You are on page 1of 436

RENR5057-04

February 2013

Specifications
3500B Generator Set Engines
GD3 1-Up (Generator ZAR 1-Up (Generator
Set) Set)
YBB 1-Up ZBR 1-Up (Generator
(Generator Set) Set)
YBC 1-Up YAT 1-Up (Generator
(Generator Set) Set)
ZAD 1-Up (Generator YBT 1-Up (Generator
Set) Set)
JDE 1-Up (Generator YAW 1-Up
Set) (Generator Set)
ZAH 1-Up (Generator YBW 1-Up
Set) (Generator Set)
ZAJ 1-Up (Generator JCY 1-Up (Generator
Set) Set)
YAM 1-Up YAY 1-Up (Generator
(Generator Set) Set)
YAN 1-Up (Generator YAZ 1-Up (Generator
Set) 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)

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 re-
placement parts or parts with equivalent speci-
fications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury
or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR5057 3
Table of Contents

Table of Contents Exhaust Flange........................ ....................... 89


Exhaust Flange........................ ....................... 91
Specifications Section Exhaust Flange........................ ....................... 93
Air Cleaner........................... ........................... 94
Engine Design ......................... ......................... 6 Engine Air Cleaner Service Indicator....... ....... 95
Engine Design ......................... ......................... 6 Air Lines............................. ............................. 96
Engine Design ......................... ......................... 7 Air Inlet and Exhaust Lines ............... .............. 97
Engine Design ......................... ......................... 7 Air Inlet and Exhaust Lines .............. ............. 100
Engine Design ......................... ......................... 8 Air Inlet and Exhaust Lines .............. ............. 102
Engine Design ......................... ......................... 8 Air Inlet and Exhaust Lines .............. ............. 105
Fuel Filter (Primary).................... .................... 10 Air Inlet and Exhaust Lines .............. ............. 108
Fuel Filter............................ .............................11 Air Inlet and Exhaust Lines .............. ..............111
Fuel Filter............................ ............................ 13 Air Shutoff ........................... ...........................113
Fuel Filter............................ ............................ 14 Air Shutoff ........................... ...........................115
Fuel Pressure Regulator................. ................ 15 Air Shutoff ........................... ...........................117
Fuel Transfer Pump .................... .................... 17 Air Shutoff ........................... .......................... 120
Fuel Priming Pump ..................... .................... 20 Prelube Pump........................ ....................... 122
Fuel Injector Mechanism ................ ................ 21 Prelube Pump........................ ....................... 124
Fuel Injector Mechanism ................ ................ 23 Prelube Pump (Air) .................... ................... 126
Fuel Injector.......................... .......................... 25 Prelube Pump........................ ....................... 127
Fuel Injector.......................... .......................... 27 Engine Oil Pump...................... ..................... 129
Fuel Injector.......................... .......................... 28 Engine Oil Pump...................... ..................... 132
Camshaft ............................ ............................ 30 Engine Oil Pump...................... ..................... 137
Camshaft ............................ ............................ 33 Engine Oil Cooler Bypass and Cooling Jet
Camshaft ............................ ............................ 35 Sequence Valves .................... .................... 143
Camshaft ............................ ............................ 37 Engine Oil Cooler Bypass and Cooling Jet
Valve Mechanism ............................................ 39 Sequence Valves .................... .................... 146
Valve Mechanism ............................................ 41 Engine Oil Filter ...................... ...................... 148
Cylinder Head......................... ........................ 43 Engine Oil Filter ...................... ...................... 150
Cylinder Head......................... ........................ 46 Engine Oil Filter ...................... ...................... 153
Cylinder Head......................... ........................ 49 Engine Oil Filter ...................... ...................... 154
Cylinder Head Valves ................... .................. 53 Engine Oil Lines...................... ...................... 156
Cylinder Head Valves ................... .................. 56 Engine Oil Lines...................... ...................... 159
Turbocharger Oil Lines .................. ................. 59 Duplex Engine Oil Filters ............... ............... 162
Turbocharger Oil Lines .................. ................. 61 Engine Oil Cooler..................... ..................... 164
Turbocharger ......................... ......................... 62 Crankcase Breather................... ................... 165
Turbocharger ......................... ......................... 65 Crankcase Breather................... ................... 167
Turbocharger ......................... ......................... 66 Crankcase Breather................... ................... 168
Turbocharger ......................... ......................... 69 Crankcase Breather................... ................... 169
Turbocharger ......................... ......................... 71 Crankcase Breather................... ................... 170
Turbocharger ......................... ......................... 72 Engine Oil Pan....................... ....................... 172
Turbocharger ......................... ......................... 75 Engine Oil Pan....................... ....................... 174
Turbocharger ......................... ......................... 77 Engine Oil Pan....................... ....................... 176
Exhaust Manifold...................... ...................... 78 Engine Oil Pan....................... ....................... 179
Exhaust Manifold...................... ...................... 80 Engine Oil Pan....................... ....................... 182
Exhaust Manifold...................... ...................... 81 Engine Oil Pan....................... ....................... 185
Exhaust Manifold...................... ...................... 83 Engine Oil Pan....................... ....................... 187
Exhaust Manifold...................... ...................... 84 Engine Oil Pan....................... ....................... 188
Exhaust Manifold...................... ...................... 85 Engine Oil Pan....................... ....................... 190
Exhaust Manifold...................... ...................... 87 Water Temperature Regulator ........... ........... 193
Water Temperature Regulator ........... ........... 195
4 RENR5057
Table of Contents

Water Lines.......................... ......................... 196 Flywheel ........................... ............................ 313


Thermostatic Valve .................... ................... 197 Flywheel Housing ..................... .................... 315
Fan Drive ........................... ........................... 200 Flywheel Housing Cover................ ............... 319
Fan Drive ........................... ........................... 202 Generator Coupling ................... ................... 320
Radiator ............................ ............................ 203 Generator Coupling ................... ................... 322
Radiator ............................ ............................ 204 Flexible Coupling ..................... ..................... 323
Radiator ............................ ............................ 205 Flexible Coupling ..................... ..................... 325
Engine Oil Sump Pump ................ ................ 206 Vibration Damper..................... ..................... 326
Water Pump......................... ......................... 207 Vibration Damper..................... ..................... 328
Water Pump......................... ......................... 209 Vibration Damper..................... ..................... 330
Water Pump......................... ..........................211 Vibration Damper..................... ..................... 332
Auxiliary Water Pump .................. ................. 215 Vibration Damper..................... ..................... 334
Auxiliary Water Pump .................. ................. 218 Vibration Damper..................... ..................... 336
Auxiliary Water Pump (Sea Water) ....... ....... 220 Vibration Damper Guard................ ............... 337
Auxiliary Water Pump .................. ................. 223 Vibration Damper Guard................ ............... 339
Cooling System Pressure Cap ........... .......... 225 Vibration Damper Guard................ ............... 340
Cylinder Block........................ ....................... 228 Vibration Damper Guard................ ............... 341
Cylinder Block........................ ....................... 233 Stub Shaft (Front) ..................... .................... 342
Cylinder Block........................ ....................... 236 Stub Shaft (Front) ..................... .................... 345
Cylinder Block........................ ....................... 240 Auxiliary Drive Pulley.................. .................. 346
Cylinder Liner........................ ........................ 243 Auxiliary Drive Pulley.................. .................. 347
Piston and Rings (One-Piece Piston) ..... ..... 246 Auxiliary Drive Pulley.................. .................. 348
Piston and Rings (One-Piece Piston) ..... ..... 249 Auxiliary Drive Shaft ................... .................. 349
Piston and Rings (Two-Piece Piston) ..... ..... 252 Belt Tension Chart .................... .................... 350
Piston and Rings (Two-Piece Piston) ..... ..... 255 Alternator and Regulator................ ............... 352
Connecting Rod...................... ...................... 258 Alternator and Regulator................ ............... 354
Connecting Rod...................... ...................... 261 Alternator and Regulator................ ............... 355
Connecting Rod...................... ...................... 264 Alternator and Regulator................ ............... 357
Connecting Rod...................... ...................... 267 Alternator Mounting ................... ................... 359
Connecting Rod and Main Bearing Journals 269 Alternator Mounting ................... ................... 361
Crankshaft .......................... .......................... 271 Electric Starting Motor ................. ................. 363
Crankshaft .......................... .......................... 272 Electric Starting Motor ................. ................. 365
Crankshaft .......................... .......................... 274 Electric Starting Motor ................. ................. 368
Crankshaft .......................... .......................... 275 Electric Starting Motor ................. ................. 370
Crankshaft .......................... .......................... 276 Electric Starting Motor ................. ................. 372
Crankshaft .......................... .......................... 277 Air Starting Motor..................... ..................... 373
Crankshaft Wear Sleeves and Seals...... ...... 279 Air Starting Motor Pressure Regulating Valve 376
Cover Group (Front Housing) ............ ........... 282 Coolant Level Switch .................. .................. 378
Housing (Front)....................... ...................... 284 Coolant Temperature Switch ............ ............ 380
Housing (Front)....................... ...................... 286 Fuel Pressure Sensor.................. ................. 381
Gear Group (Front).................... ................... 287 Fuel Pressure Sensor.................. ................. 384
Gear Group (Front).................... ................... 290 Prelube Pressure Switch ............... ............... 386
Gear Group (Rear).................... .................... 292 Coolant Level Sensor .................. ................. 388
Gear Group (Rear).................... .................... 294 Coolant Level Sensor .................. ................. 391
Gear Group (Rear).................... .................... 296 Engine Oil Pressure Sensor ............. ............ 393
Gear Group (Rear).................... .................... 299 Engine Oil Pressure Sensor ............. ............ 394
Balancer Group (Front)................. ................ 301 Engine Oil Temperature Sensor ......... .......... 396
Accessory Drive (Lower Left Hand)....... ....... 302 Engine Oil Temperature Sensor ......... .......... 399
Accessory Drive (Upper Right Hand) ............ 305 Turbocharger Inlet Pressure Sensor....... ...... 400
Accessory Drive (Upper Right Hand) ............ 308 Turbocharger Inlet Pressure Sensor....... ...... 402
Accessory Drive (Upper Right Hand) ...... ......311 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 Illustration 2 g00293349
(B) Exhaust valves Cylinder and valve location
(A) Inlet valves
Number and arrangement of cylinders ....60 degree V (B) Exhaust valves
−8
Number and arrangement of cylinders ....60 degree V
Valves per cylinder .................................................... 4 −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, Combustion ..........................................Direct injection
the crankshaft rotates in the following direction:
.........................................................Counterclockwise When the crankshaft is viewed from the flywheel end,
the crankshaft rotates in the following direction:
Firing order (injection sequence)
.........................................................Counterclockwise
Standard rotation CCW ..................1, 2, 7, 3, 4, 5, 6, 8 Firing order (injection sequence)
Valve lash
Standard rotation CCW .........1, 12, 9, 4, 5, 8, 11, 2, 3,
Inlet ............................................0.50 mm (0.020 inch) 10, 7, 6
Valve lash
Exhaust......................................1.00 mm (0.040 inch)
Inlet ............................................ 0.50 mm (0.020 inch)
Note: The front end of the engine is opposite the
flywheel end of the engine. The left side and the right Exhaust......................................1.00 mm (0.040 inch)
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.
RENR5057 7
Specifications Section

Note: The front end of the engine is opposite the Reverse rotation CW .... 1, 4, 9, 8, 5, 2, 11, 10, 3, 6, 7,
flywheel end of the engine. The left side and the right 12
side of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder on the Valve lash
right side. The number 2 cylinder is the front cylinder
on the left side. 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
Engine Design flywheel end of the engine. The left and the right side
of the engine are determined from the flywheel end.
SMCS Code: 1000
The number 1 cylinder is the front cylinder on the right
side. The number 2 cylinder is the front cylinder on
S/N: YBC1–Up
the left side.
S/N: ZAJ1–Up
i05220884
S/N: YAN1–Up
S/N: YAZ1–Up Engine Design
SMCS Code: 1000

S/N: GD31–Up

Illustration 3 g00293349
Cylinder and valve location
(A) Inlet valves
(B) Exhaust valves Illustration 4 g03337471
Cylinder and valve location
Number and arrangement of cylinders ....... 60 degree
(A) Inlet valves
V-12 (B) Exhaust valves

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


Number and arrangement of cylinders ....... 60 degree
Displacement................................. 58.5 L (3570 cu in) 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 Combustion ..........................................Direct injection
the crankshaft rotates in the following direction.
When the crankshaft is viewed from the flywheel end,
.........................................................Counterclockwise
the crankshaft rotates in the following direction.
Firing order (injection sequence) .........................................................Counterclockwise

Standard rotation CCW .........1, 12, 9, 4, 5, 8, 11, 2, 3, Firing order (injection sequence)
10, 7, 6
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, Stroke ............................................. 190 mm (7.5 inch)
11, 14, 13, 8, 7, 2
Compression ratio ................................................ 14:1
Valve lash
Combustion ..........................................Direct injection
Inlet ............................................0.50 mm (0.020 inch)
When the crankshaft is viewed from the flywheel end,
Exhaust......................................1.00 mm (0.040 inch) the crankshaft rotates in the following direction:
.........................................................Counterclockwise
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right side Firing order (injection sequence)
of the engine are determined from the flywheel end.
The number 1 cylinder is the front cylinder on the right Standard rotation CCW .........1, 2, 5, 6, 3, 4, 9, 10, 15,
side. The number 2 cylinder is the front cylinder on 16, 11, 12, 13, 14, 7, 8
the left side.
Valve lash
i01430901
Inlet ............................................ 0.50 mm (0.020 inch)
Engine Design Exhaust......................................1.00 mm (0.040 inch)
SMCS Code: 1000
Note: The front end of the engine is opposite the
S/N: YAP1–Up flywheel end of the engine. The left side and the right
side of the engine are determined from the flywheel
S/N: ZAP1–Up end. The number 1 cylinder is the front cylinder on the
right side. The number 2 cylinder is the front cylinder
S/N: ZBP1–Up on the left side.
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 Illustration 6 g00294285


Cylinder and valve location
Displacement................................. 69.1 L (4210 cu in) (A) Inlet valve
(B) Exhaust valve
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 Specification Description

1 1 7N-1628 Nut Torque to 25 ± 5 N·m (221 ± 44 lb in).

2 1 2J-0157 O-Ring Seal 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).


3 1 7S-9323 Spring 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 Specification description

1 1 6V-4589 O-Ring Seal Lightly lubricate the bore with the lubricant that is being sealed.

2 1 8L-2786 O-Ring Seal Lightly lubricate the bore with the lubricant that is being sealed.

3 5 6V-5048 O-Ring Seal Lightly lubricate the bore with the lubricant that is being sealed.

4 2 5D-5957 O-Ring Seal Lightly lubricate the bore with the lubricant that is being sealed.

5 1 6V-5049 O-Ring Seal Lightly lubricate the bore with the lubricant that is being sealed.

Length under test force is 20.75 mm (0.817 inch).

6 1 1N-2895 Spring Test force is 222 N (50 lb).

Free length after test is 62.48 mm (2.460 inch).


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 Specification Description

1 4 5D-5957 O-Ring Seal Lubricate the bore lightly with clean engine oil.

Length under test force is 20.75 mm (0.817 inch).


2 2 1N-2895 Spring 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 Specification description

1 2 5D-5957 O-Ring Seal 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 Specification Description

Length under test force is 28.4 mm (1.12 inch).


1 1 9N-4053 Spring 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 Part No.: 8N-6151


S/N: GD31–Up 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 Specification Description

Before installation, inside diameter of the terminal bushing for gear shaft is
1 4 7C-2870 Terminal Bushing 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).


2 1 268-1903 Drive Shaft As
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).
3 1 1W-4003 Idler Gear As
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 Part Specification Description

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

6V-8918 Bolt(1)
2 1 Torque to 15 ± 3 N·m (133 ± 27 lb in).
8T-7547 Bolt(2)
(1) Use if inch bolt is required
(2) Use if metric bolt is required
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 Specification Description

1 1 317-1121 Jam Nut Torque to 120 ± 15 N·m (89 ± 11 lb ft).

2 1 6J-2245 O-Ring Seal Lubricate the bore lightly with clean engine oil.

Start tightening the retainer nuts of the cap assembly by hand so that the termi-
nal studs are not cross threaded.
3 1 7E-6508 Cap As
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).


4 1 100-3878 Injector Spring 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
5 2 334-1626 Bolt
removed after initial installation.
Bore of the bushing for the rocker arm shaft after assembly is
B 1 230-2620 Bushing
45.077 ± 0.015 mm (1.7747 ± 0.0006 inch).

C 1 234-2273 Rocker Arm Shaft Diameter is 45.000 ± 0.013 mm (1.7716 ± 0.0005 inch)

Diameter is 34.950 ± 0.010 mm (1.3760 ± 0.0004 inch).


D 1 282-7944 Injector Lifter As 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 Specification Description

1 2 3J-9196 Jam Nut Torque to 70 ± 15 N·m (52 ± 11 lb ft).

Torque to 2.50 ± 0.25 N·m (22.13 ± 2.21 lb in).


2 2 7E-6507 Retainer Nut Start tightening the retainer nuts of the cap assembly by hand so that the terminal
studs are not cross threaded.

3 1 317-1121 Jam Nut Torque to 120 ± 15 N·m (89 ± 11 lb ft).

Length under test force is 85.00 mm (3.346 inch).


4 1 100-3878 Injector Spring Test force is 300 ± 25 N (67 ± 6 lb).
Free length after test is 87.65 mm (3.451 inch).

5 1 5P-7530 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.

6 2 334-1626 Bolt 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 Specification Description

9 1 234-2273 Rocker Arm Shaft 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
10 2 0L-2070 Bolt
threads.

11 1 6J-2245 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.

Bore of the bushing in the injector rocker arm assembly (7) is


B - -
45.077 ± 0.015 mm (1.7747 ± 0.0006 inch).

Bore of the bushing in the valve rocker arm assembly (8) is 45.077 ± 0.015 mm
C - -
(1.7747 ± 0.0006 inch).
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 - - Timing dimension is 64.34 ± 0.20 mm (2.533 ± 0.008 inch)

1 1 7F-8698 Bolt 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.
1 1
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).

2 1 7F-8698 Bolt Torque to 65 ± 7 N·m (48 ± 5 lb ft).

A - - 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).
3 1 230-9456 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 g03117936
Typical example
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 1
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).

2 1 7F-8698 Bolt Torque to 65 ± 7 N·m (48 ± 5 lb ft).

A - - 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).
3 1 229-0187 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).
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 Specification Description

Thickness of the groove in a new camshaft assembly is 8.75 ± 0.05 mm


A - -
(0.344 ± 0.002 inch).

C 1 5B-5821 Dowel Extension of the dowel is 12.0 ± 0.5 mm (0.47 ± 0.02 inch).

D 2 7N-3218 Thrust Washer 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 - -
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).

3 16 5P-0076 Bolt Torque to 55 ± 7 N·m (41 ± 5 lb ft).

F 1 4N-1650 Dowel 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 Specification Description

Thickness of the groove in a new camshaft assembly is 8.75 ± 0.05 mm


A - -
(0.344 ± 0.002 inch).

B 2 5B-5821 Dowel Extension of the dowel is 12.0 ± 0.5 mm (0.47 ± 0.02 inch).

C 2 7N-3218 Thrust Washer 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).
D - -
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 Part Specification Description

Use the following procedure in order to determine the camshaft lobe lift:

1. Measure camshaft lobe height (F).


- - - 2. Measure base circle (G).

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

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 Specification Description

Thickness of the groove in the new camshaft assembly for the thrust washer is
A - -
8.75 ± 0.05 mm (0.344 ± 0.002 inch).

C 2 5B-5821 Dowel Extension of the dowel is 12.0 ± 0.5 mm (0.47 ± 0.02 inch).

D 2 7N-3218 Thrust Washer Thickness of the new thrust washer is 8.50 ± 0.05 mm (0.335 ± 0.002 inch).

Diameter of bearing journals for a new camshaft is 91.88 ± 0.02 mm


(3.617 ± 0.001 inch).
E - -
Bore in camshaft bearing after installation is 92.00 ± 0.06 mm (3.622 ± 0.002 inch).

3 16 5P-0076 Bolt Torque to 55 ± 7 N·m (41 ± 5 lb ft).

F 2 4N-1650 Dowel 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 Specification Description

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

C 2 5B-5821 Dowel Extension of the dowel is 12.0 ± 0.5 mm (0.47 ± 0.02 inch).

D 2 7N-3218 Thrust Washer 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 - -
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).

3 16 5P-0076 Bolt Torque to 55 ± 7 N·m (41 ± 5 lb ft).

F 2 4N-1650 Dowel 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 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 12.73 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 Specification Description

1 2 3J-9196 Jam Nut 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


A 1 230-2633 Shaft As (1.7716 ± 0.0005 inch)

Dimension for the valve lash:


B - - 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
C 1 230-2620 Bushing
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).
D 2 263-6672 Lifter Body 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 Specification Description

1 2 3J-9196 Jam Nut Torque to 70 ± 15 N·m (52 ± 11 lb ft).

Torque to 2.50 ± 0.25 N·m (22.13 ± 2.21 lb in).


2 2 7E-6507 Retainer Nut Start tightening the retainer nuts of the cap assembly by hand so that the terminal
studs are not cross threaded.

3 1 317-1121 Jam Nut Torque to 120 ± 15 N·m (89 ± 11 lb ft).

4 1 5P-7530 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.

5 2 334-1626 Bolt 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 Specification Description

8 1 234-2273 Rocker Arm Shaft 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
9 2 0L-2070 Bolt
threads.

10 1 6J-2245 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.

Bore of the bushing in the injector rocker arm assembly (6) is


B - -
45.077 ± 0.015 mm (1.7747 ± 0.0006 inch).

Bore of the bushing in the valve rocker arm assembly (7) is 45.077 ± 0.015 mm
C - -
(1.7747 ± 0.0006 inch).
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

During installation, shrunk the valve seat insert with reduced temperature
1 2 130-2607 Valve Seat Insert (Reference temperature : −60° C (−76° F)) and ress the insert into the cylin-
der heads counterbore.
During installation, shrunk the valve seat insert with reduced temperature
2 2 130-2608 Valve Seat Insert (Reference temperature : −60° C (−76° F)) and ress the insert into the cylin-
der 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).
RENR5057 45
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 .

131-0420 Cylinder Head Fasten- Use the following procedure to tighten the bolts for the cylinder head:
6 6
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 Illus-
131-0421 Cylinder Head Fasten- tration 32 to a torque of 30 ± 5 N·m (22 ± 4 lb ft).
7 2
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
8 2 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 fi-
nal 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
RENR5057 47
Specifications Section

Illustration 33 g03120176

Table 27
Specification for 380-5795 Cylinder Head Gp

Item Qty Part Specification Description

During installation, shrunk the valve seat insert with reduced temperature (Reference
1 2 130-2607 Valve Seat Insert
temperature : −60° C (−76° F)) and ress the insert into the cylinder heads counterbore.

During installation, shrunk the valve seat insert with reduced temperature (Reference
2 2 130-2608 Valve Seat Insert
temperature : −60° C (−76° F)) and ress the insert into the cylinder heads counterbore.

Before assembly, apply high strength or high temperature Anaerobic Flange Sealant to
3 5 3B-0645 Cup Plug
the bores.
Before assembly, apply high strength or high temperature Anaerobic Flange Sealant to
4 1 3B-0623 Cup Plug
the bores.
Before assembly, apply high strength or high temperature Anaerobic Flange Sealant to
5 2 3B-0623 Cup Plug the bores.
Installation depth (E) is 1.0 ± 0.5 mm (0.04 ± 0.02 inch).

Before assembly, apply high strength or high temperature Anaerobic Flange Sealant to
6 2 3B-0623 Cup Plug 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 Part Specification Description

131-0420 Cylinder Head Fas- Use the following procedure in order to tighten the bolts for the cylinder head:
7 6
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).
8 2
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).
9 2 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 g02534738
Typical example (top view)
(3) Pipe plug
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

Before assembly, lubricate the threads of the pipe plug.with 5P-3931 Anti-Seize
3 1 5B-7890 Pipe Plug
Compound.

A 1 - 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.
B 2 3b-0623 Cup Plug 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.
D 2 3b-0623 Cup Plug 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 Part Specification Description

131-0420 Cylinder Head Fas- 1. Coat the threads of the bolts with clean engine oil.
6
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
2
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 rota-
2 5B-0213 Bolt tion of 180 ± 5 degrees.
Tighten bolts (9) and (10) only after bolt (1) through bolt (8) have been given the
final torque.
6. Tighten bolts (9) and (10) to 55 ± 10 N·m (40 ± 7 lb ft).

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 Part Specification Description

131-0420 Cylinder Head Fas- 1. Coat the threads of the bolts with clean engine oil.
6
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
2
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.
2 5B-0213 Bolt 6. Tighten bolt (1) through bolt (8) in the numerical sequence to 490 ± 15 N·m
(360 ± 11 lb ft).
Tighten bolts (9) and (10) only after bolt (1) through bolt (8) have been given fi-
nal 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
RENR5057 55
Specifications Section

Table 32
Specification for 338-8672 Cylinder Head Gp, and 317-2440 Cylinder Head Gp

Item Qty Part Specification Description

Length under test force is 60.29 mm (2.374 inch).


1 4 316-5976 Spring Test force is 460 ± 23 N (103 ± 5 lb).
Free length after test is 74.8 mm (2.94 inch).

Length under test force is 57.5 mm (2.26 inch).


2 4 316-5977 Spring Test force is 248.0 ± 12.4 N (55.8 ± 2.8 lb).
Free length after test is 71.4 mm (2.81 inch).

Install the valve stem seal to the inlet valves.


3 2 316-5980 Valve Stem Seal
Before assembly, coat with engine oil.

4 2 316-5981 Washer Install the washer to the exhaust valves.


Height from the top of the cylinder head to the top of the valve guides is
A - -
26.0 ± 1.0 mm (1.02 ± 0.04 inch).

Bore of the exhaust valve guide after installation is 12.619 ± 0.025 mm


5 2 197-6995 Valve Guide
(0.4968 ± 0.0010 inch).

Bore of the inlet valve guide after installation is 9.487 ± 0.025 mm


6 2 133-9306 Valve Guide (0.3735 ± 0.0010 inch).

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).
7 2 194-4897 Exhaust Valve
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).
8 2 210-2542 Inlet Valve
Valve diameter (E) is 56.00 ± 0.15 mm (2.205 ± 0.006 inch).
Face angle is 19.40 ± 0.25 degrees.

Diameter of exhaust valve seat insert is 60.119 ± 0.015 mm


(2.3669 ± 0.0006 inch).
9 2 130-2608 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.

Diameter of inlet valve seat insert is 60.627 ± 0.015 mm (2.3869 ± 0.0006 inch).
10 2 130-2607 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
RENR5057 57
Specifications Section

Illustration 40 g03117796

Table 33
Specification for 380-5795 Cylinder Head Gp

Item Qty Part Specification Description

Length under test force is 60.29 mm (2.374 inch).


1 4 316-5976 Spring Test force is 460 ± 23 N (103 ± 5 lb).
Free length after test is 74.8 mm (2.94 inch).

Length under test force is 57.5 mm (2.26 inch).


2 4 316-5977 Spring Test force is 248.0 ± 12.4 N (55.8 ± 2.8 lb).
Free length after test is 71.4 mm (2.81 inch).

3 2 316-5980 Valve Stem Seal Install the valve stem seal to the inlet valves.
Height from the top of the cylinder head to the top of the valve guides is
B - -
26.0 ± 1.0 mm (1.02 ± 0.04 inch).

Bore of the exhaust valve guide after installation is 12.619 ± 0.025 mm


4 2 197-6995 Valve Guide (0.4968 ± 0.0010 inch).

Bore of the inlet valve guide after installation is 9.487 ± 0.025 mm


5 2 133-9306 Valve Guide (0.3735 ± 0.0010 inch).

Diameter of exhaust valve seat insert is 60.119 ± 0.015 mm


(2.3669 ± 0.0006 inch).
6 2 130-2608 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.

Diameter of inlet valve seat insert is 60.627 ± 0.015 mm (2.3869 ± 0.0006 inch).
7 2 130-2607 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 Qty Part 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).
8 2 194-4897 Exhaust Valve
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).
9 2 210-2542 Inlet Valve
Valve diameter (F) is 56.00 ± 0.15 mm (2.205 ± 0.006 inch).
Face angle is 19.40 ± 0.25 degrees.

10 2 316-5981 Washer 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 g02852078
Typical example
Rear view of engine
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

Before assembly, apply Loctite C5A Copper Anti-Seize to the threads and the bearing surfaces
1 - -
of bolts.
Before assembly, lightly lubricate the bore for the O-ring seals with the lubricant that is being
2 - -
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 Specification Description

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.
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 g03111317
Typical example
64 RENR5057
Specifications Section

Table 37
Specification for 118-5463 Turbocharger Gp and 118-5464 Turbocharger Gp

Item Qty Part Specification description

2N-2765 High Temperature Before assembly, apply Loctite C5A Copper anti-seize to the threads and the bearing
1 16
Bolt surfaces.
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 4 7W-2297 Clamp As
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).
3 4 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).

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).
4 4 6L-3005 Band Clamp
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 Part Specification description

2N-2765 High Temperature Before assembly, apply Loctite C5A Copper anti-seize to the threads and the bearing
1 8
Bolt surfaces.

2 8 2N-2766 Locknut 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).
3 2 7W-2297 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).

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).
4 2 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 g03111156
Front view of engine
68 RENR5057
Specifications Section

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

Item Qty Part Specification description

2N-2765 High Temperature Before assembly, apply Loctite C5A Copper anti-seize to the threads and the bearing
1 16
Bolt surfaces.
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 4 4W-9977 Clamp As
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).
3 4 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).

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).
4 4 6L-3005 Band Clamp
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 Part Specification description

Before assembly, apply Loctite C5A Copper anti-seize to the threads and the bearing
2N-2765 High Temperature
1 8 surfaces.
Bolt
Torque to 54 ± 5 N·m (40 ± 4 lb ft).

188-8617 High Temperature


2 16 Torque to 40 ± 2 N·m (30 ± 1 lb ft).
Bolt

3 16 125-5375 Bolt 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 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).
1 4 6L-3005 Band Clamp
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).

2N-2765 High Temperature


2 16 Before assembly, apply Loctite C5A Copper anti-seize to washer face and threads.
Bolt
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).
3 4 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).

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).
4 4 4W-9977 Clamp As
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 Part Specification description

Before assembly, apply Loctite C5A Copper anti-seize to the threads and the bearing
2N-2765 High Temperature
1 16 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).
RENR5057 75
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 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).
1 4 6L-3005 Band Clamp
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.


9N-2038 Turbine Clamp 1. Tighten the turbine clamp assemblies to 14.0 ± 1.5 N·m (123.9 ± 13.3 lb in).
2 4
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).

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).
3 4 7W-2297 Clamp As
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).

2N-2765 High Tempera-


4 16 Before assembly, apply Loctite C5A Copper anti-seize to washer face and threads.
ture Bolt
RENR5057 77
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 Specification Description

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).

Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bear-
2N-2765 High Temperature Bolt ing surfaces.
3 8
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

Before assembly, lubricate the threads and the bearing surfaces of the locknuts
1 8 2N-2766 Locknut with Loctite C5A Copper Anti-Seize.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).

9L-2295 High Temperature Before assembly, lubricate the threads and the bearing surfaces of the bolt with
2 1
Bolt Loctite C5A Copper Anti-Seize.

7L-6443 High Temperature Before assembly, lubricate the threads and the bearing surfaces of the bolts with
3 4
Bolt Loctite C5A Copper Anti-Seize.

5P-2755 High Temperature Before assembly, lubricate the threads and the bearing surfaces of the bolts with
4 24
Bolt Loctite C5A Copper Anti-Seize.

Before assembly, lubricate the threads and the bearing surfaces of the bolts with
9L-7373 High Temperature
5 48 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 Ex-
haust Manifold Gp

Item Qty Part Specification Description

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


5P-2755 High Temperature
1 24 Before assembly, lubricate the threads and the bearing surfaces of the bolts with
Bolt
4C-5599 Anti-Seize Compound.

Torque the bolts to 50 ± 5 N·m (37 ± 4 lb ft).


9L-7373 High Temperature
2 32 Before assembly, lubricate the threads and the bearing surfaces of the bolts with
Bolt
4C-5599 Anti-Seize Compound.
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 Part Specification Description

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


7L-6443 High Temperature
1 40 Before assembly, apply 4C-5599 Anti-Seize Compound to the threads and the
Bolt
bearing surfaces of the bolts.

Torque the bolts to 50 ± 5 N·m (37 ± 4 lb ft).


9L-7373 High Temperature
2 48 Before assembly, apply 4C-5599 Anti-Seize Compound to the threads and the
Bolt
bearing surfaces of the bolts.
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

Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing
1 8 5P-3345 Bolt surfaces.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).

7L-6443 High Temperature Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing
2 4
Bolt surfaces.
Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing
5P-2755 High Temperature
3 24 surfaces.
Bolt
Torque to 55 ± 5 N·m (41 ± 4 lb ft).

Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing
9L-7373 High Temperature
4 48 surfaces.
Bolt
Torque to 50 ± 5 N·m (37 ± 4 lb ft).

9L-2295 High Temperature Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing
5 1
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

Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing
1 4 3B-1915 Bolt surfaces.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).

Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing
5P-2755 High Temperature
2 40 surfaces.
Bolt
Torque to 55 ± 5 N·m (41 ± 4 lb ft).

Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing
9L-7373 High Temperature
3 48 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 Specification Description

Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing
1 24 2N-2766 Locknut
surfaces.
Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing
2 8 5P-3345 Bolt surfaces.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).

Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing
9L-7373 High Temperature
3 64 surfaces.
Bolt
Torque to 50 ± 5 N·m (37 ± 4 lb ft).

Before assembly, apply Loctite C5A Copper Anti-Seize to threads and bearing
5P-2755 High Temperature
4 40 surfaces.
Bolt
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
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

Before assembly, lubricate the threads and the bearing surfaces of the bolts with
1 8 5P-3345 Bolt Loctite C5A Copper Anti-Seize.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).

Before assembly, lubricate the threads and the bearing surfaces of the locknuts
2 48 2N-2766 Locknut
with Loctite C5A Copper Anti-Seize.

Before assembly, lubricate the threads and the bearing surfaces of the bolts with
9L-7373 High Temperature
3 64 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 Specification Description

1 8 0S-1590 Bolt 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 Specification description

1 16 9X-8887 Bolt 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 Specification Description

Before assembly, apply 4C-5599 Anti-Seize Compound to the threads of


1 12 0S-1571 Bolt
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 Specification Description

1 - - 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 Specification Description

Torque to 2.0 ± 0.7 N·m (17.7 ± 6.2 lb in).


6I-2933 Air Filter Service
2 2 Install the air filter change indicator group with the filter side toward the air
Indicator
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 Specification Description

1 4 197-9732 U-Bolt Torque to 15 ± 2 N·m (133 ± 18 lb in).

During installation, do not crush the shield assembly.


2 4 321-5895 Shield As Install the shield assembly with the springs and hooks at the top of the hose as shown in Illus-
tration 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 g03113676
Bolt tightening sequence
RENR5057 99
Specifications Section

Table 58
Specification for 106-7596 Air Lines Gp

Item Qty Part Specification description

1 8 6V-3917 O-Ring Seal Lubricate the bore lightly with glycerine or 5P-3975 Rubber Lubricant.

Before assembly, apply Loctite C5A Copper anti-seize to the threads.


2 4 3J-5389 Plug
Torque to 20 ± 5 N·m (177 ± 44 lb in).

6V-1943 High Temperature Before assembly, apply Loctite C5A Copper anti-seize to the threads.
3 8
Bolt Torque to 55 ± 10 N·m (41 ± 7 lb ft).

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 adhe-
sive, 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.
4 10 9F-2773 Bolt 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.

5 12 6V-5101 O-Ring Seal 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 g03111416
Bolt tightening sequence
RENR5057 101
Specifications Section

Table 59
Specification for 144-2888 Air Lines Gp

Item Qty Part Specification description

1 4 6V-3917 O-Ring Seal 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 adhe-
sive, 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.
2 6 9F-2773 Bolt 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.

3 8 6V-5101 O-Ring Seal Lubricate the bore lightly with 5P-3975 Rubber Lubricant.

Before assembly, apply Loctite C5A Copper anti-seize to the threads.


4 2 3J-5389 Plug
Torque to 25 ± 5 N·m (221 ± 44 lb in).

5 4 6V-5103 O-Ring Seal 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 g03113778
Right side view of engine
104 RENR5057
Specifications Section

Illustration 71 g03113779
Bolt tightening sequence

Table 60
Specification for 162-5718 Turbocharger Air Lines Gp

Item Qty Part Specification description

1 4 6V-3917 O-Ring Seal 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 adhe-
sive, 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.
2 10 6J-0934 Bolt 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.

Before assembly, apply Loctite C5A Copper anti-seize to the threads.


3 3 3J-5389 Plug
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 g03113719
Right side view of engine
RENR5057 107
Specifications Section

Illustration 73 g03113720
Bolt tightening sequence

Table 61
Specification for 173-2947 Turbocharger Air Lines Gp

Item Qty Part Specification description

1 4 6V-3917 O-Ring Seal 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 adhe-
sive, 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.
2 10 9F-2773 Bolt 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.

Before assembly, apply Loctite C5A Copper anti-seize to the threads.


3 3 3J-5389 Plug
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 Specification Description

1 16 6V-3917 O-Ring Seal Before assembly, lubricate the bore lightly with glycerin or approved equivalent.

Before assembly, apply Loctite C5A Copper anti-seize to the threads.


2 4 3J-5389 Plug
Torque to 20 ± 5 N·m (177 ± 44 lb in).

Before assembly, apply Loctite C5A Copper anti-seize to the threads.


3 8 6V-1943 High Temperature Bolt
Torque to 55 ± 10 N·m (41 ± 7 lb ft).
RENR5057 109
Specifications Section

Illustration 75 g03113956
Right side view of engine

Illustration 76 g03113959
Bolt tightening sequence
110 RENR5057
Specifications Section

Table 63
Item Qty Part Specification Description

Use the following procedure in order to assemble the aftercooler assembly and tight-
en 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 ad-
hesive, 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.
4 12 9F-2773 Bolt 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.

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 Specification Description

1 8 6V-3917 O-Ring Seal Lubricate the bore lightly with 5P-3975 Rubber Lubricant.

Before assembly, apply Loctite C5A Copper anti-seize to the threads.


2 4 3J-5389 Plug
Torque to 20 ± 5 N·m (177 ± 44 lb in).

Before assembly, apply Loctite C5A Copper anti-seize to the threads.


3 8 6V-1943 High Temperature Bolt
Torque to 55 ± 10 N·m (41 ± 7 lb ft).
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 tight-
en 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 ad-
hesive, 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.
4 12 9F-2773 Bolt 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.

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 g02596659
Rear view
114 RENR5057
Specifications Section

Illustration 81 g02596660

Table 66
Specification for 214-5543 Air Shutoff Gp

Item Qty Part Specification Description

Maximum operating temperature of the valve is 204 °C (399 °F).


1 1 272-7094 Air Shutoff Gp
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 Specification Description

A 0.8 mm (0.03 inch) feeler gauge must not pass between the plate and the
1 1 2W-4880 Plate As
housing at any point when the plate is in the closed position.

2 1 129-3021 Ring 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).

Air shutoff group must not actuate at 14 kPa (2 psi) or below 14 kPa (2 psi). Air shutoff
2 1 296-8190 Air Shutoff Gp
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 Specification Description

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.
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 Part Specification Description

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 Specification Description

1 1 288-2758 Air Shutoff Gp Maximum operating temperature of the valve is 204 °C (399 °F).
288-2759 Air Shutoff Gp Maximum operating pressure of the valve is 300 kPa (44 psi).
2 1

Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.


3 2 263-2905 Limit Switch As
Torque to 16.27 N·m (144.00 lb in).
RENR5057 121
Specifications Section

Illustration 87 g03099622

Table 72
Item Qty Part Specification Description

Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.


4 2 215-2589 Bolt
Torque to 7 ± 1 N·m (62 ± 9 lb in).

5 1 215-2706 Air Shutoff As Before assembly, apply Loctite C5A Copper Anti-Seize to body of the shaft.

6 1 289-9132 Body
Before reassembly, apply red Loctite 596 in between the body and cover.
7 1 215-2707 Cover
Before assembly, apply Loctite C5A Copper Anti-Seize to the threads.
8 2 215-2587 Bolt
Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).

9 2 215-2587 Bolt Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).

Nominal voltage is 18 to 32 V.
10 1 230-4073 Solenoid As
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 Specification Description

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.

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

i00680561 Part No.: 302-8729


S/N: ZBR1–Up
Prelube Pump Part No.: 302-8729
SMCS Code: 1319 S/N: YBT1–Up

Part No.: 302-8729 Part No.: 302-8729


S/N: YBB1–Up S/N: YBW1–Up

Part No.: 302-8729 Part No.: 302-8729


S/N: YBC1–Up 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 kine-
- - -
matic 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 Specification Description

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.

- - - 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 Part Specification Description

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


1 2 106-9866 Gear Depth of the bore in the oil pump body for the new gear is 110.15 ± 0.02 mm
(4.337 ± 0.001 inch).

Diameter of the 106-9865 Idler Shaft is 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).
106-9867 Idler Shaft
2 2 Distance (B) from the end of the shaft to the gear face is 34.0 ± 0.5 mm (1.34 ± 0.02 inch).
Assembly
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).

106-9869 Oil Pump Bore in the bushing for oil pump drive shaft assembly is 31.811 ± 0.013 mm
4 1 (1.2524 ± 0.0005 inch).
Drive Shaft As

Distance (C) from the end of the shaft to the gear face is 47.0 ± 0.5 mm (1.85 ± 0.02 inch).

Installation depth is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).


5 6 7W-0060 Bushing
Position of bushing joints from the centerline through the bearing bores is 45 ± 15 degrees.

F 2 4M-3248 Hollow Dowel Extension of the hollow dowel from the oil pump cover is 6.0 ± 0.5 mm (0.24 ± 0.02 inch).

G 2 7N-2043 Dowel Extension of the dowel from the oil pump cover is 6.0 ± 1.0 mm (0.24 ± 0.04 inch).

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

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

Bench test specifications:

- - - Unrestricted flow rate at 1000 rpm is 410 L (108 US gal).

Pump pressure at 300 rpm with fully blocked outlet is 570 to 630 kPa (83 to 91 psi).
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 After assembly, bore in the 7W-0060 Bushing for the new shaft assembly is
31.811 ± 0.013 mm (1.2524 ± 0.0005 inch).

E 2 4M-3248 Hollow Dowel 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
F - -
(1.34 ± 0.02 inch).

Diameter is 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).


G 1 7N-5058 Pump Drive Shaft 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
H - -
(1.85 ± 0.02 inch).

Installation depth of 7W-0060 Bushing in the pump cover is 1.5 ± 0.5 mm


J 1 7W-0050 Pump Cover
(0.06 ± 0.02 inch).

Installation depth of 7W-0060 Bushing in the oil pump body assembly is


K 1 7W-0051 Oil Pump Body As
1.5 ± 0.5 mm (0.06 ± 0.02 inch).
RENR5057 135
Specifications Section

Illustration 96 g03079878

Table 80
Specification for 7N-8715 Engine Oil Pump Gp

Item Qty Part Specification Description

L 2 7N-2043 Dowel Extension from the oil pump cover is 6.0 ± 1.0 mm (0.24 ± 0.04 inch).
136 RENR5057
Specifications Section

Illustration 97 g03079902

Illustration 98 g03079958

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

Item Qty Part Specification Description

Position of 7W-0060 Bushing joints from the centerline through the bearing
M - -
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 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
E 2 4M-3248 Hollow Dowel (0.24 ± 0.02 inch).

Distance from the end of the idler shaft to the gear face is 34.0 ± 0.5 mm
F - -
(1.34 ± 0.02 inch).

Diameter of the new shaft is 31.742 ± 0.008 mm (1.2497 ± 0.0003 inch).


G 1 7W-1017 Shaft 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
H - -
(1.85 ± 0.02 inch).

Installation depth of the sleeve bearing in the pump cover is 1.5 ± 0.5 mm
J 1 7W-0050 Pump Cover
(0.06 ± 0.02 inch).

Installation depth of the sleeve bearing in the oil pump body assembly is
K 1 4P-5637 Oil Pump Body As
1.5 ± 0.5 mm (0.06 ± 0.02 inch).
RENR5057 141
Specifications Section

Illustration 102 g03088699

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

Item Qty Part Specification Description

Extension of hollow dowel from the oil pump cover is 6.0 ± 1.0 mm
L 2 7N-2043 Dowel (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 Specification Description

Position of bearing joints from the centerline through the bearing bores is 45 ± 15
M - -
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 g03071677


Front view
RENR5057 145
Specifications Section

Table 87
Specification for 115-7860 Engine Oil Lines Gp

Item Qty Part Specification Description

1 4 0S-1594 Bolt 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
2 4 0S-1571 Bolt torque..
3. Tighten two bolts (2) of the clamp assembly to the tube (4) to the standard
torque..

Length under test force is 68.3 mm (2.69 inch).


5 2 6B-9202 Spring 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).
6 1 2W-1635 Spring 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).
7 2 7N-7697 Plunger
The cooling jet sequence valves must be fully open at a pressure difference of
200 ± 30 kPa (29 ± 4 psi).

8 6 109-2332 O-Ring Seal Lubricate the bore lightly with the clean engine oil.

9 1 2W-1053 Plug 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 g01616336


Right side view
Typical example
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 Specification Description

- - 0S-1594 Bolt 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
- - 0S-1571 Bolt (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).

Length under test force is 68.3 mm (2.69 inch).


5 2 6B-9202 Spring 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).
6 1 2W-1635 Spring 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).

7 6 109-2332 O-Ring Seal Lubricate the bore lightly with the clean engine oil.

8 1 2W-1053 Plug 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 Specification Description

1 6 6V-5048 O-Ring Seal Lubricate the bore lightly with clean engine oil.

Length under test force is 102.0 mm (4.02 inch).


2 1 2W-1635 Spring 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 Start to open pressure is 287 ± 7 kPa (42 ± 1 psi).
Fully open pressure is 480 ± 7 kPa (70 ± 1 psi).

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).


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 g02632117


Front view
152 RENR5057
Specifications Section

Table 90
Specification for 112-4921 Engine Oil Filter Gp

Item Qty Part Specification Description

1 6 6V-5048 O-Ring Seal Lubricate the bore of the O-ring seals lightly with clean engine oil.

Length under test force is 102.0 mm (4.02 inch).


2 1 2W-1635 Spring Test force is 518 ± 26 N (116 ± 6 lb).
Free length after test is 143.4 mm (5.65 inch).

The bypass valve must move freely in the bore.


3 1 2W-1969 Bypass Valve 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).

4 3 165-3931 Bolt
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
5 2 0T-0573 Bolt
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 Specification Description

1 4 6V-5048 O-Ring Seal Lubricate the bore of the O-ring seals lightly with clean engine oil.

Length under test force is 102.0 mm (4.02 inch).


2 1 2W-1635 Spring Test force is 518 ± 26 N (116 ± 6 lb).
Free length after test is 143.4 mm (5.65 inch).

The bypass valve must move freely in the bore.


3 1 2W-1969 Bypass Valve 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).

4 3 165-3931 Bolt
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
5 3 0T-0573 Bolt
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 g02559976


Left side view
RENR5057 155
Specifications Section

Table 92
Specification for 115-7841 Engine Oil Filter Gp and 242-6278 Engine Oil Filter Gp

Item Qty Part Specification Description

1 - - Before assembly, lightly lubricate the bore with clean engine oil.

The bypass valve must move freely in the bore.


2 1 2W-1969 Bypass Valve 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).


3 1 2W-1635 Spring Test force is 518 ± 26 N (116 ± 6 lb).
Free length after test is 143.4 mm (5.65 inch).

4 2 264-0450 Clamp As Use the following tightening sequence for the clamp assembly:
1. Snugly tighten the clamp assembly to the tube.
100-8075 Clamp As 2. Tighten the bolts of the clamp assembly to the elbow to 47 ± 9 N·m (35 ± 7 lb ft).
5 2
3. Tighten the bolts of the clamp assembly to the tube to 47 ± 9 N·m (35 ± 7 lb ft).

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).


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 g03120216


Typical example
Front view
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 Specification Description

1 - 0S-1594 Bolt Use the following tightening sequence for the clamp bolts:
1. Snugly tighten the clamp assembly (2) to the tube assembly (4).
2 - 100-8075 Clamp As
2. Tighten the bolts (3) of the clamp assembly to the elbow (7) to 47 ± 9 N·m
3 - 0S-1571 Bolt (35 ± 7 lb ft).
3. Tighten the bolts (1) of the clamp assembly to the tube assembly (4) to
4 - 1N-3333 Tube 47 ± 9 N·m (35 ± 7 lb ft).

5 - 109-2332 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.

6 1 2W-1053 Plug 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 g03113516


Front view
RENR5057 161
Specifications Section

Table 94
Specification for 115-7860 Engine Oil Lines Gp

Item Qty Part Specification Description

1 4 0S-1594 Bolt Use the following tightening sequence for the clamp bolts:
1. Snugly tighten the clamp assembly (2) to the tube assembly (4).
2 2 100-8075 Clamp As
2. Tighten the bolts (3) of the clamp assembly to the 7N-5413 Elbow(8) to
3 2 0S-1571 Bolt 47 ± 9 N·m (35 ± 7 lb ft).
3. Tighten the bolts (1) of the clamp assembly to the tube assembly (4) to
4 1 1N-3333 Tube 47 ± 9 N·m (35 ± 7 lb ft).

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

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.
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 (6) Ball plunger assembly (15) Cover
(5) Tie rod (7) Bracket

Table 95
Specification for 120-4501 Engine Oil Filter Gp and 4W-9968 Engine Oil Filter Gp

Item Qty Part Specification Description

1 6 6V-5048 O-Ring Seal


Lubricate the bore of the O-ring seals lightly with clean engine oil.
2 4 5P-4892 O-Ring Seal

4 3 0T-0573 Bolt 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).

Length under test force is 102.0 mm (4.02 inch).


9 1 2W-1635 Spring 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.


10 1 2W-1969 Bypass Valve 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).

11 1 5H-7225 Retainer Nut


Torque to 45 ± 7 N·m (33 ± 5 lb ft).
12 1 3B-7329 Nut

13 1 9M-2610 O-Ring Seal Lubricate the bore of the O-ring seals lightly with clean engine oil.

14 3 165-3931 Bolt 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 Specification Description

1 2 109-2332 O-Ring Seal 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 Specification Description

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).
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 Specification Description

1 2 033-6031 O-Ring Seal Lubricate the bore of O-ring seals lightly with clean engine oil.

2 5P-0597 Hose Clamp


2 Torque to 3.0 ± 0.5 N·m (27 ± 4 lb in).
1 180-3007 Hose Clamp
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 Specification Description

1 3 5P-0597 Hose Clamp Torque to 3.0 ± 0.5 N·m (26.6 ± 4.4 lb in).

2 2 5P-4868 Hose Clamp Torque to 3.0 ± 0.5 N·m (26.6 ± 4.4 lb in).

3 3 033-6031 O-Ring Seal Before assembly, lightly lubricate the bore with the lubricant that is being sealed.
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 Specification Description

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.
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 Specification Description

1 4 033-6031 O-Ring Seal Lubricate the bore of O-ring seals lightly with clean engine oil.

4 5P-0597 Hose Clamp


2 Torque to 3.0 ± 0.5 N·m (27.0 ± 4.4 lb in).
2 5P-4868 Hose Clamp

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 g02844076


Top view
RENR5057 173
Specifications Section

Table 102
Specification for 7C-7185 Oil Pan Gp

Item Qty Part Specification Description

Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate


1 2 3P-0654 O-Ring Seal
the bores.
Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate
2 2 7X-1547 O-Ring Seal
the bores.
3 2 0S-1590 Bolt In order to prevent stress on the tube assembly (5), use the following tightening
procedure during assembly:
4 2 0S-1588 Bolt 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).

6 2 4B-2363 Oil Drain Plug Torque to 145 ± 15 N·m (107 ± 11 lb ft).

7 - - 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 g03090816


Top view
RENR5057 175
Specifications Section

Table 103
Specification for 7C-6887 Oil Pan Gp

Item Qty Part Specification Description

Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate


1 2 3P-0654 O-Ring Seal
the bores.
Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate
2 2 7X-1547 O-Ring Seal
the bores.
3 2 0S-1590 Bolt In order to prevent stress on the tube assembly (5), use the following tightening
procedure during assembly:
4 2 0S-1588 Bolt 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).

6 2 4B-2363 Oil Drain Plug Torque to 145 ± 15 N·m (107 ± 11 lb ft).

7 - - 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 g03090904


Top view
178 RENR5057
Specifications Section

Table 104
Specification for 7C-6752 Oil Pan Gp

Item Qty Part Specification Description

Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate


1 2 3P-0654 O-Ring Seal
the bores.
Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate
2 2 7X-1547 O-Ring Seal
the bores.
3 2 0S-1590 Bolt In order to prevent stress on the tube assembly (5), use the following tightening
procedure during assembly:
4 2 0S-1588 Bolt 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).

6 2 4B-2363 Oil Drain Plug Torque to 145 ± 15 N·m (107 ± 11 lb ft).

7 - - 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 g02844117


Top view
RENR5057 181
Specifications Section

Table 105
Specification for 7C-9938 Oil Pan Gp

Item Qty Part Specification Description

Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate


1 2 3P-0654 O-Ring Seal
the bores.
Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate
2 2 7X-1547 O-Ring Seal
the bores.
3 2 0S-1590 Bolt In order to prevent stress on the tube assembly (5), use the following tightening
procedure during assembly:
4 2 0S-1588 Bolt 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).

6 2 4B-2363 Oil Drain Plug Torque to 145 ± 15 N·m (107 ± 11 lb ft).

7 - - 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:

1. Tighten five bolts (11) to standard torque.


- 15 1A-2029 Bolt
2. Tighten bolt 1 through bolt 10 in a numerical sequence that is shown in Illustra-
tion 129 to a standard torque.

As required, apply 8T-9014 Silicone Sealant, Permatex No. 2 or 138-8436


12 - -
Liquid Gasket to the joints of the gasket prior to assembly.

Lubricate the bore of nine O-ring seals lightly with the lubricant that is being
13 - -
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
14 - -
cylinder block, and Connecting joint of the front accessory drive housing (18) and
the front of the cylinder block prior to assembly.

As required, apply 4C-9509 Wicking Sealant to the open top end of the bolt
15 38 5P-5855 Bolt
holes after assembly of the oil pan.

As required, apply 8T-9014 Silicone Sealant, Permatex No. 2 or 138-8436


16 1 142-4159 Integral Seal
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).


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 g03027916


Top view
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 Specification Description

Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate


1 2 3P-0654 O-Ring Seal
the bores.
Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate
2 2 7X-1547 O-Ring Seal
the bores.
3 2 0S-1590 Bolt In order to prevent stress on the tube assembly (5), use the following tightening
procedure during assembly:
4 2 0S-1588 Bolt 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).

6 2 4B-2363 Oil Drain Plug Torque to 145 ± 15 N·m (107 ± 11 lb ft).

7 - - 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

Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate the


1 2 3P-0654 O-Ring Seal
bores.
Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate the
2 2 7X-1547 O-Ring Seal
bores.
3 2 0S-1590 Bolt In order to prevent stress on the tube assembly (5), use the following tightening
procedure during assembly:
4 2 0S-1588 Bolt 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).

6 - - As required, apply Loctite RTV Silicone Clear to the joints of the gasket.

7 1 4B-2363 Oil Drain Plug 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

Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate the


1 2 3P-0654 O-Ring Seal
bores.
Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate the
2 2 7X-1547 O-Ring Seal
bores.
3 2 0S-1590 Bolt In order to prevent stress on the tube assembly (5), use the following tightening
procedure during assembly:
4 2 0S-1588 Bolt 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).

6 2 4B-2363 Oil Drain Plug Torque to 145 ± 15 N·m (107 ± 11 lb ft).

As required, apply Loctite RTV Silicone Clear, Permatex No # 2, or Red Loc-


7 - -
tite 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 g02843996


Top view
192 RENR5057
Specifications Section

Table 110
Specification for 7C-7178 Oil Pan Gp

Item Qty Part Specification Description

Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate


1 3 3P-0654 O-Ring Seal
the bores.
Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate
2 2 7X-1547 O-Ring Seal
the bores.
3 2 0S-1590 Bolt In order to prevent stress on the tube assembly (5), use the following tightening
procedure during assembly:
4 2 0S-1588 Bolt 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).

6 2 4B-2363 Oil Drain Plug Torque to 145 ± 15 N·m (107 ± 11 lb ft).

7 - - 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 Specification Description

A - - Minimum opening distance at fully open temperature is 10.4 mm (0.41 inch).

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

Fully open temperature is 92 °C (198 °F).


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 Specification Description

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).
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 Specification description

1 2 6V-5066 O-Ring Seal Lubricate the bore lightly with glycerin.


RENR5057 197
Specifications Section

i05210298

Thermostatic Valve
198 RENR5057
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 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 Specification Description

219-3240 Temperature Start to open temperature is 19 to 22 °C (66 to 72 °F).


1 2
Regulator Fully open temperature is 32 °C (90 °F).

2 2 3K-0360 O-Ring Seal 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


A - -
(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 Specification Description

1 1 3B-8489 Grease Fitting Before assembly, fill the cavity with green 1P-0808 Multipurpose Grease.

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 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
5 1 3B-8686 Grease Fitting
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 Specification Description

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 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
4 1 3B-8686 Grease Fitting
grease during assembling of fan drive group.

5 1 2M-4453 O-Ring Seal 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 Specification Description

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).
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 Specification Description

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 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 Specification Description

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).
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 Qty Part 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 O-
2 1 4P-5242 Oil Pickup Assembly
ring seal contacts the oil pan.
3. Unscrew the oil pickup assembly until the word “UP” is at the 12 o'clock position.
4. Hold the oil pickup assembly in position and tighten the nut (3) to a torque of
150 ± 15 N·m (111 ± 11 lb ft).
RENR5057 207
Specifications Section

i04395597

Water Pump
SMCS Code: 1361

Part No.: 2W-9726


S/N: ZAD1–Up

Illustration 144 g02847239


(2) Ring assembly
(3) Water pump seal group
208 RENR5057
Specifications Section

Table 121
Specification for 2W-9726 Water Pump Gp

Item Qty Part Specification Description

1 1 8C-5236 Lip Type Seal Do not lubricate the sealing lip of the lip type seal.

4 1 149-5462 O-Ring Seal Lubricate the bore of the O-ring seals with glycerin or an approved equivalent.

5 1 5H-6734 O-Ring Seal Lubricate the bore of the O-ring seals with glycerin or an approved equivalent.

Lubricate the shaft with a thin film of clean engine oil before pressing the impel-
ler onto the shaft. The end of the shaft must be flush with the face of the impel-
6 1 212-8180 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).

7 3 9M-2151 Taperlock Stud Torque to 35 ± 5 N·m (26 ± 4 lb ft).

8 3 9S-8752 Full Nut Torque to 27 ± 4 N·m (239 ± 35 lb in).

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


9 1 7N-4758 Thrust Washer
Width of the groove for thrust washer is 8.75 ± 0.05 mm (0.344 ± 0.002 inch).

10 Bore of the impeller for new shaft is 25.342 ± 0.013 mm


(0.9977 ± 0.0005 inch).
1 212-8187 Impeller
B Clearance between the impeller and the cover is 0.5000 ± 0.4925 mm
(0.01968 ± 0.01939 inch).

11 1 3D-2824 O-Ring Seal Lubricate the bore of the O-ring seals with glycerin or an approved equivalent.

12 1 7G-8478 Adapter 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 Specification Description

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.

Bore of the impeller for new shaft is 25.342 ± 0.013 mm


3 1 212-8184 Impeller
(0.9977 ± 0.0005 inch).

4 3 9M-2151 Taperlock Stud Torque to 35 ± 5 N·m (26 ± 4 lb ft).

5 3 9S-8752 Full Nut Torque to 27 ± 4 N·m (239 ± 35 lb in).

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


6 1 7N-4758 Thrust Washer
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.

Lubricate the shaft with a thin film of clean engine oil before pressing the impel-
ler onto the shaft. The end of the shaft must be flush with the face of the impel-
8 1 212-8180 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


B - -
(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 Specification Description

1 1 5H-6734 O-Ring Seal Lubricate the bore lightly with the fluid that is being sealed.

2 1 149-5462 O-Ring Seal Lubricate the bore lightly with the fluid that is being sealed.

3 3 9S-8752 Full Nut Torque to 27 ± 4 N·m (239 ± 35 lb in).

4 3 9M-2151 Taperlock Stud Torque to 35 ± 4 N·m (26 ± 3 lb ft).

Clearance between the cover and the vanes of the impeller after installation is
A - -
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 Specification Description

5 1 8C-5236 Lip Type Seal Do not lubricate the sealing lip.

Before pressing the impeller on the shaft, lubricate the shaft with clean engine oil.

The end of the pump shaft must be flush with the face of the impeller within ± 0.15 mm
212-8180 Pump Drive Shaft (± 0.006 inch).
6 1
As
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 - - Bore of the 212-8184 Impeller is 25.342 ± 0.013 mm (0.9977 ± 0.0005 inch).

7 1 7N-4758 Thrust Washer 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
8 1 166-4375 Seal Gp 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.

9 1 7G-8478 Adapter Torque to 100 ± 10 N·m (74 ± 7 lb ft).

10 1 3D-2824 O-Ring Seal 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
D - -
(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 g02570218


Typical example
RENR5057 217
Specifications Section

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

Item Qty Part Specification Description

Width of groove in the shaft for thrust washer is 6.25 ± 0.05 mm


A 1 212-8179 Shaft (0.246 ± 0.002 inch).

Thickness of the new thrust washer is 6.000 ± 0.025 mm


B 2 5N-4383 Thrust Washer (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).
C 1 212-8179 Shaft Diameter of new auxiliary drive shaft (not shown) is 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch).

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


D 1 212-8183 Impeller Diameter in the shaft for impeller is 19.050 to 19.063 mm
(0.7500 to 0.7505 inch).

Installation depth of the bushing in the housing assembly is 1.5 ± 0.5 mm


E 1 127-5400 Bushing
(0.06 ± 0.02 inch).

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 pres-
1 1 9X-4594 Lip Type Seal sure 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).

Lubricate the shaft with a thin film of clean engine oil before pressing the impel-
3 1 212-8179 Shaft ler (2) onto the shaft. The end of the shaft must be flush with the face of the im-
peller 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.

Lubricate the bore of the O-ring seal with clean engine oil, glycerin, or clean
5 1 9M-3786 O-Ring Seal
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
1 1 9X-4594 Lip Type Seal less than 24 cc (1.5 cu in).
Minimum leakage per minute for the water pump seal assembly at 138 kPa (20 psi) of air
pressure is less than 20 cc (1.2 cu in).

2 1 212-8183 Impeller Bore of the impeller for shaft is 19.000 ± 0.013 mm (0.7480 ± 0.0005 inch).

Lubricate the shaft with a thin film of clean engine oil before pressing the impeller (2) onto
the shaft.
3 1 212-8179 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).

B 2 5N-4383 Thrust Washer 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).
4 1 127-5400 Bushing 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).

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 Specification Description

1 1 4J-4382 Pipe Plug Remove the plug in order to prime the pump.

2 1 259-4598 O-Ring Seal Lubricate the bore lightly with 5P-3975 Rubber Lubricant.

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:
3 1 5L-7685 Zinc Rod As
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 Specification Description

Maintain 490 ± 45 N (110 ± 10 lb) load on ring while tightening socket setscrew to
5 1 175-4986 Retaining Ring
0.9 ± 0.1 N·m (8.0 ± 0.9 lb in) peen over threads as shown in Illustration 151 .

For assembly, apply green Loctite 609 .


6 1 108-4877 Hex Slotted Nut
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 For assembly, apply green Loctite 609 .

For assembly, apply green Loctite 609 .


9 1 9Y-5068 Impeller
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
2 5N-9016 Shim Thickness is 0.25 mm (0.010 inch).

2 5N-9015 Shim Thickness is 0.38 mm (0.015 inch).

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.
11 1 5N-2904 Seal Collar 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 g02570218


Typical example
224 RENR5057
Specifications Section

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

Item Qty Part Specification Description

Width of groove in the shaft for thrust washer is 6.25 ± 0.05 mm


A 1 212-8179 Shaft (0.246 ± 0.002 inch).

Thickness of the new thrust washer is 6.000 ± 0.025 mm (0.2362 ± 0.0010 inch)
B 2 5N-4383 Thrust Washer
.
Bore in the sleeve bearing for auxiliary drive shaft is 75.000 ± 0.055 mm
(2.9528 ± 0.0022 inch).
C 1 212-8179 Shaft Diameter of new auxiliary drive shaft (not shown) is 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch).

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


D 1 212-8183 Impeller Diameter in the shaft for impeller is 19.050 to 19.063 mm
(0.7500 to 0.7505 inch).

Installation depth of the bushing in the housing assembly is 1.5 ± 0.5 mm


E 1 127-5400 Bushing
(0.06 ± 0.02 inch).

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 pres-
1 1 9X-4594 Lip Type Seal sure 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).

Lubricate the shaft with a thin film of clean engine oil before pressing the impel-
3 1 212-8179 Shaft ler (2) onto the shaft. The end of the shaft must be flush with the face of the im-
peller 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.

Lubricate the bore of the O-ring seal with clean engine oil, glycerin, or clean
5 1 9M-3786 O-Ring Seal
water.
RENR5057 225
Specifications Section

i04934477

Cooling System Pressure Cap


226 RENR5057
Specifications Section

SMCS Code: 1382; 1392 S/N: YAZ1–Up

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
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 g02617919


Front view
230 RENR5057
Specifications Section

Table 131
Specification for 240-6651 Cylinder Block Gp and 240-6653 Cylinder Block Gp

Item Qty Part Specification Description

During assembly, the bottom of spacer plates must be free of fuel, oil, water, gasket
110-6994 Spacer Plate adhesives, assembly compounds, and any other contaminants.
1 16
Thickness is 12.313 mm (0.4848 inch).

During assembly, both sides of plate gasket must be free of fuel, oil, water, gasket
adhesives, assembly compounds and any other contaminants.
2 16 144-5692 Plate Gasket
Thickness is 0.194 to 0.218 mm (0.0076 to 0.0086 inch).

3 2 4W-4813 Plug Torque to 100 ± 15 N·m (74 ± 11 lb ft).

During assembly, top of cylinder block must be free of fuel, oil, water, gasket adhe-
4 - -
sives, 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
5 18 101-1198 Camshaft Bearing cylinder block.

Oil holes must be positioned from horizontal at an angle (D) of 20 ± 5 degrees.

6 8 6V-3348 O-Ring Seal 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
A 32 8T-0099 Dowel (0.83 ± 0.02 inch).

B Bore in the cylinder block for the camshaft bearings is 98.000 ± 0.020 mm
- -
(3.8583 ± 0.0008 inch).

C Extension of the dowel from the top face of the cylinder block is 21.0 ± 0.5 mm
16 197-7008 Dowel (0.83 ± 0.02 inch).

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

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

Bore in the block for the main bearings:


Standard, original new size is 169.742 ± 0.020 mm (6.6827 ± 0.0008 inch).
G - -
0.63 mm (0.025 inch) larger than original size is 170.372 ± 0.020 mm
(6.7076 ± 0.0008 inch).

Width of main bearing is 340.030 ± 0.015 mm (13.3870 ± 0.0006 inch).


H - - 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 Specification Description

7 4 5F-9657 O-Ring Seal Lubricate the bore lightly with 5P-3975 Rubber Lubricant.

Extension of the dowel from the front face of the cylinder block is 6.0 ± 0.5 mm
J 2 7N-2047 Dowel (0.24 ± 0.02 inch).

Extension of the dowel from the rear face of the cylinder block is 6.0 ± 0.5 mm
K 1 7N-2047 Dowel (0.24 ± 0.02 inch).

Extension of dowels from the rear face of the cylinder block is 19.0 ± 0.5 mm
L 2 4N-0683 Dowel (0.75 ± 0.02 inch).

Extension of dowels from the front face of the cylinder block is 40.0 ± 0.5 mm
M 2 7N-2044 Dowel (1.58 ± 0.02 inch).
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 g02848764


Front view
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 ad-
hesives, 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).

Extension of the dowel from the top face of the cylinder block is 20.0 ± 0.5 mm
3 16 8T-0099 Dowel (0.79 ± 0.02 inch).

Thickness of plate gasket that is between cylinder block and spacer plate is 0.194 to 0.218 mm
4 8 144-5692 Plate Gasket (0.0076 to 0.0086 inch).

Extension of the dowel from the top face of the cylinder block is 21.0 ± 0.5 mm
5 8 197-7008 Dowel
(0.83 ± 0.02 inch).

101-1198 Camshaft
A 10 Bore in the block for the camshaft bearing is 98.000 ± 0.020 mm (3.8583 ± 0.0008 inch).
Bearing

All centerlines through oil holes in the camshaft bearings and the camshaft bearing junctions (6)
are shown for each side of the cylinder block.
B - -
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
C - -
(23.07 inch).

7 8 6V-3348 O-Ring Seal Lubricate the bore lightly with sealant that is being sealed.

Install crankshaft bearing caps with the part number and FRONT toward the front of the block.
223-1696 Crankshaft
8 5 Each cap has a number. Each cap must be installed in the same position as the correct number
Bearing Cap
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).

Bore in the block for the crankshaft bearings:


E - - 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).

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

Use the following procedure to tighten the bolts.


1. Lubricate the threads with clean engine oil before assembly.
2. Tighten the bolts by hand.
9 20 7X-7925 Bolt 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).

Extension of the dowel from the front 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 rear face of the cylinder block is 19.0 ± 0.5 mm
J 2 4N-0683 Dowel (0.75 ± 0.02 inch).

Extension of the dowel from the front face of the cylinder block is 40.0 ± 0.5 mm
K 2 7N-2044 Dowel (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 g03022476


Front view of engine
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 Torque to 100 ± 15 N·m (74 ± 11 lb ft).

2 4 5F-9657 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.

All centerlines through oil holes in the camshaft bearings and the camshaft bear-
ing junctions must be positioned as shown in Illustration 159 on each side of cylin-
der 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.

Extension of the dowel from the top face of the cylinder block is 21.0 ± 0.5 mm
A 24 8T-0099 Dowel (0.83 ± 0.02 inch).

Extension of the dowel from the top face of the cylinder block is 21.0 ± 0.5 mm
C 12 197-7008 Dowel (0.83 ± 0.02 inch).

Width of the crankshaft bearing cap is 340.030 ± 0.015 mm


223-1696 Crankshaft Bearing (13.3870 ± 0.0006 inch).
E 7 Width of cylinder block for main bearing cap is 339.985 ± 0.015 mm
Cap
(13.3852 ± 0.0006 inch).

New dimension from centerline of crankshaft bearing bore to the top of the cylin-
F - -
der block is 586 mm (23.1 inch).

New dimension from centerline of crankshaft bearing bore to bottom of cylinder


G - -
block (pan rails) is 230 mm (9.1 inch).

Bore in the cylinder block for the main bearings is 169.742 ± 0.020 mm
H - -
(6.6827 ± 0.0008 inch).
238 RENR5057
Specifications Section

Illustration 160 g03022496


Section B-B

Table 137
Item Qty Part Specification Description

Extension of the dowel from the rear face of the cylinder block is 6.0 ± 0.5 mm
J 1 7N-2047 Dowel (0.24 ± 0.02 inch).

Extension of the dowel from the front face of the cylinder block is 6.0 ± 0.5 mm
K 1 7N-2047 Dowel (0.24 ± 0.02 inch).

Extension of the dowel from the rear face of the cylinder block is 19.0 ± 0.5 mm
L 2 4N-0683 Dowel (0.75 ± 0.012 inch).

Extension of the dowel from the front face of the cylinder block is 40.0 ± 0.5 mm
M 2 7N-2044 Dowel (1.57 ± 0.02 inch).
RENR5057 239
Specifications Section

Illustration 161 g03022536

Table 138
Item Qty Part Specification Description

Assemble dry seals on clean and dry liner grooves.


6 12 352-6061 Liner Seal
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.

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.
8 28 7X-7925 Bolt
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 Specification Description

1 2 4W-4813 Plug Torque to 100 ± 15 N·m (74 ± 11 lb ft).

2 4 5F-9657 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.

All centerlines through oil holes in the camshaft bearings and the camshaft bear-
3 18 101-1198 Camshaft Bearing ing junctions must be positioned as shown in Illustration 162 on each side of cylin-
der 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.

Extension of the dowel from the top face of the cylinder block is 21.0 ± 0.5 mm
A 32 8T-0099 Dowel (0.83 ± 0.02 inch).

Extension of the dowel from the top face of the cylinder block is 21.0 ± 0.5 mm
C 16 197-7008 Dowel (0.83 ± 0.02 inch).

Width of the crankshaft bearing cap is 340.030 ± 0.015 mm


223-1696 Crankshaft Bearing (13.3870 ± 0.0006 inch).
E 9 Width of cylinder block for main bearing cap is 339.985 ± 0.015 mm
Cap
(13.3852 ± 0.0006 inch).

New dimension from centerline of crankshaft bearing bore to the top of the cylin-
F - -
der block is 586 mm (23.1 inch).

New dimension from centerline of crankshaft bearing bore to bottom of cylinder


G - -
block (pan rails) is 230 mm (9.1 inch).

Bore in the cylinder block for the main bearings is 169.742 ± 0.020 mm
H - -
(6.6827 ± 0.0008 inch).

Illustration 163 g03022577


Section B-B
242 RENR5057
Specifications Section

Table 140
Specification for 370-9890 Cylinder Block Gp

Item Qty Part Specification Description

6 6 214-7568 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.

Extension of the dowel from the rear face of the cylinder block is 6.0 ± 0.5 mm
J 2 7N-2047 Dowel (0.24 ± 0.02 inch).

Extension of the dowel from the front face of the cylinder block is 6.0 ± 0.5 mm
K 1 7N-2047 Dowel (0.24 ± 0.02 inch).

Extension of the dowel from the rear face of the cylinder block is 19.0 ± 0.5 mm
L 2 4N-0683 Dowel (0.75 ± 0.012 inch).

Extension of the dowel from the front face of the cylinder block is 40.0 ± 0.5 mm
M 2 7N-2044 Dowel (1.57 ± 0.02 inch).

Illustration 164 g03022596


Front view

Table 141
Item Qty Part Specification Description

Assemble dry seals on clean and dry liner grooves.


7 16 352-6061 Liner Seal
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.

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.
9 36 7X-7925 Bolt
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 S/N: YAZ1–Up

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
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 Specification Description

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

Thickness (B) of flange on cylinder liner is 12.65 ± 0.02 mm (0.498 ± 0.001 inch)
2 - -
.
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 expan-
sion 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 pis-
ton ring groove. For correct use of the piston ring groove gauge group, refer to the instruction card that is with the piston ring groove gauge
group.

Before assembly of the piston rings, lubricate the ring grooves with clean engine oil. After assembly, lubricate the mating surfaces of the rings to
the cylinder liner with clean engine oil.

Install the top piston ring with the “UP-1” side toward the top of the piston.
When the new top piston ring is installed in a cylinder liner with a bore size of 170 mm
1 1 214-6066 Top Piston Ring (6.7 inch), the clearance between the ends of the piston ring is 0.625 ± 0.125 mm
(0.0246 ± 0.0049 inch).
Thickness of new top piston ring is 3.88 mm (0.153 inch).

Install the intermediate piston ring with the “UP-2” side toward the top of the piston.
When the new intermediate piston ring is installed in a cylinder liner with a bore size of
144-5695 Intermediate Piston
2 1 170 mm (6.7 inch), the clearance between the ends of the piston ring is
Ring
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).
3 1 223-6361 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.

4 - - Bore diameter for piston pin is 70.0705 ± 0.0075 mm (2.75867 ± 0.00030 inch).

Before assembly, lubricate the piston pin, the piston pin bore, the connecting rod eye,
and the connecting rod pin bearing with clean engine oil.
Outside diameter is 69.930 ± 0.005 mm (2.7531 ± 0.0002 inch).
5 1 263-8955 Piston Pin
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.
6 2 253-1238 Pin Retainer
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).

Clearance between the ends of the piston ring when the piston ring is installed in a cylinder
1 1 229-1632 Top Piston Ring
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).

144-5695 Intermediate Clearance between the ends of the piston ring when the piston ring is installed in a cylinder
2 1
Piston Ring 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).

165-6668 Oil Control Pis- Clearance between the ends of the piston ring when the piston ring is installed in a cylinder
3 1
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.

Diameter of the bore in the finished bearing that is installed into the piston skirt for the piston
4 - -
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.
5 1 302-3451 Piston Pin
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.
6 2 253-1238 Pin Retainer 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 neces-
sary 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 cyl-
inder liner with clean engine oil.

Bore in the bushing for new piston pin is 70.0525 ± 0.0075 mm


(2.75796 ± 0.00029 inch).
1 1 172-0919 Crown As
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).
2 1 155-5271 Piston Skirt
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.

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).
3 1 229-1632 Top 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 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).
144-5695 Intermediate Piston
4 1 Increase in clearance between the ends of the piston ring for each 0.03 mm
Ring
(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).

Clearance between groove and new oil piston ring is 0.050 to 0.100 mm
5 1 165-6668 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.

Before assembly, lubricate the piston pin, the piston pin bore, the connecting rod eye,
and the connecting rod pin bearing with clean engine oil.
6 1 138-8508 Piston Pin Measure the pin diameter on each end in a vertical and horizontal direction.
Outside diameter is 69.962 ± 0.005 mm (2.7544 ± 0.0002 inch).
Length is 137.55 ± 0.15 mm (5.415 ± 0.006 inch).

Thickness is 2.40 ± 0.08 mm (0.094 ± 0.003 inch).


7 2 8N-7296 Pin Retainer
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 measur-
ing 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 cyl-
inder liner with clean engine oil.

Bore in the bushing for new piston pin is 70.0525 ± 0.0075 mm


(2.75796 ± 0.00029 inch).
1 1 249-4512 Crown As
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).
2 1 155-5271 Piston Skirt
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.

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).
3 1 229-1632 Top 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 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).
144-5695 Intermediate Piston
4 1 Increase in clearance between the ends of the piston ring for each 0.03 mm
Ring
(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).

165-6668 Oil Control Piston Clearance between groove and new oil piston ring is 0.050 to 0.100 mm
5 1 (0.0020 to 0.0039 inch).
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 0.65 ± 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.

Before assembly, lubricate the piston pin bore, the connecting rod eye, and the con-
necting rod pin bearing with clean engine oil.
6 1 138-8508 Piston Pin Measure the pin diameter on each end in a vertical and horizontal direction.
Outside diameter is 69.962 ± 0.005 mm (2.7544 ± 0.0002 inch).
Length is 137.55 ± 0.15 mm (5.415 ± 0.006 inch).

Thickness is 2.40 ± 0.08 mm (0.094 ± 0.003 inch).


7 2 8N-7296 Pin Retainer
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

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

The connecting rod may be heated from 175 to 260 °C (347 to 500 °F) for the in-
B - - stallation of the bushing for the piston pin. Minimum length for heating the con-
necting 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
C 1 118-1655 Bushing
70.000 ± 0.008 mm (2.7559 ± 0.0003 inch).
Bore in the connecting rod for the bushing is 75.760 ± 0.015 mm
(2.9827 ± 0.0006 inch).

D - - Distance between the center of the bearings is 380 mm (15.0 inch).

Protrusion of the dowel from the connecting rod cap is 4.0 ± 0.5 mm
E 1 7N-2043 Dowel (0.16 ± 0.02 inch).

Bore in the connecting rod for the bearing for the crankshaft connecting rod jour-
F - - nal after applying final torque to the connecting rod bolts is 143.028 ± 0.015 mm
(5.6310 ± 0.0006 inch).

Etch the cylinder number on the connecting rod and the cap in this 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.

The chamfer side must be next to the crank pin thrust surface when the connect-
2 - -
ing 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:

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
4 4 7N-2405 Bolt
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 bear-
ing tabs and location pin (3).
1. Before assembly, apply Molylube to the bolt threads, the bolt shank, and the bolt
- 4 7N-2405 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.

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

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.
A 1 - The connecting rod may be heated from 175 to 260 °C (347 to 500 °F) for the in-
stallation of the bushing for the piston pin. Minimum length for heating the connect-
ing rod is 105 mm (4.1 inch).

Bore in the bushing for the piston pin after installation is 70.000 ± 0.008 mm
(2.7559 ± 0.0003 inch).
B 1 230-2519 Bushing
Bore in the connecting rod for the bushing for the piston pin is 75.760 ± 0.015 mm
(2.9827 ± 0.0006 inch).

Angle above centerline on either side of the bushing joint for bushing for the piston
C - -
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
E - -
(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).

Extension of the dowel from the connecting rod cap is 4.0 ± 0.5 mm
F 1 7N-2043 Dowel (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
G - - (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
C 1 377-5237 Bearing
70.000 ± 0.008 mm (2.7559 ± 0.0003 inch).
Bore in the connecting rod for the bearing is 75.760 ± 0.015 mm
(2.9827 ± 0.0006 inch).

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

Protrusion of the dowel from the connecting rod cap is 4.0 ± 0.5 mm
E 1 7N-2043 Dowel (0.16 ± 0.02 inch).

Bore in the connecting rod for the bearing for the crankshaft connecting rod journal
F - - after applying final torque to the connecting rod bolts is 143.028 ± 0.015 mm
(5.6310 ± 0.0006 inch).

Bore in the connecting rod bearing for crankshaft is 135.133 to 135.194 mm


G - -
(5.3202 to 5.3226 inch).

Etch the cylinder number on the connecting rod and the cap in this location. Mark
1 - - the connecting rod and the cap with numbers. Mark the numbers on the same side
of the connecting rod as the bearing retainer notch.

The chamfer side must be next to the crank pin thrust surface when the connect-
2 - -
ing rod and piston group is assembled in the engine.

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 bear-
ing tabs and location pin (3).
1. Before assembly, apply Molylube on the bolt threads, the bolt shank, and the
- 4 7N-2405 Bolt 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 Specification Description

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

Inside diameter of connecting rod for bearing for the piston pin is 75.760 ± 0.015 mm
B - -
(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).

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

Distance between the center of the bore for the bearing for piston pin and the center of the bore for
E - -
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.

Inside diameter of connecting rod for the bearing for crankshaft journal is 143.028 ± 0.015 mm
F - -
(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 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 Qty Part Specification Description

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 .
3 4 7N-2405 Bolt 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 S/N: GD31–Up

Connecting Rod and Main Part No.: 379-4851


S/N: YBB1–Up
Bearing Journals
Part No.: 379-4855
SMCS Code: 1230 S/N: YBC1–Up
Part No.: 8N-0337 Part No.: 101-0336, 8N-7103
270 RENR5057
Specifications Section

S/N: ZAD1–Up Table 152


Diameter Of Crankshaft Journal (Bearing Surface) For Con-
Part No.: 375-3642
necting Rod Bearings
S/N: JDE1–Up
Original Size Journal 135.000 ± 0.025 mm
Part No.: 8N-7103 (5.3150 ± 0.0010 inch)
S/N: ZAH1–Up
Undersize Journal 134.370 ± 0.025 mm
Part No.: 161-6926, 8N-7103 0.63 mm (0.025 inch) (5.2902 ± 0.0010 inch)
S/N: ZAJ1–Up
Undersize Journal 133.730 ± 0.025 mm
Part No.: 8N-7103 1.27 mm (0.050 inch) (5.2650 ± 0.0010 inch)
S/N: YAM1–Up
Part No.: 161-6926, 8N-7103 Clearance between bearing and new journal
S/N: YAN1–Up .................0.107 to 0.218 mm (0.0042 to 0.0086 inch)

Part No.: 8N-0337, 8N-7103 Main Bearing Journals


S/N: YAP1–Up Table 153

Part No.: 8N-0337, 8N-7103 Diameter Of Crankshaft Journal (Bearing Surface) For Main
Bearings
S/N: ZAP1–Up
Original Size Journal 160.000 ± 0.025 mm
Part No.: 8N-0337 (6.2992 ± 0.0010 inch)
S/N: ZBP1–Up
Undersize Journal 159.370 ± 0.025 mm
Part No.: 8N-0337, 8N-7103 0.63 mm (0.025 inch) (6.2744 ± 0.0010 inch)
S/N: PBR1–Up
Undersize Journal 158.730 ± 0.025 mm
Part No.: 8N-0337 1.27 mm (0.050 inch) (6.2492 ± 0.0010 inch)
S/N: PDR1–Up
Part No.: 161-6928, 8N-7103 Clearance between bearing and new journal
S/N: YAR1–Up .................0.122 to 0.241 mm (0.0048 to 0.0095 inch)

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
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 Specification Description

1 2 7C-6209 Thrust Plate Use only on the center main bearing as shown in the Illustration 177 .

2 8 2W-2288 Plug 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 18 128-4845 Bolt As
3. Loosen the bolts.
4. Again, tighten evenly to 70 ± 5 N·m (52 ± 4 lb ft).
5. Rotate each bolt for an additional turn of 120 ± 5 degrees.
Do not reuse counterweight bolts.

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

B - - End play for the new crankshaft is 0.17 to 0.63 mm (0.007 to 0.025 inch).

2 6 2W-2288 Plug 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.
3 36 128-4845 Bolt As
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 Specification Description

1 2 7C-6209 Thrust Plate 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).

2 6 2W-2288 Plug 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.
3 36 128-4845 Bolt As
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 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).

2 8 2W-2288 Plug 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.
3 48 128-4845 Bolt As
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 Specification Description

1 2 7C-6209 Thrust Plate Thrust plates should be used only on center main bearing.

2 8 2W-2288 Plug 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 bolt threads, the bolt shank, the washer, and the underside
3 48 128-4845 Bolt As
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.

B 32 7N-2003 Dowel 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 Use only on the center main bearing as shown in the Illustration 182 .

2 8 2W-2288 Plug 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
3 48 128-4845 Bolt As 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.

B - - 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 Part No.: 7W-3813


S/N: GD31–Up 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.

113-8433 Crankshaft Seal Install the crankshaft seal group in the flywheel housing group on a standard rota-
3 1
Gp tion engine.

113-8432 Crankshaft Seal Install the crankshaft seal group in the front housing group on a standard rotation
4 1
Gp engine.

The crankshaft seal group is installed from both ends of the crankshaft at the dis-
A - -
tance of 8.0 ± 0.5 mm (0.31 ± 0.02 inch).

The wear sleeve is installed from both ends of the crankshaft at the distance of
B - -
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 Specification Description

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 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 Specification Description

1 7 8T-6765 Pipe Plug Diameter is 1/4 inch. Length is 14.2 mm (0.56 inch).

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 - - 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 Specification Description

1 6 2A-5220 Plug 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 g03325358


Front view of engine
RENR5057 289
Specifications Section

Table 165
Specification for 8N-7174 Front Gear Gp

Item Qty Part Specification Description

After installation, bore of 127-5400 Bushing is 75.000 ± 0.055 mm


1 1 7N-5245 Pump Adapter
(2.9528 ± 0.0022 inch).

After installation, bore of 140-9597 Bushing is 90.000 ± 0.010 mm


2 1 144-8263 Idler Gear As (3.5433 ± 0.0004 inch).
Installation depth is 2.3 ± 0.5 mm (0.09 ± 0.02 inch).

3 1 7C-3260 Shaft Diameter is 89.880 ± 0.020 mm (3.5386 ± 0.0008 inch).

4 2 259-4598 O-Ring Seal 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).


5 1 7N-5239 Pump Drive Shaft As Install the 8T-2153 Socket Setscrew to the bottom of the threaded hole and tighten
to 6 ± 1 N·m (53 ± 9 lb in).

6 1 235-3546 O-Ring Seal Before assembly, lightly lubricate the bores with the lubricant that is being sealed.

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
7 2 7N-5246 Thrust Washer (0.344 ± 0.004 inch).
End play for the pump drive shaft assembly is 0.250 ± 0.075 mm
(0.0098 ± 0.0030 inch).

After installation, bore of 127-5400 Bushing is 75.000 ± 0.055 mm


(2.9528 ± 0.0022 inch).
8 1 278-4287 Pump Adapter
During assembly, flush the bushing with the pump adapter surface.
Oil hole in the bushing must be aligned with the hole in the bore.
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 Part Specification Description

Bore of 140-9597 Bushing after installation is 90.000 ± 0.010 mm (3.5433 ± 0.0004 inch).
144-8263 Idler Gear
1 1 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 Bore of 127-5400 Bushing after installation is 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch).
2 1
Adapter Diameter of the new pump drive shaft (5) is 74.900 ± 0.015 mm (2.9488 ± 0.0006 inch).

8T-2153 Socket
3 1 Torque to 6 ± 1 N·m (53 ± 9 lb in).
Setscrew
259-4598 O-Ring
4 2 Lubricate the bore lightly with the lubricant that is being sealed.
Seal

278-4287 Pump Bore of 127-5400 Bushing after installation is 75.000 ± 0.055 mm (2.9527 ± 0.0022 inch).
6 1
Adapter Bushing must be flush with the pump adapter.

235-3546 O-Ring
7 1 Lubricate the bore lightly with the lubricant that is being sealed.
Seal

7C-3258 Thrust Thickness is 7.00 ± 0.15 mm (0.276 ± 0.006 inch).


8 1
Washer Assembly 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 Specification Description

Bore of 125-9751 Bushing after installation is 81.060 ± 0.010 mm


1 2 101-1364 Idler Gear As (3.1913 ± 0.0004 inch).
Installation depth is 1.00 ± 0.25 mm (0.039 ± 0.010 inch).

2 2 101-1368 Thrust Washer Thickness is 1.90 ± 0.10 mm (0.075 ± 0.004 inch).

Bore of 101-1372 Bushing after installation is 75.060 ± 0.010 mm


3 1 114-3372 Idler Gear As (2.9551 ± 0.0004 inch).
Installation depth is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).

4 1 101-1366 Gear Shaft Diameter is 74.990 ± 0.010 mm (2.9524 ± 0.0004 inch).

5 4 8M-2530 Bolt Torque to 140 ± 10 N·m (103 ± 7 lb ft).

Before assembly, clean the taper of the camshaft and the tapered bore of the cam-
6 2 - shaft drive gear with lint free cloth saturated with cleaning solvent to remove excess
oil. Clean with alcohol wipe.

7 2 8S-2331 Bolt Torque to 240 ± 20 N·m (177 ± 15 lb ft).


RENR5057 293
Specifications Section

Illustration 191 g03104816


Rear view

Table 168
Item Qty Part Specification Description

8 2 101-1367 Idler Shaft Diameter is 81.000 ± 0.010 mm (3.1890 ± 0.0004 inch).

9 4 1B-4367 Bolt 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 Specification Description

Bore of 125-9751 Bushing after installation is 81.060 ± 0.010 mm


1 2 175-5197 Idler Gear As (3.1913 ± 0.0004 inch).
Installation depth is 1.00 ± 0.25 mm (0.039 ± 0.010 inch).

2 2 101-1368 Thrust Washer Thickness is 1.90 ± 0.10 mm (0.075 ± 0.004 inch).

Bore of 101-1372 Bushing after installation is 75.060 ± 0.010 mm


3 1 175-5200 Idler Gear As (2.9551 ± 0.0004 inch).
Installation depth is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).

4 1 101-1366 Gear Shaft Diameter is 74.990 ± 0.010 mm (2.9524 ± 0.0004 inch).

5 4 8M-2530 Bolt Torque to 140 ± 10 N·m (103 ± 7 lb ft).

Before assembly, clean the taper of the camshaft and the tapered bore of the cam-
6 2 175-5201 Camshaft Gear shaft drive gear with lint free cloth saturated with cleaning solvent to remove ex-
cess oil. Clean with alcohol wipe.
RENR5057 295
Specifications Section

Illustration 193 g03019537


Rear view

Table 170
Item Qty Part Specification Description

7 2 101-1367 Idler Shaft Diameter is 81.000 ± 0.010 mm (3.1890 ± 0.0004 inch).

8 4 1B-4367 Bolt 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

Before assembly, clean the taper of the camshaft and the tapered bore of the cam-
shaft drive gear with lint free cloth saturated with cleaning solvent to remove excess
1 2 Camshaft Drive Gear oil. Clean with alcohol wipe.
Refer to Disassembly and Assembly for the installation procedure for the left and right
camshaft drive gear .

After installation, bore of 125-9751 Bushing in the idler gear assembly is


2 2 Idler Gear Assembly 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 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


4 1 Gear Assembly 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).

5 4 8M-2530 Bolt Torque to 140 ± 10 N·m (103 ± 7 lb ft).

6 1 101-1366 Gear Shaft 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 Illus-
tration 195 .
7 2 9X-8887 Bolt
3. Place a driver against the retaining plate of the camshaft drive gear. Strike the driv-
er 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. Re-
fer to Illustration 196 .

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 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 crank-
11 1 101-1370 Crankshaft Gear
shaft gear (11).

12 2 101-1367 Idler Shaft 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 Specification Description

Before assembly, clean the taper of the camshaft and the tapered bore of the
1 2 175-5201 Camshaft Gear camshaft drive gear with lint free cloth saturated with cleaning solvent to re-
move excess oil. Clean with alcohol wipe.

Bore of 125-9751 Bushing after installation is 81.060 ± 0.010 mm


2 2 175-5197 Idler Gear As (3.1913 ± 0.0004 inch).
Installation depth is 1.00 ± 0.25 mm (0.039 ± 0.010 inch).

Bore of 101-1372 Bushing after installation is 75.060 ± 0.010 mm


3 1 175-5200 Idler Gear As (2.9551 ± 0.0004 inch).
Installation depth is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).

4 2 101-1367 Idler Shaft 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 Specification Description

5 1 101-1366 Gear Shaft Diameter is 74.990 ± 0.010 mm (2.9524 ± 0.0004 inch).

6 2 101-1368 Thrust Washer Thickness is 1.90 ± 0.10 mm (0.075 ± 0.004 inch).

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).


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 Specification Description

1 4 8M-2530 Bolt 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).
B 1 4W-4998 Gear Shaft After assembly, bore in the 7N-6983 Bushing is 75.000 ± 0.053 mm
(2.9528 ± 0.0021 inch).

C 1 101-1365 Thrust Plate Thickness is 6.35 ± 0.25 mm (0.250 ± 0.010 inch).

101-9043 Balancer Gear The mark on the balancer gear must be in alignment with the mark on the crankshaft
2 1
Assembly 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 g02576406


Section B-B
304 RENR5057
Specifications Section

Illustration 202 g02576407


Adapter assembly

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

Item Qty Part Specification Description

1 9X-7371 O-Ring Seal


Lightly lubricate the bore of the O-ring seals with the lubricant that is being
2
2 259-4598 O-Ring Seal sealed.

3 1 7C-3260 Shaft Diameter of the new shaft is 89.88 ± 0.02 mm (3.539 ± 0.001 inch).

Bore in the sleeve bearing of the idler gear assembly after installation is
4 1 144-8263 Idler Gear As 90.000 ± 0.010 mm (3.5433 ± 0.0004 inch).
Maximum roughness average (Ra) is 0.8 micrometer (31.5 microinch).

Diameter of the new auxiliary drive shaft is 74.900 ± 0.015 mm


(2.9488 ± 0.0006 inch).
7N-5874 Auxiliary Drive Width of groove in the new auxiliary drive shaft for the thrust washer is
5 1
Shaft 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).

Installation depth of the bushing in the adapter assembly is 1.5 ± 0.5 mm


C 1 127-5400 Bushing
(0.06 ± 0.02 inch).

Bore in the bushing of the adapter assembly after installation is


D 1 127-5400 Bushing
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 g02592698


Section A-A
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 Specification Description

Lightly lubricate the bore of the O-ring seals with the lubricant that is being
1 - -
sealed.
Bore in the 127-5400 Bushing of the adapter assembly after installation is
2 1 7N-5279 Adapter As
75.000 ± 0.055 mm (2.9527 ± 0.0022 inch).

Diameter of the new auxiliary drive shaft is 74.900 ± 0.015 mm


(2.9488 ± 0.0006 inch).

Width of groove in the new auxiliary drive shaft for the thrust washer is
3 1 7N-5874 Auxiliary Drive Shaft
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).

Bore in the 127-5400 Bushing of the adapter assembly after installation is


D 1 7C-4165 Adapter As
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 Specification Description

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.

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 Specification Description

Lightly lubricate the bore of the O-ring seals with the lubricant that is being
1 - -
sealed or with the approved equivalent.

2 2 7N-7539 Thrust Washer 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).
3 1 7N-5874 Auxiliary Drive Shaft
Width of groove in the new auxiliary drive shaft is 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch).

During assembly, align the hole in the sleeve bearing with the adapter.
4 1 7N-5279 Adapter As Bore in the sleeve bearing of the adapter assembly after installation is
75.000 ± 0.055 mm (2.9527 ± 0.0022 inch).

Bore in the sleeve bearing of the adapter assembly after installation is


5 1 7C-4165 Adapter As
75.000 ± 0.055 mm (2.9527 ± 0.0022 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 Fly-
wheel 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.

Before assembly, lubricate the threads of the bolts with clean engine oil, molyb-
denum disulfide, or graphite base lubricant.
3 12 9S-8893 Bolt
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 Part No.: 101-0836, 297-7000


S/N: GD31–Up 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 g02589876


Left side view
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 Fly-
wheel Housing Gp, and 7W-3722 Flywheel Housing Gp

Item Qty Part Specification Description

Before installation of the flywheel housing, inspect the front face of the flywheel housing and the rear face of the cylinder block. The components
must be free of the following substances: oil, fuel, water, gasket adhesive, assembly compounds, and any other foreign materials.

To seal the joint between the flywheel housing and the cylinder block, apply Loctite High Flex GM to the front face of the flywheel housing.

Length of 1/2 inch diameter bolt is 57.15 mm (2.250 inch).


1 6 9X-8873 Bolt
Torque to 135 ± 20 N·m (100 ± 15 lb ft).

Length of 1/2 inch diameter bolt is 88.90 mm (3.500 inch).


2 4 9X-8875 Bolt
Torque to 135 ± 20 N·m (100 ± 15 lb ft).

Length of 1/2 inch diameter bolt is 171.5 mm (6.75 inch).


9M-7269(1)
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
3 2
Length of 1/2 inch diameter bolt is 228.6 mm (9.00 inch).
6M-9613(2)
Torque to 135 ± 20 N·m (100 ± 15 lb ft).

Length of 1/2 inch diameter bolt is 203.20 mm (8.000 inch).


4 2 9S-1374 Bolt
Torque to 135 ± 20 N·m (100 ± 15 lb ft).

Length of 1/2 inch diameter bolt is 114.30 mm (4.500 inch).


5 4 8S-9089 Bolt
Torque to 135 ± 20 N·m (100 ± 15 lb ft).

Length of 5/8 inch diameter bolt is 120.65 mm (4.750 inch).


6 16 1D-4590 Bolt
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.
(1) This bolt is used if the engine is not equipped with a support bracket for the air lines.
(2) 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 Specification description

1 4 5F-0304 Plug 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 Specification Description

1 12 7X-2575 Bolt 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 Specification Description

1 12 7X-2563 Bolt 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).

2 Thickness of 137-8539 Shim is 0.254 mm (0.0100 inch).


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

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 12 5N-2317 Bolt 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.

Before installation, lubricate the face of washers and the threads of bolts with clean engine
2 8 1A-5576 Bolt 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).

Before assembly, lubricate the threads of the bolts with molybdenum disulfide base
3 6 8S-4757 Bolt 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 Before assembly, lubricate the threads of the bolts with molybdenum disulfide
base lubricant.
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
5 48 1A-2029 Bolt
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 Before assembly, lubricate the threads of the bolts with molybdenum disulfide base
lubricant.
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
4 48 1A-2029 Bolt
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 Specification Description

1 18 3B-1915 Bolt Torque to 55 ± 7 N·m (41 ± 5 lb ft).

Before assembly, apply blue Loctite 242 to the threads


2 48 1A-2029 Bolt
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 Torque to 55 ± 7 N·m (41 ± 5 lb ft)

Before assembly, apply blue Loctite 242 to the threads.


4 30 1A-2029 Bolt
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

Before assembly, lubricate the thread of the bolts with molybdenum disulfide base
6 6 8S-4757 Bolt 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 Specification Description

1 4 0S-1591 Bolt Torque to 15 ± 3 N·m (133 ± 27 lb in).

2 6 030-8535 Locking Bolt Torque to 15 ± 3 N·m (133 ± 27 lb in).


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 Specification Description

1 3 0S-1616 Bolt 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 Specification Description

1 4 0S-1591 Bolt 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 S/N: YAZ1–Up

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
344 RENR5057
Specifications Section

Illustration 228 g02578560

Table 195
Specification for 7N-7660 Fan Drive Gp

Item Qty Part Specification Description

The alignment mark on the stub shaft (3) must be aligned with the alignment
- - -
mark on the damper adapter (1).

2 6 9F-8122 Bolt 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 Qty Part Specification Description

Before assembly, lubricate threads with engine oil, molybdenum disulfide, or graphite
1 12 5N-2317 Bolt 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 Specification Description

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.

During assembly, align the hole in the bushing with the adapter assembly.
3 1 7C-4165 Adapter As 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 Specification Description

Before assembly, lightly lubricate the sealing lip with the lubricant that is being
1 1 235-2484 Lip Type Seal
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 Specification Description

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.
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 Specification Description

1 1 7C-7808 Lip Type Seal 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 fre-
quency 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 ten-
sion 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 Belt Tension “Initial”” (1) Belt Belt Tension “Used”” (3) (4)
Reference) Tension
Used(2)

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) Belt Tension “Initial ” is for a new belt.
(2) Belt tension with less than 10 hours of operation
(3) Belt tension “Used” is for a belt that has operated for more than 30 minutes of operation at the rated speed..
(4) 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 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.
1 1 -
Torque to 88.4 ± 6.8 N·m (65.0 ± 5.0 lb ft)

2 1 187-2034 Flange Nut Torque to 102 ± 7 N·m (75 ± 5 lb ft).

Use a 7/16 ring terminal for (B+) terminal.


3 - 6V-8187 Nut
(B+) terminal. Torque to 6.2 ± 0.6 N·m (55.0 ± 5.0 lb in).

The peak voltage for (R) terminal must not be less than the output voltage for
4 - -
(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

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

- - - 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.
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 Specification Description

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

1 1 187-2034 Flange Nut Torque to 102 ± 7 N·m (75 ± 5 lb ft).

Use a 7/16 ring terminal for (B+) terminal.


2 - 6V-8187 Nut
(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).

Voltage setting is not adjustable.


3T-6354 Voltage Regulator
5 1
As Permissible voltage range is 27 to 29 V.

- - - 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.
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 g02542197

Note: Load the battery with a carbon pile 4C-4911


Battery Load Tester in order to get the maximum
alternator output.
356 RENR5057
Specifications Section

Table 205
Specification for 6N-9294 Charging Alternator Gp

Item Qty Part Specification Description

Torque the bolt before you tighten the mounting bolt of the alternator.
1 - -
Torque bolt to 88.4 ± 6.8 N·m (65.2 ± 5.0 lb ft).

2 1 187-2034 Flange Nut Torque to 102 ± 7 N·m (75.23112 ± 5.16292 lb ft).

Use a 7/16 ring terminal for (B+) terminal.


3 1 6V-8187 Nut
(B+) terminal. Torque to 6.2 ± 0.6 N·m (54.9 ± 5.3 lb in).

4 1 030-9612 Screw (B-) terminal. Torque to 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in).

3T-6354 Voltage Regulator Voltage setting requires no adjustment.


5 1
As Permissible voltage range is 27 to 29 V.

- - - 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.
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 Specification Description

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

1 1 187-2034 Flange Nut Torque to 102 ± 7 N·m (75 ± 5 lb ft).

Use a 7/16 ring terminal for (B+) terminal.


2 - 6V-8187 Nut
(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).

Voltage setting is not adjustable.


3T-6354 Voltage Regulator
5 1
As Permissible voltage range is 27 to 29 V.

- - - 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).

- - - 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.
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 Specification Description

Tighten the pulley retaining nut to 110 ± 10 N·m (81 ± 7 lb ft).


2 - -
Maximum misalignment between pulley assembly (3) and pulley (1) is 0.4 degrees.

4 1 141-7116 Serpentine Belt Adjust the belt tension of the serpentine belt according to the 197-9087 Tension Chart.

5 1 235-2484 Lip Type Seal Lubricate the sealing lip lightly with the lubricant that is being sealed.

197-9087Belt Tension Chart


Table 208
Specification for 197-9087 Belt Tension Chart

Gauge
Gauge Reading Gauge (Force)
(Frequency)
Belt Tension Belt Tension
Size of Belt Width of Belt Belt Tension Belt Tension (Frequency) (Frequency)
(Force) (Force) Basic Gauge “Initial”(1) “Used”(2) (3) Gauge Number
“Initial” “Used” Number
(1) (2) (3)

8 - RIB 27.82 mm 800 ± 22 N 489 ± 44 N


BT-33-109 98 ± 10 HZ 76 ± 8 HZ Clavis Type 14
POLY - RIB (1.095 inch) (180 ± 5 lb) (110 ± 10 lb)

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) Belt tension “lnitial” is for a new belt.
(2) Belt tension “Used” is for a belt that has operated for 30 minutes or more of operation at the rated speed.
(3) 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 Specification Description

1 - - Tighten the pulley retaining nut to 110 ± 10 N·m (81 ± 7 lb ft).

2 2 2J-3506 Full Nut Torque to 200 ± 20 N·m (148 ± 15 lb ft).

3 1 141-7116 Serpentine Belt Adjust the belt tension of the serpentine belt according to the 197-9087 Tension Chart.

4 1 7E-4839 Pulley Maximum misalignment between pulley assembly (5) and pulley (4) should not exceed 0.4
300-8570 Pulley As degrees.
5 1

6 1 235-2484 Lip Type Seal 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
Gauge Reading Gauge (Force)
(Frequency)
Belt Tension Belt Tension
Size of Belt Width of Belt Belt Tension Belt Tension (Frequency) (Frequency)
(Force) (Force) Basic Gauge “Initial”(1) “Used”(2) (3) Gauge Number
“Initial” “Used” Number
(1) (2) (3)

8 - RIB 27.82 mm 800 ± 22 N 489 ± 44 N


BT-33-109 98 ± 10 HZ 76 ± 8 HZ Clavis Type 14
POLY - RIB (1.095 inch) (180 ± 5 lb) (110 ± 10 lb)

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) Belt tension “lnitial” is for a new belt.
(2) Belt tension “Used” is for a belt that has operated for 30 minutes or more of operation at the rated speed.
(3) 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 Specification Description

1 2 6V-8188 Nut 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 1
Kit 2. For Hold-in windings is 16 Amp
3. Maximum rated current is 850 Amp

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

3 1 6V-8378 Nut Torque to 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in).

A maximum of three cable terminals or wire terminals may be used with the battery terminal nut (3).
4 1 6V-8188 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).

The switch terminal must be insulated with heat shrink tubing. Do not use molded terminals.
5 1 6V-8378 Nut
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
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 Specification Description

B - - Clearance between the pinion and the housing is 9.1 mm (0.36 inch).

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).

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.
4 1 6V-8188 Nut
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 Specification Description

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

1 2 6V-8188 Nut 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
2 1 1. For Pull-in windings is 49.3 ± 3.3 amp
Motor Solenoid
2. For Hold-in windings is 6.8 amp max

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).

The switch terminal must be insulated with heat shrink tubing. Do not use molded terminals.
5 1 4B-2049 Nut
Torque to 2.25 ± 0.25 N·m (20.00 ± 2.00 lb in).

A maximum of three cable terminals or wire terminals may be used with the battery terminal nut (5).
6 1 6V-8188 Nut 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)

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 Specification Description

1 2 6V-8188 Nut Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).

Current consumption at 20V and 25 °C (77 °F):


2 1 - 1. For Pull-in current is 57 amp
2. For Hold-in current is 16 amp

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).

A maximum of three cable terminals or wire terminals may be used with the battery terminal nut. A
5 1 6V-8188 Nut 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).

The switch terminal must be insulated with heat shrink tubing. Do not use molded terminals.
6 1 6V-8378 Nut
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
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).

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.
1 - -
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).

Switch terminal. Tighten the nut to 2.6 ± 0.8 N·m (23.0 ± 7.1 lb in).
4 - -
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 S/N: YAZ1–Up

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
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 Specification Description

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).

Tighten the rotor clamp nut until clearance of 0.03 to 0.08 mm


5 - - (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).


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 Specification Description

Inlet pressure is 1723 kPa (250 psi).


1 - -
Maximum inlet pressure is 3103 kPa (450 psi).

2 - - Outlet pressure at outlet port is 621 ± 758 kPa (90 ± 110 psi).
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 Part Specification Description

Note: The liquid level switch is shown in the high liquid level position.

When the liquid level switch activates, approximate travel distance of the liquid level
switch is 6.4 mm (0.25 inch).
A - -
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 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).


1 1
- Minimum deactuation temperature is 20 °C (68 °F).

- Contact position is normally closed below deactuation temperature.


RENR5057 381
Specifications Section

i04358589

Fuel Pressure Sensor


382 RENR5057
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 383
Specifications Section

Illustration 249 g02544036

Table 220
Specification for 274-6719 Pressure Sensor Gp

Item Qty Part Specification Description

274-6719 Pressure Sensor Torque to 10 ± 2 N·m (89 ± 18 lb in)


1 1
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 Specification Description

Torque to 10 ± 2 N·m (89 ± 18 lb in).


1 1 161-1705 Pressure Sensor
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 Specification Description

Final installation torque for the pressure switch is 22 ± 3 N·m (195 ± 27 lb in).
1 - -
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 Part No.: 204-2518, 239-9957


S/N: GD31–Up 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 Specification Description

Torque to 20 ± 3 N·m (177 ± 27 lb in).


1 1 -
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 Specification Description

Final installation torque is 22 ± 3 N·m (195 ± 27 lb in).


1 - -
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 Pres-
sure Sensor Gp, and 293-5535 Pressure Sensor Gp

Item Qty Part Specification Description

1 - - Torque to 10 ± 2 N·m (89 ± 18 lb in).

- - - Operating voltage is 5.0 ± 0.5 VDC.


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).

Prior to installing the pressure sensor onto the engine, apply 5P-3413 Pipe
1 - -
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 S/N: YAZ1–Up

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
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 Specification Description

Torque to 20 ± 3 N·m (177 ± 27 lb in).


1 - - 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 Specification Description

Torque to 48 ± 5 N·m (35 ± 4 lb ft).


1 - -
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 Specification Description

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


1 - -
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 Specification Description

Torque to 10 ± 2 N·m (89 ± 18 lb in).


1 1 274-6717 Pressure Sensor
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 Specification Description

Torque to 10 ± 2 N·m (89 ± 18 lb in).


1 1 276-6793 Pressure Sensor Gp
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 part Specification Description

161-1704 Turbocharger Outlet Pressure Sen- Torque to 10 ± 2 N·m (89 ± 18 lb in).


1 1
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 Specification Description

Torque to 20 ± 3 N·m (177 ± 27 lb in).


1 - -
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 S/N: YAZ1–Up

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
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).

Operating voltage is 7.5 to 8.5 V.


1 - - 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 Part Specification Description

102-2240 Engine Coolant Tempera- Torque to 20 ± 3 N·m (177 ± 27 lb in).


1 1
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 Part No.: 163-7882, 261-6848


S/N: GD31–Up 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 Part Specification Description

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 Tem-
perature 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 Specification Description

1 - - 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 Qty 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
1 1 129-6628 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 Specification Description

Torque to 10 ± 2 N·m (89 ± 18 lb in).


1 - -
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 Specification Description

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.


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 Specification Description

Torque to 10 ± 2 N·m (90 ± 18 lb in).


1 - -
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 Specification Description

1 - - Torque to 10 ± 2 N·m (89 ± 18 lb in).

- - - Operating voltage is 5.0 ± 0.5 VDC.


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 Specification Description

Torque to 25 ± 5 N·m (18 ± 4 lb ft).


1 - -
Resistance at 25 °C (77 °F) is 142 Ω.
428 RENR5057
Specifications Section

i04707610

Engine Speed Sensor


RENR5057 429
Specifications Section

SMCS Code: 1907 S/N: YAZ1–Up

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
430 RENR5057
Specifications Section

Illustration 274 g02812838

Table 245
Specification for 318-1181 Speed Sensor Gp

Item Qty Part Specification Description

1 - - 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 S/N: YAZ1–Up

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
RENR5057 433
Specifications Section

Illustration 275 g02589698

Table 246
Specification for the 120-4498 Thermocouple Gp

Item Qty Part Specification Description

243-5752 Temperature Sen- Before assembly, apply Loctite C5A copper anti-seize to the threads.
1 1
sor Gp Torque to 12 ± 3 N·m (106 ± 27 lb in).
434 RENR5057
Index Section

Index
A Cylinder Head Valves .................................53, 56
Cylinder Liner................................................. 243
Accessory Drive (Lower Left Hand)............... 302
Accessory Drive (Upper Right Hand) ... 305, 308,
311 D
Aftercooler Coolant Temperature Sensor ...... 408
Air Cleaner....................................................... 94 Duplex Engine Oil Filters ............................... 162
Air Inlet and Exhaust Lines ......97, 100, 102, 105,
108, 111 E
Air Lines........................................................... 96
Air Shutoff ............................... 113, 115, 117, 120 Electric Starting Motor ....363, 365, 368, 370, 372
Air Shutoff Valve and Mounting (1) .............119 Engine Air Cleaner Service Indicator............... 95
Air Starting Motor........................................... 373 Engine Coolant Temperature Sensor .... 409, 412
Air Starting Motor Pressure Regulating Engine Design ............................................... 6–8
Valve ............................................................ 376 Engine Oil Cooler........................................... 164
Alternator and Regulator........ 352, 354–355, 357 Engine Oil Cooler Bypass and Cooling Jet
Alternator Mounting ............................... 359, 361 Sequence Valves ................................. 143, 146
197-9087 Belt Tension Chart ................... 360 Engine Oil Filter ..................... 148, 150, 153–154
197-9087 Belt Tension Chart ................... 362 Engine Oil Lines..................................... 156, 159
Atmospheric Pressure Sensor............... 423, 425 Engine Oil Pan.......172, 174, 176, 179, 182, 185,
Auxiliary Drive Pulley............................. 346–348 187–188, 190
Auxiliary Drive Shaft ...................................... 349 Engine Oil Pressure Sensor .................. 393–394
Auxiliary Water Pump .................... 215, 218, 223 Engine Oil Pump............................ 129, 132, 137
Auxiliary Water Pump (Sea Water)................ 220 Engine Oil Sump Pump ................................. 206
Engine Oil Temperature Sensor ............ 396, 399
Engine Speed Sensor............................ 426, 428
B Engine Speed/Timing Sensor................ 417–418
Balancer Group (Front).................................. 301 Exhaust Flange.....................................89, 91, 93
Belt Tension Chart ......................................... 350 Exhaust Manifold ............... 78, 80–81, 83–85, 87

C F
Camshaft ........................................30, 33, 35, 37 Fan Drive ............................................... 200, 202
Connecting Rod......................258, 261, 264, 267 Flexible Coupling ................................... 323, 325
Connecting Rod and Main Bearing Journals Flywheel ........................................................ 313
..................................................................... 269 Flywheel Housing .......................................... 315
Coolant Level Sensor ............................ 388, 391 Flywheel Housing Cover................................ 319
Coolant Level Switch ..................................... 378 Fuel Filter..............................................11, 13–14
Coolant Temperature Switch ......................... 380 Fuel Filter (Primary)......................................... 10
Cooling System Pressure Cap ...................... 225 Fuel Injector......................................... 25, 27–28
Cover Group (Front Housing) ........................ 282 Fuel Injector Mechanism ............................21, 23
Crankcase Breather....................... 165, 167–170 Fuel Pressure Regulator.................................. 15
Crankcase Pressure Sensor.................. 420, 422 Fuel Pressure Sensor............................ 381, 384
Crankshaft ............................. 271–272, 274–277 Fuel Priming Pump .......................................... 20
Crankshaft Wear Sleeves and Seals............. 279 Fuel Transfer Pump ......................................... 17
Cylinder Block.........................228, 233, 236, 240
Camshaft Bearing Position ........................ 232 G
Cylinder Head.......................................43, 46, 49
Bolt Tightening Procedure ........................... 50 Gear Group (Front)................................ 287, 290
RENR5057 435
Index Section

Gear Group (Rear)..................292, 294, 296, 299 Water Pump....................................207, 209, 211
Generator Coupling ............................... 320, 322 Water Temperature Regulator ............... 193, 195

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
©2013 Caterpillar CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
All Rights Reserved dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
may not be used without permission.

You might also like