Specifications 3500C Marine Engine

KENR5402-07
March 2010
Specifications
3500C Marine Engines
TTA1-Up (Engine)
TTB1-Up (Engine)
M8C1-Up (Engine)
TTC1-Up (Engine)
M8D1-Up (Engine)
TTD1-Up (Engine)
TTE1-Up (Engine)
PAF1-Up (Engine)
TTF1-Up (Engine)
TTG1-Up (Engine)
TTH1-Up (Engine)
TTJ1-Up (Engine)
SLM1-Up (Engine)
JTS1-Up (Engine)
E3W1-Up (Engine)
E3X1-Up (Engine)
E3Y1-Up (Engine)
E3Z1-Up (Engine)
SAFETY.CAT.COM
i03684547
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
KENR5402-07 3
Table of Contents
Table of Contents Engine Oil Pump .................................................. 58

Engine Oil Pump .................................................. 60
Engine Oil Scavenge Pump ................................. 61
Engine Oil Scavenge Pump ................................. 63
Specifications Section Engine Oil Cooler Bypass and Cooling Jet Sequence
Valves ................................................................. 66
Engine Design ....................................................... 5
Engine Oil Cooler Bypass and Cooling Jet Sequence
Engine Design ....................................................... 5
Valves ................................................................. 67
Engine Design ....................................................... 6
Engine Oil Filter ................................................... 69
Engine Design ....................................................... 6
Crankcase Breather ............................................. 70
Engine Design ....................................................... 7
Fuel Filter (Primary) ................................................ 7
Fuel Pressure Regulator ........................................ 8
Engine Oil Pan ..................................................... 74
Fuel Transfer Pump ............................................... 8
Engine Oil Pan ..................................................... 76
Fuel Transfer Pump ............................................... 9
Water Temperature Regulator .............................. 77
Fuel Injector Mechanism ....................................... 10
Water Temperature Regulator .............................. 78
Fuel Injector Mechanism ........................................ 11
Thermostatic Valve .............................................. 78
Fuel Injector .......................................................... 12
Water Pump ......................................................... 79
Camshaft ............................................................. 13
Auxiliary Water Pump .......................................... 81
Camshaft ............................................................. 14
Camshaft ............................................................. 15
Camshaft ............................................................. 16
Auxiliary Water Pump (Sea Water) ....................... 86
Valve Mechanism ................................................. 17
Cylinder Head ...................................................... 18
Cylinder Block ...................................................... 89
Cylinder Head Valves ........................................... 19
Cylinder Block ...................................................... 91
Turbocharger ........................................................ 21
Cylinder Block ...................................................... 92
Turbocharger ........................................................ 22
Cylinder Liner ....................................................... 93
Turbocharger ........................................................ 23
Piston and Rings (One-Piece Piston) ................... 94
Turbocharger ........................................................ 24
Piston and Rings (Two-Piece Piston) ................... 96
Turbocharger ........................................................ 25
Piston and Rings (Two-Piece Piston) ................... 98
Turbocharger ........................................................ 25
Connecting Rod ................................................... 99
Exhaust Bypass Valve ......................................... 25
Connecting Rod ................................................. 100
Exhaust Bypass Valve ......................................... 26
Connecting Rod and Main Bearing Journals ...... 102
Exhaust Manifold ................................................. 27
Crankshaft ......................................................... 103
Crankshaft ......................................................... 105
Crankshaft ......................................................... 106
Crankshaft Wear Sleeves and Seals ................. 107
Housing (Front) ................................................... 108
Housing (Front) ................................................... 109
Gear Group (Front) (Reverse Rotation) ............... 110
Gear Group (Front) (Reverse Rotation) ............... 112
Gear Group (Front) .............................................. 114
Gear Group (Front) .............................................. 115
Gear Group (Rear) ............................................... 116
Balancer Group (Front) ....................................... 117
Accessory Drive .................................................. 118
Accessory Drive ................................................. 120
Accessory Drive (Lower Left Hand) .................... 121
Exhaust Flange .................................................... 41
Accessory Drive (Lower Left Hand) .................... 122
Exhaust Flange .................................................... 42
Accessory Drive (Upper Right Hand) .................. 123
Exhaust Flange .................................................... 42
Exhaust Flange .................................................... 43
Air Cleaner ........................................................... 43
Accessory Drive (Upper Left Hand) .................... 127
Air Cleaner Adapter .............................................. 44
Accessory Drive (Upper Left Hand, Reverse
Air Cleaner Adapter .............................................. 44
Rotation) ........................................................... 129
Air Inlet and Exhaust Lines ................................... 45
Accessory Drive (Upper Left Hand, Reverse
Rotation) ........................................................... 130
Accessory Drive (Lower Left Hand, Reverse
Rotation) ........................................................... 130
Flywheel ............................................................. 131
Engine Oil Pump .................................................. 52
Flywheel Housing .............................................. 132
Engine Oil Pump .................................................. 54
Engine Oil Pump .................................................. 56
4 KENR5402-07
Table of Contents
Vibration Damper ............................................... 136

Vibration Damper Guard .................................... 140
Stub Shaft (Front) ............................................... 142
Stub Shaft (Front) ............................................... 143
Stub Shaft (Front) ............................................... 144
Alternator and Regulator .................................... 144
Alternator Mounting ........................................... 147
Electric Starting Motor ....................................... 148
Electric Starting Motor ....................................... 149
Fuel Pressure Sensor ........................................ 150
Coolant Level Sensor ......................................... 152
Coolant Level Sensor ......................................... 152
Engine Oil Pressure Sensor ............................... 152
Turbocharger Inlet Pressure Sensor ................... 153
Turbocharger Inlet Pressure Sensor ................... 153
Turbocharger Outlet Pressure Sensor ................ 154
Aftercooler Coolant Temperature Sensor ........... 154
Aftercooler Coolant Temperature Sensor ........... 154
Engine Coolant Temperature Sensor .................. 154
Engine Coolant Temperature Sensor .................. 155
Turbocharger Exhaust Temperature Sensor ....... 155
Engine Speed/Timing Sensor ............................. 156
Crankcase Pressure Sensor ............................... 156
Atmospheric Pressure Sensor ............................ 157
Atmospheric Pressure Sensor ............................ 157
Engine Speed Sensor ......................................... 157
Index Section
Index ................................................................... 158
KENR5402-07 5
Specifications Section
Specifications Section Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right side
of the engine are determined from the flywheel end.
i02414042 The number 1 cylinder is the front cylinder on the
right side. The number 2 cylinder is the front cylinder
Engine Design on the left side.
SMCS Code: 1000
i02728441
S/N: TTA1-Up
Engine Design
S/N: TTB1-Up
SMCS Code: 1000
S/N: M8C1-Up
S/N: TTE1-Up
S/N: M8D1-Up
S/N: TTF1-Up
S/N: TTG1-Up
S/N: SLM1-Up
g00293348
Illustration 1
Cylinder and valve location
(A) Inlet valves
(B) Exhaust valves
g00293349
Illustration 2
Number and arrangement of
cylinders .............................................. 60 degree V-8
(A) Inlet valves
(B) Exhaust valves
Valves per cylinder .................................................. 4
Displacement .............................. 34.5 L (2105 cu in) Number and arrangement of

cylinders ............................................ 60 degree V-12
Bore ............................................. 170 mm (6.7 inch)
Stroke .......................................... 190 mm (7.5 inch)
Displacement .............................. 58.5 L (3570 cu in)
Compression ratio ........................................... 14.7:1
Bore ............................................. 170 mm (6.7 inch)
Combustion ........................................ Direct injection
Stroke .......................................... 215 mm (8.5 inch)
When the crankshaft is viewed from the flywheel
end the crankshaft rotates in the following Compression ratio ........................................... 14.7:1
direction. ....................................... Counterclockwise
Firing order (injection sequence)
Standard rotation CCW ............... 1, 2, 7, 3, 4, 5, 6, 8 end the crankshaft rotates in the following
Valve lash
Firing order (injection sequence)
Inlet ......................................... 0.50 mm (0.020 inch)
Standard rotation
Exhaust ................................... 1.00 mm (0.040 inch) CCW ...................... 1, 2, 9, 10, 5, 6, 11, 12, 3, 4, 7, 8
6 KENR5402-07
Valve lash Firing order (injection sequence)
Inlet ......................................... 0.50 mm (0.020 inch) Standard rotation

CCW ...................... 1, 2, 9, 10, 5, 6, 11, 12, 3, 4, 7, 8
Exhaust ................................... 1.00 mm (0.040 inch)
Valve lash
Note: The front end of the engine is opposite the
flywheel end of the engine. The left and the right side Inlet ......................................... 0.50 mm (0.020 inch)
The number 1 cylinder is the front cylinder on the Exhaust ................................... 1.00 mm (0.040 inch)
on the left side. Note: The front end of the engine is opposite the
i02728442
The number 1 cylinder is the front cylinder on the
Engine Design right side. The number 2 cylinder is the front cylinder
on the left side.
SMCS Code: 1000
i02415900
S/N: TTC1-Up
S/N: E3W1-Up Engine Design
S/N: E3X1-Up SMCS Code: 1000
S/N: E3Y1-Up S/N: PAF1-Up

S/N: TTH1-Up
S/N: TTJ1-Up
S/N: JTS1-Up
g00293349
Illustration 3
(A) Inlet valves
(B) Exhaust valves
g00294285
Number and arrangement of Illustration 4
cylinders ............................................ 60 degree V-12 Cylinder and valve location
(A) Inlet valves
Valves per cylinder .................................................. 4 (B) Exhaust valves
Displacement .............................. 51.8 L (3158 cu in) Number and arrangement of

Bore ............................................. 170 mm (6.7 inch)
Stroke .......................................... 190 mm (7.5 inch)
Displacement .............................. 78.0 L (4760 cu in)
Compression ratio ........................................... 14.7:1
Bore ............................................. 170 mm (6.7 inch)
Stroke .......................................... 215 mm (8.5 inch)
end the crankshaft rotates in the following Compression ratio ........................................... 14.7:1
KENR5402-07 7
Combustion ........................................ Direct injection Compression ratio ........................................... 14.7:1
When the crankshaft is viewed from the flywheel Combustion ........................................ Direct injection
end the crankshaft rotates in the following
direction. ....................................... Counterclockwise When the crankshaft is viewed from the flywheel
end the crankshaft rotates in the following
Firing order (injection sequence) direction. ....................................... Counterclockwise
Standard rotation Firing order (injection sequence)

CCW .. 1, 2, 5, 6, 3, 4, 9, 10, 15, 16, 11, 12, 13, 14, 7, 8
Standard rotation
Valve lash CCW .. 1, 2, 5, 6, 3, 4, 9, 10, 15, 16, 11, 12, 13, 14, 7, 8
Inlet ......................................... 0.50 mm (0.020 inch) Valve lash
Exhaust ................................... 1.00 mm (0.040 inch) Inlet ......................................... 0.50 mm (0.020 inch)
Note: The front end of the engine is opposite the Exhaust ................................... 1.00 mm (0.040 inch)
of the engine are determined from the flywheel end. Note: The front end of the engine is opposite the
The number 1 cylinder is the front cylinder on the flywheel end of the engine. The left and the right side
right side. The number 2 cylinder is the front cylinder of the engine are determined from the flywheel end.
on the left side. The number 1 cylinder is the front cylinder on the
on the left side.
i02415764
Engine Design i03657840
SMCS Code: 1000 Fuel Filter (Primary)

S/N: TTD1-Up SMCS Code: 1260
S/N: E3Z1-Up Part No.: 8N-6435
g00294285 g01561538
Illustration 5 Illustration 6
(A) Inlet valves (1) Torque for the nut ..... 25 ± 5 N·m (221 ± 44 lb in)
(B) Exhaust valves
(2) Lubricate the bore and the shaft of the O-ring
Number and arrangement of seal lightly with the clean engine oil.
(3) 7S-9323 Spring
Length under test force ... 27.94 mm (1.100 inch)
Displacement .............................. 69.1 L (4210 cu in) Test force ............... 27.7 to 32.3 N (6.2 to 7.3 lb)
Free length after test ...... 42.67 mm (1.680 inch)
Bore ............................................. 170 mm (6.7 inch) Outside diameter ............ 17.32 mm (0.682 inch)
Stroke .......................................... 190 mm (7.5 inch)

8 KENR5402-07
i02723705 Part No.: 8N-6151

S/N: TTG1-Up
Fuel Pressure Regulator
Part No.: 8N-6151
SMCS Code: 1277 S/N: TTH1-Up
Part No.: 114-5477 Part No.: 8N-6151
S/N: TTJ1-Up
Part No.: 8N-6151
S/N: SLM1-Up
Part No.: 8N-6151
S/N: JTS1-Up
Part No.: 8N-6151
S/N: E3W1-Up
Part No.: 8N-6151
S/N: E3X1-Up
Part No.: 8N-6151
S/N: E3Y1-Up
g01366239
Illustration 7
Part No.: 8N-6151
Typical example S/N: E3Z1-Up
(1) Fuel manifold adapter
(3) Valve plunger
(2) 9N-4053 Spring

Length under test force ....... 28.5 mm (1.12 inch)
Test force .................... 40.8 ± 2.1 N (9.2 ± 0.5 lb)
Free length after test force .. 57.2 mm (2.25 inch)
Outside diameter ............ 15.24 mm (0.600 inch)
i03229222
Fuel Transfer Pump

SMCS Code: 1256
Part No.: 8N-6151
S/N: TTA1-Up
Part No.: 8N-6151
S/N: TTB1-Up
Part No.: 332-7928
S/N: M8C1-Up
Part No.: 8N-6151
S/N: TTC1-Up
Part No.: 332-7928
S/N: M8D1-Up g01641861
Illustration 8
Part No.: 8N-6151 (3) Check valve
S/N: TTD1-Up
When the fuel transfer pump group is viewed from
Part No.: 8N-6151 the drive end, the drive gear rotates in the clockwise
S/N: TTE1-Up direction.
Part No.: 8N-6151
S/N: PAF1-Up Minimum output .................... 21 L/min (5.5 US gpm)
Part No.: 8N-6151 Minimum output is attained under the following

S/N: TTF1-Up conditions:
KENR5402-07 9
Pump pressure ............................... 415 kPa (60 psi) i03147530
Pump speed ............................................... 2400 rpm Fuel Transfer Pump

Minimum cracking pressure of bypass SMCS Code: 1256
valve ............................................... 620 kPa (90 psi)
Part No.: 207-1349
S/N: PAF1-Up
Maximum pressure of fully open bypass
valve ............................................. 965 kPa (140 psi) Part No.: 207-1349
S/N: TTJ1-Up
(1) Dimensions for terminal bushing
Part No.: 207-1349
Inside diameter of the terminal bushing for gear S/N: JTS1-Up
shaft ............................ 12.783 mm (0.5033 inch)
Installation depth of terminal
bushing ............. 1.5 ± 0.5 mm (0.06 ± 0.02 inch)
(2) Dimensions for drive shaft assembly

Diameter of the shaft ........ 12.700 to 12.675 mm
(0.5000 to 0.4990 inch)
Diameter of the gear ............ 29.801 ± 0.006 mm
(1.1733 ± 0.0002 inch)
Length of the gear ............... 25.347 ± 0.008 mm
(0.9979 ± 0.0003 inch)
(4) Dimensions for idler gear assembly

(1.1733 ± 0.0002 inch)
(0.9979 ± 0.0003 inch)
g01641857
Illustration 9
(3) Check valve
When the fuel transfer pump group is viewed from

the drive end, the drive gear rotates in the clockwise
direction.
Minimum output .................... 28 L/min (7.4 US gpm)
Minimum output is attained under the following

conditions:
Pump pressure ............................... 415 kPa (60 psi)
Pump speed ............................................... 2400 rpm
Minimum cracking pressure of bypass

valve ............................................... 620 kPa (90 psi)
Maximum pressure of fully open bypass

valve ............................................. 965 kPa (140 psi)
10 KENR5402-07
(1) Dimensions for terminal bushing Part No.: 224-9869

S/N: SLM1-Up
Inside diameter of the terminal
bushing ....................... 12.783 mm (0.5033 inch) Part No.: 224-9869
Installation depth of terminal S/N: JTS1-Up
bushing ............. 1.5 ± 0.5 mm (0.06 ± 0.02 inch)
Part No.: 224-9869
(2) Dimensions for drive shaft assembly S/N: E3W1-Up
Diameter of the shaft ........ 12.700 to 12.675 mm Part No.: 224-9869

(0.5000 to 0.4990 inch) S/N: E3X1-Up
Diameter of the gear ............ 29.801 ± 0.006 mm Part No.: 224-9869

(1.1733 ± 0.0002 inch) S/N: E3Y1-Up
Length of the gear ............... 35.347 ± 0.008 mm Part No.: 224-9869

(1.3916 ± 0.0003 inch) S/N: E3Z1-Up
(4) Dimensions for idler gear assembly

(1.1733 ± 0.0002 inch)
(1.3916 ± 0.0003 inch)
i03601019
Fuel Injector Mechanism

SMCS Code: 1102; 1290
Part No.: 224-9869
S/N: TTA1-Up
Part No.: 224-9869
S/N: TTB1-Up
Part No.: 332-9690
S/N: M8C1-Up
g01441231
Illustration 10
Part No.: 224-9869 (3) Timing pin
S/N: TTC1-Up
Part No.: 332-9690 (A) Bore in the sleeve bearing for the rocker arm
S/N: M8D1-Up shaft after installation ........... 45.077 ± 0.015 mm
(1.7747 ± 0.0006 inch)
Part No.: 224-9869
S/N: TTD1-Up (1) Torque for the nut .... 120 ± 15 N·m (88 ± 11 lb ft)
Part No.: 224-9869 (B) Diameter of the rocker arm
S/N: TTE1-Up shaft ..................................... 45.000 ± 0.013 mm
(1.7716 ± 0.0005 inch)
Part No.: 224-9869
S/N: PAF1-Up
(2) 100-3878 Injector Spring
Part No.: 224-9869
Length under test force ... 85.00 mm (3.346 inch)
S/N: TTF1-Up
Test force .......................... 300 ± 25 N (67 ± 6 lb)
Part No.: 224-9869 Free length after test ...... 87.65 mm (3.451 inch)
S/N: TTG1-Up Outside diameter ............ 43.85 mm (1.726 inch)
Part No.: 224-9869 (C) Dimensions for the unit injector lifter assembly
S/N: TTH1-Up
Diameter of the unit injector lifter
Part No.: 224-9869 assembly ............................. 34.950 ± 0.010 mm
S/N: TTJ1-Up (1.3760 ± 0.0004 inch)
KENR5402-07 11
Bore in the head for the unit injector lifter Part No.: 281-6160
assembly ............................. 35.000 ± 0.025 mm S/N: TTJ1-Up
(1.3779 ± 0.0010 inch)
Part No.: 281-6160, 308-5356
S/N: SLM1-Up
Part No.: 281-6160
S/N: JTS1-Up
Part No.: 308-5356
S/N: E3W1-Up
Part No.: 308-5356
S/N: E3X1-Up
Part No.: 308-5356
S/N: E3Y1-Up
g01925693
Illustration 11
(4) Lubricate the bore of the O-ring seal lightly with

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

assembly by hand so that the terminal studs are not
cross threaded.
(5) Torque for the retainer nuts of the cap

assembly ............................... 2.500 ± 0.025 N·m
(22.127 ± 0.221 lb in)
(6) Apply 5P-3413 Pipe Sealant to the threads of

the bolts, if the bolts are removed after initial
installation.
i02895028
Fuel Injector Mechanism Illustration 12

g01441231
(3) Timing pin

SMCS Code: 1102; 1290
(A) Bore in the sleeve bearing for the rocker arm shaft
Part No.: 281-6160 assembly after installation ... 45.077 ± 0.015 mm
S/N: TTA1-Up (1.7747 ± 0.0006 inch)
Part No.: 281-6160
S/N: TTB1-Up (1) Torque for the nut .... 120 ± 15 N·m (90 ± 11 lb ft)
Part No.: 281-6160, 308-5356 (B) Diameter of the rocker arm

S/N: TTC1-Up shaft ..................................... 45.000 ± 0.013 mm
(1.7716 ± 0.0005 inch)
Part No.: 281-6160
S/N: TTD1-Up (2) 100-3878 Injector Spring
Part No.: 281-6160, 308-5356 Length under test force ... 85.00 mm (3.346 inch)
S/N: TTE1-Up Test force .................... 300 ± 25 N (67.4 ± 5.6 lb)
Free length after test ...... 87.65 mm (3.451 inch)
Part No.: 281-6160, 308-5356 Outside diameter ............ 43.85 mm (1.726 inch)
S/N: TTF1-Up
Part No.: 281-6160, 308-5356 (C) Dimensions for the unit injector lifter assembly
S/N: TTG1-Up Diameter of the unit injector lifter
S/N: TTH1-Up (1.3760 ± 0.0004 inch)
12 KENR5402-07
Bore in the head for the unit injector lifter Part No.: 231-7845, 248-8695
assembly ............................. 35.000 ± 0.025 mm S/N: TTH1-Up
(1.3779 ± 0.0010 inch)
Part No.: 253-2636
S/N: TTJ1-Up
Part No.: 274-0054
S/N: SLM1-Up
Part No.: 274-0054
S/N: JTS1-Up
Part No.: 274-0053
S/N: E3W1-Up
Part No.: 274-0053, 282-6903
S/N: E3X1-Up
Part No.: 274-0053
g01441136 S/N: E3Y1-Up
Illustration 13
Part No.: 274-0053, 304-1048
(4) Lubricate the bore of the O-ring seal lightly with S/N: E3Z1-Up
clean engine oil.
Note: Start the retainer nuts of the cap assembly

by hand so that the terminal studs are not cross
threaded.
(5) Torque for the cap assembly ..... 2.50 ± 0.25 N·m
(22 ± 2 lb in)
i02895694
Fuel Injector
SMCS Code: 1290
Part No.: 282-6903, 304-1048
S/N: TTA1-Up
Part No.: 274-0053
S/N: TTB1-Up
Part No.: 333-8959
S/N: M8C1-Up g01441567
Illustration 14
Part No.: 274-0053 Note: Prior to installation of the fuel injector group,
S/N: TTC1-Up lubricate the bore in the cylinder head with 1P-0808
Part No.: 333-8965 Multipurpose Grease. Use the clamp to press the
S/N: M8D1-Up injector into the bore. Do not tap on the top surface
of the injector.
Part No.: 274-0053
S/N: TTD1-Up (1) Torque for the bolt .......... 65 ± 7 N·m (48 ± 5 lb ft)
Part No.: 282-6903 (A) Timing dimension .................... 64.34 ± 0.20 mm
S/N: TTE1-Up (2.533 ± 0.008 inch)
Part No.: 231-7845
Note: Before assembly, lubricate the bore and
S/N: PAF1-Up
the threads of valve assembly (2) with 1P-0808
Part No.: 248-8695 Multipurpose Grease.
S/N: TTF1-Up
(2) Valve assembly
Part No.: 253-2636
S/N: TTG1-Up Torque for valve assembly ............. 165 ± 10 N·m
(120 ± 7 lb ft)
KENR5402-07 13
Torque for terminal nuts ................. 2.4 ± 0.2 N·m

(21 ± 2 lb in)
(3) Torque for unit injector nozzle ........ 310 ± 20 N·m

(230 ± 15 lb ft)
i02945981
Camshaft
SMCS Code: 1210
Part No.: 261-4683
S/N: TTA1-Up
Part No.: 333-2238
S/N: M8C1-Up
g01460128
Illustration 16
(E) Specified camshaft lobe lift

Inlet lobe ......................... 13.25 mm (0.522 inch)
Injector lobe ............ 13.8065 mm (0.54356 inch)
Exhaust lobe ................... 13.25 mm (0.522 inch)
Use the following procedure in order to determine the

actual camshaft lobe lift:
g01460173
Illustration 15 1. Measure camshaft lobe height (F).
(1) Left hand camshaft assembly
(2) Right hand camshaft assembly 2. Measure base circle (G).
(A) Thickness of the groove for thrust washer in a 3. Subtract the base circle (G) from the camshaft
new camshaft assembly ............ 8.75 ± 0.05 mm lobe height (F). The difference is the actual
(0.344 ± 0.002 inch) camshaft lobe lift.
(B) Extension of the dowel from the camshaft
assembly ........ 12.0 ± 0.5 mm (0.47 ± 0.02 inch)
(C) Thickness of a new thrust

washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)
(D) Dimensions for the journal surface

Diameter of bearing journal ..... 91.88 ± 0.02 mm
(3.617 ± 0.001 inch)
Bore in camshaft bearing after
installation ................................ 92.00 ± 0.06 mm
(3.622 ± 0.002 inch)
Note: End play for a new camshaft assembly is

0.15 to 0.35 mm (0.006 to 0.014 inch).
14 KENR5402-07
i02990771
Camshaft
SMCS Code: 1210
Part No.: 106-4582
S/N: TTB1-Up
Part No.: 332-7923
S/N: M8D1-Up
g01460128
Illustration 18
(E) Specified camshaft lobe lift
Illustration 17
g01515757 Inlet lobe ................. 12.7500 mm (0.50197 inch)
(1) Left hand camshaft assembly Injector lobe ............ 13.7313 mm (0.54060 inch)
(2) Right hand camshaft assembly Exhaust lobe ........... 13.2500 mm (0.52165 inch)
(A) Thickness of the groove for thrust washer in a Use the following procedure in order to determine the
new camshaft assembly ............ 8.75 ± 0.05 mm actual camshaft lobe lift:
(0.344 ± 0.002 inch)
1. Measure camshaft lobe height (F).
(B) Extension of the dowel from the camshaft
assembly ........ 12.0 ± 0.5 mm (0.47 ± 0.02 inch) 2. Measure base circle (G).
(C) Thickness of a new thrust 3. Subtract the base circle (G) from the camshaft
washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch) lobe height (F). The difference is the actual
camshaft lobe lift.
(D) Dimensions for the journal surface
Diameter of bearing journal ..... 91.88 ± 0.02 mm i02758767
(3.617 ± 0.001 inch)
Camshaft
installation ................................ 92.00 ± 0.06 mm
SMCS Code: 1210
(3.622 ± 0.002 inch)
Part No.: 273-5712, 308-5361
Note: End play for a new camshaft assembly is S/N: TTC1-Up
0.15 to 0.35 mm (0.006 to 0.014 inch).
Part No.: 273-5713
S/N: TTD1-Up
Part No.: 273-5712
S/N: TTE1-Up
Part No.: 273-5713
S/N: PAF1-Up
Part No.: 273-5712, 308-5361
S/N: TTF1-Up
Part No.: 273-5712, 308-5361
S/N: TTG1-Up
KENR5402-07 15
Part No.: 273-5713 (F) Extension of the dowel from the end of the
S/N: TTH1-Up rear right hand camshaft and the front left hand
camshaft ......... 22.0 ± 0.5 mm (0.87 ± 0.02 inch)
Part No.: 273-5713
S/N: TTJ1-Up
Part No.: 273-5712, 308-5361
S/N: SLM1-Up
Part No.: 273-5713
S/N: JTS1-Up
Part No.: 308-5361
S/N: E3W1-Up
Part No.: 308-5361
S/N: E3Y1-Up
g01447245
Illustration 20

1. Measure camshaft lobe height (H).
2. Measure base circle (J).
3. Subtract the base circle (J) from the camshaft lobe

height (H). The difference is the actual camshaft
lobe lift.
g01381231
Illustration 19
(G) Specified camshaft lobe lift
(2) Right hand camshaft assembly Inlet lobe .................. 12.7300 mm (0.50118 inch)
(A) Thickness of the groove in a new camshaft Exhaust lobe ........... 13.1000 mm (0.51575 inch)
assembly .. 8.75 ± 0.05 mm (0.344 ± 0.002 inch)
(C) Extension of the dowel from the camshaft

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

washer ...... 8.40 ± 0.05 mm (0.331 ± 0.002 inch)
(E) Dimensions for the journal surface

Diameter of bearing journal ..... 91.88 ± 0.02 mm
(3.617 ± 0.001 inch)
installation ................................ 92.00 ± 0.06 mm
(3.622 ± 0.002 inch)
Note: End play for a new camshaft assembly is

0.15 to 0.35 mm (0.006 to 0.014 inch).
(3) Torque for the 16 bolts ... 55 ± 7 N·m (41 ± 5 lb ft)

16 KENR5402-07
i02945150 (F) Extension of the dowel from the end of the

rear right hand camshaft and the front left hand
Camshaft camshaft ......... 22.0 ± 0.5 mm (0.87 ± 0.02 inch)
SMCS Code: 1210
Part No.: 308-5360
S/N: TTE1-Up
Part No.: 308-5360
S/N: E3X1-Up
Part No.: 337-9956
S/N: E3Z1-Up
g01447245
Illustration 22
(G) Specified camshaft lobe lift

Inlet lobe ................. 13.2500 mm (0.52165 inch)
Exhaust lobe ........... 13.2500 mm (0.52165 inch)

g01381231
Illustration 21
1. Measure camshaft lobe height (H).
(2) Right hand camshaft assembly
2. Measure base circle (J).
(A) Thickness of the groove for thrust washer in a
new camshaft assembly ............ 8.75 ± 0.05 mm 3. Subtract the base circle (J) from the camshaft lobe
(0.344 ± 0.002 inch) height (H). The difference is the actual camshaft
lobe lift.
(C) Extension of the dowel from the camshaft
assembly ........ 12.0 ± 0.5 mm (0.47 ± 0.02 inch)
i03577164
(D) Thickness of a new thrust Valve Mechanism

washer ...... 8.40 ± 0.05 mm (0.331 ± 0.002 inch)
SMCS Code: 1102
(E) Dimensions for the journal surface
Part No.: 224-9869, 281-6160
Diameter of bearing journal ..... 91.88 ± 0.02 mm S/N: TTA1-Up
(3.617 ± 0.001 inch)
Bore in camshaft bearing after Part No.: 224-9869, 281-6160
installation ................................ 92.00 ± 0.06 mm S/N: TTB1-Up
(3.622 ± 0.002 inch)
Part No.: 332-9690
Note: End play for a new camshaft assembly is S/N: M8C1-Up
0.15 to 0.35 mm (0.006 to 0.014 inch). Part No.: 224-9869, 281-6160, 308-5356
S/N: TTC1-Up
(3) Torque for 16 bolts ......... 55 ± 7 N·m (41 ± 5 lb ft)
Part No.: 332-9690
S/N: M8D1-Up
KENR5402-07 17
Part No.: 224-9869, 281-6160

S/N: TTD1-Up
Part No.: 224-9869, 281-6160, 308-5356
S/N: TTE1-Up
Part No.: 224-9869
S/N: PAF1-Up
Part No.: 224-9869, 281-6160, 308-5356
S/N: TTF1-Up
Part No.: 224-9869, 281-6160, 308-5356
S/N: TTG1-Up
Part No.: 224-9869, 281-6160
S/N: TTH1-Up
Part No.: 224-9869, 281-6160
S/N: TTJ1-Up
Part No.: 224-9869, 281-6160, 308-5356
S/N: SLM1-Up
Part No.: 224-9869, 281-6160
S/N: JTS1-Up
Part No.: 224-9869, 308-5356
S/N: E3W1-Up
Part No.: 224-9869, 308-5356 g01905795
Illustration 23
S/N: E3X1-Up
Part No.: 224-9869, 308-5356 Refer to Guideline for Reusable Parts and Salvage
S/N: E3Y1-Up Operations, SEBF8172, “Visual Inspection of the
7N-4782 Lifter Guide Spring − 3500 Family of
Part No.: 224-9869 Engines” for lifter guide spring (2).
S/N: E3Z1-Up
(1) Torque for two jam nuts ................... 70 ± 15 N·m
(52 ± 11 lb ft)
(A) Diameter of the rocker arm shaft

assembly ............................. 45.000 ± 0.013 mm
(1.7716 ± 0.0005 inch)
(B) Dimensions for the valve lash

Inlet ................................... 0.50 mm (0.020 inch)
Exhaust ............................. 1.00 mm (0.039 inch)
(C) Bore in the sleeve bearing for the rocker arm shaft
assembly after installation ... 45.077 ± 0.015 mm
(1.7747 ± 0.0006 inch)
(D) Dimensions for the valve lifter assembly

Diameter of the valve lifter
assembly ............................. 29.900 ± 0.010 mm
(1.1772 ± 0.0004 inch)
Bore in the head for the valve lifter
assembly ............................. 30.000 ± 0.025 mm
(1.1811 ± 0.0010 inch)
18 KENR5402-07
i03076672
Cylinder Head
SMCS Code: 1100
Part No.: 101-0830, 299-3521
S/N: TTA1-Up
Part No.: 101-0830, 299-3521
S/N: TTB1-Up
Part No.: 101-0830, 332-9693
S/N: M8C1-Up
Part No.: 101-0830, 299-3521
g01429899
S/N: TTC1-Up Illustration 24
Typical example
Part No.: 101-0830, 332-9693
S/N: M8D1-Up (1) Locating pad
Part No.: 101-0830, 299-3521 NOTICE

S/N: TTD1-Up The pipe plug at location (2) is installed in the cylinder
Part No.: 101-0830, 299-3521 head for engines with dry exhaust manifolds. If the
S/N: TTE1-Up pipe plug is not installed into the water passage, the
coolant will leak and engine damage will result. For
Part No.: 101-0830 engines with dry exhaust manifolds, make sure that
S/N: PAF1-Up the pipe plug is installed.
Part No.: 101-0830, 299-3521

S/N: TTF1-Up
Part No.: 101-0830, 299-3521
S/N: TTG1-Up
Part No.: 101-0830, 299-3521
S/N: TTH1-Up
Part No.: 101-0830, 299-3521
S/N: TTJ1-Up
Part No.: 101-0830, 299-3521
S/N: SLM1-Up
Part No.: 101-0830, 299-3521
S/N: JTS1-Up
Part No.: 101-0830, 299-3521
S/N: E3W1-Up
Part No.: 101-0830, 299-3521
S/N: E3X1-Up
g01611158
Illustration 25
Part No.: 101-0830, 299-3521 Typical example
S/N: E3Y1-Up
Top view
Part No.: 101-0830, 299-3521
S/N: E3Z1-Up (3) Before assembly, lubricate the thread of the pipe
plug.
Use the following procedure to tighten the bolts of the

cylinder head that is shown in Illustration 25:
Note: Before assembly, coat the threads of the bolt

with clean engine oil.
KENR5402-07 19
1. Tighten the bolt 1 through bolt 8 in the numerical Part No.: 101-0830, 299-3521
sequence to 30 ± 5 N·m (22 ± 4 lb ft). S/N: TTA1-Up
2. Tighten the bolt 1 through bolt 8 in the numerical Part No.: 101-0830, 299-3521
sequence to 200 ± 15 N·m (150 ± 11 lb ft). S/N: TTB1-Up
Part No.: 101-0830, 332-9693
3. Again tighten the bolt 1 through bolt 8 in
S/N: M8C1-Up
the numerical sequence to 200 ± 15 N·m
(150 ± 11 lb ft). Part No.: 101-0830, 299-3521
S/N: TTC1-Up
4. Turn the bolt 1 through bolt 8 in the numerical
sequence to an additional rotation of 180 ± 5 Part No.: 101-0830, 332-9693
degrees. S/N: M8D1-Up
Note: Tighten the bolts (4) only after the cylinder Part No.: 101-0830, 299-3521
head bolts have been given final torque. S/N: TTD1-Up
Part No.: 101-0830, 299-3521
(4) Torque for two bolts ..... 55 ± 10 N·m (41 ± 7 lb ft) S/N: TTE1-Up
Part No.: 101-0830
S/N: PAF1-Up
Part No.: 101-0830, 299-3521
S/N: TTF1-Up
Part No.: 101-0830, 299-3521
S/N: TTG1-Up
Part No.: 101-0830, 299-3521
S/N: TTH1-Up
Part No.: 101-0830, 299-3521
S/N: TTJ1-Up
Part No.: 101-0830, 299-3521
S/N: SLM1-Up
Part No.: 101-0830, 299-3521
S/N: JTS1-Up
Part No.: 101-0830, 299-3521
Illustration 26
g01413732 S/N: E3W1-Up
Typical example Part No.: 101-0830, 299-3521
S/N: E3X1-Up
(A) Height of the new cylinder
head ...... 142.00 ± 0.15 mm (5.591 ± 0.006 inch) Part No.: 101-0830, 299-3521
S/N: E3Y1-Up
Note: Before assembly, apply 6V-6640 Sealant to
the bore of the ten cup plugs. Part No.: 101-0830, 299-3521
S/N: E3Z1-Up
(B) Installation depth of two cup plugs from the top
surface of the cylinder head .......... 9.0 ± 0.5 mm
(0.35 ± 0.02 inch)
(D) Installation depth of eight cup plugs from the top

surface of the cylinder head .......... 1.0 ± 0.5 mm
(0.04 ± 0.02 inch)
i03080402
Cylinder Head Valves

SMCS Code: 1105
20 KENR5402-07
g01566713
Illustration 27
Typical example
Note: Before assembly, coat the inlet valve stems Diameter of the exhaust valve
and the exhaust valve stems with clean engine oil. stem ..................................... 12.464 ± 0.025 mm
(0.4907 ± 0.0010 inch)
(A) Height from the top of the cylinder head to the
top of the valve guides ................. 26.0 ± 1.0 mm (C) Bore in cylinder head for valve seat inserts
(1.02 ± 0.04 inch)
Inlet .. 60.508 ± 0.025 mm (2.3822 ± 0.0010 inch)
(1) 316-5976 Spring Exhaust ................................ 60.000 ± 0.025 mm
(2.3622 ± 0.0010 inch)
Quantity ............................................................ 4
Length under test force ... 60.29 mm (2.374 inch) (5) Valve guide
Test force .................. 460 ± 23 N (103.4 ± 5.2 lb)
Free length after test .......... 74.8 mm (2.94 inch) Bore of the inlet valve guide after
Outside diameter ............. 43.47 mm (1.711 inch) installation .............................. 9.487 ± 0.025 mm
(0.3735 ± 0.0010 inch)
(2) 316-5977 Spring Bore of the exhaust valve guide after
installation ............................ 12.619 ± 0.025 mm
Quantity ............................................................ 4 (0.4968 ± 0.0010 inch)
Test force ............. 248.0 ± 12.4 N (55.8 ± 2.8 lb) (D) Valve face angles
Free length after test .......... 71.4 mm (2.81 inch)
Outside diameter ................ 30.7 mm (1.21 inch) Inlet ................................... 19.40 ± 0.25 degrees
Exhaust ............................. 44.40 ± 0.25 degrees
(3) Install the valve stem seal to the inlet valves.
(E) Diameter of the valve head ..... 56.00 ± 0.15 mm
(4) Install the washer to the exhaust valves. (2.205 ± 0.006 inch)
(B) Dimension for the valves

Diameter of the inlet valve
stem .. 9.441 ± 0.010 mm (0.3717 ± 0.0004 inch)
KENR5402-07 21
i03034841
Turbocharger
SMCS Code: 1052
Part No.: 268-0009
S/N: TTA1-Up
Part No.: 333-2235
S/N: M8C1-Up
g01441032
Illustration 28
Typical example
(F) Diameter of the valve seat inserts

Inlet .. 60.627 ± 0.015 mm (2.3869 ± 0.0006 inch)
Exhaust ................................. 60.119 ± 0.015 mm
(2.3669 ± 0.0006 inch)
(G) Angle of the face of the valve seat inserts

g01616117
Inlet ................................... 20.00 ± 0.25 degrees Illustration 29
Exhaust ............................. 45.00 ± 0.25 degrees
Note: Before assembly, lubricate the threads of
(H) Depth of bore in the cylinder head for the valve the bolts and the bearing surfaces with 4C-5599
seat insert ................................ 16.00 ± 0.15 mm Anti-Seize Compound.
(0.630 ± 0.006 inch)
(1) Torque for eight bolts ..... 54 ± 5 N·m (40 ± 4 lb ft)
(J) Outside diameter of the face of the valve seat
insert .................................... 53.6 mm (2.11 inch)
g01620801
Illustration 30
Rear view
22 KENR5402-07
Note: Before assembly, lubricate the threads of i03147640

the bolts and the bearing surfaces with 4C-5599
Anti-Seize Compound. Turbocharger
Use the following procedure in order to tighten the SMCS Code: 1052
bolts of the half flange (2):
Part No.: 291-3912
S/N: TTB1-Up
1. Tighten bolts (3) in any sequence to 54 ± 5 N·m
(40 ± 4 lb ft). Part No.: 333-8961
S/N: M8D1-Up
(40 ± 4 lb ft).
g01538253
Illustration 31
Use the following procedure to tighten the clamp

assembly (5) and turbine clamp assembly (6):
g01616117
1. Tighten the clamp assemblies to 13.6 ± 1.0 N·m Illustration 32
(120 ± 9 lb in).
2. Gently tap around the clamp assemblies with a the bolts and the bearing surfaces with 4C-5599
soft faced hammer. Anti-Seize Compound.
3. Again, tighten the clamp assemblies to (1) Torque for eight bolts ..... 54 ± 5 N·m (40 ± 4 lb ft)
13.6 ± 1.0 N·m (120 ± 9 lb in).
g01619282
Illustration 33
Rear view
KENR5402-07 23
Before assembly, lubricate the threads of the bolts i03743841

and the bearing surfaces with 4C-5599 Anti-Seize
Compound. Turbocharger
Use the following procedure in order to tighten the SMCS Code: 1052
bolts of the half flange (2).
Part No.: 296-9926, 343-5687
S/N: TTC1-Up
(40 ± 4 lb ft). Part No.: 343-5687
S/N: TTD1-Up
(40 ± 4 lb ft). Part No.: 343-5687
S/N: TTF1-Up
Part No.: 328-4258
S/N: TTG1-Up
Part No.: 328-4268
S/N: TTH1-Up
Part No.: 328-4273
S/N: TTJ1-Up
Part No.: 328-4268
S/N: SLM1-Up
Part No.: 328-4277
S/N: JTS1-Up
g01538253
Illustration 34 Part No.: 296-9926, 325-3816
S/N: E3W1-Up
Use the following procedure to tighten the compressor
clamp assembly (5) and turbine clamp assembly (6): Part No.: 296-9926, 327-7739
S/N: E3X1-Up
the clamp assemblies with 4C-5599 Anti-Seize Part No.: 296-9926, 343-5687
Compound. S/N: E3Y1-Up
Part No.: 325-3816, 343-5687
1. Tighten the clamp assemblies to 16 N·m (12 lb ft).
S/N: E3Z1-Up
2. Loosen the clamp assemblies to two to three
turns.
3. Gently tap around the clamp assemblies with a

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

12.4 to 14.7 N·m (110 to 130 lb in).
g01269136
Illustration 35
Typical example
24 KENR5402-07
Use the following procedure to tighten the clamp

assembly (1):
Note: Before assembly, lubricate all the threads

of the clamp assembly with 4C-5599 Anti-Seize
Compound.
1. Tighten the clamp assembly to 18 to 20 N·m

(159 to 177 lb in).
2. Gently hit around the clamp assembly with a soft

hammer.
3. Again, tighten the clamp assembly to 18 to 20 N·m

(159 to 177 lb in).
Note: Before assembly, lubricate all the threads of

the bolt with 4C-5599 Anti-Seize Compound.
(2) Torque for the bolts ........ 40 ± 3 N·m (30 ± 2 lb ft)
g01269136
Illustration 36
i02950938
Turbocharger Note: Lubricate all the threads with 5P-3931

Anti-Seize Compound before assembly.
SMCS Code: 1052
Use the following procedure to tighten the turbine
Part No.: 304-3746, 304-8647 clamp assembly (1):
S/N: TTC1-Up
1. Tighten the turbine clamp assembly to 20 N·m
Part No.: 304-3746 (15 lb ft).
S/N: TTD1-Up
Part No.: 311-4648 2. Loosen the turbine clamp assembly by two to
S/N: TTE1-Up three turns.
Part No.: 304-3746 3. Gently hit around the turbine clamp assembley
S/N: TTF1-Up with a soft hammer.
Part No.: 303-6266 4. Again tighten the turbine clamp assembley to
S/N: TTG1-Up 18 to 20 N·m (13 to 15 lb ft).
Part No.: 304-3748
S/N: TTH1-Up
Part No.: 304-8646
S/N: TTJ1-Up
Part No.: 304-3748, 304-8649
S/N: SLM1-Up
Part No.: 304-8650
S/N: JTS1-Up
Part No.: 304-8647
S/N: E3W1-Up
Part No.: 304-8647
S/N: E3X1-Up
Part No.: 304-3746, 304-8647
S/N: E3Y1-Up
Part No.: 304-3746
S/N: E3Z1-Up
KENR5402-07 25
i03677240 i03149240
Turbocharger Turbocharger
SMCS Code: 1052 SMCS Code: 1052
Part No.: 327-7738 Part No.: 238-7769
S/N: TTE1-Up S/N: PAF1-Up
g01619692
Illustration 38
Rear view
(1) Torque for two clamp assemblies ...... 60 ± 5 N·m

(44 ± 4 lb ft)
Illustration 37
g01975335 (2) Torque for 12 bolts ......... 40 ± 5 N·m (30 ± 4 lb ft)
Use the following procedure to tighten the turbine (3) Torque for 18 bolts ......... 65 ± 5 N·m (48 ± 4 lb ft)
clamp assembly (1):
i03341711
Note: Before assembly, lubricate the threads of the
turbine clamp assembly with 4C-5599 Anti-Seize Exhaust Bypass Valve
Compound.
SMCS Code: 1057
1. Tighten the turbine clamp assembly to 18 to 20 N·m
(159 to 177 lb in). Part No.: 304-3874
S/N: TTJ1-Up
2. Gently hit around the turbine clamp assembley Part No.: 304-3874, 347-3276
with a soft hammer. S/N: SLM1-Up
3. Again, tighten the turbine clamp assembley to
18 to 20 N·m (159 to 177 lb in).
(3) Torque for the plug assembly ......... 14 to 17 N·m

(124 to 150 lb in)
g01414647
Illustration 39
(1) Torque for the locknut .................. 12.5 ± 1.0 N·m

(110 ± 9 lb in)
26 KENR5402-07
(2) 7E-4677 Spring Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft)

Free length ........................ 115.3 mm (4.54 inch) 5. Tighten all four locknuts again.
Torque ............................. 47 ± 9 N·m (35 ± 7 lb ft)
(3) 7E-4676 Spring
Free length ........................ 115.3 mm (4.54 inch) i03341316
Exhaust Bypass Valve
(4) Torque for the nut ..... 14 ± 3 N·m (125 ± 27 lb in)
SMCS Code: 1057
(5) Torque for the five screws .............. 6.5 ± 1.0 N·m
(60 ± 9 lb in) Part No.: 259-1436
S/N: PAF1-Up
(6) Before assembly, lubricate the threads and the
bearing surfaces of the setscrew with 4C-5599
Anti-Seize Compound.
g01414647
Illustration 41
(1) Torque for the locknut .................. 12.5 ± 1.0 N·m

(110 ± 9 lb in)
(2) 259-1435 Spring

Free length .......................... 127 mm (5.00 inch)
(3) 259-1434 Spring

Free length .......................... 127 mm (5.00 inch)
(4) Torque for the nut ..... 14 ± 3 N·m (125 ± 27 lb in)

g01717353
Illustration 40 (5) Torque for the five screws .............. 6.5 ± 1.0 N·m
(7) Exhaust bypass valve (60 ± 9 lb in)
(8) Locknut
(9) Gasket (6) Before assembly, lubricate the threads and the
bearing surfaces of the setscrew with 4C-5599
1. Clean the stud, the locknut, and the base of the Anti-Seize Compound.
locknut prior to assembly.
2. Apply 2P-2333 High Temperature Sealer to the

threads of the stud that extend through the flange
of the exhaust bypass valve and to the bottom of
the mating face of each locknut.
3. Tighten two diagonal locknuts.
Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft)
4. Tighten the remaining locknuts.

KENR5402-07 27
i03697281
Exhaust Manifold
SMCS Code: 1059
Part No.: 334-7032
S/N: M8C1-Up
Part No.: 334-7032
S/N: M8D1-Up
g01717353
Illustration 42
(7) Exhaust bypass valve
(8) Locknut
(9) Gasket
g01988413
Illustration 43
1. Clean the stud, the locknut, and the base of the
locknut prior to assembly. Note: Before assembly, lubricate the threads and
the bearing surfaces of the bolts with 4C-5599
2. Apply 2P-2333 High Temperature Sealer to the Anti-Seize Compound.
threads of the stud that extend through the flange
of the exhaust bypass valve and to the bottom of (1) Torque for the bolts ........ 65 ± 5 N·m (48 ± 4 lb ft)
the mating face of each locknut.
i03743861
3. Tighten two diagonal locknuts.
Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft)

Exhaust Manifold
SMCS Code: 1059
4. Tighten the remaining locknuts.
Part No.: 305-6816
Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft) S/N: TTA1-Up
5. Tighten all four locknuts again. Part No.: 305-6816

S/N: TTB1-Up
Torque ............................. 47 ± 9 N·m (35 ± 7 lb ft)
bolts and the face of the washers with 4C-5599
28 KENR5402-07
g01343420 g01343420
Note: Tighten diagonally opposite bolts (1) Torque for the full nuts ... 55 ± 5 N·m (41 ± 4 lb ft)
simultaneously.
(1) Torque for the full nuts ... 55 ± 5 N·m (41 ± 4 lb ft)
g01363929
Illustration 47

g01363929
Illustration 45
i02674274
Exhaust Manifold
SMCS Code: 1059
Part No.: 285-5345
S/N: TTA1-Up
Part No.: 285-5345
S/N: TTB1-Up
Note: Lubricate the threads of the bolts and the face

of the washers with 4C-5599 Anti-Seize Compound
before assembly. Tighten diagonally opposite bolts
simultaneously.
KENR5402-07 29
i02674271
Exhaust Manifold
SMCS Code: 1059
Part No.: 301-6823
S/N: TTF1-Up
Part No.: 301-6823
S/N: TTG1-Up
Part No.: 301-6823
S/N: TTH1-Up
Part No.: 301-6823, 304-9859
g01343528
S/N: SLM1-Up Illustration 49
Left Side View
Part No.: 301-6823
S/N: JTS1-Up
(6) Torque for the taperlock studs ........... 35 ± 5 N·m

(26 ± 4 lb ft)
g01343407
Illustration 48
Top View
Note: Lubricate the threads, the bearing surfaces,

and the inside diameter of the clamps with 4C-5599
(1) Torque for the clamps .................... 7.5 ± 1.0 N·m

(65 ± 9 lb in)
(2) Torque for the band clamps ............... 10 ± 1 N·m

(90 ± 9 lb in)
Note: Lubricate the threads of the bolts and the faces

simultaneously. g01376453
Illustration 50
(7) Lubricate the threads of the bolts and the faces of
the washers with 4C-5599 Anti-Seize Compound
(4) Lubricate the threads of the bolts and the faces of
before assembly.
before assembly.
30 KENR5402-07
i02748600
Exhaust Manifold
SMCS Code: 1059
Part No.: 282-4180
S/N: TTF1-Up
Part No.: 282-4180
S/N: TTG1-Up
Part No.: 282-4180
S/N: TTH1-Up
Part No.: 282-4180
g01377145
S/N: SLM1-Up Illustration 52
Left side view
Part No.: 282-4180
S/N: JTS1-Up

(26 ± 4 lb ft)
(5) Lubricate the washer face and the threads of the

bolts with 4C-5599 Anti-Seize Compound before
assembly.
g01377148
Illustration 51
Top view


(65 ± 9 lb in)

simultaneously.
g01377149
Illustration 53


(90 ± 9 lb in)
KENR5402-07 31
i02752116 (5) Lubricate the washer face and the threads of the
Exhaust Manifold assembly.
SMCS Code: 1059
Part No.: 284-4875
S/N: SLM1-Up
g01377839
Illustration 54
Top view


(65 ± 9 lb in) g01377149
Illustration 56

simultaneously.
(90 ± 9 lb in)
g01377840
Illustration 55
Left side view

(26 ± 4 lb ft)
32 KENR5402-07
i02748596
Exhaust Manifold
SMCS Code: 1059
Part No.: 282-4188
S/N: TTC1-Up
Part No.: 282-4188
S/N: TTD1-Up
Part No.: 282-4188
S/N: TTE1-Up
Part No.: 282-4188
g01377082
S/N: TTF1-Up Illustration 58
Left side view
Part No.: 282-4188
S/N: E3Z1-Up
(3) Lubricate the washer face and the threads of the
assembly.
g01377077
Illustration 57
Top view
Note: Lubricate the threads, the bearing surfaces


(65 ± 9 lb in)

simultaneously.
(2) Torque for the full nuts ... 55 ± 5 N·m (41 ± 4 lb ft) g01377088
Illustration 59

(4) Torque for the clamps .... 20 ± 2 N·m (15 ± 1 lb ft)

KENR5402-07 33
i02674270
Exhaust Manifold
SMCS Code: 1059
Part No.: 301-6822, 304-9860
S/N: TTC1-Up
Part No.: 301-6822
S/N: TTD1-Up
Part No.: 301-6822, 304-9860
S/N: TTE1-Up
Part No.: 301-6822, 304-9860
g01376477
S/N: TTF1-Up Illustration 61
Left Side View
Part No.: 304-9860
S/N: E3W1-Up
Part No.: 304-9860
S/N: E3X1-Up
Part No.: 304-9860
S/N: E3Y1-Up
Part No.: 301-6822
S/N: E3Z1-Up
g01343403
Illustration 60
Top View
Note: Lubricate the threads, the bearing surfaces g01376474

Illustration 62
Anti-Seize Compound before assembly. (4) Lubricate the threads of the bolts and the face of
(1) Torque for the clamps .................... 7.5 ± 1.0 N·m before assembly.
(65 ± 9 lb in)
(2) Torque for the V-band clamps ........... 20 ± 2 N·m

(15 ± 1 lb ft)

simultaneously.
34 KENR5402-07
i02748592
Exhaust Manifold
SMCS Code: 1059
Part No.: 285-8374
S/N: TTC1-Up
Part No.: 285-8374
S/N: TTE1-Up
Part No.: 285-8374
S/N: TTF1-Up
Part No.: 285-8374
g01377009
S/N: E3W1-Up Illustration 64
Left side view
Part No.: 285-8374
S/N: E3X1-Up
Part No.: 285-8374
S/N: E3Y1-Up
g01377006
Illustration 63
Top view


(65 ± 9 lb in) g01377010
Illustration 65

of the washers with 4C-5599 Anti-Seize Compound (3) Lubricate the threads of the bolts and the face of
before assembly. Tighten diagonally opposite bolts the washers with 4C-5599 Anti-Seize Compound
simultaneously. before assembly.
(2) Torque for the full nuts ... 55 ± 5 N·m (41 ± 4 lb ft) Note: Lubricate the threads, the bearing surfaces

KENR5402-07 35
i02951098 (6) Before assembly, lubricate the face of the

washers and the threads of 48 bolts with
Exhaust Manifold 4C-5599 Anti-Seize Compound.
SMCS Code: 1059
Part No.: 282-4178
S/N: TTG1-Up
g01511153
Illustration 67
Typical example
Rear view

(7) Torque for two band clamps .............. 10 ± 1 N·m

(90 ± 9 lb in)
g01511139
Illustration 66 (8) Before assembly, lubricate the face of the
Typical example washers and the threads of eight bolts with
Top view 4C-5599 Anti-Seize Compound.
(1) Torque for four bolts ....... 55 ± 5 N·m (41 ± 4 lb ft) (9) Before assembly, lubricate the face of the
washers and the threads of four bolts with
(2) Torque for four taperlock studs .......... 35 ± 5 N·m 4C-5599 Anti-Seize Compound.
(26 ± 4 lb ft)

(3) Torque for four clamp assemblies .. 7.5 ± 1.0 N·m

(65 ± 9 lb in)
(4) Torque for four clamps ................... 7.5 ± 1.0 N·m

(65 ± 9 lb in)

(5) Torque for 20 clamps ..... 25 ± 6 N·m (18 ± 4 lb ft)

36 KENR5402-07
i02752075
Exhaust Manifold
SMCS Code: 1059
Part No.: 304-9858
S/N: TTG1-Up
g01377816
Illustration 69
g01377817
Illustration 68
Top view Note: Lubricate the threads, the bearing surfaces,
Note: Lubricate the threads, the bearing surfaces, Anti-Seize Compound before assembly.
Anti-Seize Compound before assembly. (5) Torque for the clamps .................... 7.5 ± 1.0 N·m
(65 ± 9 lb in)
(65 ± 9 lb in)

(90 ± 9 lb in)
(3) Torque for the clamps ........................ 25 ± 6 N·m

(220 ± 55 lb in)
(4) Lubricate the washer faces and the threads of

the bolts with 4C-5599 Anti-Seize Compound
before assembly.
g01377818
Illustration 70
Left side view
KENR5402-07 37
g01618467
Illustration 73
Left side view
Note: Before assembly, lubricate the washer faces

and the threads of the taperlock studs with 4C-5599
g01377815
Illustration 71
(2) Torque for four taperlock studs .......... 35 ± 5 N·m
View C-C
(26 ± 4 lb ft)
(6) Torque for the bolts ........ 55 ± 5 N·m (41 ± 4 lb ft) (3) In order to avoid trapping the rear lifting eye
under the housing, hold the rear lifting eye in the
(7) Torque for the taperlock studs ........... 35 ± 5 N·m vertical position during installation.
(26 ± 4 lb ft)
(4) Torque for four bolts ....... 55 ± 5 N·m (41 ± 4 lb ft)
i03142471
Exhaust Manifold
SMCS Code: 1059
Part No.: 238-9120
S/N: PAF1-Up
g01618458
Illustration 72
Top View

38 KENR5402-07
g01618476
Illustration 74
Note: Before assembly, lubricate the washer faces

and the threads of eight bolts (5) with 4C-5599
Anti-Seize Compound. Tighten the full nuts of the
diagonally opposite bolts simultaneously.
(6) Torque for eight full nuts .................... 55 ± 5 N·m

(41 ± 4 lb ft)
(7) Before assembly, lubricate the washer faces

and the threads of eight locknuts with 4C-5599
(8) Before assembly, lubricate the washer faces and

the threads of the bolts with 4C-5599 Anti-Seize
Compound.
KENR5402-07 39
i03142382
Exhaust Manifold
SMCS Code: 1059
Part No.: 285-8370
S/N: TTJ1-Up
g01617974
Illustration 76
Rear view
Note: Before assembly, lubricate the threads, the

bearing surfaces, and the inside diameter of the band
clamps with 4C-5599 Anti-Seize Compound.
(7) Torque for two band clamps .............. 10 ± 1 N·m

(90 ± 9 lb in)

Compound.
g01511139 (9) Before assembly, lubricate the washer faces and
Illustration 75
Top view the threads of the bolts with 4C-5599 Anti-Seize
Compound.
(10) Before assembly, lubricate the face of the
(2) Torque for four taperlock studs .......... 35 ± 5 N·m washers and the threads of the bolts with
(26 ± 4 lb ft) 4C-5599 Anti-Seize Compound.

bearing surfaces, and the inside diameter of the
(3) Torque for four clamp assemblies .. 7.5 ± 1.0 N·m

(65 ± 9 lb in)
(4) Torque for four clamps ... 25 ± 6 N·m (18 ± 4 lb ft)

bearing surfaces, and the inside diameter of the

Compound.
40 KENR5402-07
i02752149 (6) In order to avoid trapping the rear lifting eye

under the adapter, hold the rear lifting eye in the
Exhaust Manifold vertical position during installation.
SMCS Code: 1059 (7) Torque for the taperlock studs ........... 35 ± 5 N·m
(26 ± 4 lb ft)
Part No.: 301-6824
S/N: TTJ1-Up
g01377862
Illustration 77
Top view
(1) Lubricate the washer faces and the threads of

the bolts with 4C-5599 Anti-Seize Compound
g01377865
before assembly. Illustration 79
Note: Lubricate the threads, the bearing surfaces, (8) Torque for the bolts ........ 55 ± 5 N·m (41 ± 4 lb ft)
i02674273

(65 ± 9 lb in)
Exhaust Manifold
SMCS Code: 1059
(220 ± 55 lb in) Part No.: 290-4131
S/N: TTJ1-Up
(90 ± 9 lb in)

(220 ± 55 lb in)
g01343413
Illustration 80
Top View

g01377864
Illustration 78 Anti-Seize Compound before assembly.
Left side view
KENR5402-07 41
(1) Torque for the clamps .................... 7.5 ± 1.0 N·m i02952998
(65 ± 9 lb in)
Exhaust Flange
(90 ± 9 lb in) SMCS Code: 1061
Part No.: 7N-6961
S/N: TTA1-Up
Part No.: 7N-6961
S/N: TTB1-Up
Part No.: 7N-6961
S/N: M8C1-Up
Part No.: 7N-6961
S/N: M8D1-Up
g01376543
Illustration 81
(4) Lubricate the threads of the bolts and the face of g01468348
Illustration 83
before assembly. (1) Apply 4C-5599 Anti-Seize Compound to the
threads of eight bolts.

(65 ± 9 lb in)
g01343542
Illustration 82
Left Side View

(26 ± 4 lb ft)
42 KENR5402-07
i02953003 Part No.: 2W-7871

S/N: TTH1-Up
Exhaust Flange
Part No.: 2W-7871
SMCS Code: 1061 S/N: TTJ1-Up
Part No.: 7N-6962 Part No.: 2W-7871
S/N: TTA1-Up S/N: SLM1-Up
Part No.: 7N-6962 Part No.: 2W-7871
S/N: TTB1-Up S/N: JTS1-Up
Part No.: 2W-7871
S/N: E3W1-Up
Part No.: 2W-7871
S/N: E3X1-Up
Part No.: 2W-7871
S/N: E3Y1-Up
Part No.: 2W-7871
S/N: E3Z1-Up
g01468407
Illustration 84
Typical example
(1) Apply 4C-5599 Anti-Seize Compound to the

threads of 12 bolts.
i02953141
Exhaust Flange
SMCS Code: 1061 Illustration 85
g01469762
Part No.: 2W-7871

S/N: TTA1-Up (1) Apply 4C-5599 Anti-Seize Compound to the
threads of 24 bolts.
Part No.: 2W-7871
S/N: TTB1-Up
Part No.: 2W-7871
S/N: M8C1-Up
Part No.: 2W-7871
S/N: TTC1-Up
Part No.: 2W-7871
S/N: M8D1-Up
Part No.: 2W-7871
S/N: TTD1-Up
Part No.: 2W-7871
S/N: TTE1-Up
Part No.: 2W-7871
S/N: TTF1-Up
Part No.: 2W-7871
S/N: TTG1-Up
KENR5402-07 43
i02836282 i02674252
Exhaust Flange Air Cleaner

Part No.: 103-6668 Part No.: 206-0884, 226-2773, 249-2865,
S/N: TTC1-Up 251-5884, 281-0694, 317-9958
S/N: TTC1-Up
Part No.: 103-6668
S/N: TTD1-Up Part No.: 206-0884, 226-2773, 249-2865,
251-5884, 281-0694, 317-9958
Part No.: 103-6668 S/N: TTD1-Up
S/N: TTE1-Up
Part No.: 206-0884, 226-2773, 249-2865,
Part No.: 103-6668 251-5884, 281-0694, 317-9958
S/N: PAF1-Up S/N: TTE1-Up
Part No.: 103-6668 Part No.: 206-0884, 249-2865
S/N: TTF1-Up S/N: PAF1-Up
Part No.: 103-6668 Part No.: 206-0884, 226-2773, 249-2865,
S/N: TTG1-Up 251-5884, 281-0694, 317-9958
S/N: TTF1-Up
Part No.: 103-6668
S/N: TTH1-Up Part No.: 206-0884, 226-2773, 249-2865,
251-5884, 281-0694, 317-9958
Part No.: 103-6668
S/N: TTG1-Up
S/N: TTJ1-Up
Part No.: 206-0884, 226-2773, 249-2865,
Part No.: 103-6668
251-5884, 281-0694, 317-9958
S/N: SLM1-Up
S/N: TTH1-Up
Part No.: 103-6668
Part No.: 206-0884, 226-2773, 249-2865,
S/N: JTS1-Up
251-5884, 281-0694, 317-9958
Part No.: 103-6668 S/N: TTJ1-Up
S/N: E3W1-Up
Part No.: 206-0884, 226-2773, 249-2865,
Part No.: 103-6668 251-5884, 317-9958
S/N: E3X1-Up S/N: SLM1-Up
Part No.: 103-6668 Part No.: 206-0884, 226-2773, 249-2865,

S/N: E3Y1-Up 251-5884, 281-0694, 317-9958
S/N: JTS1-Up
Part No.: 103-6668
S/N: E3Z1-Up Part No.: 226-2773, 317-9958
S/N: E3W1-Up
Part No.: 226-2773, 317-9958
S/N: E3X1-Up
Part No.: 226-2773, 317-9958
S/N: E3Y1-Up
Part No.: 226-2773, 317-9958
S/N: E3Z1-Up
g01414164
Illustration 86
Typical example
(1) Apply 4C-5599 Anti-Seize Compound to the

threads of the 16 bolts.
44 KENR5402-07
i02954022
Air Cleaner Adapter

SMCS Code: 1051
Part No.: 4P-2013
S/N: TTF1-Up
g01343296
Illustration 87
g01469798
Illustration 89
(1) Torque for the nut ..... 4.0 ± 0.5 N·m (35 ± 4 lb in)
(1) Torque for 28 locknuts ....................... 12 ± 4 N·m
(105 ± 35 lb in)
i02954024
Air Cleaner Adapter

SMCS Code: 1051
Part No.: 7W-9828
S/N: TTA1-Up
Part No.: 7W-9828
S/N: TTB1-Up
Part No.: 7W-9828
S/N: M8C1-Up
Part No.: 7W-9828
S/N: M8D1-Up
g01469799
Illustration 88
(1) Torque for 48 locknuts ....................... 12 ± 4 N·m

(105 ± 35 lb in)
KENR5402-07 45
i03685300
Air Inlet and Exhaust Lines

SMCS Code: 1058; 1061
Part No.: 334-4666, 334-4670
S/N: M8C1-Up
Part No.: 334-4666, 334-4670
S/N: M8D1-Up
g01984514
Illustration 91
Typical example
g01614673
Illustration 92
Bolt tightening sequence
(1) Lubricate the bore for the O-ring seals lightly with
glycerin or an approved equivalent.
Illustration 90
g01984513 Note: Before assembly, lubricate the threads of the
plugs with 4C-5599 Anti-Seize Compound.
Typical example
(2) Torque for the plugs .. 25 ± 5 N·m (221 ± 44 lb in)
(3) Use the following procedure in order to assemble

the aftercooler assembly and tighten the bolts:
1. Assemble the seals to the aftercooler core.
2. Temporarily secure the bottom seal to the

aftercooler with tape. Do not use an adhesive,
a silicone lubricant, or any other lubricant for
retention of the seal.
3. Assemble the aftercooler with seals to the inlet

manifold.
46 KENR5402-07
4. Inspect the bottom seal in order to ensure that the

seal is seating correctly in the recess.
5. Install the aftercooler cover.
6. Inspect the upper seal in order to ensure that the

7. Install the cover bolts. Hand tighten the cover

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

shown in Illustration 92 to 24 N·m (212 lb in).
9. Again, tighten the bolts in a numerical sequence

that is shown in Illustration 92 to 47 N·m (35 lb ft).
10. Remove the tape.

KENR5402-07 47
i03145606

SMCS Code: 1058; 1061
Part No.: 268-0015, 312-5651
S/N: TTA1-Up
Part No.: 268-0015, 312-5651
S/N: TTB1-Up
g01614656
Illustration 93
Right side view of engine
48 KENR5402-07
i03685063

SMCS Code: 1058; 1061
Part No.: 285-8373
S/N: TTC1-Up
Part No.: 285-8373
S/N: TTE1-Up
Part No.: 285-8373
S/N: TTF1-Up
Part No.: 284-4878
g01614673
Illustration 94 S/N: TTG1-Up
Part No.: 284-4878
S/N: SLM1-Up
glycerin or an approved equivalent. Part No.: 285-8373
S/N: E3W1-Up
the aftercooler assembly and tighten the bolts: Part No.: 285-8373
S/N: E3X1-Up
Part No.: 285-8373
2. Temporarily secure the bottom seal to the S/N: E3Y1-Up

manifold.



bolts.

shown in illustration 94 to 24 N·m (18 lb ft).

that is shown in illustration 94 to 47 N·m (35 lb ft).

plugs with 4C-5599 Anti-Seize Compound. g02022984
Illustration 95
(3) Torque for two plugs ...... 25 ± 5 N·m (18 ± 4 lb ft) Right side view
Typical example
KENR5402-07 49


manifold.



bolts.

g01981014
Illustration 96
Top view
Typical example
g01981033
Illustration 97
Note: Before assembly, lubricate the threads, bearing

surfaces and the inside diameter of the V-band
(1) Torque for the V-band clamps ....... 7.5 ± 1.0 N·m
(66.4 ± 8.9 lb in)
(2) Ensure that the bellows are assembled in the

proper flow direction. The flow direction is
indicated on bellows by an arrow.

the aftercooler assembly and tighten the bolts:

50 KENR5402-07
i03685140

SMCS Code: 1058; 1061
Part No.: 282-4177
S/N: TTD1-Up
Part No.: 282-4176
S/N: TTH1-Up
Part No.: 285-8369
S/N: TTJ1-Up
Part No.: 282-4176
g01981195
S/N: JTS1-Up Illustration 100
Part No.: 282-4177
S/N: E3Z1-Up
Note: Before assembly, lubricate the threads, bearing
surfaces and the inside diameter of the V-band
(1) Torque for the V-band clamps ....... 7.5 ± 1.0 N·m
(66.4 ± 8.9 lb in)
(2) Ensure that the bellows are assembled in the

proper flow direction. The flow direction is
indicated on bellows by an arrow.
(3) Lubricate the bore of the O-ring seals lightly with

glycerin or with an approved equivalent.

Illustration 98
g01981194 the aftercooler assembly and tighten the bolts:
Right side view
Typical example

manifold.



bolts.

g01981193
Illustration 99

KENR5402-07 51
i03685240

SMCS Code: 1058; 1061
Part No.: 239-0747
S/N: PAF1-Up
g02019853
Illustration 101
Right side view
g02019855
Illustration 102
52 KENR5402-07
Part No.: 106-9872

S/N: TTB1-Up
Part No.: 106-9872
S/N: TTC1-Up
Part No.: 106-9872
S/N: TTD1-Up
Part No.: 106-9872
S/N: TTE1-Up
Part No.: 106-9872
S/N: PAF1-Up
Part No.: 106-9872
g01981195
Illustration 103 S/N: TTF1-Up
Part No.: 106-9872
S/N: TTG1-Up
5P-3975 Rubber Lubricant. Part No.: 106-9872
S/N: TTH1-Up
the aftercooler assembly and tighten the bolts: Part No.: 106-9872
S/N: TTJ1-Up
Part No.: 106-9872
2. Temporarily secure the bottom seal to the S/N: SLM1-Up
aftercooler with tape. Do not use an adhesive, Part No.: 106-9872
a silicone lubricant, or any other lubricant for S/N: JTS1-Up
Part No.: 106-9872
3. Assemble the aftercooler with seals to the inlet S/N: E3W1-Up
manifold.
Part No.: 106-9872
4. Inspect the bottom seal in order to ensure that the S/N: E3X1-Up
Part No.: 106-9872
5. Install the aftercooler cover. S/N: E3Y1-Up
Part No.: 106-9872
6. Inspect the upper seal in order to ensure that the S/N: E3Z1-Up

bolts.
8. Tighten the bolts in a numerical sequence

that is shown in Illustration 103 to 24 ± 6 N·m
(212 ± 53 lb in).

that is shown in Illustration 103 to 47 ± 9 N·m
(35 ± 7 lb ft).
g01554195
Illustration 104
i03557502
Engine Oil Pump Note: The rotation of the drive gear is clockwise when
you view the engine oil pump from the drive end.
SMCS Code: 1304
Part No.: 106-9872
S/N: TTA1-Up
KENR5402-07 53
Note: Before you install the pump, lubricate the Bore in the sleeve bearing for the pump drive
moving parts with clean engine oil. Rotate the pump shaft after assembly ............. 31.811 ± 0.013 mm
by hand in order to ensure that the pump rotates (1.2524 ± 0.0005 inch)
freely.
(G) Distance from the gear face to the pump drive
(1) 107-7175 Spring shaft assembly ............................. 47.0 ± 0.5 mm
(1.85 ± 0.02 inch)
Length under test force ..................... 107.16 mm
(4.219 inch) (H) Installation depth of the sleeve bearing in the
Test force ............ 555.6 ± 20.0 N (124.9 ± 4.5 lb) pump cover ....... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)
Free length after test ........ 144.5 mm (5.69 inch)
Outside diameter ............ 27.00 mm (1.063 inch) (J) Installation depth of the sleeve bearing in the oil
pump body assembly ..................... 1.5 ± 0.5 mm
(0.06 ± 0.02 inch)
g01883030
Illustration 105
(B) Dimension for the gears Illustration 106

g01554196
Length of new gear ............. 110.000 ± 0.015 mm

(4.3307 ± 0.0006 inch)
Depth of the bore in the oil pump body for new
gear ....... 110.15 ± 0.02 mm (4.337 ± 0.001 inch)
(C) Dimensions for the idler shaft

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

cover ................. 6.0 ± 0.5 mm (0.24 ± 0.02 inch) g01554197
Illustration 107
(E) Distance from the end of the pump shaft

assembly to the gear face ........... 34.0 ± 0.5 mm (K) Position of the bearing joints from the centerline
(1.34 ± 0.02 inch) through the bearing bores ........ 45 ± 15 degrees
(F) Dimensions for the pump drive shaft

Diameter of new pump drive
shaft ..................................... 31.742 ± 0.008 mm
(1.2497 ± 0.0003 inch)
54 KENR5402-07
i03602902
Engine Oil Pump

SMCS Code: 1304
Part No.: 7N-8715
S/N: TTA1-Up
Part No.: 7N-8715
S/N: TTB1-Up
Part No.: 332-7927
S/N: M8C1-Up
Part No.: 332-7927
S/N: M8D1-Up
g01881373
Illustration 108
(2) Pump cover
(L) Extension of the hollow dowel from the oil pump

cover ................. 6.0 ± 1.0 mm (0.24 ± 0.04 inch)
Bench test specifications

Unrestricted flow rate per minute at 1000
rpm ....................................... 410 L (108 US gal) Illustration 109
g01554195
Pump pressure at 300 rpm with fully blocked
outlet ..................... 570 to 630 kPa (83 to 91 psi) Note: The rotation of the drive gear is clockwise when
you view the engine oil pump from the drive end.
Note: 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) 2S-2760 Spring

Length under test force .. 117.14 mm (4.612 inch)
Test force ........................ 499 ± 24 N (112 ± 5 lb)
Approximate free length after test .... 152.91 mm
(6.020 inch)
KENR5402-07 55
g01890213 g01554196
(2) Before assembly, lubricate the O-ring seal lightly

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

Length of new gear .............. 54.000 ± 0.015 mm
(2.1260 ± 0.0006 inch)
Depth of the bore in the oil pump body for the
new gear .. 54.15 ± 0.02 mm (2.132 ± 0.001 inch)
(C) Dimensions for the pump shaft

Diameter of the new shaft .... 31.742 ± 0.008 mm
(1.2497 ± 0.0003 inch)
Bore in the sleeve bearing for the new shaft after Illustration 112
g01554197
assembly .............................. 31.811 ± 0.013 mm
(1.2524 ± 0.0005 inch) (K) Position of bearing joints from the centerline
through the bearing bores ........ 45 ± 15 degrees
(D) Extension of the hollow dowel from the pump
cover ................. 6.0 ± 0.5 mm (0.24 ± 0.02 inch)
(E) Distance from the end of the idler shaft to the

gear face ......... 34.0 ± 0.5 mm (1.34 ± 0.02 inch)

(1.2497 ± 0.0003 inch)
Bore in the sleeve bearing for the new shaft after
assembly .............................. 31.811 ± 0.013 mm
(1.2524 ± 0.0005 inch)
(G) Distance from the end of the shaft to the gear

face ................. 47.0 ± 0.5 mm (1.85 ± 0.02 inch)
(H) Installation depth of the sleeve bearing in the

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

(0.06 ± 0.02 inch)
56 KENR5402-07

5P-3975 Rubber Lubricant immediately before
assembly of the engine oil pump.
g01459725
Illustration 115
(2) 2S-2760 Spring

g01927801
Illustration 113
(3) Pump cover Test force .................. 499 ± 24 N (112.2 ± 5.4 lb)
Approximate free length after test .... 152.91 mm
(L) Extension of the hollow dowel from the oil pump (6.020 inch)
cover ................. 6.0 ± 1.0 mm (0.24 ± 0.04 inch) Outside diameter ............ 27.00 mm (1.063 inch)
Unrestricted flow rate at 700 rpm ........... 135.0 L
(35.7 US gal)
outlet ..................... 570 to 630 kPa (83 to 91 psi)
i02941571
Engine Oil Pump

SMCS Code: 1304
Part No.: 244-8985
S/N: TTG1-Up
Part No.: 244-8985
S/N: SLM1-Up
g01459726
Illustration 116

(3.3071 ± 0.0006 inch)
new gear .. 84.15 ± 0.02 mm (3.313 ± 0.001 inch)
(C) Dimensions for the shafts

Illustration 114
g01459732 (1.2497 ± 0.0003 inch)
KENR5402-07 57
Bore in the sleeve bearing for the new

shaft ...................................... 31.811 ± 0.013 mm
(1.2524 ± 0.0005 inch)
(D) Extension of the hollow dowel from the oil pump

cover ................. 6.0 ± 0.5 mm (0.24 ± 0.02 inch)
(E) Distance from the end of the pump shaft

assembly to the gear face ........... 34.0 ± 0.5 mm
(1.34 ± 0.02 inch)

Diameter of new pump drive
shaft ..................................... 31.742 ± 0.008 mm
(1.2497 ± 0.0003 inch)
Bore in the sleeve bearing for the pump drive
shaft ...................................... 31.811 ± 0.013 mm
(1.2524 ± 0.0005 inch)
(G) Distance from the end of the pump drive shaft

assembly to the gear face ........... 47.0 ± 0.5 mm g01459731
Illustration 118
(1.85 ± 0.02 inch)
(L) Position of the bearing joints from the centerline
pump body assembly. .................... 1.5 ± 0.5 mm Unrestricted flow rate at 700 rpm ....... 220 L/min
(0.06 ± 0.02 inch) (58 US gpm)
outlet ................. 710 to 770 kPa (105 to 110 psi)

freely.
g01502139
Illustration 117
(K) Extension of the dowel from the oil pump

cover ................. 6.0 ± 1.0 mm (0.24 ± 0.04 inch)
58 KENR5402-07
i03560066
Engine Oil Pump

SMCS Code: 1304
Part No.: 8N-6152
S/N: TTC1-Up
Part No.: 8N-6152
S/N: TTE1-Up
Part No.: 8N-6152
S/N: TTF1-Up
Part No.: 8N-6152
S/N: E3W1-Up
Part No.: 8N-6152
S/N: E3X1-Up
Part No.: 8N-6152
S/N: E3Y1-Up
g01890213
Illustration 120
(2) Before assembly, lubricate the O-ring seal lightly

with 5P-3975 Rubber Lubricant.

(3.3071 ± 0.0006 inch)
new gear .. 84.15 ± 0.02 mm (3.313 ± 0.001 inch)
(C) Dimensions for the pump shaft

Illustration 119
g01554195 (1.2497 ± 0.0003 inch)
Note: The rotation of the drive gear is clockwise when assembly .............................. 31.811 ± 0.013 mm
you view the engine oil pump from the drive end. (1.2524 ± 0.0005 inch)
Note: Before you install the pump, lubricate the (D) Extension of hollow dowel from the oil pump
moving parts with clean engine oil. Rotate the pump cover ................. 6.0 ± 1.0 mm (0.24 ± 0.04 inch)
freely. (E) Distance from the end of the idler shaft to the
gear face ......... 34.0 ± 0.5 mm (1.34 ± 0.02 inch)
(1) 2S-2760 Spring
Test force .................. 499 ± 24 N (112.2 ± 5.4 lb) Diameter of new shaft .......... 31.742 ± 0.008 mm
Approximate free length after test .... 152.91 mm (1.2497 ± 0.0003 inch)
(6.020 inch) Bore in the sleeve bearing for the new shaft after
Outside diameter ..................... 27 mm (1.1 inch) assembly .............................. 31.811 ± 0.013 mm
(1.2524 ± 0.0005 inch)
(G) Distance from the end of the shaft to the gear

face ................. 47.0 ± 0.5 mm (1.85 ± 0.02 inch)


(0.06 ± 0.02 inch)
KENR5402-07 59
g01883675
Illustration 121
g01883017
Illustration 123
(3) Pump cover
(L) Extension of the hollow dowel from the oil pump

cover ................. 6.0 ± 0.5 mm (0.24 ± 0.02 inch)

Unrestricted flow rate at 700 rpm ....... 220 L/min
Illustration 122
g01883677 (58.1 US gpm)
(K) Position of bearing joints from the centerline outlet .................... 570 to 630 kPa (83 to 91 psi )
60 KENR5402-07
i02956520 Length of new gear ............. 110.000 ± 0.015 mm

(4.3307 ± 0.0006 inch)
Engine Oil Pump Depth of the bore in the oil pump body for the
new gear ............................. 110.150 ± 0.020 mm
SMCS Code: 1304 (4.3366 ± 0.0008 inch)
Part No.: 231-4915
(B) Dimensions for the shafts
S/N: PAF1-Up
Part No.: 231-4915
(1.2497 ± 0.0003 inch)
S/N: TTJ1-Up
Part No.: 231-4915 assembly .............................. 31.811 ± 0.013 mm
S/N: JTS1-Up (1.2524 ± 0.0005 inch)
(C) Extension of hollow dowel from the oil pump

cover ................. 6.0 ± 0.5 mm (0.24 ± 0.02 inch)
(D) Distance from the end of the idler shaft to gear

face ................. 34.0 ± 0.5 mm (1.34 ± 0.02 inch)
(E) Distance from the end of the shaft to the gear

face ................. 47.0 ± 0.5 mm (1.85 ± 0.02 inch)
(F) Installation depth of the sleeve bearing in the

(G) Installation depth of the sleeve bearing in the oil

g01349694 (0.06 ± 0.02 inch)
Illustration 124
(1) 107-7175 Spring

Length under test force ..................... 107.16 mm
(4.219 inch)
Test force ............ 555.6 ± 20.0 N (124.9 ± 4.5 lb)
g01419001
Illustration 126
g01418999
Illustration 125
(A) Dimensions for the gears

KENR5402-07 61
Part No.: 144-8267

S/N: TTH1-Up
Part No.: 144-8267
S/N: TTJ1-Up
Part No.: 144-8267
S/N: SLM1-Up
Part No.: 144-8267
S/N: JTS1-Up
Part No.: 144-8267
S/N: E3W1-Up
Part No.: 144-8267
g01430632
Illustration 127 S/N: E3X1-Up
(H) Position of bearing joints from the centerline Part No.: 144-8267
through the bearing bores ........ 45 ± 15 degrees S/N: E3Y1-Up
Part No.: 144-8267
When the engine oil pump is viewed from the S/N: E3Z1-Up
drive end the drive gear rotates in the following
direction. ................................................... Clockwise

Unrestricted flow rate at 1000 rpm ..... 410 L/min
(108 US gpm)
outlet ..................... 750 ± 30 kPa (109 ± 4.5 psi )

freely.
i02956557
Engine Oil Scavenge Pump

SMCS Code: 1312
Part No.: 144-8267
S/N: TTA1-Up
Part No.: 144-8267
S/N: TTB1-Up
Part No.: 144-8267
S/N: TTC1-Up
Part No.: 144-8267
S/N: TTD1-Up
Part No.: 144-8267
S/N: TTE1-Up
Part No.: 144-8267
S/N: PAF1-Up
Part No.: 144-8267
S/N: TTF1-Up
Part No.: 144-8267
S/N: TTG1-Up
62 KENR5402-07
g01471861
Illustration 128
(E) Dimensions for the idler shaft

NOTICE
Diameter of new idler shaft .. 31.742 ± 0.008 mm
Before operation, the pump must be lubricated with
clean engine oil and the pump must turn freely by hand (1.2497 ± 0.0003 inch)
Bore in the sleeve bearing for the new idler
or damage to parts can be the result.
shaft ..................................... 31.837 ± 0.070 mm
(1.2534 ± 0.0028 inch)
When the oil scavenge pump is viewed from
the drive end the drive rotates in the following (1) Use the following procedure in order to tighten
direction. ....................................... Counterclockwise the bolt:
(A) Dimensions for the gears Note: Before installing the drive gear onto the drive
shaft assembly, clean the shaft and clean the bore of
Length of new gear ............ 145.000 ± 0.015 mm the gear with isopropyl alcohol.
(5.7087 ± 0.0006 inch)
Depth of the bore in the scavenge oil body for the 1. Tap on the drive gear in order to seat the taper
new gear ............................ 145.150 ± 0.020 mm of the drive gear.
(5.7146 ± 0.0008 inch)
2. Tighten the bolt to 100 ± 20 N·m (75 ± 15 lb ft).
(B) Dimensions for the drive shafts
3. Repeat this procedure until the torque does not
Diameter of new drive shaft .. 31.742 ± 0.008 mm
change.
(1.2497 ± 0.0003 inch)
Bore in the sleeve bearing for the new drive
shaft ..................................... 31.837 ± 0.070 mm
(1.2534 ± 0.0028 inch)
(C) Distance from the end of the idler shaft assembly

to the gear face ............................ 34.0 ± 0.5 mm
(1.34 ± 0.02 inch)
(D) Installation depth of the sleeve bearing in the

scavenge oil body .......................... 1.5 ± 0.5 mm
(0.06 ± 0.02 inch)
KENR5402-07 63
g01473436
Illustration 129
Typical example
Part No.: 8N-9164

S/N: M8C1-Up
Part No.: 8N-9164
S/N: TTC1-Up
Part No.: 8N-9164
S/N: M8D1-Up
Part No.: 8N-9164
S/N: TTE1-Up
Part No.: 8N-9164
S/N: PAF1-Up
Part No.: 8N-9164
g01473456
Illustration 130 S/N: TTF1-Up
(F) Position of bearing joints from the centerline Part No.: 8N-9164
through the bearing bores ........ 45 ± 15 degrees S/N: TTG1-Up
Part No.: 8N-9164
(G) Extension of two hollow dowels from the cover of S/N: SLM1-Up
the scavenge pump ....................... 6.4 ± 0.5 mm
(0.25 ± 0.02 inch) Part No.: 8N-9164
S/N: E3W1-Up
scavenge pump cover ................... 1.5 ± 0.5 mm Part No.: 8N-9164
(0.06 ± 0.02 inch) S/N: E3X1-Up
Part No.: 8N-9164
i02394767 S/N: E3Y1-Up
Engine Oil Scavenge Pump
SMCS Code: 1312
Part No.: 8N-9164
S/N: TTA1-Up
Part No.: 8N-9164
S/N: TTB1-Up
64 KENR5402-07
g00118286
Illustration 131
Note: Before installing gear (5) onto the shaft, clean

NOTICE the shaft and clean the gear's bore with isopropyl
Before operation, the pump must be lubricated with alcohol.
clean engine oil and the pump must turn freely by hand
or damage to parts can be the result. Tap on gear in order to seat the taper on
the shaft. Tighten the bolt to the following
torque. ............................ 100 ± 20 N·m (75 ± 15 lb ft)
When the oil scavenge pump is viewed from
the drive end the drive rotates in the following Repeat this procedure until the torque does not
direction. ....................................... Counterclockwise change.
(1) Length of new gears ............ 84.000 ± 0.015 mm
(3.3071 ± 0.0006 inch)
Depth of bores for new gears .... 84.150 ± 0.020 mm

(3.3130 ± 0.0008 inch)
(2) Diameter of new gear shafts .. 31.742 ± 0.008 mm

(1.2497 ± 0.0003 inch)
Bore in bearings for new gear shafts after

assembly .................................... 31.837 ± 0.070 mm
(1.2534 ± 0.0028 inch)
(3) Distance from the end of the shafts to the gear

faces ............... 34.0 ± 0.5 mm (1.34 ± 0.02 inch)
(4) The bearings are installed in the pump body at

the following depth. ........................ 1.5 ± 0.5 mm
(0.06 ± 0.02 inch)
(5) Bolt
KENR5402-07 65
g00118287
Illustration 132
Typical Example
g00118288
Illustration 133
(6) Position of bearing joints from the centerline

(7) The bearings are installed in the cover at the

following depth. .. 1.5 ± 0.5 mm (0.06 ± 0.02 inch)
(8) The dowels extend from the cover at the following

distance. ........... 6.4 ± 0.5 mm (0.25 ± 0.02 inch)
66 KENR5402-07
i03686767
Engine Oil Cooler Bypass and

Cooling Jet Sequence Valves
SMCS Code: 1314; 1331
Part No.: 335-3154, 335-3155
S/N: M8C1-Up
Part No.: 335-3154, 335-3155
S/N: M8D1-Up
g01982413
Illustration 134
(1) Lubricate the bore of the O-ring seals lightly with Free length after test ......... 112.7 mm (4.44 inch)
the clean engine oil. Outside diameter ............ 24.60 mm (0.969 inch)
(2) Torque for the plug ... 100 ± 15 N·m (74 ± 11 lb ft)
i03139927
Note: The oil cooler bypass valve must open with a

pressure difference of 180 ± 20 kPa (26.1 ± 2.9 psi).
Engine Oil Cooler Bypass and
Cooling Jet Sequence Valves
(3) 2W-1635 Spring for oil cooler bypass valve
SMCS Code: 1314; 1331
Length under test force ..... 102.0 mm (4.02 inch)
Test force ........................ 518 ± 26 N (116 ± 6 lb) Part No.: 245-3678
Free length after test ........ 143.4 mm (5.65 inch) S/N: TTA1-Up
Outside diameter ........ 37.251 mm (1.4666 inch)
Part No.: 245-3678
Note: The cooling jet sequence valves must start S/N: TTB1-Up
to open at a pressure difference of 130 ± 30 kPa Part No.: 242-6277
(18.9 ± 4.4 psi). S/N: TTC1-Up
Note: The cooling jet sequence valves must be Part No.: 242-6277
fully open at a pressure difference of 200 ± 30 kPa S/N: TTD1-Up
(29.0 ± 4.4 psi).
Part No.: 242-6277
(4) 6B-9202 Spring for the cooling jet sequence S/N: TTE1-Up
valve
Part No.: 240-1914
Length under test force ....... 68.3 mm (2.69 inch) S/N: PAF1-Up
Test force ............... 85 to 100 N (19.0 to 22.4 lb)
KENR5402-07 67
Part No.: 242-6277

S/N: TTF1-Up
Part No.: 229-9579, 312-6297
S/N: TTG1-Up
Part No.: 242-6277
S/N: TTH1-Up
Part No.: 240-1914, 312-6298
S/N: TTJ1-Up
Part No.: 229-9579, 312-6297
S/N: SLM1-Up
Part No.: 240-1914, 312-6298
S/N: JTS1-Up
Part No.: 242-6277
S/N: E3W1-Up
Part No.: 242-6277
S/N: E3X1-Up
Part No.: 242-6277
S/N: E3Y1-Up
Part No.: 242-6277
S/N: E3Z1-Up
g01616336
Illustration 135
Right side view
Typical example
68 KENR5402-07

the clean engine oil.
(8) Lubricate the bore of two O-ring plugs lightly with

the clean engine oil.
(9) Torque for the plug ... 100 ± 15 N·m (75 ± 11 lb ft)
g01616353
Illustration 136
Front view
Typical example
Use the following tightening sequence for the clamp

bolts:
1. Snugly tighten the clamp assembly (3) to the tube

(4).
2. Tighten two bolts (2) of the clamp assembly to the

elbow (10) to 47 ± 9 N·m (35 ± 7 lb ft).
3. Tighten two bolts (1) of the clamp assembly to the

tube (4) to 47 ± 9 N·m (35 ± 7 lb ft).
Note: The cooling jet sequence valves must start

to open at a pressure difference of 130 ± 30 kPa
(19.0 ± 4.5 psi).
Note: The cooling jet sequence valves must be

fully open at a pressure difference of 200 ± 30 kPa
(29.0 ± 4.5 psi).
(5) 6B-9202 Spring for the cooling jet sequence

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

pressure difference of 180 ± 20 kPa (26 ± 3 psi).
(6) 2W-1635 Spring for oil cooler bypass valve

Length under test force ..... 102.0 mm (4.02 inch)
Test force .................. 518 ± 26 N (115.0 ± 5.8 lb)
KENR5402-07 69
i03670352
Engine Oil Filter

SMCS Code: 1318
Part No.: 112-4921
g01445657
Illustration 137
Front view
(1) Lubricate the bore of the O-ring seals lightly with Test force ........................ 518 ± 26 N (116 ± 6 lb)
clean engine oil. Free length after test ........ 143.4 mm (5.65 inch)
(2) 2W-1635 Spring
Note: The bypass valve (3) must move freely in the
Length under test force ..... 102.0 mm (4.02 inch) bore.
70 KENR5402-07
(3) Bypass valve

Start to open pressure ..................... 287 ± 7 kPa
(41.6 ± 1.0 psi)
Fully open pressure ......................... 480 ± 7 kPa
(69.6 ± 1.0 psi)
i02895692
Crankcase Breather
SMCS Code: 1317
Part No.: 124-5513
S/N: TTA1-Up
Part No.: 124-5513
S/N: TTB1-Up
Part No.: 124-5513, 247-4696
S/N: TTC1-Up
Part No.: 124-5513, 247-4696
S/N: TTD1-Up
Part No.: 124-5513, 247-4696
S/N: TTE1-Up
Part No.: 124-5513
S/N: PAF1-Up
Part No.: 124-5513, 247-4696
S/N: TTF1-Up
Part No.: 124-5513, 247-4696
S/N: TTG1-Up
Part No.: 124-5513, 247-4696
S/N: TTH1-Up
Part No.: 124-5513
S/N: TTJ1-Up
Part No.: 124-5513, 247-4696
S/N: SLM1-Up
Part No.: 124-5513
S/N: JTS1-Up
Part No.: 124-5513, 247-4696
S/N: E3W1-Up
Part No.: 124-5513, 247-4696
S/N: E3X1-Up
Part No.: 124-5513, 247-4696
S/N: E3Y1-Up
Part No.: 124-5513, 247-4696
S/N: E3Z1-Up
KENR5402-07 71
g01441554
Illustration 138
(2) Breather assembly (4) Cover assembly
(1) Lubricate the bore of the four O-ring seals lightly

with clean engine oil.
(3) Torque for the six hose clamps ...... 3.0 ± 0.5 N·m
(27 ± 4 lb in)
72 KENR5402-07
i03137363
Crankcase Breather
SMCS Code: 1317
Part No.: 101-0838
S/N: TTA1-Up
Part No.: 101-0838
S/N: TTB1-Up
Part No.: 101-0838
S/N: M8C1-Up
Part No.: 101-0838
S/N: M8D1-Up
g01614413
Illustration 139
(1) Lubricate the bore of two O-ring seals lightly with

clean engine oil.
(2) Torque for three hose clamps ........ 3.0 ± 0.5 N·m
(27 ± 4 lb in)
KENR5402-07 73
i03137380
Crankcase Breather
SMCS Code: 1317
Part No.: 284-4153
S/N: TTC1-Up
Part No.: 284-4153
S/N: TTD1-Up
Part No.: 284-4153
S/N: TTE1-Up
Part No.: 284-4153
S/N: PAF1-Up
Part No.: 284-4153
S/N: TTF1-Up
Part No.: 284-4153
S/N: TTG1-Up
Part No.: 284-4153
S/N: TTH1-Up
Part No.: 284-4153
S/N: TTJ1-Up
Part No.: 284-4153
S/N: SLM1-Up
Part No.: 284-4153
S/N: JTS1-Up
g01614494
Illustration 140
(1) Lubricate the bore of six O-ring seals lightly with i03139762
clean engine oil.
Engine Oil Pan
(2) Torque for ten hose clamps ........... 3.0 ± 0.5 N·m
(27 ± 4 lb in) SMCS Code: 1302
74 KENR5402-07
Part No.: 7C-6887, 7C-7178, 7C-7185

S/N: TTA1-Up
Part No.: 7C-6887, 7C-7178, 7C-7185
S/N: TTB1-Up
Part No.: 7C-6887, 7C-7185
S/N: M8C1-Up
Part No.: 7C-6752, 7C-7178, 7C-9938
S/N: TTC1-Up
Part No.: 7C-6887, 7C-7185
S/N: M8D1-Up
Part No.: 7C-7178
S/N: TTD1-Up
Part No.: 7C-6752, 7C-7178, 7C-9938
S/N: TTE1-Up
Part No.: 7C-6752, 7C-7178, 7C-9938
S/N: PAF1-Up
Part No.: 7C-6752, 7C-7178, 7C-9938
S/N: TTF1-Up
Part No.: 7C-6752, 7C-7178, 7C-9938
S/N: TTG1-Up
Part No.: 7C-7178
S/N: TTH1-Up
Part No.: 7C-7178
S/N: TTJ1-Up
Part No.: 7C-6752, 7C-7178, 7C-9938
S/N: SLM1-Up
Part No.: 7C-7178
S/N: JTS1-Up
Part No.: 7C-6752, 7C-7178, 7C-9938
S/N: E3W1-Up
Part No.: 7C-6752, 7C-9938
S/N: E3X1-Up
Part No.: 7C-6752, 7C-7178, 7C-9938
S/N: E3Y1-Up
Part No.: 7C-7178
S/N: E3Z1-Up
KENR5402-07 75
g01448462
Illustration 141
Typical example
(1) Before assembly, apply 1P-0808 Multipurpose i03139780

Grease in order to lubricate the bores of the
O-ring seals. Engine Oil Pan
(2) As required, apply 8T-9014 Silicone Sealant SMCS Code: 1302
or 138-8436 Liquid Gasket to the joints of the
Part No.: 8N-7706
gasket. S/N: TTC1-Up
(4) Torque for two oil drain plugs ......... 145 ± 15 N·m Part No.: 8N-7706
(105 ± 11 lb ft) S/N: TTE1-Up
In order to prevent stress on the tube assembly Part No.: 8N-7706

(6), use the following tightening procedure during S/N: PAF1-Up
assembly:
Part No.: 8N-7706
1. Tighten two bolts (5) to 47 ± 9 N·m (35 ± 7 lb ft). S/N: TTF1-Up
Part No.: 8N-7706
2. Tighten two bolts (3) to 47 ± 9 N·m (35 ± 7 lb ft). S/N: TTG1-Up
76 KENR5402-07
Part No.: 8N-7706

S/N: SLM1-Up
Part No.: 8N-7706
S/N: E3W1-Up
Part No.: 8N-7706
S/N: E3X1-Up
Part No.: 8N-7706
S/N: E3Y1-Up
g01616154
Illustration 142
Use the following procedure in order to tighten the (14) As required, apply 8T-9014 Silicone Sealant,
bolts of the plate: Permatex No. 2 or 138-8436 Liquid Gasket
on the sealing surface of the oil pan prior to
1. Tighten five bolts (11) to a standard torque. assembly. The sealing surfaces are the following
areas:
2. Tighten bolt 1 through bolt 10 in a numerical
sequence that is shown in Illustration 142 to a • Connecting joint of the flywheel housing (17) and
standard torque. the rear of the cylinder block
(12) As required, apply 8T-9014 Silicone Sealant, • Connecting joint of the front accessory drive
Permatex No. 2 or 138-8436 Liquid Gasket to housing (18) and the front of the cylinder block
the joints of the gasket prior to assembly.
(15) As required, apply 4C-9509 Wicking Sealant to
(13) Lubricate the bore of nine O-ring seals lightly the open top end of the bolt holes after assembly
with the lubricant that is being sealed. of the oil pan.
KENR5402-07 77
(16) As required, apply 8T-9014 Silicone Sealant,

Permatex No. 2 or 138-8436 Liquid Gasket to
the sealing surface of the integral seal prior to
assembly.
(19) Torque for the oil drain plug ......... 145 ± 15 N·m
(105 ± 11 lb ft)
(20) Torque for the oil drain plug ............. 55 ± 7 N·m

(41 ± 5 lb ft)
i03295643
Water Temperature Regulator

SMCS Code: 1355
Part No.: 6I-4950
S/N: TTA1-Up
Part No.: 6I-4950
S/N: TTB1-Up Illustration 143
g01449799
Part No.: 6I-4950

S/N: TTC1-Up Start to open temperature ....................... 81 to 84 °C
(178 to 183 °F)
Part No.: 6I-4950
S/N: TTD1-Up Fully open temperature ...................... 92 °C (198 °F)
Part No.: 6I-4950 (A) Minimum opening distance at fully open
S/N: TTE1-Up temperature ........................ 10.4 mm (0.41 inch)
Part No.: 6I-4950
Maximum opening time from closed position at
S/N: PAF1-Up
79 °C (174 °F) to fully open position at 94 °C
Part No.: 6I-4950 (201 °F) ...................................................... 3 minutes
S/N: TTF1-Up
Maximum closing time from fully open position
Part No.: 6I-4950 at 94 °C (201 °F) to closed position at 79 °C
S/N: TTG1-Up (174 °F) ...................................................... 6 minutes
Part No.: 6I-4950
S/N: TTH1-Up
Part No.: 6I-4950
S/N: TTJ1-Up
Part No.: 6I-4950
S/N: SLM1-Up
Part No.: 6I-4950
S/N: JTS1-Up
Part No.: 6I-4950
S/N: E3W1-Up
Part No.: 6I-4950
S/N: E3X1-Up
Part No.: 6I-4950
S/N: E3Y1-Up
Part No.: 6I-4950
S/N: E3Z1-Up
78 KENR5402-07
i03563503 Part No.: 216-6217

S/N: PAF1-Up
Water Temperature Regulator
Part No.: 216-6217, 282-8537, 292-6969
SMCS Code: 1355 S/N: TTF1-Up
Part No.: 248-5513 Part No.: 216-6217, 282-8537, 292-6969
S/N: TTG1-Up
Part No.: 216-6217
S/N: TTH1-Up
Part No.: 216-6217
S/N: TTJ1-Up
Part No.: 216-6217, 282-8537, 292-6969
S/N: SLM1-Up
Part No.: 216-6217
S/N: JTS1-Up
Part No.: 216-6217, 282-8537
S/N: E3W1-Up
Part No.: 216-6217, 282-8537
S/N: E3X1-Up
Part No.: 216-6217, 282-8537
S/N: E3Y1-Up
g01449799 Part No.: 216-6217

Illustration 144
S/N: E3Z1-Up
Start to open temperature ....................... 81 to 84 °C
(178 to 183 °F)
Fully open temperature ...................... 92 °C (198 °F)
(A) Minimum opening distance at fully open

temperature ........................ 10.4 mm (0.41 inch)
i03587728
Thermostatic Valve
SMCS Code: 1355
Part No.: 216-6217, 282-8537
S/N: TTA1-Up
Part No.: 216-6217, 282-8537
S/N: TTB1-Up
Part No.: 282-8537
S/N: M8C1-Up
Part No.: 216-6217, 282-8537, 292-6969
S/N: TTC1-Up
Part No.: 282-8537
S/N: M8D1-Up
g01428095
Part No.: 216-6217 Illustration 145
S/N: TTD1-Up
(1) Water temperature regulator
Part No.: 216-6217, 282-8537, 292-6969
S/N: TTE1-Up Start to open temperature ................. 18 to 23 °C
(64 to 73 °F)
KENR5402-07 79
Fully open temperature .................. 33 °C (91 °F)
(2) Apply glycerin or an approved equivalent to the

bore of the two O-ring seals.
(A) Minimum opening distance at fully open

temperature ...... 9.0 ± 0.5 mm (0.35 ± 0.02 inch)
i03700561
Water Pump
SMCS Code: 1361
Part No.: 2W-9726, 2W-9729
S/N: TTA1-Up
Part No.: 2W-9726, 2W-9729
S/N: TTB1-Up
Part No.: 334-7865
S/N: M8C1-Up
Part No.: 2W-9729
S/N: TTC1-Up
Part No.: 334-7865
S/N: M8D1-Up
Part No.: 2W-9729
S/N: TTD1-Up
Part No.: 2W-9729
S/N: TTE1-Up
Part No.: 2W-9729
S/N: PAF1-Up
Part No.: 2W-9729
S/N: TTF1-Up
Part No.: 2W-9729
S/N: TTG1-Up
Part No.: 2W-9729
S/N: TTH1-Up
Part No.: 2W-9729
S/N: TTJ1-Up
Part No.: 2W-9729
S/N: SLM1-Up
Part No.: 2W-9729
S/N: JTS1-Up
Part No.: 2W-9729
S/N: E3W1-Up
Part No.: 2W-9729
S/N: E3X1-Up
Part No.: 2W-9729
S/N: E3Y1-Up
Part No.: 2W-9729
S/N: E3Z1-Up
80 KENR5402-07
g01991398
Illustration 146
(2) Ring assembly (3) Water pump seal group
(1) Do not lubricate the sealing lip of the lip type seal. Minimum leakage per minute for the lip type seal at
138 kPa (20 psi) of air pressure is less than 24 cc
(4) Lubricate the bore of the O-ring seals with (1.5 cu in).
Minimum leakage per minute for the water pump seal
(5) Lubricate the shaft with a thin film of clean engine assembly at 138 kPa (20 psi) of air pressure is less
oil before pressing the impeller onto the shaft. than 20 cc (1.2 cu in).
The end of the shaft must be flush with the face
of the impeller within 0.15 mm (0.006 inch).
i03780690
(B) Bore of the impeller for new

shaft ..................................... 25.342 ± 0.013 mm
Auxiliary Water Pump
(0.9977 ± 0.0005 inch) SMCS Code: 1371
(C) Width of the groove for thrust Part No.: 9Y-8175
washer ...... 8.75 ± 0.05 mm (0.344 ± 0.002 inch) S/N: TTA1-Up
(D) Thickness of new thrust washer ............. 8.5 mm Part No.: 9Y-8175
(0.33 inch) S/N: TTB1-Up
(E) Clearance between the impeller and the Part No.: 9Y-8175
cover .................................. 0.5000 ± 0.4925 mm S/N: TTC1-Up
(0.01968 ± 0.01939 inch) Part No.: 9Y-8175
S/N: TTD1-Up
(26 ± 4 lb ft) Part No.: 9Y-8175
S/N: TTE1-Up
(7) Torque for the full nuts ....................... 27 ± 4 N·m
(239 ± 35 lb in) Part No.: 9Y-8175
S/N: PAF1-Up
KENR5402-07 81
Part No.: 9Y-8175

S/N: TTF1-Up
Part No.: 9Y-8175
S/N: TTG1-Up
Part No.: 9Y-8175
S/N: TTH1-Up
Part No.: 9Y-8175
S/N: TTJ1-Up
Part No.: 9Y-8175
S/N: SLM1-Up
Part No.: 9Y-8175
S/N: JTS1-Up
Part No.: 9Y-8175
S/N: E3W1-Up
Part No.: 9Y-8175
S/N: E3X1-Up
Part No.: 9Y-8175
S/N: E3Y1-Up
Part No.: 9Y-8175
S/N: E3Z1-Up
g01486033
Illustration 147
Typical example
82 KENR5402-07
(A) Width of groove in the shaft for thrust 7. Install spring (4) onto the water pump seal
washer ...... 6.25 ± 0.05 mm (0.246 ± 0.002 inch) assembly.
(B) Thickness of the new thrust Assembled length of the spring .. 17.45 ± 0.79 mm
washer ................................... 6.000 ± 0.025 mm (0.687 ± 0.031 inch)
(0.2362 ± 0.0010 inch)
Load on spring at assembled
(C) Dimensions of the shaft length ....................... 40.03 ± 4.45 N (9.0 ± 1.0 lb)
Bore in the sleeve bearing for auxiliary drive Minimum leakage per minute for the water pump seal
shaft ..................................... 75.000 ± 0.055 mm assembly at 138 kPa (20 psi) of air pressure is less
(2.9528 ± 0.0022 inch) than 20 cc (1.2 cu in).
Diameter of new auxiliary drive shaft (not
shown) ................................. 74.900 ± 0.015 mm (6) Lubricate the shaft with a thin film of clean engine
(2.9488 ± 0.0006 inch) oil before pressing the impeller (5) onto the shaft.
(D) Dimensions for the impeller of the impeller within 0.15 mm (0.006 inch).
Bore diameter of the impeller
........ 19.000 ± 0.013 mm (0.7480 ± 0.0005 inch)
Diameter in the shaft for sealant that is being sealed.
impeller ............................. 19.050 to 19.063 mm
(8) Lubricate the bore of the O-ring seal with clean
(0.7500 to 0.7505 inch)
engine oil, glycerin or clean water.
(E) Installation depth of the sleeve bearing in the
water pump housing ..................... 1.5 ± 0.5 mm i03152862
(0.06 ± 0.02 inch)
Note: Do not lubricate the sealing lip of the lip type
seal (1). SMCS Code: 1371
Minimum leakage per minute for the lip type seal at Part No.: 9Y-8909
138 kPa (20 psi) of air pressure is less than 24 cc S/N: TTA1-Up
(1.5 cu in). Part No.: 9Y-8909
S/N: TTB1-Up
the water pump seal assembly. Part No.: 9Y-8909
S/N: TTC1-Up
1. Lubricate the outside diameter of ceramic ring and
rubber seal (2) with clean water or with 207-1600 Part No.: 9Y-8909
Rubber Lubricant. S/N: TTD1-Up
2. Orient the polished face of the ceramic ring toward Part No.: 9Y-8909
water pump seal assembly. S/N: TTE1-Up
Part No.: 9Y-8909
3. Use the installation tool and hand pressure to seat S/N: PAF1-Up
the ceramic ring and the rubber seal into the water
pump housing. Part No.: 9Y-8909
S/N: TTF1-Up
4. Remove spring (4) from the water pump seal
assembly. Part No.: 9Y-8909
S/N: TTG1-Up
5. Lubricate the inside diameter of the water pump
Part No.: 9Y-8909
seal assembly with clean water or with 207-1600
S/N: TTH1-Up
Rubber Lubricant.
Part No.: 9Y-8909
6. Use the seal installation tool and hand pressure S/N: TTJ1-Up
to install the water pump seal assembly onto
the shaft until the face of the water pump seal Part No.: 9Y-8909
assembly makes light contact with the face of the S/N: SLM1-Up
ceramic ring and rubber seal.
Part No.: 9Y-8909
S/N: JTS1-Up
KENR5402-07 83
Part No.: 9Y-8909

S/N: E3W1-Up
Part No.: 9Y-8909
S/N: E3Y1-Up
g01620332
Illustration 148
Minimum leakage per minute for the lip type seal at (5) Lubricate the shaft with a thin film of clean
138 kPa (20 psi) of air pressure is less than 24 cc engine oil before pressing the impeller onto the
(1.5 cubic inch). shaft. The end of the shaft must be flush with
the face of the impeller within 0.00 ± 0.08 mm
(1) Do not lubricate the sealing lip of the lip type seal. (0.000 ± 0.003 inch).
Maximum leakage per minute for the water seal at (B) Clearance between the impeller and the water
138 kPa (20 psi) of air pressure is less than 20 cc pump cover ........................ 0.5000 ± 0.4925 mm
(1.2 cubic inch). (0.01968 ± 0.01939 inch)
Use the following procedure in order to install the (C) Distance from the impeller to the face of the
seal group (4): pump housing assembly .. 31.6526 ± 0.4425 mm
(1.24616 ± 0.01742 inch)
Note: Only use clean water or P-80 to lubricate the
parts. (6) Lubricate the O-ring seal lightly with glycerin or
an approved equivalent.
Note: The seal installation tool is part of the
replacement seal group. (7) Torque for four bolts ....... 35 ± 5 N·m (26 ± 4 lb ft)
1. Use the seal installation tool with hand pressure (8) Lubricate the O-ring seal lightly with glycerin or
to install the rubber seal (2) and the ceramic ring an approved equivalent.
(3) as a unit into the pump housing assembly.
(9) Torque for the adapter ................... 100 ± 10 N·m
2. Remove the spring from the seal group. (75 ± 7 lb ft)
3. Use the seal installation tool with hand pressure to (10) Torque for three full nuts .................. 27 ± 4 N·m
install the seal group onto the shaft until the seal (20 ± 3 lb ft)
faces make light contact.
i03150683
4. Install the spring onto the seal group.
SMCS Code: 1371
84 KENR5402-07
Part No.: 144-6081 1. Use the studs and the nuts that are provided with
S/N: TTA1-Up the auxiliary sea water pump group.
Part No.: 144-6081 Torque for studs .............. 20 ± 3 N·m (15 ± 2 lb ft)
S/N: TTB1-Up
Torque for nuts ................ 30 ± 5 N·m (22 ± 4 lb ft)
Part No.: 144-6081
S/N: TTC1-Up
Part No.: 144-6081
S/N: TTD1-Up
Part No.: 144-6081
S/N: TTE1-Up
Part No.: 144-6081
S/N: PAF1-Up
Part No.: 144-6081
S/N: TTF1-Up
Part No.: 144-6081
S/N: TTG1-Up
Part No.: 144-6081
S/N: TTH1-Up g01619964
Illustration 150
Left Side View
Part No.: 144-6081
S/N: TTJ1-Up
(3) Remove the pipe plug in order to prime the
Part No.: 144-6081 auxiliary sea water pump group.
S/N: SLM1-Up
Part No.: 144-6081
S/N: JTS1-Up
Part No.: 144-6081
S/N: E3W1-Up
Part No.: 144-6081
S/N: E3X1-Up
Part No.: 144-6081
S/N: E3Y1-Up
Part No.: 144-6081
S/N: E3Z1-Up
g01619963
Illustration 149
Top View
Use the following procedure in order to install the

elbow (1):
KENR5402-07 85
g01619957
Illustration 151
Use the following procedure in order to install the Note: Clean all the components with alcohol or
orifice (4): acetone cleaner. Apply 169-5464 Quick Cure Primer
to the threads of the locknut and pump shaft. Allow
1. Lubricate the O-ring seal lightly with the lubricant the surfaces to dry completely. Apply 154-9731
that is being sealed. Thread Lock Compound to the threads of the pump
shaft.
2. Apply 4C-4032 Bearing Mount Compound to the
nuts and taper plugs. (8) Torque for the locknut .................... 271 ± 15 N·m
(200 ± 11 lb ft)
3. Install the orifice into the pump housing. The large
diameter of the orifice is inserted toward the pump (9) Apply 4C-4030 Thread Lock Compound to the
housing. threads of three plugs.
(5) Apply 4C-4032 Bearing Mount Compound to the (10) In order to prevent bearing damage, support the
socket setscrews. pump shaft when the impeller is installed.
(6) Torque for eight bolts ..... 22 ± 4 N·m (16 ± 3 lb ft) Note: Apply 4C-4030 Thread Lock Compound to the
threads of the bearing nut.
retaining ring (7): (11) Torque for the bearing nut ............ 135 ± 15 N·m
(100 ± 11 lb ft)
1. Maintain a load of 490 ± 45 N (110.2 ± 10.1 lb) to
the retaining ring. Use the following procedure in order to install the
seal collar (12):
2. Tighten the socket setscrews to 0.9 ± 0.1 N·m
(8 ± 1 lb in). 1. Clean the pump shaft and the seal collar with a
suitable solvent.
3. Peen the threads (17) with a center punch. Refer
to Illustration 151. 2. Apply 4C-4032 Bearing Mount Compound to the
pump shaft at a distance of 15 mm (0.6 inch) from
the shoulder of the bearing.
86 KENR5402-07
3. Slide the seal collar to 180 degrees onto the pump Part No.: 8N-8466
shaft. Rotate the seal collar in order to distribute S/N: TTC1-Up
the bearing mount compound. Allow the bearing
mount compound to cure for 30 minutes. Part No.: 8N-8466
S/N: TTD1-Up
(13) As required, install shims on each side
Part No.: 8N-8466
of the impeller in order to obtain the axial
S/N: TTE1-Up
clearance. ................................. 0.20 to 0.30 mm
(0.008 to 0.012 inch) Part No.: 8N-8466
S/N: PAF1-Up
Note: Clean all the components with alcohol or
acetone cleaner. Apply 169-5464 Quick Cure Primer Part No.: 8N-8466
to the threads of the nut and pump shaft. Allow the S/N: TTF1-Up
surfaces to dry completely. Apply 154-9731 Thread
Lock Compound to the threads of the pump shaft. Part No.: 8N-8466
S/N: TTG1-Up
(14) Torque for the nut .. 140 ± 10 N·m (105 ± 7 lb ft) Part No.: 8N-8466
S/N: TTH1-Up
(15) Torque for four bolts ...... 5 ± 1 N·m (45 ± 9 lb in)
Part No.: 8N-8466
(16) Torque for six bolts ...... 22 ± 4 N·m (16 ± 3 lb ft) S/N: TTJ1-Up
Part No.: 8N-8466
S/N: SLM1-Up
Part No.: 8N-8466
S/N: JTS1-Up
Part No.: 8N-8466
S/N: E3W1-Up
Part No.: 8N-8466
S/N: E3X1-Up
Part No.: 8N-8466
S/N: E3Y1-Up
Part No.: 8N-8466
S/N: E3Z1-Up
g01619984
Illustration 152
(18) Torque for four rods ............... 18.50 ± 0.75 N·m

(14 ± 1 lb ft)
(19) Torque for four nuts ..... 29 ± 4 N·m (21 ± 3 lb ft)
i03150602

(Sea Water)
SMCS Code: 1371
Part No.: 8N-8466
S/N: TTA1-Up
Part No.: 8N-8466
S/N: TTB1-Up
KENR5402-07 87

water pump seal assembly (6):
1. Remove the spring from the water pump seal

assembly.
2. Put clean water or P-80 lubricant in order to aid the

water pump seal assembly. Use the installation
tool and hand pressure to install the rubber seal
and the ceramic ring as a unit in the housing bore.
Be certain that the shiny face of the ceramic ring
is installed toward the water pump seal assembly.
3. Use the seal installation tool and hand pressure to

install the water pump seal assembly on the shaft
until the faces of the seals make light contact with
each other.
Note: The seal installation tool is part of the

replacement water pump seal assembly.
g01619933
Illustration 153
Maximum leakage per minute for the water seal at

138 kPa (20 psi) of air pressure is less than 20 cc
(1.2 cubic inch).
Minimum leakage per minute for the lip type seal at

138 kPa (20 psi) of air pressure is less than 24 cc g01619936
Illustration 154
(1.5 cubic inch).
4. Install the spring.
(A) The sleeve bearing is installed from the end of
the housing assembly. ........... 0.00 to − 0.25 mm Assembled length (C) ............... 17.45 ± 0.79 mm
(0.000 to − 0.010 inch) (0.687 ± 0.031 inch)
(B) Bore in the new sleeve bearing after assembly for Load at assembled length ............. 40.03 ± 4.45 N
the pump shaft assembly ..... 54.122 ± 0.025 mm (9 ± 1 lb)
(2.1308 ± 0.0010 inch)
(7) Do not lubricate the sealing lip of the lip type seal.
the clean engine oil, glycerin or clean water.

the lubricant that is being sealed.
(3) Torque for the bolt .......... 38 ± 4 N·m (28 ± 3 lb ft)
(4) Torque for drain plug ...... 35 ± 5 N·m (26 ± 4 lb ft)
(5) Torque for pipe plug ....... 14 ± 2 N·m (10 ± 1 lb ft)

88 KENR5402-07
i03711141

SMCS Code: 1371
Part No.: 291-4311
S/N: TTJ1-Up
g01486033
Illustration 155
Typical example
(A) Width of groove in the shaft for thrust Bore diameter of the impeller
washer ...... 6.25 ± 0.05 mm (0.246 ± 0.002 inch) ........ 19.000 ± 0.013 mm (0.7480 ± 0.0005 inch)
Diameter in the shaft for
(B) Thickness of the new thrust impeller ............................. 19.050 to 19.063 mm
washer ................................... 6.000 ± 0.025 mm (0.7500 to 0.7505 inch)
(0.2362 ± 0.0010 inch)
(E) Installation depth of the sleeve bearing in the
(C) Dimensions of the shaft water pump housing ..................... 1.5 ± 0.5 mm
(0.06 ± 0.02 inch)
Bore in the sleeve bearing for auxiliary drive
shaft ..................................... 75.000 ± 0.055 mm Note: Do not lubricate the sealing lip of the lip type
(2.9528 ± 0.0022 inch) seal (1).
Diameter of new auxiliary drive shaft (not
shown) ................................. 74.900 ± 0.015 mm Minimum leakage per minute for the lip type seal at
(2.9488 ± 0.0006 inch) 138 kPa (20 psi) of air pressure is less than 24 cc
(1.5 cu in).
(D) Dimensions for the impeller
KENR5402-07 89
(3) Use the following procedure in order to assemble i03686680

the water pump seal assembly.
Cylinder Block
1. Lubricate the outside diameter of ceramic ring and
rubber seal (2) with clean water or with 207-1600 SMCS Code: 1201
Rubber Lubricant.
Part No.: 350-5225
S/N: M8C1-Up
2. Orient the polished face of the ceramic ring toward
water pump seal assembly. Part No.: 350-5225
S/N: M8D1-Up
3. Use the installation tool and hand pressure to seat
the ceramic ring and the rubber seal into the water
pump housing.
4. Remove spring (4) from the water pump seal

assembly.
5. Lubricate the inside diameter of the water pump

seal assembly with clean water or with 207-1600
Rubber Lubricant.
6. Use the seal installation tool and hand pressure

to install the water pump seal assembly onto
the shaft until the face of the water pump seal
assembly makes light contact with the face of the
ceramic ring and rubber seal.
7. Install spring (4) onto the water pump seal

assembly.
Assembled length of the spring .. 17.45 ± 0.79 mm

(0.687 ± 0.031 inch) g01993533
Illustration 156
Load on spring at assembled Front view of cylinder block
length ....................... 40.03 ± 4.45 N (9.0 ± 1.0 lb) (2) Camshaft bearing junction
Minimum leakage per minute for the water pump seal

assembly at 138 kPa (20 psi) of air pressure is less
than 20 cc (1.2 cu in).
(6) Lubricate the shaft with a thin film of clean engine

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

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

engine oil, glycerin or clean water.
g01993594
Illustration 157
Right side view
(1) Torque for the plugs .. 100 ± 15 N·m (74 ± 11 lb ft)

90 KENR5402-07
(A) Extension of dowels from the surface of the Use the following procedure to tighten the main
cylinder block .. 20.0 ± 0.5 mm (0.79 ± 0.02 inch) bearing cap bolts:
(B) Thickness of the spacer plates ......... 12.363 mm 1. Install main bearing caps with the part number
(0.4867 inch) and FRONT toward the front of the block. Each
cap has a number. Each cap must be installed in
(C) Height of cylinder liner the same position as the correct number on the
side of the cylinder block pan rail.
For the correct method of determining height of the
liner, refer to Testing And Adjusting, “Cylinder Liner 2. Before assembly, apply clean engine oil to the
Projection”. threads of the bolts.
(D) Thickness of gasket between the cylinder block 3. Tighten the bolts in the numerical sequence (4,
and spacer plates ................. 0.194 to 0.218 mm 5, 6, 7) to 190 ± 14 N·m (140 ± 10 lb ft). Refer to
(0.0076 to 0.0086 inch) Illustration 157 for the tightening sequence.
(E) Extension of dowels from the surface of the 4. Again, tighten the bolts in the numerical sequence
cylinder block .. 21.0 ± 0.5 mm (0.83 ± 0.02 inch) (4, 5, 6, 7) to an angle of 180 ± 5 degrees. Refer
to Illustration 157 for the tightening sequence.
(F) Bore in the block for the camshaft
bearings ............................... 98.000 ± 0.020 mm (M) Extension of dowels from the surface of the
(3.8583 ± 0.0008 inch) cylinder block .... 6.0 ± 0.5 mm (0.24 ± 0.02 inch)
(G) Oil holes must be positioned from horizontal at (N) Extension of dowels from the surface of the
the following angle. ..................... 20 ± 5 degrees cylinder block .. 19.0 ± 0.5 mm (0.75 ± 0.02 inch)
Note: All centerlines through oil holes in the camshaft (P) Extension of dowels from the surface of the
bearings (G) and the camshaft bearing junctions (2) cylinder block .. 40.0 ± 0.5 mm (1.58 ± 0.02 inch)
must be in the position that is shown for each side of
the cylinder block.
i03152764
(H) Main bearing cap width Cylinder Block

Width of main bearing ........ 340.030 ± 0.015 mm
(13.3870 ± 0.0006 inch) SMCS Code: 1201
Width of cylinder block for main bearing Part No.: 240-6653
cap ..................................... 339.985 ± 0.015 mm S/N: TTA1-Up
(13.3852 ± 0.0006 inch)
Tight press fit between the sides of the main Part No.: 240-6653
bearing cap and the cylinder block ..... 0.075 mm S/N: TTB1-Up
(0.0030 inch)
Loose press fit between the sides of the main Part No.: 240-6651, 240-6653
bearing cap and the cylinder block ..... 0.015 mm S/N: TTC1-Up
(0.0006 inch)
Part No.: 240-6653
(J) New dimension from centerline of crankshaft S/N: TTD1-Up
bearing bore to the top of the block .. 586.00 mm Part No.: 240-6651, 240-6653
(23.071 inch) S/N: TTE1-Up
(K) Bore in the block for the main bearings Part No.: 240-6653
S/N: PAF1-Up
Standard, original new
size .................................... 169.742 ± 0.020 mm Part No.: 240-6651, 240-6653
(6.6827 ± 0.0008 inch) S/N: TTF1-Up
0.63 mm (0.025 inch) larger than original
size .................................... 170.372 ± 0.020 mm Part No.: 240-6651, 240-6653
(6.7076 ± 0.0008 inch) S/N: TTG1-Up
Part No.: 240-6653
(L) New dimension from centerline of crankshaft
S/N: TTH1-Up
bearing bore to bottom of block (pan
rails) .............................. 230.00 mm (9.055 inch) Part No.: 240-6653
S/N: TTJ1-Up
(3) Main bearing cap
KENR5402-07 91
Part No.: 240-6651, 240-6653 Note: During assembly, the bottom of spacer plates,
S/N: SLM1-Up top of cylinder block and both sides of plate gasket
must be free of fuel, oil, water, gasket adhesives,
Part No.: 240-6653 assembly compounds and any other contaminants.
S/N: JTS1-Up
(A) Thickness of the spacer plate .......... 12.313 mm
Part No.: 240-6651, 240-6653
(0.4848 inch)
S/N: E3W1-Up
Part No.: 240-6651, 240-6653 (B) Thickness of the plate gasket
S/N: E3X1-Up between the cylinder block and spacer
plate ...................................... 0.194 to 0.218 mm
Part No.: 240-6651, 240-6653 (0.0076 to 0.0086 inch)
S/N: E3Y1-Up
(C) Extension of the dowel from the top face of the
Part No.: 240-6653 cylinder block .. 21.0 ± 0.5 mm (0.83 ± 0.02 inch)
S/N: E3Z1-Up
(1) Torque for four plugs ...................... 100 ± 15 N·m
(75 ± 11 lb ft)

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

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

bearings ............................... 98.000 ± 0.020 mm
(3.8583 ± 0.0008 inch)
(F) The oil holes in the camshaft bearings must

be positioned from horizontal at the following
angle: .......................................... 20 ± 5 degrees
Note: All centerlines through the oil holes in the

camshaft bearings (F) and the camshaft bearing
joints (3) must be in the position that is shown for
each side of the cylinder block.
(G) New dimension from centerline of crankshaft

bearing bore to the top of the block ....... 586 mm
g01417382
(23.1 inch)
Illustration 158
Front view (H) New dimension from centerline of crankshaft
rails) ....................................... 230 mm (9.1 inch)
(J) Bore in the block for the main bearings

size .................................... 169.742 ± 0.020 mm
(6.6827 ± 0.0008 inch)
size .................................... 170.372 ± 0.020 mm
(6.7075 ± 0.0008 inch)
(K) Dimension for crankshaft main bearing cap

Width of crankshaft main bearing
Illustration 159
g01434393 cap ..................................... 340.030 ± 0.015 mm
Right side view (13.3870 ± 0.0006 inch)
92 KENR5402-07
Width of cylinder block for crankshaft main i02674259

bearing cap ........................ 339.985 ± 0.015 mm
(13.3852 ± 0.0006 inch) Cylinder Block
Tight press fit between the sides of the
crankshaft main bearing cap and the cylinder SMCS Code: 1201
block ............................. 0.075 mm (0.0030 inch)
Part No.: 237-7957
Loose press fit between the sides of the
S/N: TTA1-Up
crankshaft main bearing cap and the cylinder
block ............................. 0.015 mm (0.0006 inch) Part No.: 237-7957
S/N: TTB1-Up
(4) Main bearing cap
Use the following procedure to tighten the crankshaft

main bearing cap bolts:
1. Install main bearing caps with the part number

and “FRONT” toward the front of the block. Each
cap has a number. Each cap must be installed in
the same position as the correct number on the
side of the cylinder block pan rail.
2. Before assembly, apply clean engine oil on the

threads of the bolts.
3. Tighten bolt (5) through bolt (8) in the numerical

sequence that is shown in Illustration 158 to a
torque of 190 ± 14 N·m (140 ± 10 lb ft).
4. Tighten bolt (5) through bolt (8) again in the

numerical sequence to a rotation of 180 ± 5
degrees.
g01343555
(L) Extension of the dowel from the rear face of the Illustration 160
cylinder block .... 6.0 ± 0.5 mm (0.24 ± 0.02 inch) Front view of cylinder block
(1) Camshaft bearing junction
(M) Extension of the dowel from the front face of the
cylinder block .... 6.0 ± 0.5 mm (0.24 ± 0.02 inch)
(N) Extension of the dowel from the rear face of the

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

cylinder block .. 40.0 ± 0.5 mm (1.57 ± 0.02 inch)
g01343968
Illustration 161
(A) Thickness of spacer plates ............... 12.313 mm

(0.4848 inch)
KENR5402-07 93
(B) Thickness of gasket between the cylinder block 1. Install main bearing caps with the part number
and spacer plates ................. 0.194 to 0.218 mm and FRONT toward the front of the block. Each
(0.0076 to 0.0086 inch) cap has a number. Each cap must be installed in
the same position as the correct number on the
(C) All dowels extend above the face by the following side of the cylinder block pan rail.
distance. ......... 20.0 ± 0.5 mm (0.79 ± 0.02 inch)
2. Put clean engine oil on the bolts before assembly.
(2) Torque for plugs ....... 100 ± 15 N·m (75 ± 11 lb ft)
3. Tighten the bolts in the numerical sequence (4, 5,
(D) Height of Cylinder liner 6, 7) to the following torque.
For the correct method of determining height of the Torque for bolts ....... 190 ± 14 N·m (140 ± 10 lb ft)
liner, refer to Testing And Adjusting, “Cylinder Liner
Projection”. 4. Tighten the bolts again in the numerical sequence
to the following rotation.
(E) Bore in the block for the camshaft
bearings ............................... 98.000 ± 0.020 mm Angle for bolts ............................ 180 ± 5 degrees
(3.8583 ± 0.0008 inch)
(L) The dowel extends from the rear face of the block
(F) Oil holes must be positioned from horizontal at by the following distance. .............. 6.0 ± 0.5 mm
the following angle. ..................... 20 ± 5 degrees (0.24 ± 0.02 inch)
Note: All centerlines through oil holes in the camshaft (M) The dowels extend from the front face of the
bearings (F) and the camshaft bearing junctions (1) block by the following distance. ..... 6.0 ± 0.5 mm
must be in the position that is shown for each side of (0.24 ± 0.02 inch)
the cylinder block.
(N) The dowels extend from the rear face of the
(G) New dimension from centerline of crankshaft block by the following distance. ... 19.0 ± 0.5 mm
bearing bore to the top of the block .. 586.00 mm (0.75 ± 0.02 inch)
(23.071 inch)
(P) The dowels extend from the front face of the
(H) Main bearing cap width block by the following distance. ... 40.0 ± 0.5 mm
(1.58 ± 0.02 inch)
Width of main bearing ........ 340.030 ± 0.015 mm
(13.3870 ± 0.0006 inch)
Width of cylinder block for main bearing i02871050
cap ..................................... 339.985 ± 0.015 mm
(13.3852 ± 0.0006 inch) Cylinder Liner
Tight press fit between the sides of the main
bearing cap and the cylinder block ..... 0.075 mm SMCS Code: 1216
(0.0030 inch) Part No.: 211-7826
Loose press fit between the sides of the main
bearing cap and the cylinder block ..... 0.015 mm
(0.0006 inch)
(J) Bore in the block for the main bearings

size .................................... 169.742 ± 0.020 mm
(6.6827 ± 0.0008 inch)
size .................................... 170.372 ± 0.020 mm
(6.7076 ± 0.0008 inch)
(K) New dimension from centerline of crankshaft

rails) .............................. 230.00 mm (9.055 inch) Illustration 162
g01399536
(3) Main bearing cap (A) Bore in new cylinder liner .. 170.025 ± 0.025 mm
(6.6939 ± 0.0010 inch)
Use the following procedure to tighten the main
bearing cap bolts: (B) Thickness of flange (1) on cylinder
liner ......... 12.65 ± 0.02 mm (0.498 ± 0.001 inch)
94 KENR5402-07
Use the liner again with any used piston or i02872093

any new piston if all the measurements are
in the following range. Use a FLEX-HONE Piston and Rings
first. ..................................... 170.000 to 170.152 mm (One-Piece Piston)
(6.6929 to 6.6989 inch)
SMCS Code: 1214
Use the liner again with the original piston
if the measurements of the upper bore are Part No.: 281-6141, 282-9965
in the following range. Use a FLEX-HONE S/N: TTA1-Up
first. ..................................... 170.000 to 170.229 mm
(6.6929 to 6.7019 inch) Part No.: 281-6141
S/N: TTB1-Up
Use the following procedure to install the cylinder
Part No.: 333-2239
liner: S/N: M8C1-Up
1. Apply liquid soap on the cylinder block liner bore Part No.: 281-6141
surfaces and the rubber seals that are on the S/N: TTC1-Up
lower end of the cylinder liner.
Part No.: 333-2239
2. Dip the filler band (2) completely in clean engine S/N: M8D1-Up
oil for a moment.
Part No.: 281-6141
3. Immediately install the filler band in the groove S/N: TTD1-Up
that is under the flange. Part No.: 281-6141
S/N: E3W1-Up
4. Immediately install the cylinder liner into the
cylinder block before the expansion of the filler Part No.: 281-6141
band. S/N: E3X1-Up
Note: Refer to Reuse And Salvage Guidelines, Part No.: 281-6141

SEBF8049, “Visual Inspection of the Piston” for more S/N: E3Y1-Up
information. Also, refer to Guideline For Reusable
Parts And Salvage Operations, SEBF8068, “Cylinder Part No.: 281-6141, 282-9965
S/N: E3Z1-Up
Liners” for more information.
g01430242
Illustration 163
Note: Refer to Guideline for Reusable Parts for

information on the pistons, the piston pins, and the
retaining rings.
KENR5402-07 95
This piston has a square top piston ring. Use the the following value. ...................... 0.5 mm to 0.8 mm
246-1176 Piston Ring Groove Gauge Gp for (0.02 to 0.03 inch)
measuring the top piston ring groove.
Note: After the piston rings have been installed,
This piston has a keystone type of intermediate rotate the piston rings so that the end gaps are 120
piston ring. Use the 1U-6431 Piston Ring Groove degrees from each other.
Gauge Gp for measuring the intermediate piston ring
groove. For correct use of the piston ring groove
gauge group, refer to the instruction card that is with
the piston ring groove gauge group.
Note: Prior to the installation of the piston rings,

the ring grooves must be completely lubricated with
clean engine oil. After assembly, the mating surfaces
of the rings to the cylinder liner must be completely
lubricated with clean engine oil.
Top Piston Ring (1)

Install the top piston ring with the “UP-1” side toward
the top of the piston.
When the new top piston ring is installed in a cylinder

liner with a bore size of 170 mm (6.7 inch), the
clearance between the ends of the piston ring is the
following value. ............................ 0.625 ± 0.125 mm
(0.0246 ± 0.0049 inch)
g01446562
Illustration 164
Thickness of new top piston ring ................ 3.88 mm
(0.153 inch) Note: Prior to assembly of the piston pin, the piston
pin, the piston pin bore, the connecting rod eye, and
Intermediate Piston Ring (2) the connecting rod pin bearing must be completely
Install the intermediate piston ring with the “UP-2”
side toward the top of the piston. Piston Pin Bore (4)
When the new intermediate piston ring is installed in (B) Angle of bushing locator on far side .. 45 degrees
a cylinder liner with a bore size of 170 mm (6.7 inch),
the clearance between the ends of the piston ring is (C) Bore diameter of piston
the following value. .......................... 1.00 ± 0.15 mm pin .................................... 70.0705 ± 0.0075 mm
(0.039 ± 0.006 inch) (2.75867 ± 0.00030 inch)
Thickness of new intermediate piston Piston Pin (5)

ring ...................................... 3.785 mm (0.1490 inch)
Dimensions for piston pin
Oil Control Piston Ring (3) Outside diameter of piston
The ends of the oil control piston ring should be a pin ... 69.930 ± 0.005 mm (2.7531 ± 0.0002 inch)
distance of 180 degrees from the ring end gap when Inside diameter of piston pin ........ 30.5 ± 0.5 mm
the oil control piston ring is assembled. The white (1.20 ± 0.02 inch)
colored portion of the piston ring must be visible at Length of piston pin ........... 102.0 + 0.0 - 0.3 mm
the ring end gap. (4.02 + 0.00 - 0.01)
Width of groove in new piston for the oil control piston Note: The 263-8955 Piston Pin is not
ring ......... 4.04 mm to 4.07 mm (0.159 to 0.160 inch) interchangeable with the former 197-0560 Piston
Pin.
Thickness of new oil control piston
ring ................ 3.97 to 3.99 mm (0.156 to 0.157 inch) Pin Retainer (6)
When the new oil control piston ring is installed in a Assemble the pin retainer with the opening above
cylinder liner with a bore size of 170 mm (6.7 inch), section A-A.
the clearance between the ends of the piston ring is
96 KENR5402-07
Refer to Table 1 for the part numbers of the tools that i03127641
are used in servicing the piston.
Piston and Rings
Table 1
(Two-Piece Piston)
Service Tools
SMCS Code: 1214
Pt. No. Description
271-0498 Expander Ring Part No.: 283-0246, 310-6962
S/N: TTE1-Up
1P-1861 Retaining Ring Pliers
Part No.: 283-0246, 310-6962
1U-7616 Piston Ring Compressor Gp
S/N: TTF1-Up
246-1176 Piston Ring Groove Gauge Gp(1)
Part No.: 283-0246
1U-6431 Piston Ring Groove Gauge Gp(2) S/N: TTG1-Up
(1) Only for the top ring groove
(2) Only for the intermediate ring groove Part No.: 283-0246, 310-6962
S/N: TTH1-Up
Part No.: 283-0246
S/N: TTJ1-Up
Part No.: 283-0246
S/N: SLM1-Up
Part No.: 283-0246
S/N: JTS1-Up
g01504020
Illustration 165
This piston has a Keystone top ring. This piston also

has a Keystone intermediate ring. The 204-8041
Piston Ring Groove Gauge Gp is necessary for
measuring the ring grooves in the Keystone pistons.
For correct use of the gauge group, refer to the
instruction card that is with the gauge group.
Note: Measure the piston pin bore in the bushings in

two places for each bushing in a vertical direction.
(1) Bore in the bushing of the crown assembly for

new piston pin .................. 70.0525 ± 0.0075 mm
(2.75796 ± 0.00030 inch)
KENR5402-07 97
Note: Measure the piston pin bore in a vertical Clearance between the groove and the new oil
direction. control piston ring ....................... 0.050 to 0.100 mm
(0.0020 to 0.0039 inch)
(2) Bore in the piston skirt for new piston
pin ... 69.988 ± 0.005 mm (2.7554 ± 0.0002 inch) Clearance between the ends of the piston
ring in a cylinder liner bore of 170 mm
Note: Prior to the installation of the rings, the ring (6.7 inch) ......... 0.65 ± 0.15 mm (0.026 ± 0.006 inch)
grooves must be completely lubricated with clean
engine oil. After assembly, the mating surfaces of Increase in the clearance between the ends of the
the rings to the cylinder liner must be completely piston ring for each 0.03 mm (0.001 inch) increase in
lubricated with clean engine oil. the cylinder liner bore ............. 0.08 mm (0.003 inch)
Note: After all of the piston rings have been installed,

Top Piston Ring (3) 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 top of the piston.
the pin bore.
Width of groove in new piston for the top piston
Note: Prior to assembly of the piston pin, the piston
ring ...................................... 4.219 mm (0.1661 inch)
the connecting rod pin bearing must be completely
Thickness of new top piston ring .. 4.5 mm (0.18 inch)
Clearance between the ends of the piston
ring in a cylinder liner bore of 170 mm Piston Pin (6)
(6.7 inch) .. 0.625 ± 0.125 mm (0.0246 ± 0.0049 inch)
Note: Measure the piston pin diameter on each end
Increase in the clearance between the ends of the in a vertical and horizontal direction.
piston ring for each 0.03 mm (0.001 inch) increase in
the cylinder liner bore ............. 0.08 mm (0.003 inch) Outside diameter ....................... 69.962 ± 0.005 mm
(2.7544 ± 0.0002 inch)
Intermediate Piston Ring (4) Length ......... 137.55 ± 0.15 mm (5.415 ± 0.006 inch)
side toward the top of the piston. Pin Retainer (7)
Width of groove in new piston for the intermediate Note: Install the pin retainer with the gap toward the
piston ring ........................... 3.514 mm (0.1383 inch) top of the piston.
Thickness of new intermediate piston Thickness of new pin retainer .......... 2.40 ± 0.08 mm
ring ...................................... 3.785 mm (0.1490 inch) (0.094 ± 0.003 inch)
Clearance between the ends of the piston Width of groove in new piston for the pin
ring in a cylinder liner bore of 170 mm retainer .................................... 2.75 mm (0.108 inch)
(6.7 inch) ......... 1.00 ± 0.15 mm (0.039 ± 0.006 inch)
Increase in the clearance between the ends of the

the cylinder liner bore ............. 0.08 mm (0.003 inch)
Oil Control Piston Ring (5)

The ends of the oil control piston ring should be a
distance of 180 degrees from the ring end gap when
the oil control piston ring is assembled. The red
colored portion of the piston ring must be visible at
the ring end gap.
Width of groove in new piston for the oil control piston

ring .......... 4.055 ± 0.015 mm (0.1596 ± 0.0006 inch)
Thickness of new oil control piston

ring .......... 3.980 ± 0.010 mm (0.1567 ± 0.0004 inch)
98 KENR5402-07
i02976009 Note: Prior to the installation of the rings, the ring

grooves must be completely lubricated with clean
Piston and Rings engine oil. After assembly, the mating surfaces of
(Two-Piece Piston) the rings to the cylinder liner must be completely
SMCS Code: 1214
Part No.: 244-8850
Top Piston Ring (3)
S/N: PAF1-Up
Part No.: 244-8850 the top of the piston. The top piston ring must be
S/N: TTG1-Up installed with the yellow colored stripe to the right of
the ring end gap.
Part No.: 244-8850
S/N: TTJ1-Up Width of groove in new piston for the top piston
ring ...................................... 4.219 mm (0.1661 inch)
Part No.: 244-8850
S/N: SLM1-Up Thickness of new top piston ring .. 4.5 mm (0.18 inch)
Part No.: 244-8850
S/N: JTS1-Up Clearance between the ends of the piston
(6.7 inch) .. 0.625 ± 0.125 mm (0.0246 ± 0.0049 inch)

Intermediate Piston Ring (4)

side toward the top of the piston.
Width of groove in new piston for the intermediate

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

ring ...................................... 3.785 mm (0.1490 inch)
Clearance between the ends of the piston

(6.7 inch) ......... 1.00 ± 0.15 mm (0.039 ± 0.006 inch)
g01504020
Illustration 166
This piston has a Keystone top ring. This piston also
has a Keystone intermediate ring. The 204-8041
Piston Ring Groove Gauge Gp is necessary for
measuring the ring grooves in the Keystone pistons. Oil Control Piston Ring (5)
For correct use of the gauge group, refer to the
instruction card that is with the gauge group. The ends of the oil control piston ring should be a
distance of 180 degrees from the ring end gap when
Note: Measure the piston pin bore in the bushings in the oil control piston ring is assembled. The white
two places for each bushing in a vertical direction. colored portion of the piston ring must be visible at
the ring end gap.
(1) Bore in the bushing of the crown assembly for
new piston pin .................. 70.0525 ± 0.0075 mm Width of groove in new piston for the oil control piston
(2.75796 ± 0.00030 inch) ring .......... 4.055 ± 0.015 mm (0.1596 ± 0.0006 inch)
Note: Measure the piston pin bore in a vertical Thickness of new oil control piston
direction. ring .......... 3.980 ± 0.010 mm (0.1567 ± 0.0004 inch)
(2) Bore in the piston skirt for new piston Clearance between the groove and the new oil
pin ... 69.988 ± 0.005 mm (2.7554 ± 0.0002 inch) control piston ring ....................... 0.050 to 0.100 mm
(0.0020 to 0.0039 inch)
KENR5402-07 99
Clearance between the ends of the piston Part No.: 144-0725

ring in a cylinder liner bore of 170 mm S/N: E3W1-Up
(6.7 inch) ......... 0.65 ± 0.15 mm (0.026 ± 0.006 inch)
Part No.: 144-0725
Increase in the clearance between the ends of the S/N: E3X1-Up
Part No.: 144-0725
S/N: E3Y1-Up
Note: After all of the piston rings have been installed, Part No.: 144-0725
rotate the piston rings so that the end gaps are S/N: E3Z1-Up
separated by 120 degrees. The ring gap for the oil
control piston ring must be aligned in the plane of
the pin bore.
Note: Prior to assembly of the piston pin, the piston

the connecting rod pin bearing must be completely
Piston Pin (6)

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

(2.7544 ± 0.0002 inch)
Length ......... 137.55 ± 0.15 mm (5.415 ± 0.006 inch)
Pin Retainer (7)

Note: Install the pin retainer with the gap toward the
top of the piston.
Thickness of new pin retainer .......... 2.40 ± 0.08 mm

(0.094 ± 0.003 inch)
Width of groove in new piston for the pin

retainer .................................... 2.75 mm (0.108 inch)
i03660673
Connecting Rod
g01416660
Illustration 167
SMCS Code: 1218
Part No.: 144-0725 (A) Angle above the centerline on either side of the
S/N: TTA1-Up bearing joint for the sleeve bearing for the piston
pin. .................................................... 10 degrees
Part No.: 144-0725
S/N: TTB1-Up Note: The connecting rod must be heated prior to
installation of the sleeve bearing for the piston pin.
Part No.: 144-0725 Do not use a torch to heat the connecting rod.
S/N: M8C1-Up
Part No.: 144-0725 (B) The connecting rod may be heated from
S/N: TTC1-Up 175 to 260 °C (347 to 500 °F) for the installation
of the sleeve bearing for the piston pin. Minimum
Part No.: 144-0725 length for heating the connecting rod .... 105 mm
S/N: M8D1-Up (4.1 inch)
Part No.: 144-0725

S/N: TTD1-Up
100 KENR5402-07
Note: Thoroughly lubricate the piston pin with clean Side clearance between two connecting rods on the
engine oil prior to assembly of the piston and the same new crankshaft pin ............. 0.850 ± 0.332 mm
connecting rod. (0.0335 ± 0.0131 inch)
(C) Dimensions for the piston pin Use the following procedure for tightening the
connecting rod bolts:
Bore in the sleeve bearing for the
piston pin after installation of the sleeve Note: Bolt 1 and bolt 2 must be on the same end of
bearing ................................. 70.000 ± 0.008 mm the connecting rod cap that has bearing tabs and
(2.7559 ± 0.0003 inch) location pin (3).
Bore in the connecting rod for the sleeve bearing
for the piston pin .................. 75.760 ± 0.015 mm 1. Before assembly, apply 6V-4876 Lubricant on the
(2.9827 ± 0.0006 inch) bolt threads, the bolt shank and the bolt seat.
(D) Distance between the center of the 2. Tighten the bolt 1 and bolt 2 to 90 ± 5 N·m
bearings ............................... 380 mm (15.0 inch) (66 ± 4 lb ft).
(E) Protrusion of the dowel from the connecting rod 3. Tighten the bolt 3 and bolt 4 to 90 ± 5 N·m
cap .................... 4.0 ± 0.5 mm (0.16 ± 0.02 inch) (66 ± 4 lb ft).
(F) Bore in the connecting rod for the bearing for 4. Again, tighten the bolt 3 and bolt 4 to 90 ± 5 N·m
the crankshaft connecting rod journal after (66 ± 4 lb ft).
applying final torque to the connecting rod
bolts ................................... 143.028 ± 0.015 mm 5. Tighten all bolts for an additional 90 ± 5 degrees.
(5.6310 ± 0.0006 inch)
(G) Bore in the connecting rod bearing for i03563228

crankshaft ..................... 135.133 to 135.194 mm
(5.3202 to 5.3226 inch) Connecting Rod
(1) Etch the cylinder number on the connecting rod SMCS Code: 1218
and the cap in this location. Mark the connecting Part No.: 230-2516
rod and the cap with numbers. Mark the numbers S/N: TTE1-Up
on the same side of the connecting rod as the
bearing retainer notch. Part No.: 230-2516
S/N: PAF1-Up
Note: Install the connecting rod in the engine with the
part number to the rear of the engine. Part No.: 230-2516
S/N: TTF1-Up
Part No.: 230-2516
S/N: TTG1-Up
Part No.: 230-2516
S/N: TTH1-Up
Part No.: 230-2516
S/N: TTJ1-Up
Part No.: 230-2516
S/N: SLM1-Up
Part No.: 230-2516
S/N: JTS1-Up
g01526418
Illustration 168
View H-H
(3) Location pin for correct installation of connecting rod caps
(2) The chamfer side must be adjacent to the crank

pin thrust surface when the connecting rod and
piston group is assembled in the engine.
KENR5402-07 101
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:
Note: 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 6V-4876 Lubricant on the

bolt threads, the bolt shank and the bolt seat.
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).
5. Tighten all bolts for an additional 90 ± 5 degrees.
(4) The chamfer must be adjacent to the crank pin

thrust surface when the connecting rod and the
piston group is assembled in the engine. The
opposite side will push the rod that mates on the
same crank pin.
Note: The connecting rod must be heated prior to

installation of the sleeve bearing for the piston pin.
Do not use a torch to heat the connecting rod.
(A) The connecting rod may be heated from

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

Bore in the sleeve bearing for the
piston pin after installation of the sleeve
bearing ................................. 70.000 ± 0.008 mm
(2.7559 ± 0.0003 inch)
Bore in the connecting rod for the sleeve bearing
for the piston pin .................. 75.760 ± 0.015 mm
(2.9827 ± 0.0006 inch)
g01478072
Illustration 169 (C) Angle above centerline on either side of the
bearing joint for the sleeve bearing for the piston
Note: When a new top end bearing is installed, pin ..................................................... 10 degrees
ensure that no residual dirt or machining debris
is trapped between the sleeve bearing (2) and (D) Distance between the center of the
the drilled hole (1) in the connecting rod. Refer to bearings .......................... 392.5 mm (15.45 inch)
Illustration 169.
Note: Take the connecting rod bearing measurements
Use the following procedure for cleaning the drilled on the centerline of the connecting rod bores.
hole (1):
(E) Dimensions for the connecting rod bearing
1. Clean the drilled hole with a suitable cleaning
solution. Use a spray nozzle in order to wash the Bore in the connecting rod bearing for the
drilled hole from the large end of the connecting crankshaft ..................... 135.133 to 135.194 mm
rod. (5.3202 to 5.3226 inch)
102 KENR5402-07
Clearance between the connecting rod bearing i01359201

and the new crankshaft ........ 0.107 to 0.218 mm
(0.0042 to 0.0086 inch) Connecting Rod and Main
Bearing Journals
(F) Extension of the dowel from the connecting rod
cap .................... 4.0 ± 0.5 mm (0.16 ± 0.02 inch) SMCS Code: 1230
(G) Dimensions for the connecting rod Part No.: 101-0336, 8N-0337
S/N: TTA1-Up
Bore in the connecting rod for the bearing for
the crankshaft connecting rod journal after Part No.: 101-0336, 8N-0337
applying final torque to the connecting rod S/N: TTB1-Up
bolts ................................... 143.028 ± 0.015 mm
(5.6310 ± 0.0006 inch) Part No.: 332-7912
Side clearance between two connecting rods on S/N: M8C1-Up
the same new crank pin ......... 0.850 ± 0.332 mm
Part No.: 8N-0337, 8N-7103
(0.0335 ± 0.0131 inch) S/N: TTC1-Up
Part No.: 332-7912
S/N: M8D1-Up
Part No.: 8N-0337
S/N: TTD1-Up
Part No.: 161-6926, 8N-0337
S/N: TTE1-Up
Part No.: 161-6928, 8N-0337
S/N: PAF1-Up
Part No.: 161-6926, 8N-0337
S/N: TTF1-Up
Part No.: 161-6926, 8N-0337
S/N: TTG1-Up
Part No.: 161-6928, 8N-0337
S/N: TTH1-Up
Part No.: 161-6928, 8N-0337
S/N: TTJ1-Up
Part No.: 161-6926, 8N-0337
S/N: SLM1-Up
Part No.: 161-6928, 8N-0337
S/N: JTS1-Up
Part No.: 8N-0337, 8N-7103
S/N: E3W1-Up
Part No.: 8N-0337, 8N-7103
S/N: E3X1-Up
Part No.: 8N-0337, 8N-7103
S/N: E3Y1-Up
Part No.: 8N-0337
S/N: E3Z1-Up
Refer to Guidelines For Reusable Parts, SEBF8009,

“Main Bearings And Connecting Rod Bearings” for
more information.
Connecting Rod Bearing Journals

KENR5402-07 103
Table 2 Part No.: 161-6928, 8N-0337

Diameter Of Crankshaft Journal (Bearing Surface)
S/N: TTJ1-Up
For Connecting Rod Bearings Part No.: 8N-0337
Original Size Journal 135.000 ± 0.025 mm S/N: SLM1-Up
(5.3150 ± 0.0010 inch)
Part No.: 161-6928, 8N-0337
Undersize Journal 134.370 ± 0.025 mm S/N: JTS1-Up
0.63 mm (0.025 inch) (5.2902 ± 0.0010 inch)
Part No.: 8N-0337
Undersize Journal 133.730 ± 0.025 mm
1.27 mm (0.050 inch) (5.2650 ± 0.0010 inch) S/N: E3W1-Up
Part No.: 8N-0337
Clearance between bearing and new S/N: E3X1-Up
journal ... 0.107 to 0.218 mm (0.0042 to 0.0086 inch)
Part No.: 8N-0337
Main Bearing Journals S/N: E3Y1-Up
Part No.: 8N-0337
Table 3
S/N: E3Z1-Up
Diameter Of Crankshaft Journal (Bearing
Surface) For Main Bearings
Original Size Journal 160.000 ± 0.025 mm
(6.2992 ± 0.0010 inch)
0.63 mm (0.025 inch) (6.2744 ± 0.0010 inch)
1.27 mm (0.050 inch) (6.2492 ± 0.0010 inch)
Clearance between bearing and new

journal ... 0.122 to 0.241 mm (0.0048 to 0.0095 inch)
i03340020
Crankshaft
SMCS Code: 1202
Part No.: 8N-0337
S/N: TTA1-Up
Part No.: 8N-0337
S/N: TTB1-Up
Part No.: 8N-0337
S/N: TTC1-Up
Part No.: 8N-0337
S/N: TTD1-Up
Part No.: 8N-0337
S/N: TTE1-Up
Part No.: 161-6928, 8N-0337
S/N: PAF1-Up
Part No.: 8N-0337
S/N: TTF1-Up
Part No.: 8N-0337
S/N: TTG1-Up
Part No.: 161-6928, 8N-0337
S/N: TTH1-Up
104 KENR5402-07
g01419944
Illustration 170
(1) Thrust plates
Refer to Specifications, “Connecting Rod And Main

Bearing Journals” for more information.
(B) Crankshaft end play ................. 0.17 to 0.63 mm

(0.007 to 0.025 inch)
(2) Torque for the plugs ....... 50 ± 7 N·m (37 ± 5 lb ft)
Note: Do not reuse counterweight bolts.
(3) Use the following procedure to tighten the bolts

of the counterweight:
1. Before assembly, lubricate the threads of the

bolts, the bolt shank, the washers and the contact
surface under the bolt head with 6V-4876
Lubricant.
2. Tighten all the bolts evenly to 70 ± 5 N·m

(50 ± 4 lb ft).
3. Rotate each bolt for an additional 120 ± 5 degrees.

KENR5402-07 105
i03530820
Crankshaft
SMCS Code: 1202
Part No.: 101-0336
S/N: TTA1-Up
Part No.: 101-0336
S/N: TTB1-Up
Part No.: 332-7912
S/N: M8C1-Up
Part No.: 332-7912
S/N: M8D1-Up
g01419944
Illustration 171
(1) Thrust plates
Refer to Specifications, “Connecting Rod And Main 1. Before assembly, lubricate the threads of the
Bearing Journals” for more information. bolts, the bolt shank, the washers and the contact
(B) Crankshaft end play ................. 0.17 to 0.63 mm Lubricant.
(0.007 to 0.025 inch)
2. Tighten the bolts to 200 ± 5 N·m (150 ± 4 lb ft).
(2) Torque for the plugs ....... 50 ± 7 N·m (37 ± 5 lb ft)
3. Loosen the bolts.
4. Again, tighten the bolts evenly to 70 ± 5 N·m
(3) Use the following procedure to tighten the bolts (50 ± 4 lb ft).
106 KENR5402-07
i03126565
Crankshaft
SMCS Code: 1202
Part No.: 8N-7103
S/N: TTC1-Up
Part No.: 161-6926
S/N: TTE1-Up
Part No.: 161-6926
S/N: TTF1-Up
Part No.: 161-6926
S/N: TTG1-Up
Part No.: 161-6926
S/N: SLM1-Up
Part No.: 8N-7103
S/N: E3W1-Up
Part No.: 8N-7103
S/N: E3X1-Up
Part No.: 8N-7103
S/N: E3Y1-Up
g01419944
Illustration 172
Refer to Specifications, “Connecting Rod And Main (B) Crankshaft end play ................. 0.17 to 0.63 mm
Bearing Journals” for more information. (0.007 to 0.025 inch)
(1) Thrust plates are used only on the center main (2) Torque for six plugs ....... 50 ± 7 N·m (37 ± 5 lb ft)
bearing journal of the crankshaft.
(3) Use the following procedure to tighten the bolts
KENR5402-07 107
1. Before assembly, lubricate the threads of the Part No.: 7W-3813

bolts, the bolt shank, the washers and the contact S/N: E3Y1-Up
Lubricant. Part No.: 7W-3813
S/N: E3Z1-Up
2. Tighten 36 bolts evenly to 70 ± 5 N·m (50 ± 4 lb ft).
i03350941
Crankshaft Wear Sleeves and

Seals
SMCS Code: 1160
Part No.: 7W-3813
S/N: TTA1-Up
Part No.: 7W-3813
S/N: TTB1-Up
Part No.: 332-7911
S/N: M8C1-Up
g01414669
Illustration 173
Part No.: 7W-3813
(1) Flywheel housing group
S/N: TTC1-Up (2) Front housing group
Part No.: 332-7911
S/N: M8D1-Up Note: The crankshaft seal group cannot be used
once the seal has been separated from the wear
Part No.: 7W-3813 sleeve.
S/N: TTD1-Up
Note: Make sure that the correct crankshaft seal
Part No.: 7W-3813 group is installed on each end of the crankshaft.
S/N: TTE1-Up
(3) 113-8433 Crankshaft Seal Gp
Part No.: 7W-3813
S/N: PAF1-Up
• Install the crankshaft seal group in the flywheel
Part No.: 7W-3813 housing group on a standard rotation engine.
S/N: TTF1-Up
• Install thecrankshaft seal group in the front housing
Part No.: 7W-3813 group on a reverse rotation engine.
S/N: TTG1-Up
(4) 113-8432 Crankshaft Seal Gp
Part No.: 7W-3813
S/N: TTH1-Up • Install the crankshaft seal group in the front
Part No.: 7W-3813 housing group on a standard rotation engine.
S/N: TTJ1-Up
• Install the crankshaft seal group in the flywheel
Part No.: 7W-3813 housing group on a reverse rotation engine.
S/N: SLM1-Up
(A) The crankshaft seal group is installed from
Part No.: 7W-3813 both ends of the crankshaft at the following
S/N: JTS1-Up distance. ........... 8.0 ± 0.5 mm (0.31 ± 0.02 inch)
Part No.: 7W-3813 (B) The wear sleeve is installed from both
S/N: E3W1-Up ends of the crankshaft at the following
Part No.: 7W-3813 distance. ........... 0.5 ± 0.5 mm (0.02 ± 0.02 inch)
S/N: E3X1-Up
108 KENR5402-07
i03671476
Housing (Front)
SMCS Code: 1162
Part No.: 333-3712
S/N: M8C1-Up
Part No.: 333-3712
S/N: M8D1-Up
g01971776
Illustration 174
Refer to table 4 for the correct position of the

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

are listed in table 4.
Table 4
Front Housing Bolt Length
Installation Chart
Diameter Location Part Number Quantity mm inch
Inch
1/2 1 9H-8260 Bolt 4 158.75 6.250
1/2 2 0S-1587 Bolt 4 44.45 1.750
1/4 4 8T-6765 Pipe 7 14.2 ± 0.3 0.56 ± 0.01
Plug
5/8 5 1D-4593 Bolt 10 139.7 5.50
(A) Installation depth for the cup plugs (3) Torque for six plugs .. 25 ± 5 N·m (221 ± 44 lb in)
.................. 1.25 ± 0.25 mm (0.050 ± 0.010 inch)
Note: Trim gasket (6) with face (7) after assembly.
KENR5402-07 109
i02875170
Housing (Front)
SMCS Code: 1162
Part No.: 4P-5426
S/N: TTA1-Up
Part No.: 4P-5426
S/N: TTB1-Up
Part No.: 4P-5426
S/N: TTC1-Up
Part No.: 4P-5426
S/N: TTD1-Up
Part No.: 4P-5426
S/N: TTE1-Up
Part No.: 4P-5426
S/N: PAF1-Up
Part No.: 4P-5426
S/N: TTF1-Up
Part No.: 4P-5426
S/N: TTG1-Up
Part No.: 4P-5426
S/N: TTH1-Up
Part No.: 4P-5426
S/N: TTJ1-Up
Part No.: 4P-5426
S/N: SLM1-Up
Part No.: 4P-5426
S/N: JTS1-Up
Part No.: 4P-5426
S/N: E3W1-Up
Part No.: 4P-5426
S/N: E3X1-Up
Part No.: 4P-5426
S/N: E3Y1-Up
Part No.: 4P-5426
S/N: E3Z1-Up
110 KENR5402-07
g01430989
Illustration 175
Refer to Table 5 for the correct position of the i03694527

fasteners.
Gear Group (Front)
Note: Use a standard torque for the fasteners that
are listed in Table 5.
(Reverse Rotation)
SMCS Code: 1206
Table 5
Front Housing Bolt Part No.: 334-5315
Length S/N: M8C1-Up
Installation Chart
Diameter mm
Location Part inch
inch
8T-6765 14.2 ± 0.56 ±
1/4 1
Pipe Plug 0.3 0.01
9H-8260
1/2 2 158.75 6.250
Bolt
0S-1587
1/2 4 44.45 1.750
Bolt
1D-4593
5/8 5 139.7 5.50
Bolt
(3) Torque for six plugs ....... 25 ± 5 N·m (18 ± 4 lb ft)
Note: Trim gasket (6) with face (7) after assembly.
g02019973
Illustration 176
Front view
(2) Crankshaft gear
(1) Thrust washer

Thickness of new thrust washer .. 8.50 ± 0.05 mm
(0.335 ± 0.002 inch)
KENR5402-07 111
Width of groove in new pump drive shaft

assembly. ............................... 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
g01985973
Illustration 177
(3) Accessory drive gear (4) Auxiliary drive gear
(5) Lubricate the bore of the O-ring seals lightly with Note: Install the socket setscrew (9) to the bottom of
lubricant that is being sealed. the threaded hole.
(6) Idler shaft (9) Torque for the socket setscrew for the pump drive
shaft assembly ................ 6 ± 1 N·m (53 ± 9 lb in)
Diameter of the new idler
shaft ...... 105.88 ± 0.02 mm (4.168 ± 0.001 inch) (10) Thrust washer
Bore in the sleeve bearing for the idler
shaft ................................... 105.970 ± 0.010 mm Thickness of new thrust washer .. 8.50 ± 0.05 mm
(4.1720 ± 0.0004 inch) (0.335 ± 0.002 inch)
(7) Auxiliary drive shaft assembly. ............................... 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
Diameter of the new auxiliary drive
shaft ..................................... 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
Bore in the sleeve bearing after
assembly ............................. 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch)
(8) Pump drive shaft assembly

Diameter of the new pump drive shaft
assembly ............................. 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
assembly ............................. 75.000 ± 0.055 mm
(2.9527± 0.0022 inch)
112 KENR5402-07
i03696090
Gear Group (Front)

(Reverse Rotation)
SMCS Code: 1206
Part No.: 334-5314
S/N: M8D1-Up
g02019973
Illustration 178
Front view
(2) Crankshaft gear
(1) Thrust washer

(0.335 ± 0.002 inch)
assembly. ............................... 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
KENR5402-07 113
g01988514
Illustration 179
(3) Water pump drive gear (4) Auxiliary drive gear
(5) Lubricate the bore of the O-ring seals lightly with (9) Torque for the socket setscrew for the pump drive
lubricant that is being sealed. shaft assembly ................ 6 ± 1 N·m (53 ± 9 lb in)
(6) Shaft (10) Thrust washer

Diameter of the new shaft ........ 89.88 ± 0.02 mm Thickness of new thrust washer .. 8.50 ± 0.05 mm
(3.539 ± 0.001 inch) (0.335 ± 0.002 inch)
Bore in sleeve bearing for the idler gear Width of groove in new pump drive shaft
assembly ............................. 90.000 ± 0.010 mm assembly. ............................... 8.750 ± 0.025 mm
(3.5433 ± 0.0004 inch) (0.3445 ± 0.0010 inch)
Installation depth of the sleeve
bearing .............. 2.3 ± 0.5 mm (0.09 ± 0.02 inch)
(7) Auxiliary drive shaft

shaft ..................................... 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
assembly ............................. 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch)

Diameter of the new pump drive shaft
assembly ............................. 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
assembly ............................. 75.000 ± 0.055 mm
(2.9527± 0.0022 inch)
Note: Install the socket setscrew (9) to the bottom of

the threaded hole.
114 KENR5402-07
i03668141 (1) Torque for the socket setscrew ............ 6 ± 1 N·m

(53 ± 9 lb in)
Gear Group (Front)
SMCS Code: 1206
Bore in sleeve bearing after
S/N: TTA1-Up (2.9527 ± 0.0022 inch)
Diameter of new pump drive shaft
Part No.: 334-5312
assembly. ............................. 74.900 ± 0.015 mm
S/N: M8C1-Up
(2.9488 ± 0.0006 inch)
Part No.: 122-9281
S/N: TTD1-Up (3) Lubricate the bore of the O-ring seals lightly with
lubricant that is being sealed.
Part No.: 122-9281
S/N: TTE1-Up (4) Thrust washer
Part No.: 122-9281 Thickness of new thrust washer .. 8.50 ± 0.05 mm
S/N: TTH1-Up (0.335 ± 0.002 inch)
Part No.: 122-9281 assembly. ............................... 8.750 ± 0.025 mm
S/N: TTJ1-Up (0.3445 ± 0.0010 inch)
Part No.: 122-9281 End play for the pump drive shaft
S/N: E3X1-Up assembly .............................. 0.175 to 0.325 mm
(0.0069 ± 0.0128 inch)
Part No.: 122-9281
S/N: E3Z1-Up (8) Idler shaft
Diameter of the idler shaft ..... 105.88 ± 0.02 mm
(4.168 ± 0.001 inch)
Bore in the sleeve bearing for idler
shaft ................................... 105.970 ± 0.010 mm
(4.1720 ± 0.0004 inch)
i03125700
Gear Group (Front)

SMCS Code: 1206
Part No.: 8N-7174
S/N: TTA1-Up
Part No.: 8N-7174
S/N: TTB1-Up
Part No.: 8N-7174
S/N: TTC1-Up
Part No.: 8N-7174
S/N: TTD1-Up
Part No.: 8N-7174
S/N: TTE1-Up
Part No.: 8N-7174
g01428397 S/N: PAF1-Up
Illustration 180
Typical example Part No.: 8N-7174
(5) Idler gear assembly S/N: TTF1-Up
(6) Water pump drive gear
(7) Crankshaft gear Part No.: 8N-7174
S/N: TTG1-Up
Note: Install the socket setscrew to the bottom of the
Part No.: 8N-7174
threaded hole.
S/N: TTH1-Up
KENR5402-07 115
Part No.: 8N-7174 Diameter of new pump drive shaft

S/N: TTJ1-Up assembly ............................. 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
Part No.: 8N-7174
S/N: SLM1-Up (3) Lubricate the bore of four O-ring seals lightly with
Part No.: 8N-7174
S/N: JTS1-Up
(4) Thrust washer
Part No.: 8N-7174
S/N: E3W1-Up
(0.335 ± 0.002 inch)
Part No.: 8N-7174 Width of groove in new pump drive shaft
S/N: E3X1-Up assembly ............................... 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
Part No.: 8N-7174 End play for the pump drive shaft
S/N: E3Y1-Up assembly ............................... 0.250 ± 0.075 mm
(0.0098 ± 0.0030 inch)
Part No.: 8N-7174
S/N: E3Z1-Up (8) Shaft
machining ............................ 90.000 ± 0.010 mm
(3.5433 ± 0.0004 inch)
Diameter of new shaft .............. 89.88 ± 0.02 mm
(3.539 ± 0.001 inch)
Note: After the sleeve bearing is installed in the gear

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

(32 microinch)
i03125621
Gear Group (Rear)

SMCS Code: 1206
Part No.: 101-0834, 101-0835
S/N: TTA1-Up
Part No.: 101-0834, 101-0835
S/N: TTB1-Up
Part No.: 334-5298, 334-5299
S/N: M8C1-Up
g01428397 Part No.: 101-0835, 124-8395, 175-5204

Illustration 181 S/N: TTC1-Up
(5) Idler gear assembly
(6) Water pump drive gear Part No.: 334-5298, 334-5299
(7) Crankshaft gear S/N: M8D1-Up
Note: Install the socket setscrew to the bottom of the Part No.: 101-0835, 175-5203, 175-5204
threaded hole. S/N: TTD1-Up
(1) Torque for the socket setscrew ............ 6 ± 1 N·m Part No.: 101-0835, 124-8395
(55 ± 9 lb in) S/N: TTE1-Up
Part No.: 101-0835, 175-5203
(2) Pump drive shaft assembly S/N: PAF1-Up
Bore in sleeve bearing after Part No.: 101-0835, 124-8395, 175-5204
assembly ............................. 75.000 ± 0.055 mm S/N: TTF1-Up
(2.9528 ± 0.0022 inch)
116 KENR5402-07
Part No.: 101-0835, 124-8395, 175-5204 Diameter of the gear shaft ... 74.990 ± 0.010 mm
S/N: TTG1-Up (2.9524 ± 0.0004 inch)
Bore in the sleeve bearing for the gear
Part No.: 101-0835, 175-5203, 175-5204 shaft ..................................... 75.060 ± 0.010 mm
S/N: TTH1-Up (2.9551 ± 0.0004 inch)
Maximum roughness average
Part No.: 101-0835, 175-5203, 175-5204
(Ra) ...................... 0.8 micrometer (32 microinch)
S/N: TTJ1-Up
Part No.: 101-0835, 175-5204 Refer to Disassembly and Assembly for the
S/N: SLM1-Up installation procedure for the right camshaft drive
gear (7).
Part No.: 101-0835, 175-5203
S/N: JTS1-Up (8) Idler shaft
Part No.: 101-0835, 124-8395, 175-5204 Diameter of the idler shaft ... 81.000 ± 0.010 mm
S/N: E3W1-Up (3.1890 ± 0.0004 inch)
Bore in the sleeve bearing for the idler
Part No.: 101-0835, 124-8395 shaft ..................................... 81.060 ± 0.010 mm
S/N: E3X1-Up (3.1913 ± 0.0004 inch)
Part No.: 101-0835, 124-8395 Maximum roughness average
S/N: E3Y1-Up (Ra) ...................... 0.8 micrometer (32 microinch)
Part No.: 101-0835

S/N: E3Z1-Up
g01256372
Illustration 183
Vertical line
(9) Use the following procedure to tighten the bolt for

the camshaft drive gears:
1. Tighten the bolt for the camshaft drive gear to

360 ± 40 N·m (270 ± 30 lb ft).
g01620759 2. Mark a vertical line on the head of the bolt for the
Illustration 182
camshaft drive gear. Refer to Illustration 183.
(1) Ring
(3) Idler gear assembly
(13) Plate 3. Place a driver against the retaining plate of the
camshaft drive gear. Strike the driver solidly with
Note: Before assembly, it is critical that the taper of a hammer 3 to 4 times.
the camshaft and the tapered bore of the camshaft
drive gear are clean, dry, and free of residue. 4. Again, tighten the bolt for the camshaft drive gear
to 360 ± 40 N·m (270 ± 30 lb ft).
Refer to Disassembly and Assembly for the
installation procedure for the left camshaft drive gear
(2).
(5) Torque for four bolts ....................... 140 ± 10 N·m

(105 ± 7 lb ft)
(6) Gear shaft

KENR5402-07 117
i03091223
Balancer Group (Front)

SMCS Code: 1220
Part No.: 101-0833
S/N: TTA1-Up
Part No.: 101-0833
S/N: TTB1-Up
Part No.: 332-7916
S/N: M8C1-Up
Part No.: 332-7916
g01256393
Illustration 184 S/N: M8D1-Up
5. Repeat Steps 3 and 4 until the mark on the

bolt turns a minimum of 90 degrees. Refer to
Illustration 184.
(10) Torque for four bolts ..................... 240 ± 20 N·m

(175 ± 15 lb ft)
(11) Torque for two bolts ..................... 240 ± 20 N·m

(175 ± 15 lb ft)
g01620761
Illustration 185
Rear view of engine
g01572454
(14) The mark on the cluster gear assembly (4) must Illustration 186
be in alignment with the mark on the crankshaft (3) Balancer gear
gear (12). (4) Crankshaft gear

(105 ± 7 lb ft)
(B) Dimensions for the gear shaft

Diameter of the new gear
shaft ..................................... 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
assembly ............................. 75.000 ± 0.053 mm
(2.9528 ± 0.0021 inch)
(C) Thickness of the thrust plate ..... 6.35 ± 0.25 mm

(0.250 ± 0.010 inch)
118 KENR5402-07
(2) The mark on the balancer gear must be in

alignment with the mark on the crankshaft gear.
i03742201
Accessory Drive
SMCS Code: 1207
Part No.: 334-5306
S/N: M8C1-Up
Part No.: 334-5306
S/N: M8D1-Up
g02021255
Illustration 187
Front view
KENR5402-07 119
g02021213
Illustration 188
(1) Lightly lubricate the bore of the O-ring seals

with the lubricant that is being sealed or with the
approved equivalent.
Note: During assembly, align the hole in the sleeve

bearing with the adapter assembly.
(2) Bore in the sleeve bearing of the adapter

(2.9527 ± 0.0022 inch)

(2.9527 ± 0.0022 inch)
(4) Auxiliary drive shaft

Diameter of new auxiliary drive
shaft ..................................... 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
Width of groove in the new auxiliary drive
shaft .. 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch)
(5) Thickness of the new thrust

washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)
120 KENR5402-07
i03742186 Diameter of new idler gear

assembly ............................. 74.900 ± 0.015 mm
Accessory Drive (2.9488 ± 0.0006 inch)
Width of groove in new idler gear assembly for
SMCS Code: 1207 thrust washer ......................... 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
Part No.: 334-5320
Bore in the accessory drive
S/N: M8C1-Up
gear ..................................... 74.980 ± 0.025 mm
(2.9520 ± 0.0010 inch)
(2) Thickness of new thrust washer .. 8.50 ± 0.05 mm

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

Hand)
SMCS Code: 1207
Part No.: 7E-7647
S/N: TTA1-Up
Part No.: 7E-7647
S/N: TTB1-Up
Part No.: 7E-7647
S/N: TTC1-Up
Illustration 189
g02021233 Part No.: 7E-7647
Front view S/N: TTD1-Up
Part No.: 7E-7647
S/N: TTE1-Up
Part No.: 7E-7647
S/N: PAF1-Up
Part No.: 7E-7647
S/N: TTF1-Up
Part No.: 7E-7647
S/N: TTG1-Up
Part No.: 7E-7647
S/N: TTH1-Up
g02021234 Part No.: 7E-7647

Illustration 190 S/N: TTJ1-Up
Section A-A
Part No.: 7E-7647
(1) Lubricate the bore of the O-ring seal with the S/N: SLM1-Up
Part No.: 7E-7647
(B) Dimensions of the shaft S/N: JTS1-Up
Diameter of the new shaft .. 105.880 ± 0.020 mm Part No.: 7E-7647

(4.1685 ± 0.0008 inch) S/N: E3W1-Up
Bore in the bearing for idler gear for the Part No.: 7E-7647
shaft ................................... 105.970 ± 0.010 mm S/N: E3X1-Up
(4.1720 ± 0.0004 inch)
Part No.: 7E-7647
(C) Dimensions of the idler gear assembly S/N: E3Y1-Up
KENR5402-07 121
Part No.: 7E-7647 Maximum roughness average

S/N: E3Z1-Up (Ra) ................... 0.8 micrometer (31.5 microinch)
Note: After the bearing is installed in the gear the

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

shaft ..................................... 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
Width of groove in the new auxiliary drive shaft
for the thrust washer .............. 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
End play for the auxiliary drive
shaft ...................................... 0.175 to 0.325 mm
(0.0069 to 0.0128 inch)

washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)
g01929453
Illustration 191
Front view
(1) Water pump drive gear
(2) Lightly lubricate the bore of the O-ring seals with

g01929474
Illustration 193
Adapter assembly
Illustration 192
g01929454 (C) Installation depth of the sleeve bearing in the
adapter assembly .......................... 1.5 ± 0.5 mm
Section B-B
(0.06 ± 0.02 inch)
(3) Diameter of the new shaft ........ 89.88 ± 0.02 mm (D) Bore in the sleeve bearing of the adapter
(3.539 ± 0.001 inch)
(2.9527 ± 0.0022 inch)
(4) Dimensions of the idler gear assembly
Bore in the sleeve bearing of the idler gear
(3.5433 ± 0.0004 inch)
122 KENR5402-07
i02889488

Hand)
SMCS Code: 1207
Part No.: 179-1511
S/N: TTA1-Up
Part No.: 179-1511
S/N: TTB1-Up
Part No.: 179-1511
S/N: TTC1-Up
g01438748
Illustration 195
Part No.: 179-1511
S/N: TTD1-Up Section A-A
Part No.: 179-1511 (1) Lubricate the bore of the four O-ring seals with
S/N: TTE1-Up the lubricant that is being sealed.
Part No.: 179-1511
S/N: TTF1-Up
Part No.: 179-1511
S/N: TTG1-Up
Part No.: 179-1511
S/N: TTH1-Up
Part No.: 179-1511
S/N: TTJ1-Up
Part No.: 179-1511
S/N: E3W1-Up
Part No.: 179-1511
S/N: E3X1-Up
g01438749
Illustration 196
Section B-B
(4) Adapter assembly
(2) Diameter of new shaft ........ 105.880 ± 0.020 mm

(4.1685 ± 0.0008 inch)
(3) Bore in the sleeve bearing after

assembly ............................. 75.000 ± 0.055 mm
g01438742 (2.9527 ± 0.0022 inch)
Illustration 194
Front view
Note: After the bearing is installed in the idler gear
the bearing must be machined to size.
(5) Bearing
Bore in the bearing after
assembly ........................... 105.970 ± 0.010 mm
(4.1720 ± 0.0004 inch)
KENR5402-07 123
(6) Auxiliary drive shaft Part No.: 166-4357

S/N: E3Z1-Up
shaft ..................................... 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
Width of groove in new auxiliary drive
shaft .. 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch)

(0.335 ± 0.002 inch)
i03605121
Accessory Drive (Upper Right

Hand)
SMCS Code: 1207
Part No.: 166-4357
S/N: TTA1-Up
Part No.: 166-4357
S/N: TTB1-Up
Part No.: 166-4357
S/N: TTC1-Up
Part No.: 334-5306
S/N: M8D1-Up
Part No.: 166-4357
S/N: TTD1-Up
Part No.: 166-4357
S/N: TTE1-Up
Part No.: 166-4357
S/N: PAF1-Up
Part No.: 166-4357
S/N: TTF1-Up
Part No.: 166-4357
S/N: TTG1-Up
Part No.: 166-4357
S/N: TTH1-Up
Part No.: 166-4357
S/N: TTJ1-Up
Part No.: 166-4357
S/N: SLM1-Up
Part No.: 166-4357
S/N: JTS1-Up
Part No.: 166-4357
S/N: E3W1-Up
Part No.: 166-4357
S/N: E3X1-Up
Part No.: 166-4357
S/N: E3Y1-Up
124 KENR5402-07
g01930053
Illustration 197
(1) Lightly lubricate the bore of the O-ring seals (4) Bore in the sleeve bearing of the adapter
with the lubricant that is being sealed or with the assembly after installation ... 75.000 ± 0.055 mm
approved equivalent. (2.9527 ± 0.0022 inch)
(2) Thickness of the new thrust (5) Bore in the sleeve bearing of the adapter
washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch) assembly after installation ... 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch)
Diameter of new auxiliary drive i03604642
shaft ..................................... 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch) Accessory Drive (Upper Right
Width of groove in the new auxiliary drive Hand)
shaft .. 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch)
SMCS Code: 1207
bearing with the adapter. Part No.: 7N-4871
S/N: TTA1-Up
Part No.: 7N-4871
S/N: TTB1-Up
KENR5402-07 125
Part No.: 7N-4871 (1) Lightly lubricate the bore of the O-ring seals with
S/N: TTC1-Up the lubricant that is being sealed.
Part No.: 7N-4871
S/N: TTD1-Up
Part No.: 7N-4871
S/N: TTE1-Up
Part No.: 7N-4871
S/N: PAF1-Up
Part No.: 7N-4871
S/N: TTF1-Up
Part No.: 7N-4871
S/N: TTG1-Up
Part No.: 7N-4871
S/N: TTH1-Up
Part No.: 7N-4871
S/N: TTJ1-Up
Part No.: 7N-4871
S/N: SLM1-Up
Part No.: 7N-4871
S/N: JTS1-Up
Part No.: 7N-4871
S/N: E3W1-Up
Part No.: 7N-4871
S/N: E3X1-Up
Part No.: 7N-4871
S/N: E3Y1-Up
Part No.: 7N-4871
S/N: E3Z1-Up
g01929618
Illustration 199
Section A-A

bearing with the adapter.

(2.9527 ± 0.0022 inch)

shaft ..................................... 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
g01929617
Illustration 198 for the thrust washer .............. 8.750 ± 0.025 mm
Front view of engine (0.3445 ± 0.0010 inch)
126 KENR5402-07
End play for the auxiliary drive Part No.: 107-7361

shaft ...................................... 0.175 to 0.325 mm S/N: TTE1-Up
(0.0069 to 0.0128 inch)
Part No.: 107-7361
(4) Thickness of the new thrust S/N: PAF1-Up
washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)
Part No.: 107-7361
S/N: TTF1-Up
Part No.: 107-7361
S/N: TTG1-Up
Part No.: 107-7361
S/N: TTH1-Up
Part No.: 107-7361
S/N: TTJ1-Up
Part No.: 107-7361
S/N: SLM1-Up
Part No.: 107-7361
S/N: JTS1-Up
Part No.: 107-7361
S/N: E3W1-Up
Part No.: 107-7361
S/N: E3X1-Up
Part No.: 107-7361
S/N: E3Y1-Up
Part No.: 107-7361
S/N: E3Z1-Up
g01929654
Illustration 200
Adapter assembly
(D) Bore in the sleeve bearing of the adapter

(2.9527 ± 0.0022 inch)
i02895664
Accessory Drive (Upper Right

Hand)
SMCS Code: 1207
Part No.: 107-7361
S/N: TTA1-Up
Part No.: 107-7361
S/N: TTB1-Up
Part No.: 107-7361
S/N: TTC1-Up
Part No.: 334-5304
S/N: M8D1-Up
g01441499
S/N: TTD1-Up
KENR5402-07 127
(1) Lubricate the bore of the O-ring seal lightly with Part No.: 334-5328
the lubricant that is being sealed. S/N: M8D1-Up
Part No.: 8N-9166
S/N: TTD1-Up
Part No.: 8N-9166
S/N: TTE1-Up
Part No.: 8N-9166
S/N: PAF1-Up
Part No.: 8N-9166
S/N: TTF1-Up
Part No.: 8N-9166
S/N: TTG1-Up
Part No.: 8N-9166
S/N: TTH1-Up
Part No.: 8N-9166
S/N: TTJ1-Up
Part No.: 8N-9166
g01441501 S/N: SLM1-Up
Illustration 202
Section A-A Part No.: 8N-9166
S/N: JTS1-Up
(B) Dimensions for the sleeve bearing
Part No.: 8N-9166
Bore in sleeve bearing before S/N: E3W1-Up
assembly ............................. 44.475 ± 0.025 mm
(1.7510 ± 0.0010 inch) Part No.: 8N-9166
Diameter of accessory drive S/N: E3X1-Up
gear ..................................... 44.400 ± 0.015 mm Part No.: 8N-9166
(1.7480 ± 0.0006 inch) S/N: E3Y1-Up
(C) Dimensions for the sleeve bearing Part No.: 8N-9166
S/N: E3Z1-Up
assembly ............................. 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch)
Diameter of accessory drive
gear ..................................... 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
i02960980
Accessory Drive (Upper Left

Hand)
SMCS Code: 1207
Part No.: 8N-9166
S/N: TTA1-Up
Part No.: 8N-9166
S/N: TTB1-Up
Part No.: 334-5328
S/N: M8C1-Up
Part No.: 8N-9166
S/N: TTC1-Up
128 KENR5402-07
g01479361
Illustration 203
(1) Lubricate the bore of six O-ring seals lightly with

(2) 127-5400 Sleeve Bearing

Quantity ............................................................ 2
assembly ............................. 75.000 ± 0.055 mm
(2.9528 ± 0.0022 inch)
(3) Dimensions for the auxiliary drive shaft

shaft ..................................... 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
Width of the groove in the new auxiliary drive
shaft for the thrust washer ..... 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
End play for the auxiliary drive
shaft ...................................... 0.175 to 0.325 mm
(0.0069 to 0.0128 inch)
(E) Thickness of the new thrust

washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)
KENR5402-07 129
i02735559 (3) Thickness of new thrust washer .. 8.50 ± 0.05 mm

(0.335 ± 0.002 inch)
Accessory Drive (Upper Left
Hand, Reverse Rotation) (4) Auxiliary drive shaft
SMCS Code: 1207
shaft ..................................... 74.900 ± 0.015 mm
Part No.: 8N-5743 (2.9488 ± 0.0006 inch)
S/N: TTB1-Up Width of groove in new auxiliary drive
shaft .. 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch)
Part No.: 334-5322 End play for auxiliary drive
S/N: M8C1-Up shaft ...................................... 0.175 to 0.325 mm
(0.0069 to 0.0128 inch)
Part No.: 8N-5743
S/N: TTC1-Up (7) Sleeve bearing
Part No.: 334-5321 Bore in the sleeve bearing after
S/N: M8D1-Up assembly ............................. 90.000 ± 0.010 mm
(3.5433 ± 0.0004 inch)
Part No.: 8N-5743
S/N: TTD1-Up Maximum roughness average
Part No.: 8N-5743
S/N: TTF1-Up Note: After the sleeve bearing is installed in the gear
the sleeve bearing must be machined to size.
Part No.: 8N-5743
S/N: TTG1-Up (8) Diameter of new shaft .......... 89.880 ± 0.020 mm
(3.5386 ± 0.0008 inch)
Part No.: 8N-5743
S/N: TTH1-Up
i02972972
Part No.: 8N-5743
S/N: TTJ1-Up Accessory Drive (Upper Left
Part No.: 8N-5743 Hand, Reverse Rotation)
S/N: E3W1-Up
SMCS Code: 1207
Part No.: 8N-5745
S/N: TTA1-Up
Part No.: 8N-5745
S/N: TTB1-Up
Part No.: 8N-5745
S/N: TTC1-Up
Part No.: 8N-5745
S/N: TTD1-Up
Part No.: 8N-5745
S/N: TTE1-Up
Part No.: 8N-5745
S/N: TTF1-Up
Part No.: 8N-5745
S/N: TTG1-Up
Part No.: 8N-5745
g01371445
Illustration 204 S/N: TTH1-Up
(2) Accessory drive gear
(5) Thrust washer Part No.: 8N-5745
(6) Idler gear S/N: TTJ1-Up
(1) Bore in the sleeve bearings after Part No.: 8N-5745

assembly ............................. 75.000 ± 0.055 mm S/N: E3W1-Up
(2.9528 ± 0.0022 inch)
130 KENR5402-07
Part No.: 8N-5745 Note: After the bearing is installed in the gear the
S/N: E3X1-Up bearing must be machined to size.
Part No.: 8N-5745
S/N: E3Z1-Up i02973686

Hand, Reverse Rotation)
SMCS Code: 3279
Part No.: 184-2445
S/N: TTA1-Up
Part No.: 184-2445
S/N: TTB1-Up
Part No.: 184-2445
S/N: TTC1-Up
Part No.: 184-2445
S/N: TTE1-Up
Part No.: 184-2445
S/N: TTF1-Up
Part No.: 184-2445
S/N: TTG1-Up
g01501789
Illustration 205
(7) Spacer
Part No.: 184-2445
S/N: E3W1-Up
(1) Bore in the sleeve bearings after Part No.: 184-2445
assembly ............................. 75.000 ± 0.055 mm S/N: E3X1-Up
(2.9528 ± .0022 inch)

washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)
(3) Diameter of the new shaft ...... 105.88 ± 0.02 mm

(4.168 ± 0.001 inch)
(4) Lubricate the bore of seven O-ring seals lightly

with the lubricant that is being sealed.
(5) Dimensions of the new auxiliary drive shaft

shaft ..................................... 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
for the thrust washer .............. 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
End play for the shaft ............ 0.175 to 0.325 mm
(0.0069 to 0.0128 inch)
(8) Dimensions of the Idler gear bearing

Bore in the idler gear bearing after
assembly ............................... 105.97 ± 0.01 mm
(4.1720 ± 0.0004 inch)
g01502148
Installation depth of the sleeve bearing in the idler Illustration 206
gear (6) ............. 2.3 ± 0.5 mm (0.09 ± 0.02 inch)
(1) Dimensions for the auxiliary drive shaft
KENR5402-07 131
Diameter of the new auxiliary drive Part No.: 7N-4851, 7N-7784

shaft ..................................... 74.900 ± 0.015 mm S/N: JTS1-Up
(2.9488 ± 0.0006 inch)
Width of the groove in the new auxiliary drive Part No.: 7N-4851, 7N-7784, 8N-6038, 8N-6439
shaft for thrust washer ........... 8.750 ± 0.025 mm S/N: E3W1-Up
(0.3445 ± 0.0010 inch)
Part No.: 7N-4851, 7N-7784, 8N-6038, 8N-6439
S/N: E3X1-Up
(0.335 ± 0.002 inch) Part No.: 7N-4851, 7N-7784
S/N: E3Y1-Up
(3) Lubricate the bore of the three O-ring seals lightly
with the lubricant that is being sealed. Part No.: 7N-4851, 7N-7784, 8N-6038, 8N-6439
S/N: E3Z1-Up
(4) Bore in the sleeve bearing after
assembly ............................. 75.000 ± 0.055 mm
(2.9528 ± 0.0022 inch)
i02869986
Flywheel
SMCS Code: 1156
Part No.: 7N-4851, 7N-7784, 8N-6038, 8N-6439
S/N: TTA1-Up
Part No.: 7N-4851, 7N-7784, 8N-6038, 8N-6439
S/N: TTB1-Up
Part No.: 333-3742, 333-3743, 336-9989,
336-9990, 7N-4851, 7N-7784, 8N-6038,
8N-6439
S/N: M8C1-Up
Part No.: 7N-4851, 7N-7784, 8N-6038, 8N-6439
S/N: TTC1-Up
Part No.: 333-3742, 333-3743, 336-9989,
336-9990, 7N-4851, 7N-7784, 8N-6038,
8N-6439
S/N: M8D1-Up
Part No.: 7N-4851, 7N-7784, 8N-6038, 8N-6439 Illustration 207
g01429511
S/N: TTD1-Up Typical example
Part No.: 7N-4851, 7N-7784, 8N-6038, 8N-6439 (1) Flywheel gear
S/N: TTE1-Up (2) Crankshaft
Part No.: 7N-4851, 7N-7784 Note: When the flywheel assembly is installed, align
S/N: PAF1-Up the dash mark on the flywheel assembly with the
dash mark on the crankshaft.
Part No.: 7N-4851, 7N-7784, 8N-6038, 8N-6439
S/N: TTF1-Up Note: Before assembly, lubricate the threads of the
bolts (3) with clean engine oil, molybdenum disulfide
Part No.: 7N-4851, 7N-7784, 8N-6038, 8N-6439
or graphite base lubricant.
S/N: TTG1-Up
Part No.: 7N-4851, 7N-7784, 8N-6038, 8N-6439 (3) Torque for the 12 bolts ................. 1150 ± 60 N·m
S/N: TTH1-Up (840 ± 44 lb ft)
Part No.: 7N-4851, 7N-7784, 8N-6038, 8N-6439

S/N: TTJ1-Up
Part No.: 7N-4851, 7N-7784
S/N: SLM1-Up
132 KENR5402-07
i03690244
Flywheel Housing
SMCS Code: 1157
Part No.: 333-7646
S/N: M8C1-Up
Part No.: 333-7646
S/N: M8D1-Up
For information on inspecting the flywheel housing,

refer to the Testing and Adjusting, “Flywheel Housing
- Inspect”.
Note: Before installation of the flywheel housing,

inspect the front face of the flywheel housing and
the rear face of the cylinder block. The components
must be free of the following substances: oil, fuel,
water, gasket adhesive, assembly compounds, and
any other foreign material.
g02019674
Illustration 209
Tighten the bolts that hold the flywheel housing to
the engine block evenly. Refer to Illustration 209 and Table 6
Table 6 for the locations and for identification of the Flywheel Housing Bolt
bolts. Bolt Length
Installation Chart
Diameter Part mm
Bolt inch
inch Number
4 1/2 9X-8873 57.15 2.250
5 1/2 1D-4574 152.4 6.00
6 3/8 0S-1594 25.4 1.00
7 5/8 1D-4597 165.1 6.50
8 1/2 9X-8878 133.35 5.250
9 5/8 1D-4602 241.3 9.50
10 5/8 1D-4593 139.7 5.50
Note: Bond the entire surface with 6V-6640 Sealant

to the flywheel housing cover assembly (3).
(4) Torque for the bolts ........................ 135 ± 20 N·m

(100 ± 15 lb ft)
g01984633
Illustration 208 (100 ± 15 lb ft)
Left side view
(6) Torque for the bolts ...... 55 ± 10 N·m (41 ± 7 lb ft)
(1) To seal the joint between the flywheel housing
and the cylinder block, apply 1U-8846 Gasket (7) Torque for the bolts ........................ 270 ± 40 N·m
Sealant to the front face of the flywheel housing. (199 ± 30 lb ft)
(2) Torque for the bolts ...... 55 ± 10 N·m (41 ± 7 lb ft) (8) Torque for the bolts ........................ 135 ± 20 N·m
(100 ± 15 lb ft)

(199 ± 30 lb ft)
(10) Torque for the bolts ...................... 270 ± 40 N·m

(199 ± 30 lb ft)
KENR5402-07 133
i02957455
Flywheel Housing
SMCS Code: 1157
Part No.: 101-1269
S/N: TTA1-Up
Part No.: 101-1269
S/N: TTB1-Up
Part No.: 101-1269
S/N: TTC1-Up
Part No.: 101-1269
S/N: TTD1-Up
Part No.: 101-1269
S/N: TTE1-Up
Part No.: 101-1269
S/N: PAF1-Up
g01505956
Illustration 210
Part No.: 101-1269
Rear view
S/N: TTF1-Up
Part No.: 101-1269 Table 7
S/N: TTG1-Up Flywheel Housing Bolt
Bolt Length
Installation Chart
Part No.: 101-1269
S/N: TTH1-Up Diameter Part mm
Bolt inch
inch Number
Part No.: 101-1269
1 1/2 9X-8875 88.9 3.50
S/N: TTJ1-Up
2 1/2 6M-9613 228.6 9.00
Part No.: 101-1269
S/N: SLM1-Up 3 1/2 9X-8873 57.15 2.250
4 1/2 9S-1374 203.2 8.00
Part No.: 101-1269
S/N: JTS1-Up 5 5/8 1D-4590 120.65 4.750
Part No.: 101-1269 6 1/2 8S-9089 114.3 4.50

S/N: E3W1-Up
Part No.: 101-1269 Tighten the bolts that hold the flywheel housing to
S/N: E3X1-Up the engine block evenly. Refer to Illustration 210 and
Table 7 for the locations and for the identification of
Part No.: 101-1269 the bolts.
S/N: E3Y1-Up
Part No.: 101-1269 (100 ± 15 lb ft)
S/N: E3Z1-Up
(2) Torque for two bolts ....................... 135 ± 20 N·m
For information on inspecting the flywheel housing, (100 ± 15 lb ft)
refer to Systems Operation/Testing and Adjusting.
(3) Torque for six bolts ........................ 135 ± 20 N·m
Note: Before installation of the flywheel housing, (100 ± 15 lb ft)
the rear face of the cylinder block. The components (4) Torque for two bolts ....................... 135 ± 20 N·m
must be free of the following substances: oil, fuel, (100 ± 15 lb ft)
any other foreign material. (5) Torque for 16 bolts .. 270 ± 40 N·m (200 ± 30 lb ft)
To seal the joint between the flywheel housing and (6) Torque for four bolts ....................... 135 ± 20 N·m
the cylinder block, apply 1U-8846 Gasket Sealant to (100 ± 15 lb ft)
the mating surface of the flywheel housing.
134 KENR5402-07
i02987334
Flywheel Housing
SMCS Code: 1157
Part No.: 107-7177
S/N: TTA1-Up
Part No.: 107-7177
S/N: TTB1-Up
Part No.: 107-7177
S/N: TTC1-Up
Part No.: 107-7177
S/N: TTD1-Up
Part No.: 107-7177
S/N: TTE1-Up
Part No.: 107-7177
S/N: PAF1-Up
g01505975
Illustration 211
Part No.: 107-7177
Left side view
S/N: TTF1-Up
(7) Apply 1U-8846 Gasket Sealant to the surface of Part No.: 107-7177
the gasket before assembly. S/N: TTG1-Up
Part No.: 107-7177
S/N: TTH1-Up
Part No.: 107-7177
S/N: TTJ1-Up
Part No.: 107-7177
S/N: SLM1-Up
Part No.: 107-7177
S/N: JTS1-Up
Part No.: 107-7177
S/N: E3W1-Up
Part No.: 107-7177
S/N: E3X1-Up
Part No.: 107-7177
S/N: E3Y1-Up
Part No.: 107-7177
S/N: E3Z1-Up
For information on inspecting the flywheel housing,

refer to Systems Operation/Testing and Adjusting.
Note: Before installation of the flywheel housing,

the rear face of the cylinder block. The components
must be free of the following substances: oil, fuel,
any other foreign material.
To seal the joint between the flywheel housing and

the cylinder block, apply 1U-8846 Gasket Sealant to
the mating surface of the flywheel housing.
KENR5402-07 135
g01513774
Illustration 212
Rear view
Table 8 Tighten the bolts that hold the flywheel housing to

Flywheel Housing Bolt the engine block evenly. Refer to Illustration 212 and
Bolt Length Table 8 for the locations and for the identification of
Installation Chart
the bolts.
Diameter Part mm
Bolt inch
inch Number (1) Torque for eight bolts ..................... 135 ± 20 N·m
1 1/2 9X-8873 57.15 2.250 (100 ± 15 lb ft)
2 1/2 1D-4574 152.4 6.00 (2) Torque for six bolts ........................ 135 ± 20 N·m
3 1/2 9X-8874 76.2 3.00 (100 ± 15 lb ft)
4 5/8 1D-4597 165.1 6.50 (3) Torque for two bolts ....................... 135 ± 20 N·m
5 5/8 1D-4593 139.7 5.50 (100 ± 15 lb ft)
6 1/2 9X-8878 133.35 5.250
7 5/8 1D-4602 241.30 9.500 (4) Torque for two bolts ....................... 270 ± 40 N·m
(200 ± 30 lb ft)
(5) Torque for 12 bolts .. 270 ± 40 N·m (200 ± 30 lb ft)

136 KENR5402-07
(6) Torque for four bolts ....................... 135 ± 20 N·m Part No.: 162-7460
(100 ± 15 lb ft) S/N: TTJ1-Up
(7) Torque for two bolts ....................... 270 ± 40 N·m Part No.: 162-7460
(200 ± 30 lb ft) S/N: SLM1-Up
Part No.: 162-7460
S/N: JTS1-Up
Part No.: 162-7460
S/N: E3W1-Up
Part No.: 162-7460
S/N: E3X1-Up
Part No.: 162-7460
S/N: E3Y1-Up
Part No.: 162-7460
S/N: E3Z1-Up
g01513803
Illustration 213
Left side view
(8) Apply 1U-8846 Gasket Sealant to the surface of

the gasket before assembly.
g01515797
i03322420 Illustration 214
Vibration Damper Note: The alignment mark on the crankshaft (1)

must be aligned with the alignment mark on the two
SMCS Code: 1205 adapters (2). The mark on the two damper groups
(3) must also be aligned with the mark on the two
Part No.: 162-7460
adapters (2).
S/N: TTA1-Up
Part No.: 162-7460 Note: Before assembly, lubricate the threads of the
S/N: TTB1-Up bolts with molybdenum disulfide base lubricant.
Part No.: 162-7460 (4) Torque for six bolts ...................... 1150 ± 60 N·m
S/N: TTC1-Up (840 ± 44 lb ft)
Part No.: 162-7460
S/N: TTD1-Up
Part No.: 162-7460
S/N: TTE1-Up
Part No.: 162-7460
S/N: PAF1-Up
Part No.: 162-7460
S/N: TTF1-Up
Part No.: 162-7460
S/N: TTG1-Up
Part No.: 162-7460
S/N: TTH1-Up
KENR5402-07 137
Part No.: 146-3740, 171-4571, 247-0845

S/N: TTH1-Up
Part No.: 146-3740, 171-4571, 247-0845
S/N: TTJ1-Up
Part No.: 146-3740, 171-4571, 247-0845
S/N: SLM1-Up
Part No.: 146-3740, 171-4571, 247-0845
S/N: JTS1-Up
Part No.: 146-3740, 171-4571, 247-0845
S/N: E3W1-Up
Part No.: 146-3740, 171-4571, 247-0845
S/N: E3X1-Up
Part No.: 146-3740, 171-4571, 247-0845
S/N: E3Y1-Up
Part No.: 146-3740, 171-4571, 247-0845
S/N: E3Z1-Up
g01434600
Illustration 215
Note: Apply 4C-4030 Thread Lock Compound to

the threads of the bolts.
(5) Torque for 48 bolts ......... 55 ± 7 N·m (41 ± 5 lb ft)
i02888713
Vibration Damper
SMCS Code: 1205
Part No.: 146-3740, 171-4571, 247-0845
S/N: TTA1-Up
Part No.: 146-3740, 171-4571, 247-0845
S/N: TTB1-Up
Part No.: 146-3740, 171-4571
S/N: M8C1-Up
g01438233
Part No.: 146-3740, 171-4571, 247-0845 Illustration 216
S/N: TTC1-Up
Note: Apply 4C-4030 Thread Lock Compound to the
Part No.: 171-4571, 247-0845 threads of the bolts (1).
S/N: M8D1-Up
Part No.: 146-3740, 171-4571, 247-0845 (1) Torque for the 48 bolts ... 55 ± 7 N·m (41 ± 5 lb ft)
S/N: TTD1-Up
i03322541
Part No.: 146-3740, 171-4571, 247-0845
S/N: TTE1-Up Vibration Damper
Part No.: 146-3740, 171-4571, 247-0845
SMCS Code: 1205
S/N: PAF1-Up
Part No.: 240-7762
Part No.: 146-3740, 171-4571, 247-0845
S/N: TTA1-Up
S/N: TTF1-Up
Part No.: 240-7762
Part No.: 146-3740, 171-4571, 247-0845
S/N: TTB1-Up
S/N: TTG1-Up
Part No.: 240-7762
S/N: TTC1-Up
138 KENR5402-07
Part No.: 240-7762 Note: Before assembly, lubricate the threads of the
S/N: TTD1-Up bolts with molybdenum disulfide base lubricant.
Part No.: 240-7762 (4) Torque for six bolts ...................... 1150 ± 60 N·m
S/N: TTE1-Up (840 ± 44 lb ft)
Part No.: 240-7762
Note: Apply 4C-4030 Thread Lock Compound to
S/N: PAF1-Up
Part No.: 240-7762
S/N: TTF1-Up (5) Torque for 48 bolts ......... 55 ± 7 N·m (41 ± 5 lb ft)
Part No.: 240-7762

S/N: TTG1-Up i03295581
Part No.: 240-7762 Vibration Damper

S/N: TTH1-Up
SMCS Code: 1205
Part No.: 240-7762
S/N: TTJ1-Up Part No.: 8N-7182
S/N: TTA1-Up
Part No.: 240-7762
S/N: SLM1-Up Part No.: 8N-7182
S/N: TTB1-Up
Part No.: 240-7762
S/N: JTS1-Up Part No.: 8N-7182
S/N: TTC1-Up
Part No.: 240-7762
S/N: E3W1-Up Part No.: 8N-7182
S/N: TTD1-Up
Part No.: 240-7762
S/N: E3X1-Up Part No.: 8N-7182
S/N: TTE1-Up
Part No.: 240-7762
S/N: E3Y1-Up Part No.: 8N-7182
S/N: PAF1-Up
Part No.: 240-7762
S/N: TTF1-Up
Part No.: 8N-7182
S/N: TTG1-Up
Part No.: 8N-7182
S/N: TTH1-Up
Part No.: 8N-7182
S/N: TTJ1-Up
Part No.: 8N-7182
S/N: SLM1-Up
Part No.: 8N-7182
S/N: JTS1-Up
Part No.: 8N-7182
S/N: E3W1-Up
Part No.: 8N-7182
S/N: E3X1-Up
Part No.: 8N-7182
g01412026
Illustration 217 S/N: E3Y1-Up
Note: The alignment mark on the crankshaft (1) must Part No.: 8N-7182
be aligned with the alignment mark on the adapter S/N: E3Z1-Up
(2). The mark on the damper group (3) must also be
aligned with the mark on the adapter (2).
KENR5402-07 139
Part No.: 174-7079, 248-0197, 8N-0339

S/N: JTS1-Up
Part No.: 174-7079, 248-0197, 8N-0339
S/N: E3W1-Up
Part No.: 174-7079, 248-0197, 8N-0339
S/N: E3X1-Up
Part No.: 174-7079, 248-0197, 8N-0339
S/N: E3Y1-Up
Part No.: 248-0197, 8N-0339
S/N: E3Z1-Up
g01515801
Illustration 218
Note: The alignment mark on the crankshaft (1) must

be aligned with the alignment mark on the damper
adapter (2).

bolts with molybdenum disulfide base lubricant.
(3) Torque for six bolts ...................... 1150 ± 60 N·m

(840 ± 44 lb ft)
i03292482
Vibration Damper
SMCS Code: 1205
Part No.: 174-7079, 248-0197, 8N-0339
S/N: TTA1-Up g01437790
Illustration 219
Part No.: 174-7079, 248-0197, 8N-0339 Typical example
S/N: TTB1-Up
Note: The alignment mark on the damper group
Part No.: 174-7079, 248-0197, 8N-0339 (2) must be aligned with the alignment mark on the
S/N: TTC1-Up adapter (1).
Part No.: 174-7079, 248-0197, 8N-0339
S/N: TTD1-Up Note: Before assembly, lubricate the threads of the
Part No.: 174-7079, 248-0197, 8N-0339
S/N: TTE1-Up (3) Torque for six bolts ...................... 1150 ± 60 N·m
(840 ± 44 lb ft)
Part No.: 174-7079, 248-0197, 8N-0339
S/N: PAF1-Up Note: Apply 4C-4030 Thread Lock Compound to
Part No.: 174-7079, 248-0197, 8N-0339
S/N: TTF1-Up (4) Torque for 48 bolts ......... 55 ± 7 N·m (41 ± 5 lb ft)
Part No.: 174-7079, 248-0197, 8N-0339
S/N: TTG1-Up i03295685
Part No.: 174-7079, 248-0197, 8N-0339

S/N: TTH1-Up
Vibration Damper
Part No.: 174-7079, 248-0197, 8N-0339 SMCS Code: 1205
S/N: TTJ1-Up Part No.: 4W-0278
Part No.: 174-7079, 248-0197, 8N-0339 S/N: TTA1-Up
S/N: SLM1-Up Part No.: 4W-0278
S/N: TTB1-Up
140 KENR5402-07
Part No.: 4W-0278 i03105503

S/N: TTC1-Up
Vibration Damper Guard
Part No.: 4W-0278
S/N: TTD1-Up SMCS Code: 1205
Part No.: 4W-0278 Part No.: 197-9052, 310-7976, 8N-9639
S/N: TTE1-Up S/N: TTA1-Up
Part No.: 4W-0278 Part No.: 197-9052, 310-7976, 8N-9639
S/N: PAF1-Up S/N: TTB1-Up
Part No.: 4W-0278 Part No.: 334-4642, 334-4643
S/N: TTF1-Up S/N: M8C1-Up
Part No.: 4W-0278 Part No.: 197-9052, 310-7976, 8N-9639
S/N: TTG1-Up S/N: TTC1-Up
Part No.: 4W-0278 Part No.: 334-4642, 334-4643
S/N: TTH1-Up S/N: M8D1-Up
Part No.: 4W-0278 Part No.: 197-9052, 310-7976, 8N-9639
S/N: TTJ1-Up S/N: TTD1-Up
Part No.: 4W-0278 Part No.: 197-9052, 310-7976, 8N-9639
S/N: SLM1-Up S/N: TTE1-Up
Part No.: 4W-0278 Part No.: 197-9052
S/N: JTS1-Up S/N: PAF1-Up
Part No.: 4W-0278 Part No.: 197-9052, 310-7976, 8N-9639
S/N: E3W1-Up S/N: TTF1-Up
Part No.: 4W-0278 Part No.: 102-8616, 197-9052, 310-7976,
S/N: E3X1-Up 8N-9639
S/N: TTG1-Up
Part No.: 4W-0278
S/N: E3Y1-Up Part No.: 102-8616, 197-9052, 310-7976,
8N-9639
Part No.: 4W-0278 S/N: TTH1-Up
S/N: E3Z1-Up
Part No.: 102-8616, 197-9052, 310-7976,
8N-9639
S/N: TTJ1-Up
Part No.: 102-8616, 197-9052, 310-7976,
8N-9639
S/N: SLM1-Up
Part No.: 102-8616, 197-9052, 310-7976,
8N-9639
S/N: JTS1-Up
Part No.: 197-9052, 310-7976, 8N-9639
S/N: E3W1-Up
Part No.: 197-9052, 310-7976, 8N-9639
g01515857
Illustration 220 S/N: E3X1-Up
Note: The alignment mark on the crankshaft (2) must Part No.: 197-9052, 8N-9639
be aligned with the alignment mark on the damper S/N: E3Y1-Up
adapter (3). Part No.: 197-9052, 8N-9639
S/N: E3Z1-Up
(1) Torque for six bolts ...................... 1150 ± 60 N·m

(840 ± 44 lb ft)
KENR5402-07 141
g01393058
Illustration 221
Typical example

142 KENR5402-07
i03879148
Stub Shaft (Front)

SMCS Code: 1237
Part No.: 7W-5237
S/N: TTB1-Up
Part No.: 334-0956, 334-0958
S/N: M8C1-Up
Part No.: 334-0955, 334-0957
S/N: M8D1-Up
g00278463
Illustration 222
Low kW (HP) attachments
g00278464
Illustration 223
High kW (HP) attachments
(1) Crankshaft (2) Adapter

KENR5402-07 143
(3) Bolts
Apply a molybdenum disulfide grease under the
bolt heads and to the threads before assembly.
Torque ......................... 1150 ± 60 N·m (850 ± 44)
(4) Alignment mark
Align the alignment mark on the stub shaft with the

alignment mark on the adapter.
i02832479
Stub Shaft (Front)

g01412641
Illustration 224
SMCS Code: 1237 Typical example
Part No.: 7N-7660
S/N: TTB1-Up (2) Torque for the six bolts .............. 1150 ± 150 N·m
(840 ± 110 lb ft)
Part No.: 7N-7660
S/N: TTC1-Up Note: The alignment mark on the stub shaft (3) must
be aligned with the alignment mark on the damper
Part No.: 7N-7660 adapter (1).
S/N: TTD1-Up
Part No.: 7N-7660
S/N: TTE1-Up
Part No.: 7N-7660
S/N: PAF1-Up
Part No.: 7N-7660
S/N: TTF1-Up
Part No.: 7N-7660
S/N: TTG1-Up
Part No.: 7N-7660
S/N: TTH1-Up
Part No.: 7N-7660
S/N: TTJ1-Up
Part No.: 7N-7660
S/N: SLM1-Up
Part No.: 7N-7660
S/N: JTS1-Up
Part No.: 7N-7660
S/N: E3W1-Up
Part No.: 7N-7660
S/N: E3X1-Up
Part No.: 7N-7660
S/N: E3Y1-Up
Part No.: 7N-7660
S/N: E3Z1-Up
144 KENR5402-07
i03292468 (1) Torque for 12 bolts ..................... 1150 ± 150 N·m

(840 ± 110 lb ft)
Stub Shaft (Front)
SMCS Code: 1237 i03694540
Part No.: 7W-3629 Alternator and Regulator

S/N: TTC1-Up
SMCS Code: 1405
Part No.: 7W-3629
S/N: TTD1-Up Part No.: 4N-3986
S/N: TTA1-Up
Part No.: 7W-3629
S/N: TTE1-Up Part No.: 4N-3986
S/N: TTB1-Up
Part No.: 7W-3629
S/N: PAF1-Up Part No.: 4N-3986
S/N: M8C1-Up
Part No.: 7W-3629
S/N: TTF1-Up Part No.: 4N-3986
S/N: TTC1-Up
Part No.: 7W-3629
S/N: TTG1-Up Part No.: 4N-3986
S/N: M8D1-Up
Part No.: 7W-3629
S/N: TTH1-Up Part No.: 4N-3986
S/N: TTD1-Up
Part No.: 7W-3629
S/N: TTJ1-Up Part No.: 4N-3986
S/N: TTE1-Up
Part No.: 7W-3629
S/N: SLM1-Up Part No.: 4N-3986
S/N: PAF1-Up
Part No.: 7W-3629
S/N: JTS1-Up Part No.: 4N-3986
S/N: TTF1-Up
Part No.: 7W-5237
S/N: E3W1-Up Part No.: 4N-3986
S/N: TTH1-Up
Part No.: 7W-3629
S/N: E3X1-Up Part No.: 4N-3986
S/N: TTJ1-Up
Part No.: 7W-3629
S/N: E3Y1-Up Part No.: 4N-3986
S/N: SLM1-Up
Part No.: 7W-3629
S/N: JTS1-Up
Part No.: 4N-3986
S/N: E3W1-Up
Part No.: 4N-3986
S/N: E3X1-Up
Part No.: 4N-3986
S/N: E3Y1-Up
Part No.: 4N-3986
S/N: E3Z1-Up
g01676708
Illustration 225
Before assembly, apply molybdenum disulfide grease

to the shoulder of the bolt heads and to the threads
of the bolt.
KENR5402-07 145
Output voltage ............................................. 28 ± 1 V
(1) Final installation torque for flange

nut ................................ 102 ± 7 N·m (75 ± 5 lb ft)
Note: Use a 7/16 ring terminal for (B+) terminal.
(2) (B+) terminal. Final installation torque for

nut ....................... 6.2 ± 0.6 N·m (54.9 ± 5.3 lb in)
(3) Final installation torque for nut .. 2.25 ± 0.25 N·m

(19.91 ± 2.21 lb in)
(4) (B-) terminal. Final installation torque for

nut ............... 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in)
(5) Voltage regulator assembly

Voltage setting ............................. No adjustment
Permissible voltage range .................. 27 to 29 V
g01985994
Illustration 226 i02806500
Alternator and Regulator

SMCS Code: 1405
Part No.: 5N-5692
S/N: TTA1-Up
Part No.: 5N-5692
S/N: TTB1-Up
Part No.: 5N-5692
S/N: TTC1-Up
Part No.: 5N-5692
S/N: TTD1-Up
Part No.: 5N-5692
S/N: TTE1-Up
Part No.: 5N-5692
S/N: PAF1-Up
Illustration 227
g01985993 Part No.: 5N-5692
S/N: TTF1-Up
View A-A
Part No.: 5N-5692
Note: Load the battery with a carbon pile 4C-4911 S/N: TTG1-Up
Battery Load Tester in order to get the maximum
alternator output. Part No.: 5N-5692
S/N: TTH1-Up
Voltage ............................................................... 24 V
Part No.: 5N-5692
Amperage ..................................................... 68 Amp S/N: TTJ1-Up
Part No.: 5N-5692
Polarity ............................................ Negative ground S/N: SLM1-Up
Rotation ............................................ Either direction Part No.: 5N-5692
S/N: JTS1-Up
Minimum full load current at 5000 rpm ......... 68 Amp
Part No.: 5N-5692
Minimum full load current at 2000 rpm ......... 42 Amp S/N: E3W1-Up
146 KENR5402-07
Part No.: 5N-5692 (2) Final installation torque for the flange
S/N: E3X1-Up nut ................................ 102 ± 7 N·m (75 ± 5 lb ft)
Part No.: 5N-5692 (3) (B+) terminal. Final installation torque for the
S/N: E3Y1-Up nut ............................. 6.2 ± 0.6 N·m (55 ± 5 lb in)
Part No.: 5N-5692
S/N: E3Z1-Up
(4) The peak voltage for (R) terminal must not be
less than the output voltage for (B+) terminal.
(5) (B-) terminal. Final installation torque for the

screw .................... 2.25 ± 0.25 N·m (20 ± 2 lb in)

i03566463
Alternator and Regulator

g01364499
Illustration 228
SMCS Code: 1405
Part No.: 333-1184
g01400391
Illustration 229
Voltage ............................................................... 24 V
Amperage ..................................................... 45 Amp
Note: Load the battery with a carbon pile 4C-4911

Battery Load Tester in order to get the maximum
alternator output.
g01889933
Illustration 230
Polarity ............................................ Negative ground
Voltage ............................................................... 24 V
Rotation ............................................ Either direction
Amperage ..................................................... 68 Amp
Minimum full load current at 5000 rpm ...... 42.3 Amp
Note: Load the battery with a carbon pile 4C-4911
Minimum full load current at 2000 rpm ...... 15.8 Amp Battery Load Tester in order to get the maximum
alternator output.
Output voltage ............................................. 28 ± 1 V
Polarity ........................................... Insulated ground
Note: Tighten the bolt (1) before tightening the
mounting bolt. Rotation ............................................ Either direction
(1) Torque for the bolt .... 88.4 ± 6.8 N·m (65 ± 5 lb ft) Minimum full load current at 5000 rpm ......... 68 Amp
KENR5402-07 147
Minimum full load current at 2000 rpm ......... 42 Amp Part No.: 7E-4836
S/N: TTA1-Up
Output voltage ............................................. 28 ± 1 V
Part No.: 7E-4836
(1) Final installation torque for the flange S/N: TTB1-Up
nut ................................ 102 ± 7 N·m (75 ± 5 lb ft)
Part No.: 335-4161
S/N: M8C1-Up
Part No.: 7E-4836
S/N: TTC1-Up
Part No.: 335-4161
S/N: M8D1-Up
Part No.: 7E-4836
S/N: TTD1-Up
Part No.: 7E-4836
S/N: TTE1-Up
Part No.: 7E-4836
S/N: PAF1-Up
Part No.: 7E-4836
S/N: TTF1-Up
Part No.: 7E-4836
S/N: TTG1-Up
Part No.: 7E-4836
S/N: TTH1-Up
Part No.: 7E-4836
S/N: TTJ1-Up
Part No.: 7E-4836
Illustration 231
g01889934 S/N: SLM1-Up
View A-A Part No.: 7E-4836
S/N: JTS1-Up
(2) (B+) terminal. Final installation torque for the
nut ....................... 6.2 ± 0.6 N·m (54.9 ± 5.3 lb in) Part No.: 7E-4836
S/N: E3W1-Up
Part No.: 7E-4836
(3) The peak voltage for (R) terminal must not be S/N: E3X1-Up
less than the output voltage for (B+) terminal. Part No.: 7E-4836
S/N: E3Y1-Up
(4) (S) terminal. Final installation torque for the
nut ............... 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in) Part No.: 7E-4836
S/N: E3Z1-Up
(5) (B-) terminal. Final installation torque for the
nut ....................... 6.2 ± 0.6 N·m (54.9 ± 5.3 lb in)

i02899397
Alternator Mounting
SMCS Code: 1405
148 KENR5402-07
g01401955
Illustration 234
View A-A
When the electric starting motor is viewed from

the pinion end, the motor rotates in the following
g01446906
Illustration 232
No load conditions at 25 °C (77 °F)
Note: Maximum misalignment between pulley Speed ...................................... 6950 ± 1650 rpm
assembly (3) and pulley (1) is 0.4 degrees. Current draw ................................. 115 ± 25 Amp
Voltage .................................................... 23 VDC
(2) Torque for the pulley retaining nut .. 110 ± 10 N·m
(80 ± 7 lb ft) (B) Clearance between the pinion and the
housing ................................. 9.1 mm (0.36 inch)
(4) Adjust the belt tension of the serpentine belt
according to the 197-9087 Tension Chart. (1) Final installation torque for the ground terminal
nut ....................... 30.5 ± 3.5 N·m (270 ± 30 lb in)
(5) Lubricate the sealing lip of the lip type seal lightly
with the lubricant that is being sealed. (2) Final installation torque for the ground terminal
nut ......................... 2.25 ± 0.25 N·m (20 ± 2 lb in)
i02787428
Note: The switch terminal must be insulated with
Electric Starting Motor heat shrink tubing. Do not use molded terminals.
SMCS Code: 1453 (3) Final installation torque for the switch terminal
nut ......................... 2.25 ± 0.25 N·m (20 ± 2 lb in)
Part No.: 237-1962
(4) Final installation torque for the motor terminal
nut ....................... 30.5 ± 3.5 N·m (270 ± 30 lb in)
Note: A maximum of three cable terminals or wire

terminals may be used with the battery terminal nut
(5). A maximum of two of the cable terminals may be
equal to or greater than 0 AWG.
(5) Final installation torque for the battery terminal

nut ....................... 30.5 ± 3.5 N·m (270 ± 30 lb in)
(6) Final installation torque for the motor frame

terminal nut ......... 30.5 ± 3.5 N·m (270 ± 30 lb in)
g01401956 Solenoid assembly

Illustration 233
Current consumption at 20V and 25 °C (77 °F)

Pull-in windings ........................... 49.3 ± 3.3 Amp
Hold-in windings ............................ 6.8 Amp max
KENR5402-07 149
i02685953 (5) Final installation torque for the battery terminal

nut ....................... 30.5 ± 3.5 N·m (270 ± 30 lb in)
Electric Starting Motor
(6) Final installation torque for the nut on the motor
SMCS Code: 1453 frame terminal. .... 30.5 ± 3.5 N·m (270 ± 30 lb in)
Part No.: 6V-0927
Solenoid
Current consumption at 20V and 25 °C (77 °F)

Pull-in windings ........................... 49.3 ± 3.3 Amp
Hold-in windings ............................ 6.8 Amp max
g01373014
Illustration 235
When the electric starting motor is viewed from

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

Speed ...................................... 6950 ± 1650 rpm
Current draw ................................. 115 ± 25 Amp
Voltage .................................................... 23 VDC
(A) The clearance between the pinion and the

housing is the following value. ................ 9.1 mm
(0.36 inch)
(1) Final installation torque for the nut on the ground

terminal. .............. 30.5 ± 3.5 N·m (270 ± 30 lb in)
(2) Final installation torque for the nut on the ground

terminal. ................ 2.25 ± 0.25 N·m (20 ± 2 lb in)
Note: The switch terminal must be insulated with

heat shrink tubing. Do not use molded terminals.
(3) Final installation torque for the switch terminal

nut ......................... 2.25 ± 0.25 N·m (20 ± 2 lb in)
(4) Final installation torque for the nut on the motor

terminal. .............. 30.5 ± 3.5 N·m (270 ± 30 lb in)
Note: A maximum of three cable terminals or wire

terminals may be used with the nut. A maximum of
two of the terminals may be equal to or greater than
0 AWG.
150 KENR5402-07
i02869400 Operating temperature ........................ −40 to 125 °C

(−40 to 257 °F)
Fuel Pressure Sensor
Operating voltage ........................... 5.00 ± 0.25 VDC
SMCS Code: 7414
Part No.: 161-1705 i02845097
S/N: TTA1-Up
Part No.: 161-1705
S/N: TTB1-Up SMCS Code: 7414
Part No.: 161-1705 Part No.: 194-6722, 194-6724, 194-6725
S/N: TTC1-Up
Part No.: 161-1705
S/N: TTD1-Up
Part No.: 161-1705
S/N: TTE1-Up
Part No.: 161-1705
S/N: PAF1-Up
Part No.: 161-1705
S/N: TTF1-Up
Part No.: 161-1705
S/N: TTG1-Up
g01068621
S/N: TTH1-Up Typical example
Part No.: 161-1705 (1) Final installation torque for the pressure sensor
S/N: TTJ1-Up group .......................... 10 ± 2 N·m (90 ± 18 lb in)
Part No.: 161-1705 Operating voltage ........................... 5.00 ± 0.25 VDC
S/N: SLM1-Up
Part No.: 161-1705 Operating temperature ....................... −40 to 125 °C
S/N: JTS1-Up (−40 to 257 °F)
Part No.: 161-1705

S/N: E3W1-Up
Part No.: 161-1705
S/N: E3Y1-Up
g01135892
Illustration 236
(1) Final installation torque for the pressure sensor

group .......................... 10 ± 2 N·m (90 ± 18 lb in)
KENR5402-07 151

(−40 to 257 °F)
SMCS Code: 7414
Part No.: 161-9932
S/N: TTA1-Up
Part No.: 161-9932
S/N: TTB1-Up
Part No.: 161-9932
S/N: M8C1-Up
Part No.: 161-9932
S/N: TTC1-Up
Part No.: 161-9932
S/N: M8D1-Up
Part No.: 161-9932
S/N: TTD1-Up
Part No.: 161-9932
S/N: TTE1-Up
Part No.: 161-9932
S/N: TTF1-Up
Part No.: 161-9932
S/N: TTG1-Up
Part No.: 161-9932
S/N: TTH1-Up
Part No.: 161-9932
S/N: TTJ1-Up
Part No.: 161-9932
S/N: E3W1-Up
Part No.: 161-9932
S/N: E3X1-Up
Part No.: 161-9932
S/N: E3Z1-Up
g01190345
Illustration 238
Typical example

group .......................... 10 ± 2 N·m (90 ± 18 lb in)
152 KENR5402-07

(−40 to 257 °F)
Coolant Level Sensor
Operating voltage ............................... 8.0 ± 0.4 VDC
SMCS Code: 7470
Part No.: 165-6634 i02894836
S/N: TTA1-Up
Coolant Level Sensor
Part No.: 165-6634
S/N: TTB1-Up SMCS Code: 7470
Part No.: 165-6634 Part No.: 204-2518
S/N: TTC1-Up
Part No.: 165-6634
S/N: TTD1-Up
Part No.: 165-6634
S/N: TTE1-Up
Part No.: 165-6634
S/N: PAF1-Up
Part No.: 165-6634
S/N: TTF1-Up
Part No.: 165-6634
S/N: TTG1-Up
g01440910
Illustration 240
Part No.: 165-6634
S/N: TTH1-Up
(1) Final installation torque for the coolant level
Part No.: 165-6634 sensor group .................. 22 ± 3 N·m (16 ± 2 lb ft)
S/N: TTJ1-Up
Operating temperature ........................ −40 to 125 °C
Part No.: 165-6634 (−40 to 257 °F)
S/N: SLM1-Up
Operating voltage .................................. 7 to 32 VDC
Part No.: 165-6634
S/N: JTS1-Up
i02845092
Part No.: 165-6634
S/N: E3W1-Up Engine Oil Pressure Sensor
Part No.: 165-6634 SMCS Code: 1924
S/N: E3Y1-Up
Part No.: 194-6725
g01513758
Illustration 239
g01068621
Typical example Illustration 241
(1) Final installation torque for the liquid level sensor (1) Final installation torque for the pressure sensor
group ............................. 22 ± 3 N·m (16 ± 2 lb ft) group .......................... 10 ± 2 N·m (90 ± 18 lb in)
KENR5402-07 153
Operating temperature ........................ −40 to 125 °C i02987331

(−40 to 257 °F)
Turbocharger Inlet Pressure
Operating voltage ........................... 5.00 ± 0.25 VDC Sensor
i02854115
SMCS Code: 1052
Turbocharger Inlet Pressure Part No.: 163-8492

S/N: TTD1-Up
Sensor
Part No.: 163-8492
SMCS Code: 1052 S/N: TTH1-Up
Part No.: 194-6722 Part No.: 163-8492

S/N: TTJ1-Up
Part No.: 163-8492
S/N: JTS1-Up
g01190345
Illustration 242

group .......................... 10 ± 2 N·m (90 ± 18 lb in) g01513769
Illustration 243
Operating temperature ........................ −40 to 125 °C group .......................... 10 ± 2 N·m (90 ± 18 lb in)
(−40 to 257 °F)
(−40 to 257 °F)

154 KENR5402-07
i02847453 Operating voltage .......................... 4.75 to 8.50 VDC

Turbocharger Outlet Pressure
Sensor i02987333
Aftercooler Coolant
SMCS Code: 1052; 1917; 1919
Temperature Sensor
Part No.: 194-6724
SMCS Code: 1063; 1395
Part No.: 102-7532
g01046622
Illustration 244
(1) Final installation torque for the pressure sensor g01513773

group .......................... 10 ± 2 N·m (90 ± 18 lb in) Illustration 246
Operating temperature ........................ −40 to 125 °C (1) Final installation torque for the temperature
(−40 to 257 °F) sensor group .................. 20 ± 3 N·m (15 ± 2 lb ft)
Operating voltage ........................... 5.00 ± 0.25 VDC Operating temperature ........................ −40 to 120 °C
(−40 to 248 °F)
i02958530 Operating voltage .......................... 4.75 to 8.50 VDC

Aftercooler Coolant
Temperature Sensor i03015964
Engine Coolant Temperature

SMCS Code: 1063; 1395
Sensor
Part No.: 102-2240
SMCS Code: 1395
Part No.: 102-2240
g01475132
Illustration 245
(1) Final installation torque for the temperature g01475132

Illustration 247
sensor group .................. 20 ± 3 N·m (15 ± 2 lb ft)
Operating temperature ........................ −40 to 120 °C (1) Final installation torque for the temperature
(−40 to 248 °F) sensor group .................. 20 ± 3 N·m (15 ± 2 lb ft)
KENR5402-07 155
Operating temperature ........................ −40 to 120 °C i02894896

(−40 to 248 °F)
Turbocharger Exhaust
Operating voltage .......................... 4.75 to 8.50 VDC Temperature Sensor
i02987360
SMCS Code: 1052; 1919
Engine Coolant Temperature Part No.: 164-2441
Sensor
SMCS Code: 1395
Part No.: 102-7532
g01441005
Illustration 249
(2) Exhaust temperature sensor group
Note: Apply 4C-5599 Anti-Seize Compound to the

threads of the adapter (1) before installation.
g01513773
Illustration 248
(1) Final installation torque for the
adapter .......................... 45 ± 5 N·m (33 ± 4 lb ft)
(1) Final installation torque for the temperature
sensor group .................. 20 ± 3 N·m (15 ± 2 lb ft)
(−40 to 1562 °F)
(−40 to 248 °F)
Operating voltage .............................. 7.5 to 8.5 VDC
Operating voltage .......................... 4.75 to 8.50 VDC
Output type ...................................................... PWM
Output frequency ................................. 500 ± 100 Hz

156 KENR5402-07
i02909994 Part No.: 161-1703

S/N: TTH1-Up
Engine Speed/Timing Sensor
Part No.: 161-1703
SMCS Code: 1905; 1907 S/N: TTJ1-Up
Part No.: 265-9034 Part No.: 161-1703
S/N: SLM1-Up
Part No.: 161-1703
S/N: JTS1-Up
Part No.: 161-1703
S/N: E3W1-Up
Part No.: 161-1703
S/N: E3X1-Up
Part No.: 161-1703
S/N: E3Y1-Up
Part No.: 161-1703
S/N: E3Z1-Up
g01372538
Illustration 250
(1) Final installation torque for the speed sensor

group ............................. 40 ± 5 N·m (30 ± 4 lb ft)
Operating voltage ................................ 12 to 14 VDC

(−40 to 248 °F)
Output frequency ................................ 9 to 10000 Hz
Duty cycle ......................................................... 50 %
i02869441 g01135892
Illustration 251
Crankcase Pressure Sensor (1) Final installation torque for the pressure sensor
group .......................... 10 ± 2 N·m (90 ± 18 lb in)
SMCS Code: 1916
Part No.: 161-1703 Operating temperature ........................ −40 to 125 °C
S/N: TTA1-Up (−40 to 257 °F)
Part No.: 161-1703 Operating voltage ........................... 5.00 ± 0.25 VDC

S/N: TTB1-Up
Part No.: 161-1703
S/N: TTC1-Up
Part No.: 161-1703
S/N: TTD1-Up
Part No.: 161-1703
S/N: TTE1-Up
Part No.: 161-1703
S/N: PAF1-Up
Part No.: 161-1703
S/N: TTF1-Up
Part No.: 161-1703
S/N: TTG1-Up
KENR5402-07 157
i02847051 i03534581
Atmospheric Pressure Sensor Engine Speed Sensor

Part No.: 161-1703 Part No.: 9X-5392
g01133887 g01448928
(1) Final installation torque for the pressure sensor Operating temperature ........................ −40 to 150 °C
group .......................... 10 ± 2 N·m (90 ± 18 lb in) (−40 to 320 °F)
Operating temperature ........................ −40 to 125 °C Clearance between the speed sensor group and the
(−40 to 257 °F) flywheel ring gear ............................ 0.50 to 0.75 mm
(0.020 to 0.030 inch)
Use the following procedure to install the speed
sensor group (1):
i02845102
Atmospheric Pressure Sensor 1. Install the speed sensor group into the 5/8
threaded hole and turn until the magnetic core
SMCS Code: 1923 makes contact with a tooth of the flywheel ring
gear.
Part No.: 194-6722
2. Back out 180 degrees.
3. Tighten the nut to 25 ± 5 mm (221± 44 inch).
g01392045
Illustration 253

group .......................... 10 ± 2 N·m (90 ± 18 lb in)

(−40 to 257 °F)
158 KENR5402-07
Index Section
Index
A F
Accessory Drive............................................ 118, 120 Flywheel .............................................................. 131

Accessory Drive (Lower Left Hand)............. 121–122 Flywheel Housing ........................................ 132–134
Accessory Drive (Lower Left Hand, Reverse Fuel Filter (Primary)................................................. 7
Rotation) ............................................................ 130 Fuel Injector........................................................... 12
Accessory Drive (Upper Left Hand)..................... 127 Fuel Injector Mechanism .................................. 10–11
Accessory Drive (Upper Left Hand, Reverse Fuel Pressure Regulator.......................................... 8
Rotation) .................................................... 129–130 Fuel Pressure Sensor.................................. 150–151
Accessory Drive (Upper Right Hand) .. 123, 125–126 Fuel Transfer Pump............................................. 8–9
Aftercooler Coolant Temperature Sensor ............ 154
Air Cleaner............................................................. 43
Air Cleaner Adapter ............................................... 44 G
Air Inlet and Exhaust Lines............ 45, 47–48, 50–51
Alternator and Regulator ............................. 144, 146 Gear Group (Front)....................................... 114–115
Alternator Mounting ............................................. 147 Gear Group (Front) (Reverse Rotation)........ 110, 112
Atmospheric Pressure Sensor............................. 157 Gear Group (Rear) ............................................... 116
Auxiliary Water Pump .......................... 81, 83–84, 88
Auxiliary Water Pump (Sea Water)........................ 86
H
B Housing (Front)............................................ 108–109
Balancer Group (Front)......................................... 117

I
C Important Safety Information ................................... 2
Camshaft ......................................................... 13–16

Connecting Rod............................................. 99–100 P
Connecting Rod and Main Bearing Journals ....... 102
Coolant Level Sensor .......................................... 152 Piston and Rings (One-Piece Piston) .................... 94
Crankcase Breather................................... 70, 72–73 Intermediate Piston Ring (2) .............................. 95
Crankcase Pressure Sensor................................ 156 Oil Control Piston Ring (3) ................................. 95
Crankshaft .......................................... 103, 105–106 Pin Retainer (6).................................................. 95
Crankshaft Wear Sleeves and Seals................... 107 Piston Pin (5) ..................................................... 95
Cylinder Block............................................ 89, 91–92 Top Piston Ring (1) ............................................ 95
Cylinder Head........................................................ 18 Piston and Rings (Two-Piece Piston) .............. 96, 98
Cylinder Head Valves ............................................ 19 Intermediate Piston Ring (4) ........................ 97–98
Cylinder Liner ........................................................ 93 Oil Control Piston Ring (5) ........................... 97–98
Pin Retainer (7)............................................ 97, 99
Piston Pin (6) ............................................... 97, 99
E Top Piston Ring (3) ...................................... 97–98
Electric Starting Motor ................................. 148–149

Engine Coolant Temperature Sensor .......... 154–155 S
Engine Design ..................................................... 5–7
Engine Oil Cooler Bypass and Cooling Jet Sequence Specifications Section ............................................. 5
Valves ............................................................ 66–67 Stub Shaft (Front) ........................................ 142–144
Engine Oil Filter ..................................................... 69
Engine Oil Pan................................................. 74, 76
Engine Oil Pressure Sensor ................................ 152 T
Engine Oil Pump............................ 52, 54, 56, 58, 60
Engine Oil Scavenge Pump............................. 61, 63 Table of Contents..................................................... 3
Engine Speed Sensor.......................................... 157 Thermostatic Valve ................................................ 78
Engine Speed/Timing Sensor .............................. 156 Turbocharger ................................................... 21–25
Exhaust Bypass Valve ..................................... 25–26 Turbocharger Exhaust Temperature Sensor ....... 155
Exhaust Flange................................................ 41–43 Turbocharger Inlet Pressure Sensor ................... 153
Exhaust Manifold ................................. 27–37, 39–40 Turbocharger Outlet Pressure Sensor................. 154
KENR5402-07 159
Index Section
Valve Mechanism .................................................. 17

Vibration Damper......................................... 136–140
Vibration Damper Guard...................................... 140
Water Pump........................................................... 79
Water Temperature Regulator ......................... 77–78
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All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
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Specifications 3500C Marine Engine

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Specifications 3500C Marine Engine

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KENR5402-07

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Engine Oil Pump .................................................. 58

Vibration Damper ............................................... 136

Displacement .............................. 34.5 L (2105 cu in) Number and arrangement of

Valve lash Firing order (injection sequence)

Inlet ......................................... 0.50 mm (0.020 inch) Standard rotation

S/N: E3Y1-Up S/N: PAF1-Up

Displacement .............................. 51.8 L (3158 cu in) Number and arrangement of

Combustion ........................................ Direct injection Compression ratio ........................................... 14.7:1

Standard rotation Firing order (injection sequence)

Inlet ......................................... 0.50 mm (0.020 inch) Valve lash

Engine Design i03657840

SMCS Code: 1000 Fuel Filter (Primary)

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

i02723705 Part No.: 8N-6151

(2) 9N-4053 Spring

Fuel Transfer Pump

Part No.: 8N-6151 Minimum output is attained under the following

Pump pressure ............................... 415 kPa (60 psi) i03147530

Pump speed ............................................... 2400 rpm Fuel Transfer Pump

(2) Dimensions for drive shaft assembly

(4) Dimensions for idler gear assembly

When the fuel transfer pump group is viewed from

Minimum output .................... 28 L/min (7.4 US gpm)

Minimum output is attained under the following

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

Pump speed ............................................... 2400 rpm

Minimum cracking pressure of bypass

Maximum pressure of fully open bypass

(1) Dimensions for terminal bushing Part No.: 224-9869

Diameter of the shaft ........ 12.700 to 12.675 mm Part No.: 224-9869

Diameter of the gear ............ 29.801 ± 0.006 mm Part No.: 224-9869

Length of the gear ............... 35.347 ± 0.008 mm Part No.: 224-9869

(4) Dimensions for idler gear assembly

Fuel Injector Mechanism

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

Note: Start tightening the retainer nuts of the cap

(5) Torque for the retainer nuts of the cap

(6) Apply 5P-3413 Pipe Sealant to the threads of

Fuel Injector Mechanism Illustration 12

(3) Timing pin

Part No.: 281-6160, 308-5356 (B) Diameter of the rocker arm

Note: Start the retainer nuts of the cap assembly

Torque for terminal nuts ................. 2.4 ± 0.2 N·m

(3) Torque for unit injector nozzle ........ 310 ± 20 N·m

(E) Specified camshaft lobe lift

Use the following procedure in order to determine the

(C) Thickness of a new thrust

(D) Dimensions for the journal surface

Note: End play for a new camshaft assembly is

(E) Specified camshaft lobe lift

Use the following procedure in order to determine the

1. Measure camshaft lobe height (H).

2. Measure base circle (J).

3. Subtract the base circle (J) from the camshaft lobe

(C) Extension of the dowel from the camshaft

(D) Thickness of a new thrust

(E) Dimensions for the journal surface

Note: End play for a new camshaft assembly is

(3) Torque for the 16 bolts ... 55 ± 7 N·m (41 ± 5 lb ft)