Caterpillar 3516 [PDF]

Zitiervorschau

RENR5057-04 February 2013

Specifications 3500B Generator Set Engines GD3 1-Up (Generator Set) YBB 1-Up (Generator Set) YBC 1-Up (Generator Set) ZAD 1-Up (Generator Set) JDE 1-Up (Generator Set) ZAH 1-Up (Generator Set) ZAJ 1-Up (Generator Set) YAM 1-Up (Generator Set) YAN 1-Up (Generator Set) YAP 1-Up (Generator Set) ZAP 1-Up (Generator Set) ZBP 1-Up (Generator Set) PBR 1-Up (Generator Set) PDR 1-Up (Generator Set) YAR 1-Up (Generator Set)

ZAR 1-Up (Generator Set) ZBR 1-Up (Generator Set) YAT 1-Up (Generator Set) YBT 1-Up (Generator Set) YAW 1-Up (Generator Set) YBW 1-Up (Generator Set) JCY 1-Up (Generator Set) YAY 1-Up (Generator Set) YAZ 1-Up (Generator Set)

SAFETY.CAT.COM

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.

RENR5057

3 Table of Contents

Table of Contents Specifications Section Engine Design ......................... ......................... 6 Engine Design ......................... ......................... 6 Engine Design ......................... ......................... 7 Engine Design ......................... ......................... 7 Engine Design ......................... ......................... 8 Engine Design ......................... ......................... 8 Fuel Filter (Primary).................... .................... 10 Fuel Filter............................ .............................11 Fuel Filter............................ ............................ 13 Fuel Filter............................ ............................ 14 Fuel Pressure Regulator................. ................ 15 Fuel Transfer Pump .................... .................... 17 Fuel Priming Pump ..................... .................... 20 Fuel Injector Mechanism ................ ................ 21 Fuel Injector Mechanism ................ ................ 23 Fuel Injector.......................... .......................... 25 Fuel Injector.......................... .......................... 27 Fuel Injector.......................... .......................... 28 Camshaft ............................ ............................ 30 Camshaft ............................ ............................ 33 Camshaft ............................ ............................ 35 Camshaft ............................ ............................ 37 Valve Mechanism ............................................ 39 Valve Mechanism ............................................ 41 Cylinder Head......................... ........................ 43 Cylinder Head......................... ........................ 46 Cylinder Head......................... ........................ 49 Cylinder Head Valves ................... .................. 53 Cylinder Head Valves ................... .................. 56 Turbocharger Oil Lines .................. ................. 59 Turbocharger Oil Lines .................. ................. 61 Turbocharger ......................... ......................... 62 Turbocharger ......................... ......................... 65 Turbocharger ......................... ......................... 66 Turbocharger ......................... ......................... 69 Turbocharger ......................... ......................... 71 Turbocharger ......................... ......................... 72 Turbocharger ......................... ......................... 75 Turbocharger ......................... ......................... 77 Exhaust Manifold...................... ...................... 78 Exhaust Manifold...................... ...................... 80 Exhaust Manifold...................... ...................... 81 Exhaust Manifold...................... ...................... 83 Exhaust Manifold...................... ...................... 84 Exhaust Manifold...................... ...................... 85 Exhaust Manifold...................... ...................... 87

Exhaust Flange........................ ....................... 89 Exhaust Flange........................ ....................... 91 Exhaust Flange........................ ....................... 93 Air Cleaner........................... ........................... 94 Engine Air Cleaner Service Indicator....... ....... 95 Air Lines............................. ............................. 96 Air Inlet and Exhaust Lines ............... .............. 97 Air Inlet and Exhaust Lines .............. ............. 100 Air Inlet and Exhaust Lines .............. ............. 102 Air Inlet and Exhaust Lines .............. ............. 105 Air Inlet and Exhaust Lines .............. ............. 108 Air Inlet and Exhaust Lines .............. ..............111 Air Shutoff ........................... ...........................113 Air Shutoff ........................... ...........................115 Air Shutoff ........................... ...........................117 Air Shutoff ........................... .......................... 120 Prelube Pump........................ ....................... 122 Prelube Pump........................ ....................... 124 Prelube Pump (Air) .................... ................... 126 Prelube Pump........................ ....................... 127 Engine Oil Pump...................... ..................... 129 Engine Oil Pump...................... ..................... 132 Engine Oil Pump...................... ..................... 137 Engine Oil Cooler Bypass and Cooling Jet Sequence Valves .................... .................... 143 Engine Oil Cooler Bypass and Cooling Jet Sequence Valves .................... .................... 146 Engine Oil Filter ...................... ...................... 148 Engine Oil Filter ...................... ...................... 150 Engine Oil Filter ...................... ...................... 153 Engine Oil Filter ...................... ...................... 154 Engine Oil Lines...................... ...................... 156 Engine Oil Lines...................... ...................... 159 Duplex Engine Oil Filters ............... ............... 162 Engine Oil Cooler..................... ..................... 164 Crankcase Breather................... ................... 165 Crankcase Breather................... ................... 167 Crankcase Breather................... ................... 168 Crankcase Breather................... ................... 169 Crankcase Breather................... ................... 170 Engine Oil Pan....................... ....................... 172 Engine Oil Pan....................... ....................... 174 Engine Oil Pan....................... ....................... 176 Engine Oil Pan....................... ....................... 179 Engine Oil Pan....................... ....................... 182 Engine Oil Pan....................... ....................... 185 Engine Oil Pan....................... ....................... 187 Engine Oil Pan....................... ....................... 188 Engine Oil Pan....................... ....................... 190 Water Temperature Regulator ........... ........... 193 Water Temperature Regulator ........... ........... 195

4

RENR5057

Table of Contents

Water Lines.......................... ......................... 196 Thermostatic Valve .................... ................... 197 Fan Drive ........................... ........................... 200 Fan Drive ........................... ........................... 202 Radiator ............................ ............................ 203 Radiator ............................ ............................ 204 Radiator ............................ ............................ 205 Engine Oil Sump Pump ................ ................ 206 Water Pump......................... ......................... 207 Water Pump......................... ......................... 209 Water Pump......................... ..........................211 Auxiliary Water Pump .................. ................. 215 Auxiliary Water Pump .................. ................. 218 Auxiliary Water Pump (Sea Water) ....... ....... 220 Auxiliary Water Pump .................. ................. 223 Cooling System Pressure Cap ........... .......... 225 Cylinder Block........................ ....................... 228 Cylinder Block........................ ....................... 233 Cylinder Block........................ ....................... 236 Cylinder Block........................ ....................... 240 Cylinder Liner........................ ........................ 243 Piston and Rings (One-Piece Piston) ..... ..... 246 Piston and Rings (One-Piece Piston) ..... ..... 249 Piston and Rings (Two-Piece Piston) ..... ..... 252 Piston and Rings (Two-Piece Piston) ..... ..... 255 Connecting Rod...................... ...................... 258 Connecting Rod...................... ...................... 261 Connecting Rod...................... ...................... 264 Connecting Rod...................... ...................... 267 Connecting Rod and Main Bearing Journals 269 Crankshaft .......................... .......................... 271 Crankshaft .......................... .......................... 272 Crankshaft .......................... .......................... 274 Crankshaft .......................... .......................... 275 Crankshaft .......................... .......................... 276 Crankshaft .......................... .......................... 277 Crankshaft Wear Sleeves and Seals...... ...... 279 Cover Group (Front Housing) ............ ........... 282 Housing (Front)....................... ...................... 284 Housing (Front)....................... ...................... 286 Gear Group (Front).................... ................... 287 Gear Group (Front).................... ................... 290 Gear Group (Rear).................... .................... 292 Gear Group (Rear).................... .................... 294 Gear Group (Rear).................... .................... 296 Gear Group (Rear).................... .................... 299 Balancer Group (Front)................. ................ 301 Accessory Drive (Lower Left Hand)....... ....... 302 Accessory Drive (Upper Right Hand) ............ 305 Accessory Drive (Upper Right Hand) ............ 308 Accessory Drive (Upper Right Hand) ...... ......311

Flywheel ........................... ............................ 313 Flywheel Housing ..................... .................... 315 Flywheel Housing Cover................ ............... 319 Generator Coupling ................... ................... 320 Generator Coupling ................... ................... 322 Flexible Coupling ..................... ..................... 323 Flexible Coupling ..................... ..................... 325 Vibration Damper..................... ..................... 326 Vibration Damper..................... ..................... 328 Vibration Damper..................... ..................... 330 Vibration Damper..................... ..................... 332 Vibration Damper..................... ..................... 334 Vibration Damper..................... ..................... 336 Vibration Damper Guard................ ............... 337 Vibration Damper Guard................ ............... 339 Vibration Damper Guard................ ............... 340 Vibration Damper Guard................ ............... 341 Stub Shaft (Front) ..................... .................... 342 Stub Shaft (Front) ..................... .................... 345 Auxiliary Drive Pulley.................. .................. 346 Auxiliary Drive Pulley.................. .................. 347 Auxiliary Drive Pulley.................. .................. 348 Auxiliary Drive Shaft ................... .................. 349 Belt Tension Chart .................... .................... 350 Alternator and Regulator................ ............... 352 Alternator and Regulator................ ............... 354 Alternator and Regulator................ ............... 355 Alternator and Regulator................ ............... 357 Alternator Mounting ................... ................... 359 Alternator Mounting ................... ................... 361 Electric Starting Motor ................. ................. 363 Electric Starting Motor ................. ................. 365 Electric Starting Motor ................. ................. 368 Electric Starting Motor ................. ................. 370 Electric Starting Motor ................. ................. 372 Air Starting Motor..................... ..................... 373 Air Starting Motor Pressure Regulating Valve 376 Coolant Level Switch .................. .................. 378 Coolant Temperature Switch ............ ............ 380 Fuel Pressure Sensor.................. ................. 381 Fuel Pressure Sensor.................. ................. 384 Prelube Pressure Switch ............... ............... 386 Coolant Level Sensor .................. ................. 388 Coolant Level Sensor .................. ................. 391 Engine Oil Pressure Sensor ............. ............ 393 Engine Oil Pressure Sensor ............. ............ 394 Engine Oil Temperature Sensor ......... .......... 396 Engine Oil Temperature Sensor ......... .......... 399 Turbocharger Inlet Pressure Sensor....... ...... 400 Turbocharger Inlet Pressure Sensor....... ...... 402 Turbocharger Outlet Pressure Sensor..... ..... 405

RENR5057

5 Table of Contents

Turbocharger Outlet Pressure Sensor..... ..... 406 Aftercooler Coolant Temperature Sensor ... .. 408 Engine Coolant Temperature Sensor ...... ..... 409 Engine Coolant Temperature Sensor ...... ..... 412 Turbocharger Exhaust Temperature Sensor 413 Turbocharger Exhaust Temperature Sensor 416 Engine Speed/Timing Sensor............ ........... 417 Engine Speed/Timing Sensor............ ........... 418 Crankcase Pressure Sensor............. ............ 420 Crankcase Pressure Sensor............. ............ 422 Atmospheric Pressure Sensor........... ........... 423 Atmospheric Pressure Sensor........... ........... 425 Engine Speed Sensor.................. ................. 426 Engine Speed Sensor.................. ................. 428 Thermocouple........................ ....................... 431

Index Section Index............................... .............................. 434

6

RENR5057

Specifications Section

Specifications Section

i01430869

i01430864

Engine Design SMCS Code: 1000

Engine Design

S/N: YBB1–Up

SMCS Code: 1000

S/N: ZAH1–Up

S/N: ZAD1–Up

S/N: YAM1–Up S/N: YAY1–Up

Illustration 1

g00293348

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

Number and arrangement of cylinders ....60 degree V −8

Illustration 2

g00293349

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

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

Number and arrangement of cylinders ....60 degree V −12

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

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

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

Displacement................................. 51.8 L (3158 cu in)

Stroke .............................................190 mm (7.5 inch)

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

Compression ratio ................................................14:1

Stroke ............................................. 190 mm (7.5 inch)

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

Compression ratio ................................................ 14:1

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

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

Firing order (injection sequence) Standard rotation CCW ..................1, 2, 7, 3, 4, 5, 6, 8 Valve lash Inlet ............................................0.50 mm (0.020 inch) Exhaust......................................1.00 mm (0.040 inch) Note: The front end of the engine is opposite the flywheel end of the engine. The left 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.

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

7

RENR5057

Specifications Section 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.

Reverse rotation CW .... 1, 4, 9, 8, 5, 2, 11, 10, 3, 6, 7, 12 Valve lash Inlet ............................................ 0.50 mm (0.020 inch) Exhaust......................................1.00 mm (0.040 inch)

i01443411

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.

Engine Design SMCS Code: 1000 S/N: YBC1–Up S/N: ZAJ1–Up

i05220884

S/N: YAN1–Up

Engine Design

S/N: YAZ1–Up

SMCS Code: 1000 S/N: GD31–Up

Illustration 3

g00293349

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

Number and arrangement of cylinders ....... 60 degree V-12 Valves per cylinder .................................................... 4

Illustration 4

g03337471

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

Displacement................................. 58.5 L (3570 cu in)

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

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

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

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

Displacement................................. 69.1 L (4210 cu in)

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

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

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

Stroke ............................................. 190 mm (7.5 inch)

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

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

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

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

8

RENR5057

Specifications Section Special Firing order (injection sequence)

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

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

Stroke ............................................. 190 mm (7.5 inch)

Valve lash Inlet ............................................0.50 mm (0.020 inch) Exhaust......................................1.00 mm (0.040 inch) Note: The front end of the engine is opposite the flywheel end of the engine. The left and the right side of the engine are determined from the flywheel end. The number 1 cylinder is the front cylinder on the right side. The number 2 cylinder is the front cylinder on the left side. i01430901

Engine Design

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

SMCS Code: 1000

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

S/N: YAP1–Up S/N: ZAP1–Up S/N: ZBP1–Up S/N: PBR1–Up

i01430926

S/N: PDR1–Up S/N: YAT1–Up

Engine Design

S/N: YBT1–Up

SMCS Code: 1000

S/N: JCY1–Up

S/N: JDE1–Up S/N: YAR1–Up S/N: ZAR1–Up S/N: ZBR1–Up S/N: YAW1–Up S/N: YBW1–Up

Illustration 5

g00294285

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

Number and arrangement of cylinders ....60 degree V −16 Valves per cylinder .................................................... 4 Displacement................................. 69.1 L (4210 cu in)

Illustration 6

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

g00294285

RENR5057

9 Specifications Section

Number and arrangement of cylinders ....... 60 degree V-16 Valves per cylinder .................................................... 4 Displacement.................................... 78 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 Valve lash Inlet ............................................0.50 mm (0.020 inch) Exhaust......................................1.00 mm (0.040 inch) Note: The front end of the engine is opposite the flywheel end of the engine. The left and the right side of the engine are determined from the flywheel end. The number 1 cylinder is the front cylinder on the right side. The number 2 cylinder is the front cylinder on the left side.

10

RENR5057

Specifications Section

i04888422

Fuel Filter (Primary) SMCS Code: 1260 Part No.: 387-0485 S/N: JDE1–Up Part No.: 387-0485 S/N: JCY1–Up

Illustration 7

g03015316

Table 1 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).

RENR5057

11 Specifications Section

i04713909

Fuel Filter

SMCS Code: 1261 Part No.: 7W-9741 S/N: ZAD1–Up Part No.: 7W-9741 S/N: ZAH1–Up Part No.: 7W-9741 S/N: ZAJ1–Up Part No.: 7W-9741 S/N: YAM1–Up Part No.: 7W-9741 S/N: YAN1–Up Part No.: 7W-9741 S/N: YAP1–Up Part No.: 7W-9741 S/N: ZAP1–Up Part No.: 7W-9741 S/N: ZBP1–Up Part No.: 7W-9741 S/N: PBR1–Up Part No.: 7W-9741 S/N: PDR1–Up Part No.: 7W-9741 S/N: YAR1–Up Part No.: 7W-9741 S/N: ZAR1–Up Part No.: 7W-9741 S/N: ZBR1–Up Part No.: 7W-9741 S/N: YAT1–Up Part No.: 7W-9741 S/N: YBT1–Up Part No.: 7W-9741 S/N: YAW1–Up Part No.: 7W-9741 S/N: YBW1–Up Part No.: 7W-9741 S/N: YAY1–Up Part No.: 7W-9741 S/N: YAZ1–Up

12

RENR5057

Specifications Section

Illustration 8

g02818461

Table 2 Specification for 7W-9741 Fuel Filter Gp Item

Qty

Part

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.

Specification description

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).

RENR5057

13 Specifications Section

i04938315

Fuel Filter

SMCS Code: 1261 Part No.: 377-5898 S/N: YBB1–Up Part No.: 377-5898 S/N: YBC1–Up Part No.: 377-5898 S/N: JDE1–Up Part No.: 377-5898 S/N: JCY1–Up

Illustration 9

g03117857

Table 3 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).

14

RENR5057

Specifications Section

i04716709

Fuel Filter

SMCS Code: 1261 Part No.: 112-4922 S/N: GD31–Up

Illustration 10

g02820796

Table 4 Specification for 112-4922 Fuel Filter Gp Item

Qty

Part

1

2

5D-5957 O-Ring Seal

Specification description Lightly lubricate the bore with the clean engine oil. Length under test force is 20.75 mm (0.817 inch).

2

1

1N-2895 Spring

Test force is 222 N (50 lb). Free length after test is 62.48 mm (2.460 inch).

RENR5057

15 Specifications Section

i04369549

Fuel Pressure Regulator SMCS Code: 1277 Part No.: 114-5477 S/N: YBB1–Up Part No.: 114-5477 S/N: YBC1–Up Part No.: 114-5477 S/N: ZAD1–Up Part No.: 114-5477 S/N: ZAH1–Up Part No.: 114-5477 S/N: ZAJ1–Up Part No.: 114-5477 S/N: YAM1–Up Part No.: 114-5477 S/N: YAN1–Up Part No.: 114-5477 S/N: YAP1–Up Part No.: 114-5477 S/N: ZAP1–Up Part No.: 114-5477 S/N: ZBP1–Up Part No.: 114-5477 S/N: PBR1–Up Part No.: 114-5477 S/N: PDR1–Up Part No.: 114-5477 S/N: YAR1–Up Part No.: 114-5477 S/N: ZAR1–Up Part No.: 114-5477 S/N: ZBR1–Up Part No.: 114-5477 S/N: YAT1–Up Part No.: 114-5477 S/N: YBT1–Up Part No.: 114-5477 S/N: YAW1–Up Part No.: 114-5477 S/N: YBW1–Up Part No.: 114-5477 S/N: YAY1–Up Part No.: 114-5477 S/N: YAZ1–Up

16

RENR5057

Specifications Section

Illustration 11

g02577996

(2) Valve plunger Table 5 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).

RENR5057

17 Specifications Section

i05196360

Fuel Transfer Pump

18

RENR5057

Specifications Section SMCS Code: 1256

S/N: YAY1–Up

Part No.: 8N-6151 S/N: GD31–Up

Part No.: 8N-6151 S/N: YAZ1–Up

Part No.: 313-7770 S/N: YBB1–Up Part No.: 313-7770 S/N: YBC1–Up Part No.: 8N-6151 S/N: ZAD1–Up Part No.: 313-7770 S/N: JDE1–Up Part No.: 8N-6151 S/N: ZAH1–Up Part No.: 8N-6151 S/N: ZAJ1–Up Part No.: 8N-6151 S/N: YAM1–Up Part No.: 8N-6151 S/N: YAN1–Up Part No.: 8N-6151 S/N: YAP1–Up Part No.: 8N-6151 S/N: ZAP1–Up Part No.: 8N-6151 S/N: ZBP1–Up Part No.: 8N-6151 S/N: PBR1–Up Part No.: 8N-6151 S/N: PDR1–Up Part No.: 8N-6151 S/N: YAR1–Up Part No.: 8N-6151 S/N: ZAR1–Up Part No.: 8N-6151 S/N: ZBR1–Up Part No.: 8N-6151 S/N: YAT1–Up Part No.: 8N-6151 S/N: YBT1–Up Part No.: 8N-6151 S/N: YAW1–Up Part No.: 8N-6151 S/N: YBW1–Up Part No.: 313-7770 S/N: JCY1–Up Part No.: 8N-6151

RENR5057

19 Specifications Section

Illustration 12

g03329769

Table 6 Specification for 8N-6151 Fuel Transfer Pump Gp, 332-7928 Fuel Transfer Pump Gp, 313-7770 Fuel Transfer Pump Gp and 377-5900 Fuel Transfer Pump Gp Item

Qty

Part

1

4

7C-2870 Terminal Bushing

2

1

268-1903 Drive Shaft As

3

1

1W-4003 Idler Gear As

Specification Description 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). 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).

20

RENR5057

Specifications Section

i04488609

Fuel Priming Pump SMCS Code: 1258 Part No.: 7N-8599 S/N: GD31–Up

Illustration 13

g02668036

Table 7 Specification for 7N-8599 Fuel Priming Pump Gp Item

Qty

1

1

Part

Specification Description

7X-2501 Bolt(1) Torque to 12 ± 3 N·m (106 ± 27 lb in). 8T-4971 Bolt(2) 6V-8918 Bolt(1) 2 (1) (2)

1

Use if inch bolt is required Use if metric bolt is required

Torque to 15 ± 3 N·m (133 ± 27 lb in). 8T-7547 Bolt(2)

RENR5057

21 Specifications Section

i05182335

Fuel Injector Mechanism SMCS Code: 1102; 1290 Part No.: 224-9869 S/N: GD31–Up Part No.: 224-9869 S/N: ZAD1–Up Part No.: 224-9869 S/N: ZAH1–Up Part No.: 224-9869 S/N: ZAJ1–Up Part No.: 224-9869 S/N: YAM1–Up Part No.: 224-9869 S/N: YAN1–Up Part No.: 224-9869 S/N: YAP1–Up Part No.: 224-9869 S/N: ZAP1–Up Part No.: 224-9869 S/N: ZBP1–Up Part No.: 224-9869 S/N: PBR1–Up Part No.: 224-9869 S/N: PDR1–Up Part No.: 224-9869 S/N: YAR1–Up Part No.: 224-9869 S/N: ZAR1–Up Part No.: 224-9869 S/N: ZBR1–Up Part No.: 224-9869 S/N: YAT1–Up Part No.: 224-9869 S/N: YBT1–Up Part No.: 224-9869 S/N: YAW1–Up Part No.: 224-9869 S/N: YBW1–Up Part No.: 224-9869 S/N: YAY1–Up Part No.: 224-9869 S/N: YAZ1–Up

22

RENR5057

Specifications Section

Illustration 14

g02529356

Table 8 Specification for 224-9869 Valve Mechanism Gp, 332-9690 Valve Mechanism Gp, and 357-9219 Valve Mechanism Gp Item

Qty

Part

1

1

317-1121 Jam Nut

2

1

6J-2245 O-Ring Seal

3

1

7E-6508 Cap As

4

1

100-3878 Injector Spring

5

2

334-1626 Bolt

B

1

230-2620 Bushing

C

1

234-2273 Rocker Arm Shaft

D

1

282-7944 Injector Lifter As

Specification Description Torque to 120 ± 15 N·m (89 ± 11 lb ft). 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 N·m (22.13 ± 2.21 lb in). 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). Apply black Loctite gasket maker #2 to the threads of the bolt, if the bolts are removed after initial installation. Bore of the bushing for the rocker arm shaft after assembly is 45.077 ± 0.015 mm (1.7747 ± 0.0006 inch). Diameter is 45.000 ± 0.013 mm (1.7716 ± 0.0005 inch) Diameter is 34.950 ± 0.010 mm (1.3760 ± 0.0004 inch). Bore in the cylinder head for the unit injector lifter assembly is 35.000 ± 0.025 mm (1.3779 ± 0.0010 inch).

RENR5057

23 Specifications Section

i04913393

Fuel Injector Mechanism SMCS Code: 1102; 1290 Part No.: 370-9889 S/N: YBB1–Up Part No.: 370-9889 S/N: YBC1–Up Part No.: 370-9889 S/N: JDE1–Up Part No.: 370-9889 S/N: JCY1–Up

Illustration 15

g03081556

Top view Table 9 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.

24

RENR5057

Specifications Section

Illustration 16

g03081557

Table 10 Item

Qty

Part

9

1

234-2273 Rocker Arm Shaft

10

2

0L-2070 Bolt

11

1

6J-2245 O-Ring Seal

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. Lubricate the bore lightly with the lubricant that is being sealed.

RENR5057

25 Specifications Section

i05213812

Fuel Injector SMCS Code: 1290 Part No.: 256-3663 S/N: GD31–Up Part No.: 256-3663 S/N: ZAD1–Up Part No.: 256-3663 S/N: ZAH1–Up Part No.: 231-7845, 256-3663 S/N: ZAJ1–Up Part No.: 256-3663 S/N: YAM1–Up Part No.: 231-7845, 256-3663 S/N: YAN1–Up Part No.: 256-3663 S/N: YAP1–Up Part No.: 256-3663 S/N: ZAP1–Up Part No.: 256-3663 S/N: ZBP1–Up Part No.: 256-3663 S/N: PBR1–Up Part No.: 256-3663 S/N: PDR1–Up Part No.: 256-3663 S/N: YAR1–Up Part No.: 231-7845, 256-3663 S/N: ZAR1–Up Part No.: 256-3663 S/N: YAT1–Up Part No.: 256-3663 S/N: YBT1–Up Part No.: 231-7845, 256-3663 S/N: YAW1–Up Part No.: 256-3663 S/N: YAY1–Up Part No.: 256-3663 S/N: YAZ1–Up

26

RENR5057

Specifications Section

Illustration 17

g03336045

Table 11 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

Timing dimension is 64.34 ± 0.20 mm (2.533 ± 0.008 inch) Torque to 65 ± 7 N·m (48 ± 5 lb ft).

RENR5057

27 Specifications Section

i04938316

Fuel Injector SMCS Code: 1290 Part No.: 384-4705 S/N: YBB1–Up Part No.: 384-4705 S/N: JCY1–Up

Illustration 18

g03117876

Table 12 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. 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 361-9354 Fuel Injection Valve Grease. Assembly 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

1

2

1

7F-8698 Bolt

A

-

-

3

1

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). 230-9456 Unit Injector Nozzle 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).

28

RENR5057

Specifications Section

i04938348

Fuel Injector SMCS Code: 1290 Part No.: 383-4050 S/N: YBC1–Up Part No.: 383-4050 S/N: JDE1–Up Part No.: 159-8832 S/N: ZBR1–Up Part No.: 159-8832 S/N: YBW1–Up

Illustration 19

Typical example

g03117936

RENR5057

29 Specifications Section

Table 13 Specification for 383-4050 Fuel Injection Pump Gp and 159-8832 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. 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 361-9354 Fuel Injection Valve Grease. 1. Tighten the valve assembly to 35 N·m (26 lb ft). Assembly 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

1

2

1

7F-8698 Bolt

A

-

-

3

1

229-0187 Unit Injector Nozzle

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).

30

RENR5057

Specifications Section

i04407569

Camshaft

SMCS Code: 1210 Part No.: 106-4595 S/N: GD31–Up Part No.: 106-4586 S/N: ZAD1–Up Part No.: 106-4586 S/N: ZAH1–Up Part No.: 106-4586 S/N: ZAJ1–Up Part No.: 106-4586 S/N: YAM1–Up Part No.: 106-4586 S/N: YAN1–Up Part No.: 106-4586, 106-4595 S/N: YAP1–Up Part No.: 106-4586, 106-4595 S/N: ZAP1–Up Part No.: 106-4595 S/N: ZBP1–Up Part No.: 106-4586, 106-4595 S/N: PBR1–Up Part No.: 106-4586, 106-4595 S/N: YAR1–Up Part No.: 106-4586, 106-4595 S/N: ZAR1–Up Part No.: 106-4595 S/N: ZBR1–Up Part No.: 106-4586, 106-4595 S/N: YAT1–Up Part No.: 106-4595 S/N: YBT1–Up Part No.: 106-4586, 106-4595 S/N: YAW1–Up Part No.: 106-4595 S/N: YBW1–Up Part No.: 106-4586 S/N: YAY1–Up Part No.: 106-4586 S/N: YAZ1–Up

RENR5057

31 Specifications Section

Illustration 20

g02603357

(1) Left-hand camshaft assembly

(2) Right-hand camshaft assembly

Table 14 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

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).

E

-

-

-

-

-

3

16

5P-0076 Bolt

F

1

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).

32

RENR5057

Specifications Section

Illustration 21

g02603358

Table 15 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: Inlet lobe is 12.7500 mm (0.50197 inch).

G

-

Injector lobe is 13.7313 mm (0.54060 inch). Exhaust lobe is 13.2499 mm (0.52165 inch).

RENR5057

33 Specifications Section

i05206168

Camshaft

SMCS Code: 1210 Part No.: 106-4582 S/N: ZAD1–Up

Illustration 22

g03327351

(1) Left-hand camshaft assembly

(2) Right-hand camshaft assembly

Table 16 Specification for 106-4582 Camshaft Gp and 332-7923 Camshaft Gp Item

Qty

Part

A

-

-

B

2

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).

34

RENR5057

Specifications Section

Illustration 23

g03327356

Table 17 Item

Qty

Specification Description

Part

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: Inlet lobe is 12.7500 mm (0.50197 inch).

E

-

Injector lobe is 13.7313 mm (0.54060 inch). Exhaust lobe is 13.2499 mm (0.52165 inch).

RENR5057

35 Specifications Section

i04939143

Camshaft

SMCS Code: 1210 Part No.: 382-3100 S/N: YBB1–Up Part No.: 382-3100 S/N: YBC1–Up Part No.: 380-2698 S/N: JDE1–Up Part No.: 380-2698 S/N: JCY1–Up

Illustration 24

g03120076

(1) Left-hand camshaft assembly

(2) Right-hand camshaft assembly

Table 18 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

E

-

-

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). Bore in camshaft bearing after installation is 92.00 ± 0.06 mm (3.622 ± 0.002 inch).

3

16

5P-0076 Bolt

F

2

4N-1650 Dowel

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).

36

RENR5057

Specifications Section

Illustration 25

g03120077

Table 19 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: Inlet lobe is 12.7500 mm (0.50197 inch).

G

-

Injector lobe is 13.7313 mm (0.54060 inch). Exhaust lobe is 13.2499 mm (0.52165 inch).

RENR5057

37 Specifications Section

i04936960

Camshaft

SMCS Code: 1210 Part No.: 231-9123 S/N: PBR1–Up Part No.: 231-9123 S/N: PDR1–Up Part No.: 231-9123 S/N: YAT1–Up Part No.: 231-9123 S/N: YBT1–Up

Illustration 26

g03113696

(1) Left-hand camshaft assembly

(2) Right-hand camshaft assembly

Table 20 Specification for 231-9123 Camshaft Gp Item

Qty

Part

A

-

-

C

2

5B-5821 Dowel

D

2

7N-3218 Thrust Washer

E

-

-

Specification Description Thickness of the groove in a 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 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).

-

-

-

3

16

5P-0076 Bolt

F

2

4N-1650 Dowel

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).

38

RENR5057

Specifications Section

Illustration 27

g03113697

Table 21 Item

Qty

Specification Description

Part

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: Inlet lobe is 12.73 mm (0.501 inch).

G

-

Exhaust lobe is 13.10 mm (0.516 inch). Injector lobe is 13.73 mm (0.541 inch).

RENR5057

39 Specifications Section

i05182336

Valve Mechanism SMCS Code: 1102

Part No.: 224-9869 S/N: GD31–Up Part No.: 224-9869 S/N: ZAD1–Up Part No.: 224-9869 S/N: ZAH1–Up Part No.: 224-9869 S/N: ZAJ1–Up Part No.: 224-9869 S/N: YAM1–Up Part No.: 224-9869 S/N: YAN1–Up Part No.: 224-9869 S/N: YAP1–Up Part No.: 224-9869 S/N: ZAP1–Up Part No.: 224-9869 S/N: ZBP1–Up Part No.: 224-9869 S/N: PBR1–Up Part No.: 224-9869 S/N: PDR1–Up Part No.: 224-9869 S/N: YAR1–Up Part No.: 224-9869 S/N: ZAR1–Up Part No.: 224-9869 S/N: ZBR1–Up Part No.: 224-9869 S/N: YAT1–Up Part No.: 224-9869 S/N: YBT1–Up Part No.: 224-9869 S/N: YAW1–Up Part No.: 224-9869 S/N: YBW1–Up Part No.: 224-9869 S/N: YAY1–Up Part No.: 224-9869 S/N: YAZ1–Up

40

RENR5057

Specifications Section

Illustration 28

g03322742

Table 22 Specification for the 224-9869 Valve Mechanism Gp 332-9690 Valve Mechanism Gp 281-6160 Valve Mechanism Gp 286-5723 Valve Mechanism Gp 308-5356 Valve Mechanism Gp 357-9219 Valve Mechanism Gp Item

Qty

Part

1

2

3J-9196 Jam Nut

A

1

230-2633 Shaft As

B

-

-

C

1

230-2620 Bushing

D

2

263-6672 Lifter Body

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 cylinder head for valve lifter assembly is 30.000 ± 0.025 mm (1.1811 ± 0.0010 inch).

RENR5057

41 Specifications Section

i04449469

Valve Mechanism SMCS Code: 1102

Part No.: 370-9889 S/N: YBB1–Up Part No.: 370-9889 S/N: YBC1–Up Part No.: 370-9889 S/N: JDE1–Up Part No.: 370-9889 S/N: JCY1–Up

Illustration 29

g02636876

Top view Table 23 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

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.

42

RENR5057

Specifications Section

Illustration 30

g02636936

Table 24 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

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. Lubricate the bore lightly with the lubricant that is being sealed.

RENR5057

43 Specifications Section

i04721894

Cylinder Head SMCS Code: 1100 Part No.: 101-0830 S/N: GD31–Up Part No.: 101-0830 S/N: ZAD1–Up Part No.: 101-0830 S/N: ZAH1–Up Part No.: 101-0830 S/N: ZAJ1–Up Part No.: 101-0830 S/N: YAM1–Up Part No.: 101-0830 S/N: YAN1–Up Part No.: 101-0830 S/N: YAP1–Up Part No.: 101-0830 S/N: ZAP1–Up Part No.: 101-0830 S/N: ZBP1–Up Part No.: 101-0830 S/N: PBR1–Up Part No.: 101-0830 S/N: PDR1–Up Part No.: 101-0830 S/N: YAR1–Up Part No.: 101-0830 S/N: ZAR1–Up Part No.: 101-0830 S/N: ZBR1–Up Part No.: 101-0830 S/N: YAT1–Up Part No.: 101-0830 S/N: YBT1–Up Part No.: 101-0830 S/N: YAW1–Up Part No.: 101-0830 S/N: YBW1–Up Part No.: 101-0830 S/N: YAY1–Up Part No.: 101-0830 S/N: YAZ1–Up

44

RENR5057

Specifications Section

Illustration 31

g02823736

Table 25 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).

45

RENR5057

Specifications Section

Illustration 32

g02823737

Table 26 Item

Qty

Part

Specification Description

5

1

5B-7890 Pipe Plug

Before assembly, lubricate the threads with Loctite C5A Copper Anti-Seize .

6

6

7

2

8

2

131-0420 Cylinder Head Fasten- Use the following procedure to tighten the bolts for the cylinder head: er Gp 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 Illus131-0421 Cylinder Head Fasten- tration 32 to a torque of 30 ± 5 N·m (22 ± 4 lb ft). er Gp 3. Again, tighten bolt 1 through bolt 8 in the numerical sequence as shown in Illustration 32 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 32 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 5B-0213 Bolt degrees as shown in Illustration 32 . 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).

46

RENR5057

Specifications Section

i04938343

Cylinder Head SMCS Code: 1100 Part No.: 380-5795 S/N: YBB1–Up Part No.: 380-5795 S/N: YBC1–Up Part No.: 380-5795 S/N: JDE1–Up Part No.: 380-5795 S/N: JCY1–Up

47

RENR5057

Specifications Section

Illustration 33

g03120176

Table 27 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).

48

RENR5057

Specifications Section

Illustration 34

g03117917

Table 28 Item

Qty

7

6

8

2

9

2

Part

Specification Description

131-0420 Cylinder Head Fas- Use the following procedure in order to tighten the bolts for the cylinder head: tener Gp Refer Illustration 34 for bolt tightening sequence. 1. Before assembly, apply clean engine oil to the threads of the bolts. 131-0421 Cylinder Head Fas- 2. Tighten bolt 1 through bolt 8 in the numerical sequence to 30 ± 5 N·m (22 ± 4 lb ft). tener Gp 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). 5B-0213 Bolt 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).

RENR5057

49 Specifications Section

i04372705

Cylinder Head SMCS Code: 1100 Part No.: 274-8568 S/N: PBR1–Up

Illustration 35

g02599196

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.

Illustration 36

Typical example (top view) (3) Pipe plug

g02534738

50

RENR5057

Specifications Section Table 29 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

2

3b-0623 Cup Plug

D

2

3b-0623 Cup Plug

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)

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.

RENR5057

51 Specifications Section

Illustration 37

g02599197

Table 30 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 6 2

-

2

Part

Specification Description

131-0420 Cylinder Head Fas- 1. Coat the threads of the bolts with clean engine oil. tener Gp 2. Tighten bolt (1) through bolt (8) in the numerical sequence to 30 ± 5 N·m (22 ± 4 lb ft). 131-0421 Cylinder Head Fas- 3. Tighten bolt (1) through bolt (8) in the numerical sequence to 200 ± 15 N·m tener Gp (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. 5B-0213 Bolt 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).

Bolt Tightening with the 362-8264 Cylinder Head Gasket Use the following procedure when the 362-8264 Cylinder Head Gasket is installed.

52

RENR5057

Specifications Section

Illustration 38

g02599198

Table 31 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 6 2

-

2

Part

Specification Description

131-0420 Cylinder Head Fas- 1. Coat the threads of the bolts with clean engine oil. tener Gp 2. Tighten bolt (1) through bolt (8) in the numerical sequence to a torque of 30 ± 5 N·m (22 ± 4 lb ft). 131-0421 Cylinder Head Fas- 3. Tighten bolt (1) through bolt (8) in the numerical sequence to 100 ± 15 N·m tener Gp (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 5B-0213 Bolt (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).

RENR5057

53 Specifications Section

i04728230

Cylinder Head Valves SMCS Code: 1105 Part No.: 317-2440 S/N: GD31–Up Part No.: 317-2440 S/N: ZAD1–Up Part No.: 317-2440 S/N: ZAH1–Up Part No.: 317-2440 S/N: ZAJ1–Up Part No.: 317-2440 S/N: YAM1–Up Part No.: 317-2440 S/N: YAN1–Up Part No.: 317-2440 S/N: YAP1–Up Part No.: 317-2440 S/N: ZAP1–Up Part No.: 317-2440 S/N: ZBP1–Up Part No.: 317-2440 S/N: PBR1–Up Part No.: 317-2440 S/N: PDR1–Up Part No.: 317-2440 S/N: YAR1–Up Part No.: 317-2440 S/N: ZAR1–Up Part No.: 317-2440 S/N: ZBR1–Up Part No.: 317-2440 S/N: YAT1–Up Part No.: 317-2440 S/N: YBT1–Up Part No.: 317-2440 S/N: YAW1–Up Part No.: 317-2440 S/N: YBW1–Up Part No.: 317-2440 S/N: YAY1–Up Part No.: 317-2440 S/N: YAZ1–Up

54

RENR5057

Specifications Section

Illustration 39

g02829216

55

RENR5057

Specifications Section Table 32 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

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).

7

8

2

2

194-4897 Exhaust Valve

210-2542 Inlet Valve

Specification Description

Install the valve stem seal to the inlet valves. Before assembly, coat with engine oil. 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. 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

Diameter of exhaust valve seat insert is 60.119 ± 0.015 mm (2.3669 ± 0.0006 inch). 130-2608 Valve Seat Insert Bore in the cylinder head is 60.000 ± 0.025 mm (2.3622 ± 0.0010 inch). Face angle is 45.00 ± 0.25 degrees.

10

2

Diameter of inlet valve seat insert is 60.627 ± 0.015 mm (2.3869 ± 0.0006 inch). 130-2607 Valve Seat Insert Bore in the cylinder head is 60.508 ± 0.025 mm (2.3822 ± 0.0010 inch). Face angle is 20.00 ± 0.25 degrees.

56

RENR5057

Specifications Section

i04935314

Cylinder Head Valves SMCS Code: 1105 Part No.: 380-5795 S/N: YBB1–Up Part No.: 380-5795 S/N: YBC1–Up Part No.: 380-5795 S/N: JDE1–Up Part No.: 380-5795 S/N: JCY1–Up

57

RENR5057

Specifications Section

Illustration 40

g03117796

Table 33 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

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).

Specification Description

316-5980 Valve Stem Seal Install the valve stem seal to the inlet valves.

6

2

Diameter of exhaust valve seat insert is 60.119 ± 0.015 mm (2.3669 ± 0.0006 inch). 130-2608 Valve Seat Insert Bore in the cylinder head is 60.000 ± 0.025 mm (2.3622 ± 0.0010 inch). Face angle is 45.00 ± 0.25 degrees.

7

2

Diameter of inlet valve seat insert is 60.627 ± 0.015 mm (2.3869 ± 0.0006 inch). 130-2607 Valve Seat Insert Bore in the cylinder head is 60.508 ± 0.025 mm (2.3822 ± 0.0010 inch). Face angle is 20.00 ± 0.25 degrees.

58

RENR5057

Specifications Section

Illustration 41

g03117799

Table 34 Item

8

Qty

2

Part

194-4897 Exhaust Valve

9

2

210-2542 Inlet Valve

10

2

316-5981 Washer

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. 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.

RENR5057

59 Specifications Section

i04758986

Turbocharger Oil Lines SMCS Code: 1052; 1307 Part No.: 111-3424 S/N: GD31–Up

Illustration 42

g02852077

Typical example Front view of engine

Illustration 43

Typical example Rear view of engine

g02852078

60

RENR5057

Specifications Section Table 35 Specification for 111-3424 Turbocharger Oil Lines Gp, 101-1255 Turbocharger Oil Lines Gp, and 272-6983 Turbocharger Oil Lines Gp Item

Qty

Part

Specification Description

1

-

-

Before assembly, apply Loctite C5A Copper Anti-Seize to the threads and the bearing surfaces of bolts.

2

-

-

Before assembly, lightly lubricate the bore for the O-ring seals with the lubricant that is being sealed.

RENR5057

61 Specifications Section

i05209213

Turbocharger Oil Lines SMCS Code: 1052; 1307 Part No.: 380-5147 S/N: YBW1–Up

Illustration 44

g03334942

Rear view Table 36 Specification for 380-5147 Turbocharger Oil Lines Gp Item

Qty

Part

1

4

0S-1571 Bolt

Before assembly, apply Loctite C5A copper anti-seize to the washer face and threads.

2

4

0S-1594 Bolt

Before assembly, apply Loctite C5A copper anti-seize to the washer face and threads.

3

1

6V-4589 O-Ring Seal

Before assembly, lubricate the bore lightly with the lubricant that is being sealed.

4

1

250-1498 Elbow As

Before assembly, lubricate the bore lightly with the lubricant that is being sealed.

5

2

5P-9890 O-Ring Seal

Before assembly, lubricate the bore lightly with the lubricant that is being sealed.

Specification Description

62

RENR5057

Specifications Section

i04935859

Turbocharger SMCS Code: 1052 Part No.: 118-5463 S/N: ZAD1–Up Part No.: 118-5463, 118-5464 S/N: YAP1–Up Part No.: 118-5463, 118-5464 S/N: ZAP1–Up Part No.: 118-5463, 118-5464 S/N: ZBP1–Up Part No.: 118-5463, 118-5464 S/N: PBR1–Up Part No.: 118-5463 S/N: PDR1–Up Part No.: 118-5463 S/N: YAR1–Up Part No.: 118-5463 S/N: ZAR1–Up Part No.: 118-5463 S/N: ZBR1–Up Part No.: 118-5463, 118-5464 S/N: YAT1–Up Part No.: 118-5463, 118-5464 S/N: YBT1–Up Part No.: 118-5463 S/N: YAW1–Up Part No.: 118-5463 S/N: YBW1–Up

RENR5057

63 Specifications Section

Illustration 45

Typical example

g03111317

64

RENR5057

Specifications Section Table 37 Specification for 118-5463 Turbocharger Gp and 118-5464 Turbocharger Gp Item

Qty

1

16

2

3

4

4

4

4

Part

Specification description

2N-2765 High Temperature Before assembly, apply Loctite C5A Copper anti-seize to the threads and the bearing Bolt surfaces.

7W-2297 Clamp As

Use the following procedure to tighten the clamp assemblies. 1. Tighten the clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in). 2. Gently hit around the clamp assemblies with a soft hammer. 3. Again, tighten the clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in).

Use the following procedure to tighten the turbine clamp assemblies. 1. Tighten the turbine clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in). 9N-2038 Turbine Clamp As 2. Gently hit around the turbine clamp assemblies with a soft hammer. 3. Again, tighten the turbine clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in).

6L-3005 Band Clamp

Use the following procedure to tighten the band clamp. 1. Tighten the band clamp to 9.5 ± 1.0 N·m (84.1 ± 8.9 lb in). 2. Gently hit around the band clamp with a soft hammer. 3. Again, tighten the band clamp to 9.5 ± 1.0 N·m (84.1 ± 8.9 lb in).

RENR5057

65 Specifications Section

i04935828

Turbocharger SMCS Code: 1052 Part No.: 145-7992 S/N: ZAD1–Up

Illustration 46

g03111057

Top view of engine Table 38 Specification for 145-7992 Turbocharger Gp Item

Qty

1

8

2

8

3

4

2

2

Part

Specification description

2N-2765 High Temperature Before assembly, apply Loctite C5A Copper anti-seize to the threads and the bearing Bolt surfaces. 2N-2766 Locknut

7W-2297 Clamp As

Torque to 54 ± 5 N·m (40 ± 4 lb ft). Use the following procedure to tighten the clamp assemblies. 1. Tighten the clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in). 2. Gently hit around the clamp assembly with a soft hammer. 3. Again, tighten the clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in).

Use the following procedure to tighten the turbine clamp assemblies. 1. Tighten the clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in). 9N-2038 Turbine Clamp As 2. Gently hit around the clamp assembly with a soft hammer. 3. Again, tighten the clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in).

66

RENR5057

Specifications Section

i04935841

Turbocharger SMCS Code: 1052 Part No.: 107-0863, 116-0687 S/N: ZAD1–Up Part No.: 107-0863, 116-0687 S/N: ZAH1–Up Part No.: 107-0863, 116-0687 S/N: ZAJ1–Up Part No.: 107-0863, 116-0687 S/N: YAM1–Up Part No.: 107-0863, 116-0687 S/N: YAN1–Up Part No.: 107-0863, 116-0687 S/N: YAP1–Up Part No.: 107-0863, 116-0687 S/N: ZAP1–Up Part No.: 107-0863, 116-0687 S/N: PBR1–Up Part No.: 107-0863, 116-0687 S/N: YAR1–Up Part No.: 107-0863, 116-0687 S/N: ZAR1–Up Part No.: 107-0863, 116-0687 S/N: YAT1–Up Part No.: 107-0863, 116-0687 S/N: YAW1–Up Part No.: 107-0863, 116-0687 S/N: YAY1–Up Part No.: 107-0863, 116-0687 S/N: YAZ1–Up

RENR5057

67 Specifications Section

Illustration 47

Front view of engine

g03111156

68

RENR5057

Specifications Section Table 39 Specification for 116-0687 Turbocharger Gp and 107-0863 Turbocharger Gp Item

Qty

1

16

2

3

4

4

4

4

Part

Specification description

2N-2765 High Temperature Before assembly, apply Loctite C5A Copper anti-seize to the threads and the bearing Bolt surfaces.

4W-9977 Clamp As

Use the following procedure to tighten the clamp assemblies. 1. Tighten the clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in). 2. Gently hit around the clamp assemblies with a soft hammer. 3. Again, tighten the clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in).

Use the following procedure to tighten the turbine clamp assemblies. 1. Tighten the turbine clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in). 9N-2038 Turbine Clamp As 2. Gently hit around the turbine clamp assemblies with a soft hammer. 3. Again, tighten the turbine clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in).

6L-3005 Band Clamp

Use the following procedure to tighten the band clamp. 1. Tighten the band clamp to 9.5 ± 1.0 N·m (84.1 ± 8.9 lb in). 2. Gently hit around the band clamp with a soft hammer. 3. Again, tighten the band clamp to 9.5 ± 1.0 N·m (84.1 ± 8.9 lb in).

RENR5057

69 Specifications Section

i04935847

Turbocharger SMCS Code: 1052 Part No.: 172-0922 S/N: ZAD1–Up Part No.: 172-0922 S/N: ZAH1–Up Part No.: 172-0922, 203-2149 S/N: ZAJ1–Up Part No.: 172-0922 S/N: YAM1–Up Part No.: 172-0922, 203-2149 S/N: YAN1–Up Part No.: 172-0922 S/N: YAP1–Up Part No.: 172-0922 S/N: ZAP1–Up Part No.: 172-0922 S/N: PBR1–Up Part No.: 172-0922 S/N: YAR1–Up Part No.: 172-0922 S/N: ZAR1–Up Part No.: 172-0922 S/N: YAT1–Up Part No.: 172-0922 S/N: YAW1–Up Part No.: 172-0922 S/N: YAY1–Up Part No.: 172-0922, 203-2149 S/N: YAZ1–Up

70

RENR5057

Specifications Section

Illustration 48

g03111198

Table 40 Specification for 203-2149 Turbocharger Gp and 172-0922 Turbocharger Gp Item

Qty

1

8

Before assembly, apply Loctite C5A Copper anti-seize to the threads and the bearing 2N-2765 High Temperature surfaces. Bolt Torque to 54 ± 5 N·m (40 ± 4 lb ft).

2

16

188-8617 High Temperature Torque to 40 ± 2 N·m (30 ± 1 lb ft). Bolt

3

16

Part

125-5375 Bolt

Specification description

Torque to 40 ± 2 N·m (30 ± 1 lb ft).

RENR5057

71 Specifications Section

i04938320

Turbocharger SMCS Code: 1052 Part No.: 379-5300 S/N: YBB1–Up

Illustration 49

g03117856

Table 41 Specification for 379-5300 Turbocharger Gp Item

Qty

Part

6L-3005 Band Clamp

Specification description Use the following procedure to tighten the band clamp. 1. Tighten the band clamp to 9.5 ± 1.0 N·m (84.1 ± 8.9 lb in). 2. Gently hit around the band clamp with a soft hammer. 3. Again, tighten the band clamp to 9.5 ± 1.0 N·m (84.1 ± 8.9 lb in).

1

4

2

16

2N-2765 High Temperature Before assembly, apply Loctite C5A Copper anti-seize to washer face and threads. Bolt

4

Use the following procedure to tighten the turbine clamp assemblies. 1. Tighten the turbine clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in). 9N-2038 Turbine Clamp As 2. Gently hit around the turbine clamp assemblies with a soft hammer. 3. Again, tighten the turbine clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in).

3

4

4

4W-9977 Clamp As

Use the following procedure to tighten the clamp assemblies. 1. Tighten the clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in). 2. Gently hit around the clamp assemblies with a soft hammer. 3. Again, tighten the clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in).

72

RENR5057

Specifications Section

i05251150

Turbocharger SMCS Code: 1052 Part No.: 322-1928 S/N: GD31–Up

RENR5057

73 Specifications Section

Illustration 50

g03345208

74

RENR5057

Specifications Section Table 42 Specification for 322-1928 Turbocharger Gp Item

Qty

1

16

Part

Specification description

Before assembly, apply Loctite C5A Copper anti-seize to the threads and the bearing 2N-2765 High Temperature surfaces. Bolt Torque to 55 ± 10 N·m (41 ± 7 lb ft). Use the following procedure to tighten the clamp assemblies:

2

4

7W-2297 Clamp As

1. Tighten the clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in). 2. Gently hit around the clamp assemblies with a soft hammer. 3. Again, tighten the clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in). Use the following procedure to tighten the turbine clamp assemblies:

3

4

9N-2038 Turbine Clamp As 1. Tighten the turbine clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in). 2. Gently hit around the turbine clamp assemblies with a soft hammer. 3. Again, tighten the turbine clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in). Use the following procedure to tighten the band clamp:

4

4

6L-3005 Band Clamp

1. Tighten the band clamp to 9.5 ± 1.0 N·m (84.1 ± 8.9 lb in). 2. Gently hit around the band clamp with a soft hammer. 3. Again, tighten the band clamp to 9.5 ± 1.0 N·m (84.1 ± 8.9 lb in).

75

RENR5057

Specifications Section

i04938288

Turbocharger SMCS Code: 1052 Part No.: 379-5302 S/N: JDE1–Up Part No.: 379-5302 S/N: JCY1–Up

76

RENR5057

Specifications Section

Illustration 51

g03117776

Table 43 Specification for 379-5302 Turbocharger Gp Item

Qty

Part

1

4

6L-3005 Band Clamp

2

4

9N-2038 Turbine Clamp As

3

4

7W-2297 Clamp As

4

16

2N-2765 High Temperature Bolt

Specification description Use the following procedure to tighten the band clamp. 1. Tighten the band clamp to 9.5 ± 1.0 N·m (84.1 ± 8.9 lb in). 2. Gently hit around the band clamp with a soft hammer. 3. Again, tighten the band clamp to 9.5 ± 1.0 N·m (84.1 ± 8.9 lb in).

Use the following procedure to tighten the turbine clamp assemblies. 1. Tighten the turbine clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in). 2. Gently hit around the turbine clamp assemblies with a soft hammer. 3. Again, tighten the turbine clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in). Use the following procedure to tighten the clamp assemblies. 1. Tighten the clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in). 2. Gently hit around the clamp assemblies with a soft hammer. 3. Again, tighten the clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in). Before assembly, apply Loctite C5A Copper anti-seize to washer face and threads.

77

RENR5057

Specifications Section

i04938361

Turbocharger SMCS Code: 1052 Part No.: 379-5323 S/N: JDE1–Up

Illustration 52

g03117993

Table 44 Specification for 379-5323 Turbocharger Gp Item

Qty

Part

1

16

125-5375 Bolt

Torque to 40 ± 2 N·m (30 ± 2 lb ft).

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, apply Loctite C5A Copper Anti-Seize to threads and bearing surfaces.

Specification Description

Torque to 54 ± 5 N·m (40 ± 4 lb ft).

78

RENR5057

Specifications Section

i04934574

Exhaust Manifold SMCS Code: 1059

Part No.: 101-1259 S/N: ZAD1–Up Part No.: 101-1259 S/N: ZAH1–Up Part No.: 101-1259 S/N: ZAJ1–Up Part No.: 101-1259 S/N: YAM1–Up Part No.: 101-1259 S/N: YAN1–Up Part No.: 101-1259 S/N: YAP1–Up Part No.: 101-1259 S/N: ZAP1–Up Part No.: 101-1259 S/N: PBR1–Up Part No.: 101-1259 S/N: YAR1–Up Part No.: 101-1259 S/N: ZAR1–Up Part No.: 101-1259 S/N: YAT1–Up Part No.: 101-1259 S/N: YAW1–Up Part No.: 101-1259 S/N: YAY1–Up Part No.: 101-1259 S/N: YAZ1–Up

RENR5057

79 Specifications Section

Illustration 53

g03106850

Front view Table 45 Specification for 101-1259 Exhaust Manifold Gp Item

Qty

Part

Specification Description

1

8

2N-2766 Locknut

Before assembly, lubricate the threads and the bearing surfaces of the locknuts with Loctite C5A Copper Anti-Seize. Torque to 55 ± 5 N·m (41 ± 4 lb ft).

2

1

9L-2295 High Temperature Before assembly, lubricate the threads and the bearing surfaces of the bolt with Loctite C5A Copper Anti-Seize. Bolt

3

4

7L-6443 High Temperature Before assembly, lubricate the threads and the bearing surfaces of the bolts with Loctite C5A Copper Anti-Seize. Bolt

4

24

5P-2755 High Temperature Before assembly, lubricate the threads and the bearing surfaces of the bolts with Loctite C5A Copper Anti-Seize. Bolt

5

48

Before assembly, lubricate the threads and the bearing surfaces of the bolts with 9L-7373 High Temperature Loctite C5A Copper Anti-Seize. Bolt Torque to 50 ± 5 N·m (37 ± 4 lb ft).

80

RENR5057

Specifications Section

i04379769

Exhaust Manifold SMCS Code: 1059

Part No.: 144-2876 S/N: ZAD1–Up

Illustration 54

g01968613

Table 46 Specification for the 144-2876 Exhaust Manifold Gp 283-1557 Exhaust Manifold Gp 288-5986 Exhaust Manifold Gp 191-8391 Exhaust Manifold Gp Item

Qty

1

24

Torque the bolts to 55 ± 5 N·m (41 ± 4 lb ft). 5P-2755 High Temperature Before assembly, lubricate the threads and the bearing surfaces of the bolts with Bolt 4C-5599 Anti-Seize Compound.

2

32

Torque the bolts to 50 ± 5 N·m (37 ± 4 lb ft). 9L-7373 High Temperature Before assembly, lubricate the threads and the bearing surfaces of the bolts with Bolt 4C-5599 Anti-Seize Compound.

Part

Specification Description

RENR5057

81 Specifications Section

i04379754

Exhaust Manifold SMCS Code: 1059

Part No.: 172-0921 S/N: ZAH1–Up Part No.: 172-0921 S/N: ZAJ1–Up Part No.: 172-0921 S/N: YAN1–Up Part No.: 172-0921 S/N: ZAP1–Up Part No.: 172-0921 S/N: PBR1–Up Part No.: 172-0921 S/N: ZAR1–Up Part No.: 172-0921 S/N: YAT1–Up Part No.: 172-0921 S/N: YAZ1–Up

82

RENR5057

Specifications Section

Illustration 55

g02543679

Table 47 Specification for the 172-0921 Exhaust Manifold Gp Item

Qty

1

40

Torque the bolts to 55 ± 5 N·m (41 ± 4 lb ft). 7L-6443 High Temperature Before assembly, apply 4C-5599 Anti-Seize Compound to the threads and the Bolt bearing surfaces of the bolts.

2

48

Torque the bolts to 50 ± 5 N·m (37 ± 4 lb ft). 9L-7373 High Temperature Before assembly, apply 4C-5599 Anti-Seize Compound to the threads and the Bolt bearing surfaces of the bolts.

Part

Specification Description

RENR5057

83 Specifications Section

i04938317

Exhaust Manifold SMCS Code: 1059

Part No.: 378-8169 S/N: YBB1–Up Part No.: 378-8169 S/N: YBC1–Up

Illustration 56

g03117858

Table 48 Specification for 378-8169 Exhaust Manifold Gp Item

Qty

Part

Specification Description

1

8

5P-3345 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

4

7L-6443 High Temperature Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing Bolt surfaces.

3

24

Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing 5P-2755 High Temperature surfaces. Bolt Torque to 55 ± 5 N·m (41 ± 4 lb ft).

4

48

Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing 9L-7373 High Temperature surfaces. Bolt Torque to 50 ± 5 N·m (37 ± 4 lb ft).

5

1

9L-2295 High Temperature Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing Bolt surfaces.

84

RENR5057

Specifications Section

i04938331

Exhaust Manifold SMCS Code: 1059

Part No.: 398-0313 S/N: YBB1–Up Part No.: 398-0313 S/N: YBC1–Up

Illustration 57

g03118096

Table 49 Specification for 398-0313 Exhaust Manifold Gp Item

Qty

Part

Specification Description

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

Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing 5P-2755 High Temperature surfaces. Bolt Torque to 55 ± 5 N·m (41 ± 4 lb ft).

3

48

Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing 9L-7373 High Temperature surfaces. Bolt Torque to 50 ± 5 N·m (37 ± 4 lb ft).

RENR5057

85 Specifications Section

i04935265

Exhaust Manifold SMCS Code: 1059

Part No.: 381-4733 S/N: JDE1–Up Part No.: 381-4733 S/N: JCY1–Up

86

RENR5057

Specifications Section

Illustration 58

g03109336

Table 50 Specification for 381-4733 Exhaust Manifold Gp Item

Qty

Part

1

24

2N-2766 Locknut

Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing surfaces.

2

8

5P-3345 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

64

Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing 9L-7373 High Temperature surfaces. Bolt Torque to 50 ± 5 N·m (37 ± 4 lb ft).

4

40

Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing 5P-2755 High Temperature surfaces. Bolt Torque to 55 ± 5 N·m (41 ± 4 lb ft).

Specification Description

RENR5057

87 Specifications Section

i04935259

Exhaust Manifold SMCS Code: 1059

Part No.: 111-6786 S/N: GD31–Up Part No.: 111-6786 S/N: YAP1–Up Part No.: 111-6786 S/N: ZAP1–Up Part No.: 111-6786 S/N: ZBP1–Up Part No.: 111-6786 S/N: PBR1–Up Part No.: 111-6786 S/N: PDR1–Up Part No.: 111-6786 S/N: YAR1–Up Part No.: 111-6786 S/N: ZAR1–Up Part No.: 111-6786 S/N: ZBR1–Up Part No.: 111-6786 S/N: YAT1–Up Part No.: 111-6786 S/N: YBT1–Up Part No.: 111-6786 S/N: YAW1–Up Part No.: 111-6786 S/N: YBW1–Up

88

RENR5057

Specifications Section

Illustration 59

g03109321

Front view of Engine Table 51 Specification for 111-6786 Exhaust Manifold Gp Item

Qty

Part

Specification Description

1

8

5P-3345 Bolt

Before assembly, lubricate the threads and the bearing surfaces of the bolts with Loctite C5A Copper Anti-Seize. Torque to 55 ± 5 N·m (41 ± 4 lb ft).

2

48

2N-2766 Locknut

Before assembly, lubricate the threads and the bearing surfaces of the locknuts with Loctite C5A Copper Anti-Seize.

3

64

Before assembly, lubricate the threads and the bearing surfaces of the bolts with 9L-7373 High Temperature Loctite C5A Copper Anti-Seize. Bolt Torque to 50 ± 5 N·m (37 ± 4 lb ft).

RENR5057

89 Specifications Section

i04380845

Exhaust Flange SMCS Code: 1061 Part No.: 7N-6961 S/N: ZAD1–Up Part No.: 7N-6961 S/N: ZAH1–Up Part No.: 7N-6961 S/N: YAM1–Up Part No.: 7N-6961 S/N: YAP1–Up Part No.: 7N-6961 S/N: ZAP1–Up Part No.: 7N-6961 S/N: ZBP1–Up Part No.: 7N-6961 S/N: PBR1–Up Part No.: 7N-6961 S/N: PDR1–Up Part No.: 7N-6961 S/N: YAR1–Up Part No.: 7N-6961 S/N: ZAR1–Up Part No.: 7N-6961 S/N: ZBR1–Up Part No.: 7N-6961 S/N: YAT1–Up Part No.: 7N-6961 S/N: YBT1–Up Part No.: 7N-6961 S/N: YAW1–Up Part No.: 7N-6961 S/N: YBW1–Up

90

RENR5057

Specifications Section

Illustration 60

g02546044

Table 52 Specification for the 7N-6961 Exhaust Flange Gp Item

Qty

Part

1

8

0S-1590 Bolt

Specification Description Apply 4C-5599 Anti-Seize Compound to the threads of the bolts.

RENR5057

91 Specifications Section

i04735510

Exhaust Flange SMCS Code: 1061 Part No.: 103-6668 S/N: GD31–Up Part No.: 103-6668 S/N: YBB1–Up Part No.: 103-6668 S/N: JDE1–Up Part No.: 103-6668 S/N: ZAH1–Up Part No.: 103-6668 S/N: ZAJ1–Up Part No.: 103-6668 S/N: YAM1–Up Part No.: 103-6668 S/N: YAN1–Up Part No.: 103-6668 S/N: YAP1–Up Part No.: 103-6668 S/N: ZAP1–Up Part No.: 103-6668 S/N: ZBP1–Up Part No.: 103-6668 S/N: PBR1–Up Part No.: 103-6668 S/N: PDR1–Up Part No.: 103-6668 S/N: YAR1–Up Part No.: 103-6668 S/N: ZAR1–Up Part No.: 103-6668 S/N: ZBR1–Up Part No.: 103-6668 S/N: YAT1–Up Part No.: 103-6668 S/N: YBT1–Up Part No.: 103-6668 S/N: YAW1–Up Part No.: 103-6668 S/N: YBW1–Up Part No.: 103-6668 S/N: JCY1–Up

92

RENR5057

Specifications Section

Illustration 61

g02834876

Table 53 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.

RENR5057

93 Specifications Section

i04380839

Exhaust Flange SMCS Code: 1061 Part No.: 7N-6962 S/N: PBR1–Up

Illustration 62

g02546021

Typical example Table 54 Specification for the 7N-6962 Exhaust Flange Gp 1W-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.

94

RENR5057

Specifications Section

i05206314

Air Cleaner

SMCS Code: 1051 Part No.: 206-0884 S/N: GD31–Up

Illustration 63

g03334504

Table 55 Specification for 317-9958 Air Cleaner Gp Item

Qty

Part

1

-

-

Specification Description Tighten the nut to 4.0 ± 0.5 N·m (35.4 ± 4.4 lb in).

RENR5057

95 Specifications Section

i04380890

Engine Air Cleaner Service Indicator SMCS Code: 7452 Part No.: 7N-6782 S/N: GD31–Up

Illustration 64

g02546280

Rear view of engine (1) Air cleaner Table 56 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

2

2

6I-2933 Air Filter Service Indicator

Specification Description 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.

96

RENR5057

Specifications Section

i04383993

Air Lines

SMCS Code: 1058; 1071 Part No.: 208-0821 S/N: GD31–Up

Illustration 65

g02638896

Typical example Table 57 Specification for 208-0821 Air Lines Gp and 285-4161 Air Lines Gp Item

Qty

Part

1

4

197-9732 U-Bolt

2

4

321-5895 Shield As

Specification Description Torque to 15 ± 2 N·m (133 ± 18 lb in). During installation, do not crush the shield assembly. Install the shield assembly with the springs and hooks at the top of the hose as shown in Illustration 65 .

RENR5057

97 Specifications Section

i04936927

Air Inlet and Exhaust Lines SMCS Code: 1058; 1061 Part No.: 106-7596 S/N: ZAD1–Up Part No.: 106-7596 S/N: ZAH1–Up Part No.: 106-7596 S/N: ZAJ1–Up Part No.: 106-7596 S/N: YAM1–Up Part No.: 106-7596 S/N: YAN1–Up Part No.: 106-7596 S/N: YAP1–Up Part No.: 106-7596 S/N: ZAP1–Up Part No.: 106-7596 S/N: PBR1–Up Part No.: 106-7596 S/N: YAR1–Up Part No.: 106-7596 S/N: ZAR1–Up Part No.: 106-7596 S/N: YAT1–Up Part No.: 106-7596 S/N: YAW1–Up Part No.: 106-7596 S/N: YAY1–Up Part No.: 106-7596 S/N: YAZ1–Up

98

RENR5057

Specifications Section

Illustration 66

g03113657

Front view of engine

Illustration 67

Bolt tightening sequence

g03113676

RENR5057

99 Specifications Section

Table 58 Specification for 106-7596 Air Lines Gp Item

Qty

Part

1

8

6V-3917 O-Ring Seal

Lubricate the bore lightly with glycerine or 5P-3975 Rubber Lubricant.

2

4

3J-5389 Plug

Before assembly, apply Loctite C5A Copper anti-seize to the threads. Torque to 20 ± 5 N·m (177 ± 44 lb in).

3

8

Specification description

6V-1943 High Temperature Before assembly, apply Loctite C5A Copper anti-seize to the threads. Torque to 55 ± 10 N·m (41 ± 7 lb ft). Bolt

4

10

9F-2773 Bolt

5

12

6V-5101 O-Ring Seal

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 67 to 24 N·m (18 lb ft). 9. Again, tighten the bolts in a numerical sequence that is shown in Illustration 67 to 47 N·m (35 lb ft). 10. Remove the tape.

Lubricate the bore lightly with glycerine or 5P-3975 Rubber Lubricant.

100

RENR5057

Specifications Section

i04935876

Air Inlet and Exhaust Lines SMCS Code: 1058; 1061 Part No.: 144-2888 S/N: ZAD1–Up

Illustration 68

g03111736

Right side view of engine

Illustration 69

Bolt tightening sequence

g03111416

RENR5057

101 Specifications Section

Table 59 Specification for 144-2888 Air Lines Gp Item

Qty

Part

1

4

6V-3917 O-Ring Seal

2

6

9F-2773 Bolt

3

8

6V-5101 O-Ring Seal

4

2

3J-5389 Plug

5

4

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: 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 69 to 24 N·m (18 lb ft). 9. Again, tighten the bolts in a numerical sequence that is shown in Illustration 69 to 47 N·m (35 lb ft). 10. Remove the tape.

Lubricate the bore lightly with 5P-3975 Rubber Lubricant. Before assembly, apply Loctite C5A Copper anti-seize to the threads. Torque to 25 ± 5 N·m (221 ± 44 lb in). Lubricate the bore lightly with 5P-3975 Rubber Lubricant.

102

RENR5057

Specifications Section

i04936976

Air Inlet and Exhaust Lines SMCS Code: 1058; 1061 Part No.: 162-5718 S/N: ZAJ1–Up Part No.: 162-5718 S/N: YAN1–Up Part No.: 162-5718 S/N: YAZ1–Up

RENR5057

103 Specifications Section

Illustration 70

Right side view of engine

g03113778

104

RENR5057

Specifications Section

Illustration 71

g03113779

Bolt tightening sequence Table 60 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 71 to 24 N·m (18 lb ft). 9. Again, tighten the bolts in a numerical sequence that is shown in Illustration 71 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.

RENR5057

105 Specifications Section

i04936959

Air Inlet and Exhaust Lines SMCS Code: 1058; 1061 Part No.: 173-2947 S/N: ZAH1–Up Part No.: 173-2947 S/N: ZAP1–Up Part No.: 173-2947 S/N: PBR1–Up Part No.: 173-2947 S/N: ZAR1–Up

106

RENR5057

Specifications Section

Illustration 72

Right side view of engine

g03113719

RENR5057

107 Specifications Section

Illustration 73

g03113720

Bolt tightening sequence Table 61 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 73 to 24 N·m (18 lb ft). 9. Again, tighten the bolts in a numerical sequence that is shown in Illustration 73 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.

108

RENR5057

Specifications Section

i04937021

Air Inlet and Exhaust Lines SMCS Code: 1058; 1061 Part No.: 198-9918 S/N: GD31–Up Part No.: 198-9918 S/N: YAP1–Up Part No.: 198-9918 S/N: ZAP1–Up Part No.: 198-9918 S/N: PBR1–Up Part No.: 198-9918 S/N: YAT1–Up

Illustration 74

g03113937

Front view of engine Table 62 Specification for 198-9918 Turbocharger Air Lines Gp Item

Qty

Part

1

16

6V-3917 O-Ring Seal

2

4

3J-5389 Plug

Before assembly, apply Loctite C5A Copper anti-seize to the threads. Torque to 20 ± 5 N·m (177 ± 44 lb in).

3

8

6V-1943 High Temperature Bolt

Before assembly, apply Loctite C5A Copper anti-seize to the threads. Torque to 55 ± 10 N·m (41 ± 7 lb ft).

Specification Description Before assembly, lubricate the bore lightly with glycerin or approved equivalent.

RENR5057

109 Specifications Section

Illustration 75

g03113956

Right side view of engine

Illustration 76

Bolt tightening sequence

g03113959

110

RENR5057

Specifications Section Table 63 Item

Qty

Part

Specification Description 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 to 24 N·m (18 lb ft). 9. Again, tighten the bolts in a numerical sequence that is shown in Illustration to 47 N·m (35 lb ft). 10. Remove the tape.

4

12

9F-2773 Bolt

5

16

6V-5101 O-Ring Seal

Before assembly, lubricate the bore lightly with glycerin or approved equivalent.

6

3

5P-8940 O-Ring Seal

Before assembly, lubricate the bore lightly with glycerin or approved equivalent.

RENR5057

111 Specifications Section

i04937052

Air Inlet and Exhaust Lines SMCS Code: 1058; 1061 Part No.: 147-6619 S/N: PBR1–Up Part No.: 147-6619 S/N: YAR1–Up Part No.: 147-6619 S/N: ZAR1–Up Part No.: 147-6619 S/N: YAT1–Up Part No.: 147-6619 S/N: YAW1–Up

Illustration 77

g03114022

Front view of engine Table 64 Specification for 147-6619 Air Lines Gp Item

Qty

Part

1

8

6V-3917 O-Ring Seal

2

4

3J-5389 Plug

Before assembly, apply Loctite C5A Copper anti-seize to the threads. Torque to 20 ± 5 N·m (177 ± 44 lb in).

3

8

6V-1943 High Temperature Bolt

Before assembly, apply Loctite C5A Copper anti-seize to the threads. Torque to 55 ± 10 N·m (41 ± 7 lb ft).

Specification Description Lubricate the bore lightly with 5P-3975 Rubber Lubricant.

112

RENR5057

Specifications Section

Illustration 78

g03114024

Right side view of engine

Illustration 79

g03114025

Bolt tightening sequence Table 65 Item

Qty

Part

Specification Description 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 to 24 N·m (18 lb ft). 9. Again, tighten the bolts in a numerical sequence that is shown in Illustration to 47 N·m (35 lb ft). 10. Remove the tape.

4

12

9F-2773 Bolt

5

3

5P-8940 O-Ring Seal

Lubricate the bore lightly with 5P-3975 Rubber Lubricant.

RENR5057

113 Specifications Section

i04405434

Air Shutoff

SMCS Code: 1078 Part No.: 214-5543 S/N: ZAD1–Up Part No.: 214-5543 S/N: ZAH1–Up Part No.: 214-5543 S/N: ZAJ1–Up

Illustration 80

Rear view

g02596659

114

RENR5057

Specifications Section

Illustration 81

g02596660

Table 66 Specification for 214-5543 Air Shutoff Gp Item

Qty

Part

1

1

272-7094 Air Shutoff Gp

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).

2

1

227-7483 Limit Switch As

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).

3

2

215-2589 Bolt

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

4

1

215-2706 Air Shutoff As

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).

7

2

215-2587 Bolt

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).

RENR5057

115 Specifications Section

i04906863

Air Shutoff

SMCS Code: 1078 Part No.: 135-0180 S/N: YBB1–Up Part No.: 135-0180 S/N: JDE1–Up Part No.: 135-0180 S/N: ZAH1–Up Part No.: 135-0180 S/N: YAM1–Up Part No.: 135-0180 S/N: YAP1–Up Part No.: 135-0180 S/N: ZAP1–Up Part No.: 135-0180 S/N: ZBP1–Up Part No.: 135-0180 S/N: PBR1–Up Part No.: 135-0180 S/N: PDR1–Up Part No.: 135-0180 S/N: YAR1–Up Part No.: 135-0180 S/N: ZAR1–Up Part No.: 135-0180 S/N: ZBR1–Up Part No.: 135-0180 S/N: YAT1–Up Part No.: 135-0180 S/N: YBT1–Up Part No.: 135-0180 S/N: YAW1–Up Part No.: 135-0180 S/N: YBW1–Up Part No.: 135-0180 S/N: JCY1–Up Part No.: 135-0180 S/N: YAY1–Up

116

RENR5057

Specifications Section

Illustration 82

g03069718

Table 67 Specification for 135-0180 Air Shutoff Gp Item

Qty

Part

1

1

2W-4880 Plate As

2

1

129-3021 Ring

Specification Description A 0.8 mm (0.03 inch) feeler gauge must not pass between the plate and the housing at any point when the plate is in the closed position. Before assembly, apply Loctite 411 to the housing.

RENR5057

117 Specifications Section

i04738394

Air Shutoff

SMCS Code: 1078 Part No.: 287-7866 S/N: YAN1–Up

Illustration 83

g02837440

Top view (1) 152-2700 Air Shutoff Valve and Mounting Table 68 Specification for 287-7866 Air Shutoff Gp Item

Qty

Part

Specification Description Nominal actuation pressure is 117 kPa (17 psi).

2

1

296-8190 Air Shutoff Gp

Air shutoff group must not actuate at 14 kPa (2 psi) or below 14 kPa (2 psi). Air shutoff group must actuate at 172 kPa (25 psi) or above 172 kPa (25 psi). Pressure should not exceed 690 kPa (100 psi).

118

RENR5057

Specifications Section

Illustration 84

g02837436

Rear view Table 69 Specification for 287-7866 Air Shutoff Gp Item

Qty

Part

3

1

3J-7354 O-Ring Seal

Before assembly, lightly lubricate the bore with glycerin or an approved equivalent.

4

3

3J-1907 O-Ring Seal

Before assembly, lightly lubricate the bore with glycerin or an approved equivalent.

5

1

6V-5048 O-Ring Seal

Before assembly, lightly lubricate the bore with glycerin or an approved equivalent.

Specification Description

RENR5057

119 Specifications Section

Air Shutoff Valve and Mounting (1)

Illustration 85

g02837438

Table 70 Specification for 152-2700 Air Shutoff Valve and Mounting Item

Qty

Specification Description

Part Nominal voltage is 24 V

Resistance at 25 ± 5 °C (77 ± 9 °F) is 32.6 ± 1.6 ohms. 7

1

152-8341 Solenoid Valve Gp Torque 111-0343 Locknut(6) to 9.0 ± 0.5 N·m (79.7 ± 4.4 lb in). Final installation torque is 108 ± 7 N·m (80 ± 5 lb ft).

120

RENR5057

Specifications Section

i04930024

Air Shutoff

SMCS Code: 1078 Part No.: 380-1077 S/N: YBC1–Up

Illustration 86

g03099620

Table 71 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).

RENR5057

121 Specifications Section

Illustration 87

g03099622

Table 72 Item

Qty

Part

4

2

215-2589 Bolt

Specification Description Before assembly, apply Loctite C5A Copper Anti-Seize to the threads. Torque to 7 ± 1 N·m (62 ± 9 lb in).

5

1

215-2706 Air Shutoff As

6

1

289-9132 Body

7

1

215-2707 Cover

8

2

215-2587 Bolt

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).

9

2

215-2587 Bolt

10

1

230-4073 Solenoid As

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.

11

2

215-2588 Bolt Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).

122

RENR5057

Specifications Section

i04908578

Prelube Pump

RENR5057

123 Specifications Section

SMCS Code: 1319 Part No.: 302-8729 S/N: YBB1–Up Part No.: 302-8729 S/N: YBC1–Up Part No.: 383-8477 S/N: JDE1–Up Part No.: 302-8729 S/N: ZAH1–Up Part No.: 302-8729 S/N: ZAJ1–Up Part No.: 302-8729 S/N: YAM1–Up Part No.: 302-8729 S/N: YAN1–Up Part No.: 302-8729 S/N: YAP1–Up Part No.: 302-8729 S/N: ZAP1–Up Part No.: 302-8729 S/N: ZBP1–Up Part No.: 302-8729 S/N: PBR1–Up Part No.: 302-8729 S/N: PDR1–Up Part No.: 302-8729 S/N: YAR1–Up Part No.: 302-8729 S/N: ZAR1–Up Part No.: 302-8729 S/N: ZBR1–Up Part No.: 302-8729 S/N: YAT1–Up Part No.: 302-8729 S/N: YBT1–Up Part No.: 302-8729 S/N: YAW1–Up Part No.: 302-8729 S/N: YBW1–Up Part No.: 383-8477 S/N: JCY1–Up Part No.: 302-8729 S/N: YAY1–Up Part No.: 302-8729 S/N: YAZ1–Up

124

RENR5057

Specifications Section

Illustration 88

g03075336

Table 73 Specification for 383-8477 Prelubrication Oil Pump Gp and 302-8729 Prelubrication Oil Pump Gp Item

Qty

Part

1

4

5P-9890 O-Ring Seal

Before assembly, lubricate the bore with 1P-0808 Multipurpose Grease.

2

2

5P-5846 O-Ring Seal

Before assembly, lubricate the bore with 1P-0808 Multipurpose Grease.

3

1

214-7568 O-Ring Seal

Before assembly, lubricate the bore with 1P-0808 Multipurpose Grease.

4

1

6V-5100 O-Ring Seal

Before assembly, lubricate the bore with 1P-0808 Multipurpose Grease.

5

1

2G-6303 Seal

Before assembly, lubricate the bore with 1P-0808 Multipurpose Grease.

-

-

-

Specification Description

Flow at 1200 rpm is 49 L/min (13 US gpm).

i00680561

Prelube Pump

Part No.: 302-8729 S/N: ZBR1–Up

SMCS Code: 1319

Part No.: 302-8729 S/N: YBT1–Up

Part No.: 302-8729 S/N: YBB1–Up

Part No.: 302-8729 S/N: YBW1–Up

Part No.: 302-8729 S/N: YBC1–Up

Part No.: 302-8729 S/N: JCY1–Up

Part No.: 302-8729 S/N: JDE1–Up Part No.: 302-8729 S/N: ZBP1–Up Part No.: 302-8729 S/N: PDR1–Up

RENR5057

125 Specifications Section

Illustration 89

g00288335

(1) Inside diameter of idler gear bearing.... 19.126 mm (.7530 inch) (2) Idler gear Thickness of electrically driven idler gear ..................22.25 to 22.28 mm (.876 to .877 inch) Pump end clearance Measure the clearance between the back of the rotor and the machined surface in the bottom housing.................................... 0.013 to 0.076 mm (.0005 to .0030 inch) (3) Outside diameter of the rotor .............85.509 to 85.547 mm (3.3665 to 3.3680 inch) (4) Idler pocket Depth of electrically driven idler pocket ........................................21.340 mm (.8402 inch)

126

RENR5057

Specifications Section

i04908624

Prelube Pump (Air) SMCS Code: 1319 Part No.: 1W-4674 S/N: YAP1–Up Part No.: 1W-4674 S/N: ZAP1–Up Part No.: 1W-4674 S/N: ZBP1–Up Part No.: 1W-4674 S/N: PBR1–Up Part No.: 1W-4674 S/N: PDR1–Up Part No.: 1W-4674 S/N: YAR1–Up Part No.: 1W-4674 S/N: ZAR1–Up Part No.: 1W-4674 S/N: ZBR1–Up

Illustration 90

g03075476

Table 74 Specification for 1W-4674 Prelubrication Oil Pump Gp Item

Qty

Part

-

-

-

Specification Description Flow at 1150 rpm and 172 kPa (25 psi) of air pressure with oil that has a kinematic viscosity of 162 is 76 L/min (20 US gpm).

RENR5057

127 Specifications Section

i04907799

Prelube Pump SMCS Code: 1319 Part No.: 4P-4925 S/N: YAP1–Up Part No.: 4P-4925 S/N: ZAP1–Up Part No.: 4P-4925 S/N: ZBP1–Up Part No.: 4P-4925 S/N: PBR1–Up Part No.: 4P-4925 S/N: YAR1–Up Part No.: 4P-4925 S/N: ZAR1–Up Part No.: 4P-4925 S/N: ZBR1–Up

128

RENR5057

Specifications Section

Illustration 91

g03073840

Table 75 Specification for 4P-4925 Prelubrication Oil Pump and Lines Gp Item

Qty

Part

1

2

5P-5846 O-Ring Seal

Before assembly, lubricate the bore with 1P-0808 Multipurpose Grease.

2

1

153-4906 O-Ring Seal

Before assembly, lubricate the bore with 1P-0808 Multipurpose Grease.

3

2

6V-5100 O-Ring Seal

Before assembly, lubricate the bore with 1P-0808 Multipurpose Grease.

4

4

5P-9890 O-Ring Seal

Before assembly, lubricate the bore with 1P-0808 Multipurpose Grease.

5

1

2G-6303 Seal

Before assembly, lubricate the bore with 1P-0808 Multipurpose Grease.

-

-

-

Specification Description

Flow at 1200 rpm is 49 L/min (13 US gpm).

RENR5057

129 Specifications Section

i04724870

Engine Oil Pump SMCS Code: 1304 Part No.: 106-9872

130

RENR5057

Specifications Section

Illustration 92

g02826456

RENR5057

131 Specifications Section

Table 76 Specification for the 106-9872 Engine Oil Pump Gp Item

Qty

Specification Description

Part

Length of the new gear is 110.000 ± 0.015 mm (4.3307 ± 0.0006 inch). 1

2

106-9866 Gear

2

106-9867 Idler Shaft Assembly

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

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

G

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). 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).

132

RENR5057

Specifications Section

i04912024

Engine Oil Pump SMCS Code: 1304 Part No.: 7W-0053 S/N: ZAD1–Up

Illustration 93

g03079576

Table 77 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.

RENR5057

133 Specifications Section

Illustration 94

g03079678

Table 78 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).

134

RENR5057

Specifications Section

Illustration 95

g03079836

Section A-A Table 79 Specification for 7N-8715 Engine Oil Pump Gp Item

Qty

Part

Specification Description Length of new gear is 54.000 ± 0.015 mm (2.1260 ± 0.0006 inch).

C

2

7N-6733 Gear

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).

D

2

7W-1017 Shaft

E

2

4M-3248 Hollow Dowel

F

-

-

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). 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). 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).

RENR5057

135 Specifications Section

Illustration 96

g03079878

Table 80 Specification for 7N-8715 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).

136

RENR5057

Specifications Section

Illustration 97

g03079902

Illustration 98

g03079958

Table 81 Specification for 7N-8715 Engine Oil Pump Gp Item

Qty

Part

M

-

-

Specification Description Position of 7W-0060 Bushing joints from the centerline through the bearing bores is 45 ± 15 degrees.

RENR5057

137 Specifications Section

i04921863

Engine Oil Pump SMCS Code: 1304 Part No.: 8N-6152 S/N: ZAD1–Up Part No.: 8N-6152 S/N: ZAH1–Up Part No.: 8N-6152 S/N: ZAJ1–Up Part No.: 8N-6152 S/N: YAM1–Up Part No.: 8N-6152 S/N: YAN1–Up Part No.: 8N-6152 S/N: YAP1–Up Part No.: 8N-6152 S/N: ZAP1–Up Part No.: 8N-6152 S/N: PBR1–Up Part No.: 8N-6152 S/N: YAR1–Up Part No.: 8N-6152 S/N: ZAR1–Up Part No.: 8N-6152 S/N: YAT1–Up Part No.: 8N-6152 S/N: YAW1–Up Part No.: 8N-6152 S/N: YAY1–Up Part No.: 8N-6152 S/N: YAZ1–Up

138

RENR5057

Specifications Section

Illustration 99

g03104511

Table 82 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.

RENR5057

139 Specifications Section

Illustration 100

g03088657

Table 83 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).

140

RENR5057

Specifications Section

Illustration 101

g03088658

Section A-A Table 84 Specification for 8N-6152 Engine Oil Pump Gp Item

Qty

Part

Specification Description Length of the new gear is 84.000 ± 0.015 mm (3.3071 ± 0.0006 inch).

C

2

7N-5052 Gear

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).

D

2

7W-1017 Shaft

E

2

4M-3248 Hollow Dowel

F

-

-

G

1

7W-1017 Shaft

H

-

-

J

1

7W-0050 Pump Cover

Installation depth of the sleeve bearing in the pump cover is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).

K

1

4P-5637 Oil Pump Body As

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

RENR5057

141 Specifications Section

Illustration 102

g03088699

Table 85 Specification for the 8N-6152 Engine Oil Pump Gp Item

Qty

Part

L

2

7N-2043 Dowel

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

142

RENR5057

Specifications Section

Illustration 103

g03106577

Illustration 104

g03106578

Table 86 Specification for the 8N-6152 Engine Oil Pump Gp Item

Qty

Part

M

-

-

Specification Description Position of bearing joints from the centerline through the bearing bores is 45 ± 15 degrees.

RENR5057

143 Specifications Section

i04907238

Engine Oil Cooler Bypass and Cooling Jet Sequence Valves SMCS Code: 1314; 1331 Part No.: 115-7860 S/N: GD31–Up Part No.: 115-7860 S/N: ZAD1–Up Part No.: 115-7860 S/N: ZAH1–Up Part No.: 115-7860 S/N: ZAJ1–Up Part No.: 115-7860 S/N: YAM1–Up Part No.: 115-7860 S/N: YAN1–Up Part No.: 115-7860 S/N: YAP1–Up Part No.: 115-7860 S/N: ZAP1–Up Part No.: 115-7860 S/N: PBR1–Up Part No.: 115-7860 S/N: PDR1–Up Part No.: 115-7860 S/N: YAR1–Up Part No.: 115-7860 S/N: ZAR1–Up Part No.: 115-7860 S/N: YAT1–Up Part No.: 115-7860 S/N: YBT1–Up Part No.: 115-7860 S/N: YAW1–Up Part No.: 115-7860 S/N: YAY1–Up Part No.: 115-7860 S/N: YAZ1–Up

144

RENR5057

Specifications Section

Illustration 105

g03071676

Right side view

Illustration 106

Front view

g03071677

RENR5057

145 Specifications Section

Table 87 Specification for 115-7860 Engine Oil Lines Gp Item

Qty

Part

1

4

0S-1594 Bolt

2

4

0S-1571 Bolt

5

2

6B-9202 Spring

Length under test force is 68.3 mm (2.69 inch). Test force is 85 to 100 N (19 to 22 lb). Free length after test is 112.7 mm (4.44 inch).

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). The oil cooler bypass valve must open with a pressure difference of 180 ± 20 kPa (26 ± 3 psi). The cooling jet sequence valves must start to open at a pressure difference of 130 ± 30 kPa (19 ± 4 psi). The cooling jet sequence valves must be fully open at a pressure difference of 200 ± 30 kPa (29 ± 4 psi).

6

1

7

2

7N-7697 Plunger

8

6

109-2332 O-Ring Seal

9

1

2W-1053 Plug

Specification Description Use the following tightening sequence for the clamp bolts: 1. Snugly tighten the clamp assembly (3) to the tube (4). 2. Tighten two bolts (1) of the clamp assembly to the elbow (10) to the standard torque.. 3. Tighten two bolts (2) of the clamp assembly to the tube (4) to the standard torque..

Lubricate the bore lightly with the clean engine oil. Torque to 100 ± 15 N·m (74 ± 11 lb ft).

146

RENR5057

Specifications Section

i04389453

Engine Oil Cooler Bypass and Cooling Jet Sequence Valves SMCS Code: 1314; 1331 Part No.: 262-0338 S/N: ZAD1–Up Part No.: 262-0338 S/N: ZAH1–Up Part No.: 262-0338 S/N: ZAJ1–Up Part No.: 262-0338 S/N: YAN1–Up Part No.: 262-0338 S/N: YAZ1–Up

Illustration 107

Right side view Typical example

g01616336

RENR5057

147 Specifications Section

Illustration 108

g02557456

Front view Typical example Table 88 Specification for 115-7860 Engine Oil Lines Gp, 202-2657 Engine Oil Lines Gp, and 262-0338 Engine Oil Lines Gp Item

Qty

Part

-

-

0S-1594 Bolt

-

-

0S-1571 Bolt

Specification Description 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 (9) 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). The cooling jet sequence valves must start to open at a pressure difference of 130 ± 30 kPa (19 ± 4 psi). The cooling jet sequence valves must be fully open at a pressure difference of 200 ± 30 kPa (29 ± 4 psi).

-

-

-

5

2

6B-9202 Spring

Length under test force is 68.3 mm (2.69 inch). Test force is 85 to 100 N (19 to 22 lb). Free length after test is 112.7 mm (4.44 inch). 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 oil cooler bypass valve must open with a pressure difference of 180 ± 20 kPa (26 ± 3 psi).

6

1

2W-1635 Spring

7

6

109-2332 O-Ring Seal

8

1

2W-1053 Plug

Lubricate the bore lightly with the clean engine oil. Torque to 100 ± 15 N·m (74 ± 11 lb ft).

148

RENR5057

Specifications Section

i04925725

Engine Oil Filter SMCS Code: 1318 Part No.: 319-2130 S/N: ZAD1–Up Part No.: 319-2130 S/N: ZAH1–Up Part No.: 319-2130 S/N: ZAJ1–Up Part No.: 319-2130 S/N: YAM1–Up Part No.: 319-2130 S/N: YAN1–Up Part No.: 319-2130 S/N: YAP1–Up Part No.: 319-2130, 4W-6874 S/N: ZAP1–Up Part No.: 319-2130 S/N: ZBP1–Up Part No.: 319-2130, 4W-6874 S/N: PBR1–Up Part No.: 319-2130 S/N: PDR1–Up Part No.: 319-2130 S/N: YAR1–Up Part No.: 319-2130, 4W-6874 S/N: ZAR1–Up Part No.: 319-2130 S/N: ZBR1–Up Part No.: 319-2130, 4W-6874 S/N: YAT1–Up Part No.: 319-2130 S/N: YBT1–Up Part No.: 319-2130 S/N: YAW1–Up Part No.: 319-2130 S/N: YBW1–Up Part No.: 319-2130 S/N: YAY1–Up Part No.: 319-2130 S/N: YAZ1–Up

RENR5057

149 Specifications Section

Illustration 109

g03093056

Table 89 Specification for 4W-6874 Engine Oil Filter Gp, 319-2130 Engine Oil Filter Gp and 319-2131 Engine Oil Filter Gp Item

Qty

Part

1

6

6V-5048 O-Ring Seal

2

1

2W-1635 Spring

Specification Description Lubricate the bore lightly with clean engine oil. Length under test force is 102.0 mm (4.02 inch). Test force is 518 ± 26 N (117 ± 6 lb). Free length after test force is 143.4 mm (5.65 inch). Valve must move freely in bore.

3

1

2W-1969 Bypass Valve

4

3

165-3931 Bolt

Torque to 55 ± 7 N·m (41 ± 5 lb ft).

5

3

0L-1143 Bolt

Torque to 55 ± 7 N·m (41 ± 5 lb ft).

Start to open pressure is 287 ± 7 kPa (42 ± 1 psi). Fully open pressure is 480 ± 7 kPa (70 ± 1 psi).

150

RENR5057

Specifications Section

i04390177

Engine Oil Filter SMCS Code: 1318 Part No.: 112-4921 S/N: GD31–Up Part No.: 112-4921 S/N: ZAD1–Up Part No.: 112-4921 S/N: ZAH1–Up Part No.: 112-4921 S/N: ZAJ1–Up Part No.: 112-4921 S/N: YAM1–Up Part No.: 112-4921 S/N: YAN1–Up Part No.: 112-4921 S/N: YAP1–Up Part No.: 112-4921 S/N: ZAP1–Up Part No.: 112-4921 S/N: ZBP1–Up Part No.: 112-4921 S/N: PBR1–Up Part No.: 112-4921 S/N: PDR1–Up Part No.: 112-4921 S/N: YAR1–Up Part No.: 112-4921 S/N: ZAR1–Up Part No.: 112-4921 S/N: ZBR1–Up Part No.: 112-4921 S/N: YAT1–Up Part No.: 112-4921 S/N: YBT1–Up Part No.: 112-4921 S/N: YAW1–Up Part No.: 112-4921 S/N: YBW1–Up Part No.: 112-4921 S/N: YAY1–Up Part No.: 112-4921 S/N: YAZ1–Up

RENR5057

151 Specifications Section

Illustration 110

Front view

g02632117

152

RENR5057

Specifications Section Table 90 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).

RENR5057

153 Specifications Section

i04907897

Engine Oil Filter SMCS Code: 1318 Part No.: 375-7427 S/N: YBB1–Up Part No.: 375-7427 S/N: YBC1–Up Part No.: 375-7427 S/N: JDE1–Up Part No.: 375-7427 S/N: JCY1–Up

Illustration 111

g03073971

Front view Table 91 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).

154

RENR5057

Specifications Section

i04390193

Engine Oil Filter SMCS Code: 1318 Part No.: 115-7841 S/N: GD31–Up

Illustration 112

g02841297

Typical example Front view

Illustration 113

Left side view

g02559976

RENR5057

155 Specifications Section

Table 92 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).

156

RENR5057

Specifications Section

i04939243

Engine Oil Lines SMCS Code: 1307 Part No.: 262-0338, 314-6062, 316-3176 S/N: ZAD1–Up Part No.: 262-0338, 314-5925, 314-6062 S/N: ZAH1–Up Part No.: 262-0338, 314-5925, 314-6062 S/N: ZAJ1–Up Part No.: 314-6062 S/N: YAM1–Up Part No.: 314-5925, 314-6062 S/N: YAN1–Up Part No.: 314-6062 S/N: YAP1–Up Part No.: 314-6062 S/N: ZAP1–Up Part No.: 314-6062 S/N: ZBP1–Up Part No.: 314-6062, 316-3176 S/N: PBR1–Up Part No.: 147-5448, 314-6062 S/N: YAR1–Up Part No.: 314-6062 S/N: ZAR1–Up Part No.: 314-6062 S/N: ZBR1–Up Part No.: 314-6062 S/N: YAT1–Up Part No.: 314-6062 S/N: YBT1–Up Part No.: 314-6062 S/N: YAW1–Up Part No.: 314-6062 S/N: YBW1–Up Part No.: 314-6062 S/N: YAY1–Up Part No.: 314-5925, 314-6062 S/N: YAZ1–Up

RENR5057

157 Specifications Section

Illustration 114

g03120217

Typical example Right side view

Illustration 115

Typical example Front view

g03120216

158

RENR5057

Specifications Section Table 93 Specification for 316-3176 Engine Oil Lines Gp, 314-5925 Engine Oil Lines Gp, 147-5448 Engine Oil Lines Gp, 262-0338 Engine Oil Lines Gp, and 314-6062 Engine Oil Lines Gp Item

Qty

Part

1

-

0S-1594 Bolt

2

-

100-8075 Clamp As

3

-

0S-1571 Bolt

4

-

1N-3333 Tube

5

-

109-2332 O-Ring Seal

6

1

2W-1053 Plug

Specification Description Use the following tightening sequence for the clamp bolts: 1. Snugly tighten the clamp assembly (2) to the tube assembly (4). 2. Tighten the bolts (3) of the clamp assembly to the elbow (7) to 47 ± 9 N·m (35 ± 7 lb ft). 3. Tighten the bolts (1) of the clamp assembly to the tube assembly (4) to 47 ± 9 N·m (35 ± 7 lb ft). Lubricate the bore lightly with the lubricant that is being sealed. Torque to 100 ± 15 N·m (74 ± 11 lb ft).

RENR5057

159 Specifications Section

i04936891

Engine Oil Lines SMCS Code: 1307 Part No.: 115-7860 S/N: GD31–Up Part No.: 115-7860 S/N: ZAD1–Up Part No.: 115-7860 S/N: ZAH1–Up Part No.: 115-7860 S/N: ZAJ1–Up Part No.: 115-7860 S/N: ZAP1–Up Part No.: 115-7860 S/N: PBR1–Up Part No.: 115-7860 S/N: PDR1–Up Part No.: 115-7860 S/N: YAR1–Up Part No.: 115-7860 S/N: ZAR1–Up Part No.: 115-7860 S/N: YAT1–Up Part No.: 115-7860 S/N: YBT1–Up

160

RENR5057

Specifications Section

Illustration 116

g03113497

Right side view

Illustration 117

Front view

g03113516

RENR5057

161 Specifications Section

Table 94 Specification for 115-7860 Engine Oil Lines Gp Item

Qty

Part

1

4

0S-1594 Bolt

2

2

100-8075 Clamp As

3

2

0S-1571 Bolt

4

1

1N-3333 Tube

5

6

109-2332 O-Ring Seal

Lubricate the bore lightly with the lubricant that is being sealed.

6

1

6V-4589 O-Ring Seal

Lubricate the bore lightly with the lubricant that is being sealed.

7

1

2W-1053 Plug

9

1

5P-7817 O-Ring Seal

Lubricate the bore lightly with the lubricant that is being sealed.

10

1

6V-5048 O-Ring Seal

Lubricate the bore lightly with the lubricant that is being sealed.

Specification Description Use the following tightening sequence for the clamp bolts: 1. Snugly tighten the clamp assembly (2) to the tube assembly (4). 2. Tighten the bolts (3) of the clamp assembly to the 7N-5413 Elbow(8) to 47 ± 9 N·m (35 ± 7 lb ft). 3. Tighten the bolts (1) of the clamp assembly to the tube assembly (4) to 47 ± 9 N·m (35 ± 7 lb ft).

Torque to 100 ± 15 N·m (74 ± 11 lb ft).

162

RENR5057

Specifications Section

i04390217

Duplex Engine Oil Filters SMCS Code: 1318 Part No.: 120-4501 S/N: ZAD1–Up Part No.: 120-4501 S/N: ZAH1–Up Part No.: 120-4501 S/N: ZAJ1–Up Part No.: 120-4501 S/N: YAM1–Up Part No.: 120-4501 S/N: YAN1–Up Part No.: 120-4501 S/N: YAP1–Up Part No.: 120-4501 S/N: ZAP1–Up Part No.: 120-4501 S/N: ZBP1–Up Part No.: 120-4501 S/N: PBR1–Up Part No.: 120-4501 S/N: PDR1–Up Part No.: 120-4501 S/N: YAR1–Up Part No.: 120-4501 S/N: ZAR1–Up Part No.: 120-4501 S/N: ZBR1–Up Part No.: 120-4501 S/N: YAT1–Up Part No.: 120-4501 S/N: YBT1–Up Part No.: 120-4501 S/N: YAW1–Up Part No.: 120-4501 S/N: YBW1–Up

RENR5057

163 Specifications Section

Illustration 118

g02638956

Front view (3) Lever (5) Tie rod

(6) Ball plunger assembly (7) Bracket

(15) Cover

Table 95 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).

164

RENR5057

Specifications Section

i05076331

Engine Oil Cooler SMCS Code: 1378 Part No.: 4W-5891 S/N: GD31–Up

Illustration 119

g03242776

Typical example Table 96 Specification for 378-7400 Engine Oil Cooler Gp and 4W-5891 Engine Oil Cooler Gp Item

Qty

Part

1

2

109-2332 O-Ring Seal

Specification Description Before assembly, lubricate the bore lightly with the lubricant that is being sealed.

RENR5057

165 Specifications Section

i04390283

Crankcase Breather SMCS Code: 1317

Part No.: 124-5512 S/N: ZAD1–Up Part No.: 124-5512 S/N: ZAH1–Up Part No.: 124-5512 S/N: ZAJ1–Up Part No.: 124-5512 S/N: YAM1–Up Part No.: 124-5512 S/N: YAN1–Up Part No.: 124-5512 S/N: YAP1–Up Part No.: 124-5512 S/N: ZAP1–Up Part No.: 124-5512 S/N: PBR1–Up Part No.: 124-5512 S/N: YAR1–Up Part No.: 124-5512 S/N: ZAR1–Up Part No.: 124-5512 S/N: YAT1–Up Part No.: 124-5512 S/N: YAW1–Up Part No.: 124-5512 S/N: YAY1–Up Part No.: 124-5512 S/N: YAZ1–Up

166

RENR5057

Specifications Section

Illustration 120

g02847456

Table 97 Specification for 124-5512 Breather Gp Item

Qty

Part

1

3

033-6031 O-Ring Seal

Before assembly, lightly 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).

3

2

180-3007 Hose Clamp

Torque to 3.0 ± 0.5 N·m (26.6 ± 4.4 lb in).

Specification Description

RENR5057

167 Specifications Section

i04392854

Crankcase Breather SMCS Code: 1317

Part No.: 101-0838 S/N: ZAD1–Up

Illustration 121

g01614413

(3) Breather assembly

(4) Cover assembly

Table 98 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

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).

2

168

RENR5057

Specifications Section

i04931607

Crankcase Breather SMCS Code: 1317

Part No.: 394-8117 S/N: YBB1–Up Part No.: 394-8117 S/N: YBC1–Up

Illustration 122

g03101696

Table 99 Specification for 394-8117 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

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.

Specification Description

RENR5057

169 Specifications Section

i04934545

Crankcase Breather SMCS Code: 1317

Part No.: 394-8140 S/N: JDE1–Up Part No.: 394-8140 S/N: JCY1–Up

Illustration 123

g03106816

Table 100 Specification for 394-8140 Breather Gp Item

Qty

Part

1

4

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

4

033-6031 O-Ring Seal

Before assembly, lubricate the bore lightly with the lubricant that is being sealed.

Specification Description

170

RENR5057

Specifications Section

i04896383

Crankcase Breather SMCS Code: 1317

Part No.: 124-5513 S/N: GD31–Up Part No.: 124-5513 S/N: YAP1–Up Part No.: 124-5513 S/N: ZAP1–Up Part No.: 124-5513 S/N: ZBP1–Up Part No.: 124-5513 S/N: PBR1–Up Part No.: 124-5513 S/N: PDR1–Up Part No.: 124-5513 S/N: YAR1–Up Part No.: 124-5513 S/N: ZAR1–Up Part No.: 124-5513 S/N: ZBR1–Up Part No.: 124-5513 S/N: YAT1–Up Part No.: 124-5513 S/N: YBT1–Up Part No.: 124-5513 S/N: YAW1–Up Part No.: 124-5513 S/N: YBW1–Up

RENR5057

171 Specifications Section

Illustration 124

g03043516

Typical example Front view Table 101 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

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).

2

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.

172

RENR5057

Specifications Section

i04747489

Engine Oil Pan SMCS Code: 1302 Part No.: 7C-7185 S/N: ZAD1–Up

Illustration 125

Top view

g02844076

RENR5057

173 Specifications Section

Table 102 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.

174

RENR5057

Specifications Section

i04923806

Engine Oil Pan SMCS Code: 1302 Part No.: 7C-6887 S/N: ZAD1–Up

Illustration 126

Top view

g03090816

RENR5057

175 Specifications Section

Table 103 Specification for 7C-6887 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.

176

RENR5057

Specifications Section

i04923815

Engine Oil Pan SMCS Code: 1302 Part No.: 7C-6752 S/N: ZAD1–Up Part No.: 7C-6752 S/N: ZAH1–Up Part No.: 7C-6752 S/N: ZAJ1–Up Part No.: 7C-6752 S/N: YAM1–Up Part No.: 7C-6752 S/N: YAN1–Up Part No.: 7C-6752 S/N: YAP1–Up Part No.: 7C-6752 S/N: ZAP1–Up Part No.: 7C-6752 S/N: PBR1–Up Part No.: 7C-6752 S/N: YAR1–Up Part No.: 7C-6752 S/N: ZAR1–Up Part No.: 7C-6752 S/N: YAT1–Up Part No.: 7C-6752 S/N: YAW1–Up Part No.: 7C-6752 S/N: YAY1–Up Part No.: 7C-6752 S/N: YAZ1–Up

RENR5057

177 Specifications Section

Illustration 127

Top view

g03090904

178

RENR5057

Specifications Section Table 104 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.

RENR5057

179 Specifications Section

i04747511

Engine Oil Pan SMCS Code: 1302 Part No.: 7C-9938 S/N: ZAD1–Up Part No.: 7C-9938 S/N: ZAH1–Up Part No.: 7C-9938 S/N: ZAJ1–Up Part No.: 7C-9938 S/N: YAM1–Up Part No.: 7C-9938 S/N: YAN1–Up Part No.: 7C-9938 S/N: YAP1–Up Part No.: 7C-9938 S/N: ZAP1–Up Part No.: 7C-9938 S/N: PBR1–Up Part No.: 7C-9938 S/N: YAR1–Up Part No.: 7C-9938 S/N: ZAR1–Up Part No.: 7C-9938 S/N: YAT1–Up Part No.: 7C-9938 S/N: YAW1–Up Part No.: 7C-9938 S/N: YAY1–Up Part No.: 7C-9938 S/N: YAZ1–Up

180

RENR5057

Specifications Section

Illustration 128

Top view

g02844117

RENR5057

181 Specifications Section

Table 105 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.

182

RENR5057

Specifications Section

i04404603

Engine Oil Pan SMCS Code: 1302 Part No.: 8N-7706 S/N: ZAD1–Up Part No.: 8N-7706 S/N: ZAH1–Up Part No.: 8N-7706 S/N: ZAJ1–Up Part No.: 8N-7706 S/N: YAM1–Up Part No.: 8N-7706 S/N: YAN1–Up Part No.: 8N-7706 S/N: YAP1–Up Part No.: 8N-7706 S/N: ZAP1–Up Part No.: 8N-7706 S/N: PBR1–Up Part No.: 8N-7706 S/N: YAR1–Up Part No.: 8N-7706 S/N: ZAR1–Up Part No.: 8N-7706 S/N: YAT1–Up Part No.: 8N-7706 S/N: YAW1–Up Part No.: 8N-7706 S/N: YAY1–Up Part No.: 8N-7706 S/N: YAZ1–Up

RENR5057

183 Specifications Section

Illustration 129

g01616154

184

RENR5057

Specifications Section Table 106 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

1A-2029 Bolt

1. Tighten five bolts (11) to standard torque. 2. Tighten bolt 1 through bolt 10 in a numerical sequence that is shown in Illustration 129 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. 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.

14

-

-

15

38

5P-5855 Bolt

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).

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

RENR5057

185 Specifications Section

i04891924

Engine Oil Pan SMCS Code: 1302 Part No.: 381-2608 S/N: YBB1–Up Part No.: 381-2608 S/N: YBC1–Up Part No.: 377-5896 S/N: JDE1–Up Part No.: 377-5896 S/N: JCY1–Up

Illustration 130

Top view

g03027916

186

RENR5057

Specifications Section Table 107 Specification for 7C-4711 Oil Pan Gp, 377-5896 Oil Pan Gp, and 381-2608 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.

RENR5057

187 Specifications Section

i04931557

Engine Oil Pan SMCS Code: 1302 Part No.: 147-3181 S/N: YAR1–Up

Illustration 131

g03104468

Table 108 Specification for 147-3181 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

-

-

7

1

4B-2363 Oil Drain Plug

In order to prevent stress on the tube assembly (5), use the following tightening procedure during assembly: 1. Tighten two bolts (3) to 47 ± 9 N·m (35 ± 7 lb ft). 2. Then tighten two bolts (2) to 47 ± 9 N·m (35 ± 7 lb ft). As required, apply Loctite RTV Silicone Clear to the joints of the gasket. Torque to 145 ± 15 N·m (107 ± 11 lb ft).

188

RENR5057

Specifications Section

i04924021

Engine Oil Pan SMCS Code: 1302 Part No.: 7C-4711 S/N: GD31–Up Part No.: 7C-4711 S/N: YAP1–Up Part No.: 7C-4711 S/N: ZAP1–Up Part No.: 7C-4711 S/N: ZBP1–Up Part No.: 7C-4711 S/N: PBR1–Up Part No.: 7C-4711 S/N: PDR1–Up Part No.: 7C-4711 S/N: YAR1–Up Part No.: 7C-4711 S/N: ZAR1–Up Part No.: 7C-4711 S/N: ZBR1–Up Part No.: 7C-4711 S/N: YAT1–Up Part No.: 7C-4711 S/N: YBT1–Up Part No.: 7C-4711 S/N: YAW1–Up Part No.: 7C-4711 S/N: YBW1–Up

RENR5057

189 Specifications Section

Illustration 132

g03093076

Top view Table 109 Specification for 7C-4711 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, Permatex No # 2, or Red Loctite High Tack GS S to the joints of the gasket.

190

RENR5057

Specifications Section

i04908574

Engine Oil Pan SMCS Code: 1302 Part No.: 7C-7178 S/N: YAP1–Up Part No.: 7C-7178 S/N: ZAP1–Up Part No.: 7C-7178 S/N: ZBP1–Up Part No.: 7C-7178 S/N: PBR1–Up Part No.: 7C-7178 S/N: PDR1–Up Part No.: 7C-7178 S/N: YAR1–Up Part No.: 7C-7178 S/N: ZAR1–Up Part No.: 7C-7178 S/N: ZBR1–Up Part No.: 7C-7178 S/N: YAT1–Up Part No.: 7C-7178 S/N: YBT1–Up Part No.: 7C-7178 S/N: YAW1–Up Part No.: 7C-7178 S/N: YBW1–Up

RENR5057

191 Specifications Section

Illustration 133

Top view

g02843996

192

RENR5057

Specifications Section Table 110 Specification for 7C-7178 Oil Pan Gp Item

Qty

Part

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

-

-

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.

RENR5057

193 Specifications Section

i04404587

Water Temperature Regulator SMCS Code: 1355 Part No.: 6I-4950 S/N: ZAD1–Up Part No.: 6I-4950 S/N: ZAH1–Up Part No.: 6I-4950 S/N: ZAJ1–Up Part No.: 6I-4950 S/N: YAM1–Up Part No.: 6I-4950 S/N: YAN1–Up Part No.: 6I-4950 S/N: YAP1–Up Part No.: 6I-4950 S/N: ZAP1–Up Part No.: 6I-4950 S/N: PBR1–Up Part No.: 6I-4950 S/N: YAR1–Up Part No.: 6I-4950 S/N: ZAR1–Up Part No.: 6I-4950 S/N: YAT1–Up Part No.: 6I-4950 S/N: YAW1–Up Part No.: 6I-4950 S/N: YAY1–Up Part No.: 6I-4950 S/N: YAZ1–Up

194

RENR5057

Specifications Section

Illustration 134

g02595056

Table 111 Specification for 6I-4950 Water Temperature Regulator Item

Qty

Part

A

-

-

Start to open temperature is 81 to 84 °C (178 to 183 °F). Fully open temperature is 92 °C (198 °F).

Specification Description Minimum opening distance at fully open temperature is 10.4 mm (0.41 inch).

RENR5057

195 Specifications Section

i04907651

Water Temperature Regulator SMCS Code: 1355 Part No.: 248-5513

Illustration 135

g02545979

Table 112 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

196

RENR5057

Specifications Section

i04743817

Water Lines SMCS Code: 1380

Part No.: 7C-8122 S/N: GD31–Up

Illustration 136

g02840876

Table 113 Specification for 7C-8122 Water Lines Gp Item

Qty

Part

1

2

6V-5066 O-Ring Seal

Specification description Lubricate the bore lightly with glycerin.

RENR5057

197 Specifications Section

i05210298

Thermostatic Valve

198 Specifications Section SMCS Code: 1355 Part No.: 216-6217 S/N: YBC1–Up Part No.: 216-6217 S/N: ZAD1–Up Part No.: 216-6217 S/N: JDE1–Up Part No.: 216-6217 S/N: ZAH1–Up Part No.: 216-6217 S/N: ZAJ1–Up Part No.: 216-6217 S/N: YAM1–Up Part No.: 216-6217 S/N: YAN1–Up Part No.: 216-6217 S/N: YAP1–Up Part No.: 216-6217 S/N: ZAP1–Up Part No.: 216-6217 S/N: ZBP1–Up Part No.: 216-6217 S/N: PBR1–Up Part No.: 216-6217 S/N: PDR1–Up Part No.: 216-6217 S/N: YAR1–Up Part No.: 216-6217 S/N: ZAR1–Up Part No.: 216-6217 S/N: ZBR1–Up Part No.: 216-6217 S/N: YAT1–Up Part No.: 216-6217 S/N: YBT1–Up Part No.: 216-6217 S/N: YAW1–Up Part No.: 216-6217 S/N: YBW1–Up Part No.: 216-6217 S/N: JCY1–Up Part No.: 216-6217 S/N: YAY1–Up Part No.: 216-6217 S/N: YAZ1–Up

RENR5057

RENR5057

199 Specifications Section

Illustration 137

g03335121

Table 114 Specification for the 216-6217 Housing and Regulator Gp 292-6969 Housing and Regulator Gp 282-8537 Housing and Regulator Gp Item

Qty

Part

1

2

219-3240 Temperature Regulator

2

2

3K-0360 O-Ring Seal

A

-

-

Specification Description Start to open temperature is 19 to 22 °C (66 to 72 °F). Fully open temperature is 32 °C (90 °F). Apply glycerin or an approved equivalent to the bore of the O-ring seals. Minimum opening distance at fully open temperature is 9.0 ± 0.5 mm (0.35 ± 0.02 inch).

200

RENR5057

Specifications Section

i04394778

Fan Drive

SMCS Code: 1359 Part No.: 7W-3953 S/N: GD31–Up Part No.: 7W-3953 S/N: ZAD1–Up Part No.: 7W-3953 S/N: ZAH1–Up Part No.: 7W-3953 S/N: ZAJ1–Up Part No.: 7W-3953 S/N: YAM1–Up Part No.: 7W-3953 S/N: YAN1–Up Part No.: 7W-3953 S/N: YAP1–Up Part No.: 7W-3953 S/N: ZAP1–Up Part No.: 7W-3953 S/N: ZBP1–Up Part No.: 7W-3953 S/N: PBR1–Up Part No.: 7W-3953 S/N: PDR1–Up Part No.: 7W-3953 S/N: YAR1–Up Part No.: 7W-3953 S/N: ZAR1–Up Part No.: 7W-3953 S/N: ZBR1–Up Part No.: 7W-3953 S/N: YAT1–Up Part No.: 7W-3953 S/N: YBT1–Up Part No.: 7W-3953 S/N: YAW1–Up Part No.: 7W-3953 S/N: YBW1–Up Part No.: 7W-3953 S/N: YAY1–Up Part No.: 7W-3953 S/N: YAZ1–Up

RENR5057

201 Specifications Section

Illustration 138

g02844316

Table 115 Specification for 7W-3953 Fan Drive Gp Item

Qty

Part

1

1

3B-8489 Grease Fitting

2

1

2M-4453 O-Ring Seal

Before assembly, lightly lubricate the bore with the lubricant that is being sealed.

3

1

1J-4034 Lip Type Seal

Before assembly, lightly lubricate the sealing lip with the lubricant that is being sealed.

4

2

7K-4370 Bolt

5

1

3B-8686 Grease Fitting

Specification Description Before assembly, fill the cavity with green 1P-0808 Multipurpose Grease.

Before assembly, apply red Loctite 271 to the threads. Apply grease into the grease fitting in order to adjust the belt tension. Do not apply grease during assembling of fan drive group.

202

RENR5057

Specifications Section

i04925877

Fan Drive

SMCS Code: 1359 Part No.: 399-4454 S/N: YBB1–Up Part No.: 399-4454 S/N: YBC1–Up Part No.: 399-4454 S/N: JDE1–Up Part No.: 399-4454 S/N: JCY1–Up

Illustration 139

g03097356

Table 116 Specification for 399-4454 Fan Drive Gp Item

Qty

Part

1

1

3B-8489 Grease Fitting

Before assembly, fill the cavity with green 1P-0808 Multipurpose Grease.

2

1

1J-4034 Lip Type Seal

Before assembly, lightly lubricate the sealing lip with the lubricant that is being sealed.

3

2

7K-4370 Bolt

4

1

3B-8686 Grease Fitting

5

1

2M-4453 O-Ring Seal

Specification Description

Before assembly, apply red Loctite 271 to the threads. Apply grease into the grease fitting in order to adjust the belt tension. Do not apply grease during assembling of fan drive group. Before assembly, lightly lubricate the bore with the lubricant that is being sealed.

RENR5057

203 Specifications Section

i04934454

Radiator

SMCS Code: 1353 Part No.: 263-8038 S/N: ZAH1–Up Part No.: 263-8038 S/N: YAM1–Up Part No.: 263-8038 S/N: ZAP1–Up Part No.: 263-8038 S/N: YAT1–Up

Illustration 140

g03106558

Left side view Table 117 Specification for 263-8038 Radiator Gp Item

Qty

Part

1

3

216-2285 Tube Joint

Tighten the nut of the joint to 12.0 ± 0.5 N·m (106.2 ± 4.4 lb in).

2

4

5P-0054 Joint

Tighten the nut of the joint to 28.0 ± 0.5 N·m (247.8 ± 4.4 lb in).

3

2

2N-5183 Joint

Tighten the nut of the joint to 34.0 ± 0.5 N·m (300.9 ± 4.4 lb in).

Specification Description

204

RENR5057

Specifications Section

i04934465

Radiator

SMCS Code: 1353 Part No.: 9Y-6676 S/N: PBR1–Up

Illustration 141

g03106596

Table 118 Specification for 9Y-6676 Radiator Gp Item

Qty

Part

1

4

5P-0054 Joint

Tighten the nut of the joint to 28.0 ± 0.5 N·m (247.8 ± 4.4 lb in).

2

8

201-2184 Bolt

Torque to 430 ± 60 N·m (317 ± 44 lb ft).

3

10

251-5715 Bolt

Torque to 430 ± 60 N·m (317 ± 44 lb ft).

4

1

319-5890 Tube Joint

Specification Description

Tighten the nut of the joint to 33.0 ± 0.5 N·m (292.1 ± 4.4 lb in).

RENR5057

205 Specifications Section

i04934474

Radiator

SMCS Code: 1353 Part No.: 263-8042 S/N: ZAP1–Up Part No.: 263-8042 S/N: YAT1–Up

Illustration 142

g03106636

Left side view Table 119 Specification for 263-8042 Radiator and Fan Gp Item

Qty

Part

1

3

216-2285 Tube Joint

Tighten the nut of the joint to 12.0 ± 0.5 N·m (106.2 ± 4.4 lb in).

2

4

5P-0054 Joint

Tighten the nut of the joint to 28.0 ± 0.5 N·m (247.8 ± 4.4 lb in).

3

2

2N-5183 Joint

Tighten the nut of the joint to 34.0 ± 0.5 N·m (300.9 ± 4.4 lb in).

Specification Description

206

RENR5057

Specifications Section

i04892047

Engine Oil Sump Pump SMCS Code: 1324 Part No.: 7W-9703, 7W-9704 S/N: PBR1–Up

Illustration 143

g02567856

(1) Sump pump group Table 120 Specification for 7W-9704 Sump Pump Gp, 7W-9703 Sump Pump Gp, and 380-3941 Sump Pump Gp Item

2

Qty

1

Part

4P-5242 Oil Pickup Assembly

Specification Description 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 Oring 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).

RENR5057

207 Specifications Section

i04395597

Water Pump SMCS Code: 1361 Part No.: 2W-9726 S/N: ZAD1–Up

Illustration 144

(2) Ring assembly (3) Water pump seal group

g02847239

208

RENR5057

Specifications Section Table 121 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.

Specification Description

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 impel212-8180 Pump Drive Shaft As ler 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).

6

1

7

3

9M-2151 Taperlock Stud

8

3

9S-8752 Full Nut

9

1

7N-4758 Thrust Washer

10 1

212-8187 Impeller

11

1

3D-2824 O-Ring Seal

12

1

7G-8478 Adapter

B

Torque to 35 ± 5 N·m (26 ± 4 lb ft). Torque to 27 ± 4 N·m (239 ± 35 lb in). 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). 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). Lubricate the bore of the O-ring seals with glycerin or an approved equivalent. Torque to 100 ± 10 N·m (74 ± 7 lb ft).

RENR5057

209 Specifications Section

i05188702

Water Pump SMCS Code: 1361 Part No.: 2W-9729 S/N: GD31–Up Part No.: 2W-9729 S/N: ZAD1–Up Part No.: 2W-9729 S/N: ZAH1–Up Part No.: 2W-9729 S/N: ZAJ1–Up Part No.: 2W-9729 S/N: YAM1–Up Part No.: 2W-9729 S/N: YAN1–Up Part No.: 2W-9729 S/N: YAP1–Up Part No.: 2W-9729 S/N: ZAP1–Up Part No.: 2W-9729 S/N: ZBP1–Up Part No.: 2W-9729 S/N: PBR1–Up Part No.: 2W-9729 S/N: PDR1–Up Part No.: 2W-9729 S/N: YAR1–Up Part No.: 2W-9729 S/N: ZAR1–Up Part No.: 2W-9729 S/N: ZBR1–Up Part No.: 2W-9729 S/N: YAT1–Up Part No.: 2W-9729 S/N: YBT1–Up Part No.: 2W-9729 S/N: YAW1–Up Part No.: 2W-9729 S/N: YBW1–Up Part No.: 2W-9729 S/N: YAY1–Up Part No.: 2W-9729 S/N: YAZ1–Up

210

RENR5057

Specifications Section

Illustration 145

g03325370

Table 122 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.

2

1

149-5462 O-Ring Seal

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

3

1

212-8184 Impeller

4

3

9M-2151 Taperlock Stud

5

3

9S-8752 Full Nut

6

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).

7

1

5H-6734 O-Ring Seal

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

8

1

B

-

Specification Description

Bore of the impeller for new shaft is 25.342 ± 0.013 mm (0.9977 ± 0.0005 inch). Torque to 35 ± 5 N·m (26 ± 4 lb ft). Torque to 27 ± 4 N·m (239 ± 35 lb in).

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 impel212-8180 Pump Drive Shaft As ler within 0.15 mm (0.006 inch). Diameter of the shaft for impeller seating is 25.400 to 25.413 mm (1.0000 to 1.0005 inch). -

Clearance between the impeller and the cover is 0.5000 ± 0.4925 mm (0.01968 ± 0.01939 inch).

RENR5057

211 Specifications Section

i04873610

Water Pump SMCS Code: 1361 Part No.: 375-3658 S/N: YBB1–Up Part No.: 375-3658 S/N: YBC1–Up Part No.: 375-3658 S/N: JDE1–Up Part No.: 375-3658 S/N: JCY1–Up

212

RENR5057

Specifications Section

Illustration 146

g03003236

Table 123 Specification for 375-3658 Water Pump Gp Item

Qty

Part

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

-

-

Specification Description

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).

RENR5057

213 Specifications Section

Illustration 147

g03003256

214

RENR5057

Specifications Section Table 124 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).

RENR5057

215 Specifications Section

i04395622

Auxiliary Water Pump SMCS Code: 1371 Part No.: 9Y-8175 S/N: GD31–Up Part No.: 9Y-8175 S/N: ZAD1–Up Part No.: 9Y-8175 S/N: ZAH1–Up Part No.: 9Y-8175 S/N: ZAJ1–Up Part No.: 9Y-8175 S/N: YAM1–Up Part No.: 9Y-8175 S/N: YAN1–Up Part No.: 9Y-8175 S/N: YAP1–Up Part No.: 9Y-8175 S/N: ZAP1–Up Part No.: 9Y-8175 S/N: ZBP1–Up Part No.: 9Y-8175 S/N: PBR1–Up Part No.: 9Y-8175 S/N: PDR1–Up Part No.: 9Y-8175 S/N: YAR1–Up Part No.: 9Y-8175 S/N: ZAR1–Up Part No.: 9Y-8175 S/N: ZBR1–Up Part No.: 9Y-8175 S/N: YAT1–Up Part No.: 9Y-8175 S/N: YBT1–Up Part No.: 9Y-8175 S/N: YAW1–Up Part No.: 9Y-8175 S/N: YBW1–Up Part No.: 9Y-8175 S/N: YAY1–Up Part No.: 9Y-8175 S/N: YAZ1–Up

216

RENR5057

Specifications Section

Illustration 148

Typical example

g02570218

RENR5057

217 Specifications Section

Table 125 Specification for the 9Y-8175 Auxiliary Water Pump Gp Item

Qty

Part

A

1

212-8179 Shaft

B

2

5N-4383 Thrust Washer

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).

C

1

212-8179 Shaft

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.

218

RENR5057

Specifications Section

i04935840

Auxiliary Water Pump SMCS Code: 1371 Part No.: 1W-9554 S/N: ZAD1–Up Part No.: 1W-9554 S/N: ZAH1–Up Part No.: 1W-9554 S/N: ZAJ1–Up Part No.: 1W-9554 S/N: YAM1–Up Part No.: 1W-9554 S/N: YAN1–Up Part No.: 1W-9554 S/N: YAP1–Up Part No.: 1W-9554 S/N: ZAP1–Up Part No.: 1W-9554, 5N-2605 S/N: PBR1–Up Part No.: 1W-9554 S/N: YAR1–Up Part No.: 1W-9554 S/N: ZAR1–Up Part No.: 1W-9554 S/N: YAT1–Up Part No.: 1W-9554 S/N: YAW1–Up Part No.: 1W-9554 S/N: YAY1–Up Part No.: 1W-9554 S/N: YAZ1–Up

RENR5057

219 Specifications Section

Illustration 149

g03111216

Table 126 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 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).

1

1

9X-4594 Lip Type Seal

2

1

212-8183 Impeller

3

1

212-8179 Shaft

B

2

5N-4383 Thrust Washer

Bore of the impeller for shaft is 19.000 ± 0.013 mm (0.7480 ± 0.0005 inch). 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.

220

RENR5057

Specifications Section

i04935852

Auxiliary Water Pump (Sea Water) SMCS Code: 1371 Part No.: 9Y-5710 S/N: ZAD1–Up Part No.: 9Y-5710 S/N: ZAH1–Up Part No.: 9Y-5710 S/N: ZAJ1–Up Part No.: 9Y-5710 S/N: YAP1–Up Part No.: 9Y-5710 S/N: ZAP1–Up Part No.: 9Y-5710 S/N: PBR1–Up Part No.: 9Y-5710 S/N: YAR1–Up Part No.: 9Y-5710 S/N: ZAR1–Up

RENR5057

221 Specifications Section

Illustration 150

g03111257

Table 127 Specification for 9Y-5710 Auxiliary Sea Water Pump Gp Item

Qty

Part

1

1

4J-4382 Pipe Plug

2

1

259-4598 O-Ring Seal

Lubricate the bore lightly with 5P-3975 Rubber Lubricant.

Specification Description Remove the plug in order to prime the pump.

3

1

5L-7685 Zinc Rod As

The 233-8525 Pipe Plug is installed in the water inlet to the pump. The 6L-2280 Zinc Rod and the plug are installed in the water outlet at this location. Assemble the zinc rod in the plug according to the following procedure: 1. Apply blue Loctite 242 on the shoulder of the rod. Do not put the sealant on the threads of the rod. 2. Tighten the rod to 7 ± 2 N·m (62 ± 18 lb in).

4

1

2H-3934 O-Ring Seal

Lubricate the bore lightly with 5P-3975 Rubber Lubricant.

222

RENR5057

Specifications Section

Illustration 151

g03111339

Table 128 Item

Qty

Part

5

1

175-4986 Retaining Ring

Maintain 490 ± 45 N (110 ± 10 lb) load on ring while tightening socket setscrew to 0.9 ± 0.1 N·m (8.0 ± 0.9 lb in) peen over threads as shown in Illustration 151 .

6

1

108-4877 Hex Slotted Nut

For assembly, apply green Loctite 609 . Torque to 135 to 175 N·m (100 to 129 lb ft).

7

1

8B-7614 Bearing Nut

Torque to 135 to 200 N·m (100 to 148 lb ft).

8

1

112-9709 Key

9

1

9Y-5068 Impeller

Specification Description

For assembly, apply green Loctite 609 . For assembly, apply green Loctite 609 . Back up the shaft when pressing impeller to prevent bearing damage.

As required, use the following shims to obtain 0.18 to 0.23 mm (0.007 to 0.009 inch) axial clearance between the port plate and the impeller: 10

11

2

5N-9016 Shim

Thickness is 0.25 mm (0.010 inch).

2

5N-9015 Shim

Thickness is 0.38 mm (0.015 inch).

1

5N-2904 Seal Collar

Use the following procedure in order to assemble the seal collar: 1. Clean shaft and seal collar with acetone-based cleaner or other suitable degreasing solvent. 2. Apply green Loctite 609 to shaft at a distance of 15 mm (0.6 inch) from shoulder at bearing diameter. 3. Slide seal collar over shaft into position and rotate 180 degree in both directions. 4. Leave the seal collar 30 minutes before handling to cure.

RENR5057

223 Specifications Section

i04395627

Auxiliary Water Pump SMCS Code: 1371 Part No.: 291-4311 S/N: YBB1–Up Part No.: 291-4311 S/N: YBC1–Up Part No.: 291-4311 S/N: JDE1–Up Part No.: 291-4311 S/N: JCY1–Up

Illustration 152

Typical example

g02570218

224

RENR5057

Specifications Section Table 129 Specification for the 291-4311 Auxiliary Water Pump Gp Item

Qty

Part

A

1

212-8179 Shaft

B

2

5N-4383 Thrust Washer

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).

C

1

212-8179 Shaft

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.

RENR5057

225 Specifications Section

i04934477

Cooling System Pressure Cap

226

RENR5057

Specifications Section SMCS Code: 1382; 1392 Part No.: 4N-3311 S/N: YBB1–Up Part No.: 4N-3311 S/N: YBC1–Up Part No.: 4N-3311 S/N: ZAD1–Up Part No.: 4N-3311 S/N: JDE1–Up Part No.: 4N-3311 S/N: ZAH1–Up Part No.: 4N-3311 S/N: ZAJ1–Up Part No.: 4N-3311 S/N: YAM1–Up Part No.: 4N-3311 S/N: YAN1–Up Part No.: 4N-3311 S/N: YAP1–Up Part No.: 4N-3311 S/N: ZAP1–Up Part No.: 4N-3311 S/N: ZBP1–Up Part No.: 4N-3311 S/N: PBR1–Up Part No.: 4N-3311 S/N: PDR1–Up Part No.: 4N-3311 S/N: YAR1–Up Part No.: 4N-3311 S/N: ZAR1–Up Part No.: 4N-3311 S/N: ZBR1–Up Part No.: 4N-3311 S/N: YAT1–Up Part No.: 4N-3311 S/N: YBT1–Up Part No.: 4N-3311 S/N: YAW1–Up Part No.: 4N-3311 S/N: YBW1–Up Part No.: 4N-3311 S/N: JCY1–Up Part No.: 4N-3311 S/N: YAY1–Up Part No.: 4N-3311

S/N: YAZ1–Up

RENR5057

227 Specifications Section

Illustration 153

g03106656

Table 130 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).

228

RENR5057

Specifications Section

i04936903

Cylinder Block SMCS Code: 1201 Part No.: 240-6653 S/N: GD31–Up Part No.: 240-6651 S/N: ZAD1–Up Part No.: 240-6651 S/N: ZAH1–Up Part No.: 240-6651 S/N: ZAJ1–Up Part No.: 240-6651 S/N: YAM1–Up Part No.: 240-6651 S/N: YAN1–Up Part No.: 240-6651, 240-6653 S/N: YAP1–Up Part No.: 240-6651, 240-6653 S/N: ZAP1–Up Part No.: 240-6653 S/N: ZBP1–Up Part No.: 240-6651, 240-6653 S/N: PBR1–Up Part No.: 240-6653 S/N: PDR1–Up Part No.: 240-6651, 240-6653 S/N: YAR1–Up Part No.: 240-6651, 240-6653 S/N: ZAR1–Up Part No.: 240-6653 S/N: ZBR1–Up Part No.: 240-6651, 240-6653 S/N: YAT1–Up Part No.: 240-6653 S/N: YBT1–Up Part No.: 240-6651, 240-6653 S/N: YAW1–Up Part No.: 240-6653 S/N: YBW1–Up Part No.: 240-6651 S/N: YAY1–Up Part No.: 240-6651 S/N: YAZ1–Up

RENR5057

229 Specifications Section

Illustration 154

Front view

g02617919

230

RENR5057

Specifications Section Table 131 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 154 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

-

-

16

197-7008 Dowel

-

-

New dimension from centerline of crankshaft bearing bore to the top of the block is 586.00 mm (23.071 inch).

-

-

New dimension from centerline of crankshaft bearing bore to bottom of block (pan rails) is 230.00 mm (9.055 inch).

B C E F

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).

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).

RENR5057

231 Specifications Section

Illustration 155

g02617921

Right side view Table 132 Specification for 240-6651 Cylinder Block Gp and 240-6653 Cylinder Block Gp Item

Qty

Part

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).

Specification Description Lubricate the bore lightly with 5P-3975 Rubber Lubricant.

232

RENR5057

Specifications Section

Camshaft Bearing Position

Illustration 156

g03113603

Right side view Table 133 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).

RENR5057

233 Specifications Section

i05236458

Cylinder Block SMCS Code: 1201 Part No.: 237-7957 S/N: ZAD1–Up

Illustration 157

Front view

g02848764

234

RENR5057

Specifications Section Table 134 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

4

8

144-5692 Plate Gasket

5

8

197-7008 Dowel

A

10

101-1198 Camshaft Bearing

B

-

-

Extension of the dowel from the top face of the cylinder block is 20.0 ± 0.5 mm (0.79 ± 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 from the top face of the cylinder block is 21.0 ± 0.5 mm (0.83 ± 0.02 inch). Bore in the block for the camshaft bearing is 98.000 ± 0.020 mm (3.8583 ± 0.0008 inch). 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 157 to 190 ± 14 N·m (140 ± 10 lb ft). 3. Again tighten the bolts in the numerical sequence as shown in Illustration 157 to an angle of 180 ± 5 degrees.

RENR5057

235 Specifications Section

Illustration 158

g02848765

Right side view Table 135 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.

236

RENR5057

Specifications Section

i04890307

Cylinder Block SMCS Code: 1201 Part No.: 383-2091 S/N: YBB1–Up Part No.: 383-2091 S/N: YBC1–Up

Illustration 159

Front view of engine

g03022476

RENR5057

237 Specifications Section

Table 136 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 159 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 159 . 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

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).

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).

238

RENR5057

Specifications Section

Illustration 160

g03022496

Section B-B Table 137 Item

Qty

Part

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).

Specification Description

RENR5057

239 Specifications Section

Illustration 161

g03022536

Table 138 Item

Qty

Part

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.

8

28

7X-7925 Bolt

Specification Description

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 161 to 190 ± 14 N·m (140 ± 10 lb ft). 4. Again, tighten the bolts for an additional angle of 180 ± 5 degrees.

240

RENR5057

Specifications Section

i04890316

Cylinder Block SMCS Code: 1201 Part No.: 370-9890 S/N: JDE1–Up Part No.: 370-9890 S/N: JCY1–Up

Illustration 162

g03022599

Front view of engine Table 139 Specification for 370-9890 Cylinder Block Gp Item

Qty

Part

1

2

4W-4813 Plug

2

4

5F-9657 O-Ring Seal

3

18

101-1198 Camshaft Bearing

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 162 on each side of cylinder block.

(continued)

RENR5057

241 Specifications Section

(Table 139, contd) Oil holes must be positioned from horizontal at an angle (D) of 20 ± 5 degrees as shown in Illustration 162 . 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

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).

Illustration 163

Section B-B

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).

g03022577

242

RENR5057

Specifications Section Table 140 Specification for 370-9890 Cylinder Block Gp Item

Qty

Part

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).

Specification Description Lubricate the bore lightly with the lubricant that is being sealed.

Illustration 164

g03022596

Front view Table 141 Item

Qty

Part

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.

9

36

7X-7925 Bolt

Specification Description

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 164 to 190 ± 14 N·m (140 ± 10 lb ft). 4. Again, tighten the bolts to an additional angle of 180 ± 5 degrees.

RENR5057

243 Specifications Section

i05186218

Cylinder Liner

244

RENR5057

Specifications Section SMCS Code: 1216 Part No.: 211-7826 S/N: YBB1–Up Part No.: 211-7826 S/N: YBC1–Up Part No.: 118-9494, 211-7826 S/N: ZAD1–Up Part No.: 211-7826 S/N: JDE1–Up Part No.: 118-9494, 211-7826 S/N: ZAH1–Up Part No.: 118-9494, 211-7826 S/N: ZAJ1–Up Part No.: 118-9494, 211-7826 S/N: YAM1–Up Part No.: 118-9494, 211-7826 S/N: YAN1–Up Part No.: 118-9494, 211-7826 S/N: YAP1–Up Part No.: 118-9494, 211-7826 S/N: ZAP1–Up Part No.: 211-7826 S/N: ZBP1–Up Part No.: 118-9494, 211-7826 S/N: PBR1–Up Part No.: 211-7826 S/N: PDR1–Up Part No.: 118-9494, 211-7826 S/N: YAR1–Up Part No.: 118-9494, 211-7826 S/N: ZAR1–Up Part No.: 211-7826 S/N: ZBR1–Up Part No.: 118-9494, 211-7826 S/N: YAT1–Up Part No.: 211-7826 S/N: YBT1–Up Part No.: 118-9494, 211-7826 S/N: YAW1–Up Part No.: 211-7826 S/N: YBW1–Up Part No.: 211-7826 S/N: JCY1–Up Part No.: 118-9494, 211-7826 S/N: YAY1–Up Part No.: 118-9494, 211-7826

S/N: YAZ1–Up

RENR5057

245 Specifications Section

Illustration 165

g03324443

Table 142 Specification for 211-7826 Cylinder Block Liner, 118-9494 Cylinder Block Liner, and 350-0074 Cylinder Liner Item

Qty

Part

1

-

-

Bore (A) in new cylinder liner is 170.025 ± 0.025 mm (6.6939 ± 0.0010 inch).

2

-

-

Thickness (B) of flange on cylinder liner is 12.65 ± 0.02 mm (0.498 ± 0.001 inch) .

Specification Description

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 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.

246

RENR5057

Specifications Section

i05186230

Piston and Rings (One-Piece Piston) SMCS Code: 1214 Part No.: 281-6139 S/N: GD31–Up Part No.: 371-0822 S/N: YBB1–Up Part No.: 281-6139 S/N: ZAD1–Up Part No.: 281-6139 S/N: ZAH1–Up Part No.: 281-6139 S/N: ZAJ1–Up Part No.: 281-6139 S/N: YAM1–Up Part No.: 281-6139 S/N: YAN1–Up Part No.: 281-6139 S/N: YAP1–Up Part No.: 281-6139, 281-6141, 282-9965 S/N: ZAP1–Up Part No.: 281-6139 S/N: ZBP1–Up Part No.: 281-6139 S/N: PBR1–Up Part No.: 281-6139 S/N: PDR1–Up Part No.: 281-6139 S/N: YAR1–Up Part No.: 281-6139 S/N: ZAR1–Up Part No.: 281-6139 S/N: YAT1–Up Part No.: 281-6139 S/N: YBT1–Up Part No.: 281-6139 S/N: YAW1–Up Part No.: 371-0822 S/N: JCY1–Up Part No.: 281-6139 S/N: YAY1–Up Part No.: 281-6139 S/N: YAZ1–Up

RENR5057

247 Specifications Section

Illustration 166

g03324445

248

RENR5057

Specifications Section Table 143 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.

1

2

1

1

3

1

4

-

214-6066 Top Piston Ring

Install the top piston ring with the “UP-1” side toward the top of the piston. When the new top piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is 0.625 ± 0.125 mm (0.0246 ± 0.0049 inch). Thickness of new top piston ring is 3.88 mm (0.153 inch).

144-5695 Intermediate Piston Ring

Install the intermediate piston ring with the “UP-2” side toward the top of the piston. When the new intermediate piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is 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). Thickness oil control piston ring is 3.97 to 3.99 mm (0.156 to 0.157 inch). 223-6361 Oil Control Piston Ring 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. -

5

1

263-8955 Piston Pin

6

2

253-1238 Pin Retainer

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. Outside diameter is 69.930 ± 0.005 mm (2.7531 ± 0.0002 inch). Length is 101.70 to 102.00 mm (4.004 to 4.016 inch). The 263-8955 Piston Pin is not interchangeable with the former 197-0560 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).

RENR5057

249 Specifications Section

i05252211

Piston and Rings (One-Piece Piston) SMCS Code: 1214 Part No.: 371-0825 S/N: YBC1–Up Part No.: 371-0825 S/N: JDE1–Up Part No.: 341-3640 S/N: ZAJ1–Up Part No.: 341-3640 S/N: YAN1–Up Part No.: 341-3640 S/N: ZAR1–Up Part No.: 341-3640 S/N: ZBR1–Up Part No.: 341-3640 S/N: YAW1–Up Part No.: 341-3640 S/N: YBW1–Up Part No.: 341-3640 S/N: YAZ1–Up

250

RENR5057

Specifications Section

Illustration 167

g02613840

RENR5057

251 Specifications Section

Table 144 Specification for 341-3640 Piston and Rod Gp, and 371-0825 Piston Item

Qty

Part

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

1

144-5695 Intermediate 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 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

1

165-6668 Oil Control Pis- Clearance between the ends of the piston ring when the piston ring is installed in a cylinder ton Ring 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

6

2

253-1238 Pin Retainer

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).

252

RENR5057

Specifications Section

i04404533

Piston and Rings (Two-Piece Piston) SMCS Code: 1214 Part No.: 253-3066 S/N: ZAJ1–Up Part No.: 253-3066 S/N: YAN1–Up Part No.: 253-3066 S/N: YAR1–Up Part No.: 253-3066 S/N: ZAR1–Up Part No.: 253-3066 S/N: YAW1–Up Part No.: 253-3066 S/N: YAZ1–Up

RENR5057

253 Specifications Section

Illustration 168

g02594836

254

RENR5057

Specifications Section Table 145 Specification for 253-3066 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. Before assembly of the 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

1

172-0919 Crown As

2

1

155-5271 Piston Skirt

Bore in the bushing for new piston pin is 70.0525 ± 0.0075 mm (2.75796 ± 0.00029 inch). Measure the pin bore in the bushings in two places for each bushing in a vertical direction. Bore in the piston skirt for new piston pin is 69.988 ± 0.005 mm (2.7554 ± 0.0002 inch). Measure the pin bore in a vertical direction. Install the piston ring with the “Up-1” side toward the top of the piston. The top piston ring must be installed with the yellow colored stripe to the right of the ring end gap.

3

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 ± 0.0050 inch). Increase in 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). Width of groove in new piston for the top piston ring is 4.219 mm (0.1661 inch). Thickness is 4.5 mm (0.18 inch). 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 1.00 ± 0.15 mm (0.039 ± 0.006 inch).

4

1

144-5695 Intermediate Piston Ring

Increase in 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). Width of groove in new piston for the intermediate piston ring is 3.514 mm (0.1383 inch). Thickness of 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 is 3.980 ± 0.010 mm (0.1567 ± 0.0004 inch). Maximum thickness of new oil piston ring is 3.980 ± 0.010 mm (0.1570 ± 0.0004 inch).

5

1

Clearance between groove and new oil piston ring is 0.050 to 0.100 mm 165-6668 Oil Control Piston Ring (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 0.65 ± 0.15 mm (0.026 ± 0.006 inch). Increase in 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).

-

-

-

After all of the piston rings have been installed, rotate the piston rings so that the end gaps are separated by 120 degrees.

6

1

138-8508 Piston Pin

Before assembly, lubricate the piston pin, the piston pin bore, the connecting rod eye, and the connecting rod pin bearing with clean engine oil. 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). Length is 137.55 ± 0.15 mm (5.415 ± 0.006 inch).

7

2

8N-7296 Pin Retainer

Thickness is 2.40 ± 0.08 mm (0.094 ± 0.003 inch). Width of groove in new piston for the pin retainer is 2.75 mm (0.108 inch).

RENR5057

255 Specifications Section

i04404549

Piston and Rings (Two-Piece Piston) SMCS Code: 1214 Part No.: 244-8850 S/N: ZAR1–Up

256

RENR5057

Specifications Section

Illustration 169

g02594848

RENR5057

257 Specifications Section

Table 146 Specification for 244-8850 Piston and Rod Gp Item

Qty

Part

Specification Description

This piston has a Keystone top ring and a 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. before assembly of the 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

1

249-4512 Crown As

2

1

155-5271 Piston Skirt

Bore in the bushing for new piston pin is 70.0525 ± 0.0075 mm (2.75796 ± 0.00029 inch). Measure the pin bore in the bushings in two places for each bushing in a vertical direction. Bore in the piston skirt for new piston pin is 69.988 ± 0.005 mm (2.7554 ± 0.0002 inch). Measure the pin bore in a vertical direction. Install the piston ring with the “Up-1” side toward the top of the piston. The top piston ring must be installed with the colored stripe to the right of the ring end gap.

3

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 ± 0.0050 inch). Increase in 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). Width of groove in new piston for the top piston ring is 4.219 mm (0.1661 inch). Thickness of 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. 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).

4

1

144-5695 Intermediate Piston Ring

Increase in 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). Width of groove in new piston for the intermediate piston ring is 3.514 mm (0.1383 inch). Thickness of 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 control piston ring is 3.980 ± 0.010 mm (0.1567 ± 0.0004 inch). Maximum thickness of new oil piston ring is 3.980 ± 0.010 mm (0.1570 ± 0.0004 inch).

5

1

165-6668 Oil Control Piston Ring

Clearance between groove and new oil piston ring is 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 0.65 ± 0.15 mm (0.026 ± 0.006 inch). Increase in 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).

-

-

-

After all of the piston rings have been installed, rotate the piston rings so that the end gaps are separated by 120 degrees.

6

1

138-8508 Piston Pin

Before assembly, lubricate the piston pin bore, the connecting rod eye, and the connecting rod pin bearing with clean engine oil. 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). Length is 137.55 ± 0.15 mm (5.415 ± 0.006 inch).

7

2

8N-7296 Pin Retainer

Thickness is 2.40 ± 0.08 mm (0.094 ± 0.003 inch). Width of groove in new piston for the pin retainer is 2.75 mm (0.108 inch).

258

RENR5057

Specifications Section

i05187342

Connecting Rod SMCS Code: 1218 Part No.: 144-0725 S/N: GD31–Up Part No.: 144-0725 S/N: YBB1–Up Part No.: 144-0725 S/N: ZAD1–Up Part No.: 144-0725 S/N: ZAH1–Up Part No.: 144-0725 S/N: ZAJ1–Up Part No.: 144-0725 S/N: YAM1–Up Part No.: 144-0725 S/N: YAN1–Up Part No.: 144-0725 S/N: YAP1–Up Part No.: 144-0725 S/N: ZAP1–Up Part No.: 144-0725 S/N: ZBP1–Up Part No.: 144-0725 S/N: PBR1–Up Part No.: 144-0725 S/N: PDR1–Up Part No.: 144-0725 S/N: YAR1–Up Part No.: 144-0725 S/N: ZAR1–Up Part No.: 144-0725 S/N: YAT1–Up Part No.: 144-0725 S/N: YBT1–Up Part No.: 144-0725 S/N: YAW1–Up Part No.: 144-0725 S/N: JCY1–Up Part No.: 144-0725 S/N: YAY1–Up Part No.: 144-0725 S/N: YAZ1–Up

RENR5057

259 Specifications Section

Illustration 170

g03324908

Illustration 171

g03324909

View G-G

260

RENR5057

Specifications Section Table 147 Specification for 144-0725 Rod As Item

Qty

Part

Specification Description

A

-

-

Angle above the centerline on either side of the bearing joint for the sleeve bearing for the piston pin is 10 degrees.

B

-

-

The connecting rod may be heated from 175 to 260 °C (347 to 500 °F) for the installation of the bushing for the piston pin. Minimum length for heating the connecting rod is 105 mm (4.1 inch). Do not use a torch to heat the connecting rod. 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).

C

1

118-1655 Bushing

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).

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.

3

-

-

Location pin for correct installation of connecting rod caps Use the following procedure for tightening the connecting rod bolts:

4

4

7N-2405 Bolt

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 each bolt for an additional 90 ± 5 degrees.

Side clearance between two connecting rods on the same new crankshaft pin is 0.850 ± 0.332 mm (0.0335 ± 0.0131 inch).

RENR5057

261 Specifications Section

i04396723

Connecting Rod SMCS Code: 1218 Part No.: 230-2516 S/N: ZAJ1–Up Part No.: 230-2516 S/N: YAN1–Up Part No.: 230-2516 S/N: YAR1–Up Part No.: 230-2516 S/N: ZAR1–Up Part No.: 230-2516 S/N: YAW1–Up Part No.: 230-2516 S/N: YAZ1–Up

262

RENR5057

Specifications Section

Illustration 172

g02573279

RENR5057

263 Specifications Section

Table 148 Specification for 230-2516 Rod As Item

Qty

Part

Specification Description

When a new top end bushing is installed, ensure that no residual dirt or machining debris is trapped between the bushing (2) and the drilled hole (1) in the connecting rod. Refer to Illustration 172 . Use the following procedure for cleaning the drilled hole (1): 1. Clean the drilled hole with a suitable cleaning solution. Use a spray nozzle in order to wash the drilled hole from the large end of the connecting rod. 2. Use a stiff plastic bristle brush to clean the drilled hole. Do not scratch the finish. 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 to the bolt threads, the bolt shank, and the bolt seat. 2. Sequentially tighten bolt 1 and bolt 2 to 90 ± 5 N·m (66 ± 4 lb ft). 3. Sequentially tighten bolt 3 and bolt 4 to 90 ± 5 N·m (66 ± 4 lb ft). 4. Sequentially again, tighten bolt 3 and bolt 4 to 90 ± 5 N·m (66 ± 4 lb ft). 5. Tighten each bolt for an additional 90 ± 5 degrees.

-

4

7N-2405 Bolt

4

-

-

The chamfer must be next to the crank pin thrust surface when the connecting rod and the piston group are assembled in the engine. The opposite side will push the rod that mates on the same crank pin.

1

-

The connecting rod must be heated prior to installation of the bushing for the piston pin. Do not use a torch to heat the connecting rod. The connecting rod may be heated from 175 to 260 °C (347 to 500 °F) for the installation of the bushing for the piston pin. Minimum length for heating the connecting rod is 105 mm (4.1 inch).

B

1

230-2519 Bushing

Bore in the bushing for the piston pin after installation is 70.000 ± 0.008 mm (2.7559 ± 0.0003 inch). Bore in the connecting rod for the bushing for the piston pin is 75.760 ± 0.015 mm (2.9827 ± 0.0006 inch).

C

-

-

Angle above centerline on either side of the bushing joint for bushing for the piston pin is 10 degrees.

D

-

-

Distance between the center is 392.5 mm (15.45 inch). Take the connecting rod bearing measurements on the centerline of the connecting rod bores. Bore in the connecting rod bearing for the crankshaft is 135.133 to 135.194 mm (5.3202 to 5.3226 inch). Clearance between the connecting rod bearing and the new crankshaft is 0.107 to 0.218 mm (0.0042 to 0.0086 inch).

A

E

-

-

F

1

7N-2043 Dowel

G

-

-

Extension of the dowel from the connecting rod cap is 4.0 ± 0.5 mm (0.16 ± 0.02 inch). 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). Side clearance between two connecting rods on the same new crank pin is 0.850 ± 0.332 mm (0.0335 ± 0.0131 inch).

264

RENR5057

Specifications Section

i04763220

Connecting Rod SMCS Code: 1218 Part No.: 381-6555 S/N: YBC1–Up Part No.: 381-6555 S/N: JDE1–Up Part No.: 381-6555 S/N: ZAJ1–Up Part No.: 381-6555 S/N: ZAR1–Up Part No.: 381-6555 S/N: ZBR1–Up Part No.: 381-6555 S/N: YAW1–Up Part No.: 381-6555 S/N: YBW1–Up

RENR5057

265 Specifications Section

Illustration 173

g02573156

Illustration 174

g02573158

View H-H (3) Location pin for correct installation of connecting rod caps

266

RENR5057

Specifications Section Table 149 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. 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).

C

1

377-5237 Bearing

D

-

-

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

Distance between the center of the bearings is 392.5 mm (15.45 inch). 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.

RENR5057

267 Specifications Section

i04889615

Connecting Rod SMCS Code: 1218 Part No.: 371-0840 S/N: YBC1–Up Part No.: 371-0840 S/N: JDE1–Up

268

RENR5057

Specifications Section

Illustration 175

g03019677

RENR5057

269 Specifications Section

Table 150 Specification for 371-0840 Connecting Rod Gp Item

Qty

Part

A

-

-

Location of the bearing joint from the horizontal centerline of the pin bore is 10 degrees.

B

-

-

Inside diameter of connecting rod for bearing for the piston pin is 75.760 ± 0.015 mm (2.9827 ± 0.0006 inch).

C

-

-

Bore diameter of bearing for the piston pin is 70.000 ± 0.008 mm (2.7559 ± 0.0003 inch).

D

-

-

Maximum length for heating the connecting rod during the installation of bearing for piston pin is 105.0 mm (4.13 inch). Temperature for heating the connecting rod is 175 to 260 °C (347 to 500 °F).

E

-

-

Distance between the center of the bore for the bearing for piston pin and the center of the bore for the crankshaft journal is 392.5 mm (15.45 inch).

-

-

-

Etch the cylinder number on the connecting rod and the cap in location (1). 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.

F

-

-

Inside diameter of connecting rod for the bearing for crankshaft journal is 143.028 ± 0.015 mm (5.6310 ± 0.0006 inch).

G

-

-

Bore in the bearing for crankshaft is 135.133 to 135.194 mm (5.3202 ± 5.3226 inch).

2

1

7N-2043 Dowel

Specification Description

Protrusion of the dowel (H) from the connecting rod cap is 4.0 ± 0.5 mm (0.16 ± 0.02 inch).

Illustration 176

g03019678

View of J-J Table 151 Item

3

Qty

4

Specification Description

Part

7N-2405 Bolt

Use the following procedure in order to tighten the bolts for the rod cap. Refer Illustration 176 for tightening sequence. 1. Before assembly, lubricate the threads and seats of the bolts with Molylube . 2. Tighten bolt 1 and bolt 2 to 90 ± 5 N·m (66 ± 4 lb ft). 3. Tighten bolt 3 and bolt 4 to 90 ± 5 N·m (66 ± 4 lb ft). 4. Again, tighten bolt 3 and bolt 4 to 90 ± 5 N·m (66 ± 4 lb ft). 6. Tighten each bolts for an additional angle of 90 ± 5 degrees.

i01359201

Connecting Rod and Main Bearing Journals

S/N: GD31–Up Part No.: 379-4851 S/N: YBB1–Up

SMCS Code: 1230

Part No.: 379-4855 S/N: YBC1–Up

Part No.: 8N-0337

Part No.: 101-0336, 8N-7103

270

RENR5057

Specifications Section S/N: ZAD1–Up Part No.: 375-3642 S/N: JDE1–Up Part No.: 8N-7103 S/N: ZAH1–Up Part No.: 161-6926, 8N-7103 S/N: ZAJ1–Up Part No.: 8N-7103 S/N: YAM1–Up

Table 152 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)

Part No.: 161-6926, 8N-7103 S/N: YAN1–Up

Clearance between bearing and new journal .................0.107 to 0.218 mm (0.0042 to 0.0086 inch)

Part No.: 8N-0337, 8N-7103 S/N: YAP1–Up

Table 153

Part No.: 8N-0337, 8N-7103 S/N: ZAP1–Up Part No.: 8N-0337 S/N: ZBP1–Up Part No.: 8N-0337, 8N-7103 S/N: PBR1–Up Part No.: 8N-0337 S/N: PDR1–Up Part No.: 161-6928, 8N-7103 S/N: YAR1–Up Part No.: 161-6928, 8N-7103 S/N: ZAR1–Up Part No.: 161-6928 S/N: ZBR1–Up Part No.: 8N-0337, 8N-7103 S/N: YAT1–Up Part No.: 8N-0337 S/N: YBT1–Up Part No.: 161-6928, 8N-7103 S/N: YAW1–Up Part No.: 161-6928 S/N: YBW1–Up Part No.: 380-2695 S/N: JCY1–Up Part No.: 8N-7103 S/N: YAY1–Up Part No.: 161-6926, 8N-7103 S/N: YAZ1–Up Refer to Guidelines For Reusable Parts, SEBF8009, “Main Bearings And Connecting Rod Bearings” for more information. Connecting Rod Bearing Journals

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)

RENR5057

271 Specifications Section

i05165475

Crankshaft

SMCS Code: 1202 Part No.: 101-0336 S/N: ZAD1–Up

Illustration 177

g01419944

Table 154 Specification for 101-0336 Crankshaft Gp Item

Qty

Part

1

2

7C-6209 Thrust Plate

2

8

2W-2288 Plug

3

18

128-4845 Bolt As

B

-

-

Specification Description Use only on the center main bearing as shown in the Illustration 177 . 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. End play for the new crankshaft is 0.17 to 0.63 mm (0.007 to 0.025 inch).

272

RENR5057

Specifications Section

i04929974

Crankshaft

SMCS Code: 1202 Part No.: 379-4851 S/N: YBB1–Up Part No.: 8N-7103 S/N: ZAD1–Up Part No.: 8N-7103 S/N: ZAH1–Up Part No.: 161-6926, 8N-7103 S/N: ZAJ1–Up Part No.: 8N-7103 S/N: YAM1–Up Part No.: 161-6926, 8N-7103 S/N: YAN1–Up Part No.: 8N-7103 S/N: YAP1–Up Part No.: 8N-7103 S/N: ZAP1–Up Part No.: 8N-7103 S/N: PBR1–Up Part No.: 8N-7103 S/N: YAR1–Up Part No.: 8N-7103 S/N: ZAR1–Up Part No.: 8N-7103 S/N: YAT1–Up Part No.: 8N-7103 S/N: YAW1–Up Part No.: 8N-7103 S/N: YAY1–Up Part No.: 161-6926, 8N-7103 S/N: YAZ1–Up

RENR5057

273 Specifications Section

Illustration 178

g03110979

Typical example Table 155 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

128-4845 Bolt As

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). 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.

274

RENR5057

Specifications Section

i05206145

Crankshaft

SMCS Code: 1202 Part No.: 379-4855 S/N: YBC1–Up

Illustration 179

g03334112

Typical example Table 156 Specification for 379-4855 Crankshaft Gp, 379-4852 Crankshaft Gp, and 379-4856 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 179 . 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.

RENR5057

275 Specifications Section

i04932381

Crankshaft

SMCS Code: 1202 Part No.: 380-2695 S/N: JCY1–Up

Illustration 180

g03104036

Typical example Table 157 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 180 . 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.

276

RENR5057

Specifications Section

i05206152

Crankshaft

SMCS Code: 1202 Part No.: 375-3642 S/N: JDE1–Up

Illustration 181

g03334121

Typical example Table 158 Specification for 375-3642 Crankshaft Gp, 379-4858 Crankshaft Gp, and 386-1487 Crankshaft Gp Item

Qty

Part

1

2

7C-6209 Thrust Plate

2

8

2W-2288 Plug

Specification Description Thrust plates should be used only on center main bearing. Torque to 50 ± 7 N·m (37 ± 5 lb ft). Use the following procedure in order to tighten the bolts:

3

48

128-4845 Bolt As

B

32

7N-2003 Dowel

-

-

-

1. Before assembly, lubricate the bolt threads, the bolt shank, the washer, and the underside of the bolt head with Molylube lubricant. 2.Tighten the bolts evenly to a torque of 70 ± 5 N·m (52 ± 4 lb ft). 3. Turn each bolt for an additional turn of 120 ± 5 degrees. Protrusion (B) of the dowel is 8.0 ± 0.5 mm (0.31 ± 0.02 inch). After assembly into cylinder block, end play of the new crankshaft is 0.17 to 0.63 mm (0.007 to 0.025 inch).

RENR5057

277 Specifications Section

i05186254

Crankshaft

SMCS Code: 1202 Part No.: 8N-0337 S/N: GD31–Up Part No.: 8N-0337 S/N: YAP1–Up Part No.: 8N-0337 S/N: ZAP1–Up Part No.: 8N-0337 S/N: ZBP1–Up Part No.: 8N-0337 S/N: PBR1–Up Part No.: 8N-0337 S/N: PDR1–Up Part No.: 161-6928 S/N: YAR1–Up Part No.: 161-6928 S/N: ZAR1–Up Part No.: 161-6928 S/N: ZBR1–Up Part No.: 8N-0337 S/N: YAT1–Up Part No.: 8N-0337 S/N: YBT1–Up Part No.: 161-6928 S/N: YAW1–Up Part No.: 161-6928 S/N: YBW1–Up

278

RENR5057

Specifications Section

Illustration 182

g03324465

Table 159 Specification for 8N-0337 Crankshaft Gp 161-6928 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

Use only on the center main bearing as shown in the Illustration 182 . Torque to 50 ± 7 N·m (37 ± 5 lb ft). Use the following procedure to tighten the bolts:

3

48

128-4845 Bolt As

B

-

-

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 (52 ± 4 lb ft). 3. Rotate each bolt for an additional 120 ± 5 degrees. Do not reuse counterweight bolts. End play for the new crankshaft is 0.17 to 0.63 mm (0.007 to 0.025 inch).

RENR5057

279 Specifications Section

i05186267

Crankshaft Wear Sleeves and Seals

280

RENR5057

Specifications Section SMCS Code: 1160

S/N: YAY1–Up

Part No.: 7W-3813 S/N: GD31–Up

Part No.: 7W-3813 S/N: YAZ1–Up

Part No.: 332-7911 S/N: YBB1–Up Part No.: 332-7911 S/N: YBC1–Up Part No.: 7W-3813 S/N: ZAD1–Up Part No.: 332-7911 S/N: JDE1–Up Part No.: 7W-3813 S/N: ZAH1–Up Part No.: 7W-3813 S/N: ZAJ1–Up Part No.: 7W-3813 S/N: YAM1–Up Part No.: 7W-3813 S/N: YAN1–Up Part No.: 7W-3813 S/N: YAP1–Up Part No.: 7W-3813 S/N: ZAP1–Up Part No.: 7W-3813 S/N: ZBP1–Up Part No.: 7W-3813 S/N: PBR1–Up Part No.: 7W-3813 S/N: PDR1–Up Part No.: 7W-3813 S/N: YAR1–Up Part No.: 7W-3813 S/N: ZAR1–Up Part No.: 7W-3813 S/N: ZBR1–Up Part No.: 7W-3813 S/N: YAT1–Up Part No.: 7W-3813 S/N: YBT1–Up Part No.: 7W-3813 S/N: YAW1–Up Part No.: 7W-3813 S/N: YBW1–Up Part No.: 332-7911 S/N: JCY1–Up Part No.: 7W-3813

RENR5057

281 Specifications Section

Illustration 183

g02575380

(1) Flywheel housing group

(2) Front housing group

Table 160 Specification for the 7W-3813 Crankshaft Seal Gp 332-7911 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. 3

1

113-8433 Crankshaft Seal Install the crankshaft seal group in the flywheel housing group on a standard rotation engine. Gp

4

1

113-8432 Crankshaft Seal Install the crankshaft seal group in the front housing group on a standard rotation Gp 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).

282

RENR5057

Specifications Section

i04397659

Cover Group (Front Housing) SMCS Code: 1151; 1166 Part No.: 107-0278 S/N: GD31–Up

Illustration 184

g02575496

Front view Table 161 Specification for 107-0278 Front Housing Cover Gp Item

Qty

Part

1

2

6V-3348 O-Ring Seal

Before assembly, lightly lubricate the bore with the lubricant that is being sealed.

2

2

235-3546 O-Ring Seal

Before assembly, lightly lubricate the bore with the lubricant that is being sealed.

3

2

3P-1896 Cup Plug

Specification Description

Installation depth (C) is 1.25 ± 0.25 mm (0.049 ± 0.010 inch).

RENR5057

283 Specifications Section

Illustration 185

g02838036

Rear view Table 162 Specification for 107-0278 Front Housing Cover Gp Item

Qty

Part

Specification Description

4

2

259-4598 O-Ring Seal

Before assembly, lightly lubricate the bore with the lubricant that is being sealed.

5

2

5P-0840 O-Ring Seal

Before assembly, lightly lubricate the bore with the lubricant that is being sealed.

284

RENR5057

Specifications Section

i05186286

Housing (Front) SMCS Code: 1162 Part No.: 4P-5426 S/N: GD31–Up Part No.: 4P-5426 S/N: ZAD1–Up Part No.: 4P-5426 S/N: ZAH1–Up Part No.: 4P-5426 S/N: ZAJ1–Up Part No.: 4P-5426 S/N: YAM1–Up Part No.: 4P-5426 S/N: YAN1–Up Part No.: 4P-5426 S/N: YAP1–Up Part No.: 4P-5426 S/N: ZAP1–Up Part No.: 4P-5426 S/N: ZBP1–Up Part No.: 4P-5426 S/N: PBR1–Up Part No.: 4P-5426 S/N: PDR1–Up Part No.: 4P-5426 S/N: YAR1–Up Part No.: 4P-5426 S/N: ZAR1–Up Part No.: 4P-5426 S/N: ZBR1–Up Part No.: 4P-5426 S/N: YAT1–Up Part No.: 4P-5426 S/N: YBT1–Up Part No.: 4P-5426 S/N: YAW1–Up Part No.: 4P-5426 S/N: YBW1–Up Part No.: 4P-5426 S/N: YAY1–Up Part No.: 4P-5426 S/N: YAZ1–Up

RENR5057

285 Specifications Section

Illustration 186

g01430989

Table 163 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).

6

-

-

Specification Description Diameter is 1/4 inch. Length is 14.2 mm (0.56 inch).

After assembly, trim gasket flush to face (7).

Use standard torque for the fasteners listed above.

286

RENR5057

Specifications Section

i04888982

Housing (Front) SMCS Code: 1162 Part No.: 381-0680 S/N: YBB1–Up Part No.: 381-0680 S/N: YBC1–Up Part No.: 381-0680 S/N: JDE1–Up Part No.: 381-0680 S/N: JCY1–Up

Illustration 187

g03017438

Table 164 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).

RENR5057

287 Specifications Section

i05188688

Gear Group (Front) SMCS Code: 1206 Part No.: 8N-7174 S/N: GD31–Up Part No.: 8N-7174 S/N: ZAD1–Up Part No.: 8N-7174 S/N: ZAH1–Up Part No.: 8N-7174 S/N: ZAJ1–Up Part No.: 8N-7174 S/N: YAM1–Up Part No.: 8N-7174 S/N: YAN1–Up Part No.: 8N-7174 S/N: YAP1–Up Part No.: 8N-7174 S/N: ZAP1–Up Part No.: 8N-7174 S/N: ZBP1–Up Part No.: 8N-7174 S/N: PBR1–Up Part No.: 8N-7174 S/N: PDR1–Up Part No.: 8N-7174 S/N: YAR1–Up Part No.: 8N-7174 S/N: ZAR1–Up Part No.: 8N-7174 S/N: ZBR1–Up Part No.: 8N-7174 S/N: YAT1–Up Part No.: 8N-7174 S/N: YBT1–Up Part No.: 8N-7174 S/N: YAW1–Up Part No.: 8N-7174 S/N: YBW1–Up Part No.: 8N-7174 S/N: YAY1–Up Part No.: 8N-7174 S/N: YAZ1–Up

288

RENR5057

Specifications Section

Illustration 188

Front view of engine

g03325358

RENR5057

289 Specifications Section

Table 165 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.

2

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 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).

1

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

8

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).

290

RENR5057

Specifications Section

i04452750

Gear Group (Front) SMCS Code: 1206 Part No.: 376-3358 S/N: YBB1–Up Part No.: 376-3358 S/N: YBC1–Up Part No.: 376-3358 S/N: JDE1–Up Part No.: 376-3358 S/N: JCY1–Up

RENR5057

291 Specifications Section

Illustration 189

g02645057

Table 166 Specification for 376-3358 Front Gear Gp Item

Qty

Specification Description

Part

Bore of 140-9597 Bushing after installation is 90.000 ± 0.010 mm (3.5433 ± 0.0004 inch). 1

1

2

1

144-8263 Idler Gear Installation depth is 2.3 ± 0.5 mm (0.09 ± 0.02 inch). As Diameter of the new shaft (9) is 89.880 ± 0.020 mm (3.5386 ± 0.0008 inch). 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).

292

RENR5057

Specifications Section

i04932634

Gear Group (Rear) SMCS Code: 1206 Part No.: 380-5096 S/N: YBB1–Up Part No.: 380-2697 S/N: JCY1–Up

Illustration 190

g03104796

Typical example Table 167 Specification for 380-5096 Rear Gear Gp and 380-2697 Rear Gear Gp Item

Qty

Part

1

2

101-1364 Idler Gear As

2

2

101-1368 Thrust Washer

3

1

114-3372 Idler Gear As

4

1

101-1366 Gear Shaft

5

4

8M-2530 Bolt

6

2

-

7

2

8S-2331 Bolt

Specification Description 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). Thickness is 1.90 ± 0.10 mm (0.075 ± 0.004 inch). 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). 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).

RENR5057

293 Specifications Section

Illustration 191

g03104816

Rear view Table 168 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).

294

RENR5057

Specifications Section

i04889556

Gear Group (Rear) SMCS Code: 1206 Part No.: 380-5093 S/N: YBC1–Up

Illustration 192

g03019536

Table 169 Specification for 380-5093 Rear Gear Gp Item

Qty

Part

1

2

175-5197 Idler Gear As

2

2

101-1368 Thrust Washer

3

1

175-5200 Idler Gear As

4

1

101-1366 Gear Shaft

5

4

8M-2530 Bolt

6

2

175-5201 Camshaft Gear

Specification Description 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). Thickness is 1.90 ± 0.10 mm (0.075 ± 0.004 inch). 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). 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.

RENR5057

295 Specifications Section

Illustration 193

g03019537

Rear view Table 170 Item

Qty

Part

7

2

101-1367 Idler Shaft

8

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).

296

RENR5057

Specifications Section

i05187215

Gear Group (Rear) SMCS Code: 1206 Part No.: 101-0835 S/N: GD31–Up

RENR5057

297 Specifications Section

Illustration 194

g03324889

Illustration 195

g03324890

Illustration 196

g03324891

298

RENR5057

Specifications Section Table 171 Specification for 124-8395 Rear Gear Gp, 175-5204 Rear Gear Gp, 101-0835 Rear Gear Gp, 334-5298 Rear Gear Gp, and 175-5203 Rear Gear Gp Item

Qty

Part

Specification Description

1

2

Camshaft Drive Gear

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 and right camshaft drive gear .

2

2

Idler Gear Assembly

After installation, bore of 125-9751 Bushing in the idler gear assembly is 81.060 ± 0.010 mm (3.1913 ± 0.0004 inch). Installation depth of the bushing is 1.00 ± 0.25 mm (0.049 ± 0.010 inch).

3

2

101-1368 Thrust Washer

4

1

Gear Assembly

5

4

8M-2530 Bolt

6

1

101-1366 Gear Shaft

Thickness of the new thrust washer is 1.90 ± 0.10 mm (0.075 ± 0.004 inch). After installation, bore of 101-1372 Bushing in the gear assembly is 75.060 ± 0.010 mm (2.9551 ± 0.0004 inch). Installation depth of the bushing is 1.5 ± 0.5 mm (0.06 ± 0.02 inch). Torque to 140 ± 10 N·m (103 ± 7 lb ft). Diameter is 74.990 ± 0.010 mm (2.9524 ± 0.0004 inch). 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 195 . 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 196 .

7

2

9X-8887 Bolt

8

4

1B-4367 Bolt

Torque to 240 ± 20 N·m (177 ± 15 lb ft).

9

2

8S-2331 Bolt

Torque to 240 ± 20 N·m (177 ± 15 lb ft).

10

1

101-1365 Thrust Plate

11

1

101-1370 Crankshaft Gear

12

2

101-1367 Idler Shaft

Thickness of the new thrust plate is 6.35 ± 0.25 mm (0.250 ± 0.010 inch). The mark on the gear assembly (4) must be in alignment with the mark on the crankshaft gear (11). Diameter is 81.000 ± 0.010 mm (3.1890 ± 0.0004 inch).

RENR5057

299 Specifications Section

i04891737

Gear Group (Rear) SMCS Code: 1206 Part No.: 382-4492 S/N: JDE1–Up

Illustration 197

g03019559

Table 172 Specification for 382-4492 Rear Gear Gp Item

Qty

Part

1

2

175-5201 Camshaft Gear

2

2

175-5197 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).

3

1

175-5200 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

2

101-1367 Idler Shaft

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.

Diameter is 81.000 ± 0.010 mm (3.1890 ± 0.0004 inch).

300

RENR5057

Specifications Section

Illustration 198

g03027339

Rear view Table 173 Item

Qty

Part

5

1

101-1366 Gear Shaft

6

2

101-1368 Thrust Washer

7

4

1B-4367 Bolt

Torque to 240 ± 20 N·m (177 ± 15 lb ft).

8

2

8S-2331 Bolt

Torque to 240 ± 20 N·m (177 ± 15 lb ft).

9

4

8M-2530 Bolt

Torque to 140 ± 10 N·m (103 ± 7 lb ft).

Specification Description Diameter is 74.990 ± 0.010 mm (2.9524 ± 0.0004 inch). Thickness is 1.90 ± 0.10 mm (0.075 ± 0.004 inch).

RENR5057

301 Specifications Section

i04397819

Balancer Group (Front) SMCS Code: 1220 Part No.: 101-0833 S/N: ZAD1–Up

Illustration 199

g02576177

Front view (3) Balancer gear

(4) Crankshaft gear

Table 174 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.

302

RENR5057

Specifications Section

i04397906

Accessory Drive (Lower Left Hand) SMCS Code: 1207 Part No.: 7E-7647 S/N: GD31–Up Part No.: 7E-7647 S/N: ZAD1–Up Part No.: 7E-7647 S/N: ZAH1–Up Part No.: 7E-7647 S/N: ZAJ1–Up Part No.: 7E-7647 S/N: YAM1–Up Part No.: 7E-7647 S/N: YAN1–Up Part No.: 7E-7647 S/N: YAP1–Up Part No.: 7E-7647 S/N: ZAP1–Up Part No.: 7E-7647 S/N: ZBP1–Up Part No.: 7E-7647 S/N: PBR1–Up Part No.: 7E-7647 S/N: PDR1–Up Part No.: 7E-7647 S/N: YAR1–Up Part No.: 7E-7647 S/N: ZAR1–Up Part No.: 7E-7647 S/N: ZBR1–Up Part No.: 7E-7647 S/N: YAT1–Up Part No.: 7E-7647 S/N: YBT1–Up Part No.: 7E-7647 S/N: YAW1–Up Part No.: 7E-7647 S/N: YBW1–Up Part No.: 7E-7647 S/N: YAY1–Up Part No.: 7E-7647 S/N: YAZ1–Up

RENR5057

303 Specifications Section

Illustration 200

g02576404

Front view (1) Water pump drive gear

Illustration 201

Section B-B

g02576406

304

RENR5057

Specifications Section

Illustration 202

g02576407

Adapter assembly Table 175 Specification for the 7E-7647 Accessory Drive Gp 156-9812 Accessory Drive Gp Qty

Part

1

9X-7371 O-Ring Seal

2

259-4598 O-Ring Seal

3

1

7C-3260 Shaft

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).

Item 2

Specification Description Lightly lubricate the bore of the O-ring seals with the lubricant that is being sealed. Diameter of the new shaft is 89.88 ± 0.02 mm (3.539 ± 0.001 inch).

5

1

7N-5874 Auxiliary Drive Shaft

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).

6

2

7N-7539 Thrust Washer

Thickness of the new thrust washer is 8.50 ± 0.05 mm (0.335 ± 0.002 inch).

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).

RENR5057

305 Specifications Section

i04403923

Accessory Drive (Upper Right Hand) SMCS Code: 1207 Part No.: 7N-4871 S/N: ZAD1–Up Part No.: 7N-4871 S/N: ZAH1–Up Part No.: 7N-4871 S/N: ZAJ1–Up Part No.: 7N-4871 S/N: YAM1–Up Part No.: 7N-4871 S/N: YAN1–Up Part No.: 7N-4871 S/N: YAP1–Up Part No.: 7N-4871 S/N: ZAP1–Up Part No.: 7N-4871 S/N: PBR1–Up Part No.: 7N-4871 S/N: YAR1–Up Part No.: 7N-4871 S/N: ZAR1–Up Part No.: 7N-4871 S/N: YAT1–Up Part No.: 7N-4871 S/N: YAW1–Up Part No.: 7N-4871 S/N: YAY1–Up Part No.: 7N-4871 S/N: YAZ1–Up

306

RENR5057

Specifications Section

Illustration 203

g02592697

Front view of engine

Illustration 204

Section A-A

g02592698

RENR5057

307 Specifications Section

Illustration 205

g02592699

Adapter assembly Table 176 Specification for 7N-4871 Accessory Drive Gp and 7C-0264 Accessory Drive Gp Item

Qty

Part

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).

Specification Description

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

Thickness of the new thrust washer is 8.50 ± 0.05 mm (0.335 ± 0.002 inch).

D

1

7C-4165 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).

308

RENR5057

Specifications Section

i04398433

Accessory Drive (Upper Right Hand)

RENR5057

309 Specifications Section

SMCS Code: 1207 Part No.: 107-7361 S/N: GD31–Up Part No.: 107-7361 S/N: ZAD1–Up Part No.: 334-5304 S/N: JDE1–Up Part No.: 107-7361 S/N: ZAH1–Up Part No.: 107-7361 S/N: ZAJ1–Up Part No.: 107-7361 S/N: YAM1–Up Part No.: 107-7361 S/N: YAN1–Up Part No.: 107-7361 S/N: YAP1–Up Part No.: 107-7361 S/N: ZAP1–Up Part No.: 107-7361 S/N: ZBP1–Up Part No.: 107-7361 S/N: PBR1–Up Part No.: 107-7361 S/N: PDR1–Up Part No.: 107-7361 S/N: YAR1–Up Part No.: 107-7361 S/N: ZAR1–Up Part No.: 107-7361 S/N: ZBR1–Up Part No.: 107-7361 S/N: YAT1–Up Part No.: 107-7361 S/N: YBT1–Up Part No.: 107-7361 S/N: YAW1–Up Part No.: 107-7361 S/N: YBW1–Up Part No.: 334-5304 S/N: JCY1–Up Part No.: 107-7361 S/N: YAY1–Up Part No.: 107-7361 S/N: YAZ1–Up

310

RENR5057

Specifications Section

Illustration 206

g02578096

Table 177 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.

Specification Description

Diameter of accessory drive gear (4) at cover assembly end (3) is 44.400 ± 0.015 mm (1.7480 ± 0.0006 inch). B

-

-

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).

C

-

Diameter of accessory drive gear (4) at adapter assembly end (5) is 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).

RENR5057

311 Specifications Section

i04398428

Accessory Drive (Upper Right Hand) SMCS Code: 1207 Part No.: 166-4357 S/N: ZAP1–Up Part No.: 166-4357 S/N: PBR1–Up Part No.: 166-4357 S/N: ZAR1–Up

312

RENR5057

Specifications Section

Illustration 207

g01930053

Table 178 Specification for the 166-4357 Accessory Drive Gp and 334-5306 Accessory Drive Gp Item

Qty

Part

1

-

-

2

2

7N-7539 Thrust Washer

3

1

7N-5874 Auxiliary Drive Shaft

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).

Specification Description Lightly lubricate the bore of the O-ring seals with the lubricant that is being sealed or with the approved equivalent. 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 is 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch).

RENR5057

313 Specifications Section

i04398458

Flywheel SMCS Code: 1156 Part No.: 7N-4851 S/N: GD31–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: ZAD1–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: ZAH1–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: ZAJ1–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: YAM1–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: YAN1–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: YAP1–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: ZAP1–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: ZBP1–Up Part No.: 286-0244, 2W-8772, 7N-4851 , 7W-0968 S/N: PBR1–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: PDR1–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: YAR1–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: ZAR1–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: ZBR1–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: YAT1–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: YBT1–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: YAW1–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: YBW1–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: YAY1–Up Part No.: 286-0244, 7N-4851, 7W-0968 S/N: YAZ1–Up

314

RENR5057

Specifications Section

Illustration 208

g02578197

Typical example (1) Flywheel gear

(2) Crankshaft

Table 179 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).

RENR5057

315 Specifications Section

i04934580

Flywheel Housing

316

RENR5057

Specifications Section SMCS Code: 1157

S/N: YAY1–Up

Part No.: 297-7000 S/N: GD31–Up

Part No.: 101-0836, 297-7000 S/N: YAZ1–Up

Part No.: 384-8033 S/N: YBB1–Up Part No.: 383-6541 S/N: YBC1–Up Part No.: 101-0836, 297-7000 S/N: ZAD1–Up Part No.: 384-8033 S/N: JDE1–Up Part No.: 101-0836, 297-7000 S/N: ZAH1–Up Part No.: 101-0836, 297-7000 S/N: ZAJ1–Up Part No.: 101-0836, 297-7000 S/N: YAM1–Up Part No.: 101-0836, 297-7000 S/N: YAN1–Up Part No.: 101-0836, 297-7000 S/N: YAP1–Up Part No.: 101-0836, 297-7000 S/N: ZAP1–Up Part No.: 297-7000 S/N: ZBP1–Up Part No.: 101-0836, 297-7000, 7W-3722 S/N: PBR1–Up Part No.: 297-7000 S/N: PDR1–Up Part No.: 101-0836, 297-7000 S/N: YAR1–Up Part No.: 101-0836, 297-7000 S/N: ZAR1–Up Part No.: 297-7000 S/N: ZBR1–Up Part No.: 101-0836, 297-7000, 7W-3722 S/N: YAT1–Up Part No.: 297-7000 S/N: YBT1–Up Part No.: 101-0836, 297-7000 S/N: YAW1–Up Part No.: 297-7000 S/N: YBW1–Up Part No.: 384-8033 S/N: JCY1–Up Part No.: 101-0836, 297-7000

RENR5057

317 Specifications Section

Illustration 209

g02188476

Bolt locations

Illustration 210

Left side view

g02589876

318

RENR5057

Specifications Section Table 180 Specification for 101-0836 Flywheel Housing Gp, 297-7000 Flywheel Housing Gp, 383-6541 Flywheel Housing Gp, 384-8033 Flywheel Housing Gp, and 7W-3722 Flywheel Housing Gp Item

Qty

Specification Description

Part

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

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).

9M-7269(1)

Length of 1/2 inch diameter bolt is 171.5 mm (6.75 inch). Torque to 135 ± 20 N·m (100 ± 15 lb ft).

6M-9613(2)

Length of 1/2 inch diameter bolt is 228.6 mm (9.00 inch). Torque to 135 ± 20 N·m (100 ± 15 lb ft).

3

(1) (2)

2

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

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).

6

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).

7

-

-

Apply blue Loctite High Flex GM to the surface of the gasket before assembly.

This bolt is used if the engine is not equipped with a support bracket for the air lines. This bolt is used if the engine is equipped with a support bracket for the air lines.

RENR5057

319 Specifications Section

i04757372

Flywheel Housing Cover SMCS Code: 1157 Part No.: 7E-6432 S/N: GD31–Up

Illustration 211

g02849379

Rear view Typical example Table 181 Specification for 4W-1529 Flywheel Housing Cover Gp, 187-4581 Rear Housing Cover Gp, 285-5929 Flywheel Housing Cover Gp, and 7E-6432 Flywheel Housing Cover Gp Item

Qty

Part

1

4

5F-0304 Plug

Specification description Torque to 70 ± 15 N·m (52 ± 11 lb ft).

320

RENR5057

Specifications Section

i05251255

Generator Coupling SMCS Code: 4456 Part No.: 276-4839 S/N: GD31–Up

Illustration 212

g03345223

Table 182 Specification for 276-4839 Generator Installation Ar Item

Qty

Part

1

12

7X-2575 Bolt

Specification Description Torque to 710 ± 60 N·m (524 ± 44 lb ft).

As required , use the following shims: 137-8533 Shim Pack consists of following shims: Thickness of 137-8534 Shim is 0.0254 mm (0.00100 inch). Thickness of 137-8535 Shim is 0.0508 mm (0.00200 inch). Thickness of 137-8536 Shim is 0.0762 mm (0.00300 inch). 2 4

137-8533 Shim Pack

Thickness of 137-8537 Shim is 0.1016 mm (0.00400 inch). Thickness of 137-8538 Shim is 0.12 mm (0.005 inch). Thickness of 137-8539 Shim is 0.254 mm (0.0100 inch). Thickness of 137-8540 Shim is 0.381 mm (0.0150 inch). Thickness of 137-8541 Shim is 0.508 mm (0.0200 inch).

(continued)

RENR5057

321 Specifications Section

(Table 182, contd) Thickness of 137-8542 Shim is 0.635 mm (0.0250 inch). Thickness of 137-8543 Shim is 1.27 mm (0.050 inch). Thickness of 137-8544 Shim is 1.91 mm (0.075 inch) Thickness of 137-8545 Shim is 2.54 mm (0.100 inch). Thickness of 137-8546 Shim is 3.05 mm (0.120 inch).

322

RENR5057

Specifications Section

i05251190

Generator Coupling SMCS Code: 4456 Part No.: 344-2538 S/N: GD31–Up

Illustration 213

g03345215

Table 183 Specification for 344-2538 Generator Installation Ar and 252-5585 Generator Installation Ar Item

Qty

Part

1

12

7X-2563 Bolt

Specification Description Torque to 350 ± 40 N·m (258 ± 30 lb ft).

As required , use the following shims: 137-8533 Shim Pack consists of following shims: Thickness of 137-8534 Shim is 0.0254 mm (0.00100 inch). Thickness of 137-8535 Shim is 0.0508 mm (0.00200 inch). Thickness of 137-8536 Shim is 0.0762 mm (0.00300 inch). Thickness of 137-8537 Shim is 0.1016 mm (0.00400 inch). Thickness of 137-8538 Shim is 0.12 mm (0.005 inch). Thickness of 137-8539 Shim is 0.254 mm (0.0100 inch).

2 4

137-8533 Shim Pack

Thickness of 137-8540 Shim is 0.381 mm (0.0150 inch). Thickness of 137-8541 Shim is 0.508 mm (0.0200 inch). Thickness of 137-8542 Shim is 0.635 mm (0.0250 inch). Thickness of 137-8543 Shim is 1.27 mm (0.050 inch). Thickness of 137-8544 Shim is 1.91 mm (0.075 inch) Thickness of 137-8545 Shim is 2.54 mm (0.100 inch). Thickness of 137-8546 Shim is 3.05 mm (0.120 inch).

RENR5057

323 Specifications Section

i05241812

Flexible Coupling SMCS Code: 3279 Part No.: 5N-3765 S/N: ZAP1–Up Part No.: 5N-3765 S/N: PBR1–Up Part No.: 5N-3765 S/N: JCY1–Up

Illustration 214

g03343016

Table 184 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 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).

(continued)

324

RENR5057

Specifications Section (Table 184, contd) 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.Bolt the plate to the coupling. 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.

RENR5057

325 Specifications Section

i04935884

Flexible Coupling SMCS Code: 3279 Part No.: 103-6226 S/N: PBR1–Up

Illustration 215

g03111477

Table 185 Specification for 103-6226 Flexible Coupling Gp Item

Qty

Part

Specification Description

1

12

5N-2317 Bolt

Apply black 4C-5592 Anti-Seize Compound to both threads and under head of the bolts. Use the following procedure to tighten the bolts: 1. Tighten the bolts to 50 N·m (37 lb ft). 2. Tighten the bolts to 400 ± 50 N·m (295 ± 37 lb ft) in star pattern. 3. Turn all the bolts to 180 ± 15 degree.

2

8

1A-5576 Bolt

Before installation, lubricate the face of washers and the threads of bolts with clean engine oil. Torque to 750 ± 80 N·m (553 ± 59 lb ft).

Refer to Special Instruction, REHS0445, Alignment Procedures For G3500 Tandem Generator Sets when the flexible coupling is serviced or when the engines are moved.

326

RENR5057

Specifications Section

i04757390

Vibration Damper SMCS Code: 1205 Part No.: 8N-7182 S/N: ZAD1–Up Part No.: 8N-7182 S/N: ZAH1–Up Part No.: 8N-7182 S/N: ZAJ1–Up Part No.: 8N-7182 S/N: YAM1–Up Part No.: 8N-7182 S/N: YAN1–Up Part No.: 8N-7182 S/N: YAP1–Up Part No.: 8N-7182 S/N: ZAP1–Up Part No.: 8N-7182 S/N: ZBP1–Up Part No.: 8N-7182 S/N: PBR1–Up Part No.: 8N-7182 S/N: PDR1–Up Part No.: 8N-7182 S/N: YAR1–Up Part No.: 8N-7182 S/N: ZAR1–Up Part No.: 8N-7182 S/N: ZBR1–Up Part No.: 8N-7182 S/N: YAT1–Up Part No.: 8N-7182 S/N: YBT1–Up Part No.: 8N-7182 S/N: YAW1–Up Part No.: 8N-7182 S/N: YBW1–Up Part No.: 8N-7182 S/N: YAY1–Up Part No.: 8N-7182 S/N: YAZ1–Up

RENR5057

327 Specifications Section

Illustration 216

g02849382

Table 186 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).

328

RENR5057

Specifications Section

i04403879

Vibration Damper SMCS Code: 1205 Part No.: 162-7460 S/N: ZAD1–Up Part No.: 162-7460 S/N: ZAH1–Up Part No.: 162-7460 S/N: ZAJ1–Up Part No.: 162-7460 S/N: YAM1–Up Part No.: 162-7460 S/N: YAN1–Up Part No.: 162-7460 S/N: YAP1–Up Part No.: 162-7460 S/N: ZAP1–Up Part No.: 162-7460 S/N: ZBP1–Up Part No.: 162-7460 S/N: PBR1–Up Part No.: 162-7460 S/N: PDR1–Up Part No.: 162-7460 S/N: YAR1–Up Part No.: 162-7460 S/N: ZAR1–Up Part No.: 162-7460 S/N: ZBR1–Up Part No.: 162-7460 S/N: YAT1–Up Part No.: 162-7460 S/N: YBT1–Up Part No.: 162-7460 S/N: YAW1–Up Part No.: 162-7460 S/N: YBW1–Up Part No.: 162-7460 S/N: YAY1–Up Part No.: 162-7460 S/N: YAZ1–Up

RENR5057

329 Specifications Section

Illustration 217

g02592497

Illustration 218

g02592498

Table 187 Specification for 162-7460 Damper Gp Item

Qty

Part

Specification Description

The alignment mark on the crankshaft (1) must be aligned with the alignment mark on the two adapters (2). The mark on the two damper groups (3) must also be aligned with the mark on the two adapters (2). Torque to 1150 ± 60 N·m (848 ± 44 lb ft). 4

6

162-7459 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). Lubricate the threads of the bolts with blue Loctite 242 .

330

RENR5057

Specifications Section

i04403676

Vibration Damper SMCS Code: 1205 Part No.: 8N-0339 S/N: GD31–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: ZAD1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: ZAH1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: ZAJ1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: YAM1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: YAN1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: YAP1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: ZAP1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: ZBP1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: PBR1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: PDR1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: YAR1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: ZAR1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: ZBR1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: YAT1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: YBT1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: YAW1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: YBW1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: YAY1–Up Part No.: 174-7079, 248-0197, 8N-0339 S/N: YAZ1–Up

RENR5057

331 Specifications Section

Illustration 219

g02591631

Typical example Table 188 Specification for 174-7079 Damper Gp, 248-0197 Damper Gp, and 8N-0339 Damper Gp Item

Qty

Part

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 .

332

RENR5057

Specifications Section

i04717250

Vibration Damper SMCS Code: 1205 Part No.: 4W-0278 S/N: ZAD1–Up Part No.: 4W-0278 S/N: ZAH1–Up Part No.: 4W-0278 S/N: ZAJ1–Up Part No.: 4W-0278 S/N: YAM1–Up Part No.: 4W-0278 S/N: YAN1–Up Part No.: 4W-0278 S/N: YAP1–Up Part No.: 4W-0278 S/N: ZAP1–Up Part No.: 4W-0278 S/N: ZBP1–Up Part No.: 4W-0278 S/N: PBR1–Up Part No.: 4W-0278 S/N: PDR1–Up Part No.: 4W-0278 S/N: YAR1–Up Part No.: 4W-0278 S/N: ZAR1–Up Part No.: 4W-0278 S/N: ZBR1–Up Part No.: 4W-0278 S/N: YAT1–Up Part No.: 4W-0278 S/N: YBT1–Up Part No.: 4W-0278 S/N: YAW1–Up Part No.: 4W-0278 S/N: YBW1–Up Part No.: 4W-0278 S/N: YAY1–Up Part No.: 4W-0278 S/N: YAZ1–Up

RENR5057

333 Specifications Section

Illustration 220

g02821260

Table 189 Specification for 4W-0278 Damper Gp Item

Qty

Part

Specification Description

The alignment mark on the crankshaft (2) must be aligned with the alignment mark on the damper adapter (3). Before assembly, lubricate the threads with molybdenum disulfide base lubricant. 1

6

8S-4757 Bolt Torque to 1150 ± 60 N·m (848 ± 44 lb ft).

334

RENR5057

Specifications Section

i04929106

Vibration Damper SMCS Code: 1205 Part No.: 380-8375 S/N: YBB1–Up Part No.: 380-8375 S/N: YBC1–Up Part No.: 380-8375 S/N: JDE1–Up Part No.: 380-8375 S/N: JCY1–Up

RENR5057

335 Specifications Section

Illustration 221

g03098416

Illustration 222

g03113781

Table 190 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).

336

RENR5057

Specifications Section

i04906447

Vibration Damper SMCS Code: 1205 Part No.: 4W-3113 S/N: ZAP1–Up Part No.: 4W-3113 S/N: PBR1–Up Part No.: 4W-3113 S/N: ZAR1–Up

Illustration 223

g03067696

Table 191 Specification for 4W-3113 Damper Gp Item

Qty

Part

Specification Description

The alignment mark on damper group (2) must be aligned with the alignment mark on adapter (1). 3

18

0S-1571 Bolt

4

30

1A-2029 Bolt

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). Before assembly, apply blue Loctite 242 to the threads.

5

3

4B-1284 Screw Tighten only after complete tightening of the bolts

6

6

8S-4757 Bolt

Before assembly, lubricate the thread of the bolts with molybdenum disulfide base lubricant. Torque to 1150 ± 60 N·m (848 ± 44 lb ft).

RENR5057

337 Specifications Section

i04888963

Vibration Damper Guard SMCS Code: 1205 Part No.: 8N-9639 S/N: GD31–Up Part No.: 197-9052, 8N-9639 S/N: ZAD1–Up Part No.: 197-9052, 8N-9639 S/N: ZAH1–Up Part No.: 197-9052, 8N-9639 S/N: ZAJ1–Up Part No.: 197-9052 S/N: YAM1–Up Part No.: 197-9052 S/N: YAN1–Up Part No.: 197-9052, 8N-9639 S/N: YAP1–Up Part No.: 197-9052, 8N-9639 S/N: ZAP1–Up Part No.: 197-9052, 8N-9639 S/N: ZBP1–Up Part No.: 197-9052, 8N-9639 S/N: PBR1–Up Part No.: 197-9052, 8N-9639 S/N: PDR1–Up Part No.: 197-9052, 8N-9639 S/N: YAR1–Up Part No.: 197-9052, 8N-9639 S/N: ZAR1–Up Part No.: 197-9052, 8N-9639 S/N: ZBR1–Up Part No.: 197-9052 S/N: YAT1–Up Part No.: 197-9052 S/N: YBT1–Up Part No.: 197-9052 S/N: YAW1–Up Part No.: 197-9052 S/N: YBW1–Up Part No.: 197-9052 S/N: YAY1–Up Part No.: 197-9052 S/N: YAZ1–Up

338

RENR5057

Specifications Section

Illustration 224

g03017277

Typical example Table 192 Specification for 102-8616 Damper Guard Gp and 4P-1602 Damper Guard Gp Item

Qty

Part

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).

Specification Description

RENR5057

339 Specifications Section

i04403760

Vibration Damper Guard SMCS Code: 1205 Part No.: 7W-6669 S/N: ZAD1–Up Part No.: 7W-6669 S/N: ZAH1–Up Part No.: 7W-6669 S/N: YAP1–Up Part No.: 7W-6669 S/N: ZAP1–Up Part No.: 7W-6669 S/N: ZBP1–Up Part No.: 7W-6669 S/N: PBR1–Up Part No.: 7W-6669 S/N: PDR1–Up

Illustration 225

g02592096

Table 193 Specification for 7W-6669 Damper Guard Gp Item

Qty

Part

1

3

0S-1616 Bolt

Specification Description Torque to 7 ± 2 N·m (60 ± 18 lb in).

340

RENR5057

Specifications Section

i03606360

Vibration Damper Guard SMCS Code: 1205 Part No.: 317-3739 S/N: YAP1–Up Part No.: 317-3739 S/N: ZBP1–Up Part No.: 317-3739 S/N: PBR1–Up Part No.: 317-3739 S/N: PDR1–Up Part No.: 317-3739 S/N: YAR1–Up Part No.: 317-3739 S/N: ZBR1–Up Part No.: 317-3739 S/N: YAY1–Up Part No.: 317-3739 S/N: YAZ1–Up

Illustration 226

g01931093

(1) Torque for the bolts.......15 ± 3 N·m (133 ± 27 lb in)

RENR5057

341 Specifications Section

i04459749

Vibration Damper Guard SMCS Code: 1205 Part No.: 376-3360 S/N: YBB1–Up Part No.: 376-3360 S/N: YBC1–Up Part No.: 376-3360 S/N: JDE1–Up Part No.: 376-3360 S/N: JCY1–Up

Illustration 227

g02645401

Table 194 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).

342

RENR5057

Specifications Section

i04906587

Stub Shaft (Front)

RENR5057

343 Specifications Section

SMCS Code: 1237 Part No.: 7N-7660 S/N: YBB1–Up Part No.: 7N-7660 S/N: YBC1–Up Part No.: 7N-7660 S/N: ZAD1–Up Part No.: 7N-7660 S/N: JDE1–Up Part No.: 7N-7660 S/N: ZAH1–Up Part No.: 7N-7660 S/N: ZAJ1–Up Part No.: 7N-7660 S/N: YAM1–Up Part No.: 7N-7660 S/N: YAN1–Up Part No.: 7N-7660 S/N: YAP1–Up Part No.: 7N-7660 S/N: ZAP1–Up Part No.: 7N-7660 S/N: ZBP1–Up Part No.: 7N-7660 S/N: PBR1–Up Part No.: 7N-7660 S/N: PDR1–Up Part No.: 7N-7660 S/N: YAR1–Up Part No.: 7N-7660 S/N: ZAR1–Up Part No.: 7N-7660 S/N: ZBR1–Up Part No.: 7N-7660 S/N: YAT1–Up Part No.: 7N-7660 S/N: YBT1–Up Part No.: 7N-7660 S/N: YAW1–Up Part No.: 7N-7660 S/N: YBW1–Up Part No.: 7N-7660 S/N: JCY1–Up Part No.: 7N-7660 S/N: YAY1–Up Part No.: 7N-7660

S/N: YAZ1–Up

344

RENR5057

Specifications Section

Illustration 228

g02578560

Table 195 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).

RENR5057

345 Specifications Section

i04403746

Stub Shaft (Front) SMCS Code: 1237 Part No.: 7W-3629 S/N: ZAP1–Up Part No.: 7W-3629 S/N: PBR1–Up Part No.: 7W-3629 S/N: ZAR1–Up

Illustration 229

g02591976

Table 196 Specification for 7W-3629 Stub Shaft Gp Item

1

Qty

12

Part

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).

346

RENR5057

Specifications Section

i04932354

Auxiliary Drive Pulley SMCS Code: 1205 Part No.: 415-8157 S/N: JDE1–Up Part No.: 415-8157 S/N: JCY1–Up

Illustration 230

g03103936

Table 197 Specification for 415-8157 Auxiliary Drive Pulley Gp Item

Qty

Part

1

1

235-2484 Lip Type Seal

Before assembly, lubricate the sealing lip lightly with the lubricant that is being sealed.

2

1

259-4598 O-Ring Seal

Before assembly, lubricate the bore lightly with the lubricant that is being sealed.

3

1

7C-4165 Adapter As

Specification Description

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 (2.9528 ± 0.0022 inch).

RENR5057

347 Specifications Section

i04399156

Auxiliary Drive Pulley SMCS Code: 1205 Part No.: 8N-8468 S/N: ZAP1–Up Part No.: 8N-8468 S/N: PBR1–Up

Illustration 231

g02579717

Table 198 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.

348

RENR5057

Specifications Section

i04403745

Auxiliary Drive Pulley SMCS Code: 1205 Part No.: 210-8602, 8N-8467 S/N: ZAP1–Up Part No.: 210-8602, 8N-8467 S/N: PBR1–Up Part No.: 210-8602, 8N-8467 S/N: ZAR1–Up

Illustration 232

g02591956

Table 199 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

RENR5057

349 Specifications Section

i04932385

Auxiliary Drive Shaft SMCS Code: 1165; 1207 Part No.: 415-8507 S/N: JDE1–Up Part No.: 209-3559, 209-3560, 209-3562 , 415-8507, 7N-8042 S/N: ZAP1–Up Part No.: 209-3559, 209-3560, 209-3562 , 7N-8042 S/N: PBR1–Up Part No.: 209-3559, 209-3560, 209-3561 , 209-3562, 415-8507, 7N-8042 S/N: ZAR1–Up Part No.: 415-8507 S/N: JCY1–Up

Illustration 233

g02849424

Table 200 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.

350

RENR5057

Specifications Section

i05084397

Belt Tension Chart SMCS Code: 1357

Part No.: 7N-9693 S/N: ZAD1–Up Part No.: 7N-9693 S/N: ZAH1–Up Part No.: 7N-9693 S/N: ZAJ1–Up Part No.: 7N-9693 S/N: YAM1–Up Part No.: 7N-9693 S/N: YAN1–Up Part No.: 7N-9693 S/N: YAP1–Up Part No.: 7N-9693 S/N: ZAP1–Up Part No.: 7N-9693 S/N: ZBP1–Up Part No.: 7N-9693 S/N: PBR1–Up Part No.: 7N-9693 S/N: PDR1–Up Part No.: 7N-9693 S/N: YAR1–Up Part No.: 7N-9693 S/N: ZAR1–Up Part No.: 7N-9693 S/N: ZBR1–Up Part No.: 7N-9693 S/N: YAT1–Up Part No.: 7N-9693 S/N: YBT1–Up Part No.: 7N-9693 S/N: YAW1–Up Part No.: 7N-9693 S/N: YBW1–Up Part No.: 7N-9693 S/N: YAY1–Up Part No.: 7N-9693 S/N: YAZ1–Up

RENR5057

351 Specifications Section

Table 201 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).

-

Table 202 Belt Tension Chart SAE or RMA Belt SIze

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

(1) (2) (3) (4)

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.

352

RENR5057

Specifications Section

i04392851

Alternator and Regulator SMCS Code: 1405 Part No.: 5N-5692 S/N: YBB1–Up Part No.: 5N-5692 S/N: YBC1–Up Part No.: 5N-5692 S/N: ZAD1–Up Part No.: 5N-5692 S/N: ZAH1–Up Part No.: 5N-5692 S/N: ZAJ1–Up Part No.: 5N-5692 S/N: YAM1–Up Part No.: 5N-5692 S/N: YAN1–Up Part No.: 5N-5692 S/N: YAP1–Up Part No.: 5N-5692 S/N: ZAP1–Up Part No.: 5N-5692 S/N: ZBP1–Up Part No.: 5N-5692 S/N: PBR1–Up Part No.: 5N-5692 S/N: PDR1–Up Part No.: 5N-5692 S/N: YAR1–Up Part No.: 5N-5692 S/N: ZAR1–Up Part No.: 5N-5692 S/N: ZBR1–Up Part No.: 5N-5692 S/N: YAT1–Up Part No.: 5N-5692 S/N: YBT1–Up Part No.: 5N-5692 S/N: YAW1–Up Part No.: 5N-5692 S/N: YBW1–Up Part No.: 5N-5692 S/N: YAY1–Up Part No.: 5N-5692 S/N: YAZ1–Up

RENR5057

353 Specifications Section

Illustration 234

g02562817

Table 203 Specification for 5N-5692 Charging Alternator Gp Item

Qty

Part

-

-

-

1

1

-

Specification Description Load the battery with a carbon pile 4C-4911 Battery Load Tester in order to get the maximum alternator output Tighten the bolt before you tighten the mounting bolt for the alternator. Torque to 88.4 ± 6.8 N·m (65.0 ± 5.0 lb ft)

2

1

187-2034 Flange Nut

3

-

6V-8187 Nut

Torque to 102 ± 7 N·m (75 ± 5 lb ft). Use a 7/16 ring terminal for (B+) terminal. (B+) terminal. Torque to 6.2 ± 0.6 N·m (55.0 ± 5.0 lb in).

4

-

-

The peak voltage for (R) terminal must not be less than the output voltage for (B+) terminal.

5

-

-

(B-) terminal. Torque to 2.25 ± 0.25 N·m (20.00 ± 2.00 lb in).

-

-

-

Voltage is 24 V.

-

-

-

Amperage is 45 amp.

-

-

-

Polarity is negative ground.

-

-

-

Rotation is Either direction.

-

-

-

Maximum turn on speed is 2500 rpm

-

-

-

-

-

Minimum full load current at 5000 rpm is 42.3 amp.

-

-

-

Minimum full load current at 2000 rpm is 15.8 amp.

-

-

-

Output voltage is 28 ± 1 V.

Alternator performance at 25 °C (77 °F)

354

RENR5057

Specifications Section

i04887991

Alternator and Regulator SMCS Code: 1405 Part No.: 333-1184 S/N: GD31–Up

Illustration 235

g03013357

Table 204 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

-

-

-

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. 3T-6354 Voltage Regulator As Permissible voltage range is 27 to 29 V.

RENR5057

355 Specifications Section

i04377195

Alternator and Regulator SMCS Code: 1405 Part No.: 6N-9294 S/N: ZAP1–Up Part No.: 6N-9294 S/N: PBR1–Up

Illustration 236

Note: Load the battery with a carbon pile 4C-4911 Battery Load Tester in order to get the maximum alternator output.

g02542197

356

RENR5057

Specifications Section Table 205 Specification for 6N-9294 Charging Alternator Gp Item

Qty

Part

1

-

-

Specification Description Torque the bolt before you tighten the mounting bolt of the alternator. Torque bolt to 88.4 ± 6.8 N·m (65.2 ± 5.0 lb ft).

2

1

187-2034 Flange Nut

3

1

6V-8187 Nut

Torque to 102 ± 7 N·m (75.23112 ± 5.16292 lb ft). Use a 7/16 ring terminal for (B+) terminal. (B+) terminal. Torque to 6.2 ± 0.6 N·m (54.9 ± 5.3 lb in).

030-9612 Screw

(B-) terminal. Torque to 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in).

4

1

5

1

-

-

-

Voltage is 24 V.

-

-

-

Amperage is 35 Amp.

-

-

-

Polarity is negative ground.

-

-

-

Rotation is in either direction.

-

-

-

Minimum full load current at 5000 rpm is 35 Amp.

-

-

-

Minimum full load current at 1500 rpm is 11 Amp.

-

-

-

Output voltage is 28 ± 1 V.

3T-6354 Voltage Regulator Voltage setting requires no adjustment. Permissible voltage range is 27 to 29 V. As

RENR5057

357 Specifications Section

i04557209

Alternator and Regulator SMCS Code: 1405 Part No.: 4N-3986 S/N: ZAP1–Up Part No.: 4N-3986 S/N: PBR1–Up Part No.: 4N-3986 S/N: ZAR1–Up

358

RENR5057

Specifications Section

Illustration 237

g02559997

Table 206 Specification for 4N-3986 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

-

-

-

Voltage is 24 V.

-

-

-

Amperage is 60 amp.

-

-

-

Polarity is negative ground.

-

-

-

Rotation is either direction.

-

-

-

Maximum turn on speed is 2000 rpm.

-

-

-

-

-

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. 3T-6354 Voltage Regulator As Permissible voltage range is 27 to 29 V.

Alternator performance at 25 °C (77 °F).

RENR5057

359 Specifications Section

i04849411

Alternator Mounting SMCS Code: 1405 Part No.: 7E-4836 S/N: GD31–Up Part No.: 7E-4836 S/N: ZAD1–Up Part No.: 7E-4836 S/N: ZAH1–Up Part No.: 7E-4836 S/N: ZAJ1–Up Part No.: 7E-4836 S/N: YAM1–Up Part No.: 7E-4836 S/N: YAN1–Up Part No.: 7E-4836 S/N: YAP1–Up Part No.: 7E-4836 S/N: ZAP1–Up Part No.: 7E-4836 S/N: ZBP1–Up Part No.: 7E-4836 S/N: PBR1–Up Part No.: 7E-4836 S/N: PDR1–Up Part No.: 7E-4836 S/N: YAR1–Up Part No.: 7E-4836 S/N: ZAR1–Up Part No.: 7E-4836 S/N: ZBR1–Up Part No.: 7E-4836 S/N: YAT1–Up Part No.: 7E-4836 S/N: YBT1–Up Part No.: 7E-4836 S/N: YAW1–Up Part No.: 7E-4836 S/N: YBW1–Up

360

RENR5057

Specifications Section

Illustration 238

g02579957

Table 207 Specification for 7E-4836 Alternator Mounting Gp and 335-4161 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) is 0.4 degrees. Adjust the belt tension of the serpentine belt according to the 197-9087 Tension Chart. Lubricate the sealing lip lightly with the lubricant that is being sealed.

197-9087Belt Tension Chart Table 208 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 (Frequency)

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

Clavis Type 14

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.

RENR5057

361 Specifications Section

i05210449

Alternator Mounting SMCS Code: 1405 Part No.: 376-4005 S/N: JDE1–Up Part No.: 376-4005 S/N: JCY1–Up

Illustration 239

g03335236

Table 209 Specification for 376-4005 Alternator Mounting Gp Item

Qty

Part

1

-

-

2

2

2J-3506 Full Nut

3

1

141-7116 Serpentine Belt

4

1

7E-4839 Pulley

5

1

300-8570 Pulley As

6

1

235-2484 Lip Type Seal

Specification Description Tighten the pulley retaining nut to 110 ± 10 N·m (81 ± 7 lb ft). Torque to 200 ± 20 N·m (148 ± 15 lb ft). Adjust the belt tension of the serpentine belt according to the 197-9087 Tension Chart. Maximum misalignment between pulley assembly (5) and pulley (4) should not exceed 0.4 degrees. Lubricate the sealing lip of the lip type seal lightly with the lubricant that is being sealed.

362

RENR5057

Specifications Section

197-9087Belt Tension Chart Table 210 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 (Frequency)

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

Clavis Type 14

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.

RENR5057

363 Specifications Section

i04390225

Electric Starting Motor SMCS Code: 1453 Part No.: 207-1556 S/N: ZAD1–Up Part No.: 207-1556 S/N: ZAH1–Up Part No.: 207-1556 S/N: ZAJ1–Up Part No.: 207-1556 S/N: YAM1–Up Part No.: 207-1556 S/N: YAN1–Up Part No.: 207-1556 S/N: YAP1–Up Part No.: 207-1556 S/N: ZAP1–Up Part No.: 207-1556 S/N: PBR1–Up Part No.: 207-1556 S/N: YAR1–Up Part No.: 207-1556 S/N: ZAR1–Up Part No.: 207-1556 S/N: YAT1–Up Part No.: 207-1556 S/N: YAW1–Up Part No.: 207-1556 S/N: YAY1–Up Part No.: 207-1556 S/N: YAZ1–Up

364

RENR5057

Specifications Section

Illustration 240

g02560026

Table 211 Specification for the 207-1556 Electric Starting Motor Gp Item

Qty

Part

1

2

6V-8188 Nut

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): 250-8279 Solenoid 1. For Pull-in windings is 57 Amp 2. For Hold-in windings is 16 Amp Kit 3. Maximum rated current is 850 Amp

2

1

B

-

-

3

1

6V-8378 Nut

Torque to 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in).

4

1

6V-8188 Nut

A maximum of three cable terminals or wire terminals may be used with the battery terminal nut (3). 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).

5

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 (19.91 ± 2.21 lb in).

6

1

6V-8188 Nut

Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 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 V

-

-

The clearance between the pinion and the housing is 9.1 mm (0.36 inch).

RENR5057

365 Specifications Section

i04392884

Electric Starting Motor SMCS Code: 1453 Part No.: 237-1962 S/N: ZAD1–Up Part No.: 237-1962 S/N: ZAH1–Up Part No.: 237-1962 S/N: ZAJ1–Up Part No.: 237-1962 S/N: YAM1–Up Part No.: 237-1962 S/N: YAN1–Up Part No.: 237-1962 S/N: YAP1–Up Part No.: 237-1962 S/N: ZAP1–Up Part No.: 237-1962 S/N: PBR1–Up Part No.: 237-1962 S/N: YAR1–Up Part No.: 237-1962 S/N: ZAR1–Up Part No.: 237-1962 S/N: YAT1–Up Part No.: 237-1962 S/N: YAW1–Up Part No.: 237-1962 S/N: YAY1–Up Part No.: 237-1962 S/N: YAZ1–Up

366

RENR5057

Specifications Section

Illustration 241

g02562997

Table 212 Specification for the 237-1962 Electric Starting Motor Gp Item

Qty

Part

B

-

-

1

2

6V-8188 Nut

Ground terminal. Torque to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).

2

2

4B-2049 Nut

Torque to 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in).

3

1

6V-8188 Nut

Motor terminal. Torque to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).

4

1

6V-8188 Nut

Specification Description Clearance between the pinion and the housing is 9.1 mm (0.36 inch).

Battery terminal. 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 (270.0 ± 31.0 lb in).

5

-

-

-

-

-

Motor frame terminal. Torque to 30.5 ± 3.5 N·m (270.0 ± 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):

(continued)

RENR5057

367 Specifications Section

(Table 212, contd) Speed is 6950 ± 1650 rpm. Current draw is 115 ± 25 Amp. Voltage is 23 VDC.

368

RENR5057

Specifications Section

i04394042

Electric Starting Motor SMCS Code: 1453 Part No.: 6V-0927 S/N: YBB1–Up Part No.: 6V-0927 S/N: YBC1–Up Part No.: 6V-0927 S/N: ZAD1–Up Part No.: 6V-0927 S/N: JDE1–Up Part No.: 6V-0927 S/N: ZAH1–Up Part No.: 6V-0927 S/N: ZAJ1–Up Part No.: 6V-0927 S/N: YAM1–Up Part No.: 6V-0927 S/N: YAN1–Up Part No.: 6V-0927 S/N: YAP1–Up Part No.: 6V-0927 S/N: ZAP1–Up Part No.: 6V-0927 S/N: ZBP1–Up Part No.: 6V-0927 S/N: PBR1–Up Part No.: 6V-0927 S/N: PDR1–Up Part No.: 6V-0927 S/N: YAR1–Up Part No.: 6V-0927 S/N: ZAR1–Up Part No.: 6V-0927 S/N: ZBR1–Up Part No.: 6V-0927 S/N: YAT1–Up Part No.: 6V-0927 S/N: YBT1–Up Part No.: 6V-0927 S/N: YAW1–Up Part No.: 6V-0927 S/N: YBW1–Up Part No.: 6V-0927 S/N: JCY1–Up

RENR5057

369 Specifications Section

Illustration 242

g02565437

Table 213 Specification for 6V-0927 Electric Starting Motor Gp Item

Qty

Part

B

-

-

1

2

6V-8188 Nut

2

1

3

1

6V-8188 Nut

Torque to 30.5 ± 3.5 N·m (270.0 ± 30.0 lb in).

4

1

4B-2049 Nut

Torque to 2.25 ± 0.25 N·m (20.00 ± 2.00 lb in).

5

1

4B-2049 Nut

The switch terminal must be insulated with heat shrink tubing. Do not use molded terminals. Torque to 2.25 ± 0.25 N·m (20.00 ± 2.00 lb in).

6

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. 30.5 ± 3.5 N·m (270.0 ± 30.0 lb in)

7

1

6V-8188 Nut

30.5 ± 3.5 N·m (270.0 ± 30.0 lb in)

-

-

Specification Description The clearance between the pinion and the housing is 9.1 mm (0.36 inch). Torque to 30.5 ± 3.5 N·m (270.0 ± 30.0 lb in).

Current consumption at 20V and 25 °C (77 °F): 338-3453 Starting 1. For Pull-in windings is 49.3 ± 3.3 amp Motor Solenoid 2. For Hold-in windings 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 performance at 25 °C (77 °F) 1. Speed is 6950 ± 1650 rpm 2. Current draw is 115 ± 25 Amp 3. Voltage is 23 VDC

370

RENR5057

Specifications Section

i04882274

Electric Starting Motor SMCS Code: 1453 Part No.: 207-1562 S/N: YBB1–Up Part No.: 207-1562 S/N: YBC1–Up Part No.: 207-1562 S/N: ZAD1–Up Part No.: 207-1562 S/N: ZAH1–Up Part No.: 207-1562 S/N: ZAJ1–Up Part No.: 207-1562 S/N: YAM1–Up Part No.: 207-1562 S/N: YAN1–Up Part No.: 207-1562 S/N: YAP1–Up Part No.: 207-1562 S/N: ZAP1–Up Part No.: 207-1562 S/N: ZBP1–Up Part No.: 207-1562 S/N: PBR1–Up Part No.: 207-1562 S/N: PDR1–Up Part No.: 207-1562 S/N: YAR1–Up Part No.: 207-1562 S/N: ZAR1–Up Part No.: 207-1562 S/N: ZBR1–Up Part No.: 207-1562 S/N: YAT1–Up Part No.: 207-1562 S/N: YBT1–Up Part No.: 207-1562 S/N: YAW1–Up Part No.: 207-1562 S/N: YBW1–Up Part No.: 207-1562 S/N: YAY1–Up Part No.: 207-1562 S/N: YAZ1–Up

RENR5057

371 Specifications Section

Illustration 243

g03006636

Table 214 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).

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

-

-

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

372

RENR5057

Specifications Section

i05208385

Electric Starting Motor SMCS Code: 1453 Part No.: 7C-0527 S/N: GD31–Up

Illustration 244

g03334757

Typical example Table 215 Specification for 7C-0526 Electric Starting Motor Gp and 7C-0527 Electric Starting Motor Gp Item

Qty

Part

Specification Description

-

-

-

When the electric starting motor is viewed from the pinion end, the motor rotates in the clockwise direction.

-

-

-

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.

-

-

-

No load conditions at 25 °C (77 °F): Speed is 7643 ± 1683 rpm minimum. Current draw is 76.5 ± 14.5 Amp maximum. Voltage is 23 VDC.

B

-

-

The clearance between the extended pinion and the housing is 9.1 mm (0.36 inch).

1

-

-

Battery terminal. A maximum of three cable terminals or wire terminals may be used with the nut. A maximum of two of the cable terminals may be equal to or greater than 0 AWG. Tighten the nut to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).

2

-

-

Ground terminal. Tighten the nut to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).

3

-

-

Ground terminal. Tighten the nut to 2.6 ± 0.8 N·m (23.0 ± 7.1 lb in).

4

-

-

Switch terminal. Tighten the nut to 2.6 ± 0.8 N·m (23.0 ± 7.1 lb in). The switch terminal must be insulated with heat shrink tubing. Do not use molded terminals.

5

-

-

Motor terminal. Tighten the nut to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).

6

-

-

Motor frame terminal. Tighten the nut to 8 ± 3 N·m (71 ± 27 lb in).

RENR5057

373 Specifications Section

i04399238

Air Starting Motor

374

RENR5057

Specifications Section SMCS Code: 1451 Part No.: 7C-3372 S/N: YBB1–Up Part No.: 7C-3372 S/N: YBC1–Up Part No.: 7C-3372 S/N: ZAD1–Up Part No.: 7C-3372 S/N: JDE1–Up Part No.: 7C-3372 S/N: ZAH1–Up Part No.: 7C-3372 S/N: ZAJ1–Up Part No.: 7C-3372 S/N: YAM1–Up Part No.: 7C-3372 S/N: YAN1–Up Part No.: 7C-3372 S/N: YAP1–Up Part No.: 7C-3372 S/N: ZAP1–Up Part No.: 7C-3372 S/N: ZBP1–Up Part No.: 7C-3372 S/N: PBR1–Up Part No.: 7C-3372 S/N: PDR1–Up Part No.: 7C-3372 S/N: YAR1–Up Part No.: 7C-3372 S/N: ZAR1–Up Part No.: 7C-3372 S/N: ZBR1–Up Part No.: 7C-3372 S/N: YAT1–Up Part No.: 7C-3372 S/N: YBT1–Up Part No.: 7C-3372 S/N: YAW1–Up Part No.: 7C-3372 S/N: YBW1–Up Part No.: 7C-3372 S/N: JCY1–Up Part No.: 7C-3372 S/N: YAY1–Up Part No.: 7C-3372

S/N: YAZ1–Up

RENR5057

375 Specifications Section

Illustration 245

g02580105

Typical example Table 216 Specification for 4W-5732 Air Starting Motor Gp, 335-4155 Air Starting Motor Gp, and 7C-3372 Air Starting Motor Gp Item

Qty

Part

1

-

-

Torque to 80 N·m (59 lb ft).

2

-

-

Torque to 36 N·m (27 lb ft).

3

-

-

Torque to 78 N·m (58 lb ft).

4

-

-

Torque to 110 N·m (81 lb ft).

5

-

-

Tighten the rotor clamp nut until clearance of 0.03 to 0.08 mm (0.001 to 0.003 inch) is reached between the rear end plate and the rotor. Check the clearance again after the bolt for the rotor clamp nut is tightened.

6

-

-

Torque to 120 N·m (89 lb ft).

Specification Description

376

RENR5057

Specifications Section

i04907197

Air Starting Motor Pressure Regulating Valve SMCS Code: 1462 Part No.: 1L-2073 S/N: YBB1–Up Part No.: 1L-2073 S/N: YBC1–Up Part No.: 1L-2073 S/N: ZAD1–Up Part No.: 1L-2073 S/N: JDE1–Up Part No.: 1L-2073 S/N: ZAH1–Up Part No.: 1L-2073 S/N: ZAJ1–Up Part No.: 1L-2073 S/N: YAM1–Up Part No.: 1L-2073 S/N: YAN1–Up Part No.: 1L-2073 S/N: YAP1–Up Part No.: 1L-2073 S/N: ZAP1–Up Part No.: 1L-2073 S/N: ZBP1–Up Part No.: 1L-2073 S/N: PBR1–Up Part No.: 1L-2073 S/N: PDR1–Up Part No.: 1L-2073 S/N: YAR1–Up Part No.: 1L-2073 S/N: ZAR1–Up Part No.: 1L-2073 S/N: ZBR1–Up Part No.: 1L-2073 S/N: YAT1–Up Part No.: 1L-2073 S/N: YBT1–Up Part No.: 1L-2073 S/N: YAW1–Up Part No.: 1L-2073 S/N: YBW1–Up Part No.: 1L-2073 S/N: JCY1–Up

RENR5057

377 Specifications Section

Illustration 246

g03071456

Table 217 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

378

RENR5057

Specifications Section

i04757411

Coolant Level Switch SMCS Code: 1395; 7422 Part No.: 2N-9768 S/N: YBB1–Up Part No.: 2N-9768 S/N: YBC1–Up Part No.: 2N-9768 S/N: ZAD1–Up Part No.: 2N-9768 S/N: JDE1–Up Part No.: 2N-9768 S/N: ZAH1–Up Part No.: 2N-9768 S/N: ZAJ1–Up Part No.: 2N-9768 S/N: YAM1–Up Part No.: 2N-9768 S/N: YAN1–Up Part No.: 2N-9768 S/N: YAP1–Up Part No.: 2N-9768 S/N: ZAP1–Up Part No.: 2N-9768 S/N: ZBP1–Up Part No.: 2N-9768 S/N: PBR1–Up Part No.: 2N-9768 S/N: PDR1–Up Part No.: 2N-9768 S/N: YAR1–Up Part No.: 2N-9768 S/N: ZAR1–Up Part No.: 2N-9768 S/N: ZBR1–Up Part No.: 2N-9768 S/N: YAT1–Up Part No.: 2N-9768 S/N: YBT1–Up Part No.: 2N-9768 S/N: YAW1–Up Part No.: 2N-9768 S/N: YBW1–Up Part No.: 2N-9768 S/N: JCY1–Up

RENR5057

379 Specifications Section

Illustration 247

g02849383

Table 218 Specification for 2N-9768 Liquid Level Switch Item

Qty

Specification Description

Part

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.

380

RENR5057

Specifications Section

i04929951

Coolant Temperature Switch SMCS Code: 1395 Part No.: 3E-0264 S/N: PBR1–Up

Illustration 248

g03099257

Table 219 Specification for 3E-0264 Temperature Switch Gp Item

1

Qty

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.

1

RENR5057

381 Specifications Section

i04358589

Fuel Pressure Sensor

382 Specifications Section SMCS Code: 7414 Part No.: 274-6719 S/N: YBB1–Up Part No.: 274-6719 S/N: YBC1–Up Part No.: 274-6719 S/N: ZAD1–Up Part No.: 274-6719 S/N: JDE1–Up Part No.: 274-6719 S/N: ZAH1–Up Part No.: 274-6719 S/N: ZAJ1–Up Part No.: 274-6719 S/N: YAM1–Up Part No.: 274-6719 S/N: YAN1–Up Part No.: 274-6719 S/N: YAP1–Up Part No.: 274-6719 S/N: ZAP1–Up Part No.: 274-6719 S/N: ZBP1–Up Part No.: 274-6719 S/N: PBR1–Up Part No.: 274-6719 S/N: PDR1–Up Part No.: 274-6719 S/N: YAR1–Up Part No.: 274-6719 S/N: ZAR1–Up Part No.: 274-6719 S/N: ZBR1–Up Part No.: 274-6719 S/N: YAT1–Up Part No.: 274-6719 S/N: YBT1–Up Part No.: 274-6719 S/N: YBW1–Up Part No.: 274-6719 S/N: JCY1–Up Part No.: 274-6719 S/N: YAY1–Up Part No.: 274-6719 S/N: YAZ1–Up

RENR5057

RENR5057

383 Specifications Section

Illustration 249

g02544036

Table 220 Specification for 274-6719 Pressure Sensor Gp Item

Qty

1

1

Part

Specification Description

274-6719 Pressure Sensor Torque to 10 ± 2 N·m (89 ± 18 lb in) Gp Operating voltage is 5.0 ± 0.5 VDC

384

RENR5057

Specifications Section

i04935269

Fuel Pressure Sensor SMCS Code: 7414

Part No.: 161-1705 S/N: ZAD1–Up Part No.: 161-1705 S/N: ZAH1–Up Part No.: 161-1705 S/N: ZAJ1–Up Part No.: 161-1705 S/N: YAM1–Up Part No.: 161-1705 S/N: YAN1–Up Part No.: 161-1705 S/N: YAP1–Up Part No.: 161-1705 S/N: ZAP1–Up Part No.: 161-1705 S/N: PBR1–Up Part No.: 161-1705 S/N: YAR1–Up Part No.: 161-1705 S/N: ZAR1–Up Part No.: 161-1705 S/N: YAT1–Up Part No.: 161-1705 S/N: YAW1–Up Part No.: 161-1705 S/N: YAY1–Up Part No.: 161-1705 S/N: YAZ1–Up

RENR5057

385 Specifications Section

Illustration 250

g03109341

Table 221 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.

386

RENR5057

Specifications Section

i04921375

Prelube Pressure Switch SMCS Code: 7400

Part No.: 150-1240 S/N: JDE1–Up Part No.: 150-1240 S/N: ZAH1–Up Part No.: 150-1240 S/N: ZAJ1–Up Part No.: 150-1240 S/N: YAM1–Up Part No.: 150-1240 S/N: YAN1–Up Part No.: 150-1240 S/N: YAP1–Up Part No.: 150-1240 S/N: ZAP1–Up Part No.: 150-1240 S/N: ZBP1–Up Part No.: 150-1240 S/N: PBR1–Up Part No.: 150-1240 S/N: PDR1–Up Part No.: 150-1240 S/N: YAR1–Up Part No.: 150-1240 S/N: ZAR1–Up Part No.: 150-1240 S/N: ZBR1–Up Part No.: 150-1240 S/N: YAT1–Up Part No.: 150-1240 S/N: YBT1–Up Part No.: 150-1240 S/N: YAW1–Up Part No.: 150-1240 S/N: YBW1–Up Part No.: 150-1240 S/N: JCY1–Up Part No.: 150-1240 S/N: YAY1–Up Part No.: 150-1240 S/N: YAZ1–Up

RENR5057

387 Specifications Section

Illustration 251

g03087079

Table 222 Specification for 150-1240 Pressure Switch Item

Qty

Part

1

-

-

Specification Description Final installation torque for the pressure switch is 22 ± 3 N·m (195 ± 27 lb in). Contact position is normally open below deactuation pressure.

-

-

-

Actuation pressure is 9.0 ± 3.0 kPa (1.3 ± 0.4 psi).

-

-

-

Minimum deactuation pressure is 7 kPa (1 psi).

388

RENR5057

Specifications Section

i04935270

Coolant Level Sensor

RENR5057

389 Specifications Section

SMCS Code: 7470

S/N: YAY1–Up

Part No.: 204-2518 S/N: GD31–Up

Part No.: 204-2518, 239-9957 S/N: YAZ1–Up

Part No.: 204-2518 S/N: YBB1–Up Part No.: 204-2518 S/N: YBC1–Up Part No.: 204-2518, 239-9957 S/N: ZAD1–Up Part No.: 204-2518 S/N: JDE1–Up Part No.: 204-2518, 239-9957 S/N: ZAH1–Up Part No.: 204-2518, 239-9957 S/N: ZAJ1–Up Part No.: 204-2518, 239-9957 S/N: YAM1–Up Part No.: 204-2518, 239-9957 S/N: YAN1–Up Part No.: 204-2518, 239-9957 S/N: YAP1–Up Part No.: 204-2518, 239-9957 S/N: ZAP1–Up Part No.: 204-2518 S/N: ZBP1–Up Part No.: 204-2518, 239-9957 S/N: PBR1–Up Part No.: 204-2518 S/N: PDR1–Up Part No.: 204-2518, 239-9957 S/N: YAR1–Up Part No.: 204-2518, 239-9957 S/N: ZAR1–Up Part No.: 204-2518 S/N: ZBR1–Up Part No.: 204-2518, 239-9957 S/N: YAT1–Up Part No.: 204-2518 S/N: YBT1–Up Part No.: 239-9957 S/N: YAW1–Up Part No.: 204-2518 S/N: YBW1–Up Part No.: 204-2518 S/N: JCY1–Up Part No.: 204-2518, 239-9957

390

RENR5057

Specifications Section

Illustration 252

g03109342

Table 223 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.

RENR5057

391 Specifications Section

i04401293

Coolant Level Sensor SMCS Code: 7470

Part No.: 165-6634 S/N: ZAD1–Up Part No.: 165-6634 S/N: ZAH1–Up Part No.: 165-6634 S/N: ZAJ1–Up Part No.: 165-6634 S/N: YAM1–Up Part No.: 165-6634 S/N: YAP1–Up Part No.: 165-6634 S/N: ZAP1–Up Part No.: 165-6634 S/N: PBR1–Up Part No.: 165-6634 S/N: YAR1–Up Part No.: 165-6634 S/N: ZAR1–Up Part No.: 165-6634 S/N: YAT1–Up Part No.: 165-6634 S/N: YAW1–Up Part No.: 165-6634 S/N: YAY1–Up Part No.: 165-6634 S/N: YAZ1–Up

392

RENR5057

Specifications Section

Illustration 253

g02584877

Table 224 Specification for 165-6634 Coolant Level Sensor Gp Item

Qty

Part

1

-

-

Specification Description Final installation torque is 22 ± 3 N·m (195 ± 27 lb in). Operating voltage is 8.0 ± 0.4 VDC.

RENR5057

393 Specifications Section

i04397599

Engine Oil Pressure Sensor SMCS Code: 1924 Part No.: 274-6719

Illustration 254

g02575276

Table 225 Specification for 274-6719 Pressure Sensor Gp, 299-3222 Pressure Sensor Gp, 248-2167 Pressure Sensor Gp, 276-9067 Pressure Sensor Gp, and 293-5535 Pressure Sensor Gp Item

Qty

Part

1

-

-

Torque to 10 ± 2 N·m (89 ± 18 lb in).

-

-

-

Operating voltage is 5.0 ± 0.5 VDC.

Specification Description

394

RENR5057

Specifications Section

i04402163

Engine Oil Pressure Sensor SMCS Code: 1924 Part No.: 161-1705 S/N: ZAD1–Up Part No.: 161-1705 S/N: ZAH1–Up Part No.: 161-1705 S/N: ZAJ1–Up Part No.: 161-1705 S/N: YAM1–Up Part No.: 161-1705 S/N: YAN1–Up Part No.: 161-1705 S/N: YAP1–Up Part No.: 161-1705 S/N: ZAP1–Up Part No.: 161-1705 S/N: PBR1–Up Part No.: 161-1705 S/N: YAR1–Up Part No.: 161-1705 S/N: ZAR1–Up Part No.: 161-1705 S/N: YAT1–Up Part No.: 161-1705 S/N: YAW1–Up Part No.: 161-1705 S/N: YAY1–Up Part No.: 161-1705 S/N: YAZ1–Up

RENR5057

395 Specifications Section

Illustration 255

g02587196

Table 226 Specification for the 161-1705 Engine Oil Pressure Sensor Item

Qty

Part

Specification Description Torque the pressure sensor to 10 ± 2 N·m (90 ± 18 lb in).

1

-

-

Prior to installing the pressure sensor onto the engine, apply 5P-3413 Pipe Sealant to the first three threads of the sensor. Operating voltage is 5.00 ± 0.25 VDC.

396

RENR5057

Specifications Section

i04753510

Engine Oil Temperature Sensor

RENR5057

397 Specifications Section

SMCS Code: 1929; 7400 Part No.: 102-2240 S/N: YBB1–Up Part No.: 102-2240 S/N: YBC1–Up Part No.: 102-2240 S/N: ZAD1–Up Part No.: 102-2240 S/N: JDE1–Up Part No.: 102-2240 S/N: ZAH1–Up Part No.: 102-2240 S/N: ZAJ1–Up Part No.: 102-2240 S/N: YAM1–Up Part No.: 102-2240 S/N: YAN1–Up Part No.: 102-2240 S/N: YAP1–Up Part No.: 102-2240 S/N: ZAP1–Up Part No.: 102-2240 S/N: ZBP1–Up Part No.: 102-2240 S/N: PBR1–Up Part No.: 102-2240 S/N: PDR1–Up Part No.: 102-2240 S/N: YAR1–Up Part No.: 102-2240 S/N: ZAR1–Up Part No.: 102-2240 S/N: ZBR1–Up Part No.: 102-2240 S/N: YAT1–Up Part No.: 102-2240 S/N: YBT1–Up Part No.: 102-2240 S/N: YAW1–Up Part No.: 102-2240 S/N: YBW1–Up Part No.: 102-2240 S/N: JCY1–Up Part No.: 102-2240 S/N: YAY1–Up Part No.: 102-2240

S/N: YAZ1–Up

398

RENR5057

Specifications Section

Illustration 256

g02848878

Table 227 Specification for 130-8299 Temperature Sensor Gp, and 102-2240 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. Output type is Analog.

RENR5057

399 Specifications Section

i04753449

Engine Oil Temperature Sensor SMCS Code: 1929; 7400 Part No.: 195-2150

Illustration 257

g02848868

Table 228 Specification for 195-2150 Temperature Sensor Gp Item

Qty

Part

1

-

-

Specification Description Torque to 48 ± 5 N·m (35 ± 4 lb ft). Operating voltage is 5 ± 0.25 VDC.

400

RENR5057

Specifications Section

i04402174

Turbocharger Inlet Pressure Sensor SMCS Code: 1052 Part No.: 161-1703 S/N: ZAD1–Up Part No.: 161-1703 S/N: ZAH1–Up Part No.: 161-1703 S/N: ZAJ1–Up Part No.: 161-1703 S/N: YAM1–Up Part No.: 161-1703 S/N: YAN1–Up Part No.: 161-1703 S/N: YAP1–Up Part No.: 161-1703 S/N: ZAP1–Up Part No.: 161-1703 S/N: PBR1–Up Part No.: 161-1703 S/N: YAR1–Up Part No.: 161-1703 S/N: ZAR1–Up Part No.: 161-1703 S/N: YAT1–Up Part No.: 161-1703 S/N: YAW1–Up Part No.: 161-1703 S/N: YAY1–Up Part No.: 161-1703 S/N: YAZ1–Up

RENR5057

401 Specifications Section

Illustration 258

g02587218

Table 229 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.

402

RENR5057

Specifications Section

i04415930

Turbocharger Inlet Pressure Sensor

RENR5057

403 Specifications Section

SMCS Code: 1052 Part No.: 274-6717 S/N: YBB1–Up Part No.: 274-6717 S/N: YBC1–Up Part No.: 274-6717 S/N: ZAD1–Up Part No.: 274-6717 S/N: JDE1–Up Part No.: 274-6717 S/N: ZAH1–Up Part No.: 274-6717 S/N: ZAJ1–Up Part No.: 274-6717 S/N: YAM1–Up Part No.: 274-6717 S/N: YAN1–Up Part No.: 274-6717 S/N: YAP1–Up Part No.: 274-6717 S/N: ZAP1–Up Part No.: 274-6717 S/N: ZBP1–Up Part No.: 274-6717 S/N: PBR1–Up Part No.: 274-6717 S/N: PDR1–Up Part No.: 274-6717 S/N: YAR1–Up Part No.: 274-6717 S/N: ZAR1–Up Part No.: 274-6717 S/N: ZBR1–Up Part No.: 274-6717 S/N: YAT1–Up Part No.: 274-6717 S/N: YBT1–Up Part No.: 274-6717 S/N: YBW1–Up Part No.: 274-6717 S/N: JCY1–Up Part No.: 274-6717 S/N: YAY1–Up Part No.: 274-6717 S/N: YAZ1–Up

404

RENR5057

Specifications Section

Illustration 259

g02614117

Table 230 Specification for 274-6717 Pressure Sensor Item

Qty

Part

1

1

274-6717 Pressure Sensor

Specification Description Torque to 10 ± 2 N·m (89 ± 18 lb in). Operating voltage is 5.0 ± 0.5 VDC.

RENR5057

405 Specifications Section

i04416053

Turbocharger Outlet Pressure Sensor SMCS Code: 1052; 1917; 1919 Part No.: 276-6793

Illustration 260

g02614362

Table 231 Specification for the 276-6793 Pressure Sensor Gp Item

Qty

part

1

1

276-6793 Pressure Sensor Gp

Specification Description Torque to 10 ± 2 N·m (89 ± 18 lb in). Operating voltage is 5.0 ± 0.5 VDC.

406

RENR5057

Specifications Section

i04402177

Turbocharger Outlet Pressure Sensor SMCS Code: 1052; 1917; 1919 Part No.: 161-1704 S/N: ZAD1–Up Part No.: 161-1704 S/N: ZAH1–Up Part No.: 161-1704 S/N: ZAJ1–Up Part No.: 161-1704 S/N: YAM1–Up Part No.: 161-1704 S/N: YAN1–Up Part No.: 161-1704 S/N: YAP1–Up Part No.: 161-1704 S/N: ZAP1–Up Part No.: 161-1704 S/N: PBR1–Up Part No.: 161-1704 S/N: YAR1–Up Part No.: 161-1704 S/N: ZAR1–Up Part No.: 161-1704 S/N: YAT1–Up Part No.: 161-1704 S/N: YAW1–Up Part No.: 161-1704 S/N: YAY1–Up Part No.: 161-1704 S/N: YAZ1–Up

RENR5057

407 Specifications Section

Illustration 261

g02587256

Table 232 Specification for 161-1704 Turbocharger Outlet Pressure Sensor Gp Item

Qty

1

1

part

Specification Description

161-1704 Turbocharger Outlet Pressure Sen- Torque to 10 ± 2 N·m (89 ± 18 lb in). sor Gp Operating voltage is 5.00 ± 0.25 VDC.

408

RENR5057

Specifications Section

i04753313

Aftercooler Coolant Temperature Sensor SMCS Code: 1063; 1395 Part No.: 102-2240

Illustration 262

g02848830

Table 233 Specification for 102-2240 Temperature Sensor Gp, and 118-7562 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.

RENR5057

409 Specifications Section

i04107829

Engine Coolant Temperature Sensor

410

RENR5057

Specifications Section SMCS Code: 1395 Part No.: 102-0050 S/N: YBB1–Up Part No.: 102-0050 S/N: YBC1–Up Part No.: 102-0050 S/N: ZAD1–Up Part No.: 102-0050 S/N: JDE1–Up Part No.: 102-0050 S/N: ZAH1–Up Part No.: 102-0050 S/N: ZAJ1–Up Part No.: 102-0050 S/N: YAM1–Up Part No.: 102-0050 S/N: YAN1–Up Part No.: 102-0050 S/N: YAP1–Up Part No.: 102-0050 S/N: ZAP1–Up Part No.: 102-0050 S/N: ZBP1–Up Part No.: 102-0050 S/N: PBR1–Up Part No.: 102-0050 S/N: PDR1–Up Part No.: 102-0050 S/N: YAR1–Up Part No.: 102-0050 S/N: ZAR1–Up Part No.: 102-0050 S/N: ZBR1–Up Part No.: 102-0050 S/N: YAT1–Up Part No.: 102-0050 S/N: YBT1–Up Part No.: 102-0050 S/N: YAW1–Up Part No.: 102-0050 S/N: YBW1–Up Part No.: 102-0050 S/N: JCY1–Up Part No.: 102-0050 S/N: YAY1–Up Part No.: 102-0050

S/N: YAZ1–Up

RENR5057

411 Specifications Section

Illustration 263

g02848807

Table 234 Specification for 102-0050 Temperature Sensor Gp Item

Qty

Part

Specification Description Torque to 20 ± 5 N·m (177 ± 44 lb in).

1

-

-

Operating voltage is 7.5 to 8.5 V. Output type is PWM. Output frequency is 500 ± 200 Hz. Duty cycle is 10 to 89 %

412

RENR5057

Specifications Section

i04402182

Engine Coolant Temperature Sensor SMCS Code: 1395 Part No.: 102-2240

Illustration 264

g02587296

Table 235 Specification for 102-2240 Engine Coolant Temperature Sensor Gp Item

Qty

1

1

Part

Specification Description

102-2240 Engine Coolant Tempera- Torque to 20 ± 3 N·m (177 ± 27 lb in). ture Sensor Gp Operating voltage is 4.75 to 8.50 VDC.

RENR5057

413 Specifications Section

i04402191

Turbocharger Exhaust Temperature Sensor

414

RENR5057

Specifications Section SMCS Code: 1052; 1919

S/N: YAY1–Up

Part No.: 261-6848 S/N: GD31–Up

Part No.: 163-7882, 261-6848 S/N: YAZ1–Up

Part No.: 261-6848 S/N: YBB1–Up Part No.: 261-6848 S/N: YBC1–Up Part No.: 163-7882, 261-6848 S/N: ZAD1–Up Part No.: 261-6848 S/N: JDE1–Up Part No.: 163-7882, 261-6848 S/N: ZAH1–Up Part No.: 163-7882, 261-6848 S/N: ZAJ1–Up Part No.: 163-7882, 261-6848 S/N: YAM1–Up Part No.: 163-7882, 261-6848 S/N: YAN1–Up Part No.: 163-7882, 261-6848 S/N: YAP1–Up Part No.: 163-7882, 261-6848 S/N: ZAP1–Up Part No.: 261-6848 S/N: ZBP1–Up Part No.: 163-7882, 261-6848 S/N: PBR1–Up Part No.: 261-6848 S/N: PDR1–Up Part No.: 163-7882, 261-6848 S/N: YAR1–Up Part No.: 163-7882, 261-6848 S/N: ZAR1–Up Part No.: 261-6848 S/N: ZBR1–Up Part No.: 163-7882, 261-6848 S/N: YAT1–Up Part No.: 261-6848 S/N: YBT1–Up Part No.: 163-7882, 261-6848 S/N: YAW1–Up Part No.: 261-6848 S/N: YBW1–Up Part No.: 261-6848 S/N: JCY1–Up Part No.: 163-7882, 261-6848

RENR5057

415 Specifications Section

Illustration 265

g02587496

(2) Exhaust temperature sensor group Table 236 Specification for the 163-7882 Turbocharger Exhaust Temperature Sensor Gp and 261-6848 Turbocharger Exhaust Temperature Sensor Gp Item

Qty

Specification Description

Part Torque to 45 ± 5 N·m (33 ± 4 lb ft).

Apply 4C-5599 Anti-Seize Compound to the threads of the adapter (1) before installation. 1

-

-

Operating voltage is 7.5 to 8.5 VDC. Output type is PWM. Output frequency is 500 ± 100 Hz.

416

RENR5057

Specifications Section

i04753129

Turbocharger Exhaust Temperature Sensor SMCS Code: 1052; 1919 Part No.: 109-4367 S/N: ZAD1–Up Part No.: 109-4367 S/N: ZAH1–Up Part No.: 109-4367 S/N: ZAJ1–Up Part No.: 109-4367 S/N: ZAP1–Up

Illustration 266

g02848799

Table 237 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

Qty

Part

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.

RENR5057

417 Specifications Section

i04402215

Engine Speed/Timing Sensor SMCS Code: 1905; 1907 Part No.: 273-5041

Illustration 267

g02587517

Table 238 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.

418

RENR5057

Specifications Section

i04403710

Engine Speed/Timing Sensor SMCS Code: 1905; 1907 Part No.: 129-6628 S/N: ZAD1–Up Part No.: 129-6628 S/N: ZAH1–Up Part No.: 129-6628 S/N: ZAJ1–Up Part No.: 129-6628 S/N: YAM1–Up Part No.: 129-6628 S/N: YAN1–Up Part No.: 129-6628 S/N: ZAP1–Up Part No.: 129-6628 S/N: PBR1–Up Part No.: 129-6628 S/N: ZAR1–Up Part No.: 129-6628 S/N: YAT1–Up Part No.: 129-6628 S/N: YAW1–Up

RENR5057

419 Specifications Section

Illustration 268

g02591856

Table 239 Specification for 129-6628 Speed Sensor Gp Item

1

Qty

1

Part

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 129-6628 Speed Sensor Gp sensor group. Operating voltage is 12 to 14 V.

420

RENR5057

Specifications Section

i04402240

Crankcase Pressure Sensor SMCS Code: 1916

Part No.: 161-1703 S/N: ZAD1–Up Part No.: 161-1703 S/N: ZAH1–Up Part No.: 161-1703 S/N: ZAJ1–Up Part No.: 161-1703 S/N: YAM1–Up Part No.: 161-1703 S/N: YAN1–Up Part No.: 161-1703 S/N: YAP1–Up Part No.: 161-1703 S/N: ZAP1–Up Part No.: 161-1703 S/N: PBR1–Up Part No.: 161-1703 S/N: YAR1–Up Part No.: 161-1703 S/N: ZAR1–Up Part No.: 161-1703 S/N: YAT1–Up Part No.: 161-1703 S/N: YAW1–Up Part No.: 161-1703 S/N: YAY1–Up Part No.: 161-1703 S/N: YAZ1–Up

RENR5057

421 Specifications Section

Illustration 269

g02587218

Table 240 Specification for 161-1703 Crankcase 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.

422

RENR5057

Specifications Section

i04928541

Crankcase Pressure Sensor SMCS Code: 1916

Part No.: 274-6717

Illustration 270

g02906357

Table 241 Specification for 306-6834 Pressure Sensor Gp, 274-6717 Pressure Sensor and 305-6873 Pressure Sensor Gp Item

Qty

Part

1

-

-

Final installation torque for the sensor group is 10 ± 2 N·m (89 ± 18 lb in).

-

-

-

Operating voltage is 5.0 ± 0.5 VDC.

Specification Description

RENR5057

423 Specifications Section

i04402249

Atmospheric Pressure Sensor SMCS Code: 1923 Part No.: 161-1703 S/N: ZAD1–Up Part No.: 161-1703 S/N: ZAH1–Up Part No.: 161-1703 S/N: ZAJ1–Up Part No.: 161-1703 S/N: YAM1–Up Part No.: 161-1703 S/N: YAN1–Up Part No.: 161-1703 S/N: YAP1–Up Part No.: 161-1703 S/N: ZAP1–Up Part No.: 161-1703 S/N: PBR1–Up Part No.: 161-1703 S/N: YAR1–Up Part No.: 161-1703 S/N: ZAR1–Up Part No.: 161-1703 S/N: YAT1–Up Part No.: 161-1703 S/N: YAW1–Up Part No.: 161-1703 S/N: YAY1–Up Part No.: 161-1703 S/N: YAZ1–Up

424

RENR5057

Specifications Section

Illustration 271

g02587218

Table 242 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.

RENR5057

425 Specifications Section

i04397550

Atmospheric Pressure Sensor SMCS Code: 1923 Part No.: 274-6717

Illustration 272

g02575237

Table 243 Specification for 274-6717 Pressure Sensor, 248-2162 Pressure Sensor Gp, 276-6793 Pressure Sensor Gp, 306-6834 Pressure Sensor Gp, 296-8060 Pressure Sensor Gp Item

Qty

Part

1

-

-

Torque to 10 ± 2 N·m (89 ± 18 lb in).

-

-

-

Operating voltage is 5.0 ± 0.5 VDC.

Specification Description

426

RENR5057

Specifications Section

i04402277

Engine Speed Sensor SMCS Code: 1907 Part No.: 189-5746 S/N: GD31–Up Part No.: 189-5746 S/N: ZAD1–Up Part No.: 189-5746 S/N: ZAH1–Up Part No.: 189-5746 S/N: ZAJ1–Up Part No.: 189-5746 S/N: YAM1–Up Part No.: 189-5746 S/N: YAN1–Up Part No.: 189-5746 S/N: YAP1–Up Part No.: 189-5746 S/N: ZAP1–Up Part No.: 189-5746 S/N: ZBP1–Up Part No.: 189-5746 S/N: PBR1–Up Part No.: 189-5746 S/N: PDR1–Up Part No.: 189-5746 S/N: YAR1–Up Part No.: 189-5746 S/N: ZAR1–Up Part No.: 189-5746 S/N: ZBR1–Up Part No.: 189-5746 S/N: YAT1–Up Part No.: 189-5746 S/N: YBT1–Up Part No.: 189-5746 S/N: YAW1–Up Part No.: 189-5746 S/N: YBW1–Up Part No.: 189-5746 S/N: YAY1–Up Part No.: 189-5746 S/N: YAZ1–Up

RENR5057

427 Specifications Section

Illustration 273

g02587736

Table 244 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.

428

RENR5057

Specifications Section

i04707610

Engine Speed Sensor

RENR5057

429 Specifications Section

SMCS Code: 1907 Part No.: 318-1181 S/N: YBB1–Up Part No.: 318-1181 S/N: YBC1–Up Part No.: 318-1181 S/N: ZAD1–Up Part No.: 318-1181 S/N: JDE1–Up Part No.: 318-1181 S/N: ZAH1–Up Part No.: 318-1181 S/N: ZAJ1–Up Part No.: 318-1181 S/N: YAM1–Up Part No.: 318-1181 S/N: YAN1–Up Part No.: 318-1181 S/N: YAP1–Up Part No.: 318-1181 S/N: ZAP1–Up Part No.: 318-1181 S/N: ZBP1–Up Part No.: 318-1181 S/N: PBR1–Up Part No.: 318-1181 S/N: PDR1–Up Part No.: 318-1181 S/N: YAR1–Up Part No.: 318-1181 S/N: ZAR1–Up Part No.: 318-1181 S/N: ZBR1–Up Part No.: 318-1181 S/N: YAT1–Up Part No.: 318-1181 S/N: YBT1–Up Part No.: 318-1181 S/N: YAW1–Up Part No.: 318-1181 S/N: YBW1–Up Part No.: 318-1181 S/N: JCY1–Up Part No.: 318-1181 S/N: YAY1–Up Part No.: 318-1181

S/N: YAZ1–Up

430

RENR5057

Specifications Section

Illustration 274

g02812838

Table 245 Specification for 318-1181 Speed Sensor Gp Item

Qty

Part

1

-

-

Specification Description Final installation torque is 25 ± 5 N·m (221 ± 44 lb in).

RENR5057

431 Specifications Section

i04888979

Thermocouple

432

RENR5057

Specifications Section SMCS Code: 7498 Part No.: 120-4498 S/N: YBB1–Up Part No.: 120-4498 S/N: YBC1–Up Part No.: 120-4498 S/N: ZAD1–Up Part No.: 120-4498 S/N: JDE1–Up Part No.: 120-4498 S/N: ZAH1–Up Part No.: 120-4498 S/N: ZAJ1–Up Part No.: 120-4498 S/N: YAM1–Up Part No.: 120-4498 S/N: YAN1–Up Part No.: 120-4498 S/N: YAP1–Up Part No.: 120-4498 S/N: ZAP1–Up Part No.: 120-4498 S/N: ZBP1–Up Part No.: 120-4498 S/N: PBR1–Up Part No.: 120-4498 S/N: PDR1–Up Part No.: 120-4498 S/N: YAR1–Up Part No.: 120-4498 S/N: ZAR1–Up Part No.: 120-4498 S/N: ZBR1–Up Part No.: 120-4498 S/N: YAT1–Up Part No.: 120-4498 S/N: YBT1–Up Part No.: 120-4498 S/N: YAW1–Up Part No.: 120-4498 S/N: YBW1–Up Part No.: 120-4498 S/N: JCY1–Up Part No.: 120-4498 S/N: YAY1–Up Part No.: 120-4498

S/N: YAZ1–Up

RENR5057

433 Specifications Section

Illustration 275

g02589698

Table 246 Specification for the 120-4498 Thermocouple Gp Item

Qty

1

1

Part

Specification Description

243-5752 Temperature Sen- Before assembly, apply Loctite C5A copper anti-seize to the threads. sor Gp Torque to 12 ± 3 N·m (106 ± 27 lb in).

434

RENR5057

Index Section

Index A Accessory Drive (Lower Left Hand)............... 302 Accessory Drive (Upper Right Hand) ... 305, 308, 311 Aftercooler Coolant Temperature Sensor ...... 408 Air Cleaner....................................................... 94 Air Inlet and Exhaust Lines ......97, 100, 102, 105, 108, 111 Air Lines........................................................... 96 Air Shutoff ............................... 113, 115, 117, 120 Air Shutoff Valve and Mounting (1) .............119 Air Starting Motor........................................... 373 Air Starting Motor Pressure Regulating Valve ............................................................ 376 Alternator and Regulator........ 352, 354–355, 357 Alternator Mounting ............................... 359, 361 197-9087 Belt Tension Chart ................... 360 197-9087 Belt Tension Chart ................... 362 Atmospheric Pressure Sensor............... 423, 425 Auxiliary Drive Pulley............................. 346–348 Auxiliary Drive Shaft ...................................... 349 Auxiliary Water Pump .................... 215, 218, 223 Auxiliary Water Pump (Sea Water)................ 220

Cylinder Head Valves .................................53, 56 Cylinder Liner................................................. 243

D Duplex Engine Oil Filters ............................... 162

E

Balancer Group (Front).................................. 301 Belt Tension Chart ......................................... 350

Electric Starting Motor ....363, 365, 368, 370, 372 Engine Air Cleaner Service Indicator............... 95 Engine Coolant Temperature Sensor .... 409, 412 Engine Design ............................................... 6–8 Engine Oil Cooler........................................... 164 Engine Oil Cooler Bypass and Cooling Jet Sequence Valves ................................. 143, 146 Engine Oil Filter ..................... 148, 150, 153–154 Engine Oil Lines..................................... 156, 159 Engine Oil Pan.......172, 174, 176, 179, 182, 185, 187–188, 190 Engine Oil Pressure Sensor .................. 393–394 Engine Oil Pump............................ 129, 132, 137 Engine Oil Sump Pump ................................. 206 Engine Oil Temperature Sensor ............ 396, 399 Engine Speed Sensor............................ 426, 428 Engine Speed/Timing Sensor................ 417–418 Exhaust Flange.....................................89, 91, 93 Exhaust Manifold ............... 78, 80–81, 83–85, 87

C

F

Camshaft ........................................30, 33, 35, 37 Connecting Rod......................258, 261, 264, 267 Connecting Rod and Main Bearing Journals ..................................................................... 269 Coolant Level Sensor ............................ 388, 391 Coolant Level Switch ..................................... 378 Coolant Temperature Switch ......................... 380 Cooling System Pressure Cap ...................... 225 Cover Group (Front Housing) ........................ 282 Crankcase Breather....................... 165, 167–170 Crankcase Pressure Sensor.................. 420, 422 Crankshaft ............................. 271–272, 274–277 Crankshaft Wear Sleeves and Seals............. 279 Cylinder Block.........................228, 233, 236, 240 Camshaft Bearing Position ........................ 232 Cylinder Head.......................................43, 46, 49 Bolt Tightening Procedure ........................... 50

Fan Drive ............................................... 200, 202 Flexible Coupling ................................... 323, 325 Flywheel ........................................................ 313 Flywheel Housing .......................................... 315 Flywheel Housing Cover................................ 319 Fuel Filter..............................................11, 13–14 Fuel Filter (Primary)......................................... 10 Fuel Injector......................................... 25, 27–28 Fuel Injector Mechanism ............................21, 23 Fuel Pressure Regulator.................................. 15 Fuel Pressure Sensor............................ 381, 384 Fuel Priming Pump .......................................... 20 Fuel Transfer Pump ......................................... 17

B

G Gear Group (Front)................................ 287, 290

RENR5057

435 Index Section

Gear Group (Rear)..................292, 294, 296, 299 Generator Coupling ............................... 320, 322

H Housing (Front)...................................... 284, 286

I Important Safety Information ............................. 2

P Piston and Rings (One-Piece Piston) ............ 246 Piston and Rings (One-Piece Piston) ............ 249 Piston and Rings (Two-Piece Piston) ............ 252 Piston and Rings (Two-Piece Piston) ............ 255 Prelube Pressure Switch ............................... 386 Prelube Pump................................ 122, 124, 127 Prelube Pump (Air) ........................................ 126

R Radiator ................................................. 203–205

S Specifications Section ....................................... 6 Stub Shaft (Front) .................................. 342, 345

T Table of Contents............................................... 3 Thermocouple................................................ 431 Thermostatic Valve ........................................ 197 Turbocharger ..........62, 65–66, 69, 71–72, 75, 77 Turbocharger Exhaust Temperature Sensor ............................................................. 413, 416 Turbocharger Inlet Pressure Sensor...... 400, 402 Turbocharger Oil Lines ...............................59, 61 Turbocharger Outlet Pressure Sensor... 405–406

V Valve Mechanism .......................................39, 41 Vibration Damper....326, 328, 330, 332, 334, 336 Vibration Damper Guard................ 337, 339–341

W Water Lines.................................................... 196

Water Pump....................................207, 209, 211 Water Temperature Regulator ............... 193, 195

©2013 Caterpillar All Rights Reserved

CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade dress as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.