Gt51789u 400s403a-11

GT51789U GT51789U
400S403A-11 2016/03/17
The information given within this parts book was correct at the time of printing and is subject to change without
notice. Always refer to your local Perkins outlet for the latest information. Only fully trained personnel should car-
ry out servicing of engines. Before working on any engine always refer to the correct user service and maintenance
manual.
Always refer to your local Perkins outlet before purchasing any parts
Subject to any existing rights of third parties, the information given in this document is the property of Perkins En-
gines Limited and should not be copied, in whole or part, without the prior written consent of the Company.
Contents
1. Introduction Pg. 4
2. How To Use Your Parts Book Pg. 4
3. Engine Breakdown Pg. 5
4. Symbol Descriptions Pg. 9
5. Parts Lists & Illustrations Pg. 11
6. Parts Index Pg. 166

Introduction
The build list of your engine, found on the front page of this parts book, provides a unique
reference to the components fitted to your engine; therefore this parts book is only applicable to
this particular engine
Always quote your build list and engine serial number when contacting your Perkins outlet.
How to use your Parts Book
This parts book has been designed to provide you with all the information you need to identify
parts to service your engine. There are several features within the book to make it easy to find
the parts you require.
Front Page
This lists your build list number and the date of publication of this book
Symbol Descriptions
Provides a quick reference guide to the symbols used within the book.
Engine Breakdown
Use this to identify all the major sections of your engine and the relevant pages within the book.
Parts Lists & Illustrations

This section shows each major section of your engine broken down into individual part numbers
along with an associated illustration for identifying the parts you require.
The illustrations used in this parts book are representational only and should only be used for
identification purposes.
For fitting instructions please refer to your engine Service Manual.
Parts Index
Using either the part number or description of the part you require this section will help you
locate the page within the Parts Lists & Illustrations section where the part appears.
Engine Breakdown
Section Page Section Page
Level 1 - Service 11 Relief Valve 37

AAAAAAGJ ACPG0010
Level 2 - Repair 13 Oil Pump 39

AAAAAAGJ U5MK8265.
Level 3 - Overhaul 15 Timing Case 41

AAAAAAGJ ADPG0042
Cylinder Block 17 Timing Case 43

ACPG0010 ADPG0042

ACPG0010 ADPG0042

ACPG0010 ADPG0042
Crankshaft, Pistons & Connecting Rods 23 Timing Case 49

ACPG0010 ADPG0042
Crankshaft, Pistons & Connecting Rods 25 Miscellaneous 51

ACPG0010 ADPG0042
Rear End Oil Seal 27 Camshaft & Gears 53

ACPG0010 ADPG0042
Cylinder Head 29 Camshaft & Gears 55

ACPG0010 ADPG0042
Cylinder Head 31 Camshaft & Gears 57

ACPG0010 ADPG0042
Rocker Shaft Assembly 33 Fuel Injection Pump 59

ACPG0010 AFPG0042
Pipes 35 High Pressure Fuel Pipes 61

ACPG0010 AFPG0042
Page 5
Engine Breakdown
Atomisers 63 Filler 89
AFPG0042 HBPG0023
Fuel Leak-Off Pipe 65 Oil Filter 91

AFPG0042 JBPG0000
Fuel Injection Pump 67 Oil Filter 93

AFPG0110 JCPG0000
High Pressure Fuel Pipes 69 Front End Drive Input 95

AFPG0110 KBPG0007
Atomisers 71 Thermostat & Housing 97

AFPG0110 LBPG0009
Fuel Leak-Off Pipe 73 Water Pump 99

AFPG0110 LBPG0009
Flywheel Housing 75 Water Pump 101

CDPG0016 LDPG0008
Flywheel & Starter Ring 77 Alternator 103

DDPG0017 NDPG0027
Starter Motor 79 Drive Belt & Tensioner 105

EDPG0007 NEPG0013
Pulleys 81 Front End Drive Output 107

FBPG0012 QCPG0027
Lubricating Oil Sump 83 Cylinder Head Cover 109

GBPG0025 TBPG0010
Dipstick & Tube 85 Air Filter Assembly 111

GBPG0025 TDPG0011
Sump 87 Pipework & Connections 113

GCPG0000 TDPG0011
Page 6
Engine Breakdown
Air Filter Assembly 115 Fan 141

TDPG0011 ZMPG5507
Exhaust Manifold 117 Fan 143

UBPG0010 ZMPG5507
Exhaust Connection 119 Guards 145

UDPG0001 ZMPG5507
Lift Pump 121 Guards 147

VBPG0021 ZMPG5507
Fuel Filter 123 Radiator & Cowling 149

VBPG0021 ZMPG5507
Pipework & Connections 125 Radiator & Cowling 151

VBPG0021 ZMPG5510
Cold Start System 127 Radiator & Cowling 153

WDPG0005 ZMPG5510
Engine Lifting Eyes 129 Fan 155

XBPG0006 ZMPG5510
Throttle & Stop Controls 131 Fan 157

ZAPG0019 ZMPG5510
Instrumentation 133 Guards 159

ZJPG0011 ZMPG5510
Instrumentation 135 Guards 161

ZLPG0008 ZMPG5510
Radiator & Cowling 137 Electrical 163

ZMPG5507 ZPPG0001
Radiator & Cowling 139 Fuel Pre-Lift Pump 165

ZMPG5507 ZVPG0002
Page 7
Engine Breakdown
Page 8
Symbols and Notes
Symbol Description
A From Engine Number
B Upto Engine Number
C Repairs and Replaces
D See Appropriate Section - Reference Number
E Alternative
F Order
G Remanufactured Part
H New for Old Part
I Number of Teeth
J Thickness
K Bottom
L Top
M Left Hand
N Right Hand
O Reference for Detailed Breakdown
P Other Service Options Available
Q Cylinder Number
R See History Section
Page 9
Level 1 - Service Plate A
AAAAAAGJ
Recommended stocking and service lists

Perkins provides Recommended stocking and service lists, for Distributor use when
recommending parts stocks for Dealers, preferred customers (eg fleets) etc. These lists
are based on agreed workshop capability and are at three distinct levels:
Level 1 - Service
The Level 1 workshop has the ability to perform basic non-intrusive maintenance on
Perkins engines.
Listes recommandées pour le stock et la maintenance
Perkins fournit des listes recommandées pour le stock et la maintenance afin d'aider le
Distributeur dans ses conseils aux Agents, aux clients habituels, etc.. Ces listes sont
basées sur le niveau technique des Ateliers avec trois niveaux distincts :
Niveau 1- Maintenance
L'atelier de niveau 1 est capable d'executer l'entretien de base des moteurs Perkins (sans
demontage).
Empfohlene Lagerbestands- und Servicelisten
Perkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche die
Vertragshändler verwenden können, um Händlern und Kunden (z.B. Fuhrparks) einen
bestimmten Ersatzteilbestand zu empfehlen. Diese Listen basieren auf den vereinbarten
Werkstattfähigkeiten, welche in die folgenden drei Stufen unterteilt werden:
Stufe 1 - Service
Werkstätten der Stufe 1 können grundlegende und einfache Wartungsarbeiten an
Perkins-Motoren ohne Spezialwerkzeug durchführen.
Listas de servicio y de stock recomendadas
Perkins proporciona Listas de servicio y de stock recomendadas, para que las use el
Distribuidor al recomendar stocks de repuestos a los Distribuidores, a los clientes
preferidos (por ejemplo, flotas), etc. Estas listas se basan en capacidad del taller
acordada y se dividen en tres niveles diferentes:
Nivel 1 - Servicio
El taller del Nivel 1 puede llevar a cabo un mantenimiento no intrusivo en los motores
Perkins.
Elenco parti consigliate ad uso stock ed assistenza
Perkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza;
ciò per soddisfare le richieste dei dealers, clienti preferenziali ecc. Questi elenchi tengono
in considerazione la capacità operativa concordata con l’officina e sono distinti in tre livelli
Livello 1 - Assistenza
Il livello 1 prevede che l’officina sia in grado di operare in maniera basilare sui motori
Perkins.
Page 10
Level 1 - Service Plate A
AAAAAAGJ
Item Part No. References Qty. Description Notes
1 1 LEVEL 1 - SERVICE
Page 11
Level 2 - Repair Plate A
AAAAAAGJ

Perkins provides Recommended stocking and service lists, for Distributor use when
recommending parts stocks for Dealers, preferred customers (eg fleets) etc. These lists are
based on agreed workshop capability and are at three distinct levels:
Level 2 - Repair
The Level 2 workshop has the ability to perform maintenance service,and inspection service on
Perkins engines.
Perkins fournit des listes recommandées pour le stock et la maintenance afin d'aider le
Distributeur dans ses conseils aux Agents, aux clients habituels, etc.. Ces listes sont basées sur
le niveau technique des Ateliers avec trois niveaux distincts :
Niveau 2 - Maintenance & reparation
L'atelier de niveau 2 est capable d’executer toutes les opérations d'entretien, la reparation des
composants externes (demarreur, alternateur,etc) et le diagnostic pour les problèmes touchant à
l'electronique
Perkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche die Vertragshändler
verwenden können, um Händlern und Kunden (z.B. Fuhrparks) einen bestimmten
Ersatzteilbestand zu empfehlen. Diese Listen basieren auf den vereinbarten
Werkstattfähigkeiten, welche in die folgenden drei Stufen unterteilt werden:
Stufe 2 - Reparatur
Werkstätten der Stufe 2 können Instandsetzungs- und Inspektionsarbeiten an Perkins-Motoren
durchführen.
Perkins proporciona Listas de servicio y de stock recomendadas, para que las use el
Distribuidor al recomendar stocks de repuestos a los Distribuidores, a los clientes preferidos
(por ejemplo, flotas), etc. Estas listas se basan en capacidad del taller acordada y se dividen en
tres niveles diferentes:
Nivel 2 - Reparación
El taller de Nivel 2 puede llevar a cabo el servicio de mantenimiento y el servicio de inspección
en los motores Perkins.
Perkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza; ciò per
soddisfare le richieste dei dealers, clienti preferenziali ecc. Questi elenchi tengono in
considerazione la capacità operativa concordata con l’officina e sono distinti in tre livelli :
Livello 2 - Riparazione
Nel livello 2 l’officina è in grado di svolgere la manutenzione e di fare controlli di
assistenza sui motori Perkins.
Page 12
Level 2 - Repair Plate A
AAAAAAGJ
1 1 LEVEL 2 - REPAIR
Page 13
Level 3 - Overhaul Plate A
AAAAAAGJ

Perkins provides Recommended stocking and service lists, for Distributor use when recommending parts
stocks for Dealers, preferred customers (eg fleets) etc. These lists are based on agreed workshop capability
and are at three distinct levels:
Level 3 - Overhaul.
The Level 3 workshop has the ability to perform complete service work on Perkins engines. Can repair and
fully overhaul engine, including engine test. Can perform all levels of electronics diagnosis and application
related faults.
Perkins fournit des listes recommandées pour le stock et la maintenance afin d'aider le Distributeur dans ses
conseils aux Agents, aux clients habituels, etc.. Ces listes sont basées sur le niveau technique des Ateliers
avec trois niveaux distincts :
Niveau 3 - Maintenance, reparation & refection
L' atelier de niveau 3 est capable de couvrir toutes les opérations d'entretien des moteurs Perkins. Il peut
aussi réparer et entièrement refaire des moteurs ainsi que les tester. Il est capable d'effectuer un diagnostic
pour les problèmes touchant à l'electronique et aux applications.
Perkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche die Vertragshändler verwenden
können, um Händlern und Kunden (z.B. Fuhrparks) einen bestimmten Ersatzteilbestand zu empfehlen. Diese
Listen basieren auf den vereinbarten Werkstattfähigkeiten, welche in die folgenden drei Stufen unterteilt
werden:
Stufe 3 - Überholung
Werkstätten der Stufe 3 können umfassende Servicearbeiten an Perkins-Motoren durchführen. Sie können
Motoren reparieren und komplett überholen und außerdem Motorprüfungen durchführen. Sie können
umfassende elektronische Diagnoseprüfungen durchführen und anwendungsspezifische Störungen
untersuchen.
Perkins proporciona Listas de servicio y de stock recomendadas, para que las use el Distribuidor al
recomendar stocks de repuestos a los Distribuidores, a los clientes preferidos (por ejemplo, flotas), etc. Estas
listas se basan en capacidad del taller acordada y se dividen en tres niveles diferentes:
Nivel 3 - Reparación general
El taller de Nivel 3 puede llevar a cabo un trabajo de servicio completo en los motores Perkins. Puede
reparar y reacondicionar completamente un motor, incluyendo probar el motor. Puede llevar a cabo todos los
niveles de diagnóstico electrónico y las fallas relacionadas con la aplicación.
Perkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza; ciò per soddisfare le
richieste dei dealers, clienti preferenziali ecc. Questi elenchi tengono in considerazione la capacità operativa
concordata con l’officina e sono distinti in tre livelli :
Livello 3 - Revisione
Nel livello 3 l’officina è in grado di svolgere lavori di assistenza completi sui motori Perkins. E’ in grado di
riparare e svolgere una revisione completa del motore, incluso le prove. Può anche effettuare diagnosi sull’
elettronica a tutti i livelli e sui relativi difetti nelle applicazioni.
Page 14
Level 3 - Overhaul Plate A
AAAAAAGJ
1 1 LEVEL 3 - OVERHAUL
Page 15
Cylinder Block Plate A
B 001547U ACPG0010
23
17
3 16
26
24
25
22
13
14 8
11
15
7
5
12
20 10
2
21
9 1
18
19
Page 16
B 001547U ACPG0010
1 1 CYLINDER BLOCK (A)

2 064210015 1 CAP
3 064210025 1 PLUG
4 064210035 2 PLUG
5 064210040 1 PLUG
6 064210040 1 PLUG
7 198466010 1 PLUG
8 198466010 2 PLUG
9 198466010 1 PLUG
10 198466940 1 PLUG
11 198466940 3 PLUG
12 198466050 1 PLUG
13 012110625 2 STUD
14 042303015 1 NEEDLE BEARING
15 036509005 1 CIRCLIP
16 040106203 1 BALL BEARING
17 064100045 1 PLUG
18 1 SHAFT (B)
19 198517592 P 1 BUSH
20 012110635 1 STUD
21 012110660 1 STUD
22 030500616 2 DOWEL
23 030501025 2 DOWEL
24 010109440 2 STUD
25 030500512 2 DOWEL
26 030309005 2 PIN
Service Options
19 198517596 J (-)0.25MM 1 BUSH
Footnotes
(A) SERVICE BY COMPLETE ENGINE

(B) REFER TO U5MK8265
Page 17
A 001548U ACPG0010
22
16
3 15
25
23
24
21
13 8
11
14
7
5
12
19 10
2
20
9 1
17
18
Page 18
A 001548U ACPG0010
1 1 CYLINDER BLOCK ASSEMBLY (A)

2 064210015 1 CAP
3 064210025 1 PLUG
4 064210035 2 PLUG
5 064209055 1 PLUG
6 064209055 1 PLUG
7 198466010 1 PLUG
8 198466010 2 PLUG
9 198466010 1 PLUG
10 198466940 1 PLUG
11 198466940 3 PLUG
12 198466050 1 PLUG
13 042303015 1 NEEDLE BEARING
14 036509005 1 CIRCLIP
16 064100045 1 PLUG
17 1 SHAFT (B)
18 198517592 P 1 BUSH
19 012110635 1 STUD
20 012110660 1 STUD
21 030500616 2 DOWEL
22 030501025 2 DOWEL
23 010109440 2 STUD
24 030500512 2 DOWEL
25 030309005 2 PIN
Service Options
18 198517596 J (-)0.25MM 1 BUSH
Footnotes
(A) SERVICE BY COMPLETE ENGINE

(B) REFER TO U5MK8265
Page 19
Cylinder Block Plate B
ACPG0010
Page 20
Cylinder Block Plate B
ACPG0010
1 U65996570 R a. 1 GASKET
2 011310612 3 SCREW
History
a.
1 165996570 1 GASKET
Page 21
Crankshaft, Pistons & Connecting Rods Plate A
ACPG0010
5
25
4
18
21
3
19
12
15
13 22
20
6
7 16 23
14
17
10
24
11
Page 22
Crankshaft, Pistons & Connecting Rods Plate A
ACPG0010
1 115256970 1 CRANKSHAFT ASSEMBLY

2 F 115256970 1 CRANKSHAFT
3 U15276280 1 CRANKSHAFT GEAR
4 030509020 1 KEY
5 030300816 1 PIN
6 110156400 1 BEARING HOLDER ASSEMBLY
7 F 110156400 1 BEARING CAP
8 F 110156400 1 BEARING CAP
9 010810840 2 SCREW
10 030500612 2 DOWEL
11 011510850 1 SCREW
13 F 110156410 1 BEARING CAP
14 F 110156410 1 BEARING CAP
15 010810840 2 SCREW
16 030500612 2 DOWEL
17 011510850 1 SCREW
19 F 110156420 1 BEARING CAP
20 F 110156420 1 BEARING CAP
21 010810845 2 BOLT
22 030500612 2 DOWEL
23 010700845 2 SCREW
24 U5MB0026 P 1 MAIN BEARING KIT
25 U5ME0031 P 1 BIG END BEARING KIT
Service Options
24 U5MB0026A J (-) 0.25MM 1 MAIN BEARING KIT - U/S
25 U5ME0031A J (-) 0.25MM 1 BIG END BEARING KIT
Page 23
Crankshaft, Pistons & Connecting Rods Plate B
ACPG0010
3 1
12
10
11
5
4
Page 24
Crankshaft, Pistons & Connecting Rods Plate B
ACPG0010
1 115017621 R a. 3 PISTON AND RING KIT

2 F 115017621 1 PISTON
3 115104090 1 PISTON RING KIT
4 115026340 3 CON ROD ASSEMBLY
5 F 115026340 1 CON ROD
6 F 115026340 1 CAP
7 115176150 2 CON ROD BOLT
8 020109075 2 CON ROD NUT
9 198517125 1 SMALL END BUSH
10 115326231 3 GUDGEON PIN
11 036500021 3 CIRCLIP
12 036500021 3 CIRCLIP
History
a.
1 115017620 3 PISTON AND RING KIT
Page 25
Rear End Oil Seal Plate A
ACPG0010
Page 26
Rear End Oil Seal Plate A
ACPG0010
1 050209107 1 SEAL - REAR END OIL (A,B)
Footnotes
(A) SEE SERVICE BULLETIN NO.195

(B) ALSO ORDER WEAR SLEEVE - 29990038
Page 27
Cylinder Head Plate A
ACPG0010
20
19
1
18
13 4
17
12
16
11
15
10 7
5
14
Page 28
Cylinder Head Plate A
ACPG0010
1 111011120 R a. 1 CYLINDER HEAD ASSEMBLY

2 F 111011120 1 CYLINDER HEAD
3 064210018 2 CAP
4 064210018 2 CAP
5 064210018 4 CAP
6 064210030 1 CAP
7 064210030 1 CAP
8 U10136460 3 VALVE SEAT INSERT INLET
9 120166360 3 INTAKE VALVE
10 U20406140 3 SEAL - VALVE STEM
11 198216700 3 VALVE SPRING
12 120186080 3 CAP
13 120226070 6 VALVE COLLET
14 120176250 3 EXHAUST VALVE
15 U20406140 3 SEAL - VALVE STEM
16 198216700 3 VALVE SPRING
17 120186080 3 CAP
18 120226070 6 VALVE COLLET
19 120216041 3 VALVE SPRING CAP
20 120216041 3 VALVE SPRING CAP
History
a.
1 111011020 1 CYLINDER HEAD ASSEMBLY
Page 29
Cylinder Head Plate B
ACPG0010
3 2
Page 30
Cylinder Head Plate B
ACPG0010
1 P 1 CYLINDER HEAD GASKET

2 111136440 11 SCREW
3 111136450 3 SCREW
4 012110625 2 STUD
Service Options
1 111147560 J 1.2MM 1 GASKET - CYLINDER HEAD
1 111147570 J 1.3MM 1 GASKET - CYLINDER HEAD
Page 31
Rocker Shaft Assembly Plate A
ACPG0010
9 8
7
10 5
1
3
16
15
11
12
14
18
13
17
Page 32
Rocker Shaft Assembly Plate A
ACPG0010
1 120037250 1 ROCKER BOX ASSEMBLY

2 F 120037250 1 ROCKER SHAFT BRACKET
3 120316300 1 ROCKER SHAFT
4 015100410 1 SCREW
5 120356200 3 ROCKER ARM ASSEMBLY
6 120356210 3 ROCKER ARM ASSEMBLY
7 198216780 2 ROCKER SHAFT SPRING
8 199280280 4 WASHER
9 199486220 6 ADJUSTING SCREW
10 020109076 6 NUT
11 198436150 1 PLUG
12 052100120 1 SEAL - O RING
13 U20996150 R a. 1 SEAL - ROCKER BOX
14 011310625 2 SCREW
15 012109177 3 STUD
16 023100008 3 NUT
17 120116160 6 TAPPET
18 120456222 6 PUSHROD
History
a.
13 120996150 1 SEAL - ROCKER BOX
Page 33
Pipes Plate A
ACPG0010
1 4
3
2
Page 34
Pipes Plate A
ACPG0010
1 140607270 1 OIL PIPE

2 198486780 1 BOLT
3 140996260 1 WASHER
4 140996260 1 WASHER
Page 35
Relief Valve Plate A
ACPG0010
Page 36
Relief Valve Plate A
ACPG0010
1 140036220 1 RELIEF VALVE

2 052109078 1 SEAL - O RING
Page 37
Oil Pump Plate A
U5MK8265.
4
5
6
7 11
10
Page 38
Oil Pump Plate A
U5MK8265.
1 U5MK8265 1 OIL PUMP IDLER GEAR

2 F U5MK8265 1 SHAFT
3 199266180 1 WASHER
4 F U5MK8265 1 OIL PUMP IDLER GEAR
5 F U5MK8265 1 ROTOR
6 140116140 1 COVER
7 P 1 SHIM
8 198216720 1 SPRING
9 199236540 1 COLLAR
10 036800010 1 CIRCLIP
11 1 LEAFLET
Service Options
7 199286150 J (+)0.10MM 1 SHIM
7 199286160 J (+)0.15MM 1 SHIM
7 199286170 J (+)0.20MM 1 SHIM
7 199286180 J (+)0.50MM 1 SHIM
Page 39
Timing Case Plate A
ADPG0042
33
35
36
34
Page 40
Timing Case Plate A
ADPG0042
32 2315C039 1 SCREW
31 2648A120 1 NUT
30 012800640 1 SCREW
28 025100006 1 WASHER
29 025100006 1 WASHER
27 023100008 1 NUT
26 030300414 1 PIN
25 052100070 1 SEAL - O RING
24 198636090 1 SEAL - FRONT END OIL
23 010109600 4 SCREW
22 024500006 1 NUT
11 125046610 1 CONTROL LEVER
21 165996640 1 GASKET
20 198217750 1 SPRING
19 125116211 1 SHAFT
10 131046560 1 BOLT
18 052100080 1 SEAL - O RING
17 131466251 1 BOLT
16 198217880 1 SPRING
15 125116221 1 SHAFT
9 1 CONTROL LEVER
8 020109239 1 NUT
6 U65116551 1 TIMING CASE
5 U98466960 1 PLUG
4 198211000 1 SPRING
3 125156263 1 ARM
2 125616121 1 BRACKET
1 1 TIMING CASE (A)
12 1 PIPE
14 1 CAP
13 1 LEVER
33 U65996620 R a. 1 GASKET - TIMING CASE
34 011310640 5 SCREW
35 011310660 5 SCREW
36 023100006 1 NUT
History
a.
33 165996620 1 GASKET - TIMING CASE
Footnotes
(A) SEE FOLLOWING PARTS LIST FOR SERVICE COMPONENTS
Page 41
Timing Case Plate B
ADPG0042
1 3
Page 42
Timing Case Plate B
ADPG0042
1 U65116551 1 TIMING CASE

2 198636090 1 SEAL - FRONT END OIL
3 030300414 1 PIN
Page 43
Timing Case Plate C
ADPG0042
10
7
6 9
1
2
11 12
3
13
Page 44
Timing Case Plate C
ADPG0042
1 125616121 1 BRACKET
2 U65996640 R a. 1 GASKET - TIMING CASE
3 125156263 1 ARM
4 198211000 1 SPRING
5 052100070 1 SEAL - O RING
6 198217750 1 SPRING
7 023100008 1 NUT
8 012810635 1 SCREW
9 2648A120 1 NUT
10 26420462 1 ANTI-TAMPER CAP
11 012810635 1 SCREW
12 2318A207 1 NUT
13 2314F004 4 SCREW
History
a.
2 165996640 1 GASKET
Page 45
Timing Case Plate D
ADPG0042
11
3 6
1
10
12
4
Page 46
Timing Case Plate D
ADPG0042

2 125116221 1 SHAFT
3 052100080 1 SEAL - O RING
4 131046560 1 BOLT
5 020800010 1 NUT
7 125116211 1 SHAFT
8 024500006 1 NUT
9 025100006 1 WASHER
10 198217880 1 SPRING
11 031100004 1 PIN
12 U98466960 1 PLUG
Page 47
Timing Case Plate E
ADPG0042
1
3
5
8
9
10
11
12
Page 48
Timing Case Plate E
ADPG0042
1 131046640 1 SCREW
2 F 131046640 1 BOLT
3 020109177 1 NUT
4 025100010 1 WASHER
5 198217900 1 SPRING
6 198346160 1 RING
7 131276440 1 ANTI-TAMPER CAP
8 131466251 1 BOLT
9 025100006 1 WASHER
10 020109239 1 NUT
11 198346160 1 RING
12 29990071 R a. 1 ANTI-TAMPER CAP
History
a.
12 064210012 1 CAP
Page 49
Miscellaneous Plate D
ADPG0042
Page 50
Miscellaneous Plate D
ADPG0042
1 198217970 1 TOOL (A)
Footnotes
(A) REFER TO WORKSHOP MANUAL
Page 51
Camshaft & Gears Plate A
B 28/09/2008 ADPG0042
2
10
Page 52
B 28/09/2008 ADPG0042
1 120026890 1 CAMSHAFT ASSEMBLY (A)

2 F 120026890 1 CAMSHAFT
3 034100508 1 KEY
4 120016220 1 CAMSHAFT GEAR
6 199216320 1 SPACER
7 125256220 1 SLIDER
8 199566651 1 PLATE
9 010700610 1 SCREW
10 011310612 1 SCREW
Footnotes
(A) ORDER 120027090 + 125256250
Page 53
A 29/09/2008 ADPG0042
2
10
Page 54
A 29/09/2008 ADPG0042
1 120027090 1 CAMSHAFT
2 F 120027090 1 CAMSHAFT
3 034100508 1 KEY
4 120016300 1 CAMSHAFT GEAR
6 199216320 1 SPACER
7 125256250 1 SLIDER
8 199566651 1 PLATE
9 010700610 1 SCREW
10 011310612 1 SCREW
Page 55
Camshaft & Gears Plate B
ADPG0042
Page 56
Camshaft & Gears Plate B
ADPG0042
1 199266180 1 WASHER
Page 57
Fuel Injection Pump Plate A
AFPG0042
Page 58
AFPG0042
1 131017961 1 FUEL INJECTION PUMP

2 P 1 SHIM (A)
3 011310620 2 SCREW
4 023100006 2 NUT
Service Options
2 131437590 X SHIM (B)
2 131437830 X SHIM (C)
2 131437600 X SHIM (D)
2 131437840 X SHIM (E)
2 131437610 X SHIM (F)
2 131437620 X SHIM (G)
2 131437630 X SHIM (H)
Footnotes
EMISSIONS CRITICAL COMPONENT - TO ENSURE CORRECT ENGINE TIMING RETAIN ORIGINAL SHIM DETAILS
(A)
FOR EXACT REPLACEMENTS.
(B) THICKNESS - 0.2MM - WITH BEAD
(C) THICKNESS - 0.25MM - WITH BEAD
(D) THICKNESS - 0.3MM - WITH BEAD
(E) THICKNESS - 0.35MM - WITH BEAD
(F) THICKNESS - 0.4MM - WITH BEAD
(G) THICKNESS - 0.5MM - WITH BEAD
(H) THICKNESS - 0.5MM - WITHOUT BEAD
Page 59
High Pressure Fuel Pipes Plate A
AFPG0042
Page 60
AFPG0042
1 131507740 1 PIPE - FUEL INJ NO 1 CYL

4 199106021 2 CLAMP
5 199106021 2 CLAMP
6 010110625 2 SCREW
7 023100006 2 NUT
Page 61
Atomisers Plate A
AFPG0042
Page 62
Atomisers Plate A
AFPG0042
1 131406560 3 INJECTOR
2 U31426200 R a. 3 SEAL - INJECTOR
History
a.
2 131426200 3 SEAL - INJECTOR
Page 63
Fuel Leak-Off Pipe Plate A
AFPG0042
6
2
Page 64
AFPG0042
1 131606920 1 PIPE - LEAK OFF

2 068204112 1 PIPE
3 131246280 1 CONNECTOR
4 025100006 1 WASHER
5 067200078 1 CLIP
6 067200078 1 CLIP
Page 65
AFPG0110
Page 66
AFPG0110
1 131011170 1 FUEL INJECTION PUMP

2 P 1 SHIM (A)
3 011310620 2 SCREW
4 023100006 2 NUT
Service Options
2 131437590 X SHIM (B)
2 131437830 X SHIM (C)
2 131437600 X SHIM (D)
2 131437840 X SHIM (E)
2 131437610 X SHIM (F)
2 131437620 X SHIM (G)
2 131437630 X SHIM (H)
Footnotes
EMISSIONS CRITICAL COMPONENT - TO ENSURE CORRECT ENGINE TIMING RETAIN ORIGINAL SHIM DETAILS
(A)
FOR EXACT REPLACEMENTS.
(B) THICKNESS - 0.2MM - WITH BEAD
(C) THICKNESS - 0.25MM - WITH BEAD
(D) THICKNESS - 0.3MM - WITH BEAD
(E) THICKNESS - 0.35MM - WITH BEAD
(F) THICKNESS - 0.4MM - WITH BEAD
(G) THICKNESS - 0.5MM - WITH BEAD
(H) THICKNESS - 0.5MM - WITHOUT BEAD
Page 67
AFPG0110
Page 68
AFPG0110

4 199106021 2 CLAMP
5 199106021 2 CLAMP
6 010110625 2 SCREW
7 023100006 2 NUT
Page 69
Atomisers Plate A
AFPG0110
Page 70
Atomisers Plate A
AFPG0110
1 131406610 3 INJECTOR
2 U31426200 3 SEAL - INJECTOR
Page 71
AFPG0110
6
2
Page 72
AFPG0110
1 131606920 1 PIPE - LEAK OFF

2 068204112 1 PIPE
3 131246280 1 CONNECTOR
4 025100006 1 WASHER
5 067200078 1 CLIP
6 067200078 1 CLIP
Page 73
Flywheel Housing Plate A
CDPG0016
Page 74
Flywheel Housing Plate A
CDPG0016
1 U10446581 R a. 1 FLYWHEEL HOUSING

2 2314J007 2 SCREW
3 2318A604 2 NUT
4 010311020 8 SCREW
5 2487646 1 PLUG
History
a.
1 110447640 1 FLYWHEEL HOUSING
Page 75
Flywheel & Starter Ring Plate A
DDPG0017
2
4
1
Page 76
Flywheel & Starter Ring Plate A
DDPG0017
1 U15356911 R a. 1 FLYWHEEL ASSEMBLY

2 F U15356911 1 FLYWHEEL
3 U15376130 F U15356911 1 STARTER RING
4 010109340 6 SCREW
History
a.
1 U15356910 1 FLYWHEEL ASSEMBLY
Page 77
Starter Motor Plate A
EDPG0007
Page 78
Starter Motor Plate A
EDPG0007
1 U5MK8259 P 1 STARTER MOTOR (A)

2 F U5MK8259 1 STARTER MOTOR
3 U85656070 1 TERMINAL KIT
4 2314J004 2 SCREW
5 2314J007 2 SCREW
6 2318A604 2 NUT
Service Options
1 U5MK8259R G 1 STARTER MOTOR - EXCHANGE
2 U85086711R 1 STARTER MOTOR - EXCHANGE (B)
Footnotes
(A) REMY
(B) NO LONGER SERVICED ORDER U5MK8259R
Page 79
Pulleys Plate A
FBPG0012
Page 80
Pulleys Plate A
FBPG0012
1 145336490 1 WATER PUMP PULLEY
Page 81
Lubricating Oil Sump Plate A
GBPG0025
4
5
6
Page 82
Lubricating Oil Sump Plate A
GBPG0025
1 110708510 1 SUMP
2 U10996900 R f. 1 GASKET - SUMP
3 2314F001 R b. 20 SCREW
R c.
4 U40406500 R e. 1 STRAINER
5 2314F001 R a. 2 SCREW
6 140987140 R d. 1 PIPE - OIL
7 052109076 1 SEAL - O RING
History
a.
5 011310612 2 SCREW
b.
3 2314F002 20 SCREW
c.
3 010109235 20 SCREW
d.
6 140986830 1 OIL PIPE
e.
4 140406500 1 STRAINER
f.
2 110996900 1 GASKET - SUMP
Page 83
Dipstick & Tube Plate A
GBPG0025
2
3
6
4
Page 84
Dipstick & Tube Plate A
GBPG0025
1 198416810 1 DIPSTICK
2 110756490 1 DIPSTICK TUBE
3 2314F001 R a. 1 SCREW
R b.
4 052100100 2 SEAL - O RING
5 U98436290 1 BLANKING PLATE
6 052100100 2 SEAL - O RING
7 2314F001 R a. 1 SCREW
History
a.
3 011310612 1 SCREW
7 011310612 1 SCREW
b.
3 010109235 1 SCREW
Page 85
Sump Plate A
GCPG0000
Page 86
Sump Plate A
GCPG0000
1 T10109238 R a. 2 SUMP DRAIN PLUG

2 025100016 2 WASHER
History
a.
1 010109238 2 SCREW
Page 87
Filler Plate A
HBPG0023
Page 88
Filler Plate A
HBPG0023
1 U98436350 1 OIL FILLER CAP

2 052100400 1 SEAL - O RING
3 198436390 1 OIL FILLER CAP
4 052100280 1 SEAL - O RING
Page 89
Oil Filter Plate A
JBPG0000
Page 90
Oil Filter Plate A
JBPG0000
1 140517050 1 OIL FILTER
Page 91
Oil Filter Plate A
JCPG0000
Page 92
Oil Filter Plate A
JCPG0000
1 140546020 1 CONNECTION
Page 93
Front End Drive Input Plate A
KBPG0007
1
3
Page 94
Front End Drive Input Plate A
KBPG0007
1 U15397310 1 CRANKSHAFT PULLEY

2 034100508 1 KEY
3 020800018 1 NUT
Page 95
Thermostat & Housing Plate A
LBPG0009
3
5
6
4
Page 96
Thermostat & Housing Plate A
LBPG0009
1 145216540 1 THERMOSTAT HOUSING

2 145206062 1 THERMOSTAT
3 U45996840 R a. 1 GASKET - THERMOSTAT HSG
4 011310660 4 SCREW
5 064500030 2 PLUG
6 064500060 1 PLUG
History
a.
3 145996840 1 GASKET - THERMOSTAT HSG
Page 97
Water Pump Plate A
LBPG0009
1 4
5
3
Page 98
Water Pump Plate A
LBPG0009
1 U45017961 1 WATER PUMP

2 U45996831 R a. 1 GASKET - WATER PUMP
R b.
3 145536051 1 HOSE
4 2481882 R c. 1 CLIP
5 2481882 R c. 1 CLIP
6 023100006 1 NUT
History
a.
2 U45996830 1 GASKET - WATER PUMP
b.
2 145996830 1 GASKET - WATER PUMP
c.
4 067100022 1 CLIP
5 067100022 1 CLIP
Page 99
Water Pump Plate A
LDPG0008
4 3
Page 100
Water Pump Plate A
LDPG0008
1 145226470 1 THERMOSTAT HOUSING

2 U45996850 R a. 1 GASKET - THERMOSTAT HSG
3 011310620 1 SCREW
4 010109440 1 STUD
5 023100006 1 NUT
History
a.
2 145996850 1 GASKET - THERMOSTAT HSG
Page 101
Alternator Plate A
NDPG0027
11
9 10
Page 102
Alternator Plate A
NDPG0027
1 185046160 G 1 ALTERNATOR
2 185726670 1 LEVER
3 011310640 2 SCREW
4 2314H004 R a. 1 SCREW
5 026109017 1 WASHER
6 011511035 1 SCREW
7 026100010 1 WASHER
8 011310635 1 SCREW
9 385620320 1 TERMINAL
10 185516061 1 REGULATOR
11 1 WATER PUMP
Service Options
1 185046160R 1 EXCHANGE ALTERNATOR
History
a.
4 011510830 1 SCREW
Page 103
Drive Belt & Tensioner Plate A
NEPG0013
Page 104
Drive Belt & Tensioner Plate A
NEPG0013
1 080109049 1 BELT
Page 105
Front End Drive Output Plate A
QCPG0027
Page 106
Front End Drive Output Plate A
QCPG0027
1 U65166570 1 PLATE
2 165206780 1 PLATE
3 052300550 1 SEAL - O RING
4 U65206890 1 PLATE
5 052300600 1 SEAL - O RING
6 2314J012 2 SCREW
7 2318A604 2 NUT
Page 107
Cylinder Head Cover Plate A
TBPG0010
3
11
4
16 14
12
13
15
10
9
Page 108
Cylinder Head Cover Plate A
TBPG0010
1 111217490 1 CYLINDER HEAD COVER

2 U11996420 R b. 1 SEAL - CYL HEAD COVER
3 110566080 1 BREATHER VALVE
4 011100408 4 METRIC BOLT
5 135566480 1 PIPE - AIR
6 U35997290 R a. 1 GASKET
R c.
7 011310620 2 SCREW
8 110666220 1 RETAINING PLATE
9 110666060 1 GAUZE
10 015600406 6 SCREW
11 011310680 3 SCREW
12 024600008 3 NUT
13 140996260 3 WASHER
14 011310630 1 SCREW
15 012110625 1 STUD
16 023100006 1 NUT
History
a.
6 U35996751 1 GASKET
b.
2 111996420 1 SEAL - CYL HEAD COVER
c.
6 135996750 1 GASKET
d.
011310625 2 SCREW
Page 109
Air Filter Assembly Plate A
TDPG0011
Page 110
Air Filter Assembly Plate A
TDPG0011
1 135016340 1 AIR FILTER ASSEMBLY

2 F 135016340 1 BODY
3 135326205 1 MAIN AIR FILTER
4 26510402 1 INDICATOR
5 26510194 1 VALVE
6 26510417 1 BRACKET
Page 111
Pipework & Connections Plate A
TDPG0011
9
6
3
5
Page 112
TDPG0011
1 135976630 1 SUPPORT BRACKET

2 2314H003 2 SCREW
3 199216340 1 SPACER
4 2314H005 2 SCREW
5 023100008 2 NUT
6 U35597810 1 HOSE
7 21825194 1 CLIP
8 21825199 1 HOSE CLIP
9 W14501010 1 COVER (A)
Footnotes
(A) IF FITTED
Page 113
Air Filter Assembly Plate B
TDPG0011
Page 114
Air Filter Assembly Plate B
TDPG0011
1 2638C245 1 LABEL (A,B)
Footnotes
(A) ETHER WARNING LABEL

(B) REFER TO SERVICE BULLETIN NO.81 (1100 SERIES)
Page 115
Exhaust Manifold Plate A
UBPG0010
Page 116
Exhaust Manifold Plate A
UBPG0010
1 135616311 1 EXHAUST MANIFOLD

2 135996541 1 GASKET - EXHAUST MANIFOLD
3 011310625 4 SCREW
4 023100006 2 NUT
Page 117
Exhaust Connection Plate A
UDPG0001
Page 118
Exhaust Connection Plate A
UDPG0001
1 W14120360 1 FLANGE
2 T415605 R a. 1 GASKET
3 011510825 4 SCREW
4 W14120360 1 FLANGE
5 T415605 R a. 1 GASKET
6 011510825 4 SCREW
History
a.
2 314990013 1 GASKET - EXHAUST
5 314990013 1 GASKET - EXHAUST
Page 119
Lift Pump Plate A
VBPG0021
Page 120
Lift Pump Plate A
VBPG0021
1 130506351 1 LIFT PUMP

2 2415A070 1 SEAL - O RING
3 2314F003 2 SCREW
Page 121
Fuel Filter Plate A
VBPG0021
7
3
11
1
10
5
4
Page 122
Fuel Filter Plate A
VBPG0021
1 2656613 1 FUEL FILTER ASSEMBLY (A)

2 U30976671 R a. 1 BRACKET
3 2314J004 R b. 2 SCREW
4 020900010 2 NUT
5 027100010 2 WASHER
6 2314H003 R c. 2 SCREW
7 26561117 1 FUEL FILTER KIT
8 F 26561117 1 ELEMENT
9 0490786 1 SEAL
10 0490786 1 SEAL
11 26560014 1 SEAL - O RING
History
a.
2 130976670 1 BRACKET
b.
3 010111030 2 BOLT
026200010 2 WASHER
c.
6 011510820 2 SCREW
026100008 2 WASHER
Footnotes
(A) CONTAINS FILTER BOWL - 26560601
Page 123
VBPG0021
11
12
13
14
2
1
4
7
6
9
10
Page 124
VBPG0021
1 131246290 1 PIPE - LOW PRESSURE FUEL

2 33811114 1 OLIVE
3 T68209625 R b. 1 HOSE
4 2481882 R b. 1 CLIP
5 2481882 1 CLIP
6 131246290 1 PIPE - LOW PRESSURE FUEL
7 33811114 1 OLIVE
8 T68209188 R a. 1 HOSE
9 2481882 1 CLIP
10 2481882 1 CLIP
11 32184226 1 PLUG
12 2411D010 R c. 1 WASHER
13 0650204 2 PLUG
14 0920154 2 WASHER
History
a.
8 068209104 1 HOSE
b.
3 068209166 1 HOSE
4 067100015 1 HOSE CLIP
067100015 1 HOSE CLIP
067100015 1 HOSE CLIP
067100015 1 HOSE CLIP
c.
12 0920146 1 WASHER
Page 125
Cold Start System Plate A
WDPG0005
5
4
Page 126
Cold Start System Plate A
WDPG0005
1 185366250 3 GLOWPLUG
2 F 185366250 1 GLOWPLUG
3 023100004 1 NUT
4 185376372 1 CONNECTOR
5 023100004 1 NUT
6 185606170 1 CABLE
Page 127
Engine Lifting Eyes Plate A
XBPG0006
1
4
Page 128
Engine Lifting Eyes Plate A
XBPG0006
1 195816540 1 LIFTING EYE

2 011510816 1 SCREW
3 195816540 1 LIFTING EYE
4 011510816 1 SCREW
Page 129
Throttle & Stop Controls Plate A
ZAPG0019
Page 130
Throttle & Stop Controls Plate A
ZAPG0019

2 U85206520 1 SOLENOID
3 025100016 1 WASHER
History
a.
U85206452 1 SOLENOID
Page 131
Instrumentation Plate A
ZJPG0011
Page 132
ZJPG0011
1 185246280 1 OIL PRESSURE SWITCH

2 198486871 1 BANJO BOLT
3 140996260 1 WASHER
4 140996260 1 WASHER
5 064400010 1 PLUG
Page 133
ZLPG0008
Page 134
ZLPG0008
1 W85720580 1 WATER TEMPERATURE SWITCH
Page 135
Radiator & Cowling Plate A
B 145501W ZMPG5507
2 5
10
Page 136
B 145501W ZMPG5507
1 U45506590 1 RADIATOR
2 F U45506590 1 RADIATOR
3 24850072 1 RADIATOR CAP
4 U45537150 1 HOSE
5 21825197 R a. 1 CLIP
6 21825197 1 CLIP
7 U45537330 1 HOSE
8 21825197 R a. 1 CLIP
9 21825197 1 CLIP
10 20186 1 HOSE CLIP
History
a.
5 0180067 1 CLIP
8 0180067 1 CLIP
Page 137
Radiator & Cowling Plate B
B 145501W ZMPG5507
4
3
6
Page 138
B 145501W ZMPG5507
1 U45976870 1 BRACKET
2 2314F006 2 SCREW
3 U45977330 R a. 1 MOUNTING
4 2314H003 2 SCREW
5 010211225 4 SCREW
6 2314J003 2 SCREW
7 U45977340 R a. 1 MOUNTING
8 2314H003 2 SCREW
9 010211225 3 SCREW
History
a.
3 U45977241 1 BRACKET
7 U45977231 1 BRACKET
6583208 1 PLUG
Page 139
Fan Plate A
B 145501W B 544844X ZMPG5507
1
2
Page 140
Fan Plate A
B 145501W B 544844X ZMPG5507
1 145386910 1 EXTENSION
2 145306880 1 FAN
3 011310625 4 SCREW
Page 141
Fan Plate A
B 145501W A 544845X ZMPG5507
Page 142
Fan Plate A
B 145501W A 544845X ZMPG5507
1 U45307130 R a. 1 FAN
2 145386920 1 EXTENSION 20MM
3 011310635 4 SCREW
History
a.
1 145306880 1 FAN
Page 143
Guards Plate A
B 145501W B 31/12/2009 ZMPG5507
5
2
Page 144
Guards Plate A
B 145501W B 31/12/2009 ZMPG5507
1 U75316261 1 FAN GUARD (A)

2 U75316251 1 FAN GUARD
3 U75316270 1 GUARD (A)
4 2314H002 2 SCREW
5 011510812 6 SCREW
Footnotes
(A) ORDER - U75316500 + U75316380
Page 145
Guards Plate A
B 145501W A 01/01/2010 ZMPG5507
Page 146
Guards Plate A
B 145501W A 01/01/2010 ZMPG5507
1 U75316500 1 FAN GUARD

2 F U75316500 1 FAN GUARD
3 2314H005 3 SCREW
4 2318A401 3 NUT
5 U75316251 1 FAN GUARD
6 U75316380 1 FAN GUARD
7 011510812 6 SCREW
Page 147
B 145501W ZMPG5507
2 3
Page 148
B 145501W ZMPG5507
1 U45977210 1 BRACKET
2 2314H003 2 SCREW
3 2314H002 2 SCREW
4 U45977201 1 BRACKET
5 2314H002 2 SCREW
6 U98116931 1 MOUNTING
7 023100008 1 NUT
8 023100008 1 NUT
Page 149
A 145502W ZMPG5510
2 5
10
Page 150
A 145502W ZMPG5510
1 U45506590 1 RADIATOR
2 F U45506590 1 RADIATOR
3 24850072 1 RADIATOR CAP
4 U45537150 1 HOSE
5 0180067 1 CLIP
6 21825197 1 CLIP
7 U45537330 1 HOSE
8 0180067 1 CLIP
9 21825197 1 CLIP
10 20186 1 HOSE CLIP
Page 151
A 145502W ZMPG5510
4
3
6
Page 152
A 145502W ZMPG5510
1 U45976870 1 BRACKET
2 2314F006 2 SCREW
4 2314H003 2 SCREW
5 010211225 4 SCREW
6 2314J003 2 SCREW
8 2314H003 2 SCREW
9 010211225 3 SCREW
Page 153
Fan Plate A
A 145502W B 544844X ZMPG5510
Page 154
Fan Plate A
A 145502W B 544844X ZMPG5510
1 U45307130 1 FAN
2 145386910 1 EXTENSION
3 011310625 4 SCREW
Page 155
Fan Plate A
A 145502W A 544845X ZMPG5510
Page 156
Fan Plate A
A 145502W A 544845X ZMPG5510
1 145306880 1 FAN
2 145386920 1 EXTENSION 20MM
3 011310635 4 SCREW
Page 157
Guards Plate A
A 145502W ZMPG5510
3 4
Page 158
Guards Plate A
A 145502W ZMPG5510
1 T413167 1 FAN GUARD

2 F T413167 1 FAN GUARD
3 T413044 1 FAN GUARD
4 2314F004 5 SCREW
5 011510812 4 SCREW
Page 159
Guards Plate B
A 145502W ZMPG5510
Page 160
Guards Plate B
A 145502W ZMPG5510
1 U45977210 1 BRACKET
2 2314H002 2 SCREW
3 2314H002 2 SCREW
4 U45977201 1 BRACKET
5 2314H003 2 SCREW
7 023100008 1 NUT
8 023100008 1 NUT
Page 161
Electrical Plate A
ZPPG0001
Page 162
Electrical Plate A
ZPPG0001
1 20195 1 CONNECTION KIT

2 F 20195 3 CONNECTION
Page 163
Fuel Pre-Lift Pump Plate A
ZVPG0002
Page 164
Fuel Pre-Lift Pump Plate A
ZVPG0002
1 130506300 1 PRIMER
Page 165
Parts Index
Page 166
Parts Index
Description Part No. Page Description Part No. Page
ADJUSTING SCREW 199486220 33 U45976870 139, 153
AIR FILTER 135016340 111 U45977201 149, 161

ASSEMBLY
U45977210 149, 161
ALTERNATOR 185046160 103
U45977231 139
ANTI-TAMPER CAP 131276440 49
U45977241 139
26420462 45
BREATHER VALVE 110566080 109
29990071 49
BUSH 198517592 17, 19
ARM 125156263 41, 45
198517596 17, 19
BALL BEARING 040106203 17, 19
CABLE 185606170 127
040109059 53, 55
CAMSHAFT 120027090 55
BANJO BOLT 198486871 133
CAMSHAFT 120026890 53
BEARING HOLDER 110156400 23 ASSEMBLY
ASSEMBLY
CAMSHAFT GEAR 120016220 53
110156410 23
120016300 55
110156420 23
CAP 064210012 49
BELT 080109049 105
064210015 17, 19
BIG END BEARING U5ME0031 23
KIT 064210018 29, 29, 29
U5ME0031A 23 064210030 29, 29
BLANKING PLATE U98436290 85 120186080 29, 29
BOLT 010111030 123 CIRCLIP 036500021 25, 25
010810845 23 036509005 17, 19
131046560 41, 47 036800010 39
131466251 41, 49 CLAMP 199106021 61, 61,

69, 69
198486780 35
CLIP 0180067 137, 137,
BRACKET 125616121 41, 45 151, 151
130976670 123 067100022 99, 99
26510417 111 067200078 65, 65,

73, 73
U30976671 123
Page 167
Parts Index
21825194 113 CYLINDER HEAD 111217490 109

COVER
21825197 137, 137,
137, 137, DIPSTICK 198416810 85
151, 151
DIPSTICK TUBE 110756490 85
2481882 99, 99,
125, 125, DOWEL 030500512 17, 19
125, 125
030500612 23, 23, 23
COLLAR 199236540 39
030500616 17, 19
CON ROD 115026340 25
030501025 17, 19
ASSEMBLY
EXCHANGE 185046160R 103
CON ROD BOLT 115176150 25
ALTERNATOR
CON ROD NUT 020109075 25
EXHAUST 135616311 117
CONNECTION 140546020 93 MANIFOLD
CONNECTION KIT 20195 163 EXHAUST VALVE 120176250 29
CONNECTOR 131246280 65, 73 EXTENSION 145386910 141, 155
185376372 127 145386920 143, 157
CONTROL LEVER 125046610 41 FAN 145306880 141, 143,

157
125046613 47
U45307130 143, 155
125306121 41, 47
FAN GUARD T413044 159
125416440 131
T413167 159
COVER 140116140 39
U75316251 145, 147
W14501010 113
U75316261 145
CRANKSHAFT 115256970 23
ASSEMBLY U75316380 147
CRANKSHAFT U15276280 23 U75316500 147

GEAR
FLANGE W14120360 119, 119
CRANKSHAFT U15397310 95
FLYWHEEL U15356910 77
PULLEY
ASSEMBLY
CYLINDER HEAD 111011020 29
U15356911 77
ASSEMBLY
FLYWHEEL 110447640 75
111011120 29
HOUSING
Page 168
Parts Index
U10446581 75 U65996620 41
FUEL FILTER 2656613 123 U65996640 45

ASSEMBLY
GASKET - WATER 145996830 99
FUEL FILTER KIT 26561117 123 PUMP
FUEL INJECTION 131011170 67 U45996830 99

PUMP
U45996831 99
131017961 59
GAUZE 110666060 109
GASKET 135996750 109
GLOWPLUG 185366250 127
165996570 21
GUARD U75316270 145
165996640 41, 45
GUDGEON PIN 115326231 25
T415605 119, 119
HOSE 068209104 125
U35996751 109
068209166 125
U35997290 109
145536051 99
U65996570 21
T68209188 125
GASKET - 111147560 31
CYLINDER HEAD T68209625 125
111147570 31 U35597810 113
GASKET - 314990013 119, 119 U45537150 137, 151

EXHAUST
U45537330 137, 151
GASKET - 135996541 117
HOSE CLIP 067100015 125, 125,
EXHAUST
125, 125
MANIFOLD
20186 137, 151
GASKET - SUMP 110996900 83
21825199 113
U10996900 83
INDICATOR 26510402 111
GASKET - 145996840 97
THERMOSTAT HSG INJECTOR 131406560 63
145996850 101 131406610 71
U45996840 97 INTAKE VALVE 120166360 29
U45996850 101 KEY 030509020 23
GASKET - TIMING 165996620 41 034100508 53, 55, 95
CASE
Page 169
Parts Index
LABEL 2638C245 115 2318A207 45
LEVER 185726670 103 2318A401 147
LIFT PUMP 130506351 121 2318A604 75, 79,

107
LIFTING EYE 195816540 129, 129
2648A120 41, 45
MAIN AIR FILTER 135326205 111
OIL FILLER CAP 198436390 89
MAIN BEARING KIT U5MB0026 23
U98436350 89
MAIN BEARING KIT U5MB0026A 23
- U/S OIL FILTER 140517050 91
METRIC BOLT 011100408 109 OIL PIPE 140607270 35
MOUNTING U45977330 139, 153 140986830 83
U45977340 139, 153 OIL PRESSURE 185246280 133

SWITCH
U98116931 149, 161
OIL PUMP IDLER U5MK8265 39
NEEDLE BEARING 042303015 17, 19 GEAR
NUT 020109076 33 OLIVE 33811114 125, 125
020109177 49 PIN 030300414 41, 43
020109239 41, 49 030300816 23
020800010 47 030309005 17, 19
020800018 95 031100004 47
020900010 123 PIPE 068204112 65, 73
023100004 127, 127 PIPE - AIR 135566480 109
023100006 41, 59, PIPE - FUEL INJ NO 131507740 61, 69
61, 67, 1 CYL
69, 99,
101, 109, PIPE - FUEL INJ NO 131507750 61, 69
117 2 CYL
023100008 33, 41, PIPE - FUEL INJ NO 131507760 61, 69

45, 113, 3 CYL
149, 149,
161, 161 PIPE - LEAK OFF 131606920 65, 73
024500006 41, 47 PIPE - LOW 131246290 125, 125

PRESSURE FUEL
024600008 109
PIPE - OIL 140987140 83
Page 170
Parts Index
PISTON AND RING 115017620 25 PUSHROD 120456222 33

KIT
RADIATOR U45506590 137, 151
115017621 25
RADIATOR CAP 24850072 137, 151
PISTON RING KIT 115104090 25
REGULATOR 185516061 103
PLATE 165206780 107
RELIEF VALVE 140036220 37
199566651 53, 55
RETAINING PLATE 110666220 109
U65166570 107
RING 198346160 49, 49
U65206890 107
ROCKER ARM 120356200 33
PLUG 064100045 17, 19 ASSEMBLY
064209055 19, 19 120356210 33
064210025 17, 19 ROCKER BOX 120037250 33

ASSEMBLY
064210035 17, 19
ROCKER SHAFT 120316300 33
064210040 17, 17
ROCKER SHAFT 198216780 33
064400010 133 SPRING
064500030 97 SCREW 010109235 83, 85
064500060 97 010109238 87
0650204 125 010109340 77
198436150 33 010109600 41
198466010 17, 17, 010110625 61, 69
17, 19,
19, 19 010211225 139, 139,
153, 153
198466050 17, 19
010311020 75
198466940 17, 17,
19, 19 010700610 53, 55
2487646 75 010700845 23
32184226 125 010810840 23, 23
6583208 139 011310612 21, 53,

55, 83,
U98466960 41, 47 85, 85
PRIMER 130506300 165
Page 171
Parts Index
011310620 59, 67, 2314F004 45, 159

101, 109
2314F006 139, 153
011310625 33, 109,
117, 141, 2314H002 145, 149,
155 149, 161,
161
011310630 109
2314H003 113, 123,
011310635 103, 143, 139, 139,
157 149, 153,
153, 161
011310640 41, 103
2314H004 103
011310660 41, 97
2314H005 113, 147
011310680 109
2314J003 139, 153
011510812 145, 147,
159 2314J004 79, 123
011510816 129, 129 2314J007 75, 79
011510820 123 2314J012 107
011510825 119, 119 2315C039 41
011510830 103 SEAL 0490786 123, 123
011510850 23, 23 SEAL - CYL HEAD 111996420 109

COVER
011511035 103
U11996420 109
012800640 41
SEAL - FRONT END 198636090 41, 43
012810635 45, 45 OIL
015100410 33 SEAL - INJECTOR 131426200 63
015600406 109 U31426200 63, 71
111136440 31 SEAL - O RING 052100070 41, 45
111136450 31 052100080 41, 47
131046640 49 052100100 85, 85
2314F001 83, 83, 052100120 33
85, 85
052100280 89
2314F002 83
052100400 89
2314F003 121
052109076 83
Page 172
Parts Index
052109078 37 U85206520 131
052300550 107 SPACER 199216320 53, 55
052300600 107 199216340 113
2415A070 121 SPRING 198211000 41, 45
26560014 123 198216720 39
SEAL - REAR END 050209107 27 198217750 41, 45

OIL
198217880 41, 47
SEAL - ROCKER 120996150 33
BOX 198217900 49
U20996150 33 STARTER MOTOR U5MK8259 79
SEAL - VALVE U20406140 29, 29 STARTER MOTOR - U5MK8259R 79

STEM EXCHANGE
SHAFT 125116211 41, 47 U85086711R 79
125116221 41, 47 STARTER RING U15376130 77
SHIM 131437590 59, 67 STRAINER 140406500 83
131437600 59, 67 U40406500 83
131437610 59, 67 STUD 010109440 17, 19,

101
131437620 59, 67
012109177 33
131437630 59, 67
012110625 17, 31,
131437830 59, 67 109
131437840 59, 67 012110635 17, 19
199286150 39 012110660 17, 19
199286160 39 SUMP 110708510 83
199286170 39 SUMP DRAIN PLUG T10109238 87
199286180 39 SUPPORT BRACKET 135976630 113
SLIDER 125256220 53 TAPPET 120116160 33
125256250 55 TERMINAL 385620320 103
SMALL END BUSH 198517125 25 TERMINAL KIT U85656070 79
SOLENOID U85206452 131 THERMOSTAT 145206062 97
Page 173
Parts Index
THERMOSTAT 145216540 97 0920154 125

HOUSING
140996260 35, 35,
145226470 101 109, 133,
133
TIMING CASE U65116551 41, 43
199266180 39, 57
TOOL 198217970 51
199280280 33
VALVE 26510194 111
2411D010 125
VALVE COLLET 120226070 29, 29
WATER PUMP U45017961 99
VALVE SEAT U10136460 29
INSERT WATER PUMP 145336490 81
PULLEY
VALVE SPRING 198216700 29, 29
WATER W85720580 135
VALVE SPRING CAP 120216041 29, 29 TEMPERATURE
SWITCH
WASHER 025100006 41, 41,
47, 49,
65, 73
025100010 49
025100016 87, 131
026100008 123
026100010 103
026109017 103
026200010 123
027100010 123
0920146 125
Page 174

Gt51789u 400s403a-11

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GT51789U GT51789U

2. How To Use Your Parts Book Pg. 4

3. Engine Breakdown Pg. 5

4. Symbol Descriptions Pg. 9

5. Parts Lists & Illustrations Pg. 11

6. Parts Index Pg. 166

How to use your Parts Book

Parts Lists & Illustrations

For fitting instructions please refer to your engine Service Manual.

Section Page Section Page

Level 1 - Service 11 Relief Valve 37

Level 2 - Repair 13 Oil Pump 39

Level 3 - Overhaul 15 Timing Case 41

Cylinder Block 17 Timing Case 43

Cylinder Block 19 Timing Case 45

Cylinder Block 21 Timing Case 47

Crankshaft, Pistons & Connecting Rods 23 Timing Case 49

Crankshaft, Pistons & Connecting Rods 25 Miscellaneous 51

Rear End Oil Seal 27 Camshaft & Gears 53

Cylinder Head 29 Camshaft & Gears 55

Cylinder Head 31 Camshaft & Gears 57

Rocker Shaft Assembly 33 Fuel Injection Pump 59

Pipes 35 High Pressure Fuel Pipes 61

Section Page Section Page

Fuel Leak-Off Pipe 65 Oil Filter 91

Fuel Injection Pump 67 Oil Filter 93

High Pressure Fuel Pipes 69 Front End Drive Input 95

Atomisers 71 Thermostat & Housing 97

Fuel Leak-Off Pipe 73 Water Pump 99

Flywheel Housing 75 Water Pump 101

Flywheel & Starter Ring 77 Alternator 103

Starter Motor 79 Drive Belt & Tensioner 105

Pulleys 81 Front End Drive Output 107

Lubricating Oil Sump 83 Cylinder Head Cover 109

Dipstick & Tube 85 Air Filter Assembly 111

Sump 87 Pipework & Connections 113

Section Page Section Page

Air Filter Assembly 115 Fan 141

Exhaust Manifold 117 Fan 143

Exhaust Connection 119 Guards 145

Lift Pump 121 Guards 147

Fuel Filter 123 Radiator & Cowling 149

Pipework & Connections 125 Radiator & Cowling 151

Cold Start System 127 Radiator & Cowling 153

Engine Lifting Eyes 129 Fan 155

Throttle & Stop Controls 131 Fan 157

Instrumentation 133 Guards 159

Instrumentation 135 Guards 161

Radiator & Cowling 137 Electrical 163

Radiator & Cowling 139 Fuel Pre-Lift Pump 165

A From Engine Number

B Upto Engine Number

C Repairs and Replaces

D See Appropriate Section - Reference Number

H New for Old Part

O Reference for Detailed Breakdown

P Other Service Options Available

R See History Section

Recommended stocking and service lists

Item Part No. References Qty. Description Notes

Recommended stocking and service lists

Item Part No. References Qty. Description Notes