2 8

2 1
0G

2.4 G A S
liter
Mitsubishi

ENGINE
PARTS
MANUAL
P.O. BOX 310 EAGLE WI 53119 PRINTED IN U.S.A.

Revision 0: 09/12/06
2.4L Gas eNGINE Table of Contents

Quick Reference Guide . ................................................................................................................................ 1

Service Recommendations ........................................................................................................................... 2
ROCKER COVER . .................................................................................................................................................. 6
CYLINDER HEAD ................................................................................................................................................... 7
CYLINDER BLOCK ................................................................................................................................................. 8
COVER, REAR PLATE & PAN .............................................................................................................................. 10
PISTON & CRANKSHAFT .................................................................................................................................... 12
BALANCER ........................................................................................................................................................... 13
CAMSHAFT & VALVE . .......................................................................................................................................... 14
OIL PUMP & FILTER ............................................................................................................................................. 16
WATER PUMP ....................................................................................................................................................... 18
WATER PIPE & THERMOSTAT . ........................................................................................................................... 19
ENGINE HANGERS & ALTERNATOR BRACKET ............................................................................................... 20
SPARK PLUG CABLE & COIL .............................................................................................................................. 21
COMMoN PARTS DRAWING ............................................................................................................................... 22
Air Cleaner . ..................................................................................................................................................... 23
Battery . ............................................................................................................................................................. 24

legend
“ A R ” A S R E Q U I R ED
“ S T D ” S TA N D A R D S I Z E
“ O . S .” O V E R S I Z E
“ U . S .” U N DE R S I Z E
“ N A ” N o t Availa b l e

NOTICE!
THE INFORMATION IN THIS MANUAL IS KNOWN TO BE ACCURATE AS OF THE DATE OF
RELEASE SHOWN ON THE COVER. HOWEVER, ENGINEERING CHANGES CAN OCCUR
WITHOUT NOTICE. TO OBTAIN THE PROPER PARTS, PLEASE BE SURE TO USE THE
MODEL NUMBER OF THE UNIT BEING SERVICED WHEN ORDERING FROM THIS MANUAL.
 2.4L Gas eNGINE Quick Reference Guide
quick reference ENGINE PARTS
ENGINE SIZE: 2.4 Liter FUEL: Gas MAKE: Mitsubishi ENGINE P/N: 0G1008 MODEL: —
OIL CAPACITY: 1.125 gallons (w/filter) COOLANT CAPACITY: 1.80 gallons User Notes
scheduled maintenance kits
Description Part Number
Oil/Air 0G100800SM
– –
common reference parts
Description Part Number Special Notes
Oil Filter (Main) 0A45310244
Oil Filter (Bypass)
Fuel Filter
Air Cleaner Element 0C8127
V-Belt 0G0951
Thermostat 0G10080276
Thermostat Gasket
Water Pump 0G10080264
Water Pump Gasket 0G10080265
Starter Motor 0E9747
Spark Plug 0G10080292

additional reference parts

Alternator

◆ Engine Oil Recommendations dangER

The unit has been filled with “break in” engine oil
at the factory. Use a high-quality detergent oil classi- Ethylene glycol base antifreeze is poisonous.
fied “For Service CC, SD, SE or SF.” Detergent oils keep
the engine cleaner and reduce carbon deposits. Use oil
having the following SAE viscosity rating, based on the
* Do not use your mouth to siphon coolant from
the radiator, recovery bottle or any container.
ambient temperature range anticipated before the next Wash your hands thoroughly after handling.
oil change: Never store used antifreeze in an open container
because animals are attracted to the smell and
Temperature Oil Grade (Recommended) taste of antifreeze even though it is poisonous to
Above 75º F (24º C) SAE 30W them.
40º to 75º F (4.4º to 24º C) SAE 20W or 15W-40
10º to 40º F (-12º to 4.4º C) SAE 10W or 15W-40
Below 10º F (-12º C) SAE 5W-30 (Synthetic) or 5W-20
Do not use any chromate base rust inhibitor with
◆ Coolant
Use a mixture of half low silicate, ethylene glycol base
* ethylene glycol base antifreeze, or chromium
hydroxide (“green slime”) will form and cause
antifreeze and half soft water. Use only soft water and overheating. Engines that have been operated
only low silicate antifreeze. If desired, you may add a with a chromate base rust inhibitor must be
high quality rust inhibitor to the recommended coolant chemically cleaned before adding ethylene glycol
mixture. When adding coolant, always add the recom- base antifreeze. Using any high silicate anti-
mended 50-50 mixture. freeze boosters or additives also will cause over-
heating. We also recommend that you DO NOT
Do not remove the radiator pressure cap while
*
use any soluble oil inhibitor for this equipment.
the engine is hot or serious burns from boiling
liquid or steam could result.


 2.4L Gas eNGINE Service Recommendations

8 kW - 35 kW Small Standby Generator Sets

Following is a recommended maintenance schedule for Generac small standby and residential generator sets
from 8 kW to 35 kW in size, and applies to both diesel engine and gas engine driven units. The established
intervals in the schedule are the maximum recommended when the unit is used in an average service applica-
tion. They will need to be decreased (performed more frequently) if the unit is used in a severe application.
Use the unit hour meter or calendar time, whichever occurs first, from the previous maintenance interval to
determine the next required maintenance interval.

Service Maintenance Interval Information:

The various service maintenance intervals are designated by interval numbers as follows:

1 An early inspection of the generator set to insure it is ready to operate when required and to identify any
potential problem areas.
Performed monthly or following each 10 hours of operation of the unit and requires approximately .5
man-hours per unit to complete.
This inspection may be performed by the end user providing the following safety steps are taken to pre-
vent the engine from starting automatically without warning:
To prevent injury, perform the following steps in the order indicated before starting any maintenance:
• Disable the generator set from starting and/or connecting to the load by setting the control panel
Auto-Off-Manual switch to the “OFF” position.
• Remove the control panel fuse.
• Turn off the battery charger.
• Remove the negative battery cable.

The battery charger must be turned off BEFORE removing the battery cable to prevent an over current con-
* dition from burning out sensitive control panel components and circuits.

F
 ollowing all maintenance, reverse these steps to insure the unit is returned to standby setup for normal
operation when required.

2 A break-in service inspection of the generator set to insure it is ready to operate and carry the load when
required, and to identify any potential problem areas.
 erformed ONLY ONCE following the first three months or the first 30 hours of operation after purchase
P
of the unit and requires approximately 2.5 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowl-
edge to accomplish and should be performed only by an authorized Generac Service Dealer.

3 An operational inspection of the generator set to insure it is ready to operate and carry the load when
required, and to identify any potential problem areas.
P
 erformed semi-annually or following each 50 hours of operation of the unit and requires approximately
1.5 man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowl-
edge to accomplish and should be performed only by an authorized Generac Service Dealer.

4 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required,
and to identify any potential problem areas.
 erformed annually or following each 100 hours of operation of the unit and requires approximately 4.0
P
man-hours per unit to complete.
This inspection contains some maintenance tasks which require special tools, equipment, and/or knowl-
edge to accomplish and should be performed only by an authorized Generac Service Dealer.


 2.4L Gas eNGINE Service Recommendations

GENERAC POWER SYSTEMS, INC.

RECOMMENDED SCHEDULED MAINTENANCE PROGRAM

SERVICE WORK TO BE PERFORMED BY FACTORY-TRAINED PERSONNEL ONLY.

DEALER INFORMATION OWNER INFORMATION

NAME: NAME:
ACCOUNT #: ADDRESS:
ADDRESS:
SITE:
PHONE: PHONE:
TECHNICIAN:
SIGNATURE: SIGNATURE:

PURCHASE DATE: START-UP DATE:

APPLICATION: Standby Power Prime Power Rental/Trailerized

GENERATOR & TRANSFER SWITCH INFORMATION

GENERATOR TRANSFER SWITCH

MODEL NUMBER: MODEL NUMBER:
SERIAL NUMBER: SERIAL NUMBER:

HOUR METER READING at Completion of the Inspection:

! WARNING! !
To prevent injury, perform the following steps in the order indicated before starting any maintenance:
• Disable the generator set from starting and/or connecting to the load by setting the control panel
Auto-Off-Manual switch to the “OFF” position.
• Remove the control panel fuse.
• Turn off the battery charger.
• Remove the negative battery cable.

NOTE:
The battery charger must be turned off BEFORE removing the battery cable to prevent an over current con-
dition from burning out sensitive control panel components and circuits.

Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal
operation when required.


2.4L Gas eNGINE Service Recommendations
Maintenance Tasks Level 1 Level 2 Level 3 Level 4
Task Task Task Task
Recommended Required to be Required to Required to be
Comp. Comp. Comp. Comp.
to be done done 3 months/ be done Semi- done Annually/
(Date- (Date- (Date- (Date-
monthly/ 10 hrs. Break-in /30 hrs. Annually/50 hrs. 100 hrs.
Initials) Initials) Initials) Initials)
1.Disable the unit from
operating per the first
page warning.
• • • •
2.Check the engine oil
level. Adjust as neces-
sary.
• • • •
3.Check the engine cool-
ant level. Adjust as nec-
essary.
• • • •
4.Check the engine cool-
ant thermal protection
level. Correct as neces- •
sary.
5.Check the natural gas
delivery system on gas
engine driven units.
Tighten connections as
• • •
necessary.
6.Check the diesel fuel
supply level for diesel
engine driven units. Fill • • • •
as necessary.
7.Drain water and sedi-
ment from the diesel
fuel tank on diesel • • •
engine driven units.
8.Drain water from the
fuel line water separa-
tor on diesel engine
driven units if the unit is
• • •
equipped with one.
9.Check the air inlets and
outlets for debris. Clean
as necessary.
• • • •
10.Check the battery
electrolyte level if
accessible. Adjust as • • • •
necessary.
11.Check the battery
posts, cables, and
charger for loose con-
nections, corrosion, • • • •
and proper operation.
Correct as necessary.
12.Check the unit wiring
for loose connections,
corrosion, and dam-
age. Correct as neces-
•
sary.
13.Check the engine
accessory drive belts
for wear, weather
cracking, and damage.
•
Replace as necessary.


 2.4L Gas eNGINE Service Recommendations
Maintenance Tasks Level 1 Level 2 Level 3 Level 4
Task Task Task Task
Recommended Required to be Required to Required to be
Comp. Comp. Comp. Comp.
to be done done 3 months/ be done Semi- done Annually/
(Date- (Date- (Date- (Date-
monthly/ 10 hrs. Break-in /30 hrs. Annually/50 hrs. 100 hrs.
Initials) Initials) Initials) Initials)
14.Visually inspect the
unit looking for leaks,
wear or damage, loose
connections or compo- • • • •
nents, and corrosion.
Correct as necessary.
15.Test the engine and
transfer switch safety
devices. Correct and/ •
or adjust as necessary.
16.Initiate an automatic
start and transfer of
the unit to site load
and exercise it for at
least 1 hour looking for
leaks, loose connec- • •
tions or components,
and abnormal operat-
ing conditions. Correct
as necessary.
17.Start and exercise
the unit at full rated
load (use a load bank
if the site load is not
enough) for at least
2 hours looking for
leaks, loose connec-
•
tions or components,
and abnormal operat-
ing conditions. Correct
as necessary.

18.Change the engine oil.

•
19.Replace the engine oil
filter(s). • •
20.Replace the engine air
filter(s). • •
21.Replace the engine
fuel filter(s) on diesel
engine driven units
and re-prime the fuel
• •
system.
22.Check the engine
spark plugs on gas
engine driven units.
Clean and re-gap orre-
• •
place as necessary.
23.Perform a 5 minute no-
load operational run of
the unit looking for any • •
post service problems.
24.Return the unit to
standby setup for
operation when • • • •
required.


2.4L Gas Engine ROCKER COVER

item part number description qty

01100A 0G10080100 COVER ASSY, ROCKER 1
01100 0G10080101 COVER, ROCKER 1
01110 0G10080102 GASKET, RCKR CVR 1
01129 0G10080103 GASKET, PCV VALVE 1
01130 0G10080104 VALVE PCV 1
01193 0G10080105 CLAMP, CABLE 2
01193Q 0G10080106 CLAMP, CABLE 1
01198 0G10080107 BOLT, RCKR CVR M6x20 6
04903A 0G10080108 CAP, OIL FILLER 1


 2.4L Gas Engine CYLINDER HEAD

item part number description qty

01200A 0G10080109 HEAD ASSY, ENG CYLINDER 1
01202 0G10080110 CASE, THRUST 1
01210 0G10080111 GASKET, CYLINDER HEAD 1
01215 0G10080112 OIL SEAL 4
01282P 0G10080113 STUD (M8x28) 3
01282Q 0G10080114 STUD M8x28 7
01282S 0G10080115 STUD (10x20) 2
01284 0G10080116 SCREW M8x20 2
01291 0G10080117 O-RING 1
01296 0G10080118 CAP SEALING 2
01297 0G10080119 BUSHING, KNOCK 2
01298P 0G10080120 BOLT ASSY, CYLINDER HEAD M11x97 10
03130 0G10080121 OIL SEAL 1


2.4L Gas Engine CYLINDER BLOCK


 2.4L Gas Engine CYLINDER BLOCK
item part number description qty
03068 0G10080123 BEARING SET CRNKSHFT STD 1
03080 0G10080124 OIL SEAL 1
04911 0G10080125 ROD ASSY OIL LEVEL GAUGE 1
04912 0G10080126 GUIDE OIL LEVEL GAUGE 1
04956 0G10080127 BOLT FLANGE M8x12 1
04999 0G10080128 O-RING 3
01300A 0G10080129 BLOCK ASSY CYLINDER 1
01385P 0G10080130 PLUG TAPER 2
01385Q 0G10080131 PLUG TAPER 1
01385S 0G10080132 PLUG 1
01385T 0G10080133 PLUG TAPER 1
01387 0G10080134 PIN DOWEL 2
01392P 0G10080135 JOINT WATER DRAIN 1
01395 0G10080118 CAP SEALING 7
01395P 0G10080136 CAP SEALING 2
01396P 0G10080138 BUSHING KNOCK 2
01396Q 0G10080119 BUSHING KNOCK 2
01396S 0G10080139 BUSHING KNOCK 2
01397P 0G10080140 BOLT BEARING CAP M10x70 7
01397Q 0G10080141 BOLT FLANGE M6x14 5
01397S 0G10080142 BOLT BEARING CAP M10x70 1
01397T 0G10080143 BOLT BEARING CAP M10x70 2
03017 0G10080144 CASE, REAR OIL SEAL 1


2.4L Gas Engine COVER, REAR PLATE & PAN

10
 2.4L Gas Engine COVER, REAR PLATE & PAN
item part number description qty
01500 0G10080146 OIL PAN, ASSY 1
01512 0G10080147 PLUG, OIL DRAIN 1
01521 0G10080148 GASKET, OIL DRAIN PLUG 1
01597 0G10080149 BOLT, FLANGE M6x10 17
01597P 0G10080150 BOLT, FLANGE M6x8 2
02007P 0G10080151 COVER ASSY, TIMING BELT, FRNT UPPER 1
02007Q 0G10080152 COVER ASSY, TIMING BELT, FRNT LOWER 1
02012 0G10080153 COVER, TIMING BELT, REAR 1
02019 0G10080154 PLUG, RUBBER 1
02994PC 0G10080155 BOLT, FLANGE M6x28 1
02994PH 0G10080156 BOLT, WASHER ASSEMBLED M6x25 2
02994Q 0G10080157 BOLT, FLANGE M6x18 8
02994W 0G10080158 BOLT, FLANGE M6x50 1
02999SB 0G10080159 GASKET, TIMING BELT COVER 1
02999SC 0G10080160 GASKET, TIMING BELT COVER 1
02999SD 0G10080161 GASKET, TIMING BELT COVER LWR 1
02999SE 0G10080162 GASKET, TIMING BELT COVER 1
02999SF 0G10080163 GASKET, TIMING BELT COVER 1
04124 0G10080164 SCREEN ASSY, OIL 1
04161 0G10080165 GASKET, OIL SCREEN 1
04171 0G10080166 WASHER, OIL STRAINER 1
04176 0G10080167 NUT, OIL STRAINER 1
04178 0G10080168 BOLT, WASHER ASSEMBLED M8x20 2
14406 0G1477 BRACKET ASSY, IGNITION COIL 1
14598Q 0G10080170 BOLT, FLANGE M8x60 3
14598S 0G10080171 BOLT, FLANGE M8x70 1

11
2.4L Gas Engine PISTON & CRANKSHAFT

item part number description qty

03000 0G10080172 CRANKSHAFT ASSY 1
03006 0G10080173 BOLT, CONNECTING 8
03010A 0G10080174 CONNECTING ROD ASSY 4
03013 0G10080175 BOLT, CRANK SPROCKET 1
03019 0G10080176 BEARING, CONN ROD 4
03020A 0G10080177 PISTON WITH PIN 4
03031 0G10080178 NUT M8 8
03054 0G10080179 PULLEY ASSY, TORSIONAL DAMPER 1
03060 0G10080180 RING SET, PISTON 1
03782 0G10080181 WASHER SPECIAL 14.5 1
03787P 0G10080182 BOLT WASHER ASSEMBLED 4
03789 0G10080183 KEY 1

12
 2.4L Gas Engine BALANCER

item part number description qty

03024 0G10080185 FLANGE, CRANKSHAFT SPROCKET 1
03039 0G10080227 SPROCKET, CRANKSHAFT "B" 1
03610L 0G10080228 SHAFT, BALANCER, LEFT 1
03610R 0G10080229 SHAFT, BALANCER, RIGHT 1
03615R 0G10080230 SPROCKET, BALANCER SHAFT 1
03616 0G10080231 TENSIONER, TIMING BELT "B" 1
03620 0G10080232 BELT, TIMING "B" 1
03685 0G10080233 WASHER, BALANCER BELT TRAIN 1
03687P 0G10080234 BOLT, BALANCER BELT TRAIN 1
03687Q 0G10080235 BOLT, BALANCER BELT TRAIN M8x45 1
03688 0G10080236 SPACER, BALANCER BELT TRAIN 1

13
2.4L Gas Engine CAMSHAFT & VALVE

14
 2.4L Gas Engine CAMSHAFT & VALVE
item part number description qty
02018 0G10080184 BRACKET, TIMING INDICATOR 1
03024 0G10080185 FLANGE 1
03038 0G10080186 SPROCKET ASSY, CRANKSHAFT 1
03100 0G10080187 CAMSHAFT ASSY 1
03110 0G10080188 BELT TIMING 1
03148 0G10080189 ARM ASSY, TENSIONER
03152 0G10080190 PULLEY, IDLER 1
03158 0G10080191 PULLEY, TENSIONER 1
03170 0G10080192 OIL SEAL 1
03171 0G10080193 SPROCKET, CAMSHAFT 1
03173 0G10080194 BRACKET ASSY, TENSIONER PULLEY 1
03178 0G10080195 TENSIONER, AUTO 1
03195 0G10080196 PIN, DOWEL 1
03277 0G10080197 BOLT, FLANGE M8x35 13
03281W 0G10080198 WASHER PLAIN 1
03282 0G10080199 SPRING PIN 1
03283W 0G10080200 BOLT, WASHER ASSEMBLED M10x25 1
03283P 0G10080201 NUT, FLANGE M10 1
03285P 0G10080202 BOLT, FLANGE 1
03285Q 0G10080203 BOLT, FLANGE M8x51 2
03285S 0G10080204 BOLT, WASHER ASSEMBLED M10x35 1
03285T 0G10080205 BOLT, WASHER ASSEMBLED M10x22 1
03285U 0G10080206 BOLT SEAL M10x22 1
03285V 0G10080207 BOLT, FLANGE 2
03285W 0G10080208 BOLT, WASHER ASSEMBLED 1
03285X. 0G10080209 BOLT, WASHER ASSEMBLED 1
03301 0G10080210 ADJUSTER, ASSY LASH 16
03324 0G10080211 ROCKER ARM ASSY "C" 4
03343P 0G10080212 ROCKER ARM ASSY "A" 4
03343Q 0G10080213 ROCKER ARM ASSY "B" 4
03348 0G10080214 SHAFT, ROCKER ARM. IN. 1
03349 0G10080215 SHAFT, ROCKER ARM. EX. 1
03356 0G10080216 SPRING, ROCKER SHAFT, INLET 4
03358 0G10080217 CAP, ROCKER SHAFT 13
03405 0G10080218 RETAINER, VALVE SPRING 16
03410 0G10080219 VALVE, INLET 8
03412 0G10080220 SEAT, VALVE SPRING, INLET 16
03419 0G10080221 SPRING, VALVE 16
03420 0G10080222 VALVE, EXHAUST 8
03450 0G10080223 LOCK, VALVE SPRING RETAINER 32
03480 0G10080224 SEAL, VALVE STEM 8
03490 0G10080224 SEAL, VALVE STEM 8
04044 0G10080225 SPROCKET, OIL PUMP 1
14588 0G10080226 SPACER, CAMSHAFT SPROCKET 1
014598YP 0G10080143 BOLT, FLANGE M6x14 4

15
2.4L Gas Engine OIL PUMP & FILTER

16
 2.4L Gas Engine OIL PUMP & FILTER

item part number description qty

04150 0A45310244 FILTER ASSY, OIL 1
04181 0G10080237 PLUG M18 1
04184 0G10080238 GASKET 1
04199P 0G10080239 BOLT WASHER ASSEMBLED M8x40 2
04199Q 0G10080240 BOLT WASHER ASSEMBLED M8x75 1
04199S 0G10080241 BOLT WASHER ASSEMBLED M8x55 1
04211 0G10080242 PLUNGER, RELIEF 1
04217 0G10080243 SPRING, RELIEF 1
02000A 0G10080244 CASE ASSY, OIL PUMP 1
02017 0G10080245 GASKET, FRONT CASE 1
02092 0G10080246 PLUG CAP 1
02093P 0G10080134 PIN, DOWEL 2
02097Q 0G10080247 BOLT, WASHER ASSEMBLED M8x20 2
02097QB 0G10080248 BOLT, WASHER ASSEMBLED M8x22 1
02097T 0G10080249 BOLT, FLANGE M8x32 1
02097V 0G10080250 BOLT, FLANGE M8x40 1
02097W 0G10080251 BOLT, FLANGE M8x16 1
0 2097X 0G10080252 BOLT, FLANGE M8x25 1
02097Z 0G10080253 BOLT, FLANGE M8x20 4
02099 0G10080254 O-RING 1
03070 0G10080255 OIL SEAL 1
03623R 0G10080256 OIL SEAL, BALANCER SHAFT, FR RH 1
04015 0G10080257 GEAR, OIL PUMP DRIVE 1
04016 0G10080258 GEAR, OIL PUMP DRIVEN 1
04028 0G10080259 OIL SEAL 1
04082 0G10080260 SCREW MACHINE 1
04085 0G10080261 PLUG TAPER 1
04096W 0G10080234 BOLT, FLANGE M8x16 1
04102A 0G10080262 BRACKET, OIL FILTER 1
04114 0G10080263 GASKET, OIL FILTER BRACKET 1

17
2.4L Gas Engine WATER PUMP

item part number description qty

10010 0G10080264 PUMP ASSY, WATER 1
10021 0G10080265 GASKET, WATER PUMP 1
10041 0G10080267 PULLEY, WATER PUMP 1
10088P 0G10080268 BOLT, FLANGE M8x65 1
10088T 0G10080269 BOLT, FLANGE M8x28 1
10088U 0G10080270 BOLT, FLANGE M8x22 2
10088V 0G10080271 BOLT, FLANGE M8x14 1
10594 0G10080272 NUT, FLANGE M6 4

18
 2.4L Gas Engine WATER PIPE & THERMOSTAT

item part number description qty

10034 0G10080274 PIPE WATER PUMP INLET 1
10100 0G10080275 CASE, THERMOSTAT 1
10110 0G10080276 THERMOSTAT 1
10118 0G10080277 FITTING, WATER INLET HOSE 1
10159 0G10080278 FITTING WATER OUTLET PIPE 1
10198 0G10080127 BOLT COOLING WATER LINE 1
10198P 0G10080253 BOLT COOLING WATER LINE 2
10198Q 0G10080250 BOLT COOLING WATER LINE 1
10198S 0G10080279 BOLT COOLING WATER LINE 1
10198T 0G10080252 BOLT COOLING WATER LINE 2
10198U 0G10080247 BOLT COOLING WATER LINE 1
10199 0G10080280 O-RING COOLING WATER LINE 3
10199P 0G10080281 O-RING COOLING WATER LINE 3
10801 0G10080282 PLUG TAPER 1

19
2.4L Gas ENGINE HANGERS & ALTERNATOR BRACKET

item part number description qty

14215 0G10080285 BRACKET ASSY 1
14788P 0G10080286 NUT ADJUST 1
14799Q 0G10080287 BOLT FLANGE M8 x 65 1
02200P 0G10080283 HANGER, ENGINE 1
02200Q 0G10080284 HANGER, ENGINE 1
02299 0G10080208 BOLT, WASHER ASSEMBLED M8 X 16 2

20
 2.4L Gas Engine SPARK PLUG CABLE & COIL

item part number description qty

14631 0G10080288 CABLE SPARK PLUG NO.1 1
14632 0G10080289 CABLE SPARK PLUG NO.2 1
14633 0G10080290 CABLE SPARK PLUG NO.3 1
14634 0G10080291 CABLE SPARK PLUG NO.4 1
14640 0G10080292 PLUG ASSY, SPARK 4
14692 0G10080293 CLAMP, HOSE 1

21
 32 1 GROUP D
30 INDICATION
31 MARK
56
55 (PART OF ITEM #1)
62
42
21
50 51
41
42 57 37
40

24
29 60
59 42
44 41
36 4 27
1 45 2 7
"A" 28 (PART OF
23 8
24 58 ITEM #1)
35
26
2
3
2.4L Gas Engine Common Parts

6
61

22
5 (PART OF ITEM #5)
53
52 26
2
34
24 47
29 54
17
22 18
33 17
43 16
39 9
24 10
25 11

TO 12 14
"A" 15
38
48
13 46
19 EXPLODED VIEW:
20 49 ENG COMMON PARTS 2.4L G2
DATE: 3/31/06 PAGE 1 OF 2 DRAWING #: 0G1141
 2.4L Gas Engine Common Parts
item part number description qty
1 0G1008 ENGINE 2.4L G2 (REWORK) 1
2 046526 (REF) WASHER LOCK M10 7
3 039414 (REF) SCREW HHC M8-1.25 X 35 G8.8 4
4 0G0149 (REF) SCREW SHC M14-1.5 X 35 G10.9 1
5 0E9868A (REF) ALTERNATOR DC W/OUT PULLEY 1
6 0F3217 (REF) SPACER DC ALTERNATOR PULLEY 1
7 042574 (REF) ADAPTOR 1/8 NPTF TO 1/8 BSPT 1
8 0A8584 (REF) SWITCH, OIL PRESSURE, 10PSI,2POL 1
9 057772 WASHER NYLON .565 1
10 057765 ADAPTER M14-1.50 X 3/8 NPT 1
11 043790 BARBED EL 90 3/8 NPT X 3/8 1
12 0C7649 CLAMP HOSE .38-.87 1
13 069860E HOSE DRAIN ASSY 28" 1
14 063076 WASHER FLAT .531ID X 1.062OD 7
15 0G1394 SCREW HHC M12-1.25 X 20 G10.9 7
16 052830 SCREW HHC M10-1.25 X 45 G8.8 2
17 025507 WASHER SHAKEPROOF EXT 7/16 STL 5
18 062963 SCREW HHC M10-1.25 X 30 G8.8 3
19 049821 SCREW SHC M8-1.25 X 30 G12.9 3
20 022129 WASHER LOCK M8-5/16 3
21 0D6029 SCREW THF M6-1X16 N WA Z/JS 3
22 0A6751 (REF) SWITCH HI-TEMP 245D X 3/8NPT 1
23 022145 (REF) WASHER FLAT 5/16-M8 ZINC 1
24 022129 (REF) WASHER LOCK M8-5/16 19
25 045771 (REF) NUT HEX M8-1.25 G8 CLEAR ZINC 3
26 022131 (REF) WASHER FLAT 3/8-M10 ZINC 5
27 049813 (REF) NUT HEX M6 X 1.0 G8 YEL CHR 3
28 046525 (REF) NUT HEX M10-1.25 G8 YEL CHR 2
29 058306 (REF) SCREW SHC M8-1.25 X 25 G12.9 15
30 022097 WASHER LOCK M6-1/4 3
31 022473 WASHER FLAT 1/4-M6 ZINC 3
32 043116 SCREW HHC M6-1.0 X 12 G8.8 3
33 026073A (REF) PLUG STD PIPE 1/4 STEEL SQ HD 2
34 057642 (REF) SCREW HHC M10-1.5 X 40 G8.8 1
35 0A8258 (REF) SCREW HHC M8-1.25 X 25 G10.9 1
36 0A45310244 (REF) OIL FILTER, G2 ENGINE 1
37 0G1502 (REF) COIL PACK 1
38 047290 HOSE 3/8 ID SINGLE BRAID (15”LG) 1
39 049340 (REF) BARBED EL 90 1/4NPT X 3/8 1
40 043146 (REF) SCREW HHC M6-1.0 X 10 G8.8 1
41 022097 (REF) WASHER LOCK M6-1/4 4
42 022473 (REF) WASHER FLAT 1/4-M6 ZINC 7
43 089617 (REF) BARBED STR 1/4NPT X 1/4 MALE 1
44 0G0951 (REF) GASKET EXHAUST MANIFOLD 1
45 0G0608 (REF) MANIFOLD EXHAUST 1
46 0F9965E FLEX PLATE 2 POLE 2.4L G2 1
47 0D2244M ASSY MAG PICKUP(3/8-24 MALE) 1
48 0F9420 ADAPTER ENGINE 2.4L MACHINE 1
49 0E9747 STARTER, 12 VOLT 1
50 0G1472A (REF) CAM SENSOR PIN ASSY 1
51 0G1477 (REF) COVER CAM GEAR G2 REWORKED 1
52 0G0707 (REF) MANIFOLD INTAKE 1
53 0G0950 (REF) GASKET INTAKE MANIFOLD 1
54 0F9583 SPACER 2.4L G2 FLEX PLATE 1
55 0G0792 SHIELD HEAT G2 1
56 0G0792A SHIELD HEAT SML 1
57 0G1501 (REF) BRACKET COIL PACK 1
58 0D2244M (REF) ASSY MAG PICKUP (3/8-24 MALE) 1
59 0F9501 (REF) ADAPTER 2.4L CRANKSHAFT MACH 1
60 0G0952 (REF) POLY V-BELT G2 1
61 0G0788 (REF) PULLEY DC ALTERNATOR 1
62 049721 (REF) SCREW HHC M6-1.0 X 35 G8.8 BLK 3

23
2.4L Gas Engine Air Cleaner

item part number description qty

1 0E6586 GASKET BOSCH 32 & 40 1
2 0E0519A ADAPTER CARBURETOR W/PVC CONN 1
3 0C8127 ELEMENT AIR CLEANER 1
4 052619 SCREW HHC M5-0.8 X 20 G8.8 4
5 022127 NUT HEX 1/4-20 STEEL 1
6 062974 STUD TH 1/4-20 X 4-1/2 G2 ZNC 1
7 0G0190 PLATE, AIR CLEANER TOP 2.4L 1
8 037561 NUT WING 1/4-20 NYLK 1
9 022097 WASHER LOCK M6-1/4 1

24
 2.4L Gas Engine Battery
GROUP C
3 TO
6 ENGINE
5
4
7
9
15
15
8 10
13

2 16
TO STARTER
1 11 SOLENOID
13
12 14

17

EXPLODED VIEW:
BATTERY 2.4L CPL
REVISION: G-7805-B
DATE: 4/3/06 PAGE 1 OF 2 DRAWING #: 0F9813

item part number description qty

1 0F3408B BATTERY TRAY C1 CPL 1
2 0F3411 STRAP BATTERY RETAINMENT 1
3 025507 WASHER SHAKEPROOF EXT 7/16 STL REF
4 052212 SCREW HHC M10-1.25 X 25 G8.8 REF
5 046526 WASHER LOCK M10 REF
6 022131 WASHER FLAT 3/8-M10 ZINC REF
7 050331A BATTERY POST COVER RED + REF
8 050331 BATTERY POST COVER BLACK - REF
9 038805Y CABLE BATTERY BLACK #1 X 18.00 1
10 03880400AE CABLE BATT RED #1 X 18.00 1
11 045771 NUT HEX M8-1.25 G8 YEL CHR REF
12 022129 WASHER LOCK M8-5/16 REF
14 0F3976 BOOT CONTACTOR CABLES 1
15 0C2454 SCREW THF M6-1 X 16 N WA Z/JS 4
16 022145 WASHER FLAT 5/16-M8 ZINC REF
17 077483 BATTERY 12VDC 75-AH 26 REF

25