0.345 r 0.002 inch)
(7) Thrust washer

Thickness 8.50 r 0.05 mm
(0.3346 t 0.0020 inch)
(8) Nut
Torque .200 f 25 N.m (150 r 18 lb ft)

(e) Stud
Torque ......... 35 t 5 N.m (26 r 4 lb ft)

(10) Nut
Torque .........27 t 4 N'm (20 r 3 lb ft)
(11) O-ring seal
Lubricate the O-ring sealwith clean engine oil.
(12) O-ring seal
Lubricate the O-ring seal with clean engine coolant.
(13) O-ring seal
Lubricate the O-ring sealwith glycerin.
(14) Adapter
Torque ..... 100 t 10 N.m (75 r 7 lb ft)
Maximum leakage per minute for the water seal at

138 kPa (20 psi) of air pressure ..... 20 cc (1.22 cu in)
Maximum leakage per minute for the oil seal at

138 kPa (20 psi)of air pressure.....24 cc (1.46 cu in)
RENR9362-08 4?A
Type 2
Typical example
(1) Oil seal (11) Stud
(2) Ring assembly Torque ......... 35 t 5 N.m (26 t 4 lb ft)

(3) Ceramic ring and rubber seal (12) Nut
(4) Seal assembly Torque .........27 t 4 N'm (20 t 3 lb ft)
(13) O-ring seal

(5) Spring
(14) Adapter
(6) Shaft
Shaft's outer diameter for
Torque ..... 100 t 10 N'm (75 t 7 lb ft)
impeller 25.400 t 0.013 mm
(1.0000 t 0.0005 inch) Assembly Procedure
Width of shaft's groove for thrust
washer ...... 8.75 r 0.05 mm (0.345 t 0.002 inch) Follow this procedure for assembly:
(7) Thrust washer Note: The seal installation tool is part of the
replacement seal assembly.
Thickness 8.50 t 0.05 mm
(0.3346 t 0.0020 inch) 1. Install ring assembly (2) and oil seal (1) into
the pump housing. Install the oil seal dry. Do
(8) lmpeller not lubricate the sealing lip. Use the correct
installation tool and use a slow, even motion to
Diameter of impeller's bore .. 25.342 t 0.013 mm press the seal into the pump housing.
(0.9977 t 0.0005 inch)
2. Install shaft (6) through the oil seal and through
(9) O-ring seal the ring assembly.
(10) O-ring seal 3. Instdll thrust washer (7).
136 RENR9362-OB
4. Lubricate the outside diameter of the ceramic Part No.: 2W -9726, 2W - 9729
ring and rubber seal (3) with clean water or with S/N: LLB1-Up
2O7 -1600 Rubber Lubricant.
Part No.: 2W -97 26, 2W - 9729
5. Orient the polished face of the ceramic ring toward S/N: LLC1-Up
seal assemb! (a). Use the installation tool and
hand pressure to seat the ceramic ring and the Part No.: 2W -9726, 2W -9729
rubber seal into the pump housing. S/N: LLE1-Up
Part No.: 2W -9726, 2W - 9729
6. Remove spring (5) from the seal assembly. S/N: LLFI-Up
Lubricate the inside diameter of the seal assembly
with clean water or with 207 - 1 600 Rubber Part No.: 2W-9729
Lubricant, S/N: SBGl-Uo
7. Use the seal installation tool and hand pressure Part No.: 2W-9729
to installthe sealassembly onto the shaft untilthe S/N: SBJ'1-Up
face of the seal assembly makes light contact with
Part No.: 2W-9729
the face of the ceramic ring and rubber seal.
S/N: SBK1-Up
8. Install the spring onto the seal assembly. Part No.: 2W-9729
S/N: SBMl-Up
9. Lubricate the shaft with clean engine oil. Place the
shaft onto a fixture that will absorb the load and Part No.: 260-8657, 2W-9729
press impeller (8) onto the shaft until the face of S/N: PESl-Up
the impeller is flush with the face of the shaft.
Part No.: 2W-9729
10. Lubricate the bore for O-ring seal (9) with clean S/N: RlSl-Up
engine oil. Part No.: 2W - 9726, 2W -9729
S/N: RMSl-Up
11. Lubricate the bore for O-ring seal (10) with clean
engine coolant. Part No.: 2W-9729
S/N: RTX1-Up
12. Tighten studs (11) according to the specified
torque. Part No.: 260-8657, 2W-9729
S/N: T2X1-Up
l3.Tighten nuts (12) according to the specified
torque.
14. Lubricate the bore for O-ring seal (13) with

glycerin.
15. Tighten adapter (14) according to the specified

torque.
Maximum leakage per minute for the water seal at

138 kPa (20 psi) of air pressure .....20 cc (1.22 cu in)
Maximum leakage per minute for the oil seal at

1 38 kPa (20 psi) of air pressu re . .. . . 24 cc (1 .46 cu in)
i03700561
Water Pump
SMCS Code: 1361
Part No.: 2W -9726, 2W - 9729
S/N: LLA1-Up
Part No.: 2W-9729
S/N: R141-Up
RENR9362-08 137
901 991 398

lllustration 237
(2) Ring assembly (3) Water pump seal group
(1) Do not lubricate the sealing lip of the lip type seal. Minimum leakage per minute for the lip type seal at
138 kPa (20 psi) of air pressure is less than 24 cc
(4) Lubricate the bore of the O-ring seals with ('1.5 cu in).
Minimum leakage per minute for the water pump seal
(5) Lubricate the shaft with a thin film of clean engine assembly at 138 kPa (20 psi) of air pressure is less
oil before pressing the impeller onto the shaft, than 20 cc (1.2 cu in).
The end of the shaft must be flush with the face
of the impellerwithin 0.15 mm (0.006 inch).
i041 07851
(B) Bore of the impeller for new

shaft .......... ........ 25.342 t 0.013 mm
(0.9977 t 0.0005 inch) SMCS Gode: 1371
(C) Width of the groove for thrust Part No.: 9Y - 8175
washer ...... 8.75 t 0.05 mm (0.344 t 0.002 inch) S/N: LLA1-Up
(D) Thickness of new thrust washer............. 8.5 mm Part No.: 9Y - 81 75
(0.33 inch) S/N: LLBl-Up
(E) Clearance between the impeller and the Part No.: 9Y - 81 75

S/N: LLCl-Up
cover......... ...... 0.5000 t 0.4925 mm
(0.01968 t 0.01939 inch) Part No.: 9Y - 81 75
S/N: LLEl-Up
(6) Torque for the taperlock studs ........... 35 t 5 N'm
(26r4rbft) Part No.: 9Y-8175
S/N: LLFl-Up
(7) Torque for the full nuts ....27 ! 4 N,m
(239 t 35 lb in) Part No.: 9Y - 81 75
S/N: SBGl-Up
138 RENR9362-08
Part No.: 9Y-8175

S/N: SBJl-Up
Part No.: 9Y-8175
S/N: SBK1-Up
Part No.: 9Y - 81 75
S/N: PESl-Up
Part No.: 9Y-8175
S/N: RlSl-Up
Part No.: 9Y - 81 75
S/N: RMS1-Up
Part No.: 9Y-8175
S/N: T2X1-Up
lllustration 238 g0 1 486033
Typical example
(A) Width of groove in the shaft for thrust Bore in the sleeve bearing for auxiliary drive
washer ...... 6.25 r 0.05 mm (0.246 t 0.002 inch) shaft.......... ........ 75.000 t 0.055 mm
(2.9528 t 0.0022 inch)
(B) Thickness of the new thrust Diameter of new auxiliary drive shaft (not
washer 6.000 r 0.023 mm shown) 74.900 r 0.015 mm
(0.2362 t 0.0010 inch) (2.9488 r 0.0006 inch)
(C) Dimensions of the shaft (D) Dimensions for the impeller

RENR9362-08 139
Bore diameter of the impeller (7) Lubricate the bore of the O-ring seal lightly with
........ 19.000 r 0.013 mm (0.7480 t 0.0005 inch) sealant that is being sealed.
Diameter in the shaft for
impeller 19.050 to 19.063 mm (B) Lubricate the bore of the O-ring seal with clean
(0.7500 to 0.7505 inch) engine oil, glycerin, or clean water.
(E) Installation depth of the sleeve bearing in the

housing assembly ....... '1.5 t 0.5 mm io37 11141
(0.06 t 0.02 inch)

Note: Do not lubricate the sealing lip of the lip type SMCS Code: 1371
seal (1).
Part No.: 291-4311
Minimum leakage per minute for the lip type seal at S/N: LLA1-Up
138 kPa (20 psi) of air pressure is less than24 cc
(1.5 cu in). Part No.: 291-4311
S/N: LLBl-Up
the water pump seal assembly: Part No.: 291-4311
S/N: LLCl-Up
1. Lubricate the outside diameter of ceramic ring and Part No.: 291-4311
rubber seal (2) with clean water or with 207 - 1 600 S/N: C8E1-Up
Rubber Lubricant.
Part No.: 291-4311
2. Orient the polished face of the ceramic ring toward S/N: LLEl-Up
water pump seal assembly.
Part No.: 291-4311
3. Use the installation tool and hand pressure to seat S/N: LLFl -Up
the ceramic ring and the rubber seal into the water
pump housing. Part No.: 291-4311
S/N: SBGl-Up
4. Remove spring (4) from the water pump seal Part No.: 291-4311
assembly. S/N: SBJl-Up
5. Lubricate the inside diameter of the water pump Part No.: 291-4311
seal assembly with clean water or with 2O7 - 1600 S/N: C8K1-Up
Rubber Lubricant.
Part No.: 291-4311
6. Use the seal installation tool and hand pressure S/N: SBK1-Up
to install the water pump seal assembly onto the Part No.: 291-4311
shaft. Install, until the face of the water pump seal S/N: PES1-Up
assembly makes light contact with the face of the
ceramic ring and rubber seal. Part No.: 291-4311
S/N: RMSl-Up
7. Install spring (4) onto the water pump seal
assembly. Part No.: 291-4311
S/N: T2X1-Up
Assembled length of the spring .. 17.45 r 0.79 mm
(0.687 t 0.031 inch)
Load on spring at assembled
length 40.03 f 4.45 N (9.00 r 1.00 lb)

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.
of the impeller within 0.076 mm (0.003 inch).
RENR9362-OB
Typical example
(A) Width of groove in the shaft for thrust (E) Installation depth of the sleeve bearing in the
washer ...... 6.25 r 0.05 mm (0.246 r 0.002 inch) water pump housing .. 1.5 r 0.5 mm
(0.06 r 0.02 inch)
(B) Thickness of the new thrust
washer 6.000 t 0.025 mm Note: Do not lubricate the sealing lip of the ip type
I
t
f
(0.2362 0.0010 inch) seal (1).

(C) Dimensions of the shaft Minimum leakage per minute for the lip type seal at
138 kPa (20 psi) of air pressure is less than 24 cc
Bore in the sleeve bearing for auxiliary drive (1.5 cu in).
shaft .......... ....,... 75.000 0.055 mmt
t
(2.9528 0.0022 inch) (3) Use the following procedure in order to assemble
Diameter of new auxiliary drive shaft (not
the water pump seal assembly.
shown) 74.900 t 0.015 mm
t
(2.9488 0.0006 inch) 1. Lubricate the outside diameter of ceramic ring and
rubber seal (2) with clean water or with 207 - 1600
(D) Dimensions for the impeller Rubber Lubricant.
Bore diameter of the impeller
........ 19.000 r 0.013 mm (0.7480 t 0.0005 inch) 2. Orient the polished face of the ceramic rinq toward
Diameter in the shaft for water pump seal assembly.
impeller 19.050 to 19.063 mm
3. Use the installation tool and hand pressure to seat
(0.7500 to 0.7505 inch)
the ceramic ring and the rubber seal into the water
pump housing.
RENR9362-08 141
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 - 1 600
Rubber Lubricant.
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 t 0.79 mm

(0.687 t 0.031 inch)
Load on spring at assembled
length 40.03 r 4.45 N (9,0 r 1.0 tb)

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 onto the shaft.
of the impeller (5) within 0.076 mm (0.0030 inch).

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

engine oil, glycerin or clean water.
142 RENR9362-08
i031 52862

SMCS Gode: 137'1
Part No.: 9Y-8909

S/N: RlAl-Up
Part No.: 9Y-8909
S/N: LLB1-Up
Part No.: 9Y-8909
S/N: SBJl-Uo
Part No.: 9Y-8909
S/N: SBK1-Up
Part No.: 9Y-8909
S/N: PESl-Up
Part No.: 9Y-8909
S/N: T2X1-Up
Minimum leakage per minute for the lip type seal at 1. Use the seal installation toolwith hand pressure
138 kPa (20 psi)of air pressure is less than 24 cc to install the rubber seal (2) and the ceramic ring
(1.5 cubic inch). (3)as a unit into the pump housing assembly.
(1) Do not lubricate the sealing lip of the lip type seal. 2. Remove the spring from the seal group.
Maximum leakage per minute for the water seal at 3. Use the seal installation toolwith hand pressure to
138 kPa (20 psi) of air pressure is less than 20 cc install the seal group onto the shaft until the seal
(1.2 cubic inch). faces make light contact.
Use the following procedure in order to install the 4. Install the spring onto the seal group.
seal group (4):
(5) Lubricate the shaft with a thin film of clean
Note: Only use clean water or P-80 to lubricate the engine oil before pressing the impeller onto the
parts. shaft. The end of the shaft must be flush with
the face of the impeller within 0.00 t 0.08 mm
Note: The seal installation tool is part of the (0.000 t 0.003 inch).
replacement seal group.
RENR9362-08 143
(B) Clearance between the impeller and the water

pump cover ..... 0.5000 t 0.4925 mm
(0.01968 r 0.01939 inch)
(C) Distance from the impeller to the face of the

pump housing assembly .. 31,6526 t 0.4425 mm
t
(1.24616 0.01742 inch)
(6) Lubricate the O-ring seal lightly with glycerin or

an approved equivalent.
(7) Torque for four bolts....... 35 t 5 N.m (26 t 4 lb ft)
(8) Lubricate the O-ring seal lightly with glycerin or

an approved equivalent.
(9) Torque forthe adapter 100 t 10 N.m

(75r7tbft)
(10) Torque for three full nuts 27 t 4 N.m
(20r3tbft)
i03686680 Right side view
Gylinder Block (1) Torque for the plugs .. 100 r 15 N.m (74 r 11 tb ft)
SMCS Code: 1201 (A) Extension of dowels from the surface of the
Part No.: 350-5225
cylinder block .. 20.0 t 0.5 mm (0.79 t 0.02 inch)
S/N: C8E1-Up (B) Thickness of the spacer plates ......... 12.363 mm
Part No.: 35O-5225 (0.4867 inch)
S/N: C8K1-Up
(C) Height of cylinder liner
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 t 0.02 inch)
(F) Bore in the block for the camshaft

bearings 98.000 r 0.020 mm
(3.8583 t 0.0008 inch)
(G) Oil holes must be positioned from horizontal at

the following angle. .. 20 r 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
Front view of cylinder block the cylinder block.
(2) Camshaft bearing junction
(H) Main bearing cap width
Width of main bearing ........ 340.030 t 0.0'15 mm
(13.3870 t 0.0006 inch)
144 RENR9362-08
Width of cylinder block for main bearing Part No.: 240-6651

cap ............ ...... 339.985 r 0.015 mm S/N: LLA1-Up
(13.3852 + 0.0006 inch)
Tight press fit between the sides of the main Part No.: 240-6651
bearing cap and the cylinder block ..... 0.075 mm S/N: R1A1-Up
(0.0030 inch)
Loose press fit between the sides of the main
Part No.: 240-6651, 240-6653
bearing cap and the cylinder block ..... 0.015 mm
S/N: LLB1-Up
(0.0006 inch) Part No.: 240-6651
S/N: LLC1-Up
(J) New dimension from centerline of crankshaft
bearing bore to the top of the block .. 586.00 mm Part No.: 240-6651
(23.071 inch) S/N: LLEl-Uo
(K) Bore in the block for the main bearings Part No.: 240 - 6651
S/N: LLF'I-Up
Standard, original new
size ........... ...... 169.742 t0.020 mm Part No.: 240-6651
(6.6827 t 0.0008 inch) S/N: SBGl-Up
0.63 mm (0.025 inch) larger than original Part No.: 240-6651, 240-6653
size ........... ...... 170.372 t 0.020 mm S/N: SBJl-Up
(6.7076 t 0.0008 inch)
Part No.: 240-6651, 240-6653
(L) New dimension from centerline of crankshaft S/N: SBK1-Up
bearing bore to bottom of block (pan
rails) .......... . 230.00 mm (9.055 inch) Part No.: 240-6653
S/N: SBMl-Up
(3) Main bearing cap
Part No.: 122-5954, 240 - 6653
Use the following procedure to tighten the main S/N: PES1-Up
bearing cap bolts: Part No.: 240-6651
S/N: R1S'1-Up
1. Install main bearing caps with the part number
and FRONT toward the front of the block. Each Part No.: 240-6651
cap has a number. Each cap must be installed in S/N: RMSl-Up
the same position as the correct number on the
side of the cylinder block pan rail. Part No.: 240-6651
S/N: RTX1-Up
2. Before assembly, apply clean engine oil to the
Part No.: 240-6651, 240-6653
S/N: T2X1-Up
3. Tighten the bolts in the numerical sequence (4,
5,6,7) to 190 t 14 N.m (140 t 10 tb ft). Referto
lllustration 242for the tightening sequence.
4. Again, tighten the bolts in the numerical sequence

(4, 5,6, 7)to an angle of 180 r 5 degrees. Refer
to lllustration 242 for the tightening sequence.
(M) Extension of dowels from the surface of the

cylinder block..., 6.0 t 0.5 mm (0.24 t 0.02 inch)
(N) Extension of dowels from the surface of the

cylinder block.. 19.0 t 0.5 mm (0.75 r 0.02 inch)
(P) Extension of dowels from the surface of the

cylinder block .. 40.0 r 0.5 mm (1.58 + 0.02 inch)
i031 52764
Gylinder Block
SMCS Gode: 1201
RENR9362-08 145
(1) Torqueforfourplugs.......... 1001'15 N'm

(75 r 11 tb ft)

(D) Height of the cylinder liner
For the correct method of determining the height

of the cylinder liner, refer to Testing And Adjusting,
"Gylinder Liner Projection".
(E) Bore in the block for the camshaft

bearings 98.000 t 0.020 mm
(3.8583 t 0,0008 inch)
(F) The oil holes in the camshaft bearings must

be positioned from horizontal at the following
angle: .... 20 t 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.
(G) New dimension from centerline of crankshaft

bearing bore to the top of the block ....... 586 mm
(23.'1 inch)
Front view (H) New dimension from centerline of crankshaft

bearing bore to bottom of block (pan
rails) ........... ......... 230 mm (9.1 inch)
(J) Bore in the block for the main bearings

size .......,.,. ...... 169.742t 0.020 mm
t 0.0008 inch)
(6.6827
0,63 mm (0.025 inch) larger than original
size ........... ...... 170.372 t 0.020 mm
(6.7075 t 0,0008 inch)
(K) Dimension for crankshaft main bearing cap

Width of crankshaft main bearing
lllustration 244
g0 1 434393 cap............ ...... 340.030 t 0.015 mm
Right side view
(13.3870 t 0.0006 inch)
Width of cylinder block for crankshaft main
bearing cap ............ 339.985 t 0.0'15 mm
Note: During assembly, the bottom of spacer plates, (13.3852 t 0.0006 inch)
top of cylinder block and both sides of plate gasket
Tight press fit between the sides of the
must be free of fuel, oil, water, gasket adhesives,
crankshaft main bearing cap and the cylinder
assembly compounds and any other contaminants.
block ......... . 0.075 mm (0.0030 inch)
Loose oress fit between the sides of the
(A) Thickness of the spacer plate .......... 12.313 mm
crankshaft main bearing cap and the cylinder
(0.4848 inch)
block ......... . 0.015 mm (0.0006 inch)
(B) Thickness of the plate gasket
(4) Main bearing cap
between the cylinder block and spacer
p|ate.......... ......... 0.194 to 0.218 mm
Use the following procedure to tighten the crankshaft
(0.0076 to 0.0086 inch)
main bearing cap bolts:
(C) Extension of the dowel from the top face of the
cylinder block .. 21.0 ! 0.5 mm (0.83 t 0.02 inch)
146 RENR9362-08
1. Install main bearing caps with the part number i04111825

and "FRONT" toward the front of the block. Each
cap has a number. Each cap must be installed in Cylinder Block
the same position as the correct number on the
side of the cylinder block pan rail. SMCS Code: 1201
2. Before assembly, apply clean engine oil on the

Part No.: 237 -7957
threads of the bolts. S/N: LLCl-Up
Part No.: 237 -7957
3. Tighten bolt (5) through bolt (8) in the numerical S/N: LLEl-Up
sequence that is shown in lllustration 2431o a
torque of 190 t 14 N.m (140 t 10 lb ft).
4. Tighten bolt (5) through bolt (8) again in the

numerical sequence to a rotation of 180 t 5
degrees.
(L) Extension of the dowel from the rear face of the

cylinder block .... 6.0 r 0.5 mm (0.24 r 0.02 inch)
(M) Extension of the dowel from the front face of the

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

cylinder block.. 19.0 t 0.5 mm (0.75 r 0.02 inch)
(P) Extension of the dowel from the front face of the

cylinder block .. 40.0 t 0.5 mm (1.57 t 0.02 inch)
Front view of cylinder block


RENR9362-0B
specification, .""1'31
Note: During assembly, the bottom of spacer plates, Standard, original new
top of cylinder block and both sides of plate gasket size ,.......... ...... 169.742t 0.020 mm
must be free from contaminants. And should also (6.6827 t 0,0008 inch)
be free of fuel, oil, water, gasket adhesives, and 0.63 mm (0.025 inch) larger than original
assembly compounds size ........... ...... 170.372 t 0.020 mm
(6.7076 t 0.0008 inch)
(A) The dowels extend above the face by the
following distance. .... 21.0 t 0.5 mm (L) New dimension from centerline of crankshaft
(0.83 r 0.02 inch) bearing bore to bottom of block (pan
rails) .......... . 230.00 mm (9.055 inch)
(B) Thickness of spacer plates '12.313 mm
(0.4848 inch) (3) Crankshaft bearing cap
(C) Thickness of gasket between the cylinder block Use the following procedure to tighten the main
and spacer plates 0.194 to 0.218 mm bearing cap bolts:
(0.0076 to 0.0086 inch)
1. Install crankshaft bearing caps with the part
(D) The dowels extend above the face by the number and FRONT toward the front of the
following distance. ....20.0 t 0.5 mm block. Each cap has a number. Each cap must
(0.79 r 0.02 inch) be installed in the same position as the correct
number on the side of the cylinder block pan rail.
(2) Torque for plugs ....... 100 r 15 N.m (75 r 11 lb ft)
2. Put clean engine oil on the bolts before assembly.
(E) Height of Cylinder liner
3. Tighten the bolts in the numerical sequence (4, 5,
For the correct method of determining height of the 6, 7) to the following torque.
liner, refer to Testing and Adjusting, "Cylinder Liner
Projection". Torque for bolts ....... 190 t 14 N.m (140 i 10lb ft)
'(F) Bore in the block for the camshaft 4. Tighten the bolts again in the numerical sequence
bearings 98,000 t 0.020 mm to the following rotation.
(3.8583 r 0.0008 inch)
Angle for bolts .......... 180 I 5 degrees
(G) Oil holes must be positioned from horizontal at
the following angle. .. 20 ! 5 degrees (M) The dowel extends from the rear face of the
block by the following distance. ..... 6.0 t 0.5 mm
Note: All centerlines through oil holes in the camshaft (0.24 ! 0.02 inch)
bearings (G) and the camshaft bearing junctions (1)
are shown for each side of the cylinder block. (N) The dowels extend from the front face of the
block by the following distance. ..... 6.0 t 0.5 mm
(H) New dimension from centerline of crankshaft (0.24 ! 0.02 inch)
bearing bore to the top of the block .. 586.00 mm
(23.071 inch) (P) The dowels extend from the rear face of the
block by the following distance. ... 19.0 t 0.5 mm
(J) Crankshaft bearing cap width (0.75 t 0.02 inch)
Width of crankshaft (R) The dowels extend from the front face of the
bearing 340.030 t 0.015 mm block by the following distance. ... 40.0 t 0.5 mm
(13.3870 t 0.0006 inch) (1.58 t 0.02 inch)
Wdth of cylinder block for crankshaft bearing
cap............ ...... 339.985 t 0.015 mm (B) Lubricate the bore of the O-ring seals lightly with
(13.3852 t 0.0006 inch) sealant that is being sealed.
Tight press fit between the sides of the crankshaft
(0.0030 inch)
Loose press fit between the sides of the
crankshaft bearing cap and the cylinder
block ......... . 0.015 mm (0.0006 inch)
(K) Bore in the block for the crankshaft bearings
148 RENR9362-08
i02909403 (4) Plug

Gylinder Block Torque ... 100 r 15 N.m (75 r 11 tb ft)
SMCS Code: 1201 (5) Height of Cylinder liner
Part No.: 350-4388 For the correct method of determining height of the
S/N: T2X1-Up liner, refer to Testing And Adjusting, "Cylinder Liner
Projection".
(6) Bore
Bore in the block for the camshaft
bearings 98.000 t 0.020 mm
(3.8583 t 0.0008 inch)

(8) Centerline through oil holes in camshaft bearings
Oil holes must be positioned from horizontal at
angle (X) to the following angle: .. 20 t 5 deOre1}
Note: All centerlines through oil holes in the camshaft

bearings (8) and bearing junctions (7) must be in the
position that is shown for each side of the cylinder
block.
(9) New dimension from centerline of crankshaft

g001 23062
bearing bore to the top of the block .. 586.00 mm
llluskation 247
(23.071 inch)
Front view of cylinder block
(10) Main bearing cap width
Width of main bearing cap .. 340.030 t 0.01S mm
(13.3870 t 0.0006 inch)
Wdth of cylinder block for main bearing
cap ............ ...... 339.985 t 0.015 mm
(13.3852 r 0.0006 inch)
Tight press fit between the sides of the main
(0.0030 inch)
i:ff ; ffi?iitl"f'.Tff ItJff ';[?? ::

*3
&?h J
(0.0006 inch)
(11) Bore in the block for the main bearings

(1) Spacer plate size ........... ...... 169.742 t 0.020 mm
t 0.0008 inch)
(6.6827
Thickness of spacer plates 1 2. 31 3 mm 0.63 mm (0.025 inch) larger than original
(0.4848 inch) size ...,....... ...... 170.372 t 0.020 mm
(6.7076 t 0.0008 inch)
(2) Gasket
(12) New dimension from the centerline of the
Thickness of gasket between the cylinder block crankshaft bearing bore to the bottom of the block
and spacer plates .. 0.18 to 0.22 mm (pan rails) ... 230.00 mm (9.055 inch)
(0.007 to 0.009 inch)
(13) Main bearing cap bolts
(3) Dowel
All dowels extend above the face by the following
distance: ......... 21.0 r 0.5 mm (0.83 t 0.02 inch)
RENR9362-08 149
Install main bearing caps with the part number and i02871 050
FRONT toward the front of the block. Each cap has
a number. Each cap must be installed in the same Gylinder Liner
position as the correct number on the side of the
cylinder block pan rail. SMCS Code: 1216
Part No.: 211-7826
Note: The procedure to tighten the main bearing cap
bolts depends on the diameter of the bolts. There is
a different procedure for 314 inch bolts and for 7/B
inch bolts.
Procedure for Tightening 314Inch Diameter Bolts

(5P-8288 Bolt)
1. Put clean engine oil on the bolts before assembly.
2. Tighten the bolts in the letter sequence.
Torque . 136 t 14 N'm (100 r 10lb ft)

3. Tighten the bolts in the letter sequence again,
lllustration 249 go13e9s36
Rotation 211lsdegrees
(A) Bore in new cylinder liner .. 170.025 t 0.025 mm
Procedure for Tightening 718Inch Diameter Bolts (6.6939 t 0.00'10 inch)
(7X-7925 Bolt)
(B) Thickness of flange (1) on cylinder
1. Put clean engine oil on the bolts before assembly. |iner......... 12.65 ! 0.02 mm (0.498 t 0,001 inch)
2. Tighten the bolts in the letter sequence. Use the liner again with any used piston or
any new piston if all the measurements are
Torque .. 190 i 14 N'm (140 t 10 lb ft) in the following range. Use a FLEX-HONE
first. ........... ....... 170.000 to 170.152 mm
3. Tighten the bolts in the letter sequence again. (6.6929 to 6.6989 inch)
Rotation 18015 deorees Use the liner again with the original piston
if the measurements of the upper bore are
(14) Dowel in the following range. Use a FLEX-HONE
The dowel extends from the rear face of the block
first. ........... ....... 170.0001o 170.229 mm
(6.6929 to 6.7019 inch)
by the following distance: 6.0 t 0.5 mm
(0.24 ! 0,02 inch)
Use the following procedure to install the cylinder
liner:
(15) Plug
Torque .. 100 t 15 N'm (75 t 11 lb ft) 1. Apply liquid soap on the cylinder block liner bore
surfaces and the rubber seals that are on the
('16) Dowel lower end of the cylinder liner.
The dowels extend from the front face of the 2. Dip the filler band (2) completely in clean engine
block by the following distance: ..... 6.0 + 0.5 mm oil for a moment.
(0.24 ! 0.02 inch)
3. lmmediately install the filler band in the groove
(17) Dowel that is under the flange.
The dowels extend from the rear face of the block 4. lmmediately install the cylinder liner into the
by the following distance: 19.0 f 0.5 mm cylinder block before the expansion of the filler
(0.75 r 0.02 inch) band.
(18) Dowel Note: Refer to Reuse And Salvage Guidelines,
The dowels extend from the front face of the SEBFB049, "Visual Inspection of the Piston" for more
block by the following distance: ... 40.0 r 0.5 mm information. Also, refer to Guideline For Reusable
(1.58 t 0.02 inch) Parts And Salvage Operations, SEBFB068, "Cylinder
Liners" for more information.
150 RENR9362-08
This piston has a square top piston ring. Use the

246-'l176 Piston Ring Groove Gauge Gp for
Piston and Rings measuring the top piston ring groove.
(One-Piece Piston)
This piston has a keystone type of intermediate
SMCS Code= 1214 piston ring. Use the 1U-6431 Piston Ring Groove
Gauge Gp for measuring the intermediate piston ring
Part No.:281 -6139,281 -6141 groove. For correct use of the piston ring groove
S/N: LLA1-Up gauge group, refer to the instruction card that is with
the piston ring groove gauge group.
Part No.:281-6139, 281 -6141
S/N: LLB1-Up Note: Prior to the installation of the piston rings,
Part No.: 281 -6139, 281 -6141 the ring grooves must be completely lubricated with
S/N: LLCl-Up clean engine oil. After assembly, the mating surfaces
of the rings to the cylinder liner must be completely
Part No.:333-2239 lubricated with clean engine oil.
S/N: C8E1-Up
Part No.: 281-6141 Top Piston Ring (1)
S/N: LLEl-Up
Install the top piston ring with the "UP-1" side toward
Part No.: 282-9965 the ton of the niston
S/N: SBG1-Up O
When the new top piston ring is installed in a cylinder
Part No.:282-9965 liner with a bore size of 170 mm (6.7 inch), the
S/N: SBJl-Up clearance between the ends of the piston ring is the
Part No.: 333-2239
following value. ........ . 0.625 t 0.125 mm
(0.0246 t 0.0049 inch)
S/N: C8K1-Up
Part No.: 281-6141 Thickness of new top piston ring ................ 3.88 mm
S/N: RMSl-Up (0.153 inch)
Part No.: 281 -6139, 281 -6141

S/N: T2X1-Up
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 linerwith a bore size of 170 mm (6.7 inch),
the clearance between the ends of the piston ring is
the following value, ........ 1.00 r 0.15 mm_
(0.03e t 0.006 inc!
Thickness of new intermediate oiston
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.
9o1430242
Width of groove in new piston for the oil control piston
lllustration 250
ring ......... 4.04 mm to 4.07 mm (0.159 to 0.160 inch)
Note: Refer to Guideline for Reusable Parts for Thickness of new oil control piston
information on the pistons, the piston pins, and the
ring................ 3.97 to 3.99 mm (0.156 to 0.157 inch)
retaining rings.
V/hen 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
RENR9362-08 151
the following value. ... 0.5 mm to 0.8 mm Refer to Table 1 for the part numbers of the tools that
(0.02 to 0.03 inch) are used in servicing the piston.
Note: After the piston rings have been installed, Table 1
rotate the piston rings so that the end gaps are 120 Service Tools
degrees from each other.
Pt. No. Description
271-0498 Expander Ring
1 P-1 861 Retaining Ring Pliers
1 U-7616 Piston Ring Compressor Gp
246-1176 Piston Ring Groove Gauge Gp(1)
1 U-6431 Piston Ring Groove Gauge Gpa

(1) Only for the top ring groove
(2) Only for the intermediate ring groove
i02674253
Piston and Rings

(Two-Piece Piston)
SMCS Code:1214
Part No.: 249-5671
S/N: LLFI-Up
Part No.: 249-5671
S/N: PES'1-Up
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
pln............. ....70.0705 t 0.0075 mm
(2.75867 t 0.00030 inch)
Piston Pin (5)

Dimensions for piston pin
Outside diameter of piston
pin ... 69.930 t 0.005 mm (2.7531 t 0.0002 inch)
Inside diameter of piston pin ........ 30.5 t 0.5 mm
(1.20 x 0.02 inch)
Length of piston pin ........... 102.0 + 0.0 - 0.3 mm lllustration 252 901 084998
(4.02+0.00-0.01)
Typical example
Note: The 263-8955 Piston Pin is not

This piston has a Keystone top ring. This piston also
interchangeable with the former 197-0560 Piston
has Keystone intermediate rings. The 204 -8041
Pin.
Piston Ring Groove Gauge Gp is necessary for
measuring the ring grooves in the Keystone pistons.
Pin Retainer (6) For correct use of the gauge group, refer to the
instruction card that is with the gauge group.
Assemble the pin retainer with the opening above
section A-A.
152 RENR9362-08
Note: Prior to the installation of the rings, the ring (4) Piston pin bore
grooves must be completely lubricated with clean
engine oil. After assembly, the mating surfaces of Note: Prior to assembly of the piston pin, the piston
the rings to the cylinder liner must be completely pin, the piston pin bore, the connecting rod eye, and
lubricated with clean enqine oil. the connecting rod pin bearing must be completely
lubricated with clean enoine oil.
(1) Top piston ring
Crown as
Install the piston ring with the "Up-1" side toward
the top of the piston. Measure the pin bore in the bushings in two
When the piston ring is installed in a cylinder places for each bushing in a vertical direction.
linerwith a bore size of 170 mm (6.7 inch), the Bore in bushing 70.0525 t 0.0075 mm
clearance between the ends of the piston ring is t
(2.75796 0.00029 inch)
the following value. ................ 0.625 t 0.125 mm
(0.0246 t 0.0050 inch) Piston skirt
The increase in the clearance between the ends
of the piston ring for each 0,03 mm (0.001 inch) Measure the pin bore in a vertical direction.
increase in the cylinder liner bore size is the
following value.
Bore ........... ....... 69.988 r 0.005 mm
0.08 mm (0.003 inch) (2.7554 t 0.0002 inch)
(2) lntermediate piston ring (5) Piston pin
lnstall the piston ring with the "Up-2" side toward Measure the pin diameter on each end in a
the top of the piston. vertical and horizontal direction.
When the piston ring is installed in a cylinder Outside diameter 69.962 t 0.005 mm
linerwith a bore size of 170 mm (6.7 inch), the (2.7544 t 0.0002 inch)
clearance between the ends of the piston ring is Inside diameter 33.0 t 0.5 mm
the following value. 1.00 r 0.15 mm (1.30 r 0.02 inch)
(0.039 t 0.006 inch) Length,.. 137.55 r 0.15 mm (5.415 t 0.006 inch)
of the piston ring for each 0.03 mm (0.001 inch) (6) Pin retainer Assemble the pin retainer
increase in the cylinder liner bore size is the with the opening above line A-A.
following value. 0.08 mm (0.003 inch)
(3) Oil piston ring

Width of groove in piston for the new oil piston
ring .... 4.055 t 0.015 mm (0.1596 t 0.0006 inch)
Maximum thickness of new oil oiston
ring .... 3.980 r 0.010 mm (0.1S70 t 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
linerwith a bore size of 170 mm (6.7 inch), the
clearance between the ends of the piston ring is
the following value. . 0,65 t 0.15 mm
(0.026 t 0.006 inch)
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)
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 allof 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.
,t 6?
RENR9362-08
i03996586 lntermediate Piston Ring (2)

Piston and Rings lnstall the intermediate piston ring with the 'UP-2"
(One-Piece Piston) side toward the too of the oiston.
SMCS Code:1214 Thickness of new intermediate piston

ring ............ ...... 3.785 mm (0.1490 inch)
Part No.: 341 -3638
S/N: R141-Uo Clearance between the ends of the piston ring when
the piston ring is installed in a cylinder liner bore of
Part No.: 341 -3638 170 mm (6.7 inch) ........ 1.00 t 0.15 mm
S/N: R1S1-Up (0.039 t 0.006 inch)
Part No.: 341 -3638
S/N: RTX1-Up 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 0.08 mm (0.003 inch)
Oil Gontrol Piston Ring (3)

Ends of the oil control piston ring should be a
the piston ring is assembled. The colored portion of
the piston ring must be visible at the ring end gap.

ring .......... 4.0551 0.015 mm (0.1596 t 0.0006 inch)
Thickness of new oil control piston

ring .......... 3.980 t 0.010 mm (0.1567 t 0.0004 inch)
Clearance between the ends of the piston rinq when

the piston ring is installed in a cylinder liner b-ore of
170 mm (6.7 inch) ......... 0.65 t 0.'15 mm
(0.026 t 0.006 inch)
lllustration 253 902174310 Increase in the clearance between the ends of the
Note: Prior to the installation of the piston rings, the cylinder liner bore 0.08 mm (0.003 inch)
lubricate the ring grooves with clean engine oil. After
assembly of the piston rings, lubricate the mating Note: After all of the piston rings have been installed,
surfaces of the rings to the cylinder liner with clean rotate the piston rings so that the end gaps are
engine oil. separated by 120 degrees. The ring gap for the oil
control piston ring must be aligned in the plane of
the pin bore.
Top Piston Ring (1)
Note: Before assembly of the piston pin, lubricate the
Install the top piston ring with the "UP-1" side toward following: piston pin, piston pin bore, and connecting
the top of the piston. rod eye with clean engine oil.
Thickness of new top piston ring .. 4.5 mm (0.18 inch)

Piston Pin Bore (4)
Clearance between the ends of the piston ring when
the piston ring is installed in a cylinder liner bore of Diameter of the bore in the finished bearing that
170 mm (6.7 inch) ..... 0.625 t 0.125 mm is installed into the piston skirt for the piston pin
(0.0246 t 0.0049 inch)
...... 70.0705 t 0.0075 mm (2.75868 t 0,00030 inch)
Increase in the clearance between the ends of the Piston Pin (5)
the cylinder liner bore 0.08 mm (0.003 inch) Outside diameter .... 69.930 t 0.005 mm
(2.7531r 0.0002 inch)
Length ......... 101.85 r 0.15 mm (4.010 t 0.006 inch)

154 RENR9362-08
Pin Retainer (6) (2) Bore in the piston skirt for new piston
pin ... 69.988 r 0.005 mm (2.7554 t 0.0002 inch)
Note: Install the pin retainer with the gap toward the
top of the piston. Note: Prior to the installation of the rings, the ring
Thickness of new pin retainer 2.36 t 0.08 mm engine oil. After assembly, the mating surfaces of
(0.093 t 0.003 inch) the rings to the cylinder liner must be completely
lubricated with clean engine oil.
Width of groove in new piston for the pin
retainer 2.75 ! 0.1 mm (0.108 r 0.004inch)
Top Piston Ring (3)
Installthe top piston ring with the "UP-1" side toward
the top of the piston. The top piston ring must be
Piston and Rings installed with the yellow colored stripe to the right of
(Two-Piece Piston) the ring end gap.
SMCS Code:1214 Width of groove in new piston for the top piston
ring ............ ....... 4.219 mm (0.1661 inch)
Part No.: 244-8850
S/N: R141-Up
"#i:T" .:;,',J:,,::::i' "''"b
Part No.: 244-8850
S/N: RTX1-Up
::l::::
ring in a cylinder liner bore of '170 mm
(6.7 inch) .. 0.625 !0.125 mm (0.0246 t 0.0049 inch)
Increase in the clearance between the ends of the

4 Intermediate Piston Ring (4)

5
Width of groove in new piston for the intermediate

piston ring ........ 3.514 mm (0.1383 inch)
Thickness of new intermediate piston

ring ............ ....... 3.785 mm (0.'1490 i nch)
Clearance between the ends of the piston

ring in a cylinder liner bore of 170 mm
i
(6.7 inch) ......... 1.00 0.15 mm (0.039 i 0.006 i nch)
o
This piston has a Keystone top ring. This piston also the cylinder liner bore 0.08 mm (0.003 inch)
has a Keystone intermediate ring. The 2O4-8041
Piston Ring Groove Gauge Gp is necessary for
measuring the ring grooves in the Keystone pistons. Oil Gontrol Piston Ring (5)
For correct use of the gauge group, refer to the
instruction card that is with the gauge group. The ends of the oil control piston ring should be a
Note: Measure the piston pin bore in the bushings in the oil control piston ring is assembled. The white
two places for each bushing in a vertical direction. colored portion of the piston ring must be visible at
the ring end gap.
(1) Bore in the bushing of the crown assembly for
new piston pin .........,........ 70.0525 r 0.0075 mm
(2.75796 t 0.00030 inch) ring .......... 4.055 r 0.015 mm (0.'1596 t 0.0006 inch)
Note: Measure the piston pin bore in a vertical Thickness of new oil control oiston
direction. ring .......... 3.980 t 0.010 mm (0.1567 t 0.0004 inch)
RENR9362-08 155
Clearance between the groove and the new oil i03127641

control piston ring ............ 0.050 to 0.100 mm
(0.0020 to 0.0039 inch) Piston and Rings
(Two'Piece Piston)
ring in a cylinder liner bore of 170 mm SMCS Code:1214
(6.7 inch) ......... 0.65 f 0.15 mm (0.026 t 0.006 inch)
Part No,: 283-0246
Increase in the clearance between the ends of the S/N: SBK1-Up
the cylinder liner bore 0.08 mm (0.003 inch) Part No.: 283 - 0246, 312 - 8841
S/N: SBM'1-Up
Note: After all of the piston rings have been installed,
separated by 120 degrees. The ring gap for the oil
control piston ring must be aligned in the plane of
the pin bore.
3
Note: Prior to assembly of the piston pin, the piston
pin, the piston pin bore, the connecting rod eye, and 4
the connecting rod pin bearing must be completely 5
Piston Pin (6)

Note: Measure the piston pin diameter on each end
in a vertical and horizontal direction.
Outside diameter .... 69.962 t 0.005 mm

(2.7544 t 0.0002 inch)
Length '137.55 + 0.15 mm (5.415 t 0.006 inch)

Pin Retainer (7)
This piston has a Keystone top ring. This piston also
Note: lnstall the pin retainer with the gap toward the has a Keystone intermediate ring, The 2O4-8041
top of the piston. Piston Ring Groove Gauge Gp is necessary for
measuring the ring grooves in the Keystone pistons.
Thickness of new pin retainer 2.40 ! 0.08 mm For correct use of the gauge group, refer to the
(0.094 r 0.003 inch) instruction card that is with the gauge group.
Width of groove in new piston for the pin Note: Measure the piston pin bore in the bushings in
retainer..............:.... 2.75 mm (0.108 inch) two places for each bushing in a vertical direction.
(1) Bore in the bushing of the crown assembly for

new piston pin .................. 70.0525 t 0.0075 mm
(2.75796 t 0.00030 inch)
Note: Measure the piston pin bore in a vertical

direction.
(2) Bore in the piston skirt for new piston

pin ... 69.988 r 0.005 mm (2.7554 r 0.0002 inch)
Note: Prior to the installation of the rings, the ring

engine oil. After assembly, the mating surfaces of
the rings to the cylinder liner must be completely
156 RENR9362-08
Top Piston Ring (3) Note: After all of the piston rings have been installed,
Install the top piston ring with the "UP-1" side toward separated by 120 degrees. The ring gap for the oil
the top of the piston. control piston ring must be aligned in the plane of
the pin bore.
Width of groove in new piston for the top piston
ring ............ .,..... 4.219 mm (0.1661 inch) Note: Prior to assembly of the piston pin, the piston
pin, the piston pin bore, the connecting rod eye, and
Thickness of new top piston ring .. 4.5 mm (0.18 inch) the connecting rod pin bearing must be completely
lubricated with clean enqine oil.
Clearance between the ends of the niston
ring in a cylinder liner bore of 170 mm
(6.7 inch) .. 0.625 t 0.125 mm (0.0246 t 0.0049 inch) Piston Pin (6)
Increase in the clearance between the ends of the Note: Measure the piston pin diameter on each end
piston ring for each 0.03 mm (0.001 inch) increase in in a vertical and horizontal direction.
Outside diameter ..., 69.962 t 0.005 mm
(2.7544 r 0.0002 inch)
lntermediate Piston Ring (4)
Pin Retainer (7)
Width of groove in new piston for the intermediate
piston ring Note: Install the pin retainer with the gap toward the
........ 3.514 mm (0.1383 inch)
top of the piston.
Thickness of new intermediate oiston
ring .......,.... ....... 3.785 mm (0.1490 inch)
Thickness of new pin retainer 2.40 t 0.08 mm
(0,094 t 0.003 inch)
ring in a cylinder liner bore of 170 mm Width of groove in new piston for the pin
(6.7 inch) ......... 1.00 t 0.15 mm (0.039 t 0.006 inch) retainer 2,75 mm (0.108 inch)
Increase in the clearance between the ends of the i03660673

the cylinder liner bore 0.08 mm (0.003 inch) Connecting Rod
SMCS Code: 1218
Oil Gontrol Piston Ring (5)
Part No.: 144-0725
The ends of the oil control piston ring should be a S/N: LLAI-Uo
the oil control piston ring is assembled. The red Part No.: 144-0725
colored portion of the piston ring must be visible at S/N: LLBl-Uo
the ring end gap.
Part No.: 144-0725
Width of groove in new piston for the oil control piston S/N: LLCl-Up
ring.......... 4.055 t 0.015 mm (0.1596 t 0.0006 inch) Part No.: 144-0725
S/N: C8E1-Uo
Thickness of new oil control piston
ring.......... 3.980 t 0.010 mm (0.1567 t 0.0004 inch) Part No.: 144-0725
S/N: LLEl-Uo
Clearance between the groove and the new oil
control piston ring ........... 0.050 to 0.100 mm Part No.: 144-0725
(0.0020 to 0.0039 inch) S/N: SBGl-Uo

Part No.: 144-0725
ring in a cylinder liner bore of 170 mm S/N: SBJl-Up
(6.7 inch) ......... 0.65 r 0.15 mm (0.026 t 0.006 inch) Part No.: 144-0725
S/N: CBKl-Up
piston ring for each 0.03 mm (0.001 inch) increase in Part No.: 144 - 0725, 223 - 6363
the cylinder liner bore 0.08 mm (0.003 inch) S/N: RMS'1-Up
RENR9362-08 157
Part No.: 144-0725 Bore in the connecting rod for the sleeve bearing
S/N: T2X1-Up for the piston pin 75.760 t 0.015 mm
(2.9827 t 0.0006 inch)
(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 t 0.5 mm (0.16 f 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 t 0.015 mm
(5.6310 r 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,
(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 lllustration 257 901526418
installation of the sleeve bearing for the piston pin.
View H-H
Do not use a torch to heat the connecting rod.
(3) Location pin for correct installation of connecting rod caps
(B) The connecting rod may be heated from
175 to 260 'C (347 to 500 'F) for the installation (2) The chamfer side must be adjacent to the crank
of the sleeve bearing for the piston pin. Minimum pin thrust surface when the connecting rod and
length for heating the connecting rod .... 105 mm piston group is assembled in the engine.
(4.1 inch)
Side clearance between two connecting rods on the
Note: Thoroughly lubricate the piston pin with clean same new crankshaft pin ............. 0.850 t 0.332 mm
engine oil prior to assembly of the piston and the (0.0335 t 0.0131 inch)
connecting rod.
Use the following procedure for tightening the
(C) Dimensions for the piston pin connecting rod bolts:
Bore in the sleeve bearing for the Note: Bolt 1 and bolt 2 must be on the same end of
piston pin after installation of the sleeve the connecting rod cap that has bearing tabs and
bearing 70.000 + 0.008 mm location pin (3).
(2.7559 t 0.0003 inch)
158 RENR9362-08
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 t S N.m

(66r4rbft).
3. Tighten the bolt 3 and bolt 4 to g0 t 5 N.m
(66r4rbft)
4. Again, tighten the bolt 3 and bolt 4 to g0 t b N.m
(66+4tbft).
5. Tighten all bolts for an additional 90 t 5 degrees.
i03563228
Connecting Rod
SMCS Code: 1218
Part No.: 230-2516
S/N: R1A'1-Uo
Part No.: 230 - 251 6
S/N: LLF'1-Up
Part No.:230-2516
S/N: SBK1-Up
Part No.: 23O-2516
S/N: SBMl-Uo
Part No.: 230 - 251 6
S/N: PESl-Uo
Part No.: 230 - 251 6
S/N: RlSl-Up
Part No.: 23O-2516
S/N: RTX1-Uo
Note: When a new top end bearing is installed,

ensure that no residual dirt or machining debris
is trapped between the sleeve bearing (2) and
the drilled hole (1) in the connecting rod. Refer to
lllustration 258.
Use the following procedure for cleaning the drilled

hole (1):
1. Clean the drilled hole with a suitable cleaning

solution. Use a spray nozzle in order to wash the
drilled hole from the large end of the connecting
rod.
RENR9362-08 159
2. Use a stiff plastic bristle brush to clean the drilled Clearance between the connecting rod bearing
hole. Do not scratch the finish. and the new crankshaft .,...... 0.107 to 0.218 mm
(0.0042 to 0.0086 inch)
Use the following procedure for tightening the
connecting rod bolts: (F) Extension of the dowel from the connecting rod
cap ..............,..... 4.0 t 0.5 mm (0.16 r 0.02 inch)
Note: Bolt 1 and bolt 2 must be on the same end of
the connecting rod cap that has bearing tabs and (G) Dimensions for the connecting rod
location pin (3).
Bore in the connecting rod for the bearing for
{. Before assembly, apply 6V-4876 Lubricant on the the crankshaft connecting rod journal after
bolt threads, the bolt shank and the bolt seat. applying final torque to the connecting rod
bolts ,...,...... ..... 143.028 t 0.015 mm
2. Tighten bolt 1 and bolt 2 to 90 r 5 N'm (66 r 4 tb ft). (5.6310 + 0.0006 inch)
Side clearance between two connecting rods on
3. Tighten bolt 3 and bolt 4 to 90 t 5 N.m (66 r 4 lb ft), the same new crank pin ......... 0.850 t 0.332 mm
(0.0335 r 0.0131 inch)
4. Again tighten bolt 3 and bolt 4 to g0 r 5 N.m
(66r4rbft).
5. Tighten all bolts for an additional 90 t 5 degrees,
(a) The chamfer must be adjacent to the crank pin

thrust surface when the connecting rod and the
piston group is assembled in the engine. The
opposite side will push the rod that mates on the
same crank pin.
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.
(A) The connecting rod may be heated from

175 to 260 "C (347 to 500 "F) for the instattation
of the sleeve bearing for the piston pin. Minimum
length for heating the connecting rod .... 105 mm
(4.1 inch)
(B) Dimensions for the piston pin

Bore in the sleeve bearing for the
piston pin after installation of the sleeve
bearing 70.000 t 0.008 mm
(2.7559 t 0.0003 inch)
Bore in the connecting rod for the sleeve bearing
for the piston pin 75.760 t 0.015 mm
(2.9827 r 0.0006 inch)
(C) Angle above centerline on either side of the

bearing joint for the sleeve bearing for the piston
pin .............. 10 deorees
(D) Distance between the center of the

bearings 392.5 mm (15.45 inch)
Note: Take the connecting rod bearing measurements

on the centerline of the connecting rod bores.
(E) Dimensions for the connecting rod bearing

Bore in the connecting rod bearing for the
crankshaft .. 135.133 to 135.194 mm
(5.3202 to 5.3226 inch)
160 RENR9362-08
i0135920'l Table 2
Gonnecting Rod and Main Diameter Of Crankshaft Journal (Bearing Sul{ace)

For Connecting Rod Bearings
Bearing Journals Original Size Journal 135.000 t 0.025 mm
SMCS Code: 1230 (5.3150 t 0.0010 inch)
Part No.: 107-7330, 149-6031

Undersize Journal t
134.370 0.025 mm
0.63 mm (0,025 inch) (5.2902 t 0.0010 inch)
S/N: LLA1-Up
Undersize Journal 133.730 t 0.025 mm
Part No.: 107 -7330, 149-6031 1.27 mm (0.050 inch) (5.2650 t 0.0010 inch)
S/N: R141-Up
Part No.: 1O7 -7330, 149 - 6031 Clearance between bearing and new
S/N: LLBl-Up journal ... 0.107 to 0.218 mm (0.0042 to 0.008G inch)
Part No.: 1 07 - 7330, 149 - 6031 Main Bearing Journals

S/N: LLCl-Up
Table 3
Part No.: 107 -733O, 149 - 6031
Diameter Of Crankshaft Journal (Bearing
S/N: C8E1-Up Surface) For Main Bearings
Part No.: 107- 7330, 149-6031 160.000 t 0.025 mm
S/N: LLEl-Up (6.2992 t 0.0010 inch)
Part No.: 107 -7330, 149 - 6031 159.370 t 0,025 mm

S/N: LLF1-Up (6.2744 t 0.0010 inch)
Part No.: 107 -7330, 149 - 6031 158.730 t 0.025 mm

S/N: SBGl-Up
(6.2492 t 0.0010 inch)
Part No.: 107 -7330, 149 - 6031 Clearance between bearing and new
S/N: SBJl-Uo journal ... 0.122 to 0.241 mm (0.0048 to 0.009b inch)
Part No.: 1O7 -7330, 149 - 6031
S/N: C8K1-Up
Part No.: 107 -7330, 149 - 6031
S/N: SBK'I-Up
Part No.: 1 49 - 6031
S/N: SBMl-Up
Part No.: 107 -7330, 149 - 6031
S/N: PES1-Up
Part No.: 161 -6926
S/N: RlSl-Up
Part No.: 107 -7330,149-6031
S/N: RMSl-Up
Part No.: 107 -7330,149-6031
S/N: RTX1-Up
Part No.: 107-7330, 149-6031
S/N: T2X1-Up
Refer to Guidelines For Reusable Parts, SEBF800g,

"Main Bearings And Connecting Rod Bearings" for
more information.
Connecting Rod Bearing Journals

RENR9362-08 161
i0287'1012
Grankshaft
SMCS Code:1202
Part No.: 332-7912
S/N: C8E1-Up
Part No.: 332-7912
S/N: C8K1-Uo
,.4
(1) Thrust plates
Refer to Specifications, "Connecting Rod And Main 4. Again, torque the bolts evenly to 70 t 5 N'm
Bearing Journals" for more information. (50r4rbft).
(B) End play for the new 5. Rotate each bolt for an additional 120 t 5 degrees.
crankshaft 0.17 to 0.63 mm
(0.007 to 0.025 inch)
(2) Torque for the plug ......... 50 t 7 N.m (37 I 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.
2. Torque the bolts evenly to 200 t 5 N.m

(145r4rbft).
3. Loosen the bolts.
162 RENR9362-08
i03530820
G ra n kshaft
SMCS Code= 1202
Part No.: 101-0336
S/N: LLCl-Uo
Part No.: 101 -0336
S/N: LLE1-Up
,tA
lllustration 260 901419s44

('1 ) Thrust plates
Refer to Specifications, "Connecting Rod And Main

Bearing Journals" for more informatron.
, the bolts evenly to 70 t 5 N.m
O
Arr.i.,ifltfin
(B) Crankshaft end play ................. 0.17 to 0.63 mm 5. Rotate each bolt for an additional 120 t 5 degrees.
(0.007 to 0.025 inch)
(2) Torque for the plugs ...... 50 r 7 N.m (37 r S tb ft) i03 1 26565
Note: Do not reuse countenveight bolts.

Grankshaft
SMCS Code:1202
(3) Use the following procedure to tighten the bolts
of the countenrueight: Part No.: 8N - 7103
S/N: LLA1-Up
1. Before assembly, lubricate the threads of the
bolts, the bolt shank, the washers and the contact Part No.: 161 - 6926, 8N - 71 03
surface under the bolt head with 6V-4876 S/N: RlAl-Up
Lubricant.
Part No.: 8N - 7103
2. Tighten the bolts to 200 t 5 N.m (150 r 4 tb ft). S/N: LLBl-Uo
Part No.: 161 -6926
3. Loosen the bolts.
S/N: LLF1 -Up
RENR9362-08
163
Part No.: 8N - 7103

S/N: SBGl-Up
Part No.: 8N - 7103
S/N: SBJ'1-Up
Part No.: 8N-7109
S/N: SBK1-Up
Part No.: 161 -6926
S/N: R151-Up
Part No.: 8N - 7103
S/N: RMSl-Up
Part No.: 161-6926
S/N: RTX1-Up
Part No.: 8N - 7103
S/N: T2X1-Uo
Refer to Specifications, "Connecting Rod And Main 1. Before assembly, lubricate the threads of the
Bearing Journals" for more information. bolts, the bolt shank, the washers and the contact
surface under the bolt head with 6V-4876
(1) Thrust plates are used only on the center main Lubricant.
bearing journal of the crankshaft.
2. Tighten 36 botts eventy to 70 t 5 N.m (50 r 4 tb ft).
(B) Crankshaft end ptay ................. 0.17 to 0.63 mm
(0.007 to 0.025 inch) 3. Rotate each bolt for an additional 120 t 5 degrees.
(2) Torque for six plugs ....... S0 r 7 N.m (37 r 5 tb ft) Note: Do not reuse counterweight bolts.
of the countenveight:
164 RENR9362-08
i03340020
Grankshaft
SMCS Code:1202
Part No.: 8N-0337
S/N: SBJl-Uo
Part No.: 161 -6928
S/N: SBMl-Up
Part No.: 1 61 - 6928
S/N: PES'1-Up
Part No.: BN-0337
S/N: T2X1-Up
(1) Thrust plates
Refer to Specifications, "Connecting Rod And Main 1. Before assembly, lubricate the threads of the
Bearing Journals" for more information. bolts, the bolt shank, the washers and the contact
surface under the bolt head with 6V -4876
(B) Crankshaftend play ................. 0.17 to 0.63 mm Lubricant.
(0.007 to 0.025 inch)
2. Tighten all the bolts evenly to 70 t 5 N.m
(2) Torque for the plugs ....... 50 t7 N'm (37 i 5 tb ft) (50i4rbft).
Note: Do not reuse countenrueight bolts. 3. Rotate each bolt for an additional 120 r 5 deqrees.

of the counterweioht:
RENR9362-08
165
i03350941
Crankshaft Wear Sleeves and

Seals
SMCS Code: 1160
Part No.: 7W-3813
S/N: LLAI-Up
Part No.: 7W-gg1g
S/N: R141-Up
Part No.: 7W-3813
S/N: LLBl-Up
Part No.: 7W- 38'1 g
S/N: LLCI-Up
Part No.: 332-7911
S/N: C8E1-Up
Part No.: 7W-3813
S/N: LLE1-Up lllustration 263 901414669
(1) Flywheel housing group
Part No.: 7W-3813 (2) Front housing group
S/N: LLFl-Up
Part No.: 7W-3819 Note: The crankshaft seal group cannot be used
once the seal has been separated from the wear
S/N: SBGl-Up
steeve.
Part No.: 7W-3819
S/N: SBJl-Up Note: Make sure that the correct crankshaft seal
group is installed on each end of the crankshaft.
Part No.: 332-7911
S/N: CBK1-Up (3) 1 13-8433 Crankshaft Seal Go
Part No.: 7W-3819 . Install the crankshaft seal group in the flywheel
S/N: SBK1-Up housing group on a standard rotation enline.
Part No.: 7W-3813
S/N: SBMl-Up
. Install thecrankshaft seal group in the front housinq
group on a reverse rotation engine.
Part No.: 7W-3819
S/N: PES1-Up (4) 113-8432 Crankshaft Seat Gp
Part No.: 7W-3819 . Install the crankshaft seal group in the front
S/N: R151-Up housing group on a standard rotation engine.
Part No.: 7W-3813 . Install the crankshaft seal group in the flywheel
S/N: RMS1-Up
housing group on a reverse rotation engine.
Part No.: 7W-3913
S/N: RTX1-Up (A) The crankshaft seal group is installed from
both ends of the crankshaft at the followino
Part No.: 7W-3810 distance. 8.0 r 0.5 mm (0.31 t O.Oi inch)
S/N: T2X1-Up
(B) The wear sleeve is installed from both
ends of the crankshaft at the followino
distance. 0.S r 0.5 mm (0.02 t O.OZ inctr)
too RENR9362-08
io367 1476
Housing (Front)
SMCS Code: 1162
Part No.: 333-3712
S/N: C8E1-Up
Part No.: 333-3712
S/N: CBK1-Up
Refer to table 4 for the correct position of the

fasteners.
Note: Use a standard torque for the fasteners that

are listed in table 4.
Table 4
Front Housing Bolt Length

Installation Chart
Diameter Location Part Number Quantity mm nch
lnch
II
1t2 9H - 8260 Bolt 4 158.75 6 250
1t2 2 0S - 1587 Bolt 4 44.45 1.750
1t4 4 8T-6765 Pipe 7 14.2 t O.3 0.56 f 0.01
Plug
5/8 5 1D-4593 Bolt 10 139.7 5.50
(A) Installation depth for the cup plugs (3) Torque for six plugs .. 25 t 5 N.m (221 r 44 lb in)
1.25 ! 0.25 mm (0.050 t 0.010 inch)
Note: Trim gasket (6)with face (7) after assembly.
RENR9362-08
to/
i028751 76
Housing (Front)
SMCS Code: 1162
PartNo.:116-0054
S/N: LLA1-Up
PartNo.:116-0054
S/N: RlAl-Up
PartNo.:116-0054
S/N: LLB1-Up
PartNo.:116-0054
S/N: LLC1-Up
PartNo.:116-0054
S/N: LLE1-Up
PartNo.:116-0054
S/N: LLF1-Up
Part No.: 1 16 - 0054
S/N: SBGl-Up
Part No.: 1 16 - 0054
S/N: SBJl-Up
PartNo.:116-0054
S/N: SBK1-Up
Part No.: 4P -5427
S/N: SBMl-Up
PartNo.:1'16-0054
S/N: PESl-Up
PartNo.:116-0054
S/N: RMS1-Up
PartNo.:116-0054
S/N: RTXI-Uo
PartNo.:116-0054
S/N: T2X1-Up
Typical example
Refer to Table 5 for the correct position of the bolts Part No.: 4P -5426
S/N: LLEl-Up
Note: Use a standard torque for the bolts that are
listed in Table 5. Part No.: 4P -5426
S/N: LLFl-Up
Table 5
Part No.: 4P -5426
Installation Chart for Front Bolt Length S/N: SBGl-Up
Housing Bolts
Diameter Bolt Part Part No.: 4P -5426
mm inch S/N: SBJl-Uo
inch Location Number
vz 1 9H - 8260 158.75 6.250 Part No.: 4P -5426
a S/N: SBKl-Up
1t2 0s-1587 44.45 1 750
5/8 4 1D-4593 139.7 550 Part No.: 4P -5426
S/N: PESl-Uo
(2) Torque for the three plugs 25r5N'm Part No.: 4P -5426
(18r4tbft) S/N: RlSl-Uo
Note: Trim the gasket (5) even with the face (6) of Part No.: 4P -5426
the housing after assembly. S/N: RMSl-Up
Part No.: 4P -5426
i02875170
S/N: RTX1-Up
Housing (Front) Part No.: 4P -5426

S/N: T2X1-Up
SMCS Code: 1162
Part No,: 4P -5426
S/N: LLA1-Up
Part No,: 4P -5426
S/N: R141-Uo
Part No.: 4P -5426
S/N: LLBl-Up
Part No.: 4P -5426
S/N: LLCl-Up
RENR9362-08
lllustration 266
Refer to Table 6 for the correct position of the Part No.: 107 -0278
fasteners. S/N: LLCI-Uo
Note: Use a standard torque for the fasteners that Part No.: 107 -0278
are listed in Table 6. S/N: CBE'1-Up
Table 6 Part No.: 107 -0278

S/N: LLEI-Uo
Front Housing Bolt
Installation Chart Length
Part No.: 107 -0278
Diameter S/N: LLF1-Up
Location Part mm inch
inch
Part No.: 107 -0278
1t4 4 U I -O//OC 14.2 t 0.56 r S/N: SBJl-Up
Pipe Plug n2 0.0'1
Part No.: 107 -0278
9H - 8260 S/N: C8K1-Uo
1t2 z 158.75 6.250
Bolt
0s-1587 Part No.: 107 -O278

1t2 4 44.45 1.750 S/N: PESI-Up
Bolt
5/8
1 D-4593 Part No.: 107 -0278
Bolt
139.7 550 S/N: RlSl-Up
Part No.: 1O7 -0278
(3) Torque for six plugs ....... 25 t 5 N.m (18 r 4 tb ft) S/N: RMS1-Up
Note: Trim gasket (6)with face (7) after assembty. Part No.: 1O7 -0278
S/N: T2X1-Up
i039921 39
Gover Group (Front Housing)

SMCS Gode: 1151: 1166
Part No.: 1O7 -0278
S/N: LLA1-Up
Part No.: 1O7 -0278
S/N: R1A1-Up
Part No.: 107 -0278
S/N: LLB1-Up
170 RENR9362-08
Part No.: 122-9281

S/N: LLEl-Uo
Part No.: 122-9281
S/N: LLF1-Up
Part No.: 334 - 531 2
S/N: C8K1-Up
Part No.: 155-8502
S/N: SBMl-Up
Part No.: 122-9281
S/N: PESl-Up
Part No.: 122-9281
S/N: RMSl-Up
lllustration 267
90217 1575 ,a
the lubricant that is beino sealed.
lllustration 268 902't73423
(C) Installation depth of the cup plugs 901 428397

lllustration 269
(2) . . . ,....., 1.25 t 0.25 mm (0.049 t 0.010 inch) Typical example
(5) ldler gear assembly
i036681 41 (6) Water pump drive gear
(7) Crankshaft gear
Gear Group (Front)
Note: Install the socket setscrew to the bottom of the
SMCS Gode: 1206 threaded hole.
Part No.: 122-9281 setscrew
S/N: LLAI-Up
(1) Torque for the socket 6 t 1 N.m
(53r9lbin)
Part No.: 122-9281
S/N: LLBl-Up (2) Pump drive shaft assembly
Part No.: 122-9281 Bore in sleeve bearing after

S/N: LLC1-Up assembly 75.000 r 0.055 mm
(2.9527 t 0.0022 inch)
Part No.: 334-5312 Diameter of new pump drive shaft
S/N: C8E1-Up assembly. .........74.900 t 0.015 mm
(2.9488 r 0.0006 inch)
RENR9362-08 171

lubricant that is being sealed.
(4) Thrust washer
Thickness of new thrust washer .. 8.50 t 0.05 mm

(0.335 t 0.002 inch)
Width of groove in new pump drive shaft
assembly. 8.750 + 0.025 mm
t
(0.3445 0.0010 inch)
End play for the pump drive shaft
assembly 0.175 to 0.325 mm
(0.0069 t 0.0128 inch)
(8) ldler shaft
Diameter of the idler shaft ..... 105.88 t 0.02 mm

t
(4.168 0.001 inch)
Bore in the sleeve bearing for idler
shaft .......... ...... 105.970 t 0.010 mm
(4.1720 + 0.0004 inch)
i031 25700
Gear Group (Front)

SMCS Gode: 1206
Part No.: 8N-7174 lllustration 270 9O1428397
S/N: LLAI-Up
Part No.: 8N-7174 (6) Water pump drive gear
(7) Crankshaft gear
S/N: R1A1-Uo
Part No.: BN-7174 Note: Install the socket setscrew to the bottom of the
S/N: LLBl-Up threaded hole.
Part No.: 8N-7174 (1) Torque for the socket setscrew 6 r 1 N.m
S/N: LLFl-Up (55r9tbin)
Part No.: BN-7174 (2) Pump drive shaft assembly
S/N: SBGl-Up
Bore in sleeve bearing after
Part No.: 8N-7174
S/N: SBJl-Up
t
(2.9528 0.0022 inch)
Part No.: 8N-7174 Diameter of new pump drive shaft
S/N: SBK1-Up assembly 74.900 t 0.015 mm
(2.9488 + 0.0006 inch)
Part No.: 8N-7174
S/N: SBMl-Up (3) Lubricate the bore of four O-ring seals lightty with
lubricant that is beino sealed.
Part No.: 8N-7174
S/N: R151-Up (4) Thrust washer
Part No.: 8N-7174 Thickness of new thrust washer .. 8.50 t 0.05 mm
S/N: RMSl-Up t
(0.335 0,002 inch)
Width of groove in new pump drive shaft
Part No.: 8N-7174 assembly 8.750 t 0.025 mm
S/N: RTX1-Up
t
(0.3445 0.0010 inch)
Part No.: 8N-7174 End play for the pump drive shaft
S/N: T2X1-Up assembly 0.250 t 0.075 mm
t
(0.0098 0.0030 inch)
(8) Shaft
172 RENR9362-08
Bore in sleeve bearing after Part No.: 101-0835, 124-8395

machining ......... 90.000 t 0.010 mm S/N: T2X1-Up
(3.5433 t 0.0004 inch)
Diameter of new shaft.............. 89.88 t 0.02 mm
(3.539 f 0.001 inch)
Note: After the sleeve bearing is installed in the gear

the sleeve bearing must be machined to size.
Maximum roughness average (Ra) .. 0.8 micrometer

(32 microinch)
i03125621
Gear Group (Rear)

SMCS Gode: 1206
Part No.: 1 24 - 8395
S/N: LLA1-Up
Part No.: 124-8395. 175-5204
S/N: RlAl-Up
Part No.: 101 -0835. 124-8395 lllustration 271 901 620759
S/N: LLB1-Up (1) Ring

Part No.: 101-0834 (13) Plate
S/N: LLC1-Up
Note: Before assembly, it is critical that the taper of
Part No.: 334-5298 the camshaft and the tapered bore of the camshaft
S/N: C8E1-Uo drive gear are clean, dry, and free of residue.
Part No.: 101 -0834
S/N: LLE1-Up Refer to Disassembly and Assembly for the
installation procedure for the left camshaft drive qear
Part No.: 124-8395, 175-5204 (2).
S/N: LLF1-Up
Part No.: 1 24 - 8395
(5) Torque for four bolts ........... 140 r 10 N.m
(105t7tbft)
S/N: SBGl-Up
(6) Gear shaft
Part No.: 101-0835, 124-8395
S/N: SBJ'1-Up Diamerer of the gear
Part No.: 334-5298
"n"o (r..Jlr;,TrlrrdSii,It
Bore in the sleeve bearing for the gear
S/N: CBK1-Up
shaft.......... .....,.. 75.060 r 0.010 mm
Part No.: 124-8395, 175-5203 (2.9551 t 0.0004 inch)
S/N: SBK1-Up Maximum roughness average
(Ra) .. ....
. 0.8 micrometer (32 microinch)
Part No.: 1 75 - 5203
S/N: SBMl-Up Refer to Disassembly and Assembly for the
installation procedure for the right camshaft drive
Part No.: 101 -0835 gear (7).
S/N: PES1-Up
Part No.: 175-5204 (B) ldler shaft
S/N: R1S1-Up Diameter of the idler shaft ... 81.000 t 0.010 mm
Part No.: 1 24 - 8395 t
(3.1890 0.0004 inch)
S/N: RMSI-Uo Bore in the sleeve bearing for the idler
shaft 81.060 t 0.010 mm
Part No.: 1 24 - 8395, 175 -5204 (3.1913 r 0.0004 inch)
S/N: RTX1-Up Maximum roughness average
(Ra) ..... .. 0.8 micrometer (32 microinch)
RENR9362-08 4-74
ttu
\__/ o \
^-r_) _/
lllustration 272 901256372 lllustration 274 901 620761
Vertical line Rear view of engine
(9) Use the following procedure to tighten the bolt for (14) The mark on the cluster gear assembly (4) must
the camshaft drive oears: be in alignment with the mark on the crankshaft
gear (12).
O 1. Tighten the bolt for the camshaft drive gear to
360 r 40 N'm (270 r 30 lb ft).
2. Mark a vertical line on the head of the bolt for the

camshaft drive gear. Refer to lllustration 272.
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 t 40 N.m Q70 x 30 lb ft).
\_-/ -o \
r-\ a) -/
5. Repeat Steps 3 and 4 until the mark on the

bolt turns a minimum of 90 degrees. Refer to
lllustration 273.
(10) Torque for four bo|ts........... 240 r 20 N.m

(175 i 15 tb ft)
(11) Torque for two bolts .......... 240 r 20 N.m

(175 ! 15 rb ft)
174 RENR9362-OB
io3091223 (2) The mark on the balancer gear must be in

alignment with the mark on the crankshaft gear.
Balancer Group (Front)
SMGS Code:1220 i03742201
Part No.: 101-0833 Accessory Drive

S/N: LLC1-Up
SMCS Code:1207
Part No.:332-7916
S/N: CBE1-Up Part No.:334-5306
S/N: C8E1-Up
Part No.: 101 -0833
S/N: LLE1-Up Part No.: 334-5306
S/N: CBK1-Uo
Part No.: 332-7916
S/N: C8K1-Up
A-A
(3) Balancer gear

(4) Crankshaft gear
(1) Torque for four bolts 140 ! 10 N.m

(105+7tbft)
(B) Dimensions for the gear shaft
Diameter of the new gear
..........
shaft ........ 74.900t 0.015 mm
t
(2.9488 0.0006 inch)
Bore in the sleeve bearing after
t
(2.9528 0.0021 inch)
(C) Thickness of the thrust plate .,... 6.35 t 0.2S mm

(0.250 t 0.010 inch)
RENR9362-08 175
A-A E-E
(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 t 0.055 mm
(2.9527 + 0.0022 inch)

(2.9527 t 0.0022 inch)
(4) Auxiliary drive shaft
Diameter of new auxiliary drive
shaft .......... ,....... 74.900 t 0.015 mm
(2.9488 t 0.0006 inch)
Width of groove in the new auxiliary drive
shaft .. 8.750 t 0.025 mm (0.3445 r 0.0010 inch)
(5) Thickness of the new thrust

washer ...... 8.50 r 0.05 mm (0.335 t 0.002 inch)
176 RENR9362-08
io3742186 (C) Dimensions of the idler gear assembly

Accessory Drive Diameter of new idler gear
SMCS Gode: 1207 t
(2.9488 0.0006 inch)
Width of groove in new idler gear assembly for
Part No.: 334-5320 thrust washer .............,.,......... 8.750 t 0.025 mm
S/N: CBEI-Uo t
(0.3445 0.0010 inch)
Part No.: 334-5320 Bore in the accessory drive
S/N: C8K1-Uo gear .......... ........ 74.980 t 0.025 mm
t
(2.9520 0.0010 inch)
(2) Thickness of new thrust washer .. 8.50 t 0 05 mm

(0.335 r 0.002 inch)
i03604440
Accessory Drive (Lower Left

Hand)
tl SMCS Gode: 1207
A
Pad No.: 7E-7647
S/N: LLA1-Up
Part No.: 1 56 -981 2, 7E-7647
S/N: R1A'1-Up
Part No.: 7E-7647
S/N: LLBl-Up
Part No.: 7E-7647
lllustration 278 902021233 S/N: LLC1-Up
Front view
Part No.: 7E-7647
S/N: LLEl-Up
Part No.: 7E-7647
S/N: LLF1-Up
Part No.: 7E-7647
S/N: SBGl-Up
Part No.: 7E-7647
S/N: SBJl-Uo
Part No.: 7E-7647
S/N: SBK1-Up
Part No.: 7E-7647
9O2O21234
S/N: R151-Up
lllustration 279
Section A-A Part No.: 7E-7647
S/N: RMSl-Up
(1) Lubricate the bore of the O-ring seal with the
lubricant that is being sealed. Part No.: 1 56 - 981 2, 7E-7647
S/N: RTXI-Up
(B) Dimensions of the shaft
Part No.: 7E-7647
Diameter of the new shaft .. '105.880 + 0.020 mm S/N: T2X1-Up
(4.1685 r 0.0008 inch)
Bore in the bearing for idler gear for the
shaft........... ..... 105,970 r 0.0'10 mm
(4.1720 t 0.0004 inch)
RENR9362-08 177
ifications Section
Note: After the bearing is installed in the gear the

bearing must be machined to size.
(5) Dimensions of the auxiliary drive shaft

Diameter of the new auxiliary drive
shaft........... .......74.900 t 0.015 mm
(2.9488 t 0,0006 inch)
Width of groove in the new auxiliary drive shaft
for the thrust washer..,........... 8.750 r 0.025 mm
(0.3445 t 0.0010 inch)
End play for the auxiliary drive
shaft ..,....... ......... 0.175 to 0.32S mm
(0.0069 to 0.0128 inch)
(6) Thickness of the new thrust

washer ...... 8.50 r 0.05 mm (0.335 t 0.002 inch)
g0'1929453
lllustration 280
Front view
(1) Water pump drive gear

the lubricant that is beinq sealed.
Adapter assembly
(C) Installation depth of the sleeve bearing in the

lllustration 28l 901 929454 adapter assembly ....... 1.5 r 0.5 mm
Section B-B (0.06 r 0.02 inch)
(3) Diameter of the new shaft,....... 89.88 t 0.02 mm (D) Bore in the sleeve bearing of the adapter
(3.539 t 0.001 inch) assembly after installation .,. 75.000 t 0.05b mm
(2.9527 t 0.0022 inch)
(4) Dimensions of the idler gear assembly
Bore in the sleeve bearing of the idler gear
assembly after installation ... 90.000 r 0.010 mm
(3.5433 t 0.0004 inch)
Maximum roughness average
(Ra) . . .......... 0.8 micrometer (31.5 microinch)
RENR9362-08
(1) Lubricate the bore of the four O-ring seals with

Hand)
SMCS Code:1207
Part No.: 179-1511
S/N: LLA1-Uo
Part No.: 1 79 - 1 51 1
S/N: R141-Uo
Part No.: 1 79 - 151 1
S/N: LLB1-Up
Part No.: 1 79 - 1 51 1
S/N: LLGI-Up
Part No.: 1 79 - 1 51 1
S/N: LLEl-Up
'.-
Fart No.: 1 79 - 1 51
S/N: LLF1-Up
1
v
Part No.: 179- 1511 lllustration 285 g0'1438749
S/N: PESl-Up Section B-B
Part No.: 1 79 - 1 51 1 (4) Adapter assembly
S/N: RMSI-Uo
(2) Diameter of new shaft ........ 105,880 t 0.020 mm
(4.1685 t 0.0008 inch)
(3) Bore in the sleeve bearing after
t
(2.9527 0.0022 inch)
Note: After the bearing is installed in the idler gear

the bearing must be machined to size.
(5) Bearing
Bore in the bearing after
assembly ........ 105.970 r C
(41720,*b3i:#lD
lllustration 283 9O1438742 Maximum roughness average
Front view
(Ra). ......
0.8 micrometer(32 microinch)
(6) Auxiliary drive shaft
Diameter of new auxiliary drive

shaft.......... ........ 74.900r 0.015 mm
(2.9488 t 0.0006 inch)
Width of groove in new auxiliary drive
shaft.. 8.750 r 0.025 mm (0.3445 + 0,0010 inch)
(7) Thickness of new thrust washer .. 8.50 r 0.05 mm
(0.335 t 0.002 inch)
lllustration 284 g0 1 438748
Section A-A
RENR9362-08 179
i0286750 1 Bore in the bearing after

Accessory Drive (Lower Left assembly ........ 105.970 t 0.010 mm
t
(4.1720 0.0004 inch)
Hand) Maximum roughness average
(Ra) ..........0.8 micrometer (32 microinch)
SMCS Code:1207
(9) Diameterof new idlershaft .. 105.880 r 0.020 mm
Part No.: 8N-5678 (4.1685 t 0.0008 inch)
S/N: R141-Up
Part No.: 8N-5678 i01915447
S/N: LLB1-Up
Hand)
SMCS Gode: 1207
Part No.: 8N-9167
S/N: R'l41-Up
Part No.: 8N-9167
S/N: LLB1-Up
Illustration 286 901428398
(2) Adapter assembly

(5) Drive gear for jacket water pump and oil pump
(1) Thrust washer

Quantity ...................... 2
Thickness ot one"n"w ihil;i
washer ...... 8.50 r 0,05 mm (0.335 t 0.002 inch)
Width of groove in new auxiliary drive
shaft .. 8.750 t 0.025 mm (0.3445 t 0.0010 inch) lllustration 287 901 001 541
End play for auxiliary drive

shaft.......... ......... 0.175 to 0.325 mm (1) Thrust washer
(0.0069 to 0.0128 inch)
Thickness of new thrust washer .. 8.50 t 0.05 mm
(3) Lubricate the bore of the four O-ring seals lightly t
(0.335 0.002 inch)
(2) Bearing
(4) Diameter of new auxiliary drive
Bore in the bearings after
shaft .......... .,...... 74.900 t 0.015 mm assembly 75.000 t 0.055 mm
(2.9488 t 0.0006 inch) (2.9528 t 0.0022 inch)
(6) Bore in the sleeve bearing after (3) Shaft
assembly 75.000 r 0.055 mm
(2.9527 t 0.0022 inch) Diameter of new shaft.......,.. 74.900 t 0.015 mm
(2.9488 r 0.0006 inch)
Note: After the bearing is installed in the idler gear Width of groove in new shaft.. 8.750 t 0.025 mm
assembly (7) the bearing must be machined to size. (0.3445 t 0.0010 inch)
(8) Bearing
End play for shaft 0.175 to 0.325 mm
(0.0069 to 0.0128 inch)
180 RENR9362-08
(4) Drive gear for jacket water pump and oil pump
(5) Crankshaft gear
(6) ldler gear

(7) Bearing
After the bearing is installed in the gear the
bearing must be machined to size.
Bore in the bearing after
t
(3.5433 0.0026 inch)
Maximum roughness average
(Ra) ..,. ... 0.8 micrometer (32 microinch)
(8) Shaft
Diameter of new shaft.......... 89.BB0 t 0.020 mm
(3.5380 r 0.0008 inch)
i036051 21
Accessory Drive (Upper Right

Hand)
SMCS Code: 1207
Part No.: 166-4357
S/N: LLA1-Up
Part No.: 1 66 - 4357
S/N: LLBI-Uo
Part No.: 1 66 - 4357
S/N: LLC1-Up
Part No.: 166-4357
S/N: LLEI-Up
Part No.: 1 66 - 4357
S/N: LLF1-Uo
Part No.: 166-4357
S/N: SBMl-Up
Part No.: 166-4357
S/N: PESl-Up
Part No.: 1 66 - 4357
S/N: RMS1-Up
Part No.: 166-4357
S/N: T2X1-Up
RENR9362-OB 181
lllustration 2BB 901 930053
(1) Lightly lubricate the bore of the O-ring seals (4) Bore in the sleeve bearing of the adapter
with the lubricant that is being sealed or with the assembly after installation ... 75.000 t 0.055 mm
approved equivalent. (2.9527 t 0.0022 inch)
(2) Thickness of the new thrust (5) Bore in the sleeve bearing of the adapter
washer ...... 8.50 t 0.05 mm (0.335 t 0.002 inch) assembly after installation ... 75.000 t 0,055 mm
(2.9527 t 0.0022 inch)
Diameter of new auxiliary drive i03604642
shaft .......... ........ 74.900 t 0.015 mm
(2.9488 t 0.0006 inch)
Width of groove in the new auxiliary drive Hand)
shaft.. 8.750 r 0.025 mm (0.3445 r 0.0010 inch)
SMCS Code:1207
bearing with the adapter. Part No.: 7N-4871
S/N: LLA'1-Up
Part No.:7N-4871
S/N: R141-Up
182 RENR9362-08
Part No.: 7N-4871

S/N: LLB1-Up
Part No.: 7N-4871
S/N: LLCl-Up
Part No.: 7N-4871
S/N: LLEI-Uo
Part No.: 7N-4871
S/N: LLFI-Uo
Part No.: 7N-4871
S/N: SBGl-Up
Part No,: 7N-4871
S/N: SBJl-Up
Part No.: 7N-4871
S/N: SBKl-Uo
Part No.: 7N-4871
S/N: SBMl-Uo
Part No.: 7N-4871
S/N: PESl-Up
Part No.: 7N-4871
S/N: RMSI-Un
Part No.: 7N-4871
S/N: RTX1-Up
Part No.: 7N-4871
S/N: T2X1-Uo
lllustration 290 ootszso!

Section A-A

bearing with the adapter.

(2.9527 t 0.0022 inch)
Diameter of the new auxiliary drive
shaft 74,900 t 0.015 mm
Front view of engine (2.9488 t 0.0006 inch)
Width of groove in the new auxiliary drive shaft
(1) Lightly lubricate the bore of the O-ring seals with for the thrust washer .............. 8.750 t 0.025 mm
the lubricant that is being sealed. t 0'0010 inch)
End pray for the auxiriary(iff"tt
shaft 0.175 to 0.325 mm
(0.0069 to 0.0'128 inch)
RENR9362-08 183
(4) Thickness of the new thrust Part No.: 107 - 7361

washer ...... 8.50 t 0.05 mm (0.335 t 0.002 inch) S/N: SBJl-Uo
Part No.: 1O7 -7361
S/N: SBKI-Up
Part No.: 1O7 -7361
S/N: SBMl-Up
Part No.: 107 -7361
S/N: PESl-Up
Part No.: 107 -7361
S/N: RlSl-Up
Part No.: 1O7 -7361
S/N: RMSl-Uo
Part No.: 107 -7361
S/N: RTX1-Up
Part No.: 107 -7361
S/N: T2X1-Uo
g0 1 929654
lllustration 291
Adapter assembly
(D) Bore in the sleeve bearing of the adapter

(2.9527 t 0.0022 inch)
i02895664

Hand)
SMCS Code:1207
Part No.: 107 -7361
S/N: LLA1-Up
Part No.: 1O7 -7361
S/N: R1A1-Up 901 441 499
lllustration 292
Part No.: 1O7 -7361
S/N: LLBl-Up (1) Lubricate the bore of the O-ring seal lightly with
Part No.: 1O7 -7361
S/N: LLCl-Up
Part No.: 107- 7361
S/N: LLE1-Up
Part No.: 1O7 -7361
S/N: LLFl-Up
Part No.: 1O7 -7361
S/N: SBG1-Up
184 RENR9362-08
Spe fications Section
Part No.: 7N -4851, 7N-7784, 7W-0968

S/N: LLEl-Up
Part No.: 7N-4851, 7N-7784, 7W-0968
S/N: LLFl -Uo
Part No.: 7N -4851, 7N -7784, 7W- 0968
S/N: SBGl-Up
Part No.: 7N-4851, 7N - 7784, 7W - 0968
S/N: SBJl-Uo
Part No.: 333-3742
S/N: C8K1-Up
Part No.: 7N -4851, 7N-7784, 7W-0968
S/N: SBK1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968
S/N: SBMl-Uo
Part No.: 7N-4851, 7N-7784, 7W-0968
S/N: PESI-Up
Part No.: 286-0244
Section A-A
S/N: R1S1-Up
(B) Dimensions for the sleeve bearing Part No.: 7N-4851, 7N-7784, 7W-0968
S/N: RMSl-Up
Bore in sleeve bearing before
assembly 44.475 t 0.025 mm Part No.: 286-0244, 7N-4851, 7N-7784, 7W-0968
(1.7510 t 0.0010 inch) S/N: RTX1-Up
Diameter of accessory drive
gear .......... ........ 44.400 t 0.015 mm Part No.: 7N -4851, 7N-7784, 7W-0968
(1.7480 i 0.0006 inch) S/N: T2X1-Uo
(C) Dimensions for the sleeve bearing

Bore in sleeve bearing after
assembly 75.000 r 0.055 mm
(2.9527 t 0.0022 inch)
Diameter of accessory drive
gear ..,..,.... ........ 74.900 r 0.015 mm
(2.9488 t 0.0006 inch)
Flywheel
SMCS Code: 1156
Part No.: 7N -4851, 7N -7784, 7W-0968
S/N: LLA1-Up
Part No.: 286 -0244, 7N-4851, 7N-7784, 7W-0968
S/N: R141-Up
Part No.: 7N-4851, 7N-7784, 7W-0968
S/N: LLBl-Up
Part No.: 7N - 4851 , 7N -7784, 7W - 0968
S/N: LLCI-Uo
Part No.: 333-3742
S/N: C8E1-Up
RENR9362-08 185
To seal the joint between the flywheel housing and

the cylinder block, apply Loctite High Flex GM to the
front face of the flywheel housing.
Tighten the bolts that hold the flywheel housing to

the engine block evenly. Refer to lllustration 295 and
Table 7 for the locations and for identification of the
bolts.
Torque for the l12inch diameter bolts .. 135 t 20 N.m

(100 r 15 tb ft)
Torque for the 5/B inch diameter bolts .. 270 t 40 N.m

(199 t 30 tb ft)
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 disutfide
or graphite base lubricant.
(3) Torque for the 12 bolts 1150 r 60 N m

(840 r 44 tb ft)
i0401s1 35
Flywheel Housing
SMCS Gode: 1157
Part No.: 333-7644
S/N: CBE1-Up
Part No.: 333-7644
S/N: C8K1-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.
186 RENR9362-OB
lllustration 295
Bolt locations
Table 7
ldentification of the Flywheel Housing Bolts

Bolt Diameter Part Number Bolt Length Qtv
1 112 inch 9X - 8873 57.15 mm (2.250 inch) o
2 112 inch 9X - 8875 88.90 mm (3.500 inch) 4
1 112 inch 9S-1374 203.20 mm (8.000 inch) 2
4 112 inch BS - 9089 114.30 mm (4.500 inch) 4
5/8 inch 1D-4590 12O.65 mm (4,750 inch) 16
RENR9362-OB 187
i040151 50
Flywheel Housing
SMCS Code: 1157
Part No.: 101 - 1269
S/N: LLA1-Up
Part No.: 101 - 1269
S/N: RlAl-Up
Part No.: 101 - 1269
S/N: LLBl-Uo
Part No.: 101 - 1269
S/N: LLC1-Up
Part No.: '101 - 1 269
S/N: LLEl-Up
Part No.: 101 - 1269
S/N: LLFl-Up
Part No.: 101 - 1 269
Left side view
S/N: PES1-Up
(6) Apply blue Loctite High Flex GM to the surface of Part No.: 101 - 1269
the gasket before assembly. S/N: RMS1-Up
Part No.: 101 - 1269
S/N: RTXI-Up
Part No.: 101 - 1 269
S/N: T2X1-Up

To seal the joint between flywheel housing and

cylinder block, apply blue Loctite High Flex GM to the
mating surfaces housing of the flywheel housing.
188 RENR9362-0B
A
4
5
5 6
5 5
Rear view Lefl side view
Table 8
(7) Apply blue Loctite High Flex GM to the surface of
ldentification of the Flywheel Housing Bolts the gasket before assembly.
Part
Bolt Diameter Bolt Length Qtv
Number
inch 88.90 mm
1 112 9X - 8875 4
(3.500 inch)
z inch 228.60 mm
112 6M-9613 z
(9.000 inch)
112 inch 9X - BB73

57.15 mm
(2.250 inch) 6
4 203,20 mm
112 inch YJ- t,J/4 2
(8.000 inch)
120.65 mm
5/8 inch 1D-4590 16
(4.750 inch)
114.30 mm
6 112 inch BS - 9089 4
(4.500 inch)
Tighten the bolts that hold the flywheel housing to

the engine block evenly. Refer to lllustration2gT and
Table 8 for the locations and for the identification of
the bolts.
Torque for the 112 inch diameter bolts .. 135 r 20 N.m

(100 r 15 tb ft)
Torque for the 5/8 inch diameter bolts .. 270 t 40 N.m

(1e9 t 30 tb ft)
RENR9362-08 189
i0401 5331
Flywheel Housing
SMCS Gode: 1157
Part No.: 107-7177
S/N: LLA1-Up
Part No.: 107-7177
S/N: RlAl-Up
Part No.: 107-7177
S/N: LLBl-Uo
Part No.: 1O7-7177
S/N: LLC1-Up
Part No.: 107 -7177
S/N: LLE1-Up
Part No.: 107 -7177
S/N: LLF1-Up
Part No.: 107-7177
S/N: PESl-Up
Part No.: 1O7-7177
S/N: RlSl-Up
Part No.: 107-7177
S/N: RMSl-Up
Part No.: 107 -7177
S/N: RTX1-Up
Part No.: 1O7-7177
S/N: T2X1-Up

To seal the joint between flywheel housing and

mating surface of the flywheel housing.
190 RENR9362-08
r
A
RENR9362-08 191
Table 9 i0401 541 3
ldentification of the Flywheel Housing Bolts Flywheel Housing

Part
Bolt Diameter
Number
Bolt Length Qtv SMCS Gode: 1157
57.15 mm Part No.: 101-0836, 297-7000
1 112 inch 9X - 8873
(2.250 inch) S/N: LLA1-Up
152.40 mm
z 112 inch 1D-4574 (6.000 inch)
o Part No.: 101 -0836, 297-7000
S/N: R'141-Up
76.20 mm z
112 inch 9X - 8874 Part No.: 101 -0836, 297 -7000
(3.000 inch)
S/N: LLBl-Up
165.10 mm
4 5/8 inch 1D-4597 (6.500 inch)
z
Part No.: 101-0836, 297-7OOO
139.70 mm S/N: LLC'I-Up
5/8 inch 1D-4593 12
(5.500 inch)
Part No.: 1 01 - 0836, 297 -7000
'133.35 mm S/N: LLEl-Up
6 112 inch 9X - 8878 4
(5.250 inch)
Part No.: .101-0836, 297-7000
241.30 mm S/N: LLFI-Up
7 5/8 inch 1D-4602 (9.500 inch)
z
Part No.: 101-0836, 297-7OOO

Tighten the bolts that hold the flywheel housing to S/N: SBGl-Up
the engine block evenly. Refer to lllustration 299 and
Part No.: 101 - 0836, 297 -7OOO
Table 9 for the locations and for the identification of
S/N: SBJl-Up
the bolts.
Part No.: 1 01 - 0836, 297 -7000
Torque forthe ll2inch diameter bolts .. 135 t 20 N.m S/N: SBK1-Up
(100 r 15 rb ft)
Part No.: 1 01 - 0836, 297 -7OOO
Toroue for the 5/8 inch diameter bolts .. 270 t 40 N.m S/N: SBMl-Up
(1ee i 30 rb ft) Part No.: 1 01 - 0836, 297 -7OOO
S/N: PES1-Up
Part No.: 101-0836. 297-7OOO
Y--Y S/N: RMS'1-Uo
Part No.: 1 01 - 0836, 297 -7OOO
S/N: RTXI-Up
Part No.: 1 01 - 0836, 297 -7OOO
S/N: T2X1-Uo

J To seal the joint between flywheel housing and

front face of the flywheel housing.
lllustration 300 s01513803 Tighten the bolts that hold the flywheel housing to
Left side view the engine block evenly, Refer to lllustration 301 and
Table 10 for the locations and for identification of the
(B) Apply blue Loctite High Flex GM to the surface of botts.
the gasket before assembly.
Torque for the 112 inch diameter bolts .. 135 t 20 N.m
(100 t 15 lb ft)
192 RENR9362-08
Torque for the 5/8 inch diameter bolts .. 270 t 40 N.m

(199 r 30 tb ft)

Bolt locations
Table 10
ldentification of the Flywheel Housing Bolts

Bolt Diameter Part number Bolt Length Qtv
1 112 inch 9X - 8873 57.2 mm (2.25 inch)
z 112 inch 9X - 8875 88.9 mm (3.50 inch) 4
9M-7269 (1)
171.5 mm (6.75 inch)
? 1/2 inch z
6M-9613 (2)
228.6 mm (9.00 inch)
4 112 inch 95- 1 374 203.2 mm (8.00 inch) z
E inch
112 BS - 9089 114.3 mm (4.50 inch) 4
o 5i8 inch 1D-4590 120.7 mm (4.75 inch) to
(1) This bolt is used if the engine is not equipped with a support
bracket forthe air lines
(2) This bolt is used if the engine is equipped with
a support bracket for the air lines.
RENR9362-08 193
i03 1 04647
Flywheel Housing Gover

SMCS Gode: 1157
Part No.: 267 -1794
S/N: RIA'l-Up
Part No.: 267 -1794
S/N: R1S1-Uo
g0'1505975
lllustration 302
Left side view
(7) Apply blue Loctite High Flex GM to the surface of

the gasket before assembly.
901 585794
lllustration 303
Typical example
(1) Apply 5P -3975 Rubber Lubricant to the entire

mating surface of the flywheel housing cover
assembly.
(2) Torque forfour plugs .. 70 t 15 N'm (50 t 11 lb ft)

(B) Distance between the cup plug and the starter
pad ............ 9,75 t 0.25 mm (0.384 t 0.010 inch)
i03606340
Flexible Goupling
SMCS Gode: 3279
Part No.:5N-3765
S/N: LLAI-Up
Part No.:5N-3765
S/N: LLB1-Up
RENR9362-08
Part No.: 5N-3765 2. Install the O-ring seals (2) in the outer coupling ('1)
S/N: LLCl-Uo
3, Center the drive coupling (3) inside the outer
Part No.: 5N-3765 coupling (1 ).
S/N: C8E'1-Up
Part No.: 5N-3765 4. Place the rubber coupling boots (5) between the
S/N: SBJl-Uo drive coupling (3) and outer coupling (1).
Part No.:5N-3765 5. Fill the cavities between the couplings and the
S/N: SBK1-Up rubber coupling boots (5) with the 5N-5S61
Silicone Lubricant.
Part No.: 5N-3765
S/N: PESl-Up 6, Bolt the outer coupling (1) into the flywheel (6).
Part No.: 5N-3765
7. Bolt the drive coupling (3) to the shaft (7).
S/N: T2X1-Up
8. As needed, modify the assembly procedure for
the installation of the flexible coupling in the field.
io+orssf
Vibration Damper
SMCS Code: 1205
Part No.: 146-3740
S/N: C8E1-Up
Part No.: 146-3740
S/N: C8K1-Up
Part No.: 146-3740
S/N: T2X1-Up
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. lllustration 305 901 438233
Use the following procedure to install the flexible Note: Lubricate the threads of the bolts with blue
coupling: Loclite 242.
1. Lubricate all the surfaces that will contact either (1) Torque for 48 bolts ......... 55 t 7 N.m (41 r 5 tb ft)
the O-ring seals (2) or the rubber coupling boots
(5) with 5N-5561 Silicone Lubricant except the
plate (4).
RENR9362-08 195
Note: The alignment mark on the crankshaft (1)

must be aligned with the alignment mark on the two
Vibration Damper adapters (2). The mark on the two damper groups
(3) must also be aligned with the mark on the two
SMCS Code: 1205 adapters (2).
Part No.: 162 -7 460, 7E -9483
S/N: LLA1-Up
bolts with molybdenum disulfide base lubricant.
Part No.: 162-7460, 7E - 9483
S/N: RlAl-Up (4) Torque for six bolts .......... 1150 t 60 N'm
(848 r 44 tb ft)
Part No.: 162 -7460, 7E -9483
S/N: LLBl-Uo
Part No.: 162 -7 460, 7E - 9483
S/N: LLCl-Up
Part No.: 162 -7 460, 7E - 9483
S/N: LLE1-Up
Part No.: 162 -7 460, 7E -9483
S/N: LLFI-Up
Part No.: 1 62 -7 460, 7E - 94Bg
S/N: SBG1-Up
Part No.: 162 -7 460, 7E-9483
S/N: SBJl-Uo
Part No.: 162 -7460, 7E- 9483
S/N: SBK1-Up
Part No.: 162 -7460, 7E - 9483
S/N: SBMl-Up
Part No.: 162-7460
S/N: PES1-Up
Note: Lubricate the threads of the bolts with blue
Part No.: 162 -7 460, 7E - 9483 Loctite 242.
S/N: RMS1-Up
(5) Torque for 48 bolts ......... 55 t 7 N'm (41 r 5 lb ft)
Part No.: 162 -7 460, 7E -9483
S/N: RTX1-Up
i03322541
Part No.: 162 -7460, 7E -9483
S/N: T2X1-Up Vibration Damper
SMCS Gode: 1205
Part No.: 24O-7762
S/N: LLAI-Uo
Part No.: 24O-7762
S/N: RlAl-Up
Part No.: 240-7762
S/N: LLBl-Up
Part No.: 240-7762
S/N: LLC1-Up
Part No.: 24O-7762
lllustration 306 901 5 1 5797 S/N: LLEl-Up
Part No.: 24O-7762
S/N: LLFI-Uo
196 RENR9362-OB
Part No.: 24O-7762 i0401 5783

S/N: SBGl-Up
Vibration Damper
Part No.: 24O-7762
S/N: SBJl-Up SMGS Code: 1205
Part No.: 24O-7762 Part No.: 174 -7079, 248 - 0197, 8N -0339
S/N: SBK1-Up S/N: LLA1-Up
Part No.: 24O-7762 Part No.: 174 -7079, 248-0197, BN -0339
S/N: SBMl-Up S/N: RlAl-Up
Part No.: 24O-7762 Part No.: 174 -7079, 248 -0197, 8N - 0339
S/N: PESl-Up S/N: LLBl-Up
Part No.: 125-9749 Part No.: 174 -7079, 248-0197, BN - 0339
S/N: R'l51-Up S/N: LLCl-Up
Part No.: 24O-7762 Part No.: 174 -7079, 248 -0197, 8N -0339
S/N: RMS1-Up S/N: LLEl-Up
Part No,: 24O-7762 Part No.: 174 -7079, 248 -0197, 8N - 0339
S/N: RTX1-Up S/N: LLF1-Up
Part No.: 240-7762 Part No.: 174 -7079, 248 -0197, BN -0339
S/N: T2X1-Uo S/N: SBGl-Up
Part No,: 174 -7079, 248-0197, BN - 0339
S/N: SBJl-Up
Part No.: 174 -7079, 248 -0197, 8N -0389
S/N: SBKI-Uo
Part No.: 174-7079,248-0197, 301 -0432,
BN - 0339
S/N: SBMl-Uo
Part No.: 174 -7079, 248 -0197, BN -0339
S/N: PES'1-Up
Part No.: 174 -7079, 248 -0197, 8N -0339
S/N: RMSl-Up
Part No.: 174 -7079, 248 -0197, 8N -0399
S/N: RTX1-Up
Part No.: 174 -7079, 248 -0197, 8N -0339
S/N: T2X1-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).

(4) Torque for six bolts .......... 1150 r 60 N.m

(840 r 44 tb ft)
Note: Apply 4C-4030 Thread Lock Compound to
the threads of the bolts.
(5) Torque for 48 bolts ......... 55 r 7 N'm (41 r S tb ft)

RENR9362-08 ,lo7
i040 1 5578
Vibration Damper
SMCS Code: 1205
Part No.:4W-3113
S/N: T2X1-Up
Typical example
Note: The alignment mark on the damper group

(2) must be aligned with the alignment mark on the
adapter ('1).
Note: Before assembly, lubricate the threads of the 9021 88893

lllustration 310
Right side view
(3) Torque for six bolts ......,... 1150 r 60 N.m
(848 r 44lb ft) Note: The alignment mark on damper group (2) must
be aligned with the alignment mark on adapter ('l).
Note: Lubricate the threads of the bolts with blue
Loclite 242. Note: Lubricate the threads of the bolts with blue
Loctite 242.
(4) Torque for the bolts ........ 55 !7 N.m (41 t 5 lb ft) (3) Torquefor43 bo|ts.........55 t 7 N'm (41 r 5lbft)
Note: Lubricate the threads of the screws with blue
Loctite 242.Tighten three screws (4) after complete
tightening of the bolts (3).
(4) Torque for three screws .. 55 t 7 N.m (41 t 5 lb ft)

bolts (5)with molybdenum disulfide base lubricant.
(5) Torque for six bolts .......... 1150 t 60 N.m

(848 r 44 lb ft)
i031 05503
Vibration Damper Guard

SMCS Code: 1205
Part No.: 197-9052, 8N-9639
S/N: LLA1-Up
Part No.: 1 97-9052, 284 -2976, 8N -9639
S/N: RlAl-Up
198 RENR9362-08
Part No.: 197-9052, BN-9639

S/N: LLB1-Up
Part No.: 197 -9052, BN - 9639
S/N: LLCl-Up
Part No.: 334-4644
S/N: CBEl-Up
Part No.: 197 -9052, BN-9639
S/N: LLE'1-Up
Part No.: 197 -9052, 8N - 9639
S/N: LLF1-Up
Part No.: 197 -9052
S/N: SBG1-Up
Part No.: 197 -9052
S/N: SBJl-Up
Part No.: 334-4644
S/N: C8K1-Up
Part No.: 197-9052
S/N: SBK1-Up
Part No.: 197 -9052
S/N: SBMI-Up
Part No.: 197 -9052, 8N - 9639
S/N: PESl-Uo lllustration 311 901393058
Typical example
Part No.: 31O-7976
S/N: RlSl-Up (1) Torque for the bolts ........ 15 r 3 N.m (11 + 2 tb ft)
Part No.: 1 97 - 9052, 8N - 9639
S/N: RMS1-Uo
Part No.: 1 97-9052, 284-2976,8N-9639
S/N: RTX1-Up
Part No.: 1 97-9052, 8N-9639
S/N: T2X1-Up
RENR9362-08 199
Vibration Damper Guard

SMCS Gode: 1205
Part No.: 7W-6669
S/N: LLB1-Up
Part No.: 7W-6669
S/N: SBGl-Up
Part No.: 7W-6669
S/N: SBJl-Up
Part No.: 7W-6669
S/N: SBK1-Up
Part No.: 7W-6669
S/N: SBMl-Up
[__]
F-----r
(1) Torque for the three bolts .. 7 t 2 N'm

(60 t 18 lb in)
200 RENR9362-08
Stub Shaft (Front)

SMCS Code:1237
Part No.: 7W-5237
S/N: R141-Uo
Part No.: 7W-5237
S/N: LLBl-Uo
Part No.: 334-0956
S/N: C8E1-Up
Part No.: 334-0956
S/N: C8K1-Uo
Part No.: 7W-5237
S/N: RTX1-Up
VIEIY A-A

Low kW (HP) attachments
o
RENR9362-08 201
+rA
\
I
Ja
900278464
lllustration 314
High kW (HP) attachments
('1) Crankshaft io3742222
(2) Adapter Stub Shaft (Front)

(3) Bolts SMGS Code= 1237
Apply a molybdenum disulfide grease under the Part No.: 334-0958

bolt heads and to the threads before assembly. S/N: CBEl-Uo
Torque ......1150 t 60 N'm (850 t 44) Part No.: 334-0958
S/N: CBK1-Up
(4) Alignment mark
Align the alignment mark on the stub shaft with the

alignment mark on the adapter.
lllustration 315 90'1744573
Typical example
Note: The alignment mark on the stub shaft (3) must

be aligned with the mark on the adapter (1)
Note: Before you tighten the bolts, apply a

molybdenum disulfide grease to the threads of the
bolts.
(2) Torque for the bolts .......... 1150 t 60 N'm

(848 + 44 tb ft)
RENR9362-OB
io2832479 (2) Torque for the six bolts 1150 t 150 N'm
Stub Shaft (Front) (840 t 110 tb ft)
Note: The alignment mark on the stub shaft (3) must
SMCS Code:1237 be aligned with the alignment mark on the damper
Part No.: 7N - 7660 adapter (1).
S/N: LLA1-Up
Part No.: 7N-7660
S/N: RlAl-Up Stub Shaft (Front)
Part No.: 7N - 7660
S/N: LLB1-Up SMCS Code:1237
Part No.:7N-7660 Part No.: 7W-3629

S/N: LLC1-Up S/N: PESl-Up

S/N: LLE1-Up S/N: T2X1-Up
Part No.: 7N-7660

S/N: LLF1-Up
Part No.: 7N-7660
S/N: SBG1-Up
Part No.: 7N-7660
S/N: SBJl-Up
Part No.: 7N-7660
S/N: SBKI-Up
Part No.: 7N-7660
S/N: SBMl-Up
Part No.: 7N-7660 lllustration 317 901 676708
S/N: PESl-Up
Before assembly, apply molybdenum disulfide grease
Part No.: 7N-7660
to the shoulder of the bolt heads and to the threads
S/N: R151-Up of the bolt.
Part No.: 7N-7660
S/N: RMS1-Up (1) Torque for 12 bolts .. 1150 t 1b0 N.m
(840 I 110 tb ft) _
Part No.: 7N-7660
S/N: RTX1-Up v
Part No.: 7N-7660
S/N: T2X1-Up
Typical example
RENR9362-08 203
i01 665231 i03577893
Stub Shaft (Rear) Auxiliary Drive Pulley

SMCS Code:1237 SMCS Gode: 1205
S/N: LLBl-Up S/N: LLBl-Up
Part No.: 8N-8468
S/N: PESl-Uo
lllustration 3'lB 900280780
(1) Crankshaft
(2) Flywheel
(3) Bolt
1. Apply clean engine oil to the threads of the bolts

prior to assembly.
2. Tighten the bolt to the following torque:
Torque 1150 r 60 N.m (840144 lb ft)
901 906433
lllustration 319
(1) Lubricate the sealing lip of the lip type seal with
io3534444
Auxiliary Drive Pulley Belt Tension Chart

Part No.: 8N-8467 Part No.: 7N-9693
S/N: LLB1-Up S/N: LLBl-Up
Part No.: BN-8467 Part No.: 7N-9693
S/N: PESl-Uo S/N: LLGl-Up
Part No.: 7N-9693
S/N: LLEl-Uo
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,
(1) Lubricate the sealing lip of the lip type seal with
the lubricant that is being sealed. Install the lip
type seal as the lip type seal is shown.
(2) Lightly lubricate the bore of the O-ring seat with

RENR9362-08 205
Table 1'l
Belt Tension Chart

tt;n11131"(r)
SAE or RMA Belt Slze Width of Belt (Top Belt Tension Belt Tension "Used"€x3)
Reference)
IN MM IN MM LB N LB N
3/8 (0.380) 10A o.42 10.72 1 45r1 0 645!44 70r1 0 311!44
7t16 (0.440) 11A 0.46 11 .68 155r'10 689144 75r1 0 333144
1/2 (0.500) 134 0.55 13.89 1 6511 0 734!44 80r1 0 356144
5V/5VX 5V 0.63 15.88 1 80t1 0 801!44 8511 0 378!44
11l16 (0.600) 15A 0.69 17.48 1 80r1 0 801!44 85r1 0 378!44
3/4 (0.660) 174 0.75 19.05 20511 0 912x44 9511 0 422!44

7/8 (o.7eo) 204 088 22.23 205!.10 912x44 95r1 0 422!44
15t16 N/A 0.98 23.83 20511 0 912144 95t'10 422-44
4K 4PK o.54 13.72 145!10 645t44 60i1 0 267!44
6K 6PK 0.82 20.94 215t10 956t44 90r1 0 400!44
8K 8PK 11 27.82 28511 0 1179!44 115110 511!44
'l0K 1 OPK 1.38 35.05 355r1 0 1579!44 1 45*1 0 645!44
12K 12PK t.oo 42.16 425x10 1891-44 1 75r1 0 778x44
14K 14PK 1.94 49.28 495r1 0 2202!44 205r'10 912144
15K 1 sPK 2.08 52.83 53011 0 2358!44 215!10 956t44

(1) Belt Tension"lnitial " is for a new belt.
(2) Belt tension "Used" is for a belt that has operated for more than 30 minutes of operation at the rated speed..
(s) lf a belt falls below the "Used" belt tension, the belt should be tightened again to B0% of the "lnitial" belt tension
Note: The chart does not apply to belts that use a

spring loaded tensioner.
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 tenston
force. lf 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.
ln 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 112 inch belts would require a used
belt tension equal to twice the value of the used belt
tension for one 112 inch belt (2 X 80 = 160 lb).
206 RENR9362-08
i02899402
Belt Tension Chart

SMCS Code: 1357
Part No.: 197 -9087
S/N: LLA1-Up
Part No.: 197 -9087
S/N: R1A1-Up
Part No.: 1 97 - 9087
S/N: LLB1-Up
Part No.: 197 -9087
S/N: LLC'1-Uo
Part No.: 197 -9087
S/N: C8E1-Up
Part No.: 197 -9087
S/N: LLE1-Up
Part No.: 197 -9087
S/N: LLF1-Up
Part No.: 1 97 - 9087
S/N: SBG1-Up
Part No.: 197-9087
S/N: SBJl-Up
Part No.: 197 -9087
S/N: CBKI-Up
Part No.: 197 -9087
S/N: SBK1-Up
Part No.: 1 97 - 9087
S/N: SBMl-Up
Part No.: 1 97 - 9087
S/N: PESl-Up
Part No.: 197 -9087
S/N: RMS1-Up
Part No.: 197-9087
S/N: RTX1-Up
Part No.: 1 97 - 9087
S/N: T2X1-Up
Note: Do not use the belt tension chart for belts with
tensioners that are spring loaded.
RENR9362-08 207
Belt Tension Chart
Suggested Suggested
Gauge Reading Gauge Gauge
(Force) Belt Tension Belt Tension (Frequency)
Width of
Size of Belt (Frequency) (Frequency)
Belt tt;111i91"(1) t'ggggl"(2)(3)
Belt Tension Belt Tension
Basic
(Force) (Force) Gauge
Gauge
"lnitial" "Used" Number
Number
(1) (2X3)
8-RIB 27.82 mm 800r22N 489t44N BT-33-1 09 98t10HZ 76x8HZ Clavis Type

POLY - RIB (1.095 inch) (180 r 5 rb) r 10lb)
(110 14
Measure the tension of the belt that is farthest from the engine.
(1) Belt tension "lnitial" is for a new belt.
(2\ Belt tension "Used" is for a belt that has operated for 30 minutes or more of operation at the rated speed
(3) lf a belt falls below the "Used" belt tension, the belt should be tightened again to the high side of the "Used" belt tension.
208 RENR9362-08
i03694540
Alternator and Reg u lator

SMCS Gode: 1405
Part No.: 4N-3986
S/N: LLA1-Up
Part No.: 4N-3986
S/N: R'1A1-Up
Part No.:4N-3986
S/N: LLBl -Up
Part No.: 4N-3986
S/N: LLCl-Uo
Part No.: 4N-3980
S/N: CBEl-Up
Part No.:4N-3986
S/N: LLE'I-Up
Part No.:4N-3986
S/N: LLF'1-Up
Fart No.: 4N-3986 Note: Load the battery with a carbon pile 4C-4911
S/N: C8K'1-Uo Battery Load Tester in order to get the maximum
alternator outout.
Part No.:4N-3986
S/N: PESl-Uo Voltage ......24V
Fart No.: 4N-3980
S/N: RMS1-Uo Amperage 68 Amp
Part No.: 4N-3986 Polarity ...... Negative ground

S/N: RTXI-Up
Rotation ...... Either direction
Minimum full load current at 5000 rpm ......... 68 Amp
Minimum full load current at 2000 rpm ,........ 42 Amp
Output voltage .......28. ,

('1) Final installation torque for flange
!
nut............. 102 !7 N.m (75 r 5 tb ft)
Note: Use a7116 ring terminal for (B+) terminal.
(2) (B+) terminal. Final installation torque for

nut..,.......... 6.2 r t 5,3 tb in)
0.6 N m (54,9
(3) Final installation torque for nut ..2,25 t 0.25 N.m

(19.91 t 2.21 tb in)
(4) (B-) terminal. Final installation torque for

!
nut ............. .. 2.25 0.25 N m (19.91 t 2.21 tb in\
(5) Voltage regulator assembly
Voltage setting No adjustment

Permissible voltage range 27Io29Y
RENR9362-08 209
i02806500
Alternator and Reg u lator

SMCS Code: '1405
Part No.: 5N-5692
S/N: LLA1-Up
Part No.: 5N-5692
S/N: R141-Uo
Part No.: 5N-5692
S/N: LLB1-Up
Part No.: 5N-5692
S/N: LLC1-Up 901 400391
lllustration 324
Part No.:5N-5692 Voltage ......24V

S/N: LLE1-Up
Part No.: 5N-5692 Amperage 45 Amp
S/N: LLFl-Uo
Note: Load the battery with a carbon pile 4C-4911
Part No.: 5N-5692 Battery Load Tester in order to get the maximum
S/N: SBG1-Up alternator outout.
Part No.: 5N-5692 Polarity ...... Negative ground

S/N: SBJ'1-Up
Part No.: 5N-5692
Rotation ...... Either direction
S/N: SBK1-Up Minimum full load current at 5000 rpm ...... 42.3 Amp
Part No.:5N-5692
S/N: SBMl-Up Minimum full load current at 2000 rpm ...... 15.8 Amp
Part No.:5N-5692 Output voltage ....... 28 t 1 V

S/N: PESl-Up
Note: Tighten the bolt (1) before tightening the
Part No.: 5N-5692 mounting bolt.
S/N: RMSl-Up
Part No.:5N-5692
(1) Torque for the bolt.... 88.4 i 6.8 N m (65 t 5 lb ft)
S/N: RTX1-Uo
(2) Final installation torque for the flange
nut .........,... 102 !7 N'm (75 ! 5 lb ft)
(3) (B+1 terminal. Final installation torque for the
nut............. 6.2 r 0.6 N.m (55 t 5 lb in)
Note: Use a 7116 ring terminal for (B+; terminal.
(4) The peak voltage for (R) terminal must not be

less than the output voltage for (B+) terminal.
(5) (B-) terminal. Final installation torque for the

screw .2.25 ! 0.25 N'm (20 t 2 lb in)

901 364499
lllustration 323 Voltage setting No adjustment
Permissible voltage range ..................27 to 29 V
210 RENR9362-OB
i02825634 Rotation .,... Either direction

Alternator and Reg ulator Minimum full load current at 5000 rpm ......... 67 Amp
SMCS Code: 1405 Minimum full load current at 2000 rpm .....,... 29 Amp
Part No.: 3E-7577
S/N: R141-Uo Output voltage ....... 28 r 1V
Part No.: 3E-7577 (2) (B-) terminal. Final installation torque for the
S/N: RlSl-Up screw .....6.2 r0.6 N m(5St5lb in)
(3) (B+) terminal. Final installation torque for the

stud ........... r t
'13.5 1.3 N.m (120 12 tb in)
(4) Voltage regu lator assembly

Permissible voltage range ...,..............27 to 2g V
(5) The peak voltage for (R) terminal must not oe

less than the output voltage for (B+1 terminal.
O
i03694720
g0 1 409463
Alternator and Regulator
lllustration 325
SMCS Gode: 1405
(1) Final installation torque for the
locknut 102!7 N'm (75 t 5 lb ft) Part No.:9X-7803
S/N: R'141-Up
Voltage ..................24'V
Amperage . 75 Amp
Note: Load the battery with a carbon pile 4C-4911

Battery Load Tester in order to get the maximum
alternator output.
Polarity Negative ground

RENR9362-OB 211
i02899397
Alternator Mounting
SMCS Gode: 1405
Part No.: 7E-4836
S/N: LLA1-Up
Part No.: 7E-4836
S/N: RlAl-Up
Part No.: 7E-4836
o 4/nn\ o
S/N: LLBl-Up
Part No.: 7E-4836
S/N: LLCl-Uo
Part No.: 335 - 41 61
S/N: C8E'l-Up
Part No.: 7E-4836
S/N: LLEl-Uo
Part No.: 7E-4836
View A-A
S/N: LLF1-Up
Voltage .....24V Part No.: 7E-4836
S/N: SBGl-Up
Amperage 95 Amp
Part No.: 7E-4836
Note: Load the battery with a carbon pile 4C-4911 S/N: SBJ.l-Up
Battery Load Tester in order to get the maximum
alternator output. Part No.: 335-4161
S/N: CBK1-Up
Polarity ...... Negative ground Part No.: 7E-4836
S/N: SBK1-Up
Rotation Clockwise
Part No.: 7E-4836
Minimum full load current at 5000 rpm ......... 95 Amp S/N: SBMl-Uo
Minimum full load current at 2000 rpm ......... 28 Amp Part No.: 7E-4836
S/N: PES1-Uo
Output voltage ...... 28 t 1 V
Part No.: 7E-4836
('1) Final installation torque for the S/N: R151-Up
locknut ....127 t 10 N'm (94 r 7 lb ft) Part No.: 7E-4836
S/N: RMS'1-Up
Note: Use a 7116 ring terminal for (B+) terminal,
Part No.: 7E-4836
(2) (B+1 terminal. Final installation torque for the S/N: RTX1-Up
nut.................18.2 r 2.4 N.m (161.1 t21.2tbin)
(3) (B-) terminal. Final installation torque for the

bolt ............ 4.4 t 1.0 N.m (39.0 r 8.8 tb in)

Permissible voltage range 27 to 29V
212 RENR9362-08
i02945902
Electric Starting Motor

SMCS Code: 1453
Part No.: 2O7 -1562
S/N: LLBl-Up
Part No.: 2O7 -1562
S/N: LLC1-Up
Part No.: 2O7 - 1562
S/N: LLEl-Up
Part No.: 2O7 - 1562
S/N: LLF1-Uo
Part No.: 2O7 - 1562
S/N: SBGl-Up
Part No.: 2O7 -1562
S/N: SBJl-Uo
Part No.: 2O7 -1562
Note: Maximum misalignment between pulley S/N: SBKl-Up
assembly (3) and pulley (1) is 0.4 degrees. Part No.: 2O7 -1562
S/N: SBMl-Up
(2) Torque forthe pulley retaining nut.. 110 r 10 N.m
(80r7tbft) Part No,: 2O7 - 1562
S/N: PES1-Up
(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
g01 460089
lllustration 331
View A-A
i
RENR9362-08 ztJ
^A
When the electric starting motor is viewed from i031 34620
the drive end, the motor rotates in the following

direction. Clockwise Electric Starting Motor
No load conditions at 25 'C (77 "F) SMCS Code: 1453
Speed 7643 ! 1683 rpm Part No.: 6V-4320

Current draw .......... 76.5 t 14.5 Amp S/N: LLBl-Uo
Voltage ................... 23 V
Part No.: 6V-4320
S/N: LLCl-Uo
(1) Final installation torque for the ground terminal
nut.....,....... 30.5 i 3.5 N'm (270 ! 30 lb in) Part No.: 6V -4320
S/N: LLEl-Up
(2) Final installation torque for the battery terminal
nut............. 30.5 r 3.5 N.m (270 x 30 lb in) Part No.: 6V-4320
S/N: LLF'1-Up
(3) Final installation torque for the ground terminal
nut............. 2.25 ! 0.25 N.m (20 t 2 lb in) Part No.: 6V-4320
S/N: SBGl-Up
(4) Final installation torque for the switch terminal Part No.: 6V-4320
nut............. 2.25 ! 0.25 N.m (20 t 2 lb in) S/N: SBJl-Up
(5) Final installation torque for the motor terminal Part No.: 6V-4320
nut,............ 30.5 r 3.5 N'm (270 t 30 lb in) S/N: SBKI-Uo
(6) Final installation torque for the motor frame Part No.: 6V-4320
terminal nut ................... 8 t 3 N.m (70 t 27 lb in) S/N: SBMl-Up
Part No.: 6V-4320
Solenoid
S/N: PESl-Uo
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)
When the electric starting motor is viewed from

No load conditions at 25 'C (77 "F)

Speed 5500 rpm minimum
Current draw .......... 140 Amp maximum
Voltage 24VDC
214 RENR9362-08
(1) Final installation torque for the nut for ground i031 34502
terminal 30.5 r 3.5 N.m (270 t 30 tb in)
Electric Starting Motor
Note: A maximum of three cable terminals or wrre
terminals may be used with the nut. A maximum of SMCS Code: 1453
two of the terminals may be equal to or greater than
O AWG. Part No.: 1 06 - 8551
S/N: LLBl-Up
(2) Final installation torque for the nut for battery Part No.: 106 - 8551
terminal 30.5 r 3.5 N.m (270 t 30 lb in) S/N: LLC1-Up
Note: The switch terminal must be insulated with Part No.: 106-8551
heat shrink tubing. Do not use molded terminals. S/N: LLEl-Uo
(3) Final installation torque for the nut for switch Part No.: 106-8551
terminal t
2.25 0.25 N.m (20 t 2 tb in) S/N: LLFl-Up
(4) Final installation torque for the nut for ground

Part No.: 1 06 - 8551
S/N: SBGl-Up
terminal 2.25 x 0.25 N.m (20 t 2 lb in)
Part No.: 106-8551
(5) Final installation torque for the nut for motor S/N: SBJl-Up
frame terminal ,.... 30.5 t 3.5 N.m Q70 t 30 lb in)
Part No.: 106 - 855'1
(6) Final installation torque for the nut for motor S/N: SBK1-Up
Part No.: 106-8551
Solenoid S/N: SBMl-Up
Part No.: 106-8551
Current consumption (draw) at24Y and at 25'C S/N: PESl-Up
(77 "F)
Pull-in windings . 51 Amp
Hold-inwindings .7Amp
'o
View A-A
RENR9362-08 215
When the electric starting motor is viewed from i02685953

direction. Clockwise Electric Starting Motor
No load conditions at25 "C (77 "F) SMCS Code: 1453
Speed 7643t 1683 rpm Part No.: 6V-0927

..........
Current draw ,. 67 .5 t 7.5 Amp S/N: R141-Up
Voltage 23 VDC
Part No.: 6V-0927
(B) The clearance between the pinion and the S/N: LLBl-Up
housing .....:.....,....... 9.'1 mm (0.36 inch) Paft No.: 6V -0927
S/N: LLF1-Up
terminal 30.5 t 3.5 N,m (270 t 30 lb in) Part No.: 6V-0927
S/N: SBGl-Up
terminal 2.25 ! 0.25 N'm (20 t 2 lb in) Part No.: 6V -0927
S/N: SBJ1-Up
Note: A maximum of three cable terminals or wire
Part No.: 6V -0927
terminals may be used with the nut. A maximum of
S/N: SBK1-Up
O AWG. Part No.: 6V-0927
S/N: SBMl-Up
(3) Final installation torque for the nut for battery
terminal 30.5 + 3.5 N.m (270 t 30 lb in) Part No.: 6V-0927
S/N: PES1-Up
Note: The switch terminal must be insulated with
heat shrink tubing. Do not use molded terminals. Part No.: 6V-0927
S/N: T2X'1-Up
(4) Final installation torque for the nut for switch
terminal 2.25 ! 0.25 N.m (20 t 2 tb in)
(5) Final installation torque for the nut for motor
B[*
(6) Final installation torque for the bolt for motor
frame terminal ............... 8 t 3 N'm (70 t 27 lb in)
Solenoid
Current consumption (draw) at 20 V and at 25 'C

(77 "F)
Pull-in windings ......., 56.5 t 4.5 Amp
Hold-in windings ....... 14.6 Amp max
When the electric starting motor is viewed from

the pinion end, the motor rotates in the following
No load conditions at 25 "C (77 "F)

Speed 6950 r '1650 rpm
Current draw.......... .... 115 t 25 Amo
Voltage 23 VDC
216 RENR9362-OB
(A) The clearance between the pinion and the io2787858

housing is the following value. .. 9.1 mm
(0.36 inch) Ain Starting Moton
(1) Final installation torque for the nut on the ground SMCS Code: 1451
terminal. . 30.5 t 3.5 N.m (270 t 30 lb in) Part No.: 4W-5732
(2) Final installation torque for the nut on the ground S/N: RlAl-Up
terminal. 2.25 t 0.25 N.m (20 r 2 lb in) Part No.: 335 - 41 55
S/N: C8E1-Uo
Note: The switch terminal must be insulated with
heat shrink tubing. Do not use molded terminals. Part No.: 335 -4155
S/N; C8K1-Up
(3) Final installation torque for the switch terminal
nut........ 2.25 ! 0.25 N.m (20 t 2 lb in)
(4) Final installation torque for the nut on the motor

terminal. 30.5 r 3.5 N'm (270 t 30 tb in)
Note: A maximum of three cable terminals or wire
terminals may be used with the nut. A maximum of
O AWG.
(5) Final installation torque for the battery terminal

nut............. 30.513.5 N.m (270 ! 30 tb in)
(6) Final installation torque for the nut on the motor
frame terminal. .... 30.5 t 3.5 N m (270 r 30 lb in) lllustration 336 901 392582
Typical example
Solenoid
(1) Cover
Current consumption at 20V and 25 "C (77 "F)
Tighten the bolts evenly in small increases until
Pull-in windings 49.3 r 3.3 Amp the following torque is reached: .... 80 N m
Hold-in windings 6.8 Amp max (60 rb ft)
(2) Bolt
Torque ........ 36 N.m (27 tb ft)
(3) Bolt
Torque . .... 78 N.m (60 tb ft)
(a) Bolt (pinion)

Torque 110 N.m (80 tb ft)
(5) Rotor clamp nut

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)
Check the clearance again after the bolt for the rotor
clamp nut is tightened.
(6) Rotor retainer bolt

Torque '120 N.m (90 lb ft)
RENR9362-OB 217
i02658703 i02651 886
Air Starting Motor Air Starting Valve

SMCS Gode: 1451 SMCS Code:1462
Part No.: 206-6480 Part No.: 4W -7203, 4W -7206, 4W -7209, 4W -721 2
S/N: LLB1-Up S/N: LLBl-Uo
lllustration 337 90'1335822 lllustration 338 901332886
Section A-A
(1) Apply 6V - 6640 Sealant to the elbow.
(1) Locknut
(2) Apply 6V-6640 Sealant to the nipple.
Torque .........32 t 7 N.m (24 r 5 tb ft)
(3) Apply 5P -3413 Pipe Sealant at the joint of the
valve and nipple.
(4) Apply 5P - 341 3 Pipe Sealant at the joint of the

valve and nipple.
(5) Apply 5P - 3413 Pipe Sealant at the joint of the

elbow and valve.
218 RENR9362-08
i02661 486 i03076601
Switches Engine Oil Level Switch

(Start/Stop) SMCS Code:7422
SMCS Gode: 7332 Part No.: 1 72 - 8660
Part No.: 7C-0331 S/N: LLBl-Up
S/N: R141-Uo Part No.: 1 72 - 8660
Part No.: 7C - 0331 S/N: PES1-Up
S/N: LLFI-Up
(A) The switch must close on rising level before

the following minimum range at 25 "C
(77 "F). 2.3 mm (0.09 inch)
(B) On falling level, the switch must open within the

following range. ........ 10 i S mm (0.4 t 0.2 inch)
Note: Assemble the liquid level switch with the

(1) Nut for the switch assembly arrows in the upward direction.
Torque ....12t 4 N'm (105 r 35lb in) (2) Torque for the liquid level switch ........ 33 t 4 N.m
(24r3tbft)
Operating temperature ..... -40
e4oJ";::-30
Contact position
Closed ......., "Position 1"
.........
Open . "Position 3"
RENR9362-08 219
Section
Operating temperature .... -40 to 125 "C

(-40 to 257 "F)
Fuel Pressure Sensor
SMCS Code:7414
Part No.: 194-6725 Fuel Pressure Sensor
S/N: LLA1-Up
SMCS Code:7414
Part No.: 194-6725
S/N: R141-Uo Part No.: 161 - 1705
S/N: LLB'1-Uo
Part No.: 194-6725
S/N: LLB1-Up PartNo.:161-1705
S/N: LLF1-Up
Part No.: 194-6725
S/N: LLCI-Up Part No.: 161-1705
S/N: SBGl-Up
Part No.: 194-6725
S/N: C8E1-Up Part No.: 161 - 1705
S/N: SBJl-Uo
Part No.: 194-6725
S/N: LLE1-Up Part No.: 161 - 1705
S/N: SBK1-Up
Part No.: 194-6725
S/N: LLF1-Up Part No.: 161 - 1705
S/N: SBMl-Up
Part No.: 194-6725
S/N: CBK1-Up Part No.: 161 - 1705
S/N: PESl-Uo
Part No.: 194-6725
S/N: PESl-Up Part No.: 161 - 1705
S/N: T2X'1-Up
Part No.: 194-6725
S/N: RlSl-Up
Part No.: 194-6725
S/N: RMSI-Up
Part No.: 194-6725
S/N: RTX1-Up
Part No.: 194-6725
S/N: T2X1-Up
901 1 35892
lllustration 342
(1) Final installation torque for the pressure sensor

group ..,..... 10 x2 N'm (90 t 18 lb in)
Operating temperature ..... -40 to 125'C

(-40 to 257 "F)
Operating voltage ......., 5.00 t 0.25 VDC

Typical example

group ........ 10 !2 N.m (90 t 18 lb in)
Operating voltage ,....... 5.00 t 0.25 VDC

220 RENR9362-08
i04079129
Coolant Level Sensor Coolant Level Sensor

SMCS Code:7470 SMCS Code=7470
Part No.: 1 65 - 6634 Part No.: 2O4-2518, 239-9957
S/N: LLA1-Up S/N: LLA1-Up
Part No.: 1 65 - 6634 Part No.: 204-2518, 239-9957
S/N: R141-Up S/N: R141-Up
Part No.: 1 65 - 6634 Part No.: 2O4-2518, 239-9957
S/N: LLBl-Up S/N: LLBl-Up
Part No.: 1 65 - 6634 Part No.: 2O4-2518, 239-9957
S/N: LLC1-Up S/N: LLC'I-Up
Part No.: 1 65 - 6634 Fart No.: 2O4-2518
S/N: LLEI-Uo S/N: C8E1-Up
Part No.: 1 65 - 6634 Part No.: 204-2518, 239-9957
S/N: LLFl-Up S/N: LLEl-Up
Part No.: 1 65 - 6634 Part No.: 204-2518, 239-9957
S/N: SBGl-Up S/N: LLF1-Up
Part No.: 1 65 - 6634 Part No.: 2O4-2518, 239-9957
S/N: SBJl-Up S/N: SBGl-Up
Part No.: 1 65 - 6634 Part No.: 2O4-2518. 239-9957
S/N: SBKI-Up S/N: SBJl-Up
Part No.: 1 65 - 6634 Part No.: 2O4-2518
S/N: SBMl-Uo S/N: C8K1-Up
Part No.: 1 65 - 6634 Part No.: 2O4-2518, 239-9957
S/N: PESl-Up S/N: SBK1-Up
Part No.: 1 65 - 6634 Part No.: 2O4 -2518, 239-9957
S/N: RMS1-Up S/N: SBMl-Up
Part No.: 2O4-2518, 239-9957
S/N: PESl-Up
Part No.: 2O4-2518
S/N: R1S1-Up
Part No.: 239-9957
S/N: RMSl-Uo
g0'l513758
lllustration 343
Typical example
(1) Final installation torque for the liquid level sensor

...,....
group ..22 ! 3 N.m (16 r 2 tb ft)

(-40 to 257 "F)
Operating voltage 8.0 r 0.4 VDC

RENR9362-08 221
(1) Final installation torque for the coolant level i02845092

sensor 9roup...............20 t 3 N.m (15 !2.2|bft)
Engine Oil Pressure Sensor
(-40 to 257 "F) SMCS Code: 1924
Part No.: 194-6725
Operating voltage 7 to 32 VDC
S/N: LLA1-Up
Part No.: 194-6725
S/N: RlAl-Up
Part No.: 194-6725
S/N: LLBl-Up
Part No.: 194-6725
S/N: LLC1-Up
Part No.: 194-6725
S/N: CBE1-Up
Part No.: 194-6725
S/N: LLEl-Up
Part No.: 194-6725
S/N: LLF1-Up
Part No.: 194-6725
S/N: CBK1-Up
Part No.: 194-6725
S/N: PES1-Up
Part No.: 194-6725
S/N: RlSl-Up
Part No.: 194-6725
S/N: RMSl-Up
Part No.: 194-6725
S/N: RTX1-Up
Part No.: 194-6725
S/N: T2X1-Up

group ........ 10 !2 N.m (90 t 18 lb in)

(-40 to 257 "F)
222 RENR9362-08
Operating voltage ........ 5.00 r 0.2S VDC 136691 21
Turbocharger Inlet Pressure

i02a47040
Sensor
Engine Oil Pressure Sensor
SMCS Code: 1052
SMCS Code:1924
Part No.: 161 -9926
Part No.: 161 - 1705 S/N: LLA1-Uo
S/N: LLBl-Uo
Part No.: 161 -9926
Part No.: 161 - 1705 S/N: R,141-Up
S/N: LLFI-Uo
Part No,: 161 -9926
Part No.: 16'1 - 1705 S/N: LLBl-Up
S/N: SBGl-Up
Part No.: 161 -9926
Part No.: 161-1705 S/N: LLCl-Uo
S/N: SBJl-Up
Part No.: 161-9926
Part No.: 161 - 1705 S/N: C8E1-Uo
S/N: SBK1-Uo
Part No.: 161 -9926
Part No.: 161 - 1705 S/N: LLEl-Uo
S/N: SBMl-Up
Part No.: 161-9926
Part No.: 161 - 1705 S/N: LLFl-Up
S/N: PESl-Uo
Part No.: 161 -9926
Part No.: 161 - 1705 S/N: C8K1-Up
S/N: T2X1-Uo
Part No.: 161 -9926
S/N: R131-Uo
Part No.: 161 -9926
S/N: RMSl-Uo
Part No.: 16'1-9926
S/N: RTX1-Up
Part No.: 161 -9926
S/N: T2X1-Uo
Prior to installing the pressure sensor onto the

engine, apply 5P - 341 3 Pipe Sealant to the first three
threads of the sensor
(1) Final installation torque for the pressure

sensor ...... 10 r 2 N.m (90 t 18 lb in)
Operating voltage ........ 5.00 r 0.2S VDC

Operating temperature ..... -40 to 12b'C

(-40 to 257 "F) (1) Final installation torque for the pressure sensor
group ........ 10 !2 N.m (90 t 18 lb in)
Operating temperature . -40 to 125 "C

(-40 to 257 "F)
n64
RENR9362-08 zzo
Maximum input pressure (absolute Operating voltage ......., 5.00 t 0.25 VDC
pressure) ... 116 kPa (17 psi)
voltage
Operating ....... 5,00 r 0.25 VDC i02847453
Maximum supply current 20 mA

Turbocha rger Outlet Pressure
Sensor
Note: Install the pressure sensor group so that the
pressure port is lower than the wire end. Mount SMCS Gode: 1052:1917; 19'19
the pressure sensor group as close to vertical as
possible. Part No.: 194-6724
S/N: LLAI-Up
i02869431 Part No.: 194-6724

S/N: RIA1-Up
Turbocharger Inlet Pressure Part No.: 194-6724
Sensor S/N: LLBl-Up
SMCS Code: 1052 Part No.: 194-6724
S/N: LLCl-Uo
Part No.: 161-1703
S/N: LLB1-Up Part No.: 194-6724
S/N: CBE'1-Uo
PartNo.:161-1703
S/N: LLF1-Up Part No.: 194-6724
S/N: LLEl-Uo
Part No.: 161 - 1703
S/N: SBG1-Uo Part No.: 194-6724
S/N: LLF1 -Up
Part No.: 161-1703
S/N: SBJl-Up Part No.: 194-6724
S/N: C8K1-Up
PartNo.:161-1703
S/N: SBKI-Uo Part No.: 194-6724
S/N: PES1-Up
Part No.: 161 -1703
S/N: SBMl-Uo Part No.: 194-6724
S/N: R151-Up
Part No.: 161-1703
S/N: PES1-Up Part No.: 194-6724
S/N: RMSl-Up
PartNo.:161-1703
S/N: T2X1-Up Part No.: 194-6724
S/N: RTX1-Uo
Part No.: 194-6724
S/N: T2X1-Uo
901 1 35892
lllustration 348

group ........ 10 !2 N.m (90 t 18 lb in)
Operating temperature ..... -40 to 125 "C

(-40 to 257 "F)
group ........ 10 !2 N.m (90 + 18 lb in)
224 RENR9362-08
Operating temperature ...... -40 to 125 "C i02894878

(-40 to 257 "F)
Engine Coolant Temperature
Operating voltage .......5.00 r 0.2S VDC Sensor
SMCS Code: '1395
i028474s4
Turbocharger Out!et Pressure Part No.: 1 95 - 2150

S/N: LLA'1-Up
Sensor
Part No.: 1 95 - 21 50
SMCS Code: 1052; 1917; 1919 S/N: LLBl-Up
Fart No.: 161-1704 Part No.: 195-2150
S/N: LLB1-Up S/N: LLCl-Uo
Part No.: 161-1704 Part No.: 195-2150
S/N: LLF1-Up S/N: C8E1-Up
Part No.: 161-1704 Part No.: '195-2150
S/N: SBGl-Uo S/N: LLEl-Uo
Part No.: 161-1704 Part No.: 195-2150
S/N: SBJl-Up S/N: LLFl -Up
Part No.: 161-1704 Fart No.: 1 95 - 2.1 50
S/N: SBK'I-Up S/N: SBGl-Up
Part No.: 161 - 1704 Part No.: 1 95 - 2150
S/N: SBMl-Up S/N: SBJl-Up
Part No.: 161-1704 Part No.: 195-2150
S/N: PESl-Up S/N: C8K1-Up
Part No.: 161-1704 Part No.: 195-2150
S/N: T2X1-Up S/N: SBKI-Uo
Part No.: 195-2150
S/N: SBMl-Up
Part No.: 195-2150
S/N: PESl-Up
Part No.: 195-2150
S/N: RMSl-Up
Part No.: 195-2150
S/N: T2X'1-Up

group........ 10t2 N.m(90t18lbin)
(-40 to 257 'F)
Operating voltage ........ 5.00 t 0.2S VDC
(1) Final installation torque for the temperature

sensor group..................48 t 5 N.m (35 r 4 lb ft)
RENR9362-08 225
Operating temperature ..... -40 to 150 "C Part No.: 163-7882, 261 -6848
(-40 to 302'F) S/N: LLEl-Up
Maximum output current 10 mA Part No.: 163 -7882, 261 - 6848

S/N: LLFl-Up
Output type ........... .. Passive
Part No.: 163 -7882, 261 - 6848
S/N: SBG1-Up
i0301 5964
Part No.: 163-7882,261 -6848
Engine Goolant Temperature S/N: SBJl-Uo
Sensor Part No.: 163 -7882, 261 - 6848
S/N: C8K'1-Up
SMCS Code: 1395
Part No.: 163-7882, 261-6848
Part No.: 1O2-2240 S/N: SBKl-Up
Part No.: 1 63-7882, 261 -6848
S/N: SBM'1-Uo
Part No.: 26'1 -6848
S/N: R1S1-Uo
Part No.: 163-7882,261 -6848
S/N: RMSl-Up
Part No.: 163-7882,261 - 6848
S/N: RTX1-Up
Part No.: 163 -7882, 261 -6848
S/N: T2X1-Up

sensor group ......... .........20 + 3 N.m (15 r 2 lb ft)

(-40 to 248'F)
Operating voltage ....... 4,75 to 8.50 VDC
i02894896
Turbocharger Exhaust
Temperature Sensor lllustration 353 901 44 1 005
(2) Exhaust temperature sensor group

SMCS Gode: 1052',1919
Part No.: 163-7882, 261 -6848 threads of the adapter (1) before installation.
S/N: LLA1-Up
Part No.: 163-7882, 261 -6848 (1) Final installation torque for the
S/N: R141-Up adapter .......45 t 5 N m (33 r4lbft)
Part No.: 163-7882, 261 -6848 Operating temperature ..... -40 to 850 'C
S/N: LLB1-Up (-40 to 1562 "F)
Part No.: 163-7882, 261 - 6848 Operating voltage 7.5 to 8.5 VDC
S/N: LLCI-Up
Outputtype ........... . ... PWM
Part No.: 163-7882, 261 -6848
S/N: CBE1-Uo
Output frequency 500 t 100 Hz
RENR9362-OB
io41077A9
Engine Speed/Timing Sensor

SMCS Code: 1905; 1907
Part No.: 273-5041
S/N: LLA1-Uo
Part No.: 273-5041
S/N: R141-Up
Part No.: 273-5041
S/N: LLB1-Up
Part No.: 273-5041
S/N: LLC1-Up lllustration 354 901441 500
Part No.: 273-5041 (1) Final installation torque for the speed sensor
S/N: C8E1-Uo group ......... .40 r 5 N.m (eO t 4 lb ft)
Part No.: 273-5041
S/N: LLEI-Uo operatins temperature
i_;t,yjAr""O
Part No.: 273-5041
S/N: LLF1-Uo Operating voltage 7.5 to 14 VDC
Part No.: 273-5041 Output frequency 9 Hz to 10 kHz
S/N: SBGl-Up
Part No.: 273-5041
S/N: SBJl-Up
Part No.: 273-5041
S/N: CBK1-Up
Part No.: 273-5041
S/N: SBK1-Up
Part No.: 273-5041
S/N: SBMl-Uo
Part No.: 273-5041
S/N: R151-Up
Part No.: 273-5041
S/N: RMSI-Uo
Part No.: 273-5041
S/N: RTX1-Up
Part No.: 273-5041
S/N: T2X1-Up
RENR9362-08 227
i03291644 Operating temperature ..... -40 to 12i 'C

(-40 to 250 'F)
SMCS Code: 1905; 1907
Operating voltage 12to 14V
Part No.: 1 29 - 6628

i0391 1 354
S/N: LLA1-Up
Part No.: 1 29 - 6628
S/N: RlAl-Up SMCS Gode: 1905; 1907
Part No.: 129-6628 Part No.: 265-9034
S/N: LLB1-Up S/N: RlAl-Up
Part No.: 129-6628 Part No.: 265 - 9034
S/N: LLC1-Up S/N: LLBl-Up
Part No.: 129-6628 Part No.: 265-9034
S/N: LLEl-Up S/N: LLF1-Up
Part No.: 1 29 - 6628 Part No.:265-9034
S/N: LLFl-Up S/N: PESl-Uo
Part No.: 129 - 6628 Part No.: 265 - 9034
S/N: SBGl-Up S/N: RTX1-Up
Part No.: 129-6628 Part No.: 265-9034
S/N: SBJl-Up S/N: T2X1-Uo
Part No.: 1 29 - 6628
S/N: SBKI-Uo
Part No.: 129-6628
S/N: SBMl-Up
Part No.: 129-6628
S/N: RMSl-Uo
Part No.: 129-6628
S/N: RTX1-Up
Part No.: 129-6628
S/N: T2X1-Uo
lflustration 356 902127933
(1) Final installation torque for the speed sensor

group ........ ..40 r S N,m (30 t 4 tb ft)
Operating voltage ........, 7.5 to 14.0 VDC
Operating temperature .,... -40 to 120 'C

(-40 to 248'F)
Output frequency 9 to 10000 Hz

Compound on the threads of speed sensor group.
(1) Torque for the speed sensor group .... 45 f S N.m

(33r4tbft)
228 RENR9362-OB
i02958537 voltage
Operating ........ 5.00 r 0.25 VDC
Grankcase Pressure Sensor Maximum supply current 20 mA
SMCS Gode: 1916 Note: Install the pressure sensor group so that the
Part No.: 161 -9926 pressure port is lower than the wire end. Mount
S/N: LLAI-Uo the pressure sensor group as close to vertical as
possible.
Part No.: 161 -9926
S/N: R141-Uo
io2869441
Part No.: 161 -9926
S/N: LLB1-Up Grankcase Pressure Sensor
Part No.: 161 -9926 SMCS Code: 19'16
S/N: LLCI-Uo
Part No.: 161 - 1703
Part No.: 161 -9926 S/N: LLBl-Uo
S/N: C8E1-Up
Part No.: 161-1703
Part No.: 161 -9926 S/N: LLF1-Uo
S/N: LLE1-Up
Part No.: 161 - 1703
Part No.: 161 -9926 S/N: SBGl-Up
S/N: LLF1-Uo
Part No.: 161-1703
Part No.: 161 -9926 S/N: SBJl-Up
S/N: C8K1-Up
PartNo.:161-1703
Part No.: 161 -9926 S/N: SBKI-Uo
S/N: R1S1-Uo
Part No.: 161 - 1703
Part No.: 161 -9926 S/N: SBMl-Uo
S/N: RMSl-Up
Part No.: '161-1703
Part No.: 161 -9926 S/N: PES1-Up
S/N: RTX1-Up
Part No.: 161 - 1703
Part No.: 161 -9926 S/N: T2X1-Up
S/N: T2X1-Uo
lllustration 358 901'135892

(1) Final installation torque for the pressure sensor group ......... 10 !2 N'm (90 t 18 lb in)
group ........ 10 !2 N.m (90 t 18 tb in)
Operating temperature ...., -40 to 125 "C
Operating temperature .... -40 to 125'C (-40 to 257 "F)
(-40 to 257 "F)
Operating voltage ........ 5.00 r 0.25 VDC
Maximum input pressure (absolute
pressure) 116 kPa (17 psi)
RENR9362-08 zzJ
^6n
i02958605 voltage
Operating ........ 5.00 t 0.25 VDC
Atmospheric Pressure Sensor Maximum supply current 20 mA
SMCS Code: 1923 Note: Install the pressure sensor group so that the
pressure port is lower than the wire end. Mount
Part No.: 161 -9926
S/N: LLA1-Up the pressure sensor group as close to vertical as
possible.
Part No.: 161-9926
S/N: R141-Up
io2847051
Part No.: 161 -9926
S/N: LLB1-Up
Atmospheric Pressure Sensor
Part No.: 161 -9926 SMCS Code: 1923
S/N: LLC1-Up
Part No.: 161 - 1 703
Part No.: 161-9926 S/N: LLBl-Up
S/N: GBE1-Up
Part No.: 161 - 1703
Part No.: 161-9926 S/N: LLFl-Uo
S/N: LLEl-Up
Part No.: 161 - 1703
Part No.: 161 -9926 S/N: SBGl-Up
S/N: LLF'I-Up
Part No.: 161 - 1703
Part No.: 161-9926 S/N: SBJI-Uo
S/N: C8K1-Up
Part No.: 161 - 1703
Part No.: 161-9926 S/N: SBK1-Up
S/N: R151-Up
Part No.: 161 - 1703
Part No.: 161-9926 S/N: SBMl-Up
S/N: RMS1-Up
Part No.: 161 - 1703
Part No.: 161-9926 S/N: PESI-Up
S/N: RTX1-Up
Part No.: 161 - 1703
Part No.: 161 -9926 S/N: T2X1-Up
S/N: T2X1-Up
901 1 33887
lllustration 360
1

(1) Final installation torque for the pressure sensor group ........ 10 !2 N.m (90 t 18 lb in)
group ........ 10 t2 N'm (90 t '18 tb in)
Operating temperature ..... -40 to 125 "C
Operating temperature ..... -40 to 125 "C (-40 to 257 "F)
(-40 to 257 "F)
Operating voltage ........ 5.00 t 0,25 VDC
Maximum input pressure (absolute
pressure) ... 116 kPa (17 psi)
230 RENR9362-08
i03242583 i03001 872
Engine Speed Sensor Engine Speed Sensor

Part No.: 7W-3355 Part No.: 189-5746
S/N: LLAI-Uo S/N: LLA1-Up
Part No.: 7W-3355 Part hlo.: 1 89 - 5746
S/N: RlAl-Up S/N: RlAl-Up
Part No.: 7W-3355 Part No.: 1 89 - 5746
S/N: LLBl-Up S/N: LLBl-Uo
Part No.: 7W-3355 Part No.: 189 - 5746
S/N: LLCl-Up S/N: LLCI-Up
Part No.: 7W-3355 Part No.: 189 - 5746
S/N: CBE1-Up S/N: C8E1-Up
Part No.: 7W-3355 Part No.: 189 - 5746
S/N: LLF1-Up S/N: LLF1 -Up
Part No.: 7W-3355 Part No.: 189-5746
S/N: R1S1-Up S/N: SBGl-Up
Part No.: 7W-3355 Fart No.: 1 89 - 5746
S/N: RMSl-Up S/N: SBJl-Up
Part No.: 1 89 - 5746
S/N: C8K1-Up
Part No.: 1 89 - 5746
S/N: SBK1-Up
Part No.: 1 89 - 5746
S/N: SBMl-Up
Part No.: 189-5746
S/N: R1S1-Uo
Part No.: 189-5746
S/N: RMSl-Up
lllustration 361 901365716 Part No.: 189-5746

S/N: RTX1-Up
While the engine is stopped, install the speed sensor Part No.: 1 89 - 5746
group into the 5/8 threaded hole. Once the speed S/N: T2X1-Up
sensor group is in contact with the flywheel ring gear,
turn the speed sensor group counterclockwise to the
following distance. ..... 1B0 t 36 degrees
(A) Clearance between speed sensor group and

flywheel ring gear .. 0.56 to 0.84 mm
(0.022 to 0.033 inch)
(1) Torque for the locknut ....45 t 7 N.m (33 t 5 lb ft)
g0 1 s21 632
lllustration 362
RENR9362-08 231
(1) Final installation torque for locknut ....25t5N.m 1. Install the speed sensor group into the 5/8
(18r4tbft) threaded hole and turn until the magnetic core
makes contact with a tooth of the flywheel ring
Operating temperature -40 to 120'C gear.
(-40 to 248'F)
2. Back out 180 degrees.
Resistance at25 "C (77 "F) ...,.....142 Q
3. Tighten the nut to 25 t 5 mm (221t 44 inch).
Minimum air gap .. 0,50 mm (0.035 inch)
Screw the speed sensor into the hole by hand until i03532204
the end of the sensor barely contacts the gear tooth,
Then, back out the sensor by a 112 turn (180 degrees
Tachometer Drive
in the counterclockwise direction),
SMCS Code:7487
Part No.: 4W-5267
i0353458 1
S/N: LLBl-Up
Engine Speed Sensor
SMCS Gode: 1907
Part No.: 9X-5392
S/N: R'141-Up
Part No.: 9X-5392
S/N: LLB1-Up
Part No.: 9X-5392
S/N: LLF1-Up
Part No.: 9X-5392
S/N: PES1-Up
Part No,: 9X-5392
S/N: RTXI-Uo
Part No.: 9X-5392
S/N: T2X1-Uo
(1) Lightly lubricate the bore for the O-ring seal with
clean engine oil.
(2) Use the following procedure in order to tighten

lllustration 363 901448928 the bolt:
Operating temperature -40 to 150'C

1. Tighten the bolt to 360 t 40 N.m (266 r 30 lb ft).
(-40 to 320'F)
2. Lightly tap on the plate in order to seat gear taper
Clearance between the speed sensor group and the on the camshaft.
flywheel ring gear ......... 0.50 to 0.75 mm
(0.020 to 0.030 inch) 3. Again, tighten the bolt to 360 t 40 N.m
(266 i 30 lb ft).
Use the following procedure to install the speed
sensor group (1): 4. Repeat the step until the torque does not change.
232 RENR9362-08
i03534521 Operating temperature .. -40 to 1095'C

(-40 to 2003 "F)
Thermocouple
SMCS Code: 7498 Compound to the threads of the temperature sensor
group.
Part No.: 120-4498
S/N: LLA1-Up
Part No.: 12O-4498 sensor group .,..,.... .... 12 ! 3 N.m (106 t 27 lb in)
S/N: LLBI-Up
Part No.: 'l2O-4498 i02661 685
S/N: LLCl-Up
Thermocouple
Part No.: 12O-4498
S/N: C8E1-Up SMCS Code: 7498
Part No.: 120-4498 Part No.: 7E-8098

S/N: LLE1-Up S/N: T2X1-Up
Part No.: 'l20-4498

S/N: LLF1-Up
Part No.: 120-4498
S/N: SBGI-Up
Part No.: 120-4498
S/N: SBJl-Uo
Part No.: 120-4498
S/N: C8K1-Up
Part No.: 120-4498
S/N: SBK1-Up
Part No.: 120-4498
S/N: SBMl-Up
Part No.: 12O-4498
S/N: PES'1-Up
Part No.: 12O-4498
S/N: RMSI-Uo
(1) Apply 4c-55ee Anti-Seize Gompound to the

threads.
g0 1 906294
lllustration 365
RENR9362-08 zcJ
Index Section
Index
A Engine Oil LevelSwitch.......,. ........... 218
EngineOilPan....... 112,114,116,118-120
Accessory Drive........... 174,176 Engine Oil Pressure Sensor ..... 221-222
Accessory Drive (Lower Left Hand) ..... 176,178-179 Engine Oil Pump.... .... 78, 80, 82, 84-85
Accessory Drive (Upper Right Hand) .. 180, 182-183 Engine Oil Scavenge Pump....... 87,90,92
Air Cleaner ...................... 51 Engine Oil Sump Pump......... ................ . 132
Adapter......
Air Cleaner 51-52 Engine Speed Sensor........ 230-231
Air lnlet and Exhaust 1ines......... ... 60,62-67, 69-70 Engine Speed/Timing Sensor..... 226-227
Air Lines..... 55-59 Exhaust Fitting......... ..,..... 50
Lines).........,
Air Lines (Air Starting 53-55 Exhaust Flange........ .. 48-50
..
Air Shutoff ... 71-74.76-77 Exhaust Manifold ....... 39-46
Motor..........
Air Starting 216-217 Exhaust Shie1d..,...... ....... 47
Va|ve...,......
Air Starting ................... 217
Alternator and Regu|ator......,...,... 208-210
Mounting
Alternator .......211 F
Atmospheric Pressure Sensor........ ..................... 229
Pulley
Auxiliary Drive 203-204 Fan Drive ..... 130
Pump.........
Auxiliary Water 138-139, 142 Flexible Coupling .....,..... 194
Flywheel .... 184
Flywheel Housing ...,, 185, 187 , 189, 191
B Flywheel Housing Cover.......... ......... 193
Fuel Filter (Primary),... ......, B
Balancer Group (Front),,....... ........... 174 Fuel Filter Base (Spin-on Filter)..... ....... I
Belt Tension Chart.......... ......... 204.206 Fuel 1njector...............,.. ...................... 14
Fuel lnjector Mechanism 12-13
Fuel Pressure Regu|ator.......................................... I
c Fuel Pressure Sensor... .................... 219
Fuel Transfer Pump ....10-11
Camshaft 14-18
Connecting Rod............ 157-158
Connecting Rod and Main Bearing Journals....... '160 G
Coolant Level Sensor.................. .... 220
Cover Group (Front Housing) .......... 169 Gear Group (Front).,. 170-171
Crankcase Breather..... 108-112 Gear Group (Rear) ....... 172
Crankcase Pressure Sensor........ ..... 228
Crankshaft 161-164
Crankshaft Wear Sleeves and Sea1s................... 165 H
Cylinder B|ock.......... 143-144,146,148
Cylinder Head.......... ..20,23 Housing (Front)..,..... ...... 166-168
BoltTighteningProcedure.........,..... 21,23
Cylinder Head Va|ves...............,. ........ 25
Cylinder Liner.......... ..... 149 I
lmportant Safety Information ............... 2

D
Duplex Engine Oil Filters ................. 105 P
Piston and Rings (One-Piece Piston) 1 50, 153

E Intermediate Piston Ring (2) 16n 153
Oil Control Piston Ring (3) 1 50, 153
Electric Starting Motor.......... ... 212-215 Pin Retainer (6),. ,. , . , tct, 154
Engine Air Cleaner Service Indicator...... ............... 52 Piston Pin (5) 151 153,
Engine Coolant Temperature Sensor 224-225 Piston Pin Bore (4) 153
Engine Design .............. 5-7 Top Piston Ring (1) .... . ,. ..... 150, 153
Engine Oil Cooler ........ 107
Valves .. 94-95, 97, 99, 101
Engine Oil Filter..... .. 102,104
Engine Oil Filter Base........... ........... 107
234 RENR9362-08
Index Section
Piston and Rings (Two-Piece Piston) .. 151, 1 54-1 55

Intermediate Piston Ring (4) 154,156
Oil Control Piston Ring (5) 154,156
Pin Retainer (7) ,... 1 55-1 56
Piston Pin (6) 1 55-1 56
Top Piston Ring (3) 154,156
s
SpecificationsSection ....... 5
Stub Shaft (Front) .. 200-202
Stub Shaft (Rear)......... ...................., 203
Switches (StarUStop). ... 218
Contents.....
Table of ......... 3
Tachometer Drive.......... ....,.............. 231
Thermocouple................ ...................232
Thermostatic Valve 128-130
Turbocharger................ 30-36,38
Turbocharger Exhaust Temperature Sensor ....... 225
Turbocharger Inlet Pressure Sensor 222-223
Turbocharger Oil Lines 27-29
Turbocharger Outlet Pressure Sensor........ . 223-224
Valve Mechanism ........... 19

VibrationDamper...... 194-197
Guard..
Vibration Damper ........ 198-199
Water Connection Group 130

Water Lines .......... 123-127
Water Lines (Aftercooler)....,... 128
136
133
Type 2 135
Water Temperature Regulator . 121-122
RENR9362-08 235
Index Section
@2011 Cateroillar Cat, Caterpillar, their respective logos, "Caterpillar Yellow" and the Power edge Printed in U.S.A.
All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.

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RENR9362-08

CATERPILLAR' January 2011

lmportant Safety Information

The meaning of this safety alert symbol is as follows.

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Air Cleaner Adapter ........ 52

o Air Inlet and Exhaust Lines

Exhaust Fitting .............114

Water Temperatu re Regulator 121 Vibration Damper ........ 194

Cylinder and valve location

Number and arrangement of

Cylinder and valve location

Firing order (injection sequence)

Standard rotation Firing order (injection sequence)

Exhaust 1.00 mm (0.040 inch) ...........

Engine Design 19699'l

SMCS Code: 1000

Cylinder and valve location

Vafves per cylinder ............ 4

Compression ratio ....

When the crankshaft is viewed from the flywheel

When the crankshaft is viewed from the flywheel ratio

Note: The front end of the engine is opposite the ............

SMCS Gode: 1000 i02415764

S/N: SBK1-Up Engine Design

Bore .......... 170 mm (6.7 inch) 69.1 L (4210 cu in)

Stroke .... 190 mm (7.5 inch) Part No.: 8N-6435

lnlet 0.50 mm (0.020 inch)

Exhaust 1.00 mm (0.040 inch)

Note: The front end of the engine is opposite the

SMCS Code: 1260

Fuel Filter Base Fuel Pressure Regulator

Part No.: 1W-7559 (2) 9N-4053 Spring

Fuel Transfer Pump

Part No.: 8N - 6151 Minimum cracking pressure of bypass

lllustration 10 901641 861

(3) Check valve

When the fuel transfer pump group is viewed from

Minimum output 2l Llmin (5.5 US gpm)

Minimum output is attained under the following

Pump pressure ............ 415 kPa (60 psi)

Pump speed 2400 rpm

i031 47530 lnside diameter of the terminal

Length of the gear 35.347 i 0.008 mm

(4) Dimensions for idler gear assembly

Diameter of thegear 29.801 t 0.006 mm

(3) Check valve

Minimum output is attained under the following Part No.: 224-9869

Part No.: 224-9869

(4) Lubricate the bore of the O-ring seal lightly with

]g':ffi rT,i'fl :i"lii,'[1ffi 5[il]lTiJ,ii:",::?"o

(5) Torque for the retainer nuts of the cap

(6) Apply 5P - 341 3 Pipe Sealant to the threads of

lllustration '12 901441231

(3) Timing pin i02895028

(A) Bore in the sleeve bearing for the rocker arm

Part No.: 281 -6160