FOREWORD

This Spare Parts Catalogue is applicable to AL 4102 G1 ENGINE.

The following information regarding mode of supply is given in the Catalogue:

A. When the components are supplied in the form of a sub-assembly or a set, or kit, specific mention
is made.

B. Similarly when parts are not serviced as components, specific mention is made. (Not Serviced
Separately - NSS)

C. No specific mention is made when component/assembly is supplied, as such.

D. All standard fasteners (Prefix H & L) are not serviced.

E. Part numbers not given but illustrations depicted are only to facilitate assembling.

While ordering for parts, due note of the above information should be taken.

In addition to the “Description” and the “Part Number”, the “Aggregate” / “Unit Description”, if given, will
enable our Parts department to process the order quickly.

Since the process of development is continuous with design changes, part numbers are likely to change.
The information given in this publication is current at the time of release. The possibility exists that the
information may need to be updated as a result of modification adopted by the manufacturer at any time
for reason of a technical or commercial nature. Relevant changes would be updated through our
Service Circular / Bulletin, if found necessary.

While all care has been taken to illustrate the components as they look, due to constraints of standardizing
the illustrations, variations will be there. The components shown in the illustration but not listed in
description column are not applicable for the models referred above.

Though every care has been taken in preparing this Parts Catalogue, no liability is under taken for any
error which may arise.

We welcome your suggestions and feed back on the contents of this catalogue. Should you require any
clarifications concerning the contents of this catalogue, please write to:

ENGINE BUSINESS UNIT

No. 1, Sardar Patel Road, Guindy, Chennai - 600 032.

PUB. NO. PC:AL4102G1ENG:EDITION 3:JULY 2010

 AL 4102 G1 ENGINE
PARTS CATALOGUE

CONTENTS

SL. NO. DESCRIPTION PAGE NO.

1 CYLINDER HEAD 3

2 CYLINDER BLOCK - I 5

3 CYLINDER BLOCK - II 6

4 PISTON AND CONNECTING ROD 7

5 CRANKSHAFT AND FLYWHEEL 8

6 CAMSHAFT 9

7 INTAKE AND EXHAUST MANIFOLD 10

8 AIR CLEANER 11

9 FUEL INJECTION PUMP 12

10 FUEL FILTER AND FUEL PIPING 13

11 OIL SUMP AND DIPSTICK 14

12 OIL PUMP 15

13 OIL FILTER 16

14 OIL COOLER 17

15 WATER PUMP AND FAN 18

16 RADIATOR AND PIPING 19

17 ALTERNATOR AND STARTER MOTOR 20

2
 AL 4102 G1 ENGINE
CYLINDER HEAD PARTS CATALOGUE

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
1 1 P9001431 OIL FILLER PLUG 1
2 2 P9001311 CYLINDER HEAD COVER 1
3 19 P9000436 VALVE SPRING (INNER) 8
4 20 P9000336 VALVE SPRING (OUTER) 8
5 21 P9000734 SPRING CAP (SPRING SEAT UPPER) 8
6 22 P9001008 VALVE KEYS(VALVE SPLIT COLLETS) 16
7 23 P9000927 INTAKE VALVE SEAL 4
8 24 P9001427 EXHAUST VALVE SEAL 4
9 25 P9000634 VALVE GUIDE 8
10 27 P9001835 CYLINDER HEAD BOLT (LONG) 14
11 28 P9001130 REAR COVER PLATE 1
12 29 P9003617 REAR COVER PLATE GASKET 1
13 30 P9001549 INJECTOR WASHER 4
14 31 P9001739 INJECTOR 4
15 P9000152 NOZZLE 4
16 34 P9001531 GLOW PLUG 4
17 41 P9001935 CYLINDER HEAD BOLT (SHORT) 4
18 48 P9000106 GLOW PLUG CONDUCTOR(GLOW PLUG CABLE) 1
19 49 P9002617 INTAKE MANIFOLD GASKET 1
20 51 P9001209 EXHAUST VALVE SEAT 4
21 52 P9000542 EXHAUST VALVE 4
22 53 P9000442 INTAKE VALVE 4
3
AL 4102 G1 ENGINE
PARTS CATALOGUE CYLINDER HEAD

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
23 54 P9001109 INTAKE VALVE SEAT 4

24 56 P9001218 CYLINDER HEAD 1

25 57 P9003717 THERMOSTAT HOUSING GASKET 1

26 58 P9000930 THERMOSTAT HOUSING 1

27 60 P2605620 HWT SAFETY SWITCH 1

28 61 P2605520 WATER TEMPERATURE SENSOR 1

29 62 P9003017 THERMOSTAT COVER GASKET 1

30 65 P9001939 THERMOSTAT 1

31 70 P9000533 ROCKER SHAFT 1

32 71 P9000711 THERMOSTAT COVER 1

33 73 P9000537 STUD AM10×60 8

34 75 P9002717 EXHAUST MANIFOLD GASKET 4

35 77 P9003835 ROCKER SHAFT BRACKET BOLT 2

36 81 P9000532 ROCKER ARM WITH BUSH 8

37 82 P9002335 VALVE CLEARANCE ADJUSTING SCREW 8

4
 AL 4102 G1 ENGINE
CYLINDER BLOCK - I PARTS CATALOGUE

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
1 1 P9001204 ENGINE FRONT BRACKET 2
2 4 P9000505 CAM SHAFT FRONT BUSHING 1
3 7 P9000402 MAIN BEARING PAIR 4
4 10 P9001318 CYLINDER BLOCK 1
5 12 P9001951 THRUST WASHER KIT 2
6 14 P2602001 ADOPTER 1
7 15 P2601901 ‘T’ CONNECTOR 1
8 16 P2605420 LOP SENSOR 1
9 17 P2605720 LOP SAFETY SWITCH 1
10 24 P9003817 REAR COVER GASKET 1
11 25 P9001011 REAR OIL SEAL COVER 1
12 26 P9000827 OIL SEAL PG105×130×12(REAR OIL SEAL) 1
13 34 P9001818 FLYWHEEL HOUSING 1
14 37 P2602204 STOP SOLENOID BRACKET 1
15 38 P2643939 STOP SOLENOID WITH LEVER 1
16 46 P9000405 CAM BUSH 2
17 48 P9000534 CYLINDER LINER 4
18 49 P9002317 CYLINDER HEAD GASKET 1

5
AL 4102 G1 ENGINE
PARTS CATALOGUE CYLINDER BLOCK - II

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
1 2 P9002517 GEAR CASE COVER GASKET 1
2 3 P9001111 GEAR CASE COVER 1
3 7 P9003917 INSPECTION WINDOW COVER GASKET 1
4 8 P9001211 INSPECTION WINDOW COVER 1
5 13 P9001027 OIL SEAL PG65×85×10(FRT OIL SEAL) 1
6 18 P9002417 GEAR CASE GASKET 1
7 21 P9001404 ALTERNATOR REAR BRACKET 1
8 22 P9001304 ALTERNATOR FRONT BRACKET 1

6
 AL 4102 G1 ENGINE
PISTON AND CONNECTING ROD PARTS CATALOGUE

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
1 1 P9000551 RINGSET 4
2 2 P9000642 PISTON SET 4
3 3 P9000651 ENGINE SET 4
4 4 P9000305 CONNECTING ROD BUSHING 4
5 5 P9000502 CONNECTING ROD BEARING (PAIR) 4
6 6 P9002239 CONNECTING ROD ASSY 4

7
AL 4102 G1 ENGINE
PARTS CATALOGUE CRANKSHAFT AND FLYWHEEL

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
1 2 P9000515 CRANKSHAFT PULLEY 1
2 6 P9000733 CRANKSHAFT 1
3 8 P9000807 FLYWHEEL RING GEAR 1
4 10 P9002035 FLYWHEEL BOLT 6
5 11 P9000918 FLYWHEEL 1

8
 AL 4102 G1 ENGINE
CAMSHAFT PARTS CATALOGUE

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
1 4 P9001016 CAMSHAFT TIMING GEAR 1
2 7 P9001030 CAMSHAFT THRUST PLATE 1
3 8 P9001609 KEY CAMSHAFT 1
4 9 P9000833 CAMSHAFT 1
5 10 P9000243 TAPPET 8
6 11 P9000632 PUSH ROD 8
7 12 P9000633 IDLE GEAR SHAFT 1
8 13 P9000516 IDLE GEAR WITH BUSHING 1

9
AL 4102 G1 ENGINE
PARTS CATALOGUE INTAKE AND EXHAUST MANIFOLD

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
1 1 P9001018 EXHAUST MANIFOLD 1
2 2 P9001118 INTAKE MANIFOLD 1
3 3 P9004017 GASKET 1
4 4 P9000113 INTAKE PIPE 1

10
 AL 4102 G1 ENGINE
AIR CLEANER PARTS CATALOGUE

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
1 1 P9001639 AIR CLEANER ASSY 1
2 2 F7A01000 AIR FILTER 1

11
AL 4102 G1 ENGINE
PARTS CATALOGUE FUEL INJECTION PUMP

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
1 1 P9001316 FIP GEAR 1
2 5 P9000414 INJECTION PUMP MOUNTING FLANGE 1
3 7 P9002039 INJECTION PUMP 1
4 21 P9003939 LIFT PUMP ASSEMBLY 1

12
 AL 4102 G1 ENGINE
FUEL FILTER AND FUEL PIPING PARTS CATALOGUE

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
1 1 P9001819 FUEL INJECTION PIPE KIT 1
2 2 P9000908 FUEL INJECTION PIPE CLAMP - LOWER 1
3 3 P9000808 FUEL INJECTION PIPE CLAMP - UPPER 1
4 5 P9001919 INJECTION PUMP LUBRICATING OIL INLET PIPE 1
5 11 P9001619 INJECTOR FUEL-RETURN PIPE 1
6 11, 12 P9001719 INJECTOR FUEL-RETURN PIPE COMBINATION 1
7 15 P2602840 FUEL FILTER 1
8 17 P9001539 FUEL FILTER ASSY WITH FILTER HEAD 1
9 20 P9001449 WASHER 4

13
AL 4102 G1 ENGINE
PARTS CATALOGUE OIL SUMP AND DIPSTICK

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
1 1 P9002817 OIL SUMP GASKET 1
2 3 P9000449 DRAIN PLUG WASHER 1
3 4 P9001731 DRAIN PLUG 1
4 14 P9000520 DIPSTICK 1

14
 AL 4102 G1 ENGINE
OIL PUMP PARTS CATALOGUE

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
1 P9002139 OIL PUMP ASSY 1
16 P9002219 OIL PIPE 1

15
AL 4102 G1 ENGINE
PARTS CATALOGUE OIL FILTER

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
1 3 P9004617 FILTER HEAD GASKET 1
2 4 P9000909 OIL FILTER SEAT 1
3 6 P9001439 OIL FILTER ASSY WITH FILTER HEAD 1
4 7 P2602740 OIL FILTER 1

16
 AL 4102 G1 ENGINE
OIL COOLER PARTS CATALOGUE

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
1 1 P9001839 LUBRICATING OIL COOLER CORE 1
2 2 P9000507 O SEAL RING 32×3.1 2
3 3 P9002917 OIL COOLER COVER GASKET 1

17
AL 4102 G1 ENGINE
PARTS CATALOGUE WATER PUMP AND FAN

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
1 3 P2606720 FAN 18.0” DIA 1
2 4 P9000315 WATER PUMP PULLEY 1
3 5 P9000203 V-BELT AV17×1082 1
4 14 P9001504 ALTERNATOR BRACKET 1
5 20 P9002019 HOSE(RUBBER HOSE) 1
6 24 P9003117 WATER PUMP STAND GASKET 1
7 P9002339 WATER PUMP ASSY 1

18
 AL 4102 G1 ENGINE
RADIATOR AND PIPING PARTS CATALOGUE

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
1 1 P2648639 RADIATOR 1
2 6 P2600610 RESERVE TANK 1
3 12 P2602304 BRACKET RESERVE TANK 1
4 19 P2648739 SHROUD 1
5 23 P2625119 HOSE RADIATOR OUTLET 1
6 26 P2625019 HOSE RADIATOR INLET 1
7 30 P2600126 AVM PADS RADIATOR 2
8 34 P2602504 BRACKET RADIATOR - RH 1
9 35 P2602404 BRACKET RADIATOR - LH 1
10 36 P2600632 TIE ROD ASSY RADIATOR 1

19
AL 4102 G1 ENGINE
PARTS CATALOGUE ALTERNATOR AND STARTER MOTOR

SL. ILL. PART

DESCRIPTION QTY REMARKS
NO. NO. NO.
1 1 P9002439 STARTING MOTOR (9 TEETH) 1
2 2 P9001239 GENERATOR 1
3 P9001116 STARTER PINION 1
4 P9001504 GENERATOR BRACKET 1

20