Professional Documents
Culture Documents
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
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
Index Section
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)
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
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
Illustration 5 g00294285
Cylinder and valve location
(A) Inlet valve
(B) Exhaust valve
i04888422
Illustration 7 g03015316
Table 1
Specification for 387-0485 Primary Fuel Filter Gp
2 1 2J-0157 O-Ring Seal Lubricate the bore of the O-ring seal and the shaft lightly with clean engine oil.
i04713909
Fuel Filter
SMCS Code: 1261
Illustration 8 g02818461
Table 2
Specification for 7W-9741 Fuel Filter Gp
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.
i04938315
Fuel Filter
SMCS Code: 1261
Illustration 9 g03117857
Table 3
Specification for 377-5898 Fuel Filter Gp
1 4 5D-5957 O-Ring Seal Lubricate the bore lightly with clean engine oil.
i04716709
Fuel Filter
SMCS Code: 1261
Illustration 10 g02820796
Table 4
Specification for 112-4922 Fuel Filter Gp
1 2 5D-5957 O-Ring Seal Lightly lubricate the bore with the clean engine oil.
i04369549
Illustration 11 g02577996
Table 5
Specification for 114-5477 Valve Plunger
i05196360
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
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 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
Illustration 13 g02668036
Table 7
Specification for 7N-8599 Fuel Priming Pump Gp
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
Illustration 14 g02529356
Table 8
Specification for 224-9869 Valve Mechanism Gp, 332-9690 Valve Mechanism Gp, and 357-9219 Valve Mechanism Gp
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).
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)
i04913393
Illustration 15 g03081556
Top view
Table 9
Specification for 370-9889 Valve Mechanism Gp
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 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
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
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.
i04938316
Fuel Injector
SMCS Code: 1290
Illustration 18 g03117876
Table 12
Specification for 384-4705 Fuel Injection Pump Gp
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).
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
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
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).
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
Illustration 20 g02603357
Table 14
Specification for 106-4595 Camshaft Gp and 106-4586 Camshaft Gp
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).
- - - End play for a new camshaft assembly is 0.15 to 0.35 mm (0.006 to 0.014 inch).
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
Use the following procedure in order to determine the camshaft lobe lift:
3. Subtract the base circle (J) from the camshaft lobe height (H). The difference
is the actual camshaft lobe lift.
Specified camshaft lobe lift:
i05206168
Camshaft
SMCS Code: 1210
Illustration 22 g03327351
Table 16
Specification for 106-4582 Camshaft Gp and 332-7923 Camshaft Gp
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).
Illustration 23 g03327356
Table 17
Item Qty Part Specification Description
Use the following procedure in order to determine the camshaft lobe lift:
3. Subtract the base circle (G) from the camshaft lobe height (F). The difference is
the actual camshaft lobe lift.
Specified camshaft lobe lift:
i04939143
Camshaft
SMCS Code: 1210
Illustration 24 g03120076
Table 18
Specification for 380-2698 Camshaft Gpand 382-3100 Camshaft Gp
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).
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:
3. Subtract the base circle (J) from the camshaft lobe height (H). The difference
is the actual camshaft lobe lift.
Specified camshaft lobe lift:
i04936960
Camshaft
SMCS Code: 1210
Illustration 26 g03113696
Table 20
Specification for 231-9123 Camshaft Gp
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).
- - - End play for a new camshaft assembly is 0.15 to 0.35 mm (0.006 to 0.014 inch).
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:
3. Subtract the base circle (J) from the camshaft lobe height (H). The difference is the actual camshaft
lobe lift.
Specified camshaft lobe lift:
i05182336
Valve Mechanism
SMCS Code: 1102
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
1 2 3J-9196 Jam Nut Torque the jam nuts to 70 ± 15 N·m (52 ± 11 lb ft).
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
Illustration 29 g02636876
Top view
Table 23
Specification for 370-9889 Valve Mechanism Gp
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
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 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
Illustration 31 g02823736
Table 25
Specification for 285-3086 Cylinder Head Gp, and 101-0830 Cylinder Head Gp
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
Illustration 33 g03120176
Table 27
Specification for 380-5795 Cylinder Head Gp
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
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
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)
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
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).
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
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
Illustration 39 g02829216
RENR5057 55
Specifications Section
Table 32
Specification for 338-8672 Cylinder Head Gp, and 317-2440 Cylinder Head Gp
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 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
Illustration 40 g03117796
Table 33
Specification for 380-5795 Cylinder Head Gp
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).
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.
i04758986
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
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
Illustration 44 g03334942
Rear view
Table 36
Specification for 380-5147 Turbocharger Oil Lines Gp
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
Illustration 45 g03111317
Typical example
64 RENR5057
Specifications Section
Table 37
Specification for 118-5463 Turbocharger Gp and 118-5464 Turbocharger Gp
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).
i04935828
Turbocharger
SMCS Code: 1052
Illustration 46 g03111057
Top view of engine
Table 38
Specification for 145-7992 Turbocharger Gp
2N-2765 High Temperature Before assembly, apply Loctite C5A Copper anti-seize to the threads and the bearing
1 8
Bolt surfaces.
i04935841
Turbocharger
SMCS Code: 1052
Illustration 47 g03111156
Front view of engine
68 RENR5057
Specifications Section
Table 39
Specification for 116-0687 Turbocharger Gp and 107-0863 Turbocharger Gp
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).
i04935847
Turbocharger
SMCS Code: 1052
Illustration 48 g03111198
Table 40
Specification for 203-2149 Turbocharger Gp and 172-0922 Turbocharger Gp
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).
i04938320
Turbocharger
SMCS Code: 1052
Illustration 49 g03117856
Table 41
Specification for 379-5300 Turbocharger Gp
i05251150
Turbocharger
SMCS Code: 1052
Illustration 50 g03345208
74 RENR5057
Specifications Section
Table 42
Specification for 322-1928 Turbocharger Gp
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).
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).
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).
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
Illustration 51 g03117776
Table 43
Specification for 379-5302 Turbocharger Gp
i04938361
Turbocharger
SMCS Code: 1052
Illustration 52 g03117993
Table 44
Specification for 379-5323 Turbocharger Gp
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
Illustration 53 g03106850
Front view
Table 45
Specification for 101-1259 Exhaust Manifold Gp
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
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
i04379754
Exhaust Manifold
SMCS Code: 1059
Illustration 55 g02543679
Table 47
Specification for the 172-0921 Exhaust Manifold Gp
i04938317
Exhaust Manifold
SMCS Code: 1059
Illustration 56 g03117858
Table 48
Specification for 378-8169 Exhaust Manifold Gp
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
Illustration 57 g03118096
Table 49
Specification for 398-0313 Exhaust Manifold Gp
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
Illustration 58 g03109336
Table 50
Specification for 381-4733 Exhaust Manifold Gp
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
Illustration 59 g03109321
Front view of Engine
Table 51
Specification for 111-6786 Exhaust Manifold Gp
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
Illustration 60 g02546044
Table 52
Specification for the 7N-6961 Exhaust Flange Gp
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
Illustration 61 g02834876
Table 53
Specification for 103-6668 Exhaust Flange Gp
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
Illustration 62 g02546021
Typical example
Table 54
Specification for the 7N-6962 Exhaust Flange Gp 1W-9488 Exhaust Flange Gp
i05206314
Air Cleaner
SMCS Code: 1051
Illustration 63 g03334504
Table 55
Specification for 317-9958 Air Cleaner Gp
i04380890
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
i04383993
Air Lines
SMCS Code: 1058; 1071
Illustration 65 g02638896
Typical example
Table 57
Specification for 208-0821 Air Lines Gp and 285-4161 Air Lines Gp
i04936927
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
1 8 6V-3917 O-Ring Seal Lubricate the bore lightly with glycerine or 5P-3975 Rubber Lubricant.
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
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
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.
5 4 6V-5103 O-Ring Seal Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
102 RENR5057
Specifications Section
i04936976
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
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.
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
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
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.
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
Illustration 74 g03113937
Front view of engine
Table 62
Specification for 198-9918 Turbocharger Air Lines Gp
1 16 6V-3917 O-Ring Seal Before assembly, lubricate the bore lightly with glycerin or approved equivalent.
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
Illustration 77 g03114022
Front view of engine
Table 64
Specification for 147-6619 Air Lines Gp
1 8 6V-3917 O-Ring Seal Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
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
Illustration 80 g02596659
Rear view
114 RENR5057
Specifications Section
Illustration 81 g02596660
Table 66
Specification for 214-5543 Air Shutoff Gp
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).
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
Illustration 82 g03069718
Table 67
Specification for 135-0180 Air Shutoff Gp
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.
i04738394
Air Shutoff
SMCS Code: 1078
Illustration 83 g02837440
Top view
(1) 152-2700 Air Shutoff Valve and Mounting
Table 68
Specification for 287-7866 Air Shutoff Gp
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).
Illustration 84 g02837436
Rear view
Table 69
Specification for 287-7866 Air Shutoff Gp
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
Illustration 85 g02837438
Table 70
Specification for 152-2700 Air Shutoff Valve and Mounting
Nominal voltage is 24 V
i04930024
Air Shutoff
SMCS Code: 1078
Illustration 86 g03099620
Table 71
Specification for 380-1077 Air Shutoff Gp
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
Illustration 87 g03099622
Table 72
Item Qty Part Specification Description
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).
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.
i04908578
Prelube Pump
RENR5057 123
Specifications Section
Illustration 88 g03075336
Table 73
Specification for 383-8477 Prelubrication Oil Pump Gp and 302-8729 Prelubrication Oil Pump Gp
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.
Illustration 89 g00288335
i04908624
Prelube Pump
(Air)
SMCS Code: 1319
Illustration 90 g03075476
Table 74
Specification for 1W-4674 Prelubrication Oil Pump Gp
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
Illustration 91 g03073840
Table 75
Specification for 4P-4925 Prelubrication Oil Pump and Lines Gp
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.
i04724870
Illustration 92 g02826456
RENR5057 131
Specifications Section
Table 76
Specification for the 106-9872 Engine Oil Pump Gp
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).
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).
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.
Pump pressure at 300 rpm with fully blocked outlet is 570 to 630 kPa (83 to 91 psi).
132 RENR5057
Specifications Section
i04912024
Illustration 93 g03079576
Table 77
Specification for 7N-8715 Engine Oil Pump Gp
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
Illustration 95 g03079836
Section A-A
Table 79
Specification for 7N-8715 Engine Oil Pump Gp
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).
Distance from the end of the shaft to the gear face is 47.0 ± 0.5 mm
H - -
(1.85 ± 0.02 inch).
Illustration 96 g03079878
Table 80
Specification for 7N-8715 Engine Oil Pump Gp
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
Position of 7W-0060 Bushing joints from the centerline through the bearing
M - -
bores is 45 ± 15 degrees.
RENR5057 137
Specifications Section
i04921863
Illustration 99 g03104511
Table 82
Specification for 8N-6152 Engine Oil Pump Gp
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
Table 83
Specification for 8N-6152 Engine Oil Pump Gp
Table 84
Specification for 8N-6152 Engine Oil Pump Gp
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).
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
Table 85
Specification for the 8N-6152 Engine Oil Pump Gp
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
Table 86
Specification for the 8N-6152 Engine Oil Pump Gp
Position of bearing joints from the centerline through the bearing bores is 45 ± 15
M - -
degrees.
RENR5057 143
Specifications Section
i04907238
Table 87
Specification for 115-7860 Engine Oil Lines Gp
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..
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.
i04389453
Table 88
Specification for 115-7860 Engine Oil Lines Gp, 202-2657 Engine Oil Lines Gp, and 262-0338 Engine Oil Lines Gp
- - 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).
7 6 109-2332 O-Ring Seal Lubricate the bore lightly with the clean engine oil.
i04925725
Table 89
Specification for 4W-6874 Engine Oil Filter Gp, 319-2130 Engine Oil Filter Gp and 319-2131 Engine Oil Filter Gp
1 6 6V-5048 O-Ring Seal Lubricate the bore lightly with clean engine oil.
i04390177
Table 90
Specification for 112-4921 Engine Oil Filter Gp
1 6 6V-5048 O-Ring Seal Lubricate the bore of the O-ring seals lightly with clean engine oil.
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
Table 91
Specification for 375-7427 Engine Oil Filter Gp
1 4 6V-5048 O-Ring Seal Lubricate the bore of the O-ring seals lightly with clean engine oil.
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
Table 92
Specification for 115-7841 Engine Oil Filter Gp and 242-6278 Engine Oil Filter Gp
1 - - Before assembly, lightly lubricate the bore with clean engine oil.
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).
i04939243
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
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.
i04936891
Table 94
Specification for 115-7860 Engine Oil Lines Gp
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.
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
Table 95
Specification for 120-4501 Engine Oil Filter Gp and 4W-9968 Engine Oil Filter Gp
Refer to Testing and Adjusting, “Duplex Oil Filter - Adjust” for correct adjustment procedures of the fluid control valve group (8).
13 1 9M-2610 O-Ring Seal Lubricate the bore of the O-ring seals lightly with clean engine oil.
i05076331
Table 96
Specification for 378-7400 Engine Oil Cooler Gp and 4W-5891 Engine Oil Cooler Gp
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
Table 97
Specification for 124-5512 Breather Gp
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
Table 98
Specification for the 101-0838 Breather Gp
1 2 033-6031 O-Ring Seal Lubricate the bore of O-ring seals lightly with clean engine oil.
i04931607
Crankcase Breather
SMCS Code: 1317
Table 99
Specification for 394-8117 Breather Gp
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
Table 100
Specification for 394-8140 Breather Gp
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
Table 101
Specification for the 124-5513 Breather Gp and 247-4696 Breather Gp
1 4 033-6031 O-Ring Seal Lubricate the bore of O-ring seals lightly with clean engine oil.
3 4 101-4199 Cover As Seat the shoulder of 4W-1287 Adapter against the cover.
i04747489
Table 102
Specification for 7C-7185 Oil Pan Gp
7 - - As required, apply Loctite RTV Silicone Clear to the joints of the gasket.
174 RENR5057
Specifications Section
i04923806
Table 103
Specification for 7C-6887 Oil Pan Gp
7 - - As required, apply Loctite RTV Silicone Clear to the joints of the gasket.
176 RENR5057
Specifications Section
i04923815
Table 104
Specification for 7C-6752 Oil Pan Gp
7 - - As required, apply Loctite RTV Silicone Clear to the joints of the gasket.
RENR5057 179
Specifications Section
i04747511
Table 105
Specification for 7C-9938 Oil Pan Gp
7 - - As required, apply Loctite RTV Silicone Clear to the joints of the gasket.
182 RENR5057
Specifications Section
i04404603
Table 106
Specification for 8N-7706 Oil Pan Gp
Use the following procedure in order to tighten the bolts of the plate:
Lubricate the bore of nine O-ring seals lightly with the lubricant that is being
13 - -
sealed or an approved equivalent.
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.
i04891924
Table 107
Specification for 7C-4711 Oil Pan Gp, 377-5896 Oil Pan Gp, and 381-2608 Oil Pan Gp
7 - - As required, apply Loctite RTV Silicone Clear to the joints of the gasket.
RENR5057 187
Specifications Section
i04931557
Table 108
Specification for 147-3181 Oil Pan Gp
6 - - As required, apply Loctite RTV Silicone Clear to the joints of the gasket.
i04924021
Table 109
Specification for 7C-4711 Oil Pan Gp
i04908574
Table 110
Specification for 7C-7178 Oil Pan Gp
7 - - As required, apply Loctite RTV Silicone Clear to the joints of the gasket.
RENR5057 193
Specifications Section
i04404587
Table 111
Specification for 6I-4950 Water Temperature Regulator
i04907651
Table 112
Specification for 248-5513 Temperature Regulator
- - - 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
Table 113
Specification for 7C-8122 Water Lines Gp
i05210298
Thermostatic Valve
198 RENR5057
Specifications Section
Table 114
Specification for the 216-6217 Housing and Regulator Gp 292-6969 Housing and Regulator Gp 282-8537 Housing and Regulator Gp
2 2 3K-0360 O-Ring Seal Apply glycerin or an approved equivalent to the bore of the O-ring seals.
i04394778
Fan Drive
SMCS Code: 1359
Table 115
Specification for 7W-3953 Fan Drive Gp
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
Table 116
Specification for 399-4454 Fan Drive Gp
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
Table 117
Specification for 263-8038 Radiator Gp
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
Table 118
Specification for 9Y-6676 Radiator Gp
1 4 5P-0054 Joint Tighten the nut of the joint to 28.0 ± 0.5 N·m (247.8 ± 4.4 lb in).
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
Table 119
Specification for 263-8042 Radiator and Fan Gp
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
Table 120
Specification for 7W-9704 Sump Pump Gp, 7W-9703 Sump Pump Gp, and 380-3941 Sump Pump Gp
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
Table 121
Specification for 2W-9726 Water Pump Gp
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).
11 1 3D-2824 O-Ring Seal Lubricate the bore of the O-ring seals with glycerin or an approved equivalent.
i05188702
Water Pump
SMCS Code: 1361
Table 122
Specification for 2W-9729 Water Pump Gp
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.
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).
i04873610
Water Pump
SMCS Code: 1361
Table 123
Specification for 375-3658 Water Pump Gp
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.
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
Table 124
Specification for 375-3658 Water Pump Gp
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).
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
Table 125
Specification for the 9Y-8175 Auxiliary Water Pump Gp
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).
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
Table 126
Specification for the 1W-9554 Auxiliary Water Pump Gp, 5N-2605 Auxiliary Water Pump Gp, and 334-8471 Water Pump Gp
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
Table 127
Specification for 9Y-5710 Auxiliary Sea Water Pump Gp
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
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 .
7 1 8B-7614 Bearing Nut Torque to 135 to 200 N·m (100 to 148 lb ft).
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).
i04395627
Table 129
Specification for the 291-4311 Auxiliary Water Pump Gp
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).
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
Table 130
Specification for 4N-3311 Pressure Cap
i04936903
Cylinder Block
SMCS Code: 1201
Table 131
Specification for 240-6651 Cylinder Block Gp and 240-6653 Cylinder Block Gp
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).
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.
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).
Table 132
Specification for 240-6651 Cylinder Block Gp and 240-6653 Cylinder Block Gp
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
Table 133
Specification for 240-6651 Cylinder Block Gp and 240-6653 Cylinder Block Gp
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
Table 134
Specification for 237-7957 Cylinder Block Gp
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.
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).
Loose press fit between the sides of the crankshaft bearing cap and the cylinder block is
0.015 mm (0.0006 inch).
New dimension from centerline of crankshaft bearing bore to bottom of block (pan rails) is
F - -
230.00 mm (9.055 inch).
Table 135
Specification for 237-7957 Cylinder Block Gp
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
Table 136
Specification for 383-2091 Cylinder Block Gp
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.
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).
New dimension from centerline of crankshaft bearing bore to the top of the cylin-
F - -
der block is 586 mm (23.1 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
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
Table 138
Item Qty Part Specification Description
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
Table 139
Specification for 370-9890 Cylinder Block Gp
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
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).
New dimension from centerline of crankshaft bearing bore to the top of the cylin-
F - -
der block is 586 mm (23.1 inch).
Bore in the cylinder block for the main bearings is 169.742 ± 0.020 mm
H - -
(6.6827 ± 0.0008 inch).
Table 140
Specification for 370-9890 Cylinder Block Gp
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).
Table 141
Item Qty Part Specification Description
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
Table 142
Specification for 211-7826 Cylinder Block Liner, 118-9494 Cylinder Block Liner, and 350-0074 Cylinder Liner
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
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
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
Table 144
Specification for 341-3640 Piston and Rod Gp, and 371-0825 Piston
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
Table 145
Specification for 253-3066 Piston and Rod Gp
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.
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).
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).
Width of groove in piston for the new oil piston ring is 4.055 ± 0.015 mm
(0.1596 ± 0.0006 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).
i04404549
Table 146
Specification for 244-8850 Piston and Rod Gp
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.
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).
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).
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).
i05187342
Connecting Rod
SMCS Code: 1218
Table 147
Specification for 144-0725 Rod As
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).
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.
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
Table 148
Specification for 230-2516 Rod As
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.
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
Table 149
Specification for 381-6555 Rod As
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).
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).
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
Table 150
Specification for 371-0840 Connecting Rod Gp
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).
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.
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)
i05165475
Crankshaft
SMCS Code: 1202
Table 154
Specification for 101-0336 Crankshaft Gp
1 2 7C-6209 Thrust Plate Use only on the center main bearing as shown in the Illustration 177 .
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
Table 155
Specification for 8N-7103 Crankshaft Gp, 161-6926 Crankshaft Gp, and 379-4851 Crankshaft Gp
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).
i05206145
Crankshaft
SMCS Code: 1202
Table 156
Specification for 379-4855 Crankshaft Gp, 379-4852 Crankshaft Gp, and 379-4856 Crankshaft Gp
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).
i04932381
Crankshaft
SMCS Code: 1202
Table 157
Specification for 379-4857 Crankshaft Gp and 380-2695 Crankshaft Gp
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).
i05206152
Crankshaft
SMCS Code: 1202
Table 158
Specification for 375-3642 Crankshaft Gp, 379-4858 Crankshaft Gp, and 386-1487 Crankshaft Gp
1 2 7C-6209 Thrust Plate Thrust plates should be used only on center main bearing.
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
Table 159
Specification for 8N-0337 Crankshaft Gp 161-6928 Crankshaft Gp
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 .
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
Table 160
Specification for the 7W-3813 Crankshaft Seal Gp 332-7911 Crankshaft Seal Gp
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
Table 161
Specification for 107-0278 Front Housing Cover Gp
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
Table 162
Specification for 107-0278 Front Housing Cover Gp
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
Table 163
Specification for 4P-5426 Front Housing Gp
1 7 8T-6765 Pipe Plug Diameter is 1/4 inch. Length is 14.2 mm (0.56 inch).
i04888982
Housing (Front)
SMCS Code: 1162
Table 164
Specification for 381-0680 Front Housing Gp
i05188688
Table 165
Specification for 8N-7174 Front Gear Gp
4 2 259-4598 O-Ring Seal Before assembly, lightly lubricate the bores with the lubricant that is being sealed.
6 1 235-3546 O-Ring Seal Before assembly, lightly lubricate the bores with the lubricant that is being sealed.
i04452750
Table 166
Specification for 376-3358 Front Gear Gp
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
i04932634
Table 167
Specification for 380-5096 Rear Gear Gp and 380-2697 Rear Gear Gp
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.
Table 168
Item Qty Part Specification Description
i04889556
Table 169
Specification for 380-5093 Rear Gear Gp
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
Table 170
Item Qty Part Specification Description
i05187215
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
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 .
3 2 101-1368 Thrust Washer Thickness of the new thrust washer is 1.90 ± 0.10 mm (0.075 ± 0.004 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 .
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).
i04891737
Table 172
Specification for 382-4492 Rear Gear Gp
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.
Table 173
Item Qty Part Specification Description
i04397819
Table 174
Specification for 332-7916 Balancer Gp and 101-0833 Balancer Gp
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).
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
Table 175
Specification for the 7E-7647 Accessory Drive Gp 156-9812 Accessory Drive Gp
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).
6 2 7N-7539 Thrust Washer Thickness of the new thrust washer is 8.50 ± 0.05 mm (0.335 ± 0.002 inch).
i04403923
Table 176
Specification for 7N-4871 Accessory Drive Gp and 7C-0264 Accessory Drive Gp
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).
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).
4 2 7N-7539 Thrust Washer Thickness of the new thrust washer is 8.50 ± 0.05 mm (0.335 ± 0.002 inch).
i04398433
Table 177
Specification for 107-7361 Accessory Drive Gp and 334-5304 Accessory Drive Gp
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.
i04398428
Table 178
Specification for the 166-4357 Accessory Drive Gp and 334-5306 Accessory Drive Gp
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).
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).
i04398458
Flywheel
SMCS Code: 1156
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
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
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
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.
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
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
i05251255
Generator Coupling
SMCS Code: 4456
Table 182
Specification for 276-4839 Generator Installation Ar
(continued)
RENR5057 321
Specifications Section
i05251190
Generator Coupling
SMCS Code: 4456
Table 183
Specification for 344-2538 Generator Installation Ar and 252-5585 Generator Installation Ar
i05241812
Flexible Coupling
SMCS Code: 3279
Table 184
Specification for 5N-3765 Flexible Coupling Gp
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
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.
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
Table 185
Specification for 103-6226 Flexible Coupling Gp
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
Table 186
Specification for 8N-7182 Damper Gp
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
Table 187
Specification for 162-7460 Damper Gp
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).
i04403676
Vibration Damper
SMCS Code: 1205
Table 188
Specification for 174-7079 Damper Gp, 248-0197 Damper Gp, and 8N-0339 Damper Gp
The alignment mark on the damper group (2) must be aligned with the alignment mark on the adapter (1).
i04717250
Vibration Damper
SMCS Code: 1205
Table 189
Specification for 4W-0278 Damper Gp
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
Table 190
Specification for 380-8375 Damper Gp
i04906447
Vibration Damper
SMCS Code: 1205
Table 191
Specification for 4W-3113 Damper Gp
The alignment mark on damper group (2) must be aligned with the alignment mark on adapter (1).
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
Table 192
Specification for 102-8616 Damper Guard Gp and 4P-1602 Damper Guard Gp
i04403760
Table 193
Specification for 7W-6669 Damper Guard Gp
i03606360
i04459749
Table 194
Specification for 376-3360 Damper Guard Gp
i04906587
Table 195
Specification for 7N-7660 Fan Drive Gp
The alignment mark on the stub shaft (3) must be aligned with the alignment
- - -
mark on the damper adapter (1).
i04403746
Table 196
Specification for 7W-3629 Stub Shaft Gp
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
Table 197
Specification for 415-8157 Auxiliary Drive Pulley Gp
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
Table 198
Specification for 8N-8468 Auxiliary Drive Pulley Gp and 334-5309 Auxiliary Drive Pulley Gp
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
Table 199
Specification for 8N-8467 Auxiliary Drive Pulley Gp and 210-8602 Auxiliary Drive Pulley Gp
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
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
1 1 7C-7808 Lip Type Seal Lubricate the sealing lip with the lubricant that is being sealed.
350 RENR5057
Specifications Section
i05084397
Table 201
Specification for the 7N-9693 Tension Chart
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
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
Table 203
Specification for 5N-5692 Charging Alternator Gp
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)
The peak voltage for (R) terminal must not be less than the output voltage for
4 - -
(B+) terminal.
- - - Voltage is 24 V.
- - - Amperage is 45 amp.
- - - Output voltage is 28 ± 1 V.
354 RENR5057
Specifications Section
i04887991
Table 204
Specification for 333-1184 Charging Alternator Gp
Load the battery with a carbon pile 4C-4911 Battery Load Tester in order to
- - -
get the maximum alternator output.
4 - 6V-8187 Nut (B-) terminal. Torque to 6.75 ± 1.50 N·m (59.74 ± 13.28 lb in).
- - - Voltage is 24 V.
- - - Amperage is 60 amp.
i04377195
Table 205
Specification for 6N-9294 Charging Alternator Gp
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).
4 1 030-9612 Screw (B-) terminal. Torque to 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in).
- - - Voltage is 24 V.
- - - Amperage is 35 Amp.
- - - Output voltage is 28 ± 1 V.
RENR5057 357
Specifications Section
i04557209
Table 206
Specification for 4N-3986 Charging Alternator Gp
Load the battery with a carbon pile 4C-4911 Battery Load Tester in order to
- - -
get the maximum alternator output.
4 - 6V-8187 Nut (B-) terminal. Torque to 6.75 ± 1.50 N·m (59.74 ± 13.28 lb in).
- - - Voltage is 24 V.
- - - Amperage is 60 amp.
- - - Output voltage is 28 ± 1 V.
RENR5057 359
Specifications Section
i04849411
Alternator Mounting
SMCS Code: 1405
Table 207
Specification for 7E-4836 Alternator Mounting Gp and 335-4161 Alternator Mounting Gp
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.
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)
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
Table 209
Specification for 376-4005 Alternator Mounting Gp
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
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)
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
Table 211
Specification for the 207-1556 Electric Starting Motor Gp
B - - The clearance between the pinion and the housing is 9.1 mm (0.36 inch).
A maximum of three cable terminals or wire terminals may be used with the battery terminal nut (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).
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
Table 212
Specification for the 237-1962 Electric Starting Motor Gp
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).
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).
When the electric starting motor is viewed from the pinion end, the motor rotates in the clockwise
- - -
direction.
(continued)
RENR5057 367
Specifications Section
Voltage is 23 VDC.
368 RENR5057
Specifications Section
i04394042
Table 213
Specification for 6V-0927 Electric Starting Motor Gp
B - - The clearance between the pinion and the housing is 9.1 mm (0.36 inch).
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)
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
Table 214
Specification for the 207-1562 Electric Starting Motor Gp
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).
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
Table 215
Specification for 7C-0526 Electric Starting Motor Gp and 7C-0527 Electric Starting Motor Gp
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.
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).
i04399238
Table 216
Specification for 4W-5732 Air Starting Motor Gp, 335-4155 Air Starting Motor Gp, and 7C-3372 Air Starting Motor Gp
i04907197
Table 217
Specification for 1L-2073 Pressure Reducing Valve
2 - - Outlet pressure at outlet port is 621 ± 758 kPa (90 ± 110 psi).
378 RENR5057
Specifications Section
i04757411
Table 218
Specification for 2N-9768 Liquid Level Switch
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
Table 219
Specification for 3E-0264 Temperature Switch Gp
- Final installation torque for the temperature switch is 52.5 ± 7.5 N·m (38.7 ± 5.5 lb ft).
i04358589
Table 220
Specification for 274-6719 Pressure Sensor Gp
i04935269
Table 221
Specification for 161-1705 Pressure Sensor
i04921375
Table 222
Specification for 150-1240 Pressure Switch
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.
i04935270
Table 223
Specification for 204-2518 Liquid Level Sensor Gp and 239-9957 Liquid Level Sensor Gp
i04401293
Table 224
Specification for 165-6634 Coolant Level Sensor Gp
i04397599
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
i04402163
Table 226
Specification for the 161-1705 Engine Oil Pressure Sensor
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
Table 227
Specification for 130-8299 Temperature Sensor Gp, and 102-2240 Temperature Sensor Gp
i04753449
Table 228
Specification for 195-2150 Temperature Sensor Gp
i04402174
Table 229
Specification for 161-1703 Turbocharger Inlet Pressure Sensor Gp
i04415930
Table 230
Specification for 274-6717 Pressure Sensor
i04416053
Table 231
Specification for the 276-6793 Pressure Sensor Gp
i04402177
Table 232
Specification for 161-1704 Turbocharger Outlet Pressure Sensor Gp
i04753313
Table 233
Specification for 102-2240 Temperature Sensor Gp, and 118-7562 Temperature Sensor Gp
i04107829
Table 234
Specification for 102-0050 Temperature Sensor Gp
i04402182
Table 235
Specification for 102-2240 Engine Coolant Temperature Sensor Gp
i04402191
Table 236
Specification for the 163-7882 Turbocharger Exhaust Temperature Sensor Gp and 261-6848 Turbocharger Exhaust Temperature
Sensor Gp
Apply 4C-5599 Anti-Seize Compound to the threads of the adapter (1) before installation.
i04753129
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
i04402215
Table 238
Specification for the 273-5041 Engine Speed / Timing Sensor Gp
i04403710
Table 239
Specification for 129-6628 Speed Sensor Gp
Operating voltage is 12 to 14 V.
420 RENR5057
Specifications Section
i04402240
Table 240
Specification for 161-1703 Crankcase Pressure Sensor Gp
i04928541
Table 241
Specification for 306-6834 Pressure Sensor Gp, 274-6717 Pressure Sensor and 305-6873 Pressure Sensor Gp
1 - - Final installation torque for the sensor group is 10 ± 2 N·m (89 ± 18 lb in).
i04402249
Table 242
Specification for the 161-1703 Atmospheric Pressure Sensor Gp
i04397550
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
i04402277
Table 244
Specification for the 189-5746 Engine Speed Sensor Gp and 116-6680 Engine Speed Sensor
i04707610
Table 245
Specification for 318-1181 Speed Sensor Gp
i04888979
Thermocouple
432 RENR5057
Specifications Section
Table 246
Specification for the 120-4498 Thermocouple Gp
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
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