RENR5077-12
November 2012
Specifications
3500B and 3500C Marine Engines
9F21-Up (Engine)
CG21-Up (Engine)
ED21-Up (Engine)
WF21-Up (Engine)
9F31-Up (Engine)
9H31-Up (Generator Set)
ED31-Up (Engine)
9H41-Up (Generator)
JB41-Up (Engine)
9H51-Up (Generator Set)
ED51-Up (Generator)
9H61-Up (Generator Set)
GS61-Up (Generator Set)
GS71-Up (Generator Set)
ED81-Up (Generator Set)
MD81-Up (Engine)
GSA1-Up (Generator Set)
M8A1-Up (Engine)
P8A1-Up (Engine)
S2A1-Up (Engine)
M8B1-Up (Engine)
S2B1-Up (Engine)
EDC1-Up (Engine)
S2D1-Up (Engine)
S2E1-Up (Engine)
S2F1-Up (Engine)
B5G1-Up (Engine)
EDG1-Up (Generator Set)
MRG1-Up (Engine)
PAG1-Up (Engine)
S2G1-Up (Engine)
EDH1-Up (Engine)
MKH1-Up (Engine)
S2H1-Up (Engine)
SRH1-Up (Engine)
EDJ1-Up (Engine)
S2J1-Up (Engine)
S2K1-Up (Engine)
SRK1-Up (Engine)
S2L1-Up (Engine)
MXM1-Up (Engine)
S2M1-Up (Engine)
S2N1-Up (Engine)
EDP1-Up (Generator Set)
S2P1-Up (Engine)
MXR1-Up (Engine)
S2R1-Up (Engine)
S2S1-Up (Engine)
SAFETY.CAT.COM
S2T1-Up (Engine)
S2W1-Up (Engine)
S2X1-Up (Engine)
S2Y1-Up (Engine)
S2Z1-Up (Engine)
SRZ1-Up (Engine)
i05086812
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform
these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you
verify that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that you are authorized to perform this work, and that the
product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair
procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.
When replacement parts are required for this
product Caterpillar recommends using Cat replacement parts or parts with equivalent specifications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR5077-12
Table of Contents
Specifications Section
Engine Design ....................................................... 6
Engine Design ....................................................... 7
Engine Design ....................................................... 8
Engine Design ....................................................... 8
Engine Design ....................................................... 9
Engine Design ..................................................... 10
Fuel Filter (Primary) ............................................... 11
Fuel Filter (Primary) .............................................. 12
Fuel Filter Base .................................................... 13
Fuel Filter ............................................................. 14
Fuel Filter ............................................................. 15
Fuel Filter ............................................................. 17
Fuel Pressure Regulator ...................................... 19
Fuel Transfer Pump ............................................. 20
Fuel Transfer Pump ............................................. 21
Fuel Injector Mechanism ....................................... 23
Fuel Injector Mechanism ....................................... 25
Fuel Injector Mechanism ....................................... 28
Fuel Injector .......................................................... 30
Fuel Injector .......................................................... 31
Fuel Injector .......................................................... 33
Fuel Injector .......................................................... 34
Fuel Injector .......................................................... 36
Fuel Injector .......................................................... 37
Camshaft ............................................................. 38
Camshaft ............................................................. 40
Camshaft ............................................................. 41
Camshaft ............................................................. 43
Camshaft ............................................................. 45
Camshaft ............................................................. 47
Camshaft ............................................................. 49
Camshaft ............................................................. 50
Camshaft ............................................................. 52
Camshaft ............................................................. 54
Camshaft ............................................................. 56
Valve Mechanism ................................................. 58
Valve Mechanism ................................................. 60
Valve Mechanism ................................................. 62
Cylinder Head ...................................................... 64
Cylinder Head ...................................................... 68
Cylinder Head ...................................................... 71
Cylinder Head ...................................................... 73
Cylinder Head Valves ........................................... 76
Cylinder Head Valves ........................................... 78
Cylinder Head Valves ........................................... 80
Cylinder Head Valves ........................................... 82
Cylinder Head Valves ........................................... 85
Turbocharger ........................................................ 87
Turbocharger ........................................................ 88
Turbocharger ........................................................ 90
Turbocharger ........................................................ 91
Turbocharger ........................................................ 93
Turbocharger ........................................................ 96
Turbocharger ........................................................ 97
Turbocharger ........................................................ 98
Turbocharger ........................................................ 99
Turbocharger ...................................................... 100
3
Table of Contents
Turbocharger ...................................................... 101
Turbocharger ...................................................... 102
Turbocharger ...................................................... 103
Turbocharger ...................................................... 104
Turbocharger ...................................................... 105
Turbocharger ...................................................... 105
Turbocharger ...................................................... 106
Turbocharger Support ......................................... 107
Accumulator ....................................................... 108
Exhaust Bypass Valve ....................................... 108
Exhaust Bypass Valve ....................................... 109
Exhaust Manifold ................................................ 110
Exhaust Manifold ................................................ 111
Exhaust Manifold ................................................ 112
Exhaust Manifold ................................................ 112
Exhaust Manifold ................................................ 114
Exhaust Manifold ................................................ 115
Exhaust Manifold ................................................ 116
Exhaust Manifold ................................................ 118
Exhaust Manifold ................................................ 119
Exhaust Manifold ............................................... 121
Exhaust Manifold ............................................... 122
Exhaust Manifold ............................................... 123
Exhaust Manifold ............................................... 124
Exhaust Manifold ............................................... 125
Exhaust Manifold ............................................... 126
Exhaust Manifold ............................................... 127
Exhaust Flange .................................................. 128
Exhaust Flange .................................................. 129
Exhaust Flange .................................................. 130
Exhaust Flange .................................................. 131
Exhaust Flange .................................................. 132
Exhaust Flange .................................................. 134
Air Cleaner ......................................................... 135
Air Cleaner ......................................................... 136
Air Cleaner ......................................................... 136
Air Cleaner Adapter ............................................ 138
Air Cleaner Adapter ............................................ 139
Air Cleaner Adapter ............................................ 140
Engine Air Cleaner Service Indicator .................. 141
Engine Air Cleaner Service Indicator .................. 143
Engine Air Cleaner Service Indicator .................. 144
Air Inlet and Exhaust Lines ................................. 145
Air Inlet and Exhaust Lines ................................. 146
Air Inlet and Exhaust Lines ................................. 149
Air Inlet and Exhaust Lines ................................. 151
Air Inlet and Exhaust Lines ................................. 153
Air Inlet and Exhaust Lines ................................. 155
Air Inlet and Exhaust Lines ................................. 157
Air Inlet and Exhaust Lines ................................. 159
Air Inlet and Exhaust Lines ................................. 161
Air Shutoff ........................................................... 163
Air Shutoff ........................................................... 165
Air Shutoff ........................................................... 167
Air Shutoff ........................................................... 169
Air Shutoff ........................................................... 171
Air Shutoff ........................................................... 173
Air Shutoff ........................................................... 175
Engine Oil Pump ................................................ 178
Engine Oil Pump ................................................ 181
Engine Oil Pump ................................................ 186
Engine Oil Pump ................................................ 191
Engine Oil Pump ................................................ 195
4
Table of Contents
Engine Oil Scavenge Pump ............................... 199
Engine Oil Scavenge Pump ............................... 201
Engine Oil Cooler Bypass and Cooling Jet Sequence
Valves ............................................................... 204
Engine Oil Cooler Bypass and Cooling Jet Sequence
Valves ............................................................... 205
Engine Oil Filter ................................................. 207
Engine Oil Filter ................................................. 209
Engine Oil Filter .................................................. 211
Engine Oil Filter ................................................. 213
Engine Oil Filter ................................................. 214
Engine Oil Filter (Duplex) .................................... 215
Engine Oil Lines ................................................. 217
Engine Oil Lines (Front Mounted Engine Oil
Filter) ................................................................. 218
Engine Oil Lines ................................................. 219
Engine Oil Lines ................................................. 221
Engine Oil Lines ................................................. 222
Engine Oil Lines ................................................. 224
Duplex Engine Oil Filters ................................... 225
Duplex Engine Oil Filters ................................... 227
Engine Oil Filter Base ........................................ 229
Crankcase Breather ........................................... 231
Crankcase Breather ........................................... 232
Crankcase Breather ........................................... 233
Crankcase Breather ........................................... 234
Crankcase Breather ........................................... 235
Crankcase Breather ........................................... 236
Crankcase Breather ........................................... 236
Crankcase Breather ........................................... 238
Engine Oil Pan ................................................... 239
Engine Oil Pan ................................................... 240
Engine Oil Pan ................................................... 242
Engine Oil Pan ................................................... 244
Engine Oil Pan ................................................... 246
Engine Oil Pan ................................................... 249
Engine Oil Pan ................................................... 250
Engine Oil Pan ................................................... 253
Engine Oil Pan ................................................... 254
Engine Oil Pan ................................................... 256
Water Temperature Regulator ............................ 257
Water Temperature Regulator ............................ 259
Water Temperature Regulator ............................ 260
Water Lines ......................................................... 261
Water Lines ......................................................... 261
Water Lines ......................................................... 263
Water Lines ......................................................... 265
Water Lines ......................................................... 267
Water Lines ......................................................... 268
Water Lines ......................................................... 269
Engine Oil Sump Pump ...................................... 270
Engine Oil Sump Pump ...................................... 271
Engine Oil Sump Pump ...................................... 272
Engine Oil Sump Pump ...................................... 273
Engine Oil Sump Pump ...................................... 274
Water Pump ....................................................... 275
Water Pump ....................................................... 277
Water Pump ....................................................... 278
Water Pump ....................................................... 280
Water Pump ....................................................... 281
Auxiliary Water Pump ........................................ 285
Auxiliary Water Pump ........................................ 287
Cooling System Pressure Cap ........................... 289
RENR5077-12
Cylinder Block .................................................... 291
Cylinder Block .................................................... 296
Cylinder Block .................................................... 301
Cylinder Block .................................................... 304
Cylinder Block .................................................... 308
Cylinder Block ..................................................... 311
Cylinder Block .................................................... 316
Cylinder Liner ..................................................... 317
Piston and Rings (One-Piece Piston) ................. 319
Piston and Rings (One-Piece Piston) ................. 321
Piston and Rings (Two-Piece Piston) ................. 324
Piston and Rings ................................................ 326
Piston and Rings (Two-Piece Piston) ................. 328
Piston and Rings (Two-Piece Piston) ................. 330
Piston and Rings (One-Piece Piston) ................. 331
Connecting Rod ................................................. 333
Connecting Rod ................................................. 336
Connecting Rod ................................................. 339
Connecting Rod and Main Bearing Journals ...... 342
Crankshaft ......................................................... 343
Crankshaft ......................................................... 344
Crankshaft ......................................................... 345
Crankshaft ......................................................... 346
Crankshaft ......................................................... 348
Crankshaft ......................................................... 350
Crankshaft ......................................................... 351
Crankshaft ......................................................... 352
Crankshaft Wear Sleeves and Seals ................. 354
Housing (Front) ................................................... 356
Housing (Front) ................................................... 357
Housing (Front) ................................................... 359
Gear Group (Front) (Reverse Rotation) .............. 360
Gear Group (Front) (Reverse Rotation) .............. 362
Gear Group (Front) ............................................. 364
Gear Group (Front) ............................................. 365
Gear Group (Front) ............................................. 368
Gear Group (Front) ............................................. 370
Gear Group (Rear) .............................................. 372
Gear Group (Rear) .............................................. 374
Gear Group (Rear) .............................................. 377
Balancer Group (Front) ...................................... 380
Balancer Group (Front) ...................................... 381
Accessory Drive ................................................. 382
Accessory Drive ................................................. 384
Accessory Drive ................................................. 386
Accessory Drive (Lower Left Hand) .................... 388
Accessory Drive (Lower Left Hand) .................... 391
Accessory Drive (Upper Right Hand) .................. 393
Accessory Drive (Upper Right Hand) .................. 395
Accessory Drive (Upper Right Hand) .................. 398
Accessory Drive (Upper Right Hand) .................. 399
Accessory Drive (Upper Right Hand) .................. 401
Accessory Drive (Upper Left Hand) .................... 403
Accessory Drive (Upper Left Hand) .................... 404
Accessory Drive (Upper Left Hand) .................... 406
Accessory Drive (Upper Left Hand) .................... 408
Accessory Drive (Upper Left Hand, Reverse
Rotation) ........................................................... 410
Flywheel .............................................................. 411
Flywheel ............................................................. 412
Flywheel ............................................................. 413
Flywheel Housing .............................................. 415
Flywheel Housing .............................................. 416
RENR5077-12
Flywheel Housing .............................................. 418
Flywheel Housing .............................................. 420
Flywheel Housing .............................................. 422
Flywheel Housing .............................................. 423
Flexible Coupling ................................................ 425
Engine Mount (Front) (Hydraulic Pump Drive or PTO
Clutch) ............................................................... 427
Engine Mount (Front) .......................................... 428
Engine Trunnion .................................................. 429
Engine Trunnion .................................................. 430
Vibration Damper ............................................... 431
Vibration Damper ............................................... 432
Vibration Damper ............................................... 434
Vibration Damper ............................................... 435
Vibration Damper ............................................... 437
Vibration Damper Guard .................................... 438
Vibration Damper Guard .................................... 439
Vibration Damper Guard .................................... 440
Vibration Damper Guard .................................... 442
Vibration Damper Guard .................................... 443
Vibration Damper Guard .................................... 444
Stub Shaft (Front) ............................................... 445
Stub Shaft (Front) ............................................... 445
Stub Shaft (Front) ............................................... 446
Stub Shaft (Front) ............................................... 447
Stub Shaft (Front) ............................................... 448
Stub Shaft (Front) ............................................... 450
Stub Shaft (Front) ............................................... 451
Stub Shaft (Front) ............................................... 452
Stub Shaft (Front) ............................................... 453
Auxiliary Drive Pulley ......................................... 454
Auxiliary Drive Pulley ......................................... 455
Auxiliary Drive Pulley ......................................... 456
Auxiliary Drive Pulley ......................................... 457
Auxiliary Drive Pulley ......................................... 459
Auxiliary Drive Shaft .......................................... 461
Auxiliary Drive Shaft .......................................... 462
Belt Tension Chart ............................................. 463
Belt Tension Chart ............................................. 465
Alternator and Regulator .................................... 467
Alternator and Regulator .................................... 469
Alternator Mounting ........................................... 471
Alternator Mounting ........................................... 473
Alternator Mounting ........................................... 475
Electric Starting Motor ....................................... 477
Electric Starting Motor ....................................... 478
Electric Starting Motor ....................................... 480
Electric Starting Motor ....................................... 482
Air Starting Motor ............................................... 484
Air Starting Motor ............................................... 487
Air Starting Motor ............................................... 488
Air Starting Motor ............................................... 489
Air Starting Motor Pressure Regulating Valve ... 491
Jacket Water Heater .......................................... 493
Engine Harness (Rigid Wiring Harness) ............. 493
Coolant Level Switch ......................................... 496
Coolant Temperature Switch ............................... 497
Fuel Pressure Sensor ........................................ 498
Magnetic Switch ................................................. 500
Coolant Level Sensor ......................................... 502
Engine Oil Pressure Sensor ............................... 504
Engine Oil Pressure Sensor ............................... 504
Turbocharger Inlet Pressure Sensor ................... 505
5
Table of Contents
Turbocharger Outlet Pressure Sensor ................
Turbocharger Outlet Pressure Sensor ................
Turbocharger Outlet Pressure Sensor ................
Aftercooler Coolant Temperature Sensor ...........
Engine Coolant Temperature Sensor ..................
Turbocharger Exhaust Temperature Sensor .......
Engine Speed/Timing Sensor .............................
Engine Speed/Timing Sensor .............................
Engine Speed/Timing Sensor .............................
Engine Speed/Timing Sensor .............................
Engine Speed/Timing Sensor .............................
Crankcase Pressure Sensor ...............................
Atmospheric Pressure Sensor ............................
Atmospheric Pressure Sensor ............................
Atmospheric Pressure Sensor ............................
Engine Speed Sensor .........................................
Engine Speed Sensor .........................................
506
508
509
510
512
513
514
515
516
517
519
519
520
521
522
523
525
Index Section
Index ................................................................... 527
6
Specifications Section
RENR5077-12
Specifications Section
Standard rotation CCW ............... 1, 2, 7, 3, 4, 5, 6, 8
Reverse rotation CW .................. 1, 8, 7, 2, 6, 5, 4, 3
i01939435
Engine Design
Inlet ......................................... 0.50 mm (0.020 inch)
SMCS Code: 1000
Exhaust ................................... 1.00 mm (0.040 inch)
S/N: GS71-Up
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right side
of the engine are determined from the flywheel end.
The number 1 cylinder is the front cylinder on the
right side. The number 2 cylinder is the front cylinder
on the left side.
S/N: M8A1-Up
S/N: P8A1-Up
S/N: S2A1-Up
S/N: M8B1-Up
S/N: S2B1-Up
S/N: S2D1-Up
S/N: S2E1-Up
S/N: S2F1-Up
Illustration 1
g00293348
Cylinder and valve location
(A) Inlet valves
(B) Exhaust valves
Number and arrangement of
cylinders .............................................. 60 degree V-8
Valves per cylinder .................................................. 4
Displacement .............................. 34.5 L (2105 cu in)
Bore ............................................. 170 mm (6.7 inch)
Stroke .......................................... 190 mm (7.5 inch)
Compression ratio .............................................. 14:1
Combustion ........................................ Direct injection
When the crankshaft is viewed from the flywheel
end the crankshaft rotates in the following
direction. ....................................... Counterclockwise
Firing order (injection sequence)
Valve lash
RENR5077-12
7
Specifications Section
i01939560
Bore ............................................. 170 mm (6.7 inch)
Engine Design
Stroke .......................................... 190 mm (7.5 inch)
SMCS Code: 1000
Compression ratio .............................................. 14:1
S/N: ED21-Up
Combustion ........................................ Direct injection
S/N: WF21-Up
When the crankshaft is viewed from the flywheel
end the crankshaft rotates in the following
direction. ....................................... Counterclockwise
S/N: 9H31-Up
S/N: ED31-Up
S/N: 9H41-Up
Firing order (injection sequence)
S/N: ED51-Up
Standard rotation
CCW ...................... 1, 12, 9, 4, 5, 8, 11, 2, 3, 10, 7, 6
S/N: GS61-Up
Reverse rotation
CW ......................... 1, 4, 9, 8, 5, 2, 11, 10, 3, 6, 7, 12
S/N: ED81-Up
S/N: MD81-Up
Valve lash
S/N: S2G1-Up
Inlet ......................................... 0.50 mm (0.020 inch)
S/N: S2H1-Up
Exhaust ................................... 1.00 mm (0.040 inch)
S/N: SRH1-Up
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right side
of the engine are determined from the flywheel end.
The number 1 cylinder is the front cylinder on the
right side. The number 2 cylinder is the front cylinder
on the left side.
S/N: S2K1-Up
S/N: SRK1-Up
S/N: S2L1-Up
S/N: MXM1-Up
S/N: S2M1-Up
S/N: SRZ1-Up
Illustration 2
g00293349
Cylinder and valve location
(A) Inlet valves
(B) Exhaust valves
Number and arrangement of
cylinders ............................................ 60 degree V-12
Valves per cylinder .................................................. 4
Displacement .............................. 51.8 L (3158 cu in)
8
Specifications Section
RENR5077-12
i01443411
Engine Design
Exhaust ................................... 1.00 mm (0.040 inch)
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right side
of the engine are determined from the flywheel end.
The number 1 cylinder is the front cylinder on the
right side. The number 2 cylinder is the front cylinder
on the left side.
SMCS Code: 1000
S/N: MRG1-Up
S/N: MKH1-Up
S/N: S2J1-Up
i01430901
S/N: S2N1-Up
Engine Design
SMCS Code: 1000
S/N: 9F21-Up
S/N: CG21-Up
S/N: JB41-Up
S/N: 9H51-Up
S/N: 9H61-Up
S/N: GSA1-Up
Illustration 3
g00293349
Cylinder and valve location
(A) Inlet valves
(B) Exhaust valves
Number and arrangement of
cylinders ............................................ 60 degree V-12
S/N: EDC1-Up
S/N: EDG1-Up
S/N: EDH1-Up
S/N: EDP1-Up
S/N: MXR1-Up
Valves per cylinder .................................................. 4
Displacement .............................. 58.5 L (3570 cu in)
Bore ............................................. 170 mm (6.7 inch)
Stroke .......................................... 215 mm (8.5 inch)
Compression ratio ........................................... 15.5:1
Combustion ........................................ Direct injection
When the crankshaft is viewed from the flywheel
end the crankshaft rotates in the following
direction. ....................................... Counterclockwise
Firing order (injection sequence)
Standard rotation
CCW ...................... 1, 12, 9, 4, 5, 8, 11, 2, 3, 10, 7, 6
Illustration 4
g00294285
Cylinder and valve location
(A) Inlet valve
(B) Exhaust valve
Number and arrangement of
cylinders ........................................... 60 degree V−16
Reverse rotation
CW ......................... 1, 4, 9, 8, 5, 2, 11, 10, 3, 6, 7, 12
Valves per cylinder .................................................. 4
Valve lash
Displacement .............................. 69.1 L (4210 cu in)
Inlet ......................................... 0.50 mm (0.020 inch)
Bore ............................................. 170 mm (6.7 inch)
RENR5077-12
9
Specifications Section
Stroke .......................................... 190 mm (7.5 inch)
Compression ratio .............................................. 14:1
Combustion ........................................ Direct injection
When the crankshaft is viewed from the flywheel
end, the crankshaft rotates in the following
direction: ....................................... Counterclockwise
Firing order (injection sequence)
Standard rotation
CCW .. 1, 2, 5, 6, 3, 4, 9, 10, 15, 16, 11, 12, 13, 14, 7, 8
Valve lash
Number and arrangement of
cylinders ............................................ 60 degree V-16
Valves per cylinder .................................................. 4
Displacement .............................. 69.1 L (4210 cu in)
Bore ............................................. 170 mm (6.7 inch)
Stroke .......................................... 190 mm (7.5 inch)
Compression ratio .............................................. 14:1
Combustion ........................................ Direct injection
Inlet ......................................... 0.50 mm (0.020 inch)
When the crankshaft is viewed from the flywheel
end the crankshaft rotates in the following
direction. ....................................... Counterclockwise
Exhaust ................................... 1.00 mm (0.040 inch)
Firing order (injection sequence)
Note: The front end of the engine is opposite the
flywheel end of the engine. The left side and the right
side of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder on
the right side. The number 2 cylinder is the front
cylinder on the left side.
Standard rotation
CCW .. 1, 2, 5, 6, 3, 4, 9, 10, 15, 16, 11, 12, 13, 14, 7, 8
i01939608
Inlet ......................................... 0.50 mm (0.020 inch)
Engine Design
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right side
of the engine are determined from the flywheel end.
The number 1 cylinder is the front cylinder on the
right side. The number 2 cylinder is the front cylinder
on the left side.
S/N: S2P1-Up
S/N: S2R1-Up
S/N: S2S1-Up
S/N: S2W1-Up
S/N: S2Y1-Up
Cylinder and valve location
(A) Inlet valves
(B) Exhaust valves
Valve lash
Exhaust ................................... 1.00 mm (0.040 inch)
SMCS Code: 1000
Illustration 5
Reverse rotation
CW .. 1, 6, 5, 4, 3, 10, 9, 16, 15, 12, 11, 14, 13, 8, 7, 2
g00294285
10
Specifications Section
RENR5077-12
i01939644
Valve lash
Engine Design
Inlet ......................................... 0.50 mm (0.020 inch)
SMCS Code: 1000
Exhaust ................................... 1.00 mm (0.040 inch)
S/N: 9F31-Up
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right side
of the engine are determined from the flywheel end.
The number 1 cylinder is the front cylinder on the
right side. The number 2 cylinder is the front cylinder
on the left side.
S/N: B5G1-Up
S/N: PAG1-Up
S/N: EDJ1-Up
S/N: S2T1-Up
S/N: S2X1-Up
S/N: S2Z1-Up
Illustration 6
g00294285
Cylinder and valve location
(A) Inlet valves
(B) Exhaust valves
Number and arrangement of
cylinders ............................................ 60 degree V-16
Valves per cylinder .................................................. 4
Displacement .............................. 78.0 L (4760 cu in)
Bore ............................................. 170 mm (6.7 inch)
Stroke .......................................... 215 mm (8.5 inch)
Compression ratio ........................................... 15.5:1
Combustion ........................................ Direct injection
When the crankshaft is viewed from the flywheel
end the crankshaft rotates in the following
direction. ....................................... Counterclockwise
Firing order (injection sequence)
Standard rotation
CCW .. 1, 2, 5, 6, 3, 4, 9, 10, 15, 16, 11, 12, 13, 14, 7, 8
Reverse rotation
CW .. 1, 6, 5, 4, 3, 10, 9, 16, 15, 12, 11, 14, 13, 8, 7, 2
RENR5077-12
11
Specifications Section
i04369499
Fuel Filter (Primary)
SMCS Code: 1260
Part No.: 8N-6435
S/N: CG21-Up
Part No.: 8N-6435
S/N: WF21-Up
Part No.: 8N-6435
S/N: GS61-Up
Part No.: 8N-6435
S/N: GS71-Up
Part No.: 8N-6435
S/N: MD81-Up
Part No.: 8N-6435
S/N: GSA1-Up
Part No.: 8N-6435
S/N: MXM1-Up
Part No.: 8N-6435
S/N: MXR1-Up
Illustration 7
g02577938
12
Specifications Section
RENR5077-12
Table 1
Specification for 8N-6435 Primary Fuel Filter Gp, 7E-6719 Primary Fuel Filter Gp, and 2W-6071 Primary Fuel Filter Gp
Item
Qty
Part
1
1
7N-1628 Nut
2
1
2J-0157 O-Ring Seal
3
1
7S-9323 Spring
Specification Description
Torque to 25 ± 5 N·m (221 ± 44 lb in).
Lubricate the bore of the O-ring seal and the shaft lightly with clean
engine oil.
Length under test force is 27.94 mm (1.100 inch).
Test force 27.7 to 32.3 N (6.2 to 7.3 lb).
Free length after test is 42.67 mm (1.680 inch).
i04888422
Fuel Filter (Primary)
SMCS Code: 1260
Part No.: 387-0485
S/N: 9H41-Up
Part No.: 387-0485
S/N: 9H61-Up
Part No.: 387-0485
S/N: ED81-Up
Part No.: 387-0485
S/N: EDG1-Up
Illustration 8
g03015316
RENR5077-12
13
Specifications Section
Table 2
Specification for 387-0485 Primary Fuel Filter Gp
Item
Qty
Part
1
1
7N-1628 Nut
2
1
2J-0157 O-Ring Seal
3
1
7S-9323 Spring
Specification Description
Torque to 25 ± 5 N·m (221 ± 44 lb in).
Lubricate the bore of the O-ring seal and the shaft lightly with clean
engine oil.
Length under test force is 27.94 mm (1.100 inch).
Test force 27.7 to 32.3 N (6.2 to 7.3 lb).
Free length after test is 42.67 mm (1.680 inch).
i04369514
Fuel Filter Base
Part No.: 8N-3481
S/N: S2K1-Up
SMCS Code: 1262
Part No.: 8N-3481
S/N: S2L1-Up
Part No.: 8N-3481
S/N: WF21-Up
Part No.: 8N-3481
S/N: S2M1-Up
Part No.: 8N-3481
S/N: GS61-Up
Part No.: 8N-3481
S/N: S2N1-Up
Part No.: 8N-3481
S/N: GS71-Up
Part No.: 8N-3481
S/N: S2P1-Up
Part No.: 8N-3481
S/N: GSA1-Up
Part No.: 8N-3481
S/N: S2R1-Up
Part No.: 8N-3481
S/N: S2A1-Up
Part No.: 8N-3481
S/N: S2S1-Up
Part No.: 8N-3481
S/N: S2B1-Up
Part No.: 8N-3481
S/N: S2T1-Up
Part No.: 8N-3481
S/N: S2D1-Up
Part No.: 8N-3481
S/N: S2W1-Up
Part No.: 8N-3481
S/N: S2E1-Up
Part No.: 8N-3481
S/N: S2X1-Up
Part No.: 8N-3481
S/N: S2F1-Up
Part No.: 8N-3481
S/N: S2Y1-Up
Part No.: 8N-3481
S/N: B5G1-Up
Part No.: 8N-3481
S/N: S2Z1-Up
Part No.: 8N-3481
S/N: MRG1-Up
Part No.: 8N-3481
S/N: SRZ1-Up
Part No.: 8N-3481
S/N: PAG1-Up
Part No.: 8N-3481
S/N: S2G1-Up
Part No.: 8N-3481
S/N: MKH1-Up
Part No.: 8N-3481
S/N: S2H1-Up
Part No.: 8N-3481
S/N: S2J1-Up
14
Specifications Section
RENR5077-12
g02577977
Illustration 9
Table 3
Specification for 1W-7559 Fuel Filter Base As
Item
Qty
Part
Specification Description
1
1
8N-3653 Taperlock Stud
Apply red Loctite 271 to the tapered end of the taperlock stud for the length
of 10.0 ± 1.5 mm (0.39 ± 0.06 inch).
Torque the taperlock stud to 68 ± 7 N·m (50 ± 5 lb ft).
i03609520
Fuel Filter
Part No.: 115-7842
S/N: S2K1-Up
SMCS Code: 1261
Part No.: 115-7842
S/N: S2L1-Up
Part No.: 335-5612
S/N: M8A1-Up
Part No.: 115-7842
S/N: S2N1-Up
Part No.: 115-7842
S/N: S2A1-Up
Part No.: 115-7842
S/N: S2P1-Up
Part No.: 335-5612
S/N: M8B1-Up
Part No.: 115-7842
S/N: S2R1-Up
Part No.: 115-7842
S/N: S2B1-Up
Part No.: 115-7842
S/N: S2S1-Up
Part No.: 115-7842
S/N: S2D1-Up
Part No.: 115-7842
S/N: S2T1-Up
Part No.: 115-7842
S/N: S2E1-Up
Part No.: 115-7842
S/N: S2W1-Up
Part No.: 115-7842
S/N: S2G1-Up
Part No.: 115-7842
S/N: S2X1-Up
Part No.: 115-7842
S/N: S2H1-Up
Part No.: 115-7842
S/N: S2Z1-Up
Part No.: 115-7842
S/N: S2J1-Up
RENR5077-12
15
Specifications Section
Part No.: 7W-9741
S/N: PAG1-Up
Part No.: 7W-9741
S/N: S2G1-Up
Part No.: 7W-9741
S/N: MKH1-Up
Part No.: 7W-9741
S/N: S2H1-Up
Part No.: 7W-9741
S/N: S2J1-Up
Illustration 10
g01934499
Typical example
Part No.: 7W-9741
S/N: S2K1-Up
Part No.: 7W-9741
S/N: S2L1-Up
(1) Manual valve assembly
(3) Fuel filter element
Note: Lightly lubricate the bore of the O-ring seals
with the lubricant that is being sealed or an approved
equivalent.
(2) 1N-2895 Spring
Length under test force ... 20.75 mm (0.817 inch)
Test force ....................................... 222 N (50 lb)
Free length after test ..... 62.48 mm (2.460 inch)
Outside diameter ................ 88.9 mm (3.50 inch)
i04713909
Part No.: 7W-9741
S/N: S2M1-Up
Part No.: 7W-9741
S/N: S2N1-Up
Part No.: 7W-9741
S/N: S2P1-Up
Part No.: 7W-9741
S/N: S2R1-Up
Part No.: 7W-9741
S/N: S2S1-Up
Fuel Filter
Part No.: 7W-9741
S/N: S2T1-Up
SMCS Code: 1261
Part No.: 7W-9741
S/N: S2W1-Up
Part No.: 7W-9741
S/N: GS61-Up
Part No.: 7W-9741
S/N: GS71-Up
Part No.: 7W-9741
S/N: GSA1-Up
Part No.: 7W-9741
S/N: S2A1-Up
Part No.: 7W-9741
S/N: S2B1-Up
Part No.: 7W-9741
S/N: S2D1-Up
Part No.: 7W-9741
S/N: S2E1-Up
Part No.: 7W-9741
S/N: S2F1-Up
Part No.: 7W-9741
S/N: B5G1-Up
Part No.: 7W-9741
S/N: MRG1-Up
Part No.: 7W-9741
S/N: S2X1-Up
Part No.: 7W-9741
S/N: S2Y1-Up
Part No.: 7W-9741
S/N: S2Z1-Up
16
Specifications Section
RENR5077-12
g02818461
Illustration 11
Table 4
Specification for 7W-9741 Fuel Filter Gp
Item
Qty
Part
Specification description
1
1
6V-4589 O-Ring Seal
Lightly lubricate the bore with the lubricant that is being sealed.
2
1
8L-2786 O-Ring Seal
Lightly lubricate the bore with the lubricant that is being sealed.
3
5
6V-5048 O-Ring Seal
Lightly lubricate the bore with the lubricant that is being sealed.
4
2
5D-5957 O-Ring Seal
Lightly lubricate the bore with the lubricant that is being sealed.
5
1
6V-5049 O-Ring Seal
Lightly lubricate the bore with the lubricant that is being sealed.
Length under test force is 20.75 mm (0.817 inch).
6
1
1N-2895 Spring
Test force is 222 N (50 lb).
Free length after test is 62.48 mm (2.460 inch).
RENR5077-12
17
Specifications Section
i04938315
Fuel Filter
SMCS Code: 1261
Part No.: 377-5898
S/N: CG21-Up
Part No.: 377-5898
S/N: 9H41-Up
Part No.: 377-5898
S/N: 9H61-Up
Part No.: 377-5898
S/N: ED81-Up
Part No.: 377-5898
S/N: MD81-Up
Part No.: 377-5898
S/N: EDG1-Up
Part No.: 377-5898
S/N: MXM1-Up
Part No.: 377-5898
S/N: MXR1-Up
g03117857
Illustration 12
Table 5
Specification for 377-5898 Fuel Filter Gp
Item
Qty
Part
1
4
5D-5957 O-Ring Seal
2
2
1N-2895 Spring
Specification Description
Lubricate the bore lightly with clean engine oil.
Length under test force is 20.75 mm (0.817 inch).
Test force is 222 N (50 lb).
Free length after test is 62.48 mm (2.460 inch).
18
Specifications Section
RENR5077-12
i04369549
Fuel Pressure Regulator
Part No.: 114-5477
S/N: EDC1-Up
SMCS Code: 1277
Part No.: 114-5477
S/N: S2D1-Up
Part No.: 114-5477
S/N: 9F21-Up
Part No.: 114-5477
S/N: S2E1-Up
Part No.: 114-5477
S/N: CG21-Up
Part No.: 114-5477
S/N: S2F1-Up
Part No.: 114-5477
S/N: ED21-Up
Part No.: 114-5477
S/N: B5G1-Up
Part No.: 114-5477
S/N: WF21-Up
Part No.: 114-5477
S/N: EDG1-Up
Part No.: 114-5477
S/N: 9F31-Up
Part No.: 114-5477
S/N: MRG1-Up
Part No.: 114-5477
S/N: 9H31-Up
Part No.: 114-5477
S/N: PAG1-Up
Part No.: 114-5477
S/N: ED31-Up
Part No.: 114-5477
S/N: S2G1-Up
Part No.: 114-5477
S/N: 9H41-Up
Part No.: 114-5477
S/N: EDH1-Up
Part No.: 114-5477
S/N: JB41-Up
Part No.: 114-5477
S/N: MKH1-Up
Part No.: 114-5477
S/N: 9H51-Up
Part No.: 114-5477
S/N: S2H1-Up
Part No.: 114-5477
S/N: ED51-Up
Part No.: 114-5477
S/N: SRH1-Up
Part No.: 114-5477
S/N: 9H61-Up
Part No.: 114-5477
S/N: EDJ1-Up
Part No.: 114-5477
S/N: GS61-Up
Part No.: 114-5477
S/N: S2J1-Up
Part No.: 114-5477
S/N: GS71-Up
Part No.: 114-5477
S/N: S2K1-Up
Part No.: 114-5477
S/N: ED81-Up
Part No.: 114-5477
S/N: SRK1-Up
Part No.: 114-5477
S/N: MD81-Up
Part No.: 114-5477
S/N: S2L1-Up
Part No.: 114-5477
S/N: GSA1-Up
Part No.: 114-5477
S/N: MXM1-Up
Part No.: 114-5477
S/N: M8A1-Up
Part No.: 114-5477
S/N: S2M1-Up
Part No.: 114-5477
S/N: S2A1-Up
Part No.: 114-5477
S/N: S2N1-Up
Part No.: 114-5477
S/N: M8B1-Up
Part No.: 114-5477
S/N: EDP1-Up
Part No.: 114-5477
S/N: S2B1-Up
Part No.: 114-5477
S/N: S2P1-Up
RENR5077-12
19
Specifications Section
Part No.: 114-5477
S/N: MXR1-Up
Part No.: 114-5477
S/N: S2R1-Up
Part No.: 114-5477
S/N: S2S1-Up
Part No.: 114-5477
S/N: S2T1-Up
Part No.: 114-5477
S/N: S2W1-Up
Part No.: 114-5477
S/N: S2X1-Up
Part No.: 114-5477
S/N: S2Y1-Up
Part No.: 114-5477
S/N: S2Z1-Up
Part No.: 114-5477
S/N: SRZ1-Up
g02577996
Illustration 13
(2) Valve plunger
Table 6
Specification for 114-5477 Valve Plunger
Item
Qty
Part
1
1
9N-4053 Spring
Specification Description
Length under test force is 28.4 mm (1.12 inch).
Test force is 40.79 ± 2.05 N (9.17 ± 0.46 lb).
Free length after test force is 57.15 mm (2.250 inch).
20
Specifications Section
RENR5077-12
i04448729
Fuel Transfer Pump
SMCS Code: 1256
Part No.: 313-7770
S/N: M8A1-Up
Part No.: 313-7770
S/N: M8B1-Up
g02577836
Illustration 14
Table 7
Specification for 313-7770 Fuel Transfer Pump Gp
Item
Qty
Part
Specification Description
1
4
7C-2870 Terminal Bushing
Inside diameter of the terminal bushing for gear shaft is 12.783 mm
(0.5033 inch).
Installation depth of terminal bushing is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).
2
1
268-1903 Drive Shaft As
3
1
1W-4003 Idler Gear As
Diameter of the gear is 29.801 ± 0.006 mm (1.1733 ± 0.0002 inch).
Length of the gear is 25.347 ± 0.008 mm (0.9979 ± 0.0003 inch).
Diameter of the idler gear assembly is 29.801 ± 0.006 mm
(1.1733 ± 0.0002 inch).
Length of the gear is 25.347 ± 0.008 mm (0.9979 ± 0.0003 inch).
i04906690
Fuel Transfer Pump
Part No.: 377-5900
S/N: WF21-Up
SMCS Code: 1256
Part No.: 377-5900
S/N: 9F31-Up
Part No.: 377-5900
S/N: 9F21-Up
Part No.: 377-5900
S/N: 9H31-Up
Part No.: 377-5900
S/N: CG21-Up
Part No.: 377-5900
S/N: ED31-Up
Part No.: 377-5900
S/N: ED21-Up
Part No.: 377-5900
S/N: 9H41-Up
RENR5077-12
21
Specifications Section
Part No.: 377-5900
S/N: JB41-Up
Part No.: 8N-6151
S/N: S2H1-Up
Part No.: 377-5900
S/N: 9H51-Up
Part No.: 377-5900
S/N: SRH1-Up
Part No.: 377-5900
S/N: ED51-Up
Part No.: 377-5900
S/N: EDJ1-Up
Part No.: 377-5900
S/N: 9H61-Up
Part No.: 8N-6151
S/N: S2J1-Up
Part No.: 8N-6151
S/N: GS61-Up
Part No.: 8N-6151
S/N: S2K1-Up
Part No.: 8N-6151
S/N: GS71-Up
Part No.: 377-5900
S/N: SRK1-Up
Part No.: 377-5900
S/N: ED81-Up
Part No.: 8N-6151
S/N: S2L1-Up
Part No.: 377-5900
S/N: MD81-Up
Part No.: 377-5900
S/N: MXM1-Up
Part No.: 8N-6151
S/N: GSA1-Up
Part No.: 8N-6151
S/N: S2M1-Up
Part No.: 332-7928
S/N: P8A1-Up
Part No.: 8N-6151
S/N: S2N1-Up
Part No.: 8N-6151
S/N: S2A1-Up
Part No.: 377-5900
S/N: EDP1-Up
Part No.: 8N-6151
S/N: S2B1-Up
Part No.: 8N-6151
S/N: S2P1-Up
Part No.: 377-5900
S/N: EDC1-Up
Part No.: 377-5900
S/N: MXR1-Up
Part No.: 8N-6151
S/N: S2D1-Up
Part No.: 8N-6151
S/N: S2R1-Up
Part No.: 8N-6151
S/N: S2E1-Up
Part No.: 8N-6151
S/N: S2S1-Up
Part No.: 8N-6151
S/N: S2F1-Up
Part No.: 8N-6151
S/N: S2T1-Up
Part No.: 8N-6151
S/N: B5G1-Up
Part No.: 8N-6151
S/N: S2W1-Up
Part No.: 377-5900
S/N: EDG1-Up
Part No.: 8N-6151
S/N: S2X1-Up
Part No.: 8N-6151
S/N: MRG1-Up
Part No.: 8N-6151
S/N: S2Y1-Up
Part No.: 8N-6151
S/N: PAG1-Up
Part No.: 8N-6151
S/N: S2Z1-Up
Part No.: 8N-6151
S/N: S2G1-Up
Part No.: 377-5900
S/N: SRZ1-Up
Part No.: 377-5900
S/N: EDH1-Up
Part No.: 8N-6151
S/N: MKH1-Up
22
Specifications Section
RENR5077-12
g02577836
Illustration 15
Table 8
Specification for 8N-6151 Fuel Transfer Pump Gp, 332-7928 Fuel Transfer Pump Gp,
and 377-5900 Fuel Transfer Pump Gp
Item
Qty
Part
Specification Description
1
4
7C-2870 Terminal Bushing
Before installation, inside diameter of the terminal bushing for gear
shaft is 12.783 mm (0.5033 inch).
Installation depth of terminal bushing is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).
2
1
268-1903 Drive Shaft As
3
1
1W-4003 Idler Gear As
Diameter of the gear is 29.801 ± 0.006 mm (1.1733 ± 0.0002 inch).
Length of the gear is 25.347 ± 0.008 mm (0.9979 ± 0.0003 inch).
Diameter of the idler gear assembly is 29.801 ± 0.006 mm
(1.1733 ± 0.0002 inch).
Length of the gear is 25.347 ± 0.008 mm (0.9979 ± 0.0003 inch).
i04706669
Fuel Injector Mechanism
Part No.: 224-9869
S/N: S2B1-Up
SMCS Code: 1102; 1290
Part No.: 224-9869
S/N: S2D1-Up
Part No.: 224-9869
S/N: GS61-Up
Part No.: 224-9869
S/N: S2E1-Up
Part No.: 224-9869
S/N: GS71-Up
Part No.: 224-9869
S/N: S2F1-Up
Part No.: 224-9869
S/N: GSA1-Up
Part No.: 224-9869
S/N: B5G1-Up
Part No.: 332-9690
S/N: M8A1-Up
Part No.: 224-9869
S/N: MRG1-Up
Part No.: 332-9690
S/N: P8A1-Up
Part No.: 224-9869
S/N: PAG1-Up
Part No.: 224-9869
S/N: S2A1-Up
Part No.: 224-9869
S/N: S2G1-Up
Part No.: 332-9690
S/N: M8B1-Up
Part No.: 224-9869
S/N: MKH1-Up
RENR5077-12
Part No.: 224-9869
S/N: S2H1-Up
Part No.: 224-9869
S/N: S2J1-Up
Part No.: 224-9869
S/N: S2K1-Up
Part No.: 224-9869
S/N: S2L1-Up
Part No.: 224-9869
S/N: S2M1-Up
Part No.: 224-9869
S/N: S2N1-Up
Part No.: 224-9869
S/N: S2P1-Up
Part No.: 224-9869
S/N: S2R1-Up
Part No.: 224-9869
S/N: S2S1-Up
Part No.: 224-9869
S/N: S2T1-Up
Part No.: 224-9869
S/N: S2W1-Up
Part No.: 224-9869
S/N: S2X1-Up
Part No.: 224-9869
S/N: S2Y1-Up
Part No.: 224-9869
S/N: S2Z1-Up
23
Specifications Section
24
Specifications Section
RENR5077-12
g02529356
Illustration 16
Table 9
Specification for 224-9869 Valve Mechanism Gp, 332-9690 Valve Mechanism Gp,
and 357-9219 Valve Mechanism Gp
Item
Qty
Part
Specification Description
B
1
230-2620 Bushing
Bore of the bushing for the rocker arm shaft after assembly
is 45.077 ± 0.015 mm (1.7747 ± 0.0006 inch).
1
1
317-1121 Jam Nut
Torque to 120 ± 15 N·m (89 ± 11 lb ft).
C
1
234-2273 Rocker Arm Shaft
2
1
6J-2245 O-Ring Seal
3
1
7E-6508 Cap As
4
1
100-3878 Injector Spring
D
1
282-7944 Injector Lifter As
5
2
334-1626 Bolt
i04913393
Fuel Injector Mechanism
SMCS Code: 1102; 1290
Diameter is 45.000 ± 0.013 mm (1.7716 ± 0.0005 inch)
Lubricate the bore lightly with clean engine oil.
Start tightening the retainer nuts of the cap assembly by
hand so that the terminal studs are not cross threaded.
Tighten the retainer nuts of the cap assembly to
2.50 ± 0.25 mm (0.098 ± 0.010 inch).
Length under test force is 85.00 mm (3.346 inch).
Test force is 300 ± 25 N (67 ± 6 lb).
Free length after test is 87.65 mm (3.451 inch).
Diameter is 34.950 ± 0.010 mm (1.3760 ± 0.0004 inch).
Bore of the head for the unit injector lifter assembly is
35.000 ± 0.025 mm (1.3779 ± 0.0010 inch).
Apply black Loctite gasket maker #2 to the threads of the
bolt, if the bolts are removed after initial installation.
Part No.: 370-9889
S/N: 9F21-Up
Part No.: 370-9889
S/N: CG21-Up
RENR5077-12
Part No.: 370-9889
S/N: ED21-Up
Part No.: 370-9889
S/N: WF21-Up
Part No.: 370-9889
S/N: 9F31-Up
Part No.: 370-9889
S/N: 9H31-Up
Part No.: 370-9889
S/N: ED31-Up
Part No.: 370-9889
S/N: 9H41-Up
Part No.: 370-9889
S/N: JB41-Up
Part No.: 370-9889
S/N: 9H51-Up
Part No.: 370-9889
S/N: ED51-Up
Part No.: 370-9889
S/N: 9H61-Up
Part No.: 370-9889
S/N: ED81-Up
Part No.: 370-9889
S/N: MD81-Up
Part No.: 370-9889
S/N: EDC1-Up
Part No.: 370-9889
S/N: EDG1-Up
Part No.: 370-9889
S/N: EDH1-Up
Part No.: 370-9889
S/N: SRH1-Up
Part No.: 370-9889
S/N: EDJ1-Up
Part No.: 370-9889
S/N: SRK1-Up
Part No.: 370-9889
S/N: EDP1-Up
Part No.: 370-9889
S/N: MXR1-Up
Part No.: 370-9889
S/N: SRZ1-Up
25
Specifications Section
26
Specifications Section
RENR5077-12
g03081556
Illustration 17
Top view
Table 10
Specification for 370-9889 Valve Mechanism Gp
Item
Qty
Part
1
2
3J-9196 Jam Nut
2
2
7E-6507 Retainer Nut
3
1
317-1121 Jam Nut
4
1
100-3878 Injector Spring
5
1
5P-7530 O-Ring Seal
6
2
334-1626 Bolt
Specification Description
Torque to 70 ± 15 N·m (52 ± 11 lb ft).
Torque to 2.50 ± 0.25 N·m (22.13 ± 2.21 lb in).
Start tightening the retainer nuts of the cap assembly by hand so that
the terminal studs are not cross threaded.
Torque to 120 ± 15 N·m (89 ± 11 lb ft).
Length under test force is 85.00 mm (3.346 inch).
Test force is 300 ± 25 N (67 ± 6 lb).
Free length after test is 87.65 mm (3.451 inch).
Lubricate the bore lightly with the lubricant that is being sealed.
If the bolt is removed for service, apply black Loctite Gasket Maker
to the threads.
RENR5077-12
27
Specifications Section
g03081557
Illustration 18
Table 11
Item
Qty
Part
9
1
234-2273 Rocker Arm Shaft
10
2
0L-2070 Bolt
11
1
6J-2245 O-Ring Seal
Lubricate the bore lightly with the lubricant that is being sealed.
B
-
-
Bore of the bushing in the injector rocker arm assembly (7) is
45.077 ± 0.015 mm (1.7747 ± 0.0006 inch).
C
-
-
Bore of the bushing in the valve rocker arm assembly (8) is
45.077 ± 0.015 mm (1.7747 ± 0.0006 inch).
Specification Description
Diameter is 45.000 ± 0.013 mm (1.7717 ± 0.0005 inch).
If the bolt is removed for service, apply black Loctite Gasket Maker
to the threads.
28
Specifications Section
RENR5077-12
i04916584
Fuel Injector Mechanism
SMCS Code: 1102; 1290
Part No.: 379-4835
S/N: MXM1-Up
g03084216
Illustration 19
Top view
Table 12
Specification for 379-4835 Valve Mechanism Gp
Item
Qty
Part
1
2
3J-9196 Jam Nut
2
2
7E-6507 Retainer Nut
3
1
317-1121 Jam Nut
4
1
100-3878 Injector Spring
Specification Description
Torque to 70 ± 15 N·m (52 ± 11 lb ft).
Start tightening the retainer nuts of the cap assembly by hand so that
the terminal studs are not cross threaded.
Torque to 2.50 ± 0.25 N·m (22.13 ± 2.21 lb in).
Torque to 120 ± 15 N·m (89 ± 11 lb ft).
Length under test force is 85.00 mm (3.346 inch).
Test force is 300 ± 25 N (67 ± 6 lb).
Free length after test is 87.65 mm (3.451 inch).
RENR5077-12
29
Specifications Section
g03084217
Illustration 20
Table 13
Item
Qty
Part
5
1
234-2273 Rocker Arm Shaft
B
-
-
After installation, bore of the bushing in the injector rocker arm assembly
(6) is 45.077 ± 0.015 mm (1.7747 ± 0.0006 inch).
C
-
-
After installation, bore of the bushing in the valve rocker arm assembly
(7) is 45.077 ± 0.015 mm (1.7747 ± 0.0006 inch).
8
1
6J-2245 O-Ring Seal
Before assembly, lubricate the bore lightly with the lubricant that is being
sealed.
Specification Description
Diameter is 45.000 ± 0.013 mm (1.7717 ± 0.0005 inch).
30
Specifications Section
RENR5077-12
i04896412
Fuel Injector
SMCS Code: 1290
Part No.: 346-4716
S/N: P8A1-Up
g03045460
Illustration 21
Table 14
Specification for 346-4716 Fuel Injection Pump Gp
Item
Qty
Part
-
-
-
1
1
7F-8698 Bolt
B
-
-
Specification Description
Before assembly, lubricate the bore for the fuel injection pump with
1P-0808 Multipurpose Grease.
Torque to 65 ± 7 N·m (48 ± 5 lb ft).
Timing dimension is 64.34 ± 0.20 mm (2.533 ± 0.008 inch).
i04916587
Fuel Injector
Part No.: 250-1300
S/N: M8A1-Up
SMCS Code: 1290
Part No.: 256-3663
S/N: S2A1-Up
Part No.: 116-7010
S/N: GS61-Up
Part No.: 250-1300
S/N: M8B1-Up
Part No.: 256-3663
S/N: GS71-Up
Part No.: 256-3663
S/N: S2B1-Up
Part No.: 256-3663
S/N: GSA1-Up
Part No.: 256-3663
S/N: S2D1-Up
RENR5077-12
Part No.: 256-3663
S/N: S2E1-Up
Part No.: 256-3663
S/N: S2F1-Up
Part No.: 256-3663
S/N: B5G1-Up
Part No.: 256-3663
S/N: MRG1-Up
Part No.: 256-3663
S/N: PAG1-Up
Part No.: 256-3663
S/N: S2G1-Up
Part No.: 256-3663
S/N: MKH1-Up
Part No.: 256-3663
S/N: S2H1-Up
Part No.: 256-3663
S/N: S2J1-Up
Part No.: 256-3663
S/N: S2K1-Up
Part No.: 256-3663
S/N: S2L1-Up
Part No.: 256-3663
S/N: S2M1-Up
Part No.: 256-3663
S/N: S2N1-Up
Part No.: 256-3663
S/N: S2P1-Up
Part No.: 256-3663
S/N: S2R1-Up
Part No.: 256-3663
S/N: S2S1-Up
Part No.: 256-3663
S/N: S2T1-Up
Part No.: 256-3663
S/N: S2W1-Up
Part No.: 256-3663
S/N: S2X1-Up
Part No.: 256-3663
S/N: S2Y1-Up
Part No.: 256-3663
S/N: S2Z1-Up
31
Specifications Section
32
Specifications Section
RENR5077-12
g02589716
Illustration 22
Table 15
Specification for 256-3663 Fuel Injection Pump Gp, 252-0064 Fuel Injection Pump Gp, 253-2636 Fuel Injection
Pump Gp, 254-1417 Fuel Injection Pump Gp, 144-0726 Fuel Injection Pump Gp, 231-7845 Fuel Injection
Pump Gp, 282-5076 Fuel Injection Pump Gp, 147-0625 Fuel Injection Pump Gp, 157-2831 Fuel Injection
Pump Gp, 274-0053 Fuel Injection Pump Gp, and 282-6903 Fuel Injection Pump Gp
Item
Qty
Part
Specification Description
Prior to installation of the fuel injector group, lubricate the bore in the cylinder head with 1P-0808 Multipurpose Grease. Use
the clamp to press the injector into the bore. Do not tap on the top surface of the injector.
A
-
-
1
1
7F-8698 Bolt
2
3
Timing dimension is 64.34 ± 0.20 mm (2.533 ± 0.008 inch)
Torque to 65 ± 7 N·m (48 ± 5 lb ft).
1
-
Use the following procedure in order to tighten the valve assembly:
Before assembly, lubricate the bore and the threads of valve
assembly with 1P-0808 Multipurpose Grease.
1. Tighten the valve assembly to 35 N·m (26 lb ft).
2. Turn to reach the final turn angle of 19 ± 1 degrees.
3. Again, tighten to 115 to 290 N·m (85 to 214 lb ft).
1
-
Use the following procedure in order to tighten the unit injector nozzle:
1. Tighten the injector nozzle to 30 N·m (266 lb in).
2. Turn to reach the final turn angle of 58 ± 2 degrees.
3. Again, tighten to 180 to 340 N·m (133 to 251 lb ft).
RENR5077-12
33
Specifications Section
i04938316
Fuel Injector
SMCS Code: 1290
Part No.: 384-4705
S/N: 9H41-Up
Part No.: 384-4705
S/N: 9H61-Up
Part No.: 384-4705
S/N: ED81-Up
Part No.: 384-4705
S/N: EDG1-Up
Illustration 23
g03117876
34
Specifications Section
RENR5077-12
Table 16
Specification for 384-4705 Fuel Injection Pump Gp
Item
Qty
Part
Specification Description
Prior to installation of the fuel injector group, lubricate the bore in the cylinder head with 1P-0808 Multipurpose Grease. Use
injector clamp (3) to press the injector into the bore. Do not tap on the top surface of the injector.
1
1
361-9354 Fuel Injection
Valve Assembly
2
1
7F-8698 Bolt
A
-
-
1
230-9456 Unit Injector
Nozzle
3
Use the following procedure in order to tighten the fuel injection valve
assembly:
Before assembly, lubricate the bore and the threads with 1P-0808
Multipurpose Grease.
1. Tighten the valve assembly to 35 N·m (26 lb ft).
2. Turn to reach the final turn angle of 19 ± 1 degrees.
3. Again, tighten to 115 to 290 N·m (85 to 214 lb ft).
Torque to 65 ± 7 N·m (48 ± 5 lb ft).
Timing dimension is 64.34 ± 0.20 mm (2.533 ± 0.008 inch)
Use the following procedure in order to tighten the unit injector nozzle:
1. Tighten the unit injector nozzle to 30 N·m (266 lb in).
2. Turn to reach the final turn angle of 58 ± 2 degrees.
3. Again, tighten to 180 to 340 N·m (133 to 251 lb ft).
i05160092
Fuel Injector
Part No.: 380-2699
S/N: SRH1-Up
SMCS Code: 1290
Part No.: 383-4053
S/N: EDJ1-Up
Part No.: 380-2699
S/N: 9F21-Up
Part No.: 380-2699
S/N: SRK1-Up
Part No.: 380-2699
S/N: CG21-Up
Part No.: 382-3709
S/N: EDP1-Up
Part No.: 380-2699
S/N: ED21-Up
Part No.: 380-2699
S/N: MXR1-Up
Part No.: 383-0868
S/N: WF21-Up
Part No.: 383-0868
S/N: SRZ1-Up
Part No.: 383-4053
S/N: 9F31-Up
Part No.: 380-2699
S/N: 9H31-Up
Part No.: 380-2699
S/N: ED31-Up
Part No.: 382-3709
S/N: JB41-Up
Part No.: 382-3709
S/N: 9H51-Up
Part No.: 380-2699
S/N: ED51-Up
Part No.: 380-2699
S/N: MD81-Up
Part No.: 382-3709
S/N: EDC1-Up
Part No.: 380-2699
S/N: EDH1-Up
RENR5077-12
35
Specifications Section
g03314616
Illustration 24
Typical example
Table 17
Specification for 380-2699 Fuel Injection Pump Gp , 382-3709 Fuel Injection Pump Gp , 383-0868 Fuel
Injection Pump Gp , 332-7922 Fuel Injection Pump Gp and 383-4053 Fuel Injection Pump Gp
Item
Qty
Part
Specification Description
Prior to installation of the fuel injector group, lubricate the bore in the cylinder head with 1P-0808 Multipurpose Grease. Use
the clamp to press the injector into the bore. Do not tap on the top surface of the injector.
A
-
-
1
1
7F-8698 Bolt
Timing dimension is 64.34 ± 0.20 mm (2.533 ± 0.008 inch).
Torque to 65 ± 7 N·m (48 ± 5 lb ft).
36
Specifications Section
RENR5077-12
i04916593
Fuel Injector
SMCS Code: 1290
Part No.: 383-4055
S/N: MXM1-Up
g02823436
Illustration 25
Typical example
Table 18
Specification for 382-5102 Fuel Injection Pump Gp, 382-5103 Fuel Injection Pump Gp, 383-8895 Fuel Injection Pump
Gp, 383-8911 Fuel Injection Pump Gp, 383-4051 Fuel Injection Pump Gp, and 383-4055 Fuel Injection Pump Gp
Item
Qty
Part
Specification Description
Prior to installation of the fuel injector group, lubricate the bore in the cylinder head with 1P-0808 Multipurpose Grease. Use
the clamp to press the injector into the bore. Do not tap on the top surface of the injector.
1
1
7F-8698 Bolt
A
-
-
Timing dimension is 64.34 ± 0.20 mm (2.533 ± 0.008 inch).
-
Use the following procedure in order to tighten the valve assembly:
Before assembly, lubricate the bore and the threads with 1P-0808
Multipurpose Grease.
1. Tighten to 35 N·m (26 lb ft).
2. Turn to reach the final turn angle of 19 ± 1 degrees.
3. Again, tighten to 115 to 290 N·m (85 to 214 lb ft).
2
1
Torque to 65 ± 7 N·m (48 ± 5 lb ft).
RENR5077-12
37
Specifications Section
i04916586
Fuel Injector
SMCS Code: 1290
Part No.: 248-8695
S/N: B5G1-Up
Part No.: 248-8695
S/N: MRG1-Up
Part No.: 248-8695
S/N: MKH1-Up
g02823436
Illustration 26
Table 19
Specification for 253-2636 Fuel Injection Pump Gp, 248-8695 Fuel Injection Pump Gp,
and 274-0054 Fuel Injection Pump Gp
Item
Qty
Part
Specification Description
Prior to installation of the fuel injector group, lubricate the bore in the cylinder head with 1P-0808 Multipurpose Grease. Use
the clamp to press the injector into the bore. Do not tap on the top surface of the injector.
1
1
7F-8698 Bolt
A
-
-
Timing dimension is 64.34 ± 0.20 mm (2.533 ± 0.008 inch).
-
Use the following procedure in order to tighten the valve assembly:
Before assembly, lubricate the bore and the threads with 1P-0808
Multipurpose Grease.
1. Tighten to 35 N·m (26 lb ft).
2. Turn to reach the final turn angle of 19 ± 1 degrees.
3. Again, tighten to 115 to 290 N·m (85 to 214 lb ft).
2
1
Torque to 65 ± 7 N·m (48 ± 5 lb ft).
i04407569
Camshaft
Part No.: 106-4586
S/N: GS61-Up
SMCS Code: 1210
Part No.: 106-4595
S/N: GSA1-Up
Part No.: 106-4595
S/N: 9F31-Up
Part No.: 106-4586, 106-4595
S/N: S2A1-Up
38
Specifications Section
Part No.: 106-4586, 106-4595
S/N: S2B1-Up
Part No.: 106-4586, 106-4595
S/N: S2D1-Up
Part No.: 106-4586, 106-4595
S/N: S2E1-Up
Part No.: 106-4586
S/N: S2F1-Up
Part No.: 106-4595
S/N: B5G1-Up
Part No.: 106-4586, 106-4595
S/N: MRG1-Up
Part No.: 106-4595
S/N: PAG1-Up
Part No.: 106-4586, 106-4595
S/N: S2G1-Up
Part No.: 106-4586, 106-4595
S/N: MKH1-Up
Part No.: 106-4586, 106-4595
S/N: S2H1-Up
Part No.: 106-4595
S/N: EDJ1-Up
Part No.: 106-4586, 106-4595
S/N: S2J1-Up
Part No.: 106-4586, 106-4595
S/N: S2K1-Up
Part No.: 106-4586, 106-4595
S/N: S2L1-Up
Part No.: 106-4586, 106-4595
S/N: S2M1-Up
Part No.: 106-4586, 106-4595
S/N: S2N1-Up
Part No.: 106-4586, 106-4595
S/N: S2P1-Up
Part No.: 106-4586, 106-4595
S/N: S2R1-Up
Part No.: 106-4586, 106-4595
S/N: S2S1-Up
Part No.: 106-4586, 106-4595
S/N: S2T1-Up
Part No.: 106-4586, 106-4595
S/N: S2W1-Up
Part No.: 106-4586, 106-4595
S/N: S2X1-Up
Part No.: 106-4586, 106-4595
S/N: S2Y1-Up
RENR5077-12
Part No.: 106-4586
S/N: S2Z1-Up
RENR5077-12
39
Specifications Section
g02603357
Illustration 27
(1) Left-hand camshaft assembly
(2) Right-hand camshaft assembly
Table 20
Specification for 106-4595 Camshaft Gp and 106-4586 Camshaft Gp
Item
Qty
Part
A
-
-
C
1
5B-5821 Dowel
D
2
7N-3218 Thrust Washer
E
-
-
-
-
-
3
16
5P-0076 Bolt
F
1
4N-1650 Dowel
Illustration 28
Specification Description
Thickness of the groove in a new camshaft assembly is
8.75 ± 0.05 mm (0.344 ± 0.002 inch).
Extension of the dowel is 12.0 ± 0.5 mm (0.47 ± 0.02 inch).
Thickness of a new thrust washer is 8.50 ± 0.05 mm
(0.335 ± 0.002 inch).
Diameter of bearing journals for a new camshaft is 91.88 ± 0.02 mm
(3.617 ± 0.001 inch).
Bore in camshaft bearing after installation is 92.00 ± 0.06 mm
(3.622 ± 0.002 inch).
End play for a new camshaft assembly is 0.15 to 0.35 mm
(0.006 to 0.014 inch).
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
Extension of the dowel is 22.0 ± 0.5 mm (0.87 ± 0.02 inch).
g02603358
40
Specifications Section
RENR5077-12
Table 21
Specification for 106-4595 Camshaft Gp and 106-4586 Camshaft Gp
Item
Qty
Part
Specification Description
Use the following procedure in order to determine the camshaft
lobe lift:
-
-
-
1. Measure camshaft lobe height (H).
2. Measure base circle (J).
3. Subtract the base circle (J) from the camshaft lobe height (H). The
difference is the actual camshaft lobe lift.
Specified camshaft lobe lift:
G
-
-
Inlet lobe is 12.7500 mm (0.50197 inch).
Injector lobe is 13.7313 mm (0.54060 inch).
Exhaust lobe is 13.2499 mm (0.52165 inch).
i01390111
Camshaft
(3) LH camshaft
SMCS Code: 1210
(4) RH camshaft
Part No.: 143-8726
S/N: S2A1-Up
(5) Journal surface
Part No.: 333-8957
S/N: M8B1-Up
Diameter of surface (journals) for new camshaft
bearings .. 91.88 ± 0.02 mm (3.617 ± 0.001 inch)
Bore in bearings for camshafts after
assembly ................................. 92.00 ± 0.06 mm
(3.622 ± 0.002 inch)
Part No.: 143-8726
S/N: S2D1-Up
Illustration 29
End play for new camshafts ..... 0.15 to 0.35 mm
(0.006 to 0.014 inch)
g00289972
Typical example
Illustration 30
(1) Pin
(6) Camshaft lobe height
The pin extends from the camshaft by the
following distance: ....................... 12.0 ± 0.5 mm
(0.47 ± 0.02 inch)
(2) New washer
Thickness of a new washer ....... 8.50 ± 0.05 mm
(0.335 ± 0.002 inch)
Thickness of the groove in a new
camshaft ... 8.75 ± 0.05 mm (0.344 ± 0.002 inch)
g00290053
In order to determine the height, use the procedure
that follows:
1. Measure camshaft lobe height (6).
2. Measure base circle (8).
3. Subtract the base circle (Step 2) from the lobe
height (Step 1). The difference is the actual lobe
lift.
RENR5077-12
41
Specifications Section
4. Specified camshaft lobe lift (7)
Inlet lobe ...................... 13.250 mm (0.5217 inch)
Injector lobe ................. 13.731 mm (0.5406 inch)
Exhaust lobe ................ 13.250 mm (0.5217 inch)
i04936911
Camshaft
SMCS Code: 1210
Part No.: 106-4582
S/N: GS71-Up
Part No.: 332-7923
S/N: M8A1-Up
Part No.: 332-7923
S/N: P8A1-Up
Part No.: 106-4582
S/N: S2B1-Up
Part No.: 106-4582
S/N: S2E1-Up
Part No.: 106-4582
S/N: S2F1-Up
Illustration 31
g03084598
42
Specifications Section
RENR5077-12
Table 22
Specification for 106-4582 Camshaft Gp, and 332-7923 Camshaft Gp
Item
Qty
Part
A
-
-
B
1
5B-5821 Dowel
C
2
7N-3218 Thrust Washer
D
-
-
-
-
-
Specification Description
Thickness of the groove in a new camshaft assembly is 8.75 ± 0.05 mm
(0.344 ± 0.002 inch).
Extension of the dowel is 12.0 ± 0.5 mm (0.47 ± 0.02 inch).
Thickness of a new thrust washer is 8.50 ± 0.05 mm (0.335 ± 0.002 inch).
Diameter of bearing journals for a new camshaft is 91.88 ± 0.02 mm
(3.617 ± 0.001 inch).
Bore in camshaft bearing after installation is 92.00 ± 0.06 mm
(3.622 ± 0.002 inch).
End play for a new camshaft assembly is 0.15 to 0.35 mm
(0.006 to 0.014 inch).
g03113658
Illustration 32
Table 23
Item
Qty
Part
Specification Description
Use the following procedure in order to determine the camshaft lobe lift:
1. Measure camshaft lobe height (F).
-
-
-
2. Measure base circle (G).
3. Subtract the base circle (G) from the camshaft lobe height (F). The
difference is the actual camshaft lobe lift.
Specified camshaft lobe lift:
E
-
-
Inlet lobe is 12.7500 mm (0.50197 inch).
Injector lobe is 13.7313 mm (0.54060 inch).
Exhaust lobe is 13.2499 mm (0.52165 inch).
RENR5077-12
43
Specifications Section
i05160570
Camshaft
SMCS Code: 1210
Part No.: 380-9135
S/N: 9H31-Up
Part No.: 380-9135
S/N: ED31-Up
Part No.: 380-9135
S/N: ED51-Up
Part No.: 380-9135
S/N: SRK1-Up
g03315137
Illustration 33
Table 24
Specification for 380-9135 Camshaft Gp
Item
Qty
Part
Specification Description
A
-
-
C
2
4N-1650 Dowel
Extension of the dowel is 22.0 ± 0.5 mm (0.87 ± 0.02 inch).
D
2
5B-5821 Dowel
Extension of the dowel is 12.0 ± 0.5 mm (0.47 ± 0.02 inch).
E
2
7N-3218 Thrust Washer
F
-
-
1
16
5P-0076 Bolt
Dimension of groove in a new camshaft for the thrust washer is
8.75 ± 0.05 mm (0.344 ± 0.002 inch).
Thickness of a new thrust washer is 8.50 ± 0.05 mm (0.335 ± 0.002 inch).
Diameter of bearing journal is 91.88 ± 0.02 mm (3.617 ± 0.001 inch).
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
44
Specifications Section
RENR5077-12
g03315157
Illustration 34
Table 25
Specification for 380-9135 Camshaft Gp
Item
Qty
Part
Specification Description
-
-
-
Use the following procedure in order to determine the actual
camshaft lobe lift:
1. Measure camshaft lobe height (H).
2. Measure base circle (J).
3. Subtract the base circle (J) from the camshaft lobe height (H).
The difference is the actual camshaft lobe lift.
G
-
-
Specified camshaft lobe lift for:
Inlet lobe is 13.250 mm (0.5217 inch).
Injector lobe is 13.731 mm (0.5406 inch).
Exhaust lobe is 13.250 mm (0.5217 inch).
RENR5077-12
45
Specifications Section
i04939143
Camshaft
SMCS Code: 1210
Part No.: 380-2698
S/N: 9F21-Up
Part No.: 380-2698
S/N: CG21-Up
Part No.: 382-3100
S/N: ED21-Up
Part No.: 382-3100
S/N: WF21-Up
Part No.: 382-3100
S/N: 9H41-Up
Part No.: 380-2698
S/N: 9H61-Up
Part No.: 382-3100
S/N: ED81-Up
Part No.: 382-3100
S/N: MD81-Up
Part No.: 380-2698
S/N: EDG1-Up
Part No.: 380-2698
S/N: EDH1-Up
Part No.: 382-3100
S/N: SRH1-Up
Part No.: 380-2698
S/N: MXR1-Up
Part No.: 382-3100
S/N: SRZ1-Up
g03120076
Illustration 35
(1) Left-hand camshaft assembly
(2) Right-hand camshaft assembly
46
Specifications Section
RENR5077-12
Table 26
Specification for 380-2698 Camshaft Gpand 382-3100 Camshaft Gp
Item
Qty
Part
A
-
-
C
2
5B-5821 Dowel
D
2
7N-3218 Thrust Washer
Specification Description
Thickness of the groove in the new camshaft assembly for the thrust
washer is 8.75 ± 0.05 mm (0.344 ± 0.002 inch).
Extension of the dowel is 12.0 ± 0.5 mm (0.47 ± 0.02 inch).
Thickness of the new thrust washer is 8.50 ± 0.05 mm (0.335 ± 0.002 inch).
Diameter of bearing journals for a new camshaft is 91.88 ± 0.02 mm
(3.617 ± 0.001 inch).
E
-
-
3
16
5P-0076 Bolt
F
2
4N-1650 Dowel
Bore in camshaft bearing after installation is 92.00 ± 0.06 mm
(3.622 ± 0.002 inch).
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
Extension of the dowel is 22.0 ± 0.5 mm (0.87 ± 0.02 inch).
g03120077
Illustration 36
Table 27
Item
Qty
Part
Specification Description
Use the following procedure in order to determine the camshaft
lobe lift:
-
-
-
1. Measure camshaft lobe height (H).
2. Measure base circle (J).
3. Subtract the base circle (J) from the camshaft lobe height (H). The
difference is the actual camshaft lobe lift.
Specified camshaft lobe lift:
G
-
-
Inlet lobe is 12.7500 mm (0.50197 inch).
Injector lobe is 13.7313 mm (0.54060 inch).
Exhaust lobe is 13.2499 mm (0.52165 inch).
RENR5077-12
47
Specifications Section
i04889503
Camshaft
SMCS Code: 1210
Part No.: 380-9601
S/N: MXM1-Up
g03019437
Illustration 37
Table 28
Specification for 380-9601 Camshaft Gp
Item
Qty
Part
1
16
5P-0076 Bolt
2
2
128-5993 Thrust
Washer
Illustration 38
Specification Description
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
Thickness is 8.40 ± 0.05 mm (0.331 ± 0.002 inch).
Width of the groove in the camshaft for thrust washer is 8.75 ± 0.05 mm
(0.344 ± 0.002 inch).
g03019438
48
Specifications Section
RENR5077-12
Table 29
Item
Qty
Part
Specification Description
A
-
-
Diameter of bearing journal is 91.880 ± 0.020 mm (3.6173 ± 0.0008 inch).
B
1
4N-1650 Dowel
Extension of dowel from the end of camshaft assembly is 22.0 ± 0.5 mm
(0.87 ± 0.02 inch).
C
1
5B-5821 Dowel
Extension of dowel from the end of camshaft assembly is 12.0 ± 0.5 mm
(0.47 ± 0.02 inch).
g03019436
Illustration 39
Table 30
Item
-
Qty
-
Part
Specification Description
-
Use the following procedure in order to determine the actual camshaft lobe lift:
1. Measure camshaft lobe height (E).
2. Measure the base circle (F).
3. Subtract the base circle (F) from the camshaft lobe height (E). The
difference is the actual camshaft lobe lift (D).
Specified camshaft lobe lift for:
D
-
-
Inlet lobe is 12.7300 mm (0.50118 inch).
Exhaust lobe is 13.1000 mm (0.51575 inch).
Injector lobe is 13.8065 mm (0.54356 inch).
RENR5077-12
49
Specifications Section
i03021227
Camshaft
Note: End play for a new camshaft assembly is
0.15 to 0.35 mm (0.006 to 0.014 inch).
(3) Torque for 16 bolts ......... 55 ± 7 N·m (41 ± 5 lb ft)
SMCS Code: 1210
(F) Extension of the dowel from the end of the
rear right hand camshaft and the front left hand
camshaft ......... 22.0 ± 0.5 mm (0.87 ± 0.02 inch)
Part No.: 143-8727
S/N: S2G1-Up
Part No.: 143-8727
S/N: S2K1-Up
Part No.: 143-8728
S/N: S2P1-Up
Part No.: 163-1451
S/N: S2T1-Up
Part No.: 143-8728
S/N: S2W1-Up
Part No.: 163-1451
S/N: S2Z1-Up
Illustration 41
g01447245
Use the following procedure in order to determine the
actual camshaft lobe lift:
1. Measure camshaft lobe height (H).
2. Measure base circle (J).
3. Subtract the base circle (J) from the camshaft lobe
height (H). The difference is the actual camshaft
lobe lift.
Illustration 40
g01381231
(1) Left hand camshaft assembly
(2) Right hand camshaft assembly
(A) Thickness of the groove in a new camshaft
assembly .. 8.75 ± 0.05 mm (0.344 ± 0.002 inch)
(C) Extension of the dowel from the camshaft
assembly ........ 12.0 ± 0.5 mm (0.47 ± 0.02 inch)
(D) Thickness of a new thrust
washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)
(E) Dimensions for the journal surface
Diameter of bearing journal ..... 91.88 ± 0.02 mm
(3.617 ± 0.001 inch)
Bore in camshaft bearing after
installation ................................ 92.00 ± 0.06 mm
(3.622 ± 0.002 inch)
(G) Specified camshaft lobe lift
Inlet lobe ..................... 13.250 mm (0.5217 inch)
Injector lobe ................ 13.731 mm (0.5406 inch)
Exhaust lobe ............... 13.250 mm (0.5217 inch)
50
Specifications Section
RENR5077-12
i04371754
Camshaft
SMCS Code: 1210
Part No.: 163-1419
S/N: S2N1-Up
g02582277
Illustration 42
Typical example
Table 31
Specification for 163-1419 Camshaft Gp
Item
Qty
Part
Specification Description
A
-
-
Dimension of groove in a new camshaft for the thrust washer assembly is
8.75 ± 0.05 mm (0.344 ± 0.002 inch).
C
2
4N-1650 Dowel
Extension of the dowels between the camshafts is 22.0 ± 0.5 mm
(0.87 ± 0.02 inch).
D
2
5B-5821 Dowel
Extension of the dowel from the camshaft assembly is 12.0 ± 0.5 mm
(0.47 ± 0.02 inch).
E
2
7N-3218 Thrust Washer
F
-
-
Diameter of bearing journal is 91.88 ± 0.02 mm (3.617 ± 0.001 inch).
Bore in camshaft bearing after installation is 92.00 ± 0.06 mm
(3.622 ± 0.002 inch).
-
-
-
End play for a new camshaft assembly is 0.15 to 0.35 mm
(0.006 to 0.014 inch).
1
16
5P-0076 Bolt
Thickness of a new thrust washer is 8.50 ± 0.05 mm (0.335 ± 0.002 inch).
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
RENR5077-12
51
Specifications Section
g02582338
Illustration 43
Table 32
Specification for 163-1419 Camshaft Gp
Item
Qty
Part
Specification Description
-
-
-
Use the following procedure in order to determine the actual
camshaft lobe lift:
1. Measure camshaft lobe height (H).
2. Measure base circle (J).
3. Subtract the base circle (J) from the camshaft lobe height (H).
The difference is the actual camshaft lobe lift.
G
-
-
Specified camshaft lobe lift for
Inlet lobe is 13.250 mm (0.5217 inch).
Injector lobe is 13.731 mm (0.5406 inch).
Exhaust lobe is 13.250 mm (0.5217 inch).
52
Specifications Section
RENR5077-12
i04371852
Camshaft
SMCS Code: 1210
Part No.: 281-7848
S/N: B5G1-Up
Part No.: 281-7848
S/N: MRG1-Up
Part No.: 281-7848
S/N: PAG1-Up
Part No.: 281-7849
S/N: MKH1-Up
Illustration 44
Typical example
g02582277
RENR5077-12
53
Specifications Section
Table 33
Specification for 281-7849 Camshaft Gp and 281-7848 Camshaft Gp
Item
Qty
Part
Specification Description
A
-
-
Dimension of groove in a new camshaft for the thrust washer assembly
is 8.75 ± 0.05 mm (0.344 ± 0.002 inch).
C
2
4N-1650 Dowel
Extension of the dowels between the camshafts is 22.0 ± 0.5 mm
(0.87 ± 0.02 inch).
D
2
5B-5821 Dowel
Extension of the dowel from the camshaft assembly is 12.0 ± 0.5 mm
(0.47 ± 0.02 inch).
E
2
128-5993 Thrust Washer
F
-
-
Diameter of bearing journal is 91.88 ± 0.02 mm (3.617 ± 0.001 inch).
Bore in camshaft bearing after installation is 92.00 ± 0.06 mm
(3.622 ± 0.002 inch).
-
-
-
End play for a new camshaft assembly is 0.15 to 0.35 mm
(0.006 to 0.014 inch).
1
16
5P-0076 Bolt
Illustration 45
Thickness of a new thrust washer is 8.40 ± 0.05 mm (0.331 ± 0.002 inch).
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
g02582338
54
Specifications Section
RENR5077-12
Table 34
Specification for 281-7849 Camshaft Gp and 281-7848 Camshaft Gp
Item
-
G
Qty
-
-
Part
Specification Description
-
Use the following procedure in order to determine the actual camshaft
lobe lift:
1. Measure camshaft lobe height (H).
2. Measure base circle (J).
3. Subtract the base circle (J) from the camshaft lobe height (H). The
difference is the actual camshaft lobe lift.
-
Specified camshaft lobe lift for
Inlet lobe is 12.73 mm (0.501 inch).
Injector lobe is 13.7313 mm (0.54060 inch).
Exhaust lobe is 13.1 mm (0.52 inch).
i04936960
Camshaft
SMCS Code: 1210
Part No.: 231-9123
S/N: B5G1-Up
Part No.: 231-9123
S/N: PAG1-Up
g03113696
Illustration 46
(1) Left-hand camshaft assembly
(2) Right-hand camshaft assembly
RENR5077-12
55
Specifications Section
Table 35
Specification for 231-9123 Camshaft Gp
Item
Qty
Part
Specification Description
A
-
-
Thickness of the groove in a new camshaft assembly for the thrust washer
is 8.75 ± 0.05 mm (0.344 ± 0.002 inch).
C
2
5B-5821 Dowel
D
2
7N-3218 Thrust Washer
Extension of the dowel is 12.0 ± 0.5 mm (0.47 ± 0.02 inch).
Thickness of a new thrust washer is 8.50 ± 0.05 mm (0.335 ± 0.002 inch).
Diameter of bearing journals for a new camshaft is 91.88 ± 0.02 mm
(3.617 ± 0.001 inch).
E
-
-
-
-
-
3
16
5P-0076 Bolt
F
2
4N-1650 Dowel
Bore in camshaft bearing after installation is 92.00 ± 0.06 mm
(3.622 ± 0.002 inch).
End play for a new camshaft assembly is 0.15 to 0.35 mm
(0.006 to 0.014 inch).
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
Extension of the dowel is 22.0 ± 0.5 mm (0.87 ± 0.02 inch).
g03113697
Illustration 47
Table 36
Item
Qty
Part
Specification Description
Use the following procedure in order to determine the camshaft lobe lift:
1. Measure camshaft lobe height (H).
-
-
-
2. Measure base circle (J).
3. Subtract the base circle (J) from the camshaft lobe height (H). The difference is the
actual camshaft lobe lift.
Specified camshaft lobe lift:
G
-
-
Inlet lobe is 12.73 mm (0.501 inch).
Exhaust lobe is 13.10 mm (0.516 inch).
Injector lobe is 13.73 mm (0.541 inch).
56
Specifications Section
RENR5077-12
i05162940
Camshaft
SMCS Code: 1210
Part No.: 381-1946
S/N: JB41-Up
Part No.: 381-1946
S/N: 9H51-Up
Part No.: 381-1946
S/N: EDC1-Up
Part No.: 381-1946
S/N: EDP1-Up
g03317018
Illustration 48
Table 37
Specification for 381-1946 Camshaft Gp
Item
Qty
Part
Specification Description
A
-
-
C
2
4N-1650 Dowel
Extension of the dowel is 22.0 ± 0.5 mm (0.87 ± 0.02 inch).
D
2
5B-5821 Dowel
Extension of the dowel is 12.0 ± 0.5 mm (0.47 ± 0.02 inch).
E
2
7N-3218 Thrust Washer
F
-
-
1
16
5P-0076 Bolt
Dimension of groove in a new camshaft for the thrust washer is
8.75 ± 0.05 mm (0.344 ± 0.002 inch).
Thickness of a new thrust washer is 8.50 ± 0.05 mm (0.335 ± 0.002 inch).
Diameter of bearing journal is 91.88 ± 0.02 mm (3.617 ± 0.001 inch).
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
RENR5077-12
57
Specifications Section
g03317017
Illustration 49
Table 38
Specification for 381-1946 Camshaft Gp
Item
Qty
Part
Specification Description
-
-
-
Use the following procedure in order to determine the actual
camshaft lobe lift:
1. Measure camshaft lobe height (H).
2. Measure base circle (J).
3. Subtract the base circle (J) from the camshaft lobe height (H).
The difference is the actual camshaft lobe lift.
G
-
-
Specified camshaft lobe lift for
Inlet lobe is 13.250 mm (0.5217 inch).
Injector lobe is 13.731 mm (0.5406 inch).
Exhaust lobe is 13.250 mm (0.5217 inch).
i05092369
Valve Mechanism
Part No.: 332-9690
S/N: P8A1-Up
SMCS Code: 1102
Part No.: 224-9869
S/N: S2A1-Up
Part No.: 224-9869
S/N: GS61-Up
Part No.: 332-9690
S/N: M8B1-Up
Part No.: 224-9869
S/N: GS71-Up
Part No.: 224-9869
S/N: S2B1-Up
Part No.: 224-9869
S/N: GSA1-Up
Part No.: 224-9869
S/N: S2D1-Up
Part No.: 332-9690
S/N: M8A1-Up
Part No.: 224-9869
S/N: S2E1-Up
58
Specifications Section
Part No.: 224-9869
S/N: S2F1-Up
Part No.: 224-9869
S/N: B5G1-Up
Part No.: 224-9869
S/N: MRG1-Up
Part No.: 224-9869
S/N: PAG1-Up
Part No.: 224-9869
S/N: S2G1-Up
Part No.: 224-9869
S/N: MKH1-Up
Part No.: 224-9869
S/N: S2H1-Up
Part No.: 224-9869
S/N: S2J1-Up
Part No.: 224-9869
S/N: S2K1-Up
Part No.: 224-9869
S/N: S2L1-Up
Part No.: 224-9869
S/N: S2M1-Up
Part No.: 224-9869
S/N: S2N1-Up
Part No.: 224-9869
S/N: S2P1-Up
Part No.: 224-9869
S/N: S2R1-Up
Part No.: 224-9869
S/N: S2S1-Up
Part No.: 224-9869
S/N: S2T1-Up
Part No.: 224-9869
S/N: S2W1-Up
Part No.: 224-9869
S/N: S2X1-Up
Part No.: 224-9869
S/N: S2Y1-Up
Part No.: 224-9869
S/N: S2Z1-Up
RENR5077-12
RENR5077-12
59
Specifications Section
g02605877
Illustration 50
Table 39
Specification for the 224-9869 Valve Mechanism Gp332-9690 Valve Mechanism Gp281-6160 Valve Mechanism
Gp286-5723 Valve Mechanism Gp308-5356 Valve Mechanism Gp357-9219 Valve Mechanism Gp
Refer to Guideline for Reusable Parts and Salvage Operations, SEBF8066, “Visual Inspection of the 7N-4782 Lifter Guide
Spring − 3500 Family of Engines” for lifter guide spring (2).
Item
Qty
Part
1
2
3J-9196 Jam Nut
A
1
230-2633 Shaft As
B
-
-
C
1
230-2620 Bushing
D
2
263-6674 Valve Lifter As
Specification Description
Torque the jam nuts to 70 ± 15 N·m (52 ± 11 lb ft).
Diameter of the rocker arm shaft assembly is 45.000 ± 0.013 mm
(1.7716 ± 0.0005 inch)
Dimension for the valve lash:
Inlet valve 0.50 mm (0.020 inch)
Exhaust valve 1.00 mm (0.040 inch).
Bore in the bushing for the rocker arm shaft assembly after
installation is 45.077 ± 0.015 mm (1.7747 ± 0.0006 inch).
Diameter of the valve lifter assembly is 29.900 ± 0.010 mm
(1.1772 ± 0.0004 inch).
Bore in the head for the valve lifter assembly is 30.000 ± 0.025 mm
(1.1811 ± 0.0010 inch).
i04449469
Valve Mechanism
Part No.: 370-9889
S/N: ED21-Up
SMCS Code: 1102
Part No.: 370-9889
S/N: WF21-Up
Part No.: 370-9889
S/N: 9F21-Up
Part No.: 370-9889
S/N: 9F31-Up
Part No.: 370-9889
S/N: CG21-Up
Part No.: 370-9889
S/N: 9H31-Up
60
Specifications Section
Part No.: 370-9889
S/N: ED31-Up
Part No.: 370-9889
S/N: 9H41-Up
Part No.: 370-9889
S/N: JB41-Up
Part No.: 370-9889
S/N: 9H51-Up
Part No.: 370-9889
S/N: ED51-Up
Part No.: 370-9889
S/N: 9H61-Up
Part No.: 370-9889
S/N: ED81-Up
Part No.: 370-9889
S/N: MD81-Up
Part No.: 370-9889
S/N: EDC1-Up
Part No.: 370-9889
S/N: EDG1-Up
Part No.: 370-9889
S/N: EDH1-Up
Part No.: 370-9889
S/N: SRH1-Up
Part No.: 370-9889
S/N: EDJ1-Up
Part No.: 370-9889
S/N: SRK1-Up
Part No.: 370-9889
S/N: EDP1-Up
Part No.: 370-9889
S/N: MXR1-Up
Part No.: 370-9889
S/N: SRZ1-Up
RENR5077-12
RENR5077-12
61
Specifications Section
g02636876
Illustration 51
Top view
Table 40
Specification for 370-9889 Valve Mechanism Gp
Item
Qty
Part
1
2
3J-9196 Jam Nut
2
2
7E-6507 Retainer Nut
3
1
317-1121 Jam Nut
4
1
5P-7530 O-Ring Seal
5
2
334-1626 Bolt
Illustration 52
Specification Description
Torque to 70 ± 15 N·m (52 ± 11 lb ft).
Torque to 2.50 ± 0.25 N·m (22.13 ± 2.21 lb in).
Start tightening the retainer nuts of the cap assembly by hand so that
the terminal studs are not cross threaded.
Torque to 120 ± 15 N·m (89 ± 11 lb ft).
Lubricate the bore lightly with the lubricant that is being sealed.
If the bolt is removed for service, apply black Loctite Gasket Maker
to the threads.
g02636936
62
Specifications Section
RENR5077-12
Table 41
Specification for 370-9889 Valve Mechanism Gp
Item
Qty
Part
8
1
234-2273 Rocker Arm Shaft
9
2
0L-2070 Bolt
10
1
6J-2245 O-Ring Seal
Lubricate the bore lightly with the lubricant that is being sealed.
B
-
-
Bore of the bushing in the injector rocker arm assembly (6) is
45.077 ± 0.015 mm (1.7747 ± 0.0006 inch).
C
-
-
Bore of the bushing in the valve rocker arm assembly (7) is
45.077 ± 0.015 mm (1.7747 ± 0.0006 inch).
Specification Description
Diameter is 45.000 ± 0.013 mm (1.7717 ± 0.0005 inch).
If the bolt is removed for service, apply black Loctite Gasket Maker
to the threads.
i04888968
Valve Mechanism
SMCS Code: 1102
Part No.: 379-4835
S/N: MXM1-Up
g03017336
Illustration 53
Top view
Table 42
Specification for 379-4835 Valve Mechanism Gp
Item
Qty
Part
1
2
3J-9196 Jam Nut
2
2
7E-6507 Retainer Nut
3
1
317-1121 Jam Nut
4
1
100-3878 Injector Spring
Specification Description
Torque to 70 ± 15 N·m (52 ± 11 lb ft).
Start tightening the retainer nuts of the cap assembly by hand so that
the terminal studs are not cross threaded.
Torque to 2.50 ± 0.25 N·m (22.13 ± 2.21 lb in).
Torque to 120 ± 15 N·m (89 ± 11 lb ft).
Length under test force is 85.00 mm (3.346 inch).
Test force is 300 ± 25 N (67 ± 6 lb).
Free length after test is 87.65 mm (3.451 inch).
RENR5077-12
63
Specifications Section
g03017337
Illustration 54
Table 43
Item
Qty
Part
5
1
234-2273 Rocker Arm Shaft
B
-
-
After installation, bore of the bushing in the injector rocker arm assembly
(6) is 45.077 ± 0.015 mm (1.7747 ± 0.0006 inch).
C
-
-
After installation, bore of the bushing in the valve rocker arm assembly
(7) is 45.077 ± 0.015 mm (1.7747 ± 0.0006 inch).
8
1
6J-2245 O-Ring Seal
Before assembly, lubricate the bore lightly with the lubricant that is being
sealed.
Specification Description
Diameter is 45.000 ± 0.013 mm (1.7717 ± 0.0005 inch).
64
Specifications Section
RENR5077-12
i04372705
Cylinder Head
SMCS Code: 1100
Part No.: 332-9694
S/N: M8A1-Up
Part No.: 332-9694
S/N: P8A1-Up
Part No.: 332-9694
S/N: M8B1-Up
Illustration 55
Typical example
(1) Locating pad
NOTICE
The pipe plug at location (2) is installed in the cylinder
head for engines with dry exhaust manifolds. If the
pipe plug is not installed into the water passage, the
coolant will leak and engine damage will result. For
engines with dry exhaust manifolds, make sure that
the pipe plug is installed.
g02599196
RENR5077-12
65
Specifications Section
g02534738
Illustration 56
Typical example (top view)
(3) Pipe plug
Table 44
Specification for 101-0830 Cylinder Head Gp, 299-3521 Cylinder Head Gp, 332-9693 Cylinder
Head Gp, 274-8568 Cylinder Head Gp, 317-2441 Cylinder Head Gp, 291-1463 Cylinder Head Gp,
285-3086 Cylinder Head Gp, and 368-9073 Cylinder Head Gp
Item
Qty
Part
Specification Description
3
1
5B-7890 Pipe Plug
Before assembly, lubricate the threads of the pipe plug.with 5P-3931
Anti-Seize Compound.
A
1
-
B
D
2
2
3b-0623 Cup Plug
3b-0623 Cup Plug
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
Cylinder Head Gasket
Use the following procedure when the 110-6991
Cylinder Head Gasket is installed.
Height of the new cylinder head is 142.00 ± 0.15 mm
(5.591 ± 0.006 inch).
Apply Anaerobic Flange Sealant to the bores of the cup plugs before
assembly.
Installation depth of plugs from the top surface of the cylinder head is
9.0 ± 0.5 mm (0.35 ± 0.02 inch)
Apply Anaerobic Flange Sealant to the bores of the cup plugs before
assembly.
Installation depth of plugs from the top surface of the cylinder head is
1.0 ± 0.5 mm (0.04 ± 0.02 inch)
66
Specifications Section
RENR5077-12
g02599197
Illustration 57
Table 45
Specification for 101-0830 Cylinder Head Gp, 299-3521 Cylinder Head Gp, 332-9693 Cylinder
Head Gp, 274-8568 Cylinder Head Gp, 317-2441 Cylinder Head Gp, 291-1463 Cylinder Head Gp,
285-3086 Cylinder Head Gp, and 368-9073 Cylinder Head Gp
Item
Qty
Part
6
131-0420 Cylinder Head
Fastener Gp
2
131-0421 Cylinder Head
Fastener Gp
2
5B-0213 Bolt
-
Bolt Tightening with the 362-8264
Cylinder Head Gasket
Use the following procedure when the 362-8264
Cylinder Head Gasket is installed.
Specification Description
1. Coat the threads of the bolts with clean engine oil.
2. Tighten bolt (1) through bolt (8) in the numerical sequence to
30 ± 5 N·m (22 ± 4 lb ft).
3. Tighten bolt (1) through bolt (8) in the numerical sequence to
200 ± 15 N·m (150 ± 11 lb ft).
4. Again tighten bolt (1) through bolt (8) in the numerical sequence
to 200 ± 15 N·m (150 ± 11 lb ft).
5. Turn bolt (1) through bolt (8) in the numerical sequence to an
additional rotation of 180 ± 5 degrees.
Tighten bolts (9) and (10) only after bolt (1) through bolt (8) have
been given the final torque.
6. Tighten bolts (9) and (10) to 55 ± 10 N·m (40 ± 7 lb ft).
RENR5077-12
67
Specifications Section
g02599198
Illustration 58
Table 46
Specification for 101-0830 Cylinder Head Gp, 299-3521 Cylinder Head Gp, 332-9693 Cylinder
Head Gp, 274-8568 Cylinder Head Gp, 317-2441 Cylinder Head Gp, 291-1463 Cylinder Head Gp,
285-3086 Cylinder Head Gp, and 368-9073 Cylinder Head Gp
Item
Qty
Part
Specification Description
6
131-0420 Cylinder Head
Fastener Gp
2
131-0421 Cylinder Head
Fastener Gp
2
5B-0213 Bolt
-
1. Coat the threads of the bolts with clean engine oil.
2. Tighten bolt (1) through bolt (8) in the numerical sequence to a
torque of 30 ± 5 N·m (22 ± 4 lb ft).
3. Tighten bolt (1) through bolt (8) in the numerical sequence to
100 ± 15 N·m (75 ± 11 lb ft).
4. Tighten bolt (1) through bolt (8) in the numerical sequence to
450 ± 15 N·m (330 ± 11 lb ft).
5. Loosen bolt (1) through bolt (8) in the numerical sequence for an
angle of 90 ± 5 degrees.
6. Tighten bolt (1) through bolt (8) in the numerical sequence to
490 ± 15 N·m (360 ± 11 lb ft).
Tighten bolts (9) and (10) only after bolt (1) through bolt (8) have
been given final torque.
7. Tighten bolts (9) and (10) to 55 ± 10 N·m (40 ± 7 lb ft).
i04721894
Cylinder Head
Part No.: 101-0830
S/N: S2B1-Up
SMCS Code: 1100
Part No.: 101-0830
S/N: S2D1-Up
Part No.: 101-0830
S/N: GS61-Up
Part No.: 101-0830
S/N: S2E1-Up
Part No.: 101-0830
S/N: GS71-Up
Part No.: 101-0830
S/N: S2F1-Up
Part No.: 101-0830
S/N: GSA1-Up
Part No.: 101-0830
S/N: B5G1-Up
Part No.: 101-0830
S/N: S2A1-Up
Part No.: 101-0830
S/N: MRG1-Up
68
Specifications Section
Part No.: 101-0830
S/N: PAG1-Up
Part No.: 101-0830
S/N: S2G1-Up
Part No.: 101-0830
S/N: MKH1-Up
Part No.: 101-0830
S/N: S2H1-Up
Part No.: 101-0830
S/N: S2J1-Up
Part No.: 101-0830
S/N: S2K1-Up
Part No.: 101-0830
S/N: S2L1-Up
Part No.: 101-0830
S/N: S2M1-Up
Part No.: 101-0830
S/N: S2N1-Up
Part No.: 101-0830
S/N: S2P1-Up
Part No.: 101-0830
S/N: S2R1-Up
Part No.: 101-0830
S/N: S2S1-Up
Part No.: 101-0830
S/N: S2T1-Up
Part No.: 101-0830
S/N: S2W1-Up
Part No.: 101-0830
S/N: S2X1-Up
Part No.: 101-0830
S/N: S2Y1-Up
Part No.: 101-0830
S/N: S2Z1-Up
RENR5077-12
RENR5077-12
69
Specifications Section
g02823736
Illustration 59
Table 47
Specification for 285-3086 Cylinder Head Gp, and 101-0830 Cylinder Head Gp
Item
Qty
Part
Specification Description
1
2
130-2607 Valve Seat Insert
During installation, shrunk the valve seat insert with reduced
temperature (Reference temperature : −60° C (−76° F)) and ress
the insert into the cylinder heads counterbore.
2
2
130-2608 Valve Seat Insert
During installation, shrunk the valve seat insert with reduced
temperature (Reference temperature : −60° C (−76° F)) and ress
the insert into the cylinder heads counterbore.
3
5
3B-0623 Cup Plug
Apply Loctite 11358 to the bores for the cup plugs prior to the
installation.
4
5
3B-0645 Cup Plug
Apply Loctite 11358 to the bores for the cup plugs prior to the
installation.
D
-
-
Installation depth for cup plug is 9.0 ± 0.5 mm (0.35 ± 0.02 inch).
E
-
-
Installation depth for cup plug is 1.0 ± 0.5 mm (0.04 ± 0.02 inch).
70
Specifications Section
RENR5077-12
g02823737
Illustration 60
Table 48
Item
Qty
Part
Specification Description
5
1
5B-7890 Pipe Plug
6
6
131-0420 Cylinder Head
Fastener Gp
7
2
131-0421 Cylinder Head
Fastener Gp
8
2
5B-0213 Bolt
i04938343
Cylinder Head
Before assembly, lubricate the threads with Loctite C5A Copper
Anti-Seize.
Use the following procedure to tighten the bolts for the cylinder
head:
1. Before assembly, apply clean engine oil to the threads of the
bolts.
2. Tighten bolt 1 through bolt 8 in the numerical sequence as
shown in Illustration 60 to a torque of 30 ± 5 N·m (22 ± 4 lb ft).
3. Again, tighten bolt 1 through bolt 8 in the numerical sequence as
shown in Illustration 60 to a torque of 200 ± 15 N·m (148 ± 11 lb ft).
4. Again, retighten bolt 1 through bolt 8 in the numerical
sequence as shown in Illustration 60 to a torque of 200 ± 15 N·m
(148 ± 11 lb ft).
5. Turn bolt 1 through bolt 8 in the numerical sequence to an
angle of 180 ± 5 degrees as shown in Illustration 60 .
6. Tighten two bolts (8) only after bolt 1 through bolt 8 have been
given the final torque.
7. Tighten two bolts (8) to 55 ± 10 N·m (41 ± 7 lb ft).
Part No.: 380-5795
S/N: ED21-Up
SMCS Code: 1100
Part No.: 380-5795
S/N: WF21-Up
Part No.: 380-5795
S/N: 9F21-Up
Part No.: 380-5795
S/N: 9H41-Up
Part No.: 380-5795
S/N: CG21-Up
Part No.: 380-5795
S/N: 9H61-Up
RENR5077-12
71
Specifications Section
Part No.: 380-5795
S/N: ED81-Up
Part No.: 380-5795
S/N: MD81-Up
Part No.: 380-5795
S/N: EDG1-Up
Part No.: 380-5795
S/N: EDH1-Up
Part No.: 380-5795
S/N: SRH1-Up
Part No.: 380-5795
S/N: MXR1-Up
Part No.: 380-5795
S/N: SRZ1-Up
Illustration 61
g03120176
72
Specifications Section
RENR5077-12
Table 49
Specification for 380-5795 Cylinder Head Gp
Item
Qty
Part
Specification Description
1
2
130-2607 Valve Seat Insert
During installation, shrunk the valve seat insert with reduced temperature
(Reference temperature : −60° C (−76° F)) and ress the insert into the
cylinder heads counterbore.
2
2
130-2608 Valve Seat Insert
During installation, shrunk the valve seat insert with reduced temperature
(Reference temperature : −60° C (−76° F)) and ress the insert into the
cylinder heads counterbore.
3
5
3B-0645 Cup Plug
Before assembly, apply high strength or high temperature Anaerobic
Flange Sealant to the bores.
4
1
3B-0623 Cup Plug
Before assembly, apply high strength or high temperature Anaerobic
Flange Sealant to the bores.
5
2
3B-0623 Cup Plug
Before assembly, apply high strength or high temperature Anaerobic
Flange Sealant to the bores.
Installation depth (E) is 1.0 ± 0.5 mm (0.04 ± 0.02 inch).
6
2
3B-0623 Cup Plug
Before assembly, apply high strength or high temperature Anaerobic
Flange Sealant to the bores.
Installation depth (D) is 9.0 ± 0.5 mm (0.35 ± 0.02 inch).
Illustration 62
g03117917
RENR5077-12
73
Specifications Section
Table 50
Item
Qty
Part
Specification Description
7
6
131-0420 Cylinder Head
Fastener Gp
8
2
131-0421 Cylinder Head
Fastener Gp
9
2
5B-0213 Bolt
Use the following procedure in order to tighten the bolts for the cylinder head:
Refer Illustration 62 for bolt tightening sequence.
1. Before assembly, apply clean engine oil to the threads of the bolts.
2. Tighten bolt 1 through bolt 8 in the numerical sequence to 30 ± 5 N·m
(22 ± 4 lb ft).
3. Again, tighten bolt 1 through bolt 8 in the numerical sequence to
200 ± 15 N·m (148 ± 11 lb ft).
4. Again, retighten bolt 1 through bolt 8 in the numerical sequence to
200 ± 15 N·m (148 ± 11 lb ft).
5. Turn bolt 1 through bolt 8 in the numerical sequence to an angle of 180 ±
5 degrees .
6. Tighten two bolts (9) only after bolt 1 through bolt 8 have been given the
final torque.
7. Tighten two bolts (9) to 55 ± 10 N·m (41 ± 7 lb ft).
i04449733
Cylinder Head
SMCS Code: 1100
Part No.: 290-1351
S/N: 9F31-Up
Part No.: 290-1351
S/N: 9H31-Up
Part No.: 290-1351
S/N: ED31-Up
Part No.: 290-1351
S/N: JB41-Up
Part No.: 290-1351
S/N: 9H51-Up
Part No.: 290-1351
S/N: ED51-Up
Part No.: 290-1351
S/N: EDC1-Up
Part No.: 290-1351
S/N: EDJ1-Up
Part No.: 290-1351
S/N: SRK1-Up
Part No.: 290-1351
S/N: MXM1-Up
Part No.: 290-1351
S/N: EDP1-Up
74
Specifications Section
RENR5077-12
g02637022
Illustration 63
Table 51
Specification for 290-1351 Cylinder Head
Item
Qty
Part
Specification Description
1
2
183-8809 Valve Seat Insert
During installation, shrunk the valve seat insert and ress the insert
into the cylinder heads counterbore.
2
2
289-9745 Valve Seat Insert
During installation, shrunk the valve seat insert and ress the insert
into the cylinder heads counterbore.
3
5
3B-0623 Cup Plug
Apply Loctite 11358 to the bores for the cup plugs prior to the
installation.
4
5
3B-0645 Cup Plug
Apply Loctite 11358 to the bores for the cup plugs prior to the
installation.
D
-
-
Installation depth for cup plug (3) is 9.0 ± 0.5 mm (0.35 ± 0.02 inch).
E
-
-
Installation depth for cup plug (4) is 1.0 ± 0.5 mm (0.04 ± 0.02 inch).
RENR5077-12
75
Specifications Section
g02668504
Illustration 64
Table 52
Specification for 290-1351 Cylinder Head
Item
Qty
Part
5
1
5B-7890 Pipe Plug
6
6
131-0420 Cylinder Head
Fastener Gp
7
2
131-0421 Cylinder Head
Fastener Gp
8
2
5B-0213 Bolt
Specification Description
Before assembly, lubricate the threads with Loctite C5A Copper
Anti-Seize.
Use the following procedure to tighten the bolts for the cylinder
head:
Before assembly, apply clean engine oil to the threads of the bolts.
Tighten bolt 1 through bolt 8 in the numerical sequence as shown
in Illustration 64 to a torque of 30 ± 5 N·m (22 ± 4 lb ft).
Again, tighten bolt 1 through bolt 8 in the numerical sequence as
shown in Illustration 64 to a torque of 200 ± 15 N·m (148 ± 11 lb ft).
Again, retighten bolt 1 through bolt 8 in the numerical sequence as
shown in Illustration 64 to a torque of 200 ± 15 N·m (148 ± 11 lb ft).
Turn bolt 1 through bolt 8 in the numerical sequence to an angle
of 180 ± 5 degrees as shown in Illustration 64 .
Tighten two bolts (8) only after bolt 1 through bolt 8 have been
given the final torque.
Tighten two bolts (8) to 55 ± 10 N·m (41 ± 7 lb ft).
76
Specifications Section
RENR5077-12
i05153471
Cylinder Head Valves
SMCS Code: 1105
Part No.: 332-9694
S/N: M8A1-Up
Part No.: 332-9694
S/N: M8B1-Up
Illustration 65
Typical example
g02624516
RENR5077-12
77
Specifications Section
Table 53
Specification for 335-6218 Cylinder Head Gp, 285-3086 Cylinder Head Gp, and 317-2440 Cylinder Head Gp
Item
Qty
Part
1
4
316-5976 Spring
Length under test force is 60.29 mm (2.374 inch).
Test force is 460 ± 23 N (103 ± 5 lb).
Free length after test is 74.8 mm (2.94 inch).
2
4
316-5977 Spring
Length under test force is 57.5 mm (2.26 inch).
Test force is 248.0 ± 12.4 N (55.8 ± 2.8 lb).
Free length after test is 71.4 mm (2.81 inch).
3
2
316-5980 Valve
Stem Seal
Install the valve stem seal to the inlet valves.
A
-
-
4
2
316-5981 Washer
5
2
197-6995 Valve Guide
Bore of the exhaust valve guide after installation is 12.619 ± 0.025 mm
(0.4968 ± 0.0010 inch).
6
2
133-9306 Valve Guide
Bore of the inlet valve guide after installation is 9.487 ± 0.025 mm
(0.3735 ± 0.0010 inch).
7
2
194-4897 Exhaust
Valve
8
2
210-2542 Inlet Valve
Before assembly, coat the inlet valve stems with clean engine oil.
Stem diameter is 9.441 ± 0.010 mm (0.3717 ± 0.0004 inch).
Face angle is 19.40 ± 0.25 degrees.
9
2
130-2608 Valve Seat
Insert (Exhaust)
Diameter of exhaust valve seat insert is 60.119 ± 0.015 mm
(2.3669 ± 0.0006 inch).
Bore in the cylinder head is 60.000 ± 0.025 mm (2.3622 ± 0.0010 inch).
Face angle is 45.00 ± 0.25 degrees.
2
130-2607 Valve Seat
Insert (inlet)
Diameter of inlet valve seat insert is 60.627 ± 0.015 mm
(2.3869 ± 0.0006 inch).
Bore in the cylinder head is 60.508 ± 0.025 mm (2.3822 ± 0.0010 inch).
Face angle is 20.00 ± 0.25 degrees.
10
Specification Description
Height from the top of the cylinder head to the top of the valve guides
is 26.0 ± 1.0 mm (1.02 ± 0.04 inch).
Install the washer to the exhaust valves.
Before assembly, coat the exhaust valve stems with clean engine oil.
Stem diameter is 12.464 ± 0.025 mm (0.4907 ± 0.0010 inch).
Face angle is 44.40 ± 0.25 degrees.
i04728230
Cylinder Head Valves
Part No.: 317-2440
S/N: S2E1-Up
SMCS Code: 1105
Part No.: 317-2440
S/N: S2F1-Up
Part No.: 317-2440
S/N: GS61-Up
Part No.: 317-2440
S/N: B5G1-Up
Part No.: 317-2440
S/N: GS71-Up
Part No.: 317-2440
S/N: MRG1-Up
Part No.: 317-2440
S/N: GSA1-Up
Part No.: 317-2440
S/N: PAG1-Up
Part No.: 317-2440
S/N: P8A1-Up
Part No.: 317-2440
S/N: S2G1-Up
Part No.: 317-2440
S/N: S2A1-Up
Part No.: 317-2440
S/N: MKH1-Up
Part No.: 317-2440
S/N: S2B1-Up
Part No.: 317-2440
S/N: S2H1-Up
Part No.: 317-2440
S/N: S2D1-Up
Part No.: 317-2440
S/N: S2J1-Up
78
Specifications Section
RENR5077-12
Part No.: 317-2440
S/N: S2K1-Up
Part No.: 317-2440
S/N: S2L1-Up
Part No.: 317-2440
S/N: S2M1-Up
Part No.: 317-2440
S/N: S2N1-Up
Part No.: 317-2440
S/N: S2P1-Up
Part No.: 317-2440
S/N: S2R1-Up
Part No.: 317-2440
S/N: S2S1-Up
Part No.: 317-2440
S/N: S2T1-Up
Part No.: 317-2440
S/N: S2W1-Up
Part No.: 317-2440
S/N: S2X1-Up
Part No.: 317-2440
S/N: S2Y1-Up
Part No.: 317-2440
S/N: S2Z1-Up
Illustration 66
g02829216
RENR5077-12
79
Specifications Section
Table 54
Specification for 338-8672 Cylinder Head Gp, and 317-2440 Cylinder Head Gp
Item
Qty
Part
1
4
316-5976 Spring
Length under test force is 60.29 mm (2.374 inch).
Test force is 460 ± 23 N (103 ± 5 lb).
Free length after test is 74.8 mm (2.94 inch).
2
4
316-5977 Spring
Length under test force is 57.5 mm (2.26 inch).
Test force is 248.0 ± 12.4 N (55.8 ± 2.8 lb).
Free length after test is 71.4 mm (2.81 inch).
3
2
316-5980 Valve
Stem Seal
Install the valve stem seal to the inlet valves.
Before assembly, coat with engine oil.
4
2
316-5981 Washer
A
-
-
Height from the top of the cylinder head to the top of the valve guides
is 26.0 ± 1.0 mm (1.02 ± 0.04 inch).
5
2
197-6995 Valve Guide
Bore of the exhaust valve guide after installation is 12.619 ± 0.025 mm
(0.4968 ± 0.0010 inch).
6
2
133-9306 Valve Guide
Bore of the inlet valve guide after installation is 9.487 ± 0.025 mm
(0.3735 ± 0.0010 inch).
2
194-4897 Exhaust
Valve
7
Specification Description
Install the washer to the exhaust valves.
Before assembly, coat the exhaust valve stems with clean engine oil.
Stem diameter (B) is 12.464 ± 0.025 mm (0.4907 ± 0.0010 inch).
Valve diameter (D) is 56.00 ± 0.15 mm (2.205 ± 0.006 inch).
Face angle is 44.40 ± 0.25 degrees.
8
2
210-2542 Inlet Valve
Before assembly, coat the inlet valve stems with clean engine oil.
Stem diameter (C) is 9.441 ± 0.010 mm (0.3717 ± 0.0004 inch).
Valve diameter (E) is 56.00 ± 0.15 mm (2.205 ± 0.006 inch).
Face angle is 19.40 ± 0.25 degrees.
9
2
130-2608 Valve Seat
Insert
Diameter of exhaust valve seat insert is 60.119 ± 0.015 mm
(2.3669 ± 0.0006 inch).
Bore in the cylinder head is 60.000 ± 0.025 mm (2.3622 ± 0.0010 inch).
Face angle is 45.00 ± 0.25 degrees.
2
130-2607 Valve Seat
Insert
Diameter of inlet valve seat insert is 60.627 ± 0.015 mm
(2.3869 ± 0.0006 inch).
Bore in the cylinder head is 60.508 ± 0.025 mm (2.3822 ± 0.0010 inch).
Face angle is 20.00 ± 0.25 degrees.
10
80
Specifications Section
RENR5077-12
i04935314
Cylinder Head Valves
SMCS Code: 1105
Part No.: 380-5795
S/N: 9F21-Up
Part No.: 380-5795
S/N: CG21-Up
Part No.: 380-5795
S/N: ED21-Up
Part No.: 380-5795
S/N: WF21-Up
Part No.: 380-5795
S/N: 9H41-Up
Part No.: 380-5795
S/N: 9H61-Up
Part No.: 380-5795
S/N: ED81-Up
Part No.: 380-5795
S/N: MD81-Up
Part No.: 380-5795
S/N: EDG1-Up
Part No.: 380-5795
S/N: EDH1-Up
Part No.: 380-5795
S/N: SRH1-Up
Part No.: 380-5795
S/N: MXR1-Up
Part No.: 380-5795
S/N: SRZ1-Up
Illustration 67
g03117796
RENR5077-12
81
Specifications Section
Table 55
Specification for 380-5795 Cylinder Head Gp
Item
Qty
Part
1
4
316-5976 Spring
Length under test force is 60.29 mm (2.374 inch).
Test force is 460 ± 23 N (103 ± 5 lb).
Free length after test is 74.8 mm (2.94 inch).
2
4
316-5977 Spring
Length under test force is 57.5 mm (2.26 inch).
Test force is 248.0 ± 12.4 N (55.8 ± 2.8 lb).
Free length after test is 71.4 mm (2.81 inch).
3
2
316-5980 Valve
Stem Seal
Install the valve stem seal to the inlet valves.
B
-
-
Height from the top of the cylinder head to the top of the valve guides
is 26.0 ± 1.0 mm (1.02 ± 0.04 inch).
4
2
197-6995 Valve Guide
Bore of the exhaust valve guide after installation is 12.619 ± 0.025 mm
(0.4968 ± 0.0010 inch).
5
2
133-9306 Valve Guide
Bore of the inlet valve guide after installation is 9.487 ± 0.025 mm
(0.3735 ± 0.0010 inch).
2
130-2608 Valve Seat
Insert
Diameter of exhaust valve seat insert is 60.119 ± 0.015 mm
(2.3669 ± 0.0006 inch).
Bore in the cylinder head is 60.000 ± 0.025 mm (2.3622 ± 0.0010 inch).
Face angle is 45.00 ± 0.25 degrees.
2
130-2607 Valve Seat
Insert
Diameter of inlet valve seat insert is 60.627 ± 0.015 mm
(2.3869 ± 0.0006 inch).
Bore in the cylinder head is 60.508 ± 0.025 mm (2.3822 ± 0.0010 inch).
Face angle is 20.00 ± 0.25 degrees.
6
7
Illustration 68
Specification Description
g03117799
82
Specifications Section
RENR5077-12
Table 56
Item
8
Qty
Part
2
194-4897 Exhaust
Valve
Specification Description
Before assembly, coat the exhaust valve stems with clean engine oil.
Stem diameter (C) is 12.464 ± 0.025 mm (0.4907 ± 0.0010 inch).
Valve diameter (E) is 56.00 ± 0.15 mm (2.205 ± 0.006 inch).
Face angle is 45.60 ± 0.25 degrees.
9
2
210-2542 Inlet Valve
10
2
316-5981 Washer
Before assembly, coat the inlet valve stems with clean engine oil.
Stem diameter (D) is 9.441 ± 0.010 mm (0.3717 ± 0.0004 inch).
Valve diameter (F) is 56.00 ± 0.15 mm (2.205 ± 0.006 inch).
Face angle is 19.40 ± 0.25 degrees.
Install the washer to the exhaust valves.
i04921310
Cylinder Head Valves
SMCS Code: 1105
Part No.: 376-0393
S/N: 9F31-Up
Part No.: 380-5798
S/N: 9H31-Up
Part No.: 380-5798
S/N: ED31-Up
Part No.: 376-0393
S/N: JB41-Up
Part No.: 376-0393
S/N: 9H51-Up
Part No.: 380-5798
S/N: ED51-Up
Part No.: 376-0393
S/N: EDC1-Up
Part No.: 376-0393
S/N: EDJ1-Up
Part No.: 380-5798
S/N: SRK1-Up
Part No.: 376-0393
S/N: MXM1-Up
Part No.: 376-0393
S/N: EDP1-Up
RENR5077-12
Illustration 69
Typical example
83
Specifications Section
g03111276
84
Specifications Section
RENR5077-12
Table 57
Specification for 380-5798 Cylinder Head Gp and 376-0393 Cylinder Head Gp
Item
Qty
Part
1
4
316-5976 Spring
Length under test force is 60.29 mm (2.374 inch).
Test force is 460 ± 23 N (103 ± 5 lb).
Free length after test is 74.8 mm (2.94 inch).
2
4
316-5977 Spring
Length under test force is 57.5 mm (2.26 inch).
Test force is 248.0 ± 12.4 N (55.8 ± 2.8 lb).
Free length after test is 71.4 mm (2.81 inch).
3
2
316-5980 Valve
Stem Seal
Install the valve stem seal to the inlet valves.
4
2
316-5981 Washer
A
-
-
Height from the top of the cylinder head to the top of the valve guides
is 26.0 ± 1.0 mm (1.02 ± 0.04 inch).
5
2
197-6995 Valve Guide
Bore of the exhaust valve guide after installation is 12.619 ± 0.025 mm
(0.4968 ± 0.0010 inch).
6
2
133-9306 Valve Guide
Bore of the inlet valve guide after installation is 9.487 ± 0.025 mm
(0.3735 ± 0.0010 inch).
2
194-4897 Exhaust
Valve
7
Specification Description
Install the washer to the exhaust valves.
Before assembly, coat the exhaust valve stems with clean engine oil.
Stem diameter (B) is 12.464 ± 0.025 mm (0.4907 ± 0.0010 inch).
Valve diameter (D) is 56.00 ± 0.15 mm (2.205 ± 0.006 inch).
Face angle is 45.60 ± 0.25 degrees.
8
2
210-2542 Inlet Valve
Before assembly, coat the inlet valve stems with clean engine oil.
Stem diameter (C) is 9.441 ± 0.010 mm (0.3717 ± 0.0004 inch).
Valve diameter (E) is 56.00 ± 0.15 mm (2.205 ± 0.006 inch).
Face angle is 19.40 ± 0.25 degrees.
9
2
289-9745 Valve Seat
Insert
Diameter of exhaust valve seat insert is 60.119 ± 0.015 mm
(2.3669 ± 0.0006 inch).
Bore in the cylinder head is 60.000 ± 0.025 mm (2.3622 ± 0.0010 inch).
Face angle is 45.00 ± 0.25 degrees.
2
183-8809 Valve Seat
Insert
Diameter of inlet valve seat insert is 60.627 ± 0.015 mm
(2.3869 ± 0.0006 inch).
Bore in the cylinder head is 60.508 ± 0.025 mm (2.3822 ± 0.0010 inch).
Face angle is 20.00 ± 0.25 degrees.
10
RENR5077-12
85
Specifications Section
i04728329
Cylinder Head Valves
SMCS Code: 1105
Part No.: 335-6220
S/N: S2Z1-Up
Illustration 70
g02829241
86
Specifications Section
RENR5077-12
Table 58
Specification for 335-6220 Cylinder Head Gp
Item
Qty
Part
1
4
316-5976 Spring
Length under test force is 60.29 mm (2.374 inch).
Test force is 460 ± 23 N (103 ± 5 lb).
Free length after test is 74.8 mm (2.94 inch).
2
4
316-5977 Spring
Length under test force is 57.5 mm (2.26 inch).
Test force is 248.0 ± 12.4 N (55.8 ± 2.8 lb).
Free length after test is 71.4 mm (2.81 inch).
3
2
316-5980 Valve
Stem Seal
Install the valve stem seal to the inlet valves.
4
2
316-5981 Washer
A
-
-
Height from the top of the cylinder head to the top of the valve guides
is 26.0 ± 1.0 mm (1.02 ± 0.04 inch).
5
2
197-6995 Valve Guide
Bore of the exhaust valve guide after installation is 12.619 ± 0.025 mm
(0.4968 ± 0.0010 inch).
6
2
133-9306 Valve Guide
Bore of the inlet valve guide after installation is 9.487 ± 0.025 mm
(0.3735 ± 0.0010 inch).
2
194-4897 Exhaust
Valve
7
Specification Description
Install the washer to the exhaust valves.
Before assembly, coat the exhaust valve stems with clean engine oil.
Stem diameter (B) is 12.464 ± 0.025 mm (0.4907 ± 0.0010 inch).
Valve diameter (D) is 56.00 ± 0.15 mm (2.205 ± 0.006 inch).
Face angle is 44.40 ± 0.25 degrees.
8
2
210-2542 Inlet Valve
Before assembly, coat the inlet valve stems with clean engine oil.
Stem diameter (C) is 9.441 ± 0.010 mm (0.3717 ± 0.0004 inch).
Valve diameter (E) is 56.00 ± 0.15 mm (2.205 ± 0.006 inch).
Face angle is 19.40 ± 0.25 degrees.
9
2
289-9745 Valve Seat
Insert
Diameter of exhaust valve seat insert is 60.119 ± 0.015 mm
(2.3669 ± 0.0006 inch).
Bore in the cylinder head is 60.000 ± 0.025 mm (2.3622 ± 0.0010 inch).
Face angle is 45.00 ± 0.25 degrees.
2
183-8809 Valve Seat
Insert
Diameter of inlet valve seat insert is 60.627 ± 0.015 mm
(2.3869 ± 0.0006 inch).
Bore in the cylinder head is 60.508 ± 0.025 mm (2.3822 ± 0.0010 inch).
Face angle is 20.00 ± 0.25 degrees.
10
RENR5077-12
87
Specifications Section
i03139721
Turbocharger
1. Tighten the clamp assemblies to 14 ± 3 N·m
(125 ± 27 lb in).
2. Gently tap around the clamp assemblies.
SMCS Code: 1052
3. Again, tighten the clamp assemblies to 14 ± 3 N·m
(125 ± 27 lb in).
Part No.: 107-9524
S/N: GS71-Up
Use the following procedure in order to tighten the
bolts for the half flange (3):
1. Tighten bolts (4) in any sequence to 54 ± 5 N·m
(40 ± 4 lb ft).
2. Tighten bolts (5) in any sequence to 54 ± 5 N·m
(40 ± 4 lb ft).
Illustration 71
g01616117
Note: Before assembly, lubricate the threads and the
bearing surface of the bolts (1) and the bolts (2) with
4C-5599 Anti-Seize Compound.
(1) Torque for eight bolts ..... 54 ± 5 N·m (40 ± 4 lb ft)
Illustration 72
g01616133
Use the following procedure in order to tighten the
clamp assemblies (2):
88
Specifications Section
RENR5077-12
i05164362
Turbocharger
SMCS Code: 1052
Part No.: 346-4715
S/N: P8A1-Up
Illustration 73
g03317444
Illustration 74
g03317445
Bolt tightening sequence for 6V-6753 High Temperature Bolt (1)
RENR5077-12
89
Specifications Section
g03317443
Illustration 75
Bolt tightening sequence for 6V-6753 High Temperature Bolt (4)
Table 59
Specification for 346-4715 Turbocharger Gp
Item
Qty
Part
Specification Description
Use the following procedure in order to tighten the bolts for the half flange:
1
8
6V-6753 High
Temperature Bolt
1. Before assembly, lubricate the threads and the bearing surfaces with Loctite C5A
Copper Anti-Seize.
2. Tighten bolts 1 in any sequence to 54 ± 5 N·m (40 ± 4 lb ft).
3. Tighten bolts 2 in any sequence to 54 ± 5 N·m (40 ± 4 lb ft).
2
2
9N-2038 Turbine
Clamp As
Use the following procedure in order to tighten the clamp assemblies:
3
2
7W-2297 Clamp
As
1. Tighten the clamp assemblies to 14 ± 3 N·m (124 ± 27 lb in).
2. Gently tap around the clamp assemblies.
3. Again, tighten the clamp assemblies to 14 ± 3 N·m (124 ± 27 lb in).
Use the following procedure in order to tighten the bolts for the half flange:
4
8
6V-6753 High
Temperature Bolt
1. Before assembly, lubricate the threads and the bearing surfaces with Loctite C5A
Copper Anti-Seize.
2. Tighten bolts 1 in any sequence to 54 ± 5 N·m (40 ± 4 lb ft).
3. Tighten bolts 2 in any sequence to 54 ± 5 N·m (40 ± 4 lb ft).
5
8
2N-2765 High
Temperature Bolt
Before assembly, lubricate the threads and the bearing surfaces with Loctite C5A
Copper Anti-Seize.
Torque to 54 ± 5 N·m (40 ± 4 lb ft).
90
Specifications Section
RENR5077-12
i03670347
Turbocharger
SMCS Code: 1052
Part No.: 333-2233
S/N: M8A1-Up
Part No.: 145-7993
S/N: S2A1-Up
Part No.: 333-8955
S/N: M8B1-Up
Part No.: 145-7995
S/N: S2B1-Up
Part No.: 145-7995
S/N: S2E1-Up
Part No.: 145-7995
S/N: S2G1-Up
Illustration 77
Part No.: 145-7995
S/N: S2K1-Up
g01619282
Rear view
Before assembly, lubricate the threads and the
bearing surfaces of the bolts with 4C-5599
Anti-Seize Compound.
Use the following procedure in order to tighten the
bolts of the half flange (2).
1. Tighten bolts 3 in any sequence to 54 ± 5 N·m
(40 ± 4 lb ft).
2. Tighten bolts 4 in any sequence to 54 ± 5 N·m
(40 ± 4 lb ft).
Illustration 76
g01616117
Note: Before assembly, lubricate the threads and
the bearing surfaces of the bolts with 4C-5599
Anti-Seize Compound.
(1) Torque for the bolts ........ 54 ± 5 N·m (40 ± 4 lb ft)
Illustration 78
g01538253
Use the following procedure to tighten the clamp
assembly (5) and turbine clamp assembly (6):
1. Tighten the clamp assemblies to 14 ± 3 N·m
(124 ± 27 lb in).
2. Gently tap around the clamp assemblies with a
soft faced hammer.
RENR5077-12
91
Specifications Section
3. Again, tighten the clamp assemblies to 14 ± 3 N·m
(124 ± 27 lb in).
i05163065
Turbocharger
SMCS Code: 1052
Part No.: 379-5317
S/N: 9F31-Up
Part No.: 379-5317
S/N: 9H41-Up
Part No.: 379-5317
S/N: ED81-Up
Part No.: 379-5317
S/N: EDJ1-Up
Illustration 79
g03317046
92
Specifications Section
RENR5077-12
g03317058
Illustration 80
Bolt tightening sequence for 6V-6753 High Temperature Bolt (2)
g03317059
Illustration 81
Bolt tightening sequence for 6V-1943 High Temperature Bolt (3)
Table 60
Specification for 379-5317 Turbocharger Gp
Item
Qty
Part
Specification Description
1
16
125-5375 Bolt
Before assembly, lubricate the threads with Loctite C5A Copper Anti-Seize.
Torque to 40 ± 3 N·m (30 ± 2 lb ft).
2
8
6V-6753 High
Temperature Bolt
Use the following procedure in order to tighten the bolts for the half flange:
3
12
6V-1943 High
Temperature Bolt
1. Before assembly, lubricate the threads and the bearing surfaces with Loctite C5A
Copper Anti-Seize.
2. Tighten bolts 1 in any sequence to 54 ± 5 N·m (40 ± 4 lb ft).
3. Tighten bolts 2 in any sequence to 54 ± 5 N·m (40 ± 4 lb ft).
4
16
369-3458 High
Temperature Bolt
Before assembly, lubricate the threads with Loctite C5A Copper Anti-Seize.
Torque to 40 ± 3 N·m (30 ± 2 lb ft).
Use the following procedure in order to tighten the turbo-exhaust manifold joint bolt:
5
8
300-8579 Bolt
Before assembly, lubricate the threads and the bearing surfaces with Loctite C5A
Copper Anti-Seize.
1. Align joints in order to get all four nuts started on the bolts.
2. Snug up all the bolts on the joint.
3. First tighten one bolt to 54 ± 5 N·m (40 ± 4 lb ft).
4. Tighten diagonally opposite bolt to 54 ± 5 N·m (40 ± 4 lb ft).
5. Tighten remaining two bolts to 54 ± 5 N·m (40 ± 4 lb ft).
6. Repeat procedure Step 3 to Step 5 in order to verify that all bolts are torqued to
54 ± 5 N·m (40 ± 4 lb ft).
RENR5077-12
93
Specifications Section
i05163160
Turbocharger
SMCS Code: 1052
Part No.: 379-5319
S/N: ED21-Up
Part No.: 379-5321
S/N: WF21-Up
Part No.: 379-5319
S/N: 9H31-Up
Part No.: 379-5319
S/N: ED31-Up
Part No.: 379-5319
S/N: ED51-Up
Part No.: 379-5319
S/N: MD81-Up
Part No.: 379-5319
S/N: SRH1-Up
Part No.: 379-5319
S/N: SRK1-Up
Part No.: 379-5321
S/N: SRZ1-Up
94
Specifications Section
RENR5077-12
Illustration 82
g03317102
Illustration 83
g03317104
Bolt tightening sequence for 6V-6753 High Temperature Bolt (2)
RENR5077-12
95
Specifications Section
g03317101
Illustration 84
Bolt tightening sequence for 6V-1943 High Temperature Bolt (3)
Table 61
Specification for 379-5319 Turbocharger Gp and 379-5321 Turbocharger Gp
Item
Qty
Part
1
16
125-5375 Bolt
Before assembly, lubricate the threads with Loctite C5A Copper Anti-Seize.
Torque to 40 ± 3 N·m (30 ± 2 lb ft).
2
8
6V-6753 High
Temperature Bolt
Use the following procedure in order to tighten the bolts for the half flange:
3
12
6V-1943 High
Temperature Bolt
1. Before assembly, lubricate the threads and the bearing surfaces with Loctite C5A
Copper Anti-Seize.
2. Tighten bolts 1 in any sequence to 54 ± 5 N·m (40 ± 4 lb ft).
3. Tighten bolts 2 in any sequence to 54 ± 5 N·m (40 ± 4 lb ft).
4
16
369-3458 High
Temperature Bolt
Before assembly, lubricate the threads with Loctite C5A Copper Anti-Seize.
Torque to 40 ± 3 N·m (30 ± 2 lb ft).
5
8
2N-2765 High
Temperature Bolt
Before assembly, lubricate the threads and the bearing surfaces with Loctite C5A
Copper Anti-Seize.
Torque to 54 ± 5 N·m (40 ± 4 lb ft).
Specification Description
96
Specifications Section
RENR5077-12
i05164357
Turbocharger
SMCS Code: 1052
Part No.: 355-1661
S/N: MXM1-Up
g03317429
Illustration 85
Table 62
Specification for 355-1661 Turbocharger Gp
Item
Qty
Part
Specification Description
1
10
287-7200 Bolt
Before assembly, lubricate the threads with Loctite C5A Copper Anti-Seize.
Torque to 40 ± 3 N·m (30 ± 2 lb ft).
Use the following procedure in order to tighten the nut of the clamp
assembly:
Before assembly, lubricate the threads with Loctite C5A Copper Anti-Seize.
1. Tighten the nut approximately to 20 N·m (177 lb in).
2
1
283-4294 Clamp As
2. Gently hit around the clamp assembly with a soft hammer.
3. Again, tighten the nut to 30 ± 2 N·m (266 ± 18 lb in).
4. Again, gently hit around the clamp assembly with a soft hammer.
5. Again, re tighten the nut to 30 ± 2 N·m (266 ± 18 lb in)
RENR5077-12
97
Specifications Section
i03414341
Turbocharger
SMCS Code: 1052
Part No.: 173-7676
S/N: GS61-Up
Part No.: 173-7676
S/N: S2H1-Up
Part No.: 173-7676
S/N: S2L1-Up
Part No.: 259-8431
S/N: S2M1-Up
Part No.: 165-6678
S/N: S2T1-Up
Illustration 87
g01770114
Use the following procedure in order to tighten the
bolts for the half flange (2):
1. Tighten bolts (3) in any sequence to 54 ± 5 N·m
(40 ± 4 lb ft).
2. Tighten bolts (4) in any sequence to 54 ± 5 N·m
(40 ± 4 lb ft).
Illustration 86
g01616117
Note: Before assembly, lubricate the threads and the
bearing surface of the bolts with 4C-5599 Anti-Seize
Compound.
(1) Torque for the bolts to the exhaust
manifold ......................... 54 ± 5 N·m (40 ± 4 lb ft)
(5) Cartridge's bolt torque ... 40 ± 2 N·m (30 ± 1 lb ft)
98
Specifications Section
RENR5077-12
i03411202
Turbocharger
SMCS Code: 1052
Part No.: 159-8828
S/N: S2H1-Up
Part No.: 159-8828
S/N: S2J1-Up
Part No.: 176-3231
S/N: S2M1-Up
Part No.: 159-8828
S/N: S2R1-Up
Part No.: 159-8828
S/N: S2S1-Up
Part No.: 159-8828, 250-6111
S/N: S2Z1-Up
Illustration 89
g01753233
Use the following procedure in order to tighten the
bolts for the half flange (2):
1. Tighten bolts (3) in any sequence to 54 ± 5 N·m
(40 ± 4 lb ft).
2. Tighten bolts (4) in any sequence to 54 ± 5 N·m
(40 ± 4 lb ft).
(5) Cartridge's bolt torque ... 40 ± 2 N·m (30 ± 1 lb ft)
Illustration 88
g01616117
Note: Before assembly, lubricate the threads and the
bearing surface of the bolts with 4C-5599 Anti-Seize
Compound.
(1) Torque for the bolts ........ 54 ± 5 N·m (40 ± 4 lb ft)
RENR5077-12
99
Specifications Section
i03035044
Turbocharger
SMCS Code: 1052
Part No.: 167-1762
S/N: S2H1-Up
Part No.: 167-1762
S/N: S2J1-Up
Part No.: 167-1762
S/N: S2R1-Up
Part No.: 167-1762
S/N: S2S1-Up
Part No.: 167-1762
S/N: S2Z1-Up
Illustration 91
g01538619
(2) Torque for four bolts ....... 54 ± 5 N·m (40 ± 4 lb ft)
(3) Torque for eight bolts for the turbine
housing .......................... 40 ± 2 N·m (30 ± 1 lb ft)
(4) Torque for eight bolts for the compressor
housing. ......................... 40 ± 2 N·m (30 ± 1 lb ft)
Illustration 90
g01538593
Note: Before assembly, apply 4C-5599 Anti-Seize
Compound to the threads and to the bearing surface
of the bolts.
(1) Torque for 20 bolts ......... 54 ± 5 N·m (40 ± 4 lb ft)
100
Specifications Section
RENR5077-12
i03743841
Turbocharger
SMCS Code: 1052
Part No.: 343-5687
S/N: S2J1-Up
Part No.: 327-7739
S/N: S2K1-Up
Part No.: 343-5682, 352-3459
S/N: S2L1-Up
Part No.: 343-5682
S/N: S2W1-Up
Illustration 92
g01269136
Typical example
Use the following procedure to tighten the clamp
assembly (1):
Note: Before assembly, lubricate all the threads
of the clamp assembly with 4C-5599 Anti-Seize
Compound.
1. Tighten the clamp assembly to 18 to 20 N·m
(159 to 177 lb in).
2. Gently hit around the clamp assembly with a soft
hammer.
3. Again, tighten the clamp assembly to 18 to 20 N·m
(159 to 177 lb in).
Note: Before assembly, lubricate all the threads of
the bolt with 4C-5599 Anti-Seize Compound.
(2) Torque for the bolts ........ 40 ± 3 N·m (30 ± 2 lb ft)
RENR5077-12
101
Specifications Section
i04775473
Turbocharger
SMCS Code: 1052
Part No.: 327-7738
S/N: S2N1-Up
g02876756
Illustration 93
Table 63
Specification for 327-7738 Turbocharger Gp
Item
Qty
Part
Specification Description
Use the following procedure in order to tighten the nut of the clamp
assembly:
Before assembly, lubricate the threads with Loctite C5A Copper Anti-Seize.
1. Tighten the nut approximately to 20 N·m (177 lb in).
1
1
283-4294 Clamp As
2. Gently hit around the clamp assembly with a soft hammer.
3. Again, tighten the nut to 30 ± 2 N·m (266 ± 18 lb in).
4. Again, gently hit around the clamp assembly with a soft hammer.
5. Again, re tighten the nut to 30 ± 2 N·m (266 ± 18 lb in)
2
8
287-7200 Bolt
3
1
332-0971 Plug As
4
-
330-9744 Connector As
Torque to 40 ± 3 N·m (30 ± 2 lb ft).
Torque to 15.5 ± 1.5 N·m (137.2 ± 13.3 lb in).
Before assembly, lubricate the threads of the connector assembly with
Loctite Gasket Maker #2.
102
Specifications Section
RENR5077-12
i02051385
Turbocharger
SMCS Code: 1052
Part No.: 238-7771
S/N: B5G1-Up
Part No.: 238-7774
S/N: MRG1-Up
Part No.: 238-7772
S/N: MKH1-Up
Illustration 94
g01052152
(1) Bolt
Torque ............................ 40 ± 5 N·m (30 ± 4 lb ft)
(2) Bolt
Torque ............................ 65 ± 5 N·m (48 ± 4 lb ft)
(3) Clamp
Tighten each clamp in two places.
Torque ............................ 60 ± 5 N·m (44 ± 4 lb ft)
RENR5077-12
103
Specifications Section
i05163027
Turbocharger
SMCS Code: 1052
Part No.: 379-5314
S/N: JB41-Up
Part No.: 379-5314
S/N: 9H51-Up
Part No.: 379-5314
S/N: EDC1-Up
Part No.: 379-5314
S/N: EDP1-Up
g03317032
Illustration 95
Table 64
Specification for 379-5314 Turbocharger Gp
Item
Qty
Part
Specification Description
1
16
125-5375 Bolt
2
16
188-8617 High
Temperature Bolt
Torque to 40 ± 2 N·m (30 ± 2 lb ft).
3
8
2N-2765 High
Temperature Bolt
Before assembly, lubricate the threads and the bearing surfaces with
Loctite C5A copper anti-seize.
Torque to 54 ± 5 N·m (40 ± 4 lb ft).
Torque to 26 ± 2 N·m (230 ± 18 lb in).
104
Specifications Section
RENR5077-12
i05163002
Turbocharger
SMCS Code: 1052
Part No.: 379-5293
S/N: 9F21-Up
Part No.: 379-5293
S/N: CG21-Up
Part No.: 379-5351
S/N: 9H61-Up
Part No.: 379-5351
S/N: EDG1-Up
Part No.: 379-5293
S/N: EDH1-Up
Part No.: 379-5293
S/N: MXR1-Up
g03317027
Illustration 96
Table 65
Specification for 379-5293 Turbocharger Gp and 379-5351 Turbocharger Gp
Item
Qty
Part
Specification Description
1
16
6V-4248 Bolt
2
16
8C-8581 High
Temperature Bolt
3
2
4W-9029 Plug
Torque to 70 ± 10 N·m (52 ± 7 lb ft).
4
16
7X-0409 High
Temperature Bolt
Torque to 55 ± 10 N·m (41 ± 7 lb ft).
Torque to 55 ± 10 N·m (41 ± 7 lb ft).
Before assembly, lubricate the threads and the washer faces with
Loctite C5A copper anti-seize.
Torque to 45 ± 10 N·m (33 ± 7 lb ft).
RENR5077-12
105
Specifications Section
i01909990
Turbocharger
SMCS Code: 1052
Lubricate the bolt's bearing surfaces and threads
with 4C-5597 Anti-Seize Compound.
Torque .......................... 45 ± 10 N·m (33 ± 7 lb ft)
(8) Bolt
Part No.: 4P-2581
S/N: GSA1-Up
Torque .......................... 55 ± 10 N·m (41 ± 7 lb ft)
Part No.: 4P-2581
S/N: S2R1-Up
i03140083
Turbocharger
SMCS Code: 1052
Part No.: 159-8829
S/N: S2R1-Up
Part No.: 159-8829
S/N: S2S1-Up
Part No.: 159-8829
S/N: S2X1-Up
Illustration 97
g00976451
(1) Bolt
(2) Washers
Illustration 98
g01616497
(3) Nut
Rear view
Lubricate the bearing surfaces of bolt (1), washers
(2), and nut (3) and lubricate the threads of the bolt
and the nut with 4C-5597 Anti-Seize Compound.
(1) Torque for four V-band clamp
assemblies ..................... 60 ± 5 N·m (44 ± 4 lb ft)
(4) Bolt
Torque .......................... 55 ± 10 N·m (41 ± 7 lb ft)
(5) Lock
After assembly, bend the short end of the lock against
the bolt head. Bend the long end of the lock around
the turbine clamp. Do not reuse an opened lock.
(6) Washer
Lubricate the bearing surfaces of washer (6) with
4C-5597 Anti-Seize Compound.
(7) Bolt
106
Specifications Section
RENR5077-12
i03149240
Turbocharger
SMCS Code: 1052
Part No.: 238-7769
S/N: PAG1-Up
Illustration 99
g01619692
Rear view
(1) Torque for two clamp assemblies ...... 60 ± 5 N·m
(44 ± 4 lb ft)
(2) Torque for 12 bolts ......... 40 ± 5 N·m (30 ± 4 lb ft)
(3) Torque for 18 bolts ......... 65 ± 5 N·m (48 ± 4 lb ft)
RENR5077-12
107
Specifications Section
i03119342
Turbocharger Support
SMCS Code: 1052
Part No.: 139-0600
S/N: S2G1-Up
Part No.: 139-0600
S/N: S2H1-Up
Part No.: 139-0600
S/N: S2P1-Up
Part No.: 139-0600
S/N: S2R1-Up
Part No.: 139-0600
S/N: S2Z1-Up
Illustration 100
(1) Torque for 21 bolts ... 120 ± 20 N·m (90 ± 15 lb ft)
(2) Torque for 10 bolts .. 135 ± 20 N·m (100 ± 15 lb ft)
g01595655
108
Specifications Section
RENR5077-12
i02835300
i03341711
Accumulator
Exhaust Bypass Valve
SMCS Code: 1320
SMCS Code: 1057
S/N: S2Y1-Up
Part No.: 165-4406
S/N: PAG1-Up
Part No.: 165-4406, 282-3015
S/N: MKH1-Up
Illustration 102
Illustration 101
g01433346
(1) Accumulator assembly
Charging medium ............................ Dry nitrogen
Internal volume of compartment for
gas .......................................... 3786 mL (231 in3)
Charged pressure ..................... 138 kPa (20 psi)
Service pressure ....................... 138 kPa (20 psi)
Bursting pressure ............. 34500 kPa (5000 psi)
g01414647
(1) Torque for the locknut .................. 12.5 ± 1.0 N·m
(110 ± 9 lb in)
(2) 7E-4677 Spring
Free length ........................ 115.3 mm (4.54 inch)
Outside diameter ............ 82.55 mm (3.250 inch)
(3) 7E-4676 Spring
Free length ........................ 115.3 mm (4.54 inch)
Outside diameter ............ 62.48 mm (2.460 inch)
(4) Torque for the nut ..... 14 ± 3 N·m (125 ± 27 lb in)
(5) Torque for the five screws .............. 6.5 ± 1.0 N·m
(60 ± 9 lb in)
(6) Before assembly, lubricate the threads and the
bearing surfaces of the setscrew with 4C-5599
Anti-Seize Compound.
RENR5077-12
109
Specifications Section
i03341316
Exhaust Bypass Valve
SMCS Code: 1057
Part No.: 259-1436
S/N: B5G1-Up
Part No.: 259-1436
S/N: PAG1-Up
Illustration 104
Illustration 103
g01717353
(7) Exhaust bypass valve
(8) Locknut
(9) Gasket
1. Clean the stud, the locknut, and the base of the
locknut prior to assembly.
2. Apply 2P-2333 High Temperature Sealer to the
threads of the stud that extend through the flange
of the exhaust bypass valve and to the bottom of
the mating face of each locknut.
3. Tighten two diagonal locknuts.
Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft)
4. Tighten the remaining locknuts.
Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft)
5. Tighten all four locknuts again.
Torque ............................. 47 ± 9 N·m (35 ± 7 lb ft)
g01414647
(1) Torque for the locknut .................. 12.5 ± 1.0 N·m
(110 ± 9 lb in)
(2) 259-1435 Spring
Free length .......................... 127 mm (5.00 inch)
Outside diameter ............ 82.55 mm (3.250 inch)
(3) 259-1434 Spring
Free length .......................... 127 mm (5.00 inch)
Outside diameter ............ 62.48 mm (2.460 inch)
(4) Torque for the nut ..... 14 ± 3 N·m (125 ± 27 lb in)
(5) Torque for the five screws .............. 6.5 ± 1.0 N·m
(60 ± 9 lb in)
(6) Before assembly, lubricate the threads and the
bearing surfaces of the setscrew with 4C-5599
Anti-Seize Compound.
110
Specifications Section
RENR5077-12
i03697281
Exhaust Manifold
SMCS Code: 1059
Part No.: 334-7032
S/N: M8A1-Up
Part No.: 334-7032
S/N: M8B1-Up
Illustration 105
g01717353
(7) Exhaust bypass valve
(8) Locknut
(9) Gasket
Illustration 106
1. Clean the stud, the locknut, and the base of the
locknut prior to assembly.
2. Apply 2P-2333 High Temperature Sealer to the
threads of the stud that extend through the flange
of the exhaust bypass valve and to the bottom of
the mating face of each locknut.
3. Tighten two diagonal locknuts.
Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft)
4. Tighten the remaining locknuts.
Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft)
5. Tighten all four locknuts again.
Torque ............................. 47 ± 9 N·m (35 ± 7 lb ft)
g01988413
Note: Before assembly, lubricate the threads and
the bearing surfaces of the bolts with 4C-5599
Anti-Seize Compound.
(1) Torque for the bolts ........ 65 ± 5 N·m (48 ± 4 lb ft)
RENR5077-12
111
Specifications Section
i03114083
i03114039
Exhaust Manifold
Exhaust Manifold
SMCS Code: 1059
SMCS Code: 1059
Part No.: 123-0324
S/N: S2A1-Up
Part No.: 100-3144
S/N: GS71-Up
Part No.: 123-0324
S/N: S2B1-Up
Part No.: 100-3144
S/N: GSA1-Up
Part No.: 123-0324
S/N: S2D1-Up
Part No.: 129-5488
S/N: S2A1-Up
Part No.: 123-0324
S/N: S2E1-Up
Part No.: 129-5488
S/N: S2B1-Up
Part No.: 123-0324
S/N: S2F1-Up
Part No.: 129-5488
S/N: S2D1-Up
Part No.: 129-5488
S/N: S2E1-Up
Part No.: 129-5488
S/N: S2F1-Up
Part No.: 129-5488
S/N: S2G1-Up
Part No.: 129-5488
S/N: S2H1-Up
Part No.: 129-5488
S/N: S2J1-Up
Illustration 107
g01592399
Top view of engine
Note: Apply 4C-5599 Anti-Seize Compound to the
threads of the bolts and to the face of the washers.
Tighten diagonally opposite bolts simultaneously.
(1) Torque for the bolts ........ 55 ± 5 N·m (41 ± 4 lb ft)
Part No.: 129-5488
S/N: S2K1-Up
Part No.: 129-5488
S/N: S2L1-Up
Part No.: 129-5488
S/N: S2M1-Up
Part No.: 129-5488
S/N: S2N1-Up
Part No.: 129-5488
S/N: S2P1-Up
Part No.: 129-5488
S/N: S2R1-Up
Part No.: 129-5488, 161-2503, 167-1759
S/N: S2S1-Up
Part No.: 129-5488, 167-1759
S/N: S2T1-Up
Illustration 108
g01592401
Note: Apply 4C-5599 Anti-Seize Compound to the
threads of the bolts and to the face of the washers.
(2) Torque for the bolts ........ 65 ± 5 N·m (48 ± 4 lb ft)
Part No.: 129-5488
S/N: S2W1-Up
Part No.: 129-5488, 161-2503
S/N: S2X1-Up
Part No.: 129-5488, 161-2503
S/N: S2Y1-Up
112
Specifications Section
RENR5077-12
Part No.: 161-2502
S/N: S2F1-Up
Part No.: 129-5488, 167-1759
S/N: S2Z1-Up
Part No.: 161-2502
S/N: S2G1-Up
Part No.: 161-2502
S/N: S2H1-Up
Part No.: 161-2502
S/N: S2J1-Up
Part No.: 161-2502
S/N: S2K1-Up
Part No.: 161-2502
S/N: S2L1-Up
Illustration 109
g01592366
Typical example
Part No.: 161-2502
S/N: S2M1-Up
Part No.: 161-2502
S/N: S2N1-Up
Top view of engine
Part No.: 161-2502
S/N: S2P1-Up
Part No.: 161-2502
S/N: S2R1-Up
Part No.: 161-2502
S/N: S2S1-Up
Part No.: 161-2502
S/N: S2T1-Up
Part No.: 161-2502
S/N: S2W1-Up
Illustration 110
g01592373
Rear view of engine
Note: Apply 4C-5599 Anti-Seize Compound to the
threads of the bolts and to the face of the washers.
Tighten diagonally opposite bolts simultaneously.
(1) Torque for the bolts ........ 55 ± 5 N·m (41 ± 4 lb ft)
i04379751
Exhaust Manifold
SMCS Code: 1059
Part No.: 161-2502
S/N: GS61-Up
Part No.: 161-2502
S/N: S2A1-Up
Part No.: 161-2502
S/N: S2B1-Up
Part No.: 161-2502
S/N: S2D1-Up
Part No.: 161-2502
S/N: S2E1-Up
Part No.: 161-2502
S/N: S2X1-Up
Part No.: 161-2502
S/N: S2Y1-Up
Part No.: 161-2502
S/N: S2Z1-Up
RENR5077-12
113
Specifications Section
g02543657
Illustration 111
Top view of engine
Table 66
Specification for the 161-2502 Exhaust Manifold Gp
Item
Qty
Part
Specification Description
1
80
3E-6916 Full Nut
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
Apply 4C-5599 Anti-Seize Compound to the threads of the bolts
and to the face of the washers. Tighten diagonally opposite bolts
simultaneously.
2
48
9L-7373 High
Temperature Bolt
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
Apply 4C-5599 Anti-Seize Compound to the threads of the bolts
and to the face of the washers. Tighten diagonally opposite bolts
simultaneously.
114
Specifications Section
RENR5077-12
i05166885
Exhaust Manifold
SMCS Code: 1059
Part No.: 398-9927
S/N: 9H31-Up
Part No.: 398-9927
S/N: ED31-Up
Part No.: 398-9927
S/N: ED51-Up
Part No.: 398-9927
S/N: SRK1-Up
g03318695
Illustration 112
Table 67
Specification for the 398-9927 Exhaust Manifold Gp
Item
Qty
Part
Specification Description
1
8
9L-7373 High
Temperature Bolt
Before assembly, lubricate the threads and the washer faces with
Loctite C5A copper anti-seize.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
Tighten diagonally opposite bolts simultaneously.
2
80
7L-6443 High
Temperature Bolt
Before assembly, lubricate the threads and the washer faces with
Loctite C5A copper anti-seize.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
Tighten diagonally opposite bolts simultaneously.
3
40
9L-7373 High
Temperature Bolt
Before assembly, lubricate the threads and the washer faces with
Loctite C5A copper anti-seize.
Torque to 65 ± 5 N·m (48 ± 4 lb ft).
RENR5077-12
115
Specifications Section
i04936992
Exhaust Manifold
SMCS Code: 1059
Part No.: 393-9363
S/N: 9H31-Up
Part No.: 393-9363
S/N: ED51-Up
g03113876
Illustration 113
Table 68
Specification for 393-9363 Exhaust Manifold Gp
Item
Qty
Part
1
4
3B-1915 Bolt
2
40
5P-2755 High Temperature
Bolt
3
48
3B-1915 Bolt
Specification Description
Before assembly, apply Loctite C5A Copper Anti-Seize to threads
and bearing surfaces.
Before assembly, apply Loctite C5A Copper Anti-Seize to threads
and bearing surfaces.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
Before assembly, apply Loctite C5A Copper Anti-Seize to threads
and bearing surfaces.
Torque to 50 ± 5 N·m (37 ± 4 lb ft).
116
Specifications Section
RENR5077-12
i05132330
Exhaust Manifold
SMCS Code: 1059
Part No.: 399-2647
S/N: ED21-Up
Part No.: 399-2647
S/N: 9H41-Up
Part No.: 399-2647
S/N: ED81-Up
Part No.: 399-2647
S/N: MD81-Up
Part No.: 399-2647
S/N: SRH1-Up
Illustration 114
g03291316
RENR5077-12
117
Specifications Section
Table 69
Specification for the 399-2647 Exhaust Manifold Gp
Item
Qty
Part
Specification Description
80
7L-6443 High
Temperature Bolt
Before assembly, lubricate the threads and the bearing surfaces with
Loctite C5A copper anti-seize.
Tighten diagonally opposite bolts simultaneously.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
2
8
9L-7373 High
Temperature Bolt
Before assembly, lubricate the threads and the bearing surfaces with
Loctite C5A copper anti-seize.
Tighten diagonally opposite bolts simultaneously.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
3
40
9L-7373 High
Temperature Bolt
Before assembly, lubricate the threads and the bearing surfaces with
Loctite C5A copper anti-seize.
Tighten diagonally opposite bolts simultaneously.
Torque to 65 ± 5 N·m (48 ± 4 lb ft).
1
118
Specifications Section
RENR5077-12
i04938331
Exhaust Manifold
SMCS Code: 1059
Part No.: 398-0313
S/N: ED21-Up
Part No.: 398-0313
S/N: 9H41-Up
Part No.: 398-0313
S/N: ED81-Up
Part No.: 398-0313
S/N: MD81-Up
Part No.: 398-0313
S/N: SRH1-Up
Illustration 115
g03118096
RENR5077-12
119
Specifications Section
Table 70
Specification for 398-0313 Exhaust Manifold Gp
Item
Qty
Part
1
4
3B-1915 Bolt
Before assembly, apply Loctite C5A Copper Anti-Seize to threads
and bearing surfaces.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
2
40
5P-2755 High
Temperature Bolt
Before assembly, apply Loctite C5A Copper Anti-Seize to threads
and bearing surfaces.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
3
48
9L-7373 High
Temperature Bolt
Before assembly, apply Loctite C5A Copper Anti-Seize to threads
and bearing surfaces.
Torque to 50 ± 5 N·m (37 ± 4 lb ft).
Specification Description
i05166125
Exhaust Manifold
SMCS Code: 1059
Part No.: 381-4758
S/N: MXM1-Up
Illustration 116
g03318264
120
Specifications Section
RENR5077-12
Table 71
Specification for the 381-4758 Exhaust Manifold Gp
Item
Qty
Part
1
4
374-8142 Band Clamp
Before assembly, lubricate the threads, bearing surfaces and the
inside diameter of clamps with Loctite C5A copper anti-seize.
Torque to 17 ± 2 N·m (151 ± 18 lb in).
2
8
9L-7373 High
Temperature Bolt
Before assembly, lubricate the threads and bearing surfaces with
Loctite C5A copper anti-seize.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
3
80
7L-6443 High
Temperature Bolt
Before assembly, lubricate the threads and bearing surfaces with
Loctite C5A copper anti-seize.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
Tighten diagonally opposite bolts simultaneously.
4
40
9L-7373 High
Temperature Bolt
Before assembly, lubricate the threads and bearing surfaces with
Loctite C5A copper anti-seize.
Torque to 65 ± 5 N·m (48 ± 4 lb ft).
Specification Description
RENR5077-12
121
Specifications Section
i05166836
Exhaust Manifold
SMCS Code: 1059
Part No.: 382-6553
S/N: WF21-Up
Part No.: 382-6553
S/N: SRZ1-Up
g03318664
Illustration 117
Table 72
Specification for the 382-6553 Exhaust Manifold Gp
Item
Qty
Part
1
80
7L-6443 High
Temperature Bolt
Before assembly, lubricate the threads and bearing surfaces with
Loctite Nickel Anti Seize.
2
80
3E-6916 Full Nut
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
Tighten diagonally opposite bolts simultaneously.
48
5P-7128 High
Temperature Bolt
Before assembly, lubricate the threads and bearing surfaces with
Loctite Nickel Anti Seize.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
Tighten diagonally opposite bolts simultaneously.
3
Specification Description
122
Specifications Section
RENR5077-12
i05166929
Exhaust Manifold
SMCS Code: 1059
Part No.: 399-2646
S/N: WF21-Up
Part No.: 399-2646
S/N: SRZ1-Up
g03318735
Illustration 118
Table 73
Specification for the 399-2646 Exhaust Manifold Gp
Item
Qty
Part
1
80
7L-6443 High
Temperature Bolt
Before assembly, lubricate the threads and the washer faces with
Loctite C5A copper anti-seize.
2
80
3E-6916 Full Nut
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
Tighten diagonally opposite bolts simultaneously.
48
9L-7373 High
Temperature Bolt
Before assembly, lubricate the threads and the washer faces with
Loctite C5A copper anti-seize.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
Tighten diagonally opposite bolts simultaneously.
3
Specification Description
RENR5077-12
123
Specifications Section
i02051171
Exhaust Manifold
SMCS Code: 1059
Part No.: 238-9120
S/N: PAG1-Up
Part No.: 239-0731
S/N: MKH1-Up
g01052090
Illustration 119
(1) Clamp
Torque ............................ 25 ± 6 N·m (18 ± 4 lb ft)
(2) Bolt
Lubricate the washer face and the thread
with 5P-3931 Anti-Seize Compound before
assembly. Tighten diagonally opposite bolts
simultaneously.
Torque ............................ 55 ± 5 N·m (41 ± 4 lb ft)
(3) Bolt
Lubricate the washer face and the thread with
5P-3931 Anti-Seize Compound before assembly.
(4) Bolt
Lubricate the washer face and the thread with
5P-3931 Anti-Seize Compound before assembly.
(5) Stud
Torque ............................ 35 ± 5 N·m (26 ± 4 lb ft)
(6) Bolt
Torque ............................ 55 ± 5 N·m (41 ± 4 lb ft)
124
Specifications Section
RENR5077-12
i03695742
Exhaust Manifold
SMCS Code: 1059
Part No.: 240-0745
S/N: B5G1-Up
Part No.: 239-0732
S/N: MRG1-Up
Illustration 120
Typical example
(1) Before assembly, lubricate the threads and the
bearing surfaces of the bolts with 4C-5599
Anti-Seize Compound.
Note: Before assembly, lubricate the threads and
the bearing surfaces of the clamps with 4C-5599
Anti-Seize Compound.
(2) Torque for the clamps ........................ 25 ± 6 N·m
(221 ± 53 lb in)
(3) Before assembly, lubricate the threads and the
bearing surfaces of the locknuts with 4C-5599
Anti-Seize Compound.
Note: Before assembly, lubricate the threads and
the bearing surfaces of the bolts with 4C-5599
Anti-Seize Compound. Tighten diagonally opposite
bolts simultaneously.
(4) Torque for the bolts ........ 55 ± 5 N·m (41 ± 4 lb ft)
g01987274
RENR5077-12
125
Specifications Section
i05132257
Exhaust Manifold
SMCS Code: 1059
Part No.: 381-4755
S/N: 9F31-Up
Part No.: 381-4755
S/N: EDJ1-Up
g03291276
Illustration 121
Table 74
Specification for the 381-4755 Exhaust Manifold Gp
Item
Qty
Part
Specification Description
1
112
7L-6443 High
Temperature Bolt
Before assembly, lubricate the threads and the bearing surfaces with
Loctite C5A copper anti-seize.
Tighten diagonally opposite bolts simultaneously.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
2
8
9L-7373 High
Temperature Bolt
Before assembly, lubricate the threads and the bearing surfaces with
Loctite C5A copper anti-seize.
Tighten diagonally opposite bolts simultaneously.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
56
9L-7373 High
Temperature Bolt
Before assembly, lubricate the threads and the bearing surfaces with
Loctite C5A copper anti-seize.
Tighten diagonally opposite bolts simultaneously.
Torque to 65 ± 5 N·m (48 ± 4 lb ft).
3
126
Specifications Section
RENR5077-12
i05166040
Exhaust Manifold
SMCS Code: 1059
Part No.: 381-4750
S/N: 9H51-Up
Part No.: 381-4750
S/N: EDP1-Up
g03318222
Illustration 122
Table 75
Specification for the 381-4750 Exhaust Manifold Gp
Item
Qty
Part
1
4
3B-1915 Bolt
Before assembly, lubricate the threads and the washer faces with
Loctite C5A copper anti-seize.
2
8
9L-7373 High
Temperature Bolt
Before assembly, lubricate the threads and the washer faces with
Loctite C5A copper anti-seize.
Torque to 65 ± 5 N·m (48 ± 4 lb ft).
3
112
7L-6443 High
Temperature Bolt
Before assembly, lubricate the threads and the washer faces with
Loctite C5A copper anti-seize.
4
112
3E-6916 Full Nut
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
Tighten diagonally opposite bolts simultaneously.
56
9L-7373 High
Temperature Bolt
Before assembly, lubricate the threads and the washer faces with
Loctite C5A copper anti-seize.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
Tighten diagonally opposite bolts simultaneously.
5
Specification Description
RENR5077-12
127
Specifications Section
i05164410
Exhaust Manifold
SMCS Code: 1059
Part No.: 381-4745
S/N: 9F21-Up
Part No.: 381-4745
S/N: CG21-Up
Part No.: 381-4745
S/N: 9H61-Up
Part No.: 381-4745
S/N: EDG1-Up
Part No.: 381-4745
S/N: EDH1-Up
Part No.: 381-4745
S/N: MXR1-Up
Illustration 123
g03317501
128
Specifications Section
RENR5077-12
Table 76
Specification for the 381-4745 Exhaust Manifold Gp and 381-4747 Exhaust Manifold Gp
Item
Qty
Part
1
4
6V-4606 High
Temperature Bolt
Before assembly, lubricate the threads and the washer faces with
Loctite C5A copper anti-seize.
2
8
6V-4605 Locknut
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
Tighten diagonally opposite bolts simultaneously.
3
124
7L-6443 High
Temperature Bolt
Before assembly, lubricate the threads and the washer faces with
Loctite C5A copper anti-seize.
4
16
3E-6916 Full Nut
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
Tighten diagonally opposite bolts simultaneously.
5
4
9X-8285 High
Temperature Bolt
Before assembly, lubricate the threads and the washer faces with
Loctite C5A copper anti-seize.
6
2
5M-6213 Pipe Plug
Before assembly, lubricate the threads and the washer faces with
Loctite C5A copper anti-seize.
7
4
5P-2755 High
Temperature Bolt
Before assembly, lubricate the threads and the washer faces with
Loctite C5A copper anti-seize.
8
64
9L-7373 High
Temperature Bolt
Before assembly, lubricate the threads and the washer faces with
Loctite C5A copper anti-seize.
Torque to 65 ± 5 N·m (48 ± 4 lb ft).
Specification Description
i04380848
Exhaust Flange
SMCS Code: 1061
Part No.: 2W-7871
S/N: GS61-Up
Part No.: 2W-7866, 2W-7871
S/N: GS71-Up
g02546076
Illustration 124
Typical example
Table 77
Specification for 2W-7871 Exhaust Flange Gp and 2W-7866 Exhaust Flange Gp
Item
Qty
Part
1
12
5L-4398 Bolt
Specification Description
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
RENR5077-12
129
Specifications Section
i04380839
Exhaust Flange
SMCS Code: 1061
Part No.: 7N-6962
S/N: GS61-Up
Part No.: 7N-6962
S/N: M8A1-Up
Part No.: 7N-6962
S/N: S2A1-Up
Part No.: 7N-6962
S/N: M8B1-Up
Part No.: 7N-6962
S/N: S2B1-Up
Part No.: 7N-6962
S/N: S2D1-Up
Part No.: 7N-6962
S/N: S2E1-Up
Part No.: 7N-6962
S/N: S2F1-Up
Part No.: 7N-6962
S/N: S2G1-Up
Part No.: 7N-6962
S/N: S2H1-Up
Part No.: 7N-6962
S/N: S2J1-Up
Part No.: 7N-6962
S/N: S2K1-Up
Part No.: 7N-6962
S/N: S2L1-Up
Part No.: 7N-6962
S/N: S2M1-Up
Part No.: 7N-6962
S/N: S2N1-Up
Part No.: 7N-6962
S/N: S2P1-Up
Part No.: 7N-6962
S/N: S2R1-Up
Part No.: 7N-6962
S/N: S2S1-Up
Part No.: 7N-6962
S/N: S2T1-Up
Part No.: 7N-6962
S/N: S2W1-Up
Part No.: 7N-6962
S/N: S2X1-Up
Part No.: 7N-6962
S/N: S2Y1-Up
130
Specifications Section
RENR5077-12
g02546021
Illustration 125
Typical example
Table 78
Specification for the 7N-6962 Exhaust Flange Gp1W-9488 Exhaust Flange Gp
Item
Qty
Part
1
12
0S-1571 Bolt
Specification Description
Before assembly, apply 4C-5599 Anti-Seize Compound to the
threads of bolts.
i04380840
Exhaust Flange
SMCS Code: 1061
Part No.: 2W-7756
S/N: GS61-Up
Illustration 126
g02546039
RENR5077-12
131
Specifications Section
Table 79
Specification for 2W-7756 Exhaust Flange Gp
Item
Qty
Part
1
12
9X-8873 Bolt
Specification Description
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
i04889493
Exhaust Flange
SMCS Code: 1061
Part No.: 380-3904
S/N: CG21-Up
Part No.: 380-3904
S/N: 9H61-Up
Part No.: 380-3904
S/N: MD81-Up
Part No.: 380-3904
S/N: EDG1-Up
Part No.: 380-3904
S/N: MXM1-Up
Part No.: 380-3904
S/N: MXR1-Up
Illustration 127
g02834876
132
Specifications Section
RENR5077-12
Table 80
Specification for 380-3904 Exhaust Flange Gp
Item
Qty
Part
1
16
9X-8887 Bolt
Specification description
Before assembly, apply Loctite C5A Copper anti-seize to the threads.
i04735510
Exhaust Flange
SMCS Code: 1061
Part No.: 103-6668
S/N: GSA1-Up
Part No.: 103-6668
S/N: PAG1-Up
Part No.: 103-6668
S/N: MKH1-Up
Part No.: 103-6668
S/N: S2J1-Up
Part No.: 103-6668
S/N: S2K1-Up
Part No.: 103-6668
S/N: S2P1-Up
Part No.: 103-6668
S/N: S2R1-Up
Part No.: 103-6668
S/N: S2S1-Up
Part No.: 103-6668
S/N: S2T1-Up
Part No.: 103-6668
S/N: S2W1-Up
Part No.: 103-6668
S/N: S2X1-Up
Part No.: 103-6668
S/N: S2Y1-Up
Part No.: 103-6668
S/N: S2Z1-Up
RENR5077-12
133
Specifications Section
g02834876
Illustration 128
Table 81
Specification for 103-6668 Exhaust Flange Gp
Item
Qty
Part
1
16
9X-8887 Bolt
Specification description
Before assembly, apply Loctite C5A Copper anti-seize to the threads.
134
Specifications Section
RENR5077-12
i04929922
Exhaust Flange
SMCS Code: 1061
Part No.: 394-2294
S/N: WF21-Up
Part No.: 394-2294
S/N: 9F31-Up
Part No.: 394-2294
S/N: 9H31-Up
Part No.: 394-2294
S/N: 9H41-Up
Part No.: 394-2294
S/N: 9H51-Up
Part No.: 394-2294
S/N: ED51-Up
Part No.: 394-2294
S/N: ED81-Up
Part No.: 394-2294
S/N: EDJ1-Up
Part No.: 394-2294
S/N: EDP1-Up
Part No.: 394-2294
S/N: SRZ1-Up
g03099216
Illustration 129
Table 82
Specification for 394-2294 Exhaust Flange Gp
Item
Qty
Part
1
12
0S-1571 Bolt
Specification Description
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
i05167067
Air Cleaner
SMCS Code: 1051
Part No.: 8N-3378
S/N: CG21-Up
Part No.: 8N-3378
S/N: WF21-Up
RENR5077-12
135
Specifications Section
Part No.: 8N-3378
S/N: 9F31-Up
Part No.: 8N-3378
S/N: GS61-Up
Part No.: 8N-3378
S/N: GS71-Up
Part No.: 8N-3378
S/N: MD81-Up
Part No.: 8N-3378
S/N: EDJ1-Up
Part No.: 8N-3378
S/N: MXM1-Up
Part No.: 8N-3378
S/N: MXR1-Up
g03318829
Illustration 130
Table 83
Specification for 8N-3378 Air Cleaner Gp
Item
Qty
Part
A
-
-
Specification Description
Distance that is required to remove the element for the air cleaner is 538 mm
(21.2 inch).
136
Specifications Section
RENR5077-12
i01659336
Air Cleaner
Part No.: 4P-0558
S/N: 9H61-Up
SMCS Code: 1051
Part No.: 4P-0558
S/N: GS61-Up
Part No.: 5N-8728
S/N: S2A1-Up
Part No.: 4P-0558
S/N: ED81-Up
Part No.: 4P-0558
S/N: MD81-Up
Part No.: 4P-0558
S/N: GSA1-Up
Part No.: 4P-0558
S/N: EDG1-Up
Part No.: 4P-0558
S/N: EDJ1-Up
Part No.: 4P-0558
S/N: MXM1-Up
Part No.: 4P-0558
S/N: MXR1-Up
Part No.: 4P-0558
S/N: SRZ1-Up
Illustration 131
g00856159
(1) Washer
In order to align the precleaner with the air cleaner,
use the 8T-4896 Hard Washers as spacers for the
air cleaner.
(2) Bolt
Torque .............................. 12 ± 4 N·m (9 ± 3 lb ft)
(3) Washer
In order to align the precleaner with the air cleaner,
use the 8T-4122 Hard Washers as spacers for the
precleaner.
i04735669
Air Cleaner
SMCS Code: 1051
Part No.: 4P-0558
S/N: CG21-Up
Part No.: 4P-0558
S/N: WF21-Up
Part No.: 4P-0558
S/N: 9F31-Up
Part No.: 4P-0558
S/N: 9H41-Up
RENR5077-12
137
Specifications Section
g02835056
Illustration 132
Table 84
Specification for 4P-0558 Air Cleaner Gp, and 4P-0559 Air Cleaner Gp
Item
Qty
Part
Specification Description
A
-
-
Distance that is required to remove the element for the air cleaner is 741.0 mm
(29.17 inch).
138
Specifications Section
RENR5077-12
i04380877
Air Cleaner Adapter
SMCS Code: 1051
Part No.: 7W-9828
S/N: M8A1-Up
Part No.: 7W-9828
S/N: P8A1-Up
Part No.: 7W-9828
S/N: S2A1-Up
Part No.: 7W-9828
S/N: M8B1-Up
Part No.: 7W-9828
S/N: S2B1-Up
Part No.: 7W-9828
S/N: S2D1-Up
Part No.: 7W-9828
S/N: S2E1-Up
Part No.: 7W-9828
S/N: S2F1-Up
Part No.: 7W-9828
S/N: S2G1-Up
Part No.: 7W-9828
S/N: S2K1-Up
Part No.: 7W-9828
S/N: S2N1-Up
Part No.: 7W-9828
S/N: S2P1-Up
Part No.: 7W-9828
S/N: S2R1-Up
Part No.: 7W-9828
S/N: S2W1-Up
Part No.: 7W-9828
S/N: S2Z1-Up
Illustration 133
g02546218
RENR5077-12
139
Specifications Section
Table 85
Specification for the 7W-9828 Air Cleaner Adapter
Item
Qty
Part
1
48
031-4155 Locknut
Specification Description
Torque the locknuts to 12 ± 4 N·m (105 ± 35 lb in).
i04929959
Air Cleaner Adapter
SMCS Code: 1051
Part No.: 384-3619
S/N: CG21-Up
Part No.: 384-3619
S/N: 9H41-Up
Part No.: 384-3619
S/N: 9H61-Up
Part No.: 384-3619
S/N: ED81-Up
Part No.: 384-3619
S/N: MD81-Up
Part No.: 384-3619
S/N: EDG1-Up
Part No.: 384-3619
S/N: MXR1-Up
g03099300
Illustration 134
Table 86
Specification for 384-3619 Air Cleaner Adapter
Item
Qty
Part
1
28
4M-6425 Bolt
Specification Description
Torque to 12 ± 4 N·m (106 ± 35 lb in).
140
Specifications Section
RENR5077-12
i04380879
Air Cleaner Adapter
SMCS Code: 1051
Part No.: 4P-2013
S/N: GS61-Up
Part No.: 4P-2013
S/N: GSA1-Up
Part No.: 4P-2013
S/N: MRG1-Up
Part No.: 4P-2013
S/N: S2G1-Up
Part No.: 4P-2013
S/N: S2H1-Up
Part No.: 4P-2013
S/N: S2J1-Up
Part No.: 4P-2013
S/N: S2L1-Up
Part No.: 4P-2013
S/N: S2M1-Up
Part No.: 4P-2013
S/N: S2R1-Up
Part No.: 4P-2013
S/N: S2S1-Up
Part No.: 4P-2013
S/N: S2T1-Up
Part No.: 4P-2013
S/N: S2X1-Up
Part No.: 4P-2013
S/N: S2Z1-Up
g02546238
Illustration 135
Table 87
Specification for the 4P-2013 Air Cleaner Adapter
Item
Qty
Part
1
28
031-4155 Locknut
Specification Description
Torque to 12 ± 4 N·m (106 ± 35 lb in).
RENR5077-12
141
Specifications Section
i04380890
Engine Air Cleaner Service
Indicator
SMCS Code: 7452
Part No.: 7N-6782
S/N: 9F21-Up
Part No.: 7N-6782
S/N: CG21-Up
Part No.: 7N-6782
S/N: ED21-Up
Part No.: 7N-6782
S/N: WF21-Up
Part No.: 7N-6782
S/N: 9F31-Up
Part No.: 7N-6782
S/N: 9H31-Up
Part No.: 7N-6782
S/N: ED31-Up
Part No.: 7N-6782
S/N: 9H41-Up
Part No.: 7N-6782
S/N: JB41-Up
Part No.: 7N-6782
S/N: 9H51-Up
Part No.: 7N-6782
S/N: ED51-Up
Part No.: 7N-6782
S/N: 9H61-Up
Part No.: 7N-6782
S/N: GS61-Up
Part No.: 7N-6782
S/N: GS71-Up
Part No.: 7N-6782
S/N: ED81-Up
Part No.: 7N-6782
S/N: MD81-Up
Part No.: 7N-6782
S/N: GSA1-Up
Part No.: 213-1412, 7N-6782
S/N: S2A1-Up
Part No.: 213-1412, 7N-6782
S/N: S2B1-Up
Part No.: 7N-6782
S/N: EDC1-Up
Part No.: 7N-6782
S/N: EDG1-Up
Part No.: 213-1412, 7N-6782
S/N: S2G1-Up
Part No.: 7N-6782
S/N: EDH1-Up
Part No.: 213-1412, 7N-6782
S/N: S2H1-Up
Part No.: 7N-6782
S/N: SRH1-Up
Part No.: 7N-6782
S/N: EDJ1-Up
Part No.: 7N-6782
S/N: SRK1-Up
Part No.: 7N-6782
S/N: EDP1-Up
Part No.: 213-1412, 7N-6782
S/N: S2P1-Up
Part No.: 7N-6782
S/N: MXR1-Up
Part No.: 213-1412, 7N-6782
S/N: S2R1-Up
Part No.: 213-1412, 7N-6782
S/N: S2Z1-Up
Part No.: 7N-6782
S/N: SRZ1-Up
142
Specifications Section
RENR5077-12
g02546280
Illustration 136
Rear view of engine
(1) Air cleaner
Table 88
Specification for 213-1412 Air Filter Change Indicator Gp, 7N-6782 Air Filter Change Indicator
Gp, and 335-5516 Air Filter Change Indicator Gp
Item
Qty
Part
Specification Description
2
2
6I-2933 Air Filter Service
Indicator
Torque to 2.0 ± 0.7 N·m (17.7 ± 6.2 lb in).
Install the air filter change indicator group with the filter side toward
the air cleaner.
RENR5077-12
143
Specifications Section
i04929978
Engine Air Cleaner Service
Indicator
SMCS Code: 7452
Part No.: 384-1288
S/N: 9H41-Up
Part No.: 384-1288
S/N: 9H61-Up
Part No.: 384-1288
S/N: ED81-Up
Part No.: 384-1288
S/N: EDG1-Up
g03099358
Illustration 137
Table 89
Specification for 384-1288 Air Filter Change Indicator Gp
Item
Qty
Part
1
2
6I-2933 Air Filter Service
Indicator
Specification Description
Install the fitting for the air filter change indicator group with the filter
side toward the service gauge.
Torque to 2.0 ± 0.7 N·m (17.7 ± 6.2 lb in).
144
Specifications Section
RENR5077-12
i04470509
Engine Air Cleaner Service
Indicator
SMCS Code: 7452
Part No.: 335-1903
S/N: WF21-Up
g02652156
Illustration 138
Table 90
Specification for 335-1903 Air Filter Change Indicator Gp
Item
Qty
Part
1
2
6I-2933 Air Filter Service Indicator
Specification Description
Torque to 2.0 ± 0.7 N·m (17.7 ± 6.2 lb in).
RENR5077-12
145
Specifications Section
i03688471
Air Inlet and Exhaust Lines
SMCS Code: 1058; 1061
Part No.: 334-4668
S/N: M8A1-Up
Part No.: 334-4668
S/N: M8B1-Up
Illustration 140
g01983494
Illustration 141
g01983495
Bolt tightening sequence
(2) Torque for the bolts .. 120 ± 20 N·m (89 ± 15 lb ft)
Note: Before assembly, lubricate the threads of the
plugs with 4C-5599 Anti-Seize Compound.
Illustration 139
g01983493
(1) Before assembly, lubricate the bore of the O-ring
seals lightly with 5P-3975 Rubber Lubricant.
(3) Torque for the plugs .. 25 ± 5 N·m (221 ± 44 lb in)
(4) Use the following procedure in order to tighten
the bolts of the aftercooler assembly:
1. Assemble the seals to the aftercooler core.
2. Temporarily secure the bottom seal to the
aftercooler with tape. Do not use an adhesive,
a silicone lubricant, or any other lubricant for
retention of the seal.
3. Assemble the aftercooler with seals to the inlet
manifold.
4. Inspect the bottom seal in order to ensure that the
seal is seating correctly in the recess.
146
Specifications Section
RENR5077-12
5. Install the aftercooler cover.
6. Inspect the upper seal in order to ensure that the
seal is seating correctly in the recess.
Part No.: 173-2947
S/N: S2S1-Up
Part No.: 173-2947
S/N: S2T1-Up
7. Install the cover bolts. Hand tighten the cover
bolts.
Part No.: 173-2947
S/N: S2W1-Up
8. Tighten the bolts in the numerical sequence to
24 ± 6 N·m (212 ± 53 lb in). Refer to Illustration
141.
Part No.: 173-2947
S/N: S2X1-Up
9. Again, tighten the bolts in the numerical sequence
to 47 ± 9 N·m (35 ± 7 lb ft). Refer to Illustration 141.
10. Remove the tape.
i04936959
Air Inlet and Exhaust Lines
SMCS Code: 1058; 1061
Part No.: 173-2947
S/N: GS61-Up
Part No.: 173-2947
S/N: S2A1-Up
Part No.: 173-2947
S/N: S2B1-Up
Part No.: 173-2947
S/N: S2D1-Up
Part No.: 173-2947
S/N: S2E1-Up
Part No.: 173-2947
S/N: S2F1-Up
Part No.: 173-2947
S/N: S2G1-Up
Part No.: 173-2947
S/N: S2H1-Up
Part No.: 173-2947
S/N: S2J1-Up
Part No.: 173-2947
S/N: S2K1-Up
Part No.: 173-2947
S/N: S2L1-Up
Part No.: 173-2947
S/N: S2M1-Up
Part No.: 173-2947
S/N: S2N1-Up
Part No.: 173-2947
S/N: S2P1-Up
Part No.: 173-2947
S/N: S2R1-Up
Part No.: 173-2947
S/N: S2Y1-Up
Part No.: 173-2947
S/N: S2Z1-Up
RENR5077-12
Illustration 142
Right side view of engine
147
Specifications Section
g03113719
148
Specifications Section
RENR5077-12
g03113720
Illustration 143
Bolt tightening sequence
Table 91
Specification for 173-2947 Turbocharger Air Lines Gp
Item
Qty
Part
1
4
6V-3917 O-Ring Seal
Specification description
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
2
10
9F-2773 Bolt
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. Install the aftercooler cover.
6. Inspect the upper seal in order to ensure that the seal is seating correctly
in the recess.
7. Install the cover bolts. Hand tighten the cover bolts.
8. Tighten the bolts in a numerical sequence as shown in Illustration 143
to 24 N·m (18 lb ft).
9. Again, tighten the bolts in a numerical sequence that is shown in
Illustration 143 to 47 N·m (35 lb ft).
10. Remove the tape.
3
3
3J-5389 Plug
Before assembly, apply Loctite C5A Copper anti-seize to the threads.
Torque to 20 ± 5 N·m (177 ± 44 lb in).
4
2
9X-8874 Bolt
Torque to 120 ± 20 N·m (89 ± 15 lb ft).
5
12
6V-5101 O-Ring Seal
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
6
4
6V-5103 O-Ring Seal
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
RENR5077-12
149
Specifications Section
i03690160
Air Inlet and Exhaust Lines
SMCS Code: 1058; 1061
Part No.: 107-0860
S/N: GS71-Up
Part No.: 107-0860
S/N: S2A1-Up
Part No.: 107-0860
S/N: S2B1-Up
Part No.: 107-0860
S/N: S2D1-Up
Part No.: 107-0860
S/N: S2E1-Up
Part No.: 107-0860
S/N: S2F1-Up
Illustration 144
Right side view of engine
g01984493
150
Specifications Section
Illustration 145
RENR5077-12
g01614673
Bolt tightening sequence
(1) Before assembly, lubricate the bore of the O-ring
seals lightly with 5P-3975 Rubber Lubricant.
(2) Use the following procedure in order to tighten
the bolts of the aftercooler assembly:
1. Assemble the seals to the aftercooler core.
2. Temporarily secure the bottom seal to the
aftercooler with tape. Do not use an adhesive,
a silicone lubricant, or any other lubricant for
retention of the seal.
3. Assemble the aftercooler with seals to the inlet
manifold.
4. Inspect the bottom seal in order to ensure that the
seal is seating correctly in the recess.
5. Install the aftercooler cover.
6. Inspect the upper seal in order to ensure that the
seal is seating correctly in the recess.
7. Install the cover bolts. Hand tighten the cover
bolts.
8. Tighten the bolts in the numerical sequence to
24 ± 6 N·m (212 ± 53 lb in). Refer to Illustration
145.
9. Again, tighten the bolts in the numerical sequence
to 24 ± 6 N·m (212 ± 53 lb in). Refer to Illustration
145.
10. Remove the tape.
Note: Before assembly, lubricate the threads of the
plugs with 4C-5599 Anti-Seize Compound.
(3) Torque for the plugs .. 20 ± 5 N·m (177 ± 44 lb in)
(4) Torque for the bolts .. 120 ± 20 N·m (89 ± 15 lb ft)
RENR5077-12
151
Specifications Section
i05166822
Air Inlet and Exhaust Lines
SMCS Code: 1058; 1061
Part No.: 424-9801
S/N: ED21-Up
Part No.: 424-9801
S/N: WF21-Up
Part No.: 424-9801
S/N: 9H41-Up
Part No.: 424-9801
S/N: ED81-Up
Part No.: 424-9801
S/N: MD81-Up
Part No.: 424-9801
S/N: SRH1-Up
Part No.: 424-9801
S/N: MXM1-Up
Illustration 146
g03318650
152
Specifications Section
RENR5077-12
g03113720
Illustration 147
Bolt tightening sequence
Table 92
Specification for 424-9801 Air Lines Gp
Item
Qty
Part
1
4
6V-3917 O-Ring Seal
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
2
4
6V-5103 O-Ring Seal
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
Specification description
Use the following procedure in order to assemble the aftercooler assembly and
tighten the bolts:
3
10
9F-2773 Bolt
4
12
6V-5101 O-Ring Seal
1. Assemble the seals to the aftercooler core.
2. Temporarily secure the bottom seal to the aftercooler with tape. Do not use an
adhesive, a silicone lubricant, or any other lubricant for retention of the seal.
3. Assemble the aftercooler with seals to the inlet manifold.
4. Inspect the bottom seal in order to ensure that the seal is seating correctly
in the recess.
5. Install the aftercooler cover.
6. Inspect the upper seal in order to ensure that the seal is seating correctly in
the recess.
7. Install the cover bolts. Hand tighten the cover bolts.
8. Tighten the bolts in a numerical sequence as shown in Illustration 147 to 24 N·m
(18 lb ft).
9. Again, tighten the bolts in a numerical sequence that is shown in Illustration
147 to 47 N·m (35 lb ft).
10. Remove the tape.
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
RENR5077-12
153
Specifications Section
i05166821
Air Inlet and Exhaust Lines
SMCS Code: 1058; 1061
Part No.: 385-6695, 385-6700
S/N: ED21-Up
Part No.: 385-6695
S/N: WF21-Up
Part No.: 385-6695, 385-6700
S/N: 9H41-Up
Part No.: 385-6695, 385-6700
S/N: ED81-Up
Part No.: 385-6695, 385-6700
S/N: MD81-Up
Part No.: 385-6695, 385-6700
S/N: SRH1-Up
Part No.: 385-6695, 385-6700
S/N: MXM1-Up
Illustration 148
g03318644
154
Specifications Section
RENR5077-12
g03113720
Illustration 149
Bolt tightening sequence
Table 93
Specification for 385-6695 Air Lines Gp and 385-6700 Turbocharger Air Lines Gp
Item
Qty
Part
1
4
6V-3917 O-Ring Seal
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
2
4
6V-5103 O-Ring Seal
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
Specification description
Use the following procedure in order to assemble the aftercooler assembly and
tighten the bolts:
3
10
9F-2773 Bolt
4
12
6V-5101 O-Ring Seal
1. Assemble the seals to the aftercooler core.
2. Temporarily secure the bottom seal to the aftercooler with tape. Do not use an
adhesive, a silicone lubricant, or any other lubricant for retention of the seal.
3. Assemble the aftercooler with seals to the inlet manifold.
4. Inspect the bottom seal in order to ensure that the seal is seating correctly
in the recess.
5. Install the aftercooler cover.
6. Inspect the upper seal in order to ensure that the seal is seating correctly in
the recess.
7. Install the cover bolts. Hand tighten the cover bolts.
8. Tighten the bolts in a numerical sequence as shown in Illustration 149 to 24 N·m
(18 lb ft).
9. Again, tighten the bolts in a numerical sequence that is shown in Illustration
149 to 47 N·m (35 lb ft).
10. Remove the tape.
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
RENR5077-12
155
Specifications Section
i04936976
Air Inlet and Exhaust Lines
SMCS Code: 1058; 1061
Part No.: 162-5718
S/N: S2J1-Up
Illustration 150
Right side view of engine
g03113778
156
Specifications Section
RENR5077-12
g03113779
Illustration 151
Bolt tightening sequence
Table 94
Specification for 162-5718 Turbocharger Air Lines Gp
Item
Qty
Part
1
4
6V-3917 O-Ring Seal
Specification description
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
2
10
6J-0934 Bolt
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. Install the aftercooler cover.
6. Inspect the upper seal in order to ensure that the seal is seating correctly
in the recess.
7. Install the cover bolts. Hand tighten the cover bolts.
8. Tighten the bolts in a numerical sequence as shown in Illustration 151
to 24 N·m (18 lb ft).
9. Again, tighten the bolts in a numerical sequence that is shown in
Illustration 151 to 47 N·m (35 lb ft).
10. Remove the tape.
3
3
3J-5389 Plug
Before assembly, apply Loctite C5A Copper anti-seize to the threads.
Torque to 20 ± 5 N·m (177 ± 44 lb in).
4
2
9X-8874 Bolt
Torque to 120 ± 20 N·m (89 ± 15 lb ft).
5
2
6V-5101 O-Ring Seal
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
6
10
4S-5898 O-Ring Seal
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
7
4
6V-5103 O-Ring Seal
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
RENR5077-12
157
Specifications Section
i05166820
Air Inlet and Exhaust Lines
SMCS Code: 1058; 1061
Part No.: 385-6715
S/N: 9F31-Up
Part No.: 385-6715
S/N: EDJ1-Up
Illustration 152
Right side view
g03318656
158
Specifications Section
RENR5077-12
g03318660
Illustration 153
Bolt tightening sequence
Table 95
Specification for 385-6715 Air Lines Gp
Item
Qty
Part
1
4
6V-3917 O-Ring Seal
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
2
4
6V-5103 O-Ring Seal
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
3
2
6V-3968 O-Ring Seal
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
Specification Description
Use the following procedure in order to assemble the aftercooler assembly
and tighten the bolts:
4
12
6J-0934 Bolt
5
16
6V-5101 O-Ring Seal
1. Assemble the seals to the aftercooler core.
2. Temporarily secure the bottom seal to the aftercooler with tape. Do not use
an adhesive, a silicone lubricant, or any other lubricant for retention of the seal.
3. Assemble the aftercooler with seals to the inlet manifold.
4. Inspect the bottom seal in order to ensure that the seal is seating correctly
in the recess.
5. Install the aftercooler cover.
6. Inspect the upper seal in order to ensure that the seal is seating correctly
in the recess.
7. Install the cover bolts. Hand tighten the cover bolts.
8. Tighten the bolts in a numerical sequence that is shown in Illustration 153
to 24 ± 6 N·m (18 ± 4 lb ft).
9. Again, tighten the bolts in a numerical sequence that is shown in Illustration
153 to 47 ± 9 N·m (35 ± 7 lb ft).
10. Remove the tape.
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
RENR5077-12
159
Specifications Section
i05166852
Air Inlet and Exhaust Lines
SMCS Code: 1058; 1061
Part No.: 386-7198
S/N: 9F21-Up
Part No.: 386-7198
S/N: CG21-Up
Part No.: 386-7198
S/N: 9H61-Up
Part No.: 386-7198
S/N: EDG1-Up
Part No.: 386-7198
S/N: EDH1-Up
Part No.: 386-7198
S/N: MXR1-Up
Illustration 154
g03318676
160
Specifications Section
RENR5077-12
g03318675
Illustration 155
Bolt tightening sequence
Table 96
Specification for 386-7198 Turbocharger Air Lines Gp
Item
Qty
Part
1
8
6V-5103 O-Ring Seal
Specification Description
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
Use the following procedure in order to assemble the aftercooler assembly
and tighten the bolts:
2
12
6J-0934 Bolt
3
16
6V-5101 O-Ring Seal
1. Assemble the seals to the aftercooler core.
2. Temporarily secure the bottom seal to the aftercooler with tape. Do not use
an adhesive, a silicone lubricant, or any other lubricant for retention of the seal.
3. Assemble the aftercooler with seals to the inlet manifold.
4. Inspect the bottom seal in order to ensure that the seal is seating correctly
in the recess.
5. Install the aftercooler cover.
6. Inspect the upper seal in order to ensure that the seal is seating correctly
in the recess.
7. Install the cover bolts. Hand tighten the cover bolts.
8. Tighten the bolts in a numerical sequence that is shown in Illustration 155
to 24 ± 6 N·m (18 ± 4 lb ft).
9. Again, tighten the bolts in a numerical sequence that is shown in Illustration
155 to 47 ± 9 N·m (35 ± 7 lb ft).
10. Remove the tape.
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
RENR5077-12
161
Specifications Section
i03137489
Air Inlet and Exhaust Lines
SMCS Code: 1058; 1061
Part No.: 107-0862
S/N: GSA1-Up
Part No.: 144-2885
S/N: S2P1-Up
Part No.: 107-0862
S/N: S2R1-Up
Part No.: 107-0862
S/N: S2S1-Up
Part No.: 144-2885
S/N: S2W1-Up
g01614613
Illustration 156
Right side view of engine
Illustration 157
g01614614
View A-A
(1) Lubricate the bore for the O-ring seals with
glycerin or an approved equivalent.
162
Specifications Section
RENR5077-12
g01614616
Illustration 158
Bolt tightening sequence
(2) Use the following procedure in order to tighten
the bolts of the aftercooler assembly:
1. Assemble the seals to the aftercooler core.
2. Temporarily secure the bottom seal to the
aftercooler with tape. Do not use an adhesive,
a silicone lubricant, or any other lubricant for
retention of the seal.
3. Assemble the aftercooler with seals to the inlet
manifold.
4. Inspect the bottom seal in order to ensure that the
seal is seating correctly in the recess.
Illustration 159
g01614623
5. Install the aftercooler cover.
View B-B
6. Inspect the upper seal in order to ensure that the
seal is seating correctly in the recess.
Note: Lubricate the threads of the plugs with
4C-5599 Anti-Seize Compound before assembly.
7. Install the cover bolts. Hand tighten the cover
bolts.
(4) Torque for two plugs ...... 20 ± 5 N·m (15 ± 4 lb ft)
8. Tighten the bolts in the numerical sequence to
24 N·m (18 lb ft).
9. Again, tighten the bolts in the numerical sequence
to 47 N·m (35 lb ft).
10. Remove the tape.
(3) Torque for the bolts .. 120 ± 20 N·m (90 ± 15 lb ft)
RENR5077-12
163
Specifications Section
i04388272
Air Shutoff
SMCS Code: 1078
Part No.: 274-5749
S/N: GS61-Up
Part No.: 274-5749
S/N: GS71-Up
g02837284
Illustration 160
Rear view
Table 97
Specification for 274-5749 Air Shutoff Gp
Item
Qty
Part
1
2
263-2905 Limit Switch As
Specification Description
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 16.3 N·m (12.0 lb ft).
164
Specifications Section
RENR5077-12
g02555077
Illustration 161
Table 98
Item
Qty
Part
2
2
215-2589 Bolt
3
1
215-2706 Air Shutoff As
4
1
289-9132 Body
5
1
215-2707 Cover
6
4
215-2587 Bolt
7
1
230-4073 Solenoid As
8
2
215-2588 Bolt
Specification Description
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 7 ± 1 N·m (62 ± 9 lb in).
Before assembly, apply Loctite C5A Copper Anti-Seize to the body.
Before reassembly, apply red Loctite 596 in between the body and cover.
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
Nominal voltage is 18 to 32 V.
Resistance at 25 °C (77 °F) is 1.485 to 1.815 Ohms.
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
RENR5077-12
165
Specifications Section
i04388252
Air Shutoff
SMCS Code: 1078
Part No.: 335-1898
S/N: M8A1-Up
Part No.: 335-1898
S/N: M8B1-Up
g02849388
Illustration 162
Table 99
Specification for 335-1898 Air Shutoff Gp
Item
Qty
Part
1
1
288-2758 Air Shutoff Gp
2
1
288-2759 Air Shutoff Gp
3
2
263-2905 Limit Switch As
Specification Description
Maximum operating temperature of the valve is 204 °C (399 °F).
Maximum operating pressure of the valve is 300 kPa (44 psi).
Before you assemble in the shutoff valve, apply Loctite C5A Copper
Anti-Seize to the threads.
Torque to 16 N·m (12 lb ft).
166
Specifications Section
RENR5077-12
g02555036
Illustration 163
Table 100
Specification for 335-1898 Air Shutoff Gp
Item
Qty
Part
4
2
215-2589 Bolt
5
1
215-2706 Air Shutoff As
6
1
289-9133 Body
7
1
215-2707 Cover
8
2
215-2587 Bolt
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
9
2
215-2588 Bolt
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
10
1
230-4073 Solenoid As
Specification Description
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 7 ± 1 N·m (62 ± 9 lb in).
Before assembly, apply Loctite C5A Copper Anti-Seize to the shaft of air
shutoff assembly.
Before assembly, apply red Loctite 596 between the body and the cover.
Operating voltage is 18 to 32 VDC.
i04405434
Air Shutoff
Part No.: 214-5543
S/N: S2G1-Up
SMCS Code: 1078
Part No.: 214-5543
S/N: S2H1-Up
Part No.: 214-5543
S/N: S2A1-Up
Part No.: 214-5543
S/N: S2J1-Up
Part No.: 214-5543
S/N: S2B1-Up
Part No.: 214-5543
S/N: S2K1-Up
Part No.: 214-5543
S/N: S2D1-Up
Part No.: 214-5543
S/N: S2L1-Up
Part No.: 214-5543
S/N: S2E1-Up
Part No.: 214-5543
S/N: S2M1-Up
Part No.: 214-5543
S/N: S2F1-Up
Part No.: 214-5543
S/N: S2N1-Up
RENR5077-12
167
Specifications Section
Part No.: 214-5543
S/N: S2P1-Up
Part No.: 214-5543
S/N: S2S1-Up
Part No.: 214-5543
S/N: S2T1-Up
Part No.: 214-5543
S/N: S2W1-Up
Part No.: 214-5543
S/N: S2Z1-Up
Illustration 164
g02596659
Rear view
Illustration 165
g02596660
168
Specifications Section
RENR5077-12
Table 101
Specification for 214-5543 Air Shutoff Gp
Item
Qty
Part
1
1
272-7094 Air Shutoff Gp
2
1
227-7483 Limit
Switch As
3
2
215-2589 Bolt
4
1
215-2706 Air Shutoff As
-
-
-
7
2
215-2587 Bolt
Specification Description
Maximum operating temperature of the valve is 204 °C (399 °F).
Maximum operating pressure of the valve is 300 kPa (44 psi).
Torque to 16.3 N·m (12.0 lb ft).
Before you assemble the limit switch assembly (2) in the shutoff
valve, apply 4C-5599 Anti-Seize Compound to the threads of the
plug.
Torque to 7 ± 1 N·m (62 ± 9 lb in).
Apply 4C-5599 Anti-Seize Compound to the threads of the bolts (3)
and to the threads of the bolts (7).
Apply 4C-5599 Anti-Seize Compound to the shaft of the air shutoff
assembly.
Before assembly, apply 4C-9614 Silicone Sealant between the body
(5) and the cover (6).
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
Operating voltage is 18 to 32 VDC.
9
1
230-4073 Solenoid As
Resistance at 25 °C (77 °F) is 1.485 to 1.815 Ohms.
Torque the bolts (8) to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
RENR5077-12
169
Specifications Section
i04930024
Air Shutoff
SMCS Code: 1078
Part No.: 380-1077
S/N: ED21-Up
Part No.: 380-1077
S/N: 9F31-Up
Part No.: 380-1077
S/N: ED31-Up
Part No.: 380-1077
S/N: 9H41-Up
Part No.: 380-1077
S/N: JB41-Up
Part No.: 380-1077
S/N: ED81-Up
Part No.: 380-1077
S/N: MD81-Up
Part No.: 380-1077
S/N: EDC1-Up
Part No.: 380-1077
S/N: SRH1-Up
Part No.: 380-1077
S/N: EDJ1-Up
Part No.: 380-1077
S/N: SRK1-Up
Illustration 166
g03099620
170
Specifications Section
RENR5077-12
Table 102
Specification for 380-1077 Air Shutoff Gp
Item
Qty
Part
1
1
288-2758 Air Shutoff Gp
2
1
288-2759 Air Shutoff Gp
3
2
263-2905 Limit Switch As
Specification Description
Maximum operating temperature of the valve is 204 °C (399 °F).
Maximum operating pressure of the valve is 300 kPa (44 psi).
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 16.27 N·m (144.00 lb in).
g03099622
Illustration 167
Table 103
Item
Qty
Part
4
2
215-2589 Bolt
5
1
215-2706 Air Shutoff As
6
1
289-9132 Body
7
1
215-2707 Cover
8
2
215-2587 Bolt
9
2
215-2587 Bolt
10
1
230-4073 Solenoid As
11
2
215-2588 Bolt
Specification Description
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 7 ± 1 N·m (62 ± 9 lb in).
Before assembly, apply Loctite C5A Copper Anti-Seize to body of the
shaft.
Before reassembly, apply red Loctite 596 in between the body and cover.
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
Nominal voltage is 18 to 32 V.
Resistance at 25 °C (77 °F) is 1.485 to 1.815 Ohms.
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
RENR5077-12
171
Specifications Section
i05167579
Air Shutoff
SMCS Code: 1078
Part No.: 384-3060
S/N: WF21-Up
Part No.: 384-3060
S/N: SRZ1-Up
g03319172
Illustration 168
Rear view of engine
Table 104
Specification for 384-7998 Air Shutoff Gp and 384-3060 Air Shutoff Gp
Item
Qty
Part
1
2
263-2905 Limit Switch As
Before you assemble in the shutoff valve, apply Loctite C5A Copper
Anti-Seize to the threads.
Torque to 16 N·m (12 lb ft).
2
1
288-2761 Air Shutoff Gp
Maximum operating temperature of the valve is 204 °C (399 °F).
Maximum operating pressure of the valve is 300 kPa (44 psi).
3
1
288-2760 Air Shutoff Gp
Maximum operating temperature of the valve is 204 °C (399 °F).
Maximum operating pressure of the valve is 300 kPa (44 psi).
4
-
-
5
1
152-8341 Solenoid
Valve Gp
Specification Description
Final installation torque for the nut is 9.0 ± 0.5 N·m (79.7 ± 4.4 lb in).
Final installation torque is 108 ± 7 N·m (80 ± 5 lb ft).
Operating voltage is 24 VDC.
172
Specifications Section
RENR5077-12
Air Shutoff Group
Illustration 169
g03319173
Illustration 170
g03319174
RENR5077-12
173
Specifications Section
Table 105
Item
Qty
Part
6
2
215-5518 Bolt
7
1
6K-1972 Flared Elbow
Before assembly, apply white Loctite Breakloose PST to the threads.
8
2
215-2588 Bolt
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
9
1
215-2706 Air Shutoff As
Before assembly, apply Loctite C5A Copper Anti-Seize to the shaft of air
shutoff assembly.
10
1
289-9133 Body
Before assembly, apply red Loctite 596 between the body and the cover.
11
1
215-2707 Cover
Before assembly, apply red Loctite 596 between the body and the cover.
12
1
215-2329 Spring
Free length after test is 139.2 mm (5.48 inch).
13
2
215-2589 Bolt
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 7 ± 1 N·m (62 ± 9 lb in).
14
2
215-2587 Bolt
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
Specification Description
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
i05076154
Air Shutoff
SMCS Code: 1078
Part No.: 274-5750
S/N: GSA1-Up
Illustration 171
g03242597
174
Specifications Section
RENR5077-12
Table 106
Specification for 274-5750 Air Shutoff Gp
Item
Qty
Part
1
2
263-2905 Limit Switch As
Before you assemble in the shutoff valve, apply Loctite C5A Copper
Anti-Seize to the threads.
Torque to 16 N·m (12 lb ft).
2
1
288-2758 Air Shutoff Gp
Maximum operating temperature is 204 °C (399 °F).
Maximum operating pressure is 300 kPa (44 psi).
3
1
288-2759 Air Shutoff Gp
Maximum operating temperature is 204 °C (399 °F).
Maximum operating pressure is 300 kPa (44 psi).
Specification Description
g03242598
Illustration 172
Table 107
Item
Qty
Part
4
2
215-2589 Bolt
5
1
215-2706 Air Shutoff As
6
1
289-9133 Body
7
1
215-2707 Cover
8
2
215-2587 Bolt
9
1
230-4073 Solenoid As
10
2
215-2588 Bolt
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
11
2
215-2587 Bolt
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
Specification Description
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 7 ± 1 N·m (62 ± 9 lb in).
Before assembly, apply Loctite C5A Copper Anti-Seize to the shaft.
During assembly, apply red Loctite 596 between the body and the cover.
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
Operating voltage is 18 to 32 VDC.
RENR5077-12
175
Specifications Section
i05167617
Air Shutoff
SMCS Code: 1078
Part No.: 384-8006
S/N: 9F21-Up
Part No.: 384-8006
S/N: CG21-Up
Part No.: 384-8006
S/N: 9F31-Up
Part No.: 384-8006
S/N: JB41-Up
Part No.: 384-8006
S/N: 9H61-Up
Part No.: 384-8006
S/N: EDC1-Up
Part No.: 384-8006
S/N: EDG1-Up
Part No.: 384-8006
S/N: EDH1-Up
Part No.: 384-8006
S/N: EDJ1-Up
Part No.: 384-8006
S/N: MXR1-Up
Illustration 173
g03319222
176
Specifications Section
RENR5077-12
Table 108
Specification for 384-8006 Air Shutoff Gp
Item
Qty
Part
1
2
263-2905 Limit Switch As
Before you assemble in the shutoff valve, apply Loctite C5A Copper
Anti-Seize to the threads.
Torque to 16.26 ± 3.00 N·m (143.91 ± 26.55 lb in).
2
1
288-2758 Air Shutoff Gp
Maximum operating temperature of the valve is 204 °C (399 °F).
Maximum operating pressure of the valve is 300 kPa (44 psi).
3
1
288-2759 Air Shutoff Gp
Maximum operating temperature of the valve is 204 °C (399 °F).
Maximum operating pressure of the valve is 300 kPa (44 psi).
Specification Description
Air Shutoff Group
Illustration 174
g03319218
Illustration 175
g03319219
RENR5077-12
177
Specifications Section
Table 109
Item
Qty
Part
4
1
230-4073 Solenoid As
5
2
215-2587 Bolt
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
6
2
215-2588 Bolt
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
7
1
215-2706 Air Shutoff As
Before assembly, apply Loctite C5A Copper Anti-Seize to the shaft of air
shutoff assembly.
8
1
289-9132 Body
Before assembly, apply red Loctite 596 between the body and the cover.
9
1
215-2707 Cover
Before assembly, apply red Loctite 596 between the body and the cover.
10
1
215-2329 Spring
Free length after test is 139.2 mm (5.48 inch).
11
2
215-2589 Bolt
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 7 ± 1 N·m (62 ± 9 lb in).
12
2
215-2587 Bolt
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
Specification Description
Operating voltage is 18 to 32 VDC.
Resistance at 25 °C (77 °F) is 1.485 to 1.815 Ohms.
i04724870
Engine Oil Pump
Part No.: 106-9872
S/N: B5G1-Up
SMCS Code: 1304
Part No.: 106-9872
S/N: EDG1-Up
Part No.: 106-9872
S/N: 9F21-Up
Part No.: 106-9872
S/N: MRG1-Up
Part No.: 106-9872
S/N: CG21-Up
Part No.: 106-9872
S/N: PAG1-Up
Part No.: 106-9872
S/N: 9F31-Up
Part No.: 106-9872
S/N: S2G1-Up
Part No.: 106-9872
S/N: JB41-Up
Part No.: 106-9872
S/N: EDH1-Up
Part No.: 106-9872
S/N: 9H51-Up
Part No.: 106-9872
S/N: MKH1-Up
Part No.: 106-9872
S/N: 9H61-Up
Part No.: 106-9872
S/N: S2H1-Up
Part No.: 106-9872
S/N: GSA1-Up
Part No.: 106-9872
S/N: EDJ1-Up
Part No.: 106-9872
S/N: S2A1-Up
Part No.: 106-9872
S/N: S2J1-Up
Part No.: 106-9872
S/N: S2B1-Up
Part No.: 106-9872
S/N: S2K1-Up
Part No.: 106-9872
S/N: EDC1-Up
Part No.: 106-9872
S/N: S2L1-Up
Part No.: 106-9872
S/N: S2D1-Up
Part No.: 106-9872
S/N: S2M1-Up
Part No.: 106-9872
S/N: S2E1-Up
Part No.: 106-9872
S/N: S2N1-Up
Part No.: 106-9872
S/N: S2F1-Up
Part No.: 106-9872
S/N: EDP1-Up
178
Specifications Section
Part No.: 106-9872
S/N: S2P1-Up
Part No.: 106-9872
S/N: MXR1-Up
Part No.: 106-9872
S/N: S2R1-Up
Part No.: 106-9872
S/N: S2S1-Up
Part No.: 106-9872
S/N: S2T1-Up
Part No.: 106-9872
S/N: S2W1-Up
Part No.: 106-9872
S/N: S2X1-Up
Part No.: 106-9872
S/N: S2Y1-Up
Part No.: 106-9872
S/N: S2Z1-Up
RENR5077-12
RENR5077-12
Illustration 176
179
Specifications Section
g02826456
180
Specifications Section
RENR5077-12
Table 110
Specification for the 106-9872 Engine Oil Pump Gp
Item
Qty
Part
Specification Description
Length of the new gear is 110.000 ± 0.015 mm (4.3307 ± 0.0006 inch).
1
2
106-9866 Gear
Depth of the bore in the oil pump body for the new gear is 110.15 ± 0.02 mm
(4.337 ± 0.001 inch).
Diameter of the 106-9865 Idler Shaft is 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
2
2
106-9867 Idler Shaft
Assembly
Distance (B) from the end of the shaft to the gear face is 34.0 ± 0.5 mm
(1.34 ± 0.02 inch).
Bore in the bushing for idler shaft assembly is 31.811 ± 0.013 mm
(1.2524 ± 0.0005 inch).
Length under test force is 107.16 mm (4.219 inch).
3
1
107-7175 Spring
Test force is 555.6 ± 20.0 N (124.9 ± 4.5 lb).
Free length after test is 144.5 mm (5.69 inch).
Diameter of the new 106-9868 Shaft is 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
4
1
106-9869 Oil Pump
Drive Shaft As
Bore in the bushing for oil pump drive shaft assembly is 31.811 ± 0.013 mm
(1.2524 ± 0.0005 inch).
Distance (C) from the end of the shaft to the gear face is 47.0 ± 0.5 mm
(1.85 ± 0.02 inch).
Installation depth is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).
5
6
7W-0060 Bushing
Position of bushing joints from the centerline through the bearing bores is 45 ±
15 degrees.
F
2
4M-3248 Hollow
Dowel
Extension of the hollow dowel from the oil pump cover is 6.0 ± 0.5 mm
(0.24 ± 0.02 inch).
G
2
7N-2043 Dowel
Extension of the dowel from the oil pump cover is 6.0 ± 1.0 mm (0.24 ± 0.04 inch).
The rotation of the drive gear is clockwise when you view the engine oil pump from the drive end.
Before you install the pump, lubricate the moving parts with clean engine oil. Rotate the pump by hand in order to ensure
that the pump rotates freely.
Bench test specifications:
-
-
-
Unrestricted flow rate at 1000 rpm is 410 L (108 US gal).
Pump pressure at 300 rpm with fully blocked outlet is 570 to 630 kPa (83 to 91 psi ).
RENR5077-12
181
Specifications Section
i04912024
Engine Oil Pump
SMCS Code: 1304
Part No.: 7W-0053
S/N: GS71-Up
Part No.: 7W-0053
S/N: M8A1-Up
Part No.: 7W-0053
S/N: P8A1-Up
Part No.: 7W-0053
S/N: S2A1-Up
Part No.: 7W-0053
S/N: M8B1-Up
Part No.: 7W-0053
S/N: S2B1-Up
Part No.: 7W-0053
S/N: S2D1-Up
Part No.: 7W-0053
S/N: S2E1-Up
g03079576
Illustration 177
Table 111
Specification for 7N-8715 Engine Oil Pump Gp
Item
Qty
Part
Specification Description
The rotation of the drive gear is clockwise when you view the engine oil pump from the drive end.
Before you install the pump, lubricate the moving parts with clean engine oil. Rotate the pump by hand in order to ensure
that the pump rotates freely.
1
1
298-6387 O-Ring Seal
Before assembly, lubricate the bore lightly with 5P-3975 Rubber
Lubricant.
182
Specifications Section
RENR5077-12
g03079678
Illustration 178
Table 112
Specification for 7N-8715 Engine Oil Pump Gp
Item
Qty
Part
Specification Description
Length under test force is 117.14 mm (4.612 inch).
2
1
2S-2760 Spring
Test force is 499 ± 24 N (112 ± 5 lb).
Free length after test is 152.91 mm (6.020 inch).
RENR5077-12
183
Specifications Section
g03079836
Illustration 179
Section A-A
Table 113
Specification for 7N-8715 Engine Oil Pump Gp
Item
Qty
Part
C
2
7N-6733 Gear
D
2
7W-1017 Shaft
E
2
4M-3248 Hollow Dowel
F
-
-
Specification Description
Length of new gear is 54.000 ± 0.015 mm (2.1260 ± 0.0006 inch).
Depth of the bore in the oil pump body for the new gear is
54.15 ± 0.02 mm (2.132 ± 0.001 inch).
Diameter is 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
After assembly, bore in the 7W-0060 Bushing for the new shaft
assembly is 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch).
Extension from the oil pump cover is 6.0 ± 0.5 mm (0.24 ± 0.02 inch).
Distance from the end of the idler shaft to the gear face is
34.0 ± 0.5 mm (1.34 ± 0.02 inch).
Diameter is 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
G
1
7N-5058 Pump Drive Shaft
H
-
-
J
1
7W-0050 Pump Cover
Installation depth of 7W-0060 Bushing in the pump cover is
1.5 ± 0.5 mm (0.06 ± 0.02 inch).
K
1
7W-0051 Oil Pump Body As
Installation depth of 7W-0060 Bushing in the oil pump body
assembly is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).
After assembly, bore in the 7W-0060 Bushing for the new shaft
assembly is 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch).
Distance from the end of the shaft to the gear face is 47.0 ± 0.5 mm
(1.85 ± 0.02 inch).
184
Specifications Section
RENR5077-12
g03079878
Illustration 180
Table 114
Specification for 7N-8715 Engine Oil Pump Gp
Item
Qty
Part
Specification Description
L
2
7N-2043 Dowel
Extension from the oil pump cover is 6.0 ± 1.0 mm (0.24 ± 0.04 inch).
Illustration 181
g03079902
RENR5077-12
185
Specifications Section
g03079958
Illustration 182
Table 115
Specification for 7N-8715 Engine Oil Pump Gp
Item
Qty
Part
Specification Description
M
-
-
Position of 7W-0060 Bushing joints from the centerline through the
bearing bores is 45 ± 15 degrees.
i04921863
Engine Oil Pump
Part No.: 8N-6152
S/N: S2J1-Up
SMCS Code: 1304
Part No.: 8N-6152
S/N: S2K1-Up
Part No.: 8N-6152
S/N: GS61-Up
Part No.: 8N-6152
S/N: S2L1-Up
Part No.: 8N-6152
S/N: S2A1-Up
Part No.: 8N-6152
S/N: S2M1-Up
Part No.: 8N-6152
S/N: S2B1-Up
Part No.: 8N-6152
S/N: S2N1-Up
Part No.: 8N-6152
S/N: S2D1-Up
Part No.: 8N-6152
S/N: S2P1-Up
Part No.: 8N-6152
S/N: S2E1-Up
Part No.: 8N-6152
S/N: S2R1-Up
Part No.: 8N-6152
S/N: S2F1-Up
Part No.: 8N-6152
S/N: S2S1-Up
Part No.: 8N-6152
S/N: S2G1-Up
Part No.: 8N-6152
S/N: S2T1-Up
Part No.: 8N-6152
S/N: MKH1-Up
Part No.: 8N-6152
S/N: S2W1-Up
Part No.: 8N-6152
S/N: S2H1-Up
Part No.: 8N-6152
S/N: S2X1-Up
186
Specifications Section
RENR5077-12
Part No.: 8N-6152
S/N: S2Y1-Up
Part No.: 8N-6152
S/N: S2Z1-Up
g03104511
Illustration 183
Table 116
Specification for 8N-6152 Engine Oil Pump Gp
Item
Qty
Part
Specification Description
The rotation of the drive gear is clockwise when you view the engine oil pump from the drive end.
Before you install the pump, lubricate the moving parts with clean engine oil. Rotate the pump by hand in order to ensure
that the pump rotates freely.
1
1
298-6387 O-Ring Seal
Before assembly, lubricate the O-ring seal lightly with 5P-3975
Rubber Lubricant.
RENR5077-12
187
Specifications Section
g03088657
Illustration 184
Table 117
Specification for 8N-6152 Engine Oil Pump Gp
Item
Qty
Part
Specification Description
Length under test force is 117.14 mm (4.612 inch).
2
1
2S-2760 Spring
Test force is 499 ± 24 N (112 ± 5 lb).
Free length after test is 152.91 mm (6.020 inch).
188
Specifications Section
RENR5077-12
g03088658
Illustration 185
Section A-A
Table 118
Specification for 8N-6152 Engine Oil Pump Gp
Item
Qty
Part
C
2
7N-5052 Gear
D
2
7W-1017 Shaft
E
2
4M-3248 Hollow Dowel
F
-
-
G
1
7W-1017 Shaft
H
-
-
J
1
7W-0050 Pump Cover
K
1
4P-5637 Oil Pump
Body As
Specification Description
Length of the new gear is 84.000 ± 0.015 mm (3.3071 ± 0.0006 inch).
Depth of the bore in the oil pump body for the new gear is
84.15 ± 0.02 mm (3.313 ± 0.001 inch).
Diameter of the new shaft is 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
Bore in the sleeve bearing for the new shaft assembly is
31.811 ± 0.013 mm (1.2524 ± 0.0005 inch).
Extension of the hollow dowel from the oil pump cover is 6.0 ± 0.5 mm
(0.24 ± 0.02 inch).
Distance from the end of the idler shaft to the gear face is
34.0 ± 0.5 mm (1.34 ± 0.02 inch).
Diameter of the new shaft is 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
Bore in the sleeve bearing for the new shaft after assembly is
31.811 ± 0.013 mm (1.2524 ± 0.0005 inch).
Distance from the end of the shaft to the gear face is 47.0 ± 0.5 mm
(1.85 ± 0.02 inch).
Installation depth of the sleeve bearing in the pump cover is
1.5 ± 0.5 mm (0.06 ± 0.02 inch).
Installation depth of the sleeve bearing in the oil pump body assembly
is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).
RENR5077-12
189
Specifications Section
g03088699
Illustration 186
Table 119
Specification for the 8N-6152 Engine Oil Pump Gp
Item
Qty
Part
L
2
7N-2043 Dowel
Illustration 187
Specification Description
Extension of hollow dowel from the oil pump cover is 6.0 ± 1.0 mm
(0.24 ± 0.04 inch).
g03106577
190
Specifications Section
RENR5077-12
g03106578
Illustration 188
Table 120
Specification for the 8N-6152 Engine Oil Pump Gp
Item
Qty
Part
Specification Description
M
-
-
Position of bearing joints from the centerline through the bearing bores
is 45 ± 15 degrees.
RENR5077-12
191
Specifications Section
i05021051
Engine Oil Pump
SMCS Code: 1304
Part No.: 378-8449
S/N: ED21-Up
Part No.: 378-8449
S/N: WF21-Up
Part No.: 378-8449
S/N: 9H31-Up
Part No.: 378-8449
S/N: ED31-Up
Part No.: 378-8449
S/N: 9H41-Up
Part No.: 378-8449
S/N: ED51-Up
Part No.: 378-8449
S/N: ED81-Up
Part No.: 378-8449
S/N: MD81-Up
Part No.: 378-8449
S/N: SRH1-Up
Part No.: 378-8449
S/N: SRK1-Up
Part No.: 378-8449
S/N: MXM1-Up
Part No.: 378-8449
S/N: SRZ1-Up
Illustration 189
g03192556
192
Specifications Section
RENR5077-12
Table 121
Specification for 378-8449 Engine Oil Pump Gp
Item
Qty
Part
Specification Description
Before you install the pump, lubricate the moving parts with clean engine oil. Rotate the pump by hand in order to ensure
that the pump rotates freely.
1
1
298-6387 O-Ring Seal
Before assembly, immediately lubricate the bore lightly with 5P-3975 Rubber
Lubricant.
g03192557
Illustration 190
Table 122
Item
Qty
Part
2
1
2S-2760 Spring
Specification Description
Length under test force is 117.14 mm (4.612 inch).
Test force is 499 ± 24 N (112 ± 5 lb).
Free length after test is 152.91 mm (6.020 inch).
RENR5077-12
193
Specifications Section
g03192558
Illustration 191
Section A-A
Table 123
Item
Qty
Part
Specification Description
3
2
7N-5052 Gear
4
2
7W-0059 Pump Shaft
Assembly
Diameter is 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
Distance (C) from the end of the idler shaft to the gear face is 34.0 ± 0.5 mm
(1.34 ± 0.02 inch).
5
1
2W-6618 Pump Drive
Shaft As
Diameter is 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
Distance (D) from the end of the shaft to the gear face is 47.0 ± 0.5 mm
(1.85 ± 0.02 inch).
Length of new gear is 84.000 ± 0.015 mm (3.3071 ± 0.0006 inch).
Depth in the oil pump body for the new gear is 84.150 ± 0.020 mm
(3.3130 ± 0.0008 inch).
194
Specifications Section
RENR5077-12
g03192559
Illustration 192
1N-4637 Pump Cover
Table 124
Item
Qty
Part
Specification Description
6
2
7N-2043 Dowel
Protrusion (E) from the pump cover is 6.0 ± 1.0 mm (0.24 ± 0.04 inch).
g03192560
Illustration 193
4P-5637 Oil Pump Body As
Table 125
Item
7
Qty
3
Part
Specification Description
7W-0060 Bushing
After assembly, bore in the bushing for the new shaft assembly is 31.811 ± 0.013 mm
(1.2524 ± 0.0005 inch).
Installation depth is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).
Position (F) of bushing joints from the centerline through the bearing bores is 45 ± 15
degrees.
RENR5077-12
195
Specifications Section
g03192561
Illustration 194
7W-0050 Pump Cover
Table 126
Item
Qty
Part
Specification Description
After assembly, bore in the bushing for the new shaft assembly is 31.811 ± 0.013 mm
(1.2524 ± 0.0005 inch).
Installation depth is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).
Position (G) of bushing joints from the centerline through the bearing bores is 45
± 15 degrees.
8
3
7W-0060 Bushing
-
-
-
Extension of 4M-3248 Hollow Dowel from the pump cover is 6.0 ± 0.5 mm
(0.24 ± 0.02 inch).
i04388550
Engine Oil Pump
SMCS Code: 1304
Part No.: 244-8985
S/N: MRG1-Up
Part No.: 244-8985
S/N: MKH1-Up
Illustration 195
g02555999
196
Specifications Section
RENR5077-12
Table 127
Specification for 244-8985 Engine Oil Pump Gp
Item
Qty
Part
Specification Description
Before you install the pump, lubricate the moving parts with clean engine oil. Rotate the pump by hand in order to ensure
that the pump rotates freely.
1
1
298-6387 O-Ring Seal
Before assembly, lightly lubricate the bore with 5P-3975 Rubber Lubricant.
g02556002
Illustration 196
Table 128
Specification for 244-8985 Engine Oil Pump Gp
Item
Qty
Part
2
1
2S-2760 Spring
Illustration 197
Section A-A
Specification Description
Length under test force is 117.14 mm (4.612 inch).
Test force is 499 ± 24 N (112.2 ± 5.4 lb).
Approximate free length after test is 152.91 mm (6.020 inch).
g02556004
RENR5077-12
197
Specifications Section
Table 129
Specification for 244-8985 Engine Oil Pump Gp
Item
Qty
Part
Specification Description
C
1
7N-5052 Gear
Length is 84.000 ± 0.015 mm (3.3071 ± 0.0006 inch).
Depth of the bore in the oil pump body for the new gear is 84.15 ± 0.02 mm
(3.313 ± 0.001 inch).
D
1
7W-1017 Shaft
Diameter is 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
After assembly, bore in the 7W-0060 Bushing for the new shaft assembly
is 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch).
E
2
4M-3248 Hollow Dowel
F
-
-
Distance from the end of the idler shaft to the gear face is 34.0 ± 0.5 mm
(1.34 ± 0.02 inch).
G
1
7N-5058 Pump Drive Shaft
Diameter is 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
After assembly, bore in the 7W-0060 Bushing for the new shaft assembly
is 31.811 ± 0.013 mm (1.2524 ± 0.0005 inch).
H
-
-
J
1
7W-0050 Pump Cover
K
1
4P-5637 Oil Pump Body As
Extension from the oil pump cover is 6.0 ± 0.5 mm (0.24 ± 0.02 inch).
Distance from the end of the shaft to the gear face is 47.0 ± 0.5 mm
(1.85 ± 0.02 inch).
Installation depth of 7W-0060 Bushing in the pump cover is 1.5 ± 0.5 mm
(0.06 ± 0.02 inch).
Installation depth of 7W-0060 Bushing in the oil pump body assembly
is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).
g02556006
Illustration 198
Table 130
Specification for 244-8985 Engine Oil Pump Gp
Item
Qty
Part
L
2
7N-2043 Dowel
Specification Description
Extension from the oil pump cover is 6.0 ± 1.0 mm (0.24 ± 0.04 inch).
198
Specifications Section
RENR5077-12
g02556007
Illustration 199
Table 131
Specification for 244-8985 Engine Oil Pump Gp
Item
Qty
Part
Specification Description
M
-
-
Position of 7W-0060 Bushing joints from the centerline through the bearing
bores is 45 ± 15 degrees.
-
Bench test specifications:
Unrestricted flow rate at 700 rpm is 220 L/min (58 US gpm).
Pump pressure at 300 rpm with fully blocked outlet is 710 to 770 kPa
(105 to 110 psi).
-
-
RENR5077-12
199
Specifications Section
i04405416
Engine Oil Scavenge Pump
SMCS Code: 1312
Part No.: 8N-9164
S/N: M8A1-Up
Part No.: 8N-9164
S/N: M8B1-Up
Illustration 200
NOTICE
Before operation, the pump must be lubricated with
clean engine oil and the pump must turn freely by hand
or damage to parts can be the result.
g01471861
200
Specifications Section
RENR5077-12
Table 132
Specification for 8N-9164 Engine Oil Scavenge Pump
Item
Qty
Part
Specification Description
Length is 84.000 ± 0.015 mm (3.3071 ± 0.0006 inch).
A
1
7N-5052 Gear
B
1
161-2509 Drive Shaft
C
-
-
D
1
1W-6005 Bushing
Depth of the bore in the scavenge oil body for the new gear is
84.150 ± 0.020 mm (3.3130 ± 0.0008 inch).
Diameter is 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
Bore in the bushing for new drive shaft before installation is 31.837 ± 0.070 mm
(1.2534 ± 0.0028 inch).
Distance from the end of the idler shaft assembly to the gear face is
34.0 ± 0.5 mm (1.34 ± 0.02 inch).
Installation depth in the 2W-6895 Scavenge Pump Body is 1.5 ± 0.5 mm
(0.06 ± 0.02 inch).
Diameter is 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
E
1
7W-1017 Shaft
Bore in the bushing for new idler shaft before installation is 31.837 ± 0.070 mm
(1.2534 ± 0.0028 inch).
Use the following procedure in order to tighten the bolt:
Before installing the drive gear onto the drive shaft assembly, clean the shaft
and clean the bore of the gear.
1
1
0S-0484 Bolt
1. Tap on the drive gear in order to seat the taper of the drive gear.
2. Tighten the bolt to 100 ± 20 N·m (75 ± 15 lb ft).
3. Repeat this procedure until the torque does not change.
g02596558
Illustration 201
Table 133
Specification for 8N-9164 Engine Oil Scavenge Pump
Item
Qty
Part
F
-
-
G
2
4M-3248 Hollow Dowel
H
2
1W-6005 Bushing
Specification Description
Position of bushing joints from the centerline through the bearing bores is
45 ± 15 degrees.
Extension of hollow dowels is 6.4 ± 0.5 mm (0.25 ± 0.02 inch).
Installation depth of the bushing in the 7N-8814 Scavenge Pump Cover is
1.5 ± 0.5 mm (0.06 ± 0.02 inch).
RENR5077-12
201
Specifications Section
i04389412
Engine Oil Scavenge Pump
SMCS Code: 1312
Part No.: 1W-8508
S/N: WF21-Up
Part No.: 1W-8508
S/N: 9H31-Up
Part No.: 1W-8508
S/N: 9H41-Up
Part No.: 1W-8508
S/N: ED51-Up
Part No.: 1W-8508
S/N: ED81-Up
Part No.: 1W-8508
S/N: SRZ1-Up
Illustration 202
Bottom view of engine
g01460015
202
Specifications Section
Illustration 203
RENR5077-12
g02557256
Section A-A
NOTICE
Before operation, the pump must be lubricated with
clean engine oil and the pump must turn freely by hand
or damage to parts can be the result.
Illustration 204
g02557257
RENR5077-12
203
Specifications Section
Table 134
Specification for 1W-8508 Scavenge Pump
Item
Qty
part
1
2
3P-0657 O-Ring Seal
Before assembly, lightly lubricate the bore with clean engine oil.
B
1
1W-8515 Gear
Length is 110.000 ± 0.015 mm (4.3307 ± 0.0006 inch).
Depth of the bore in the scavenge oil body for the new gear is
110.15 ± 0.02 mm (4.337 ± 0.001 inch).
C
1
161-2510 Drive Shaft
Diameter is 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
After assembly, bore of 1W-6005 Bushing for the new drive shaft is
31.837 ± 0.070 mm (1.2534 ± 0.0028 inch).
D
1
1W-8509 Scavenge
Oil Body
Installation depth of 1W-6005 Bushing in the scavenge oil body is
1.5 ± 0.5 mm (0.06 ± 0.02 inch).
E
1
1W-8511 Idler Shaft
Assembly
Distance from the end of the idler shaft assembly to the gear face is
34.0 ± 0.5 mm (1.34 ± 0.02 inch).
F
1
106-9865 Idler Shaft
Diameter shaft is 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
Bore in the 1W-6005 Bushing for the new idler shaft is 31.837 ± 0.070 mm
(1.2534 ± 0.0028 inch).
Specification Description
Use the following procedure in order to tighten the bolt:
Before installing the drive gear onto the drive shaft assembly, clean the
shaft and clean the bore of the gear.
1. Tap on the drive gear in order to seat the taper of the drive gear.
2. Tighten the bolt to 100 ± 20 N·m (75 ± 15 lb ft).
3. Repeat this procedure until the torque does not change.
2
1
0S-0484 Bolt
G
-
-
H
2
1W-6005 Bushing
Installation depth in the 7N-8527 Pump Cover is 1.5 ± 0.5 mm
(0.06 ± 0.02 inch).
J
2
4M-3248 Hollow Dowel
Extension of the hollow dowel is 6.4 ± 0.5 mm (0.25 ± 0.02 inch).
Position of the bushing joints from the centerline through the bearing
bores is 45 ± 15 degrees.
204
Specifications Section
RENR5077-12
i04389427
Engine Oil Cooler Bypass and
Cooling Jet Sequence Valves
SMCS Code: 1314; 1331
Part No.: 335-3155
S/N: 9H41-Up
Part No.: 335-3155
S/N: 9H61-Up
Part No.: 335-3155
S/N: ED81-Up
Part No.: 335-3154, 335-3155
S/N: M8A1-Up
Part No.: 335-3154, 335-3155
S/N: M8B1-Up
Part No.: 335-3155
S/N: EDG1-Up
Illustration 205
Typical example
Top rear view
g02840977
RENR5077-12
205
Specifications Section
Table 135
Specification for 335-3154 Engine Oil Lines Gp and 335-3155 Engine Oil Lines Gp
Item
Qty
Part
1
2
109-2332 O-Ring Seal
2
1
2W-1053 Plug
3
1
2W-1969 Bypass Valve
Specification Description
Before assembly, lightly lubricate the bore with clean engine oil.
Torque to 100 ± 15 N·m (74 ± 11 lb ft).
Valve must open with a pressure difference of 180 ± 20 kPa (26 ± 3 psi).
Length under test force is 102.0 mm (4.02 inch).
4
2W-1635 Spring
1
Test force is 518 ± 26 N (116 ± 6 lb).
Free length after test is 143.4 mm (5.65 inch).
5
2
7N-7697 Plunger
Valves must start to open at a pressure difference of 130 ± 30 kPa (19 ± 4 psi).
Valves must be fully open at a pressure difference of 200 ± 30 kPa (29 ± 4 psi).
Length under test force is 68.3 mm (2.69 inch).
6
2
6B-9202 Spring
Test force is 85 to 100 N (19.0 to 22.4 lb).
Free length after test is 112.7 mm (4.44 inch).
i03139927
Engine Oil Cooler Bypass and
Cooling Jet Sequence Valves
SMCS Code: 1314; 1331
Part No.: 115-7860
S/N: S2A1-Up
Part No.: 115-7860
S/N: S2B1-Up
Part No.: 115-7860
S/N: S2D1-Up
Part No.: 115-7860
S/N: S2E1-Up
Part No.: 115-7860
S/N: S2F1-Up
Part No.: 115-7860
S/N: B5G1-Up
Part No.: 115-7860
S/N: MRG1-Up
Part No.: 115-7860
S/N: PAG1-Up
Part No.: 115-7860
S/N: S2G1-Up
Part No.: 115-7860
S/N: MKH1-Up
Part No.: 115-7860
S/N: S2H1-Up
Part No.: 115-7860
S/N: S2J1-Up
Part No.: 115-7860
S/N: S2K1-Up
Part No.: 115-7860
S/N: S2L1-Up
Part No.: 115-7860
S/N: S2M1-Up
Part No.: 115-7860
S/N: S2N1-Up
Part No.: 115-7860
S/N: S2P1-Up
Part No.: 115-7860
S/N: S2R1-Up
Part No.: 115-7860
S/N: S2S1-Up
Part No.: 115-7860
S/N: S2T1-Up
Part No.: 115-7860
S/N: S2W1-Up
Part No.: 115-7860
S/N: S2X1-Up
Part No.: 115-7860
S/N: S2Y1-Up
Part No.: 115-7860
S/N: S2Z1-Up
206
Specifications Section
RENR5077-12
g01616336
Illustration 206
Right side view
Typical example
Note: The cooling jet sequence valves must start
to open at a pressure difference of 130 ± 30 kPa
(19.0 ± 4.5 psi).
Note: The cooling jet sequence valves must be
fully open at a pressure difference of 200 ± 30 kPa
(29.0 ± 4.5 psi).
(5) 6B-9202 Spring for the cooling jet sequence
valve
Quantity ............................................................ 2
Length under test force ....... 68.3 mm (2.69 inch)
Test force ..................... 85 to 102 N (19 to 23 lb)
Free length after test ......... 112.7 mm (4.44 inch)
Outside diameter ............ 24.60 mm (0.969 inch)
Note: The oil cooler bypass valve must open with a
pressure difference of 180 ± 20 kPa (26 ± 3 psi).
(6) 2W-1635 Spring for oil cooler bypass valve
Illustration 207
g01616353
Front view
Typical example
Use the following tightening sequence for the clamp
bolts:
1. Snugly tighten the clamp assembly (3) to the tube
(4).
2. Tighten two bolts (2) of the clamp assembly to the
elbow (10) to 47 ± 9 N·m (35 ± 7 lb ft).
3. Tighten two bolts (1) of the clamp assembly to the
tube (4) to 47 ± 9 N·m (35 ± 7 lb ft).
Length under test force ..... 102.0 mm (4.02 inch)
Test force .................. 518 ± 26 N (115.0 ± 5.8 lb)
Free length after test ........ 143.4 mm (5.65 inch)
Outside diameter ........ 37.251 mm (1.4666 inch)
(7) Lubricate the bore of the O-ring seals lightly with
the clean engine oil.
(8) Lubricate the bore of two O-ring plugs lightly with
the clean engine oil.
(9) Torque for the plug ... 100 ± 15 N·m (75 ± 11 lb ft)
RENR5077-12
207
Specifications Section
i04390177
Engine Oil Filter
Part No.: 112-4921
S/N: S2T1-Up
SMCS Code: 1318
Part No.: 112-4921
S/N: S2W1-Up
Part No.: 112-4921
S/N: M8A1-Up
Part No.: 112-4921
S/N: S2X1-Up
Part No.: 112-4921
S/N: S2A1-Up
Part No.: 112-4921
S/N: S2Y1-Up
Part No.: 112-4921
S/N: M8B1-Up
Part No.: 112-4921
S/N: S2Z1-Up
Part No.: 112-4921
S/N: S2B1-Up
Part No.: 112-4921
S/N: S2D1-Up
Part No.: 112-4921
S/N: S2E1-Up
Part No.: 112-4921
S/N: S2F1-Up
Part No.: 112-4921
S/N: B5G1-Up
Part No.: 112-4921
S/N: MRG1-Up
Part No.: 112-4921
S/N: PAG1-Up
Part No.: 112-4921
S/N: S2G1-Up
Part No.: 112-4921
S/N: MKH1-Up
Part No.: 112-4921
S/N: S2H1-Up
Part No.: 112-4921
S/N: S2J1-Up
Part No.: 112-4921
S/N: S2K1-Up
Part No.: 112-4921
S/N: S2L1-Up
Part No.: 112-4921
S/N: S2M1-Up
Part No.: 112-4921
S/N: S2N1-Up
Part No.: 112-4921
S/N: S2P1-Up
Part No.: 112-4921
S/N: S2R1-Up
Part No.: 112-4921
S/N: S2S1-Up
208
Specifications Section
Illustration 208
Front view
RENR5077-12
g02632117
RENR5077-12
209
Specifications Section
Table 136
Specification for 112-4921 Engine Oil Filter Gp
Item
Qty
Part
1
6
6V-5048 O-Ring Seal
2
1
2W-1635 Spring
3
1
2W-1969 Bypass Valve
4
3
165-3931 Bolt
5
2
0T-0573 Bolt
Specification Description
Lubricate the bore of the O-ring seals lightly with clean engine oil.
Length under test force is 102.0 mm (4.02 inch).
Test force is 518 ± 26 N (116 ± 6 lb).
Free length after test is 143.4 mm (5.65 inch).
The bypass valve must move freely in the bore.
Start to open pressure is 287 ± 7 kPa (41.6 ± 1.0 psi).
Fully open pressure is 480 ± 7 kPa (69.6 ± 1.0 psi).
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
i04390193
Engine Oil Filter
Part No.: 242-6278
S/N: S2H1-Up
SMCS Code: 1318
Part No.: 242-6278
S/N: S2J1-Up
Part No.: 242-6278
S/N: GS61-Up
Part No.: 242-6278
S/N: S2K1-Up
Part No.: 242-6278
S/N: GS71-Up
Part No.: 242-6278
S/N: S2L1-Up
Part No.: 242-6278
S/N: GSA1-Up
Part No.: 242-6278
S/N: S2M1-Up
Part No.: 242-6278
S/N: M8A1-Up
Part No.: 242-6278
S/N: S2N1-Up
Part No.: 242-6278
S/N: S2A1-Up
Part No.: 242-6278
S/N: S2P1-Up
Part No.: 242-6278
S/N: M8B1-Up
Part No.: 242-6278
S/N: S2R1-Up
Part No.: 242-6278
S/N: S2B1-Up
Part No.: 242-6278
S/N: S2S1-Up
Part No.: 242-6278
S/N: S2D1-Up
Part No.: 242-6278
S/N: S2T1-Up
Part No.: 242-6278
S/N: S2E1-Up
Part No.: 242-6278
S/N: S2W1-Up
Part No.: 242-6278
S/N: S2F1-Up
Part No.: 242-6278
S/N: S2X1-Up
Part No.: 242-6278
S/N: B5G1-Up
Part No.: 242-6278
S/N: S2Y1-Up
Part No.: 242-6278
S/N: MRG1-Up
Part No.: 242-6278
S/N: S2Z1-Up
Part No.: 242-6278
S/N: PAG1-Up
Part No.: 242-6278
S/N: S2G1-Up
Part No.: 242-6278
S/N: MKH1-Up
210
Specifications Section
Illustration 209
RENR5077-12
g02841297
Typical example
Front view
Illustration 210
Left side view
g02559976
RENR5077-12
211
Specifications Section
Table 137
Specification for 115-7841 Engine Oil Filter Gp and 242-6278 Engine Oil Filter Gp
Item
Qty
Part
1
-
-
2
1
2W-1969 Bypass Valve
3
1
2W-1635 Spring
4
2
264-0450 Clamp As
5
2
100-8075 Clamp As
6
3
165-3931 Bolt
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
7
3
0L-1143 Bolt
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
Specification Description
Before assembly, lightly lubricate the bore with clean engine oil.
The bypass valve must move freely in the bore.
Start to open pressure is 287 ± 7 kPa (42 ± 1 psi).
Fully open pressure is 480 ± 7 kPa (70 ± 1 psi).
Length under test force is 102.0 mm (4.02 inch).
Test force is 518 ± 26 N (116 ± 6 lb).
Free length after test is 143.4 mm (5.65 inch).
Use the following tightening sequence for the clamp assembly:
1. Snugly tighten the clamp assembly to the tube.
2. Tighten the bolts of the clamp assembly to the elbow to 47 ± 9 N·m
(35 ± 7 lb ft).
3. Tighten the bolts of the clamp assembly to the tube to 47 ± 9 N·m
(35 ± 7 lb ft).
i03742181
Engine Oil Filter
Part No.: 115-7841, 4W-6874
S/N: S2R1-Up
SMCS Code: 1318
Part No.: 115-7841, 4W-6874
S/N: S2S1-Up
Part No.: 115-7841, 4W-6874
S/N: S2A1-Up
Part No.: 115-7841, 4W-6874
S/N: S2T1-Up
Part No.: 115-7841, 4W-6874
S/N: S2B1-Up
Part No.: 115-7841, 4W-6874
S/N: S2W1-Up
Part No.: 115-7841, 4W-6874
S/N: S2D1-Up
Part No.: 115-7841, 4W-6874
S/N: S2X1-Up
Part No.: 115-7841, 4W-6874
S/N: S2E1-Up
Part No.: 115-7841, 4W-6874
S/N: S2Y1-Up
Part No.: 115-7841, 4W-6874
S/N: S2F1-Up
Part No.: 115-7841, 147-3172, 4W-6874
S/N: S2Z1-Up
Part No.: 115-7841, 4W-6874
S/N: S2G1-Up
Part No.: 115-7841, 4W-6874
S/N: S2H1-Up
Part No.: 115-7841, 4W-6874
S/N: S2J1-Up
Part No.: 115-7841, 4W-6874
S/N: S2K1-Up
Part No.: 115-7841, 4W-6874
S/N: S2L1-Up
Part No.: 115-7841, 4W-6874
S/N: S2M1-Up
Part No.: 115-7841, 4W-6874
S/N: S2N1-Up
Part No.: 115-7841, 4W-6874
S/N: S2P1-Up
212
Specifications Section
Illustration 211
Front view
(1) Lubricate the bore of the O-ring seals lightly with
clean engine oil.
(2) Torque for the bolts ........ 55 ± 7 N·m (41 ± 5 lb ft)
(3) 2W-1635 Spring
Length under test force ..... 102.0 mm (4.02 inch)
Test force ........................ 518 ± 26 N (117 ± 6 lb)
Free length after test force ................. 143.4 mm
(5.65 inch)
Outside diameter ........ 37.251 mm (1.4666 inch)
Note: Bypass valve (4) must move freely in the bore.
(4) Bypass valve
Start to open pressure: .. 287 ± 7 kPa (42 ± 1 psi)
Fully open pressure: ..... 480 ± 7 kPa (70 ± 1 psi)
RENR5077-12
g01417897
RENR5077-12
213
Specifications Section
i04887937
Engine Oil Filter
SMCS Code: 1318
Part No.: 381-2071
S/N: CG21-Up
Part No.: 381-2071
S/N: 9H41-Up
Part No.: 381-2071
S/N: 9H61-Up
Part No.: 381-2071
S/N: ED81-Up
Part No.: 381-2071
S/N: MD81-Up
Part No.: 381-2071
S/N: EDG1-Up
Part No.: 381-2071
S/N: MXM1-Up
Part No.: 381-2071
S/N: MXR1-Up
Illustration 212
Front view
g03013140
214
Specifications Section
RENR5077-12
Table 138
Specification for 381-2071 Engine Oil Filter Gp
Item
Qty
Part
1
3
0L-1143 Bolt
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
2
3
165-3931 Bolt
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
3
1
2W-1969 Bypass Valve
The bypass valve must move freely in the bore.
4
1
2W-1635 Spring
Length under test force is 102.0 mm (4.02 inch).
Test force is 518 ± 26 N (116 ± 6 lb).
Free length after test is 143.4 mm (5.65 inch).
Specification Description
i04907897
Engine Oil Filter
SMCS Code: 1318
Part No.: 375-7427
S/N: CG21-Up
Part No.: 375-7427
S/N: MD81-Up
Part No.: 375-7427
S/N: MXM1-Up
Part No.: 375-7427
S/N: MXR1-Up
Illustration 213
Front view
g03073971
RENR5077-12
215
Specifications Section
Table 139
Specification for 375-7427 Engine Oil Filter Gp
Item
Qty
Part
1
4
6V-5048 O-Ring Seal
2
1
2W-1635 Spring
3
1
2W-1969 Bypass Valve
4
3
165-3931 Bolt
5
3
0T-0573 Bolt
Specification Description
Lubricate the bore of the O-ring seals lightly with clean engine oil.
Length under test force is 102.0 mm (4.02 inch).
Test force is 518 ± 26 N (116 ± 6 lb).
Free length after test is 143.4 mm (5.65 inch).
The bypass valve must move freely in the bore.
Start to open pressure is 287 ± 7 kPa (41.6 ± 1.0 psi).
Fully open pressure is 480 ± 7 kPa (69.6 ± 1.0 psi).
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
i05038071
Engine Oil Filter
(Duplex)
SMCS Code: 1318
Part No.: 383-9787
S/N: 9F31-Up
Part No.: 383-9787
S/N: EDJ1-Up
Illustration 214
g03208376
216
Specifications Section
RENR5077-12
g03208377
Illustration 215
Right side view
Table 140
Specification for 383-9787 Engine Oil Filter Gp
Item
Qty
Part
Specification Description
1
6
6V-5048 O-Ring Seal
Before assembly, lubricate the bore lightly with clean engine oil.
2
4
5P-4892 O-Ring Seal
Before assembly, lubricate the bore lightly with clean engine oil.
3
3
0T-0573 Bolt
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
4
3
165-3931 Bolt
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
5
1
2W-1635 Spring
Length under test force is 102.0 mm (4.02 inch).
Test force is 518 ± 26 N (116 ± 6 lb).
Free length after test is 143.4 mm (5.65 inch).
6
1
2W-1969 Bypass Valve
The bypass valve must move freely in the bore.
Start to open pressure is 287 ± 7 kPa (41.6 ± 1.0 psi).
Fully open pressure is 480 ± 7 kPa (69.6 ± 1.0 psi).
RENR5077-12
217
Specifications Section
i03686744
Engine Oil Lines
i01906041
Engine Oil Lines
(Front Mounted Engine Oil
Filter)
SMCS Code: 1307
Part No.: 335-3157
S/N: M8A1-Up
SMCS Code: 1307
Part No.: 335-3157
S/N: M8B1-Up
Part No.: 242-6279
S/N: M8A1-Up
Part No.: 107-7180, 242-6279
S/N: S2A1-Up
Part No.: 242-6279
S/N: M8B1-Up
Part No.: 107-7180, 242-6279
S/N: S2B1-Up
Part No.: 107-7180, 242-6279
S/N: S2D1-Up
Part No.: 107-7180, 242-6279
S/N: S2E1-Up
Part No.: 107-7180, 242-6279
S/N: S2F1-Up
Part No.: 107-7180, 242-6279
S/N: B5G1-Up
Part No.: 107-7180, 242-6279
S/N: MRG1-Up
Part No.: 107-7180, 242-6279
S/N: PAG1-Up
Part No.: 107-7180, 242-6279
S/N: S2G1-Up
Illustration 216
g01982333
Typical example
Part No.: 107-7180, 242-6279
S/N: MKH1-Up
(1) Lubricate the bore of the O-ring seals lightly with
the clean engine oil.
Part No.: 107-7180, 242-6279
S/N: S2H1-Up
Use the following tightening sequence to tighten the
bolts of the clamp assembly (2):
Part No.: 107-7180, 242-6279
S/N: S2J1-Up
1. Snugly tighten the clamp assembly to the tube .
Part No.: 107-7180, 242-6279
S/N: S2K1-Up
2. Tighten the bolts of the clamp assembly to the
elbow to 47 ± 9 N·m (35 ± 7 lb ft).
Part No.: 107-7180, 242-6279
S/N: S2L1-Up
3. Tighten the bolts of the clamp assembly to the
tube to 47 ± 9 N·m (35 ± 7 lb ft).
Part No.: 107-7180, 242-6279
S/N: S2M1-Up
Part No.: 107-7180, 242-6279
S/N: S2N1-Up
Part No.: 107-7180, 242-6279
S/N: S2P1-Up
Part No.: 107-7180, 242-6279
S/N: S2R1-Up
218
Specifications Section
RENR5077-12
Part No.: 107-7180, 242-6279
S/N: S2S1-Up
(1) Clamp bolts
Torque ............................ 47 ± 9 N·m (35 ± 7 lb ft)
Part No.: 107-7180, 242-6279
S/N: S2T1-Up
Tightening sequence for the clamp bolts
Part No.: 107-7180, 242-6279
S/N: S2W1-Up
1. Snugly tighten the clamp assembly to the tube.
Part No.: 107-7180, 242-6279
S/N: S2X1-Up
2. Tighten the clamp assembly to the elbow.
3. Tighten the clamp assembly to the tube.
Part No.: 107-7180, 242-6279
S/N: S2Y1-Up
(2) O-rings
Part No.: 107-7180, 242-6279
S/N: S2Z1-Up
Lubricate the O-rings with clean engine oil prior to
assembly.
Illustration 217
g00992667
Right side view
Illustration 218
Front view (typical example)
g00992788
RENR5077-12
219
Specifications Section
i04778397
Engine Oil Lines
SMCS Code: 1307
Part No.: 381-1327
S/N: 9H41-Up
Part No.: 381-1327
S/N: 9H61-Up
Part No.: 381-1327
S/N: ED81-Up
Part No.: 381-1327
S/N: MD81-Up
Part No.: 381-1327
S/N: EDG1-Up
Part No.: 381-1327
S/N: MXM1-Up
Illustration 219
Front View
g02986419
220
Specifications Section
RENR5077-12
Table 141
Specification for 381-1327 Engine Oil Lines Gp
Item
Qty
Part
1
1
2W-1053 Plug
2
1
2W-1969 Bypass Valve
Specification Description
Torque to 100 ± 15 N·m (74 ± 11 lb ft).
Valve must open with a pressure difference of 180 ± 20 kPa
(26 ± 3 psi).
Length under test force is 102.0 mm (4.02 inch).
3
2W-1635 Spring
1
Test force is 518 ± 26 N (116 ± 6 lb).
Free length after test is 143.4 mm (5.65 inch).
g02986420
Illustration 220
Right side view
Table 142
Specification for 381-1327 Engine Oil Lines Gp
Item
4
Qty
2
Part
7N-7697 Plunger
Specification Description
Valves must start to open at a pressure difference of 130 ± 30 kPa
(19 ± 4 psi) .
Valves must be fully open at a pressure difference of 200 ± 30 kPa
(29 ± 4 psi).
Length under test force is 68.3 mm (2.69 inch).
5
2
6B-9202 Spring
Test force is 84.5 to 99.6 N (19.0 to 22.4 lb).
Free length after test is 112.7 mm (4.44 inch).
i05166886
Engine Oil Lines
SMCS Code: 1307
Part No.: 381-2072
S/N: CG21-Up
Part No.: 381-2072
S/N: 9H41-Up
RENR5077-12
221
Specifications Section
Part No.: 381-2072
S/N: 9H61-Up
Part No.: 381-2072
S/N: ED81-Up
Part No.: 381-2072
S/N: MD81-Up
Part No.: 381-2072
S/N: EDG1-Up
Part No.: 381-2072
S/N: MXM1-Up
Part No.: 381-2072
S/N: MXR1-Up
Illustration 221
g03318710
222
Specifications Section
RENR5077-12
Table 143
Specification for 381-2072 Engine Oil Lines Gp
Item
Qty
Part
1
4
0S-1571 Bolt
2
4
0S-1594 Bolt
3
4
109-2332 O-Ring Seal
Specification Description
Use the following tightening sequence in order to tighten the clamp bolts:
1. Snug the clamp assembly to the tube assembly
2. Tighten the clamp assembly to the elbow with mating group.
3. Then, tighten the clamp assembly to the tube assembly.
Lightly, lubricate the bore with the fluid that is being sealed.
i05166869
Engine Oil Lines
SMCS Code: 1307
Part No.: 381-1326
S/N: CG21-Up
Part No.: 381-1326
S/N: MD81-Up
Part No.: 381-1326
S/N: MXM1-Up
Part No.: 381-1326
S/N: MXR1-Up
Illustration 222
g03318690
RENR5077-12
223
Specifications Section
Table 144
Specification for 381-1326 Engine Oil Lines Gp
Item
Qty
Part
1
4
109-2332 O-Ring Seal
2
2
0S-1571 Bolt
3
2
0S-1594 Bolt
Specification Description
Lightly, lubricate the bore with the fluid that is being sealed.
Use the following tightening sequence in order to tighten the clamp bolts:
1. Snug the clamp assembly to the tube assembly.
2. Tighten the clamp assembly to the elbow within mating group.
3. Then, tighten the clamp assembly to the tube assembly..
224
Specifications Section
RENR5077-12
i05167541
Engine Oil Lines
SMCS Code: 1307
Part No.: 381-7041
S/N: CG21-Up
Part No.: 381-7041
S/N: 9H61-Up
Part No.: 381-7041
S/N: EDG1-Up
Part No.: 381-7041
S/N: MXR1-Up
Illustration 223
g03319161
RENR5077-12
225
Specifications Section
Table 145
Specification for 381-7041 Engine Oil Lines Gp
Item
Qty
Part
1
1
2W-1969 Bypass Valve
Specification Description
Valve must open with a pressure difference of 180 ± 20 kPa (26 ± 3 psi).
Length under test force is 102.0 mm (4.02 inch).
2
1
2W-1635 Spring
Test force is 518 ± 26 N (116 ± 6 lb).
Free length after test is 143.4 mm (5.65 inch).
3
1
2W-1053 Plug
4
2
7N-7697 Plunger
Torque to 100 ± 15 N·m (74 ± 11 lb ft).
Valves must start to open at a pressure difference of 130 ± 30 kPa (19 ± 4 psi).
Valves must be fully open at 200 ± 30 kPa (29 ± 4 psi).
Length under test force is 68.3 mm (2.69 inch).
5
2
6B-9202 Spring
Test force is 85 to 100 N (19.0 to 22.4 lb).
Free length after test is 112.7 mm (4.44 inch).
i04390217
Duplex Engine Oil Filters
Part No.: 120-4501
S/N: MKH1-Up
SMCS Code: 1318
Part No.: 120-4501
S/N: S2H1-Up
Part No.: 120-4501
S/N: GS61-Up
Part No.: 120-4501
S/N: S2J1-Up
Part No.: 120-4501
S/N: GS71-Up
Part No.: 120-4501
S/N: S2K1-Up
Part No.: 120-4501
S/N: GSA1-Up
Part No.: 120-4501
S/N: S2L1-Up
Part No.: 120-4501
S/N: M8A1-Up
Part No.: 120-4501
S/N: S2M1-Up
Part No.: 120-4501
S/N: S2A1-Up
Part No.: 120-4501
S/N: S2N1-Up
Part No.: 120-4501
S/N: M8B1-Up
Part No.: 120-4501
S/N: S2P1-Up
Part No.: 120-4501
S/N: S2B1-Up
Part No.: 120-4501
S/N: S2R1-Up
Part No.: 120-4501
S/N: S2D1-Up
Part No.: 120-4501
S/N: S2S1-Up
Part No.: 120-4501
S/N: S2E1-Up
Part No.: 120-4501
S/N: S2T1-Up
Part No.: 120-4501
S/N: S2F1-Up
Part No.: 120-4501
S/N: S2W1-Up
Part No.: 120-4501
S/N: B5G1-Up
Part No.: 120-4501
S/N: S2X1-Up
Part No.: 120-4501
S/N: MRG1-Up
Part No.: 120-4501
S/N: S2Y1-Up
Part No.: 120-4501
S/N: PAG1-Up
Part No.: 120-4501, 4W-9968
S/N: S2Z1-Up
Part No.: 120-4501
S/N: S2G1-Up
226
Specifications Section
RENR5077-12
g02638956
Illustration 224
Front view
(3) Lever
(5) Tie rod
(6) Ball plunger assembly
(7) Bracket
(15) Cover
Table 146
Specification for 120-4501 Engine Oil Filter Gp and 4W-9968 Engine Oil Filter Gp
Item
Qty
Part
1
6
6V-5048 O-Ring Seal
2
4
5P-4892 O-Ring Seal
4
3
0T-0573 Bolt
Specification Description
Lubricate the bore of the O-ring seals lightly with clean engine oil.
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
Refer to Testing and Adjusting, “Duplex Oil Filter - Adjust” for correct adjustment procedures of the fluid control valve group (8).
9
1
2W-1635 Spring
10
1
2W-1969 Bypass Valve
11
1
5H-7225 Retainer Nut
12
1
3B-7329 Nut
13
1
9M-2610 O-Ring Seal
14
3
165-3931 Bolt
Length under test force is 102.0 mm (4.02 inch).
Test force is 518 ± 26 N (116 ± 6 lb).
Free length after test is 143.4 mm (5.65 inch).
The bypass valve must move freely in the bore.
Start to open pressure is 287 ± 7 kPa (41.6 ± 1.0 psi).
Fully open pressure is 480 ± 7 kPa (69.6 ± 1.0 psi).
Torque to 45 ± 7 N·m (33 ± 5 lb ft).
Lubricate the bore of the O-ring seals lightly with clean engine oil.
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
RENR5077-12
227
Specifications Section
i04451849
Duplex Engine Oil Filters
SMCS Code: 1318
Part No.: 378-0546
S/N: CG21-Up
Part No.: 378-0546
S/N: 9H41-Up
Part No.: 378-0546
S/N: 9H61-Up
Part No.: 378-0546
S/N: ED81-Up
Part No.: 378-0546
S/N: MD81-Up
Part No.: 378-0546
S/N: EDG1-Up
Part No.: 378-0546
S/N: MXM1-Up
Part No.: 378-0546
S/N: MXR1-Up
Illustration 225
g02638938
228
Specifications Section
RENR5077-12
Table 147
Specification for 378-0546 Engine Oil Filter Gp
Item
Qty
Part
1
3
165-3931 Bolt
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
2
3
0T-0573 Bolt
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
3
1
2W-1635 Spring
4
1
2W-1969 Bypass Valve
Specification Description
Length under test force is 102.0 mm (4.02inch).
Test force is 518 ± 26 N (116 ± 6 lb).
Free length after test is 143.4 mm (5.65 inch).
The bypass valve must move freely in the bore.
Start to open pressure is 287 ± 7 kPa (42 ± 1 psi).
Fully open pressure is 480 ± 7 kPa (70 ± 1 psi).
g02639056
Illustration 226
(5) 7W-3816 Fluid Control Valve Group
Table 148
Specification for 378-0546 Engine Oil Filter Gp
Item
Qty
Part
Specification Description
6
1
5H-7225 Retainer Nut
Torque to 45 ± 7 N·m (33 ± 5 lb ft).
7
1
3B-7329 Nut
Torque to 45 ± 7 N·m (33 ± 5 lb ft).
8
1
6V-5048 O-Ring Seal
Before assembly, lubricate the bore with clean engine oil.
9
1
9M-2610 O-Ring Seal
Before assembly, lubricate the bore with clean engine oil.
i04390223
Engine Oil Filter Base
Part No.: 151-9270, 8N-2001
S/N: M8B1-Up
SMCS Code: 1306
Part No.: 151-9270, 8N-2001
S/N: S2B1-Up
Part No.: 151-9270
S/N: WF21-Up
Part No.: 151-9270, 8N-2001
S/N: S2D1-Up
Part No.: 151-9270, 8N-2001
S/N: M8A1-Up
Part No.: 151-9270, 8N-2001
S/N: S2E1-Up
Part No.: 151-9270, 8N-2001
S/N: S2A1-Up
Part No.: 151-9270, 8N-2001
S/N: S2F1-Up
RENR5077-12
Part No.: 151-9270, 8N-2001
S/N: B5G1-Up
Part No.: 151-9270, 8N-2001
S/N: MRG1-Up
Part No.: 151-9270, 8N-2001
S/N: PAG1-Up
Part No.: 151-9270, 8N-2001
S/N: S2G1-Up
Part No.: 151-9270, 8N-2001
S/N: MKH1-Up
Part No.: 151-9270, 8N-2001
S/N: S2H1-Up
Part No.: 151-9270, 8N-2001
S/N: S2J1-Up
Part No.: 151-9270, 8N-2001
S/N: S2K1-Up
Part No.: 151-9270, 8N-2001
S/N: S2L1-Up
Part No.: 151-9270, 8N-2001
S/N: S2M1-Up
Part No.: 151-9270, 8N-2001
S/N: S2N1-Up
Part No.: 151-9270, 8N-2001
S/N: S2P1-Up
Part No.: 151-9270, 8N-2001
S/N: S2R1-Up
Part No.: 151-9270, 8N-2001
S/N: S2S1-Up
Part No.: 151-9270, 8N-2001
S/N: S2T1-Up
Part No.: 151-9270, 8N-2001
S/N: S2W1-Up
Part No.: 151-9270, 8N-2001
S/N: S2X1-Up
Part No.: 151-9270, 8N-2001
S/N: S2Y1-Up
Part No.: 151-9270, 8N-2001
S/N: S2Z1-Up
Part No.: 151-9270, 8N-2001
S/N: SRZ1-Up
229
Specifications Section
230
Specifications Section
RENR5077-12
g02560136
Illustration 227
Typical example
Table 149
Specification for 151-9270 Oil Filter Base As and 8N-2001 Oil Filter Base As
Item
Qty
Part
Specification Description
A
-
-
Apply Loctite 271 on the tapered end of the hollow stud to a distance
of 10.2 ± 1.5 mm (0.40 ± 0.06 inch).
1
1
2P-4304 Hollow Stud
Torque to 80 ± 14 N·m (59 ± 10 lb ft).
i04896383
Crankcase Breather
Part No.: 124-5513
S/N: S2G1-Up
SMCS Code: 1317
Part No.: 124-5513
S/N: MKH1-Up
Part No.: 247-4696
S/N: GSA1-Up
Part No.: 124-5513
S/N: S2H1-Up
Part No.: 124-5513
S/N: S2A1-Up
Part No.: 124-5513
S/N: S2J1-Up
Part No.: 124-5513
S/N: S2B1-Up
Part No.: 124-5513
S/N: S2K1-Up
Part No.: 124-5513
S/N: S2D1-Up
Part No.: 124-5513
S/N: S2L1-Up
Part No.: 124-5513
S/N: S2E1-Up
Part No.: 124-5513
S/N: S2N1-Up
Part No.: 124-5513
S/N: B5G1-Up
Part No.: 124-5513, 247-4696
S/N: S2P1-Up
Part No.: 124-5513
S/N: MRG1-Up
Part No.: 124-5513, 247-4696
S/N: S2R1-Up
Part No.: 124-5513
S/N: PAG1-Up
Part No.: 124-5513, 247-4696
S/N: S2S1-Up
RENR5077-12
231
Specifications Section
Part No.: 124-5513, 247-4696
S/N: S2T1-Up
Part No.: 124-5513, 247-4696
S/N: S2W1-Up
Part No.: 124-5513, 247-4696
S/N: S2X1-Up
Part No.: 124-5513, 247-4696
S/N: S2Y1-Up
Part No.: 247-4696
S/N: S2Z1-Up
g03043516
Illustration 228
Typical example
Front view
Table 150
Specification for the 124-5513 Breather Gp and 247-4696 Breather Gp
Item
Qty
Part
1
4
033-6031 O-Ring Seal
4
5P-0597 Hose Clamp
2
5P-4868 Hose Clamp
2
Specification Description
Lubricate the bore of O-ring seals lightly with clean engine oil.
Torque to 3.0 ± 0.5 N·m (27.0 ± 4.4 lb in).
Apply green Loctite 620 to the joint surfaces.
3
4
101-4199 Cover As
Seat the shoulder of 4W-1287 Adapter against the cover.
Apply green Loctite 290 to 4W-1287 Adapter after assembly.
232
Specifications Section
RENR5077-12
i04392854
Crankcase Breather
SMCS Code: 1317
Part No.: 101-0838
S/N: GS71-Up
Part No.: 101-0838
S/N: M8A1-Up
Part No.: 101-0838
S/N: S2A1-Up
Part No.: 101-0838
S/N: M8B1-Up
Part No.: 101-0838
S/N: S2B1-Up
Part No.: 101-0838
S/N: S2D1-Up
Part No.: 101-0838
S/N: S2E1-Up
Part No.: 101-0838
S/N: S2F1-Up
g01614413
Illustration 229
(3) Breather assembly
(4) Cover assembly
Table 151
Specification for the 101-0838 Breather Gp
Item
Qty
Part
1
2
033-6031 O-Ring Seal
2
5P-0597 Hose Clamp
1
180-3007 Hose Clamp
2
Specification Description
Lubricate the bore of O-ring seals lightly with clean engine oil.
Torque to 3.0 ± 0.5 N·m (27 ± 4 lb in).
RENR5077-12
233
Specifications Section
i05166001
Crankcase Breather
SMCS Code: 1317
Part No.: 247-4695
S/N: GS61-Up
g03318211
Illustration 230
Table 152
Specification for 247-4695 Breather Gp
Item
Qty
Part
1
3
5P-0597 Hose Clamp
Torque to 3.0 ± 0.5 N·m (26.6 ± 4.4 lb in).
2
3
033-6031 O-Ring Seal
Lubricate the bore with clean engine oil.
Specification Description
i05166002
Crankcase Breather
Part No.: 394-8124
S/N: ED31-Up
SMCS Code: 1317
Part No.: 394-8124
S/N: 9H41-Up
Part No.: 394-8124
S/N: ED21-Up
Part No.: 394-8124
S/N: ED51-Up
Part No.: 394-8124
S/N: 9H31-Up
Part No.: 394-8124
S/N: ED81-Up
234
Specifications Section
RENR5077-12
Part No.: 394-8124
S/N: MD81-Up
Part No.: 394-8124
S/N: SRH1-Up
Part No.: 394-8124
S/N: SRK1-Up
g03318224
Illustration 231
Table 153
Specification for 394-8124 Breather Gp
Item
Qty
Part
1
3
033-6031 O-Ring Seal
Lubricate the bore with clean engine oil.
2
3
5P-0597 Hose Clamp
Torque to 3.0 ± 0.5 N·m (26.6 ± 4.4 lb in).
Specification Description
RENR5077-12
235
Specifications Section
i04873290
Crankcase Breather
SMCS Code: 1317
Part No.: 380-8380
S/N: CG21-Up
Part No.: 380-8380
S/N: MD81-Up
Part No.: 380-8380
S/N: MXM1-Up
Part No.: 380-8380
S/N: MXR1-Up
g02998698
Illustration 232
Table 154
Specification for the 380-8380 Breather Gp
Item
Qty
Part
1
4
133-6270 Bolt
Specification Description
Torque to 25 ± 6 N·m (221 ± 53 lb in).
Apply green Loctite 620 to the joint surfaces.
2
1
155-2572 Cover As
Seat the shoulder of 4W-1287 Adapter against the cover.
Apply green Loctite 290 to 4W-1287 Adapter after assembly.
236
Specifications Section
RENR5077-12
i04931607
Crankcase Breather
SMCS Code: 1317
Part No.: 394-8117
S/N: WF21-Up
Part No.: 394-8117
S/N: SRZ1-Up
g03101696
Illustration 233
Table 155
Specification for 394-8117 Breather Gp
Item
Qty
Part
Specification Description
1
3
5P-0597 Hose Clamp
Torque to 3.0 ± 0.5 N·m (26.6 ± 4.4 lb in).
2
2
5P-4868 Hose Clamp
Torque to 3.0 ± 0.5 N·m (26.6 ± 4.4 lb in).
3
3
033-6031 O-Ring Seal
Before assembly, lightly lubricate the bore with the lubricant that is being
sealed.
i05166010
Crankcase Breather
Part No.: 394-8129
S/N: 9H61-Up
SMCS Code: 1317
Part No.: 394-8129
S/N: EDC1-Up
Part No.: 394-8129
S/N: 9F21-Up
Part No.: 394-8129
S/N: EDG1-Up
Part No.: 394-8129
S/N: CG21-Up
Part No.: 394-8129
S/N: EDH1-Up
Part No.: 394-8129
S/N: 9F31-Up
Part No.: 394-8129
S/N: EDJ1-Up
Part No.: 394-8129
S/N: JB41-Up
Part No.: 394-8129
S/N: EDP1-Up
Part No.: 394-8129
S/N: 9H51-Up
Part No.: 394-8129
S/N: MXR1-Up
RENR5077-12
237
Specifications Section
g03318247
Illustration 234
Table 156
Specification for 394-8129 Breather Gp
Item
Qty
Part
Specification Description
1
4
033-6031 O-Ring Seal
Lubricate the bore with clean engine oil.
2
4
5P-0597 Hose Clamp
Torque to 3.0 ± 0.5 N·m (26.6 ± 4.4 lb in).
238
Specifications Section
RENR5077-12
i03117145
Crankcase Breather
SMCS Code: 1317
Part No.: 247-4696
S/N: S2P1-Up
Part No.: 247-4696
S/N: S2R1-Up
Part No.: 247-4696
S/N: S2S1-Up
Part No.: 247-4696
S/N: S2T1-Up
Part No.: 247-4696
S/N: S2W1-Up
Part No.: 247-4696
S/N: S2X1-Up
Part No.: 247-4696
S/N: S2Y1-Up
Part No.: 247-4696
S/N: S2Z1-Up
Illustration 235
g01594054
(1) Lubricate the bore for the seal with clean engine
oil.
(2) Torque for the hose clamps ........... 3.0 ± 0.5 N·m
(27 ± 4 lb in)
RENR5077-12
239
Specifications Section
i03139762
Engine Oil Pan
SMCS Code: 1302
Part No.: 335-3170
S/N: M8A1-Up
Part No.: 335-3170
S/N: M8B1-Up
Illustration 236
g01448462
Typical example
(1) Before assembly, apply 1P-0808 Multipurpose
Grease in order to lubricate the bores of the
O-ring seals.
(2) As required, apply 8T-9014 Silicone Sealant
or 138-8436 Liquid Gasket to the joints of the
gasket.
(4) Torque for two oil drain plugs ......... 145 ± 15 N·m
(105 ± 11 lb 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 ± 9 N·m (35 ± 7 lb ft).
240
Specifications Section
RENR5077-12
2. Tighten two bolts (3) to 47 ± 9 N·m (35 ± 7 lb ft).
i04404594
Engine Oil Pan
SMCS Code: 1302
Part No.: 8N-6164
S/N: S2A1-Up
Part No.: 8N-6164
S/N: S2B1-Up
Part No.: 8N-6164
S/N: S2D1-Up
Part No.: 8N-6164
S/N: S2E1-Up
Part No.: 8N-6164
S/N: S2F1-Up
Part No.: 8N-6164
S/N: MRG1-Up
Part No.: 8N-6164
S/N: PAG1-Up
Part No.: 8N-6164
S/N: S2G1-Up
Part No.: 8N-6164
S/N: MKH1-Up
Part No.: 8N-6164
S/N: S2H1-Up
Part No.: 8N-6164
S/N: S2J1-Up
Part No.: 8N-6164
S/N: S2K1-Up
Part No.: 8N-6164
S/N: S2L1-Up
Part No.: 8N-6164
S/N: S2M1-Up
Part No.: 8N-6164
S/N: S2N1-Up
Part No.: 8N-6164
S/N: S2P1-Up
Part No.: 8N-6164
S/N: S2R1-Up
Part No.: 8N-6164
S/N: S2S1-Up
Part No.: 8N-6164
S/N: S2T1-Up
Part No.: 8N-6164
S/N: S2W1-Up
Part No.: 8N-6164
S/N: S2X1-Up
Part No.: 8N-6164
S/N: S2Y1-Up
RENR5077-12
Illustration 237
241
Specifications Section
g02843936
Top view
Illustration 238
Right side view
g02843937
242
Specifications Section
RENR5077-12
Table 157
Specification for 8N-6164 Oil Pan Gp and 152-6013 Oil Pan Gp
Item
Part
Qty
Specification Description
Use the following procedure in order to tighten the bolts:
-
1A-2029 Bolt
15
1. Tighten five bolts (12) to standard torque.
2. Tighten bolt (1) through bolt (10) in a numerical sequence that is shown in
Illustration 237 to standard torque.
11
-
-
Before assembly, apply red Loctite 596, Permatex No. 2 or red Loctite High
Tack GS S to the joints of the gasket.
13
-
-
Before assembly, lightly lubricate the bore for the O-ring seals with the
lubricant that is being sealed or an approved equivalent.
14
-
-
Before assembly, apply red Loctite 596, Permatex No. 2 or red Loctite High
Tack GS S on connecting joint of the flywheel housing (17) and the rear of
cylinder block, and connecting joint of the front accessory drive housing
(18) and the front of cylinder block.
15
1
142-4159 Integral Seal
Before assembly, apply red Loctite 596, Permatex No. 2 or red Loctite High
Tack GS S to the sealing surface.
16
38
5P-5855 Bolt
Apply green Loctite 290 to the open top end of the bolt holes after assembly
of the oil pan.
19
1
4B-2363 Oil Drain Plug
Torque to 145 ± 15 N·m (107 ± 11 lb ft).
20
1
6I-0723 Oil Drain Plug
Before assembly, lightly lubricate the threads with the lubricant that is being
sealed or an approved equivalent.
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
i04747489
Engine Oil Pan
SMCS Code: 1302
Part No.: 7C-7185
S/N: GS71-Up
Part No.: 7C-7185
S/N: S2A1-Up
Part No.: 7C-7185
S/N: S2B1-Up
Part No.: 7C-7185
S/N: S2D1-Up
Part No.: 7C-7185
S/N: S2E1-Up
Part No.: 7C-7185
S/N: S2F1-Up
RENR5077-12
Illustration 239
Top view
243
Specifications Section
g02844076
244
Specifications Section
RENR5077-12
Table 158
Specification for 7C-7185 Oil Pan Gp
Item
Qty
Part
1
2
3P-0654 O-Ring Seal
Before assembly, apply 1P-0808 Multipurpose Grease in order to
lubricate the bores.
2
2
7X-1547 O-Ring Seal
Before assembly, apply 1P-0808 Multipurpose Grease in order to
lubricate the bores.
3
2
0S-1590 Bolt
4
2
0S-1588 Bolt
6
2
4B-2363 Oil Drain Plug
7
-
-
Specification Description
In order to prevent stress on the tube assembly (5), use the
following tightening procedure during assembly:
1. Tighten two bolts (4) to 47 ± 9 N·m (35 ± 7 lb ft).
2. Then tighten two bolts (3) to 47 ± 9 N·m (35 ± 7 lb ft).
Torque to 145 ± 15 N·m (107 ± 11 lb ft).
As required, apply Loctite RTV Silicone Clear to the joints of the
gasket.
i04923806
Engine Oil Pan
SMCS Code: 1302
Part No.: 7C-6887
S/N: GS71-Up
Part No.: 7C-6887
S/N: M8A1-Up
Part No.: 7C-6887
S/N: S2A1-Up
Part No.: 7C-6887
S/N: M8B1-Up
Part No.: 7C-6887
S/N: S2B1-Up
Part No.: 7C-6887
S/N: S2D1-Up
Part No.: 7C-6887
S/N: S2E1-Up
Part No.: 7C-6887
S/N: S2F1-Up
RENR5077-12
245
Specifications Section
g03090816
Illustration 240
Top view
Table 159
Specification for 7C-6887 Oil Pan Gp
Item
Qty
Part
Specification Description
1
2
3P-0654 O-Ring Seal
Before assembly, apply 1P-0808 Multipurpose Grease in order to
lubricate the bores.
2
2
7X-1547 O-Ring Seal
Before assembly, apply 1P-0808 Multipurpose Grease in order to
lubricate the bores.
3
2
0S-1590 Bolt
4
2
0S-1588 Bolt
6
2
4B-2363 Oil Drain Plug
7
-
-
In order to prevent stress on the tube assembly (5), use the
following tightening procedure during assembly:
1. Tighten two bolts (4) to 47 ± 9 N·m (35 ± 7 lb ft).
2. Then tighten two bolts (3) to 47 ± 9 N·m (35 ± 7 lb ft).
Torque to 145 ± 15 N·m (107 ± 11 lb ft).
As required, apply Loctite RTV Silicone Clear to the joints of the
gasket.
246
Specifications Section
RENR5077-12
i04404603
Engine Oil Pan
SMCS Code: 1302
Part No.: 8N-7706
S/N: S2A1-Up
Part No.: 8N-7706
S/N: S2B1-Up
Part No.: 8N-7706
S/N: S2D1-Up
Part No.: 8N-7706
S/N: S2E1-Up
Part No.: 8N-7706
S/N: S2F1-Up
Part No.: 8N-7706
S/N: MRG1-Up
Part No.: 8N-7706
S/N: PAG1-Up
Part No.: 8N-7706
S/N: S2G1-Up
Part No.: 8N-7706
S/N: MKH1-Up
Part No.: 8N-7706
S/N: S2H1-Up
Part No.: 8N-7706
S/N: S2J1-Up
Part No.: 8N-7706
S/N: S2K1-Up
Part No.: 8N-7706
S/N: S2L1-Up
Part No.: 8N-7706
S/N: S2M1-Up
Part No.: 8N-7706
S/N: S2N1-Up
Part No.: 8N-7706
S/N: S2P1-Up
Part No.: 8N-7706
S/N: S2R1-Up
Part No.: 8N-7706
S/N: S2S1-Up
Part No.: 8N-7706
S/N: S2T1-Up
Part No.: 8N-7706
S/N: S2W1-Up
Part No.: 8N-7706
S/N: S2X1-Up
Part No.: 8N-7706
S/N: S2Y1-Up
Part No.: 8N-7706
S/N: S2Z1-Up
RENR5077-12
Illustration 241
247
Specifications Section
g01616154
248
Specifications Section
RENR5077-12
Table 160
Specification for 8N-7706 Oil Pan Gp
Item
Qty
Part
Specification Description
Use the following procedure in order to tighten the bolts of the plate:
-
15
1. Tighten five bolts (11) to standard torque.
1A-2029 Bolt
2. Tighten bolt 1 through bolt 10 in a numerical sequence that is
shown in Illustration 241 to a standard torque.
12
-
-
As required, apply 8T-9014 Silicone Sealant, Permatex No. 2 or
138-8436 Liquid Gasket to the joints of the gasket prior to assembly.
13
-
-
Lubricate the bore of nine O-ring seals lightly with the lubricant that is
being sealed or an approved equivalent.
14
-
-
As required, apply 8T-9014 Silicone Sealant, Permatex No. 2 or
138-8436 Liquid Gasket on Connecting joint of the flywheel housing
(17) and the rear of the cylinder block, and Connecting joint of the
front accessory drive housing (18) and the front of the cylinder block
prior to assembly.
15
38
5P-5855 Bolt
As required, apply 4C-9509 Wicking Sealant to the open top end of
the bolt holes after assembly of the oil pan.
16
1
142-4159 Integral Seal
As required, apply 8T-9014 Silicone Sealant, Permatex No. 2 or
138-8436 Liquid Gasket to the sealing surface of the integral seal
prior to assembly.
19
1
4B-2363 Oil Drain Plug
Torque to 145 ± 15 N·m (105 ± 11 lb ft).
20
1
6I-0723 Oil Drain Plug
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
i04908574
Engine Oil Pan
Part No.: 7C-7178
S/N: PAG1-Up
SMCS Code: 1302
Part No.: 7C-7178
S/N: S2G1-Up
Part No.: 381-2606
S/N: 9F31-Up
Part No.: 7C-7178
S/N: MKH1-Up
Part No.: 381-2606
S/N: 9H61-Up
Part No.: 7C-7178
S/N: S2H1-Up
Part No.: 7C-7178
S/N: GSA1-Up
Part No.: 381-2606
S/N: EDJ1-Up
Part No.: 7C-7178
S/N: S2A1-Up
Part No.: 7C-7178
S/N: S2J1-Up
Part No.: 7C-7178
S/N: S2B1-Up
Part No.: 7C-7178
S/N: S2K1-Up
Part No.: 7C-7178
S/N: S2D1-Up
Part No.: 7C-7178
S/N: S2L1-Up
Part No.: 7C-7178
S/N: S2E1-Up
Part No.: 7C-7178
S/N: S2N1-Up
Part No.: 7C-7178
S/N: B5G1-Up
Part No.: 7C-7178
S/N: S2P1-Up
Part No.: 381-2606
S/N: EDG1-Up
Part No.: 7C-7178
S/N: S2R1-Up
Part No.: 7C-7178
S/N: MRG1-Up
Part No.: 7C-7178
S/N: S2S1-Up
RENR5077-12
249
Specifications Section
Part No.: 7C-7178
S/N: S2T1-Up
Part No.: 7C-7178
S/N: S2W1-Up
Part No.: 7C-7178
S/N: S2X1-Up
Part No.: 7C-7178
S/N: S2Y1-Up
Part No.: 7C-7178
S/N: S2Z1-Up
Illustration 242
Top view
g02843996
250
Specifications Section
RENR5077-12
Table 161
Specification for 7C-7178 Oil Pan Gp
Item
Qty
Part
Specification Description
1
3
3P-0654 O-Ring Seal
Before assembly, apply 1P-0808 Multipurpose Grease in order to
lubricate the bores.
2
2
7X-1547 O-Ring Seal
Before assembly, apply 1P-0808 Multipurpose Grease in order to
lubricate the bores.
3
2
0S-1590 Bolt
4
2
0S-1588 Bolt
6
2
4B-2363 Oil Drain Plug
7
-
-
In order to prevent stress on the tube assembly (5), use the
following tightening procedure during assembly:
1. Tighten two bolts (4) to 47 ± 9 N·m (35 ± 7 lb ft).
2. Then tighten two bolts (3) to 47 ± 9 N·m (35 ± 7 lb ft).
Torque to 145 ± 15 N·m (107 ± 11 lb ft).
As required, apply Loctite RTV Silicone Clear to the joints of the
gasket.
i04747511
Engine Oil Pan
Part No.: 7C-9938
S/N: S2N1-Up
SMCS Code: 1302
Part No.: 7C-9938
S/N: S2P1-Up
Part No.: 7C-9938
S/N: GS61-Up
Part No.: 7C-9938
S/N: S2R1-Up
Part No.: 7C-9938
S/N: S2B1-Up
Part No.: 7C-9938
S/N: S2S1-Up
Part No.: 7C-9938
S/N: S2D1-Up
Part No.: 7C-9938
S/N: S2T1-Up
Part No.: 7C-9938
S/N: S2E1-Up
Part No.: 7C-9938
S/N: S2W1-Up
Part No.: 7C-9938
S/N: S2F1-Up
Part No.: 7C-9938
S/N: S2X1-Up
Part No.: 7C-9938
S/N: MRG1-Up
Part No.: 7C-9938
S/N: S2Y1-Up
Part No.: 7C-9938
S/N: PAG1-Up
Part No.: 7C-9938
S/N: S2G1-Up
Part No.: 7C-9938
S/N: MKH1-Up
Part No.: 7C-9938
S/N: S2H1-Up
Part No.: 7C-9938
S/N: S2J1-Up
Part No.: 7C-9938
S/N: S2K1-Up
Part No.: 7C-9938
S/N: S2L1-Up
Part No.: 7C-9938
S/N: S2M1-Up
RENR5077-12
Illustration 243
Top view
251
Specifications Section
g02844117
252
Specifications Section
RENR5077-12
Table 162
Specification for 7C-9938 Oil Pan Gp
Item
Qty
Part
1
2
3P-0654 O-Ring Seal
Before assembly, apply 1P-0808 Multipurpose Grease in order to
lubricate the bores.
2
2
7X-1547 O-Ring Seal
Before assembly, apply 1P-0808 Multipurpose Grease in order to
lubricate the bores.
3
2
0S-1590 Bolt
4
2
0S-1588 Bolt
6
2
4B-2363 Oil Drain Plug
7
-
-
Specification Description
In order to prevent stress on the tube assembly (5), use the
following tightening procedure during assembly:
1. Tighten two bolts (4) to 47 ± 9 N·m (35 ± 7 lb ft).
2. Then tighten two bolts (3) to 47 ± 9 N·m (35 ± 7 lb ft).
Torque to 145 ± 15 N·m (107 ± 11 lb ft).
As required, apply Loctite RTV Silicone Clear to the joints of the
gasket.
RENR5077-12
253
Specifications Section
i04923815
Engine Oil Pan
SMCS Code: 1302
Part No.: 7C-6752
S/N: GS61-Up
Illustration 244
Top view
g03090904
254
Specifications Section
RENR5077-12
Table 163
Specification for 7C-6752 Oil Pan Gp
Item
Qty
Part
1
2
3P-0654 O-Ring Seal
Before assembly, apply 1P-0808 Multipurpose Grease in order to
lubricate the bores.
2
2
7X-1547 O-Ring Seal
Before assembly, apply 1P-0808 Multipurpose Grease in order to
lubricate the bores.
3
2
0S-1590 Bolt
4
2
0S-1588 Bolt
6
2
4B-2363 Oil Drain Plug
7
-
-
Specification Description
In order to prevent stress on the tube assembly (5), use the
following tightening procedure during assembly:
1. Tighten two bolts (4) to 47 ± 9 N·m (35 ± 7 lb ft).
2. Then tighten two bolts (3) to 47 ± 9 N·m (35 ± 7 lb ft).
Torque to 145 ± 15 N·m (107 ± 11 lb ft).
As required, apply Loctite RTV Silicone Clear to the joints of the
gasket.
i04891924
Engine Oil Pan
SMCS Code: 1302
Part No.: 377-5896
S/N: CG21-Up
Part No.: 377-5896
S/N: 9H61-Up
Part No.: 381-2608
S/N: MD81-Up
Part No.: 377-5896
S/N: EDG1-Up
Part No.: 381-2608
S/N: MXM1-Up
Part No.: 377-5896
S/N: MXR1-Up
RENR5077-12
255
Specifications Section
g03027916
Illustration 245
Top view
Table 164
Specification for 7C-4711 Oil Pan Gp, 377-5896 Oil Pan Gp, and 381-2608 Oil Pan Gp
Item
Qty
Part
Specification Description
1
2
3P-0654 O-Ring Seal
Before assembly, apply 1P-0808 Multipurpose Grease in order to
lubricate the bores.
2
2
7X-1547 O-Ring Seal
Before assembly, apply 1P-0808 Multipurpose Grease in order to
lubricate the bores.
3
2
0S-1590 Bolt
4
2
0S-1588 Bolt
6
2
4B-2363 Oil Drain Plug
7
-
-
In order to prevent stress on the tube assembly (5), use the
following tightening procedure during assembly:
1. Tighten two bolts (4) to 47 ± 9 N·m (35 ± 7 lb ft).
2. Then tighten two bolts (3) to 47 ± 9 N·m (35 ± 7 lb ft).
Torque to 145 ± 15 N·m (107 ± 11 lb ft).
As required, apply Loctite RTV Silicone Clear to the joints of the
gasket.
256
Specifications Section
RENR5077-12
i04931637
Engine Oil Pan
SMCS Code: 1302
Part No.: 382-6564
S/N: WF21-Up
Part No.: 382-6564
S/N: 9H31-Up
Part No.: 382-6564
S/N: 9H41-Up
Part No.: 382-6564
S/N: ED51-Up
Part No.: 382-6564
S/N: ED81-Up
Part No.: 382-6564
S/N: SRZ1-Up
Illustration 246
g03101876
RENR5077-12
257
Specifications Section
Table 165
Specification for 382-6564 Oil Pan Gp
Item
Qty
Part
Specification Description
1
-
-
Before assembly , as required apply red Loctite 596 above and below to the
joints of the gasket.
2
38
5P-5855 Bolt
After assembly, as required apply green Loctite 290 to the threads.
3
5
4
10
1A-2029 Bolt
Use the following procedure in order to tighten the bolts:
1. Tighten five bolts (3) to standard torque.
2. Tighten bolt 1 through bolt 10 in a numerical sequence that is shown in
Illustration 246 to a standard torque.
5
4
5P-5700 O-Ring Seal
Before assembly, lubricate the bore lightly with the lubricant that is being
sealed.
6
2
6V-4315 O-Ring Seal
Before assembly, lubricate the bore lightly with the lubricant that is being
sealed.
7
2
3P-0654 O-Ring Seal
Before assembly, lubricate the bore lightly with the lubricant that is being
sealed.
i04907651
Water Temperature Regulator
SMCS Code: 1355
Part No.: 248-5513
S/N: CG21-Up
Part No.: 248-5513
S/N: WF21-Up
Part No.: 248-5513
S/N: 9F31-Up
Part No.: 248-5513
S/N: 9H41-Up
Part No.: 248-5513
S/N: 9H61-Up
Part No.: 248-5513
S/N: GS61-Up
Part No.: 248-5513
S/N: GS71-Up
Part No.: 248-5513
S/N: ED81-Up
Part No.: 248-5513
S/N: MD81-Up
Part No.: 248-5513
S/N: GSA1-Up
Part No.: 248-5513
S/N: EDG1-Up
Part No.: 248-5513
S/N: EDJ1-Up
Part No.: 248-5513
S/N: MXM1-Up
Part No.: 248-5513
S/N: MXR1-Up
258
Specifications Section
RENR5077-12
g02545979
Illustration 247
Table 166
Specification for 248-5513 Temperature Regulator
Item
Qty
Part
A
-
-
Minimum opening distance at fully open temperature is 10.4 mm (0.41 inch).
-
-
-
Opening temperature is 81 to 84 °C (178 to 183 °F).
-
-
-
Fully open temperature is 92 °C (198 °F).
-
-
-
Leakage at the seat and sleeve shall not exceed minimum 10.0 cc (0.6 cubic inch) at
207 kPa (30 psi).
-
-
-
Force required to separate valve from seat is 165 ± 9 N (37 ± 2 lb), measured at
temperature 75 °C (167 °F).
Specification Description
i01957454
Water Temperature Regulator
Part No.: 4W-4794
S/N: S2J1-Up
SMCS Code: 1355
Part No.: 4W-4794
S/N: S2K1-Up
Part No.: 4W-4794
S/N: S2A1-Up
Part No.: 4W-4794
S/N: S2L1-Up
Part No.: 4W-4794
S/N: S2B1-Up
Part No.: 4W-4794
S/N: S2M1-Up
Part No.: 4W-4794
S/N: S2D1-Up
Part No.: 4W-4794
S/N: S2N1-Up
Part No.: 4W-4794
S/N: S2E1-Up
Part No.: 4W-4794
S/N: S2P1-Up
Part No.: 4W-4794
S/N: S2F1-Up
Part No.: 4W-4794
S/N: S2R1-Up
Part No.: 4W-4794
S/N: S2G1-Up
Part No.: 4W-4794
S/N: S2S1-Up
Part No.: 4W-4794
S/N: S2H1-Up
Part No.: 4W-4794
S/N: S2T1-Up
RENR5077-12
259
Specifications Section
Part No.: 4W-4794
S/N: S2W1-Up
Part No.: 4W-4794
S/N: S2X1-Up
Part No.: 4W-4794
S/N: S2Y1-Up
Illustration 248
g00286978
Fully open temperature ...................... 92 °C (197 °F)
Minimum opening distance at 92 °C
(197 °F) ..................................... 10.4 mm (0.41 inch)
260
Specifications Section
RENR5077-12
i04878775
Water Temperature Regulator
SMCS Code: 1355
Part No.: 219-3240
S/N: 9F21-Up
Part No.: 219-3240
S/N: WF21-Up
Part No.: 219-3240
S/N: JB41-Up
Part No.: 219-3240
S/N: EDC1-Up
Part No.: 219-3240
S/N: EDH1-Up
Part No.: 219-3240
S/N: SRZ1-Up
g03003458
Illustration 249
Table 167
Specification for 219-3240 Temperature Regulator
Item
Qty
Part
Specification Description
A
-
-
Minimum opening distance at fully open temperature is 10.4 mm (0.41 inch).
-
-
-
Opening temperature is 18 to 23 °C (64 to 73 °F).
-
-
-
Fully open temperature is 33 °C (91 °F).
RENR5077-12
261
Specifications Section
i03686730
Water Lines
Part No.: 249-2846
S/N: MRG1-Up
SMCS Code: 1380
Part No.: 249-2846
S/N: S2G1-Up
Part No.: 334-8768
S/N: P8A1-Up
Part No.: 249-2846
S/N: MKH1-Up
Part No.: 249-2846
S/N: S2H1-Up
Part No.: 249-2846
S/N: S2J1-Up
Part No.: 249-2846
S/N: S2K1-Up
Part No.: 249-2846
S/N: S2L1-Up
Part No.: 249-2846
S/N: S2M1-Up
Part No.: 249-2846
S/N: S2N1-Up
Part No.: 249-2846
S/N: S2P1-Up
Illustration 250
g01982302
(1) Lightly lubricate the bore of the O-ring seals with
glycerin or an approved equivalent.
i02636978
Part No.: 249-2846
S/N: S2R1-Up
Part No.: 249-2846
S/N: S2S1-Up
Part No.: 249-2846
S/N: S2T1-Up
Water Lines
Part No.: 249-2846
S/N: S2W1-Up
SMCS Code: 1380
Part No.: 249-2846
S/N: S2X1-Up
Part No.: 335-1845
S/N: M8A1-Up
Part No.: 249-2846
S/N: S2A1-Up
Part No.: 335-1845
S/N: M8B1-Up
Part No.: 249-2846
S/N: S2B1-Up
Part No.: 249-2846
S/N: S2D1-Up
Part No.: 249-2846
S/N: S2E1-Up
Part No.: 249-2846
S/N: S2F1-Up
Part No.: 249-2846
S/N: B5G1-Up
Part No.: 249-2846
S/N: S2Y1-Up
Part No.: 249-2846
S/N: S2Z1-Up
262
Specifications Section
RENR5077-12
g01322263
Illustration 251
Zinc rod
i04394116
Water Lines
SMCS Code: 1380
Part No.: 278-7527
S/N: GS61-Up
Part No.: 278-7527
S/N: GS71-Up
Part No.: 278-7527
S/N: GSA1-Up
Illustration 252
g01322268
Typical example of zinc rod assembly
1. Apply 9S-3263 Thread Lock Compound to
shoulder (2) of a new zinc rod (1). Do not apply
sealant to threads (3) of the rod.
2. Lightly lubricate the bores for the zinc rods and
the plugs with liquid soap.
Torque for the zinc rod .. 2.25 ± .25 N·m (20 ± 2 lb in)
Part No.: 278-7527
S/N: S2A1-Up
Part No.: 278-7527
S/N: S2B1-Up
Part No.: 278-7527
S/N: S2D1-Up
Part No.: 278-7527
S/N: S2E1-Up
RENR5077-12
Part No.: 278-7527
S/N: S2F1-Up
Part No.: 278-7527
S/N: B5G1-Up
Part No.: 278-7527
S/N: S2G1-Up
Part No.: 278-7527
S/N: MKH1-Up
Part No.: 278-7527
S/N: S2H1-Up
Part No.: 278-7527
S/N: S2J1-Up
Part No.: 278-7527
S/N: S2K1-Up
Part No.: 278-7527
S/N: S2L1-Up
Part No.: 278-7527
S/N: S2M1-Up
Part No.: 278-7527
S/N: S2N1-Up
Part No.: 278-7527
S/N: S2P1-Up
Part No.: 278-7527
S/N: S2R1-Up
Part No.: 278-7527
S/N: S2S1-Up
Part No.: 278-7527
S/N: S2T1-Up
Part No.: 278-7527
S/N: S2W1-Up
Part No.: 278-7527
S/N: S2X1-Up
Part No.: 278-7527
S/N: S2Y1-Up
Part No.: 278-7527
S/N: S2Z1-Up
263
Specifications Section
264
Specifications Section
RENR5077-12
Illustration 253
g02565740
Illustration 254
g02565741
Typical example of zinc rod assembly
RENR5077-12
265
Specifications Section
Table 168
Specification for 278-7527 Water Lines Gp
Item
Qty
Part
1
2
6V-9027 O-Ring Seal
2
2
4L-9564 O-Ring Seal
3
1
6V-6609 O-Ring Seal
4
-
-
Lightly lubricate the bores for the zinc rods and the plugs with liquid
soap.
Apply blue Loctite 242 to the shoulder of the zinc rod, do not apply
sealant to threads.
5
-
-
Torque to 2.25 ± 0.25 N·m (20.0 ± 2.21 lb in).
Specification Description
Before assembly, lightly lubricate the bore with 5P-3975 Rubber
Lubricant.
i05166907
Water Lines
Part No.: 393-9274
S/N: SRH1-Up
SMCS Code: 1380
Part No.: 393-9274
S/N: EDJ1-Up
Part No.: 393-9274
S/N: 9F21-Up
Part No.: 393-9274
S/N: SRK1-Up
Part No.: 393-9274
S/N: CG21-Up
Part No.: 393-9274
S/N: MXM1-Up
Part No.: 393-9274
S/N: ED21-Up
Part No.: 393-9274
S/N: MXR1-Up
Part No.: 393-9274
S/N: 9F31-Up
Part No.: 393-9274
S/N: 9H31-Up
Part No.: 393-9274
S/N: ED31-Up
Part No.: 393-9274
S/N: 9H41-Up
Part No.: 393-9274
S/N: JB41-Up
Part No.: 393-9274
S/N: ED51-Up
Part No.: 393-9274
S/N: 9H61-Up
Part No.: 393-9274
S/N: ED81-Up
Part No.: 393-9274
S/N: MD81-Up
Part No.: 393-9274
S/N: EDC1-Up
Part No.: 393-9274
S/N: EDG1-Up
Part No.: 393-9274
S/N: EDH1-Up
266
Specifications Section
RENR5077-12
g03318746
Illustration 255
Table 169
Specification for 393-9274 Water Lines Gp
Item
1
Qty
2
Part
116-7011 Zinc Rod As
Specification Description
Use the following procedure in order to tighten the zinc rod assembly:
1. Before assembly, apply blue Loctite 242 to the shoulder of the zinc rod
assembly. Do not apply sealant to the threads.
2. Torque to 1.50 ± 0.25 N·m (13.28 ± 2.21 lb in).
RENR5077-12
267
Specifications Section
i05167509
Water Lines
SMCS Code: 1380
Part No.: 382-4876
S/N: WF21-Up
Part No.: 382-4876
S/N: 9H41-Up
Part No.: 382-4876
S/N: ED81-Up
Part No.: 382-4876
S/N: MD81-Up
Part No.: 382-4876
S/N: MXM1-Up
g03319134
Illustration 256
Table 170
Specification for 382-4876 Water Lines Gp
Item
Qty
Part
Specification Description
1
2
6V-1454 O-Ring Seal
Lubricate the bore lightly with the 5P-3975 Rubber Lubricant that is being sealed.
2
1
6V-5066 O-Ring Seal
Lubricate the bore lightly with the 5P-3975 Rubber Lubricant that is being sealed.
268
Specifications Section
RENR5077-12
i05167510
Water Lines
SMCS Code: 1380
Part No.: 382-4878
S/N: WF21-Up
Part No.: 382-4878
S/N: SRZ1-Up
g03319136
Illustration 257
Table 171
Specification for 382-4878 Water Lines Gp
Item
Qty
Part
Specification Description
1
4
6V-5066 O-Ring Seal
Lubricate the bore lightly with the 5P-3975 Rubber Lubricant that is being used.
RENR5077-12
269
Specifications Section
i05166986
Water Lines
SMCS Code: 1380
Part No.: 382-7824
S/N: 9F31-Up
Part No.: 382-7824
S/N: 9H51-Up
Part No.: 382-7824
S/N: 9H61-Up
Part No.: 382-7824
S/N: EDG1-Up
Part No.: 382-7824
S/N: EDJ1-Up
Part No.: 382-7824
S/N: EDP1-Up
g03318774
Illustration 258
Table 172
Specification for 382-7824 Water Lines Gp
Item
Qty
Part
Specification Description
1
4
8T-1919 O-Ring Seal
Lubricate the bore lightly with the 5P-3975 Rubber Lubricant that is being used.
2
1
5B-4399 O-Ring Seal
Lubricate the bore lightly with the 5P-3975 Rubber Lubricant that is being used.
270
Specifications Section
RENR5077-12
i04892047
Engine Oil Sump Pump
SMCS Code: 1324
Part No.: 380-3941
S/N: CG21-Up
Part No.: 7W-9703, 7W-9704
S/N: GS61-Up
Part No.: 7W-9704
S/N: GS71-Up
Part No.: 380-3941
S/N: MD81-Up
Part No.: 7W-9704
S/N: GSA1-Up
Part No.: 380-3941
S/N: MXM1-Up
Part No.: 380-3941
S/N: MXR1-Up
g02567856
Illustration 259
(1) Sump pump group
Table 173
Specification for 7W-9704 Sump Pump Gp, 7W-9703 Sump Pump Gp, and 380-3941 Sump Pump Gp
Item
2
Qty
1
Part
Specification Description
4P-5242 Oil Pickup Assembly
Use the following procedure in order to install the oil pickup assembly:
1.Before assembly, coat the threads with white Loctite Breakloose PST
prior to assembly.
2. Hand tighten the 0L-0701 Nut (3) against the oil pickup assembly (2)
until the O-ring seal contacts the oil pan.
3. Unscrew the oil pickup assembly until the word “UP” is at the 12 o'clock
position.
4. Hold the oil pickup assembly in position and tighten the nut (3) to a
torque of 150 ± 15 N·m (111 ± 11 lb ft).
RENR5077-12
271
Specifications Section
i04014370
Engine Oil Sump Pump
SMCS Code: 1324
Part No.: 7W-9703
S/N: M8A1-Up
Part No.: 7W-9703
S/N: M8B1-Up
Illustration 260
g01434049
(1) Sump pump group
Use the following procedure to install the oil pickup
assembly (2):
Note: Coat the threads of the oil pickup assembly
with 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 ± 15 N·m
(110 ± 11 lb ft).
272
Specifications Section
RENR5077-12
i05167661
Engine Oil Sump Pump
SMCS Code: 1324
Part No.: 380-3943
S/N: 9H41-Up
Part No.: 380-3943
S/N: 9H61-Up
Part No.: 380-3943
S/N: ED81-Up
Part No.: 335-3176, 380-3943
S/N: MD81-Up
Part No.: 335-3176
S/N: P8A1-Up
Part No.: 380-3943
S/N: EDG1-Up
Part No.: 335-3176, 380-3943
S/N: MXM1-Up
Illustration 261
Typical example
g03319256
RENR5077-12
273
Specifications Section
Table 174
Specification for 335-3176 Sump Pump Gp and 380-3943 Sump Pump Gp
Item
1
Qty
1
Part
Specification Description
4P-5242 Oil Pickup Assembly
Use the following procedure in order to install the oil pickup assembly:
1.Before assembly, coat the threads with white Loctite Breakloose PST
prior to assembly.
2. Hand tighten the 0L-0701 Nut (2) against the oil pickup assembly (1)
until the O-ring seal contacts the engine oil pan.
3. Unscrew the oil pickup assembly until the word “UP” is at top position.
Hold the oil pickup assembly in position and tighten the nut (2) to a torque
of 150 ± 15 N·m (111 ± 11 lb ft).
i04888408
Engine Oil Sump Pump
SMCS Code: 1324
Part No.: 385-6928
S/N: CG21-Up
Part No.: 385-6928
S/N: MD81-Up
Part No.: 385-6928
S/N: MXM1-Up
Part No.: 385-6928
S/N: MXR1-Up
Illustration 262
g03015136
274
Specifications Section
RENR5077-12
Table 175
Specification for 385-6928 Sump Pump Gp
Item
1
Part
Specification Description
4P-5242 Oil Pickup Assembly
Use the following procedure in order to install the oil pickup assembly:
1.Before assembly, coat the threads with white Loctite Breakloose PST.
2. Hand tighten the 0L-0701 Nut (2) against the oil pickup assembly until
the O-ring seal contacts the oil pan.
3. Back off the oil pickup assembly until the word “UP” is at the 12 o'clock
position.
4. Hold the oil pickup assembly in position and tighten the nut (2) to
150 ± 15 N·m (111 ± 11 lb ft).
Qty
1
i04888404
Engine Oil Sump Pump
SMCS Code: 1324
Part No.: 380-3936
S/N: CG21-Up
Part No.: 380-3936
S/N: MD81-Up
Part No.: 380-3936
S/N: MXM1-Up
Part No.: 380-3936
S/N: MXR1-Up
Illustration 263
g03015097
RENR5077-12
275
Specifications Section
Table 176
Specification for 380-3936 Sump Pump Gp
Item
1
Part
Specification Description
4P-5242 Oil Pickup Assembly
Use the following procedure in order to install the oil pickup assembly:
1.Before assembly, coat the threads with white Loctite Breakloose PST.
2. Hand tighten the 0L-0701 Nut (2) against the oil pickup assembly until
the O-ring seal contacts the oil pan.
3. Back off the oil pickup assembly until the word “UP” is at the 12 o'clock
position.
4. Hold the oil pickup assembly in position and tighten the nut (2) to
150 ± 15 N·m (111 ± 11 lb ft).
Qty
1
i04395597
Water Pump
SMCS Code: 1361
Part No.: 2W-9726
S/N: GS71-Up
Illustration 264
(2) Ring assembly
(3) Water pump seal group
g02847239
276
Specifications Section
RENR5077-12
Table 177
Specification for 2W-9726 Water Pump Gp
Item
Qty
Part
1
1
8C-5236 Lip Type Seal
Do not lubricate the sealing lip of the lip type seal.
4
1
149-5462 O-Ring Seal
Lubricate the bore of the O-ring seals with glycerin or an approved
equivalent.
5
1
5H-6734 O-Ring Seal
Lubricate the bore of the O-ring seals with glycerin or an approved
equivalent.
Lubricate the shaft with a thin film of clean engine oil before
pressing the impeller onto the shaft. The end of the shaft must be
flush with the face of the impeller within 0.15 mm (0.006 inch).
Diameter of the shaft to the impeller seating is 25.400 to 25.413 mm
(1.0000 to 1.0005 inch).
Specification Description
6
1
212-8180 Pump Drive
Shaft As
7
3
9M-2151 Taperlock Stud
8
3
9S-8752 Full Nut
9
1
7N-4758 Thrust Washer
Thickness of new thrust washer is 8.5 mm (0.33 inch).
Width of the groove for thrust washer is 8.75 ± 0.05 mm
(0.344 ± 0.002 inch).
1
212-8187 Impeller
Bore of the impeller for new shaft is 25.342 ± 0.013 mm
(0.9977 ± 0.0005 inch).
Clearance between the impeller and the cover is
0.5000 ± 0.4925 mm (0.01968 ± 0.01939 inch).
11
1
3D-2824 O-Ring Seal
12
1
7G-8478 Adapter
10
B
Torque to 35 ± 5 N·m (26 ± 4 lb ft).
Torque to 27 ± 4 N·m (239 ± 35 lb in).
Lubricate the bore of the O-ring seals with glycerin or an approved
equivalent.
Torque to 100 ± 10 N·m (74 ± 7 lb ft).
RENR5077-12
277
Specifications Section
i03700561
Water Pump
SMCS Code: 1361
Part No.: 334-7865
S/N: M8A1-Up
Part No.: 334-7865
S/N: M8B1-Up
g01991398
Illustration 265
(2) Ring assembly
(3) Water pump seal group
(1) Do not lubricate the sealing lip of the lip type seal.
(4) Lubricate the bore of the O-ring seals with
glycerin or an approved equivalent.
(5) Lubricate the shaft with a thin film of clean engine
oil before pressing the impeller onto the shaft.
The end of the shaft must be flush with the face
of the impeller within 0.15 mm (0.006 inch).
(E) Clearance between the impeller and the
cover .................................. 0.5000 ± 0.4925 mm
(0.01968 ± 0.01939 inch)
(6) Torque for the taperlock studs ........... 35 ± 5 N·m
(26 ± 4 lb ft)
(7) Torque for the full nuts ....................... 27 ± 4 N·m
(239 ± 35 lb in)
(B) Bore of the impeller for new
shaft ..................................... 25.342 ± 0.013 mm
(0.9977 ± 0.0005 inch)
Minimum leakage per minute for the lip type seal at
138 kPa (20 psi) of air pressure is less than 24 cc
(1.5 cu in).
(C) Width of the groove for thrust
washer ...... 8.75 ± 0.05 mm (0.344 ± 0.002 inch)
Minimum leakage per minute for the water pump seal
assembly at 138 kPa (20 psi) of air pressure is less
than 20 cc (1.2 cu in).
(D) Thickness of new thrust washer ............. 8.5 mm
(0.33 inch)
278
Specifications Section
RENR5077-12
i04896936
Water Pump
Part No.: 2W-9729
S/N: S2W1-Up
SMCS Code: 1361
Part No.: 2W-9729
S/N: S2X1-Up
Part No.: 2W-9729
S/N: GS61-Up
Part No.: 2W-9729
S/N: S2Y1-Up
Part No.: 2W-9729
S/N: GSA1-Up
Part No.: 2W-9729
S/N: S2Z1-Up
Part No.: 2W-9729
S/N: S2A1-Up
Part No.: 2W-9729
S/N: S2B1-Up
Part No.: 2W-9729
S/N: S2D1-Up
Part No.: 2W-9729
S/N: S2E1-Up
Part No.: 2W-9729
S/N: S2F1-Up
Part No.: 2W-9729
S/N: B5G1-Up
Part No.: 2W-9729
S/N: MRG1-Up
Part No.: 2W-9729
S/N: PAG1-Up
Part No.: 2W-9729
S/N: S2G1-Up
Part No.: 2W-9729
S/N: MKH1-Up
Part No.: 2W-9729
S/N: S2H1-Up
Part No.: 2W-9729
S/N: S2J1-Up
Part No.: 2W-9729
S/N: S2L1-Up
Part No.: 2W-9729
S/N: S2M1-Up
Part No.: 2W-9729
S/N: S2N1-Up
Part No.: 2W-9729
S/N: S2P1-Up
Part No.: 2W-9729
S/N: S2R1-Up
Part No.: 2W-9729
S/N: S2S1-Up
Part No.: 2W-9729
S/N: S2T1-Up
RENR5077-12
279
Specifications Section
g02610416
Illustration 266
(2) Ring assembly
(3) Water pump seal group
Table 178
Specification for 2W-9729 Water Pump Gp
Item
Qty
Part
1
1
8C-5236 Lip Type Seal
Do not lubricate the sealing lip of the lip type seal.
4
1
149-5462 O-Ring Seal
Lubricate the bore of the O-ring seals with glycerin or an approved
equivalent.
5
1
5H-6734 O-Ring Seal
Lubricate the bore of the O-ring seals with glycerin or an approved
equivalent.
Lubricate the shaft with a thin film of clean engine oil before
pressing the impeller onto the shaft. The end of the shaft must be
flush with the face of the impeller within 0.15 mm (0.006 inch).
Diameter of the shaft to the impeller seating is 25.400 to 25.413 mm
(1.0000 to 1.0005 inch).
Specification Description
6
1
212-8180 Pump Drive
Shaft As
7
3
9M-2151 Taperlock Stud
8
3
9S-8752 Full Nut
9
1
7N-4758 Thrust Washer
Thickness of new thrust washer is 8.5 mm (0.33 inch).
Width of the groove for thrust washer is 8.75 ± 0.05 mm
(0.344 ± 0.002 inch).
212-8184 Impeller
Bore of the impeller for new shaft is 25.342 ± 0.013 mm
(0.9977 ± 0.0005 inch).
Clearance (B) between the impeller and the cover is
0.5000 ± 0.4925 mm (0.01968 ± 0.01939 inch).
10
1
Torque to 35 ± 5 N·m (26 ± 4 lb ft).
Torque to 27 ± 4 N·m (239 ± 35 lb in).
280
Specifications Section
RENR5077-12
i05021141
Water Pump
SMCS Code: 1361
Part No.: 379-3978
S/N: 9H31-Up
Part No.: 379-3978
S/N: ED31-Up
Part No.: 379-3978
S/N: ED51-Up
Part No.: 379-3978
S/N: SRK1-Up
g03192659
Illustration 267
Table 179
Specification for 379-3978 Water Pump Gp
Item
Qty
Part
Specification Description
1
1
5H-6734 O-Ring Seal
2
1
8C-5236 Lip Type Seal
Do not lubricate the sealing lip of the lip type seal.
3
1
149-5462 O-Ring Seal
Before assembly, lubricate the bore lightly with 5P-3975 Rubber
Lubricant.
Before assembly, lubricate the bore lightly with 5P-3975 Rubber
Lubricant.
4
1
212-8180 Pump Drive
Shaft As
Lubricate the shaft with a thin film of clean engine oil before pressing the
impeller onto the shaft. The end of the shaft must be flush with the face of
the impeller within 0.15 mm (0.006 inch).
Diameter of the shaft to the impeller seating is 25.400 to 25.413 mm
(1.0000 to 1.0005 inch).
5
1
7N-4758 Thrust Washer
Thickness of new thrust washer is 8.5 mm (0.33 inch).
Width of the groove for thrust washer is 8.75 ± 0.05 mm
(0.344 ± 0.002 inch).
6
1
212-8187 Impeller
Bore of the impeller for new shaft is 25.342 ± 0.013 mm
(0.9977 ± 0.0005 inch).
Clearance between the impeller and the cover is 0.5000 ± 0.4925 mm
(0.01968 ± 0.01939 inch).
RENR5077-12
281
Specifications Section
i04873610
Water Pump
SMCS Code: 1361
Part No.: 375-3658
S/N: 9F21-Up
Part No.: 375-3658
S/N: CG21-Up
Part No.: 375-3658
S/N: ED21-Up
Part No.: 375-3658
S/N: WF21-Up
Part No.: 375-3658
S/N: 9F31-Up
Part No.: 375-3658
S/N: 9H41-Up
Part No.: 375-3658
S/N: JB41-Up
Part No.: 375-3658
S/N: 9H51-Up
Part No.: 375-3658
S/N: 9H61-Up
Part No.: 375-3658
S/N: ED81-Up
Part No.: 375-3658
S/N: MD81-Up
Part No.: 375-3658
S/N: EDC1-Up
Part No.: 375-3658
S/N: EDG1-Up
Part No.: 375-3658
S/N: EDH1-Up
Part No.: 375-3658
S/N: SRH1-Up
Part No.: 375-3658
S/N: EDJ1-Up
Part No.: 375-3658
S/N: MXM1-Up
Part No.: 375-3658
S/N: EDP1-Up
Part No.: 375-3658
S/N: MXR1-Up
Part No.: 375-3658
S/N: SRZ1-Up
282
Specifications Section
RENR5077-12
g03003236
Illustration 268
Table 180
Specification for 375-3658 Water Pump Gp
Item
Qty
Part
Specification Description
1
1
5H-6734 O-Ring Seal
Lubricate the bore lightly with the fluid that is being sealed.
2
1
149-5462 O-Ring Seal
Lubricate the bore lightly with the fluid that is being sealed.
3
3
9S-8752 Full Nut
4
3
9M-2151 Taperlock Stud
A
-
-
Torque to 27 ± 4 N·m (239 ± 35 lb in).
Torque to 35 ± 4 N·m (26 ± 3 lb ft).
Clearance between the cover and the vanes of the impeller after installation is
0.5000 ± 0.4925 mm (0.01969 ± 0.01939 inch).
RENR5077-12
Illustration 269
283
Specifications Section
g03003256
284
Specifications Section
RENR5077-12
Table 181
Specification for 375-3658 Water Pump Gp
Item
Qty
Part
5
1
8C-5236 Lip Type Seal
Specification Description
Do not lubricate the sealing lip.
Before pressing the impeller on the shaft, lubricate the shaft with clean engine oil.
6
1
212-8180 Pump Drive
Shaft As
The end of the pump shaft must be flush with the face of the impeller within
± 0.15 mm (± 0.006 inch).
Diameter of the shaft for the impeller is 25.400 to 25.413 mm
(1.0000 to 1.0005 inch).
Width in the groove of the shaft for the thrust washer is 8.75 ± 0.05 mm
(0.344 ± 0.002 inch).
B
-
-
7
1
7N-4758 Thrust Washer
8
1
166-4375 Seal Gp
9
1
7G-8478 Adapter
10
1
3D-2824 O-Ring Seal
D
-
-
Bore of the 212-8184 Impeller is 25.342 ± 0.013 mm (0.9977 ± 0.0005 inch).
Thickness is 8.5 mm (0.33 inch)
Use the following procedure to install the seal group.
1. Lubricate the outside diameter of the ceramic ring and rubber seal with clean
water or with P80 lubricant.
2. Use installation tool and hand pressure to seat the ceramic ring and the
rubber seal into the housing.
3. Remove the spring from the seal assembly .
4. Use installation tool and hand pressure to press the seal assembly on the
shaft until the faces of the seal makes the contact lightly.
5. Install the spring.
Torque to 100 ± 10 N·m (74 ± 7 lb ft).
Lubricate the bore lightly with glycerine or equivalent.
Distance between the vanes of the impeller and the outside of the housing is
31.58 mm (1.243 inch).
i04935840
Auxiliary Water Pump
Part No.: 334-8471
S/N: 9H51-Up
SMCS Code: 1371
Part No.: 334-8471
S/N: ED51-Up
Part No.: 334-8471
S/N: 9F21-Up
Part No.: 334-8471
S/N: 9H61-Up
Part No.: 334-8471
S/N: CG21-Up
Part No.: 334-8471
S/N: ED81-Up
Part No.: 334-8471
S/N: ED21-Up
Part No.: 334-8471
S/N: MD81-Up
Part No.: 334-8471
S/N: WF21-Up
Part No.: 334-8471
S/N: M8A1-Up
Part No.: 334-8471
S/N: 9F31-Up
Part No.: 334-8471
S/N: M8B1-Up
Part No.: 334-8471
S/N: 9H31-Up
Part No.: 334-8471
S/N: EDC1-Up
Part No.: 334-8471
S/N: ED31-Up
Part No.: 334-8471
S/N: EDG1-Up
Part No.: 334-8471
S/N: 9H41-Up
Part No.: 334-8471
S/N: EDH1-Up
Part No.: 334-8471
S/N: JB41-Up
Part No.: 334-8471
S/N: SRH1-Up
RENR5077-12
285
Specifications Section
Part No.: 334-8471
S/N: EDJ1-Up
Part No.: 334-8471
S/N: SRK1-Up
Part No.: 334-8471
S/N: MXM1-Up
Part No.: 334-8471
S/N: EDP1-Up
Part No.: 334-8471
S/N: MXR1-Up
Part No.: 334-8471
S/N: SRZ1-Up
Illustration 270
g03111216
286
Specifications Section
RENR5077-12
Table 182
Specification for the 1W-9554 Auxiliary Water Pump Gp, 5N-2605 Auxiliary Water
Pump Gp, and 334-8471 Water Pump Gp
Item
Qty
Part
Specification Description
1
1
9X-4594 Lip Type Seal
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 (1.5 cu in).
Minimum leakage per minute for the water pump seal assembly at 138 kPa
(20 psi) of air pressure is less than 20 cc (1.2 cu in).
2
1
212-8183 Impeller
Bore of the impeller for shaft is 19.000 ± 0.013 mm (0.7480 ± 0.0005 inch).
3
1
212-8179 Shaft
B
2
5N-4383 Thrust Washer
Lubricate the shaft with a thin film of clean engine oil before pressing the
impeller (2) onto the shaft.
Diameter (D) is 19.050 to 19.063 mm (0.7500 to 0.7505 inch).
Width (A) of groove in the shaft for thrust washer is 6.25 ± 0.05 mm
(0.246 ± 0.002 inch).
Thickness of the new thrust washer is 6.000 ± 0.025 mm
(0.2362 ± 0.0010 inch).
After assembly, bore (C) in the bushing for auxiliary drive shaft is
75.000 ± 0.055 mm (2.9528 ± 0.0022 inch).
Diameter of new auxiliary drive shaft (not shown) is 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch).
Installation depth (E) in the housing assembly is 1.5 ± 0.5 mm
(0.06 ± 0.02 inch).
4
1
127-5400 Bushing
5
1
9M-3786 O-Ring Seal
Lubricate the bore of the O-ring seal with clean engine oil, glycerin, or clean
water.
6
1
235-3546 O-Ring Seal
Lubricate the bore of the O-ring seal lightly with sealant that is being sealed.
i04395622
Auxiliary Water Pump
Part No.: 9Y-8175
S/N: PAG1-Up
SMCS Code: 1371
Part No.: 9Y-8175
S/N: S2G1-Up
Part No.: 9Y-8175
S/N: GS61-Up
Part No.: 9Y-8175
S/N: MKH1-Up
Part No.: 9Y-8175
S/N: GS71-Up
Part No.: 9Y-8175
S/N: S2H1-Up
Part No.: 9Y-8175
S/N: GSA1-Up
Part No.: 9Y-8175
S/N: S2J1-Up
Part No.: 9Y-8175
S/N: S2A1-Up
Part No.: 9Y-8175
S/N: S2K1-Up
Part No.: 9Y-8175
S/N: S2B1-Up
Part No.: 9Y-8175
S/N: S2L1-Up
Part No.: 9Y-8175
S/N: S2D1-Up
Part No.: 9Y-8175
S/N: S2M1-Up
Part No.: 9Y-8175
S/N: S2E1-Up
Part No.: 9Y-8175
S/N: S2N1-Up
Part No.: 9Y-8175
S/N: S2F1-Up
Part No.: 9Y-8175
S/N: S2P1-Up
Part No.: 9Y-8175
S/N: B5G1-Up
Part No.: 9Y-8175
S/N: S2R1-Up
Part No.: 9Y-8175
S/N: MRG1-Up
Part No.: 9Y-8175
S/N: S2S1-Up
RENR5077-12
287
Specifications Section
Part No.: 9Y-8175
S/N: S2T1-Up
Part No.: 9Y-8175
S/N: S2W1-Up
Part No.: 9Y-8175
S/N: S2X1-Up
Part No.: 9Y-8175
S/N: S2Y1-Up
Part No.: 9Y-8175
S/N: S2Z1-Up
Illustration 271
Typical example
g02570218
288
Specifications Section
RENR5077-12
Table 183
Specification for the 9Y-8175 Auxiliary Water Pump Gp
Item
Qty
Part
A
1
212-8179 Shaft
B
2
5N-4383 Thrust Washer
C
1
212-8179 Shaft
Specification Description
Width of groove in the shaft for thrust washer is 6.25 ± 0.05 mm
(0.246 ± 0.002 inch).
Thickness of the new thrust washer is 6.000 ± 0.025 mm
(0.2362 ± 0.0010 inch).
Bore in the sleeve bearing for auxiliary drive shaft is
75.000 ± 0.055 mm (2.9528 ± 0.0022 inch).
Diameter of new auxiliary drive shaft (not shown) is
74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
D
1
212-8183 Impeller
Bore diameter of the impeller is 19.000 ± 0.013 mm
(0.7480 ± 0.0005 inch).
Diameter in the shaft for impeller is 19.050 to 19.063 mm
(0.7500 to 0.7505 inch).
E
1
127-5400 Bushing
Installation depth of the bushing in the housing assembly is
1.5 ± 0.5 mm (0.06 ± 0.02 inch).
1
1
9X-4594 Lip Type Seal
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 (1.5 cu in).
Minimum leakage per minute for the water pump seal assembly at
138 kPa (20 psi) of air pressure is less than 20 cc (1.2 cu in).
3
1
212-8179 Shaft
Lubricate the shaft with a thin film of clean engine oil before pressing
the impeller (2) onto the shaft. The end of the shaft must be flush
with the face of the impeller within 0.076 mm (0.003 inch).
4
1
235-3546 O-Ring Seal
Lubricate the bore of the O-ring seal lightly with sealant that is being
sealed.
5
1
9M-3786 O-Ring Seal
Lubricate the bore of the O-ring seal with clean engine oil, glycerin,
or clean water.
i04934477
Cooling System Pressure Cap
Part No.: 4N-3311
S/N: 9H61-Up
SMCS Code: 1382; 1392
Part No.: 4N-3311
S/N: GS61-Up
Part No.: 4N-3311
S/N: 9F21-Up
Part No.: 4N-3311
S/N: GS71-Up
Part No.: 4N-3311
S/N: CG21-Up
Part No.: 4N-3311
S/N: ED81-Up
Part No.: 4N-3311
S/N: 9F31-Up
Part No.: 4N-3311
S/N: MD81-Up
Part No.: 4N-3311
S/N: 9H31-Up
Part No.: 4N-3311
S/N: GSA1-Up
Part No.: 4N-3311
S/N: 9H41-Up
Part No.: 4N-3311
S/N: M8A1-Up
Part No.: 4N-3311
S/N: JB41-Up
Part No.: 4N-3311
S/N: S2A1-Up
Part No.: 4N-3311
S/N: 9H51-Up
Part No.: 4N-3311
S/N: M8B1-Up
Part No.: 4N-3311
S/N: ED51-Up
Part No.: 4N-3311
S/N: S2B1-Up
RENR5077-12
289
Specifications Section
Part No.: 4N-3311
S/N: EDC1-Up
Part No.: 4N-3311
S/N: S2S1-Up
Part No.: 4N-3311
S/N: S2D1-Up
Part No.: 4N-3311
S/N: S2T1-Up
Part No.: 4N-3311
S/N: S2E1-Up
Part No.: 4N-3311
S/N: S2W1-Up
Part No.: 4N-3311
S/N: S2F1-Up
Part No.: 4N-3311
S/N: S2X1-Up
Part No.: 4N-3311
S/N: B5G1-Up
Part No.: 4N-3311
S/N: S2Y1-Up
Part No.: 4N-3311
S/N: EDG1-Up
Part No.: 4N-3311
S/N: S2Z1-Up
Part No.: 4N-3311
S/N: MRG1-Up
Part No.: 4N-3311
S/N: PAG1-Up
Part No.: 4N-3311
S/N: S2G1-Up
Part No.: 4N-3311
S/N: EDH1-Up
Part No.: 4N-3311
S/N: MKH1-Up
Part No.: 4N-3311
S/N: S2H1-Up
Part No.: 4N-3311
S/N: EDJ1-Up
Part No.: 4N-3311
S/N: S2J1-Up
Part No.: 4N-3311
S/N: S2K1-Up
Part No.: 4N-3311
S/N: S2L1-Up
Part No.: 4N-3311
S/N: MXM1-Up
Part No.: 4N-3311
S/N: S2M1-Up
Part No.: 4N-3311
S/N: S2N1-Up
Part No.: 4N-3311
S/N: EDP1-Up
Part No.: 4N-3311
S/N: S2P1-Up
Part No.: 4N-3311
S/N: MXR1-Up
Part No.: 4N-3311
S/N: S2R1-Up
290
Specifications Section
RENR5077-12
g03106656
Illustration 272
Table 184
Specification for 4N-3311 Pressure Cap
Item
Qty
Part
-
-
-
Specification Description
Pressure that opens the cap relief valve is 48 kPa (7 psi).
Maximum vacuum that opens the suction valve is 7 kPa (1 psi).
RENR5077-12
291
Specifications Section
i04936900
Cylinder Block
SMCS Code: 1201
Part No.: 350-5225
S/N: M8A1-Up
Part No.: 350-5225
S/N: P8A1-Up
Part No.: 350-5225
S/N: M8B1-Up
Illustration 273
g02840856
Front view
Illustration 274
Bolt tightening sequence
g02852037
292
Specifications Section
RENR5077-12
Table 185
Specification for 350-5225 Cylinder Block Gp
Item
Qty
Part
A
16
8T-0099 Dowel
B
8
362-9677 Spacer Plate
Specification Description
Extension from top face of the cylinder block is 20.0 ± 0.5 mm
(0.79 ± 0.02 inch).
During assembly, bottom of the plate, top of block, and both sides of plate
gasket must be free from of fuel, oil, water, gasket adhesives, assembly
compounds or any other contaminates.
Thickness of one plate is 12.333 mm (0.4856 inch).
Thickness of one gasket between the cylinder block and spacer plates is
0.182 to 0.220 mm (0.0072 to 0.0087 inch).
C
8
144-5692 Plate Gasket
D
8
197-7008 Dowel
1
2
4W-4813 Plug
E
-
-
New dimension from centerline of crankshaft bearing bore to the top of the
block is 586.00 mm (23.071 inch).
Width of main bearing (F) is 340.030 ± 0.015 mm (13.3870 ± 0.0006 inch).
Width of cylinder block for main bearing cap is 339.985 ± 0.015 mm
(13.3852 ± 0.0006 inch).
Tight press fit between the sides of the main bearing cap and the cylinder
block is 0.075 mm (0.0030 inch).
Loose press fit between the sides of the main bearing cap and the cylinder
block is 0.015 mm (0.0006 inch).
Extension from top face of the cylinder block is 21.0 ± 0.5 mm
(0.83 ± 0.02 inch).
Torque to 100 ± 15 N·m (74 ± 11 lb ft).
2
5
223-1696 Crankshaft
Bearing Cap
G
-
-
New dimension from centerline of crankshaft bearing bore to bottom of block
(pan rails) is 230 mm (9.1 inch).
7X-7925 Bolt
Use the following procedure in order to tighten the bolts (3):
1. Install main bearing caps with the part number and FRONT toward the
front of the block. Each cap has a number. Each cap must be installed in the
same position as the correct number on the side of the cylinder block pan rail.
2. Before assembly, apply clean engine oil to the threads of the bolts.
3. Tighten the bolt in the numerical sequence as shown in Illustration 274 to
190 ± 14 N·m (140 ± 10 lb ft).
4. Again, tighten the bolt in the numerical sequence as shown in Illustration
274 to an angle of 180 ± 5 degrees.
3
20
RENR5077-12
293
Specifications Section
g02840857
Illustration 275
Front view
Table 186
Specification for 350-5225 Cylinder Block Gp
Item
Qty
Part
Specification Description
4
8
211-7826 Cylinder
Block Liner
5
8
352-6061 Liner Seal
H
-
-
Bore in the block for the camshaft bearings is 98.000 ± 0.020 mm
(3.8583 ± 0.0008 inch).
J
-
-
Oil holes must be positioned from horizontal at angle of 20 ± 5 degrees.
All centerlines through oil holes in the camshaft bearings and bearing
junctions must be in the position that is shown for each side of the cylinder
block.
6
24
7N-2046 O-Ring Seal
Before assembly, cover seals with either P-80 Rubber Lubricant Emulsion
or liquid soap.
7
8
6V-3348 O-Ring Seal
Before assembly, lightly lubricate the bore with the lubricant that is being
sealed.
K
-
-
For the correct method of determining height of the liner, refer to Testing
and Adjusting, “Cylinder Liner Projection”.
Before assembly, cover seals with either P-80 Rubber Lubricant Emulsion
or liquid soap.
Assemble dry seals on clean and dry liner grooves.
Bore in the block for the main bearings is 169.742 ± 0.020 mm
(6.6827 ± 0.0008 inch).
294
Specifications Section
RENR5077-12
g02840858
Illustration 276
Right side view
Table 187
Specification for 350-5225 Cylinder Block Gp
Item
Qty
Part
Specification Description
8
4
5F-9657 O-Ring Seal
Before assembly, lightly lubricate the bore with 5P-3975 Rubber Lubricant.
L
3
7N-2047 Dowel
Extension of dowel from the surface of the cylinder block is 6.0 ± 0.5 mm
(0.24 ± 0.02 inch).
M
2
4N-0683 Dowel
Extension of dowel from the surface of the cylinder block is 19.0 ± 0.5 mm
(0.75 ± 0.02 inch).
N
2
7N-2044 Dowel
Extension of dowel from the surface of the cylinder block is 40.0 ± 0.5 mm
(1.57 ± 0.02 inch).
RENR5077-12
295
Specifications Section
Camshaft Bearing Position
g03113600
Illustration 277
Left side view of engine
Table 188
Specification for 350-5225 Cylinder Block Gp
Item
Qty
Part
Specification Description
The camshaft bearings are installed into the cylinder block at the following positions:
-
-
-
Distance (A) from rear face of cylinder block is 1120.0 ± 1.5 mm (44.09 ± 0.06 inch).
-
-
-
Distance (B) from rear face of cylinder block is 850.0 ± 1.5 mm (33.46 ± 0.06 inch).
-
-
-
Distance (C) from rear face of cylinder block is 580.0 ± 1.5 mm (22.83 ± 0.06 inch).
-
-
-
Distance (D) from rear face of cylinder block is 310.0 ± 1.5 mm (12.20 ± 0.06 inch).
-
-
-
Distance (E) from rear face of cylinder block is 40.0 ± 1.5 mm (1.58 ± 0.06 inch).
i04936903
Cylinder Block
Part No.: 240-6653
S/N: GSA1-Up
SMCS Code: 1201
Part No.: 240-6653
S/N: S2A1-Up
Part No.: 240-6651
S/N: GS61-Up
Part No.: 240-6653
S/N: S2B1-Up
296
Specifications Section
Part No.: 240-6653
S/N: S2D1-Up
Part No.: 240-6653
S/N: S2E1-Up
Part No.: 240-6651
S/N: S2F1-Up
Part No.: 240-6653
S/N: B5G1-Up
Part No.: 240-6653
S/N: MRG1-Up
Part No.: 240-6653
S/N: PAG1-Up
Part No.: 240-6653
S/N: S2G1-Up
Part No.: 240-6653
S/N: MKH1-Up
Part No.: 240-6653
S/N: S2H1-Up
Part No.: 240-6653
S/N: S2J1-Up
Part No.: 240-6653
S/N: S2K1-Up
Part No.: 240-6653
S/N: S2L1-Up
Part No.: 240-6651
S/N: S2M1-Up
Part No.: 240-6653
S/N: S2N1-Up
Part No.: 240-6653
S/N: S2P1-Up
Part No.: 240-6653
S/N: S2R1-Up
Part No.: 240-6653
S/N: S2S1-Up
Part No.: 240-6653
S/N: S2T1-Up
Part No.: 240-6653
S/N: S2W1-Up
Part No.: 240-6653
S/N: S2X1-Up
Part No.: 240-6653
S/N: S2Y1-Up
Part No.: 240-6651
S/N: S2Z1-Up
RENR5077-12
RENR5077-12
Illustration 278
Front view
297
Specifications Section
g02617919
298
Specifications Section
RENR5077-12
Table 189
Specification for 240-6651 Cylinder Block Gp and 240-6653 Cylinder Block Gp
Item
1
Qty
16
Part
110-6994 Spacer Plate
Specification Description
During assembly, the bottom of spacer plates must be free of fuel,
oil, water, gasket adhesives, assembly compounds, and any other
contaminants.
Thickness is 12.313 mm (0.4848 inch).
2
16
144-5692 Plate Gasket
During assembly, both sides of plate gasket must be free of fuel,
oil, water, gasket adhesives, assembly compounds and any other
contaminants.
Thickness is 0.194 to 0.218 mm (0.0076 to 0.0086 inch).
3
2
4W-4813 Plug
4
-
-
5
18
101-1198 Camshaft
Bearing
Torque to 100 ± 15 N·m (74 ± 11 lb ft).
During assembly, top of cylinder block must be free of fuel, oil, water,
gasket adhesives, assembly compounds, and any other contaminants.
All centerlines through oil holes in the camshaft bearings and the
camshaft bearing junctions (5) must be positioned that is shown in
Illustration 278 for each side of the cylinder block.
Oil holes must be positioned from horizontal at an angle (D) of 20 ±
5 degrees.
6
8
6V-3348 O-Ring Seal
A
32
8T-0099 Dowel
B
-
-
16
197-7008 Dowel
E
-
-
New dimension from centerline of crankshaft bearing bore to the top of
the block is 586.00 mm (23.071 inch).
F
-
-
New dimension from centerline of crankshaft bearing bore to bottom of
block (pan rails) is 230.00 mm (9.055 inch).
G
-
-
Bore in the block for the main bearings:
Standard, original new size is 169.742 ± 0.020 mm (6.6827 ± 0.0008 inch).
0.63 mm (0.025 inch) larger than original size is 170.372 ± 0.020 mm
(6.7076 ± 0.0008 inch).
H
-
-
Width of main bearing is 340.030 ± 0.015 mm (13.3870 ± 0.0006 inch).
Width of cylinder block for main bearing cap is 339.985 ± 0.015 mm
(13.3852 ± 0.0006 inch).
C
Lubricate the bore lightly with the lubricant that is being sealed.
Extension of the dowel from the top face of the cylinder block is
21.0 ± 0.5 mm (0.83 ± 0.02 inch).
Bore in the cylinder block for the camshaft bearings is 98.000 ± 0.020 mm
(3.8583 ± 0.0008 inch).
Extension of the dowel from the top face of the cylinder block is
21.0 ± 0.5 mm (0.83 ± 0.02 inch).
RENR5077-12
299
Specifications Section
g02617921
Illustration 279
Right side view
Table 190
Specification for 240-6651 Cylinder Block Gp and 240-6653 Cylinder Block Gp
Item
Qty
Part
Specification Description
7
4
5F-9657 O-Ring Seal
J
2
7N-2047 Dowel
Extension of the dowel from the front face of the cylinder block is
6.0 ± 0.5 mm (0.24 ± 0.02 inch).
K
1
7N-2047 Dowel
Extension of the dowel from the rear face of the cylinder block is
6.0 ± 0.5 mm (0.24 ± 0.02 inch).
L
2
4N-0683 Dowel
Extension of dowels from the rear face of the cylinder block is
19.0 ± 0.5 mm (0.75 ± 0.02 inch).
M
2
7N-2044 Dowel
Extension of dowels from the front face of the cylinder block is
40.0 ± 0.5 mm (1.58 ± 0.02 inch).
Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
300
Specifications Section
RENR5077-12
Camshaft Bearing Position
g03113603
Illustration 280
Right side view
Table 191
Specification for 240-6651 Cylinder Block Gp and 240-6653 Cylinder Block Gp
Item
Qty
Part
Specification Description
The camshaft bearings are installed into the cylinder block at the following positions:
-
-
-
Distance (A) from front face of cylinder block is 2200.0 ± 1.5 mm (86.61 ± 0.06 inch).
-
-
-
Distance (B) from front face of cylinder block is 1930.0 ± 1.5 mm (75.98 ± 0.06 inch).
-
-
-
Distance (C) from front face of cylinder block is 1660.0 ± 1.5 mm (65.35 ± 0.06 inch).
-
-
-
Distance (D) from front face of cylinder block is 1390.0 ± 1.5 mm (54.72 ± 0.06 inch).
-
-
-
Distance (E) from front face of cylinder block is 1120.0 ± 1.5 mm (44.09 ± 0.06 inch).
-
-
-
Distance (F) from front face of cylinder block is 850.0 ± 1.5 mm (33.46 ± 0.06 inch).
-
-
-
Distance (G) from front face of cylinder block is 580.0 ± 1.5 mm (22.83 ± 0.06 inch).
-
-
-
Distance (H) from front face of cylinder block is 310.0 ± 1.5 mm (12.20 ± 0.06 inch).
-
-
-
Distance (J) from front face of cylinder block is 40.0 ± 1.5 mm (1.58 ± 0.06 inch).
RENR5077-12
301
Specifications Section
i04751049
Cylinder Block
SMCS Code: 1201
Part No.: 237-7957
S/N: GS71-Up
Part No.: 237-7957
S/N: S2A1-Up
Part No.: 237-7957
S/N: S2B1-Up
Part No.: 237-7957
S/N: S2D1-Up
Part No.: 237-7957
S/N: S2E1-Up
Part No.: 237-7957
S/N: S2F1-Up
Illustration 281
Front view
g02848764
302
Specifications Section
RENR5077-12
Table 192
Specification for 237-7957 Cylinder Block Gp
Item
Qty
Part
Specification Description
The top face of the cylinder block, bottom surface of spacer plate (2) and both sides of plate gasket (4) must be free
of fuel, oil, water, gasket adhesives, assembly compounds and any other contaminants during assembly.
1
2
4W-4813 Plug
Torque to 100 ± 15 N·m (74 ± 11 lb ft).
2
8
110-6994
Spacer Plate
Thickness is 12.313 mm (0.4848 inch).
3
16
8T-0099 Dowel
Extension of the dowel from the top face of the cylinder block is 20.0 ± 0.5 mm
(0.79 ± 0.02 inch).
4
8
144-5692 Plate
Gasket
Thickness of plate gasket that is between cylinder block and spacer plate is
0.194 to 0.218 mm (0.0076 to 0.0086 inch).
5
8
197-7008
Dowel
Extension of the dowel from the top face of the cylinder block is 21.0 ± 0.5 mm
(0.83 ± 0.02 inch).
A
10
101-1198
Camshaft
Bearing
Bore in the block for the camshaft bearing is 98.000 ± 0.020 mm (3.8583 ± 0.0008 inch).
B
-
-
All centerlines through oil holes in the camshaft bearings and the camshaft bearing
junctions (6) are shown for each side of the cylinder block.
Oil holes must be positioned from horizontal at an angle of 20 ± 5 degrees.
New dimension from centerline of crankshaft bearing bore to the top of the block is
586.0 mm (23.07 inch).
C
-
-
7
8
6V-3348
O-Ring Seal
Lubricate the bore lightly with sealant that is being sealed.
8
5
223-1696
Crankshaft
Bearing Cap
Install crankshaft bearing caps with the part number and FRONT toward the front of the
block. Each cap has a number. Each cap must be installed in the same position as the
correct number on the side of the cylinder block pan rail.
Width of crankshaft bearing cap (8) is 340.030 ± 0.015 mm (13.3870 ± 0.0006 inch).
Width of cylinder block for crankshaft bearing cap is 339.985 ± 0.015 mm
(13.3852 ± 0.0006 inch).
D
-
-
Tight press fit between the sides of the crankshaft bearing cap and the cylinder block is
0.075 mm (0.0030 inch).
Loose press fit between the sides of the crankshaft bearing cap and the cylinder block is
0.015 mm (0.0006 inch).
E
-
-
Bore in the block for the crankshaft bearings:
Standard, original new size is 169.742 ± 0.020 mm (6.6827 ± 0.0008 inch).
0.63 mm (0.025 inch) larger than original size is 170.372 ± 0.020 mm
(6.7076 ± 0.0008 inch).
F
-
-
New dimension from centerline of crankshaft bearing bore to bottom of block (pan rails) is
230.00 mm (9.055 inch).
9
20
7X-7925 Bolt
Use the following procedure to tighten the bolts.
1. Lubricate the threads with clean engine oil before assembly.
2. Tighten the bolts by hand.
2. Tighten the bolts in the numerical sequence as shown in Illustration 281 to
190 ± 14 N·m (140 ± 10 lb ft).
3. Again tighten the bolts in the numerical sequence as shown in Illustration 281 to an
angle of 180 ± 5 degrees.
RENR5077-12
303
Specifications Section
g02848765
Illustration 282
Right side view
Table 193
Specification for 237-7957 Cylinder Block Gp
Item
Qty
Part
Specification Description
G
1
7N-2047 Dowel
Extension of the dowel from the rear face of the cylinder block is 6.0 ± 0.5 mm
(0.24 ± 0.02 inch).
H
2
7N-2047 Dowel
Extension of the dowel from the front face of the cylinder block is 6.0 ± 0.5 mm
(0.24 ± 0.02 inch).
J
2
4N-0683 Dowel
Extension of the dowel from the rear face of the cylinder block is 19.0 ± 0.5 mm
(0.75 ± 0.02 inch).
K
2
7N-2044 Dowel
Extension of the dowel from the front face of the cylinder block is 40.0 ± 0.5 mm
(1.58 ± 0.02 inch).
10
4
5F-9657
O-Ring Seal
Lubricate the bore lightly with sealant that is being sealed.
i04890307
Cylinder Block
Part No.: 383-2091
S/N: ED31-Up
SMCS Code: 1201
Part No.: 383-2091
S/N: 9H41-Up
Part No.: 383-2091
S/N: ED21-Up
Part No.: 383-2091
S/N: ED51-Up
Part No.: 383-2091
S/N: WF21-Up
Part No.: 383-2091
S/N: ED81-Up
Part No.: 383-2091
S/N: 9H31-Up
Part No.: 383-2091
S/N: MD81-Up
304
Specifications Section
RENR5077-12
Part No.: 383-2091
S/N: SRH1-Up
Part No.: 383-2091
S/N: SRK1-Up
Part No.: 383-2091
S/N: MXM1-Up
Part No.: 383-2091
S/N: SRZ1-Up
Illustration 283
Front view of engine
g03022476
RENR5077-12
305
Specifications Section
Table 194
Specification for 383-2091 Cylinder Block Gp
Item
Qty
Part
Specification Description
During assembly, bottom of the plate, top of the block, and both the sides of the gasket plate must be free of all visible fuel,
oil, water and gasket adhesives, assembly compounds, or any other contaminates.
1
3
4W-4813 Plug
2
4
5F-9657 O-Ring Seal
Torque to 100 ± 15 N·m (74 ± 11 lb ft).
Lubricate the bore lightly with the lubricant that is being sealed.
All centerlines through oil holes in the camshaft bearings and the
camshaft bearing junctions must be positioned as shown in Illustration
283 on each side of cylinder block.
3
14
101-1198 Camshaft Bearing
Oil holes must be positioned from horizontal at an angle (D) of 20 ± 5
degrees as shown in Illustration 283.
Bore of the camshaft bearing after installation 90.32 ± 0.06 mm
(3.556 ± 0.002 inch).
4
2
7X-4805 O-Ring Seal
Lubricate the bore lightly with the lubricant that is being sealed.
5
8
6V-3348 O-Ring Seal
Lubricate the bore lightly with the lubricant that is being sealed.
A
24
8T-0099 Dowel
Extension of the dowel from the top face of the cylinder block is
21.0 ± 0.5 mm (0.83 ± 0.02 inch).
C
12
197-7008 Dowel
Extension of the dowel from the top face of the cylinder block is
21.0 ± 0.5 mm (0.83 ± 0.02 inch).
E
7
223-1696 Crankshaft
Bearing Cap
Width of the crankshaft bearing cap is 340.030 ± 0.015 mm
(13.3870 ± 0.0006 inch).
Width of cylinder block for main bearing cap is 339.985 ± 0.015 mm
(13.3852 ± 0.0006 inch).
F
-
-
New dimension from centerline of crankshaft bearing bore to the top
of the cylinder block is 586 mm (23.1 inch).
G
-
-
New dimension from centerline of crankshaft bearing bore to bottom of
cylinder block (pan rails) is 230 mm (9.1 inch).
H
-
-
Bore in the cylinder block for the main bearings is 169.742 ± 0.020 mm
(6.6827 ± 0.0008 inch).
306
Specifications Section
RENR5077-12
g03022496
Illustration 284
Section B-B
Table 195
Item
Qty
Part
Specification Description
J
1
7N-2047 Dowel
Extension of the dowel from the rear face of the cylinder block is 6.0 ± 0.5 mm
(0.24 ± 0.02 inch).
K
1
7N-2047 Dowel
Extension of the dowel from the front face of the cylinder block is 6.0 ± 0.5 mm
(0.24 ± 0.02 inch).
L
2
4N-0683 Dowel
Extension of the dowel from the rear face of the cylinder block is 19.0 ± 0.5 mm
(0.75 ± 0.012 inch).
M
2
7N-2044 Dowel
Extension of the dowel from the front face of the cylinder block is
40.0 ± 0.5 mm (1.57 ± 0.02 inch).
RENR5077-12
307
Specifications Section
g03022536
Illustration 285
Table 196
Item
Qty
Part
Specification Description
6
12
352-6061 Liner Seal
Assemble dry seals on clean and dry liner grooves.
Before assembly, cover seals with either P-80 Rubber Lubricant Emulsion or
liquid soap.
7
36
7N-2046 O-Ring Seal
Before assembly, cover seals with either P-80 Rubber Lubricant Emulsion or
liquid soap.
7X-7925 Bolt
Use the following procedure in order to tighten the crankshaft bearing cap
bolts:
1. Before assembly, lubricate the threads completely with clean engine oil.
2. Hand tighten the bolts in the tapped holes.
3. Tighten the bolts in the numerical sequence as shown in Illustration 285 to
190 ± 14 N·m (140 ± 10 lb ft).
4. Again, tighten the bolts for an additional angle of 180 ± 5 degrees.
8
28
308
Specifications Section
RENR5077-12
i04935311
Cylinder Block
SMCS Code: 1201
Part No.: 383-7223
S/N: 9H51-Up
Part No.: 383-7223
S/N: EDP1-Up
Illustration 286
Front view
g03109442
RENR5077-12
309
Specifications Section
Table 197
Specification for 240-6652 Cylinder Block Gp and 383-7223 Cylinder Block Gp
Item
Qty
Part
Specification Description
The top face of the cylinder block, bottom surface of spacer plate (4) and both sides of plate gasket (2) must be free of fuel,
oil, water, gasket adhesives, assembly compounds and any other contaminants during assembly.
1
16
197-7008 Dowel
2
16
144-5692 Plate Gasket
3
32
8T-0099 Dowel
4
16
110-6994 Spacer Plate
Thickness is 12.313 mm (0.4848 inch).
5
2
4W-4813 Plug
Torque to 100 ± 15 N·m (74 ± 11 lb ft).
A
18
116-1359 Camshaft Bearing
B
-
-
Extension of the dowel is 21.0 ± 0.5 mm (0.83 ± 0.02 inch).
Thickness of plate gasket that is between cylinder block and spacer plate
is 0.194 to 0.218 mm (0.0076 to 0.0086 inch).
Extension of the dowel is 21.0 ± 0.5 mm (0.83 ± 0.02 inch).
Bore of the bearing after installation is 86.00 ± 0.06 mm
(3.386 ± 0.002 inch).
All centerlines through oil holes in the camshaft bearings and the camshaft
bearing junctions (6) must be positioned as shown in Illustration 286 on
each side of the cylinder block.
Oil holes must be positioned from horizontal at an angle of 20.0 ± 0.5
degrees.
New dimension from centerline of crankshaft bearing bore to the top of
the block is 586 mm (23.1 inch).
C
-
-
7
8
6V-3348 O-Ring Seal
Lubricate the bore lightly with sealant that is being sealed.
Install crankshaft bearing caps with the part number and FRONT toward
the front of the block. Each cap has a number. Each cap must be installed
in the same position as the correct number on the side of the cylinder
block pan rail.
Width (D) of crankshaft bearing cap is 340.030 ± 0.015 mm
(13.3858 ± 0.0006 inch).
Width in the cylinder block for crankshaft bearing cap is
339.985 ± 0.015 mm (13.3852 ± 0.0006 inch).
8
9
223-1696 Crankshaft
Bearing Cap
E
-
-
Bore in the block for the crankshaft bearings is 169.742 ± 0.020 mm
(6.6827 ± 0.0008 inch).
F
-
-
New dimension from centerline of crankshaft bearing bore to bottom of
block (pan rails) is 230.00 mm (9.055 inch).
310
Specifications Section
RENR5077-12
g03109443
Illustration 287
Table 198
Item
Qty
Part
Specification Description
9
16
352-6061 Liner Seal
Before assembly, cover seals with either P-80 Rubber Lubricant Emulsion
or liquid soap.
10
48
7N-2046 O-Ring Seal
Before assembly, cover seals with either P-80 Rubber Lubricant Emulsion
or liquid soap.
Assemble dry seals on clean and dry liner grooves.
11
36
7X-7925 Bolt
Use the following procedure in order to tighten the crankshaft bearing
cap bolts.
1. Before assembly, Lubricate the threads with clean engine oil .
2. Tighten the bolts by hand.
Tighten the bolts in the numerical sequence as shown in Illustration 287
to 190 ± 14 N·m (140 ± 10 lb ft).
Again tighten the bolts to an additional angle of 180 ± 5 degrees
RENR5077-12
311
Specifications Section
g03109445
Illustration 288
Right side view
Table 199
Item
Qty
Part
Specification Description
G
3
7N-2047 Dowel
Extension of the dowel is 6.0 ± 0.5 mm (0.24 ± 0.02 inch).
12
4
5F-9657 O-Ring Seal
Lubricate the bore lightly with sealant that is being sealed.
H
2
4N-0683 Dowel
Extension of the dowel is 19.0 ± 0.5 mm (0.75 ± 0.02 inch).
J
2
7N-2044 Dowel
Extension of the dowel is 40.0 ± 0.5 mm (1.58 ± 0.02 inch).
i04890316
Cylinder Block
Part No.: 370-9890
S/N: EDG1-Up
SMCS Code: 1201
Part No.: 370-9890
S/N: EDH1-Up
Part No.: 370-9890
S/N: 9F21-Up
Part No.: 370-9890
S/N: EDJ1-Up
Part No.: 370-9890
S/N: CG21-Up
Part No.: 370-9890
S/N: MXR1-Up
Part No.: 370-9890
S/N: 9F31-Up
Part No.: 370-9890
S/N: JB41-Up
Part No.: 370-9890
S/N: 9H61-Up
Part No.: 370-9890
S/N: EDC1-Up
312
Specifications Section
Illustration 289
Front view of engine
RENR5077-12
g03022599
RENR5077-12
313
Specifications Section
Table 200
Specification for 370-9890 Cylinder Block Gp
Item
Qty
Part
1
2
4W-4813 Plug
2
4
5F-9657 O-Ring Seal
Specification Description
Torque to 100 ± 15 N·m (74 ± 11 lb ft).
Lubricate the bore lightly with the lubricant that is being sealed.
All centerlines through oil holes in the camshaft bearings and the
camshaft bearing junctions must be positioned as shown in Illustration
289 on each side of cylinder block.
3
18
101-1198 Camshaft Bearing
Oil holes must be positioned from horizontal at an angle (D) of 20 ± 5
degrees as shown in Illustration 289.
Bore of the camshaft bearing after installation is 90.32 ± 0.06 mm
(3.556 ± 0.002 inch).
4
3
7X-4805 O-Ring Seal
Lubricate the bore lightly with the lubricant that is being sealed.
5
8
6V-3348 O-Ring Seal
Lubricate the bore lightly with the lubricant that is being sealed.
A
32
8T-0099 Dowel
Extension of the dowel from the top face of the cylinder block is
21.0 ± 0.5 mm (0.83 ± 0.02 inch).
C
16
197-7008 Dowel
Extension of the dowel from the top face of the cylinder block is
21.0 ± 0.5 mm (0.83 ± 0.02 inch).
E
9
223-1696 Crankshaft
Bearing Cap
Width of the crankshaft bearing cap is 340.030 ± 0.015 mm
(13.3870 ± 0.0006 inch).
Width of cylinder block for main bearing cap is 339.985 ± 0.015 mm
(13.3852 ± 0.0006 inch).
F
-
-
New dimension from centerline of crankshaft bearing bore to the top
of the cylinder block is 586 mm (23.1 inch).
G
-
-
New dimension from centerline of crankshaft bearing bore to bottom of
cylinder block (pan rails) is 230 mm (9.1 inch).
H
-
-
Bore in the cylinder block for the main bearings is 169.742 ± 0.020 mm
(6.6827 ± 0.0008 inch).
314
Specifications Section
RENR5077-12
g03022577
Illustration 290
Section B-B
Table 201
Specification for 370-9890 Cylinder Block Gp
Item
Qty
Part
Specification Description
6
6
214-7568 O-Ring Seal
J
2
7N-2047 Dowel
Extension of the dowel from the rear face of the cylinder block is 6.0 ± 0.5 mm
(0.24 ± 0.02 inch).
K
1
7N-2047 Dowel
Extension of the dowel from the front face of the cylinder block is 6.0 ± 0.5 mm
(0.24 ± 0.02 inch).
L
2
4N-0683 Dowel
Extension of the dowel from the rear face of the cylinder block is 19.0 ± 0.5 mm
(0.75 ± 0.012 inch).
M
2
7N-2044 Dowel
Extension of the dowel from the front face of the cylinder block is
40.0 ± 0.5 mm (1.57 ± 0.02 inch).
Lubricate the bore lightly with the lubricant that is being sealed.
RENR5077-12
315
Specifications Section
g03022596
Illustration 291
Front view
Table 202
Item
Qty
Part
Specification Description
7
16
352-6061 Liner Seal
Assemble dry seals on clean and dry liner grooves.
Before assembly, cover seals with either P-80 Rubber Lubricant Emulsion or
liquid soap.
8
48
7N-2046 O-Ring Seal
Before assembly, cover seals with either P-80 Rubber Lubricant Emulsion or
liquid soap.
7X-7925 Bolt
Use the following procedure in order to tighten the crankshaft bearing cap
bolts:
1. Before assembly, lubricate the threads completely with clean engine oil.
2. Hand tighten the bolts in the tapped holes.
3. Tighten the bolts in the numerical sequence as shown in Illustration 291 to
190 ± 14 N·m (140 ± 10 lb ft).
4. Again, tighten the bolts to an additional angle of 180 ± 5 degrees.
9
36
316
Specifications Section
RENR5077-12
i03152764
Cylinder Block
SMCS Code: 1201
(B) Thickness of the plate gasket
between the cylinder block and spacer
plate ...................................... 0.194 to 0.218 mm
(0.0076 to 0.0086 inch)
(C) Extension of the dowel from the top face of the
cylinder block .. 21.0 ± 0.5 mm (0.83 ± 0.02 inch)
Part No.: 122-5954
S/N: S2Z1-Up
(1) Torque for four plugs ...................... 100 ± 15 N·m
(75 ± 11 lb ft)
(2) Lubricate the bore of the O-ring seals lightly with
the lubricant that is being sealed.
(D) Height of the cylinder liner
For the correct method of determining the height
of the cylinder liner, refer to Testing And Adjusting,
“Cylinder Liner Projection”.
(E) Bore in the block for the camshaft
bearings ............................... 98.000 ± 0.020 mm
(3.8583 ± 0.0008 inch)
(F) The oil holes in the camshaft bearings must
be positioned from horizontal at the following
angle: .......................................... 20 ± 5 degrees
Note: All centerlines through the oil holes in the
camshaft bearings (F) and the camshaft bearing
joints (3) must be in the position that is shown for
each side of the cylinder block.
Illustration 292
g01417382
Front view
(G) New dimension from centerline of crankshaft
bearing bore to the top of the block ....... 586 mm
(23.1 inch)
(H) New dimension from centerline of crankshaft
bearing bore to bottom of block (pan
rails) ....................................... 230 mm (9.1 inch)
(J) Bore in the block for the main bearings
Standard, original new
size .................................... 169.742 ± 0.020 mm
(6.6827 ± 0.0008 inch)
0.63 mm (0.025 inch) larger than original
size .................................... 170.372 ± 0.020 mm
(6.7075 ± 0.0008 inch)
(K) Dimension for crankshaft main bearing cap
Illustration 293
g01434393
Right side view
Note: During assembly, the bottom of spacer plates,
top of cylinder block and both sides of plate gasket
must be free of fuel, oil, water, gasket adhesives,
assembly compounds and any other contaminants.
(A) Thickness of the spacer plate .......... 12.313 mm
(0.4848 inch)
Width of crankshaft main bearing
cap ..................................... 340.030 ± 0.015 mm
(13.3870 ± 0.0006 inch)
Width of cylinder block for crankshaft main
bearing cap ........................ 339.985 ± 0.015 mm
(13.3852 ± 0.0006 inch)
Tight press fit between the sides of the
crankshaft main bearing cap and the cylinder
block ............................. 0.075 mm (0.0030 inch)
RENR5077-12
317
Specifications Section
Loose press fit between the sides of the
crankshaft main bearing cap and the cylinder
block ............................. 0.015 mm (0.0006 inch)
(4) Main bearing cap
Use the following procedure to tighten the crankshaft
main bearing cap bolts:
1. Install main bearing caps with the part number
and “FRONT” toward the front of the block. Each
cap has a number. Each cap must be installed in
the same position as the correct number on the
side of the cylinder block pan rail.
2. Before assembly, apply clean engine oil on the
threads of the bolts.
3. Tighten bolt (5) through bolt (8) in the numerical
sequence that is shown in Illustration 292 to a
torque of 190 ± 14 N·m (140 ± 10 lb ft).
4. Tighten bolt (5) through bolt (8) again in the
numerical sequence to a rotation of 180 ± 5
degrees.
(L) Extension of the dowel from the rear face of the
cylinder block .... 6.0 ± 0.5 mm (0.24 ± 0.02 inch)
(M) Extension of the dowel from the front face of the
cylinder block .... 6.0 ± 0.5 mm (0.24 ± 0.02 inch)
(N) Extension of the dowel from the rear face of the
cylinder block .. 19.0 ± 0.5 mm (0.75 ± 0.02 inch)
(P) Extension of the dowel from the front face of the
cylinder block .. 40.0 ± 0.5 mm (1.57 ± 0.02 inch)
i04396472
Cylinder Liner
SMCS Code: 1216
Part No.: 211-7826
Illustration 294
g02572576
318
Specifications Section
RENR5077-12
Table 203
Specification for the 211-7826 Cylinder Block Liner118-9494 Cylinder Block Liner350-0074 Cylinder Liner
Item
Qty
Part
A
-
-
Bore in new cylinder liner is 170.025 ± 0.025 mm
(6.6939 ± 0.0010 inch).
B
-
-
Thickness of flange (1) on cylinder liner is 12.65 ± 0.02 mm
(0.498 ± 0.001 inch).
-
-
-
Use the liner again with any used piston or any new piston if all the
measurements are in the following range of 170.000 to 170.152 mm
(6.6929 to 6.6989 inch). Use a FLEX-HONE first.
-
-
-
Use the liner again with the original piston if the measurements of
the upper bore are in the following range of 170.000 to 170.229 mm
(6.6929 to 6.7019 inch). Use a FLEX-HONE first.
-
Use the following procedure to install the cylinder liner:
1. Apply liquid soap on the cylinder block liner bore surfaces and the
rubber seals that are on the lower end of the cylinder liner.
2. Dip the filler band (2) completely in clean engine oil for a moment.
3. Immediately install the filler band in the groove that is under the
flange.
4. Immediately install the cylinder liner into the cylinder block before
the expansion of the filler band.
-
-
Specification Description
Refer to Reuse And Salvage Guidelines, SEBF8049, “Visual Inspection of the Piston” for more information. Also, refer to
Guideline For Reusable Parts And Salvage Operations, SEBF8068, “Cylinder Liners” for more information.
i04935247
Piston and Rings
(One-Piece Piston)
SMCS Code: 1214
Part No.: 371-0822
S/N: 9F21-Up
Part No.: 371-0822
S/N: CG21-Up
Part No.: 371-0822
S/N: ED21-Up
Part No.: 371-0822
S/N: WF21-Up
Part No.: 371-0822
S/N: 9H31-Up
Part No.: 371-0822
S/N: ED31-Up
Part No.: 371-0822
S/N: 9H41-Up
Part No.: 371-0822
S/N: JB41-Up
Part No.: 371-0822
S/N: 9H51-Up
Part No.: 371-0822
S/N: ED51-Up
Part No.: 371-0822
S/N: 9H61-Up
Part No.: 281-6139
S/N: GS61-Up
Part No.: 281-6139
S/N: GS71-Up
Part No.: 371-0822
S/N: ED81-Up
Part No.: 371-0822
S/N: MD81-Up
Part No.: 281-6139
S/N: GSA1-Up
Part No.: 332-7924
S/N: M8A1-Up
Part No.: 332-7924
S/N: P8A1-Up
Part No.: 332-7924
S/N: M8B1-Up
Part No.: 371-0822
S/N: EDC1-Up
Part No.: 371-0822
S/N: EDG1-Up
Part No.: 371-0822
S/N: EDH1-Up
Part No.: 371-0822
S/N: SRH1-Up
RENR5077-12
319
Specifications Section
Part No.: 371-0822
S/N: SRK1-Up
Part No.: 371-0822
S/N: EDP1-Up
Part No.: 371-0822
S/N: MXR1-Up
Part No.: 371-0822
S/N: SRZ1-Up
Illustration 295
g02572656
320
Specifications Section
RENR5077-12
Table 204
Specification for 281-6139 Piston and Rod Gp, 281-6141 Piston and Rod Gp, 333-2239 Piston
and Rod Gp, 282-9965 Piston and Rod Gp, 282-0645 Piston and Rod Gp, 341-2955 Piston and
Rod Gp, 371-0822 Piston, and 332-7924 Piston and Rod Gp
Item
-
Qty
-
Part
Specification Description
-
Refer to Guideline for Reusable Parts for information on the pistons, the
piston pins, and the retaining rings.
This piston has a square top piston ring. Use the 246-1176 Piston Ring
Groove Gauge Gp for measuring the top piston ring groove.
-
-
-
This piston has a keystone type of intermediate piston ring. Use the
1U-6431 Piston Ring Groove Gauge Gp for measuring the intermediate
piston ring groove. For correct use of the piston ring groove gauge group,
refer to the instruction card that is with the piston ring groove gauge group.
-
-
-
Before assembly of the piston rings, lubricate the ring grooves with clean
engine oil. After assembly, lubricate the mating surfaces of the rings to the
cylinder liner with clean engine oil.
Install the top piston ring with the “UP-1” side toward the top of the piston.
1
1
214-6066 Top Piston Ring
When the new top piston ring is installed in a cylinder liner with a bore size
of 170 mm (6.7 inch), the clearance between the ends of the piston ring is
0.625 ± 0.125 mm (0.0246 ± 0.0049 inch).
Thickness of new top piston ring is 3.88 mm (0.153 inch).
Install the intermediate piston ring with the “UP-2” side toward the top
of the piston.
2
1
144-5695 Intermediate
Piston Ring
When the new intermediate piston ring is installed in a cylinder liner with a
bore size of 170 mm (6.7 inch), the clearance between the ends of the
piston ring is 1.00 ± 0.15 mm (0.039 ± 0.006 inch).
Thickness intermediate piston ring is 3.785 mm (0.1490 inch).
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.
Width of groove in new piston for the oil control piston ring is
4.04 to 4.07 mm (0.159 to 0.160 inch).
3
1
223-6361 Oil Control
Piston Ring
Thickness oil Control piston ring is 3.97 to 3.99 mm (0.156 to 0.157 inch).
When the new oil control piston ring is installed in a cylinder liner with a
bore size of 170 mm (6.7 inch), the clearance between the ends of the
piston ring is 0.5 to 0.8 mm (0.02 to 0.03 inch).
After the piston rings have been installed, rotate the piston rings so that
the end gaps are 120 degrees from each other.
4
-
-
Bore diameter for piston pin is 70.0705 ± 0.0075 mm
(2.75867 ± 0.00030 inch).
Before assembly, lubricate the piston pin, the piston pin bore, the
connecting rod eye, and the connecting rod pin bearing with clean engine
oil.
5
1
263-8955 Piston Pin
Outside diameter is 69.930 ± 0.005 mm (2.7531 ± 0.0002 inch).
Length is 101.70 ± 102.00 mm (4.004 ± 4.016 inch).
The 263-8955 Piston Pin is not interchangeable with the former
197-0560 Piston Pin.
6
2
253-1238 Pin Retainer
Assemble the pin retainer with the gap towards the top of the piston.
Thickness is 2.36 ± 0.08 mm (0.093 ± 0.003 inch).
-
-
-
Refer to Table 205 for the part numbers of the tools that are used in
servicing the piston.
RENR5077-12
321
Specifications Section
Table 205
Service Tools
(1)
(2)
Item
Qty
Part
-
-
271-0498
Expander Ring
-
-
1P-1861
Retaining Ring Pliers
-
-
1U-7616
Piston Ring Compressor Gp
-
-
246-1176
Piston Ring Groove Gauge Gp(1)
-
-
1U-6431
Piston Ring Groove Gauge Gp(2)
Specification Description
Only for the top ring groove
Only for the intermediate ring groove
i04930033
Piston and Rings
(One-Piece Piston)
SMCS Code: 1214
Part No.: 223-6363
S/N: S2A1-Up
Part No.: 223-6363
S/N: S2B1-Up
Part No.: 223-6363
S/N: S2D1-Up
Part No.: 223-6363
S/N: S2E1-Up
Part No.: 223-6363
S/N: S2F1-Up
Part No.: 223-6363
S/N: B5G1-Up
Part No.: 223-6363
S/N: MRG1-Up
Part No.: 223-6363
S/N: PAG1-Up
Part No.: 223-6363
S/N: S2G1-Up
Part No.: 223-6363
S/N: MKH1-Up
Part No.: 223-6363
S/N: S2H1-Up
Part No.: 223-6363
S/N: S2J1-Up
Part No.: 223-6363
S/N: S2K1-Up
Part No.: 223-6363
S/N: S2L1-Up
Part No.: 223-6363
S/N: S2M1-Up
Part No.: 223-6363
S/N: S2N1-Up
Part No.: 223-6363
S/N: S2P1-Up
Part No.: 223-6363
S/N: S2R1-Up
Part No.: 223-6363
S/N: S2S1-Up
Part No.: 223-6363
S/N: S2T1-Up
Part No.: 223-6363
S/N: S2W1-Up
Part No.: 223-6363
S/N: S2X1-Up
Part No.: 223-6363
S/N: S2Y1-Up
Part No.: 223-6363
S/N: S2Z1-Up
322
Specifications Section
Illustration 296
RENR5077-12
g03099656
RENR5077-12
323
Specifications Section
Table 206
Specification for 223-6362 Piston and Rod Gp and 223-6363 Piston and Rod Gp
Item
-
Qty
-
Part
Specification Description
-
Refer to Guideline for Reusable Parts for information on the pistons, the
piston pins, and the retaining rings.
This piston has a square top piston ring. Use the 246-1176 Piston Ring
Groove Gauge Gp for measuring the top piston ring groove.
-
-
-
This piston has a keystone type of intermediate piston ring. Use the
1U-6431 Piston Ring Groove Gauge Gp for measuring the intermediate
piston ring groove. For correct use of the piston ring groove gauge group,
refer to the instruction card that is with the piston ring groove gauge group.
-
-
-
Before assembly of the piston rings, lubricate the ring grooves with clean
engine oil. After assembly, lubricate the mating surfaces of the rings to the
cylinder liner with clean engine oil.
Install the top piston ring with the “UP-1” side toward the top of the piston.
1
1
214-6066 Top Piston Ring
When the new top piston ring is installed in a cylinder liner with a bore size
of 170 mm (6.7 inch), the clearance between the ends of the piston ring is
0.625 ± 0.125 mm (0.0246 ± 0.0049 inch).
Thickness of new top piston ring is 3.88 mm (0.153 inch).
Install the intermediate piston ring with the “UP-2” side toward the top
of the piston.
2
1
144-5695 Intermediate
Piston Ring
When the new intermediate piston ring is installed in a cylinder liner with a
bore size of 170 mm (6.7 inch), the clearance between the ends of the
piston ring is 1.00 ± 0.15 mm (0.039 ± 0.006 inch).
Thickness intermediate piston ring is 3.785 mm (0.1490 inch).
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.
Width of groove in new piston for the oil control piston ring is
4.04 to 4.07 mm (0.159 to 0.160 inch).
3
1
223-6361 Oil Control
Piston Ring
Thickness oil Control piston ring is 3.97 to 3.99 mm (0.156 to 0.157 inch).
When the new oil control piston ring is installed in a cylinder liner with a
bore size of 170 mm (6.7 inch), the clearance between the ends of the
piston ring is 0.5 to 0.8 mm (0.02 to 0.03 inch).
After the piston rings have been installed, rotate the piston rings so that
the end gaps are 120 degrees from each other.
4
5
-
1
-
197-0560 Piston Pin
Bore diameter for piston pin is 70.060 to 70.075 mm (2.7583 to 2.7589 inch).
Before assembly, lubricate the piston pin, the piston pin bore, the
connecting rod eye, and the connecting rod pin bearing with clean engine
oil.
Outside diameter is 69.962 ± 0.005 mm (2.7544 ± 0.0002 inch).
Length is 101.85 ± 0.15 mm (4.010 ± 0.006 inch).
6
2
253-1238 Pin Retainer
Assemble the pin retainer with the gap towards the top of the piston.
Thickness is 2.36 ± 0.08 mm (0.093 ± 0.003 inch).
-
-
-
Refer to Table 207 for the part numbers of the tools that are used in
servicing the piston.
324
Specifications Section
RENR5077-12
Table 207
Service Tools
Item
Qty
Part
-
-
6V-4020
Piston Ring Expander Gp
-
-
6V-4023
Handle As
-
-
6V-4024
Guide Ring
-
-
1P-1861
Retaining Ring Pliers
-
-
1U-7616
Piston Ring Compressor Gp
-
-
246-1176
Piston Ring Groove Gauge Gp(1)
-
-
1U-6431
Piston Ring Groove Gauge Gp(2)
(1)
(2)
Specification Description
Only for the top ring groove
Only for the intermediate ring groove
i03132941
Piston and Rings
(Two-Piece Piston)
SMCS Code: 1214
Part No.: 101-0829
S/N: S2A1-Up
Part No.: 101-0829
S/N: S2B1-Up
Part No.: 101-0829
S/N: S2D1-Up
Part No.: 101-0829
S/N: S2E1-Up
Part No.: 101-0829
S/N: S2S1-Up
Part No.: 101-0829
S/N: S2T1-Up
Part No.: 101-0829
S/N: S2W1-Up
Part No.: 101-0829
S/N: S2X1-Up
Part No.: 101-0829
S/N: S2Y1-Up
Part No.: 101-0829
S/N: S2Z1-Up
Part No.: 101-0829
S/N: S2F1-Up
Part No.: 101-0829
S/N: S2G1-Up
Part No.: 101-0829
S/N: S2H1-Up
Part No.: 101-0829
S/N: S2J1-Up
Part No.: 101-0829
S/N: S2K1-Up
Part No.: 101-0829
S/N: S2L1-Up
Part No.: 101-0829
S/N: S2M1-Up
Part No.: 101-0829
S/N: S2N1-Up
Part No.: 101-0829
S/N: S2P1-Up
Part No.: 101-0829
S/N: S2R1-Up
Illustration 297
g01611477
This piston has a Keystone top and Keystone
intermediate rings. The 1U-6431 Piston Ring Groove
Gauge is necessary for measuring the ring grooves in
Keystone pistons. For correct use of the gauge group,
see the instruction card that is with the gauge group.
RENR5077-12
Top Piston Ring (1)
Install the top ring with the “Up-1” side toward the
top of the piston.
Thickness of new top piston ring ................ 3.91 mm
(0.154 inch)
When the piston ring is installed in a cylinder liner
with a bore size of 170 mm (6.7 inch), the clearance
between the ends of the piston ring is the following
value. ...... 0.625 ± 0.125 mm (0.0246 ± 0.0049 inch)
The increase in the clearance between the ends
of the piston ring for each 0.03 mm (0.001 inch)
increase in the cylinder liner bore size is the following
value. ...................................... 0.08 mm (0.003 inch)
Intermediate Piston Ring (2)
Install the intermediate ring with the “Up-2” side
toward the top of the piston.
Thickness of new intermediate piston
ring ...................................... 3.785 mm (0.1490 inch)
When the piston is installed in a cylinder liner with
a bore size of 170 mm (6.7 inch), the clearance
between the ends of the piston ring is the following
value. .............. 1.00 ± 0.15 mm (0.039 ± 0.006 inch)
The increase in the clearance between the ends
of the piston ring for each 0.03 mm (0.001 inch)
increase in the cylinder liner bore size is the following
value. ...................................... 0.08 mm (0.003 inch)
Oil Control Piston Ring (3)
Width of groove in piston for the new piston
ring .......... 5.050 ± 0.010 mm (0.1988 ± 0.0004 inch)
Thickness of new piston ring ....... 4.954 ± 0.019 mm
(0.1950 ± 0.0007 inch)
Clearance between groove and new piston
ring ........ 0.067 to 0.125 mm (0.0026 to 0.0049 inch)
When the piston ring is installed in a cylinder liner
with a bore size of 170 mm (6.7 inch), the clearance
between the ends of the piston ring is the following
value. .............. 0.70 ± 0.19 mm (0.028 ± 0.007 inch)
The increase in the clearance between the ends
of the piston ring for each 0.03 mm (0.001 inch)
increase in the cylinder liner bore size is the following
value. ...................................... 0.08 mm (0.003 inch)
Install the oil control ring so that the gap in the spring
is 180 degrees away from the gap in the ring. The
white portion of the spring must be visible at the ring
gap.
325
Specifications Section
After all of the piston rings have been installed, rotate
the rings so that the end gaps are separated by 120
degrees. The ring gap for the oil ring must be aligned
in the plane of the pin bore.
Piston Pin Bore (4)
Measure the piston pin bore in the bushings in two
places for each bushing in a vertical direction.
Bore diameter in the crown assembly for piston
pin ......... 70.035 ± 0.005 mm (2.7573 ± 0.0002 inch)
Bore diameter in the piston skirts for piston
pin ......... 69.983 ± 0.005 mm (2.7552 ± 0.0002 inch)
Piston Pin (5)
Measure the piston pin diameter on each end in a
vertical and horizontal direction.
Inside diameter of the piston pin ........ 35.0 ± 0.5 mm
(1.38 ± 0.02 inch)
Outside diameter of the piston
pin ......... 69.962 ± 0.005 mm (2.7544 ± 0.0002 inch)
Length of the piston pin ............... 133.00 ± 0.13 mm
(5.236 ± 0.005 inch)
Pin Retainer (6)
Assemble the retainer with the opening toward the
top of the piston.
326
Specifications Section
RENR5077-12
i04932333
Piston and Rings
SMCS Code: 1214
Part No.: 371-0823
S/N: MXM1-Up
Illustration 298
g03103876
RENR5077-12
327
Specifications Section
Table 208
Specification for 371-0823 Piston
Item
Qty
Part
Specification Description
Before assembly of the piston rings, lubricate the ring grooves with clean engine oil. After assembly, lubricate the mating
surfaces of the rings to the cylinder liner with clean engine oil.
1
2
1
1
214-6066 Top Piston Ring
144-5695 Intermediate
Piston Ring
Install the top piston ring with the “UP-1” side towards the top of the piston.
When the new top piston ring is installed in a cylinder liner, the
clearance between the ends of the piston ring is 0.625 ± 0.125 mm
(0.0246 ± 0.0049 inch).
Thickness of new top piston ring is 3.88 mm (0.153 inch).
Install the intermediate piston ring with the “UP-2” side towards the top
of the piston.
When the new intermediate piston ring is installed in a cylinder liner,
the clearance between the ends of the piston ring is 1.00 ± 0.15 mm
(0.039 ± 0.006 inch).
Thickness of intermediate piston ring is 3.785 mm (0.1490 inch).
3
1
223-6361 Oil Control
Piston Ring
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.
Width of groove in new piston for the oil control piston ring is
4.04 mm to 4.07 mm (0.159 to 0.160 inch).
Thickness of oil Control piston ring is 3.97 to 3.99 mm (0.156 to 0.157 inch).
When the new oil control piston ring is installed in a cylinder liner, the
clearance between the ends of the piston ring is 0.5 mm to 0.8 mm
(0.02 to 0.03 inch).
-
-
-
After the piston rings have been installed, rotate the piston rings so that the
end gaps are 120 degrees from each other.
4
2
253-1238 Pin Retainer
5
1
263-8955 Piston Pin
Assemble the pin retainer with the gap towards the top of the piston.
Thickness is 2.36 ± 0.08 mm (0.093 ± 0.003 inch).
Before assembly, lubricate the piston pin, the piston pin bore, the connecting
rod eye, and the connecting rod pin bearing with clean engine oil.
Outside diameter is 69.930 ± 0.005 mm (2.7531 ± 0.0002 inch).
Length is 101.7 to 102.0 mm (4.00 to 4.02 inch).
Bore diameter in the piston for the piston pin is 70.0705 ± 0.0075 mm
(2.75867 ± 0.00030 inch).
328
Specifications Section
RENR5077-12
i04415052
Piston and Rings
(Two-Piece Piston)
SMCS Code: 1214
Part No.: 160-5910
S/N: S2J1-Up
Part No.: 160-5910
S/N: S2N1-Up
Part No.: 160-5910
S/N: S2T1-Up
Part No.: 160-5910
S/N: S2X1-Up
Part No.: 160-5910
S/N: S2Z1-Up
g02612156
Illustration 299
Typical example
Table 209
Specification for 160-5910 Piston and Rod Gp
Item
Qty
Part
Specification Description
This piston has a Keystone top ring. This piston also has Keystone intermediate rings. The 204-8041 Piston Ring Groove
Gauge Gp is necessary for measuring the ring grooves in the Keystone pistons. For correct use of the gauge group,
refer to the instruction card that is with the gauge group.
Prior to the installation of the rings, lubricate the ring grooves with clean engine oil. Lubricate the mating surfaces of the rings
to the cylinder liner with clean engine oil, after assembly.
(continued)
RENR5077-12
329
Specifications Section
(Table 209, contd)
Install the piston ring with the “Up-1” side toward the top of the piston.
1
1
229-1632 Top Piston
Ring
When the piston ring is installed in a cylinder liner with a bore size of
170 mm (6.7 inch), the clearance between the ends of the piston ring
is 0.625 ± 0.125 mm (0.0246 ± 0.0049 inch).
The increase in the clearance between the ends of the piston ring
for each 0.03 mm (0.001 inch) increase in the cylinder liner bore size
is 0.08 mm (0.003 inch).
Thickness of the new top piston ring is 4.5 mm (0.18 inch).
Install the piston ring with the “Up-2” side toward the top of the piston.
2
1
144-5695 Intermediate
Piston Ring
When the piston ring is installed in a cylinder liner with a bore size
of 170 mm (6.7 inch), the clearance between the ends of the piston
ring is 1.00 ± 0.15 mm (0.039 ± 0.006 inch).
The increase in the clearance between the ends of the piston ring
for each 0.03 mm (0.001 inch) increase in the cylinder liner bore size
is 0.08 mm (0.003 inch).
Thickness of the new intermediate piston ring is 3.785 mm
(0.1490 inch).
Width of groove in piston for the new oil piston ring is
4.055 ± 0.015 mm (0.1596 ± 0.0006 inch).
Thickness of new oil piston ring is 3.980 ± 0.010 mm
(0.1567 ± 0.0004 inch).
3
1
165-6668 Oil Control
Piston Ring
Clearance between groove and new oil piston ring is
0.050 mm to 0.100 mm (0.0020 mm to 0.0039 inch).
When the piston ring is installed in a cylinder liner with a bore size
of 170 mm (6.7 inch), the clearance between the ends of the piston
ring is 0.65 ± 0.15 mm (0.026 ± 0.006 inch).
The increase in the clearance between the ends of the piston ring
for each 0.03 mm (0.001 inch) increase in the cylinder liner bore size
is 0.08 mm (0.003 inch).
-
4
-
-
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.
After all of the piston rings have been installed, rotate the piston rings
so that the end gaps are separated by 120 degrees. The ring gap for
the oil piston ring must be aligned in the plane of the pin bore.
-
-
Before assembly of the piston pin, lubricate the piston pin, the piston
pin bore, the connecting rod eye, and the connecting rod pin bearing
with clean engine oil.
1
172-0919 Crown As
Measure the pin bore in the bushings in two places for each bushing
in a vertical direction.
Bore for the piston pin is 70.0525 ± 0.0075 mm
(2.75796 ± 0.00029 inch).
1
155-5271 Piston Skirt
Measure the pin bore in a vertical direction.
Bore is 69.988 ± 0.005 mm (2.7554 ± 0.0002 inch).
5
1
138-8508 Piston Pin
Measure the pin diameter on each end in a vertical and horizontal
direction.
Outside diameter is 69.962 ± 0.005 mm (2.7544 ± 0.0002 inch).
Inside diameter is 33.0 ± 0.5 mm (1.30 ± 0.02 inch).
Length is 137.55 ± 0.15 mm (5.415 ± 0.006 inch).
6
2
8N-7296 Pin Retainer
Assemble the pin retainer with the opening towards top of the piston.
330
Specifications Section
RENR5077-12
i02674253
Piston and Rings
(Two-Piece Piston)
(2) Intermediate piston ring
Install the piston ring with the “Up-2” side toward
the top of the piston.
When the piston ring is installed in a cylinder
liner with a bore size of 170 mm (6.7 inch), the
clearance between the ends of the piston ring is
the following value. .................... 1.00 ± 0.15 mm
(0.039 ± 0.006 inch)
The increase in the clearance between the ends
of the piston ring for each 0.03 mm (0.001 inch)
increase in the cylinder liner bore size is the
following value. ................. 0.08 mm (0.003 inch)
SMCS Code: 1214
Part No.: 249-5671
S/N: B5G1-Up
Part No.: 249-5671
S/N: MRG1-Up
(3) Oil piston ring
Width of groove in piston for the new oil piston
ring .... 4.055 ± 0.015 mm (0.1596 ± 0.0006 inch)
Maximum thickness of new oil piston
ring .... 3.980 ± 0.010 mm (0.1570 ± 0.0004 inch)
Clearance between groove and new oil piston
ring .. 0.050 to 0.100 mm (0.0020 to 0.0039 inch)
When the piston ring is installed in a cylinder
liner with a bore size of 170 mm (6.7 inch), the
clearance between the ends of the piston ring is
the following value. .................... 0.65 ± 0.15 mm
(0.026 ± 0.006 inch)
The increase in the clearance between the ends
of the piston ring for each 0.03 mm (0.001 inch)
increase in the cylinder liner bore size is the
following value. ................. 0.08 mm (0.003 inch)
Illustration 300
g01084998
Typical example
This piston has a Keystone top ring. This piston also
has Keystone intermediate rings. The 204-8041
Piston Ring Groove Gauge Gp is necessary for
measuring the ring grooves in the Keystone pistons.
For correct use of the gauge group, refer to the
instruction card that is with the gauge group.
Note: Prior to the installation of the rings, the ring
grooves must be completely lubricated with clean
engine oil. After assembly, the mating surfaces of
the rings to the cylinder liner must be completely
lubricated with clean engine oil.
(1) Top piston ring
Install the piston ring with the “Up-1” side toward
the top of the piston.
When the piston ring is installed in a cylinder
liner with a bore size of 170 mm (6.7 inch), the
clearance between the ends of the piston ring is
the following value. ................ 0.625 ± 0.125 mm
(0.0246 ± 0.0050 inch)
The increase in the clearance between the ends
of the piston ring for each 0.03 mm (0.001 inch)
increase in the cylinder liner bore size is the
following value. ................. 0.08 mm (0.003 inch)
Note: Install the oil piston ring so that the gap in the
spring is 180 degrees away from the gap in the piston
ring. The white portion of the spring must be visible
at the ring end gap.
Note: After all of the piston rings have been installed,
rotate the piston rings so that the end gaps are
separated by 120 degrees. The ring gap for the oil
piston ring must be aligned in the plane of the pin
bore.
(4) Piston pin bore
Note: Prior to assembly of the piston pin, the piston
pin, the piston pin bore, the connecting rod eye, and
the connecting rod pin bearing must be completely
lubricated with clean engine oil.
Crown as
Measure the pin bore in the bushings in two
places for each bushing in a vertical direction.
Bore in bushing ................ 70.0525 ± 0.0075 mm
(2.75796 ± 0.00029 inch)
Piston skirt
Measure the pin bore in a vertical direction.
Bore ..................................... 69.988 ± 0.005 mm
(2.7554 ± 0.0002 inch)
RENR5077-12
331
Specifications Section
(5) Piston pin
Measure the pin diameter on each end in a
vertical and horizontal direction.
Outside diameter ................. 69.962 ± 0.005 mm
(2.7544 ± 0.0002 inch)
Inside diameter ............................ 33.0 ± 0.5 mm
(1.30 ± 0.02 inch)
Length ... 137.55 ± 0.15 mm (5.415 ± 0.006 inch)
(6) Pin retainer ................ Assemble the pin retainer
with the opening above line A-A.
i04935261
Piston and Rings
(One-Piece Piston)
SMCS Code: 1214
Part No.: 371-0825
S/N: 9F31-Up
Part No.: 371-0825
S/N: EDJ1-Up
Illustration 301
g02613840
332
Specifications Section
RENR5077-12
Table 210
Specification for 341-3640 Piston and Rod Gp, and 371-0825 Piston
Item
Part
Qty
Specification Description
Prior to the installation of the piston rings, lubricate the ring grooves with clean engine oil. After assembly of the piston rings,
lubricate the mating surfaces of the rings to the cylinder liner with clean engine oil.
Install the top piston ring with the “UP-1” side toward the top of the piston.
Thickness of new top piston ring is 4.5 mm (0.18 inch).
1
1
229-1632 Top
Piston Ring
Clearance between the ends of the piston ring when the piston ring is installed in a
cylinder liner bore of 170 mm (6.7 inch) is 0.625 ± 0.125 mm (0.0246 ± 0.0049 inch).
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 is 0.08 mm (0.003 inch).
Install the intermediate piston ring with the “UP-2” side toward the top of the piston.
Thickness of new intermediate piston ring is 3.785 mm (0.1490 inch).
2
144-5695
Intermediate
Piston Ring
1
Clearance between the ends of the piston ring when the piston ring is installed in a
cylinder liner bore of 170 mm (6.7 inch) is 1.00 ± 0.15 mm (0.039 ± 0.006 inch).
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 is 0.08 mm (0.003 inch).
Ends of the oil control piston ring should be a distance of 180 degrees from the ring
end gap when the piston ring is assembled.
Width of groove in new piston for the oil control piston ring is 4.055 ± 0.015 mm
(0.1596 ± 0.0006 inch).
Thickness of new oil control piston ring is 3.980 ± 0.010 mm (0.1567 ± 0.0004 inch).
3
165-6668 Oil
Control Piston
Ring
1
Clearance between the ends of the piston ring when the piston ring is installed in a
cylinder liner bore of 170 mm (6.7 inch) is 0.65 ± 0.15 mm (0.026 ± 0.006 inch).
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 is 0.08 mm (0.003 inch).
After all of the piston rings have been installed, rotate the piston rings so that the
end gaps are separated by 120 degrees. The ring gap for the oil control piston ring
must be aligned in the plane of the pin bore.
4
-
-
5
1
302-3451 Piston
Pin
2
253-1238 Pin
Retainer
6
Diameter of the bore in the finished bearing that is installed into the piston skirt for
the piston pin is 70.0705 ± 0.0075 mm (2.75868 ± 0.00030 inch).
Before assembly of the piston pin, lubricate piston pin, piston pin bore, and
connecting rod eye with clean engine oil.
Outside diameter is 69.930 ± 0.005 mm (2.7531 ± 0.0002 inch).
Length is 101.85 ± 0.15 mm (4.010 ± 0.006 inch).
Install the pin retainer with the gap toward the top of the piston.
Thickness of new pin retainer is 2.36 ± 0.08 mm (0.093 ± 0.003 inch).
Width of groove in new piston for the pin retainer is 2.75 ± 0.1 mm
(0.108 ± 0.004inch).
i04396578
Connecting Rod
Part No.: 144-0725
S/N: 9H31-Up
SMCS Code: 1218
Part No.: 144-0725
S/N: ED31-Up
Part No.: 144-0725
S/N: 9F21-Up
Part No.: 144-0725
S/N: 9H41-Up
Part No.: 144-0725
S/N: CG21-Up
Part No.: 144-0725
S/N: JB41-Up
Part No.: 144-0725
S/N: ED21-Up
Part No.: 144-0725
S/N: 9H51-Up
Part No.: 144-0725
S/N: WF21-Up
Part No.: 144-0725
S/N: ED51-Up
RENR5077-12
Part No.: 144-0725
S/N: 9H61-Up
Part No.: 144-0725
S/N: GS61-Up
Part No.: 144-0725
S/N: GS71-Up
Part No.: 144-0725
S/N: ED81-Up
Part No.: 144-0725
S/N: MD81-Up
Part No.: 144-0725
S/N: GSA1-Up
Part No.: 144-0725
S/N: P8A1-Up
Part No.: 144-0725
S/N: EDC1-Up
Part No.: 144-0725
S/N: EDG1-Up
Part No.: 144-0725
S/N: EDH1-Up
Part No.: 144-0725
S/N: SRH1-Up
Part No.: 144-0725
S/N: SRK1-Up
Part No.: 144-0725
S/N: MXM1-Up
Part No.: 144-0725
S/N: EDP1-Up
Part No.: 144-0725
S/N: MXR1-Up
Part No.: 144-0725
S/N: SRZ1-Up
333
Specifications Section
334
Specifications Section
Illustration 302
RENR5077-12
g02573156
RENR5077-12
335
Specifications Section
g02573158
Illustration 303
View H-H
(3) Location pin for correct installation of
connecting rod caps
Table 211
Specification for 144-0725 Rod As
Item
Qty
Part
Specification Description
Angle (A) above the centerline on either side of the bearing joint for the sleeve bearing for the piston pin is 10 degrees.
The connecting rod may be heated from 175 to 260 °C (347 to 500 °F) for the installation of the sleeve bearing for the piston
pin. Minimum length (B) for heating the connecting rod is 105 mm (4.1 inch). Do not use a torch to heat the connecting rod.
C
1
118-1655 Bushing
Thoroughly lubricate the piston pin with clean engine oil prior to
assembly of the piston and the connecting rod.
Bore in the bushing for the piston pin after installation of the bushing
is 70.000 ± 0.008 mm (2.7559 ± 0.0003 inch).
Bore in the connecting rod for the bushing is 75.760 ± 0.015 mm
(2.9827 ± 0.0006 inch).
D
-
-
Distance between the center of the bearings is 380 mm (15.0 inch).
E
1
7N-2043 Dowel
Protrusion of the dowel from the connecting rod cap is 4.0 ± 0.5 mm
(0.16 ± 0.02 inch).
F
-
-
Bore in the connecting rod for the bearing for the crankshaft
connecting rod journal after applying final torque to the connecting
rod bolts is 143.028 ± 0.015 mm (5.6310 ± 0.0006 inch).
G
-
-
Bore in the connecting rod bearing for crankshaft is
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.
Install the connecting rod in the engine with the part number to the
rear of the engine.
2
-
-
The chamfer side must be next to the crank pin thrust surface when
the connecting rod and piston group is assembled in the engine.
7N-2405 Bolt
Use the following procedure for tightening the connecting rod bolts:
Bolt 1 and bolt 2 must be on the same end of the connecting rod cap
that has bearing tabs and location pin (3).
1. Before assembly, apply Molylube on the bolt threads, the bolt
shank, and the bolt seat.
2. Sequentially tighten the bolt 1 and bolt 2 to 90 ± 5 N·m (66 ± 4 lb ft).
3. Sequentially tighten the bolt 3 and bolt 4 to 90 ± 5 N·m (66 ± 4 lb ft).
4. Again, sequentially tighten the bolt 3 and bolt 4 to 90 ± 5 N·m
(66 ± 4 lb ft).
5. Tighten all bolts for an additional 90 ± 5 degrees.
-
4
Side clearance between two connecting rods on the same new crankshaft pin is 0.850 ± 0.332 mm (0.0335 ± 0.0131 inch).
336
Specifications Section
RENR5077-12
i04895881
Connecting Rod
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2T1-Up
SMCS Code: 1218
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2W1-Up
Part No.: 144-0725
S/N: M8A1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2X1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2A1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2Y1-Up
Part No.: 144-0725
S/N: M8B1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2Z1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2B1-Up
Part No.: 101-0829, 144-0725, 161-2500,
223-6363
S/N: S2D1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2E1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2F1-Up
Part No.: 144-0725
S/N: B5G1-Up
Part No.: 144-0725
S/N: MRG1-Up
Part No.: 144-0725
S/N: PAG1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2G1-Up
Part No.: 144-0725
S/N: MKH1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2H1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2J1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2K1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2L1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2M1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2N1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2P1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2R1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2S1-Up
RENR5077-12
Illustration 304
337
Specifications Section
g03047278
338
Specifications Section
RENR5077-12
g03047279
Illustration 305
View H-H
(4) Location pin for correct installation of
connecting rod caps
Table 212
Specification for 190-3936 Connecting Rod Gp, 6I-2861 Piston and Rod Gp, 101-0829 Piston and Rod Gp,
118-1654 Connecting Rod, 161-2500 Rod As, 223-6362 Piston and Rod Gp and 223-6363 Piston and Rod Gp
Item
Qty
Part
Specification Description
Angle (A) above the centerline on either side of the bearing joint for the sleeve bearing for the piston pin is 10 degrees.
The connecting rod may be heated from 175 to 260 °C (347 to 500 °F) for the installation of the sleeve bearing for the piston
pin. Minimum length (B) for heating the connecting rod is 105 mm (4.1 inch). Do not use a torch to heat the connecting rod.
C
1
118-1655 Bushing
Thoroughly lubricate the piston pin with clean engine oil prior to
assembly of the piston and the connecting rod.
Bore in the bushing for the piston pin after installation of the bushing
is 70.000 ± 0.008 mm (2.7559 ± 0.0003 inch).
Bore in the connecting rod for the bushing is 75.760 ± 0.015 mm
(2.9827 ± 0.0006 inch).
D
-
-
Distance between the center of the bearings is 380 mm (15.0 inch).
E
1
7N-2043 Dowel
Protrusion of the dowel from the connecting rod cap is 4.0 ± 0.5 mm
(0.16 ± 0.02 inch).
F
-
-
Bore in the connecting rod for the bearing for the crankshaft
connecting rod journal after applying final torque to the connecting
rod bolts is 143.028 ± 0.015 mm (5.6310 ± 0.0006 inch).
G
-
-
Bore in the connecting rod bearing for crankshaft is
135.133 to 135.194 mm (5.3202 to 5.3226 inch).
-
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.
Install the connecting rod in the engine with the part number to the
rear of the engine.
1
-
2
4
7N-2405 Bolt
Use the following procedure for tightening the connecting rod bolts:
Bolt 1 and bolt 2 must be on the same end of the connecting rod cap
that has bearing tabs and location pin (4).
1. Before assembly, apply Molylube on the bolt threads, the bolt
shank, and the bolt seat.
2. Sequentially tighten the bolt 1 and bolt 2 to 90 ± 5 N·m (66 ± 4 lb ft).
3. Sequentially tighten the bolt 3 and bolt 4 to 90 ± 5 N·m (66 ± 4 lb ft).
4. Again, sequentially tighten the bolt 3 and bolt 4 to 90 ± 5 N·m
(66 ± 4 lb ft).
5. Tighten all bolts for an additional 90 ± 5 degrees.
3
-
-
The chamfer side must be next to the crank pin thrust surface when
the connecting rod and piston group is assembled in the engine.
Side clearance between two connecting rods on the same new crankshaft pin is 0.850 ± 0.332 mm (0.0335 ± 0.0131 inch).
RENR5077-12
339
Specifications Section
i04763220
Connecting Rod
SMCS Code: 1218
Part No.: 371-0840
S/N: 9F31-Up
Part No.: 371-0840
S/N: EDJ1-Up
Illustration 306
g02573156
340
Specifications Section
RENR5077-12
g02573158
Illustration 307
View H-H
(3) Location pin for correct installation of
connecting rod caps
Table 213
Specification for 381-6555 Rod As
Item
Qty
Part
Specification Description
Angle (A) above the centerline on either side of the bearing joint for the sleeve bearing for the piston pin is 10 degrees.
The connecting rod may be heated from 175 to 260 °C (347 to 500 °F) for the installation of the bearing for the piston pin.
Minimum length (B) for heating the connecting rod is 105 mm (4.1 inch). Do not use a torch to heat the connecting rod.
C
1
377-5237 Bearing
Thoroughly lubricate the piston pin with clean engine oil prior to
assembly of the piston and the connecting rod.
Bore in the bearing for the piston pin after installation of the bushing is
70.000 ± 0.008 mm (2.7559 ± 0.0003 inch).
Bore in the connecting rod for the bearing is 75.760 ± 0.015 mm
(2.9827 ± 0.0006 inch).
D
-
-
Distance between the center of the bearings is 392.5 mm (15.45 inch).
E
1
7N-2043 Dowel
F
-
-
Bore in the connecting rod for the bearing for the crankshaft connecting
rod journal after applying final torque to the connecting rod bolts is
143.028 ± 0.015 mm (5.6310 ± 0.0006 inch).
G
-
-
Bore in the connecting rod bearing for crankshaft is
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.
2
-
-
The chamfer side must be next to the crank pin thrust surface when
the connecting rod and piston group is assembled in the engine.
-
4
7N-2405 Bolt
Protrusion of the dowel from the connecting rod cap is 4.0 ± 0.5 mm
(0.16 ± 0.02 inch).
Use the following procedure for tightening the connecting rod bolts:
Bolt 1 and bolt 2 must be on the same end of the connecting rod cap
that has bearing tabs and location pin (3).
1. Before assembly, apply Molylube on the bolt threads, the bolt
shank, and the bolt seat.
2. Sequentially tighten the bolt 1 and bolt 2 to 90 ± 5 N·m (66 ± 4 lb ft).
3. Sequentially tighten the bolt 3 and bolt 4 to 90 ± 5 N·m (66 ± 4 lb ft).
4. Again, sequentially tighten the bolt 3 and bolt 4 to 90 ± 5 N·m
(66 ± 4 lb ft).
5. Tighten all bolts for an additional angle of 90 ± 5 degrees.
RENR5077-12
341
Specifications Section
i01359201
Connecting Rod and Main
Bearing Journals
SMCS Code: 1230
Part No.: 380-2695
S/N: 9F21-Up
Part No.: 380-2695
S/N: CG21-Up
Part No.: 379-4851
S/N: ED21-Up
Part No.: 379-4852
S/N: WF21-Up
Part No.: 379-4857
S/N: 9F31-Up
Part No.: 379-4852
S/N: 9H31-Up
Part No.: 379-4852
S/N: ED31-Up
Part No.: 379-4852
S/N: 9H41-Up
Part No.: 380-2695
S/N: JB41-Up
Part No.: 380-2695
S/N: 9H51-Up
Part No.: 379-4852
S/N: ED51-Up
Part No.: 380-2695
S/N: 9H61-Up
Part No.: 8N-7103
S/N: GS61-Up
Part No.: 101-0336
S/N: GS71-Up
Part No.: 379-4852
S/N: ED81-Up
Part No.: 379-4851
S/N: MD81-Up
Part No.: 8N-0337
S/N: GSA1-Up
Part No.: 107-7330, 149-6031
S/N: M8A1-Up
Part No.: 332-7912
S/N: P8A1-Up
Part No.: 107-7330, 149-6031
S/N: S2A1-Up
Part No.: 107-7330, 149-6031
S/N: M8B1-Up
Part No.: 107-7330, 149-6031
S/N: S2B1-Up
Part No.: 380-2695
S/N: EDC1-Up
Part No.: 107-7330, 149-6031
S/N: S2D1-Up
Part No.: 107-7330, 149-6031
S/N: S2E1-Up
Part No.: 107-7330, 149-6031
S/N: S2F1-Up
Part No.: 107-7330, 149-6031
S/N: B5G1-Up
Part No.: 380-2695
S/N: EDG1-Up
Part No.: 107-7330, 149-6031
S/N: MRG1-Up
Part No.: 107-7330, 149-6031
S/N: PAG1-Up
Part No.: 107-7330, 149-6031
S/N: S2G1-Up
Part No.: 380-2695
S/N: EDH1-Up
Part No.: 107-7330, 149-6031
S/N: MKH1-Up
Part No.: 107-7330, 149-6031
S/N: S2H1-Up
Part No.: 379-4851
S/N: SRH1-Up
Part No.: 379-4857
S/N: EDJ1-Up
Part No.: 107-7330, 149-6031
S/N: S2J1-Up
Part No.: 107-7330, 149-6031
S/N: S2K1-Up
Part No.: 379-4852
S/N: SRK1-Up
Part No.: 107-7330, 149-6031
S/N: S2L1-Up
Part No.: 379-4851
S/N: MXM1-Up
Part No.: 107-7330, 149-6031
S/N: S2M1-Up
Part No.: 107-7330, 149-6031
S/N: S2N1-Up
342
Specifications Section
RENR5077-12
Part No.: 380-2695
S/N: EDP1-Up
Table 215
Part No.: 107-7330, 149-6031
S/N: S2P1-Up
Part No.: 380-2695
S/N: MXR1-Up
Part No.: 107-7330, 149-6031
S/N: S2R1-Up
Part No.: 107-7330, 149-6031
S/N: S2S1-Up
Part No.: 107-7330, 149-6031
S/N: S2T1-Up
Part No.: 107-7330, 149-6031
S/N: S2W1-Up
Part No.: 107-7330, 149-6031
S/N: S2X1-Up
Part No.: 107-7330, 149-6031
S/N: S2Y1-Up
Part No.: 107-7330, 149-6031
S/N: S2Z1-Up
Part No.: 379-4852
S/N: SRZ1-Up
Refer to Guidelines For Reusable Parts, SEBF8009,
“Main Bearings And Connecting Rod Bearings” for
more information.
Connecting Rod Bearing Journals
Table 214
Diameter Of Crankshaft Journal (Bearing Surface)
For Connecting Rod Bearings
Original Size Journal
135.000 ± 0.025 mm
(5.3150 ± 0.0010 inch)
Undersize Journal
0.63 mm (0.025 inch)
134.370 ± 0.025 mm
(5.2902 ± 0.0010 inch)
Undersize Journal
1.27 mm (0.050 inch)
133.730 ± 0.025 mm
(5.2650 ± 0.0010 inch)
Clearance between bearing and new
journal ... 0.107 to 0.218 mm (0.0042 to 0.0086 inch)
Main Bearing Journals
Diameter Of Crankshaft Journal (Bearing
Surface) For Main Bearings
Original Size Journal
160.000 ± 0.025 mm
(6.2992 ± 0.0010 inch)
Undersize Journal
0.63 mm (0.025 inch)
159.370 ± 0.025 mm
(6.2744 ± 0.0010 inch)
Undersize Journal
1.27 mm (0.050 inch)
158.730 ± 0.025 mm
(6.2492 ± 0.0010 inch)
Clearance between bearing and new
journal ... 0.122 to 0.241 mm (0.0048 to 0.0095 inch)
RENR5077-12
343
Specifications Section
i05165475
Crankshaft
SMCS Code: 1202
Part No.: 101-0336
S/N: GS71-Up
g01419944
Illustration 308
Table 216
Specification for 101-0336 Crankshaft Gp
Item
Qty
Part
1
2
7C-6209 Thrust Plate
2
8
2W-2288 Plug
Specification Description
Use only on the center main bearing as shown in the Illustration 308.
Torque to 50 ± 7 N·m (37 ± 5 lb ft).
3
18
128-4845 Bolt As
Use the following procedure in order to tighten the bolts:
1. Before assembly, lubricate the threads, the shank, the washer, and the
underside of the bolt head with 6V-4876 Lubricant.
2. Tighten evenly to 200 ± 5 N·m (148 ± 4 lb ft).
3. Loosen the bolts.
4. Again, tighten evenly to 70 ± 5 N·m (52 ± 4 lb ft).
5. Rotate each bolt for an additional turn of 120 ± 5 degrees.
Do not reuse counterweight bolts.
B
-
-
End play for the new crankshaft is 0.17 to 0.63 mm (0.007 to 0.025 inch).
344
Specifications Section
RENR5077-12
i04397104
Crankshaft
SMCS Code: 1202
Part No.: 332-7912
S/N: P8A1-Up
g01419944
Illustration 309
Table 217
Specification for 332-7912 Crankshaft Gp
Item
Qty
Part
Specification Description
Refer to Specifications, “Connecting Rod And Main Bearing Journals” for more information.
1
2
7C-6209 Thrust Plate
B
-
-
2
8
2W-2288 Plug
3
18
128-4845 Bolt As
Use only on the center main bearing as shown in the Illustration 309.
End play for the new crankshaft is 0.17 to 0.63 mm (0.007 to 0.025 inch).
Torque to 50 ± 7 N·m (37 ± 5 lb ft).
Use the following procedure in order to tighten the bolts:
1. Before assembly, lubricate the threads, the shank, the washer, and the
underside of the bolt head with 6V-4876 Lubricant.
2. Tighten evenly to 200 ± 5 N·m (148 ± 4 lb ft).
3. Loosen the bolts.
4. Again, tighten evenly to 70 ± 5 N·m (52 ± 4 lb ft).
5. Rotate each bolt for an additional turn of 120 ± 5 degrees.
Do not reuse counterweight bolts.
RENR5077-12
345
Specifications Section
i02871012
Crankshaft
SMCS Code: 1202
Part No.: 152-7625
S/N: M8A1-Up
Part No.: 152-7625
S/N: S2A1-Up
Part No.: 152-7625
S/N: M8B1-Up
Part No.: 152-7625
S/N: S2B1-Up
Part No.: 152-7625
S/N: S2D1-Up
Part No.: 152-7625
S/N: S2E1-Up
Part No.: 152-7625
S/N: S2F1-Up
g01419944
Illustration 310
(1) Thrust plates
Refer to Specifications, “Connecting Rod And Main
Bearing Journals” for more information.
(B) End play for the new
crankshaft ................................. 0.17 to 0.63 mm
(0.007 to 0.025 inch)
(2) Torque for the plug ......... 50 ± 7 N·m (37 ± 5 lb ft)
Note: Do not reuse counterweight bolts.
(3) Use the following procedure to tighten the bolts:
1. Prior to assembly, lubricate the bolt threads, the
bolt shank, the washer and the underside of the
bolt head with 6V-4876 Lubricant.
346
Specifications Section
RENR5077-12
2. Torque the bolts evenly to 200 ± 5 N·m
(145 ± 4 lb ft).
Part No.: 128-6786, 128-6788
S/N: S2R1-Up
3. Loosen the bolts.
Part No.: 128-6786, 128-6788
S/N: S2S1-Up
4. Again, torque the bolts evenly to 70 ± 5 N·m
(50 ± 4 lb ft).
Part No.: 128-6786, 128-6788
S/N: S2T1-Up
5. Rotate each bolt for an additional 120 ± 5 degrees.
Part No.: 128-6786, 128-6788
S/N: S2X1-Up
i04035774
Part No.: 128-6786, 128-6788
S/N: S2Y1-Up
Crankshaft
SMCS Code: 1202
Part No.: 128-6786, 128-6788
S/N: S2A1-Up
Part No.: 128-6786, 128-6788
S/N: S2B1-Up
Part No.: 128-6786, 128-6788
S/N: S2D1-Up
Part No.: 128-6786, 128-6788
S/N: S2E1-Up
Part No.: 128-6786
S/N: S2F1-Up
Part No.: 128-6788
S/N: B5G1-Up
Part No.: 128-6788
S/N: MRG1-Up
Part No.: 128-6788
S/N: PAG1-Up
Part No.: 128-6786, 128-6788
S/N: S2G1-Up
Part No.: 128-6788
S/N: MKH1-Up
Part No.: 128-6786, 128-6788
S/N: S2H1-Up
Part No.: 128-6786, 128-6788
S/N: S2J1-Up
Part No.: 128-6786, 128-6788
S/N: S2K1-Up
Part No.: 128-6786, 128-6788
S/N: S2L1-Up
Part No.: 128-6786
S/N: S2M1-Up
Part No.: 128-6786, 128-6788
S/N: S2N1-Up
Part No.: 128-6786, 128-6788
S/N: S2P1-Up
Part No.: 128-6786, 128-6788
S/N: S2Z1-Up
RENR5077-12
Illustration 311
Refer to Specifications, “Connecting Rod And Main
Bearing Journals” for more information.
(1) Torque for the plugs ....... 50 ± 7 N·m (37 ± 5 lb ft)
Note: Do not reuse the counterweight bolts.
Use the following procedure to tighten the bolts (2):
1. Before assembly, lubricate the threads of the
bolts, the bolt shank, the washers, and the contact
surface under the bolt head with molylube.
2. Tighten the bolts evenly to 70 ± 5 N·m (50 ± 4 lb ft).
3. Rotate each bolt for an additional 120 ± 5 degrees.
Note: After the crankshaft is assembled into the
cylinder block, the crankshaft end play should be
between 0.17 to 0.63 mm (0.007 to 0.025 inch)
347
Specifications Section
g02231633
348
Specifications Section
RENR5077-12
i04932374
Crankshaft
SMCS Code: 1202
Part No.: 379-4852
S/N: WF21-Up
Part No.: 379-4852
S/N: 9H31-Up
Part No.: 379-4852
S/N: ED31-Up
Part No.: 379-4852
S/N: 9H41-Up
Part No.: 379-4852
S/N: ED51-Up
Part No.: 379-4852
S/N: ED81-Up
Part No.: 379-4852
S/N: SRK1-Up
Part No.: 379-4852
S/N: SRZ1-Up
Illustration 312
typical example
g03103999
RENR5077-12
349
Specifications Section
Table 218
Specification for 379-4855 Crankshaft Gp and 379-4852 Crankshaft Gp
Item
Qty
Part
1
2
7C-6209 Thrust Plate
-
-
-
2
6
2W-2288 Plug
3
36
128-4845 Bolt As
Specification Description
Use only on the center main bearing as shown in the Illustration 312.
End play for the new crankshaft is 0.17 to 0.63 mm (0.007 to 0.025 inch).
Torque to 50 ± 7 N·m (37 ± 5 lb ft).
Use the following procedure in order to tighten the bolts:
1. Before assembly, lubricate the threads, the shank, the washer, and the
underside of the bolt head with 6V-4876 Lubricant.
2. Tighten evenly to 70 ± 5 N·m (52 ± 4 lb ft).
3. Rotate each bolt for an additional turn of 120 ± 5 degrees.
Do not reuse counterweight bolts.
350
Specifications Section
RENR5077-12
i04929974
Crankshaft
SMCS Code: 1202
Part No.: 379-4851
S/N: ED21-Up
Part No.: 8N-7103
S/N: GS61-Up
Part No.: 379-4851
S/N: MD81-Up
Part No.: 379-4851
S/N: SRH1-Up
Part No.: 379-4851
S/N: MXM1-Up
Illustration 313
Typical example
g03110979
RENR5077-12
351
Specifications Section
Table 219
Specification for 8N-7103 Crankshaft Gp, 161-6926 Crankshaft Gp, and 379-4851 Crankshaft Gp
Item
Qty
Part
Specification Description
Refer to Specifications, “Connecting Rod And Main Bearing Journals” for more information.
1
2
7C-6209 Thrust Plate
B
-
-
2
6
2W-2288 Plug
3
36
Use only on the center main bearing as shown in the Illustration
End play for the new crankshaft is 0.17 to 0.63 mm
(0.007 to 0.025 inch).
Torque to 50 ± 7 N·m (37 ± 5 lb ft).
128-4845 Bolt As
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 70 ± 5 N·m (50 ± 4 lb ft).
3. Rotate each bolt for an additional 120 ± 5 degrees.
Do not reuse counterweight bolts.
i04397632
Crankshaft
SMCS Code: 1202
Part No.: 8N-0337
S/N: GSA1-Up
Illustration 314
(1)Thrust Plates
g01419944
352
Specifications Section
RENR5077-12
Table 220
Specification for 8N-0337 Crankshaft Gp161-6928 Crankshaft Gp
Item
Qty
Part
Specification Description
Refer to Specifications, “Connecting Rod And Main Bearing Journals” for more information.
B
-
-
2
8
2W-2288 Plug
3
48
End play for the new crankshaft is 0.17 to 0.63 mm
(0.007 to 0.025 inch).
Torque to 50 ± 7 N·m (37 ± 5 lb ft).
128-4845 Bolt As
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 molylube.
2. Torque the bolts evenly to 70 ± 5 N·m (50 ± 4 lb ft).
3. Rotate each bolt for an additional 120 ± 5 degrees.
Do not reuse counterweight bolts.
i04932381
Crankshaft
SMCS Code: 1202
Part No.: 380-2695
S/N: 9F21-Up
Part No.: 380-2695
S/N: CG21-Up
Part No.: 379-4857
S/N: 9F31-Up
Part No.: 380-2695
S/N: JB41-Up
Part No.: 380-2695
S/N: 9H51-Up
Part No.: 380-2695
S/N: 9H61-Up
Part No.: 380-2695
S/N: EDC1-Up
Part No.: 380-2695
S/N: EDG1-Up
Part No.: 380-2695
S/N: EDH1-Up
Part No.: 379-4857
S/N: EDJ1-Up
Part No.: 380-2695
S/N: EDP1-Up
Part No.: 380-2695
S/N: MXR1-Up
RENR5077-12
353
Specifications Section
g03104036
Illustration 315
Typical example
Table 221
Specification for 379-4857 Crankshaft Gp and 380-2695 Crankshaft Gp
Item
Qty
Part
Specification Description
Refer to Specifications, “Connecting Rod And Main Bearing Journals” for more information.
1
2
7C-6209 Thrust Plate
-
-
-
2
8
2W-2288 Plug
3
48
128-4845 Bolt As
Use only on the center main bearing as shown in the Illustration 315.
End play for the new crankshaft is 0.17 to 0.63 mm (0.007 to 0.025 inch).
Torque to 50 ± 7 N·m (37 ± 5 lb ft).
Use the following procedure in order to tighten the bolts:
1. Before assembly, lubricate the threads, the shank, the washer, and the
underside of the bolt head with 6V-4876 Lubricant.
2. Tighten the bolts evenly to 70 ± 5 N·m (52 ± 4 lb ft).
3. Rotate each bolt for an additional turn of 120 ± 5 degrees.
Do not reuse counterweight bolts.
i04397640
Crankshaft Wear Sleeves and
Seals
SMCS Code: 1160
Part No.: 332-7911
S/N: 9F21-Up
Part No.: 332-7911
S/N: CG21-Up
Part No.: 332-7911
S/N: ED21-Up
Part No.: 332-7911
S/N: WF21-Up
Part No.: 332-7911
S/N: 9F31-Up
Part No.: 332-7911
S/N: 9H31-Up
Part No.: 332-7911
S/N: ED31-Up
Part No.: 332-7911
S/N: 9H41-Up
354
Specifications Section
RENR5077-12
Part No.: 332-7911
S/N: JB41-Up
Part No.: 332-7911
S/N: EDH1-Up
Part No.: 332-7911
S/N: 9H51-Up
Part No.: 7W-3813
S/N: MKH1-Up
Part No.: 332-7911
S/N: ED51-Up
Part No.: 7W-3813
S/N: S2H1-Up
Part No.: 332-7911
S/N: 9H61-Up
Part No.: 332-7911
S/N: SRH1-Up
Part No.: 7W-3813
S/N: GS61-Up
Part No.: 332-7911
S/N: EDJ1-Up
Part No.: 7W-3813
S/N: GS71-Up
Part No.: 7W-3813
S/N: S2J1-Up
Part No.: 332-7911
S/N: ED81-Up
Part No.: 7W-3813
S/N: S2K1-Up
Part No.: 332-7911
S/N: MD81-Up
Part No.: 332-7911
S/N: SRK1-Up
Part No.: 7W-3813
S/N: GSA1-Up
Part No.: 7W-3813
S/N: S2L1-Up
Part No.: 332-7911
S/N: M8A1-Up
Part No.: 332-7911
S/N: MXM1-Up
Part No.: 332-7911
S/N: P8A1-Up
Part No.: 7W-3813
S/N: S2M1-Up
Part No.: 7W-3813
S/N: S2A1-Up
Part No.: 7W-3813
S/N: S2N1-Up
Part No.: 332-7911
S/N: M8B1-Up
Part No.: 332-7911
S/N: EDP1-Up
Part No.: 7W-3813
S/N: S2B1-Up
Part No.: 7W-3813
S/N: S2P1-Up
Part No.: 332-7911
S/N: EDC1-Up
Part No.: 332-7911
S/N: MXR1-Up
Part No.: 7W-3813
S/N: S2D1-Up
Part No.: 7W-3813
S/N: S2R1-Up
Part No.: 7W-3813
S/N: S2E1-Up
Part No.: 7W-3813
S/N: S2S1-Up
Part No.: 7W-3813
S/N: S2F1-Up
Part No.: 7W-3813
S/N: S2T1-Up
Part No.: 7W-3813
S/N: B5G1-Up
Part No.: 7W-3813
S/N: S2W1-Up
Part No.: 332-7911
S/N: EDG1-Up
Part No.: 7W-3813
S/N: S2X1-Up
Part No.: 7W-3813
S/N: MRG1-Up
Part No.: 7W-3813
S/N: S2Y1-Up
Part No.: 7W-3813
S/N: PAG1-Up
Part No.: 7W-3813
S/N: S2Z1-Up
Part No.: 7W-3813
S/N: S2G1-Up
Part No.: 332-7911
S/N: SRZ1-Up
RENR5077-12
355
Specifications Section
g02575380
Illustration 316
(1) Flywheel housing group
(2) Front housing group
Table 222
Specification for the 7W-3813 Crankshaft Seal Gp332-7911 Crankshaft Seal Gp
Item
Qty
Part
Specification Description
The crankshaft seal group cannot be used once the seal has been separated from the wear sleeve.
Make sure that the correct crankshaft seal group is installed on each end of the crankshaft.
1
113-8433 Crankshaft
Seal Gp
Install the crankshaft seal group in the flywheel housing group on a
standard rotation engine.
Install the crankshaft seal group in the front housing group on a
reverse rotation engine.
4
1
113-8432 Crankshaft
Seal Gp
Install the crankshaft seal group in the front housing group on a
standard rotation engine.
Install the crankshaft seal group in the flywheel housing group on a
reverse rotation engine.
A
-
-
The crankshaft seal group is installed from both ends of the
crankshaft at the distance of 8.0 ± 0.5 mm (0.31 ± 0.02 inch).
B
-
-
The wear sleeve is installed from both ends of the crankshaft at the
distance of 0.5 ± 0.5 mm (0.02 ± 0.02 inch).
3
356
Specifications Section
RENR5077-12
i04397645
Housing (Front)
SMCS Code: 1162
Part No.: 333-3712
S/N: M8A1-Up
Part No.: 333-3712
S/N: M8B1-Up
g02847417
Illustration 317
Table 223
Specification for 333-3712 Front Housing Gp
Item
Qty
Part
Specification Description
-
-
-
1
4
9H-8260 Bolt
Length of 1/2 diameter inch bolt is 158.75 mm (6.250 inch).
2
4
0S-1587 Bolt
Length of 1/2 diameter inch bolt is 44.45 mm (1.750 inch).
3
6
2A-5220 Plug
Torque to 25 ± 5 N·m (221 ± 44 lb in).
4
7
8T-6765 Pipe Plug
Length of 1/4 diameter inch plug is 14.2 mm (0.56 inch).
5
10
1D-4593 Bolt
Length of 5/8 diameter inch bolt is 139.7 mm (5.50 inch).
A
2
3P-1896 Cup Plug
Installation depth is 1.25 ± 0.25 mm (0.050 ± 0.010 inch).
-
-
-
Use a standard torque for the fasteners.
Trim gasket (6) with face (7) after assembly.
i04397650
Housing (Front)
SMCS Code: 1162
Part No.: 4P-5426
S/N: GS61-Up
Part No.: 4P-5426
S/N: GS71-Up
RENR5077-12
357
Specifications Section
Part No.: 4P-5426
S/N: GSA1-Up
Part No.: 4P-5426
S/N: S2Y1-Up
Part No.: 4P-5426
S/N: S2A1-Up
Part No.: 4P-5426
S/N: S2Z1-Up
Part No.: 4P-5426
S/N: S2B1-Up
Part No.: 4P-5426
S/N: S2D1-Up
Part No.: 4P-5426
S/N: S2E1-Up
Part No.: 4P-5426
S/N: S2F1-Up
Part No.: 4P-5426
S/N: B5G1-Up
Part No.: 4P-5426
S/N: MRG1-Up
Part No.: 4P-5426
S/N: PAG1-Up
Part No.: 4P-5426
S/N: S2G1-Up
Part No.: 4P-5426
S/N: MKH1-Up
Part No.: 4P-5426
S/N: S2H1-Up
Part No.: 4P-5426
S/N: S2J1-Up
Part No.: 4P-5426
S/N: S2K1-Up
Part No.: 4P-5426
S/N: S2L1-Up
Part No.: 4P-5426
S/N: S2M1-Up
Part No.: 4P-5426
S/N: S2N1-Up
Part No.: 4P-5426
S/N: S2P1-Up
Part No.: 4P-5426
S/N: S2R1-Up
Part No.: 4P-5426
S/N: S2S1-Up
Part No.: 4P-5426
S/N: S2T1-Up
Part No.: 4P-5426
S/N: S2W1-Up
Part No.: 4P-5426
S/N: S2X1-Up
358
Specifications Section
RENR5077-12
g01430989
Illustration 318
Table 224
Specification for 4P-5426 Front Housing Gp
Item
Qty
Part
1
7
8T-6765 Pipe Plug
2
4
9H-8260 Bolt
Diameter is 1/2 inch. Length is 158.75 mm (6.250 inch).
3
6
2A-5220 Plug
Torque to 25 ± 5 N·m (221 ± 44 lb in).
4
4
0S-1587 Bolt
Diameter is 1/2 inch. Length is 44.45 mm (1.750 inch).
5
10
1D-4593 Bolt
Diameter is 5/8 inch. Length is 139.7 mm (5.50 inch).
-
-
-
Specification Description
Diameter is 1/4 inch. Length is 14.2 mm (0.56 inch).
Trim gasket (6) with face (7) after assembly.
Use standard torque for the fasteners listed above.
i04888982
Housing (Front)
Part No.: 381-0680
S/N: 9H41-Up
SMCS Code: 1162
Part No.: 381-0680
S/N: JB41-Up
Part No.: 381-0680
S/N: 9F21-Up
Part No.: 381-0680
S/N: 9H51-Up
Part No.: 381-0680
S/N: CG21-Up
Part No.: 381-0680
S/N: ED51-Up
Part No.: 381-0680
S/N: ED21-Up
Part No.: 381-0680
S/N: 9H61-Up
Part No.: 381-0680
S/N: WF21-Up
Part No.: 381-0680
S/N: ED81-Up
Part No.: 381-0680
S/N: 9F31-Up
Part No.: 381-0680
S/N: MD81-Up
Part No.: 381-0680
S/N: 9H31-Up
Part No.: 381-0680
S/N: EDC1-Up
Part No.: 381-0680
S/N: ED31-Up
RENR5077-12
359
Specifications Section
Part No.: 381-0680
S/N: EDG1-Up
Part No.: 381-0680
S/N: EDH1-Up
Part No.: 381-0680
S/N: SRH1-Up
Part No.: 381-0680
S/N: EDJ1-Up
Part No.: 381-0680
S/N: SRK1-Up
Part No.: 381-0680
S/N: MXM1-Up
Part No.: 381-0680
S/N: EDP1-Up
Part No.: 381-0680
S/N: MXR1-Up
Part No.: 381-0680
S/N: SRZ1-Up
g03017438
Illustration 319
Table 225
Specification for 381-0680 Front Housing Gp
Item
Qty
Part
1
6
2A-5220 Plug
-
-
-
Specification Description
Torque to 25 ± 5 N·m (221 ± 44 lb in).
After installation, trim 7N-3049 Gasket to flush with face (2).
360
Specifications Section
RENR5077-12
i03696090
Gear Group (Front)
(Reverse Rotation)
SMCS Code: 1206
Part No.: 334-5314
S/N: M8A1-Up
Illustration 320
g02019973
Front view
(2) Crankshaft gear
(1) Thrust washer
Thickness of new thrust washer .. 8.50 ± 0.05 mm
(0.335 ± 0.002 inch)
Width of groove in new pump drive shaft
assembly. ............................... 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
RENR5077-12
361
Specifications Section
g01988514
Illustration 321
(3) Water pump drive gear
(4) Auxiliary drive gear
(5) Lubricate the bore of the O-ring seals lightly with
lubricant that is being sealed.
(9) Torque for the socket setscrew for the pump drive
shaft assembly ................ 6 ± 1 N·m (53 ± 9 lb in)
(6) Shaft
(10) Thrust washer
Diameter of the new shaft ........ 89.88 ± 0.02 mm
(3.539 ± 0.001 inch)
Bore in sleeve bearing for the idler gear
assembly ............................. 90.000 ± 0.010 mm
(3.5433 ± 0.0004 inch)
Installation depth of the sleeve
bearing .............. 2.3 ± 0.5 mm (0.09 ± 0.02 inch)
(7) Auxiliary drive shaft
Diameter of the new auxiliary drive
shaft ..................................... 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
Bore in the sleeve bearing after
assembly ............................. 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch)
(8) Pump drive shaft assembly
Diameter of the new pump drive shaft
assembly ............................. 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
Bore in the sleeve bearing after
assembly ............................. 75.000 ± 0.055 mm
(2.9527± 0.0022 inch)
Note: Install the socket setscrew (9) to the bottom of
the threaded hole.
Thickness of new thrust washer .. 8.50 ± 0.05 mm
(0.335 ± 0.002 inch)
Width of groove in new pump drive shaft
assembly. ............................... 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
362
Specifications Section
RENR5077-12
i03694527
Gear Group (Front)
(Reverse Rotation)
SMCS Code: 1206
Part No.: 334-5315
S/N: M8B1-Up
Illustration 322
g02019973
Front view
(2) Crankshaft gear
(1) Thrust washer
Thickness of new thrust washer .. 8.50 ± 0.05 mm
(0.335 ± 0.002 inch)
Width of groove in new pump drive shaft
assembly. ............................... 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
RENR5077-12
363
Specifications Section
g01985973
Illustration 323
(3) Accessory drive gear
(4) Auxiliary drive gear
(5) Lubricate the bore of the O-ring seals lightly with
lubricant that is being sealed.
(9) Torque for the socket setscrew for the pump drive
shaft assembly ................ 6 ± 1 N·m (53 ± 9 lb in)
(6) Idler shaft
(10) Thrust washer
Diameter of the new idler
shaft ...... 105.88 ± 0.02 mm (4.168 ± 0.001 inch)
Bore in the sleeve bearing for the idler
shaft ................................... 105.970 ± 0.010 mm
(4.1720 ± 0.0004 inch)
Thickness of new thrust washer .. 8.50 ± 0.05 mm
(0.335 ± 0.002 inch)
Width of groove in new pump drive shaft
assembly. ............................... 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
(7) Auxiliary drive shaft
Diameter of the new auxiliary drive
shaft ..................................... 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
Bore in the sleeve bearing after
assembly ............................. 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch)
(8) Pump drive shaft assembly
Diameter of the new pump drive shaft
assembly ............................. 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
Bore in the sleeve bearing after
assembly ............................. 75.000 ± 0.055 mm
(2.9527± 0.0022 inch)
Note: Install the socket setscrew (9) to the bottom of
the threaded hole.
i03668141
Gear Group (Front)
SMCS Code: 1206
Part No.: 122-9281
S/N: S2A1-Up
Part No.: 334-5312
S/N: M8B1-Up
Part No.: 122-9281
S/N: S2D1-Up
Part No.: 122-9281
S/N: B5G1-Up
Part No.: 122-9281
S/N: MRG1-Up
364
Specifications Section
RENR5077-12
Part No.: 122-9281
S/N: PAG1-Up
Part No.: 122-9281
S/N: S2G1-Up
Part No.: 122-9281
S/N: MKH1-Up
Part No.: 122-9281
S/N: S2J1-Up
Part No.: 122-9281
S/N: S2K1-Up
Part No.: 122-9281
S/N: S2L1-Up
Part No.: 122-9281
S/N: S2M1-Up
Part No.: 122-9281
S/N: S2N1-Up
Part No.: 122-9281
S/N: S2P1-Up
Part No.: 122-9281
S/N: S2R1-Up
Part No.: 122-9281
S/N: S2S1-Up
Part No.: 122-9281
S/N: S2T1-Up
Part No.: 122-9281
S/N: S2W1-Up
Part No.: 122-9281
S/N: S2X1-Up
Part No.: 122-9281
S/N: S2Y1-Up
Part No.: 122-9281
S/N: S2Z1-Up
Illustration 324
g01428397
Typical example
(5) Idler gear assembly
(6) Water pump drive gear
(7) Crankshaft gear
Note: Install the socket setscrew to the bottom of the
threaded hole.
(1) Torque for the socket setscrew ............ 6 ± 1 N·m
(53 ± 9 lb in)
(2) Pump drive shaft assembly
Bore in sleeve bearing after
assembly ............................. 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch)
Diameter of new pump drive shaft
assembly. ............................. 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
(3) Lubricate the bore of the O-ring seals lightly with
lubricant that is being sealed.
(4) Thrust washer
Thickness of new thrust washer .. 8.50 ± 0.05 mm
(0.335 ± 0.002 inch)
Width of groove in new pump drive shaft
assembly. ............................... 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
End play for the pump drive shaft
assembly .............................. 0.175 to 0.325 mm
(0.0069 ± 0.0128 inch)
(8) Idler shaft
RENR5077-12
365
Specifications Section
Diameter of the idler shaft ..... 105.88 ± 0.02 mm
(4.168 ± 0.001 inch)
Bore in the sleeve bearing for idler
shaft ................................... 105.970 ± 0.010 mm
(4.1720 ± 0.0004 inch)
i04897033
Gear Group (Front)
SMCS Code: 1206
Part No.: 8N-7174
S/N: GS61-Up
Part No.: 8N-7174
S/N: GS71-Up
Part No.: 8N-7174
S/N: GSA1-Up
Part No.: 334-5311
S/N: M8A1-Up
Part No.: 8N-7174
S/N: S2A1-Up
Part No.: 334-5311
S/N: M8B1-Up
Part No.: 8N-7174
S/N: S2B1-Up
Part No.: 8N-7174
S/N: S2D1-Up
Part No.: 8N-7174
S/N: S2E1-Up
Part No.: 8N-7174
S/N: S2F1-Up
Part No.: 8N-7174
S/N: B5G1-Up
Part No.: 8N-7174
S/N: MRG1-Up
Part No.: 8N-7174
S/N: PAG1-Up
Part No.: 8N-7174
S/N: S2G1-Up
Part No.: 8N-7174
S/N: MKH1-Up
Part No.: 8N-7174
S/N: S2H1-Up
Part No.: 8N-7174
S/N: S2J1-Up
Part No.: 8N-7174
S/N: S2K1-Up
Part No.: 8N-7174
S/N: S2L1-Up
Part No.: 8N-7174
S/N: S2M1-Up
Part No.: 8N-7174
S/N: S2N1-Up
Part No.: 8N-7174
S/N: S2P1-Up
Part No.: 8N-7174
S/N: S2R1-Up
Part No.: 8N-7174
S/N: S2S1-Up
Part No.: 8N-7174
S/N: S2T1-Up
Part No.: 8N-7174
S/N: S2W1-Up
Part No.: 8N-7174
S/N: S2X1-Up
Part No.: 8N-7174
S/N: S2Y1-Up
Part No.: 8N-7174
S/N: S2Z1-Up
366
Specifications Section
Illustration 325
Front view of engine
RENR5077-12
g03045699
RENR5077-12
367
Specifications Section
Table 226
Specification for 8N-7174 Front Gear Gp
Item
Qty
Part
1
1
7N-5245 Pump Adapter
After installation, bore of 127-5400 Bushing is 75.000 ± 0.055 mm
(2.9528 ± 0.0022 inch).
2
1
144-8263 Idler Gear As
After installation, bore of 140-9597 Bushing is 90.000 ± 0.010 mm
(3.5433 ± 0.0004 inch).
Installation depth is 2.3 ± 0.5 mm (0.09 ± 0.02 inch).
3
1
7C-3260 Shaft
4
2
259-4598 O-Ring Seal
5
1
7N-5239 Pump Drive Shaft As
6
1
235-3546 O-Ring Seal
Before assembly, lightly lubricate the bores with the lubricant that is
being sealed.
7N-5246 Thrust Washer
Thickness is 8.50 ± 0.05 mm (0.335 ± 0.002 inch).
Width of groove in new pump drive shaft assembly (8) is 8.75 ± 0.10 mm
(0.344 ± 0.004 inch).
End play for the pump drive shaft assembly is 0.250 ± 0.075 mm
(0.0098 ± 0.0030 inch).
278-4287 Pump Adapter
After installation, bore of 127-5400 Bushing is 75.000 ± 0.055 mm
(2.9528 ± 0.0022 inch).
During assembly, flush the bushing with the pump adapter surface.
Oil hole in the bushing must be aligned with the hole in the bore.
7
9
2
1
Specification Description
Diameter is 89.880 ± 0.020 mm (3.5386 ± 0.0008 inch).
Before assembly, lightly lubricate the bores with the lubricant that is
being sealed.
Diameter is 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
Install the 8T-2153 Socket Setscrew to the bottom of the threaded hole
and tighten to 6 ± 1 N·m (53 ± 9 lb in).
368
Specifications Section
RENR5077-12
i04932525
Gear Group (Front)
SMCS Code: 1206
Part No.: 377-5905
S/N: 9F31-Up
Part No.: 377-5905
S/N: 9H31-Up
Part No.: 377-5905
S/N: ED31-Up
Part No.: 377-5905
S/N: JB41-Up
Part No.: 377-5905
S/N: 9H51-Up
Part No.: 377-5905
S/N: ED51-Up
Part No.: 377-5905
S/N: EDC1-Up
Part No.: 377-5905
S/N: EDJ1-Up
Part No.: 377-5905
S/N: SRK1-Up
Part No.: 377-5905
S/N: EDP1-Up
Illustration 326
g03104504
RENR5077-12
369
Specifications Section
g03104501
Illustration 327
Rear view
Table 227
Specification for 377-5905 Front Gear Gp
Item
Qty
Part
1
1
6V-3348 O-Ring Seal
2
1
278-4287 Pump Adapter
3
1
7N-5245 Pump Adapter
4
1
8T-2153 Socket Setscrew
Specification Description
During assembly, apply approved retention compound in order to secure.
After installation , bore of 127-5400 Bushing is 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch).
Bushing must be flush with the pump adapter.
After installation, bore of 127-5400 Bushing is 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch).
Diameter of the new pump drive shaft (8) is 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch).
Torque to 6 ± 1 N·m (53 ± 9 lb in).
After installation, bore of 116-1365 Bushing is 105.970 ± 0.010 mm
(4.17204 ± 0.0004 inch).
5
1
116-3242 Idler Gear As
Installation depth is 2.3 ± 0.5 mm (0.09 ± 0.02 inch).
Diameter of the new shaft (10) is 105.88 ± 0.02 mm (4.169 ± 0.001 inch).
6
1
7C-3258 Thrust Washer
Assembly
Thickness is 7.00 ± 0.15 mm (0.276 ± 0.006 inch).
7
1
235-3546 O-Ring Seal
Lubricate the bore lightly with the lubricant that is being sealed.
9
2
259-4598 O-Ring Seal
Lubricate the bore lightly with the lubricant that is being sealed.
Protrusion of the dowel (B) is 4.5 ± 0.5 mm (0.18 ± 0.02 inch).
370
Specifications Section
RENR5077-12
i04452750
Gear Group (Front)
SMCS Code: 1206
Part No.: 376-3358
S/N: 9F21-Up
Part No.: 376-3358
S/N: CG21-Up
Part No.: 376-3358
S/N: ED21-Up
Part No.: 376-3358
S/N: WF21-Up
Part No.: 376-3358
S/N: 9H41-Up
Part No.: 376-3358
S/N: 9H61-Up
Part No.: 376-3358
S/N: ED81-Up
Part No.: 376-3358
S/N: MD81-Up
Part No.: 376-3358
S/N: EDG1-Up
Part No.: 376-3358
S/N: EDH1-Up
Part No.: 376-3358
S/N: SRH1-Up
Part No.: 376-3358
S/N: MXM1-Up
Part No.: 376-3358
S/N: MXR1-Up
Part No.: 376-3358
S/N: SRZ1-Up
RENR5077-12
371
Specifications Section
g02645057
Illustration 328
Table 228
Specification for 376-3358 Front Gear Gp
Item
Qty
Part
1
144-8263 Idler
Gear As
Specification Description
Bore of 140-9597 Bushing after installation is 90.000 ± 0.010 mm (3.5433 ± 0.0004 inch).
1
Installation depth is 2.3 ± 0.5 mm (0.09 ± 0.02 inch).
Diameter of the new shaft (9) is 89.880 ± 0.020 mm (3.5386 ± 0.0008 inch).
2
1
7N-5245 Pump
Adapter
3
1
8T-2153 Socket
Setscrew
4
2
259-4598 O-Ring
Seal
6
1
278-4287 Pump
Adapter
7
1
235-3546 O-Ring
Seal
8
1
7C-3258 Thrust
Washer Assembly
Bore of 127-5400 Bushing after installation is 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch).
Diameter of the new pump drive shaft (5) is 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
Torque to 6 ± 1 N·m (53 ± 9 lb in).
Lubricate the bore lightly with the lubricant that is being sealed.
Bore of 127-5400 Bushing after installation is 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch).
Bushing must be flush with the pump adapter.
Lubricate the bore lightly with the lubricant that is being sealed.
Thickness is 7.00 ± 0.15 mm (0.276 ± 0.006 inch).
Protrusion of the dowel (B) is 4.5 ± 0.5 mm (0.18 ± 0.02 inch).
372
Specifications Section
RENR5077-12
i03125621
Gear Group (Rear)
Part No.: 124-8395, 175-5203, 175-5204
S/N: S2T1-Up
SMCS Code: 1206
Part No.: 124-8395
S/N: S2W1-Up
Part No.: 334-5298
S/N: M8A1-Up
Part No.: 124-8395, 175-5203, 175-5204
S/N: S2X1-Up
Part No.: 124-8395
S/N: S2A1-Up
Part No.: 124-8395
S/N: S2Y1-Up
Part No.: 334-5298
S/N: M8B1-Up
Part No.: 124-8395
S/N: S2Z1-Up
Part No.: 124-8395
S/N: S2B1-Up
Part No.: 124-8395
S/N: S2D1-Up
Part No.: 124-8395
S/N: S2E1-Up
Part No.: 124-8395
S/N: S2F1-Up
Part No.: 175-5203, 175-5204
S/N: B5G1-Up
Part No.: 175-5203, 175-5204
S/N: MRG1-Up
Part No.: 175-5203, 175-5204
S/N: PAG1-Up
Part No.: 124-8395
S/N: S2G1-Up
Part No.: 124-8395, 175-5203, 175-5204
S/N: MKH1-Up
Part No.: 124-8395
S/N: S2H1-Up
Part No.: 124-8395, 175-5204
S/N: S2J1-Up
Part No.: 124-8395
S/N: S2K1-Up
Part No.: 124-8395
S/N: S2L1-Up
Part No.: 124-8395
S/N: S2M1-Up
Part No.: 124-8395
S/N: S2N1-Up
Part No.: 124-8395
S/N: S2P1-Up
Part No.: 124-8395
S/N: S2R1-Up
Part No.: 124-8395
S/N: S2S1-Up
Illustration 329
g01620759
(1) Ring
(3) Idler gear assembly
(13) Plate
Note: Before assembly, it is critical that the taper of
the camshaft and the tapered bore of the camshaft
drive gear are clean, dry, and free of residue.
Refer to Disassembly and Assembly for the
installation procedure for the left camshaft drive gear
(2).
(5) Torque for four bolts ....................... 140 ± 10 N·m
(105 ± 7 lb ft)
(6) Gear shaft
Diameter of the gear shaft ... 74.990 ± 0.010 mm
(2.9524 ± 0.0004 inch)
Bore in the sleeve bearing for the gear
shaft ..................................... 75.060 ± 0.010 mm
(2.9551 ± 0.0004 inch)
Maximum roughness average
(Ra) ...................... 0.8 micrometer (32 microinch)
Refer to Disassembly and Assembly for the
installation procedure for the right camshaft drive
gear (7).
RENR5077-12
373
Specifications Section
(8) Idler shaft
Diameter of the idler shaft ... 81.000 ± 0.010 mm
(3.1890 ± 0.0004 inch)
Bore in the sleeve bearing for the idler
shaft ..................................... 81.060 ± 0.010 mm
(3.1913 ± 0.0004 inch)
Maximum roughness average
(Ra) ...................... 0.8 micrometer (32 microinch)
(10) Torque for four bolts ..................... 240 ± 20 N·m
(175 ± 15 lb ft)
(11) Torque for two bolts ..................... 240 ± 20 N·m
(175 ± 15 lb ft)
Illustration 332
g01620761
Rear view of engine
Illustration 330
g01256372
Vertical line
(14) The mark on the cluster gear assembly (4) must
be in alignment with the mark on the crankshaft
gear (12).
(9) Use the following procedure to tighten the bolt for
the camshaft drive gears:
1. Tighten the bolt for the camshaft drive gear to
360 ± 40 N·m (270 ± 30 lb ft).
i04397713
Gear Group (Rear)
SMCS Code: 1206
2. Mark a vertical line on the head of the bolt for the
camshaft drive gear. Refer to Illustration 330.
Part No.: 124-8395
S/N: GS61-Up
3. Place a driver against the retaining plate of the
camshaft drive gear. Strike the driver solidly with
a hammer 3 to 4 times.
Part No.: 101-0835
S/N: GS71-Up
4. Again, tighten the bolt for the camshaft drive gear
to 360 ± 40 N·m (270 ± 30 lb ft).
Part No.: 101-0835
S/N: GSA1-Up
Part No.: 101-0835
S/N: S2A1-Up
Part No.: 101-0835
S/N: S2B1-Up
Part No.: 101-0835
S/N: S2D1-Up
Part No.: 101-0835
S/N: S2E1-Up
Part No.: 101-0835
S/N: B5G1-Up
Illustration 331
g01256393
5. Repeat Steps 3 and 4 until the mark on the
bolt turns a minimum of 90 degrees. Refer to
Illustration 331.
Part No.: 101-0835
S/N: MRG1-Up
Part No.: 101-0835
S/N: PAG1-Up
Part No.: 101-0835
S/N: S2G1-Up
374
Specifications Section
Part No.: 101-0835
S/N: MKH1-Up
Part No.: 101-0835
S/N: S2H1-Up
Part No.: 101-0835
S/N: S2J1-Up
Part No.: 101-0835
S/N: S2K1-Up
Part No.: 101-0835
S/N: S2L1-Up
Part No.: 101-0835
S/N: S2N1-Up
Part No.: 101-0835
S/N: S2P1-Up
Part No.: 101-0835
S/N: S2R1-Up
Part No.: 101-0835
S/N: S2S1-Up
Part No.: 101-0835
S/N: S2T1-Up
Part No.: 101-0835
S/N: S2W1-Up
Part No.: 101-0835
S/N: S2X1-Up
Part No.: 101-0835
S/N: S2Y1-Up
Part No.: 101-0835
S/N: S2Z1-Up
RENR5077-12
RENR5077-12
375
Specifications Section
g02575820
Illustration 333
(1) Ring
Illustration 334
(13) Plate
g02575836
Vertical line
Illustration 335
g02575837
376
Specifications Section
RENR5077-12
g02575838
Illustration 336
Rear view of engine
Table 229
Specification for 124-8395 Rear Gear Gp175-5204 Rear Gear Gp101-0835 Rear Gear
Gp334-5298 Rear Gear Gp175-5203 Rear Gear Gp
Item
Qty
Part
Specification Description
Before assembly, clean the taper of the camshaft and the tapered bore of the camshaft drive gear with lint free
cloth saturated with cleaning solvent to remove excess oil. Clean with alcohol wipe.
Refer to Disassembly and Assembly for the installation procedure for the left camshaft drive gear (2).
2
101-1364 Idler Gear As
Bore in the 125-9751 Bushing for the idler gear assembly is
81.060 ± 0.010 mm (3.1913 ± 0.0004 inch).
Installation depth of the 125-9751 Bushing is 1.00 ± 0.25 mm
(0.049 ± 0.010 inch).
4
1
114-3372 Cluster Gear
Assembly
Bore in the 101-1372 Bushing for the cluster gear assembly is
75.060 ± 0.010 mm (2.9551 ± 0.0004 inch).
Installation depth of the 101-1372 Bushing is 1.5 ± 0.5 mm
(0.06 ± 0.02 inch).
5
4
8M-2530 Bolt
6
1
101-1366 Gear Shaft
3
Torque to 140 ± 10 N·m (103 ± 7 lb ft).
Diameter of the gear shaft is 74.990 ± 0.010 mm (2.9524 ± 0.0004 inch).
Refer to Disassembly and Assembly for the installation procedure for the right camshaft drive gear (7).
8
2
101-1367 Idler Shaft
Diameter of the idler shaft is 81.000 ± 0.010 mm (3.1890 ± 0.0004 inch).
9
2
9X-8887 Bolt
Use the following procedure to tighten the bolt for the camshaft drive
gears:
1. Tighten the bolt for the camshaft drive gear to 360 ± 40 N·m
(266 ± 30 lb ft).
2. Mark a vertical line on the head of the bolt for the camshaft drive gear.
Refer to Illustration 334.
3. Place a driver against the retaining plate of the camshaft drive gear.
Strike the driver solidly with a hammer 3 to 4 times.
4. Again, tighten the bolt for the camshaft drive gear to 360 ± 40 N·m
(266 ± 30 lb ft).
5. Repeat steps 3 and 4 until the mark on the bolt turns a minimum of 90
degrees. Refer to Illustration 335.
10
4
1B-4367 Bolt
Torque to 240 ± 20 N·m (177 ± 15 lb ft).
11
2
8S-2331 Bolt
Torque to 240 ± 20 N·m (177 ± 15 lb ft).
14
-
-
The mark on the cluster gear assembly (4) must be in alignment with the
mark on the crankshaft gear (12).
RENR5077-12
377
Specifications Section
i04932634
Gear Group (Rear)
SMCS Code: 1206
Part No.: 380-2697
S/N: 9F21-Up
Part No.: 380-2697
S/N: CG21-Up
Part No.: 380-5096
S/N: ED21-Up
Part No.: 380-2697
S/N: 9F31-Up
Part No.: 380-5096
S/N: 9H31-Up
Part No.: 380-5096
S/N: ED31-Up
Part No.: 380-5096
S/N: 9H41-Up
Part No.: 380-2697
S/N: JB41-Up
Part No.: 380-2697
S/N: 9H51-Up
Part No.: 380-5096
S/N: ED51-Up
Part No.: 380-2697
S/N: 9H61-Up
Part No.: 380-5096
S/N: ED81-Up
Part No.: 380-5096
S/N: MD81-Up
Part No.: 380-2697
S/N: EDC1-Up
Part No.: 380-2697
S/N: EDG1-Up
Part No.: 380-2697
S/N: EDH1-Up
Part No.: 380-5096
S/N: SRH1-Up
Part No.: 380-2697
S/N: EDJ1-Up
Part No.: 380-5096
S/N: SRK1-Up
Part No.: 380-5096
S/N: MXM1-Up
Part No.: 380-2697
S/N: EDP1-Up
Part No.: 380-2697
S/N: MXR1-Up
378
Specifications Section
RENR5077-12
g03104796
Illustration 337
Typical example
Table 230
Specification for 380-5096 Rear Gear Gp and 380-2697 Rear Gear Gp
Item
Qty
Part
Specification Description
1
2
101-1364 Idler Gear As
Bore of 125-9751 Bushing after installation is 81.060 ± 0.010 mm
(3.1913 ± 0.0004 inch).
Installation depth is 1.00 ± 0.25 mm (0.039 ± 0.010 inch).
2
2
101-1368 Thrust Washer
Thickness is 1.90 ± 0.10 mm (0.075 ± 0.004 inch).
3
1
114-3372 Idler Gear As
Bore of 101-1372 Bushing after installation is 75.060 ± 0.010 mm
(2.9551 ± 0.0004 inch).
Installation depth is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).
4
1
101-1366 Gear Shaft
5
4
8M-2530 Bolt
6
2
-
7
2
8S-2331 Bolt
Diameter is 74.990 ± 0.010 mm (2.9524 ± 0.0004 inch).
Torque to 140 ± 10 N·m (103 ± 7 lb ft).
Before assembly, clean the taper of the camshaft and the tapered bore
of the camshaft drive gear with lint free cloth saturated with cleaning
solvent to remove excess oil. Clean with alcohol wipe.
Torque to 240 ± 20 N·m (177 ± 15 lb ft).
RENR5077-12
379
Specifications Section
g03104816
Illustration 338
Rear view
Table 231
Item
Qty
Part
8
2
101-1367 Idler Shaft
9
4
1B-4367 Bolt
Specification Description
Diameter is 81.000 ± 0.010 mm (3.1890 ± 0.0004 inch).
Torque to 240 ± 20 N·m (177 ± 15 lb ft).
380
Specifications Section
RENR5077-12
i04929854
Balancer Group (Front)
SMCS Code: 1220
Part No.: 332-7916
S/N: M8A1-Up
Part No.: 332-7916
S/N: M8B1-Up
g03099018
Illustration 339
Table 232
Specification for 7N-8711 Balancer Gp
Item
Qty
Part
1
4
8M-2530 Bolt
2
1
4W-4998 Gear Shaft
3
1
7N-6983 Bushing
4
1
101-1365 Thrust Plate
5
-
-
Specification Description
Torque to 140 ± 10 N·m (105 ± 7 lb ft).
Diameter is 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
Bore of the bushing after assembly is 75.000 ± 0.053 mm
(2.9528 ± 0.0021 inch).
Thickness is 6.35 ± 0.25 mm (0.250 ± 0.010 inch)
The mark on the balancer gear must be in alignment with the mark on
the crankshaft gear.
RENR5077-12
381
Specifications Section
i04397819
Balancer Group (Front)
SMCS Code: 1220
Part No.: 101-0833
S/N: GS71-Up
Part No.: 101-0833
S/N: S2A1-Up
Part No.: 101-0833
S/N: S2B1-Up
Part No.: 101-0833
S/N: S2D1-Up
Part No.: 101-0833
S/N: S2E1-Up
Part No.: 101-0833
S/N: S2F1-Up
g02576177
Illustration 340
Front view
(3) Balancer gear
(4) Crankshaft gear
Table 233
Specification for 332-7916 Balancer Gp and 101-0833 Balancer Gp
Item
Qty
Part
1
4
8M-2530 Bolt
B
1
4W-4998 Gear Shaft
C
1
101-1365 Thrust Plate
2
1
101-9043 Balancer
Gear Assembly
Specification Description
Torque to 140 ± 10 N·m (103 ± 7 lb ft).
Diameter of the new gear shaft is 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
After assembly, bore in the 7N-6983 Bushing is 75.000 ± 0.053 mm
(2.9528 ± 0.0021 inch).
Thickness is 6.35 ± 0.25 mm (0.250 ± 0.010 inch).
The mark on the balancer gear must be in alignment with the mark on the
crankshaft gear.
382
Specifications Section
RENR5077-12
i04397848
Accessory Drive
SMCS Code: 1207
Part No.: 334-5320
S/N: 9F31-Up
Part No.: 334-5320
S/N: 9H31-Up
Part No.: 334-5320
S/N: ED31-Up
Part No.: 334-5320
S/N: JB41-Up
Part No.: 334-5320
S/N: 9H51-Up
Part No.: 334-5320
S/N: ED51-Up
Part No.: 334-5320
S/N: M8B1-Up
Part No.: 334-5320
S/N: EDC1-Up
Part No.: 334-5320
S/N: EDJ1-Up
Part No.: 334-5320
S/N: SRK1-Up
Part No.: 334-5320
S/N: EDP1-Up
Illustration 341
Front view
g02576298
RENR5077-12
383
Specifications Section
g02576299
Illustration 342
Section A-A
Table 234
Specification for the 334-5320 Accessory Drive Gp
Item
Qty
Part
1
1
259-4598 O-Ring Seal
2
1
116-3242 Idler Gear As
Specification Description
Before assembly, lightly lubricate the bore with the fluid that is being
sealed.
After assembly, bore of 116-1365 Bearing is 105.970 ± 0.010 mm
(4.1720 ± 0.0004 inch).
Installation depth is 2.3 ± 0.5 mm (0.09 ± 0.02 inch).
3
1
7C-3257 Thrust Washer
B
1
7C-3259 Shaft
Thickness of new thrust washer is 7.00 ± 0.15 mm (0.276 ± 0.006 inch).
Diameter is 105.880 ± 0.020 mm (4.1685 ± 0.0008 inch).
Diameter is 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
C
1
7N-5874 Auxiliary Drive Shaft
Width of groove for thrust washer is 8.75 ± 0.10 mm
(0.344 ± 0.004 inch).
Bore in the 2W-7320 Accessory Drive Gear is 74.980 ± 0.025 mm
(2.9520 ± 0.0010 inch).
4
1
7N-7539 Thrust Washer
Thickness of one new thrust washer is 8.50 ± 0.05 mm
(0.335 ± 0.002 inch).
384
Specifications Section
RENR5077-12
i04404530
Accessory Drive
SMCS Code: 1207
Part No.: 334-5306
S/N: M8A1-Up
Part No.: 334-5306
S/N: P8A1-Up
Part No.: 334-5306
S/N: M8B1-Up
Illustration 343
Front view
g02594821
RENR5077-12
Illustration 344
385
Specifications Section
g02826376
386
Specifications Section
RENR5077-12
Table 235
Specification for 334-5306 Accessory Drive Gp
Item
Part
Qty
Specification Description
Diameter is 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
1
1
7N-5874 Auxiliary Drive Shaft
2
1
235-3546 O-Ring Seal
Before assembly, lightly lubricate the bore with the fluid that is being
sealed.
Width of groove for thrust washer is 8.75 ± 0.10 mm
(0.344 ± 0.004 inch).
3
1
7N-5279 Adapter As
During assembly, align the hole in the bushing with the adapter
assembly.
After assembly, bore in the 127-5400 Bushing is 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch).
4
1
6V-3348 O-Ring Seal
Before assembly, lightly lubricate the bore with the fluid that is being
sealed.
5
1
5P-0840 O-Ring Seal
Before assembly, lightly lubricate the bore with the fluid that is being
sealed.
6
1
259-4598 O-Ring Seal
Before assembly, lightly lubricate the bore with the fluid that is being
sealed.
During assembly, align the hole in the bushing with the adapter
assembly.
After assembly, bore in the 127-5400 Bushing is 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch).
7
1
7C-4165 Adapter As
8
2
7N-7539 Thrust Washer
Thickness of one new thrust washer is 8.50 ± 0.05 mm
(0.335 ± 0.002 inch).
i04863849
Accessory Drive
Part No.: 334-5317
S/N: SRH1-Up
SMCS Code: 1207
Part No.: 334-5317
S/N: MXM1-Up
Part No.: 334-5317
S/N: 9F21-Up
Part No.: 334-5317
S/N: MXR1-Up
Part No.: 334-5317
S/N: CG21-Up
Part No.: 334-5317
S/N: SRZ1-Up
Part No.: 334-5317
S/N: ED21-Up
Part No.: 334-5317
S/N: WF21-Up
Part No.: 334-5317
S/N: 9H41-Up
Part No.: 334-5317
S/N: 9H61-Up
Part No.: 334-5317
S/N: ED81-Up
Part No.: 334-5317
S/N: MD81-Up
Part No.: 334-5317
S/N: EDG1-Up
Part No.: 334-5317
S/N: EDH1-Up
RENR5077-12
387
Specifications Section
g02991376
Illustration 345
Table 236
Specification for 334-5317 Accessory Drive Gp
Item
Qty
Part
Specification Description
Bore of the 140-9597 Bushing after assembly is 90.000 ± 0.010 mm
(3.5433 ± 0.0004 inch).
1
1
144-8263 Idler Gear As
Installation depth for the 140-9597 Bushing is 2.3 ± 0.5 mm
(0.09 ± 0.02 inch).
Diameter of the 7E-0273 Idler Gear is 96.000 ± 0.025 mm
(3.7795 ± 0.0010 inch).
2
1
259-4598 O-Ring Seal
3
1
7C-3260 Shaft
4
1
7N-5874 Auxiliary Drive Shaft
5
1
7E-0275 Water Pump Drive Gear
Lubricate the bore lightly with the lubricant that is being sealed.
Diameter is 89.88 ± 0.02 mm (3.539 ± 0.001 inch).
Diameter is 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
Bore is 74.980 ± 0.025 mm (2.9520 ± 0.0010 inch).
Apply blue Loctite 242 to the 7N-2047 Dowel.
6
1
7C-3258 Thrust Washer Assembly
Protrusion of the 7N-2047 Dowel from the surface is 4.5 ± 0.5 mm
(0.18 ± 0.02 inch).
Thickness is 7.00 ± 0.15 mm (0.276 ± 0.006 inch).
7
2
7N-7539 Thrust Washer
Thickness is 8.50 ± 0.05 mm (0.335 ± 0.002 inch).
388
Specifications Section
RENR5077-12
i04397906
Accessory Drive (Lower Left
Hand)
SMCS Code: 1207
Part No.: 7E-7647
S/N: GS61-Up
Part No.: 7E-7647
S/N: GS71-Up
Part No.: 7E-7647
S/N: GSA1-Up
Part No.: 7E-7647
S/N: S2A1-Up
Part No.: 7E-7647
S/N: S2B1-Up
Part No.: 7E-7647
S/N: S2D1-Up
Part No.: 7E-7647
S/N: S2E1-Up
Part No.: 7E-7647
S/N: S2F1-Up
Part No.: 7E-7647
S/N: B5G1-Up
Part No.: 7E-7647
S/N: MRG1-Up
Part No.: 7E-7647
S/N: PAG1-Up
Part No.: 7E-7647
S/N: S2G1-Up
Part No.: 7E-7647
S/N: MKH1-Up
Part No.: 7E-7647
S/N: S2H1-Up
Part No.: 7E-7647
S/N: S2J1-Up
Part No.: 7E-7647
S/N: S2K1-Up
Part No.: 7E-7647
S/N: S2L1-Up
Part No.: 7E-7647
S/N: S2M1-Up
Part No.: 7E-7647
S/N: S2N1-Up
Part No.: 7E-7647
S/N: S2P1-Up
Part No.: 7E-7647
S/N: S2R1-Up
Part No.: 7E-7647
S/N: S2S1-Up
Part No.: 7E-7647
S/N: S2T1-Up
Part No.: 7E-7647
S/N: S2W1-Up
Part No.: 7E-7647
S/N: S2X1-Up
Part No.: 7E-7647
S/N: S2Y1-Up
Part No.: 7E-7647
S/N: S2Z1-Up
RENR5077-12
Illustration 346
389
Specifications Section
g02576404
Front view
(1) Water pump drive gear
Illustration 347
Section B-B
g02576406
390
Specifications Section
RENR5077-12
g02576407
Illustration 348
Adapter assembly
Table 237
Specification for the 7E-7647 Accessory Drive Gp156-9812 Accessory Drive Gp
Item
Qty
Part
1
9X-7371 O-Ring Seal
2
259-4598 O-Ring Seal
Lightly lubricate the bore of the O-ring seals with the lubricant that
is being sealed.
3
1
7C-3260 Shaft
Diameter of the new shaft is 89.88 ± 0.02 mm (3.539 ± 0.001 inch).
4
1
144-8263 Idler Gear As
Bore in the sleeve bearing of the idler gear assembly after installation
is 90.000 ± 0.010 mm (3.5433 ± 0.0004 inch).
Maximum roughness average (Ra) is 0.8 micrometer (31.5 microinch).
Diameter of the new auxiliary drive shaft is 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch).
Width of groove in the new auxiliary drive shaft for the thrust washer
is 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch).
End play for the auxiliary drive shaft is 0.175 to 0.325 mm
(0.0069 to 0.0128 inch).
2
Specification Description
5
1
7N-5874 Auxiliary
Drive Shaft
6
2
7N-7539 Thrust Washer
C
1
127-5400 Bushing
Installation depth of the bushing in the adapter assembly is
1.5 ± 0.5 mm (0.06 ± 0.02 inch).
D
1
127-5400 Bushing
Bore in the bushing of the adapter assembly after installation is
75.000 ± 0.055 mm (2.9527 ± 0.0022 inch).
Thickness of the new thrust washer is 8.50 ± 0.05 mm
(0.335 ± 0.002 inch).
RENR5077-12
391
Specifications Section
i04397947
Accessory Drive (Lower Left
Hand)
SMCS Code: 1207
Part No.: 179-1511
S/N: S2A1-Up
Part No.: 179-1511
S/N: S2B1-Up
Part No.: 179-1511
S/N: S2D1-Up
Part No.: 179-1511
S/N: S2E1-Up
Part No.: 179-1511
S/N: S2F1-Up
Part No.: 179-1511
S/N: B5G1-Up
Part No.: 179-1511
S/N: MRG1-Up
Part No.: 179-1511
S/N: PAG1-Up
Part No.: 179-1511
S/N: S2G1-Up
Part No.: 179-1511
S/N: MKH1-Up
Part No.: 179-1511
S/N: S2H1-Up
Part No.: 179-1511
S/N: S2J1-Up
Part No.: 179-1511
S/N: S2K1-Up
Part No.: 179-1511
S/N: S2L1-Up
Part No.: 179-1511
S/N: S2M1-Up
Part No.: 179-1511
S/N: S2N1-Up
Part No.: 179-1511
S/N: S2P1-Up
Part No.: 179-1511
S/N: S2R1-Up
Part No.: 179-1511
S/N: S2S1-Up
Part No.: 179-1511
S/N: S2T1-Up
Part No.: 179-1511
S/N: S2W1-Up
Part No.: 179-1511
S/N: S2X1-Up
Part No.: 179-1511
S/N: S2Y1-Up
Part No.: 179-1511
S/N: S2Z1-Up
392
Specifications Section
Illustration 349
RENR5077-12
g02576537
Front view
Illustration 350
g02576538
Section A-A
Illustration 351
Section B-B
(4) Adapter assembly
g02576539
RENR5077-12
393
Specifications Section
Table 238
Specification for the 179-1511 Accessory Drive Gp
Item
Qty
Part
1
2
259-4598 O-Ring Seal
2
1
7C-3259 Shaft
Specification Description
Lubricate the bore of the four O-ring seals with the lubricant that is
being sealed.
Diameter of new shaft is 105.880 ± 0.020 mm (4.1685 ± 0.0008 inch).
3
1
127-5400 Bushing
5
-
-
6
1
7N-5874 Auxiliary
Drive Shaft
7
1
7C-3257 Thrust Washer
Bore in the bushing after assembly is 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch).
After the bearing is installed in the idler gear, the bearing must be
machined to size.
Bore in the bearing after assembly is 105.970 ± 0.010 mm
(4.1720 ± 0.0004 inch).
Maximum roughness average (Ra) is 0.8 micrometer (32 microinch).
Diameter of new auxiliary drive shaft is 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch).
Width of groove in new auxiliary drive shaft is 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch).
Thickness of new thrust washer is 7.00 ± 0.15 mm
(0.276 ± 0.006 inch).
i04398428
Accessory Drive (Upper Right
Hand)
SMCS Code: 1207
Part No.: 166-4357
S/N: GS61-Up
Part No.: 166-4357
S/N: GS71-Up
Part No.: 166-4357
S/N: GSA1-Up
Part No.: 334-5306
S/N: P8A1-Up
Part No.: 166-4357
S/N: S2A1-Up
Part No.: 166-4357
S/N: S2B1-Up
Part No.: 166-4357
S/N: S2D1-Up
Part No.: 166-4357
S/N: S2E1-Up
Part No.: 166-4357
S/N: S2F1-Up
Part No.: 166-4357
S/N: PAG1-Up
Part No.: 166-4357
S/N: S2G1-Up
Part No.: 166-4357
S/N: MKH1-Up
Part No.: 166-4357
S/N: S2H1-Up
Part No.: 166-4357
S/N: S2J1-Up
Part No.: 166-4357
S/N: S2K1-Up
Part No.: 166-4357
S/N: S2L1-Up
Part No.: 166-4357
S/N: S2M1-Up
Part No.: 166-4357
S/N: S2N1-Up
Part No.: 166-4357
S/N: S2P1-Up
Part No.: 166-4357
S/N: S2R1-Up
Part No.: 166-4357
S/N: S2S1-Up
Part No.: 166-4357
S/N: S2T1-Up
Part No.: 166-4357
S/N: S2W1-Up
Part No.: 166-4357
S/N: S2X1-Up
Part No.: 166-4357
S/N: S2Y1-Up
Part No.: 166-4357
S/N: S2Z1-Up
394
Specifications Section
RENR5077-12
g01930053
Illustration 352
Table 239
Specification for the 166-4357 Accessory Drive Gp and 334-5306 Accessory Drive Gp
Item
Qty
Part
Specification Description
1
-
-
Lightly lubricate the bore of the O-ring seals with the lubricant that is
being sealed or with the approved equivalent.
2
2
7N-7539 Thrust Washer
1
7N-5874 Auxiliary
Drive Shaft
Diameter of new auxiliary drive shaft is 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch).
Width of groove in the new auxiliary drive shaft is 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch).
3
Thickness of the new thrust washer is 8.50 ± 0.05 mm
(0.335 ± 0.002 inch).
4
1
7N-5279 Adapter As
During assembly, align the hole in the sleeve bearing with the
adapter.
Bore in the sleeve bearing of the adapter assembly after installation
is 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch).
5
1
7C-4165 Adapter As
Bore in the sleeve bearing of the adapter assembly after installation
is 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch).
RENR5077-12
395
Specifications Section
i04403923
Accessory Drive (Upper Right
Hand)
SMCS Code: 1207
Part No.: 7N-4871
S/N: GS61-Up
Part No.: 7N-4871
S/N: S2A1-Up
Part No.: 7N-4871
S/N: S2B1-Up
Part No.: 7N-4871
S/N: S2D1-Up
Part No.: 7N-4871
S/N: S2E1-Up
Part No.: 7N-4871
S/N: S2F1-Up
Part No.: 7N-4871
S/N: B5G1-Up
Part No.: 7N-4871
S/N: MRG1-Up
Part No.: 7N-4871
S/N: PAG1-Up
Part No.: 7N-4871
S/N: S2G1-Up
Part No.: 7N-4871
S/N: MKH1-Up
Part No.: 7N-4871
S/N: S2H1-Up
Part No.: 7N-4871
S/N: S2J1-Up
Part No.: 7N-4871
S/N: S2K1-Up
Part No.: 7N-4871
S/N: S2L1-Up
Part No.: 7N-4871
S/N: S2M1-Up
Part No.: 7N-4871
S/N: S2N1-Up
Part No.: 7N-4871
S/N: S2P1-Up
Part No.: 7N-4871
S/N: S2R1-Up
Part No.: 7N-4871
S/N: S2S1-Up
Part No.: 7N-4871
S/N: S2T1-Up
Part No.: 7N-4871
S/N: S2W1-Up
Part No.: 7N-4871
S/N: S2X1-Up
Part No.: 7N-4871
S/N: S2Y1-Up
Part No.: 7N-4871
S/N: S2Z1-Up
396
Specifications Section
Illustration 353
RENR5077-12
g02592697
Front view of engine
Illustration 354
Section A-A
g02592698
RENR5077-12
397
Specifications Section
g02592699
Illustration 355
Adapter assembly
Table 240
Specification for 7N-4871 Accessory Drive Gp and 7C-0264 Accessory Drive Gp
Item
Qty
Part
Specification Description
1
-
-
Lightly lubricate the bore of the O-ring seals with the lubricant that is
being sealed.
2
1
7N-5279 Adapter As
Bore in the 127-5400 Bushing of the adapter assembly after
installation is 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch).
Diameter of the new auxiliary drive shaft is 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch).
3
1
7N-5874 Auxiliary
Drive Shaft
Width of groove in the new auxiliary drive shaft for the thrust washer
is 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch).
End play for the auxiliary drive shaft is 0.175 to 0.325 mm
(0.0069 to 0.0128 inch).
4
2
7N-7539 Thrust Washer
D
1
7C-4165 Adapter As
Thickness of the new thrust washer is 8.50 ± 0.05 mm
(0.335 ± 0.002 inch).
Bore in the 127-5400 Bushing of the adapter assembly after
installation is 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch).
i04398433
Accessory Drive (Upper Right
Hand)
SMCS Code: 1207
Part No.: 334-5304
S/N: CG21-Up
Part No.: 334-5304
S/N: WF21-Up
Part No.: 334-5304
S/N: 9H41-Up
Part No.: 334-5304
S/N: 9H61-Up
398
Specifications Section
RENR5077-12
Part No.: 107-7361
S/N: GS61-Up
Part No.: 107-7361
S/N: S2N1-Up
Part No.: 107-7361
S/N: GS71-Up
Part No.: 107-7361
S/N: S2P1-Up
Part No.: 334-5304
S/N: ED81-Up
Part No.: 334-5304
S/N: MXR1-Up
Part No.: 334-5304
S/N: MD81-Up
Part No.: 107-7361
S/N: S2R1-Up
Part No.: 107-7361
S/N: GSA1-Up
Part No.: 107-7361
S/N: S2S1-Up
Part No.: 334-5304
S/N: M8A1-Up
Part No.: 107-7361
S/N: S2T1-Up
Part No.: 107-7361
S/N: S2A1-Up
Part No.: 107-7361
S/N: S2W1-Up
Part No.: 107-7361
S/N: S2B1-Up
Part No.: 107-7361
S/N: S2X1-Up
Part No.: 107-7361
S/N: S2D1-Up
Part No.: 107-7361
S/N: S2Y1-Up
Part No.: 107-7361
S/N: S2E1-Up
Part No.: 107-7361
S/N: S2Z1-Up
Part No.: 107-7361
S/N: S2F1-Up
Part No.: 107-7361
S/N: B5G1-Up
Part No.: 334-5304
S/N: EDG1-Up
Part No.: 107-7361
S/N: MRG1-Up
Part No.: 107-7361
S/N: PAG1-Up
Part No.: 107-7361
S/N: S2G1-Up
Part No.: 107-7361
S/N: MKH1-Up
Part No.: 107-7361
S/N: S2H1-Up
Part No.: 107-7361
S/N: S2J1-Up
Part No.: 107-7361
S/N: S2K1-Up
Part No.: 107-7361
S/N: S2L1-Up
Part No.: 334-5304
S/N: MXM1-Up
Part No.: 107-7361
S/N: S2M1-Up
RENR5077-12
399
Specifications Section
g02578096
Illustration 356
Table 241
Specification for 107-7361 Accessory Drive Gp and 334-5304 Accessory Drive Gp
Item
Qty
Part
1
1
259-4598 O-Ring Seal
Lubricate the bore lightly with the lubricant that is being sealed.
2
1
235-3546 O-Ring Seal
Lubricate the bore lightly with the lubricant that is being sealed.
B
C
-
-
Specification Description
Diameter of accessory drive gear (4) at cover assembly end (3) is
44.400 ± 0.015 mm (1.7480 ± 0.0006 inch).
-
Bore in 2S-7056 Bushing for accessory drive gear is
44.577 ± 0.023 mm (1.7550 ± 0.0009 inch).
Bore in 127-5400 Bushing after assembly for accessory drive gear
is 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch).
-
Diameter of accessory drive gear (4) at adapter assembly end (5) is
74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
i05167721
Accessory Drive (Upper Right
Hand)
SMCS Code: 1207
Part No.: 424-9794
S/N: CG21-Up
Part No.: 424-9794
S/N: 9H41-Up
Part No.: 424-9794
S/N: 9H61-Up
Part No.: 424-9794
S/N: ED81-Up
Part No.: 424-9794
S/N: MD81-Up
Part No.: 424-9794
S/N: EDG1-Up
Part No.: 424-9794
S/N: MXM1-Up
Part No.: 424-9794
S/N: MXR1-Up
400
Specifications Section
RENR5077-12
g03319612
Illustration 357
Table 242
Specification for the 424-9794 Accessory Drive Gp
Item
Qty
Part
Specification Description
Bore in the 127-5400 Bushing after installation is 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch).
During assembly, align the hole in the bushing with the hole in the
adapter assembly.
1
1
7C-4165 Adapter As
2
1
259-4598 O-Ring Seal
3
1
7N-5279 Adapter As
4
2
7N-7539 Thrust Washer
5
1
7N-5874 Auxiliary
Drive Shaft
6
1
235-3546 O-Ring Seal
Lightly lubricate the bore with the lubricant that is being sealed.
7
1
6V-3348 O-Ring Seal
Lightly lubricate the bore with the lubricant that is being sealed.
Lightly lubricate the bore with the lubricant that is being sealed.
During assembly, align the hole in the bushing with the hole in the
adapter assembly.
Bore in the 127-5400 Bushing after installation is 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch).
Thickness of the new thrust washer is 8.50 ± 0.05 mm
(0.335 ± 0.002 inch).
Diameter of new auxiliary drive shaft is 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch).
Width of groove in the new auxiliary drive shaft for thrust washer is
8.75 ± 0.10 mm (0.344 ± 0.004 inch).
RENR5077-12
401
Specifications Section
i04863569
Accessory Drive (Upper Right
Hand)
SMCS Code: 1207
Part No.: 383-0621
S/N: CG21-Up
Part No.: 383-0621
S/N: 9H41-Up
Part No.: 383-0621
S/N: 9H61-Up
Part No.: 383-0621
S/N: ED81-Up
Part No.: 383-0621
S/N: MD81-Up
Part No.: 383-0621
S/N: EDG1-Up
Part No.: 383-0621
S/N: MXM1-Up
Part No.: 383-0621
S/N: MXR1-Up
402
Specifications Section
Illustration 358
Typical example
RENR5077-12
g02991196
RENR5077-12
403
Specifications Section
Table 243
Specification for 383-9797 Accessory Drive Gp and 383-0621 Accessory Drive Gp
Item
Qty
Part
1
1
7N-5875 Auxiliary Drive Gear
2
1
6V-3348 O-Ring Seal
Lubricate the bore lightly with the lubricant that is being sealed.
3
1
235-3546 O-Ring Seal
Lubricate the bore lightly with the lubricant that is being sealed.
4
2
7N-7539 Thrust Washer
Thickness is 8.50 ± 0.05 mm (0.335 ± 0.002 inch).
5
1
7N-5874 Auxiliary Drive Shaft
Diameter is 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
6
1
7N-5248 Auxiliary Drive Gear
Diameter is 74.980 ± 0.025 mm (2.9520 ± 0.0010 inch).
7
1
7N-5279 Adapter As
8
1
7C-4165 Adapter As
9
1
259-4598 O-Ring Seal
Lubricate the bore lightly with the lubricant that is being sealed.
10
1
5P-0840 O-Ring Seal
Lubricate the bore lightly with the lubricant that is being sealed.
Specification Description
Diameter is 74.980 ± 0.025 mm (2.9520 ± 0.0010 inch).
Bore of the 127-5400 Bushing after assembly is 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch).
Bore of the 127-5400 Bushing after assembly is 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch).
i02960980
Accessory Drive (Upper Left
Hand)
SMCS Code: 1207
Part No.: 334-5328
S/N: M8B1-Up
g01479361
Illustration 359
(1) Lubricate the bore of six O-ring seals lightly with
the lubricant that is being sealed.
(2) 127-5400 Sleeve Bearing
Quantity ............................................................ 2
Bore in the sleeve bearing after
assembly ............................. 75.000 ± 0.055 mm
(2.9528 ± 0.0022 inch)
(3) Dimensions for the auxiliary drive shaft
404
Specifications Section
RENR5077-12
Diameter of the new auxiliary drive
shaft ..................................... 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
Width of the groove in the new auxiliary drive
shaft for the thrust washer ..... 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
End play for the auxiliary drive
shaft ...................................... 0.175 to 0.325 mm
(0.0069 to 0.0128 inch)
(E) Thickness of the new thrust
washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)
i04753314
Accessory Drive (Upper Left
Hand)
SMCS Code: 1207
Part No.: 8N-9166
S/N: GS61-Up
Part No.: 8N-9166
S/N: GS71-Up
Part No.: 8N-9166
S/N: GSA1-Up
Part No.: 8N-9166
S/N: S2A1-Up
Part No.: 8N-9166
S/N: S2B1-Up
Part No.: 8N-9166
S/N: S2D1-Up
Part No.: 8N-9166
S/N: S2E1-Up
Part No.: 8N-9166
S/N: S2F1-Up
Part No.: 8N-9166
S/N: PAG1-Up
Part No.: 8N-9166
S/N: S2G1-Up
Part No.: 8N-9166
S/N: MKH1-Up
Part No.: 8N-9166
S/N: S2H1-Up
Part No.: 8N-9166
S/N: S2J1-Up
Part No.: 8N-9166
S/N: S2K1-Up
Part No.: 8N-9166
S/N: S2L1-Up
Part No.: 8N-9166
S/N: S2M1-Up
Part No.: 8N-9166
S/N: S2N1-Up
Part No.: 8N-9166
S/N: S2P1-Up
Part No.: 8N-9166
S/N: S2R1-Up
Part No.: 8N-9166
S/N: S2S1-Up
Part No.: 8N-9166
S/N: S2T1-Up
Part No.: 8N-9166
S/N: S2W1-Up
Part No.: 8N-9166
S/N: S2X1-Up
Part No.: 8N-9166
S/N: S2Y1-Up
Part No.: 8N-9166
S/N: S2Z1-Up
RENR5077-12
405
Specifications Section
g02848837
Illustration 360
Table 244
Specification for 8N-9166 Accessory Drive Gp
Item
Qty
Part
Specification description
1
1
235-3546 O-Ring Seal
Lightly lubricate the bore with the lubricant that is being sealed.
2
1
259-4598 O-Ring Seal
Lightly lubricate the bore with the lubricant that is being sealed.
3
2
9X-7371 O-Ring Seal
Lightly lubricate the bore with the lubricant that is being sealed.
4
2
127-5400 Bushing
Inside diameter of the bushing after assembly in the adapter assembly
is 75.000 ± 0.055 mm (2.9528 ± 0.0022 inch).
Diameter is 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
5
1
7N-5874 Auxiliary
Drive Shaft
Width of the groove in the new auxiliary drive shaft for the thrust washer
is 8.75 ± 0.10 mm (0.344 ± 0.004 inch).
End play for the auxiliary drive shaft is 0.175 to 0.325 mm
(0.0069 to 0.0128 inch).
Thickness of the new thrust washer is 8.50 ± 0.05 mm
(0.335 ± 0.002 inch).
E
2
7N-7539 Thrust Washer
6
1
5P-0840 O-Ring Seal
Lightly lubricate the bore with the lubricant that is being sealed.
7
1
6V-3348 O-Ring Seal
Lightly lubricate the bore with the lubricant that is being sealed.
406
Specifications Section
RENR5077-12
i04863689
Accessory Drive (Upper Left
Hand)
SMCS Code: 1207
Part No.: 380-5019
S/N: CG21-Up
Part No.: 380-5019
S/N: WF21-Up
Part No.: 380-5019
S/N: 9H41-Up
Part No.: 380-5019
S/N: 9H61-Up
Part No.: 380-5019
S/N: ED81-Up
Part No.: 380-5019
S/N: MD81-Up
Part No.: 380-5019
S/N: EDG1-Up
Part No.: 380-5019
S/N: MXM1-Up
Part No.: 380-5019
S/N: MXR1-Up
Illustration 361
Left side view
g02991296
RENR5077-12
407
Specifications Section
Table 245
Specification for 380-5019 Accessory Drive Gp
Item
Qty
Part
1
1
235-3546 O-Ring Seal
Lubricate the bore lightly with the lubricant that is being sealed.
2
2
7N-7539 Thrust Washer
Thickness is 8.50 ± 0.05 mm (0.335 ± 0.002 inch).
Specification Description
g02991297
Illustration 362
Table 246
Specification for 380-5019 Accessory Drive Gp
Item
Qty
Part
Specification Description
3
1
7N-5279 Adapter As
4
1
7N-5875 Auxiliary Drive Gear
Bore is 74.980 ± 0.025 mm (2.9520 ± 0.0010 inch).
5
1
7N-5874 Auxiliary Drive Shaft
Diameter is 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
6
1
7N-5248 Auxiliary Drive Gear
Bore is 74.980 ± 0.025 mm (2.9520 ± 0.0010 inch).
Bore of the 127-5400 Bushing after assembly is 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch).
408
Specifications Section
RENR5077-12
i05169493
Accessory Drive (Upper Left
Hand)
SMCS Code: 1207
Part No.: 424-9760
S/N: CG21-Up
Part No.: 424-9760
S/N: 9H41-Up
Part No.: 424-9760
S/N: 9H61-Up
Part No.: 424-9760
S/N: ED81-Up
Part No.: 424-9760
S/N: MD81-Up
Part No.: 424-9760
S/N: EDG1-Up
Part No.: 424-9760
S/N: MXM1-Up
Part No.: 424-9760
S/N: MXR1-Up
Illustration 363
g03319633
RENR5077-12
409
Specifications Section
g03319639
Illustration 364
Left side view
Table 247
Specification for 424-9760 Accessory Drive Gp
Item
Qty
Part
Specification description
1
1
7N-5874 Auxiliary
Drive Shaft
2
1
7N-5279 Adapter As
3
2
7N-7539 Thrust Washer
Thickness of the new thrust washer is 8.50 ± 0.05 mm
(0.335 ± 0.002 inch).
4
1
235-3546 O-Ring Seal
Lightly lubricate the bore with the lubricant that is being sealed.
Diameter is 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).
Width of the groove in the new auxiliary drive shaft for the thrust washer
is 8.75 ± 0.10 mm (0.344 ± 0.004 inch).
Inside diameter of the 127-5400 Bushing after assembly in the adapter
assembly is 75.000 ± 0.055 mm (2.9528 ± 0.0022 inch).
410
Specifications Section
RENR5077-12
i02735559
Accessory Drive (Upper Left
Hand, Reverse Rotation)
(8) Diameter of new shaft .......... 89.880 ± 0.020 mm
(3.5386 ± 0.0008 inch)
i04398458
SMCS Code: 1207
Flywheel
Part No.: 334-5322
S/N: M8B1-Up
SMCS Code: 1156
Part No.: 7N-4851
S/N: GS61-Up
Part No.: 7N-4851
S/N: GS71-Up
Part No.: 7N-4851
S/N: GSA1-Up
Part No.: 333-3742, 7N-4851, 7N-7784,
7W-0968, 8N-6038
S/N: M8A1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968
S/N: S2A1-Up
Part No.: 333-3742, 7N-4851, 7N-7784,
7W-0968, 8N-6038
S/N: M8B1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968
S/N: S2B1-Up
Illustration 365
g01371445
(2) Accessory drive gear
(5) Thrust washer
(6) Idler gear
(1) Bore in the sleeve bearings after
assembly ............................. 75.000 ± 0.055 mm
(2.9528 ± 0.0022 inch)
(3) Thickness of new thrust washer .. 8.50 ± 0.05 mm
(0.335 ± 0.002 inch)
(4) Auxiliary drive shaft
Diameter of new auxiliary drive
shaft ..................................... 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
Width of groove in new auxiliary drive
shaft .. 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch)
End play for auxiliary drive
shaft ...................................... 0.175 to 0.325 mm
(0.0069 to 0.0128 inch)
(7) Sleeve bearing
Bore in the sleeve bearing after
assembly ............................. 90.000 ± 0.010 mm
(3.5433 ± 0.0004 inch)
Maximum roughness average
(Ra) ...................... 0.8 micrometer (32 microinch)
Note: After the sleeve bearing is installed in the gear
the sleeve bearing must be machined to size.
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2D1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2E1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2F1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: B5G1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: MRG1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: PAG1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968
S/N: S2G1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: MKH1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968
S/N: S2H1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2J1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2K1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2L1-Up
RENR5077-12
411
Specifications Section
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2M1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2N1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968
S/N: S2P1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968
S/N: S2R1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2S1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2T1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2W1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2X1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2Y1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968
S/N: S2Z1-Up
g02578197
Illustration 366
Typical example
(1) Flywheel gear
(2) Crankshaft
412
Specifications Section
RENR5077-12
Table 248
Specification for the 7N-4851 Flywheel Gp, 7N-7784 Flywheel Gp, 7W-0968 Flywheel Gp, 286-0244 Flywheel
Gp, 333-3742 Flywheel Gp, 8N-6038 Flywheel Gp, 8N-6439 Flywheel Gp, 2W-8772 Flywheel Gp, 333-3743
Flywheel Gp, 336-9989 Flywheel Gp, 336-9990 Flywheel Gp, and 317-4398 Flywheel Gp
Item
Qty
Part
Specification Description
When the flywheel assembly is installed, align the dash mark on the flywheel assembly with the dash mark on the crankshaft.
3
12
9S-8893 Bolt
Before assembly, lubricate the threads of the bolts with clean engine
oil, molybdenum disulfide, or graphite base lubricant.
Torque to 1150 ± 60 N·m (840 ± 44 lb ft).
i05165635
Flywheel
SMCS Code: 1156
Part No.: 380-5141
S/N: CG21-Up
Part No.: 382-9486
S/N: WF21-Up
Part No.: 382-9486
S/N: 9F31-Up
Part No.: 382-9486
S/N: 9H31-Up
Part No.: 380-5141, 382-9486
S/N: 9H41-Up
Part No.: 382-9486
S/N: 9H51-Up
Part No.: 382-9486
S/N: ED51-Up
Part No.: 380-5141, 382-9486
S/N: 9H61-Up
Part No.: 380-5141, 382-9486
S/N: ED81-Up
Part No.: 380-5141
S/N: MD81-Up
Part No.: 380-5141, 382-9486
S/N: EDG1-Up
Part No.: 382-9486
S/N: EDJ1-Up
Part No.: 380-5141
S/N: MXM1-Up
Part No.: 382-9486
S/N: EDP1-Up
Part No.: 380-5141
S/N: MXR1-Up
Part No.: 382-9486
S/N: SRZ1-Up
RENR5077-12
413
Specifications Section
g03299416
Illustration 367
Table 249
Specification for 380-5141 Flywheel Gp and 382-9486 Flywheel Gp
Item
Qty
Part
Specification Description
During installation, align the dash mark on the flywheel and the dash mark on
the crankshaft.
1
12
9S-8863 Bolt
Before assembly, lubricate the threads with clean engine oil, molybdenum
disulfide, or with graphite base lubricant .
Torque to 1150 ± 60 N·m (848 ± 44 lb ft).
i05141789
Flywheel
Part No.: 382-9485
S/N: 9H61-Up
SMCS Code: 1156
Part No.: 382-9485
S/N: ED81-Up
Part No.: 382-9485
S/N: WF21-Up
Part No.: 382-9485
S/N: EDG1-Up
Part No.: 382-9485
S/N: 9F31-Up
Part No.: 382-9485
S/N: EDJ1-Up
Part No.: 382-9485
S/N: 9H31-Up
Part No.: 382-9485
S/N: EDP1-Up
Part No.: 382-9485
S/N: 9H41-Up
Part No.: 382-9485
S/N: SRZ1-Up
Part No.: 382-9485
S/N: 9H51-Up
Part No.: 382-9485
S/N: ED51-Up
414
Specifications Section
RENR5077-12
g03299416
Illustration 368
Typical example
Table 250
Specification for 382-9485 Flywheel Gp and 382-9486 Flywheel Gp
Item
Qty
Part
1
12
5P-8865 Bolt
Specification Description
Before assembly, lubricate the threads with clean engine oil, molybdenum
disulfide, or with graphite base lubricant .
Torque to 1150 ± 60 N·m (848 ± 44 lb ft).
RENR5077-12
415
Specifications Section
i04403898
Flywheel Housing
SMCS Code: 1157
Part No.: 101-1269
S/N: GS61-Up
Part No.: 101-1269
S/N: GS71-Up
Part No.: 101-1269
S/N: GSA1-Up
Illustration 369
g02592608
Rear view
Illustration 370
Left side view
g02592609
416
Specifications Section
RENR5077-12
Table 251
Specification for 101-1269 Flywheel Housing Gp
Item
Qty
Part
Specification Description
-
-
-
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 materials.
-
-
-
To seal the joint between the flywheel housing and the cylinder block, apply blue
Loctite High Flex GM to the mating surfaces.
1
4
9X-8875 Bolt
Length of 1/2 inch diameter bolt is 88.90 mm (3.500 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
2
2
6M-9613 Bolt
Length of 1/2 inch diameter bolt is 228.60 mm (9.000 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
3
6
9X-8873 Bolt
Length of 1/2 inch diameter bolt is 57.15 mm (2.250 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
4
2
9S-1374 Bolt
Length of 1/2 inch diameter bolt is 203.20 mm (8.000 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
5
16
1D-4590 Bolt
Length of 5/8 inch diameter bolt is 120.65 mm (4.750 inch).
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
6
4
8S-9089 Bolt
Length of 1/2 inch diameter bolt is 114.30 mm (4.500 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
7
-
-
Before assembly, apply blue Loctite High Flex GM to the surface of the gasket.
i03690244
Flywheel Housing
SMCS Code: 1157
Part No.: 333-7646
S/N: M8A1-Up
Part No.: 333-7646
S/N: M8B1-Up
For information on inspecting the flywheel housing,
refer to the Testing and Adjusting, “Flywheel Housing
- Inspect”.
Note: Before installation of the flywheel housing,
inspect the front face of the flywheel housing and
the rear face of the cylinder block. The components
must be free of the following substances: oil, fuel,
water, gasket adhesive, assembly compounds, and
any other foreign material.
Tighten the bolts that hold the flywheel housing to
the engine block evenly. Refer to Illustration 372 and
Table 252 for the locations and for identification of
the bolts.
Illustration 371
g01984633
Left side view
(1) To seal the joint between the flywheel housing
and the cylinder block, apply 1U-8846 Gasket
Sealant to the front face of the flywheel housing.
(2) Torque for the bolts ...... 55 ± 10 N·m (41 ± 7 lb ft)
RENR5077-12
417
Specifications Section
i04403120
Flywheel Housing
SMCS Code: 1157
Part No.: 102-3540, 107-7177
S/N: S2A1-Up
Part No.: 102-3540, 107-7177
S/N: S2B1-Up
Part No.: 102-3540, 107-7177
S/N: S2D1-Up
Part No.: 102-3540, 107-7177
S/N: S2E1-Up
Part No.: 102-3540, 107-7177
S/N: S2F1-Up
Part No.: 102-3540, 107-7177
S/N: B5G1-Up
g02019674
Illustration 372
Table 252
Flywheel Housing Bolt
Installation Chart
Bolt Length
Bolt
Diameter
inch
Part
Number
mm
inch
4
1/2
9X-8873
57.15
2.250
5
1/2
1D-4574
152.4
6.00
6
3/8
0S-1594
25.4
1.00
7
5/8
1D-4597
165.1
6.50
8
1/2
9X-8878
133.35
5.250
9
5/8
1D-4602
241.3
9.50
10
5/8
1D-4593
139.7
5.50
Part No.: 102-3540, 107-7177
S/N: MRG1-Up
Part No.: 102-3540, 107-7177
S/N: PAG1-Up
Part No.: 102-3540, 107-7177
S/N: S2G1-Up
Part No.: 102-3540, 107-7177
S/N: MKH1-Up
Part No.: 102-3540, 107-7177
S/N: S2H1-Up
Part No.: 102-3540, 107-7177
S/N: S2J1-Up
Part No.: 102-3540, 107-7177
S/N: S2K1-Up
Note: Bond the entire surface with 6V-6640 Sealant
to the flywheel housing cover assembly (3).
Part No.: 102-3540, 107-7177
S/N: S2L1-Up
(4) Torque for the bolts ........................ 135 ± 20 N·m
(100 ± 15 lb ft)
Part No.: 102-3540, 107-7177
S/N: S2M1-Up
(5) Torque for the bolts ........................ 135 ± 20 N·m
(100 ± 15 lb ft)
Part No.: 102-3540, 107-7177
S/N: S2N1-Up
(6) Torque for the bolts ...... 55 ± 10 N·m (41 ± 7 lb ft)
Part No.: 102-3540, 107-7177
S/N: S2P1-Up
(7) Torque for the bolts ........................ 270 ± 40 N·m
(199 ± 30 lb ft)
Part No.: 102-3540, 107-7177
S/N: S2R1-Up
(8) Torque for the bolts ........................ 135 ± 20 N·m
(100 ± 15 lb ft)
Part No.: 102-3540, 107-7177
S/N: S2S1-Up
(9) Torque for the bolts ........................ 270 ± 40 N·m
(199 ± 30 lb ft)
(10) Torque for the bolts ...................... 270 ± 40 N·m
(199 ± 30 lb ft)
Part No.: 102-3540, 107-7177
S/N: S2T1-Up
Part No.: 102-3540, 107-7177
S/N: S2W1-Up
418
Specifications Section
RENR5077-12
Part No.: 102-3540, 107-7177
S/N: S2X1-Up
Part No.: 102-3540, 107-7177
S/N: S2Y1-Up
Part No.: 102-3540, 107-7177
S/N: S2Z1-Up
Illustration 373
Rear view of the engine
g01513774
RENR5077-12
419
Specifications Section
g02589857
Illustration 374
Left side view
Table 253
Specification for 107-7177 Flywheel Housing Gp and 102-3540 Flywheel Housing Gp
Item
Qty
Part
Specification Description
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 materials.
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.
1
6
9X-8873 Bolt
Length of 1/2 inch diameter bolt is 57.15 mm (2.250 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
2
6
1D-4574 Bolt
Length of 1/2 inch diameter bolt is 152.40 mm (6.000 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
3
2
9X-8874 Bolt
Length of 1/2 inch diameter bolt is 76.20 mm (3.000 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
4
2
1D-4597 Bolt
Length of 5/8 inch diameter bolt is 165.10 mm (6.500 inch).
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
5
12
1D-4593 Bolt
Length of 5/8 inch diameter bolt is 139.70 mm (5.500 inch).
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
6
4
9X-8878 Bolt
Length of 1/2 inch diameter bolt is 133.35 mm (5.250 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
7
2
1D-4602 Bolt
Length of 5/8 inch diameter bolt is 241.30 mm (9.500 inch).
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
8
-
-
Apply blue Loctite High Flex GM to the surface of the gasket before
assembly.
420
Specifications Section
RENR5077-12
i05140076
Flywheel Housing
SMCS Code: 1157
Part No.: 383-6558
S/N: CG21-Up
Part No.: 383-6558
S/N: 9H41-Up
Part No.: 383-6558
S/N: 9H61-Up
Part No.: 383-6558
S/N: ED81-Up
Part No.: 383-6558
S/N: MD81-Up
Part No.: 383-6558
S/N: EDG1-Up
Part No.: 383-6558
S/N: MXM1-Up
Part No.: 383-6558
S/N: MXR1-Up
Illustration 375
g03299276
RENR5077-12
421
Specifications Section
g03299277
Illustration 376
Left side view
Table 254
Specification for 383-6558 Flywheel Housing Gp
Item
Qty
Part
Specification Description
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 materials.
To seal the joint between the flywheel housing and the cylinder block, apply blue Loctite High Flex GM to the mating surfaces.
1
4
9X-8875 Bolt
Length of 1/2 inch diameter bolt is 88.90 mm (3.500 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
2
6
9X-8873 Bolt
Length of 1/2 inch diameter bolt is 57.15 mm (2.250 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
3
2
9S-1374 Bolt
Length of 1/2 inch diameter bolt is 203.20 mm (8.000 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
4
4
8S-9089 Bolt
Length of 1/2 inch diameter bolt is 114.30 mm (4.500 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
5
16
1D-4590 Bolt
Length of 5/8 inch diameter bolt is 120.65 mm (4.750 inch).
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
6
2
6M-9613 Bolt
Length of 1/2 inch diameter bolt is 228.60 mm (9.000 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
422
Specifications Section
RENR5077-12
i04934569
Flywheel Housing
SMCS Code: 1157
Part No.: 415-7108
S/N: WF21-Up
Part No.: 415-7108
S/N: 9F31-Up
Part No.: 415-7108
S/N: 9H31-Up
Part No.: 415-7108
S/N: 9H41-Up
Part No.: 415-7108
S/N: ED51-Up
Part No.: 415-7108
S/N: ED81-Up
Part No.: 415-7108
S/N: EDJ1-Up
Part No.: 415-7108
S/N: SRZ1-Up
Illustration 377
Typical example
Rear view
g03106844
RENR5077-12
423
Specifications Section
Table 255
Specification for 415-7108 Flywheel Housing Gp and 382-5107 Flywheel Housing Gp
Item
Qty
Part
Specification Description
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 materials.
Before assembly, apply blue Loctite High Flex GM to the surface of the gasket.
1
4
9X-8875 Bolt
Length of 1/2 inch diameter bolt is 88.90 mm (3.500 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
2
6
9X-8873 Bolt
Length of 1/2 inch diameter bolt is 57.15 mm (2.250 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
3
2
9S-1374 Bolt
Length of 1/2 inch diameter bolt is 203.20 mm (8.000 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
4
16
1D-4590 Bolt
Length of 5/8 inch diameter bolt is 120.65 mm (4.750 inch).
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
5
4
8S-9089 Bolt
Length of 1/2 inch diameter bolt is 114.30 mm (4.500 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
i05141633
Flywheel Housing
SMCS Code: 1157
Part No.: 383-6560
S/N: WF21-Up
Illustration 378
Typical example
g03299337
424
Specifications Section
RENR5077-12
g03299338
Illustration 379
Right side view
Typical example
Table 256
Specification for 383-6559 Flywheel Housing Gp and 383-6560 Flywheel Housing Gp
Item
Qty
Part
Specification Description
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 materials.
To seal the joint between the flywheel housing and the cylinder block, apply blue Loctite High Flex GM to the front face of
the flywheel housing.
1
6
1D-4574 Bolt
Length of 1/2 inch diameter bolt is 152.40 mm (6.000 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
2
2
9X-8874 Bolt
Length of 1/2 inch diameter bolt is 76.20 mm (3.000 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
3
8
9X-8873 Bolt
Length of 1/2 inch diameter bolt is 57.15 mm (2.250 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
4
2
1D-4597 Bolt
Length of 5/8 inch diameter bolt is 165.10 mm (6.500 inch).
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
5
12
1D-4593 Bolt
Length of 5/8 inch diameter bolt is 139.70 mm (5.500 inch).
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
6
4
9X-8878 Bolt
Length of 1/2 inch diameter bolt is 133.35 mm (5.250 inch).
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
7
2
1D-4602 Bolt
Length of 5/8 inch diameter bolt is 241.30 mm (9.500 inch).
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
RENR5077-12
425
Specifications Section
i04403157
Flexible Coupling
Part No.: 5N-3765
S/N: SRH1-Up
SMCS Code: 3279
Part No.: 5N-3765
S/N: EDJ1-Up
Part No.: 5N-3765
S/N: 9F21-Up
Part No.: 5N-3765
S/N: SRK1-Up
Part No.: 5N-3765
S/N: CG21-Up
Part No.: 5N-3765
S/N: MXM1-Up
Part No.: 5N-3765
S/N: ED21-Up
Part No.: 5N-3765
S/N: EDP1-Up
Part No.: 5N-3765
S/N: 9F31-Up
Part No.: 5N-3765
S/N: S2P1-Up
Part No.: 5N-3765
S/N: 9H31-Up
Part No.: 5N-3765
S/N: MXR1-Up
Part No.: 5N-3765
S/N: ED31-Up
Part No.: 5N-3765
S/N: S2R1-Up
Part No.: 5N-3765
S/N: 9H41-Up
Part No.: 5N-3765
S/N: JB41-Up
Part No.: 5N-3765
S/N: 9H51-Up
Part No.: 5N-3765
S/N: ED51-Up
Part No.: 5N-3765
S/N: 9H61-Up
Part No.: 5N-3765
S/N: GS61-Up
Part No.: 5N-3765
S/N: ED81-Up
Part No.: 5N-3765
S/N: MD81-Up
Part No.: 5N-3765
S/N: S2A1-Up
Part No.: 5N-3765
S/N: S2B1-Up
Part No.: 5N-3765
S/N: EDC1-Up
Part No.: 5N-3765
S/N: EDG1-Up
Part No.: 5N-3765
S/N: S2G1-Up
Part No.: 5N-3765
S/N: EDH1-Up
Part No.: 5N-3765
S/N: S2H1-Up
426
Specifications Section
RENR5077-12
g02589977
Illustration 380
Table 257
Specification for 5N-3765 Flexible Coupling Gp
Item
Qty
Part
Specification Description
Use the following procedure to install the flexible coupling:
Before you install the outer coupling (1) the flywheel (6) must be clean and free from oil, paint, dirt, and protective coating.
1. Lubricate all the surfaces that will contact either the O-ring seals
(2) or the rubber coupling boots (5) with 5N-5561 Silicone Lubricant
except the plate (4).
2. Install the O-ring seals (2) in the outer coupling (1).
3. Center the drive coupling (3) inside the outer coupling (1).
-
-
-
4. Place the rubber coupling boots (5) between the drive coupling
(3) and outer coupling (1).
5. Fill the cavities between the couplings and the rubber coupling
boots (5) with the 5N-5561 Silicone Lubricant.
6. Bolt the outer coupling (1) into the flywheel (6).
7. Bolt the drive coupling (3) to the shaft (7).
8. As needed, modify the assembly procedure for the installation of
the flexible coupling in the field.
RENR5077-12
427
Specifications Section
i01691646
Engine Mount (Front)
(Hydraulic Pump Drive or PTO
Clutch)
SMCS Code: 1152
Part No.: 7W-0284
S/N: GS61-Up
Part No.: 7W-0284
S/N: S2A1-Up
Part No.: 7W-0284
S/N: S2B1-Up
Part No.: 7W-0284
S/N: S2D1-Up
Part No.: 7W-0284
S/N: S2E1-Up
Part No.: 7W-0284
S/N: S2G1-Up
Part No.: 7W-0284
S/N: S2H1-Up
Part No.: 7W-0284
S/N: S2J1-Up
Part No.: 7W-0284
S/N: S2K1-Up
Part No.: 7W-0284
S/N: S2L1-Up
Part No.: 7W-0284
S/N: S2N1-Up
Part No.: 7W-0284
S/N: S2P1-Up
Part No.: 7W-0284
S/N: S2R1-Up
Illustration 381
(1) Damper
(2) Adapter
(3) Damper adapter
Torque ................ 1125 ± 100 N·m (820 ± 75 lb ft)
(4) Coupling
Put a dash mark on the coupling in alignment with
the marks on the damper adapter and the crankshaft.
i05165654
Part No.: 7W-0284
S/N: S2S1-Up
Engine Mount (Front)
Part No.: 7W-0284
S/N: S2T1-Up
SMCS Code: 1152
Part No.: 7W-0284
S/N: S2W1-Up
Part No.: 7W-0284
S/N: S2X1-Up
Part No.: 7W-0284
S/N: S2Z1-Up
g00280831
Part No.: 387-7421
S/N: 9F21-Up
Part No.: 387-7421
S/N: CG21-Up
Part No.: 387-7421
S/N: ED21-Up
Part No.: 387-7421
S/N: 9F31-Up
Part No.: 387-7421
S/N: ED31-Up
428
Specifications Section
RENR5077-12
Part No.: 387-7421
S/N: JB41-Up
Part No.: 387-7421
S/N: MD81-Up
Part No.: 387-7421
S/N: EDC1-Up
Part No.: 387-7421
S/N: EDH1-Up
Part No.: 387-7421
S/N: SRH1-Up
Part No.: 387-7421
S/N: EDJ1-Up
Part No.: 387-7421
S/N: SRK1-Up
Part No.: 387-7421
S/N: MXM1-Up
Part No.: 387-7421
S/N: MXR1-Up
Illustration 382
g03318208
RENR5077-12
429
Specifications Section
Table 258
Specification for 387-7421 Hydraulic Pump Drive Mounting Gp
Item
Part
Qty
Specification Description
Put a dash mark on the coupling in alignment with the marks on the damper adapter and the crankshaft.
1
6
5F-6932 Bolt
Torque to 1125 ± 100 N·m (830 ± 74 lb ft).
i02958521
Engine Trunnion
Part No.: 4P-3309
S/N: S2W1-Up
SMCS Code: 1153
Part No.: 4P-3309
S/N: S2X1-Up
Part No.: 335-3181
S/N: M8A1-Up
Part No.: 4P-3309
S/N: S2Y1-Up
Part No.: 335-3181
S/N: M8B1-Up
Part No.: 4P-3309
S/N: S2F1-Up
Part No.: 4P-3309
S/N: B5G1-Up
Part No.: 4P-3309
S/N: MRG1-Up
Part No.: 4P-3309
S/N: PAG1-Up
Part No.: 4P-3309
S/N: S2G1-Up
Part No.: 4P-3309
S/N: MKH1-Up
Part No.: 4P-3309
S/N: S2H1-Up
Part No.: 4P-3309
S/N: S2J1-Up
Part No.: 4P-3309
S/N: S2K1-Up
Part No.: 4P-3309
S/N: S2L1-Up
Part No.: 4P-3309
S/N: S2M1-Up
Part No.: 4P-3309
S/N: S2N1-Up
Part No.: 4P-3309
S/N: S2P1-Up
Part No.: 4P-3309
S/N: S2R1-Up
Part No.: 4P-3309
S/N: S2S1-Up
Part No.: 4P-3309
S/N: S2T1-Up
Illustration 383
g01475072
(1) Torque for 16 bolts .. 190 ± 30 N·m (140 ± 22 lb ft)
(2) Torque for 20 bolts .. 135 ± 20 N·m (100 ± 15 lb ft)
430
Specifications Section
RENR5077-12
i04714089
Engine Trunnion
SMCS Code: 1153
Part No.: 7N-1863
S/N: S2D1-Up
Part No.: 7N-1863
S/N: S2E1-Up
Part No.: 7N-1863
S/N: S2K1-Up
Part No.: 7N-1863
S/N: S2L1-Up
Part No.: 7N-1863
S/N: S2N1-Up
g02818638
Illustration 384
Table 259
Specification for 7N-1863 Engine Trunnion Gp
Item
Qty
Part
Specification Description
1
16
8S-4734 Bolt
Torque to 190 ± 30 N·m (140 ± 22 lb ft).
2
20
1D-4566 Bolt
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
RENR5077-12
431
Specifications Section
i04403676
Vibration Damper
SMCS Code: 1205
Part No.: 8N-0339
S/N: GS61-Up
Part No.: 8N-0339
S/N: GS71-Up
Part No.: 8N-0339
S/N: GSA1-Up
g02591631
Illustration 385
Typical example
Table 260
Specification for 174-7079 Damper Gp, 248-0197 Damper Gp, and 8N-0339 Damper Gp
Item
Part
Qty
Specification Description
The alignment mark on the damper group (2) must be aligned with the alignment mark on the adapter (1).
Torque to 1150 ± 60 N·m (848 ± 44 lb ft).
3
6
8S-4757 Bolt
4
48
1A-2029 Bolt
Before assembly, lubricate the threads of the bolts with molybdenum
disulfide base lubricant.
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
Lubricate the threads of the bolts with blue Loctite 242.
i04757390
Vibration Damper
Part No.: 8N-7182
S/N: S2B1-Up
SMCS Code: 1205
Part No.: 8N-7182
S/N: S2D1-Up
Part No.: 8N-7182
S/N: GS71-Up
Part No.: 8N-7182
S/N: S2E1-Up
Part No.: 8N-7182
S/N: S2A1-Up
Part No.: 8N-7182
S/N: S2F1-Up
432
Specifications Section
Part No.: 8N-7182
S/N: B5G1-Up
Part No.: 8N-7182
S/N: MRG1-Up
Part No.: 8N-7182
S/N: PAG1-Up
Part No.: 8N-7182
S/N: S2G1-Up
Part No.: 8N-7182
S/N: MKH1-Up
Part No.: 8N-7182
S/N: S2H1-Up
Part No.: 8N-7182
S/N: S2J1-Up
Part No.: 8N-7182
S/N: S2K1-Up
Part No.: 8N-7182
S/N: S2L1-Up
Part No.: 8N-7182
S/N: S2M1-Up
Part No.: 8N-7182
S/N: S2N1-Up
Part No.: 8N-7182
S/N: S2P1-Up
Part No.: 8N-7182
S/N: S2R1-Up
Part No.: 8N-7182
S/N: S2S1-Up
Part No.: 8N-7182
S/N: S2T1-Up
Part No.: 8N-7182
S/N: S2W1-Up
Part No.: 8N-7182
S/N: S2X1-Up
Part No.: 8N-7182
S/N: S2Y1-Up
Part No.: 8N-7182
S/N: S2Z1-Up
RENR5077-12
RENR5077-12
433
Specifications Section
g02849382
Illustration 386
Table 261
Specification for 8N-7182 Damper Gp
Item
Qty
Part
Specification description
The alignment mark on the crankshaft (1) must be aligned with the alignment mark on the damper adapter (2).
3
6
8S-4757 Bolt
Before assembly, lubricate the threads of the bolts with molybdenum
disulfide base lubricant.
Torque to 1150 ± 60 N·m (848 ± 44 lb ft).
i04403162
Vibration Damper
Part No.: 146-3740
S/N: S2B1-Up
SMCS Code: 1205
Part No.: 146-3740
S/N: S2D1-Up
Part No.: 146-3740
S/N: CG21-Up
Part No.: 146-3740
S/N: S2E1-Up
Part No.: 146-3740
S/N: 9H41-Up
Part No.: 146-3740
S/N: S2F1-Up
Part No.: 146-3740
S/N: 9H61-Up
Part No.: 146-3740
S/N: B5G1-Up
Part No.: 146-3740
S/N: GS61-Up
Part No.: 146-3740
S/N: EDG1-Up
Part No.: 146-3740
S/N: GS71-Up
Part No.: 146-3740
S/N: MRG1-Up
Part No.: 146-3740
S/N: ED81-Up
Part No.: 146-3740
S/N: PAG1-Up
Part No.: 146-3740
S/N: MD81-Up
Part No.: 146-3740
S/N: S2G1-Up
Part No.: 146-3740
S/N: GSA1-Up
Part No.: 146-3740
S/N: MKH1-Up
Part No.: 247-0845
S/N: M8A1-Up
Part No.: 146-3740
S/N: S2H1-Up
Part No.: 146-3740
S/N: S2A1-Up
Part No.: 146-3740
S/N: S2J1-Up
Part No.: 146-3740
S/N: M8B1-Up
Part No.: 146-3740
S/N: S2K1-Up
434
Specifications Section
RENR5077-12
Part No.: 146-3740
S/N: S2L1-Up
Part No.: 146-3740
S/N: MXM1-Up
Part No.: 146-3740
S/N: S2M1-Up
Part No.: 146-3740
S/N: S2N1-Up
Part No.: 146-3740
S/N: S2P1-Up
Part No.: 146-3740
S/N: MXR1-Up
Part No.: 146-3740
S/N: S2R1-Up
Part No.: 146-3740
S/N: S2S1-Up
Part No.: 146-3740
S/N: S2T1-Up
Part No.: 146-3740
S/N: S2W1-Up
Part No.: 146-3740
S/N: S2X1-Up
Part No.: 146-3740
S/N: S2Y1-Up
Part No.: 146-3740
S/N: S2Z1-Up
Illustration 387
g02590001
RENR5077-12
435
Specifications Section
Table 262
Specification for 146-3740 Damper Gp, 247-0845 Damper Gp, and 171-4571 Damper Gp
Item
Qty
Part
1
48
1A-2029 Bolt
Specification Description
Lubricate the threads of the bolts with blue Loctite 242.
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
i04403165
Vibration Damper
Part No.: 125-9749, 240-7762
S/N: S2S1-Up
SMCS Code: 1205
Part No.: 125-9749, 240-7762
S/N: S2T1-Up
Part No.: 125-9749, 240-7762
S/N: S2A1-Up
Part No.: 125-9749, 240-7762
S/N: S2W1-Up
Part No.: 125-9749, 240-7762
S/N: S2B1-Up
Part No.: 125-9749, 240-7762
S/N: S2X1-Up
Part No.: 125-9749, 240-7762
S/N: S2D1-Up
Part No.: 125-9749, 240-7762
S/N: S2Y1-Up
Part No.: 125-9749, 240-7762
S/N: S2E1-Up
Part No.: 125-9749, 240-7762
S/N: S2Z1-Up
Part No.: 125-9749, 240-7762
S/N: S2F1-Up
Part No.: 125-9749, 240-7762
S/N: B5G1-Up
Part No.: 125-9749, 240-7762
S/N: MRG1-Up
Part No.: 125-9749, 240-7762
S/N: PAG1-Up
Part No.: 125-9749, 240-7762
S/N: S2G1-Up
Part No.: 125-9749, 240-7762
S/N: MKH1-Up
Part No.: 125-9749, 240-7762
S/N: S2H1-Up
Part No.: 125-9749, 240-7762
S/N: S2J1-Up
Part No.: 125-9749, 240-7762
S/N: S2K1-Up
Part No.: 125-9749, 240-7762
S/N: S2L1-Up
Part No.: 125-9749, 240-7762
S/N: S2M1-Up
Part No.: 125-9749, 240-7762
S/N: S2N1-Up
Part No.: 125-9749, 240-7762
S/N: S2P1-Up
Part No.: 125-9749, 240-7762
S/N: S2R1-Up
436
Specifications Section
RENR5077-12
g02590096
Illustration 388
Table 263
Specification for the 240-7762 Damper Gp and 125-9749 Damper Gp
Item
Qty
Part
Specification Description
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).
Torque to 1150 ± 60 N·m (840 ± 44 lb ft).
4
6
8S-4757 Bolt
5
48
1A-2029 Bolt
Before assembly, lubricate the threads of the bolts with molybdenum
disulfide base lubricant.
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
Apply 4C-4030 Thread Lock Compound to the threads of the bolts.
RENR5077-12
437
Specifications Section
i04929106
Vibration Damper
SMCS Code: 1205
Part No.: 380-8375
S/N: WF21-Up
Part No.: 380-8375
S/N: 9F31-Up
Part No.: 380-8375
S/N: EDJ1-Up
Part No.: 380-8375
S/N: MXM1-Up
Part No.: 380-8375
S/N: SRZ1-Up
Illustration 389
g03098416
Illustration 390
g03113781
438
Specifications Section
RENR5077-12
Table 264
Specification for 380-8375 Damper Gp
Item
Qty
Part
1
18
3B-1915 Bolt
2
48
1A-2029 Bolt
Specification Description
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
Before assembly, apply blue Loctite 242 to the threads
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
i04403174
Vibration Damper Guard
SMCS Code: 1205
Part No.: 8N-9639
S/N: GS61-Up
Part No.: 8N-9639
S/N: GS71-Up
Part No.: 8N-9639
S/N: GSA1-Up
g02590156
Illustration 391
Typical example
Left side view
Table 265
Specification for 197-9052 Damper Guard Gp, 8N-9639 Damper Guard Gp, and 310-7976 Damper Guard Gp
Item
Qty
Part
1
6
030-8535 Locking Bolt
2
4
0S-1591 Bolt
Specification Description
Torque to 15 ± 3 N·m (133 ± 27 lb in).
RENR5077-12
439
Specifications Section
i04901031
Vibration Damper Guard
SMCS Code: 1205
Part No.: 334-4642, 334-4644
S/N: M8A1-Up
Part No.: 334-4642, 334-4644
S/N: M8B1-Up
g03053862
Illustration 392
Typical example
Table 266
Specification for 334-4642 Damper Guard Gp, 334-4643 Damper Guard Gp, and 334-4644 Damper Guard Gp
Item
Qty
Part
1
4
0S-1591 Bolt
Specification Description
Torque to 15 ± 3 N·m (133 ± 27 lb in).
i04888963
Vibration Damper Guard
Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2E1-Up
SMCS Code: 1205
Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2F1-Up
Part No.: 197-9052, 8N-9639
S/N: S2A1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: B5G1-Up
Part No.: 197-9052, 8N-9639
S/N: S2B1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: MRG1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2D1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: PAG1-Up
440
Specifications Section
Part No.: 197-9052, 8N-9639
S/N: S2G1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: MKH1-Up
Part No.: 197-9052, 8N-9639
S/N: S2H1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2J1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2K1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2L1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2M1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2N1-Up
Part No.: 197-9052, 8N-9639
S/N: S2P1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2R1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2S1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2T1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2W1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2X1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2Y1-Up
Part No.: 197-9052, 8N-9639
S/N: S2Z1-Up
RENR5077-12
RENR5077-12
441
Specifications Section
g03017277
Illustration 393
Typical example
Table 267
Specification for 102-8616 Damper Guard Gp and 4P-1602 Damper Guard Gp
Item
Qty
Part
Specification Description
1
4
0S-1591 Bolt
Torque to 15 ± 3 N·m (133 ± 27 lb in).
2
6
030-8535 Locking Bolt
Torque to 15 ± 3 N·m (133 ± 27 lb in).
442
Specifications Section
RENR5077-12
i04403673
Vibration Damper Guard
SMCS Code: 1205
Part No.: 334-4644
S/N: CG21-Up
Part No.: 334-4644
S/N: 9H41-Up
Part No.: 334-4644
S/N: 9H61-Up
Part No.: 334-4644
S/N: ED81-Up
Part No.: 334-4644
S/N: MD81-Up
Part No.: 334-4644
S/N: EDG1-Up
Part No.: 334-4644
S/N: MXR1-Up
g02591596
Illustration 394
Left side view
Table 268
Specification for 334-4644 Damper Guard Gp
Item
Qty
Part
1
4
0S-1591 Bolt
Specification Description
Torque to 15 ± 3 N·m (133 ± 27 lb in).
RENR5077-12
443
Specifications Section
i04459749
Vibration Damper Guard
SMCS Code: 1205
Part No.: 376-3360
S/N: MXM1-Up
g02645401
Illustration 395
Table 269
Specification for 376-3360 Damper Guard Gp
Item
Qty
Part
1
4
0S-1591 Bolt
Specification Description
Torque to 15 ± 3 N·m (133 ± 27 lb in).
444
Specifications Section
RENR5077-12
i04934730
Vibration Damper Guard
SMCS Code: 1205
Part No.: 380-2604
S/N: WF21-Up
Part No.: 380-2604
S/N: SRZ1-Up
g03107301
Illustration 396
Table 270
Specification for 380-2604 Damper Guard Gp
Item
Qty
Part
1
4
4L-9337 Bolt
Specification Description
Torque to 15 ± 3 N·m (133 ± 27 lb in).
RENR5077-12
445
Specifications Section
i04906587
Stub Shaft (Front)
SMCS Code: 1237
Part No.: 7N-7660
S/N: GS61-Up
Part No.: 7N-7660
S/N: GS71-Up
Part No.: 7N-7660
S/N: GSA1-Up
g02578560
Illustration 397
Table 271
Specification for 7N-7660 Fan Drive Gp
Item
Qty
Part
-
-
-
2
6
9F-8122 Bolt
Specification Description
The alignment mark on the stub shaft (3) must be aligned with the
alignment mark on the damper adapter (1).
Torque to 1150 ± 150 N·m (840 ± 110 lb ft).
i04398490
Stub Shaft (Front)
SMCS Code: 1237
Part No.: 334-0958
S/N: M8B1-Up
Illustration 398
Right side view
g02578423
446
Specifications Section
RENR5077-12
Table 272
Specification for 334-0958 Stub Shaft Gp
Item
Qty
Part
-
-
-
The alignment mark on the 5N-2322 Stub Shaft (3) must be aligned with the
mark on the 1N-3482 Adapter (1).
2
12
5N-2317 Bolt
Before assembly, lubricate the threads with engine oil, molybdenum disulfide
grease, or graphite base lubricant.
Torque to 1150 ± 60 N·m (848 ± 44 lb ft).
Specification Description
i03742222
Stub Shaft (Front)
SMCS Code: 1237
Part No.: 334-0958
S/N: M8B1-Up
Illustration 399
g01744573
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 ± 60 N·m
(848 ± 44 lb ft)
RENR5077-12
447
Specifications Section
i03879148
Stub Shaft (Front)
SMCS Code: 1237
Part No.: 7W-5237
S/N: S2A1-Up
Part No.: 334-0956
S/N: M8B1-Up
Part No.: 7W-5237
S/N: S2B1-Up
Part No.: 7W-5237
S/N: S2D1-Up
Part No.: 7W-5237
S/N: S2E1-Up
Part No.: 7W-5237
S/N: S2F1-Up
Part No.: 7W-5237
S/N: S2Z1-Up
Illustration 400
Low kW (HP) attachments
g00278463
448
Specifications Section
RENR5077-12
g00278464
Illustration 401
High kW (HP) attachments
Part No.: 7W-3629
S/N: S2J1-Up
(1) Crankshaft
(2) Adapter
Part No.: 7W-3629
S/N: S2K1-Up
(3) Bolts
Apply a molybdenum disulfide grease under the
bolt heads and to the threads before assembly.
Part No.: 7W-3629
S/N: S2L1-Up
Torque ......................... 1150 ± 60 N·m (850 ± 44)
Part No.: 7W-3629
S/N: S2M1-Up
(4) Alignment mark
Align the alignment mark on the stub shaft with the
alignment mark on the adapter.
i04403746
Part No.: 7W-3629
S/N: S2N1-Up
Part No.: 7W-3629
S/N: S2P1-Up
Stub Shaft (Front)
Part No.: 7W-3629
S/N: S2R1-Up
SMCS Code: 1237
Part No.: 7W-3629
S/N: S2S1-Up
Part No.: 7W-3629
S/N: GS61-Up
Part No.: 7W-3629
S/N: S2E1-Up
Part No.: 7W-3629
S/N: PAG1-Up
Part No.: 7W-3629
S/N: S2G1-Up
Part No.: 7W-3629
S/N: MKH1-Up
Part No.: 7W-3629
S/N: S2H1-Up
Part No.: 7W-3629
S/N: S2T1-Up
Part No.: 7W-3629
S/N: S2W1-Up
Part No.: 7W-3629
S/N: S2X1-Up
Part No.: 7W-3629
S/N: S2Y1-Up
RENR5077-12
449
Specifications Section
g02591976
Illustration 402
Table 273
Specification for 7W-3629 Stub Shaft Gp
Item
Qty
Part
1
12
5N-2317 Bolt
Specification Description
Before assembly, lubricate threads with engine oil, molybdenum disulfide,
or graphite base lubricant.
Torque to 1150 ± 150 N·m (848 ± 111 lb ft).
450
Specifications Section
RENR5077-12
i04889839
Stub Shaft (Front)
SMCS Code: 1237
Part No.: 380-0681
S/N: CG21-Up
Part No.: 380-0681
S/N: MD81-Up
Part No.: 380-0681
S/N: MXM1-Up
Part No.: 380-0681
S/N: MXR1-Up
g03020240
Illustration 403
Table 274
Specification for 380-0681 Stub Shaft Gp
Item
Qty
Part
1
12
5N-2317 Bolt
Specification Description
Torque to 1150 ± 150 N·m (848 ± 111 lb ft).
RENR5077-12
451
Specifications Section
i04889858
Stub Shaft (Front)
SMCS Code: 1237
Part No.: 378-8171
S/N: CG21-Up
Part No.: 378-8171
S/N: WF21-Up
Part No.: 378-8171
S/N: 9H41-Up
Part No.: 378-8171
S/N: 9H61-Up
Part No.: 378-8171
S/N: ED81-Up
Part No.: 378-8171
S/N: MD81-Up
Part No.: 378-8171
S/N: EDG1-Up
Part No.: 378-8171
S/N: MXM1-Up
Part No.: 378-8171
S/N: MXR1-Up
g03020418
Illustration 404
Table 275
Specification for 378-8171 Stub Shaft Gp
Item
Qty
Part
1
6
9F-8122 Bolt
Specification Description
Torque to 1150 ± 150 N·m (848 ± 111 lb ft).
452
Specifications Section
RENR5077-12
i04934742
Stub Shaft (Front)
SMCS Code: 1237
Part No.: 383-4032
S/N: WF21-Up
Part No.: 383-4032
S/N: 9F31-Up
Part No.: 383-4032
S/N: EDJ1-Up
Part No.: 383-4032
S/N: SRZ1-Up
g03107398
Illustration 405
Table 276
Specification for 383-4032 Stub Shaft Gp
Item
Qty
Part
1
12
5N-2317 Bolt
Specification Description
Before assembly, lubricate the threads with engine oil, molybdenum disulfide
grease, or graphite base lubricant.
Torque to 1150 ± 60 N·m (848 ± 44 lb ft).
RENR5077-12
453
Specifications Section
i04934752
Stub Shaft (Front)
SMCS Code: 1237
Part No.: 383-4031
S/N: 9F31-Up
Part No.: 383-4031
S/N: EDJ1-Up
g03107400
Illustration 406
Table 277
Specification for 383-4031 Stub Shaft Gp
Item
Qty
Part
1
12
269-1881 Bolt
Specification Description
Before assembly, lubricate the threads with engine oil, molybdenum disulfide
grease, or graphite base lubricant.
Torque to 1150 ± 60 N·m (848 ± 44 lb ft).
454
Specifications Section
RENR5077-12
i04399156
Auxiliary Drive Pulley
SMCS Code: 1205
Part No.: 8N-8468
S/N: GS61-Up
Part No.: 334-5309
S/N: M8A1-Up
Part No.: 334-5309
S/N: M8B1-Up
g02579717
Illustration 407
Table 278
Specification for 8N-8468 Auxiliary Drive Pulley Gp and 334-5309 Auxiliary Drive Pulley Gp
Item
Qty
Part
1
1
235-2484 Lip Type Seal
Specification Description
Before assembly, lightly lubricate the sealing lip with the lubricant that
is being sealed.
RENR5077-12
455
Specifications Section
i03702647
Auxiliary Drive Pulley
SMCS Code: 1205
Part No.: 210-9214
S/N: GS61-Up
Illustration 408
g01993614
(1) Lightly lubricate the sealing lip of the lip type seal
with the lubricant that is being sealed. Refer to
Illustration408 for installation.
(2) Torque for the bolts ........ 55 ± 7 N·m (41 ± 5 lb ft)
456
Specifications Section
RENR5077-12
i04403745
Auxiliary Drive Pulley
SMCS Code: 1205
Part No.: 8N-8467
S/N: GS61-Up
g02591956
Illustration 409
Table 279
Specification for 8N-8467 Auxiliary Drive Pulley Gp and 210-8602 Auxiliary Drive Pulley Gp
Item
Qty
Part
1
1
235-2484 Lip Type Seal
Before assembly, lightly lubricate the sealing lip with the lubricant that is
being sealed.
2
1
259-4598 O-Ring Seal
Before assembly, lightly lubricate the bore with the lubricant that is being
sealed.
Specification Description
RENR5077-12
457
Specifications Section
i04864332
Auxiliary Drive Pulley
SMCS Code: 1205
Part No.: 334-5329
S/N: CG21-Up
Part No.: 334-5329
S/N: MD81-Up
Part No.: 334-5329
S/N: MXM1-Up
Part No.: 334-5329
S/N: MXR1-Up
Illustration 410
g02993936
458
Specifications Section
RENR5077-12
Table 280
Specification for 334-5329 Auxiliary Drive Pulley Gp
Item
Qty
Part
1
1
259-4598 O-Ring Seal
2
1
8N-8210 Adapter As
Specification Description
Lightly, lubricate the bore with the fluid that is being sealed.
Bore of the 127-5400 Bushing after assembly is 75.000 ± 0.055 mm
(2.9528 ± 0.0022 inch).
Installation depth is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).
3
1
5P-0840 O-Ring Seal
4
1
7C-7808 Lip Type Seal
5
1
9X-7371 O-Ring Seal
6
8
0L-1352 Bolt
Lightly, lubricate the bore with the fluid that is being sealed.
Before assembly, lightly lubricate the sealing lip with the fluid that is being
sealed.
Lightly, lubricate the bore with the fluid that is being sealed.
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
RENR5077-12
459
Specifications Section
i04864229
Auxiliary Drive Pulley
SMCS Code: 1205
Part No.: 334-5327
S/N: CG21-Up
Part No.: 334-5327
S/N: MD81-Up
Part No.: 334-5327
S/N: MXM1-Up
Part No.: 334-5327
S/N: MXR1-Up
Illustration 411
g02991777
460
Specifications Section
RENR5077-12
Table 281
Specification for 334-5327 Auxiliary Drive Pulley Gp
Item
Qty
Part
Specification Description
1
1
235-2484 Lip Type Seal
Before assembly, lightly lubricate the sealing lip with the fluid that is being
sealed.
2
1
259-4598 O-Ring Seal
3
1
7C-4165 Adapter As
Lightly, lubricate the bore with the fluid that is being sealed.
Bore of the 127-5400 Bushing after assembly is 75.000 ± 0.055 mm
(2.9528 ± 0.0022 inch).
i04932385
Auxiliary Drive Shaft
Part No.: 209-3559, 209-3561, 209-3562
S/N: S2F1-Up
SMCS Code: 1165; 1207
Part No.: 415-8507
S/N: EDG1-Up
Part No.: 415-8507
S/N: WF21-Up
Part No.: 209-3562
S/N: MRG1-Up
Part No.: 415-8507
S/N: 9F31-Up
Part No.: 209-3559, 7N-8042
S/N: PAG1-Up
Part No.: 415-8507
S/N: 9H31-Up
Part No.: 209-3559, 209-3560, 209-3561,
209-3562, 7N-8042
S/N: S2G1-Up
Part No.: 415-8507
S/N: 9H41-Up
Part No.: 415-8507
S/N: 9H51-Up
Part No.: 415-8507
S/N: ED51-Up
Part No.: 415-8507
S/N: 9H61-Up
Part No.: 209-3559, 209-3560, 209-3562,
7N-8042
S/N: GS61-Up
Part No.: 415-8507
S/N: ED81-Up
Part No.: 209-3562
S/N: M8A1-Up
Part No.: 209-3559, 209-3560, 209-3561,
209-3562, 7N-8042
S/N: S2A1-Up
Part No.: 209-3562
S/N: M8B1-Up
Part No.: 209-3559, 209-3560, 209-3561,
209-3562, 7N-8042
S/N: S2B1-Up
Part No.: 209-3559, 209-3560, 209-3562,
7N-8042
S/N: S2D1-Up
Part No.: 209-3559, 209-3560, 209-3562,
7N-8042
S/N: S2E1-Up
Part No.: 209-3559, 209-3562, 7N-8042
S/N: MKH1-Up
Part No.: 209-3559, 209-3560, 209-3561,
209-3562, 7N-8042
S/N: S2H1-Up
Part No.: 415-8507
S/N: EDJ1-Up
Part No.: 209-3559, 209-3560, 209-3562,
7N-8042
S/N: S2J1-Up
Part No.: 209-3559, 209-3560, 209-3562,
7N-8042
S/N: S2K1-Up
Part No.: 209-3559, 209-3560, 209-3562,
7N-8042
S/N: S2L1-Up
Part No.: 209-3559, 209-3560, 209-3561,
209-3562
S/N: S2M1-Up
Part No.: 209-3559, 209-3560, 209-3562,
7N-8042
S/N: S2N1-Up
Part No.: 415-8507
S/N: EDP1-Up
Part No.: 209-3559, 209-3560, 209-3561,
209-3562, 7N-8042
S/N: S2P1-Up
RENR5077-12
461
Specifications Section
Part No.: 209-3559, 209-3560, 209-3561,
209-3562, 7N-8042
S/N: S2R1-Up
Part No.: 209-3559, 209-3560, 209-3561,
209-3562, 7N-8042
S/N: S2S1-Up
Part No.: 209-3559, 209-3560, 209-3561,
209-3562, 7N-8042
S/N: S2T1-Up
Part No.: 209-3559, 209-3560, 209-3561,
209-3562, 7N-8042
S/N: S2W1-Up
Part No.: 209-3559, 209-3560, 209-3561,
209-3562, 7N-8042
S/N: S2X1-Up
Part No.: 209-3559, 209-3561, 209-3562
S/N: S2Y1-Up
Part No.: 209-3559, 209-3560, 209-3562,
7N-8042
S/N: S2Z1-Up
Part No.: 415-8507
S/N: SRZ1-Up
g02849424
Illustration 412
Table 282
Specification for 7N-8042 Auxiliary Drive Shaft, 209-3559 Auxiliary Drive Shaft, 209-3560 Auxiliary Drive Shaft,
209-3561 Auxiliary Drive Shaft, 415-8507 Auxiliary Drive Shaft, and 209-3562 Auxiliary Drive Shaft
Item
Qty
Part
1
1
7C-7808 Lip Type Seal
Specification Description
Lubricate the sealing lip with the lubricant that is being sealed.
462
Specifications Section
RENR5077-12
i04868349
Auxiliary Drive Shaft
SMCS Code: 1165; 1207
Part No.: 334-5330
S/N: CG21-Up
Part No.: 334-5330
S/N: MD81-Up
Part No.: 334-5330
S/N: MXM1-Up
Part No.: 334-5330
S/N: MXR1-Up
Illustration 413
g02994118
RENR5077-12
463
Specifications Section
Table 283
Specification for 334-5330 Auxiliary Drive Shaft
Item
Qty
Part
1
1
259-4598 O-Ring Seal
Lightly, lubricate the bore with the fluid that is being sealed.
2
1
5P-0840 O-Ring Seal
Lightly, lubricate the bore with the fluid that is being sealed.
3
1
8N-8210 Adapter As
Bore of the 127-5400 Bushing after assembly is 75.000 ± 0.055 mm
(2.9528 ± 0.0022 inch).
Specification Description
Installation depth is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).
4
1
9X-7371 O-Ring Seal
5
1
7C-7808 Lip Type Seal
Before assembly, lightly lubricate the sealing lip with the fluid that is
being sealed.
6
1
9Y-4957 Stub Shaft
Diameter over bushing end is 73.00 ± 0.08 mm (2.874 ± 0.003 inch).
Lightly, lubricate the bore with the fluid that is being sealed.
i05084397
Belt Tension Chart
SMCS Code: 1357
Part No.: 7N-9693
S/N: S2A1-Up
Part No.: 7N-9693
S/N: S2B1-Up
Part No.: 7N-9693
S/N: S2G1-Up
Part No.: 7N-9693
S/N: S2H1-Up
Part No.: 7N-9693
S/N: S2R1-Up
Table 284
Specification for the 7N-9693 Tension Chart
Item
-
Qty
-
Part
Specification Description
-
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.
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 tension force. If the Clavis frequency gauge cannot be used, then use the
appropriate Kent-Moore belt tension gauge to measure the belt tension force.
When matched sets of belts are used, check the tension of all the belts in order to verify
that the lowest belt is in the acceptable tolerance range. Variations in tension between the
belts can vary by as much as 65 pounds.
In order to determine the tension of a “banded” belt, refer to the chart above. Multiply the
tension value of the belt by the number of belts that are banded together.Two 1/2 inch
belts would require a used belt tension equal to twice the value of the used belt tension for
one 1/2 inch belt (2 X 80 = 160 lb).
464
Specifications Section
RENR5077-12
Table 285
Belt Tension Chart
SAE or RMA Belt SIze
(1)
(2)
(3)
(4)
Width of Belt (Top
Reference)
Belt
Tension
Used(2)
Belt Tension
“Initial”(1)
Belt Tension
“Used”(3)(4)
IN
MM
IN
MM
LB
N
LB
N
LB
N
3/8
(0.380)
10A
0.42
10.72
145±10
645±44
115±10
510±44
70±10
311±44
7/16
(0.440)
11A
0.46
11.68
155±10
689±44
125±10
560±10
75±10
333±44
1/2
(0.500)
13A
0.55
13.89
165±10
734±44
130±10
580±10
80±10
356±44
5V/5VX
5V
0.63
15.88
180±10
801±44
145±10
645±10
85±10
378±44
11/16
(0.600)
15A
0.69
17.48
180±10
801±44
145±10
645±10
85±10
378±44
3/4
(0.660)
17A
0.75
19.05
205±10
912±44
165±10
730±44
95±10
422±44
7/8
(0.790)
20A
0.88
22.23
205±10
912±44
165±10
730±44
95±10
422±44
15/16
N/A
0.98
23.83
205±10
912±44
165±10
730±44
95±10
422±44
4K
4PK
0.54
13.72
145±10
645±44
115±10
510±44
60±10
267±44
6K
6PK
0.82
20.94
215±10
956±44
170±10
755±10
90±10
400±44
8K
8PK
1.1
27.82
285±10
1179±44
230±10
1025±10
115±10
511±44
10K
10PK
1.38
35.05
355±10
1579±44
285±10
1270±10
145±10
645±44
12K
12PK
1.66
42.16
425±10
1891±44
340±10
1510±10
175±10
778±44
14K
14PK
1.94
49.28
495±10
2202±44
395±10
1755±10
205±10
912±44
15K
15PK
2.08
52.83
530±10
2358±44
425±10
1890±44
215±10
956±44
Belt Tension“Initial ” is for a new belt.
Belt tension with less than 10 hours of operation
Belt tension “Used” is for a belt that has operated for more than 30 minutes of operation at the rated speed..
If a belt falls below the “Used” belt tension, the belt should be tightened again to 80% of the “Initial” belt tension.
i04399165
Belt Tension Chart
Part No.: 197-9087
S/N: GS71-Up
SMCS Code: 1357
Part No.: 197-9087
S/N: ED81-Up
Part No.: 197-9087
S/N: CG21-Up
Part No.: 197-9087
S/N: MD81-Up
Part No.: 197-9087
S/N: WF21-Up
Part No.: 197-9087
S/N: GSA1-Up
Part No.: 197-9087
S/N: 9H41-Up
Part No.: 197-9087
S/N: M8A1-Up
Part No.: 197-9087
S/N: 9H51-Up
Part No.: 197-9087
S/N: S2A1-Up
Part No.: 197-9087
S/N: 9H61-Up
Part No.: 197-9087
S/N: M8B1-Up
Part No.: 197-9087
S/N: GS61-Up
Part No.: 197-9087
S/N: S2B1-Up
RENR5077-12
465
Specifications Section
Part No.: 197-9087
S/N: S2D1-Up
Part No.: 197-9087
S/N: S2X1-Up
Part No.: 197-9087
S/N: S2E1-Up
Part No.: 197-9087
S/N: S2Y1-Up
Part No.: 197-9087
S/N: S2F1-Up
Part No.: 197-9087
S/N: S2Z1-Up
Part No.: 197-9087
S/N: B5G1-Up
Part No.: 197-9087
S/N: EDG1-Up
Part No.: 197-9087
S/N: MRG1-Up
Part No.: 197-9087
S/N: PAG1-Up
Part No.: 197-9087
S/N: S2G1-Up
Part No.: 197-9087
S/N: MKH1-Up
Part No.: 197-9087
S/N: S2H1-Up
Part No.: 197-9087
S/N: S2J1-Up
Part No.: 197-9087
S/N: S2K1-Up
Part No.: 197-9087
S/N: S2L1-Up
Part No.: 197-9087
S/N: MXM1-Up
Part No.: 197-9087
S/N: S2M1-Up
Part No.: 197-9087
S/N: S2N1-Up
Part No.: 197-9087
S/N: EDP1-Up
Part No.: 197-9087
S/N: S2P1-Up
Part No.: 197-9087
S/N: MXR1-Up
Part No.: 197-9087
S/N: S2R1-Up
Part No.: 197-9087
S/N: S2S1-Up
Part No.: 197-9087
S/N: S2T1-Up
Part No.: 197-9087
S/N: S2W1-Up
466
Specifications Section
RENR5077-12
Table 286
Specification for 197-9087 Belt Tension Chart
Gauge Reading
Size of Belt
8 - RIB
POLY - RIB
Width of
Belt
27.82 mm
(1.095 inch)
Belt Tension
(Force)
“Initial”
Belt Tension
(Force)
“Used”
(1)
(2)(3)
800 ± 22 N
(180 ± 5 lb)
489 ± 44 N
(110 ± 10 lb)
Gauge
(Force)
Basic
Gauge
Number
BT-33-109
Belt Tension
(Frequency)
“Initial”(1)
Belt Tension
(Frequency)
“Used”(2)(3)
Gauge
Number
98 ± 10 HZ
76 ± 8 HZ
Do not use the belt tension chart for belts with tensioners that are spring loaded.
Measure the tension of the belt that is farthest from the engine.
(1)
(2)
(3)
Belt tension “lnitial” is for a new belt.
Belt tension “Used” is for a belt that has operated for 30 minutes or more of operation at the rated speed.
If a belt falls below the “Used” belt tension, the belt should be tightened again to the high side of the “Used” belt tension.
i04887991
Alternator and Regulator
Gauge
(Frequency)
Part No.: 333-1184
S/N: M8B1-Up
SMCS Code: 1405
Part No.: 333-1184
S/N: S2B1-Up
Part No.: 333-1184
S/N: CG21-Up
Part No.: 333-1184
S/N: EDC1-Up
Part No.: 333-1184
S/N: WF21-Up
Part No.: 333-1184
S/N: S2D1-Up
Part No.: 333-1184
S/N: 9F31-Up
Part No.: 333-1184
S/N: S2E1-Up
Part No.: 333-1184
S/N: 9H41-Up
Part No.: 333-1184
S/N: S2F1-Up
Part No.: 333-1184
S/N: JB41-Up
Part No.: 333-1184
S/N: B5G1-Up
Part No.: 333-1184
S/N: 9H61-Up
Part No.: 333-1184
S/N: EDG1-Up
Part No.: 333-1184
S/N: GS61-Up
Part No.: 333-1184
S/N: MRG1-Up
Part No.: 333-1184
S/N: GS71-Up
Part No.: 333-1184
S/N: PAG1-Up
Part No.: 333-1184
S/N: ED81-Up
Part No.: 333-1184
S/N: S2G1-Up
Part No.: 333-1184
S/N: MD81-Up
Part No.: 333-1184
S/N: MKH1-Up
Part No.: 333-1184
S/N: GSA1-Up
Part No.: 333-1184
S/N: S2H1-Up
Part No.: 333-1184
S/N: M8A1-Up
Part No.: 333-1184
S/N: EDJ1-Up
Part No.: 333-1184
S/N: S2A1-Up
Part No.: 333-1184
S/N: S2J1-Up
Clavis Type
14
RENR5077-12
467
Specifications Section
Part No.: 333-1184
S/N: S2K1-Up
Part No.: 333-1184
S/N: S2L1-Up
Part No.: 333-1184
S/N: MXM1-Up
Part No.: 333-1184
S/N: S2M1-Up
Part No.: 333-1184
S/N: S2N1-Up
Part No.: 333-1184
S/N: S2P1-Up
Part No.: 333-1184
S/N: MXR1-Up
Part No.: 333-1184
S/N: S2R1-Up
Part No.: 333-1184
S/N: S2S1-Up
Part No.: 333-1184
S/N: S2T1-Up
Part No.: 333-1184
S/N: S2W1-Up
Part No.: 333-1184
S/N: S2X1-Up
Part No.: 333-1184
S/N: S2Y1-Up
Part No.: 333-1184
S/N: S2Z1-Up
Illustration 414
g03013357
468
Specifications Section
RENR5077-12
Table 287
Specification for 333-1184 Charging Alternator Gp
Item
Qty
Part
-
-
-
1
1
187-2034 Flange Nut
2
-
6V-8187 Nut
Use a 7/16 ring terminal for (B+) terminal.
(B+) terminal. Torque to 6.75 ± 1.50 N·m (59.74 ± 13.28 lb in).
3
1
4B-2047 Nut
Torque to 2.25 ± 0.25 N·m (20.00 ± 2.00 lb in)
4
-
6V-8187 Nut
(B-) terminal. Torque to 6.75 ± 1.50 N·m (59.74 ± 13.28 lb in).
5
1
3T-6354 Voltage
Regulator As
-
-
-
Voltage is 24 V.
-
-
-
Amperage is 60 amp.
-
-
-
Polarity is negative ground.
-
-
-
Rotation is either direction.
-
-
-
Maximum turn on speed is 2000 rpm.
-
-
-
Alternator performance at 25 °C (77 °F) is:
Minimum full load current at 5000 rpm is 68 amp.
Minimum full load current at 2000 rpm is 42 amp.
Output voltage is 28 ± 1 V.
Specification Description
Load the battery with a carbon pile 4C-4911 Battery Load Tester
in order to get the maximum alternator output.
Torque to 102 ± 7 N·m (75 ± 5 lb ft).
Voltage setting is not adjustable.
Permissible voltage range is 27 to 29 V.
RENR5077-12
469
Specifications Section
i04399189
Alternator and Regulator
SMCS Code: 1405
Part No.: 3E-7577
S/N: WF21-Up
Part No.: 3E-7577
S/N: 9F31-Up
Part No.: 5N-5692
S/N: 9H31-Up
Part No.: 5N-5692
S/N: 9H41-Up
Part No.: 5N-5692
S/N: 9H51-Up
Part No.: 5N-5692
S/N: ED51-Up
Part No.: 5N-5692
S/N: 9H61-Up
Part No.: 5N-5692
S/N: ED81-Up
Part No.: 5N-5692
S/N: EDG1-Up
Part No.: 3E-7577
S/N: EDJ1-Up
Part No.: 5N-5692
S/N: EDP1-Up
Part No.: 3E-7577
S/N: SRZ1-Up
Illustration 415
g02579856
470
Specifications Section
RENR5077-12
g02579857
Illustration 416
Table 288
Specification for 5N-5692 Charging Alternator Gp
Item
Qty
Part
Specification Description
Load the battery with a carbon pile 4C-4911 Battery Load Tester in order to get the maximum alternator output
1
1
187-2034 Flange Nut
2
1-
9S-2011 Screw
3
1
9S-2389 Stud As
(B+) terminal. Torque to 13.5 ± 1.3 N·m (120 ± 11.50597 lb in).
4
1-
3T-6354 Voltage
Regulator As
No adjustment for voltage setting.
Permissible voltage range is 27 to 29 V.
5
-
-
The peak voltage for (R) terminal must not be less than the output
voltage for (B+) terminal.
-
-
-
Voltage is 24 V.
-
-
-
Amperage is 75 amp.
-
-
-
Polarity is negative ground.
-
-
-
Rotation is Either direction.
Torque to 102 ± 7 N·m (75 ± 5 lb ft).
(B-) terminal. Torque to 6.2 ± 0.6 N·m (55.0 ± 5.0 lb in).
Minimum full load current at 5000 rpm is 67 amp.
Alternator performance at 25 °C (77 °F)
Minimum full load current at 2000 rpm is 29 amp.
Output voltage is 28 ± 1 V.
RENR5077-12
471
Specifications Section
i04849349
Alternator Mounting
SMCS Code: 1405
Part No.: 335-4161
S/N: M8A1-Up
Part No.: 335-4161
S/N: M8B1-Up
Illustration 417
g01446906
Note: Maximum misalignment between pulley
assembly (3) and pulley (1) is 0.4 degrees.
(2) Torque for the pulley retaining nut .. 110 ± 10 N·m
(81 ± 7 lb ft)
(4) Adjust the belt tension of the serpentine belt
according to the 197-9087 Tension Chart.
(5) Lubricate the sealing lip of the lip type seal lightly
with the lubricant that is being sealed.
472
Specifications Section
RENR5077-12
197-9087 Belt Tension Chart
Table 289
Specification for 197-9087 Belt Tension Chart
Gauge Reading
Size of Belt
8 - RIB
POLY - RIB
Width of
Belt
27.82 mm
(1.095 inch)
Belt Tension
(Force)
“Initial”
Belt Tension
(Force)
“Used”
(1)
(2)(3)
800 ± 22 N
(180 ± 5 lb)
489 ± 44 N
(110 ± 10 lb)
Gauge
(Force)
Basic
Gauge
Number
BT-33-109
Belt Tension
(Frequency)
“Initial”(1)
Belt Tension
(Frequency)
“Used”(2)(3)
Gauge
Number
98 ± 10 HZ
76 ± 8 HZ
Do not use the belt tension chart for belts with tensioners that are spring loaded.
Measure the tension of the belt that is farthest from the engine.
(1)
(2)
(3)
Belt tension “lnitial” is for a new belt.
Belt tension “Used” is for a belt that has operated for 30 minutes or more of operation at the rated speed.
If a belt falls below the “Used” belt tension, the belt should be tightened again to the high side of the “Used” belt tension.
i04849411
Alternator Mounting
Gauge
(Frequency)
Part No.: 7E-4836
S/N: PAG1-Up
SMCS Code: 1405
Part No.: 7E-4836
S/N: S2G1-Up
Part No.: 7E-4836
S/N: GS61-Up
Part No.: 7E-4836
S/N: MKH1-Up
Part No.: 7E-4836
S/N: GS71-Up
Part No.: 7E-4836
S/N: S2H1-Up
Part No.: 7E-4836
S/N: GSA1-Up
Part No.: 7E-4836
S/N: S2J1-Up
Part No.: 7E-4836
S/N: M8A1-Up
Part No.: 7E-4836
S/N: S2K1-Up
Part No.: 7E-4836
S/N: S2A1-Up
Part No.: 7E-4836
S/N: S2L1-Up
Part No.: 7E-4836
S/N: M8B1-Up
Part No.: 7E-4836
S/N: S2M1-Up
Part No.: 7E-4836
S/N: S2B1-Up
Part No.: 7E-4836
S/N: S2N1-Up
Part No.: 7E-4836
S/N: S2D1-Up
Part No.: 7E-4836
S/N: S2P1-Up
Part No.: 7E-4836
S/N: S2E1-Up
Part No.: 7E-4836
S/N: S2R1-Up
Part No.: 7E-4836
S/N: S2F1-Up
Part No.: 7E-4836
S/N: S2S1-Up
Part No.: 7E-4836
S/N: B5G1-Up
Part No.: 7E-4836
S/N: S2T1-Up
Part No.: 7E-4836
S/N: MRG1-Up
Part No.: 7E-4836
S/N: S2W1-Up
Clavis Type
14
RENR5077-12
473
Specifications Section
Part No.: 7E-4836
S/N: S2X1-Up
Part No.: 7E-4836
S/N: S2Y1-Up
Part No.: 7E-4836
S/N: S2Z1-Up
g02579957
Illustration 418
Table 290
Specification for 7E-4836 Alternator Mounting Gp and 335-4161 Alternator Mounting Gp
Item
Qty
Part
Specification Description
2
-
-
Tighten the pulley retaining nut to 110 ± 10 N·m (81 ± 7 lb ft).
Maximum misalignment between pulley assembly (3) and pulley (1) is 0.4
degrees.
4
1
141-7116 Serpentine Belt
Adjust the belt tension of the serpentine belt according to the 197-9087
Tension Chart.
5
1
235-2484 Lip Type Seal
Lubricate the sealing lip lightly with the lubricant that is being sealed.
474
Specifications Section
RENR5077-12
197-9087 Belt Tension Chart
Table 291
Specification for 197-9087 Belt Tension Chart
Gauge Reading
Size of Belt
8 - RIB
POLY - RIB
Width of
Belt
27.82 mm
(1.095 inch)
Belt Tension
(Force)
“Initial”
Belt Tension
(Force)
“Used”
(1)
(2)(3)
800 ± 22 N
(180 ± 5 lb)
489 ± 44 N
(110 ± 10 lb)
Gauge
(Force)
Basic
Gauge
Number
BT-33-109
Belt Tension
(Frequency)
“Initial”(1)
Belt Tension
(Frequency)
“Used”(2)(3)
Gauge
Number
98 ± 10 HZ
76 ± 8 HZ
Do not use the belt tension chart for belts with tensioners that are spring loaded.
Measure the tension of the belt that is farthest from the engine.
(1)
(2)
(3)
Gauge
(Frequency)
Belt tension “lnitial” is for a new belt.
Belt tension “Used” is for a belt that has operated for 30 minutes or more of operation at the rated speed.
If a belt falls below the “Used” belt tension, the belt should be tightened again to the high side of the “Used” belt tension.
Clavis Type
14
RENR5077-12
475
Specifications Section
i04890341
Alternator Mounting
SMCS Code: 1405
Part No.: 376-4005
S/N: CG21-Up
Part No.: 376-4005
S/N: WF21-Up
Part No.: 376-4005
S/N: 9H41-Up
Part No.: 376-4005
S/N: 9H61-Up
Part No.: 376-4005
S/N: ED81-Up
Part No.: 376-4005
S/N: MD81-Up
Part No.: 376-4005
S/N: EDG1-Up
Part No.: 376-4005
S/N: MXM1-Up
Part No.: 376-4005
S/N: MXR1-Up
Illustration 419
g03022837
476
Specifications Section
RENR5077-12
Table 292
Specification for 376-4005 Alternator Mounting Gp
Item
Qty
Part
2
-
-
4
1
141-7116 Serpentine Belt
5
1
235-2484 Lip Type Seal
Specification Description
Tighten the pulley retaining nut to 110 ± 10 N·m (81 ± 7 lb ft).
Maximum misalignment between pulley assembly (3) and pulley (1) should
not exceed 0.4 degrees.
Adjust the belt tension of the serpentine belt according to the 197-9087
Tension Chart.
Lubricate the seal run surface lightly with the lubricant that is being sealed.
197-9087 Belt Tension Chart
Table 293
Specification for 197-9087 Belt Tension Chart
Gauge Reading
Size of Belt
8 - RIB
POLY - RIB
Width of
Belt
27.82 mm
(1.095 inch)
Belt Tension
(Force)
“Initial”
Belt Tension
(Force)
“Used”
(1)
(2)(3)
800 ± 22 N
(180 ± 5 lb)
489 ± 44 N
(110 ± 10 lb)
Gauge
(Force)
Basic
Gauge
Number
BT-33-109
Belt Tension
(Frequency)
“Initial”(1)
Belt Tension
(Frequency)
“Used”(2)(3)
Gauge
Number
98 ± 10 HZ
76 ± 8 HZ
Do not use the belt tension chart for belts with tensioners that are spring loaded.
Measure the tension of the belt that is farthest from the engine.
(1)
(2)
(3)
Gauge
(Frequency)
Belt tension “lnitial” is for a new belt.
Belt tension “Used” is for a belt that has operated for 30 minutes or more of operation at the rated speed.
If a belt falls below the “Used” belt tension, the belt should be tightened again to the high side of the “Used” belt tension.
Clavis Type
14
RENR5077-12
477
Specifications Section
i02619193
Torque ...................... 30.5 ± 3.5 N·m (23 ± 3 lb ft)
Electric Starting Motor
SMCS Code: 1453
Part No.: 7C-0526, 7C-0527
S/N: GS61-Up
Part No.: 7C-0526, 7C-0527
S/N: GS71-Up
Part No.: 7C-0526, 7C-0527
S/N: GSA1-Up
Illustration 421
g01312658
Typical example
(3) Ground terminal nut
Torque ................... 2.25 ± 0.25 N·m (20 ± 2 lb in)
(4) Switch terminal nut
The terminal must be insulated with heat shrink
tubing. Do not use molded terminals.
Torque ................... 2.25 ± 0.25 N·m (20 ± 2 lb in)
(5) Motor terminal nut
Torque ...................... 30.5 ± 3.5 N·m (23 ± 3 lb ft)
(6) Motor frame terminal nut
g01312290
Torque ........................... 8 ± 3 N·m (70 ± 27 lb in)
When the electric starting motor is viewed from
the drive end, the motor rotates in the following
direction. ................................................... Clockwise
i04392953
Illustration 420
Typical example
Pull-in current at 25 °C (77 °F) ......... 57 Amp at 20 V
Hold-in current at 25 °C (77 °F) ....... 16 Amp at 20 V
No load conditions at 25 °C (77 °F)
Speed ...................................... 7643 ± 1683 rpm
Current draw ............................. 76.5 ± 14.5 Amp
Voltage ......................................................... 23 V
(A) Clearance between the extended pinion and the
housing ................................. 9.1 mm (0.36 inch)
(1) Battery terminal nut
A maximum of three cable terminals or wire
terminals may be used with the nut. A maximum
of two of the terminals may be equal to or greater
than 0 AWG.
Torque ...................... 30.5 ± 3.5 N·m (23 ± 3 lb ft)
(2) Ground terminal nut
Electric Starting Motor
SMCS Code: 1453
Part No.: 207-1557
S/N: M8A1-Up
Part No.: 207-1557
S/N: S2A1-Up
Part No.: 207-1557
S/N: M8B1-Up
Part No.: 207-1557
S/N: S2B1-Up
Part No.: 207-1557
S/N: S2D1-Up
Part No.: 207-1557
S/N: S2E1-Up
Part No.: 207-1557
S/N: S2F1-Up
478
Specifications Section
Part No.: 207-1557
S/N: PAG1-Up
Part No.: 207-1557
S/N: S2G1-Up
Part No.: 207-1557
S/N: MKH1-Up
Part No.: 207-1557
S/N: S2H1-Up
Part No.: 207-1557
S/N: S2J1-Up
Part No.: 207-1557
S/N: S2K1-Up
Part No.: 207-1557
S/N: S2L1-Up
Part No.: 207-1557
S/N: S2M1-Up
Part No.: 207-1557
S/N: S2N1-Up
Part No.: 207-1557
S/N: S2P1-Up
Part No.: 207-1557
S/N: S2R1-Up
Part No.: 207-1557
S/N: S2S1-Up
Part No.: 207-1557
S/N: S2T1-Up
Part No.: 207-1557
S/N: S2W1-Up
Part No.: 207-1557
S/N: S2X1-Up
Part No.: 207-1557
S/N: S2Y1-Up
Part No.: 207-1557
S/N: S2Z1-Up
RENR5077-12
RENR5077-12
479
Specifications Section
g02563097
Illustration 422
Table 294
Specification for the 207-1549 Electric Starting Motor Gp, 207-1562 Electric Starting Motor
Gp, and 207-1557 Electric Starting Motor Gp
Item
Qty
Part
Specification Description
B
-
-
1
2
6V-8188 Nut
2
1
-
3
1
6V-8188 Nut
Torque to 30.5 ± 3.5 N·m (269.9 ± 30.9 lb in).
4
1
6V-8378 Nut
Torque to 2.25 ± 0.25 N·m (20 ± 2 lb in).
The clearance between the pinion and the housing is 9.1 mm (0.36 inch).
Torque to 30.5 ± 3.5 N·m (270 ± 31 lb in).
Current consumption at 20V and 25 °C (77 °F):
1. For Pull-in current is 57 Amp
2. For Hold-in current is 16 Amp max
5
1
6V-8188 Nut
A maximum of three cable terminals or wire terminals may be used with the battery
terminal nut (5). A maximum of two of the terminals may be equal to or greater than
0 AWG.
Torque to 30.5 ± 3.5 N·m (270 ± 30 lb in).
6
1
6V-8378 Nut
The switch terminal must be insulated with heat shrink tubing. Do not use molded
terminals.
Torque to 2.25 ± 0.25 N·m (20 ± 2 lb in).
7
-
-
Torque to 8 ± 3 N·m (71 ± 27 lb in).
-
When the electric starting motor is viewed from the pinion end, the motor rotates in
the clockwise direction.
No load conditions at 25 °C (77 °F)
1. Speed is 7643 ± 1683 rpm
2. Current draw is 76.5 ± 14.5 Amp
3. Voltage is 23 VDC
-
-
i04882274
Electric Starting Motor
Part No.: 207-1562
S/N: 9H61-Up
SMCS Code: 1453
Part No.: 207-1562
S/N: GS61-Up
Part No.: 207-1562
S/N: CG21-Up
Part No.: 207-1562
S/N: GS71-Up
480
Specifications Section
Part No.: 207-1562
S/N: MD81-Up
Part No.: 207-1562
S/N: GSA1-Up
Part No.: 207-1562
S/N: M8A1-Up
Part No.: 207-1562
S/N: S2A1-Up
Part No.: 207-1562
S/N: S2B1-Up
Part No.: 207-1562
S/N: S2E1-Up
Part No.: 207-1562
S/N: S2F1-Up
Part No.: 207-1562
S/N: EDG1-Up
Part No.: 207-1562
S/N: PAG1-Up
Part No.: 207-1562
S/N: S2G1-Up
Part No.: 207-1562
S/N: MKH1-Up
Part No.: 207-1562
S/N: S2H1-Up
Part No.: 207-1562
S/N: S2J1-Up
Part No.: 207-1562
S/N: S2K1-Up
Part No.: 207-1562
S/N: S2L1-Up
Part No.: 207-1562
S/N: MXM1-Up
Part No.: 207-1562
S/N: S2M1-Up
Part No.: 207-1562
S/N: S2N1-Up
Part No.: 207-1562
S/N: S2P1-Up
Part No.: 207-1562
S/N: MXR1-Up
Part No.: 207-1562
S/N: S2S1-Up
Part No.: 207-1562
S/N: S2T1-Up
Part No.: 207-1562
S/N: S2Y1-Up
RENR5077-12
Part No.: 207-1562
S/N: S2Z1-Up
RENR5077-12
481
Specifications Section
g03006636
Illustration 423
Table 295
Specification for the 207-1562 Electric Starting Motor Gp
Item
Qty
Part
1
2
6V-8188 Nut
2
1
-
3
1
6V-8188 Nut
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
4
1
6V-8378 Nut
Torque to 2.6 ± 0.8 N·m (23.0 ± 7.0 lb in).
Specification Description
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
Current consumption at 20V and 25 °C (77 °F):
1. For Pull-in current is 57 amp
2. For Hold-in current is 16 amp
5
1
6V-8188 Nut
A maximum of three cable terminals or wire terminals may be used with the battery
terminal nut. A maximum of two of the terminals may be equal to or greater than
0 AWG.
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
6
1
6V-8378 Nut
The switch terminal must be insulated with heat shrink tubing. Do not use molded
terminals.
Torque to 2.6 ± 0.8 N·m (23.0 ± 7.0 lb in).
7
-
-
Torque to 8 ± 3 N·m (71 ± 27 lb in).
-
When the electric starting motor is viewed from the pinion end, the motor rotates in
the clockwise direction.
No load conditions at 25 °C (77 °F)
1. Speed is 7643 ± 1683 rpm
2. Current draw is 76.5 ± 14.5 amp
3. Voltage is 23 VDC
-
-
482
Specifications Section
RENR5077-12
i04110169
Electric Starting Motor
SMCS Code: 1453
Part No.: 352-9766
S/N: CG21-Up
Part No.: 352-9766
S/N: 9H41-Up
Part No.: 352-9766
S/N: 9H61-Up
Part No.: 352-9766
S/N: ED81-Up
Part No.: 352-9766
S/N: MD81-Up
Part No.: 352-9766
S/N: EDG1-Up
Part No.: 352-9766
S/N: MXM1-Up
Part No.: 352-9766
S/N: MXR1-Up
Illustration 424
g02563096
RENR5077-12
483
Specifications Section
Table 296
Specification for the 338-3454 Electric Starting Motor Gp and 352-9766 Electric Motor Gp
Item
Qty
Part
B
-
-
1
5
6V-8188 Nut
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
2
1
4B-2049 Nut
Torque to 3.4 ± 1.2 N·m (30.1 ± 10.6 lb in).
3
1
4B-2049 Nut
The switch terminal must be insulated with heat shrinkable tubing. Do not use molded
terminals.
Torque to 3.4 ± 1.2 N·m (30.1 ± 10.6 lb in).
4
1
6V-8188 Nut
Specification Description
Clearance between the pinion and the housing is 9.1 mm (0.36 inch).
A maximum of three cable terminals or wire terminals may be used with the battery
terminal nut. A maximum of two of the cable terminals may be equal to or greater
than 0 AWG.
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
-
-
-
-
-
-
Pull-in current at 20 V and 25 °C (77 °F) is 49.3 ± 3.3 Amp.
Hold-in current at 20 V and 25 °C (77 °F) is 6.8 Amp max.
When the electric starting motor is viewed from the pinion end, the motor rotates in
the clockwise direction.
No load conditions at 25 °C (77 °F):
-
-
-
Speed is 6950 ± 1650 rpm.
Current draw is 115 ± 25 Amp.
Voltage is 23 VDC.
484
Specifications Section
RENR5077-12
i04887985
Air Starting Motor
SMCS Code: 1451
Part No.: 143-5174
S/N: GS61-Up
Part No.: 143-5174
S/N: GS71-Up
Part No.: 143-5174
S/N: GSA1-Up
g03013422
Illustration 425
Table 297
Specifications for 143-5174 Air Starting Motor Gp
Item
1
Qty
3
Part
5B-7666 Elbow
Specification Description
Apply High Strength or High Temperature Anaerobic Flange Sealant at the
joint of the elbow and valve.
Apply white Loctite Low Breakloose PST to the threads.
2
1
5B-7643 Pipe Nipple
Apply High Strength or High Temperature Anaerobic Flange Sealant at the
joint of the valve and nipple.
Apply white Loctite Low Breakloose PST to the threads.
RENR5077-12
485
Specifications Section
g03013459
Illustration 426
Table 298
Specifications for 143-5174 Air Starting Motor Gp
Item
Qty
Part
3
1
143-5177 Pipe Nipple
Illustration 427
Specification Description
Apply white Loctite Low Breakloose PST to the threads.
g03013418
486
Specifications Section
RENR5077-12
Table 299
Specifications for 143-5168 Air Starting Motor Gp
Item
Qty
Part
4
1
5N-8381 Clutch Spring
Free length is 30.5 mm (1.20 inch).
5
1
5N-8372 Spring
Free length is 203.5 mm (8.01 inch).
6
1
5N-8380 Pinion Spring
Free length is 65.0 mm (2.56 inch).
Specification Description
RENR5077-12
487
Specifications Section
i02787858
Air Starting Motor
SMCS Code: 1451
Tighten the bolts evenly in small increases until
the following torque is reached: ............... 80 N·m
(60 lb ft)
(2) Bolt
Part No.: 8N-8477
S/N: GS61-Up
Torque ....................................... 36 N·m (27 lb ft)
(3) Bolt
Part No.: 7C-3371
S/N: GS71-Up
Torque ....................................... 78 N·m (60 lb ft)
Part No.: 8N-8477
S/N: GSA1-Up
(4) Bolt (pinion)
Torque ...................................... 110 N·m (80 lb ft)
Part No.: 7C-3371, 8N-8477
S/N: S2A1-Up
(5) Rotor clamp nut
Part No.: 7C-3371, 8N-8477
S/N: S2B1-Up
Tighten the rotor clamp nut until the following
clearance between the rear end plate and the
rotor is reached: ........................ 0.03 to 0.08 mm
(0.001 to 0.003 inch)
Part No.: 8N-8477
S/N: S2G1-Up
Part No.: 8N-8477
S/N: S2H1-Up
Check the clearance again after the bolt for the rotor
clamp nut is tightened.
Part No.: 8N-8477
S/N: S2J1-Up
(6) Rotor retainer bolt
Torque ..................................... 120 N·m (90 lb ft)
Part No.: 8N-8477
S/N: S2M1-Up
i05053331
Part No.: 7C-3371, 8N-8477
S/N: S2P1-Up
Air Starting Motor
Part No.: 7C-3371, 8N-8477
S/N: S2R1-Up
SMCS Code: 1451
Part No.: 392-9035
S/N: 9F21-Up
Part No.: 7C-3371
S/N: S2W1-Up
Part No.: 392-9035
S/N: CG21-Up
Part No.: 8N-8477
S/N: S2X1-Up
Part No.: 392-9035
S/N: ED21-Up
Part No.: 7C-3371, 8N-8477
S/N: S2Z1-Up
Part No.: 392-9035
S/N: 9F31-Up
Part No.: 392-9035
S/N: 9H41-Up
Part No.: 392-9035
S/N: JB41-Up
Part No.: 392-9035
S/N: 9H51-Up
Part No.: 392-9035
S/N: 9H61-Up
Illustration 428
Typical example
(1) Cover
g01392582
Part No.: 392-9035
S/N: ED81-Up
Part No.: 392-9035
S/N: MD81-Up
488
Specifications Section
RENR5077-12
Part No.: 392-9035
S/N: EDC1-Up
Part No.: 392-9035
S/N: EDG1-Up
Part No.: 392-9035
S/N: EDH1-Up
Part No.: 392-9035
S/N: SRH1-Up
Part No.: 392-9035
S/N: EDJ1-Up
Part No.: 392-9035
S/N: EDP1-Up
Part No.: 392-9035
S/N: MXR1-Up
Illustration 429
g03221156
RENR5077-12
489
Specifications Section
Table 300
Specification for 392-9035 Air Starting Lines Gp
Item
Qty
Part
Specification Description
1
1
2L-2811 Fitting
Before assembly, apply white Loctite Low Breakloose PST to the threads.
2
2
6B-3685 Elbow
Before assembly, apply white Loctite Low Breakloose PST to the threads.
3
2
5B-7643 Pipe Nipple
Before assembly, apply white Loctite Low Breakloose PST to the threads.
4
1
3B-6492 Pipe Coupling
Before assembly, apply white Loctite Low Breakloose PST to the threads.
5
1
6K-1972 Flared Elbow
Position of the elbow from intake pipe is 45 ± 10 degrees .
6
1
5B-7666 Elbow
Before assembly, apply white Loctite Low Breakloose PST to the threads.
Before assembly, apply white Loctite Low Breakloose PST to the threads.
7
1
3L-8993 Fitting
8
1
2L-2811 Fitting
Before assembly, apply high strength/ high temperature anaerobic flange
sealant at valve to nipple joints only.
Before assembly, apply white Loctite Low Breakloose PST to the threads.
Before assembly, apply high strength/ high temperature anaerobic flange
sealant at valve to nipple joints only.
i05065051
Air Starting Motor
Part No.: 392-9042
S/N: EDC1-Up
SMCS Code: 1451
Part No.: 392-9042, 421-6801
S/N: EDG1-Up
Part No.: 392-9042
S/N: 9F21-Up
Part No.: 392-9042
S/N: EDH1-Up
Part No.: 392-9042
S/N: CG21-Up
Part No.: 392-9042
S/N: SRH1-Up
Part No.: 392-9042
S/N: ED21-Up
Part No.: 392-9042
S/N: EDJ1-Up
Part No.: 392-9042
S/N: 9F31-Up
Part No.: 421-6801
S/N: MXM1-Up
Part No.: 421-6801
S/N: 9H31-Up
Part No.: 392-9042, 421-6801
S/N: EDP1-Up
Part No.: 421-6801
S/N: ED31-Up
Part No.: 392-9042
S/N: MXR1-Up
Part No.: 392-9042, 421-6801
S/N: 9H41-Up
Part No.: 392-9042
S/N: JB41-Up
Part No.: 392-9042, 421-6801
S/N: 9H51-Up
Part No.: 421-6801
S/N: ED51-Up
Part No.: 392-9042, 421-6801
S/N: 9H61-Up
Part No.: 392-9042, 421-6801
S/N: ED81-Up
Part No.: 392-9042, 421-6801
S/N: MD81-Up
490
Specifications Section
RENR5077-12
g03231460
Illustration 430
Typical example
Table 301
Specification for 392-9042 Air Starting Motor Gp and 421-6801 Air Starting Motor Gp
Item
Qty
Part
Specification Description
1
1
2L-2811 Fitting
Before assembly, apply white Loctite Low Breakloose PST to the threads.
2
2
6B-3685 Elbow
Before assembly, apply white Loctite Low Breakloose PST to the threads.
3
2
5B-7643 Pipe Nipple
Before assembly, apply white Loctite Low Breakloose PST to the threads.
4
1
3B-6492 Pipe Coupling
Before assembly, apply white Loctite Low Breakloose PST to the threads.
5
1
5B-7666 Elbow
Before assembly, apply white Loctite Low Breakloose PST to the threads.
6
1
6K-1972 Flared Elbow
As shown in Illustration 430, position the elbow at angle of 75 ± 10
degrees from the intake pipe.
Before assembly, apply white Loctite Low Breakloose PST to the threads.
7
1
3L-8993 Fitting
Before assembly, apply high strength or high temperature anaerobic
flange sealant at valve to nipple joints only.
Before assembly, apply white Loctite Low Breakloose PST to the threads.
8
1
2L-2811 Fitting
Before assembly, apply high strength or high temperature anaerobic
flange sealant at valve to nipple joints only.
i04907197
Air Starting Motor Pressure
Regulating Valve
SMCS Code: 1462
Part No.: 1L-2073
S/N: 9H41-Up
Part No.: 1L-2073
S/N: 9H61-Up
Part No.: 1L-2073
S/N: GS61-Up
RENR5077-12
491
Specifications Section
Part No.: 1L-2073
S/N: ED81-Up
Part No.: 1L-2073
S/N: S2X1-Up
Part No.: 1L-2073
S/N: GSA1-Up
Part No.: 1L-2073
S/N: S2Y1-Up
Part No.: 1L-2073
S/N: M8A1-Up
Part No.: 1L-2073
S/N: S2Z1-Up
Part No.: 1L-2073
S/N: S2A1-Up
Part No.: 1L-2073
S/N: M8B1-Up
Part No.: 1L-2073
S/N: S2B1-Up
Part No.: 1L-2073
S/N: S2D1-Up
Part No.: 1L-2073
S/N: S2E1-Up
Part No.: 1L-2073
S/N: S2F1-Up
Part No.: 1L-2073
S/N: EDG1-Up
Part No.: 1L-2073
S/N: PAG1-Up
Part No.: 1L-2073
S/N: S2G1-Up
Part No.: 1L-2073
S/N: S2H1-Up
Part No.: 1L-2073
S/N: S2J1-Up
Part No.: 1L-2073
S/N: S2K1-Up
Part No.: 1L-2073
S/N: S2L1-Up
Part No.: 1L-2073
S/N: S2M1-Up
Part No.: 1L-2073
S/N: S2N1-Up
Part No.: 1L-2073
S/N: S2P1-Up
Part No.: 1L-2073
S/N: S2R1-Up
Part No.: 1L-2073
S/N: S2S1-Up
Part No.: 1L-2073
S/N: S2T1-Up
Part No.: 1L-2073
S/N: S2W1-Up
492
Specifications Section
RENR5077-12
g03071456
Illustration 431
Table 302
Specification for 1L-2073 Pressure Reducing Valve
Item
Qty
Part
1
-
-
Inlet pressure is 1723 kPa (250 psi).
Maximum inlet pressure is 3103 kPa (450 psi).
2
-
-
Outlet pressure at outlet port is 621 ± 758 kPa (90 ± 110 psi).
Specification Description
i01668530
Jacket Water Heater
Part No.: 7E-6247
S/N: S2D1-Up
SMCS Code: 1383
Part No.: 7E-6247
S/N: S2E1-Up
Part No.: 7E-6247
S/N: 9H41-Up
Part No.: 7E-6247
S/N: PAG1-Up
Part No.: 7E-6247
S/N: GS61-Up
Part No.: 7E-6247
S/N: S2G1-Up
Part No.: 7E-6247
S/N: GS71-Up
Part No.: 7E-6247
S/N: MKH1-Up
Part No.: 7E-6247
S/N: ED81-Up
Part No.: 7E-6247
S/N: S2H1-Up
Part No.: 7E-6247
S/N: GSA1-Up
Part No.: 7E-6247
S/N: S2J1-Up
Part No.: 7E-6247
S/N: M8A1-Up
Part No.: 7E-6247
S/N: S2K1-Up
Part No.: 7E-6247
S/N: S2A1-Up
Part No.: 7E-6247
S/N: S2L1-Up
Part No.: 7E-6247
S/N: M8B1-Up
Part No.: 7E-6247
S/N: S2M1-Up
Part No.: 7E-6247
S/N: S2B1-Up
Part No.: 7E-6247
S/N: S2N1-Up
RENR5077-12
493
Specifications Section
Part No.: 7E-6247
S/N: S2P1-Up
i02053647
Engine Harness
(Rigid Wiring Harness)
Part No.: 7E-6247
S/N: S2R1-Up
SMCS Code: 1408
Part No.: 7E-6247
S/N: S2S1-Up
Part No.: 232-0013, 232-0014
S/N: MRG1-Up
Part No.: 7E-6247
S/N: S2T1-Up
Part No.: 232-0014
S/N: S2G1-Up
Part No.: 7E-6247
S/N: S2W1-Up
Part No.: 232-0013, 232-0014
S/N: MKH1-Up
Part No.: 7E-6247
S/N: S2X1-Up
Part No.: 232-0014
S/N: S2H1-Up
Part No.: 7E-6247
S/N: S2Z1-Up
Part No.: 232-0013, 232-0014
S/N: S2J1-Up
Part No.: 232-0013, 232-0014
S/N: S2K1-Up
Part No.: 232-0013, 232-0014
S/N: S2L1-Up
Part No.: 232-0013, 232-0014
S/N: S2M1-Up
Part No.: 232-0013, 232-0014
S/N: S2N1-Up
Illustration 432
g00279581
Typical example
Power ...................................................... 3000 Watts
Voltage ...................................................... 120/240 V
(1) Hose
Assemble the hose in order to maintain a gradual rise
from the heater outlet to the engine.
(2) Jacket water heater
(3) Reference dimension .. 60 ± 6 mm (2.4 ± .2 inch)
(4) Thermostat
(5) Coolant outlet
(6) Coolant inlet
494
Specifications Section
Illustration 433
Typical example
RENR5077-12
g01053142
RENR5077-12
495
Specifications Section
g01053143
Illustration 434
Typical example
(1) Nut
Torque ...................................... 2.5 N·m (22 lb in)
(2) Nut
Torque ......................................... 8 N·m (70 lb in)
(6) Nut
Torque ...................................... 2.5 N·m (22 lb in)
(7) Nut
Torque ...................................... 2.5 N·m (22 lb in)
(3) Nut
Torque ...................................... 2.5 N·m (22 lb in)
(4) Nut
Torque ........................................ 15 N·m (11 lb ft)
(5) Nut
Torque ......................................... 10 N·m (7 lb ft)
i04757411
Coolant Level Switch
SMCS Code: 1395; 7422
Part No.: 2N-9768
S/N: CG21-Up
Part No.: 2N-9768
S/N: 9F31-Up
496
Specifications Section
RENR5077-12
Part No.: 2N-9768
S/N: 9H41-Up
Part No.: 2N-9768
S/N: S2L1-Up
Part No.: 2N-9768
S/N: 9H61-Up
Part No.: 2N-9768
S/N: MXM1-Up
Part No.: 2N-9768
S/N: GS61-Up
Part No.: 2N-9768
S/N: S2N1-Up
Part No.: 2N-9768
S/N: GS71-Up
Part No.: 2N-9768
S/N: S2P1-Up
Part No.: 2N-9768
S/N: ED81-Up
Part No.: 2N-9768
S/N: MXR1-Up
Part No.: 2N-9768
S/N: MD81-Up
Part No.: 2N-9768
S/N: S2R1-Up
Part No.: 2N-9768
S/N: GSA1-Up
Part No.: 2N-9768
S/N: S2S1-Up
Part No.: 2N-9768
S/N: M8A1-Up
Part No.: 2N-9768
S/N: S2T1-Up
Part No.: 2N-9768
S/N: S2A1-Up
Part No.: 2N-9768
S/N: S2W1-Up
Part No.: 2N-9768
S/N: M8B1-Up
Part No.: 2N-9768
S/N: S2X1-Up
Part No.: 2N-9768
S/N: S2B1-Up
Part No.: 2N-9768
S/N: S2Z1-Up
Part No.: 2N-9768
S/N: S2D1-Up
Part No.: 2N-9768
S/N: S2E1-Up
Part No.: 2N-9768
S/N: B5G1-Up
Part No.: 2N-9768
S/N: EDG1-Up
Part No.: 2N-9768
S/N: MRG1-Up
Part No.: 2N-9768
S/N: PAG1-Up
Part No.: 2N-9768
S/N: S2G1-Up
Part No.: 2N-9768
S/N: MKH1-Up
Part No.: 2N-9768
S/N: S2H1-Up
Part No.: 2N-9768
S/N: EDJ1-Up
Part No.: 2N-9768
S/N: S2J1-Up
Part No.: 2N-9768
S/N: S2K1-Up
RENR5077-12
497
Specifications Section
g02849383
Illustration 435
Table 303
Specification for 2N-9768 Liquid Level Switch
Item
Qty
Part
Specification Description
Note: The liquid level switch is shown in the high liquid level position.
A
-
-
When the liquid level switch activates, approximate travel distance of the
liquid level switch is 6.4 mm (0.25 inch).
Contact position is Normally closed.
i04929951
Coolant Temperature Switch
SMCS Code: 1395
Part No.: 3E-0264
S/N: 9F31-Up
Part No.: 3E-0264
S/N: EDJ1-Up
Part No.: 3E-0264
S/N: S2Z1-Up
Illustration 436
g03099257
498
Specifications Section
RENR5077-12
Table 304
Specification for 3E-0264 Temperature Switch Gp
Item
1
Qty
1
Part
Specification Description
-
Final installation torque for the temperature switch is 52.5 ± 7.5 N·m
(38.7 ± 5.5 lb ft).
-
Actuation temperature to open at 27.0 ± 2.8 °C (80.6 ± 5.0 °F).
-
Minimum deactuation temperature is 20 °C (68 °F).
-
Contact position is normally closed below deactuation temperature.
i04935269
Fuel Pressure Sensor
Part No.: 161-1705
S/N: S2M1-Up
SMCS Code: 7414
Part No.: 161-1705
S/N: S2N1-Up
Part No.: 161-1705
S/N: M8A1-Up
Part No.: 161-1705
S/N: S2P1-Up
Part No.: 161-1705
S/N: S2A1-Up
Part No.: 161-1705
S/N: S2R1-Up
Part No.: 161-1705
S/N: M8B1-Up
Part No.: 161-1705
S/N: S2S1-Up
Part No.: 161-1705
S/N: S2B1-Up
Part No.: 161-1705
S/N: S2T1-Up
Part No.: 161-1705
S/N: S2D1-Up
Part No.: 161-1705
S/N: S2W1-Up
Part No.: 161-1705
S/N: S2E1-Up
Part No.: 161-1705
S/N: S2X1-Up
Part No.: 161-1705
S/N: S2F1-Up
Part No.: 161-1705
S/N: S2Y1-Up
Part No.: 161-1705
S/N: B5G1-Up
Part No.: 161-1705
S/N: S2Z1-Up
Part No.: 161-1705
S/N: MRG1-Up
Part No.: 161-1705
S/N: PAG1-Up
Part No.: 161-1705
S/N: S2G1-Up
Part No.: 161-1705
S/N: MKH1-Up
Part No.: 161-1705
S/N: S2H1-Up
Part No.: 161-1705
S/N: S2J1-Up
Part No.: 161-1705
S/N: S2K1-Up
Part No.: 161-1705
S/N: S2L1-Up
RENR5077-12
499
Specifications Section
g03109341
Illustration 437
Table 305
Specification for 161-1705 Pressure Sensor
Item
Qty
Part
1
1
161-1705 Pressure Sensor
Specification Description
Torque to 10 ± 2 N·m (89 ± 18 lb in).
Operating voltage is 5.00 ± 0.25 VDC.
i04753733
Magnetic Switch
Part No.: 9X-8124
S/N: GS71-Up
SMCS Code: 7499
Part No.: 9X-8124
S/N: ED81-Up
Part No.: 9X-8124
S/N: 9F21-Up
Part No.: 9X-8124
S/N: MD81-Up
Part No.: 9X-8124
S/N: CG21-Up
Part No.: 9X-8124
S/N: GSA1-Up
Part No.: 9X-8124
S/N: ED21-Up
Part No.: 9X-8124
S/N: M8A1-Up
Part No.: 9X-8124
S/N: 9F31-Up
Part No.: 9X-8124
S/N: S2A1-Up
Part No.: 9X-8124
S/N: 9H31-Up
Part No.: 9X-8124
S/N: M8B1-Up
Part No.: 9X-8124
S/N: ED31-Up
Part No.: 9X-8124
S/N: S2B1-Up
Part No.: 9X-8124
S/N: 9H41-Up
Part No.: 9X-8124
S/N: EDC1-Up
Part No.: 9X-8124
S/N: JB41-Up
Part No.: 9X-8124
S/N: S2D1-Up
Part No.: 9X-8124
S/N: 9H51-Up
Part No.: 9X-8124
S/N: S2E1-Up
Part No.: 9X-8124
S/N: ED51-Up
Part No.: 9X-8124
S/N: S2F1-Up
Part No.: 9X-8124
S/N: 9H61-Up
Part No.: 9X-8124
S/N: B5G1-Up
Part No.: 9X-8124
S/N: GS61-Up
Part No.: 9X-8124
S/N: EDG1-Up
500
Specifications Section
RENR5077-12
Part No.: 9X-8124
S/N: MRG1-Up
Part No.: 9X-8124
S/N: S2Y1-Up
Part No.: 9X-8124
S/N: PAG1-Up
Part No.: 9X-8124
S/N: S2Z1-Up
Part No.: 9X-8124
S/N: S2G1-Up
Part No.: 9X-8124
S/N: EDH1-Up
Part No.: 9X-8124
S/N: MKH1-Up
Part No.: 9X-8124
S/N: S2H1-Up
Part No.: 9X-8124
S/N: SRH1-Up
Part No.: 9X-8124
S/N: EDJ1-Up
Part No.: 9X-8124
S/N: S2J1-Up
Part No.: 9X-8124
S/N: S2K1-Up
Part No.: 9X-8124
S/N: SRK1-Up
Part No.: 9X-8124
S/N: S2L1-Up
Part No.: 9X-8124
S/N: MXM1-Up
Part No.: 9X-8124
S/N: S2M1-Up
Part No.: 9X-8124
S/N: S2N1-Up
Part No.: 9X-8124
S/N: EDP1-Up
Part No.: 9X-8124
S/N: S2P1-Up
Part No.: 9X-8124
S/N: MXR1-Up
Part No.: 9X-8124
S/N: S2R1-Up
Part No.: 9X-8124
S/N: S2S1-Up
Part No.: 9X-8124
S/N: S2T1-Up
Part No.: 9X-8124
S/N: S2W1-Up
Part No.: 9X-8124
S/N: S2X1-Up
RENR5077-12
501
Specifications Section
g02848949
Illustration 438
Table 306
Specification for 9X-8124 Magnetic Switch As, 175-2329 Magnetic Switch Gp, and 175-2330 Magnetic Switch Gp
Item
Qty
Part
1
-
-
Specification Description
Tighten the nuts to 5.5 ± 0.5 N·m (48.7 ± 4.4 lb in).
Contact position is Normally open.
i04935270
Coolant Level Sensor
Part No.: 204-2518
S/N: M8A1-Up
SMCS Code: 7470
Part No.: 204-2518, 239-9957
S/N: S2A1-Up
Part No.: 204-2518
S/N: CG21-Up
Part No.: 204-2518
S/N: M8B1-Up
Part No.: 204-2518
S/N: WF21-Up
Part No.: 204-2518, 239-9957
S/N: S2B1-Up
Part No.: 239-9957
S/N: 9H31-Up
Part No.: 204-2518, 239-9957
S/N: S2D1-Up
Part No.: 204-2518, 239-9957
S/N: 9H41-Up
Part No.: 204-2518, 239-9957
S/N: S2E1-Up
Part No.: 239-9957
S/N: 9H51-Up
Part No.: 204-2518, 239-9957
S/N: S2F1-Up
Part No.: 239-9957
S/N: ED51-Up
Part No.: 204-2518, 239-9957
S/N: B5G1-Up
Part No.: 204-2518, 239-9957
S/N: 9H61-Up
Part No.: 204-2518, 239-9957
S/N: EDG1-Up
Part No.: 204-2518, 239-9957
S/N: GS61-Up
Part No.: 204-2518, 239-9957
S/N: MRG1-Up
Part No.: 204-2518
S/N: GS71-Up
Part No.: 204-2518, 239-9957
S/N: PAG1-Up
Part No.: 204-2518, 239-9957
S/N: ED81-Up
Part No.: 204-2518, 239-9957
S/N: S2G1-Up
Part No.: 204-2518
S/N: MD81-Up
Part No.: 204-2518, 239-9957
S/N: MKH1-Up
Part No.: 204-2518
S/N: GSA1-Up
Part No.: 204-2518, 239-9957
S/N: S2H1-Up
502
Specifications Section
RENR5077-12
Part No.: 204-2518, 239-9957
S/N: S2J1-Up
Part No.: 204-2518, 239-9957
S/N: S2K1-Up
Part No.: 204-2518, 239-9957
S/N: S2L1-Up
Part No.: 204-2518
S/N: MXM1-Up
Part No.: 204-2518, 239-9957
S/N: S2M1-Up
Part No.: 204-2518, 239-9957
S/N: S2N1-Up
Part No.: 239-9957
S/N: EDP1-Up
Part No.: 204-2518, 239-9957
S/N: S2P1-Up
Part No.: 204-2518
S/N: MXR1-Up
Part No.: 204-2518, 239-9957
S/N: S2R1-Up
Part No.: 204-2518, 239-9957
S/N: S2S1-Up
Part No.: 204-2518, 239-9957
S/N: S2T1-Up
Part No.: 204-2518, 239-9957
S/N: S2W1-Up
Part No.: 204-2518, 239-9957
S/N: S2X1-Up
Part No.: 204-2518, 239-9957
S/N: S2Y1-Up
Part No.: 204-2518, 239-9957
S/N: S2Z1-Up
Illustration 439
g03109342
RENR5077-12
503
Specifications Section
Table 307
Specification for 204-2518 Liquid Level Sensor Gp and 239-9957 Liquid Level Sensor Gp
Item
Qty
Part
1
1
-
Specification Description
Torque to 20 ± 3 N·m (177 ± 27 lb in).
Operating voltage is 7 to 32 VDC.
i04753349
Engine Oil Pressure Sensor
Part No.: 194-6725
S/N: EDG1-Up
SMCS Code: 1924
Part No.: 194-6725
S/N: MRG1-Up
Part No.: 194-6725
S/N: CG21-Up
Part No.: 194-6725
S/N: PAG1-Up
Part No.: 194-6725
S/N: WF21-Up
Part No.: 194-6725
S/N: S2G1-Up
Part No.: 194-6725
S/N: ED31-Up
Part No.: 194-6725
S/N: MKH1-Up
Part No.: 194-6725
S/N: 9H41-Up
Part No.: 194-6725
S/N: S2H1-Up
Part No.: 194-6725
S/N: 9H61-Up
Part No.: 194-6725
S/N: S2J1-Up
Part No.: 194-6725
S/N: GS61-Up
Part No.: 194-6725
S/N: S2K1-Up
Part No.: 194-6725
S/N: GS71-Up
Part No.: 194-6725
S/N: SRK1-Up
Part No.: 194-6725
S/N: ED81-Up
Part No.: 194-6725
S/N: S2L1-Up
Part No.: 194-6725
S/N: MD81-Up
Part No.: 194-6725
S/N: MXM1-Up
Part No.: 194-6725
S/N: GSA1-Up
Part No.: 194-6725
S/N: S2M1-Up
Part No.: 194-6725
S/N: M8A1-Up
Part No.: 194-6725
S/N: S2N1-Up
Part No.: 194-6725
S/N: S2A1-Up
Part No.: 194-6725
S/N: S2P1-Up
Part No.: 194-6725
S/N: M8B1-Up
Part No.: 194-6725
S/N: MXR1-Up
Part No.: 194-6725
S/N: S2B1-Up
Part No.: 194-6725
S/N: S2R1-Up
Part No.: 194-6725
S/N: S2D1-Up
Part No.: 194-6725
S/N: S2S1-Up
Part No.: 194-6725
S/N: S2E1-Up
Part No.: 194-6725
S/N: S2T1-Up
Part No.: 194-6725
S/N: S2F1-Up
Part No.: 194-6725
S/N: S2W1-Up
Part No.: 194-6725
S/N: B5G1-Up
Part No.: 194-6725
S/N: S2X1-Up
504
Specifications Section
RENR5077-12
Part No.: 194-6725
S/N: S2Y1-Up
Part No.: 194-6725
S/N: S2Z1-Up
g02554200
Illustration 440
Table 308
Specification for the 194-6725 Pressure Sensor Gp, 161-9931 Pressure Sensor Gp, 163-8523 Pressure
Sensor Gp, 299-3222 Pressure Sensor Gp, 161-9926 Pressure Sensor Gp, 239-2396 Pressure Sensor
Gp, 239-3478 Pressure Sensor Gp, and 3E-8652 Pressure Sensor Gp
Item
Qty
Part
1
1
-
Specification Description
Torque to 10 ± 2 N·m (90 ± 18 lb in).
Operating voltage is 5.00 ± 0.25 VDC.
i02030238
Engine Oil Pressure Sensor
SMCS Code: 1924
Part No.: 103-6092, 143-9695, 161-9931
S/N: S2Z1-Up
Torque ........................ 10 ± 2 N·m (90 ± 18 lb in)
Operating temperature ........................ −40 to 125 °C
(−40 to 257 °F)
Maximum input pressure (absolute
pressure) ..................................... 1135 kPa (165 psi)
Input supply voltage ............................. 5 ± 0.25 VDC
Maximum supply current ................................. 20 mA
Install the sensor so that the pressure port is lower
than the wire end. Mount the sensor as close to
vertical as possible.
i04402174
Turbocharger Inlet Pressure
Sensor
Illustration 441
g01046769
Typical example
(1) Sensor assembly
(2) Plug with socket A, socket B, and socket C
(3) Port fitting
SMCS Code: 1052
Part No.: 161-1703
S/N: S2A1-Up
Part No.: 161-1703
S/N: S2B1-Up
Part No.: 161-1703
S/N: S2D1-Up
RENR5077-12
Part No.: 161-1703
S/N: S2E1-Up
Part No.: 161-1703
S/N: S2F1-Up
Part No.: 161-1703
S/N: B5G1-Up
Part No.: 161-1703
S/N: MRG1-Up
Part No.: 161-1703
S/N: PAG1-Up
Part No.: 161-1703
S/N: S2G1-Up
Part No.: 161-1703
S/N: MKH1-Up
Part No.: 161-1703
S/N: S2H1-Up
Part No.: 161-1703
S/N: S2J1-Up
Part No.: 161-1703
S/N: S2K1-Up
Part No.: 161-1703
S/N: S2L1-Up
Part No.: 161-1703
S/N: S2M1-Up
Part No.: 161-1703
S/N: S2N1-Up
Part No.: 161-1703
S/N: S2P1-Up
Part No.: 161-1703
S/N: S2R1-Up
Part No.: 161-1703
S/N: S2S1-Up
Part No.: 161-1703
S/N: S2T1-Up
Part No.: 161-1703
S/N: S2W1-Up
Part No.: 161-1703
S/N: S2X1-Up
Part No.: 161-1703
S/N: S2Y1-Up
Part No.: 161-1703
S/N: S2Z1-Up
505
Specifications Section
506
Specifications Section
RENR5077-12
g02587218
Illustration 442
Table 309
Specification for 161-1703 Turbocharger Inlet Pressure Sensor Gp
Item
Qty
Part
1
-
-
Specification Description
Final installation torque for sensor group is 10 ± 2 N·m (89 ± 18 lb in).
Operating voltage is 5.00 ± 0.25 VDC.
i04753391
Turbocharger Outlet Pressure
Sensor
SMCS Code: 1052; 1917; 1919
Part No.: 194-6724
S/N: CG21-Up
Part No.: 194-6724
S/N: WF21-Up
Part No.: 194-6724
S/N: 9F31-Up
Part No.: 194-6724
S/N: 9H31-Up
Part No.: 194-6724
S/N: 9H41-Up
Part No.: 194-6724
S/N: 9H51-Up
Part No.: 194-6724
S/N: ED51-Up
Part No.: 194-6724
S/N: 9H61-Up
Part No.: 194-6724
S/N: GS61-Up
Part No.: 194-6724
S/N: GS71-Up
Part No.: 194-6724
S/N: ED81-Up
Part No.: 194-6724
S/N: MD81-Up
Part No.: 194-6724
S/N: GSA1-Up
Part No.: 194-6724
S/N: EDC1-Up
Part No.: 194-6724
S/N: EDG1-Up
Part No.: 194-6724
S/N: EDH1-Up
Part No.: 194-6724
S/N: EDJ1-Up
Part No.: 194-6724
S/N: MXM1-Up
Part No.: 194-6724
S/N: EDP1-Up
Part No.: 194-6724
S/N: MXR1-Up
RENR5077-12
507
Specifications Section
g02848860
Illustration 443
Table 310
Specification for 161-9926 Pressure Sensor Gp, 163-8522 Pressure Sensor Gp,194-6725 Pressure Sensor Gp,
194-6722 Pressure Sensor Gp, 194-6723 Pressure Sensor Gp, and 194-6724 Pressure Sensor Gp
Item
Qty
Part
1
-
-
Specification Description
Torque to 10 ± 2 N·m (89 ± 18 lb in).
Operating voltage is 5.00 ± 0.25 VDC.
i04402175
Turbocharger Outlet Pressure
Sensor
SMCS Code: 1052; 1917; 1919
Part No.: 194-6724
S/N: M8A1-Up
Part No.: 194-6724
S/N: S2A1-Up
Part No.: 194-6724
S/N: M8B1-Up
Part No.: 194-6724
S/N: S2B1-Up
Part No.: 194-6724
S/N: S2D1-Up
Part No.: 194-6724
S/N: S2E1-Up
Part No.: 194-6724
S/N: S2F1-Up
Part No.: 194-6724
S/N: B5G1-Up
Part No.: 194-6724
S/N: MRG1-Up
Part No.: 194-6724
S/N: PAG1-Up
Part No.: 194-6724
S/N: S2G1-Up
Part No.: 194-6724
S/N: MKH1-Up
Part No.: 194-6724
S/N: S2H1-Up
Part No.: 194-6724
S/N: S2J1-Up
Part No.: 194-6724
S/N: S2K1-Up
Part No.: 194-6724
S/N: S2L1-Up
Part No.: 194-6724
S/N: S2M1-Up
Part No.: 194-6724
S/N: S2N1-Up
Part No.: 194-6724
S/N: S2P1-Up
Part No.: 194-6724
S/N: S2R1-Up
Part No.: 194-6724
S/N: S2S1-Up
Part No.: 194-6724
S/N: S2T1-Up
Part No.: 194-6724
S/N: S2W1-Up
Part No.: 194-6724
S/N: S2X1-Up
508
Specifications Section
RENR5077-12
Part No.: 194-6724
S/N: S2Y1-Up
Part No.: 194-6724
S/N: S2Z1-Up
g02587237
Illustration 444
Table 311
Specification for 194-6724 Turbocharger Outlet Pressure Sensor Gp
Item
Qty
Part
Specification Description
1
1
194-6724 Turbocharger Outlet
Pressure Sensor Gp
-
i04402177
Turbocharger Outlet Pressure
Sensor
SMCS Code: 1052; 1917; 1919
Part No.: 161-1704
S/N: S2A1-Up
Part No.: 161-1704
S/N: S2B1-Up
Part No.: 161-1704
S/N: S2D1-Up
Part No.: 161-1704
S/N: S2E1-Up
Part No.: 161-1704
S/N: S2F1-Up
Part No.: 161-1704
S/N: B5G1-Up
Part No.: 161-1704
S/N: MRG1-Up
Part No.: 161-1704
S/N: PAG1-Up
Part No.: 161-1704
S/N: S2G1-Up
Torque to 10 ± 2 N·m (89 ± 18 lb in).
Operating voltage is 5.00 ± 0.25 VDC.
Part No.: 161-1704
S/N: MKH1-Up
Part No.: 161-1704
S/N: S2H1-Up
Part No.: 161-1704
S/N: S2J1-Up
Part No.: 161-1704
S/N: S2K1-Up
Part No.: 161-1704
S/N: S2L1-Up
Part No.: 161-1704
S/N: S2M1-Up
Part No.: 161-1704
S/N: S2N1-Up
Part No.: 161-1704
S/N: S2P1-Up
Part No.: 161-1704
S/N: S2R1-Up
Part No.: 161-1704
S/N: S2S1-Up
Part No.: 161-1704
S/N: S2T1-Up
Part No.: 161-1704
S/N: S2W1-Up
RENR5077-12
509
Specifications Section
Part No.: 161-1704
S/N: S2X1-Up
Part No.: 161-1704
S/N: S2Y1-Up
Part No.: 161-1704
S/N: S2Z1-Up
g02587256
Illustration 445
Table 312
Specification for 161-1704 Turbocharger Outlet Pressure Sensor Gp
Item
Qty
part
1
1
161-1704 Turbocharger Outlet
Pressure Sensor Gp
i04753209
Aftercooler Coolant
Temperature Sensor
SMCS Code: 1063; 1395
Part No.: 102-7532
S/N: CG21-Up
Part No.: 102-7532
S/N: 9F31-Up
Part No.: 102-7532
S/N: 9H31-Up
Part No.: 102-7532
S/N: ED31-Up
Part No.: 102-7532
S/N: 9H41-Up
Part No.: 102-7532
S/N: 9H51-Up
Part No.: 102-7532
S/N: 9H61-Up
Part No.: 102-7532
S/N: GS61-Up
Specification Description
Torque to 10 ± 2 N·m (89 ± 18 lb in).
Operating voltage is 5.00 ± 0.25 VDC.
Part No.: 102-7532
S/N: GS71-Up
Part No.: 102-7532
S/N: ED81-Up
Part No.: 102-7532
S/N: MD81-Up
Part No.: 102-7532
S/N: GSA1-Up
Part No.: 102-7532
S/N: M8A1-Up
Part No.: 102-7532
S/N: S2A1-Up
Part No.: 102-7532
S/N: M8B1-Up
Part No.: 102-7532
S/N: S2B1-Up
Part No.: 102-7532
S/N: EDC1-Up
Part No.: 102-7532
S/N: S2D1-Up
Part No.: 102-7532
S/N: S2E1-Up
510
Specifications Section
RENR5077-12
Part No.: 102-7532
S/N: S2F1-Up
Part No.: 102-7532
S/N: S2X1-Up
Part No.: 102-7532
S/N: B5G1-Up
Part No.: 102-7532
S/N: S2Y1-Up
Part No.: 102-7532
S/N: EDG1-Up
Part No.: 102-7532
S/N: S2Z1-Up
Part No.: 102-7532
S/N: MRG1-Up
Part No.: 102-7532
S/N: PAG1-Up
Part No.: 102-7532
S/N: S2G1-Up
Part No.: 102-7532
S/N: EDH1-Up
Part No.: 102-7532
S/N: MKH1-Up
Part No.: 102-7532
S/N: S2H1-Up
Part No.: 102-7532
S/N: EDJ1-Up
Part No.: 102-7532
S/N: S2J1-Up
Part No.: 102-7532
S/N: S2K1-Up
Part No.: 102-7532
S/N: S2L1-Up
Part No.: 102-7532
S/N: MXM1-Up
Part No.: 102-7532
S/N: S2M1-Up
Part No.: 102-7532
S/N: S2N1-Up
Part No.: 102-7532
S/N: EDP1-Up
Part No.: 102-7532
S/N: S2P1-Up
Part No.: 102-7532
S/N: MXR1-Up
Part No.: 102-7532
S/N: S2R1-Up
Part No.: 102-7532
S/N: S2S1-Up
Part No.: 102-7532
S/N: S2T1-Up
Part No.: 102-7532
S/N: S2W1-Up
RENR5077-12
511
Specifications Section
g02848824
Illustration 446
Table 313
Specification for 102-7532 Temperature Sensor Gp, and 128-4347 Temperature Sensor Gp
Item
Qty
Part
1
-
-
Specification Description
Torque to 20 ± 3 N·m (177 ± 27 lb in).
Operating voltage is 4.75 to 8.50 VDC.
i02987360
Engine Coolant Temperature
Sensor
SMCS Code: 1395
Part No.: 102-7532
S/N: CG21-Up
Part No.: 102-7532
S/N: 9F31-Up
Part No.: 102-7532
S/N: 9H31-Up
Part No.: 102-7532
S/N: ED31-Up
Part No.: 102-7532
S/N: 9H41-Up
Part No.: 102-7532
S/N: 9H51-Up
Part No.: 102-7532
S/N: 9H61-Up
Part No.: 102-7532
S/N: GS61-Up
Part No.: 102-7532
S/N: GS71-Up
Part No.: 102-7532
S/N: ED81-Up
Part No.: 102-7532
S/N: MD81-Up
Part No.: 102-7532
S/N: GSA1-Up
Part No.: 102-7532
S/N: M8A1-Up
Part No.: 102-7532
S/N: S2A1-Up
Part No.: 102-7532
S/N: M8B1-Up
Part No.: 102-7532
S/N: S2B1-Up
Part No.: 102-7532
S/N: EDC1-Up
Part No.: 102-7532
S/N: S2D1-Up
Part No.: 102-7532
S/N: S2E1-Up
Part No.: 102-7532
S/N: S2F1-Up
Part No.: 102-7532
S/N: B5G1-Up
Part No.: 102-7532
S/N: EDG1-Up
Part No.: 102-7532
S/N: MRG1-Up
Part No.: 102-7532
S/N: PAG1-Up
Part No.: 102-7532
S/N: S2G1-Up
512
Specifications Section
RENR5077-12
Part No.: 102-7532
S/N: EDH1-Up
Part No.: 102-7532
S/N: MKH1-Up
Part No.: 102-7532
S/N: S2H1-Up
Part No.: 102-7532
S/N: EDJ1-Up
Part No.: 102-7532
S/N: S2J1-Up
Part No.: 102-7532
S/N: S2K1-Up
Illustration 447
Part No.: 102-7532
S/N: S2L1-Up
(1) Final installation torque for the temperature
sensor group .................. 20 ± 3 N·m (15 ± 2 lb ft)
Part No.: 102-7532
S/N: MXM1-Up
g01513773
Operating temperature ........................ −40 to 120 °C
(−40 to 248 °F)
Part No.: 102-7532
S/N: S2M1-Up
Operating voltage .......................... 4.75 to 8.50 VDC
Part No.: 102-7532
S/N: S2N1-Up
i04753129
Part No.: 102-7532
S/N: EDP1-Up
Turbocharger Exhaust
Temperature Sensor
Part No.: 102-7532
S/N: S2P1-Up
SMCS Code: 1052; 1919
Part No.: 102-7532
S/N: MXR1-Up
Part No.: 164-2441
S/N: CG21-Up
Part No.: 102-7532
S/N: S2R1-Up
Part No.: 164-2441
S/N: 9F31-Up
Part No.: 102-7532
S/N: S2S1-Up
Part No.: 164-2441
S/N: 9H31-Up
Part No.: 102-7532
S/N: S2T1-Up
Part No.: 164-2441
S/N: ED31-Up
Part No.: 102-7532
S/N: S2W1-Up
Part No.: 164-2441
S/N: 9H41-Up
Part No.: 102-7532
S/N: S2X1-Up
Part No.: 164-2441
S/N: 9H51-Up
Part No.: 102-7532
S/N: S2Y1-Up
Part No.: 164-2441
S/N: 9H61-Up
Part No.: 102-7532
S/N: S2Z1-Up
Part No.: 164-2441
S/N: GS61-Up
Part No.: 164-2441
S/N: GS71-Up
Part No.: 164-2441
S/N: ED81-Up
Part No.: 164-2441
S/N: MD81-Up
RENR5077-12
513
Specifications Section
Part No.: 164-2441
S/N: GSA1-Up
Part No.: 164-2441
S/N: S2N1-Up
Part No.: 164-2441
S/N: M8A1-Up
Part No.: 164-2441
S/N: EDP1-Up
Part No.: 164-2441
S/N: S2A1-Up
Part No.: 164-2441
S/N: S2P1-Up
Part No.: 164-2441
S/N: M8B1-Up
Part No.: 164-2441
S/N: MXR1-Up
Part No.: 164-2441
S/N: S2B1-Up
Part No.: 164-2441
S/N: S2R1-Up
Part No.: 164-2441
S/N: EDC1-Up
Part No.: 164-2441
S/N: S2S1-Up
Part No.: 164-2441
S/N: S2D1-Up
Part No.: 164-2441
S/N: S2T1-Up
Part No.: 164-2441
S/N: S2E1-Up
Part No.: 164-2441
S/N: S2W1-Up
Part No.: 164-2441
S/N: S2F1-Up
Part No.: 164-2441
S/N: S2X1-Up
Part No.: 164-2441
S/N: B5G1-Up
Part No.: 164-2441
S/N: S2Y1-Up
Part No.: 164-2441
S/N: EDG1-Up
Part No.: 164-2441
S/N: S2Z1-Up
Part No.: 164-2441
S/N: MRG1-Up
Part No.: 164-2441
S/N: PAG1-Up
Part No.: 164-2441
S/N: S2G1-Up
Part No.: 164-2441
S/N: EDH1-Up
Part No.: 164-2441
S/N: MKH1-Up
Part No.: 164-2441
S/N: S2H1-Up
Part No.: 164-2441
S/N: EDJ1-Up
Part No.: 164-2441
S/N: S2J1-Up
Part No.: 164-2441
S/N: S2K1-Up
Part No.: 164-2441
S/N: S2L1-Up
Part No.: 164-2441
S/N: MXM1-Up
Part No.: 164-2441
S/N: S2M1-Up
514
Specifications Section
RENR5077-12
g02848799
Illustration 448
Table 314
Specification for 163-7882 Exhaust Temperature Sensor Gp, 261-6848 Exhaust Temperature Sensor Gp,
164-2441 Exhaust Temperature Sensor Gp, and 109-4367 Exhaust Temperature Sensor Gp
Item
Part
Qty
Specification Description
Apply 4C-5599 Anti-Seize Compound to the threads before installation.
Torque to 45 ± 5 N·m (33 ± 4 lb ft).
1
1
261-6847 Adapter
Operating voltage is 7.5 to 8.5 VDC.
Output type is PWM.
Output frequency is 500 ± 100 Hz.
i04402220
Engine Speed/Timing Sensor
Part No.: 265-9034
S/N: MD81-Up
SMCS Code: 1905; 1907
Part No.: 265-9034
S/N: GSA1-Up
Part No.: 265-9034
S/N: CG21-Up
Part No.: 265-9034
S/N: M8A1-Up
Part No.: 265-9034
S/N: 9F31-Up
Part No.: 265-9034
S/N: M8B1-Up
Part No.: 265-9034
S/N: 9H31-Up
Part No.: 265-9034
S/N: EDC1-Up
Part No.: 265-9034
S/N: ED31-Up
Part No.: 265-9034
S/N: EDG1-Up
Part No.: 265-9034
S/N: 9H41-Up
Part No.: 265-9034
S/N: EDH1-Up
Part No.: 265-9034
S/N: 9H51-Up
Part No.: 265-9034
S/N: EDJ1-Up
Part No.: 265-9034
S/N: 9H61-Up
Part No.: 265-9034
S/N: MXM1-Up
Part No.: 265-9034
S/N: GS61-Up
Part No.: 265-9034
S/N: EDP1-Up
Part No.: 265-9034
S/N: GS71-Up
Part No.: 265-9034
S/N: MXR1-Up
Part No.: 265-9034
S/N: ED81-Up
RENR5077-12
515
Specifications Section
g02587556
Illustration 449
Table 315
Specification for the 265-9034 Engine Speed / Timing Sensor Gp
Item
Qty
Part
Specification Description
Torque to 40 ± 5 N·m (30 ± 4 lb ft).
1
-
-
Operating voltage is 7.5 to 14.0 VDC.
Output frequency is 9 to 10000 Hz.
i04887243
Engine Speed/Timing Sensor
Part No.: 102-9029
S/N: S2J1-Up
SMCS Code: 1905; 1907
Part No.: 102-9029
S/N: S2K1-Up
Part No.: 102-9029
S/N: S2A1-Up
Part No.: 102-9029
S/N: S2L1-Up
Part No.: 102-9029
S/N: S2B1-Up
Part No.: 102-9029
S/N: S2M1-Up
Part No.: 102-9029
S/N: S2D1-Up
Part No.: 102-9029
S/N: S2N1-Up
Part No.: 102-9029
S/N: S2E1-Up
Part No.: 102-9029
S/N: S2P1-Up
Part No.: 102-9029
S/N: S2F1-Up
Part No.: 102-9029
S/N: S2R1-Up
Part No.: 102-9029
S/N: B5G1-Up
Part No.: 102-9029
S/N: S2S1-Up
Part No.: 102-9029
S/N: MRG1-Up
Part No.: 102-9029
S/N: S2T1-Up
Part No.: 102-9029
S/N: PAG1-Up
Part No.: 102-9029
S/N: S2W1-Up
Part No.: 102-9029
S/N: S2G1-Up
Part No.: 102-9029
S/N: S2X1-Up
Part No.: 102-9029
S/N: MKH1-Up
Part No.: 102-9029
S/N: S2Y1-Up
Part No.: 102-9029
S/N: S2H1-Up
Part No.: 102-9029
S/N: S2Z1-Up
516
Specifications Section
RENR5077-12
g03010697
Illustration 450
Table 316
Specification for 102-9029 Speed Sensor Gp
Item
Qty
Part
Specification Description
1
-
-
Before installation, coat the sensor assembly threads with Loctite C5A
copper anti-seize.
Final Installation torque for the speed sensor group is 40 ± 5 N·m
(30 ± 4 lb ft).
-
-
-
Operating voltage is 12 to 14 VDC.
i04402215
Engine Speed/Timing Sensor
Part No.: 273-5041
S/N: S2H1-Up
SMCS Code: 1905; 1907
Part No.: 273-5041
S/N: S2J1-Up
Part No.: 273-5041
S/N: WF21-Up
Part No.: 273-5041
S/N: S2K1-Up
Part No.: 273-5041
S/N: ED31-Up
Part No.: 273-5041
S/N: SRK1-Up
Part No.: 273-5041
S/N: S2A1-Up
Part No.: 273-5041
S/N: S2L1-Up
Part No.: 273-5041
S/N: S2B1-Up
Part No.: 273-5041
S/N: S2N1-Up
Part No.: 273-5041
S/N: S2D1-Up
Part No.: 273-5041
S/N: S2P1-Up
Part No.: 273-5041
S/N: S2E1-Up
Part No.: 273-5041
S/N: S2R1-Up
Part No.: 273-5041
S/N: B5G1-Up
Part No.: 273-5041
S/N: S2S1-Up
Part No.: 273-5041
S/N: MRG1-Up
Part No.: 273-5041
S/N: S2T1-Up
Part No.: 273-5041
S/N: PAG1-Up
Part No.: 273-5041
S/N: S2W1-Up
Part No.: 273-5041
S/N: S2G1-Up
Part No.: 273-5041
S/N: S2X1-Up
Part No.: 273-5041
S/N: MKH1-Up
Part No.: 273-5041
S/N: S2Z1-Up
RENR5077-12
517
Specifications Section
g02587517
Illustration 451
Table 317
Specification for the 273-5041 Engine Speed / Timing Sensor Gp
Item
Qty
Part
1
-
-
Specification Description
Torque to 40 ± 5 N·m (30 ± 4 lb ft).
Operating voltage is 7.5 to 14 VDC.
Output frequency is 9 Hz to 10 kHz.
i04403710
Engine Speed/Timing Sensor
Part No.: 129-6628
S/N: S2K1-Up
SMCS Code: 1905; 1907
Part No.: 129-6628
S/N: S2L1-Up
Part No.: 129-6628
S/N: S2A1-Up
Part No.: 129-6628
S/N: S2N1-Up
Part No.: 129-6628
S/N: S2B1-Up
Part No.: 129-6628
S/N: S2P1-Up
Part No.: 129-6628
S/N: S2D1-Up
Part No.: 129-6628
S/N: S2R1-Up
Part No.: 129-6628
S/N: S2E1-Up
Part No.: 129-6628
S/N: S2S1-Up
Part No.: 129-6628
S/N: B5G1-Up
Part No.: 129-6628
S/N: S2T1-Up
Part No.: 129-6628
S/N: MRG1-Up
Part No.: 129-6628
S/N: S2W1-Up
Part No.: 129-6628
S/N: PAG1-Up
Part No.: 129-6628
S/N: S2X1-Up
Part No.: 129-6628
S/N: S2G1-Up
Part No.: 129-6628
S/N: S2Z1-Up
Part No.: 129-6628
S/N: MKH1-Up
Part No.: 129-6628
S/N: S2H1-Up
Part No.: 129-6628
S/N: S2J1-Up
518
Specifications Section
RENR5077-12
g02591856
Illustration 452
Table 318
Specification for 129-6628 Speed Sensor Gp
Item
1
Qty
Part
1
129-6628 Speed
Sensor Gp
Specification Description
Torque to 45 ± 5 N·m (33 ± 4 lb ft).
Before assembly, apply 4C-5599 Anti-Seize Compound on the
threads of speed sensor group.
Operating voltage is 12 to 14 V.
i02788159
Engine Speed/Timing Sensor
Part No.: 127-1008
S/N: S2H1-Up
SMCS Code: 1905; 1907
Part No.: 127-1008
S/N: S2J1-Up
Part No.: 127-1008
S/N: S2A1-Up
Part No.: 127-1008
S/N: S2K1-Up
Part No.: 127-1008
S/N: S2B1-Up
Part No.: 127-1008
S/N: S2L1-Up
Part No.: 127-1008
S/N: S2D1-Up
Part No.: 127-1008
S/N: S2N1-Up
Part No.: 127-1008
S/N: S2E1-Up
Part No.: 127-1008
S/N: S2P1-Up
Part No.: 127-1008
S/N: B5G1-Up
Part No.: 127-1008
S/N: S2R1-Up
Part No.: 127-1008
S/N: MRG1-Up
Part No.: 127-1008
S/N: S2S1-Up
Part No.: 127-1008
S/N: PAG1-Up
Part No.: 127-1008
S/N: S2T1-Up
Part No.: 127-1008
S/N: S2G1-Up
Part No.: 127-1008
S/N: S2W1-Up
Part No.: 127-1008
S/N: MKH1-Up
Part No.: 127-1008
S/N: S2X1-Up
RENR5077-12
519
Specifications Section
Part No.: 163-8492
S/N: MKH1-Up
Part No.: 129-6628
S/N: S2Z1-Up
Part No.: 161-9926
S/N: SRK1-Up
Part No.: 163-8492
S/N: S2S1-Up
Part No.: 163-8492
S/N: S2T1-Up
Part No.: 163-8492
S/N: S2W1-Up
Part No.: 163-8492
S/N: S2X1-Up
Illustration 453
g01046790
Typical example
Part No.: 143-9696, 161-9926, 163-8492
S/N: S2Z1-Up
(1) Sensor slip head
1. Extend the sensor slip head to a minimum
distance of 4 mm (.16 inch) prior to installation.
(2) Control assembly
Put 4C-5599 Anti-Seize Compound on the
threads.
Torque ............................ 40 ± 5 N·m (30 ± 4 lb ft)
Operating temperature ............ −40 °C to 121 °C
(−40 °F to 250 °F)
Input supply voltage ....................... 12 to 14 VDC
(3) Plug with socket A, socket B, and socket C.
i04753089
Crankcase Pressure Sensor
SMCS Code: 1916
Part No.: 161-9926
S/N: WF21-Up
Part No.: 161-9926
S/N: ED31-Up
Part No.: 161-9926, 163-8492
S/N: S2D1-Up
Part No.: 161-9926, 163-8492
S/N: S2E1-Up
Part No.: 161-9926, 163-8492
S/N: S2F1-Up
Part No.: 163-8492
S/N: B5G1-Up
Part No.: 163-8492
S/N: MRG1-Up
Part No.: 163-8492
S/N: PAG1-Up
Part No.: 163-8492
S/N: S2Y1-Up
520
Specifications Section
RENR5077-12
g02848797
Illustration 454
Table 319
Specification for 161-9926 Pressure Sensor Gp, 143-9696 Pressure Sensor Gp, and 163-8492 Pressure Sensor Gp
Item
Qty
Part
Specification Description
Note: Install the pressure sensor group so that the pressure port is lower than the wire end. Mount the pressure sensor
group as close to vertical as possible.
1
-
-
Torque to 10 ± 2 N·m (89 ± 18 lb in).
Operating voltage is 5.00 ± 0.25 VDC.
i04385589
Atmospheric Pressure Sensor
Part No.: 194-6722
S/N: GSA1-Up
SMCS Code: 1923
Part No.: 194-6722
S/N: M8A1-Up
Part No.: 194-6722
S/N: CG21-Up
Part No.: 194-6722
S/N: M8B1-Up
Part No.: 194-6722
S/N: 9F31-Up
Part No.: 194-6722
S/N: EDC1-Up
Part No.: 194-6722
S/N: 9H31-Up
Part No.: 194-6722
S/N: EDG1-Up
Part No.: 194-6722
S/N: ED31-Up
Part No.: 194-6722
S/N: EDH1-Up
Part No.: 194-6722
S/N: 9H41-Up
Part No.: 194-6722
S/N: EDJ1-Up
Part No.: 194-6722
S/N: 9H51-Up
Part No.: 194-6722
S/N: MXM1-Up
Part No.: 194-6722
S/N: 9H61-Up
Part No.: 194-6722
S/N: EDP1-Up
Part No.: 194-6722
S/N: GS61-Up
Part No.: 194-6722
S/N: MXR1-Up
Part No.: 194-6722
S/N: GS71-Up
Part No.: 194-6722
S/N: ED81-Up
Part No.: 194-6722
S/N: MD81-Up
RENR5077-12
521
Specifications Section
g02554277
Illustration 455
Table 320
Specification for the 194-6722 Pressure Sensor Gp, 194-6724 Pressure Sensor Gp, 194-6725 Pressure
Sensor Gp,163-8530 Pressure Sensor Gp, and 239-3478 Pressure Sensor Gp
Item
Qty
Part
1
1
-
Specification Description
Torque to 10 ± 2 N·m (90 ± 18 lb in).
Operating voltage is 5.00 ± 0.25 VDC.
i04402249
Atmospheric Pressure Sensor
Part No.: 161-1703
S/N: S2J1-Up
SMCS Code: 1923
Part No.: 161-1703
S/N: S2K1-Up
Part No.: 161-1703
S/N: S2A1-Up
Part No.: 161-1703
S/N: S2L1-Up
Part No.: 161-1703
S/N: S2B1-Up
Part No.: 161-1703
S/N: S2M1-Up
Part No.: 161-1703
S/N: S2D1-Up
Part No.: 161-1703
S/N: S2N1-Up
Part No.: 161-1703
S/N: S2E1-Up
Part No.: 161-1703
S/N: S2P1-Up
Part No.: 161-1703
S/N: S2F1-Up
Part No.: 161-1703
S/N: S2R1-Up
Part No.: 161-1703
S/N: B5G1-Up
Part No.: 161-1703
S/N: S2S1-Up
Part No.: 161-1703
S/N: MRG1-Up
Part No.: 161-1703
S/N: S2T1-Up
Part No.: 161-1703
S/N: PAG1-Up
Part No.: 161-1703
S/N: S2W1-Up
Part No.: 161-1703
S/N: S2G1-Up
Part No.: 161-1703
S/N: S2X1-Up
Part No.: 161-1703
S/N: MKH1-Up
Part No.: 161-1703
S/N: S2Y1-Up
Part No.: 161-1703
S/N: S2H1-Up
Part No.: 161-1703
S/N: S2Z1-Up
522
Specifications Section
RENR5077-12
g02587218
Illustration 456
Table 321
Specification for the 161-1703 Atmospheric Pressure Sensor Gp
Item
Qty
Part
1
-
-
Specification Description
Torque to 10 ± 2 N·m (90 ± 18 lb in).
Operating voltage is 5.00 ± 0.25 VDC.
i04753029
Atmospheric Pressure Sensor
SMCS Code: 1923
Part No.: 161-9926
S/N: S2D1-Up
Part No.: 161-9926
S/N: S2E1-Up
Part No.: 161-9926
S/N: S2F1-Up
Part No.: 161-9926
S/N: S2Z1-Up
Illustration 457
g02848781
RENR5077-12
523
Specifications Section
Table 322
Specification for 161-9926 Pressure Sensor Gp
Item
Qty
Part
Specification Description
Note: Install the pressure sensor group so that the pressure port is lower than the wire end. Mount the pressure sensor
group as close to vertical as possible.
1
-
-
Torque to 10 ± 2 N·m (89 ± 18 lb in).
Operating voltage is 5.00 ± 0.25 VDC.
i04402287
Engine Speed Sensor
Part No.: 9X-5392
S/N: EDJ1-Up
SMCS Code: 1907
Part No.: 9X-5392
S/N: MXM1-Up
Part No.: 9X-5392
S/N: CG21-Up
Part No.: 9X-5392
S/N: EDP1-Up
Part No.: 9X-5392
S/N: 9F31-Up
Part No.: 9X-5392
S/N: MXR1-Up
Part No.: 9X-5392
S/N: 9H31-Up
Part No.: 9X-5392
S/N: ED31-Up
Part No.: 9X-5392
S/N: 9H41-Up
Part No.: 9X-5392
S/N: 9H51-Up
Part No.: 9X-5392
S/N: 9H61-Up
Part No.: 9X-5392
S/N: GS61-Up
Part No.: 9X-5392
S/N: GS71-Up
Part No.: 9X-5392
S/N: ED81-Up
Part No.: 9X-5392
S/N: MD81-Up
Part No.: 9X-5392
S/N: GSA1-Up
Part No.: 9X-5392
S/N: M8A1-Up
Part No.: 9X-5392
S/N: M8B1-Up
Part No.: 9X-5392
S/N: EDC1-Up
Part No.: 9X-5392
S/N: EDG1-Up
Part No.: 9X-5392
S/N: EDH1-Up
524
Specifications Section
RENR5077-12
g02587757
Illustration 458
Table 323
Specification for 9X-5392 Engine Speed Sensor Gp
Item
Qty
Part
1
-
-
Specification Description
Final installation torque for the locknut is 25 ± 5 N·m (221 ± 44 lb in).
Clearance between the speed sensor group and the flywheel ring gear is 0.50 to 0.75 mm
(0.020 to 0.030 inch).
i04402277
Engine Speed Sensor
Part No.: 189-5746
S/N: 9H61-Up
SMCS Code: 1907
Part No.: 189-5746
S/N: GS71-Up
Part No.: 189-5746
S/N: 9F21-Up
Part No.: 189-5746
S/N: ED81-Up
Part No.: 189-5746
S/N: CG21-Up
Part No.: 189-5746
S/N: MD81-Up
Part No.: 189-5746
S/N: ED21-Up
Part No.: 189-5746
S/N: S2A1-Up
Part No.: 189-5746
S/N: WF21-Up
Part No.: 189-5746
S/N: S2B1-Up
Part No.: 189-5746
S/N: 9F31-Up
Part No.: 189-5746
S/N: EDC1-Up
Part No.: 189-5746
S/N: 9H31-Up
Part No.: 189-5746
S/N: S2D1-Up
Part No.: 189-5746
S/N: ED31-Up
Part No.: 189-5746
S/N: S2E1-Up
Part No.: 189-5746
S/N: 9H41-Up
Part No.: 189-5746
S/N: B5G1-Up
Part No.: 189-5746
S/N: JB41-Up
Part No.: 189-5746
S/N: EDG1-Up
Part No.: 189-5746
S/N: 9H51-Up
Part No.: 189-5746
S/N: MRG1-Up
Part No.: 189-5746
S/N: ED51-Up
Part No.: 189-5746
S/N: PAG1-Up
RENR5077-12
Part No.: 189-5746
S/N: S2G1-Up
Part No.: 189-5746
S/N: EDH1-Up
Part No.: 189-5746
S/N: MKH1-Up
Part No.: 189-5746
S/N: S2H1-Up
Part No.: 189-5746
S/N: SRH1-Up
Part No.: 189-5746
S/N: EDJ1-Up
Part No.: 189-5746
S/N: S2J1-Up
Part No.: 189-5746
S/N: S2K1-Up
Part No.: 189-5746
S/N: SRK1-Up
Part No.: 189-5746
S/N: S2L1-Up
Part No.: 189-5746
S/N: MXM1-Up
Part No.: 189-5746
S/N: S2N1-Up
Part No.: 189-5746
S/N: EDP1-Up
Part No.: 189-5746
S/N: S2P1-Up
Part No.: 189-5746
S/N: MXR1-Up
Part No.: 189-5746
S/N: S2R1-Up
Part No.: 189-5746
S/N: S2S1-Up
Part No.: 189-5746
S/N: S2T1-Up
Part No.: 189-5746
S/N: S2W1-Up
Part No.: 189-5746
S/N: S2X1-Up
Part No.: 189-5746
S/N: S2Z1-Up
Part No.: 189-5746
S/N: SRZ1-Up
525
Specifications Section
526
Specifications Section
RENR5077-12
g02587736
Illustration 459
Table 324
Specification for the 189-5746 Engine Speed Sensor Gp and 116-6680 Engine Speed Sensor
Item
Qty
Part
1
-
-
Specification Description
Torque to 25 ± 5 N·m (18 ± 4 lb ft).
Resistance at 25 °C (77 °F) is 142 Ω.
RENR5077-12
527
Index Section
Index
A
E
Accessory Drive................................... 382, 384, 386
Accessory Drive (Lower Left Hand)............. 388, 391
Accessory Drive (Upper Left
Hand) ......................................... 403–404, 406, 408
Accessory Drive (Upper Left Hand, Reverse
Rotation) ............................................................ 410
Accessory Drive (Upper Right
Hand) ................................. 393, 395, 398–399, 401
Accumulator......................................................... 108
Aftercooler Coolant Temperature Sensor ............ 510
Air Cleaner................................................... 135–136
Air Cleaner Adapter ..................................... 138–140
Air Inlet and Exhaust
Lines .. 145–146, 149, 151, 153, 155, 157, 159, 161
Air Shutoff............ 163, 165, 167, 169, 171, 173, 175
Air Shutoff Group ..................................... 172, 176
Air Starting Motor................................. 484, 487–489
Air Starting Motor Pressure Regulating Valve ..... 491
Alternator and Regulator ............................. 467, 469
Alternator Mounting ............................. 471, 473, 475
197-9087 Belt Tension Chart ......... 472, 474, 476
Atmospheric Pressure Sensor..................... 520–522
Auxiliary Drive Pulley........................... 454–457, 459
Auxiliary Drive Shaft .................................... 461–462
Auxiliary Water Pump .................................. 285, 287
Electric Starting Motor ................. 477–478, 480, 482
Engine Air Cleaner Service Indicator... 141, 143–144
Engine Coolant Temperature Sensor .................. 512
Engine Design ................................................... 6–10
Engine Harness (Rigid Wiring Harness).............. 493
Engine Mount (Front)........................................... 428
Engine Mount (Front) (Hydraulic Pump Drive or PTO
Clutch) ............................................................... 427
Engine Oil Cooler Bypass and Cooling Jet Sequence
Valves ........................................................ 204–205
Engine Oil Filter .................... 207, 209, 211, 213–214
Engine Oil Filter (Duplex) .................................... 215
Engine Oil Filter Base.......................................... 229
Engine Oil Lines .................. 217, 219, 221–222, 224
Engine Oil Lines (Front Mounted Engine Oil
Filter).................................................................. 218
Engine Oil Pan............................................ 239–240,
242, 244, 246, 249–250, 253–254, 256
Engine Oil Pressure Sensor ................................ 504
Engine Oil Pump.................. 178, 181, 186, 191, 195
Engine Oil Scavenge Pump......................... 199, 201
Engine Oil Sump Pump ............................... 270–274
Engine Speed Sensor.................................. 523, 525
Engine Speed/Timing Sensor .............. 514–517, 519
Engine Trunnion .......................................... 429–430
Exhaust Bypass Valve ................................. 108–109
Exhaust Flange.................................... 128–132, 134
Exhaust Manifold ......................................... 110–112,
114–116,
118–119,
121–127
B
Balancer Group (Front)................................ 380–381
Belt Tension Chart ....................................... 463, 465
C
Camshaft ... 38, 40–41, 43, 45, 47, 49–50, 52, 54, 56
Connecting Rod................................... 333, 336, 339
Connecting Rod and Main Bearing Journals ....... 342
Coolant Level Sensor .......................................... 502
Coolant Level Switch ........................................... 496
Coolant Temperature Switch ............................... 497
Cooling System Pressure Cap ............................ 289
Crankcase Breather............................. 231–236, 238
Crankcase Pressure Sensor................................ 519
Crankshaft .......................... 343–346, 348, 350–352
Crankshaft Wear Sleeves and Seals................... 354
Cylinder Block....... 291, 296, 301, 304, 308, 311, 316
Camshaft Bearing Position ...................... 295, 300
Cylinder Head...................................... 64, 68, 71, 73
Bolt Tightening Procedure ................................. 65
Cylinder Head Valves .................... 76, 78, 80, 82, 85
Cylinder Liner ...................................................... 317
D
Duplex Engine Oil Filters ............................. 225, 227
F
Flexible Coupling ................................................. 425
Flywheel ....................................................... 411–413
Flywheel Housing ........ 415–416, 418, 420, 422–423
Fuel Filter................................................... 14–15, 17
Fuel Filter (Primary).......................................... 11–12
Fuel Filter Base ..................................................... 13
Fuel Injector............................. 30–31, 33–34, 36–37
Fuel Injector Mechanism ........................... 23, 25, 28
Fuel Pressure Regulator........................................ 19
Fuel Pressure Sensor.......................................... 498
Fuel Transfer Pump......................................... 20–21
G
Gear Group (Front)...................... 364–365, 368, 370
Gear Group (Front) (Reverse Rotation)....... 360, 362
Gear Group (Rear) .............................. 372, 374, 377
H
Housing (Front).................................... 356–357, 359
I
Important Safety Information ................................... 2
J
Jacket Water Heater ............................................ 493
M
Magnetic Switch .................................................. 500
P
Piston and Rings ................................................. 326
Piston and Rings (One-Piece Piston) .. 319, 321, 331
Piston and Rings (Two-Piece Piston) .. 324, 328, 330
Intermediate Piston Ring (2) ............................ 325
Oil Control Piston Ring (3) ............................... 325
Pin Retainer (6)................................................ 325
Piston Pin (5) ................................................... 325
Piston Pin Bore (4)........................................... 325
Top Piston Ring (1) .......................................... 325
S
Specifications Section ............................................. 6
Stub Shaft (Front) ........................ 445–448, 450–453
T
Table of Contents..................................................... 3
Turbocharger ................... 87–88, 90–91, 93, 96–106
Turbocharger Exhaust Temperature Sensor ....... 513
Turbocharger Inlet Pressure Sensor ................... 505
Turbocharger Outlet Pressure Sensor .. 506, 508–509
Turbocharger Support ......................................... 107
V
Valve Mechanism ...................................... 58, 60, 62
Vibration Damper................. 431–432, 434–435, 437
Vibration Damper Guard.............. 438–440, 442–444
W
Water Lines ......................... 261, 263, 265, 267–269
Water Pump......................... 275, 277–278, 280–281
Water Temperature Regulator ............. 257, 259–260
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All Rights Reserved
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