Specifications 3500C Marine Engines

RENR5077-11
July 2010
Specifications
3500B and 3500C Marine Engines
M8A1-Up (Engine) S2Y1-Up (Engine)
S2A1-Up (Engine) S2Z1-Up (Engine)
M8B1-Up (Engine)
S2B1-Up (Engine)
S2D1-Up (Engine)
S2E1-Up (Engine)
S2F1-Up (Engine)
B5G1-Up (Engine)
MRG1-Up (Engine)
PAG1-Up (Engine)
S2G1-Up (Engine)
MKH1-Up (Engine)
S2H1-Up (Engine)
S2J1-Up (Engine)
S2K1-Up (Engine)
S2L1-Up (Engine)
S2M1-Up (Engine)
S2N1-Up (Engine)
S2P1-Up (Engine)
S2R1-Up (Engine)
S2S1-Up (Engine)
S2T1-Up (Engine)
S2W1-Up (Engine)
S2X1-Up (Engine)
SAFETY.CAT.COM
i03991620
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. Cat dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci-
fications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR5077-11 3
Table of Contents
Table of Contents Engine Oil Cooler Bypass and Cooling Jet Sequence
Valves ................................................................. 64
Engine Oil Filter ................................................... 66
Engine Oil Filter ................................................... 67
Specifications Section Engine Oil Lines ................................................... 69
Engine Oil Lines (Front Mounted Engine Oil
Engine Design ....................................................... 5
Filter) ................................................................... 70
Engine Design ....................................................... 5
Duplex Engine Oil Filters ..................................... 71
Engine Design ....................................................... 6
Engine Oil Filter Base .......................................... 73
Engine Design ....................................................... 7
Crankcase Breather ............................................. 73
Engine Design ....................................................... 7
Fuel Filter (Primary) ................................................ 8
Fuel Filter Base ...................................................... 9
Engine Oil Pan ..................................................... 76
Fuel Filter ............................................................. 10
Engine Oil Pan ..................................................... 78
Fuel Pressure Regulator ...................................... 10
Engine Oil Pan ..................................................... 80
Fuel Transfer Pump .............................................. 11
Water Temperature Regulator .............................. 82
Fuel Injector Mechanism ....................................... 12
Water Lines ........................................................... 83
Fuel Injector .......................................................... 14
Engine Oil Sump Pump ........................................ 85
Camshaft ............................................................. 15
Water Pump ......................................................... 86
Camshaft ............................................................. 16
Auxiliary Water Pump .......................................... 87
Camshaft ............................................................. 17
Cooling System Pressure Cap ............................. 89
Camshaft ............................................................. 18
Cylinder Block ...................................................... 90
Camshaft ............................................................. 19
Cylinder Block ...................................................... 91
Camshaft ............................................................. 20
Cylinder Block ...................................................... 93
Valve Mechanism ................................................. 21
Cylinder Liner ....................................................... 95
Cylinder Head ...................................................... 22
Piston and Rings (One-Piece Piston) ................... 95
Cylinder Head Valves ........................................... 24
Piston and Rings (One-Piece Piston) ................... 97
Turbocharger ........................................................ 26
Piston and Rings (Two-Piece Piston) ................... 99
Turbocharger ........................................................ 27
Piston and Rings (Two-Piece Piston) ................. 101
Turbocharger ........................................................ 28
Connecting Rod ................................................. 102
Turbocharger ........................................................ 29
Connecting Rod and Main Bearing Journals ...... 104
Turbocharger ........................................................ 30
Crankshaft ......................................................... 105
Turbocharger ........................................................ 30
Crankshaft ......................................................... 106
Turbocharger ........................................................ 31
Crankshaft Wear Sleeves and Seals ................. 108
Turbocharger ........................................................ 31
Housing (Front) ................................................... 109
Turbocharger Support ........................................... 32
Housing (Front) .................................................... 110
Accumulator ......................................................... 33
Gear Group (Front) (Reverse Rotation) ............... 111
Exhaust Bypass Valve ......................................... 33
Gear Group (Front) (Reverse Rotation) ............... 113
Exhaust Bypass Valve ......................................... 34
Gear Group (Front) .............................................. 115
Exhaust Manifold ................................................. 35
Gear Group (Front) .............................................. 116
Gear Group (Rear) ............................................... 117
Balancer Group (Front) ....................................... 119
Accessory Drive ................................................. 120
Accessory Drive ................................................. 122
Exhaust Flange .................................................... 40
Accessory Drive (Lower Left Hand) .................... 123
Exhaust Flange .................................................... 40
Accessory Drive (Lower Left Hand) .................... 124
Air Cleaner ........................................................... 41
Accessory Drive (Upper Right Hand) .................. 126
Air Cleaner Adapter .............................................. 41
Air Cleaner Adapter .............................................. 42
Engine Air Cleaner Service Indicator .................... 42
Accessory Drive (Upper Left Hand) .................... 131
Air Inlet and Exhaust Lines ................................... 43
Accessory Drive (Upper Left Hand, Reverse
Rotation) ........................................................... 132
Flywheel ............................................................. 133
Flywheel Housing .............................................. 134
Air Shutoff ............................................................. 51
Flywheel Housing .............................................. 135
Air Shutoff ............................................................. 52
Flexible Coupling ................................................ 137
Engine Oil Pump .................................................. 53
Engine Mount (Front) (Hydraulic Pump Drive or PTO
Engine Oil Pump .................................................. 55
Clutch) ............................................................... 138
Engine Oil Pump .................................................. 57
Engine Trunnion .................................................. 139
Engine Oil Pump .................................................. 59
Vibration Damper ............................................... 140
Engine Oil Scavenge Pump ................................. 61
Engine Oil Cooler Bypass and Cooling Jet Sequence
Valves ................................................................. 63
Vibration Damper Guard .................................... 143
4 RENR5077-11
Table of Contents
Stub Shaft (Front) ............................................... 143

Stub Shaft (Front) ............................................... 144
Stub Shaft (Front) ............................................... 145
Auxiliary Drive Pulley ......................................... 146
Auxiliary Drive Shaft .......................................... 147
Belt Tension Chart ............................................. 148
Belt Tension Chart ............................................. 149
Alternator and Regulator .................................... 150
Alternator Mounting ........................................... 151
Electric Starting Motor ....................................... 152
Air Starting Motor ............................................... 153
Air Starting Motor Pressure Regulating Valve ... 154
Jacket Water Heater .......................................... 155
Engine Harness (Rigid Wiring Harness) ............. 155
Coolant Level Switch ......................................... 158
Coolant Temperature Switch ............................... 158
Fuel Pressure Sensor ........................................ 159
Magnetic Switch ................................................. 159
Coolant Level Sensor ......................................... 160
Engine Oil Pressure Sensor ............................... 160
Engine Oil Pressure Sensor ............................... 161
Turbocharger Inlet Pressure Sensor ................... 161
Turbocharger Outlet Pressure Sensor ................ 162
Turbocharger Outlet Pressure Sensor ................ 163
Aftercooler Coolant Temperature Sensor ........... 163
Engine Coolant Temperature Sensor .................. 163
Turbocharger Exhaust Temperature Sensor ....... 164
Engine Speed/Timing Sensor ............................. 164
Crankcase Pressure Sensor ............................... 168
Atmospheric Pressure Sensor ............................ 168
Engine Speed Sensor ......................................... 170
Engine Speed Sensor ......................................... 170
Index Section
Index ................................................................... 172
RENR5077-11 5
Specifications Section
Specifications Section Reverse rotation CW .................. 1, 8, 7, 2, 6, 5, 4, 3
Valve lash
i01939435
Inlet ......................................... 0.50 mm (0.020 inch)
Engine Design
Exhaust ................................... 1.00 mm (0.040 inch)
SMCS Code: 1000
Note: The front end of the engine is opposite the
S/N: M8A1-Up
flywheel end of the engine. The left and the right side
S/N: S2A1-Up of the engine are determined from the flywheel end.
The number 1 cylinder is the front cylinder on the
S/N: M8B1-Up right side. The number 2 cylinder is the front cylinder
on the left side.
S/N: S2B1-Up
S/N: S2D1-Up i01939560
S/N: S2E1-Up Engine Design

S/N: S2F1-Up
SMCS Code: 1000
S/N: S2G1-Up
S/N: S2H1-Up
S/N: S2K1-Up
S/N: S2L1-Up
S/N: S2M1-Up
g00293348
Illustration 1
Cylinder and valve location
(A) Inlet valves
(B) Exhaust valves
Number and arrangement of

cylinders .............................................. 60 degree V-8
Valves per cylinder .................................................. 4

g00293349
Illustration 2
Displacement .............................. 34.5 L (2105 cu in) Cylinder and valve location
(A) Inlet valves
Bore ............................................. 170 mm (6.7 inch) (B) Exhaust valves
Stroke .......................................... 190 mm (7.5 inch) Number and arrangement of

cylinders ............................................ 60 degree V-12
Compression ratio .............................................. 14:1
Combustion ........................................ Direct injection
Displacement .............................. 51.8 L (3158 cu in)
When the crankshaft is viewed from the flywheel
end the crankshaft rotates in the following Bore ............................................. 170 mm (6.7 inch)
direction. ....................................... Counterclockwise
Stroke .......................................... 190 mm (7.5 inch)
Firing order (injection sequence)
Standard rotation CCW ............... 1, 2, 7, 3, 4, 5, 6, 8
Combustion ........................................ Direct injection
6 RENR5077-11
When the crankshaft is viewed from the flywheel Bore ............................................. 170 mm (6.7 inch)
end the crankshaft rotates in the following
direction. ....................................... Counterclockwise Stroke .......................................... 215 mm (8.5 inch)
Firing order (injection sequence) Compression ratio ........................................... 15.5:1
Standard rotation Combustion ........................................ Direct injection

CCW ...................... 1, 12, 9, 4, 5, 8, 11, 2, 3, 10, 7, 6
When the crankshaft is viewed from the flywheel
Reverse rotation end the crankshaft rotates in the following
CW ......................... 1, 4, 9, 8, 5, 2, 11, 10, 3, 6, 7, 12 direction. ....................................... Counterclockwise
Valve lash Firing order (injection sequence)
Inlet ......................................... 0.50 mm (0.020 inch) Standard rotation

CCW ...................... 1, 12, 9, 4, 5, 8, 11, 2, 3, 10, 7, 6
Exhaust ................................... 1.00 mm (0.040 inch)
Reverse rotation
Note: The front end of the engine is opposite the CW ......................... 1, 4, 9, 8, 5, 2, 11, 10, 3, 6, 7, 12
of the engine are determined from the flywheel end. Valve lash
The number 1 cylinder is the front cylinder on the
right side. The number 2 cylinder is the front cylinder Inlet ......................................... 0.50 mm (0.020 inch)
on the left side.
Exhaust ................................... 1.00 mm (0.040 inch)
i01443411
Note: The front end of the engine is opposite the
Engine Design flywheel end of the engine. The left and the right side
of the engine are determined from the flywheel end.
SMCS Code: 1000 The number 1 cylinder is the front cylinder on the
right side. The number 2 cylinder is the front cylinder
S/N: MRG1-Up on the left side.
S/N: MKH1-Up
S/N: S2J1-Up
S/N: S2N1-Up
g00293349
Illustration 3
(A) Inlet valves
(B) Exhaust valves


RENR5077-11 7
i01939608 Inlet ......................................... 0.50 mm (0.020 inch)

Engine Design Exhaust ................................... 1.00 mm (0.040 inch)
SMCS Code: 1000 Note: The front end of the engine is opposite the
S/N: S2P1-Up
of the engine are determined from the flywheel end.
S/N: S2R1-Up The number 1 cylinder is the front cylinder on the
S/N: S2S1-Up on the left side.
S/N: S2W1-Up
i01939644
S/N: S2Y1-Up
Engine Design
SMCS Code: 1000
S/N: B5G1-Up
S/N: PAG1-Up
S/N: S2T1-Up
S/N: S2X1-Up
S/N: S2Z1-Up
g00294285
Illustration 4
(A) Inlet valves
(B) Exhaust valves


g00294285
Illustration 5
Bore ............................................. 170 mm (6.7 inch)
Stroke .......................................... 190 mm (7.5 inch) (A) Inlet valves
(B) Exhaust valves
Combustion ........................................ Direct injection cylinders ............................................ 60 degree V-16
When the crankshaft is viewed from the flywheel Valves per cylinder .................................................. 4
direction. ....................................... Counterclockwise Displacement .............................. 78.0 L (4760 cu in)
Firing order (injection sequence) Bore ............................................. 170 mm (6.7 inch)
Standard rotation Stroke .......................................... 215 mm (8.5 inch)

CCW .. 1, 2, 5, 6, 3, 4, 9, 10, 15, 16, 11, 12, 13, 14, 7, 8
Compression ratio ........................................... 15.5:1
Reverse rotation
CW .. 1, 6, 5, 4, 3, 10, 9, 16, 15, 12, 11, 14, 13, 8, 7, 2 Combustion ........................................ Direct injection
Valve lash When the crankshaft is viewed from the flywheel

direction. ....................................... Counterclockwise
8 RENR5077-11
Firing order (injection sequence) Part No.: 8N-6435

S/N: S2K1-Up
Standard rotation
CCW .. 1, 2, 5, 6, 3, 4, 9, 10, 15, 16, 11, 12, 13, 14, 7, 8 Part No.: 8N-6435
S/N: S2L1-Up
Reverse rotation
Part No.: 8N-6435
CW .. 1, 6, 5, 4, 3, 10, 9, 16, 15, 12, 11, 14, 13, 8, 7, 2
S/N: S2M1-Up
Valve lash Part No.: 8N-6435
S/N: S2N1-Up
Inlet ......................................... 0.50 mm (0.020 inch)
Part No.: 8N-6435
Exhaust ................................... 1.00 mm (0.040 inch) S/N: S2P1-Up
Note: The front end of the engine is opposite the Part No.: 8N-6435
flywheel end of the engine. The left and the right side S/N: S2R1-Up
of the engine are determined from the flywheel end. Part No.: 8N-6435
The number 1 cylinder is the front cylinder on the S/N: S2S1-Up
on the left side. Part No.: 8N-6435
S/N: S2T1-Up
i03657840 Part No.: 8N-6435
S/N: S2W1-Up
Fuel Filter (Primary)
Part No.: 8N-6435
SMCS Code: 1260 S/N: S2X1-Up
Part No.: 8N-6435 Part No.: 8N-6435
S/N: M8A1-Up S/N: S2Y1-Up
S/N: S2A1-Up S/N: S2Z1-Up
Part No.: 8N-6435
S/N: M8B1-Up
Part No.: 8N-6435
S/N: S2B1-Up
Part No.: 8N-6435
S/N: S2D1-Up
Part No.: 8N-6435
S/N: S2E1-Up
Part No.: 8N-6435
S/N: S2F1-Up
Part No.: 8N-6435 g01561538
S/N: MRG1-Up Illustration 6
Part No.: 8N-6435 (1) Torque for the nut ..... 25 ± 5 N·m (221 ± 44 lb in)
S/N: PAG1-Up
(2) Lubricate the bore and the shaft of the O-ring
Part No.: 8N-6435 seal lightly with the clean engine oil.
S/N: S2G1-Up
Part No.: 8N-6435 (3) 7S-9323 Spring
S/N: MKH1-Up Length under test force ... 27.94 mm (1.100 inch)
Part No.: 8N-6435 Test force ............... 27.7 to 32.3 N (6.2 to 7.3 lb)
S/N: S2H1-Up Free length after test ...... 42.67 mm (1.680 inch)
Outside diameter ............ 17.32 mm (0.682 inch)
Part No.: 8N-6435
S/N: S2J1-Up
RENR5077-11 9
i03083460 Part No.: 8N-3481

S/N: S2X1-Up
Fuel Filter Base
Part No.: 8N-3481
SMCS Code: 1262 S/N: S2Y1-Up
Part No.: 8N-3481
S/N: S2B1-Up
Part No.: 8N-3481
S/N: S2D1-Up
Part No.: 8N-3481
S/N: S2E1-Up
Part No.: 8N-3481
S/N: S2F1-Up
Part No.: 8N-3481
S/N: B5G1-Up
Part No.: 8N-3481 g01563177
Illustration 7
S/N: MRG1-Up
Typical example
Part No.: 8N-3481
S/N: PAG1-Up (A) Length for applying 154-9731 Thread Lock
Compound on the tapered end of the taperlock
Part No.: 8N-3481 stud ................. 10.0 ± 1.5 mm (0.39 ± 0.06 inch)
S/N: S2G1-Up
Part No.: 8N-3481 (1) Torque for the taperlock stud ............. 68 ± 7 N·m
(50 ± 5 lb ft)
S/N: MKH1-Up
Part No.: 8N-3481
i03609520
S/N: S2H1-Up
Part No.: 8N-3481
Fuel Filter
S/N: S2J1-Up
SMCS Code: 1261
Part No.: 8N-3481
Part No.: 335-5612
S/N: S2K1-Up
S/N: M8A1-Up
Part No.: 8N-3481
Part No.: 115-7842, 7W-9741
S/N: S2L1-Up
S/N: S2A1-Up
Part No.: 8N-3481
Part No.: 335-5612
S/N: S2M1-Up
S/N: M8B1-Up
Part No.: 8N-3481
Part No.: 115-7842, 7W-9741
S/N: S2N1-Up
S/N: S2B1-Up
Part No.: 8N-3481
Part No.: 115-7842, 7W-9741
S/N: S2P1-Up
S/N: S2D1-Up
Part No.: 8N-3481
Part No.: 115-7842, 7W-9741
S/N: S2R1-Up
S/N: S2E1-Up
Part No.: 8N-3481
Part No.: 7W-9741
S/N: S2S1-Up
S/N: S2F1-Up
Part No.: 8N-3481
Part No.: 7W-9741
S/N: S2T1-Up
S/N: B5G1-Up
Part No.: 8N-3481
Part No.: 7W-9741
S/N: S2W1-Up
S/N: MRG1-Up
10 RENR5077-11
Part No.: 7W-9741

S/N: PAG1-Up
Part No.: 115-7842, 7W-9741
S/N: S2G1-Up
Part No.: 7W-9741
S/N: MKH1-Up
Part No.: 115-7842, 7W-9741
S/N: S2H1-Up
Part No.: 115-7842, 7W-9741
S/N: S2J1-Up
Part No.: 115-7842, 7W-9741
g01934499
S/N: S2K1-Up Illustration 8
Typical example
Part No.: 115-7842, 7W-9741
S/N: S2L1-Up (1) Manual valve assembly
(3) Fuel filter element
Part No.: 7W-9741
S/N: S2M1-Up Note: Lightly lubricate the bore of the O-ring seals
with the lubricant that is being sealed or an approved
Part No.: 115-7842, 7W-9741 equivalent.
S/N: S2N1-Up
(2) 1N-2895 Spring
Part No.: 115-7842, 7W-9741
S/N: S2P1-Up Length under test force ... 20.75 mm (0.817 inch)
Test force ....................................... 222 N (50 lb)
Part No.: 115-7842, 7W-9741 Free length after test ..... 62.48 mm (2.460 inch)
S/N: S2R1-Up Outside diameter ................ 88.9 mm (3.50 inch)
Part No.: 115-7842, 7W-9741
S/N: S2S1-Up i02723705
Part No.: 115-7842, 7W-9741 Fuel Pressure Regulator

S/N: S2T1-Up
SMCS Code: 1277
Part No.: 115-7842, 7W-9741
S/N: S2W1-Up Part No.: 114-5477
Part No.: 115-7842, 7W-9741
S/N: S2X1-Up
Part No.: 7W-9741
S/N: S2Y1-Up
Part No.: 115-7842, 7W-9741
S/N: S2Z1-Up
g01366239
Illustration 9
Typical example
(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)
RENR5077-11 11
Outside diameter ............ 15.24 mm (0.600 inch) Part No.: 8N-6151

S/N: S2S1-Up
i03229222 Part No.: 8N-6151
S/N: S2T1-Up
Fuel Transfer Pump
Part No.: 8N-6151
SMCS Code: 1256 S/N: S2W1-Up
Part No.: 313-7770 Part No.: 8N-6151
S/N: M8A1-Up S/N: S2X1-Up
S/N: S2A1-Up S/N: S2Y1-Up
Part No.: 313-7770 Part No.: 8N-6151
S/N: M8B1-Up S/N: S2Z1-Up
Part No.: 8N-6151
S/N: S2B1-Up
Part No.: 8N-6151
S/N: S2D1-Up
Part No.: 8N-6151
S/N: S2E1-Up
Part No.: 8N-6151
S/N: S2F1-Up
Part No.: 8N-6151
S/N: B5G1-Up
Part No.: 8N-6151
S/N: MRG1-Up
Part No.: 8N-6151
S/N: PAG1-Up
Part No.: 8N-6151
S/N: S2G1-Up
Part No.: 8N-6151
S/N: MKH1-Up
Part No.: 8N-6151
S/N: S2H1-Up
Part No.: 8N-6151 Illustration 10
g01641861
S/N: S2J1-Up (3) Check valve
Part No.: 8N-6151

S/N: S2K1-Up When the fuel transfer pump group is viewed from
the drive end, the drive gear rotates in the clockwise
Part No.: 8N-6151 direction.
S/N: S2L1-Up
Minimum output .................... 21 L/min (5.5 US gpm)
Part No.: 8N-6151
S/N: S2M1-Up Minimum output is attained under the following
conditions:
Part No.: 8N-6151
S/N: S2N1-Up Pump pressure ............................... 415 kPa (60 psi)
Part No.: 8N-6151
S/N: S2P1-Up Pump speed ............................................... 2400 rpm
Part No.: 8N-6151 Minimum cracking pressure of bypass

S/N: S2R1-Up valve ............................................... 620 kPa (90 psi)
12 RENR5077-11
Maximum pressure of fully open bypass Part No.: 224-9869

valve ............................................. 965 kPa (140 psi) S/N: S2H1-Up
(1) Dimensions for terminal bushing Part No.: 224-9869

S/N: S2J1-Up
Inside diameter of the terminal bushing for gear
shaft ............................ 12.783 mm (0.5033 inch) Part No.: 224-9869
Installation depth of terminal S/N: S2K1-Up
bushing ............. 1.5 ± 0.5 mm (0.06 ± 0.02 inch)
Part No.: 224-9869
S/N: S2L1-Up
(2) Dimensions for drive shaft assembly
Part No.: 224-9869
Diameter of the shaft ........ 12.700 to 12.675 mm
S/N: S2M1-Up
(0.5000 to 0.4990 inch)
Diameter of the gear ............ 29.801 ± 0.006 mm Part No.: 224-9869
(1.1733 ± 0.0002 inch) S/N: S2N1-Up
Length of the gear ............... 25.347 ± 0.008 mm
(0.9979 ± 0.0003 inch) Part No.: 224-9869
S/N: S2P1-Up
(4) Dimensions for idler gear assembly
Part No.: 224-9869
Diameter of the gear ............ 29.801 ± 0.006 mm S/N: S2R1-Up
(1.1733 ± 0.0002 inch)
Length of the gear ............... 25.347 ± 0.008 mm Part No.: 224-9869
(0.9979 ± 0.0003 inch) S/N: S2S1-Up
Part No.: 224-9869
i03601019 S/N: S2T1-Up
Fuel Injector Mechanism Part No.: 224-9869

S/N: S2W1-Up
SMCS Code: 1102; 1290 Part No.: 224-9869
Part No.: 332-9690 S/N: S2X1-Up
S/N: M8A1-Up Part No.: 224-9869
Part No.: 224-9869 S/N: S2Y1-Up
S/N: S2A1-Up Part No.: 224-9869
Part No.: 332-9690 S/N: S2Z1-Up
S/N: M8B1-Up
Part No.: 224-9869
S/N: S2B1-Up
Part No.: 224-9869
S/N: S2D1-Up
Part No.: 224-9869
S/N: S2E1-Up
Part No.: 224-9869
S/N: S2F1-Up
Part No.: 224-9869
S/N: B5G1-Up
Part No.: 224-9869
S/N: MRG1-Up
Part No.: 224-9869
S/N: PAG1-Up
Part No.: 224-9869 Illustration 11
g01441231
S/N: S2G1-Up
(3) Timing pin
Part No.: 224-9869
S/N: MKH1-Up
RENR5077-11 13
(A) Bore in the sleeve bearing for the rocker arm Part No.: 250-1300
shaft after installation ........... 45.077 ± 0.015 mm S/N: M8A1-Up
(1.7747 ± 0.0006 inch)
Part No.: 256-3663
(1) Torque for the nut .... 120 ± 15 N·m (88 ± 11 lb ft) S/N: S2A1-Up
Part No.: 250-1300
(B) Diameter of the rocker arm
S/N: M8B1-Up
shaft ..................................... 45.000 ± 0.013 mm
(1.7716 ± 0.0005 inch) Part No.: 256-3663
S/N: S2B1-Up
(2) 100-3878 Injector Spring
Part No.: 256-3663
Length under test force ... 85.00 mm (3.346 inch) S/N: S2D1-Up
Test force .......................... 300 ± 25 N (67 ± 6 lb)
Free length after test ...... 87.65 mm (3.451 inch) Part No.: 256-3663
Outside diameter ............ 43.85 mm (1.726 inch) S/N: S2E1-Up
(C) Dimensions for the unit injector lifter assembly Part No.: 256-3663
S/N: S2F1-Up
Diameter of the unit injector lifter
assembly ............................. 34.950 ± 0.010 mm Part No.: 248-8695, 256-3663
(1.3760 ± 0.0004 inch) S/N: B5G1-Up
Bore in the head for the unit injector lifter Part No.: 248-8695, 256-3663
assembly ............................. 35.000 ± 0.025 mm S/N: MRG1-Up
(1.3779 ± 0.0010 inch)
Part No.: 256-3663
S/N: PAG1-Up
Part No.: 256-3663
S/N: S2G1-Up
Part No.: 248-8695, 256-3663
S/N: MKH1-Up
Part No.: 256-3663
S/N: S2H1-Up
Part No.: 256-3663
S/N: S2J1-Up
Part No.: 256-3663
Illustration 12
g01925693 S/N: S2K1-Up
Part No.: 256-3663
(4) Lubricate the bore of the O-ring seal lightly with
S/N: S2L1-Up
clean engine oil.
Part No.: 256-3663
Note: Start tightening the retainer nuts of the cap S/N: S2M1-Up
assembly by hand so that the terminal studs are not
cross threaded. Part No.: 256-3663
S/N: S2N1-Up
(5) Torque for the retainer nuts of the cap
assembly ............................... 2.500 ± 0.025 N·m Part No.: 256-3663
(22.127 ± 0.221 lb in) S/N: S2P1-Up
Part No.: 256-3663
(6) Apply 5P-3413 Pipe Sealant to the threads of S/N: S2R1-Up
the bolts, if the bolts are removed after initial
installation. Part No.: 256-3663
S/N: S2S1-Up
i02895694 Part No.: 256-3663
Fuel Injector S/N: S2T1-Up
Part No.: 256-3663
14 RENR5077-11
Part No.: 256-3663 Part No.: 106-4586, 106-4595

S/N: S2X1-Up S/N: S2A1-Up
Part No.: 256-3663 Part No.: 106-4586, 106-4595
S/N: S2Y1-Up S/N: S2B1-Up
Part No.: 256-3663 Part No.: 106-4586, 106-4595
S/N: S2Z1-Up S/N: S2D1-Up
Part No.: 106-4586, 106-4595
S/N: S2E1-Up
Part No.: 106-4586
S/N: S2F1-Up
Part No.: 106-4595
S/N: B5G1-Up
Part No.: 106-4586, 106-4595
S/N: MRG1-Up
Part No.: 106-4595
S/N: PAG1-Up
Part No.: 106-4586, 106-4595
S/N: S2G1-Up
Part No.: 106-4586, 106-4595
S/N: MKH1-Up
Part No.: 106-4586, 106-4595
g01441567 S/N: S2H1-Up
Illustration 13
Part No.: 106-4586, 106-4595
Note: Prior to installation of the fuel injector group, S/N: S2J1-Up
lubricate the bore in the cylinder head with 1P-0808
Multipurpose Grease. Use the clamp to press the Part No.: 106-4586, 106-4595
injector into the bore. Do not tap on the top surface S/N: S2K1-Up
of the injector.
Part No.: 106-4586, 106-4595
S/N: S2L1-Up
(1) Torque for the bolt .......... 65 ± 7 N·m (48 ± 5 lb ft)
Part No.: 106-4586, 106-4595
(A) Timing dimension .................... 64.34 ± 0.20 mm S/N: S2M1-Up
(2.533 ± 0.008 inch)
Part No.: 106-4586, 106-4595
Note: Before assembly, lubricate the bore and S/N: S2N1-Up
the threads of valve assembly (2) with 1P-0808
Multipurpose Grease. Part No.: 106-4586, 106-4595
S/N: S2P1-Up
(2) Valve assembly Part No.: 106-4586, 106-4595
Torque for valve assembly ............. 165 ± 10 N·m S/N: S2R1-Up
(120 ± 7 lb ft) Part No.: 106-4586, 106-4595
Torque for terminal nuts ................. 2.4 ± 0.2 N·m S/N: S2S1-Up
(21 ± 2 lb in)
Part No.: 106-4586, 106-4595
(3) Torque for unit injector nozzle ........ 310 ± 20 N·m S/N: S2T1-Up
(230 ± 15 lb ft)
Part No.: 106-4586, 106-4595
S/N: S2W1-Up
i02874925
Part No.: 106-4586, 106-4595
Camshaft S/N: S2X1-Up
SMCS Code: 1210 Part No.: 106-4586, 106-4595
S/N: S2Y1-Up
RENR5077-11 15
Part No.: 106-4586

S/N: S2Z1-Up
g01381515
Illustration 15
Illustration 14
g01430676 Use the following procedure in order to determine
(1) Left hand camshaft assembly
the camshaft lobe lift:
(2) Right hand camshaft assembly
1. Measure camshaft lobe height (H).
(A) Thickness of the groove in a new camshaft
assembly .. 8.75 ± 0.05 mm (0.344 ± 0.002 inch) 2. Measure base circle (J).
(C) Extension of the dowel from the camshaft 3. Subtract the base circle (J) from the camshaft lobe
assembly ........ 12.0 ± 0.5 mm (0.47 ± 0.02 inch) height (H). The difference is the actual camshaft
lobe lift.
(D) Thickness of a new thrust
washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch) (G) Specified camshaft lobe lift
Inlet lobe ................. 12.7500 mm (0.50197 inch)
(E) Journal surface
Injector lobe ............ 13.7313 mm (0.54060 inch)
Diameter of bearing journals for a new Exhaust lobe ........... 13.2499 mm (0.52165 inch)
camshaft .. 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).
(3) Torque for 16 bolts ......... 55 ± 7 N·m (41 ± 5 lb ft)
(F) Extension of the dowel from the end of the

rear right hand camshaft and the front left hand
camshaft ......... 22.0 ± 0.5 mm (0.87 ± 0.02 inch)
16 RENR5077-11
i01390111
Camshaft
SMCS Code: 1210
Part No.: 143-8726
S/N: S2A1-Up
Part No.: 333-8957
S/N: M8B1-Up
Part No.: 143-8726
S/N: S2D1-Up
g00290053
Illustration 17
(6) Camshaft lobe height
In order to determine the height, use the procedure

that follows:
1. Measure camshaft lobe height (6).
2. Measure base circle (8).
3. Subtract the base circle (Step 2) from the lobe

height (Step 1). The difference is the actual lobe
Illustration 16
g00289972 lift.
Typical example
4. Specified camshaft lobe lift (7)
(1) Pin
Inlet lobe ...................... 13.250 mm (0.5217 inch)
The pin extends from the camshaft by the
following distance: ....................... 12.0 ± 0.5 mm Injector lobe ................. 13.731 mm (0.5406 inch)
(0.47 ± 0.02 inch)
Exhaust lobe ................ 13.250 mm (0.5217 inch)
(2) New washer
Thickness of a new washer ....... 8.50 ± 0.05 mm
(0.335 ± 0.002 inch)
Thickness of the groove in a new
camshaft ... 8.75 ± 0.05 mm (0.344 ± 0.002 inch)
End play for new camshafts ..... 0.15 to 0.35 mm
(0.006 to 0.014 inch)
(3) LH camshaft
(4) RH camshaft
(5) Journal surface

Diameter of surface (journals) for new camshaft
bearings .. 91.88 ± 0.02 mm (3.617 ± 0.001 inch)
Bore in bearings for camshafts after
assembly ................................. 92.00 ± 0.06 mm
(3.622 ± 0.002 inch)
RENR5077-11 17
i02990771
Camshaft
SMCS Code: 1210
Part No.: 332-7923
S/N: M8A1-Up
Part No.: 106-4582
S/N: S2B1-Up
Part No.: 106-4582
S/N: S2E1-Up
Part No.: 106-4582
S/N: S2F1-Up
g01460128
Illustration 19
(E) Specified camshaft lobe lift

Inlet lobe ................. 12.7500 mm (0.50197 inch)
Injector lobe ............ 13.7313 mm (0.54060 inch)
Exhaust lobe ........... 13.2500 mm (0.52165 inch)
Use the following procedure in order to determine the

g01515757 actual camshaft lobe lift:
Illustration 18
(1) Left hand camshaft assembly 1. Measure camshaft lobe height (F).
2. Measure base circle (G).

(A) Thickness of the groove for thrust washer in a
new camshaft assembly ............ 8.75 ± 0.05 mm 3. Subtract the base circle (G) from the camshaft
(0.344 ± 0.002 inch) lobe height (F). The difference is the actual
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)
installation ................................ 92.00 ± 0.06 mm
(3.622 ± 0.002 inch)

0.15 to 0.35 mm (0.006 to 0.014 inch).
18 RENR5077-11
i03021227 Bore in camshaft bearing after

installation ................................ 92.00 ± 0.06 mm
Camshaft (3.622 ± 0.002 inch)
SMCS Code: 1210 Note: End play for a new camshaft assembly is
0.15 to 0.35 mm (0.006 to 0.014 inch).
Part No.: 143-8727
S/N: S2G1-Up
Part No.: 143-8727
S/N: S2K1-Up (F) Extension of the dowel from the end of the
Part No.: 163-1419 camshaft ......... 22.0 ± 0.5 mm (0.87 ± 0.02 inch)
S/N: S2N1-Up
Part No.: 143-8728
S/N: S2P1-Up
Part No.: 163-1451
S/N: S2T1-Up
Part No.: 143-8728
S/N: S2W1-Up
Part No.: 163-1451
S/N: S2Z1-Up
g01447245
Illustration 21

actual camshaft lobe lift:
2. Measure base circle (J).
3. Subtract the base circle (J) from the camshaft lobe

height (H). The difference is the actual camshaft
g01381231
lobe lift.
Illustration 20
(1) Left hand camshaft assembly (G) Specified camshaft lobe lift
Inlet lobe ..................... 13.250 mm (0.5217 inch)
(A) Thickness of the groove in a new camshaft Injector lobe ................ 13.731 mm (0.5406 inch)
assembly .. 8.75 ± 0.05 mm (0.344 ± 0.002 inch) Exhaust lobe ............... 13.250 mm (0.5217 inch)
(C) Extension of the dowel from the camshaft

assembly ........ 12.0 ± 0.5 mm (0.47 ± 0.02 inch)

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

(3.617 ± 0.001 inch)
RENR5077-11 19
i03021222 (F) Extension of the dowel from the end of the

Camshaft camshaft ......... 22.0 ± 0.5 mm (0.87 ± 0.02 inch)
SMCS Code: 1210
Part No.: 281-7848
S/N: B5G1-Up
Part No.: 281-7848
S/N: MRG1-Up
Part No.: 281-7848
S/N: PAG1-Up
Part No.: 281-7849
S/N: MKH1-Up
g01447245
Illustration 23


height (H). The difference is the actual camshaft
lobe lift.
g01381231
Illustration 22
(G) Specified camshaft lobe lift
(2) Right hand camshaft assembly Inlet lobe .................. 12.7300 mm (0.50118 inch)
Injector lobe .............. 13.7313 mm (0.5406 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)

assembly ........ 12.0 ± 0.5 mm (0.47 ± 0.02 inch)

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

(3.617 ± 0.001 inch)
installation ................................ 92.00 ± 0.06 mm
(3.622 ± 0.002 inch)

0.15 to 0.35 mm (0.006 to 0.014 inch).

20 RENR5077-11
i03295700
Camshaft
SMCS Code: 1210
Part No.: 231-9123
S/N: B5G1-Up
Part No.: 231-9123
S/N: PAG1-Up
g01447245
Illustration 25


Illustration 24
g01381231 height (H). The difference is the actual camshaft
lobe lift.
(G) Specified camshaft lobe lift
(A) Thickness of the groove in a new camshaft Inlet lobe ..................... 12.730 mm (0.5012 inch)
assembly .. 8.75 ± 0.05 mm (0.344 ± 0.002 inch) Injector lobe ............ 13.7313 mm (0.54060 inch)
Exhaust lobe ............... 13.100 mm (0.5157 inch)
assembly ........ 12.0 ± 0.5 mm (0.47 ± 0.02 inch)
i03577164
washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch) Valve Mechanism
(E) Dimensions for the journal surface SMCS Code: 1102
Diameter of bearing journal ..... 91.88 ± 0.02 mm Part No.: 332-9690

(3.617 ± 0.001 inch) S/N: M8A1-Up
Bore in camshaft bearing after Part No.: 224-9869
installation ................................ 92.00 ± 0.06 mm S/N: S2A1-Up
(3.622 ± 0.002 inch)
Part No.: 332-9690
Note: End play for a new camshaft assembly is S/N: M8B1-Up
0.15 to 0.35 mm (0.006 to 0.014 inch).
Part No.: 224-9869
(3) Torque for 16 bolts ......... 55 ± 7 N·m (41 ± 5 lb ft) S/N: S2B1-Up
(F) Extension of the dowel from the end of the Part No.: 224-9869
rear right hand camshaft and the front left hand S/N: S2D1-Up
camshaft ......... 22.0 ± 0.5 mm (0.87 ± 0.02 inch) Part No.: 224-9869
S/N: S2E1-Up
RENR5077-11 21
Part No.: 224-9869

S/N: S2F1-Up
Part No.: 224-9869
S/N: B5G1-Up
Part No.: 224-9869
S/N: MRG1-Up
Part No.: 224-9869
S/N: PAG1-Up
Part No.: 224-9869
S/N: S2G1-Up
Part No.: 224-9869
S/N: MKH1-Up
Part No.: 224-9869
S/N: S2H1-Up
Part No.: 224-9869
S/N: S2J1-Up
Part No.: 224-9869
S/N: S2K1-Up
Part No.: 224-9869
S/N: S2L1-Up
Part No.: 224-9869 g01905795
Illustration 26
S/N: S2M1-Up
Part No.: 224-9869 Refer to Guideline for Reusable Parts and Salvage
S/N: S2N1-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: S2P1-Up
(1) Torque for two jam nuts ................... 70 ± 15 N·m
Part No.: 224-9869 (52 ± 11 lb ft)
S/N: S2R1-Up
Part No.: 224-9869 (A) Diameter of the rocker arm shaft
S/N: S2S1-Up assembly ............................. 45.000 ± 0.013 mm
(1.7716 ± 0.0005 inch)
Part No.: 224-9869
S/N: S2T1-Up (B) Dimensions for the valve lash
Part No.: 224-9869 Inlet ................................... 0.50 mm (0.020 inch)

S/N: S2W1-Up Exhaust ............................. 1.00 mm (0.039 inch)
Part No.: 224-9869 (C) Bore in the sleeve bearing for the rocker arm shaft
S/N: S2X1-Up assembly after installation ... 45.077 ± 0.015 mm
(1.7747 ± 0.0006 inch)
Part No.: 224-9869
S/N: S2Y1-Up
(D) Dimensions for the valve lifter assembly
Part No.: 224-9869
Diameter of the valve lifter
S/N: S2Z1-Up
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)
22 RENR5077-11
i03076672 Part No.: 101-0830

S/N: S2T1-Up
Cylinder Head
Part No.: 101-0830
Part No.: 332-9694 Part No.: 101-0830
Part No.: 101-0830 Part No.: 101-0830
Part No.: 332-9694 Part No.: 101-0830
Part No.: 101-0830
S/N: S2B1-Up
Part No.: 101-0830
S/N: S2D1-Up
Part No.: 101-0830
S/N: S2E1-Up
Part No.: 101-0830
S/N: S2F1-Up
Part No.: 101-0830
S/N: B5G1-Up
Part No.: 101-0830 g01429899
Illustration 27
S/N: MRG1-Up
Typical example
Part No.: 101-0830 (1) Locating pad
S/N: PAG1-Up
Part No.: 101-0830 NOTICE
S/N: S2G1-Up The pipe plug at location (2) is installed in the cylinder
head for engines with dry exhaust manifolds. If the
Part No.: 101-0830 pipe plug is not installed into the water passage, the
S/N: MKH1-Up coolant will leak and engine damage will result. For
engines with dry exhaust manifolds, make sure that
Part No.: 101-0830 the pipe plug is installed.
S/N: S2H1-Up
Part No.: 101-0830
S/N: S2J1-Up
Part No.: 101-0830
S/N: S2K1-Up
Part No.: 101-0830
S/N: S2L1-Up
Part No.: 101-0830
S/N: S2M1-Up
Part No.: 101-0830
S/N: S2N1-Up
Part No.: 101-0830
S/N: S2P1-Up
Part No.: 101-0830
S/N: S2R1-Up
Part No.: 101-0830
S/N: S2S1-Up
RENR5077-11 23
g01611158 g01413732
Illustration 28 Illustration 29
Typical example Typical example
Top view
(A) Height of the new cylinder
(3) Before assembly, lubricate the thread of the pipe head ...... 142.00 ± 0.15 mm (5.591 ± 0.006 inch)
plug.
Note: Before assembly, apply 6V-6640 Sealant to
Use the following procedure to tighten the bolts of the the bore of the ten cup plugs.
cylinder head that is shown in Illustration 28:
(B) Installation depth of two cup plugs from the top
Note: Before assembly, coat the threads of the bolt surface of the cylinder head .......... 9.0 ± 0.5 mm
with clean engine oil. (0.35 ± 0.02 inch)
1. Tighten the bolt 1 through bolt 8 in the numerical (D) Installation depth of eight cup plugs from the top
sequence to 30 ± 5 N·m (22 ± 4 lb ft). surface of the cylinder head .......... 1.0 ± 0.5 mm
(0.04 ± 0.02 inch)
2. Tighten the bolt 1 through bolt 8 in the numerical
sequence to 200 ± 15 N·m (150 ± 11 lb ft).
i03080402
3. Again tighten the bolt 1 through bolt 8 in Cylinder Head Valves

the numerical sequence to 200 ± 15 N·m
(150 ± 11 lb ft). SMCS Code: 1105
4. Turn the bolt 1 through bolt 8 in the numerical Part No.: 332-9694
sequence to an additional rotation of 180 ± 5 S/N: M8A1-Up
degrees.
Part No.: 101-0830
Note: Tighten the bolts (4) only after the cylinder S/N: S2A1-Up
head bolts have been given final torque. Part No.: 332-9694
S/N: M8B1-Up
(4) Torque for two bolts ..... 55 ± 10 N·m (41 ± 7 lb ft)
Part No.: 101-0830
S/N: S2B1-Up
Part No.: 101-0830
S/N: S2D1-Up
Part No.: 101-0830
S/N: S2E1-Up
Part No.: 101-0830
S/N: S2F1-Up
24 RENR5077-11
Part No.: 101-0830

S/N: B5G1-Up
Part No.: 101-0830
S/N: MRG1-Up
Part No.: 101-0830
S/N: PAG1-Up
Part No.: 101-0830
S/N: S2G1-Up
Part No.: 101-0830
S/N: MKH1-Up
Part No.: 101-0830
S/N: S2H1-Up
Part No.: 101-0830
S/N: S2J1-Up
Part No.: 101-0830
S/N: S2K1-Up
Part No.: 101-0830
S/N: S2L1-Up
Part No.: 101-0830
S/N: S2M1-Up
Part No.: 101-0830
S/N: S2N1-Up
Part No.: 101-0830
S/N: S2P1-Up
Part No.: 101-0830
S/N: S2R1-Up
Part No.: 101-0830
S/N: S2S1-Up
Part No.: 101-0830
S/N: S2T1-Up
Part No.: 101-0830
S/N: S2W1-Up
Part No.: 101-0830
S/N: S2X1-Up
Part No.: 101-0830
S/N: S2Y1-Up
Part No.: 101-0830, 335-6220
S/N: S2Z1-Up
RENR5077-11 25
g01566713
Illustration 30
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)
26 RENR5077-11
i03670347
Turbocharger
SMCS Code: 1052
Part No.: 333-2233
S/N: M8A1-Up
Part No.: 145-7993
S/N: S2A1-Up
Part No.: 333-8955
S/N: M8B1-Up
Part No.: 145-7995
S/N: S2B1-Up
Part No.: 145-7995
S/N: S2E1-Up
Part No.: 145-7995
S/N: S2G1-Up
g01441032
Illustration 31
Part No.: 145-7995
Typical example
S/N: S2K1-Up
(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

Inlet ................................... 20.00 ± 0.25 degrees
Exhaust ............................. 45.00 ± 0.25 degrees
(H) Depth of bore in the cylinder head for the valve

seat insert ................................ 16.00 ± 0.15 mm
(0.630 ± 0.006 inch)
(J) Outside diameter of the face of the valve seat

insert .................................... 53.6 mm (2.11 inch)
g01616117
Illustration 32
Note: Before assembly, lubricate the threads and

the bearing surfaces of the bolts with 4C-5599
Anti-Seize Compound.
(1) Torque for the bolts ........ 54 ± 5 N·m (40 ± 4 lb ft)

RENR5077-11 27
3. Again, tighten the clamp assemblies to 14 ± 3 N·m

(124 ± 27 lb in).
i03414341
Turbocharger
SMCS Code: 1052
Part No.: 173-7676
S/N: S2H1-Up
Part No.: 173-7676
S/N: S2L1-Up
Part No.: 259-8431
S/N: S2M1-Up
Part No.: 165-6678
S/N: S2T1-Up
g01619282
Illustration 33
Rear view
Before assembly, lubricate the threads and the

bearing surfaces of the bolts with 4C-5599
Use the following procedure in order to tighten the

bolts of the half flange (2).
1. Tighten bolts 3 in any sequence to 54 ± 5 N·m

(40 ± 4 lb ft).
2. Tighten bolts 4 in any sequence to 54 ± 5 N·m

(40 ± 4 lb ft).
g01616117
Illustration 35
Note: Before assembly, lubricate the threads and the

bearing surface of the bolts with 4C-5599 Anti-Seize
Compound.
(1) Torque for the bolts to the exhaust

manifold ......................... 54 ± 5 N·m (40 ± 4 lb ft)
g01538253
Illustration 34
Use the following procedure to tighten the clamp

assembly (5) and turbine clamp assembly (6):
1. Tighten the clamp assemblies to 14 ± 3 N·m

(124 ± 27 lb in).
2. Gently tap around the clamp assemblies with a

soft faced hammer.
28 RENR5077-11
i03411202
Turbocharger
SMCS Code: 1052
Part No.: 159-8828
S/N: S2H1-Up
Part No.: 159-8828
S/N: S2J1-Up
Part No.: 176-3231
S/N: S2M1-Up
Part No.: 159-8828
S/N: S2R1-Up
Part No.: 159-8828
S/N: S2S1-Up
Part No.: 159-8828, 250-6111
S/N: S2Z1-Up
g01770114
Illustration 36

bolts for the half flange (2):
1. Tighten bolts (3) in any sequence to 54 ± 5 N·m

(40 ± 4 lb ft).

(40 ± 4 lb ft).
(5) Cartridge's bolt torque ... 40 ± 2 N·m (30 ± 1 lb ft)
g01616117
Illustration 37
Note: Before assembly, lubricate the threads and the

bearing surface of the bolts with 4C-5599 Anti-Seize
Compound.

RENR5077-11 29
i03035044
Turbocharger
SMCS Code: 1052
Part No.: 167-1762
S/N: S2H1-Up
Part No.: 167-1762
S/N: S2J1-Up
Part No.: 167-1762
S/N: S2R1-Up
Part No.: 167-1762
S/N: S2S1-Up
Part No.: 167-1762
S/N: S2Z1-Up
g01753233
Illustration 38

bolts for the half flange (2):

(40 ± 4 lb ft).

(40 ± 4 lb ft).
(5) Cartridge's bolt torque ... 40 ± 2 N·m (30 ± 1 lb ft)

g01538593
Illustration 39
Note: Before assembly, apply 4C-5599 Anti-Seize

Compound to the threads and to the bearing surface
of the bolts.

30 RENR5077-11
Torque ............................ 40 ± 5 N·m (30 ± 4 lb ft)
(2) Bolt
Torque ............................ 65 ± 5 N·m (48 ± 4 lb ft)
(3) Clamp
Tighten each clamp in two places.
Torque ............................ 60 ± 5 N·m (44 ± 4 lb ft)
i01909990
Turbocharger
SMCS Code: 1052
Part No.: 4P-2581
S/N: S2R1-Up
g01538619
Illustration 40
(2) Torque for four bolts ....... 54 ± 5 N·m (40 ± 4 lb ft)
(3) Torque for eight bolts for the turbine

housing .......................... 40 ± 2 N·m (30 ± 1 lb ft)
(4) Torque for eight bolts for the compressor

housing. ......................... 40 ± 2 N·m (30 ± 1 lb ft)
i02051385
Turbocharger
SMCS Code: 1052
Part No.: 238-7771
S/N: B5G1-Up
g00976451
S/N: MRG1-Up
Part No.: 238-7772 (1) Bolt
S/N: MKH1-Up
(2) Washers
(3) Nut
Lubricate the bearing surfaces of bolt (1), washers

(2), and nut (3) and lubricate the threads of the bolt
and the nut with 4C-5597 Anti-Seize Compound.
(4) Bolt
Torque .......................... 55 ± 10 N·m (41 ± 7 lb ft)
(5) Lock
After assembly, bend the short end of the lock against

g01052152 the bolt head. Bend the long end of the lock around
Illustration 41
the turbine clamp. Do not reuse an opened lock.
(1) Bolt (6) Washer
RENR5077-11 31
Lubricate the bearing surfaces of washer (6) with i03149240

4C-5597 Anti-Seize Compound.
Turbocharger
(7) Bolt
SMCS Code: 1052
Lubricate the bolt's bearing surfaces and threads
with 4C-5597 Anti-Seize Compound. Part No.: 238-7769
S/N: PAG1-Up
Torque .......................... 45 ± 10 N·m (33 ± 7 lb ft)
(8) Bolt
Torque .......................... 55 ± 10 N·m (41 ± 7 lb ft)
i03140083
Turbocharger
SMCS Code: 1052
Part No.: 159-8829
S/N: S2R1-Up
Part No.: 159-8829 g01619692
S/N: S2S1-Up Illustration 44
Rear view
Part No.: 159-8829
S/N: S2X1-Up (1) Torque for two clamp assemblies ...... 60 ± 5 N·m
(44 ± 4 lb ft)
g01616497
Illustration 43
Rear view
(1) Torque for four V-band clamp

assemblies ..................... 60 ± 5 N·m (44 ± 4 lb ft)
32 RENR5077-11
i03119342
Turbocharger Support
SMCS Code: 1052
Part No.: 139-0600
S/N: S2G1-Up
Part No.: 139-0600
S/N: S2H1-Up
Part No.: 139-0600
S/N: S2P1-Up
Part No.: 139-0600
S/N: S2R1-Up
Part No.: 139-0600
S/N: S2Z1-Up
g01595655
Illustration 45
(1) Torque for 21 bolts ... 120 ± 20 N·m (90 ± 15 lb ft)
(2) Torque for 10 bolts .. 135 ± 20 N·m (100 ± 15 lb ft)

RENR5077-11 33
i02835300 i03341711
Accumulator Exhaust Bypass Valve

SMCS Code: 1320 SMCS Code: 1057
S/N: S2Y1-Up Part No.: 165-4406
S/N: PAG1-Up
Part No.: 165-4406, 282-3015
S/N: MKH1-Up
g01414647
Illustration 47
(1) Torque for the locknut .................. 12.5 ± 1.0 N·m

g01433346
Illustration 46 (110 ± 9 lb in)
(1) Accumulator assembly (2) 7E-4677 Spring

Charging medium ............................ Dry nitrogen Free length ........................ 115.3 mm (4.54 inch)
Internal volume of compartment for Outside diameter ............ 82.55 mm (3.250 inch)
gas .......................................... 3786 mL (231 in3)
Charged pressure ..................... 138 kPa (20 psi) (3) 7E-4676 Spring
Service pressure ....................... 138 kPa (20 psi)
Bursting pressure ............. 34500 kPa (5000 psi) Free length ........................ 115.3 mm (4.54 inch)
(4) Torque for the nut ..... 14 ± 3 N·m (125 ± 27 lb in)
(5) Torque for the five screws .............. 6.5 ± 1.0 N·m
(60 ± 9 lb in)
(6) Before assembly, lubricate the threads and the

bearing surfaces of the setscrew with 4C-5599
34 RENR5077-11
i03341316
Exhaust Bypass Valve

SMCS Code: 1057
Part No.: 259-1436
S/N: B5G1-Up
Part No.: 259-1436
S/N: PAG1-Up
g01414647
Illustration 49
g01717353
(1) Torque for the locknut .................. 12.5 ± 1.0 N·m
Illustration 48 (110 ± 9 lb in)
(7) Exhaust bypass valve
(8) Locknut (2) 259-1435 Spring
(9) Gasket
Free length .......................... 127 mm (5.00 inch)
1. Clean the stud, the locknut, and the base of the Outside diameter ............ 82.55 mm (3.250 inch)
locknut prior to assembly.
(3) 259-1434 Spring
2. Apply 2P-2333 High Temperature Sealer to the
threads of the stud that extend through the flange Free length .......................... 127 mm (5.00 inch)
of the exhaust bypass valve and to the bottom of Outside diameter ............ 62.48 mm (2.460 inch)
the mating face of each locknut.
(4) Torque for the nut ..... 14 ± 3 N·m (125 ± 27 lb in)
3. Tighten two diagonal locknuts.
(5) Torque for the five screws .............. 6.5 ± 1.0 N·m
Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft) (60 ± 9 lb in)
4. Tighten the remaining locknuts. (6) Before assembly, lubricate the threads and the
bearing surfaces of the setscrew with 4C-5599
Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft) Anti-Seize Compound.
5. Tighten all four locknuts again.
Torque ............................. 47 ± 9 N·m (35 ± 7 lb ft)

RENR5077-11 35
i03697281
Exhaust Manifold
SMCS Code: 1059
Part No.: 334-7032
S/N: M8A1-Up
Part No.: 334-7032
S/N: M8B1-Up
g01717353
Illustration 50
(7) Exhaust bypass valve
(8) Locknut
(9) Gasket
g01988413
Illustration 51
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.
3. Tighten two diagonal locknuts.
Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft)
4. Tighten the remaining locknuts.
Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft)
5. Tighten all four locknuts again.
Torque ............................. 47 ± 9 N·m (35 ± 7 lb ft)

36 RENR5077-11
i03114083 i03114039
Exhaust Manifold Exhaust Manifold

Part No.: 123-0324 Part No.: 129-5488, 161-2502
S/N: S2A1-Up S/N: S2A1-Up
Part No.: 123-0324 Part No.: 129-5488, 161-2502
S/N: S2B1-Up S/N: S2B1-Up
Part No.: 123-0324 Part No.: 129-5488, 161-2502
S/N: S2D1-Up S/N: S2D1-Up
Part No.: 123-0324 Part No.: 129-5488, 161-2502
S/N: S2E1-Up S/N: S2E1-Up
Part No.: 123-0324 Part No.: 129-5488, 161-2502
S/N: S2F1-Up S/N: S2F1-Up
Part No.: 129-5488, 161-2502
S/N: S2G1-Up
Part No.: 129-5488, 161-2502
S/N: S2H1-Up
Part No.: 129-5488, 161-2502
S/N: S2J1-Up
Part No.: 129-5488, 161-2502
S/N: S2K1-Up
Part No.: 129-5488, 161-2502
S/N: S2L1-Up
g01592399 Part No.: 129-5488, 161-2502

Illustration 52
S/N: S2M1-Up
Top view of engine
Part No.: 129-5488, 161-2502
Note: Apply 4C-5599 Anti-Seize Compound to the S/N: S2N1-Up
threads of the bolts and to the face of the washers.
Tighten diagonally opposite bolts simultaneously. Part No.: 129-5488, 161-2502
S/N: S2P1-Up
(1) Torque for the bolts ........ 55 ± 5 N·m (41 ± 4 lb ft) Part No.: 129-5488, 161-2502
S/N: S2R1-Up
Part No.: 129-5488, 161-2502, 161-2503,
167-1759
S/N: S2S1-Up
Part No.: 129-5488, 161-2502, 167-1759
S/N: S2T1-Up
Part No.: 129-5488, 161-2502
S/N: S2W1-Up
Part No.: 129-5488, 161-2502, 161-2503
S/N: S2X1-Up
Part No.: 129-5488, 161-2502, 161-2503
g01592401
Illustration 53 S/N: S2Y1-Up
Note: Apply 4C-5599 Anti-Seize Compound to the Part No.: 129-5488, 161-2502, 167-1759
threads of the bolts and to the face of the washers. S/N: S2Z1-Up

RENR5077-11 37
g01592366
Illustration 54
Typical example
Top view of engine
g01592373
Illustration 55
Rear view of engine
Note: Apply 4C-5599 Anti-Seize Compound to the

threads of the bolts and to the face of the washers.
Tighten diagonally opposite bolts simultaneously.

38 RENR5077-11
i02051171
Exhaust Manifold
SMCS Code: 1059
Part No.: 238-9120
S/N: PAG1-Up
Part No.: 239-0731
S/N: MKH1-Up
g01052090
Illustration 56
(1) Clamp Torque ............................ 35 ± 5 N·m (26 ± 4 lb ft)

Torque ............................ 25 ± 6 N·m (18 ± 4 lb ft) (6) Bolt
(2) Bolt Torque ............................ 55 ± 5 N·m (41 ± 4 lb ft)
Lubricate the washer face and the thread
with 5P-3931 Anti-Seize Compound before
assembly. Tighten diagonally opposite bolts
simultaneously.
Torque ............................ 55 ± 5 N·m (41 ± 4 lb ft)
(3) Bolt
Lubricate the washer face and the thread with

5P-3931 Anti-Seize Compound before assembly.
(4) Bolt
Lubricate the washer face and the thread with

5P-3931 Anti-Seize Compound before assembly.
(5) Stud
RENR5077-11 39
i03695742
Exhaust Manifold
SMCS Code: 1059
Part No.: 240-0745
S/N: B5G1-Up
Part No.: 239-0732
S/N: MRG1-Up
g01987274
Illustration 57
Typical example
(1) Before assembly, lubricate the threads and the Part No.: 7N-6962
bearing surfaces of the bolts with 4C-5599 S/N: M8A1-Up
Part No.: 7N-6962
Note: Before assembly, lubricate the threads and S/N: S2A1-Up
the bearing surfaces of the clamps with 4C-5599 Part No.: 7N-6962
S/N: M8B1-Up
(2) Torque for the clamps ........................ 25 ± 6 N·m Part No.: 7N-6962
(221 ± 53 lb in) S/N: S2B1-Up
(3) Before assembly, lubricate the threads and the Part No.: 7N-6962
bearing surfaces of the locknuts with 4C-5599 S/N: S2D1-Up
Part No.: 7N-6962
Note: Before assembly, lubricate the threads and S/N: S2E1-Up
the bearing surfaces of the bolts with 4C-5599 Part No.: 7N-6962
Anti-Seize Compound. Tighten diagonally opposite S/N: S2F1-Up
bolts simultaneously.
Part No.: 7N-6962
(4) Torque for the bolts ........ 55 ± 5 N·m (41 ± 4 lb ft) S/N: S2G1-Up
Part No.: 7N-6962
i02953003 S/N: S2H1-Up
Exhaust Flange Part No.: 7N-6962
S/N: S2J1-Up
SMCS Code: 1061
40 RENR5077-11
Part No.: 7N-6962 i02836282

S/N: S2K1-Up
Exhaust Flange
Part No.: 7N-6962
S/N: S2L1-Up SMCS Code: 1061
Part No.: 7N-6962 Part No.: 103-6668
S/N: S2M1-Up S/N: PAG1-Up
Part No.: 7N-6962 Part No.: 103-6668
S/N: S2N1-Up S/N: MKH1-Up
Part No.: 7N-6962 Part No.: 103-6668
S/N: S2P1-Up S/N: S2J1-Up
Part No.: 7N-6962 Part No.: 103-6668
S/N: S2R1-Up S/N: S2K1-Up
Part No.: 7N-6962 Part No.: 103-6668
S/N: S2S1-Up S/N: S2P1-Up
Part No.: 7N-6962 Part No.: 103-6668
S/N: S2T1-Up S/N: S2R1-Up
Part No.: 7N-6962 Part No.: 103-6668
S/N: S2W1-Up S/N: S2S1-Up
Part No.: 7N-6962 Part No.: 103-6668
S/N: S2X1-Up S/N: S2T1-Up
Part No.: 7N-6962 Part No.: 103-6668
S/N: S2Y1-Up S/N: S2W1-Up
Part No.: 103-6668
S/N: S2X1-Up
Part No.: 103-6668
S/N: S2Y1-Up
Part No.: 103-6668
S/N: S2Z1-Up
g01468407
Illustration 58
Typical example
(1) Apply 4C-5599 Anti-Seize Compound to the

threads of 12 bolts.
g01414164
Illustration 59
Typical example

threads of the 16 bolts.
RENR5077-11 41
i01659336 i02954024
Air Cleaner Air Cleaner Adapter

Part No.: 5N-8728 Part No.: 7W-9828
S/N: S2A1-Up S/N: M8A1-Up
Part No.: 7W-9828
S/N: S2A1-Up
Part No.: 7W-9828
S/N: M8B1-Up
Part No.: 7W-9828
S/N: S2B1-Up
Part No.: 7W-9828
S/N: S2D1-Up
Part No.: 7W-9828
S/N: S2E1-Up
Part No.: 7W-9828
S/N: S2F1-Up
Part No.: 7W-9828
S/N: S2G1-Up
Part No.: 7W-9828
g00856159 S/N: S2K1-Up
Illustration 60
Part No.: 7W-9828
(1) Washer S/N: S2N1-Up
In order to align the precleaner with the air cleaner, Part No.: 7W-9828
use the 8T-4896 Hard Washers as spacers for the S/N: S2P1-Up
air cleaner.
Part No.: 7W-9828
S/N: S2R1-Up
(2) Bolt
Part No.: 7W-9828
Torque .............................. 12 ± 4 N·m (9 ± 3 lb ft)
S/N: S2W1-Up
(3) Washer Part No.: 7W-9828
S/N: S2Z1-Up
In order to align the precleaner with the air cleaner,
use the 8T-4122 Hard Washers as spacers for the
precleaner.
g01469799
Illustration 61
(1) Torque for 48 locknuts ....................... 12 ± 4 N·m

(105 ± 35 lb in)
42 RENR5077-11
i02954022 i02894887
Air Cleaner Adapter Engine Air Cleaner Service

SMCS Code: 1051
Indicator
Part No.: 4P-2013 SMCS Code: 7452
S/N: MRG1-Up
Part No.: 213-1412, 7N-6782
Part No.: 4P-2013 S/N: S2A1-Up
S/N: S2G1-Up
Part No.: 213-1412, 7N-6782
Part No.: 4P-2013 S/N: S2B1-Up
S/N: S2H1-Up
Part No.: 213-1412, 7N-6782
Part No.: 4P-2013 S/N: S2G1-Up
S/N: S2J1-Up
Part No.: 213-1412, 7N-6782
Part No.: 4P-2013 S/N: S2H1-Up
S/N: S2L1-Up
Part No.: 213-1412, 7N-6782
Part No.: 4P-2013 S/N: S2P1-Up
S/N: S2M1-Up
Part No.: 213-1412, 7N-6782
Part No.: 4P-2013 S/N: S2R1-Up
S/N: S2R1-Up
Part No.: 213-1412, 7N-6782
Part No.: 4P-2013 S/N: S2Z1-Up
S/N: S2S1-Up
Part No.: 4P-2013
S/N: S2T1-Up
Part No.: 4P-2013
S/N: S2X1-Up
Part No.: 4P-2013
S/N: S2Z1-Up
g01440984
Illustration 63
Rear view of engine
g01469798 (1) Air cleaner
Illustration 62
(1) Torque for 28 locknuts ....................... 12 ± 4 N·m Note: Install the air filter change indicator group with
(105 ± 35 lb in) the filter side toward the air cleaner.
(2) Torque for the two air filter change indicator

groups ....................... 2.0 ± 0.7 N·m (18 ± 6 lb in)
RENR5077-11 43
i03688471
Air Inlet and Exhaust Lines

SMCS Code: 1058; 1061
Part No.: 334-4668
S/N: M8A1-Up
Part No.: 334-4668
S/N: M8B1-Up
g01983494
Illustration 65
g01983495
Illustration 66
Bolt tightening sequence
(2) Torque for the bolts .. 120 ± 20 N·m (89 ± 15 lb ft)
Note: Before assembly, lubricate the threads of the

plugs with 4C-5599 Anti-Seize Compound.
g01983493
Illustration 64
(3) Torque for the plugs .. 25 ± 5 N·m (221 ± 44 lb in)
(1) Before assembly, lubricate the bore of the O-ring (4) Use the following procedure in order to tighten
seals lightly with 5P-3975 Rubber Lubricant. the bolts of the aftercooler assembly:
1. Assemble the seals to the aftercooler core.
2. Temporarily secure the bottom seal to the

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

manifold.
4. Inspect the bottom seal in order to ensure that the

seal is seating correctly in the recess.
44 RENR5077-11
5. Install the aftercooler cover. Part No.: 173-2947

S/N: S2T1-Up
6. Inspect the upper seal in order to ensure that the
seal is seating correctly in the recess. Part No.: 173-2947
S/N: S2W1-Up
7. Install the cover bolts. Hand tighten the cover
Part No.: 173-2947
bolts.
S/N: S2X1-Up
8. Tighten the bolts in the numerical sequence to Part No.: 173-2947
24 ± 6 N·m (212 ± 53 lb in). Refer to Illustration 66. S/N: S2Y1-Up
9. Again, tighten the bolts in the numerical sequence Part No.: 173-2947
to 47 ± 9 N·m (35 ± 7 lb ft). Refer to Illustration 66. S/N: S2Z1-Up
10. Remove the tape.
i03295780

SMCS Code: 1058; 1061
Part No.: 173-2947
S/N: S2A1-Up
Part No.: 173-2947
S/N: S2B1-Up
Part No.: 173-2947
S/N: S2D1-Up
Part No.: 173-2947
S/N: S2E1-Up
Part No.: 173-2947
S/N: S2F1-Up
Part No.: 173-2947
S/N: S2G1-Up
Part No.: 173-2947
S/N: S2H1-Up
Part No.: 162-5718, 173-2947
S/N: S2J1-Up
Part No.: 173-2947
S/N: S2K1-Up
Part No.: 173-2947
S/N: S2L1-Up
Part No.: 173-2947
S/N: S2M1-Up
Part No.: 162-5718, 173-2947
S/N: S2N1-Up
Part No.: 173-2947
S/N: S2P1-Up
Part No.: 173-2947
S/N: S2R1-Up
Part No.: 173-2947
S/N: S2S1-Up
RENR5077-11 45
g01679613
Illustration 67
Right side view
(1) Lubricate the bore for the O-ring seals with

glycerin or an approved equivalent.
46 RENR5077-11
g01614754
Illustration 68
(2) Use the following procedure in order to tighten

the bolts of the aftercooler assembly:


manifold.

5. Install the aftercooler cover.


bolts.
8. Tighten the bolts in the numerical sequence to

24 N·m (18 lb ft).
9. Again, tighten the bolts in the numerical sequence

to 47 N·m (35 lb ft).
Note: Lubricate the threads of the plugs with

4C-5599 Anti-Seize Compound before assembly.
(3) Torque for three plugs .... 20 ± 5 N·m (15 ± 4 lb ft)

RENR5077-11 47
i03690160

SMCS Code: 1058; 1061
Part No.: 107-0860
S/N: S2A1-Up
Part No.: 107-0860
S/N: S2B1-Up
Part No.: 107-0860
S/N: S2D1-Up
Part No.: 107-0860
S/N: S2E1-Up
Part No.: 107-0860
S/N: S2F1-Up
g01984493
Illustration 69
Right side view of engine
48 RENR5077-11
g01614673
Illustration 70
(1) Before assembly, lubricate the bore of the O-ring

seals lightly with 5P-3975 Rubber Lubricant.



manifold.

5. Install the aftercooler cover.


bolts.

24 ± 6 N·m (212 ± 53 lb in). Refer to Illustration 70.

to 24 ± 6 N·m (212 ± 53 lb in). Refer to Illustration
70.

plugs with 4C-5599 Anti-Seize Compound.
(3) Torque for the plugs .. 20 ± 5 N·m (177 ± 44 lb in)

RENR5077-11 49
i03137489

SMCS Code: 1058; 1061
Part No.: 144-2885
S/N: S2P1-Up
Part No.: 107-0862
S/N: S2R1-Up
Part No.: 107-0862
S/N: S2S1-Up
Part No.: 144-2885
S/N: S2W1-Up
g01614613
Illustration 71
Right side view of engine
g01614614
Illustration 72
View A-A
(1) Lubricate the bore for the O-ring seals with

50 RENR5077-11
g01614616
Illustration 73



manifold.

seal is seating correctly in the recess. g01614623
Illustration 74
5. Install the aftercooler cover. View B-B
6. Inspect the upper seal in order to ensure that the Note: Lubricate the threads of the plugs with
seal is seating correctly in the recess. 4C-5599 Anti-Seize Compound before assembly.
7. Install the cover bolts. Hand tighten the cover (4) Torque for two plugs ...... 20 ± 5 N·m (15 ± 4 lb ft)
bolts.

24 N·m (18 lb ft).

to 47 N·m (35 lb ft).

RENR5077-11 51
i03688482
Air Shutoff
SMCS Code: 1078
Part No.: 335-1898
S/N: M8A1-Up
Part No.: 335-1898
S/N: M8B1-Up
g01983517
Illustration 75
(1) Air shutoff group

Maximum operating temperature of the
valve .......................................... 204 °C (399 °F)
Maximum operating pressure of the
valve ......................................... 300 kPa (44 psi)
Note: Before you assemble the limit switch assembly

(2) in the shutoff valve, apply 4C-5599 Anti-Seize
Compound to the threads of the plug.
(2) Torque for the limit switch assembly ..... 16.3 N·m
(12.0 lb ft)
g01927222
Illustration 76
52 RENR5077-11
Note: Apply 4C-5599 Anti-Seize Compound to the Part No.: 214-5543

threads of the bolts (3) and to the threads of the bolts S/N: S2P1-Up
(7).
Part No.: 214-5543
(3) Torque for the bolts ......... 7 ± 1 N·m (62 ± 9 lb in) S/N: S2S1-Up
Part No.: 214-5543
S/N: S2T1-Up
shaft of the air shutoff assembly.
Part No.: 214-5543
Note: Before assembly, apply 4C-9614 Silicone S/N: S2W1-Up
Sealant between the body (5) and the cover (6).
Part No.: 214-5543
(7) Torque for the bolts ........................ 9.5 ± 1.5 N·m S/N: S2Z1-Up
(84.1 ± 13.3 lb in)
(9) Solenoid assembly

Operating voltage .......................... 18 to 32 VDC
Resistance at 25 °C
(77 °F) ................................ 1.485 to 1.815 Ohms
Torque for the bolts (8) .................. 9.5 ± 1.5 N·m
(84.1 ± 13.3 lb in)
i03601965
Air Shutoff
SMCS Code: 1078
Part No.: 214-5543
S/N: S2A1-Up
Part No.: 214-5543
S/N: S2B1-Up
g01927221
S/N: S2D1-Up Rear view
Part No.: 214-5543

S/N: S2E1-Up (1) Air shutoff group
Part No.: 214-5543 Maximum operating temperature of the

S/N: S2F1-Up valve .......................................... 204 °C (399 °F)
Maximum operating pressure of the
Part No.: 214-5543 valve ......................................... 300 kPa (44 psi)
S/N: S2G1-Up
Note: Before you assemble the limit switch assembly
Part No.: 214-5543, 274-5749 (2) in the shutoff valve, apply 4C-5599 Anti-Seize
S/N: S2H1-Up Compound to the threads of the plug.
Part No.: 214-5543 (2) Torque for the limit switch assembly ..... 16.3 N·m
S/N: S2J1-Up (12.0 lb ft)
Part No.: 214-5543
S/N: S2K1-Up
Part No.: 214-5543
S/N: S2L1-Up
Part No.: 214-5543
S/N: S2M1-Up
Part No.: 214-5543
S/N: S2N1-Up
RENR5077-11 53
Part No.: 106-9872

S/N: S2F1-Up
Part No.: 106-9872
S/N: B5G1-Up
Part No.: 106-9872
S/N: MRG1-Up
Part No.: 106-9872
S/N: PAG1-Up
Part No.: 106-9872
S/N: S2G1-Up
Part No.: 106-9872
S/N: MKH1-Up
Part No.: 106-9872
S/N: S2H1-Up
Part No.: 106-9872
S/N: S2J1-Up
g01927222
Illustration 78
Part No.: 106-9872
Note: Apply 4C-5599 Anti-Seize Compound to the S/N: S2K1-Up
threads of the bolts (3) and to the threads of the bolts Part No.: 106-9872
(7). S/N: S2L1-Up
(3) Torque for the bolts ......... 7 ± 1 N·m (62 ± 9 lb in) Part No.: 106-9872
S/N: S2M1-Up
shaft of the air shutoff assembly. Part No.: 106-9872
S/N: S2N1-Up
Note: Before assembly, apply 4C-9614 Silicone
Part No.: 106-9872
Sealant between the body (5) and the cover (6).
S/N: S2P1-Up
(7) Torque for the bolts ........................ 9.5 ± 1.5 N·m Part No.: 106-9872
(84.1 ± 13.3 lb in) S/N: S2R1-Up
(9) Solenoid assembly Part No.: 106-9872
S/N: S2S1-Up
Operating voltage .......................... 18 to 32 VDC
Resistance at 25 °C Part No.: 106-9872
(77 °F) ................................ 1.485 to 1.815 Ohms S/N: S2T1-Up
Torque for the bolts (8) .................. 9.5 ± 1.5 N·m
(84.1 ± 13.3 lb in) Part No.: 106-9872
S/N: S2W1-Up
i03557502 Part No.: 106-9872

S/N: S2X1-Up
Engine Oil Pump
Part No.: 106-9872
Part No.: 106-9872 Part No.: 106-9872

Part No.: 106-9872

S/N: S2B1-Up
Part No.: 106-9872
S/N: S2D1-Up
Part No.: 106-9872
S/N: S2E1-Up
54 RENR5077-11
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)
(E) Distance from the end of the pump shaft

assembly to the gear face ........... 34.0 ± 0.5 mm
(1.34 ± 0.02 inch)
(F) Dimensions for the pump drive shaft

g01554195
Illustration 79 Diameter of new pump drive
shaft ..................................... 31.742 ± 0.008 mm
Note: The rotation of the drive gear is clockwise when (1.2497 ± 0.0003 inch)
you view the engine oil pump from the drive end. Bore in the sleeve bearing for the pump drive
shaft after assembly ............. 31.811 ± 0.013 mm
Note: Before you install the pump, lubricate the (1.2524 ± 0.0005 inch)
moving parts with clean engine oil. Rotate the pump
by hand in order to ensure that the pump rotates (G) Distance from the gear face to the pump drive
freely. shaft assembly ............................. 47.0 ± 0.5 mm
(1.85 ± 0.02 inch)
(1) 107-7175 Spring
(H) Installation depth of the sleeve bearing in the
Length under test force ..................... 107.16 mm pump cover ....... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)
(4.219 inch)
Test force ............ 555.6 ± 20.0 N (124.9 ± 4.5 lb) (J) Installation depth of the sleeve bearing in the oil
Free length after test ........ 144.5 mm (5.69 inch) pump body assembly ..................... 1.5 ± 0.5 mm
Outside diameter ............ 27.00 mm (1.063 inch) (0.06 ± 0.02 inch)
g01883030
g01554196
(B) Dimension for the gears

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

RENR5077-11 55
i03602902
Engine Oil Pump

SMCS Code: 1304
Part No.: 7W-0053
S/N: M8A1-Up
Part No.: 7N-8715
S/N: S2A1-Up
Part No.: 7W-0053
S/N: M8B1-Up
Part No.: 7N-8715
g01554197
Illustration 82 S/N: S2B1-Up
(K) Position of the bearing joints from the centerline Part No.: 7N-8715
through the bearing bores ........ 45 ± 15 degrees S/N: S2D1-Up
Part No.: 7N-8715
S/N: S2E1-Up
g01554195
Illustration 84
Note: The rotation of the drive gear is clockwise when

you view the engine oil pump from the drive end.
g01881373
Illustration 83
(2) Pump cover Note: Before you install the pump, lubricate the
(L) Extension of the hollow dowel from the oil pump by hand in order to ensure that the pump rotates
cover ................. 6.0 ± 1.0 mm (0.24 ± 0.04 inch) freely.
Bench test specifications (1) 2S-2760 Spring
Unrestricted flow rate per minute at 1000 Length under test force .. 117.14 mm (4.612 inch)
rpm ....................................... 410 L (108 US gal) Test force ........................ 499 ± 24 N (112 ± 5 lb)
Pump pressure at 300 rpm with fully blocked Approximate free length after test .... 152.91 mm
outlet ..................... 570 to 630 kPa (83 to 91 psi) (6.020 inch)
56 RENR5077-11
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 87
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)

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

pump body assembly ..................... 1.5 ± 0.5 mm
(0.06 ± 0.02 inch)
RENR5077-11 57
Part No.: 8N-6152

S/N: S2J1-Up
Part No.: 8N-6152
S/N: S2K1-Up
Part No.: 8N-6152
S/N: S2L1-Up
Part No.: 8N-6152
S/N: S2M1-Up
Part No.: 8N-6152
S/N: S2N1-Up
Part No.: 8N-6152
S/N: S2P1-Up
Part No.: 8N-6152
S/N: S2R1-Up
Part No.: 8N-6152
S/N: S2S1-Up
g01927801
Illustration 88
Part No.: 8N-6152
(3) Pump cover
S/N: S2T1-Up
(L) Extension of the hollow dowel from the oil pump Part No.: 8N-6152
cover ................. 6.0 ± 1.0 mm (0.24 ± 0.04 inch) S/N: S2W1-Up
Bench test specifications Part No.: 8N-6152

S/N: S2X1-Up
Unrestricted flow rate at 700 rpm ........... 135.0 L
(35.7 US gal) Part No.: 8N-6152
Pump pressure at 300 rpm with fully blocked S/N: S2Y1-Up
outlet ..................... 570 to 630 kPa (83 to 91 psi)
Part No.: 8N-6152
S/N: S2Z1-Up
i03560066
Engine Oil Pump

SMCS Code: 1304
Part No.: 8N-6152
S/N: S2A1-Up
Part No.: 8N-6152
S/N: S2B1-Up
Part No.: 8N-6152
S/N: S2D1-Up
Part No.: 8N-6152
S/N: S2E1-Up Illustration 89
g01554195
Part No.: 8N-6152

Note: The rotation of the drive gear is clockwise when
S/N: S2F1-Up
you view the engine oil pump from the drive end.
Part No.: 8N-6152
S/N: S2G1-Up Note: Before you install the pump, lubricate the
Part No.: 8N-6152 by hand in order to ensure that the pump rotates
S/N: MKH1-Up freely.
Part No.: 8N-6152 (1) 2S-2760 Spring
S/N: S2H1-Up
Length under test force .. 117.14 mm (4.612 inch)
Test force .................. 499 ± 24 N (112.2 ± 5.4 lb)
58 RENR5077-11
Approximate free length after test .... 152.91 mm (J) Installation depth of the sleeve bearing in the oil
(6.020 inch) pump body assembly ..................... 1.5 ± 0.5 mm
Outside diameter ..................... 27 mm (1.1 inch) (0.06 ± 0.02 inch)
g01890213 g01883675
(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

(1.2497 ± 0.0003 inch)
Bore in the sleeve bearing for the new shaft after Illustration 92
g01883677
assembly .............................. 31.811 ± 0.013 mm
(1.2524 ± 0.0005 inch) (K) Position of bearing joints from the centerline
(D) Extension of hollow dowel from the oil pump
cover ................. 6.0 ± 1.0 mm (0.24 ± 0.04 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)

pump cover ....... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)
RENR5077-11 59
i02941571
Engine Oil Pump

SMCS Code: 1304
Part No.: 244-8985
S/N: MRG1-Up
Part No.: 244-8985
S/N: MKH1-Up
g01459732
Illustration 94
g01883017
Illustration 93 5P-3975 Rubber Lubricant immediately before
(3) Pump cover assembly of the engine oil pump.
(L) Extension of the hollow dowel from the oil pump

cover ................. 6.0 ± 0.5 mm (0.24 ± 0.02 inch)
Bench test specifications

Unrestricted flow rate at 700 rpm ....... 220 L/min
(58.1 US gpm)
Pump pressure at 300 rpm with fully blocked
outlet .................... 570 to 630 kPa (83 to 91 psi )
g01459725
Illustration 95
(2) 2S-2760 Spring

Length under test force .. 117.14 mm (4.612 inch)
Test force .................. 499 ± 24 N (112.2 ± 5.4 lb)
Approximate free length after test .... 152.91 mm
(6.020 inch)
60 RENR5077-11
g01459726
Illustration 96

(3.3071 ± 0.0006 inch)
g01502139
new gear .. 84.15 ± 0.02 mm (3.313 ± 0.001 inch) Illustration 97
(C) Dimensions for the shafts (K) Extension of the dowel from the oil pump
cover ................. 6.0 ± 1.0 mm (0.24 ± 0.04 inch)
(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)
(E) Distance from the end of the pump shaft

(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)
g01459731
(G) Distance from the end of the pump drive shaft Illustration 98
(1.85 ± 0.02 inch) (L) Position of the bearing joints from the centerline
pump cover ....... 1.5 ± 0.5 mm (0.06 ± 0.02 inch) Bench test specifications
(J) Installation depth of the sleeve bearing in the oil Unrestricted flow rate at 700 rpm ....... 220 L/min
pump body assembly. .................... 1.5 ± 0.5 mm (58 US gpm)
(0.06 ± 0.02 inch)
RENR5077-11 61
Pump pressure at 300 rpm with fully blocked

outlet ................. 710 to 770 kPa (105 to 110 psi)
Note: Before you install the pump, lubricate the

by hand in order to ensure that the pump rotates
freely.
i02394919
Engine Oil Scavenge Pump

SMCS Code: 1312
Part No.: 8N-9164
S/N: M8A1-Up
Part No.: 8N-9164
S/N: M8B1-Up
g00118286
Illustration 99
1W-8508 Pump Group ....... 110.000 ± 0.015 mm

NOTICE (4.3307 ± 0.0006 inch)
Before operation, the pump must be lubricated with 144-8267 Pump Group .... 145.000 ± 0.015 mm
clean engine oil and the pump must turn freely by hand (5.7087 ± 0.0006 inch)
or damage to parts can be the result.
Depth of bores for new gears
When the oil scavenge pump is viewed from 8N-9164 Pump Group ........ 84.150 ± 0.020 mm
the drive end the drive rotates in the following (3.3130 ± 0.0008 inch)
direction. ....................................... Counterclockwise 1W-8508 Pump Group ....... 110.150 ± 0.020 mm
(4.3366 ± 0.0008 inch)
(1) Length of new gears 144-8267 Pump Group .... 145.150 ± 0.020 mm
(5.7146 ± 0.0008 inch)
8N-9164 Pump Group ........ 84.000 ± 0.015 mm
(3.3071 ± 0.0006 inch)
62 RENR5077-11
(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
Note: Before installing a gear onto the shaft, clean

the shaft and clean the gear's bore with isopropyl
alcohol.
1. Tap on gear in order to seat the taper on the shaft.
2. Tighten the bolt to the following torque:
Torque for bolt ........... 100 ± 20 N·m (75 ± 15 lb ft)
Repeat this procedure until the torque does not

change.
g00118287
Illustration 100
Typical example
RENR5077-11 63
g00118288
Illustration 101
(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)
i03686767
Engine Oil Cooler Bypass and

Cooling Jet Sequence Valves
SMCS Code: 1314; 1331
Part No.: 335-3154, 335-3155
S/N: M8A1-Up
Part No.: 335-3154, 335-3155
S/N: M8B1-Up
g01982413
Illustration 102
(1) Lubricate the bore of the O-ring seals lightly with (2) Torque for the plug ... 100 ± 15 N·m (74 ± 11 lb ft)
the clean engine oil.
64 RENR5077-11
Note: The oil cooler bypass valve must open with a Part No.: 115-7860
pressure difference of 180 ± 20 kPa (26.1 ± 2.9 psi). S/N: S2J1-Up
(3) 2W-1635 Spring for oil cooler bypass valve Part No.: 115-7860
S/N: S2K1-Up
Length under test force ..... 102.0 mm (4.02 inch)
Test force ........................ 518 ± 26 N (116 ± 6 lb) Part No.: 115-7860
Free length after test ........ 143.4 mm (5.65 inch) S/N: S2L1-Up
Outside diameter ........ 37.251 mm (1.4666 inch)
Part No.: 115-7860
S/N: S2M1-Up
Note: The cooling jet sequence valves must start
to open at a pressure difference of 130 ± 30 kPa Part No.: 115-7860
(18.9 ± 4.4 psi). S/N: S2N1-Up
Note: The cooling jet sequence valves must be Part No.: 115-7860
fully open at a pressure difference of 200 ± 30 kPa S/N: S2P1-Up
(29.0 ± 4.4 psi).
Part No.: 115-7860
(4) 6B-9202 Spring for the cooling jet sequence S/N: S2R1-Up
valve Part No.: 115-7860
Length under test force ....... 68.3 mm (2.69 inch) S/N: S2S1-Up
Test force ............... 85 to 100 N (19.0 to 22.4 lb) Part No.: 115-7860
Free length after test ......... 112.7 mm (4.44 inch) S/N: S2T1-Up
Part No.: 115-7860
S/N: S2W1-Up
i03139927
Part No.: 115-7860
Engine Oil Cooler Bypass and S/N: S2X1-Up
Cooling Jet Sequence Valves Part No.: 115-7860
SMCS Code: 1314; 1331 S/N: S2Y1-Up
Part No.: 115-7860 Part No.: 115-7860

Part No.: 115-7860

S/N: S2B1-Up
Part No.: 115-7860
S/N: S2D1-Up
Part No.: 115-7860
S/N: S2E1-Up
Part No.: 115-7860
S/N: S2F1-Up
Part No.: 115-7860
S/N: B5G1-Up
Part No.: 115-7860
S/N: MRG1-Up
Part No.: 115-7860
S/N: PAG1-Up
Part No.: 115-7860
S/N: S2G1-Up
Part No.: 115-7860
S/N: MKH1-Up
Part No.: 115-7860
S/N: S2H1-Up
RENR5077-11 65
g01616336
Illustration 103
Right side view
Typical example
Note: The cooling jet sequence valves must start

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

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

valve
Quantity ............................................................ 2
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

g01616353
Illustration 104 Length under test force ..... 102.0 mm (4.02 inch)
Front view Test force .................. 518 ± 26 N (115.0 ± 5.8 lb)
Typical example Free length after test ........ 143.4 mm (5.65 inch)
Use the following tightening sequence for the clamp
bolts: (7) Lubricate the bore of the O-ring seals lightly with
1. Snugly tighten the clamp assembly (3) to the tube
(4). (8) Lubricate the bore of two O-ring plugs lightly with
2. Tighten two bolts (2) of the clamp assembly to the
elbow (10) to 47 ± 9 N·m (35 ± 7 lb ft). (9) Torque for the plug ... 100 ± 15 N·m (75 ± 11 lb ft)
3. Tighten two bolts (1) of the clamp assembly to the

tube (4) to 47 ± 9 N·m (35 ± 7 lb ft).
66 RENR5077-11
i03670352
Engine Oil Filter

SMCS Code: 1318
Part No.: 112-4921
g01445657
Illustration 105
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.
RENR5077-11 67
(3) Bypass valve Part No.: 115-7841, 242-6278, 4W-6874

S/N: S2P1-Up
Start to open pressure ..................... 287 ± 7 kPa
(41.6 ± 1.0 psi) Part No.: 115-7841, 242-6278, 4W-6874
Fully open pressure ......................... 480 ± 7 kPa S/N: S2R1-Up
(69.6 ± 1.0 psi)
Part No.: 115-7841, 242-6278, 4W-6874
(4) Torque for the bolts ........ 55 ± 7 N·m (41 ± 5 lb ft) S/N: S2S1-Up
Part No.: 115-7841, 242-6278, 4W-6874
i03742181 S/N: S2T1-Up
Engine Oil Filter Part No.: 115-7841, 242-6278, 4W-6874

S/N: S2W1-Up
SMCS Code: 1318
Part No.: 115-7841, 242-6278, 4W-6874
Part No.: 242-6278 S/N: S2X1-Up
S/N: M8A1-Up
Part No.: 115-7841, 242-6278, 4W-6874
Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2Y1-Up
S/N: S2A1-Up
Part No.: 115-7841, 147-3172, 242-6278,
Part No.: 242-6278 4W-6874
Part No.: 115-7841, 242-6278, 4W-6874

S/N: S2B1-Up
Part No.: 115-7841, 242-6278, 4W-6874
S/N: S2D1-Up
Part No.: 115-7841, 242-6278, 4W-6874
S/N: S2E1-Up
Part No.: 115-7841, 242-6278, 4W-6874
S/N: S2F1-Up
Part No.: 242-6278
S/N: B5G1-Up
Part No.: 242-6278
S/N: MRG1-Up
Part No.: 242-6278
S/N: PAG1-Up
Part No.: 115-7841, 242-6278, 4W-6874
S/N: S2G1-Up
Part No.: 242-6278
S/N: MKH1-Up
Part No.: 115-7841, 242-6278, 4W-6874
S/N: S2H1-Up
Part No.: 115-7841, 242-6278, 4W-6874
S/N: S2J1-Up
Part No.: 115-7841, 242-6278, 4W-6874
S/N: S2K1-Up
Part No.: 115-7841, 242-6278, 4W-6874
S/N: S2L1-Up
Part No.: 115-7841, 242-6278, 4W-6874
S/N: S2M1-Up
Part No.: 115-7841, 242-6278, 4W-6874
S/N: S2N1-Up
68 RENR5077-11
g01417897
Illustration 106
Front view
(1) Lubricate the bore of the O-ring seals lightly with

clean engine oil.
(3) 2W-1635 Spring

Test force ........................ 518 ± 26 N (117 ± 6 lb)
Free length after test force ................. 143.4 mm
(5.65 inch)
Note: Bypass valve (4) must move freely in the bore.
(4) Bypass valve

Start to open pressure: .. 287 ± 7 kPa (42 ± 1 psi)
Fully open pressure: ..... 480 ± 7 kPa (70 ± 1 psi)
RENR5077-11 69
i03686744 i01906041
Engine Oil Lines Engine Oil Lines

SMCS Code: 1307
(Front Mounted Engine Oil
Part No.: 335-3157
Filter)
S/N: M8A1-Up SMCS Code: 1307
Part No.: 335-3157 Part No.: 242-6279
S/N: M8B1-Up S/N: M8A1-Up
Part No.: 107-7180, 242-6279
S/N: S2A1-Up
Part No.: 242-6279
S/N: M8B1-Up
Part No.: 107-7180, 242-6279
S/N: S2B1-Up
Part No.: 107-7180, 242-6279
S/N: S2D1-Up
Part No.: 107-7180, 242-6279
S/N: S2E1-Up
Part No.: 107-7180, 242-6279
S/N: S2F1-Up
Part No.: 107-7180, 242-6279
S/N: B5G1-Up
Part No.: 107-7180, 242-6279
S/N: MRG1-Up
Part No.: 107-7180, 242-6279
S/N: PAG1-Up
Part No.: 107-7180, 242-6279
S/N: S2G1-Up
g01982333
Illustration 107 Part No.: 107-7180, 242-6279
Typical example S/N: MKH1-Up
(1) Lubricate the bore of the O-ring seals lightly with Part No.: 107-7180, 242-6279
the clean engine oil. S/N: S2H1-Up
Use the following tightening sequence to tighten the Part No.: 107-7180, 242-6279
bolts of the clamp assembly (2): S/N: S2J1-Up
Part No.: 107-7180, 242-6279
1. Snugly tighten the clamp assembly to the tube . S/N: S2K1-Up
2. Tighten the bolts of the clamp assembly to the Part No.: 107-7180, 242-6279
elbow to 47 ± 9 N·m (35 ± 7 lb ft). S/N: S2L1-Up
3. Tighten the bolts of the clamp assembly to the Part No.: 107-7180, 242-6279
tube to 47 ± 9 N·m (35 ± 7 lb ft). S/N: S2M1-Up
Part No.: 107-7180, 242-6279
S/N: S2N1-Up
Part No.: 107-7180, 242-6279
S/N: S2P1-Up
Part No.: 107-7180, 242-6279
S/N: S2R1-Up
70 RENR5077-11
Part No.: 107-7180, 242-6279 (1) Clamp bolts

S/N: S2S1-Up
Torque ............................ 47 ± 9 N·m (35 ± 7 lb ft)
Part No.: 107-7180, 242-6279
S/N: S2T1-Up Tightening sequence for the clamp bolts
Part No.: 107-7180, 242-6279 1. Snugly tighten the clamp assembly to the tube.
S/N: S2W1-Up
2. Tighten the clamp assembly to the elbow.
Part No.: 107-7180, 242-6279
S/N: S2X1-Up
3. Tighten the clamp assembly to the tube.
Part No.: 107-7180, 242-6279
S/N: S2Y1-Up (2) O-rings
Part No.: 107-7180, 242-6279 Lubricate the O-rings with clean engine oil prior to
S/N: S2Z1-Up assembly.
i03694821
Duplex Engine Oil Filters

SMCS Code: 1318
Part No.: 120-4501
S/N: M8A1-Up
Part No.: 120-4501
S/N: S2A1-Up
Part No.: 120-4501
S/N: M8B1-Up
Part No.: 120-4501
S/N: S2B1-Up
Part No.: 120-4501
S/N: S2D1-Up
g00992667 Part No.: 120-4501

Illustration 108 S/N: S2E1-Up
Right side view
Part No.: 120-4501
S/N: S2F1-Up
Part No.: 120-4501
S/N: B5G1-Up
Part No.: 120-4501
S/N: MRG1-Up
Part No.: 120-4501
S/N: PAG1-Up
Part No.: 120-4501
S/N: S2G1-Up
Part No.: 120-4501
S/N: MKH1-Up
Part No.: 120-4501
S/N: S2H1-Up
Part No.: 120-4501
S/N: S2J1-Up
g00992788
Illustration 109 Part No.: 120-4501
Front view (typical example) S/N: S2K1-Up
RENR5077-11 71
Part No.: 120-4501

S/N: S2L1-Up
Part No.: 120-4501
S/N: S2M1-Up
Part No.: 120-4501
S/N: S2N1-Up
Part No.: 120-4501
S/N: S2P1-Up
Part No.: 120-4501
S/N: S2R1-Up
Part No.: 120-4501
S/N: S2S1-Up
Part No.: 120-4501
S/N: S2T1-Up
Part No.: 120-4501
S/N: S2W1-Up
Part No.: 120-4501
S/N: S2X1-Up
Part No.: 120-4501
S/N: S2Y1-Up
Part No.: 120-4501, 4W-9968
S/N: S2Z1-Up
72 RENR5077-11
g02002813
Illustration 110
Front view
(2) Lever (5) Tie rod (7) Bracket
(3) Lever (6) Ball plunger assembly (11) Cover
Note: Refer to Testing and Adjusting, “Duplex Oil Note: The bypass valve (9) must move freely in
Filter - Adjust” for correct adjustment procedures of the bore. The bypass valve must start to open at
the fluid control valve group (10). 287 ± 7 kPa (42 ± 1 psi). The bypass valve must be
fully open at 480 ± 7 kPa (70 ± 1 psi).
(1) Lightly lubricate the O-ring seals with clean
engine oil.
(8) 2W-1635 Spring

Test force ........................ 518 ± 26 N (116 ± 6 lb)
Free length after test ........ 143.4 mm (5.65 inch)
RENR5077-11 73
i02947466 Part No.: 124-5513

S/N: S2G1-Up
Engine Oil Filter Base
Part No.: 124-5513
SMCS Code: 1306 S/N: MKH1-Up
Part No.: 151-9270, 8N-2001 Part No.: 124-5513
S/N: S2H1-Up
Part No.: 124-5513
S/N: S2J1-Up
Part No.: 124-5513
S/N: S2K1-Up
Part No.: 124-5513
S/N: S2L1-Up
Part No.: 124-5513
S/N: S2N1-Up
Part No.: 124-5513, 247-4696
S/N: S2P1-Up
Part No.: 124-5513, 247-4696
S/N: S2R1-Up
Part No.: 124-5513, 247-4696
S/N: S2S1-Up
g01460980 Part No.: 124-5513, 247-4696

Illustration 111
S/N: S2T1-Up
Typical example
Part No.: 124-5513, 247-4696
(A) Length for applying 154-9731 Thread Lock S/N: S2W1-Up
Compound to the threads of the hollow
stud ................. 10.2 ± 1.5 mm (0.40 ± 0.06 inch) Part No.: 124-5513, 247-4696
S/N: S2X1-Up
(1) Torque for the hollow stud ............... 80 ± 14 N·m Part No.: 124-5513, 247-4696
(60 ± 10 lb ft) S/N: S2Y1-Up
Part No.: 247-4696
i02895692
S/N: S2Z1-Up
Crankcase Breather
SMCS Code: 1317
Part No.: 124-5513
S/N: S2A1-Up
Part No.: 124-5513
S/N: S2B1-Up
Part No.: 124-5513
S/N: S2D1-Up
Part No.: 124-5513
S/N: S2E1-Up
Part No.: 124-5513
S/N: B5G1-Up
Part No.: 124-5513
S/N: MRG1-Up
Part No.: 124-5513
S/N: PAG1-Up
74 RENR5077-11
g01441554
Illustration 112
(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)
RENR5077-11 75
i03137363
Crankcase Breather
SMCS Code: 1317
Part No.: 101-0838
S/N: M8A1-Up
Part No.: 101-0838
S/N: S2A1-Up
Part No.: 101-0838
S/N: M8B1-Up
Part No.: 101-0838
S/N: S2B1-Up
Part No.: 101-0838
S/N: S2D1-Up
Part No.: 101-0838
S/N: S2E1-Up
Part No.: 101-0838
S/N: S2F1-Up
g01614413
Illustration 113
(3) Breather assembly (4) Cover assembly
(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)
76 RENR5077-11
i03117145 Part No.: 8N-6164

S/N: S2A1-Up
Crankcase Breather
Part No.: 8N-6164
SMCS Code: 1317 S/N: S2B1-Up
Part No.: 247-4696 Part No.: 8N-6164
S/N: S2P1-Up S/N: S2D1-Up
Part No.: 247-4696 Part No.: 8N-6164
S/N: S2R1-Up S/N: S2E1-Up
Part No.: 247-4696 Part No.: 8N-6164
S/N: S2S1-Up S/N: S2F1-Up
Part No.: 247-4696 Part No.: 8N-6164
S/N: S2T1-Up S/N: MRG1-Up
Part No.: 247-4696 Part No.: 8N-6164
S/N: S2W1-Up S/N: PAG1-Up
Part No.: 247-4696 Part No.: 8N-6164
S/N: S2X1-Up S/N: S2G1-Up
Part No.: 247-4696 Part No.: 8N-6164
S/N: S2Y1-Up S/N: MKH1-Up
Part No.: 247-4696 Part No.: 8N-6164
S/N: S2Z1-Up S/N: S2H1-Up
Part No.: 8N-6164
S/N: S2J1-Up
Part No.: 8N-6164
S/N: S2K1-Up
Part No.: 8N-6164
S/N: S2L1-Up
Part No.: 8N-6164
S/N: S2M1-Up
Part No.: 8N-6164
S/N: S2N1-Up
Part No.: 8N-6164
S/N: S2P1-Up
Part No.: 8N-6164
S/N: S2R1-Up
Part No.: 8N-6164
g01594054 S/N: S2S1-Up
Illustration 114
Part No.: 8N-6164
(1) Lubricate the bore for the seal with clean engine S/N: S2T1-Up
oil.
Part No.: 8N-6164
(2) Torque for the hose clamps ........... 3.0 ± 0.5 N·m S/N: S2W1-Up
(27 ± 4 lb in)
Part No.: 8N-6164
S/N: S2X1-Up
i02948560
Part No.: 8N-6164
Engine Oil Pan S/N: S2Y1-Up
SMCS Code: 1302

RENR5077-11 77
g01462912
Illustration 115
g01462767
Illustration 116
Use the following procedure in order to tighten the (14) As required, apply 4C-9614 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 (12) to 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 115 to • Connecting joint of the flywheel housing (17) and
standard torque. the rear of the cylinder block
(11) As required, apply 4C-9614 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 six joints of the gasket prior to assembly.
(15) As required, apply 4C-9614 Silicone Sealant,
(13) Lubricate the bore of nine O-ring seals lightly Permatex No. 2 or 138-8436 Liquid Gasket to
with the lubricant that is being sealed or an the sealing surface of the integral seal prior to
approved equivalent. assembly.
78 RENR5077-11
(16) As required, apply 4C-9509 Wicking Sealant to Part No.: 8N-7706

the open top end of the bolt holes after assembly S/N: S2S1-Up
of the oil pan.
Part No.: 8N-7706
(19) Torque for the oil drain plug ......... 145 ± 15 N·m S/N: S2T1-Up
(105 ± 11 lb ft)
Part No.: 8N-7706
S/N: S2W1-Up
(20) Torque for the oil drain plug ............. 55 ± 7 N·m
(41 ± 5 lb ft) Part No.: 8N-7706
S/N: S2X1-Up
i03139780 Part No.: 8N-7706
Engine Oil Pan S/N: S2Y1-Up
Part No.: 8N-7706
SMCS Code: 1302 S/N: S2Z1-Up
Part No.: 8N-7706
S/N: S2A1-Up
Part No.: 8N-7706
S/N: S2B1-Up
Part No.: 8N-7706
S/N: S2D1-Up
Part No.: 8N-7706
S/N: S2E1-Up
Part No.: 8N-7706
S/N: S2F1-Up
Part No.: 8N-7706
S/N: MRG1-Up
Part No.: 8N-7706
S/N: PAG1-Up
Part No.: 8N-7706
S/N: S2G1-Up
Part No.: 8N-7706
S/N: MKH1-Up
Part No.: 8N-7706
S/N: S2H1-Up
Part No.: 8N-7706
S/N: S2J1-Up
Part No.: 8N-7706
S/N: S2K1-Up
Part No.: 8N-7706
S/N: S2L1-Up
Part No.: 8N-7706
S/N: S2M1-Up
Part No.: 8N-7706
S/N: S2N1-Up
Part No.: 8N-7706
S/N: S2P1-Up
Part No.: 8N-7706
S/N: S2R1-Up
RENR5077-11 79
g01616154
Illustration 117
Use the following procedure in order to tighten the (15) As required, apply 4C-9509 Wicking Sealant to
bolts of the plate: the open top end of the bolt holes after assembly
of the oil pan.
1. Tighten five bolts (11) to a standard torque.
(16) As required, apply 8T-9014 Silicone Sealant,
2. Tighten bolt 1 through bolt 10 in a numerical Permatex No. 2 or 138-8436 Liquid Gasket to
sequence that is shown in Illustration 117 to a the sealing surface of the integral seal prior to
standard torque. assembly.
(12) As required, apply 8T-9014 Silicone Sealant, (19) Torque for the oil drain plug ......... 145 ± 15 N·m
Permatex No. 2 or 138-8436 Liquid Gasket to (105 ± 11 lb ft)
the joints of the gasket prior to assembly.
(20) Torque for the oil drain plug ............. 55 ± 7 N·m
(13) Lubricate the bore of nine O-ring seals lightly (41 ± 5 lb ft)
with the lubricant that is being sealed.
i03139762
(14) As required, apply 8T-9014 Silicone Sealant,
Permatex No. 2 or 138-8436 Liquid Gasket
on the sealing surface of the oil pan prior to
Engine Oil Pan
assembly. The sealing surfaces are the following SMCS Code: 1302
areas:
Part No.: 335-3170, 7C-6887
• Connecting joint of the flywheel housing (17) and S/N: M8A1-Up
the rear of the cylinder block
Part No.: 7C-6887, 7C-7178, 7C-7185
• Connecting joint of the front accessory drive S/N: S2A1-Up
housing (18) and the front of the cylinder block
80 RENR5077-11
Part No.: 335-3170, 7C-6887 Part No.: 7C-7178

Part No.: 7C-6887, 7C-7178, 7C-7185, 7C-9938
S/N: S2B1-Up
Part No.: 7C-6887, 7C-7178, 7C-7185, 7C-9938
S/N: S2D1-Up
Part No.: 7C-6887, 7C-7178, 7C-7185, 7C-9938
S/N: S2E1-Up
Part No.: 7C-6887, 7C-7185, 7C-9938
S/N: S2F1-Up
Part No.: 7C-7178
S/N: B5G1-Up
Part No.: 7C-7178, 7C-9938
S/N: MRG1-Up
Part No.: 7C-7178, 7C-9938
S/N: PAG1-Up
Part No.: 7C-7178, 7C-9938
S/N: S2G1-Up
Part No.: 7C-7178, 7C-9938
S/N: MKH1-Up
Part No.: 7C-7178, 7C-9938
S/N: S2H1-Up
Part No.: 7C-7178, 7C-9938
S/N: S2J1-Up
Part No.: 7C-7178, 7C-9938
S/N: S2K1-Up
Part No.: 7C-7178, 7C-9938
S/N: S2L1-Up
Part No.: 7C-9938
S/N: S2M1-Up
Part No.: 7C-7178, 7C-9938
S/N: S2N1-Up
Part No.: 7C-7178, 7C-9938
S/N: S2P1-Up
Part No.: 7C-7178, 7C-9938
S/N: S2R1-Up
Part No.: 7C-7178, 7C-9938
S/N: S2S1-Up
Part No.: 7C-7178, 7C-9938
S/N: S2T1-Up
Part No.: 7C-7178, 7C-9938
S/N: S2W1-Up
Part No.: 7C-7178, 7C-9938
S/N: S2X1-Up
Part No.: 7C-7178, 7C-9938
S/N: S2Y1-Up
RENR5077-11 81
g01448462
Illustration 118
Typical example
(1) Before assembly, apply 1P-0808 Multipurpose i01957454

Grease in order to lubricate the bores of the
O-ring seals. Water Temperature Regulator
(2) As required, apply 8T-9014 Silicone Sealant SMCS Code: 1355
or 138-8436 Liquid Gasket to the joints of the
Part No.: 248-5513
gasket. S/N: M8A1-Up
(4) Torque for two oil drain plugs ......... 145 ± 15 N·m Part No.: 248-5513, 4W-4794
(105 ± 11 lb ft) S/N: S2A1-Up
In order to prevent stress on the tube assembly Part No.: 248-5513

(6), use the following tightening procedure during S/N: M8B1-Up
assembly:
Part No.: 248-5513, 4W-4794
1. Tighten two bolts (5) to 47 ± 9 N·m (35 ± 7 lb ft). S/N: S2B1-Up
Part No.: 248-5513, 4W-4794
2. Tighten two bolts (3) to 47 ± 9 N·m (35 ± 7 lb ft). S/N: S2D1-Up
82 RENR5077-11
Part No.: 248-5513, 4W-4794

S/N: S2E1-Up
Part No.: 248-5513, 4W-4794
S/N: S2F1-Up
Part No.: 248-5513, 4W-4794
S/N: B5G1-Up
Part No.: 248-5513, 4W-4794
S/N: MRG1-Up
Part No.: 248-5513, 4W-4794
S/N: PAG1-Up
Part No.: 248-5513, 4W-4794
g00286978
S/N: S2G1-Up Illustration 119
Part No.: 248-5513, 4W-4794 Fully open temperature ...................... 92 °C (197 °F)
S/N: MKH1-Up
Part No.: 248-5513, 4W-4794 Minimum opening distance at 92 °C
S/N: S2H1-Up (197 °F) ..................................... 10.4 mm (0.41 inch)
Part No.: 248-5513, 4W-4794

i02636978
S/N: S2J1-Up
Part No.: 248-5513, 4W-4794
Water Lines
S/N: S2K1-Up
SMCS Code: 1380
Part No.: 248-5513, 4W-4794
Part No.: 335-1845
S/N: S2L1-Up
S/N: M8A1-Up
Part No.: 248-5513, 4W-4794
Part No.: 249-2846, 278-7527
S/N: S2M1-Up
S/N: S2A1-Up
Part No.: 248-5513, 4W-4794
Part No.: 335-1845
S/N: S2N1-Up
S/N: M8B1-Up
Part No.: 248-5513, 4W-4794
Part No.: 249-2846, 278-7527
S/N: S2P1-Up
S/N: S2B1-Up
Part No.: 248-5513, 4W-4794
Part No.: 249-2846, 278-7527
S/N: S2R1-Up
S/N: S2D1-Up
Part No.: 248-5513, 4W-4794
Part No.: 249-2846, 278-7527
S/N: S2S1-Up
S/N: S2E1-Up
Part No.: 248-5513, 4W-4794
Part No.: 249-2846, 278-7527
S/N: S2T1-Up
S/N: S2F1-Up
Part No.: 248-5513, 4W-4794
Part No.: 249-2846, 278-7527
S/N: S2W1-Up
S/N: B5G1-Up
Part No.: 248-5513, 4W-4794
Part No.: 249-2846
S/N: S2X1-Up
S/N: MRG1-Up
Part No.: 248-5513, 4W-4794
Part No.: 249-2846, 278-7527
S/N: S2Y1-Up
S/N: S2G1-Up
Part No.: 248-5513, 4W-4794
Part No.: 249-2846, 278-7527
S/N: S2Z1-Up
S/N: MKH1-Up
Part No.: 249-2846, 278-7527
S/N: S2H1-Up
Part No.: 249-2846, 278-7527
S/N: S2J1-Up
RENR5077-11 83
Part No.: 249-2846, 278-7527

S/N: S2K1-Up
Part No.: 249-2846, 278-7527
S/N: S2L1-Up
Part No.: 249-2846, 278-7527
S/N: S2M1-Up
Part No.: 249-2846, 278-7527
S/N: S2N1-Up
Part No.: 249-2846, 278-7527
S/N: S2P1-Up
Part No.: 249-2846, 278-7527
S/N: S2R1-Up
Part No.: 249-2846, 278-7527
S/N: S2S1-Up
Part No.: 249-2846, 278-7527
S/N: S2T1-Up
Part No.: 249-2846, 278-7527
S/N: S2W1-Up
Part No.: 249-2846, 278-7527
S/N: S2X1-Up
Part No.: 249-2846, 278-7527
S/N: S2Y1-Up
Part No.: 249-2846, 278-7527
S/N: S2Z1-Up
84 RENR5077-11
g01322263
Illustration 120
Zinc rod
g01322268
Illustration 121
Typical example of zinc rod assembly
1. Apply 9S-3263 Thread Lock Compound to

shoulder (2) of a new zinc rod (1). Do not apply
sealant to threads (3) of the rod.
2. Lightly lubricate the bores for the zinc rods and

the plugs with liquid soap.
Torque for the zinc rod .. 2.25 ± .25 N·m (20 ± 2 lb in)
RENR5077-11 85
i02843386 i03700561
Engine Oil Sump Pump Water Pump

Part No.: 7W-9703 Part No.: 334-7865
S/N: M8A1-Up S/N: M8A1-Up
Part No.: 7W-9703 Part No.: 212-8177
S/N: M8B1-Up S/N: S2A1-Up
Part No.: 334-7865
S/N: M8B1-Up
Part No.: 212-8177
S/N: S2B1-Up
Part No.: 212-8177
S/N: S2D1-Up
Part No.: 212-8177
S/N: S2E1-Up
Part No.: 212-8177
S/N: S2F1-Up
Part No.: 212-8177
S/N: B5G1-Up
Part No.: 212-8177
S/N: MRG1-Up
Part No.: 212-8177
S/N: PAG1-Up
Part No.: 212-8177
S/N: S2G1-Up
Part No.: 212-8177
S/N: MKH1-Up
g01434049
Illustration 122 Part No.: 212-8177
(1) Sump pump group S/N: S2H1-Up
Part No.: 212-8177
Use the following procedure to install the oil pickup
S/N: S2J1-Up
assembly (2):
Part No.: 212-8177
Note: Coat the threads of the oil pickup assembly S/N: S2L1-Up
with 5P-3413 Pipe Sealant prior to assembly.
Part No.: 212-8177
1. Keep nut (3) held against the oil pickup assembly S/N: S2M1-Up
and hand tighten the nut until the O-ring seal
contacts the oil pan. Part No.: 212-8177
S/N: S2N1-Up
2. Unscrew the oil pickup assembly until the word Part No.: 212-8177
“UP” is at the 12 o'clock position. S/N: S2P1-Up
3. Hold the oil pickup assembly in position and Part No.: 212-8177
tighten the nut to a torque of 150 ± 15 N·m S/N: S2R1-Up
(110 ± 11 lb ft).
Part No.: 212-8177
S/N: S2S1-Up
Part No.: 212-8177
S/N: S2T1-Up
86 RENR5077-11
Part No.: 212-8177

S/N: S2W1-Up
Part No.: 212-8177
S/N: S2X1-Up
Part No.: 212-8177
S/N: S2Y1-Up
Part No.: 212-8177
S/N: S2Z1-Up
g01991398
Illustration 123
(2) Ring assembly (3) Water pump seal group
(1) Do not lubricate the sealing lip of the lip type seal. (E) Clearance between the impeller and the
cover .................................. 0.5000 ± 0.4925 mm
(4) Lubricate the bore of the O-ring seals with (0.01968 ± 0.01939 inch)
(6) Torque for the taperlock studs ........... 35 ± 5 N·m
(5) Lubricate the shaft with a thin film of clean engine (26 ± 4 lb ft)
oil before pressing the impeller onto the shaft.
The end of the shaft must be flush with the face (7) Torque for the full nuts ....................... 27 ± 4 N·m
of the impeller within 0.15 mm (0.006 inch). (239 ± 35 lb in)
(B) Bore of the impeller for new Minimum leakage per minute for the lip type seal at
shaft ..................................... 25.342 ± 0.013 mm 138 kPa (20 psi) of air pressure is less than 24 cc
(0.9977 ± 0.0005 inch) (1.5 cu in).
(C) Width of the groove for thrust Minimum leakage per minute for the water pump seal
washer ...... 8.75 ± 0.05 mm (0.344 ± 0.002 inch) assembly at 138 kPa (20 psi) of air pressure is less
than 20 cc (1.2 cu in).
(D) Thickness of new thrust washer ............. 8.5 mm
(0.33 inch)
RENR5077-11 87
i03780690 Part No.: 9Y-8175

S/N: S2T1-Up
Auxiliary Water Pump
Part No.: 9Y-8175
Part No.: 334-8471 Part No.: 9Y-8175
Part No.: 9Y-8175 Part No.: 9Y-8175
Part No.: 334-8471 Part No.: 9Y-8175
Part No.: 9Y-8175
S/N: S2B1-Up
Part No.: 9Y-8175
S/N: S2D1-Up
Part No.: 9Y-8175
S/N: S2E1-Up
Part No.: 9Y-8175
S/N: S2F1-Up
Part No.: 9Y-8175
S/N: B5G1-Up
Part No.: 9Y-8175
S/N: MRG1-Up
Part No.: 9Y-8175
S/N: PAG1-Up
Part No.: 9Y-8175
S/N: S2G1-Up
Part No.: 9Y-8175
S/N: MKH1-Up
Part No.: 9Y-8175
S/N: S2H1-Up
Part No.: 9Y-8175
S/N: S2J1-Up
Part No.: 9Y-8175
S/N: S2K1-Up
Part No.: 9Y-8175
S/N: S2L1-Up
Part No.: 9Y-8175
S/N: S2M1-Up
Part No.: 9Y-8175
S/N: S2N1-Up
Part No.: 9Y-8175
S/N: S2P1-Up
Part No.: 9Y-8175
S/N: S2R1-Up
Part No.: 9Y-8175
S/N: S2S1-Up
88 RENR5077-11
g01486033
Illustration 124
Typical example
(A) Width of groove in the shaft for thrust (E) Installation depth of the sleeve bearing in the
washer ...... 6.25 ± 0.05 mm (0.246 ± 0.002 inch) water pump housing ..................... 1.5 ± 0.5 mm
(0.06 ± 0.02 inch)
(B) Thickness of the new thrust
washer ................................... 6.000 ± 0.025 mm Note: Do not lubricate the sealing lip of the lip type
(0.2362 ± 0.0010 inch) seal (1).
(C) Dimensions of the shaft Minimum leakage per minute for the lip type seal at
138 kPa (20 psi) of air pressure is less than 24 cc
Bore in the sleeve bearing for auxiliary drive (1.5 cu in).
shaft ..................................... 75.000 ± 0.055 mm
(2.9528 ± 0.0022 inch) (3) Use the following procedure in order to assemble
Diameter of new auxiliary drive shaft (not the water pump seal assembly.
shown) ................................. 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch) 1. Lubricate the outside diameter of ceramic ring and
rubber seal (2) with clean water or with 207-1600
(D) Dimensions for the impeller Rubber Lubricant.
Bore diameter of the impeller
2. Orient the polished face of the ceramic ring toward
........ 19.000 ± 0.013 mm (0.7480 ± 0.0005 inch)
water pump seal assembly.
Diameter in the shaft for
impeller ............................. 19.050 to 19.063 mm
3. Use the installation tool and hand pressure to seat
(0.7500 to 0.7505 inch)
the ceramic ring and the rubber seal into the water
pump housing.
RENR5077-11 89
4. Remove spring (4) from the water pump seal i01704040

assembly.
Cooling System Pressure Cap
5. Lubricate the inside diameter of the water pump
seal assembly with clean water or with 207-1600 SMCS Code: 1382; 1392
Rubber Lubricant.
Part No.: 4N-3311
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)
Load on spring at assembled

length ....................... 40.03 ± 4.45 N (9.0 ± 1.0 lb)
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 (5) onto the shaft.
The end of the shaft must be flush with the face
of the impeller within 0.15 mm (0.006 inch).

sealant that is being sealed.
(8) Lubricate the bore of the O-ring seal with clean Illustration 125
g00877286
engine oil, glycerin or clean water.
Pressure that opens the cap relief valve ........ 48 kPa
(7 psi)
Maximum vacuum that opens the suction

valve ..................................................... 7 kPa (1 psi)
90 RENR5077-11
i03686680 (A) Extension of dowels from the surface of the

cylinder block .. 20.0 ± 0.5 mm (0.79 ± 0.02 inch)
Cylinder Block
(B) Thickness of the spacer plates ......... 12.363 mm
SMCS Code: 1201 (0.4867 inch)
Part No.: 350-5225
(C) Height of cylinder liner
S/N: M8A1-Up
Part No.: 350-5225 For the correct method of determining height of the
S/N: M8B1-Up liner, refer to Testing And Adjusting, “Cylinder Liner
Projection”.
(D) Thickness of gasket between the cylinder block

and spacer plates ................. 0.194 to 0.218 mm
(0.0076 to 0.0086 inch)
(E) Extension of dowels from the surface of the

(F) Bore in the block for the camshaft

bearings ............................... 98.000 ± 0.020 mm
(3.8583 ± 0.0008 inch)
(G) Oil holes must be positioned from horizontal at

the following angle. ..................... 20 ± 5 degrees
Note: All centerlines through oil holes in the camshaft

bearings (G) and the camshaft bearing junctions (2)
must be in the position that is shown for each side of
the cylinder block.
g01993533 (H) Main bearing cap width

Illustration 126
Front view of cylinder block Width of main bearing ........ 340.030 ± 0.015 mm
(2) Camshaft bearing junction (13.3870 ± 0.0006 inch)
Width of cylinder block for main bearing
cap ..................................... 339.985 ± 0.015 mm
(13.3852 ± 0.0006 inch)
Tight press fit between the sides of the main
bearing cap and the cylinder block ..... 0.075 mm
(0.0030 inch)
Loose press fit between the sides of the main
(0.0006 inch)
(J) New dimension from centerline of crankshaft

bearing bore to the top of the block .. 586.00 mm
(23.071 inch)
(K) Bore in the block for the main bearings

Standard, original new
size .................................... 169.742 ± 0.020 mm
(6.6827 ± 0.0008 inch)
0.63 mm (0.025 inch) larger than original
size .................................... 170.372 ± 0.020 mm
(6.7076 ± 0.0008 inch)
g01993594
Illustration 127
Right side view (L) New dimension from centerline of crankshaft
bearing bore to bottom of block (pan
(1) Torque for the plugs .. 100 ± 15 N·m (74 ± 11 lb ft) rails) .............................. 230.00 mm (9.055 inch)
(3) Main bearing cap

RENR5077-11 91
Use the following procedure to tighten the main Part No.: 240-6651, 240-6653
bearing cap bolts: S/N: S2H1-Up
1. Install main bearing caps with the part number Part No.: 240-6651, 240-6653
and FRONT toward the front of the block. Each S/N: S2J1-Up
cap has a number. Each cap must be installed in
Part No.: 240-6651, 240-6653
the same position as the correct number on the
S/N: S2K1-Up
side of the cylinder block pan rail.
Part No.: 240-6651, 240-6653
2. Before assembly, apply clean engine oil to the S/N: S2L1-Up
threads of the bolts.
Part No.: 240-6651
3. Tighten the bolts in the numerical sequence (4, S/N: S2M1-Up
5, 6, 7) to 190 ± 14 N·m (140 ± 10 lb ft). Refer to
Illustration 127 for the tightening sequence. Part No.: 240-6651, 240-6653
S/N: S2N1-Up
4. Again, tighten the bolts in the numerical sequence Part No.: 240-6651, 240-6653
(4, 5, 6, 7) to an angle of 180 ± 5 degrees. Refer S/N: S2P1-Up
to Illustration 127 for the tightening sequence.
Part No.: 240-6651, 240-6653
(M) Extension of dowels from the surface of the S/N: S2R1-Up
cylinder block .... 6.0 ± 0.5 mm (0.24 ± 0.02 inch)
Part No.: 240-6651, 240-6653
(N) Extension of dowels from the surface of the S/N: S2S1-Up
Part No.: 122-5954, 240-6651, 240-6653
(P) Extension of dowels from the surface of the S/N: S2T1-Up
cylinder block .. 40.0 ± 0.5 mm (1.58 ± 0.02 inch) Part No.: 240-6651, 240-6653
S/N: S2W1-Up
i03152764
Part No.: 122-5954, 240-6651, 240-6653
Cylinder Block S/N: S2X1-Up
Part No.: 240-6651, 240-6653
Part No.: 240-6651, 240-6653 Part No.: 122-5954, 240-6651
Part No.: 240-6651, 240-6653
S/N: S2B1-Up
Part No.: 240-6651, 240-6653
S/N: S2D1-Up
Part No.: 240-6651, 240-6653
S/N: S2E1-Up
Part No.: 240-6651
S/N: S2F1-Up
Part No.: 240-6653
S/N: B5G1-Up
Part No.: 240-6651, 240-6653
S/N: MRG1-Up
Part No.: 240-6653
S/N: PAG1-Up
Part No.: 240-6651, 240-6653
S/N: S2G1-Up
Part No.: 240-6651, 240-6653
S/N: MKH1-Up
92 RENR5077-11
(1) Torque for four plugs ...................... 100 ± 15 N·m

(75 ± 11 lb ft)

the lubricant that is being sealed.
(D) Height of the cylinder liner
For the correct method of determining the height

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

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

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

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

bearing bore to the top of the block ....... 586 mm
(23.1 inch)
g01417382
Illustration 128
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 129
g01434393 cap ..................................... 340.030 ± 0.015 mm
(13.3870 ± 0.0006 inch)
Right side view
Width of cylinder block for crankshaft main
bearing cap ........................ 339.985 ± 0.015 mm
Note: During assembly, the bottom of spacer plates,
(13.3852 ± 0.0006 inch)
top of cylinder block and both sides of plate gasket
Tight press fit between the sides of the
must be free of fuel, oil, water, gasket adhesives,
crankshaft main bearing cap and the cylinder
assembly compounds and any other contaminants.
block ............................. 0.075 mm (0.0030 inch)
Loose press fit between the sides of the
(A) Thickness of the spacer plate .......... 12.313 mm
crankshaft main bearing cap and the cylinder
(0.4848 inch)
block ............................. 0.015 mm (0.0006 inch)
(B) Thickness of the plate gasket
between the cylinder block and spacer
plate ...................................... 0.194 to 0.218 mm
Use the following procedure to tighten the crankshaft
(0.0076 to 0.0086 inch)
main bearing cap bolts:
(C) Extension of the dowel from the top face of the
RENR5077-11 93
1. Install main bearing caps with the part number i02674259

and “FRONT” toward the front of the block. Each
cap has a number. Each cap must be installed in Cylinder Block
side of the cylinder block pan rail. SMCS Code: 1201
Part No.: 237-7957
2. Before assembly, apply clean engine oil on the
S/N: S2A1-Up
threads of the bolts.
Part No.: 237-7957
3. Tighten bolt (5) through bolt (8) in the numerical S/N: S2B1-Up
sequence that is shown in Illustration 128 to a
torque of 190 ± 14 N·m (140 ± 10 lb ft). Part No.: 237-7957
S/N: S2D1-Up
4. Tighten bolt (5) through bolt (8) again in the
numerical sequence to a rotation of 180 ± 5 Part No.: 237-7957
degrees. S/N: S2E1-Up
Part No.: 237-7957
(L) Extension of the dowel from the rear face of the S/N: S2F1-Up
(M) Extension of the dowel from the front face of the

(N) Extension of the dowel from the rear face of the

(P) Extension of the dowel from the front face of the

g01343555
Illustration 130
Front view of cylinder block
(1) Camshaft bearing junction
94 RENR5077-11
Width of cylinder block for main bearing

cap ..................................... 339.985 ± 0.015 mm
(13.3852 ± 0.0006 inch)
Tight press fit between the sides of the main
(0.0030 inch)
Loose press fit between the sides of the main
(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

g01343968 rails) .............................. 230.00 mm (9.055 inch)
Illustration 131

(A) Thickness of spacer plates ............... 12.313 mm
(0.4848 inch)
Use the following procedure to tighten the main
bearing cap bolts:
(B) Thickness of gasket between the cylinder block
and spacer plates ................. 0.194 to 0.218 mm
1. Install main bearing caps with the part number
(0.0076 to 0.0086 inch)
and FRONT toward the front of the block. Each
cap has a number. Each cap must be installed in
(C) All dowels extend above the face by the following
distance. ......... 20.0 ± 0.5 mm (0.79 ± 0.02 inch)
side of the cylinder block pan rail.
(2) Torque for plugs ....... 100 ± 15 N·m (75 ± 11 lb ft)
2. Put clean engine oil on the bolts before assembly.
(D) Height of Cylinder liner
3. Tighten the bolts in the numerical sequence (4, 5,
6, 7) to the following torque.
For the correct method of determining height of the
liner, refer to Testing And Adjusting, “Cylinder Liner
Torque for bolts ....... 190 ± 14 N·m (140 ± 10 lb ft)
Projection”.
4. Tighten the bolts again in the numerical sequence
(E) Bore in the block for the camshaft
to the following rotation.
bearings ............................... 98.000 ± 0.020 mm
(3.8583 ± 0.0008 inch)
Angle for bolts ............................ 180 ± 5 degrees
(F) Oil holes must be positioned from horizontal at
(L) The dowel extends from the rear face of the block
the following angle. ..................... 20 ± 5 degrees
by the following distance. .............. 6.0 ± 0.5 mm
(0.24 ± 0.02 inch)
Note: All centerlines through oil holes in the camshaft
bearings (F) and the camshaft bearing junctions (1)
(M) The dowels extend from the front face of the
must be in the position that is shown for each side of
block by the following distance. ..... 6.0 ± 0.5 mm
the cylinder block.
(0.24 ± 0.02 inch)
(G) New dimension from centerline of crankshaft
(N) The dowels extend from the rear face of the
bearing bore to the top of the block .. 586.00 mm
block by the following distance. ... 19.0 ± 0.5 mm
(23.071 inch)
(0.75 ± 0.02 inch)
(H) Main bearing cap width
(P) The dowels extend from the front face of the
Width of main bearing ........ 340.030 ± 0.015 mm block by the following distance. ... 40.0 ± 0.5 mm
(13.3870 ± 0.0006 inch) (1.58 ± 0.02 inch)
RENR5077-11 95
i02871050 i02872093
Cylinder Liner Piston and Rings

SMCS Code: 1216
(One-Piece Piston)
Part No.: 211-7826 SMCS Code: 1214
Part No.: 332-7924
S/N: M8A1-Up
Part No.: 332-7924
S/N: M8B1-Up
g01399536
Illustration 132
(A) Bore in new cylinder liner .. 170.025 ± 0.025 mm

(6.6939 ± 0.0010 inch)
(B) Thickness of flange (1) on cylinder

liner ......... 12.65 ± 0.02 mm (0.498 ± 0.001 inch)
Use the liner again with any used piston or

any new piston if all the measurements are
in the following range. Use a FLEX-HONE
first. ..................................... 170.000 to 170.152 mm
g01430242
(6.6929 to 6.6989 inch) Illustration 133
Use the liner again with the original piston Note: Refer to Guideline for Reusable Parts for
if the measurements of the upper bore are information on the pistons, the piston pins, and the
in the following range. Use a FLEX-HONE retaining rings.
first. ..................................... 170.000 to 170.229 mm
(6.6929 to 6.7019 inch) This piston has a square top piston ring. Use the
246-1176 Piston Ring Groove Gauge Gp for
Use the following procedure to install the cylinder measuring the top piston ring groove.
liner:
This piston has a keystone type of intermediate
1. Apply liquid soap on the cylinder block liner bore piston ring. Use the 1U-6431 Piston Ring Groove
surfaces and the rubber seals that are on the Gauge Gp for measuring the intermediate piston ring
lower end of the cylinder liner. groove. For correct use of the piston ring groove
gauge group, refer to the instruction card that is with
2. Dip the filler band (2) completely in clean engine the piston ring groove gauge group.
oil for a moment.
Note: Prior to the installation of the piston rings,
3. Immediately install the filler band in the groove the ring grooves must be completely lubricated with
that is under the flange. clean engine oil. After assembly, the mating surfaces
of the rings to the cylinder liner must be completely
4. Immediately install the cylinder liner into the lubricated with clean engine oil.
cylinder block before the expansion of the filler
band.
Top Piston Ring (1)
Note: Refer to Reuse And Salvage Guidelines,
Install the top piston ring with the “UP-1” side toward
SEBF8049, “Visual Inspection of the Piston” for more
the top of the piston.
information. Also, refer to Guideline For Reusable
Parts And Salvage Operations, SEBF8068, “Cylinder
Liners” for more information.
96 RENR5077-11
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)
Thickness of new top piston ring ................ 3.88 mm

(0.153 inch)
Intermediate Piston Ring (2)

Install the intermediate piston ring with the “UP-2”
side toward the top of the piston.
When the new intermediate piston ring is installed in

a cylinder liner with a bore size of 170 mm (6.7 inch),
the clearance between the ends of the piston ring is
the following value. .......................... 1.00 ± 0.15 mm
(0.039 ± 0.006 inch)
Thickness of new intermediate piston g01446562

ring ...................................... 3.785 mm (0.1490 inch) Illustration 134
Note: Prior to assembly of the piston pin, the piston

Oil Control Piston Ring (3) pin, the piston pin bore, the connecting rod eye, and
the connecting rod pin bearing must be completely
The ends of the oil control piston ring should be a lubricated with clean engine oil.
distance of 180 degrees from the ring end gap when
the oil control piston ring is assembled. The white
colored portion of the piston ring must be visible at Piston Pin Bore (4)
the ring end gap.
(B) Angle of bushing locator on far side .. 45 degrees
Width of groove in new piston for the oil control piston
ring ......... 4.04 mm to 4.07 mm (0.159 to 0.160 inch) (C) Bore diameter of piston
pin .................................... 70.0705 ± 0.0075 mm
Thickness of new oil control piston (2.75867 ± 0.00030 inch)
ring ................ 3.97 to 3.99 mm (0.156 to 0.157 inch)
Piston Pin (5)
When the new oil control piston ring is installed in a
cylinder liner with a bore size of 170 mm (6.7 inch), Dimensions for piston pin
the following value. ...................... 0.5 mm to 0.8 mm Outside diameter of piston
(0.02 to 0.03 inch) pin ... 69.930 ± 0.005 mm (2.7531 ± 0.0002 inch)
Inside diameter of piston pin ........ 30.5 ± 0.5 mm
Note: After the piston rings have been installed, (1.20 ± 0.02 inch)
rotate the piston rings so that the end gaps are 120 Length of piston pin ........... 102.0 + 0.0 - 0.3 mm
degrees from each other. (4.02 + 0.00 - 0.01)
Note: The 263-8955 Piston Pin is not

interchangeable with the former 197-0560 Piston
Pin.
Pin Retainer (6)

Assemble the pin retainer with the opening above
section A-A.
Refer to Table 1 for the part numbers of the tools that

are used in servicing the piston.
RENR5077-11 97
Table 1 Part No.: 223-6363

Service Tools
S/N: S2N1-Up
Pt. No. Description Part No.: 223-6363

S/N: S2P1-Up
271-0498 Expander Ring
Part No.: 223-6363
1P-1861 Retaining Ring Pliers
S/N: S2R1-Up
1U-7616 Piston Ring Compressor Gp
Part No.: 223-6363
246-1176 Piston Ring Groove Gauge Gp(1) S/N: S2S1-Up
1U-6431 Piston Ring Groove Gauge Gp(2)
Part No.: 223-6363
(1) Only for the top ring groove S/N: S2T1-Up
(2) Only for the intermediate ring groove
Part No.: 223-6363
S/N: S2W1-Up
i03661131
Part No.: 223-6363
Piston and Rings S/N: S2X1-Up
(One-Piece Piston) Part No.: 223-6363
S/N: S2Y1-Up
SMCS Code: 1214
Part No.: 223-6363
Part No.: 223-6363
S/N: S2Z1-Up
S/N: S2A1-Up
Part No.: 223-6363
S/N: S2B1-Up
Part No.: 223-6363
S/N: S2D1-Up
Part No.: 223-6363
S/N: S2E1-Up
Part No.: 223-6363
S/N: S2F1-Up
Part No.: 223-6363
S/N: B5G1-Up
Part No.: 223-6363
S/N: MRG1-Up
Part No.: 223-6363
S/N: PAG1-Up
Part No.: 223-6363
g01430242
Part No.: 223-6363 Use the 246-1176 Piston Ring Groove Gauge Gp
S/N: MKH1-Up for measuring the top ring groove.
Part No.: 223-6363
S/N: S2H1-Up Use the 1U-6431 Piston Ring Groove Gauge Gp for
measuring the intermediate ring groove. Refer to the
Part No.: 223-6363 instruction card that is with the gauge group.
S/N: S2J1-Up
Part No.: 223-6363 Top Piston Ring (1)
S/N: S2K1-Up
Install the top piston ring with the “UP-1” side toward
Part No.: 223-6363 the top of the piston.
S/N: S2L1-Up
When the new top piston ring is installed in a cylinder
Part No.: 223-6363 liner with a bore size of 170 mm (6.7 inch), the
S/N: S2M1-Up clearance between the ends of the piston ring is the
98 RENR5077-11
following value. ............................ 0.625 ± 0.125 mm

(0.0246 ± 0.0049 inch)
Thickness of new top piston ring ................ 3.88 mm

(0.153 inch)
Intermediate Piston Ring (2)

Install the intermediate piston ring with the “UP-2”
side toward the top of the piston.
When the new intermediate piston ring is installed in

a cylinder liner with a bore size of 170 mm (6.7 inch),
the following value. .......................... 1.00 ± 0.15 mm
(0.039 ± 0.006 inch)
Thickness of new intermediate piston

ring ...................................... 3.785 mm (0.1490 inch)
Oil Control Piston Ring (3) Illustration 136

g01446562
Orient the ends of the oil ring spring to 180 degrees Note: Prior to assembly of the piston pin, the piston
from the gap. The white colored portion of the piston pin, the piston pin bore, the connecting rod eye, and
ring must be visible at the ring end gap. the connecting rod pin bearing must be completely
lubricated with clean engine oil.
Width of groove in new piston for the oil control piston
ring ......... 4.04 mm to 4.07 mm (0.159 to 0.160 inch)
Piston Pin Bore (4)
Thickness of new oil control piston
ring .......... 3.980 ± 0.010 mm (0.1567 ± 0.0004 inch) Note: Measure the pin bore in two places. Take
one measurement within the minor diameter. Move
When the new oil control piston ring is installed in a laterally and take another measurement within the
cylinder liner with a bore size of 170 mm (6.7 inch), minor diameter. Take the measurements close to the
the clearance between the ends of the piston ring is center of the pin bore. Do not take the measurements
the following value. ............................. 0.5 to 0.8 mm on the outside edges.
(0.02 to 0.03 inch)
(B) Angle of bushing locator on far side .. 45 degrees
Note: After the piston rings have been installed,
rotate the piston rings so that the end gaps are 120 (C) Bore diameter of piston
degrees from each other. pin ..................................... 70.060 to 70.075 mm
(2.7583 to 2.7562 inch)
Piston Pin (5)

Outside diameter ....................... 69.962 ± 0.005 mm
(2.7544 ± 0.0002 inch)
Inside diameter ..... 30.5 ± 0.5 mm (1.20 ± 0.02 inch)
Length ......... 101.85 ± 0.15 mm (4.010 ± 0.006 inch)
Note: The 197-0560 Piston Pin is not

interchangeable with other pistons and connecting
rods.
Pin Retainer (6)

Assemble the retainer with the opening above line
A-A.
RENR5077-11 99
Refer to Table 2 for the part numbers of the tools that Part No.: 101-0829
are used in servicing the piston. S/N: S2R1-Up
Table 2 Part No.: 101-0829

S/N: S2S1-Up
Service Tools
Pt. No. Description Part No.: 101-0829
S/N: S2T1-Up
6V-4020 Piston Ring Expander Gp
Part No.: 101-0829
6V-4023 Handle As
S/N: S2W1-Up
6V-4024 Guide Ring
Part No.: 101-0829
1P-1861 Retaining Ring Pliers S/N: S2X1-Up
1U-7616 Piston Ring Compressor Gp Part No.: 101-0829
246-1176 Piston Ring Groove Gauge Gp (1) S/N: S2Y1-Up
1U-6431 Piston Ring Groove Gauge Gp (2)
Part No.: 101-0829
(1) Only for the top ring groove S/N: S2Z1-Up
(2) Only for the intermediate ring groove
i03132941
Piston and Rings

(Two-Piece Piston)
SMCS Code: 1214
Part No.: 101-0829
S/N: S2A1-Up
Part No.: 101-0829
S/N: S2B1-Up
Part No.: 101-0829
S/N: S2D1-Up
Part No.: 101-0829
S/N: S2E1-Up
Part No.: 101-0829 g01611477
S/N: S2F1-Up Illustration 137
Part No.: 101-0829 This piston has a Keystone top and Keystone
S/N: S2G1-Up intermediate rings. The 1U-6431 Piston Ring Groove
Gauge is necessary for measuring the ring grooves in
Part No.: 101-0829 Keystone pistons. For correct use of the gauge group,
S/N: S2H1-Up see the instruction card that is with the gauge group.
Part No.: 101-0829
S/N: S2J1-Up Top Piston Ring (1)
Part No.: 101-0829 Install the top ring with the “Up-1” side toward the
S/N: S2K1-Up top of the piston.
Part No.: 101-0829
S/N: S2L1-Up Thickness of new top piston ring ................ 3.91 mm
(0.154 inch)
Part No.: 101-0829
S/N: S2M1-Up When the piston ring is installed in a cylinder liner
with a bore size of 170 mm (6.7 inch), the clearance
Part No.: 101-0829 between the ends of the piston ring is the following
S/N: S2N1-Up value. ...... 0.625 ± 0.125 mm (0.0246 ± 0.0049 inch)
Part No.: 101-0829 The increase in the clearance between the ends
S/N: S2P1-Up of the piston ring for each 0.03 mm (0.001 inch)
100 RENR5077-11
increase in the cylinder liner bore size is the following Piston Pin (5)
value. ...................................... 0.08 mm (0.003 inch)
Measure the piston pin diameter on each end in a
Intermediate Piston Ring (2) vertical and horizontal direction.
Install the intermediate ring with the “Up-2” side Inside diameter of the piston pin ........ 35.0 ± 0.5 mm
toward the top of the piston. (1.38 ± 0.02 inch)
Thickness of new intermediate piston Outside diameter of the piston

ring ...................................... 3.785 mm (0.1490 inch) pin ......... 69.962 ± 0.005 mm (2.7544 ± 0.0002 inch)
When the piston is installed in a cylinder liner with Length of the piston pin ............... 133.00 ± 0.13 mm
a bore size of 170 mm (6.7 inch), the clearance (5.236 ± 0.005 inch)
between the ends of the piston ring is the following
value. .............. 1.00 ± 0.15 mm (0.039 ± 0.006 inch) Pin Retainer (6)
The increase in the clearance between the ends Assemble the retainer with the opening toward the
of the piston ring for each 0.03 mm (0.001 inch) top of the piston.
increase in the cylinder liner bore size is the following
value. ...................................... 0.08 mm (0.003 inch)
Oil Control Piston Ring (3)

Width of groove in piston for the new piston
ring .......... 5.050 ± 0.010 mm (0.1988 ± 0.0004 inch)
Thickness of new piston ring ....... 4.954 ± 0.019 mm

(0.1950 ± 0.0007 inch)
Clearance between groove and new piston

ring ........ 0.067 to 0.125 mm (0.0026 to 0.0049 inch)
When the piston ring is installed in a cylinder liner

with a bore size of 170 mm (6.7 inch), the clearance
between the ends of the piston ring is the following
value. .............. 0.70 ± 0.19 mm (0.028 ± 0.007 inch)
The increase in the clearance between the ends

of the piston ring for each 0.03 mm (0.001 inch)
increase in the cylinder liner bore size is the following
value. ...................................... 0.08 mm (0.003 inch)
Install the oil control ring so that the gap in the spring
is 180 degrees away from the gap in the ring. The
white portion of the spring must be visible at the ring
gap.
After all of the piston rings have been installed, rotate

the rings so that the end gaps are separated by 120
degrees. The ring gap for the oil ring must be aligned
in the plane of the pin bore.
Piston Pin Bore (4)

Measure the piston pin bore in the bushings in two
places for each bushing in a vertical direction.
Bore diameter in the crown assembly for piston

pin ......... 70.035 ± 0.005 mm (2.7573 ± 0.0002 inch)
Bore diameter in the piston skirts for piston

pin ......... 69.983 ± 0.005 mm (2.7552 ± 0.0002 inch)
RENR5077-11 101
i02674253 (1) Top piston ring

Piston and Rings Install the piston ring with the “Up-1” side toward
(Two-Piece Piston)
When the piston ring is installed in a cylinder
SMCS Code: 1214 liner with a bore size of 170 mm (6.7 inch), the
clearance between the ends of the piston ring is
Part No.: 249-5671 the following value. ................ 0.625 ± 0.125 mm
S/N: B5G1-Up (0.0246 ± 0.0050 inch)
Part No.: 249-5671 of the piston ring for each 0.03 mm (0.001 inch)
S/N: MRG1-Up increase in the cylinder liner bore size is the
Part No.: 160-5910 following value. ................. 0.08 mm (0.003 inch)
S/N: S2J1-Up
(2) Intermediate piston ring
Part No.: 160-5910
S/N: S2N1-Up Install the piston ring with the “Up-2” side toward
Part No.: 160-5910 When the piston ring is installed in a cylinder
S/N: S2T1-Up liner with a bore size of 170 mm (6.7 inch), the
Part No.: 160-5910
S/N: S2X1-Up the following value. .................... 1.00 ± 0.15 mm
(0.039 ± 0.006 inch)
Part No.: 160-5910 The increase in the clearance between the ends
S/N: S2Z1-Up of the piston ring for each 0.03 mm (0.001 inch)
increase in the cylinder liner bore size is the
following value. ................. 0.08 mm (0.003 inch)
(3) Oil piston ring

Width of groove in piston for the new oil piston
ring .... 4.055 ± 0.015 mm (0.1596 ± 0.0006 inch)
Maximum thickness of new oil piston
ring .... 3.980 ± 0.010 mm (0.1570 ± 0.0004 inch)
Clearance between groove and new oil piston
ring .. 0.050 to 0.100 mm (0.0020 to 0.0039 inch)
When the piston ring is installed in a cylinder
liner with a bore size of 170 mm (6.7 inch), the
the following value. .................... 0.65 ± 0.15 mm
(0.026 ± 0.006 inch)
of the piston ring for each 0.03 mm (0.001 inch)
increase in the cylinder liner bore size is the
following value. ................. 0.08 mm (0.003 inch)
Note: Install the oil piston ring so that the gap in the
g01084998
Illustration 138 spring is 180 degrees away from the gap in the piston
Typical example ring. The white portion of the spring must be visible
at the ring end gap.
This piston has a Keystone top ring. This piston also
has Keystone intermediate rings. The 204-8041 Note: After all of the piston rings have been installed,
Piston Ring Groove Gauge Gp is necessary for rotate the piston rings so that the end gaps are
measuring the ring grooves in the Keystone pistons. separated by 120 degrees. The ring gap for the oil
For correct use of the gauge group, refer to the piston ring must be aligned in the plane of the pin
instruction card that is with the gauge group. bore.
Note: Prior to the installation of the rings, the ring (4) Piston pin bore
grooves must be completely lubricated with clean
engine oil. After assembly, the mating surfaces of Note: Prior to assembly of the piston pin, the piston
the rings to the cylinder liner must be completely pin, the piston pin bore, the connecting rod eye, and
lubricated with clean engine oil. the connecting rod pin bearing must be completely
lubricated with clean engine oil.
102 RENR5077-11
Crown as Part No.: 144-0725

S/N: MKH1-Up
Measure the pin bore in the bushings in two
places for each bushing in a vertical direction. Part No.: 101-0829, 144-0725, 161-2500
Bore in bushing ................ 70.0525 ± 0.0075 mm S/N: S2H1-Up
(2.75796 ± 0.00029 inch) Part No.: 101-0829, 144-0725, 161-2500
S/N: S2J1-Up
Piston skirt
Part No.: 101-0829, 144-0725, 161-2500
Measure the pin bore in a vertical direction. S/N: S2K1-Up
Bore ..................................... 69.988 ± 0.005 mm
(2.7554 ± 0.0002 inch) Part No.: 101-0829, 144-0725, 161-2500
S/N: S2L1-Up
(5) Piston pin
Part No.: 101-0829, 144-0725, 161-2500
Measure the pin diameter on each end in a S/N: S2M1-Up
vertical and horizontal direction.
Part No.: 101-0829, 144-0725, 161-2500
Outside diameter ................. 69.962 ± 0.005 mm S/N: S2N1-Up
(2.7544 ± 0.0002 inch)
Inside diameter ............................ 33.0 ± 0.5 mm Part No.: 101-0829, 144-0725, 161-2500
(1.30 ± 0.02 inch) S/N: S2P1-Up
Length ... 137.55 ± 0.15 mm (5.415 ± 0.006 inch)
Part No.: 101-0829, 144-0725, 161-2500
(6) Pin retainer ................ Assemble the pin retainer S/N: S2R1-Up
with the opening above line A-A. Part No.: 101-0829, 144-0725, 161-2500
S/N: S2S1-Up
i03660673
Part No.: 101-0829, 144-0725, 161-2500
Connecting Rod S/N: S2T1-Up
Part No.: 101-0829, 144-0725, 161-2500
Part No.: 144-0725 Part No.: 101-0829, 144-0725, 161-2500
Part No.: 101-0829, 144-0725, 161-2500 Part No.: 101-0829, 144-0725, 161-2500
Part No.: 144-0725 Part No.: 101-0829, 144-0725, 161-2500
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2B1-Up
Part No.: 101-0829, 144-0725, 161-2500,
223-6363
S/N: S2D1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2E1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2F1-Up
Part No.: 144-0725
S/N: B5G1-Up
Part No.: 144-0725
S/N: MRG1-Up
Part No.: 144-0725
S/N: PAG1-Up
Part No.: 101-0829, 144-0725, 161-2500
S/N: S2G1-Up
RENR5077-11 103
(D) Distance between the center of the

bearings ............................... 380 mm (15.0 inch)
(E) Protrusion of the dowel from the connecting rod

cap .................... 4.0 ± 0.5 mm (0.16 ± 0.02 inch)
(F) Bore in the connecting rod for the bearing for

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

crankshaft ..................... 135.133 to 135.194 mm
(5.3202 to 5.3226 inch)
(1) Etch the cylinder number on the connecting rod

and the cap in this location. Mark the connecting
rod and the cap with numbers. Mark the numbers
on the same side of the connecting rod as the
bearing retainer notch.
Note: Install the connecting rod in the engine with the

part number to the rear of the engine.
g01416660
Illustration 139
(A) Angle above the centerline on either side of the

bearing joint for the sleeve bearing for the piston
pin. .................................................... 10 degrees g01526418
Illustration 140
Note: The connecting rod must be heated prior to View H-H

installation of the sleeve bearing for the piston pin. (3) Location pin for correct installation of connecting rod caps
Do not use a torch to heat the connecting rod.
(2) The chamfer side must be adjacent to the crank
(B) The connecting rod may be heated from pin thrust surface when the connecting rod and
175 to 260 °C (347 to 500 °F) for the installation piston group is assembled in the engine.
of the sleeve bearing for the piston pin. Minimum
length for heating the connecting rod .... 105 mm Side clearance between two connecting rods on the
(4.1 inch) same new crankshaft pin ............. 0.850 ± 0.332 mm
(0.0335 ± 0.0131 inch)
Note: Thoroughly lubricate the piston pin with clean
engine oil prior to assembly of the piston and the Use the following procedure for tightening the
connecting rod. connecting rod bolts:
(C) Dimensions for the piston pin Note: Bolt 1 and bolt 2 must be on the same end of
the connecting rod cap that has bearing tabs and
Bore in the sleeve bearing for the location pin (3).
piston pin after installation of the sleeve
bearing ................................. 70.000 ± 0.008 mm 1. Before assembly, apply 6V-4876 Lubricant on the
(2.7559 ± 0.0003 inch) bolt threads, the bolt shank and the bolt seat.
Bore in the connecting rod for the sleeve bearing
for the piston pin .................. 75.760 ± 0.015 mm 2. Tighten the bolt 1 and bolt 2 to 90 ± 5 N·m
(2.9827 ± 0.0006 inch) (66 ± 4 lb ft).
104 RENR5077-11
3. Tighten the bolt 3 and bolt 4 to 90 ± 5 N·m

(66 ± 4 lb ft).
4. Again, tighten the bolt 3 and bolt 4 to 90 ± 5 N·m

(66 ± 4 lb ft).
5. Tighten all bolts for an additional 90 ± 5 degrees.
i01359201
Connecting Rod and Main

Bearing Journals
SMCS Code: 1230
Part No.: 107-7330, 149-6031
Refer to Guidelines For Reusable Parts, SEBF8009,

“Main Bearings And Connecting Rod Bearings” for
more information.
Connecting Rod Bearing Journals
Table 3
Diameter Of Crankshaft Journal (Bearing Surface)

For Connecting Rod Bearings
Original Size Journal 135.000 ± 0.025 mm
(5.3150 ± 0.0010 inch)
Undersize Journal 134.370 ± 0.025 mm
0.63 mm (0.025 inch) (5.2902 ± 0.0010 inch)
1.27 mm (0.050 inch) (5.2650 ± 0.0010 inch)
Clearance between bearing and new

journal ... 0.107 to 0.218 mm (0.0042 to 0.0086 inch)
Main Bearing Journals
Table 4
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)
RENR5077-11 105
i02871012
Crankshaft
SMCS Code: 1202
Part No.: 152-7625
S/N: M8A1-Up
Part No.: 152-7625
S/N: S2A1-Up
Part No.: 152-7625
S/N: M8B1-Up
Part No.: 152-7625
S/N: S2B1-Up
Part No.: 152-7625
S/N: S2D1-Up
Part No.: 152-7625
S/N: S2E1-Up
Part No.: 152-7625
S/N: S2F1-Up
g01419944
Illustration 141
(1) Thrust plates
Refer to Specifications, “Connecting Rod And Main Note: Do not reuse counterweight bolts.
Bearing Journals” for more information.
(3) Use the following procedure to tighten the bolts:
(B) End play for the new
crankshaft ................................. 0.17 to 0.63 mm 1. Prior to assembly, lubricate the bolt threads, the
(0.007 to 0.025 inch) bolt shank, the washer and the underside of the
bolt head with 6V-4876 Lubricant.
(2) Torque for the plug ......... 50 ± 7 N·m (37 ± 5 lb ft)
106 RENR5077-11
2. Torque the bolts evenly to 200 ± 5 N·m Part No.: 128-6786, 128-6788
(145 ± 4 lb ft). S/N: S2R1-Up
3. Loosen the bolts. Part No.: 128-6786, 128-6788

S/N: S2S1-Up
4. Again, torque the bolts evenly to 70 ± 5 N·m
Part No.: 128-6786, 128-6788
(50 ± 4 lb ft).
S/N: S2T1-Up
5. Rotate each bolt for an additional 120 ± 5 degrees. Part No.: 128-6786, 128-6788
S/N: S2X1-Up
i03062802 Part No.: 128-6786, 128-6788
Crankshaft S/N: S2Y1-Up
Part No.: 128-6786, 128-6788
SMCS Code: 1202 S/N: S2Z1-Up
Part No.: 128-6786, 128-6788
S/N: S2A1-Up
Part No.: 128-6786, 128-6788
S/N: S2B1-Up
Part No.: 128-6786, 128-6788
S/N: S2D1-Up
Part No.: 128-6786, 128-6788
S/N: S2E1-Up
Part No.: 128-6786
S/N: S2F1-Up
Part No.: 128-6788
S/N: B5G1-Up
Part No.: 128-6788
S/N: MRG1-Up
Part No.: 128-6788
S/N: PAG1-Up
Part No.: 128-6786, 128-6788
S/N: S2G1-Up
Part No.: 128-6788
S/N: MKH1-Up
Part No.: 128-6786, 128-6788
S/N: S2H1-Up
Part No.: 128-6786, 128-6788
S/N: S2J1-Up
Part No.: 128-6786, 128-6788
S/N: S2K1-Up
Part No.: 128-6786, 128-6788
S/N: S2L1-Up
Part No.: 128-6786
S/N: S2M1-Up
Part No.: 128-6786, 128-6788
S/N: S2N1-Up
Part No.: 128-6786, 128-6788
S/N: S2P1-Up
RENR5077-11 107
g01419944
Illustration 142
(1) Thrust plates
Refer to Specifications, “Connecting Rod And Main Part No.: 7W-3813

Bearing Journals” for more information. S/N: S2A1-Up
(B) Crankshaft end play ................. 0.17 to 0.63 mm Part No.: 332-7911
(0.007 to 0.025 inch) S/N: M8B1-Up
Part No.: 7W-3813
(2) Torque for six plugs ....... 50 ± 7 N·m (37 ± 5 lb ft)
S/N: S2B1-Up
Note: Do not reuse counterweight bolts. Part No.: 7W-3813
S/N: S2D1-Up
(3) Use the following procedure to tighten the bolts:
Part No.: 7W-3813
1. Before assembly, lubricate the threads of the S/N: S2E1-Up
bolts, the bolt shank, the washers and the contact
surface under the bolt head with 6V-4876 Part No.: 7W-3813
Lubricant. S/N: S2F1-Up
Part No.: 7W-3813
2. Tighten the bolts evenly to 70 ± 5 N·m (50 ± 4 lb ft). S/N: B5G1-Up
3. Rotate each bolt for an additional 120 ± 5 degrees. Part No.: 7W-3813
S/N: MRG1-Up
i03350941 Part No.: 7W-3813
S/N: PAG1-Up
Crankshaft Wear Sleeves and
Seals Part No.: 7W-3813
S/N: S2G1-Up
SMCS Code: 1160 Part No.: 7W-3813
Part No.: 332-7911 S/N: MKH1-Up
S/N: M8A1-Up Part No.: 7W-3813
S/N: S2H1-Up
108 RENR5077-11
Part No.: 7W-3813 Note: Make sure that the correct crankshaft seal
S/N: S2J1-Up group is installed on each end of the crankshaft.
Part No.: 7W-3813 (3) 113-8433 Crankshaft Seal Gp
S/N: S2K1-Up
Part No.: 7W-3813 • Install the crankshaft seal group in the flywheel
housing group on a standard rotation engine.
S/N: S2L1-Up
Part No.: 7W-3813 • Install thecrankshaft seal group in the front housing
S/N: S2M1-Up group on a reverse rotation engine.
Part No.: 7W-3813 (4) 113-8432 Crankshaft Seal Gp

S/N: S2N1-Up
Part No.: 7W-3813
• Install the crankshaft seal group in the front
housing group on a standard rotation engine.
S/N: S2P1-Up
Part No.: 7W-3813 • Install the crankshaft seal group in the flywheel
S/N: S2R1-Up housing group on a reverse rotation engine.
Part No.: 7W-3813 (A) The crankshaft seal group is installed from
S/N: S2S1-Up both ends of the crankshaft at the following
distance. ........... 8.0 ± 0.5 mm (0.31 ± 0.02 inch)
Part No.: 7W-3813
S/N: S2T1-Up (B) The wear sleeve is installed from both
ends of the crankshaft at the following
Part No.: 7W-3813
distance. ........... 0.5 ± 0.5 mm (0.02 ± 0.02 inch)
S/N: S2W1-Up
Part No.: 7W-3813
S/N: S2X1-Up
Part No.: 7W-3813
S/N: S2Y1-Up
Part No.: 7W-3813
S/N: S2Z1-Up
g01414669
Illustration 143
(1) Flywheel housing group
(2) Front housing group
Note: The crankshaft seal group cannot be used

once the seal has been separated from the wear
sleeve.
RENR5077-11 109
i03671476
Housing (Front)
SMCS Code: 1162
Part No.: 333-3712
S/N: M8A1-Up
Part No.: 333-3712
S/N: M8B1-Up
g01971776
Illustration 144
Refer to table 5 for the correct position of the

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

are listed in table 5.
Table 5
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.
110 RENR5077-11
i02875170 Part No.: 4P-5426

S/N: S2X1-Up
Housing (Front)
Part No.: 4P-5426
Part No.: 4P-5426 Part No.: 4P-5426
Part No.: 4P-5426
S/N: S2B1-Up
Part No.: 4P-5426
S/N: S2D1-Up
Part No.: 4P-5426
S/N: S2E1-Up
Part No.: 4P-5426
S/N: S2F1-Up
Part No.: 4P-5426
S/N: B5G1-Up
Part No.: 4P-5426
S/N: MRG1-Up
Part No.: 4P-5426
S/N: PAG1-Up
Part No.: 4P-5426
S/N: S2G1-Up
Part No.: 4P-5426
S/N: MKH1-Up
Part No.: 4P-5426
S/N: S2H1-Up
Part No.: 4P-5426
S/N: S2J1-Up
Part No.: 4P-5426
S/N: S2K1-Up
Part No.: 4P-5426
S/N: S2L1-Up
Part No.: 4P-5426
S/N: S2M1-Up
Part No.: 4P-5426
S/N: S2N1-Up
Part No.: 4P-5426
S/N: S2P1-Up
Part No.: 4P-5426
S/N: S2R1-Up
Part No.: 4P-5426
S/N: S2S1-Up
Part No.: 4P-5426
S/N: S2T1-Up
Part No.: 4P-5426
S/N: S2W1-Up
RENR5077-11 111
g01430989
Illustration 145
Refer to Table 6 for the correct position of the i03696090

fasteners.
Gear Group (Front)
Note: Use a standard torque for the fasteners that
are listed in Table 6.
(Reverse Rotation)
SMCS Code: 1206
Table 6
Front Housing Bolt Part No.: 334-5314
Length S/N: M8A1-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 146
Front view
(2) Crankshaft gear
(1) Thrust washer

Thickness of new thrust washer .. 8.50 ± 0.05 mm
(0.335 ± 0.002 inch)
112 RENR5077-11
Width of groove in new pump drive shaft

assembly. ............................... 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
g01988514
Illustration 147
(3) Water pump 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) 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 shaft ........ 89.88 ± 0.02 mm
(3.539 ± 0.001 inch) (10) Thrust washer
Bore in sleeve bearing for the idler gear
assembly ............................. 90.000 ± 0.010 mm Thickness of new thrust washer .. 8.50 ± 0.05 mm
(3.5433 ± 0.0004 inch) (0.335 ± 0.002 inch)
Installation depth of the sleeve Width of groove in new pump drive shaft
bearing .............. 2.3 ± 0.5 mm (0.09 ± 0.02 inch) assembly. ............................... 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
(7) Auxiliary drive shaft
Diameter of the new auxiliary drive
shaft ..................................... 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
Bore in the sleeve bearing after
assembly ............................. 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch)
(8) Pump drive shaft assembly

Diameter of the new pump drive shaft
assembly ............................. 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)
assembly ............................. 75.000 ± 0.055 mm
(2.9527± 0.0022 inch)
RENR5077-11 113
i03694527
Gear Group (Front)

(Reverse Rotation)
SMCS Code: 1206
Part No.: 334-5315
S/N: M8B1-Up
g02019973
Illustration 148
Front view
(2) Crankshaft gear
(1) Thrust washer

(0.335 ± 0.002 inch)
assembly. ............................... 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
114 RENR5077-11
g01985973
Illustration 149
(3) Accessory 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) Idler shaft (10) Thrust washer

Diameter of the new idler Thickness of new thrust washer .. 8.50 ± 0.05 mm
shaft ...... 105.88 ± 0.02 mm (4.168 ± 0.001 inch) (0.335 ± 0.002 inch)
Bore in the sleeve bearing for the idler Width of groove in new pump drive shaft
shaft ................................... 105.970 ± 0.010 mm assembly. ............................... 8.750 ± 0.025 mm
(4.1720 ± 0.0004 inch) (0.3445 ± 0.0010 inch)

i03668141
shaft ..................................... 74.900 ± 0.015 mm Gear Group (Front)
(2.9488 ± 0.0006 inch)
Bore in the sleeve bearing after SMCS Code: 1206
assembly ............................. 75.000 ± 0.055 mm Part No.: 122-9281
(2.9527 ± 0.0022 inch) S/N: S2A1-Up
(8) Pump drive shaft assembly Part No.: 334-5312
S/N: M8B1-Up
Diameter of the new pump drive shaft
(2.9488 ± 0.0006 inch) S/N: S2D1-Up
(2.9527± 0.0022 inch) S/N: B5G1-Up
Note: Install the socket setscrew (9) to the bottom of Part No.: 122-9281
the threaded hole. S/N: MRG1-Up
RENR5077-11 115
Part No.: 122-9281

S/N: PAG1-Up
Part No.: 122-9281
S/N: S2G1-Up
Part No.: 122-9281
S/N: MKH1-Up
Part No.: 122-9281
S/N: S2J1-Up
Part No.: 122-9281
S/N: S2K1-Up
Part No.: 122-9281
S/N: S2L1-Up
Part No.: 122-9281
S/N: S2M1-Up
Part No.: 122-9281
S/N: S2N1-Up
Part No.: 122-9281
S/N: S2P1-Up
Part No.: 122-9281
S/N: S2R1-Up
Part No.: 122-9281 g01428397
Illustration 150
S/N: S2S1-Up
Typical example
Part No.: 122-9281 (5) Idler gear assembly
S/N: S2T1-Up (6) Water pump drive gear
(7) Crankshaft gear
Part No.: 122-9281
S/N: S2W1-Up Note: Install the socket setscrew to the bottom of the
threaded hole.
Part No.: 122-9281
S/N: S2X1-Up (1) Torque for the socket setscrew ............ 6 ± 1 N·m
Part No.: 122-9281 (53 ± 9 lb in)
S/N: S2Y1-Up
Part No.: 122-9281
S/N: S2Z1-Up Bore in sleeve bearing after
assembly ............................. 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch)
Diameter of new pump drive shaft
assembly. ............................. 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch)

lubricant that is being sealed.
(4) Thrust washer

(0.335 ± 0.002 inch)
assembly. ............................... 8.750 ± 0.025 mm
(0.3445 ± 0.0010 inch)
End play for the pump drive shaft
assembly .............................. 0.175 to 0.325 mm
(0.0069 ± 0.0128 inch)
(8) Idler shaft

116 RENR5077-11
Diameter of the idler shaft ..... 105.88 ± 0.02 mm Part No.: 8N-7174
(4.168 ± 0.001 inch) S/N: S2R1-Up
Bore in the sleeve bearing for idler
shaft ................................... 105.970 ± 0.010 mm Part No.: 8N-7174
(4.1720 ± 0.0004 inch) S/N: S2S1-Up
Part No.: 8N-7174
i03125700 S/N: S2T1-Up
Gear Group (Front) Part No.: 8N-7174

S/N: S2W1-Up
SMCS Code: 1206
Part No.: 8N-7174
Part No.: 334-5311 S/N: S2X1-Up
S/N: M8A1-Up
Part No.: 8N-7174
Part No.: 8N-7174 S/N: S2Y1-Up
S/N: S2A1-Up
Part No.: 8N-7174
Part No.: 334-5311 S/N: S2Z1-Up
S/N: M8B1-Up
Part No.: 8N-7174
S/N: S2B1-Up
Part No.: 8N-7174
S/N: S2D1-Up
Part No.: 8N-7174
S/N: S2E1-Up
Part No.: 8N-7174
S/N: S2F1-Up
Part No.: 8N-7174
S/N: B5G1-Up
Part No.: 8N-7174
S/N: MRG1-Up
Part No.: 8N-7174
S/N: PAG1-Up
Part No.: 8N-7174
S/N: S2G1-Up
Part No.: 8N-7174
S/N: MKH1-Up
Part No.: 8N-7174
S/N: S2H1-Up g01428397
Illustration 151
Part No.: 8N-7174 (5) Idler gear assembly
S/N: S2J1-Up (6) Water pump drive gear
(7) Crankshaft gear
Part No.: 8N-7174
S/N: S2K1-Up Note: Install the socket setscrew to the bottom of the
threaded hole.
Part No.: 8N-7174
S/N: S2L1-Up (1) Torque for the socket setscrew ............ 6 ± 1 N·m
(55 ± 9 lb in)
Part No.: 8N-7174
S/N: S2M1-Up
Part No.: 8N-7174
Bore in sleeve bearing after
S/N: S2N1-Up
assembly ............................. 75.000 ± 0.055 mm
Part No.: 8N-7174 (2.9528 ± 0.0022 inch)
S/N: S2P1-Up
RENR5077-11 117
Diameter of new pump drive shaft Part No.: 101-0835, 175-5203, 175-5204
assembly ............................. 74.900 ± 0.015 mm S/N: PAG1-Up
(2.9488 ± 0.0006 inch)
Part No.: 101-0835, 124-8395
(3) Lubricate the bore of four O-ring seals lightly with S/N: S2G1-Up
Part No.: 101-0835, 124-8395, 175-5203,
175-5204
(4) Thrust washer S/N: MKH1-Up
Part No.: 101-0835, 124-8395
(0.335 ± 0.002 inch) S/N: S2H1-Up
assembly ............................... 8.750 ± 0.025 mm Part No.: 101-0835, 124-8395, 175-5204
(0.3445 ± 0.0010 inch) S/N: S2J1-Up
End play for the pump drive shaft
assembly ............................... 0.250 ± 0.075 mm Part No.: 101-0835, 124-8395
(0.0098 ± 0.0030 inch) S/N: S2K1-Up
(8) Shaft Part No.: 101-0835, 124-8395

S/N: S2L1-Up
Bore in sleeve bearing after
machining ............................ 90.000 ± 0.010 mm Part No.: 124-8395
(3.5433 ± 0.0004 inch) S/N: S2M1-Up
Diameter of new shaft .............. 89.88 ± 0.02 mm Part No.: 101-0835, 124-8395
(3.539 ± 0.001 inch) S/N: S2N1-Up
Note: After the sleeve bearing is installed in the gear Part No.: 101-0835, 124-8395
the sleeve bearing must be machined to size. S/N: S2P1-Up
Maximum roughness average (Ra) .. 0.8 micrometer Part No.: 101-0835, 124-8395
(32 microinch) S/N: S2R1-Up
Part No.: 101-0835, 124-8395
i03125621 S/N: S2S1-Up
Gear Group (Rear) Part No.: 101-0835, 124-8395, 175-5203,

175-5204
SMCS Code: 1206 S/N: S2T1-Up
Part No.: 334-5298 Part No.: 101-0835, 124-8395

S/N: M8A1-Up S/N: S2W1-Up
Part No.: 101-0835, 124-8395 Part No.: 101-0835, 124-8395, 175-5203,

S/N: S2A1-Up 175-5204
S/N: S2X1-Up
Part No.: 334-5298
S/N: M8B1-Up Part No.: 101-0835, 124-8395
S/N: S2Y1-Up
Part No.: 101-0835, 124-8395
S/N: S2B1-Up Part No.: 101-0835, 124-8395
S/N: S2Z1-Up
Part No.: 101-0835, 124-8395
S/N: S2D1-Up
Part No.: 101-0835, 124-8395
S/N: S2E1-Up
Part No.: 124-8395
S/N: S2F1-Up
Part No.: 101-0835, 175-5203, 175-5204
S/N: B5G1-Up
Part No.: 101-0835, 175-5203, 175-5204
S/N: MRG1-Up
118 RENR5077-11
g01256372
Illustration 153
Vertical line
(9) Use the following procedure to tighten the bolt for

the camshaft drive gears:
Illustration 152
g01620759 1. Tighten the bolt for the camshaft drive gear to
360 ± 40 N·m (270 ± 30 lb ft).
(1) Ring
(3) Idler gear assembly
(13) Plate 2. Mark a vertical line on the head of the bolt for the
camshaft drive gear. Refer to Illustration 153.
Note: Before assembly, it is critical that the taper of
the camshaft and the tapered bore of the camshaft 3. Place a driver against the retaining plate of the
drive gear are clean, dry, and free of residue. camshaft drive gear. Strike the driver solidly with
a hammer 3 to 4 times.
Refer to Disassembly and Assembly for the
installation procedure for the left camshaft drive gear 4. Again, tighten the bolt for the camshaft drive gear
(2). to 360 ± 40 N·m (270 ± 30 lb ft).
(5) Torque for four bolts ....................... 140 ± 10 N·m

(105 ± 7 lb ft)
(6) Gear shaft

Diameter of the gear shaft ... 74.990 ± 0.010 mm
(2.9524 ± 0.0004 inch)
Bore in the sleeve bearing for the gear
shaft ..................................... 75.060 ± 0.010 mm
(2.9551 ± 0.0004 inch)
Maximum roughness average
(Ra) ...................... 0.8 micrometer (32 microinch)
Refer to Disassembly and Assembly for the

g01256393
installation procedure for the right camshaft drive Illustration 154
gear (7).
5. Repeat Steps 3 and 4 until the mark on the
(8) Idler shaft bolt turns a minimum of 90 degrees. Refer to
Illustration 154.
Diameter of the idler shaft ... 81.000 ± 0.010 mm
(3.1890 ± 0.0004 inch) (10) Torque for four bolts ..................... 240 ± 20 N·m
Bore in the sleeve bearing for the idler (175 ± 15 lb ft)
shaft ..................................... 81.060 ± 0.010 mm
(3.1913 ± 0.0004 inch) (11) Torque for two bolts ..................... 240 ± 20 N·m
Maximum roughness average (175 ± 15 lb ft)
(Ra) ...................... 0.8 micrometer (32 microinch)
RENR5077-11 119
i03091223
Balancer Group (Front)

SMCS Code: 1220
Part No.: 332-7916
S/N: M8A1-Up
Part No.: 101-0833
S/N: S2A1-Up
Part No.: 332-7916
S/N: M8B1-Up
Part No.: 101-0833
g01620761
Illustration 155 S/N: S2B1-Up
Rear view of engine
Part No.: 101-0833
S/N: S2D1-Up
(14) The mark on the cluster gear assembly (4) must
be in alignment with the mark on the crankshaft Part No.: 101-0833
gear (12). S/N: S2E1-Up
Part No.: 101-0833
S/N: S2F1-Up
g01572454
Illustration 156
(3) Balancer gear
(4) Crankshaft gear
(1) Torque for four bolts ....................... 140 ± 10 N·m

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

120 RENR5077-11
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)
(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: M8A1-Up
Part No.: 334-5306
S/N: M8B1-Up
g02021255
Illustration 157
Front view
RENR5077-11 121
g02021213
Illustration 158
(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

assembly after installation ... 75.000 ± 0.055 mm
(2.9527 ± 0.0022 inch)

(2.9527 ± 0.0022 inch)

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)
122 RENR5077-11
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: M8B1-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: S2A1-Up
Part No.: 7E-7647
S/N: S2B1-Up
Part No.: 7E-7647
S/N: S2D1-Up
Illustration 159
g02021233 Part No.: 7E-7647
Front view S/N: S2E1-Up
Part No.: 7E-7647
S/N: S2F1-Up
Part No.: 7E-7647
S/N: B5G1-Up
Part No.: 7E-7647
S/N: MRG1-Up
Part No.: 7E-7647
S/N: PAG1-Up
Part No.: 7E-7647
S/N: S2G1-Up
g02021234 Part No.: 7E-7647

Illustration 160 S/N: MKH1-Up
Section A-A
Part No.: 7E-7647
(1) Lubricate the bore of the O-ring seal with the S/N: S2H1-Up
Part No.: 7E-7647
(B) Dimensions of the shaft S/N: S2J1-Up
Diameter of the new shaft .. 105.880 ± 0.020 mm Part No.: 7E-7647

(4.1685 ± 0.0008 inch) S/N: S2K1-Up
Bore in the bearing for idler gear for the Part No.: 7E-7647
shaft ................................... 105.970 ± 0.010 mm S/N: S2L1-Up
(4.1720 ± 0.0004 inch)
Part No.: 7E-7647
(C) Dimensions of the idler gear assembly S/N: S2M1-Up
RENR5077-11 123
Part No.: 7E-7647

S/N: S2N1-Up
Part No.: 7E-7647
S/N: S2P1-Up
Part No.: 7E-7647
S/N: S2R1-Up
Part No.: 7E-7647
S/N: S2S1-Up
Part No.: 7E-7647
S/N: S2T1-Up
Part No.: 7E-7647
S/N: S2W1-Up
Part No.: 7E-7647
S/N: S2X1-Up
Part No.: 7E-7647
S/N: S2Y1-Up
g01929454
Illustration 162
Part No.: 7E-7647
Section B-B
S/N: S2Z1-Up
(3) Diameter of the new shaft ........ 89.88 ± 0.02 mm
(3.539 ± 0.001 inch)
(4) Dimensions of the idler gear assembly

Bore in the sleeve bearing of the idler gear
(3.5433 ± 0.0004 inch)
(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
Illustration 161
g01929453 (0.3445 ± 0.0010 inch)
End play for the auxiliary drive
Front view
shaft ...................................... 0.175 to 0.325 mm
(1) Water pump drive gear (0.0069 to 0.0128 inch)
(2) Lightly lubricate the bore of the O-ring seals with (6) Thickness of the new thrust
the lubricant that is being sealed. washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)
124 RENR5077-11
Part No.: 179-1511

S/N: MRG1-Up
Part No.: 179-1511
S/N: PAG1-Up
Part No.: 179-1511
S/N: S2G1-Up
Part No.: 179-1511
S/N: MKH1-Up
Part No.: 179-1511
S/N: S2H1-Up
Part No.: 179-1511
S/N: S2J1-Up
Part No.: 179-1511
S/N: S2K1-Up
Part No.: 179-1511
S/N: S2L1-Up
Part No.: 179-1511
S/N: S2M1-Up
Part No.: 179-1511
S/N: S2N1-Up
g01929474 Part No.: 179-1511

Illustration 163
S/N: S2P1-Up
Adapter assembly
Part No.: 179-1511
(C) Installation depth of the sleeve bearing in the S/N: S2R1-Up
adapter assembly .......................... 1.5 ± 0.5 mm
(0.06 ± 0.02 inch) Part No.: 179-1511
S/N: S2S1-Up
(D) Bore in the sleeve bearing of the adapter Part No.: 179-1511
assembly after installation ... 75.000 ± 0.055 mm S/N: S2T1-Up
(2.9527 ± 0.0022 inch)
Part No.: 179-1511
S/N: S2W1-Up
i02889488
Part No.: 179-1511

Accessory Drive (Lower Left S/N: S2X1-Up
Hand) Part No.: 179-1511
Part No.: 179-1511 Part No.: 179-1511

Part No.: 179-1511

S/N: S2B1-Up
Part No.: 179-1511
S/N: S2D1-Up
Part No.: 179-1511
S/N: S2E1-Up
Part No.: 179-1511
S/N: S2F1-Up
Part No.: 179-1511
S/N: B5G1-Up
RENR5077-11 125
(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
(2.9527 ± 0.0022 inch)
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)
g01438742
Illustration 164 Maximum roughness average
Front view (Ra) ...................... 0.8 micrometer (32 microinch)

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)
(7) Thickness of new thrust washer .. 8.50 ± 0.05 mm

(0.335 ± 0.002 inch)
i03605121
g01438748
Accessory Drive (Upper Right
Illustration 165
Section A-A
Hand)
(1) Lubricate the bore of the four O-ring seals with SMCS Code: 1207
the lubricant that is being sealed. Part No.: 166-4357
S/N: S2A1-Up
Part No.: 166-4357
S/N: S2B1-Up
Part No.: 166-4357
S/N: S2D1-Up
Part No.: 166-4357
S/N: S2E1-Up
Part No.: 166-4357
S/N: S2F1-Up
Part No.: 166-4357
S/N: PAG1-Up
Part No.: 166-4357
S/N: S2G1-Up
Part No.: 166-4357
S/N: MKH1-Up
Illustration 166
g01438749 Part No.: 166-4357
S/N: S2H1-Up
Section B-B
(4) Adapter assembly Part No.: 166-4357
S/N: S2J1-Up
126 RENR5077-11
Part No.: 166-4357

S/N: S2K1-Up
Part No.: 166-4357
S/N: S2L1-Up
Part No.: 166-4357
S/N: S2M1-Up
Part No.: 166-4357
S/N: S2N1-Up
Part No.: 166-4357
S/N: S2P1-Up
Part No.: 166-4357
S/N: S2R1-Up
Part No.: 166-4357
S/N: S2S1-Up
Part No.: 166-4357
S/N: S2T1-Up
Part No.: 166-4357
S/N: S2W1-Up
Part No.: 166-4357
S/N: S2X1-Up
Part No.: 166-4357
S/N: S2Y1-Up
Part No.: 166-4357
S/N: S2Z1-Up
RENR5077-11 127
g01930053
Illustration 167
(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)
(3) Dimensions of the auxiliary drive shaft
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: S2A1-Up
Part No.: 7N-4871
S/N: S2B1-Up
128 RENR5077-11
Part No.: 7N-4871

S/N: S2D1-Up
Part No.: 7N-4871
S/N: S2E1-Up
Part No.: 7N-4871
S/N: S2F1-Up
Part No.: 7N-4871
S/N: B5G1-Up
Part No.: 7N-4871
S/N: MRG1-Up
Part No.: 7N-4871
S/N: PAG1-Up
Part No.: 7N-4871
S/N: S2G1-Up
Part No.: 7N-4871
S/N: MKH1-Up
g01929617
Illustration 168
Part No.: 7N-4871
Front view of engine
S/N: S2H1-Up
Part No.: 7N-4871 (1) Lightly lubricate the bore of the O-ring seals with
S/N: S2J1-Up the lubricant that is being sealed.
Part No.: 7N-4871

S/N: S2K1-Up
Part No.: 7N-4871
S/N: S2L1-Up
Part No.: 7N-4871
S/N: S2M1-Up
Part No.: 7N-4871
S/N: S2N1-Up
Part No.: 7N-4871
S/N: S2P1-Up
Part No.: 7N-4871
S/N: S2R1-Up
Part No.: 7N-4871
S/N: S2S1-Up
Part No.: 7N-4871
S/N: S2T1-Up
Part No.: 7N-4871
S/N: S2W1-Up
Part No.: 7N-4871
S/N: S2X1-Up
Part No.: 7N-4871
S/N: S2Y1-Up
Part No.: 7N-4871
S/N: S2Z1-Up
RENR5077-11 129
(4) Thickness of the new thrust

washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)
g01929654
Illustration 170
Adapter assembly
(D) Bore in the sleeve bearing of the adapter

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

Illustration 169
g01929618
Hand)
Section A-A
SMCS Code: 1207
bearing with the adapter. Part No.: 334-5304
S/N: M8A1-Up
Part No.: 107-7361
S/N: S2A1-Up
(2.9527 ± 0.0022 inch)
Part No.: 107-7361
(3) Dimensions of the auxiliary drive shaft S/N: S2B1-Up
Diameter of the new auxiliary drive Part No.: 107-7361
shaft ..................................... 74.900 ± 0.015 mm S/N: S2D1-Up
(2.9488 ± 0.0006 inch)
Width of groove in the new auxiliary drive shaft Part No.: 107-7361
for the thrust washer .............. 8.750 ± 0.025 mm S/N: S2E1-Up
(0.3445 ± 0.0010 inch)
End play for the auxiliary drive Part No.: 107-7361
shaft ...................................... 0.175 to 0.325 mm S/N: S2F1-Up
(0.0069 to 0.0128 inch) Part No.: 107-7361
S/N: B5G1-Up
130 RENR5077-11
Part No.: 107-7361

S/N: MRG1-Up
Part No.: 107-7361
S/N: PAG1-Up
Part No.: 107-7361
S/N: S2G1-Up
Part No.: 107-7361
S/N: MKH1-Up
Part No.: 107-7361
S/N: S2H1-Up
Part No.: 107-7361
S/N: S2J1-Up
Part No.: 107-7361
S/N: S2K1-Up
Part No.: 107-7361
S/N: S2L1-Up
Part No.: 107-7361
S/N: S2M1-Up
Part No.: 107-7361
S/N: S2N1-Up
Part No.: 107-7361 g01441499
Illustration 171
S/N: S2P1-Up
Part No.: 107-7361 (1) Lubricate the bore of the O-ring seal lightly with
S/N: S2R1-Up the lubricant that is being sealed.
Part No.: 107-7361

S/N: S2S1-Up
Part No.: 107-7361
S/N: S2T1-Up
Part No.: 107-7361
S/N: S2W1-Up
Part No.: 107-7361
S/N: S2X1-Up
Part No.: 107-7361
S/N: S2Y1-Up
Part No.: 107-7361
S/N: S2Z1-Up
g01441501
Illustration 172
Section A-A
(B) Dimensions for the sleeve bearing

Bore in sleeve bearing before
assembly ............................. 44.475 ± 0.025 mm
(1.7510 ± 0.0010 inch)
RENR5077-11 131
Diameter of accessory drive Part No.: 8N-9166

gear ..................................... 44.400 ± 0.015 mm S/N: S2P1-Up
(1.7480 ± 0.0006 inch)
Part No.: 8N-9166
(C) Dimensions for the sleeve bearing S/N: S2R1-Up
Bore in sleeve bearing after Part No.: 8N-9166

assembly ............................. 75.000 ± 0.055 mm S/N: S2S1-Up
(2.9527 ± 0.0022 inch)
Part No.: 8N-9166
Diameter of accessory drive
S/N: S2T1-Up
gear ..................................... 74.900 ± 0.015 mm
(2.9488 ± 0.0006 inch) Part No.: 8N-9166
S/N: S2W1-Up
i02960980 Part No.: 8N-9166
Accessory Drive (Upper Left S/N: S2X1-Up
Hand) Part No.: 8N-9166

S/N: S2Y1-Up
SMCS Code: 1207 Part No.: 8N-9166
Part No.: 334-5328 S/N: S2Z1-Up
S/N: M8A1-Up
Part No.: 8N-9166
S/N: S2A1-Up
Part No.: 334-5328
S/N: M8B1-Up
Part No.: 8N-9166
S/N: S2B1-Up
Part No.: 8N-9166
S/N: S2D1-Up
Part No.: 8N-9166
S/N: S2E1-Up
Part No.: 8N-9166
S/N: S2F1-Up
Part No.: 8N-9166
S/N: PAG1-Up
Part No.: 8N-9166
S/N: S2G1-Up
Part No.: 8N-9166
S/N: MKH1-Up
Part No.: 8N-9166
S/N: S2H1-Up
Part No.: 8N-9166
S/N: S2J1-Up
Part No.: 8N-9166
S/N: S2K1-Up
Part No.: 8N-9166
S/N: S2L1-Up
Part No.: 8N-9166
S/N: S2M1-Up
Part No.: 8N-9166
S/N: S2N1-Up
132 RENR5077-11
g01479361
Illustration 173
(1) Lubricate the bore of six O-ring seals lightly with i02735559
Accessory Drive (Upper Left
(2) 127-5400 Sleeve Bearing Hand, Reverse Rotation)
Quantity ............................................................ 2
SMCS Code: 1207
(2.9528 ± 0.0022 inch) S/N: M8B1-Up
(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)
g01371445
Illustration 174
(2) Accessory drive gear
(5) Thrust washer
(6) Idler gear
(1) Bore in the sleeve bearings after

assembly ............................. 75.000 ± 0.055 mm
(2.9528 ± 0.0022 inch)
RENR5077-11 133
(3) Thickness of new thrust washer .. 8.50 ± 0.05 mm Part No.: 7N-4851, 7N-7784, 7W-0968
(0.335 ± 0.002 inch) S/N: S2G1-Up
(4) Auxiliary drive shaft Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: MKH1-Up
shaft ..................................... 74.900 ± 0.015 mm Part No.: 7N-4851, 7N-7784, 7W-0968
(2.9488 ± 0.0006 inch) S/N: S2H1-Up
Width of groove in new auxiliary drive
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
shaft .. 8.750 ± 0.025 mm (0.3445 ± 0.0010 inch)
S/N: S2J1-Up
End play for auxiliary drive
shaft ...................................... 0.175 to 0.325 mm Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
(0.0069 to 0.0128 inch) S/N: S2K1-Up
(7) Sleeve bearing Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2L1-Up
assembly ............................. 90.000 ± 0.010 mm Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
(3.5433 ± 0.0004 inch) S/N: S2M1-Up
(Ra) ...................... 0.8 micrometer (32 microinch) Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2N1-Up
Note: After the sleeve bearing is installed in the gear Part No.: 7N-4851, 7N-7784, 7W-0968
the sleeve bearing must be machined to size. S/N: S2P1-Up
(8) Diameter of new shaft .......... 89.880 ± 0.020 mm Part No.: 7N-4851, 7N-7784, 7W-0968
(3.5386 ± 0.0008 inch) S/N: S2R1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
i02869986 S/N: S2S1-Up
Flywheel Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2T1-Up
SMCS Code: 1156
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
Part No.: 333-3742, 7N-4851, 7N-7784, S/N: S2W1-Up
7W-0968, 8N-6038
S/N: M8A1-Up Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2X1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968
S/N: S2A1-Up Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2Y1-Up
Part No.: 333-3742, 7N-4851, 7N-7784,
7W-0968, 8N-6038 Part No.: 7N-4851, 7N-7784, 7W-0968
Part No.: 7N-4851, 7N-7784, 7W-0968

S/N: S2B1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2D1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2E1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: S2F1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: B5G1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: MRG1-Up
Part No.: 7N-4851, 7N-7784, 7W-0968, 8N-6038
S/N: PAG1-Up
134 RENR5077-11
Note: Before installation of the flywheel housing,

inspect the front face of the flywheel housing and
the rear face of the cylinder block. The components
must be free of the following substances: oil, fuel,
water, gasket adhesive, assembly compounds, and
any other foreign material.
Tighten the bolts that hold the flywheel housing to

the engine block evenly. Refer to Illustration 177 and
Table 7 for the locations and for identification of the
bolts.
g01429511
Illustration 175
Typical example
(1) Flywheel gear
(2) Crankshaft
g01984633
Illustration 176
Note: When the flywheel assembly is installed, align
Left side view
the dash mark on the flywheel assembly with the
dash mark on the crankshaft.
(1) To seal the joint between the flywheel housing
and the cylinder block, apply 1U-8846 Gasket
Sealant to the front face of the flywheel housing.
bolts (3) with clean engine oil, molybdenum disulfide
or graphite base lubricant.
(2) Torque for the bolts ...... 55 ± 10 N·m (41 ± 7 lb ft)
(3) Torque for the 12 bolts ................. 1150 ± 60 N·m
(840 ± 44 lb ft)
i03690244
Flywheel Housing
SMCS Code: 1157
Part No.: 333-7646
S/N: M8A1-Up
Part No.: 333-7646
S/N: M8B1-Up
For information on inspecting the flywheel housing,

refer to the Testing and Adjusting, “Flywheel Housing
- Inspect”.
g02019674
Illustration 177
RENR5077-11 135
Table 7 Part No.: 102-3540, 107-7177

Flywheel Housing Bolt S/N: MRG1-Up
Bolt Length
Installation Chart
Part No.: 102-3540, 107-7177
Diameter Part S/N: PAG1-Up
Bolt mm inch
inch Number
Part No.: 102-3540, 107-7177
4 1/2 9X-8873 57.15 2.250 S/N: S2G1-Up
5 1/2 1D-4574 152.4 6.00
Part No.: 102-3540, 107-7177
6 3/8 0S-1594 25.4 1.00 S/N: MKH1-Up
7 5/8 1D-4597 165.1 6.50 Part No.: 102-3540, 107-7177
8 1/2 9X-8878 133.35 5.250 S/N: S2H1-Up
9 5/8 1D-4602 241.3 9.50 Part No.: 102-3540, 107-7177

S/N: S2J1-Up
10 5/8 1D-4593 139.7 5.50
Part No.: 102-3540, 107-7177
Note: Bond the entire surface with 6V-6640 Sealant S/N: S2K1-Up
to the flywheel housing cover assembly (3). Part No.: 102-3540, 107-7177
S/N: S2L1-Up
(4) Torque for the bolts ........................ 135 ± 20 N·m
(100 ± 15 lb ft) Part No.: 102-3540, 107-7177
S/N: S2M1-Up
(100 ± 15 lb ft) Part No.: 102-3540, 107-7177
S/N: S2N1-Up
(6) Torque for the bolts ...... 55 ± 10 N·m (41 ± 7 lb ft)
Part No.: 102-3540, 107-7177
(7) Torque for the bolts ........................ 270 ± 40 N·m S/N: S2P1-Up
(199 ± 30 lb ft) Part No.: 102-3540, 107-7177
S/N: S2R1-Up
(100 ± 15 lb ft) Part No.: 102-3540, 107-7177
S/N: S2S1-Up
(199 ± 30 lb ft) Part No.: 102-3540, 107-7177
S/N: S2T1-Up
(10) Torque for the bolts ...................... 270 ± 40 N·m
Part No.: 102-3540, 107-7177
(199 ± 30 lb ft)
S/N: S2W1-Up
Part No.: 102-3540, 107-7177
i02987334
S/N: S2X1-Up
Flywheel Housing Part No.: 102-3540, 107-7177
S/N: S2Y1-Up
SMCS Code: 1157
Part No.: 102-3540, 107-7177
Part No.: 102-3540, 107-7177
S/N: S2Z1-Up
S/N: S2A1-Up
Part No.: 102-3540, 107-7177 For information on inspecting the flywheel housing,
S/N: S2B1-Up refer to Systems Operation/Testing and Adjusting.
Part No.: 102-3540, 107-7177 Note: Before installation of the flywheel housing,
S/N: S2D1-Up inspect the front face of the flywheel housing and
the rear face of the cylinder block. The components
Part No.: 102-3540, 107-7177 must be free of the following substances: oil, fuel,
S/N: S2E1-Up water, gasket adhesive, assembly compounds, and
Part No.: 102-3540, 107-7177 any other foreign material.
S/N: S2F1-Up
To seal the joint between the flywheel housing and
Part No.: 102-3540, 107-7177 the cylinder block, apply 1U-8846 Gasket Sealant to
S/N: B5G1-Up the mating surface of the flywheel housing.
136 RENR5077-11
g01513774
Illustration 178
Rear view
Table 8 Tighten the bolts that hold the flywheel housing to

Flywheel Housing Bolt the engine block evenly. Refer to Illustration 178 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)

RENR5077-11 137
(6) Torque for four bolts ....................... 135 ± 20 N·m i03606340

(100 ± 15 lb ft)
Flexible Coupling
(7) Torque for two bolts ....................... 270 ± 40 N·m
(200 ± 30 lb ft) SMCS Code: 3279
Part No.: 5N-3765
S/N: S2A1-Up
Part No.: 5N-3765
S/N: S2B1-Up
Part No.: 5N-3765
S/N: S2G1-Up
Part No.: 5N-3765
S/N: S2H1-Up
Part No.: 5N-3765
S/N: S2P1-Up
Part No.: 5N-3765
S/N: S2R1-Up
g01513803
Illustration 179
Left side view
(8) Apply 1U-8846 Gasket Sealant to the surface of

the gasket before assembly.
g01931073
Illustration 180
Note: Before you install the outer coupling (1) the

flywheel (6) must be clean and free from the following
substances: oil, paint, dirt, and protective coating.
138 RENR5077-11
Use the following procedure to install the flexible Part No.: 7W-0284
coupling: S/N: S2P1-Up
1. Lubricate all the surfaces that will contact either Part No.: 7W-0284
the O-ring seals (2) or the rubber coupling boots S/N: S2R1-Up
(5) with 5N-5561 Silicone Lubricant except the
Part No.: 7W-0284
plate (4).
S/N: S2S1-Up
2. Install the O-ring seals (2) in the outer coupling (1). Part No.: 7W-0284
S/N: S2T1-Up
3. Center the drive coupling (3) inside the outer
coupling (1). Part No.: 7W-0284
S/N: S2W1-Up
4. Place the rubber coupling boots (5) between the
drive coupling (3) and outer coupling (1). Part No.: 7W-0284
S/N: S2X1-Up
5. Fill the cavities between the couplings and the Part No.: 7W-0284
rubber coupling boots (5) with the 5N-5561 S/N: S2Z1-Up
Silicone Lubricant.
6. Bolt the outer coupling (1) into the flywheel (6).
7. Bolt the drive coupling (3) to the shaft (7).
8. As needed, modify the assembly procedure for

the installation of the flexible coupling in the field.
i01691646
Engine Mount (Front)

(Hydraulic Pump Drive or PTO
Clutch)
SMCS Code: 1152
Part No.: 7W-0284
S/N: S2A1-Up
Part No.: 7W-0284
S/N: S2B1-Up
Part No.: 7W-0284
S/N: S2D1-Up
Part No.: 7W-0284
S/N: S2E1-Up
g00280831
Illustration 181
Part No.: 7W-0284
S/N: S2G1-Up (1) Damper
Part No.: 7W-0284
S/N: S2H1-Up (2) Adapter
Part No.: 7W-0284 (3) Damper adapter

S/N: S2J1-Up
Torque ................ 1125 ± 100 N·m (820 ± 75 lb ft)
Part No.: 7W-0284
S/N: S2K1-Up (4) Coupling
Part No.: 7W-0284 Put a dash mark on the coupling in alignment with
S/N: S2L1-Up the marks on the damper adapter and the crankshaft.
Part No.: 7W-0284
S/N: S2N1-Up
RENR5077-11 139
i02958521 Part No.: 4P-3309

S/N: S2X1-Up
Engine Trunnion
Part No.: 4P-3309
Part No.: 335-3181
S/N: M8A1-Up
Part No.: 335-3181
S/N: M8B1-Up
Part No.: 7N-1863
S/N: S2D1-Up
Part No.: 7N-1863
S/N: S2E1-Up
Part No.: 4P-3309
S/N: S2F1-Up
Part No.: 4P-3309
S/N: B5G1-Up
Part No.: 4P-3309
S/N: MRG1-Up
Part No.: 4P-3309
S/N: PAG1-Up g01475072
Illustration 182
Part No.: 4P-3309
S/N: S2G1-Up (1) Torque for 16 bolts .. 190 ± 30 N·m (140 ± 22 lb ft)
Part No.: 4P-3309 (2) Torque for 20 bolts .. 135 ± 20 N·m (100 ± 15 lb ft)
S/N: MKH1-Up
Part No.: 4P-3309 i02888713
S/N: S2H1-Up
Vibration Damper
Part No.: 4P-3309, 7N-1863
S/N: S2J1-Up SMCS Code: 1205
Part No.: 4P-3309, 7N-1863 Part No.: 247-0845
S/N: S2K1-Up S/N: M8A1-Up
Part No.: 4P-3309, 7N-1863 Part No.: 146-3740
S/N: S2L1-Up S/N: S2A1-Up
Part No.: 4P-3309 Part No.: 146-3740
S/N: S2M1-Up S/N: M8B1-Up
Part No.: 4P-3309, 7N-1863 Part No.: 146-3740
S/N: S2N1-Up S/N: S2B1-Up
Part No.: 4P-3309 Part No.: 146-3740
S/N: S2P1-Up S/N: S2D1-Up
Part No.: 4P-3309 Part No.: 146-3740
S/N: S2R1-Up S/N: S2E1-Up
Part No.: 4P-3309 Part No.: 146-3740
S/N: S2S1-Up S/N: S2F1-Up
Part No.: 4P-3309 Part No.: 146-3740
S/N: S2T1-Up S/N: B5G1-Up
Part No.: 4P-3309 Part No.: 146-3740
S/N: S2W1-Up S/N: MRG1-Up
140 RENR5077-11
Part No.: 146-3740

S/N: PAG1-Up
Part No.: 146-3740
S/N: S2G1-Up
Part No.: 146-3740
S/N: MKH1-Up
Part No.: 146-3740
S/N: S2H1-Up
Part No.: 146-3740
S/N: S2J1-Up
Part No.: 146-3740
S/N: S2K1-Up
Part No.: 146-3740
S/N: S2L1-Up
Part No.: 146-3740
S/N: S2M1-Up
g01438233
Illustration 183
Part No.: 146-3740
S/N: S2N1-Up Note: Apply 4C-4030 Thread Lock Compound to the
Part No.: 146-3740 threads of the bolts (1).
S/N: S2P1-Up
(1) Torque for the 48 bolts ... 55 ± 7 N·m (41 ± 5 lb ft)
Part No.: 146-3740
S/N: S2R1-Up
i03322541
Part No.: 146-3740
S/N: S2S1-Up Vibration Damper
S/N: S2T1-Up
Part No.: 125-9749, 240-7762
Part No.: 146-3740 S/N: S2A1-Up
S/N: S2W1-Up
Part No.: 125-9749, 240-7762
Part No.: 146-3740 S/N: S2B1-Up
S/N: S2X1-Up
Part No.: 125-9749, 240-7762
Part No.: 146-3740 S/N: S2D1-Up
S/N: S2Y1-Up
Part No.: 125-9749, 240-7762
Part No.: 146-3740 S/N: S2E1-Up
S/N: S2Z1-Up
Part No.: 125-9749, 240-7762
S/N: S2F1-Up
Part No.: 125-9749, 240-7762
S/N: B5G1-Up
Part No.: 125-9749, 240-7762
S/N: MRG1-Up
Part No.: 125-9749, 240-7762
S/N: PAG1-Up
Part No.: 125-9749, 240-7762
S/N: S2G1-Up
Part No.: 125-9749, 240-7762
S/N: MKH1-Up
RENR5077-11 141
Part No.: 125-9749, 240-7762 Note: The alignment mark on the crankshaft (1) must
S/N: S2H1-Up be aligned with the alignment mark on the adapter
(2). The mark on the damper group (3) must also be
Part No.: 125-9749, 240-7762 aligned with the mark on the adapter (2).
S/N: S2J1-Up
Part No.: 125-9749, 240-7762
bolts with molybdenum disulfide base lubricant.
S/N: S2K1-Up
Part No.: 125-9749, 240-7762 (4) Torque for six bolts ...................... 1150 ± 60 N·m
S/N: S2L1-Up (840 ± 44 lb ft)
Part No.: 125-9749, 240-7762 Note: Apply 4C-4030 Thread Lock Compound to
S/N: S2M1-Up the threads of the bolts.
Part No.: 125-9749, 240-7762 (5) Torque for 48 bolts ......... 55 ± 7 N·m (41 ± 5 lb ft)
S/N: S2N1-Up
Part No.: 125-9749, 240-7762 i03295581
S/N: S2P1-Up
Part No.: 125-9749, 240-7762
Vibration Damper
S/N: S2R1-Up SMCS Code: 1205
Part No.: 125-9749, 240-7762 Part No.: 8N-7182
S/N: S2S1-Up S/N: S2A1-Up
Part No.: 125-9749, 240-7762 Part No.: 8N-7182
S/N: S2T1-Up S/N: S2B1-Up
Part No.: 125-9749, 240-7762 Part No.: 8N-7182
S/N: S2W1-Up S/N: S2D1-Up
Part No.: 125-9749, 240-7762 Part No.: 8N-7182
S/N: S2X1-Up S/N: S2E1-Up
Part No.: 125-9749, 240-7762 Part No.: 8N-7182
S/N: S2Y1-Up S/N: S2F1-Up
Part No.: 125-9749, 240-7762 Part No.: 8N-7182
S/N: S2Z1-Up S/N: B5G1-Up
Part No.: 8N-7182
S/N: MRG1-Up
Part No.: 8N-7182
S/N: PAG1-Up
Part No.: 8N-7182
S/N: S2G1-Up
Part No.: 8N-7182
S/N: MKH1-Up
Part No.: 8N-7182
S/N: S2H1-Up
Part No.: 8N-7182
S/N: S2J1-Up
Part No.: 8N-7182
S/N: S2K1-Up
Part No.: 8N-7182
Illustration 184
g01412026 S/N: S2L1-Up
Part No.: 8N-7182
S/N: S2M1-Up
142 RENR5077-11
Part No.: 8N-7182 Part No.: 334-4642, 334-4644

S/N: S2N1-Up S/N: M8B1-Up
Part No.: 8N-7182 Part No.: 197-9052, 8N-9639
S/N: S2P1-Up S/N: S2B1-Up
Part No.: 8N-7182 Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2R1-Up S/N: S2D1-Up
Part No.: 8N-7182 Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2S1-Up S/N: S2E1-Up
Part No.: 8N-7182 Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2T1-Up S/N: S2F1-Up
Part No.: 8N-7182 Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2W1-Up S/N: B5G1-Up
Part No.: 8N-7182 Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2X1-Up S/N: MRG1-Up
Part No.: 8N-7182 Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2Y1-Up S/N: PAG1-Up
Part No.: 8N-7182 Part No.: 197-9052, 8N-9639
S/N: S2Z1-Up S/N: S2G1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: MKH1-Up
Part No.: 197-9052, 8N-9639
S/N: S2H1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2J1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2K1-Up
Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2L1-Up
g01515801 Part No.: 102-8616, 197-9052, 8N-9639

Illustration 185
S/N: S2M1-Up
Note: The alignment mark on the crankshaft (1) must Part No.: 102-8616, 197-9052, 8N-9639
be aligned with the alignment mark on the damper S/N: S2N1-Up
adapter (2).
Part No.: 197-9052, 8N-9639
Note: Before assembly, lubricate the threads of the S/N: S2P1-Up
bolts with molybdenum disulfide base lubricant.
Part No.: 102-8616, 197-9052, 8N-9639
(3) Torque for six bolts ...................... 1150 ± 60 N·m S/N: S2R1-Up
(840 ± 44 lb ft) Part No.: 102-8616, 197-9052, 8N-9639
S/N: S2S1-Up
i03105503
Part No.: 102-8616, 197-9052, 8N-9639
Vibration Damper Guard S/N: S2T1-Up
Part No.: 102-8616, 197-9052, 8N-9639
Part No.: 334-4642, 334-4644 Part No.: 102-8616, 197-9052, 8N-9639
Part No.: 197-9052, 8N-9639 Part No.: 102-8616, 197-9052, 8N-9639
RENR5077-11 143
Part No.: 197-9052, 8N-9639 Note: Before you tighten the bolts, apply a
S/N: S2Z1-Up molybdenum disulfide grease to the threads of the
bolts.
(2) Torque for the bolts ...................... 1150 ± 60 N·m

(848 ± 44 lb ft)
g01393058
Illustration 186
Typical example
i03742222
Stub Shaft (Front)

SMCS Code: 1237
Part No.: 334-0958
S/N: M8B1-Up
g01744573
Illustration 187
Typical example
Note: The alignment mark on the stub shaft (3) must

be aligned with the mark on the adapter (1).
144 RENR5077-11
i03879148
Stub Shaft (Front)

SMCS Code: 1237
Part No.: 7W-5237
S/N: S2A1-Up
Part No.: 334-0956
S/N: M8B1-Up
Part No.: 7W-5237
S/N: S2B1-Up
Part No.: 7W-5237
S/N: S2D1-Up
Part No.: 7W-5237
S/N: S2E1-Up
Part No.: 7W-5237
S/N: S2F1-Up
Part No.: 7W-5237
S/N: S2Z1-Up
g00278463
Illustration 188
Low kW (HP) attachments
RENR5077-11 145
g00278464
Illustration 189
High kW (HP) attachments
(1) Crankshaft Part No.: 7W-3629

S/N: S2K1-Up
(2) Adapter
Part No.: 7W-3629
(3) Bolts S/N: S2L1-Up
Apply a molybdenum disulfide grease under the Part No.: 7W-3629

bolt heads and to the threads before assembly. S/N: S2M1-Up
Torque ......................... 1150 ± 60 N·m (850 ± 44) Part No.: 7W-3629
S/N: S2N1-Up
(4) Alignment mark
Part No.: 7W-3629
Align the alignment mark on the stub shaft with the S/N: S2P1-Up
alignment mark on the adapter.
Part No.: 7W-3629
S/N: S2R1-Up
i03292468
Part No.: 7W-3629
Stub Shaft (Front) S/N: S2S1-Up
SMCS Code: 1237 Part No.: 7W-3629

S/N: S2T1-Up
Part No.: 7W-3629
S/N: S2E1-Up Part No.: 7W-3629
S/N: S2W1-Up
Part No.: 7W-3629
S/N: PAG1-Up Part No.: 7W-3629
S/N: S2X1-Up
Part No.: 7W-3629
S/N: S2G1-Up Part No.: 7W-3629
S/N: S2Y1-Up
Part No.: 7W-3629
S/N: MKH1-Up
Part No.: 7W-3629
S/N: S2H1-Up
Part No.: 7W-3629
S/N: S2J1-Up
146 RENR5077-11
i03577893
Auxiliary Drive Pulley

SMCS Code: 1205
Part No.: 334-5309
S/N: M8A1-Up
Part No.: 334-5309
S/N: M8B1-Up
g01676708
Illustration 190
Before assembly, apply molybdenum disulfide grease

to the shoulder of the bolt heads and to the threads
of the bolt.
(1) Torque for 12 bolts ..................... 1150 ± 150 N·m

(840 ± 110 lb ft)
g01906433
Illustration 191
(1) Lubricate the sealing lip of the lip type seal with
i01940316
Auxiliary Drive Shaft

SMCS Code: 1165; 1207
Part No.: 209-3562
S/N: M8A1-Up
Part No.: 209-3559, 209-3560, 209-3561,
209-3562, 7N-8042
S/N: S2A1-Up
RENR5077-11 147
Part No.: 209-3562 Part No.: 209-3559, 209-3560, 209-3561,

S/N: M8B1-Up 209-3562, 7N-8042
S/N: S2T1-Up
Part No.: 209-3559, 209-3560, 209-3561,
209-3562, 7N-8042 Part No.: 209-3559, 209-3560, 209-3561,
S/N: S2B1-Up 209-3562, 7N-8042
S/N: S2W1-Up
Part No.: 209-3559, 209-3560, 209-3562,
7N-8042 Part No.: 209-3559, 209-3560, 209-3561,
S/N: S2D1-Up 209-3562, 7N-8042
S/N: S2X1-Up
Part No.: 209-3559, 209-3560, 209-3562,
7N-8042 Part No.: 209-3559, 209-3561, 209-3562
S/N: S2E1-Up S/N: S2Y1-Up
Part No.: 209-3559, 209-3561, 209-3562 Part No.: 209-3559, 209-3560, 209-3562,
S/N: S2F1-Up 7N-8042
S/N: S2Z1-Up
Part No.: 209-3562
S/N: MRG1-Up
Part No.: 209-3559, 7N-8042
S/N: PAG1-Up
Part No.: 209-3559, 209-3560, 209-3561,
209-3562, 7N-8042
S/N: S2G1-Up
Part No.: 209-3559, 209-3562, 7N-8042
S/N: MKH1-Up
Part No.: 209-3559, 209-3560, 209-3561,
209-3562, 7N-8042
S/N: S2H1-Up
Part No.: 209-3559, 209-3560, 209-3562,
7N-8042
S/N: S2J1-Up
Part No.: 209-3559, 209-3560, 209-3562,
7N-8042
S/N: S2K1-Up Illustration 192
g00280784
Part No.: 209-3559, 209-3560, 209-3562,

7N-8042 (1) Bolt
S/N: S2L1-Up Torque ............................ 47 ± 9 N·m (35 ± 6 lb ft)
Part No.: 209-3559, 209-3560, 209-3561,
209-3562 Install the seal as the seal is shown. Lubricate the
S/N: S2M1-Up sealing lip with the lubricant that is being sealed.
Part No.: 209-3559, 209-3560, 209-3562,

7N-8042
S/N: S2N1-Up
Part No.: 209-3559, 209-3560, 209-3561,
209-3562, 7N-8042
S/N: S2P1-Up
Part No.: 209-3559, 209-3560, 209-3561,
209-3562, 7N-8042
S/N: S2R1-Up
Part No.: 209-3559, 209-3560, 209-3561,
209-3562, 7N-8042
S/N: S2S1-Up
148 RENR5077-11
i03859469
Belt Tension Chart

SMCS Code: 1357
Part No.: 7N-9693
S/N: S2A1-Up
Part No.: 7N-9693
S/N: S2B1-Up
Part No.: 7N-9693
S/N: S2G1-Up
Part No.: 7N-9693
S/N: S2H1-Up
Part No.: 7N-9693
S/N: S2R1-Up
The new belt tension chart has been standardized.

The belt tension chart eliminates confusion about the
correct belt tension to use. Studies were completed
with different belt suppliers and the information that
was gathered from the studies was developed into a
new belt tension for each belt size.
Table 9
Belt Tension Chart
SAE or RMA Belt SIze Width of Belt (Top Belt Tension “Initial”(1) Belt Tension “Used”(2)(3)
Reference)
IN MM IN MM LB N LB N
3/8 (0.380) 10A 0.42 10.72 145±10 645±44 70±10 311±44
7/16 (0.440) 11A 0.46 11.68 155±10 689±44 75±10 333±44
1/2 (0.500) 13A 0.55 13.89 165±10 734±44 80±10 356±44
5V/5VX 5V 0.63 15.88 180±10 801±44 85±10 378±44
11/16 (0.600) 15A 0.69 17.48 180±10 801±44 85±10 378±44
3/4 (0.660) 17A 0.75 19.05 205±10 912±44 95±10 422±44
7/8 (0.790) 20A 0.88 22.23 205±10 912±44 95±10 422±44
15/16 N/A 0.98 23.83 205±10 912±44 95±10 422±44
4K 4PK 0.54 13.72 145±10 645±44 60±10 267±44
6K 6PK 0.82 20.94 215±10 956±44 90±10 400±44
8K 8PK 1.1 27.82 285±10 1179±44 115±10 511±44
10K 10PK 1.38 35.05 355±10 1579±44 145±10 645±44
12K 12PK 1.66 42.16 425±10 1891±44 175±10 778±44
14K 14PK 1.94 49.28 495±10 2202±44 205±10 912±44
15K 15PK 2.08 52.83 530±10 2358±44 215±10 956±44
(1) Belt Tension“Initial ” is for a new belt.
(2) Belt tension “Used” is for a belt that has operated for more than 30 minutes of operation at the rated speed..
(3) If a belt falls below the “Used” belt tension, the belt should be tightened again to 80% of the “Initial” belt tension.
Note: The chart does not apply to belts that use a

spring loaded tensioner.
RENR5077-11 149
For more accurate results, a Clavis frequency gauge

should be used in order to measure the natural
frequency of the belt. By the use of a formula, the
natural frequency is converted into the belt tension
force. If the Clavis frequency gauge can not be used,
then use the appropriate Kent-Moore belt tension
gauge to measure the belt tension force.
When matched sets of belts are used, check the

tension of all the belts in order to verify that the lowest
belt is in the acceptable tolerance range. Variations
in tension between the belts can vary by as much
as 65 pounds.
In order to determine the tension of a “banded” belt,

refer to the chart above. Multiply the tension value
of the belt by the number of belts that are banded
together.Two 1/2 inch belts would require a used
belt tension equal to twice the value of the used belt
tension for one 1/2 inch belt (2 X 80 = 160 lb).
i02899402
Belt Tension Chart

SMCS Code: 1357
Part No.: 197-9087
Note: Do not use the belt tension chart for belts with
tensioners that are spring loaded.
Table 10
Belt Tension Chart
Suggested Suggested
Gauge Reading Gauge Gauge
(Force) Belt Tension Belt Tension (Frequency)
Width of
Size of Belt (Frequency) (Frequency)
Belt
Belt Tension Belt Tension “Initial”(1) “Used”(2)(3)
Basic
(Force) (Force) Gauge
Gauge
“Initial” “Used” Number
(1) (2)(3)
Number
8 - RIB 27.82 mm 800 ± 22 N 489 ± 44 N Clavis Type

BT-33-109 98 ± 10 HZ 76 ± 8 HZ
POLY - RIB (1.095 inch) (180 ± 5 lb) (110 ± 10 lb) 14
Measure the tension of the belt that is farthest from the engine.
(1) Belt tension “lnitial” is for a new belt.
(2) Belt tension “Used” is for a belt that has operated for 30 minutes or more of operation at the rated speed.
(3) If a belt falls below the “Used” belt tension, the belt should be tightened again to the high side of the “Used” belt tension.
150 RENR5077-11
i03879943
Alternator and Regulator

SMCS Code: 1405
Part No.: 333-1184
g02125953 g02125979
View A-A
Voltage ............................................................... 24 V
(2) (B+) terminal. Final installation torque for the
Amperage ..................................................... 68 Amp nut ....................... 6.2 ± 0.6 N·m (54.9 ± 5.3 lb in)
Note: Load the battery with a carbon pile 4C-4911 Note: Use a 7/16 ring terminal for (B+) terminal.
Battery Load Tester in order to get the maximum
alternator output. (3) The peak voltage for (R) terminal must not be
less than the output voltage for (B+) terminal.
Polarity ........................................... Insulated ground
(4) Final installation torque for the
Rotation ............................................ Either direction fastener .......................... 88 ± 7 N·m (65 ± 5 lb ft)
Minimum full load current at 5000 rpm ......... 68 Amp (5) (S) terminal. Final installation torque for the
nut ............... 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in)
Minimum full load current at 2000 rpm ......... 42 Amp
(6) (B-) terminal. Final installation torque for the
Output voltage ............................................. 28 ± 1 V nut ....................... 6.2 ± 0.6 N·m (54.9 ± 5.3 lb in)
(1) Final installation torque for the flange (7) Voltage regulator assembly
nut ................................ 102 ± 7 N·m (75 ± 5 lb ft)
Voltage setting ............................. No adjustment
Permissible voltage range .................. 27 to 29 V
i02899397
Alternator Mounting
SMCS Code: 1405
Part No.: 335-4161, 7E-4836
S/N: M8A1-Up
RENR5077-11 151
Part No.: 7E-4836 Part No.: 7E-4836

Part No.: 335-4161, 7E-4836 Part No.: 7E-4836
Part No.: 7E-4836
S/N: S2B1-Up
Part No.: 7E-4836
S/N: S2D1-Up
Part No.: 7E-4836
S/N: S2E1-Up
Part No.: 7E-4836
S/N: S2F1-Up
Part No.: 7E-4836
S/N: B5G1-Up
Part No.: 7E-4836
S/N: MRG1-Up
Part No.: 7E-4836
S/N: PAG1-Up
Part No.: 7E-4836
S/N: S2G1-Up g01446906
Illustration 195
Part No.: 7E-4836
S/N: MKH1-Up Note: Maximum misalignment between pulley
assembly (3) and pulley (1) is 0.4 degrees.
Part No.: 7E-4836
S/N: S2H1-Up (2) Torque for the pulley retaining nut .. 110 ± 10 N·m
(80 ± 7 lb ft)
Part No.: 7E-4836
S/N: S2J1-Up
(4) Adjust the belt tension of the serpentine belt
Part No.: 7E-4836 according to the 197-9087 Tension Chart.
S/N: S2K1-Up
(5) Lubricate the sealing lip of the lip type seal lightly
Part No.: 7E-4836 with the lubricant that is being sealed.
S/N: S2L1-Up
Part No.: 7E-4836 i02945902
S/N: S2M1-Up
Electric Starting Motor
Part No.: 7E-4836
S/N: S2N1-Up SMCS Code: 1453
Part No.: 7E-4836 Part No.: 207-1557, 207-1562
S/N: S2P1-Up S/N: M8A1-Up
Part No.: 7E-4836 Part No.: 207-1557, 207-1562
S/N: S2R1-Up S/N: S2A1-Up
Part No.: 7E-4836 Part No.: 207-1557, 207-1562
S/N: S2S1-Up S/N: M8B1-Up
Part No.: 7E-4836 Part No.: 207-1557, 207-1562
S/N: S2T1-Up S/N: S2B1-Up
Part No.: 7E-4836 Part No.: 207-1557, 207-1562
S/N: S2W1-Up S/N: S2D1-Up
Part No.: 7E-4836 Part No.: 207-1557, 207-1562
S/N: S2X1-Up S/N: S2E1-Up
152 RENR5077-11
Part No.: 207-1557, 207-1562

S/N: S2F1-Up
Part No.: 207-1557, 207-1562
S/N: PAG1-Up
Part No.: 207-1557, 207-1562
S/N: S2G1-Up
Part No.: 207-1557, 207-1562
S/N: MKH1-Up
Part No.: 207-1557, 207-1562
S/N: S2H1-Up
Part No.: 207-1557, 207-1562
g01460088
S/N: S2J1-Up Illustration 196
Part No.: 207-1557, 207-1562

S/N: S2K1-Up
Part No.: 207-1557, 207-1562
S/N: S2L1-Up
Part No.: 207-1557, 207-1562
S/N: S2M1-Up
Part No.: 207-1557, 207-1562
S/N: S2N1-Up
Part No.: 207-1557, 207-1562
S/N: S2P1-Up
Part No.: 207-1557, 207-1562 Illustration 197
g01460089
S/N: S2R1-Up
View A-A
Part No.: 207-1557, 207-1562
S/N: S2S1-Up When the electric starting motor is viewed from
the drive end, the motor rotates in the following
Part No.: 207-1557, 207-1562 direction. ................................................... Clockwise
S/N: S2T1-Up
No load conditions at 25 °C (77 °F)
Part No.: 207-1557, 207-1562
S/N: S2W1-Up Speed ...................................... 7643 ± 1683 rpm
Current draw ............................. 76.5 ± 14.5 Amp
Part No.: 207-1557, 207-1562 Voltage ......................................................... 23 V
S/N: S2X1-Up
Part No.: 207-1557, 207-1562 (1) Final installation torque for the ground terminal
S/N: S2Y1-Up nut ....................... 30.5 ± 3.5 N·m (270 ± 30 lb in)
Part No.: 207-1557, 207-1562 (2) Final installation torque for the battery terminal
S/N: S2Z1-Up nut ....................... 30.5 ± 3.5 N·m (270 ± 30 lb in)
(3) Final installation torque for the ground terminal

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

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

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

terminal nut ................... 8 ± 3 N·m (70 ± 27 lb in)
Solenoid
RENR5077-11 153
Current consumption at 20 V and 25 °C (77 °F) Tighten the bolts evenly in small increases until
the following torque is reached: ............... 80 N·m
Pull in windings ....................................... 57 Amp (60 lb ft)
Hold in windings ..................................... 16 Amp
(2) Bolt
(B) Clearance between the pinion and the
housing ................................. 9.1 mm (0.36 inch) Torque ....................................... 36 N·m (27 lb ft)
(3) Bolt
i02787858
Torque ....................................... 78 N·m (60 lb ft)
Air Starting Motor
(4) Bolt (pinion)
SMCS Code: 1451
Torque ...................................... 110 N·m (80 lb ft)
Part No.: 7C-3371, 8N-8477
S/N: S2A1-Up (5) Rotor clamp nut
Part No.: 7C-3371, 8N-8477 Tighten the rotor clamp nut until the following
S/N: S2B1-Up clearance between the rear end plate and the
Part No.: 8N-8477 rotor is reached: ........................ 0.03 to 0.08 mm
S/N: S2G1-Up (0.001 to 0.003 inch)
Part No.: 8N-8477 Check the clearance again after the bolt for the rotor
S/N: S2H1-Up clamp nut is tightened.
Part No.: 8N-8477 (6) Rotor retainer bolt

S/N: S2J1-Up
Torque ..................................... 120 N·m (90 lb ft)
Part No.: 8N-8477
S/N: S2M1-Up
i02817180
Part No.: 7C-3371, 8N-8477
S/N: S2P1-Up Air Starting Motor Pressure
Part No.: 7C-3371, 8N-8477 Regulating Valve
S/N: S2R1-Up
SMCS Code: 1462
Part No.: 7C-3371
S/N: S2W1-Up Part No.: 1L-2073
S/N: M8A1-Up
Part No.: 8N-8477
S/N: S2X1-Up Part No.: 1L-2073
S/N: S2A1-Up
Part No.: 7C-3371, 8N-8477
S/N: S2Z1-Up Part No.: 1L-2073
S/N: M8B1-Up
Part No.: 1L-2073
S/N: S2B1-Up
Part No.: 1L-2073
S/N: S2D1-Up
Part No.: 1L-2073
S/N: S2E1-Up
Part No.: 1L-2073
S/N: S2F1-Up
Part No.: 1L-2073
S/N: PAG1-Up
g01392582
Illustration 198 Part No.: 1L-2073
Typical example S/N: S2G1-Up
(1) Cover Part No.: 1L-2073

S/N: S2H1-Up
154 RENR5077-11
Part No.: 1L-2073 (3) Outlet pressure at outlet port ...... 620 to 750 kPa
S/N: S2J1-Up (90 to 110 psi)
Part No.: 1L-2073
S/N: S2K1-Up i01668530
Part No.: 1L-2073 Jacket Water Heater

S/N: S2L1-Up
SMCS Code: 1383
Part No.: 1L-2073
S/N: S2M1-Up Part No.: 7E-6247
S/N: M8A1-Up
Part No.: 1L-2073
S/N: S2N1-Up Part No.: 7E-6247
S/N: S2A1-Up
Part No.: 1L-2073
S/N: S2P1-Up Part No.: 7E-6247
S/N: M8B1-Up
Part No.: 1L-2073
S/N: S2R1-Up Part No.: 7E-6247
S/N: S2B1-Up
Part No.: 1L-2073
S/N: S2S1-Up Part No.: 7E-6247
S/N: S2D1-Up
Part No.: 1L-2073
S/N: S2T1-Up Part No.: 7E-6247
S/N: S2E1-Up
Part No.: 1L-2073
S/N: S2W1-Up Part No.: 7E-6247
S/N: PAG1-Up
Part No.: 1L-2073
S/N: S2X1-Up Part No.: 7E-6247
S/N: S2G1-Up
Part No.: 1L-2073
S/N: S2Y1-Up Part No.: 7E-6247
S/N: MKH1-Up
Part No.: 1L-2073
S/N: S2Z1-Up Part No.: 7E-6247
S/N: S2H1-Up
Part No.: 7E-6247
S/N: S2J1-Up
Part No.: 7E-6247
S/N: S2K1-Up
Part No.: 7E-6247
S/N: S2L1-Up
Part No.: 7E-6247
S/N: S2M1-Up
Part No.: 7E-6247
S/N: S2N1-Up
Part No.: 7E-6247
S/N: S2P1-Up
Part No.: 7E-6247
S/N: S2R1-Up
g01392594
Part No.: 7E-6247
Illustration 199 S/N: S2S1-Up
(1) Bolt
Part No.: 7E-6247
(2) Inlet port S/N: S2T1-Up
Inlet pressure ........................ 1700 kPa (250 psi) Part No.: 7E-6247
Maximum inlet pressure ....... 3100 kPa (450 psi) S/N: S2W1-Up
RENR5077-11 155
Part No.: 7E-6247 Part No.: 232-0013, 232-0014

S/N: S2X1-Up S/N: MKH1-Up
Part No.: 7E-6247 Part No.: 232-0014
Part No.: 232-0013, 232-0014
S/N: S2J1-Up
Part No.: 232-0013, 232-0014
S/N: S2K1-Up
Part No.: 232-0013, 232-0014
S/N: S2L1-Up
Part No.: 232-0013, 232-0014
S/N: S2M1-Up
Part No.: 232-0013, 232-0014
S/N: S2N1-Up
g00279581
Illustration 200
Typical example
Power ...................................................... 3000 Watts
Voltage ...................................................... 120/240 V
(1) Hose
Assemble the hose in order to maintain a gradual rise

from the heater outlet to the engine.
(2) Jacket water heater
(3) Reference dimension .. 60 ± 6 mm (2.4 ± .2 inch)
(4) Thermostat
(5) Coolant outlet
(6) Coolant inlet
i02053647
Engine Harness
(Rigid Wiring Harness)
SMCS Code: 1408
Part No.: 232-0013, 232-0014
S/N: MRG1-Up
Part No.: 232-0014
S/N: S2G1-Up
156 RENR5077-11
g01053142
Illustration 201
Typical example
RENR5077-11 157
g01053143
Illustration 202
Typical example
(1) Nut (6) Nut

Torque ...................................... 2.5 N·m (22 lb in) Torque ...................................... 2.5 N·m (22 lb in)
(2) Nut (7) Nut

Torque ......................................... 8 N·m (70 lb in) Torque ...................................... 2.5 N·m (22 lb in)
(3) Nut
i03292465
Torque ...................................... 2.5 N·m (22 lb in)
Coolant Level Switch
(4) Nut
SMCS Code: 1395; 7422
Torque ........................................ 15 N·m (11 lb ft)
Part No.: 2N-9768
(5) Nut S/N: M8A1-Up
Torque ......................................... 10 N·m (7 lb ft) Part No.: 2N-9768

S/N: S2A1-Up
158 RENR5077-11
Part No.: 2N-9768

S/N: M8B1-Up
Part No.: 2N-9768
S/N: S2B1-Up
Part No.: 2N-9768
S/N: S2D1-Up
Part No.: 2N-9768
S/N: S2E1-Up
Part No.: 2N-9768
S/N: B5G1-Up
Part No.: 2N-9768
g01676703
Part No.: 2N-9768 Note: The liquid level switch is shown in the high
S/N: PAG1-Up liquid level position.
Part No.: 2N-9768
S/N: S2G1-Up (A) When the liquid level switch activates,
approximate travel distance of the liquid level
Part No.: 2N-9768 switch is the following distance. .............. 6.4 mm
S/N: MKH1-Up (0.25 inch)
Part No.: 2N-9768 Operating temperature range ............. −53 to 107 °C

S/N: S2H1-Up (−63 to 225 °F)
Part No.: 2N-9768 Contact position ............................... Normally closed
S/N: S2J1-Up
Part No.: 2N-9768 i02995920
S/N: S2K1-Up
Part No.: 2N-9768
Coolant Temperature Switch
S/N: S2L1-Up SMCS Code: 1395
Part No.: 2N-9768 Part No.: 3E-0264
S/N: S2N1-Up S/N: S2Z1-Up
Part No.: 2N-9768
S/N: S2P1-Up
Part No.: 2N-9768
S/N: S2R1-Up
Part No.: 2N-9768
S/N: S2S1-Up
Part No.: 2N-9768
S/N: S2T1-Up
Part No.: 2N-9768
S/N: S2W1-Up
Part No.: 2N-9768
g01392736
S/N: S2X1-Up Illustration 204
Part No.: 2N-9768 (1) Final installation torque for the temperature
S/N: S2Z1-Up switch group ............ 52.5 ± 7.5 N·m (39 ± 6 lb ft)
Contact position .......................................... Normally

closed below deactuation temperature
Actuation temperature ....... 27.0 ± 2.8 °C (81 ± 5 °F)

RENR5077-11 159
Minimum deactuation temperature ...... 20 °C (68 °F) i02896484
Operating temperature ........................ −40 to 150 °C Magnetic Switch

(−40 to 302 °F)
SMCS Code: 7499
i02869400 Part No.: 9X-8124
Fuel Pressure Sensor

SMCS Code: 7414
Part No.: 161-1705
g01135892
Illustration 205
g01442059
Illustration 206
(1) Final installation torque for the pressure sensor
group .......................... 10 ± 2 N·m (90 ± 18 lb in) (1) Final installation torque for the two
nuts ........................... 5.5 ± 0.5 N·m (50 ± 4 lb in)
Operating temperature ........................ −40 to 125 °C
(−40 to 257 °F) Operating temperature range ............. −60 to 121 °C
(−76 to 250 °F)
Operating voltage ........................... 5.00 ± 0.25 VDC
Operating voltage ......................................... 24 VDC
Contact position ................................. Normally open
Maximum pull-in voltage at 25 °C (77 °F) ..... 16 VDC
Maximum hold-in voltage at 25 °C (77 °F) ...... 8 VDC
Resistance at 20 °C (68 °F) ........ 27.50 ± 0.28 Ohms
Maximum current draw .............................. 1.25 Amp
i02894836
Coolant Level Sensor

SMCS Code: 7470
Part No.: 204-2518
S/N: M8A1-Up
Part No.: 204-2518, 239-9957
S/N: S2A1-Up
Part No.: 204-2518
S/N: M8B1-Up
160 RENR5077-11
Part No.: 204-2518, 239-9957

S/N: S2B1-Up
Part No.: 204-2518, 239-9957
S/N: S2D1-Up
Part No.: 204-2518, 239-9957
S/N: S2E1-Up
Part No.: 204-2518, 239-9957
S/N: S2F1-Up
Part No.: 204-2518, 239-9957
S/N: B5G1-Up
Part No.: 204-2518, 239-9957
g01440910
Part No.: 204-2518, 239-9957 (1) Final installation torque for the coolant level
S/N: PAG1-Up sensor group .................. 22 ± 3 N·m (16 ± 2 lb ft)
Part No.: 204-2518, 239-9957
S/N: S2G1-Up Operating temperature ........................ −40 to 125 °C
(−40 to 257 °F)
Part No.: 204-2518, 239-9957
S/N: MKH1-Up Operating voltage .................................. 7 to 32 VDC
Part No.: 204-2518, 239-9957

S/N: S2H1-Up i02845092
Part No.: 204-2518, 239-9957 Engine Oil Pressure Sensor

S/N: S2J1-Up
SMCS Code: 1924
Part No.: 204-2518, 239-9957
S/N: S2K1-Up Part No.: 194-6725
Part No.: 204-2518, 239-9957

S/N: S2L1-Up
Part No.: 204-2518, 239-9957
S/N: S2M1-Up
Part No.: 204-2518, 239-9957
S/N: S2N1-Up
Part No.: 204-2518, 239-9957
S/N: S2P1-Up
Part No.: 204-2518, 239-9957
S/N: S2R1-Up
Part No.: 204-2518, 239-9957 Illustration 208
g01068621
S/N: S2S1-Up
Part No.: 204-2518, 239-9957 group .......................... 10 ± 2 N·m (90 ± 18 lb in)
S/N: S2T1-Up
Part No.: 204-2518, 239-9957 Operating temperature ........................ −40 to 125 °C
S/N: S2W1-Up (−40 to 257 °F)
Part No.: 204-2518, 239-9957 Operating voltage ........................... 5.00 ± 0.25 VDC
S/N: S2X1-Up
Part No.: 204-2518, 239-9957
S/N: S2Y1-Up
Part No.: 204-2518, 239-9957
S/N: S2Z1-Up
RENR5077-11 161
i02030238 Part No.: 161-1703

S/N: S2E1-Up
Engine Oil Pressure Sensor
Part No.: 161-1703
SMCS Code: 1924 S/N: S2F1-Up
Part No.: 103-6092, 143-9695, 161-9931 Part No.: 161-1703
S/N: S2Z1-Up S/N: B5G1-Up
Part No.: 161-1703
S/N: MRG1-Up
Part No.: 161-1703
S/N: PAG1-Up
Part No.: 161-1703
S/N: S2G1-Up
Part No.: 161-1703
S/N: MKH1-Up
Part No.: 161-1703
S/N: S2H1-Up
g01046769 Part No.: 161-1703

Illustration 209
S/N: S2J1-Up
Typical example
Part No.: 161-1703
(1) Sensor assembly S/N: S2K1-Up
(2) Plug with socket A, socket B, and socket C Part No.: 161-1703
S/N: S2L1-Up
(3) Port fitting Part No.: 161-1703
Torque ........................ 10 ± 2 N·m (90 ± 18 lb in) S/N: S2M1-Up
Part No.: 161-1703
S/N: S2N1-Up
(−40 to 257 °F)
Part No.: 161-1703
Maximum input pressure (absolute S/N: S2P1-Up
pressure) ..................................... 1135 kPa (165 psi)
Part No.: 161-1703
Input supply voltage ............................. 5 ± 0.25 VDC S/N: S2R1-Up
Maximum supply current ................................. 20 mA Part No.: 161-1703

S/N: S2S1-Up
Install the sensor so that the pressure port is lower Part No.: 161-1703
than the wire end. Mount the sensor as close to S/N: S2T1-Up
vertical as possible.
Part No.: 161-1703
S/N: S2W1-Up
i02869431
Part No.: 161-1703
Turbocharger Inlet Pressure S/N: S2X1-Up
Sensor Part No.: 161-1703
Part No.: 161-1703 Part No.: 161-1703

Part No.: 161-1703

S/N: S2B1-Up
Part No.: 161-1703
S/N: S2D1-Up
162 RENR5077-11
i02847454
Turbocharger Outlet Pressure

Sensor
SMCS Code: 1052; 1917; 1919
Part No.: 161-1704
S/N: S2A1-Up
Part No.: 161-1704
S/N: S2B1-Up
Part No.: 161-1704
S/N: S2D1-Up
g01135892
Illustration 210
Part No.: 161-1704
S/N: S2E1-Up
group .......................... 10 ± 2 N·m (90 ± 18 lb in) Part No.: 161-1704
S/N: S2F1-Up
(−40 to 257 °F) Part No.: 161-1704
S/N: B5G1-Up
Part No.: 161-1704
S/N: MRG1-Up
i02847453
Part No.: 161-1704
Turbocharger Outlet Pressure S/N: PAG1-Up
Sensor Part No.: 161-1704
S/N: S2G1-Up
SMCS Code: 1052; 1917; 1919
Part No.: 161-1704
Part No.: 194-6724 S/N: MKH1-Up
Part No.: 161-1704
S/N: S2H1-Up
Part No.: 161-1704
S/N: S2J1-Up
Part No.: 161-1704
S/N: S2K1-Up
Part No.: 161-1704
S/N: S2L1-Up
Part No.: 161-1704
S/N: S2M1-Up
Illustration 211
g01046622 Part No.: 161-1704
S/N: S2N1-Up
group .......................... 10 ± 2 N·m (90 ± 18 lb in) Part No.: 161-1704
S/N: S2P1-Up
Operating temperature ........................ −40 to 125 °C Part No.: 161-1704
(−40 to 257 °F) S/N: S2R1-Up
Operating voltage ........................... 5.00 ± 0.25 VDC Part No.: 161-1704
S/N: S2S1-Up
Part No.: 161-1704
S/N: S2T1-Up
RENR5077-11 163
Part No.: 161-1704 Operating temperature ........................ −40 to 120 °C

S/N: S2W1-Up (−40 to 248 °F)
Part No.: 161-1704 Operating voltage .......................... 4.75 to 8.50 VDC
S/N: S2X1-Up
Part No.: 161-1704 i02987360
S/N: S2Y1-Up
Engine Coolant Temperature
Part No.: 161-1704
S/N: S2Z1-Up Sensor
SMCS Code: 1395
Part No.: 102-7532
g01133887
Illustration 212

group .......................... 10 ± 2 N·m (90 ± 18 lb in) Illustration 214
g01513773
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)
i02987333
Operating voltage .......................... 4.75 to 8.50 VDC
Aftercooler Coolant
Temperature Sensor
SMCS Code: 1063; 1395
Part No.: 102-7532
g01513773
Illustration 213
(1) Final installation torque for the temperature

sensor group .................. 20 ± 3 N·m (15 ± 2 lb ft)
164 RENR5077-11
i02894896 i03911354
Turbocharger Exhaust Engine Speed/Timing Sensor

Temperature Sensor SMCS Code: 1905; 1907
SMCS Code: 1052; 1919 Part No.: 265-9034
S/N: M8A1-Up
Part No.: 164-2441
Part No.: 265-9034
S/N: M8B1-Up
g01441005
Illustration 215
(2) Exhaust temperature sensor group
g02127933
Illustration 216
Note: Apply 4C-5599 Anti-Seize Compound to the
threads of the adapter (1) before installation. (1) Final installation torque for the speed sensor
group ............................. 40 ± 5 N·m (30 ± 4 lb ft)
(1) Final installation torque for the
adapter .......................... 45 ± 5 N·m (33 ± 4 lb ft) Operating voltage ............................ 7.5 to 14.0 VDC
Operating temperature ........................ −40 to 850 °C Operating temperature ........................ −40 to 120 °C
(−40 to 1562 °F) (−40 to 248 °F)
Operating voltage .............................. 7.5 to 8.5 VDC Output frequency ................................ 9 to 10000 Hz
Output type ...................................................... PWM

i02995988
Output frequency ................................. 500 ± 100 Hz
Engine Speed/Timing Sensor
SMCS Code: 1905; 1907
Part No.: 102-9029
S/N: S2A1-Up
Part No.: 102-9029
S/N: S2B1-Up
Part No.: 102-9029
S/N: S2D1-Up
Part No.: 102-9029
S/N: S2E1-Up
Part No.: 102-9029
S/N: S2F1-Up
Part No.: 102-9029
S/N: B5G1-Up
Part No.: 102-9029
S/N: MRG1-Up
RENR5077-11 165
Part No.: 102-9029 Note: Before installation, coat the sensor assembly's
S/N: PAG1-Up threads with 4c-5599 Anti-Seize Compound.
Part No.: 102-9029 (1) Final installation torque for the sensor
S/N: S2G1-Up assembly ....................... 40 ± 5 N·m (30 ± 4 lb ft)
Part No.: 102-9029
S/N: MKH1-Up
(−40 to 250 °F)
Part No.: 102-9029
S/N: S2H1-Up Operating voltage ..................................... 12 to 14 V
Part No.: 102-9029 (2) Sliphead

S/N: S2J1-Up
Before installation, make sure that the sliphead is
Part No.: 102-9029 fully extended.
S/N: S2K1-Up
Part No.: 102-9029 i03535661
S/N: S2L1-Up
Part No.: 102-9029
S/N: S2M1-Up SMCS Code: 1905; 1907
Part No.: 102-9029 Part No.: 273-5041
S/N: S2N1-Up S/N: S2A1-Up
Part No.: 102-9029 Part No.: 273-5041
S/N: S2P1-Up S/N: S2B1-Up
Part No.: 102-9029 Part No.: 273-5041
S/N: S2R1-Up S/N: S2D1-Up
Part No.: 102-9029 Part No.: 273-5041
S/N: S2S1-Up S/N: S2E1-Up
Part No.: 102-9029 Part No.: 273-5041
S/N: S2T1-Up S/N: B5G1-Up
Part No.: 102-9029 Part No.: 273-5041
S/N: S2W1-Up S/N: MRG1-Up
Part No.: 102-9029 Part No.: 273-5041
S/N: S2X1-Up S/N: PAG1-Up
Part No.: 102-9029 Part No.: 273-5041
S/N: S2Y1-Up S/N: S2G1-Up
Part No.: 102-9029 Part No.: 273-5041
S/N: S2Z1-Up S/N: MKH1-Up
Part No.: 273-5041
S/N: S2H1-Up
Part No.: 273-5041
S/N: S2J1-Up
Part No.: 273-5041
S/N: S2K1-Up
Part No.: 273-5041
S/N: S2L1-Up
Part No.: 273-5041
S/N: S2N1-Up
Illustration 217
g01519083 Part No.: 273-5041
S/N: S2P1-Up
166 RENR5077-11
Part No.: 273-5041 Part No.: 129-6628

S/N: S2R1-Up S/N: B5G1-Up
Part No.: 273-5041 Part No.: 129-6628
S/N: S2S1-Up S/N: MRG1-Up
Part No.: 273-5041 Part No.: 129-6628
S/N: S2T1-Up S/N: PAG1-Up
Part No.: 273-5041 Part No.: 129-6628
S/N: S2W1-Up S/N: S2G1-Up
Part No.: 273-5041 Part No.: 129-6628
S/N: S2X1-Up S/N: MKH1-Up
Part No.: 273-5041 Part No.: 129-6628
Part No.: 129-6628
S/N: S2J1-Up
Part No.: 129-6628
S/N: S2K1-Up
Part No.: 129-6628
S/N: S2L1-Up
Part No.: 129-6628
S/N: S2N1-Up
Part No.: 129-6628
S/N: S2P1-Up
g01441500 Part No.: 129-6628

Illustration 218
S/N: S2R1-Up
(1) Final installation torque for the speed sensor Part No.: 129-6628
group ............................. 40 ± 5 N·m (30 ± 4 lb ft) S/N: S2S1-Up
Operating temperature ........................ −40 to 120 °C Part No.: 129-6628

(−40 to 248 °F) S/N: S2T1-Up
Operating voltage ................................ 12 to 14 VDC Part No.: 129-6628

S/N: S2W1-Up
Output frequency ............................... 9 Hz to 10 kHz Part No.: 129-6628
S/N: S2X1-Up
Duty cycle ......................................................... 50 %
Part No.: 129-6628
S/N: S2Z1-Up
i03291644

SMCS Code: 1905; 1907
Part No.: 129-6628
S/N: S2A1-Up
Part No.: 129-6628
S/N: S2B1-Up
Part No.: 129-6628
S/N: S2D1-Up
Part No.: 129-6628
S/N: S2E1-Up g01706934
Illustration 219
RENR5077-11 167
Note: Before assembly, apply 4C-5599 Anti-Seize Part No.: 127-1008

Compound on the threads of speed sensor group. S/N: S2T1-Up
(1) Torque for the speed sensor group .... 45 ± 5 N·m Part No.: 127-1008
(33 ± 4 lb ft) S/N: S2W1-Up
Part No.: 127-1008
S/N: S2X1-Up
(−40 to 250 °F)
Part No.: 129-6628
Operating voltage ..................................... 12 to 14 V S/N: S2Z1-Up
i02788159

SMCS Code: 1905; 1907
Part No.: 127-1008
S/N: S2A1-Up
Part No.: 127-1008
S/N: S2B1-Up
Part No.: 127-1008
S/N: S2D1-Up
g01046790
S/N: S2E1-Up Typical example
Part No.: 127-1008 (1) Sensor slip head

S/N: B5G1-Up
1. Extend the sensor slip head to a minimum
Part No.: 127-1008
distance of 4 mm (.16 inch) prior to installation.
S/N: MRG1-Up
Part No.: 127-1008 (2) Control assembly
S/N: PAG1-Up
Put 4C-5599 Anti-Seize Compound on the
Part No.: 127-1008 threads.
S/N: S2G1-Up Torque ............................ 40 ± 5 N·m (30 ± 4 lb ft)
Operating temperature ............ −40 °C to 121 °C
Part No.: 127-1008 (−40 °F to 250 °F)
S/N: MKH1-Up Input supply voltage ....................... 12 to 14 VDC
Part No.: 127-1008
S/N: S2H1-Up (3) Plug with socket A, socket B, and socket C.
Part No.: 127-1008

S/N: S2J1-Up
Part No.: 127-1008
S/N: S2K1-Up
Part No.: 127-1008
S/N: S2L1-Up
Part No.: 127-1008
S/N: S2N1-Up
Part No.: 127-1008
S/N: S2P1-Up
Part No.: 127-1008
S/N: S2R1-Up
Part No.: 127-1008
S/N: S2S1-Up
168 RENR5077-11
i02958537 Maximum input pressure (absolute

pressure) ......................................... 116 kPa (17 psi)
Crankcase Pressure Sensor
SMCS Code: 1916
Maximum supply current ................................. 20 mA
Part No.: 161-9926, 163-8492
S/N: S2D1-Up
Note: Install the pressure sensor group so that the
Part No.: 161-9926, 163-8492 pressure port is lower than the wire end. Mount
S/N: S2E1-Up the pressure sensor group as close to vertical as
possible.
Part No.: 161-9926, 163-8492
S/N: S2F1-Up
i02845102
Part No.: 163-8492
S/N: B5G1-Up Atmospheric Pressure Sensor
S/N: MRG1-Up
Part No.: 194-6722
Part No.: 163-8492 S/N: M8A1-Up
S/N: PAG1-Up
Part No.: 194-6722
Part No.: 163-8492 S/N: M8B1-Up
S/N: MKH1-Up
Part No.: 163-8492
S/N: S2S1-Up
Part No.: 163-8492
S/N: S2T1-Up
Part No.: 163-8492
S/N: S2W1-Up
Part No.: 163-8492
S/N: S2X1-Up
Part No.: 163-8492
S/N: S2Y1-Up
g01392045
Illustration 222
Part No.: 143-9696, 161-9926, 163-8492
S/N: S2Z1-Up
group .......................... 10 ± 2 N·m (90 ± 18 lb in)

(−40 to 257 °F)
i02847051
Atmospheric Pressure Sensor

SMCS Code: 1923
Part No.: 161-1703
Illustration 221
g01190345 S/N: S2A1-Up
Part No.: 161-1703
S/N: S2B1-Up
group .......................... 10 ± 2 N·m (90 ± 18 lb in)
Part No.: 161-1703
Operating temperature ........................ −40 to 125 °C S/N: S2D1-Up
(−40 to 257 °F)
RENR5077-11 169
Part No.: 161-1703

S/N: S2E1-Up
Part No.: 161-1703
S/N: S2F1-Up
Part No.: 161-1703
S/N: B5G1-Up
Part No.: 161-1703
S/N: MRG1-Up
Part No.: 161-1703
S/N: PAG1-Up
Part No.: 161-1703
g01133887
Part No.: 161-1703 (1) Final installation torque for the pressure sensor
S/N: MKH1-Up group .......................... 10 ± 2 N·m (90 ± 18 lb in)
Part No.: 161-1703
S/N: S2H1-Up Operating temperature ........................ −40 to 125 °C
(−40 to 257 °F)
Part No.: 161-1703
S/N: S2J1-Up Operating voltage ........................... 5.00 ± 0.25 VDC
Part No.: 161-1703

S/N: S2K1-Up i02958605
Part No.: 161-1703 Atmospheric Pressure Sensor

S/N: S2L1-Up
SMCS Code: 1923
Part No.: 161-1703
S/N: S2M1-Up Part No.: 161-9926
S/N: S2D1-Up
Part No.: 161-1703
S/N: S2N1-Up Part No.: 161-9926
S/N: S2E1-Up
Part No.: 161-1703
S/N: S2P1-Up Part No.: 161-9926
S/N: S2F1-Up
Part No.: 161-1703
S/N: S2R1-Up Part No.: 161-9926
S/N: S2Z1-Up
Part No.: 161-1703
S/N: S2S1-Up
Part No.: 161-1703
S/N: S2T1-Up
Part No.: 161-1703
S/N: S2W1-Up
Part No.: 161-1703
S/N: S2X1-Up
Part No.: 161-1703
S/N: S2Y1-Up
Part No.: 161-1703
S/N: S2Z1-Up Illustration 224
g01190345

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

(−40 to 257 °F)
170 RENR5077-11
Maximum input pressure (absolute i03001872

pressure) ......................................... 116 kPa (17 psi)
Engine Speed Sensor
SMCS Code: 1907
Maximum supply current ................................. 20 mA
Part No.: 189-5746
S/N: S2A1-Up
Note: Install the pressure sensor group so that the
pressure port is lower than the wire end. Mount Part No.: 189-5746
the pressure sensor group as close to vertical as S/N: S2B1-Up
possible.
Part No.: 189-5746
S/N: S2D1-Up
i03534581
Part No.: 189-5746
Engine Speed Sensor S/N: S2E1-Up
SMCS Code: 1907 Part No.: 189-5746
S/N: B5G1-Up
Part No.: 9X-5392
S/N: M8A1-Up Part No.: 189-5746
S/N: MRG1-Up
Part No.: 9X-5392
S/N: M8B1-Up Part No.: 189-5746
S/N: PAG1-Up
Part No.: 189-5746
S/N: S2G1-Up
Part No.: 189-5746
S/N: MKH1-Up
Part No.: 189-5746
S/N: S2H1-Up
Part No.: 189-5746
S/N: S2J1-Up
Part No.: 189-5746
S/N: S2K1-Up
g01448928
Illustration 225
Part No.: 189-5746
S/N: S2L1-Up
(−40 to 320 °F) Part No.: 189-5746
S/N: S2N1-Up
Clearance between the speed sensor group and the
flywheel ring gear ............................ 0.50 to 0.75 mm Part No.: 189-5746
(0.020 to 0.030 inch) S/N: S2P1-Up
Use the following procedure to install the speed Part No.: 189-5746
sensor group (1): S/N: S2R1-Up
Part No.: 189-5746
1. Install the speed sensor group into the 5/8 S/N: S2S1-Up
threaded hole and turn until the magnetic core
makes contact with a tooth of the flywheel ring Part No.: 189-5746
gear. S/N: S2T1-Up
2. Back out 180 degrees. Part No.: 189-5746

S/N: S2W1-Up
3. Tighten the nut to 25 ± 5 mm (221± 44 inch).
Part No.: 189-5746
S/N: S2X1-Up
Part No.: 189-5746
S/N: S2Z1-Up
RENR5077-11 171
g01521632
Illustration 226
(1) Final installation torque for locknut .... 25 ± 5 N·m

(18 ± 4 lb ft)

(−40 to 248 °F)
Resistance at 25 °C (77 °F) ............................. 142 Ω
Minimum air gap ..................... 0.50 mm (0.035 inch)
Screw the speed sensor into the hole by hand until

the end of the sensor barely contacts the gear tooth.
Then, back out the sensor by a 1/2 turn (180 degrees
in the counterclockwise direction).
172 RENR5077-11
Index Section
Index
A Engine Harness (Rigid Wiring Harness).............. 155
Engine Mount (Front) (Hydraulic Pump Drive or PTO
Accessory Drive........................................... 120, 122 Clutch) ............................................................... 138
Accessory Drive (Lower Left Hand)............. 123–124 Engine Oil Cooler Bypass and Cooling Jet Sequence
Accessory Drive (Upper Left Hand)..................... 131 Valves ............................................................ 63–64
Accessory Drive (Upper Left Hand, Reverse Engine Oil Filter ............................................... 66–67
Rotation) ............................................................ 132 Engine Oil Filter Base............................................ 73
Accessory Drive (Upper Right Hand) .. 126, 128, 130 Engine Oil Lines .................................................... 69
Accumulator........................................................... 33 Engine Oil Lines (Front Mounted Engine Oil
Aftercooler Coolant Temperature Sensor ............ 163 Filter).................................................................... 70
Air Cleaner............................................................. 41 Engine Oil Pan........................................... 76, 78, 80
Air Cleaner Adapter ......................................... 41–42 Engine Oil Pressure Sensor ........................ 160–161
Air Inlet and Exhaust Lines.................. 43–44, 47, 49 Engine Oil Pump.................................. 53, 55, 57, 59
Air Shutoff........................................................ 51–52 Engine Oil Scavenge Pump................................... 61
Air Starting Motor................................................. 153 Engine Oil Sump Pump ......................................... 85
Air Starting Motor Pressure Regulating Valve ..... 154 Engine Speed Sensor.......................................... 170
Alternator and Regulator ..................................... 150 Engine Speed/Timing Sensor ...................... 164–167
Alternator Mounting ............................................. 151 Engine Trunnion .................................................. 139
Atmospheric Pressure Sensor..................... 168–169 Exhaust Bypass Valve ..................................... 33–34
Auxiliary Drive Pulley........................................... 146 Exhaust Flange...................................................... 40
Auxiliary Drive Shaft ............................................ 147 Exhaust Manifold ................................. 35–36, 38–39
Auxiliary Water Pump ............................................ 87
F
B
Flexible Coupling ................................................. 137
Balancer Group (Front)......................................... 119 Flywheel .............................................................. 133
Belt Tension Chart ....................................... 148–149 Flywheel Housing ........................................ 134–135
Fuel Filter............................................................... 10
Fuel Filter (Primary)................................................. 8
C Fuel Filter Base ....................................................... 9
Fuel Injector........................................................... 14
Camshaft ......................................................... 15–20 Fuel Injector Mechanism ....................................... 12
Connecting Rod................................................... 102 Fuel Pressure Regulator........................................ 10
Connecting Rod and Main Bearing Journals ....... 104 Fuel Pressure Sensor.......................................... 159
Coolant Level Sensor .......................................... 160 Fuel Transfer Pump................................................ 11
Coolant Level Switch ........................................... 158
Coolant Temperature Switch ............................... 158
Cooling System Pressure Cap .............................. 89 G
Crankcase Breather................................... 73, 75–76
Crankcase Pressure Sensor................................ 168 Gear Group (Front)....................................... 115–116
Crankshaft .................................................. 105–106 Gear Group (Front) (Reverse Rotation)........ 111, 113
Crankshaft Wear Sleeves and Seals................... 108 Gear Group (Rear) ............................................... 117
Cylinder Block............................................ 90–91, 93
Cylinder Head........................................................ 22
Cylinder Head Valves ............................................ 24 H
Cylinder Liner ........................................................ 95
Housing (Front)............................................. 109–110
D
I
Duplex Engine Oil Filters ....................................... 71
Important Safety Information ................................... 2
E
J
Electric Starting Motor ......................................... 152
Engine Air Cleaner Service Indicator..................... 42 Jacket Water Heater............................................ 155
Engine Coolant Temperature Sensor .................. 163
Engine Design ..................................................... 5–7
RENR5077-11 173
Index Section
Magnetic Switch .................................................. 159
Piston and Rings (One-Piece Piston) .............. 95, 97

Intermediate Piston Ring (2) ........................ 96, 98
Oil Control Piston Ring (3) ........................... 96, 98
Pin Retainer (6)............................................ 96, 98
Piston Pin (5) ............................................... 96, 98
Top Piston Ring (1) ...................................... 95, 97
Piston and Rings (Two-Piece Piston) ............ 99, 101
Intermediate Piston Ring (2) ............................ 100
Oil Control Piston Ring (3) ............................... 100
Pin Retainer (6)................................................ 100
Piston Pin (5) ................................................... 100
Piston Pin Bore (4)........................................... 100
Top Piston Ring (1) ............................................ 99
Specifications Section ............................................. 5

Stub Shaft (Front) ........................................ 143–145
Table of Contents..................................................... 3
Turbocharger ................................................... 26–31
Turbocharger Exhaust Temperature Sensor ....... 164
Turbocharger Inlet Pressure Sensor ................... 161
Turbocharger Outlet Pressure Sensor......... 162–163
Turbocharger Support ........................................... 32
Valve Mechanism .................................................. 21

Vibration Damper......................................... 140–142
Vibration Damper Guard...................................... 143
Water Lines ........................................................... 83

Water Pump........................................................... 86
Water Temperature Regulator ............................... 82
174 RENR5077-11
Index Section
RENR5077-11 175
Index Section
©2010 Caterpillar Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge Printed in U.S.A.
All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.

Specifications 3500C Marine Engines

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Specifications 3500C Marine Engines

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RENR5077-11

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-

Stub Shaft (Front) ............................................... 143

Specifications Section Reverse rotation CW .................. 1, 8, 7, 2, 6, 5, 4, 3

S/N: S2E1-Up Engine Design

Number and arrangement of

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

Stroke .......................................... 190 mm (7.5 inch) Number and arrangement of

Firing order (injection sequence) Compression ratio ........................................... 15.5:1

Standard rotation Combustion ........................................ Direct injection

Valve lash Firing order (injection sequence)

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

Number and arrangement of

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

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

i01939608 Inlet ......................................... 0.50 mm (0.020 inch)

Number and arrangement of

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

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

Firing order (injection sequence) Bore ............................................. 170 mm (6.7 inch)

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

Valve lash When the crankshaft is viewed from the flywheel

Firing order (injection sequence) Part No.: 8N-6435

i03083460 Part No.: 8N-3481

Part No.: 7W-9741

Part No.: 115-7842, 7W-9741 Fuel Pressure Regulator

(2) 9N-4053 Spring

Outside diameter ............ 15.24 mm (0.600 inch) Part No.: 8N-6151

Part No.: 8N-6151

Part No.: 8N-6151 Minimum cracking pressure of bypass

Maximum pressure of fully open bypass Part No.: 224-9869

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

Fuel Injector Mechanism Part No.: 224-9869

Part No.: 256-3663 Part No.: 106-4586, 106-4595

Part No.: 106-4586

Note: End play for a new camshaft assembly is

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

(F) Extension of the dowel from the end of the

(6) Camshaft lobe height

In order to determine the height, use the procedure

1. Measure camshaft lobe height (6).

2. Measure base circle (8).

3. Subtract the base circle (Step 2) from the lobe

(5) Journal surface

(E) Specified camshaft lobe lift

Use the following procedure in order to determine the

2. Measure base circle (G).

(C) Thickness of a new thrust

(D) Dimensions for the journal surface

Note: End play for a new camshaft assembly is

i03021227 Bore in camshaft bearing after

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

i03021222 (F) Extension of the dowel from the end of the

Use the following procedure in order to determine the

1. Measure camshaft lobe height (H).