Senr1017!04!00 Manuals Service Modules Specifications

SENR1017-04
December 2008
Specifications
3408E and 3412E Engines for
Caterpillar Built Machines
SAFETY.CAT.COM
i01658146
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.
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. 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 be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this

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

ture failures, product damage, personal injury or
death.
SENR1017-04 3
Table of Contents
Table of Contents Crankcase Breather ............................................. 94

Coolant Conditioner Base .................................... 96
Water Temperature Regulator .............................. 98
Water Pump ....................................................... 101
Specifications Section Cylinder Block .................................................... 102
Cylinder Block .................................................... 105
Engine Design ....................................................... 5
Cylinder Block .................................................... 108
Fuel Transfer Pump ............................................... 8
Cylinder Liner ...................................................... 110
Fuel Filter Base ...................................................... 9
Crankshaft .......................................................... 111
Fuel Filter Base ..................................................... 11
Crankshaft .......................................................... 113
Fuel Filter Base ..................................................... 11
Vibration Damper ................................................ 116
Fuel Filter Base .................................................... 12
Fuel Filter Base .................................................... 12
Fuel Filter (Primary) .............................................. 13
Connecting Rod and Main Bearing Journals ....... 119
Ether Starting Aid .................................................. 15
Connecting Rod ................................................. 120
Ether Starting Aid .................................................. 16
Piston and Rings ................................................ 123
Hydraulic Pump Drive ........................................... 19
Piston and Rings ................................................ 126
Unit Injector Hydraulic Pump ................................ 22
Housing (Front) ................................................... 128
Injection Actuation Pressure Control Valve ........... 26
Housing (Front) ................................................... 130
Unit Injector ........................................................... 28
Housing (Front) ................................................... 130
Unit Injector Wiring ............................................... 31
Housing (Front) ................................................... 131
Valve Rocker Arms, Lifters, and Bridges ............. 34
Housing (Front) ................................................... 132
Valve Rocker Arms, Lifters, and Bridges ............. 35
Gear Group (Front) ............................................. 134
Valve Mechanism Cover ...................................... 39
Gear Group (Front) ............................................. 136
Gear Group (Front) ............................................. 137
Gear Group (Front) ............................................. 138
Cylinder Head Valves ........................................... 43
Gear Group (Rear) .............................................. 140
Cylinder Head Valves ........................................... 46
Gear Group (Rear) .............................................. 143
Cylinder Head ...................................................... 47
Gear Group (Rear) .............................................. 143
Cylinder Head ...................................................... 50
Gear Group (Rear) .............................................. 144
Cylinder Head ...................................................... 52
Flywheel ............................................................. 145
Cylinder Head ...................................................... 54
Flywheel ............................................................. 145
Turbocharger ........................................................ 56
Flywheel ............................................................. 146
Turbocharger ........................................................ 57
Flywheel ............................................................. 146
Turbocharger ........................................................ 59
Flywheel ............................................................. 147
Turbocharger ........................................................ 59
Flywheel ............................................................. 148
Turbocharger ........................................................ 60
Flywheel ............................................................. 148
Aftercooler ........................................................... 62
Flywheel ............................................................. 149
Aftercooler ........................................................... 62
Flywheel ............................................................. 150
Exhaust Manifold ................................................. 63
Flywheel ............................................................. 151
Flywheel ............................................................. 151
Flywheel Housing .............................................. 152
Camshaft ............................................................. 70
Camshaft ............................................................. 73
Camshaft ............................................................. 74
Belt Tension Chart ............................................. 163
Camshaft Bearings .............................................. 77
Alternator and Regulator .................................... 165
Engine Oil Lines ................................................... 78
Engine Oil Lines ................................................... 79
Engine Oil Filter Base .......................................... 80
Engine Oil Filter Bypass Valve .............................. 84
Prelubrication Oil Pump ........................................ 87
Engine Oil Bypass Valve ...................................... 88
Engine Oil Pan ..................................................... 89
Engine Oil Pan ..................................................... 90
Engine Oil Pan ..................................................... 91
Alternator Mounting ........................................... 182
Engine Oil Pan ..................................................... 91
Electric Starting Motor ....................................... 184
Engine Oil Pan ..................................................... 92
Crankcase Breather ............................................. 94
4 SENR1017-04
Table of Contents

Magnetic Pickup ................................................ 191
Magnetic Pickup ................................................ 192
Coolant Temperature Sensor ............................. 194
Coolant Flow Switch .......................................... 198
Jacket Water Heater .......................................... 199
Jacket Water Heater .......................................... 201
Fuel Temperature Sensor ................................... 203
Injection Actuation Pressure Sensor ................... 208
Engine Oil Pressure Sensor ............................... 210
Engine Oil Pressure Sensor ............................... 212
Engine Oil Temperature Sensor .......................... 213
Engine Oil Temperature Sensor (If Equipped) .... 215
Atmospheric Pressure Sensor ............................ 218
Inlet Air Temperature Sensor .............................. 219
Turbocharger Outlet Pressure Sensor ................ 224
Speed/Timing Sensor ........................................ 226
Index Section
Index ................................................................... 227
SENR1017-04 5
Specifications Section
Specifications Section 3412E Engines
i01761012
Engine Design
SMCS Code: 1201
3408E Engines
g00495276
Illustration 2
(A) Inlet Valves
(B) Exhaust Valves
Bore ........................................ 137.2 mm (5.40 inch)
Stroke ..................................... 152.4 mm (6.00 inch)

g00673205
Illustration 1
Displacement ..................................... 27 L (1648 in3)
(A) Inlet Valves
Arrangement of cylinders ................. 65 degrees V12
(B) Exhaust Valves
Valves per Cylinder ................................................. 4
Bore ........................................ 137.2 mm (5.40 inch)
The Adjustment For The Inlet Valve Lash is the
Stroke ..................................... 152.4 mm (6.00 inch) Following Value. ...................... 0.38 mm (0.015 inch)
Displacement ..................................... 18 L (1099 in3) The Adjustment For The Exhaust Valve Lash is the
Following Value. ...................... 0.76 mm (0.030 inch)
Arrangement of cylinders ................... 65 degrees V8
Firing Order ............ 1, 4, 9, 8, 5, 2, 11, 10, 3, 6, 7, 12
Valves per Cylinder ................................................. 4
Crankshaft rotation ........................ counterclockwise
The Adjustment For The Inlet Valve Lash is the
Following Value. ...................... 0.38 mm (0.015 inch) Number one cylinder is the front cylinder on the left
side of the cylinder block.
The Adjustment For The Exhaust Valve Lash is the
Following Value. ...................... 0.76 mm (0.030 inch) Number two cylinder is the front cylinder on the right
Firing Order ................................. 1, 8, 4, 3, 6, 5, 7, 2
Note: The front of the engine is opposite of the
Crankshaft rotation ........................ counterclockwise flywheel end of the engine. The left side of the engine
and the right side of the engine is viewed from the
Number one cylinder is the front cylinder on the left flywheel end of the engine.
i02902369
Number two cylinder is the front cylinder on the right
side of the cylinder block. Fuel Transfer Pump
Note: The front of the engine is opposite of the SMCS Code: 1256
flywheel end of the engine. The left side of the engine
and the right side of the engine is viewed from the Part No.: 149-1950
flywheel end of the engine. S/N: AAA1-Up
6 SENR1017-04
Part No.: 149-1950 Part No.: 149-1950

S/N: BCA1-Up S/N: 7KK1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: BDA1-Up S/N: AAK1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 1AB1-Up S/N: ABK1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 1FB1-Up S/N: ASK1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 1NB1-Up S/N: AWK1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: BBB1-Up S/N: 7TL1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: BEC1-Up S/N: 7TL1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 1JD1-Up S/N: 8BL1-Up
Part No.: 149-1950 Part No.: 149-1950
Part No.: 149-1950 Part No.: 149-1950
S/N: 2YD1-Up S/N: ACL1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 2YD1-Up S/N: 7GN1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 8YG1-Up S/N: 8HN1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: CEH1-Up S/N: BBN1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 3BJ1-Up S/N: 2ZR1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 6XJ1-Up S/N: 3KR1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 7MJ1-Up S/N: 3KR1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 7XJ1-Up S/N: 4FR1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 7XJ1-Up S/N: 4YR1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: NBJ1-Up S/N: 4YR1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 3SK1-Up S/N: 4YR1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 3TK1-Up S/N: 4YR6-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 67K1-Up S/N: 5HR1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 7HK1-Up S/N: 5TR1-Up
SENR1017-04 7
Part No.: 149-1950 Part No.: 149-1950

S/N: 5XR1-Up S/N: 9YS1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 5YR1-Up S/N: AAT1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 5YR1-Up S/N: AKT1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 6JR1-Up S/N: AXT1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 6KR1-Up S/N: 24W1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 6PR1-Up S/N: 25W1-Up
Part No.: 149-1950 Part No.: 149-1950
Part No.: 149-1950 Part No.: 149-1950
S/N: 6TR1-Up S/N: 50W1-Up
Part No.: 149-1950 Part No.: 149-1950
Part No.: 149-1950 Part No.: 149-1950
S/N: 7BR1-Up S/N: 63W1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 7ER1-Up S/N: 64W1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 7FR1-Up S/N: 64W1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 7KR1-Up S/N: BLW1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 7KR1-Up S/N: 01X1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: BCR1-Up S/N: 01X1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: CLR1-Up S/N: 01X1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 2PS1-Up S/N: 42X1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 5SS1-Up S/N: 99X1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 6YS1-Up S/N: 53Y1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 7CS1-Up S/N: 1YZ1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 8AS1-Up S/N: 1ZZ1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 8GS1-Up S/N: 2KZ1-Up
Part No.: 149-1950 Part No.: 149-1950
S/N: 9XS1-Up S/N: 49Z1-Up
8 SENR1017-04
Part No.: 149-1950 Part No.: 127-0291

S/N: 86Z1-Up S/N: BDA1-Up
Part No.: 149-1950 Part No.: 127-0291
S/N: 86Z1-Up S/N: 1AB1-Up
Part No.: 149-1950 Part No.: 127-0291
S/N: 87Z1-Up S/N: 1FB1-Up
Part No.: 149-1950 Part No.: 127-0291
S/N: 87Z1-Up S/N: 1NB1-Up
Part No.: 149-1950 Part No.: 127-0291
S/N: 89Z1-Up S/N: BBB1-Up
Part No.: 149-1950 Part No.: 127-0291
S/N: 89Z1-Up S/N: BEC1-Up
Part No.: 149-1950 Part No.: 127-0291
S/N: 90Z1-Up S/N: CEH1-Up
Part No.: 149-1950 Part No.: 127-0291
S/N: 90Z1-Up S/N: 6XJ1-Up
Part No.: 149-1950 Part No.: 127-0291
Part No.: 149-1950 Part No.: 127-0291
Part No.: 149-1950 Part No.: 127-0291
S/N: BKZ1-Up S/N: NBJ1-Up
Part No.: 127-0291
S/N: 3SK1-Up
Part No.: 127-0291
S/N: 3TK1-Up
Part No.: 127-0291
S/N: 7HK1-Up
Part No.: 127-0291
S/N: 7KK1-Up
Part No.: 127-0291
S/N: ABK1-Up
g01137694 Part No.: 127-0291

Illustration 3
S/N: ASK1-Up
(1) Inlet port
(2) Outlet port Part No.: 127-0291
S/N: AWK1-Up
Fuel flow requirements at 2700 pump rpm:
Part No.: 127-0291
Minimum outlet flow ..... 10.9 L/min (2.9 US gpm) S/N: 7TL1-Up
Pressure ................................... 430 kPa (62 psi)
Temperature .................................. 29 °C (84 °F) Part No.: 127-0291
Maximum output pressure ...... 725 kPa (105 psi) S/N: 7TL1-Up
Part No.: 127-0291
i02699060 S/N: 8BL1-Up
Fuel Filter Base Part No.: 127-0291
S/N: 8BL1-Up
SMCS Code: 1261; 1262
Part No.: 127-0291
Part No.: 127-0291 S/N: ACL1-Up
S/N: BCA1-Up
SENR1017-04 9
Part No.: 127-0291 Part No.: 127-0291

S/N: BBN1-Up S/N: 53Y1-Up
Part No.: 127-0291 Part No.: 127-0291
S/N: 2ZR1-Up S/N: 1YZ1-Up
Part No.: 127-0291 Part No.: 127-0291
S/N: 3KR1-Up S/N: 1ZZ1-Up
Part No.: 127-0291 Part No.: 127-0291
S/N: 5TR1-Up S/N: 90Z1-Up
Part No.: 127-0291 Part No.: 127-0291
S/N: 5YR1-Up S/N: 90Z1-Up
Part No.: 127-0291 Part No.: 127-0291
S/N: 6JR1-Up S/N: 91Z1-Up
Part No.: 127-0291 Part No.: 127-0291
S/N: 6PR1-Up S/N: 91Z1-Up
Part No.: 127-0291 Part No.: 127-0291
S/N: 7BR1-Up S/N: BKZ1-Up
Part No.: 127-0291
S/N: 7FR1-Up
Part No.: 127-0291
S/N: CLR1-Up
Part No.: 127-0291
S/N: 2PS1-Up
Part No.: 127-0291
S/N: 5SS1-Up
Part No.: 127-0291
S/N: 6YS1-Up
Part No.: 127-0291
S/N: 8AS1-Up
Part No.: 127-0291
S/N: 8GS1-Up
Part No.: 127-0291
S/N: 9XS1-Up g01330577
Illustration 4
Part No.: 127-0291 Fuel filter base
S/N: 9YS1-Up
Part No.: 127-0291
S/N: AXT1-Up
Part No.: 127-0291
S/N: 63W1-Up
Part No.: 127-0291
S/N: 64W1-Up
Part No.: 127-0291
S/N: 64W1-Up
Part No.: 127-0291
S/N: BLW1-Up
Part No.: 127-0291
S/N: 01X1-Up
10 SENR1017-04
Part No.: 6N-2946

S/N: NBJ1-Up
Part No.: 6N-2946
S/N: AAK1-Up
Part No.: 6N-2946
S/N: ASK1-Up
Part No.: 6N-2946
S/N: 7GN1-Up
Part No.: 6N-2946
S/N: 8HN1-Up
Part No.: 6N-2946
S/N: BBN1-Up
Part No.: 6N-2946
S/N: 3KR1-Up
Part No.: 6N-2946
S/N: 4FR1-Up
g01365334
Illustration 5
Part No.: 6N-2946
Section A-A
S/N: 4YR1-Up
(A) Apply 154-9731 Thread Lock Compound on the Part No.: 6N-2946
tapered end of the hollow stud to the following S/N: 4YR1-Up
distance. ........... 7.7 ± 0.8 mm (0.30 ± 0.03 inch)
Part No.: 6N-2946
(B) Distance from the sealing surface of the filter base S/N: 4YR1-Up
to the end of the hollow stud ........ 24.6 ± 1.3 mm
(0.97 ± 0.05 inch) Part No.: 6N-2946
S/N: 5HR1-Up
(1) Torque for the hollow stud ............... 70 ± 15 N·m Part No.: 6N-2946
(50 ± 11 lb ft) S/N: 5YR1-Up
Part No.: 6N-2946
i03051902
S/N: 6PR1-Up
Fuel Filter Base Part No.: 6N-2946
S/N: 6TR1-Up
SMCS Code: 1261; 1262
Part No.: 6N-2946
Part No.: 6N-2946 S/N: 7ER1-Up
S/N: AAA1-Up
Part No.: 6N-2946
Part No.: 6N-2946 S/N: 7KR1-Up
S/N: BDA1-Up
Part No.: 6N-2946
Part No.: 6N-2946 S/N: BCR1-Up
S/N: BEC1-Up
Part No.: 6N-2946
Part No.: 6N-2946 S/N: 7CS1-Up
S/N: 2YD1-Up
Part No.: 6N-2946
Part No.: 6N-2946 S/N: 9YS1-Up
S/N: 2YD1-Up
Part No.: 6N-2946
Part No.: 6N-2946 S/N: AAT1-Up
S/N: 3BJ1-Up
Part No.: 6N-2946
Part No.: 6N-2946 S/N: AKT1-Up
S/N: 7MJ1-Up
Part No.: 6N-2946
Part No.: 6N-2946 S/N: 63W1-Up
S/N: 7XJ1-Up
SENR1017-04 11
Part No.: 6N-2946 (2) Torque for the hollow stud ............... 70 ± 15 N·m
S/N: 63W1-Up (50 ± 11 lb ft)
Part No.: 6N-2946
S/N: 64W1-Up i03034523
Part No.: 6N-2946 Fuel Filter Base

S/N: 01X1-Up
SMCS Code: 1261; 1262
Part No.: 6N-2946
S/N: 42X1-Up Part No.: 237-9310
S/N: 1FB1-Up
Part No.: 6N-2946
S/N: 99X1-Up Part No.: 237-9310
S/N: 4YR1-Up
Part No.: 6N-2946
S/N: 2KZ1-Up Part No.: 237-9310
S/N: 4YR1-Up
Part No.: 6N-2946
S/N: 49Z1-Up Part No.: 237-9310
S/N: 6TR1-Up
Part No.: 6N-2946
S/N: 89Z1-Up Part No.: 237-9310
S/N: 6TR1-Up
Part No.: 6N-2946
S/N: 89Z1-Up Part No.: 237-9310
S/N: 7KR1-Up
Part No.: 237-9310
S/N: 26W1-Up
g01550095
Illustration 6
(1) Install the check valve to the bottom of the seat.

In order to hold the check valve tight, mark the g01537896
fuel filter base in three places by using a punch. Illustration 7
Note: Do not damage the check valve. The marks Note: Apply 154-9731 Thread Lock Compound on
must be small. the tapered end of the hollow stud before assembly
into the base assembly.
(A) Distance from the sealing surface of the base to
the end of the hollow stud ............ 24.6 ± 1.3 mm (A) Dimension from the surface of the base to the
(0.97 ± 0.05 inch) end of the stud ............................. 25.5 ± 1.0 mm
(1.00 ± 0.04 inch)
(B) Length for applying 154-9731 Thread Lock
Compound on the tapered end of the hollow (1) Torque for the hollow stud ............... 70 ± 15 N·m
stud ................... 7.6 ± 1.5 mm (0.30 ± 0.06 inch) (50 ± 11 lb ft)
12 SENR1017-04
i03285121 (B) Distance from the sealing surface of the base to

the end of the hollow stud ... 24.6 mm (0.97 inch)
Fuel Filter Base
(1) Torque for the hollow stud ............... 70 ± 15 N·m
SMCS Code: 1261; 1262 (50 ± 11 lb ft)
Part No.: 1W-3892
S/N: 8YG1-Up i03288060
Part No.: 1W-3892 Fuel Filter Base

S/N: 3BJ1-Up
SMCS Code: 1261; 1262
Part No.: 1W-3892
S/N: 7FR1-Up Part No.: 130-1137
S/N: 1JD1-Up
Part No.: 1W-3892
S/N: 7KR1-Up Part No.: 130-1137
S/N: 1JD1-Up
Part No.: 1W-3892
S/N: 50W1-Up Part No.: 130-1137
S/N: 7TL1-Up
Part No.: 1W-3892
S/N: 01X1-Up Part No.: 130-1137
S/N: 7TL1-Up
Part No.: 1W-3892
S/N: 01X1-Up Part No.: 130-1137
S/N: 8BL1-Up
Part No.: 1W-3892
S/N: 86Z1-Up Part No.: 130-1137
S/N: 8BL1-Up
Part No.: 1W-3892
S/N: 86Z1-Up
Part No.: 1W-3892
S/N: 87Z1-Up
Part No.: 1W-3892
S/N: 87Z1-Up
g01674215
Illustration 9
(1) Apply 154-9731 Thread Lock Compound to the

threads of the pipe plugs.
g01671976
Illustration 8
(A) Length for applying 154-9731 Thread Lock

Compound on the tapered end of the hollow
stud ....................................... 7.6 mm (0.30 inch)
SENR1017-04 13
Part No.: 8H-7204

S/N: 6TR1-Up
Part No.: 8H-7204
S/N: 7ER1-Up
Part No.: 8H-4681
S/N: 2PS1-Up
Part No.: 8H-4681
S/N: 5SS1-Up
Part No.: 8H-4681
S/N: 6YS1-Up
Part No.: 8H-7204
g01674217
Illustration 10 S/N: 7CS1-Up
Section A-A
Part No.: 8H-7204
S/N: 63W1-Up
(B) Distance from the sealing surface of the filter base
to the end of the hollow stud ........ 24.6 ± 1.2 mm Part No.: 8H-7204
(0.97 ± 0.05 inch) S/N: 64W1-Up
(C) Length for applying 154-9731 Thread Lock Part No.: 8H-4681
Compound on the tapered end of the hollow S/N: 01X1-Up
stud ................... 7.6 ± 0.5 mm (0.30 ± 0.02 inch)
(2) Torque for the hollow stud ......... 67.6 ± 13.5 N·m
(50 ± 10 lb ft)
i03292473
Fuel Filter (Primary)

SMCS Code: 1260
Part No.: 8H-4681
S/N: 1AB1-Up
Part No.: 8H-4681
g00111701
S/N: 1FB1-Up Illustration 11
Part No.: 8H-4681 (1) Torque for nut ................ 25 ± 4 N·m (18 ± 3 lb ft)
S/N: 1NB1-Up
Part No.: 8H-7204 (2) 7S-9323 Spring
S/N: 7XJ1-Up Length under test force ... 27.94 mm (1.100 inch)
Part No.: 8H-7204 Test force ............... 27.7 to 32.3 N (6.2 to 7.3 lb)
S/N: 4YR1-Up Free length after test ...... 42.67 mm (1.680 inch)
Outside diameter ............ 17.32 mm (0.682 inch)
Part No.: 8H-7204
S/N: 5HR1-Up
i03293391
Part No.: 8H-4681
S/N: 5TR1-Up
Ether Starting Aid
Part No.: 8H-7204 SMCS Code: 1456
S/N: 5YR1-Up
Part No.: 6T-7303
Part No.: 8H-4681 S/N: 1JD1-Up
S/N: 6JR1-Up
Part No.: 6T-7603
Part No.: 8H-7204 S/N: 1JD1-Up
S/N: 6KR1-Up
Part No.: 7T-3148
S/N: 2YD1-Up
14 SENR1017-04
Part No.: 7T-3148, 8E-5662 Part No.: 128-6799, 134-1441, 220-1701,

S/N: 2YD1-Up 6G-3650, 6G-3660
S/N: 5YR1-Up
Part No.: 6G-8300
S/N: 3BJ1-Up Part No.: 134-1441
S/N: 5YR1-Up
Part No.: 6T-7303
S/N: 6XJ1-Up Part No.: 6G-8300
S/N: 6JR1-Up
Part No.: 1N-4398
S/N: 7MJ1-Up Part No.: 6G-8480
S/N: 6KR1-Up
Part No.: 6G-8480
S/N: 7XJ1-Up Part No.: 128-6799, 134-1441, 6G-3650,
6G-3660
Part No.: 6G-8480 S/N: 6PR1-Up
S/N: 7XJ1-Up
Part No.: 128-6799
Part No.: 8E-5662 S/N: 6PR1-Up
S/N: 3SK1-Up
Part No.: 128-6799, 134-1441, 220-1701,
Part No.: 9U-1479 6G-3650, 6G-3660
Part No.: 103-7574 Part No.: 6G-8480
S/N: ABK1-Up S/N: 7ER1-Up
Part No.: 200-2378 Part No.: 128-6799
S/N: ASK1-Up S/N: 7KR1-Up
Part No.: 103-7574 Part No.: 128-6799, 134-1441, 6G-3650,
S/N: 7TL1-Up 6G-3660
S/N: 7KR1-Up
Part No.: 103-7574
S/N: 7TL1-Up Part No.: 6G-8300
S/N: 5SS1-Up
Part No.: 103-7574
S/N: 8BL1-Up Part No.: 6G-8300
S/N: 6YS1-Up
Part No.: 103-7574
S/N: 8BL1-Up Part No.: 6G-8480
S/N: 7CS1-Up
Part No.: 103-7574
S/N: ACL1-Up Part No.: 6G-8480
S/N: 8AS1-Up
Part No.: 114-8998
S/N: 3KR1-Up Part No.: 8N-2800
S/N: 50W1-Up
Part No.: 114-8998, 8E-5662
S/N: 3KR1-Up Part No.: 6G-8480
S/N: 63W1-Up
Part No.: 9U-1479
S/N: 4FR1-Up Part No.: 6G-8480
S/N: 63W1-Up
Part No.: 134-1441, 6G-3650
S/N: 4YR1-Up Part No.: 6G-8480
S/N: 64W1-Up
Part No.: 134-1441
S/N: 64W1-Up
Part No.: 134-1441
S/N: 01X1-Up
Part No.: 134-1441
S/N: 01X1-Up
Part No.: 6G-8300
S/N: 5TR1-Up Part No.: 6G-8300
S/N: 01X1-Up
SENR1017-04 15
Part No.: 1N-4398 Note: The orifice is not visible when the ether
S/N: 49Z1-Up atomizer is installed on the engine. An indicator in the
shape of an arrow has been stamped in the hex nut
Part No.: 6G-3660 of the ether atomizer in order to indicate the location
S/N: 86Z1-Up of the orifice.
Part No.: 6G-3660
S/N: 86Z1-Up
Part No.: 6G-3660
S/N: 87Z1-Up
Part No.: 6G-3660
S/N: 87Z1-Up
Part No.: 6G-3650
S/N: 89Z1-Up
Part No.: 6G-3650
S/N: 89Z1-Up
Part No.: 6G-3650
S/N: 90Z1-Up
Part No.: 6G-3650
S/N: 90Z1-Up
Part No.: 6G-3650
S/N: 91Z1-Up
Part No.: 6G-3650
S/N: 91Z1-Up
g00908020
Illustration 12
Typical example
Install the ether atomizer (1) into the air inlet elbow
(2). The spray orifice must be directed toward the
air inlet elbow. When the ether starting aid system is
activated, the ether atomizer should be injected with
the normal air flow of the engine.
16 SENR1017-04
i03293500
Ether Starting Aid

SMCS Code: 1456
Part No.: 9U-0241
S/N: 8YG1-Up
Part No.: 9U-0241
S/N: 2ZR1-Up
g01677536
Illustration 13
(1) Torque for the bolt .......... 14 ± 4 N·m (10 ± 3 lb ft) i03062700
Install the ether atomizer (2) into the air inlet elbow. Hydraulic Pump Drive
The spray orifice must be directed toward the air
inlet elbow. When the ether starting aid system is SMCS Code: 5073-PD
activated, the ether atomizer should be injected with
Part No.: 125-3431
the normal air flow of the engine. S/N: AAA1-Up
Note: The orifice is not visible when the ether Part No.: 125-3428
atomizer is installed on the engine. An indicator in the S/N: BCA1-Up
shape of an arrow has been stamped in the hex nut
of the ether atomizer in order to indicate the location Part No.: 125-3431
of the orifice. S/N: BDA1-Up
Part No.: 125-3428
S/N: 1AB1-Up
SENR1017-04 17
Part No.: 125-3428 Part No.: 125-3431

Part No.: 125-3428 Part No.: 125-3428
Part No.: 125-3428 Part No.: 125-3428
Part No.: 125-3431 Part No.: 125-3428
Part No.: 125-3428 Part No.: 125-3428
Part No.: 125-3428 Part No.: 125-3428
Part No.: 125-3431 Part No.: 125-3427
Part No.: 125-3431 Part No.: 125-3431
Part No.: 125-3428 Part No.: 125-3431
Part No.: 125-3428 Part No.: 125-3431
Part No.: 125-3428 Part No.: 125-3428
Part No.: 125-3428 Part No.: 125-3431
Part No.: 125-3431 Part No.: 125-3431
Part No.: 125-3431 Part No.: 125-3431
Part No.: 125-3431 Part No.: 125-3431
Part No.: 125-3431 Part No.: 125-3431
Part No.: 125-3431 Part No.: 125-3431
Part No.: 125-3428 Part No.: 125-3431
Part No.: 125-3431 Part No.: 125-3431
Part No.: 125-3431 Part No.: 125-3428
Part No.: 125-3431 Part No.: 125-3431
S/N: 7KK1-Up S/N: 5XR1-Up
Part No.: 125-3431 Part No.: 125-3428
S/N: AAK1-Up S/N: 5YR1-Up
Part No.: 125-3427 Part No.: 125-3431
S/N: ABK1-Up S/N: 5YR1-Up
18 SENR1017-04
Part No.: 125-3428 Part No.: 125-3428

S/N: 6JR1-Up S/N: 24W1-Up
Part No.: 125-3431 Part No.: 125-3428
Part No.: 125-3428 Part No.: 125-3428
Part No.: 125-3431 Part No.: 125-3428
Part No.: 125-3431 Part No.: 125-3431
Part No.: 125-3428 Part No.: 125-3431
Part No.: 125-3428 Part No.: 125-3428
Part No.: 125-3431 Part No.: 125-3431
Part No.: 125-3428 Part No.: 125-3427
S/N: 7FR1-Up S/N: BLW1-Up
Part No.: 125-3428 Part No.: 125-3428
Part No.: 125-3431 Part No.: 125-3431
Part No.: 125-3431 Part No.: 125-3428
Part No.: 125-3428 Part No.: 125-3431
Part No.: 125-3428 Part No.: 125-3428
Part No.: 125-3428 Part No.: 125-3428
S/N: 5SS1-Up S/N: 53Y1-Up
Part No.: 125-3428 Part No.: 125-3427
S/N: 6YS1-Up S/N: 1ZZ1-Up
Part No.: 125-3431 Part No.: 125-3431
S/N: 8AS1-Up S/N: 2KZ1-Up
Part No.: 125-3428 Part No.: 125-3431
S/N: 8GS1-Up S/N: 49Z1-Up
Part No.: 125-3427 Part No.: 125-3431
Part No.: 125-3427 Part No.: 125-3428
S/N: 9YS1-Up S/N: 86Z1-Up
Part No.: 125-3431 Part No.: 125-3428
S/N: AAT1-Up S/N: 87Z1-Up
Part No.: 125-3431 Part No.: 125-3431
S/N: AKT1-Up S/N: 87Z1-Up
Part No.: 125-3428 Part No.: 125-3431
S/N: AXT1-Up S/N: 89Z1-Up
SENR1017-04 19
Part No.: 125-3431

S/N: 89Z1-Up
Part No.: 125-3431
S/N: 90Z1-Up
Part No.: 125-3431
S/N: 90Z1-Up
Part No.: 125-3431
S/N: 91Z1-Up
Part No.: 125-3431
S/N: 91Z1-Up
Part No.: 125-3427
g01554333
S/N: BKZ1-Up Illustration 15
View A-A
Use the following procedure to tighten the bolts of the

unit injection hydraulic pump drive:
1. Tighten four bolts (5) to a torque of 5 ± 3 N·m

(45 ± 27 lb in).
2. Install the pin (6) and tighten the pin to a torque of

105 ± 10 N·m (75 ± 7 lb ft).
3. Again tighten four bolts (5) to a torque of

55 ± 7 N·m (41 ± 5 lb ft).
i03069300
Unit Injector Hydraulic Pump

SMCS Code: 1714
Part No.: 126-7292
Illustration 14
g01554321 S/N: AAA1-Up
(1) Lubricate the bore of the O-ring seal lightly with Part No.: 126-7292
the lubricant that is being sealed. S/N: BCA1-Up
Part No.: 126-7292
(2) Before installing the shaft assembly, lubricate the S/N: BDA1-Up
shaft and the bearing bore of the oil drive gear
with clean engine oil. Part No.: 126-7292
S/N: 1AB1-Up
(3) Lubricate the thrust plate lightly with clean engine
oil. Part No.: 126-7292
S/N: 1FB1-Up
(4) Before installing the shaft assembly, lubricate the
Part No.: 126-7292
shaft and the bearing bore of the shaft assembly
S/N: 1NB1-Up
with clean engine oil.
Part No.: 126-7292
S/N: BBB1-Up
Part No.: 126-7292
S/N: BEC1-Up
Part No.: 126-7292
S/N: 1JD1-Up
Part No.: 126-7292
S/N: 1JD1-Up
20 SENR1017-04
Part No.: 126-7292 Part No.: 126-7292

Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
S/N: ASK1-Up S/N: 6JR1-Up
Part No.: 126-7292 Part No.: 126-7292
S/N: AWK1-Up S/N: 6KR1-Up
Part No.: 126-7292 Part No.: 126-7292
S/N: 7TL1-Up S/N: 6PR1-Up
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
S/N: 8BL1-Up S/N: 6TR1-Up
Part No.: 126-7292 Part No.: 126-7292
SENR1017-04 21
Part No.: 126-7292 Part No.: 126-7292

Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
S/N: 24W1-Up S/N: 89Z1-Up
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
Part No.: 126-7292 Part No.: 126-7292
22 SENR1017-04
Part No.: 126-7292

S/N: 91Z1-Up
Part No.: 126-7292
S/N: BKZ1-Up
g01557933
Illustration 16
Top view
(1) Torque for the bolt ... 10.0 ± 0.2 N·m (90 ± 2 lb in)
(2) Torque for four bolts ................... 7.45 ± 0.65 N·m

(65 ± 6 lb in)
(3) Torque for the plug ..................... 7.45 ± 0.65 N·m

(65 ± 6 lb in)
(4) Remove the plug on top of the pump. Fill the

pump crankcase with clean engine oil. The pump
crankcase will hold approximately 0.75 L (0.8 qt)
of engine oil.
Note: Lubricate the bore of the O-ring seal lightly

(5) Torque for the pressure sensor

group .......................... 10 ± 2 N·m (90 ± 18 lb in)
Note: Lubricate the bore of the O-ring seal lightly

(6) Torque for the temperature sensor

group ........................ 20 ± 3 N·m (175 ± 27 lb in)
SENR1017-04 23
g01557975
Illustration 17
Note: Provide an appropriate plug so that the plug (13) Torque for the plug ................. 12.25 ± 0.15 N·m
must provide a load sensing pressure of 5.4 ± 0.6 kPa (110 ± 1 lb in)
(1.0 ± 0.1 psi).
(14) Torque for four bolts .. 16 ± 1 N·m (140 ± 9 lb in)
(7) Torque for the plug .... 25 ± 3 N·m (220 ± 27 lb in)
(15) Torque for the nut ........................ 140 ± 14 N·m
(8) Torque for the plugs ..................... 15.5 ± 0.5 N·m (105 ± 10 lb ft)
(135 ± 4 lb in)
(16) Torque for the plugs ................... 10.0 ± 0.2 N·m
Note: Before assembly, lubricate the seals of the (90 ± 2 lb in)
injection actuation pressure control valve (9) with the
lubricant that is being sealed. The coil and the valve
i02271778
of the injection actuation pressure control valve must
be assembled as matched set. Injection Actuation Pressure
(9) Torque for the injection actuation pressure control Control Valve
valve .............................. 50 ± 5 N·m (37 ± 4 lb ft)
SMCS Code: 5051
(10) Final installation torque for the
nut ........................... 5.5 ± 1.5 N·m (50 ± 13 lb in) Part No.: 107-0677
S/N: AAA1-Up
(11) Torque for eight bolts ....................... 20 ± 1 N·m Part No.: 107-0677
(175 ± 9 lb in) S/N: BCA1-Up
(12) Torque for 11 bolts ..................... 27.5 ± 2.5 N·m Part No.: 107-0677
(245 ± 22 lb in) S/N: BDA1-Up
24 SENR1017-04
Part No.: 107-0677 Part No.: 107-0677

Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
SENR1017-04 25
Part No.: 107-0677 Part No.: 107-0677

Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
Part No.: 107-0677 Part No.: 107-0677
26 SENR1017-04
Part No.: 107-0677 Part No.: 206-2630

Part No.: 107-0677 Part No.: 206-2630
Part No.: 107-0677 Part No.: 206-2630
Part No.: 107-0677 Part No.: 209-2785
Part No.: 107-0677 Part No.: 206-2630
Part No.: 107-0677 Part No.: 206-2630
S/N: 90Z1-Up S/N: 1JD1-Up
Part No.: 107-0677 Part No.: 206-2630
Part No.: 107-0677 Part No.: 206-2630
S/N: 91Z1-Up S/N: 2YD1-Up
Part No.: 107-0677 Part No.: 206-2630
S/N: BKZ1-Up S/N: 2YD1-Up
Part No.: 206-2630
S/N: 8YG1-Up
Part No.: 206-2630
S/N: CEH1-Up
Part No.: 206-2630
S/N: 3BJ1-Up
Part No.: 209-2785
S/N: 6XJ1-Up
Part No.: 206-2630
S/N: 7MJ1-Up
g01138133 Part No.: 206-2630

Illustration 18
S/N: 7XJ1-Up
(1) Install the injection actuation pressure control Part No.: 206-2630
valve. Tighten the valve to the following S/N: 7XJ1-Up
torque. ........................... 50 ± 5 N·m (37 ± 4 lb ft)
Part No.: 206-2630
(2) Tighten the nut to the following S/N: NBJ1-Up
torque. .................... 5.5 ± 1.5 N·m (50 ± 13 lb in)
Part No.: 206-2630
(3) Spacer S/N: 3SK1-Up
Part No.: 108-7090
i03293502 S/N: 3TK1-Up
Unit Injector Part No.: 206-2630

S/N: 67K1-Up
SMCS Code: 1290 Part No.: 206-2630
Part No.: 206-2630 S/N: 7HK1-Up
S/N: AAA1-Up Part No.: 206-2630
Part No.: 209-2785 S/N: 7KK1-Up
S/N: BCA1-Up Part No.: 206-2630
Part No.: 209-2785 S/N: AAK1-Up
S/N: BDA1-Up
SENR1017-04 27
Part No.: 209-2785 Part No.: 206-2630

Part No.: 209-2785 Part No.: 206-2630
Part No.: 206-2630 Part No.: 206-2630
Part No.: 206-2630 Part No.: 206-2630
Part No.: 206-2630 Part No.: 206-2630
Part No.: 108-7090 Part No.: 206-2630
Part No.: 206-2630 Part No.: 206-2630
Part No.: 209-2785 Part No.: 206-2630
S/N: ACL1-Up S/N: 7BR1-Up
Part No.: 108-7090 Part No.: 206-2630
S/N: 7GN1-Up S/N: 7ER1-Up
Part No.: 108-7090 Part No.: 206-2630
S/N: 8HN1-Up S/N: 7FR1-Up
Part No.: 209-2785 Part No.: 206-2630
S/N: BBN1-Up S/N: 7KR1-Up
Part No.: 206-2630 Part No.: 206-2630
S/N: 2ZR1-Up S/N: 7KR1-Up
Part No.: 206-2630 Part No.: 209-2785
S/N: 3KR1-Up S/N: BCR1-Up
Part No.: 206-2630 Part No.: 206-2630
S/N: 3KR1-Up S/N: CLR1-Up
Part No.: 206-2630 Part No.: 206-2630
S/N: 4FR1-Up S/N: 2PS1-Up
Part No.: 206-2630 Part No.: 206-2630
S/N: 4YR1-Up S/N: 5SS1-Up
Part No.: 206-2630 Part No.: 206-2630
S/N: 4YR1-Up S/N: 6YS1-Up
Part No.: 206-2630 Part No.: 206-2630
S/N: 4YR1-Up S/N: 7CS1-Up
Part No.: 206-2630 Part No.: 206-2630
S/N: 4YR6-Up S/N: 8AS1-Up
Part No.: 206-2630 Part No.: 206-2630
S/N: 5HR1-Up S/N: 8GS1-Up
Part No.: 206-2630 Part No.: 206-2630
S/N: 5TR1-Up S/N: 9XS1-Up
Part No.: 206-2630 Part No.: 206-2630
Part No.: 206-2630 Part No.: 206-2630
28 SENR1017-04
Part No.: 209-2785 Part No.: 206-2630

Part No.: 206-2630 Part No.: 206-2630
Part No.: 206-2630 Part No.: 206-2630
Part No.: 206-2630 Part No.: 206-2630
Part No.: 206-2630 Part No.: 206-2630
Part No.: 206-2630 Part No.: 206-2630
Part No.: 206-2630 Part No.: 206-2630
Part No.: 206-2630 Part No.: 206-2630
Part No.: 206-2630 Part No.: 206-2630
S/N: 64W1-Up S/N: BKZ1-Up
Part No.: 206-2630
S/N: 64W1-Up
Part No.: 206-2630
S/N: BLW1-Up
Part No.: 206-2630
S/N: 01X1-Up
Part No.: 206-2630
S/N: 01X1-Up
Part No.: 206-2630
S/N: 01X1-Up
Part No.: 206-2630
S/N: 42X1-Up
Part No.: 206-2630
S/N: 99X1-Up
Part No.: 206-2630
S/N: 53Y1-Up g01446870
Illustration 19
Part No.: 206-2630
S/N: 1YZ1-Up (1) Lubricate the O-ring seal and the bore lightly with
engine oil.
Part No.: 206-2630
S/N: 1ZZ1-Up
Part No.: 206-2630
S/N: 2KZ1-Up
Part No.: 206-2630
S/N: 49Z1-Up
Part No.: 206-2630
S/N: 86Z1-Up
Part No.: 206-2630
S/N: 86Z1-Up
SENR1017-04 29
Part No.: 109-0401

S/N: 1NB1-Up
Part No.: 109-0401
S/N: BBB1-Up
Part No.: 109-0401
S/N: BEC1-Up
Part No.: 109-0401
S/N: 1JD1-Up
Part No.: 109-0401
S/N: 1JD1-Up
Part No.: 109-0401
g01677553
Illustration 20 S/N: 2YD1-Up
View A-A
Part No.: 109-0401
S/N: 2YD1-Up
Part No.: 109-0401
S/N: 8YG1-Up
Part No.: 109-0401
S/N: CEH1-Up
Part No.: 109-0401
S/N: 3BJ1-Up
Part No.: 109-0401
S/N: 6XJ1-Up
Part No.: 109-0401
g01677554 S/N: 7MJ1-Up
Illustration 21
Tightening sequence for the injector elbow bolts Part No.: 109-0401
S/N: 7XJ1-Up
Use the following procedure to tighten the bolts.
Part No.: 109-0401
1. Tighten bolts 1 and 2 to 5 ± 3 N·m (44 ± 27 lb in). S/N: 7XJ1-Up
Part No.: 109-0401
2. Tighten bolts 3 and 4 to 47 ± 9 N·m (35 ± 7 lb ft). S/N: NBJ1-Up
3. Again tighten bolts 1 and 2 to 47 ± 9 N·m Part No.: 109-0401
(35 ± 7 lb ft). S/N: 3SK1-Up
Part No.: 109-0401
i03285325 S/N: 3TK1-Up
Unit Injector Wiring Part No.: 109-0401
S/N: 67K1-Up
SMCS Code: 1290
Part No.: 109-0401
Part No.: 109-0401 S/N: 7HK1-Up
S/N: AAA1-Up
Part No.: 109-0401
Part No.: 109-0401 S/N: 7KK1-Up
S/N: BCA1-Up
Part No.: 109-0401
S/N: BDA1-Up
Part No.: 109-0401
Part No.: 109-0401 S/N: ABK1-Up
S/N: 1AB1-Up
Part No.: 109-0401
Part No.: 109-0401 S/N: ASK1-Up
S/N: 1FB1-Up
30 SENR1017-04
Part No.: 109-0401 Part No.: 109-0401

Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
SENR1017-04 31
Part No.: 109-0401 Part No.: 109-0401

Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401 Part No.: 109-0401
Part No.: 109-0401
S/N: 64W1-Up
Part No.: 109-0401
S/N: BLW1-Up
Part No.: 109-0401
S/N: 01X1-Up
Part No.: 109-0401
S/N: 01X1-Up
Part No.: 109-0401
S/N: 01X1-Up
Part No.: 109-0401 g01672156
Illustration 22
S/N: 42X1-Up
Typical example
Part No.: 109-0401 (1) Connector identification for the rear cylinder
S/N: 99X1-Up (2) Connector identification for the front cylinder
(3) Cylinder
Part No.: 109-0401 (4) Flywheel housing
S/N: 53Y1-Up (5) Rear of engine
Part No.: 109-0401 Note: The front of the engine is opposite the flywheel
S/N: 1YZ1-Up housing end. The left side and the right side of the
engine are viewed from the flywheel housing. The
Part No.: 109-0401 front of the machine may not be the front of the
S/N: 1ZZ1-Up engine. The front of the machine should not be used
Part No.: 109-0401 as a reference for determining the orientation of the
engine.
S/N: 2KZ1-Up
Part No.: 109-0401
S/N: 49Z1-Up
Part No.: 109-0401
S/N: 86Z1-Up
Part No.: 109-0401
S/N: 86Z1-Up
Part No.: 109-0401
S/N: 87Z1-Up
Part No.: 109-0401
S/N: 87Z1-Up
32 SENR1017-04
Part No.: 108-1551

S/N: BCA1-Up
Part No.: 108-1874
S/N: BDA1-Up
Part No.: 108-1551
S/N: 1AB1-Up
Part No.: 108-1551
S/N: 1FB1-Up
Part No.: 108-1551
S/N: 1NB1-Up
Part No.: 108-1551
S/N: BBB1-Up
Part No.: 108-1874
S/N: BEC1-Up
Part No.: 108-1551
S/N: 1JD1-Up
g01672158
Illustration 23
Part No.: 108-1551
Top view of cylinder head
S/N: 1JD1-Up
(8) Sleeve.(13) Flywheel housing. (14) Centerline of the crankshaft.
Part No.: 108-1874
(9) Lubricate the O-ring seal and the bore lightly with S/N: 2YD1-Up
clean engine oil.
Part No.: 108-1551
1. One engine harness assembly is used for two S/N: CEH1-Up
cylinders under each valve cover. Part No.: 108-1551
S/N: 6XJ1-Up
2. The white connector (6) is marked “F” (7).
Assemble the white connector (6) to the injector Part No.: 108-1874
on the front cylinder for the wire harness. The front S/N: 7XJ1-Up
cylinder numbers are 1, 5, and 9 on the left side of
the engine. The front cylinder numbers are 2, 6, Part No.: 108-1874
and 10 on the right side of the engine. S/N: 7XJ1-Up
3. The black connector (12) is marked “R” (11). Part No.: 108-1874
Assemble the black connector (12) to the injector S/N: NBJ1-Up
on the rear cylinder for the wire harness. The rear Part No.: 108-1551
cylinder numbers are 3, 7, and 11 on the left side S/N: 3TK1-Up
of the engine. The rear cylinder numbers are 4, 8,
and 12 on the right side of the engine. Part No.: 108-1874
S/N: 67K1-Up
4. Tighten the nuts (10) to 2.50 ± 0.25 N·m
(22 ± 2 lb in). Part No.: 108-1874
S/N: 7KK1-Up
Note: Cylinders 9, 10, 11, and 12 are not applicable
Part No.: 108-1874
for an eight cylinder engine.
S/N: AAK1-Up
i03194000
Part No.: 108-1551
S/N: ABK1-Up
Valve Rocker Arms, Lifters, Part No.: 108-1874
and Bridges S/N: ASK1-Up
SMCS Code: 1102; 1121; 1209 Part No.: 108-1551

S/N: AWK1-Up
Part No.: 108-1874
S/N: 7TL1-Up
SENR1017-04 33
Part No.: 108-1551 Part No.: 108-1551, 108-1874

Part No.: 108-1551 Part No.: 108-1874
Part No.: 108-1551 Part No.: 108-1551
Part No.: 108-1874 Part No.: 108-1874
Part No.: 108-1874 Part No.: 108-1551
Part No.: 108-1874 Part No.: 108-1551, 108-1874
Part No.: 108-1551 Part No.: 108-1874
Part No.: 108-1874 Part No.: 108-1874
Part No.: 108-1874 Part No.: 108-1551
Part No.: 108-1874 Part No.: 108-1551
Part No.: 108-1874 Part No.: 108-1551
Part No.: 108-1874 Part No.: 108-1551
Part No.: 108-1874 Part No.: 108-1874
Part No.: 108-1874 Part No.: 108-1874
Part No.: 108-1874 Part No.: 108-1551
S/N: 5HR1-Up S/N: 9XS1-Up
Part No.: 108-1551 Part No.: 108-1874
S/N: 5TR1-Up S/N: 9YS1-Up
Part No.: 108-1874 Part No.: 108-1874
S/N: 5XR1-Up S/N: AAT1-Up
Part No.: 108-1551, 108-1874 Part No.: 108-1874
Part No.: 108-1874 Part No.: 108-1551
S/N: 5YR1-Up S/N: AXT1-Up
Part No.: 108-1551 Part No.: 108-1551
Part No.: 108-1874 Part No.: 108-1551
Part No.: 108-1874 Part No.: 108-1551
Part No.: 108-1551, 108-1874 Part No.: 108-1874
34 SENR1017-04
Part No.: 108-1874

S/N: 63W1-Up
Part No.: 108-1874
S/N: 64W1-Up
Part No.: 108-1874
S/N: 64W1-Up
Part No.: 108-1551
S/N: BLW1-Up
Part No.: 108-1551
S/N: 01X1-Up
Part No.: 108-1551
S/N: 01X1-Up
Part No.: 108-1551
S/N: 01X1-Up
Part No.: 108-1551
S/N: 99X1-Up
Part No.: 108-1551
S/N: 53Y1-Up
Part No.: 108-1551
S/N: 1YZ1-Up
Part No.: 108-1551 g01627678
Illustration 24
S/N: 1ZZ1-Up
Front view of head
Part No.: 108-1874
S/N: 2KZ1-Up
Part No.: 108-1551
S/N: BKZ1-Up
g01627681
Illustration 25
Top view of head
(1) Refer to Specifications, “Cylinder Head” for

information that relates to the procedure for
tightening the cylinder head bolts.
Note: Tighten cylinder head bolts (1) before you

tighten rocker arm shaft bolts (6).
SENR1017-04 35
Note: Apply 8T-2998 Lubricant to the ball and the Part No.: 4N-4298
ball socket of the pushrod, and the lifter bore, with a S/N: 3BJ1-Up
mixture that consists of 50% camshaft lubricant and
50% engine oil prior to the assembly of the valve Part No.: 4N-7352
train components. S/N: 7MJ1-Up
Part No.: 4N-7352
(A) Valve lash
S/N: 7XJ1-Up
Inlet valves ................................. 0.38 ± 0.10 mm
Part No.: 4N-7352
(0.015 ± 0.004 inch)
S/N: 3SK1-Up
Exhaust valves .......................... 0.76 ± 0.10 mm
(0.030 ± 0.004 inch) Part No.: 4N-7352
S/N: 7HK1-Up
(2) Torque for the adjustment screw locknut
....................................... 30 ± 4 N·m (22 ± 3 lb ft) Part No.: 4N-4298
S/N: 7TL1-Up
Note: Recheck valve lash setting.
Part No.: 4N-4298
(B) Dimensions for the rocker arm shaft S/N: 8BL1-Up
Part No.: 4N-4298
Bore in the sleeve bearing for the rocker arm shaft S/N: 50W1-Up
assembly after installation ...................... 24.803 mm
(0.9765 inch) Part No.: 4N-7352
S/N: 63W1-Up
Diameter of the rocker arm shaft .. 24.752 ± 0.013 mm
(0.9745 ± 0.0005 inch) Part No.: 4N-7352
S/N: 64W1-Up
(3) Lifter guide springs must not be used again.
Part No.: 4N-4298
Always install new lifter guide springs.
S/N: 01X1-Up
(C) Dimensions for the valve lifter assembly Part No.: 4N-4298
S/N: 01X1-Up
Bore in the head for the valve lifter
assembly .................................... 27.953 ± 0.019 mm Part No.: 4N-7352
(1.1005 ± 0.0007 inch) S/N: 49Z1-Up
Diameter of the valve lifter Part No.: 4N-4298

assembly .................................... 27.896 ± 0.013 mm S/N: 86Z1-Up
(1.0983 ± 0.0005 inch)
Part No.: 4N-4298
S/N: 86Z1-Up
Note: Special tooling, specifications, and procedures
are needed to install sleeves in the cylinder block Part No.: 4N-4298
lifter bores. Refer to Guideline For Reusable Parts S/N: 87Z1-Up
And Salvage Operations, SEBF8069, “Procedure To
Repair Engine Lifter Bores” for the salvage procedure Part No.: 4N-4298
of the lifter bores in the cylinder block. S/N: 87Z1-Up
Part No.: 4N-7352
i02765349 S/N: 89Z1-Up
Valve Rocker Arms, Lifters, Part No.: 4N-7352
S/N: 89Z1-Up
and Bridges
Part No.: 4N-7352
SMCS Code: 1102; 1121; 1209 S/N: 90Z1-Up
Part No.: 4N-4298 Part No.: 4N-7352
S/N: 1JD1-Up S/N: 90Z1-Up
S/N: 2YD1-Up S/N: 91Z1-Up
S/N: 8YG1-Up S/N: 91Z1-Up
36 SENR1017-04
Type 1 Diameter of the valve lifter bore that is in the cylinder

block ..... 27.953 ± 0.019 mm (1.1005 ± 0.0007 inch)
Note: Lubricate the bore in the cylinder block for the

valve lifter assembly with the 50/50 mixture of clean
engine oil and 8T-2998 Lubricant before installation.
Refer to Reuse And Salvage Guidelines, SEBF8069,

“Procedure to Repair Lifter Bores for Engines” for
more information.
g01384159
Illustration 26
(1) Refer to Specifications, “Cylinder Head” for Illustration 27

g01384173
information that is related to the tightening
sequence of the cylinder head bolts. (D) Diameter of new rocker arm
shaft ..................................... 24.752 ± 0.013 mm
(A) Valve lash setting (0.9745 ± 0.0005 inch)
Inlet valve .. 0.38 ± 0.10 mm (0.015 ± 0.004 inch) (E) The protrusion of the dowel above the top
Exhaust valve ............................ 0.76 ± 0.10 mm surface of the shaft bracket is the following
(0.030 ± 0.004 inch) value. ................ 9.7 ± 1.0 mm (0.38 ± 0.04 inch)
Note: Tighten the nut after you set the valve lash. (F) Use the required number of washers (6) in order
to obtain the end play for rocker arm to the
(2) Torque for nut ................ 47 ± 9 N·m (35 ± 7 lb ft) following value. ........................ 0.30 to 1.40 mm
(0.012 to 0.055 inch)
(B) Bore in the rocker arm for the rocker arm
shaft ............................ 24.803 mm (0.9765 inch) (5) 2N-7229 Spring
(3) Lubricate the ball and the socket of the pushrod Length under test force ... 74.17 mm (2.920 inch)
assembly with the 50/50 mixture of clean engine Test force ................. 44.5 to 53.4 N (10 to 12 lb)
oil and 8T-2998 Lubricant before installation. Free length after test ......... 114.3 mm (4.50 inch)
(4) Guide spring
Refer to Reuse And Salvage Guidelines, SEBF8066,

“Visual Inspection of Lifter Guide Springs in 3400
Series Engines” in order to obtain reuse information
on guide springs.
(C) Diameter of new lifter body .. 27.896 ± 0.013 mm

(1.0983 ± 0.0005 inch)
SENR1017-04 37
Type 2 Diameter of the valve lifter bore that is in the cylinder

block ..... 27.953 ± 0.019 mm (1.1005 ± 0.0007 inch)
Note: Lubricate the bore in the cylinder block for the

valve lifter assembly with the 50/50 mixture of clean
engine oil and 8T-2998 Lubricant before installation.
Reference: Refer to Reuse And Salvage Guidelines,

SEBF8069, “Procedure to Repair Lifter Bores for
Engines” for more information.
g01384158
Illustration 28
(7) Refer to Specifications, “Cylinder Head” for Illustration 29

g01384527
information that is related to the tightening
sequence for the cylinder head bolts. (L) Diameter of new rocker arm
shaft ..................................... 24.752 ± 0.013 mm
(G) Valve lash setting (0.9745 ± 0.0005 inch)
Inlet valve .. 0.38 ± 0.10 mm (0.015 ± 0.004 inch)
Exhaust valve ............................ 0.76 ± 0.10 mm (M) Protrusion of the dowel above the top surface of
(0.030 ± 0.004 inch) the shaft bracket ............................ 9.7 ± 1.0 mm
(0.38 ± 0.04 inch)
(8) Torque for nut ................ 30 ± 4 N·m (22 ± 3 lb ft)
(N) Use the required number of washers (12) in
Note: Tighten nut (9) after you set the valve lash. order to obtain the end play for rocker arm to the
following value. ........................ 0.30 to 1.40 mm
(9) Torque for nut ................ 47 ± 9 N·m (35 ± 7 lb ft) (0.012 to 0.055 inch)
(H) Height to top of the dowel .. 32.3 mm (1.27 inch) (11) 2N-7229 Spring
Length under test force ... 74.17 mm (2.920 inch)
(J) Bore in the rocker arm for the rocker arm Test force ................. 44.5 to 53.4 N (10 to 12 lb)
shaft ............................ 24.803 mm (0.9765 inch) Free length after test ......... 114.3 mm (4.50 inch)
(10) Guide spring
Refer to Reuse And Salvage Guidelines, SEBF8066, i01775788

“Visual Inspection of Lifter Guide Springs in 3400
Series Engines” in order to obtain reuse information Valve Mechanism Cover
on guide springs.
SMCS Code: 1107
(K) Diameter of new lifter body .. 27.896 ± 0.013 mm Part No.: 127-8941
(1.0983 ± 0.0005 inch) S/N: AAA1-Up
38 SENR1017-04
Part No.: 127-8941 Part No.: 131-3260

S/N: BCA1-Up S/N: 5XR1-Up
Part No.: 127-8941 Part No.: 131-3260
S/N: BDA1-Up S/N: 5YR1-Up
Part No.: 127-8941 Part No.: 127-8941
S/N: 1AB1-Up S/N: 5YR1-Up
Part No.: 127-8941 Part No.: 127-8941
S/N: 1FB1-Up S/N: 6JR1-Up
Part No.: 127-8941 Part No.: 127-8941
S/N: 1NB1-Up S/N: 6KR1-Up
Part No.: 127-8941 Part No.: 131-3260
S/N: BBB1-Up S/N: 6PR1-Up
Part No.: 127-8941 Part No.: 127-8941
S/N: BEC1-Up S/N: 6PR1-Up
Part No.: 127-8941 Part No.: 127-8941
S/N: CEH1-Up S/N: 6TR1-Up
Part No.: 127-8941 Part No.: 131-3260
S/N: 7XJ1-Up S/N: 6TR1-Up
Part No.: 127-8941 Part No.: 127-8941
S/N: NBJ1-Up S/N: 7BR1-Up
Part No.: 127-8941 Part No.: 127-8941
S/N: 67K1-Up S/N: 7ER1-Up
Part No.: 127-8941 Part No.: 127-8941
S/N: 7KK1-Up S/N: 7FR1-Up
Part No.: 127-8941 Part No.: 127-8941
S/N: AAK1-Up S/N: 7KR1-Up
Part No.: 127-8941 Part No.: 131-3260
Part No.: 127-8941 Part No.: 127-8941
S/N: AWK1-Up S/N: BCR1-Up
Part No.: 127-8941 Part No.: 127-8941
S/N: 7GN1-Up S/N: CLR1-Up
Part No.: 127-8941 Part No.: 127-8941
S/N: 8HN1-Up S/N: 2PS1-Up
Part No.: 127-8941 Part No.: 127-8941
S/N: BBN1-Up S/N: 5SS1-Up
Part No.: 127-8941 Part No.: 127-8941
S/N: 2ZR1-Up S/N: 6YS1-Up
Part No.: 127-8941 Part No.: 127-8941
S/N: 4FR1-Up S/N: 7CS1-Up
Part No.: 127-8941 Part No.: 127-8941
Part No.: 127-8941 Part No.: 127-8941
Part No.: 127-8941 Part No.: 127-8941
SENR1017-04 39
Part No.: 127-8941

S/N: AAT1-Up
Part No.: 127-8941
S/N: AKT1-Up
Part No.: 127-8941
S/N: AXT1-Up
Part No.: 127-8941
S/N: 24W1-Up
Part No.: 127-8941
S/N: 25W1-Up
Part No.: 127-8941
S/N: 26W1-Up
Part No.: 127-8941
S/N: BLW1-Up
Part No.: 127-8941
S/N: 99X1-Up
g00507107
Illustration 31
Part No.: 127-8941
Typical example 3412E
S/N: 1YZ1-Up
Part No.: 127-8941 (X) Front face of cylinder block
S/N: 1ZZ1-Up
(1) Breather assembly
Part No.: 127-8941
S/N: 2KZ1-Up (2) Cap assembly
Part No.: 127-8941
S/N: BKZ1-Up i02793534
Valve Mechanism Cover

SMCS Code: 1107
Part No.: 4W-2581, 4W-5388, 4W-8310
S/N: 2YD1-Up
Part No.: 4W-8310
S/N: 2YD1-Up
Part No.: 4W-8311
S/N: 7MJ1-Up
Part No.: 4W-2581, 4W-5388, 7C-8089
S/N: 7XJ1-Up
Part No.: 4W-2581, 4W-5388, 4W-8310, 7C-8089
S/N: 7XJ1-Up
Part No.: 4W-8310
S/N: 3SK1-Up
g00907886 Part No.: 4W-8311

Illustration 30
S/N: 7HK1-Up
Typical example 3408E
Part No.: 4W-2581
S/N: 7KK1-Up
Part No.: 4W-2581, 4W-5388
S/N: 4YR1-Up
Part No.: 4W-2581, 4W-5388
S/N: 4YR1-Up
40 SENR1017-04
Part No.: 4W-2581, 4W-5388, 4W-8310, 7C-8090

S/N: 4YR1-Up
Part No.: 4W-2581, 4W-5388
S/N: 4YR1-Up
Part No.: 4W-2581, 4W-5388, 4W-8310, 7C-8089
S/N: 63W1-Up
Part No.: 4W-2581, 4W-5388, 7C-8089
S/N: 63W1-Up
Part No.: 4W-2581, 4W-5388, 4W-8310, 7C-8089
S/N: 64W1-Up
Part No.: 4W-2581, 4W-5388, 7C-8089
g01395027
S/N: 64W1-Up Illustration 33
Tightening sequence for the arm cover base
Part No.: 4W-8311
S/N: 49Z1-Up
Part No.: 7C-8090
S/N: 89Z1-Up
Part No.: 7C-8090
S/N: 89Z1-Up
Part No.: 7C-8090
S/N: 90Z1-Up
Part No.: 7C-8090
S/N: 90Z1-Up
Part No.: 7C-8090
S/N: 91Z1-Up g01395018
Illustration 34
Part No.: 7C-8090 Tightening sequence for the valve mechanism cover
S/N: 91Z1-Up
(1) Tighten the bolts for the arm cover base in the
numerical sequence that is shown to the following
torque. ...................... 14 ± 4 N·m (125 ± 35 lb in)
(2) Tighten the bolts for the valve mechanism cover

in the numerical sequence that is shown to the
following torque. ....... 14 ± 4 N·m (125 ± 35 lb in)
Note: Coat both ends of the seals (5) with 3S-6252

Sealant prior to installation.
(3) Cut the seal for the valve mechanism cover to the
following length. ....................... 1409.7 ± 6.4 mm
(55.50 ± 0.25 inch)
(4) Cut the seal for the arm cover base to the
following length. ....................... 1625.6 ± 6.4 mm
(64.00 ± 0.25 inch)
i02758806
Illustration 32
g01393882
Valve Mechanism Cover
SMCS Code: 1107
Part No.: 4W-6823, 4W-6824, 4W-6828
S/N: 1AB1-Up
SENR1017-04 41
Part No.: 4W-6823, 4W-6824, 4W-6828 Part No.: 4W-6824

S/N: 1FB1-Up S/N: 87Z1-Up
Part No.: 4W-6823, 4W-6824, 4W-6828
S/N: 1NB1-Up
Part No.: 4W-6823, 4W-6827, 4W-6828
S/N: 1JD1-Up
Part No.: 4W-6823, 4W-6827, 4W-6828
S/N: 1JD1-Up
Part No.: 7C-7978
S/N: 3BJ1-Up
Part No.: 4W-6823, 4W-6827, 4W-6828
S/N: 6XJ1-Up
Part No.: 4W-6828
S/N: 3TK1-Up
Part No.: 4W-6823, 4W-6827, 4W-6828
S/N: ABK1-Up
Part No.: 4W-6823, 4W-6828
S/N: 7TL1-Up g01393882
Illustration 35
Part No.: 4W-6823, 4W-6827, 4W-6828
S/N: 7TL1-Up
Part No.: 4W-6823, 4W-6827, 4W-6828
S/N: 8BL1-Up
Part No.: 4W-6823, 4W-6827, 4W-6828
S/N: 8BL1-Up
Part No.: 4W-6823, 4W-6827, 4W-6828
S/N: ACL1-Up
Part No.: 4W-6828
S/N: 3KR1-Up
Part No.: 4W-6827, 4W-6828
g01393915
S/N: 3KR1-Up Illustration 36
Tightening sequence for the arm cover base
Part No.: 7E-6689
S/N: 50W1-Up
Part No.: 4W-6823, 4W-6828, 7C-7978
S/N: 01X1-Up
Part No.: 4W-6823, 4W-6828
S/N: 01X1-Up
Part No.: 4W-6823, 4W-6838, 7C-7978
S/N: 01X1-Up
Part No.: 4W-6823, 4W-6827, 4W-6828
S/N: 53Y1-Up
Part No.: 4W-6824
S/N: 86Z1-Up g01394066
Illustration 37
Part No.: 4W-6824 Tightening sequence for the valve mechanism cover
S/N: 86Z1-Up
(1) Tighten the bolts for the arm cover base in the
Part No.: 4W-6824
numerical sequence that is shown to the following
S/N: 87Z1-Up
torque. ..................... 14 ± 4 N·m (125 ± 35 lb in)
42 SENR1017-04
(2) Tighten the bolts for the valve mechanism cover Part No.: 108-1887
in the numerical sequence that is shown to the S/N: 67K1-Up
following torque. ....... 14 ± 4 N·m (125 ± 35 lb in)
Part No.: 108-1887
Note: Coat both ends of the seals (5) with 3S-6252 S/N: 7KK1-Up
Sealant prior to installation.
Part No.: 108-1887
S/N: AAK1-Up
(3) Cut the seal for arm cover base to the following
length. ....... 1847.9 ± 6.4 mm (72.75 ± 0.25 inch) Part No.: 143-3614
S/N: ABK1-Up
(4) Cut the seal for the valve mechanism cover to the
following length. ....................... 1765.3 ± 6.4 mm Part No.: 108-1887
(69.50 ± 0.25 inch) S/N: ASK1-Up
Part No.: 107-7319, 143-3614
i03194083 S/N: AWK1-Up
Cylinder Head Valves Part No.: 143-3614
S/N: 7TL1-Up
SMCS Code: 1105
Part No.: 143-3614
Part No.: 108-1887 S/N: 7TL1-Up
S/N: AAA1-Up
Part No.: 143-3614
Part No.: 107-7319, 143-3614 S/N: 8BL1-Up
S/N: BCA1-Up
Part No.: 143-3614
Part No.: 108-1887 S/N: 8BL1-Up
S/N: BDA1-Up
Part No.: 143-3614
Part No.: 107-7319, 143-3614 S/N: ACL1-Up
S/N: 1AB1-Up
Part No.: 108-1887
Part No.: 107-7319, 143-3614 S/N: 7GN1-Up
S/N: 1FB1-Up
Part No.: 108-1887
Part No.: 107-7319, 143-3614 S/N: 8HN1-Up
S/N: 1NB1-Up
Part No.: 108-1887
Part No.: 107-7319, 143-3614 S/N: BBN1-Up
S/N: BBB1-Up
Part No.: 107-7319, 143-3614
Part No.: 108-1887 S/N: 2ZR1-Up
S/N: BEC1-Up
Part No.: 108-1887
Part No.: 143-3614 S/N: 3KR1-Up
S/N: 1JD1-Up
Part No.: 108-1887
Part No.: 108-1887, 143-3614 S/N: 3KR1-Up
S/N: 2YD1-Up
Part No.: 108-1887
Part No.: 107-7319, 143-3614 S/N: 4FR1-Up
S/N: CEH1-Up
Part No.: 108-1887
Part No.: 143-3614 S/N: 4YR1-Up
S/N: 6XJ1-Up
Part No.: 108-1887
Part No.: 108-1887 S/N: 4YR1-Up
S/N: 7XJ1-Up
Part No.: 108-1887
Part No.: 108-1887 S/N: 4YR1-Up
S/N: 7XJ1-Up
Part No.: 108-1887
Part No.: 108-1887 S/N: 4YR1-Up
S/N: NBJ1-Up
Part No.: 108-1887, 143-3614
Part No.: 143-3614 S/N: 5HR1-Up
S/N: 3TK1-Up
SENR1017-04 43
Part No.: 107-7319, 143-3614 Part No.: 108-1887

Part No.: 107-7319, 108-1887, 143-3614 Part No.: 108-1887
Part No.: 108-1887 Part No.: 108-1887
Part No.: 107-7319, 143-3614 Part No.: 107-7319, 143-3614
Part No.: 108-1887 Part No.: 107-7319, 143-3614
Part No.: 108-1887 Part No.: 107-7319, 143-3614
Part No.: 107-7319, 108-1887, 143-3614 Part No.: 107-7319, 143-3614
Part No.: 107-7319, 108-1887, 143-3614 Part No.: 108-1887
Part No.: 108-1887 Part No.: 108-1887
Part No.: 107-7319, 143-3614 Part No.: 108-1887
Part No.: 108-1887 Part No.: 107-7319, 143-3614
S/N: 7ER1-Up S/N: BLW1-Up
Part No.: 107-7319 Part No.: 107-7319, 143-3614
S/N: 7FR1-Up S/N: 01X1-Up
Part No.: 108-1887 Part No.: 107-7319, 143-3614
Part No.: 107-7319, 108-1887, 143-3614 Part No.: 107-7319, 143-3614
Part No.: 108-1887 Part No.: 143-3614
S/N: BCR1-Up S/N: 53Y1-Up
Part No.: 107-7319, 143-3614 Part No.: 143-3614
S/N: CLR1-Up S/N: 1YZ1-Up
Part No.: 107-7319, 143-3614 Part No.: 107-7319, 143-3614
S/N: 2PS1-Up S/N: 1ZZ1-Up
Part No.: 107-7319 Part No.: 107-7319
S/N: 5SS1-Up S/N: 2KZ1-Up
Part No.: 107-7319 Part No.: 107-7319, 143-3614
S/N: 6YS1-Up S/N: BKZ1-Up
Part No.: 108-1887 Note: The Reuse and Salvage Guidelines, “Valve
S/N: 7CS1-Up and Valve Spring Specifications” has the necessary
procedure and specifications for checking used
Part No.: 108-1887
valves and springs.
S/N: 8AS1-Up
Part No.: 143-3614
S/N: 8GS1-Up
Part No.: 143-3614
S/N: 9XS1-Up
44 SENR1017-04
g01381203 g01381208
Illustration 38 Illustration 39
(1) 4N-5906 Spring (E) Diameter of valve seat insert

Length under test force ... 54.99 mm (2.165 inch) Exhaust valve ...................... 42.850 ± 0.013 mm
Test force ....................... 344 ± 34 N (77 ± 7.6 lb) (1.6870 ± 0.0005 inch)
Free length after test ...... 62.74 mm (2.470 inch) Inlet valve ............................ 46.025 ± 0.013 mm
Outside diameter ............ 31.75 mm (1.250 inch) (1.8120 ± 0.0005 inch)
(A) Height to top of valve guide ..... 32.26 ± 0.76 mm (F) Depth of bore in cylinder head for new valve seat
(1.270 ± 0.030 inch) insert ............... 15.7 ± 0.5 mm (0.62 ± 0.02 inch)
Note: Apply clean engine oil to the valve stems prior Bore in cylinder head for valve seat insert
to installation in the cylinder head.
Exhaust valve ...................... 42.774 ± 0.025 mm
(B) Diameter of new valve stem .. 9.441 ± 0.010 mm (1.6840 ± 0.0010 inch)
(0.3717 ± 0.0004 inch) Inlet valve ............................ 45.949 ± 0.025 mm
(1.8090 ± 0.0010 inch)
The minimum diameter of the valve stems for use
in the cylinder head (G) Projection height of the valve
Exhaust valves ............. 9.309 mm (0.3665 inch) Maximum permissible projection of the inlet
Inlet valves .................... 9.309 mm (0.3665 inch) valves and the exhaust valves from the face of
Bore in the new valve guide that is installed in the cylinder head ................ −1.219 to 0.203 mm
cylinder head ......................... 9.487 ± 0.020 mm (−0.0480 to 0.0080 inch)
(0.3735 ± 0.0008 inch)
(H) Angle of face of valve seat insert
(C) Diameter of valve head
Exhaust valve ................... 44.75 ± 0.50 degrees
Exhaust valve .......................... 41.81 ± 0.13 mm Inlet valve ......................... 30.25 ± 0.50 degrees
(1.646 ± 0.005 inch)
Inlet valve ................................ 44.98 ± 0.13 mm (J) Outside diameter of the face of the valve seat
(1.771 ± 0.005 inch) insert
Exhaust seat ............... 39.268 mm (1.5460 inch)
(D) Angle of valve face
Inlet seat ..................... 40.894 mm (1.6100 inch)
Inlet valve ......................... 29.25 ± 0.25 degrees i02758743
Cylinder Head Valves

SMCS Code: 1105
SENR1017-04 45
Part No.: 4W-7005 Part No.: 4W-7007

S/N: 1FB1-Up S/N: 7BR1-Up
S/N: 1NB1-Up S/N: 7FR1-Up
S/N: 1JD1-Up S/N: 24W1-Up
S/N: 2YD1-Up S/N: 26W1-Up
S/N: 8YG1-Up S/N: 63W1-Up
S/N: 3BJ1-Up S/N: 63W1-Up
S/N: 6XJ1-Up S/N: 64W1-Up
S/N: 7MJ1-Up S/N: 01X1-Up
S/N: 7XJ1-Up S/N: 01X1-Up
S/N: 3TK1-Up S/N: 01X1-Up
Part No.: 108-1887 Part No.: 108-1887
S/N: 67K1-Up S/N: 42X1-Up
S/N: 7HK1-Up S/N: 99X1-Up
S/N: 7KK1-Up S/N: 53Y1-Up
S/N: ABK1-Up S/N: 49Z1-Up
S/N: 7TL1-Up S/N: 86Z1-Up
Part No.: 4W-7005, 4W-7007 Part No.: 4W-7005
S/N: 8BL1-Up S/N: 86Z1-Up
S/N: 8BL1-Up S/N: 87Z1-Up
S/N: ACL1-Up S/N: 87Z1-Up
Part No.: 108-1887 Part No.: 4W-7007
S/N: 3KR1-Up S/N: 89Z1-Up
46 SENR1017-04
Part No.: 4W-7007 (D) Angle of valve face

S/N: 90Z1-Up
Part No.: 4W-7007 Inlet valve ......................... 29.25 ± 0.25 degrees
S/N: 91Z1-Up
Note: The Reuse and Salvage Guidelines, “Valve

and Valve Spring Specifications” has the necessary
procedure and specifications for checking used
valves and springs.
g01381208
Illustration 41
(E) Diameter of valve seat insert

Exhaust valve ...................... 42.850 ± 0.013 mm
(1.6870 ± 0.0005 inch)
Illustration 40
g01381203 Inlet valve ............................ 46.025 ± 0.013 mm
(1.8120 ± 0.0005 inch)
(1) 4N-5906 Spring
(F) Depth of bore in cylinder head for new valve seat
Length under test force ... 54.99 mm (2.165 inch) insert ............... 15.7 ± 0.5 mm (0.62 ± 0.02 inch)
Test force ....................... 344 ± 34 N (77 ± 7.6 lb)
Free length after test ...... 62.74 mm (2.470 inch) Bore in cylinder head for valve seat insert
Exhaust valve ...................... 42.774 ± 0.025 mm
(A) Height to top of valve guide ................ 32.26 mm (1.6840 ± 0.0010 inch)
(1.270 inch) Inlet valve ............................ 45.949 ± 0.025 mm
(1.8090 ± 0.0010 inch)
Note: Apply clean engine oil to the valve stems prior
to installation in the cylinder head. (G) Projection height of the valve
Maximum permissible projection of the inlet
(B) Diameter of new valve stem .. 9.441 ± 0.010 mm valves and the exhaust valves from the face of
(0.3717 ± 0.0004 inch)
the cylinder head ................ −1.219 to 0.203 mm
(−0.0480 to 0.0080 inch)
The minimum diameter of the valve stems for use
in the cylinder head
(H) Angle of face of valve seat insert
Exhaust valves ............. 9.309 mm (0.3665 inch) Exhaust valve ................... 44.75 ± 0.50 degrees
Inlet valves .................... 9.309 mm (0.3665 inch)
Inlet valve ......................... 30.25 ± 0.50 degrees
Bore in the new valve guide that is installed in
cylinder head ......................... 9.487 ± 0.020 mm (J) Outside diameter of the face of the valve seat
(0.3735 ± 0.0008 inch)
insert
(C) Diameter of valve head Exhaust seat ............... 39.268 mm (1.5460 inch)
Inlet seat ..................... 40.894 mm (1.6100 inch)
Exhaust valve .......................... 41.81 ± 0.13 mm
(1.646 ± 0.005 inch)
Inlet valve ................................ 44.98 ± 0.13 mm
(1.771 ± 0.005 inch)
SENR1017-04 47
i03196053 Part No.: 108-1552

S/N: 5HR1-Up
Cylinder Head
Part No.: 108-1552
SMCS Code: 1100 S/N: 5XR1-Up
Part No.: 108-1552 Part No.: 108-1552
S/N: AAA1-Up S/N: 5YR1-Up
Part No.: 108-1552 Part No.: 108-1552
Part No.: 108-1552 Part No.: 108-1552
S/N: BEC1-Up S/N: 6KR1-Up
Part No.: 108-1552, 127-3513, 172-6507 Part No.: 108-1552
S/N: 2YD1-Up S/N: 6PR1-Up
Part No.: 172-6507 Part No.: 108-1552
S/N: 2YD1-Up S/N: 6PR1-Up
Part No.: 108-1552 Part No.: 108-1552
Part No.: 108-1552 Part No.: 108-1552
S/N: NBJ1-Up S/N: 6TR1-Up
Part No.: 108-1552 Part No.: 108-1552
Part No.: 108-1552 Part No.: 108-1552
S/N: 7KK1-Up S/N: 7KR1-Up
Part No.: 108-1552 Part No.: 108-1552
Part No.: 108-1552 Part No.: 108-1552
S/N: ASK1-Up S/N: BCR1-Up
Part No.: 108-1552 Part No.: 108-1552
S/N: 7GN1-Up S/N: 7CS1-Up
Part No.: 108-1552 Part No.: 108-1552
S/N: 8HN1-Up S/N: 8AS1-Up
Part No.: 108-1552 Part No.: 108-1552
S/N: BBN1-Up S/N: 9YS1-Up
Part No.: 172-6507 Part No.: 108-1552
S/N: 3KR1-Up S/N: AAT1-Up
Part No.: 127-3513, 172-6507 Part No.: 172-6507
S/N: 3KR1-Up S/N: AKT1-Up
Part No.: 108-1552 Part No.: 108-1552
Part No.: 108-1552 Part No.: 108-1552
S/N: 4YR1-Up S/N: 64W1-Up
Part No.: 108-1552 Part No.: 108-1552
S/N: 4YR1-Up S/N: 42X1-Up
Part No.: 108-1552 Part No.: 108-1552
S/N: 4YR1-Up S/N: 2KZ1-Up
Part No.: 108-1552
S/N: 4YR1-Up
48 SENR1017-04
g01628126
Illustration 42
Use the following procedure to tighten the cylinder

head bolts:
1. Tighten the bolt 1 through bolt 26 in a numerical

sequence to 270 ± 25 N·m (200 ± 18 lb ft).
2. Again, tighten the bolt 1 through bolt 26

in a numerical sequence to 450 ± 25 N·m
(330 ± 18 lb ft).
3. Finally tighten the bolt 1 through bolt 26

(330 ± 18 lb ft).
4. Tighten the nuts 27 through bolt 39 in a numerical

sequence to 47 ± 7 N·m (35± 5 lb ft).
g01628138
Illustration 44
Section A-A
(4) Lubricate the O-ring seals and the bore lightly

Note: Apply 4C-5599 Anti-Seize Compound to

threads of the sleeves before assembly.
g01628136 (5) Torque for the sleeves ................... 100 ± 10 N·m

Illustration 43
(75 ± 7 lb ft)
Right side view
(1) Torque for four plugs ...................... 215 ± 20 N·m

(160 ± 15 lb ft)
(2) Apply 5P-3413 Pipe Sealant to threads of the

adapter.
(3) Torque for the taperlock studs into each cylinder

heads ............................. 35 ± 5 N·m (26 ± 4 lb ft)
SENR1017-04 49
(F) The cup plugs are installed into the cylinder head
at the following depth. .................... 2.0 ± 0.5 mm
(0.08 ± 0.02 inch)
i03196110
Cylinder Head
SMCS Code: 1100
Part No.: 4W-7007
S/N: 2YD1-Up
Part No.: 4W-7007
S/N: 2YD1-Up
g01628124
Illustration 45
Part No.: 4W-7006
(B) Height of the new cylinder S/N: 7MJ1-Up
head ....... 112.78 ± 0.25 mm (4.440 ± 0.010 inch)
Part No.: 4W-7007
S/N: 7XJ1-Up
Part No.: 4W-7007
S/N: 7XJ1-Up
Part No.: 4W-7007
S/N: 3SK1-Up
Part No.: 4W-7006
S/N: 7HK1-Up
Part No.: 4W-7007
S/N: 7KK1-Up
Part No.: 4W-7007
S/N: 4YR1-Up
Part No.: 4W-7007
S/N: 63W1-Up
Part No.: 4W-7007
S/N: 63W1-Up
Part No.: 4W-7007
S/N: 64W1-Up
Part No.: 4W-7007
S/N: 64W1-Up
Part No.: 4W-7006
S/N: 49Z1-Up
Part No.: 4W-7007
S/N: 89Z1-Up
Part No.: 4W-7007
S/N: 89Z1-Up
g01628125
Illustration 46
Part No.: 4W-7007
S/N: 90Z1-Up
Note: Before assembly,apply 6V-6640 Sealant to
the cup plugs. Part No.: 4W-7007
S/N: 90Z1-Up
(E) The cup plugs are installed into the cylinder head
at the following depth. .................... 4.5 ± 0.5 mm Part No.: 4W-7007
(0.18 ± 0.02 inch) S/N: 91Z1-Up
50 SENR1017-04
Part No.: 4W-7007

S/N: 91Z1-Up
g01628239
Illustration 47
Note: Use clean engine oil to lubricate the threads of

the cylinder head bolts before assembly.
g01628738
Illustration 48
Use the following procedure to tighten the cylinder
head bolts: If equipped, use the following procedure in order to
tighten the bracket for the fuel pump and the bracket
1. Tighten for bolt 1 through bolt 14 in a numerical for the timing cover to the cylinder heads.
sequence to 270 ± 25 N·m (200 ± 18 lb ft).
2. Again, tighten the bolt 1 through bolt 14 the bolts prior to installation.
(330 ± 15 lb ft). Note: Tighten the bolts only after the cylinder head
bolts have been given final torque.
in a numerical sequence to 450 ± 20 N·m (2) Use the following procedure to tighten the bolts:
(330 ± 15 lb ft).
1. Position the fuel pump brackets over the bolt holes
4. Install the rocker arm assemblies onto the cylinder that are in the cylinder head. Install the cylinder
head. head bolts (3) through the bracket. Finger tighten
the bolts.
5. Tighten the bolt 15 through bolt 26 in a numerical
sequence to 270 ± 25 N·m (200 ± 18 lb ft). 2. Remove the two bolts from the fuel pump in order
to install the bolts (2).
6. Again, tighten the bolt 15 through bolt 26
in a numerical sequence to 450 ± 20 N·m 3. Align the fuel pump against the fuel pump brackets
(330 ± 15 lb ft). and install the bolts 2. Tighten the bolts to the
standard torque.
in a numerical sequence to 450 ± 20 N·m 4. Tighten the bolts (3) to 44 ± 7 N·m (32 ± 5 lb ft).
(330 ± 15 lb ft).
(4) Installation depth of the cup plugs in the front and
Note: Tighten the bolt 27 through bolt 39 only after rear side of each cylinder head ..... 4.3 ± 0.8 mm
the cylinder head bolts have been given final torque. (0.17 ± 0.03 inch)
8. Tighten the bolt 27 through bolt 39 in a numerical (5) Installation depth of the cup plugs in the front and
sequence to 47 ± 7 N·m (35 ± 5 lb ft). rear side of cylinder head. ............. 2.5 ± 0.8 mm
(0.10 ± 0.03 inch)
(1) Torque for the taperlock studs ........... 35 ± 5 N·m
(26 ± 4 lb ft)
SENR1017-04 51
g01391843
Illustration 49
(A) Height of new cylinder head ... 112.78 ± 0.25 mm

(4.440 ± 0.010 inch)
g01678174
Illustration 51
Note: Apply liquid soap (40% solid) to the O-ring

seal (7) and to the bore of the cylinder head prior to
installation of the nozzle adapter.
Note: Apply 4C-5599 Anti-Seize Compound onto

the threads of the nozzle adapter prior to installation.
(6) Tighten the nozzle adapter to the following

torque. ................... 200 ± 14 N·m (150 ± 10 lb ft)
i03194673
Cylinder Head
SMCS Code: 1100
g01391847
Part No.: 107-7319
Illustration 50 S/N: BCA1-Up
(D) The cup plugs are installed into the cylinder head Part No.: 107-7319
at the following depth. .................... 4.5 ± 0.5 mm S/N: 1AB1-Up
(0.18 ± 0.02 inch)
Part No.: 107-7319
(E) The cup plugs are installed into the cylinder head S/N: 1FB1-Up
at the following depth. .................... 2.0 ± 0.5 mm Part No.: 107-7319
(0.08 ± 0.02 inch) S/N: 1NB1-Up
Part No.: 107-7319
S/N: BBB1-Up
Part No.: 164-2208
S/N: 1JD1-Up
Part No.: 107-7319
S/N: CEH1-Up
Part No.: 164-2208
S/N: 6XJ1-Up
Part No.: 107-7319
S/N: 3TK1-Up
52 SENR1017-04
Part No.: 164-2208 Part No.: 107-7319

S/N: ABK1-Up S/N: 26W1-Up
Part No.: 107-7319 Part No.: 107-7319
S/N: AWK1-Up S/N: BLW1-Up
Part No.: 164-2208 Part No.: 107-7319
S/N: 7TL1-Up S/N: 01X1-Up
Part No.: 164-2208 Part No.: 107-7319
S/N: ACL1-Up S/N: 99X1-Up
Part No.: 107-7319 Part No.: 164-2208
S/N: 2ZR1-Up S/N: 53Y1-Up
Part No.: 107-7319 Part No.: 107-7319
S/N: 5HR1-Up S/N: 1YZ1-Up
Part No.: 107-7319 Part No.: 107-7319
S/N: 5TR1-Up S/N: 1ZZ1-Up
Part No.: 107-7319 Part No.: 107-7319
S/N: 5YR1-Up S/N: BKZ1-Up
Part No.: 107-7319
S/N: 6JR1-Up
Part No.: 107-7319
S/N: 6PR1-Up
Part No.: 107-7319
S/N: 6TR1-Up
Part No.: 107-7319
S/N: 7BR1-Up
Part No.: 107-7319
S/N: 7FR1-Up
Part No.: 107-7319 g01628097
Illustration 52
S/N: 7KR1-Up
Part No.: 107-7319 Use the following procedure to tighten the cylinder
S/N: CLR1-Up head bolts:
Part No.: 107-7319 1. Tighten the bolt 1 through bolt 18 in a numerical

S/N: 2PS1-Up sequence to 270 ± 25 N·m (200 ± 18 lb ft).
Part No.: 107-7319 2. Again, tighten the bolt 1 through bolt 18
S/N: 5SS1-Up in a numerical sequence to 450 ± 15 N·m
Part No.: 107-7319 (330 ± 11 lb ft).
S/N: 6YS1-Up
Part No.: 107-7319 in a numerical sequence to 450 ± 15 N·m
S/N: 8GS1-Up (330 ± 11 lb ft).
Part No.: 107-7319 4. Tighten the nut 19 through nut 27 in a numerical

S/N: 9XS1-Up sequence to 47 ± 7 N·m (35± 5 lb ft).
Part No.: 107-7319
(1) Torque for the taperlock studs into each cylinder
S/N: AXT1-Up
head ............................... 35 ± 5 N·m (26 ± 4 lb ft)
Part No.: 107-7319
S/N: 24W1-Up
Part No.: 107-7319
S/N: 25W1-Up
SENR1017-04 53
g01628102 g01628121
Right side view
(B) Height of the new cylinder
(2) Torque for four plugs ...................... 215 ± 20 N·m head ....... 112.78 ± 0.25 mm (4.440 ± 0.010 inch)
(160 ± 15 lb ft)
g01628106
Illustration 54
Section A-A
(3) Lubricate the O-ring seals and the bore lightly

Note: Apply 4C-5599 Anti-Seize Compound to

threads of the sleeves before assembly.
(4) Torque for the sleeves ................... 100 ± 10 N·m

(75 ± 7 lb ft)
g01628119
Illustration 56
Note: Before installation, apply 6V-6640 Sealant to

the cup plugs.
at the following depth. .................... 4.5 ± 0.5 mm
(0.18 ± 0.02 inch)
54 SENR1017-04
(F) The cup plugs are installed into the cylinder head Note: Use clean engine oil to lubricate the threads of
at the following depth. .................... 2.0 ± 0.5 mm the cylinder head bolts before assembly.
(0.08 ± 0.02 inch)
The tightening sequence for the cylinder head bolts
follows:
i02756972
Cylinder Head 1. Tighten bolt (1) through bolt (10) in a numerical

sequence.
SMCS Code: 1100
Torque ..................... 270 ± 25 N·m (200 ± 18 lb ft)
Part No.: 4W-7005
S/N: 1JD1-Up 2. Again, tighten bolt (1) through bolt (10) in a
numerical sequence.
Part No.: 4W-7005
S/N: 8YG1-Up Torque ..................... 450 ± 20 N·m (330 ± 15 lb ft)
Part No.: 4W-7005 3. Finally tighten bolt (1) through bolt (10) in a
S/N: 3BJ1-Up numerical sequence.
Part No.: 4W-7005
S/N: 7TL1-Up Torque ..................... 450 ± 20 N·m (330 ± 15 lb ft)
Part No.: 4W-7005 4. Install the rocker arm assemblies onto the cylinder
S/N: 8BL1-Up head.
Part No.: 4W-7005 5. Tighten bolt (11) through bolt (18) in a numerical
S/N: 8BL1-Up sequence.
Part No.: 4W-7005
Torque ..................... 270 ± 25 N·m (200 ± 18 lb ft)
S/N: 50W1-Up
Part No.: 4W-7005 6. Again tighten bolt (11) through bolt (18) in a
S/N: 01X1-Up numerical sequence.
Part No.: 4W-7005 Torque ..................... 450 ± 20 N·m (330 ± 15 lb ft)

S/N: 01X1-Up
7. Finally tighten bolt (11) through bolt (18) in a
Part No.: 4W-7005 numerical sequence.
S/N: 86Z1-Up
Part No.: 4W-7005 Torque ..................... 450 ± 20 N·m (330 ± 15 lb ft)
S/N: 86Z1-Up
Note: Tighten the bolt (19) through bolt (27) only after
Part No.: 4W-7005 the cylinder head bolts have been given final torque.
S/N: 87Z1-Up
8. Use any tightening sequence to tighten the bolt
Part No.: 4W-7005 (19) through bolt (27).
S/N: 87Z1-Up
Torque ............................. 47 ± 7 N·m (35 ± 5 lb ft)
(28) Tighten the taperlock studs into each cylinder

head to the following torque. ............. 35 ± 5 N·m
(26 ± 4 lb ft)
g01392039
Illustration 57
SENR1017-04 55
(32) Install the cup plugs in the rear side

of each cylinder head to the following
distance. ........... 4.3 ± 0.8 mm (0.17 ± 0.03 inch)
(33) Install the cup plugs in the front and rear

side of each cylinder head to the following
distance. ........... 2.5 ± 0.8 mm (0.10 ± 0.03 inch)
g01391584
Illustration 58 g01017447
Illustration 59
If equipped, use the following procedures in order to
tighten the bracket for the fuel pump and the bracket (A) Height of new cylinder head ... 112.78 ± 0.25 mm
for the timing cover to the cylinder heads: (4.440 ± 0.010 inch)

the bolts prior to installation.
Note: Tighten the bolts only after the cylinder head

bolts have been given final torque.
(30) Use the following procedure to tighten the bolts:
1. Position the fuel pump brackets over the bolt holes

that are in the cylinder head. Install the bolts (30)
through the bracket. Finger tighten the bolts.
2. Remove the two bolts from the fuel pump in order

to install the bolts (29).
3. Align the fuel pump against the fuel pump brackets

and install the bolts (29). Tighten the bolts to the
standard torque.
4. Tighten the bolts (30).

g01388111
Illustration 60
Torque ............................. 44 ± 7 N·m (32 ± 5 lb ft)
Note: Use 6V-6640 Sealant on the cup plugs.
(31) Use the following procedure to tighten the bolts:
(D) The cup plugs are installed into the cylinder head
1. Position the housing support over the bolt holes at the following depth. .................... 4.5 ± 0.5 mm
that are in the cylinder head. Install the bolts (31) (0.18 ± 0.02 inch)
through the supports. Finger tighten the bolts.
2. Install the timing gear housing to the supports and at the following depth. .................... 2.0 ± 0.5 mm
tighten the bolts to the standard torque. (0.08 ± 0.02 inch)
3. Tighten the bolts (31).
Torque ............................. 44 ± 7 N·m (32 ± 5 lb ft)

56 SENR1017-04
Part No.: 174-1472

S/N: 7TL1-Up
Part No.: 174-1472
S/N: ACL1-Up
Part No.: 183-1199
S/N: 2ZR1-Up
Part No.: 183-1199
S/N: 24W1-Up
Part No.: 183-1199
S/N: 25W1-Up
Part No.: 183-1199
S/N: 26W1-Up
Part No.: 183-1199
S/N: BLW1-Up
Part No.: 183-1199
S/N: 01X1-Up
g01391664
Illustration 61
Part No.: 183-1199
Note: Apply liquid soap (40% solid) to the O-ring S/N: 01X1-Up
seal (35) and to the bore of the cylinder head prior to Part No.: 183-1199
installation of the nozzle adapter. S/N: 01X1-Up
Note: Apply 4C-5599 Anti-Seize Compound onto Part No.: 174-1472
the threads of the nozzle adapter prior to installation. S/N: 53Y1-Up
(34) Tighten the nozzle adapter to the following Part No.: 183-1199
torque. ................... 200 ± 14 N·m (150 ± 10 lb ft) S/N: BKZ1-Up
i03199081
Turbocharger
SMCS Code: 1052
Part No.: 183-1199
S/N: BCA1-Up
Part No.: 183-1199
S/N: 1AB1-Up
Part No.: 183-1199
S/N: 1FB1-Up
g01630655
Illustration 62
Part No.: 183-1199
S/N: BBB1-Up Use the following procedure to tighten compressor
Part No.: 174-1472 clamp assembly (1) and turbine clamp assembly (2) :
S/N: 1JD1-Up
1. Tighten the clamp assemblies to 18 N·m
Part No.: 174-1472 (160 lb in).
S/N: 6XJ1-Up
2. Loosen the clamp assemblies to 6 N·m (55 lb in).
Part No.: 183-1199
S/N: 7KK1-Up 3. Again, tighten the clamp assemblies to
13.5 ± 1.0 N·m (120 ± 9 lb in).
Part No.: 174-1472
S/N: ABK1-Up
Note: Apply 4C-5599 Anti-Seize Compound to the
Part No.: 174-1472 threads of the bolts and the threads of the locknuts
S/N: 7TL1-Up that are used to mount the turbocharger.
SENR1017-04 57
(3) Torque for locknuts ........ 55 ± 9 N·m (41 ± 7 lb ft) Part No.: 127-9177
S/N: 7FR1-Up
i03199101 Part No.: 196-5946
S/N: BCR1-Up
Turbocharger
Part No.: 127-9177
SMCS Code: 1052 S/N: 5SS1-Up
Part No.: 113-7923 Part No.: 127-9177
S/N: AAA1-Up S/N: 6YS1-Up
Part No.: 196-5946 Part No.: 196-5946
S/N: BDA1-Up S/N: 7CS1-Up
Part No.: 207-7439 Part No.: 196-5946
S/N: BEC1-Up S/N: 8AS1-Up
Part No.: 127-9177 Part No.: 129-1560
S/N: 3BJ1-Up S/N: 8GS1-Up
Part No.: 196-5946 Part No.: 127-9177
S/N: 7XJ1-Up S/N: 9XS1-Up
Part No.: 127-9177 Part No.: 113-7923
S/N: 3TK1-Up S/N: AAT1-Up
Part No.: 127-9813 Part No.: 8N-2036
S/N: 67K1-Up S/N: 50W1-Up
Part No.: 113-7923 Part No.: 196-5946
S/N: AAK1-Up S/N: 63W1-Up
Part No.: 4P-8729 Part No.: 196-5946
S/N: 8BL1-Up S/N: 64W1-Up
Part No.: 113-7923 Part No.: 127-9177
S/N: 7GN1-Up S/N: 1YZ1-Up
Part No.: 113-7923 Part No.: 127-9177
S/N: 8HN1-Up S/N: 1ZZ1-Up
Part No.: 196-5946 Part No.: 196-5946
S/N: BBN1-Up S/N: 2KZ1-Up
Part No.: 127-9177 Part No.: 7W-0831
Part No.: 127-9813 Part No.: 7W-0831
S/N: 5XR1-Up S/N: 86Z1-Up
Part No.: 127-9813 Part No.: 7W-0831
Part No.: 127-9177 Part No.: 7W-0831
Part No.: 196-5946
S/N: 6KR1-Up
Part No.: 127-9813
S/N: 6TR1-Up
Part No.: 125-1189
S/N: 7BR1-Up
Part No.: 196-5946
S/N: 7ER1-Up
58 SENR1017-04
Part No.: 4W-1495

S/N: CEH1-Up
Part No.: 4W-5288
S/N: 6XJ1-Up
Part No.: 1N-3258
S/N: 7MJ1-Up
Part No.: 6N-1362
S/N: 3SK1-Up
Part No.: 6I-4803
S/N: 7HK1-Up
Part No.: 4W-1495
S/N: AWK1-Up
Part No.: 8N-3721
S/N: 8BL1-Up
Part No.: 8N-3721
S/N: 4YR1-Up
g01630674
Illustration 63
Part No.: 8N-3721
Use the following procedure to tighten clamp S/N: 4YR1-Up
assemblies (1): Part No.: 8N-3721
S/N: 4YR1-Up
1. Tighten the clamp assemblies to 14 ± 3 N·m
(125 ± 27 lb in). Part No.: 8N-3721
S/N: 4YR1-Up
2. Gently hit around the clamp assemblies with a
soft hammer. Part No.: 4W-1495
S/N: 5YR1-Up
3. Again, tighten the clamp assemblies to 14 ± 3 N·m
Part No.: 4W-1495
(125 ± 27 lb in).
S/N: 6PR1-Up
i03199046
Part No.: 4W-1495
S/N: 6PR1-Up
Turbocharger Part No.: 4W-1495
SMCS Code: 1052 S/N: 6TR1-Up

S/N: 1AB1-Up S/N: 7KR1-Up

S/N: 1FB1-Up S/N: 7KR1-Up

S/N: 1NB1-Up S/N: CLR1-Up

S/N: 1JD1-Up S/N: 2PS1-Up

S/N: 1JD1-Up S/N: AXT1-Up
Part No.: 6N-1362, 8N-3721 Part No.: 1N-3258, 4W-5288

S/N: 2YD1-Up S/N: 53Y1-Up

S/N: 2YD1-Up S/N: 49Z1-Up

S/N: 8YG1-Up S/N: 89Z1-Up
SENR1017-04 59
Part No.: 8N-3721 Part No.: 129-6835

S/N: 89Z1-Up S/N: NBJ1-Up
Part No.: 8N-3721 Part No.: 129-6835
S/N: 90Z1-Up S/N: ASK1-Up
Part No.: 8N-3721 Part No.: 129-6835
S/N: 90Z1-Up S/N: 5HR1-Up
Part No.: 8N-3721 Part No.: 129-6835
S/N: 91Z1-Up S/N: 6KR1-Up
Part No.: 8N-3721 Part No.: 129-6835
S/N: 91Z1-Up S/N: 7ER1-Up
Part No.: 129-6835
S/N: 7CS1-Up
Part No.: 129-6835
S/N: 8AS1-Up
Part No.: 129-6835
S/N: 9YS1-Up
Part No.: 129-6835
S/N: 63W1-Up
Part No.: 129-6835
S/N: 63W1-Up
Part No.: 129-6835
S/N: 64W1-Up
Part No.: 129-6835
S/N: 64W1-Up
Part No.: 129-6835
S/N: 42X1-Up
g01630629
Illustration 64
Typical example
(1) Apply 4C-5599 Anti-Seize Compound to the

threads of bolts.
(2) Torque for four locknuts .................... 55 ± 5 N·m

(41 ± 4 lb ft)
g01630675
Illustration 65
i03199222 Front view
Turbocharger (1) Apply 4C-5599 Anti-Seize Compound to the

threads of bolts.
SMCS Code: 1052
Part No.: 129-6835 (2) Torque for the locknuts .. 55 ± 5 N·m (41 ± 4 lb ft)
S/N: 7XJ1-Up
Part No.: 129-6835
S/N: 7XJ1-Up
60 SENR1017-04
i03199023 Part No.: 9N-6613

S/N: 1JD1-Up
Turbocharger
Part No.: 8N-2404
SMCS Code: 1052 S/N: 2YD1-Up
Part No.: 174-1471 Part No.: 128-2313, 8N-2404
S/N: 2YD1-Up S/N: 2YD1-Up
Part No.: 174-1471 Part No.: 9N-6613
S/N: 3KR1-Up S/N: 8YG1-Up
Part No.: 174-1471 Part No.: 4N-5833
S/N: 3KR1-Up S/N: 3BJ1-Up
Part No.: 174-1471 Part No.: 9N-6613
S/N: AKT1-Up S/N: 6XJ1-Up
Part No.: 4N-8099
S/N: 7XJ1-Up
Part No.: 129-6836, 4N-8099
S/N: 7XJ1-Up
Part No.: 298-3908
S/N: NBJ1-Up
Part No.: 8N-2404
S/N: 3SK1-Up
Part No.: 126-7290
S/N: 3TK1-Up
g01678103 Part No.: 131-3272

Illustration 66
S/N: 67K1-Up
Use the following procedure to tighten compressor Part No.: 4N-8099
clamp assembly (1) and turbine clamp assembly (2) : S/N: 7HK1-Up
1. Tighten the clamp assemblies to 18 N·m Part No.: 9N-6613

(160 lb in). S/N: ABK1-Up
2. Loosen the clamp assemblies to 6 N·m (55 lb in). Part No.: 9N-6613
S/N: 7TL1-Up
3. Again, tighten the clamp assemblies to Part No.: 126-0767, 131-3272, 4N-5833,
13.5 ± 1.0 N·m (120 ± 9 lb in). 9N-6613
S/N: 7TL1-Up
i03250760
Part No.: 9N-6613
Aftercooler S/N: 8BL1-Up
Part No.: 126-0767, 9N-6613
SMCS Code: 1063 S/N: 8BL1-Up
Part No.: 126-0767, 4N-5833, 9N-6613 Part No.: 9N-6613
S/N: 1AB1-Up S/N: ACL1-Up
Part No.: 126-0767, 9N-6613 Part No.: 128-2313, 9N-6613
Part No.: 126-0767, 9N-6613 Part No.: 128-2313
Part No.: 129-6836 Part No.: 122-9520
S/N: BEC1-Up S/N: 4FR1-Up
Part No.: 9N-6613 Part No.: 131-3272
S/N: 1JD1-Up S/N: 4YR1-Up
SENR1017-04 61
Part No.: 131-3272 Part No.: 129-6836

Part No.: 131-3272, 8N-2404 Part No.: 126-7290
S/N: 4YR1-Up S/N: 8GS1-Up
Part No.: 131-3272 Part No.: 126-7290
S/N: 4YR1-Up S/N: 9XS1-Up
Part No.: 129-6836 Part No.: 129-6836
S/N: 5HR1-Up S/N: 9YS1-Up
Part No.: 126-7290 Part No.: 126-7290, 4N-5833
Part No.: 131-3272 Part No.: 126-7290, 4N-5833
S/N: 5XR1-Up S/N: 25W1-Up
Part No.: 131-3272 Part No.: 126-7290, 4N-5833
Part No.: 131-3272 Part No.: 125-4632, 126-7290
Part No.: 126-7290 Part No.: 129-6836, 4N-8099
Part No.: 129-6836 Part No.: 4N-8099
Part No.: 131-3272 Part No.: 129-6836, 4N-8099
Part No.: 131-3272 Part No.: 126-7290
S/N: 6PR1-Up S/N: BLW1-Up
Part No.: 131-3272 Part No.: 4N-5833
S/N: 6TR1-Up S/N: 01X1-Up
Part No.: 126-7290, 131-3272 Part No.: 4N-5833
Part No.: 126-7290 Part No.: 126-7290, 4N-5833
S/N: 7BR1-Up S/N: 01X1-Up
Part No.: 129-6836 Part No.: 122-9520, 129-6836
S/N: 7ER1-Up S/N: 42X1-Up
Part No.: 126-7290 Part No.: 126-7290, 4N-5833
Part No.: 131-3272 Part No.: 9N-6613
S/N: 7KR1-Up S/N: 53Y1-Up
Part No.: 131-3272 Part No.: 126-7290
S/N: 7KR1-Up S/N: 1YZ1-Up
Part No.: 126-0767 Part No.: 126-7290
S/N: 2PS1-Up S/N: 1ZZ1-Up
Part No.: 126-7290 Part No.: 122-9520
S/N: 5SS1-Up S/N: 2KZ1-Up
Part No.: 126-7290 Part No.: 9N-6613
Part No.: 129-6836 Part No.: 9N-6613
S/N: 7CS1-Up S/N: 86Z1-Up
62 SENR1017-04
Part No.: 9N-6613 i02312085

S/N: 87Z1-Up
Aftercooler
Part No.: 9N-6613
S/N: 87Z1-Up SMCS Code: 1063
Part No.: 8N-2404 Part No.: 163-5804
Part No.: 8N-2404 Part No.: 163-5804
Part No.: 8N-2404 Part No.: 163-5804
S/N: 90Z1-Up S/N: ABK1-Up
Part No.: 8N-2404 Part No.: 163-5804
S/N: 90Z1-Up S/N: 7TL1-Up
Part No.: 8N-2404 Part No.: 163-5804
S/N: 91Z1-Up S/N: ACL1-Up
Part No.: 8N-2404 Part No.: 163-5804
S/N: 91Z1-Up S/N: 53Y1-Up
Part No.: 126-7290
S/N: BKZ1-Up
g00678632
Illustration 68
Right side view
g01651816
Illustration 67
Typical example
(1) Lubricate the O-ring seals lightly with engine oil

or with glycerin or an equivalent.
g01160613
Illustration 69
Front view
SENR1017-04 63
Part No.: 108-4740, 179-7026

S/N: AAK1-Up
Part No.: 108-4740, 179-7026
S/N: 7GN1-Up
Part No.: 179-7026
S/N: 8HN1-Up
Part No.: 166-5437
S/N: BBN1-Up
Part No.: 127-5134, 179-7024, 212-4246
S/N: 3KR1-Up
Part No.: 108-4740, 166-5437, 179-7026
g01160617
Illustration 70 S/N: 4FR1-Up
View A-A
Part No.: 108-4740, 127-5134, 179-7024,
8N-0617
(1) Lubricate the bore for the O-ring seal lightly with
S/N: 4YR1-Up
engine oil or with glycerin.
Part No.: 127-5134, 179-7024
S/N: 5YR1-Up
Part No.: 127-5134, 179-7024
S/N: 6PR1-Up
Part No.: 127-5134, 179-7024
S/N: 6TR1-Up
Part No.: 127-5134, 179-7024
S/N: 7KR1-Up
Part No.: 166-5437
S/N: BCR1-Up
Part No.: 108-4740, 179-7026
g01156975 S/N: AAT1-Up
Illustration 71
Bolt tightening sequence for the aftercooler gasket
Part No.: 212-4246
S/N: AKT1-Up
Tighten bolt (1) through bolt (17) in a numerical
sequence to the following torque. ............ 47 ± 9 N·m Part No.: 108-4740
(35 ± 7 lb ft) S/N: 42X1-Up
Part No.: 166-5437
i03242208 S/N: 2KZ1-Up
Exhaust Manifold Part No.: 8N-0617
S/N: 89Z1-Up
SMCS Code: 1059
Part No.: 8N-0617
Part No.: 108-4740, 179-7026 S/N: 89Z1-Up
S/N: AAA1-Up
Part No.: 8N-0617
Part No.: 212-4246, 8N-0617 S/N: 90Z1-Up
S/N: 2YD1-Up
Part No.: 8N-0617
Part No.: 8N-0617 S/N: 91Z1-Up
S/N: 3SK1-Up
Part No.: 8N-0617
Part No.: 127-5134 S/N: 91Z1-Up
S/N: 67K1-Up
Part No.: 127-5134, 179-7024, 8N-0617
S/N: 7KK1-Up
64 SENR1017-04
g01146187
Illustration 73
Tightening sequence for exhaust manifold
Use the following procedure to tighten the locknuts

(1):
Note: Before assembly, apply 4C-5599 Anti-Seize

Compound to the threads of the locknuts.
1. Tighten the locknuts in a numerical sequence

that is shown in Illustration 73 to 20 ± 3 N·m
(15 ± 2 lb ft).
2. Again, tighten the locknuts in a numerical

sequence that is shown in Illustration 73 to
38 ± 5 N·m (28 ± 4 lb ft).
i03296021
Exhaust Manifold
SMCS Code: 1059
Part No.: 1N-3177
S/N: 7MJ1-Up
Illustration 72
g01645355 Part No.: 179-7024
Typical example
S/N: 7KK1-Up
Front view of engine Part No.: 179-7024
S/N: 3KR1-Up
Note: Use a centering tool in at least one oversize
hole per manifold section in order to align the Part No.: 179-7024
manifolds. Do not remove the centering tools until S/N: 4YR1-Up
removal is required to tighten the locknuts.
Part No.: 179-7024
(2) Before assembly, apply a thin coat of 2P-2333 S/N: 4YR1-Up
High Temperature Sealer to the outside diameter Part No.: 179-7024
of the male end of the exhaust manifold. S/N: 4YR1-Up
Remove excess high temperature sealer from
the assembled joint. Part No.: 179-7024
S/N: 5XR1-Up
(3) Coat the female ends of the exhaust manifold
with clean engine oil. Part No.: 179-7024
S/N: 5YR1-Up
(4) Torque for the taperlock studs ........... 35 ± 5 N·m
Part No.: 179-7024
(26 ± 4 lb ft)
S/N: 5YR1-Up
SENR1017-04 65
Part No.: 179-7024 Part No.: 164-4603

S/N: 6PR1-Up S/N: BEC1-Up
Part No.: 179-7024 Part No.: 1N-3177
S/N: 6PR1-Up S/N: 7MJ1-Up
Part No.: 179-7024 Part No.: 1W-0416
S/N: 6TR1-Up S/N: 7XJ1-Up
Part No.: 179-7024 Part No.: 164-4603, 1W-0416
S/N: 6TR1-Up S/N: 7XJ1-Up
Part No.: 179-7024 Part No.: 164-4603
S/N: 7KR1-Up S/N: NBJ1-Up
Part No.: 179-7024 Part No.: 1N-3177
S/N: 7KR1-Up S/N: 7HK1-Up
Part No.: 1N-3177 Part No.: 179-7024
S/N: 49Z1-Up S/N: 7KK1-Up
Part No.: 164-4603
S/N: ASK1-Up
Part No.: 179-7024
S/N: 4YR1-Up
Part No.: 179-7024
S/N: 4YR1-Up
Part No.: 164-4603
S/N: 5HR1-Up
Part No.: 179-7024
S/N: 5YR1-Up
g01679893 Part No.: 164-4603

Illustration 74
S/N: 6KR1-Up
Typical example for right side view of exhaust manifold
Part No.: 179-7024
Note: Before assembly, apply a thin coat of 2P-2333 S/N: 6PR1-Up
High Temperature Sealer on the outside diameter of
the male ends of the exhaust manifold. Remove the Part No.: 179-7024
high temperature sealant from the assembled joints. S/N: 6TR1-Up
Part No.: 164-4603
Use the following procedure to tighten the locknuts:
S/N: 7ER1-Up
Note: Apply 4C-5599 Anti-Seize Compound to the Part No.: 179-7024
threads of the locknuts. S/N: 7KR1-Up
1. Tighten the locknuts in a numerical sequence Part No.: 164-4603

that is shown in Illustration 74 to 20 ± 3 N·m S/N: 7CS1-Up
(15 ± 2 lb ft).
Part No.: 164-4603
2. Again, tighten the locknuts in a numerical S/N: 8AS1-Up
sequence that is shown in Illustration 74 to Part No.: 164-4603
38 ± 5 N·m (28 ± 4 lb ft). S/N: 9YS1-Up
Part No.: 164-4603, 1W-0416
i03242557
S/N: 63W1-Up
Exhaust Manifold Part No.: 1W-0416
S/N: 63W1-Up
SMCS Code: 1059
Part No.: 164-4603, 1W-0416
Part No.: 164-4603 S/N: 64W1-Up
S/N: BDA1-Up
66 SENR1017-04
Part No.: 1N-3177 Note: Before assembly, apply 4C-5599 Anti-Seize

S/N: 49Z1-Up Compound to the threads of the locknuts.

(15 ± 2 lb ft).

38 ± 5 N·m (28 ± 4 lb ft).
i03242622
Exhaust Manifold
SMCS Code: 1059
g01645593
Illustration 75 Part No.: 166-0164
Front view of engine S/N: BCA1-Up
Part No.: 166-0164
S/N: 1AB1-Up
Part No.: 166-0164
S/N: 1FB1-Up
Part No.: 166-0164
S/N: BBB1-Up
Part No.: 166-0164
S/N: 5TR1-Up
Part No.: 166-0164
S/N: 6JR1-Up
Part No.: 166-0164
S/N: 2PS1-Up
Part No.: 166-0164
S/N: 5SS1-Up
Part No.: 166-0164
g01645378 S/N: 6YS1-Up
Illustration 76
Part No.: 166-0164
S/N: 9XS1-Up
Part No.: 166-0164
S/N: 24W1-Up
Part No.: 166-0164
S/N: 25W1-Up
Part No.: 166-0164
S/N: 26W1-Up
Part No.: 166-0164
S/N: BLW1-Up
Part No.: 166-0164
g01146187
Illustration 77 S/N: 01X1-Up
Part No.: 166-0164
S/N: 99X1-Up
(1): Part No.: 166-0164
S/N: 1YZ1-Up
SENR1017-04 67
Part No.: 166-0164

S/N: 1ZZ1-Up
Part No.: 166-0164
S/N: BKZ1-Up
g01644045
Illustration 80

g01645636
(1):
Illustration 78
Front view of engine Note: Before assembly, apply 4C-5599 Anti-Seize

(15 ± 2 lb ft).

38 ± 5 N·m (28 ± 4 lb ft).
i03235965
Exhaust Manifold
SMCS Code: 1059
Part No.: 179-7023, 8N-0080
S/N: 1AB1-Up
Part No.: 179-7023
S/N: 1FB1-Up
Part No.: 179-7023
S/N: 1NB1-Up
Part No.: 7N-9578
S/N: 1JD1-Up
Part No.: 179-7023, 7N-9578
g01645574
Illustration 79 S/N: 1JD1-Up
Note: Use a centering tool in at least one oversize Part No.: 179-7022
hole per manifold section in order to align the S/N: 2YD1-Up
manifolds. Do not remove the centering tools until
Part No.: 7N-9578
removal is required to tighten the locknuts.
S/N: 8YG1-Up
Part No.: 179-7023
S/N: CEH1-Up
Part No.: 179-7022
S/N: 3BJ1-Up
68 SENR1017-04
Part No.: 179-7023, 7N-9578 Part No.: 8N-0080

Part No.: 179-7022 Part No.: 179-7022, 8N-0080
S/N: 3TK1-Up S/N: 50W1-Up
Part No.: 179-7023 Part No.: 179-7022
S/N: ABK1-Up S/N: BLW1-Up
Part No.: 179-7023 Part No.: 179-7022, 8N-0080
S/N: AWK1-Up S/N: 01X1-Up
Part No.: 179-7023, 7N-9578 Part No.: 179-7022
S/N: 8BL1-Up S/N: 99X1-Up
Part No.: 179-7023, 7N-9578 Part No.: 179-7023, 7N-9578, 8N-0080
S/N: 8BL1-Up S/N: 53Y1-Up
Part No.: 179-7023, 7N-9578 Part No.: 179-7022
S/N: ACL1-Up S/N: 1YZ1-Up
Part No.: 179-7023 Part No.: 179-7022
S/N: 2ZR1-Up S/N: 1ZZ1-Up
Part No.: 179-7022 Part No.: 7N-9578
Part No.: 179-7023 Part No.: 7N-9578
Part No.: 179-7023 Part No.: 7N-9578
Part No.: 179-7023 Part No.: 179-7022
S/N: 6TR1-Up S/N: BKZ1-Up
Part No.: 179-7022, 8N-0080
S/N: 7BR1-Up
Part No.: 179-7022
S/N: 7FR1-Up
Part No.: 179-7023
S/N: 7KR1-Up
Part No.: 179-7023
S/N: CLR1-Up
Part No.: 179-7023
S/N: 2PS1-Up
Part No.: 179-7022
S/N: 8GS1-Up
Part No.: 179-7022
S/N: 9YS1-Up
Part No.: 179-7023
S/N: AXT1-Up
Part No.: 8N-0080
S/N: 24W1-Up
SENR1017-04 69

(3):
Note: Before assembly, apply 4C-5599 Anti-Seize


(15 ± 2 lb ft).

38 ± 5 N·m (28 ± 4 lb ft).
i03242588
Exhaust Manifold
SMCS Code: 1059
Part No.: 9Y-1232
S/N: 5TR1-Up
Part No.: 9Y-1232
S/N: 6JR1-Up
Part No.: 9Y-1232
S/N: 7FR1-Up
g01644113
Illustration 81
Part No.: 9Y-1232
Typical example S/N: 5SS1-Up
Note: Use a centering tool in at least one oversize Part No.: 9Y-1232
hole per manifold section in order to align the S/N: 6YS1-Up
removal is required to tighten the locknuts. Part No.: 9Y-1232
S/N: 9XS1-Up
(1) Coat the female ends of the exhaust manifold
Part No.: 9Y-1232
S/N: 26W1-Up
(2) Before assembly, apply a thin coat of 2P-2333 Part No.: 9Y-1232
High Temperature Sealer to the outside diameter S/N: 01X1-Up
of the male end of the exhaust manifold.
Remove excess high temperature sealer from Part No.: 9Y-1232
the assembled joint. S/N: 1YZ1-Up
Part No.: 9Y-1232
S/N: 1ZZ1-Up
g01644045
Illustration 82
g01645398
Illustration 83
70 SENR1017-04
Note: Use a centering tool in at least one oversize Part No.: 4N-0965
hole per manifold section in order to align the S/N: 63W1-Up
removal is required to tighten the locknuts. Part No.: 4N-0965
S/N: 64W1-Up
Part No.: 4N-0965
S/N: 64W1-Up
Part No.: 4N-0965
S/N: 49Z1-Up
Part No.: 4N-0965
S/N: 89Z1-Up
Part No.: 4N-0965
S/N: 89Z1-Up
Part No.: 4N-0965
S/N: 90Z1-Up
g01645427
Illustration 84 Part No.: 4N-0965
Tightening sequence for exhaust manifold S/N: 90Z1-Up
Note: Before assembly, apply 4C-5599 Anti-Seize Part No.: 4N-0965

Compound to the threads of the locknuts. S/N: 91Z1-Up
Part No.: 4N-0965
(1) Tighten the locknuts in a numerical sequence S/N: 91Z1-Up
that is shown in Illustration 84. .......... 38 ± 5 N·m
(28 ± 4 lb ft)
i01763978
Camshaft
SMCS Code: 1210
Part No.: 4N-0965
S/N: 2YD1-Up
Part No.: 4N-0965
S/N: 2YD1-Up
Part No.: 4N-0965 g00358397
S/N: 7MJ1-Up Illustration 85
Part No.: 4N-0965 (1) Do not use a torch to heat the gear. Maximum
S/N: 7XJ1-Up temperature of the gear for installation on the
camshaft .................................... 215 °C (419 °F)
Part No.: 4N-0965
S/N: 7XJ1-Up (2) Fit between the gear and the
Part No.: 4N-0965 camshaft ................................. 0.64 to 0.140 mm
S/N: 3SK1-Up (.0252 to .0055 inch)
Part No.: 4N-0965 (3) Diameter of the journals on a new camshaft for
S/N: 7HK1-Up camshaft bearings ............... 69.850 ± 0.013 mm
(2.7500 ± .0005 inch)
Part No.: 4N-0965
S/N: 7KK1-Up Bore in front and rear bearings for new
camshaft .. 69.969 ± 0.048 mm (2.7547 ± .0019 inch)
Part No.: 4N-0965
S/N: 4YR1-Up Bore in five inner bearings for new
Part No.: 4N-0965 camshaft .. 69.982 ± 0.061 mm (2.7552 ± .0024 inch)
S/N: 63W1-Up
SENR1017-04 71
(4) Thickness of new thrust plate .... 4.65 ± 0.03 mm Part No.: 108-1547
(.183 ± .001 inch) S/N: 1NB1-Up
End play of camshaft ...................... 0.10 to 0.25 mm Part No.: 108-1547

(.004 to .010 inch) S/N: BBB1-Up
Part No.: 108-1553, 185-7909
S/N: BEC1-Up
Part No.: 108-1547
S/N: 1JD1-Up
Part No.: 108-1553, 185-7909
S/N: 2YD1-Up
Part No.: 108-1547
S/N: CEH1-Up
Part No.: 108-1547
S/N: 6XJ1-Up
Part No.: 108-1553, 185-7909
g00285343
Illustration 86 S/N: 7XJ1-Up
(6) Procedure for camshaft lobe height Part No.: 108-1553, 185-7909
S/N: NBJ1-Up
1. Measure the camshaft lobe height (6).
Part No.: 108-1547
2. Measure the base circle (7). S/N: 3TK1-Up
Part No.: 108-1553
3. Subtract the base circle (Step 2) from the camshaft S/N: 67K1-Up
lobe height (Step 1). The difference is the actual
lobe lift. Part No.: 108-1553, 185-7909
S/N: 7KK1-Up
4. Specified camshaft lobe lift (5)
Part No.: 108-1553, 185-7909
Exhaust lobe .................... 8.783 mm (.3458 inch) S/N: AAK1-Up
Part No.: 108-1547, 185-7909
Inlet lobe .......................... 8.100 mm (.3189 inch)
S/N: ABK1-Up
The maximum permissible difference between Part No.: 108-1553, 185-7909
actual lobe lift (Step 3) and the specified lobe lift S/N: ASK1-Up
(Step 4) is the following value. ............... 0.13 mm
(.005 inch) Part No.: 108-1547
S/N: AWK1-Up
i03246546 Part No.: 108-1547
S/N: 7TL1-Up
Camshaft
Part No.: 108-1547
SMCS Code: 1210 S/N: 7TL1-Up
Part No.: 108-1553, 185-7909 Part No.: 108-1547
S/N: AAA1-Up S/N: 8BL1-Up
Part No.: 108-1547 Part No.: 108-1547
S/N: BCA1-Up S/N: ACL1-Up
Part No.: 108-1553, 185-7909 Part No.: 108-1553, 185-7909
S/N: BDA1-Up S/N: 7GN1-Up
Part No.: 108-1547 Part No.: 108-1553, 185-7909
S/N: 1AB1-Up S/N: 8HN1-Up
Part No.: 108-1547 Part No.: 108-1553, 185-7909
S/N: 1FB1-Up S/N: BBN1-Up
72 SENR1017-04
Part No.: 108-1547 Part No.: 108-1553, 185-7909

S/N: 2ZR1-Up S/N: BCR1-Up
Part No.: 108-1547, 108-1553, 185-7909 Part No.: 108-1547
Part No.: 108-1553, 185-7909 Part No.: 108-1547
Part No.: 108-1553 Part No.: 108-1547
Part No.: 108-1553, 185-7909 Part No.: 108-1547
Part No.: 108-1553 Part No.: 108-1553, 185-7909
Part No.: 108-1553 Part No.: 108-1553, 185-7909
Part No.: 185-7909 Part No.: 108-1547
Part No.: 108-1547 Part No.: 108-1547
Part No.: 108-1553 Part No.: 185-7909
Part No.: 108-1547, 108-1553, 185-7909 Part No.: 108-1553, 185-7909
Part No.: 108-1553 Part No.: 108-1553, 185-7909
Part No.: 108-1547 Part No.: 108-1547
Part No.: 185-7909 Part No.: 108-1547
Part No.: 108-1553 Part No.: 108-1547
Part No.: 108-1547, 108-1553, 185-7909 Part No.: 108-1547
Part No.: 108-1547, 108-1553, 185-7909 Part No.: 108-1553, 185-7909
Part No.: 108-1553 Part No.: 108-1553, 185-7909
Part No.: 108-1547 Part No.: 108-1547
S/N: 7BR1-Up S/N: BLW1-Up
Part No.: 108-1553, 185-7909 Part No.: 108-1547
Part No.: 108-1547 Part No.: 108-1553
Part No.: 108-1553 Part No.: 108-1547
Part No.: 108-1547, 108-1553, 185-7909 Part No.: 108-1547
SENR1017-04 73
Part No.: 108-1547

S/N: 1YZ1-Up
Part No.: 108-1547
S/N: 1ZZ1-Up
Part No.: 108-1553, 185-7909
S/N: 2KZ1-Up
Part No.: 108-1547
S/N: BKZ1-Up
g01647619
Illustration 88
(D) Specified camshaft lobe lift

Exhaust lobe ................. 8.783 mm (0.3458 inch)
Inlet lobe ....................... 8.100 mm (0.3189 inch)
Use the following procedure in order to determine

the actual lobe lift:
g01647617
1. Measure camshaft lobe height (E).
Illustration 87
2. Measure base circle (F).
Note: Lubricate the camshaft lobes with a 50/50
mixture of 8T-2998 Lubricant and clean engine oil. 3. Subtract the base circle (F) from the camshaft lobe
height (E). The difference is the actual camshaft
Note: Lubricate the camshaft bearings with clean lobe lift (D).
engine oil prior to installing the camshaft.
Maximum permissible difference between the actual
(1) Lubricate the plate with clean engine oil. lobe lift that was found in Step 3 and the specified
lobe lift of a new camshaft ...... 0.13 mm (0.005 inch)
(A) Interference fit between the gear and the
camshaft ........................... 0.10 mm (0.004 inch)
i02756959
(B) Diameter of the bearing journal
........ 69.850 ± 0.013 mm (2.7500 ± 0.0005 inch) Camshaft
Bore in front and rear bearings for new SMCS Code: 1210
camshaft .................................... 69.969 ± 0.048 mm Part No.: 4N-0963
(2.7547 ± 0.0019 inch) S/N: 1JD1-Up
Bore in five inner bearings for new Part No.: 4N-0963
camshaft .................................... 69.982 ± 0.061 mm S/N: 1JD1-Up
(2.7552 ± 0.0024 inch)
Part No.: 4N-0963
(C) Thickness of new thrust plate ... 4.83 ± 0.06 mm S/N: 8YG1-Up
(0.190 ± 0.002 inch)
Part No.: 4N-0963
End play of camshaft ...................... 0.10 to 0.25 mm S/N: 3BJ1-Up
(0.004 to 0.010 inch) Part No.: 4N-0963
S/N: 6XJ1-Up
Part No.: 4N-0963
S/N: ABK1-Up
Part No.: 4N-0963
S/N: 7TL1-Up
74 SENR1017-04
Part No.: 4N-0963

S/N: 7TL1-Up
Part No.: 4N-0963
S/N: 8BL1-Up
Part No.: 4N-0963
S/N: 8BL1-Up
Part No.: 4N-0963
S/N: ACL1-Up
Part No.: 4N-0963
S/N: 7BR1-Up
Part No.: 4N-0963
S/N: 24W1-Up
Part No.: 4N-0963
S/N: 25W1-Up
Part No.: 4N-0963
S/N: 26W1-Up
g01380521
Illustration 89
Part No.: 4N-0963
(1) Camshaft drive gear
S/N: 50W1-Up (2) Camshaft
Part No.: 4N-0963
S/N: 01X1-Up (A) Diameter of the bearing journals for a new
camshaft .............................. 69.850 ± 0.013 mm
Part No.: 4N-0963 (2.7500 ± 0.0005 inch)
S/N: 01X1-Up
Bore in the front and the rear bearings for a new
Part No.: 4N-0963 camshaft .................................... 69.969 ± 0.048 mm
S/N: 01X1-Up (2.7547 ± 0.0019 inch)
Part No.: 4N-0963
Bore of inner bearings for a new
S/N: 99X1-Up
camshaft .................................... 69.982 ± 0.061 mm
Part No.: 4N-0963 (2.7552 ± 0.0024 inch)
S/N: 53Y1-Up
(B) Protrusion of dowel ................... 8.76 ± 0.25 mm
Part No.: 4N-0963 (0.345 ± 0.010 inch)
S/N: 86Z1-Up
(C) Plate
Part No.: 4N-0963
S/N: 86Z1-Up Thickness of a new plate ........... 4.65 ± 0.03 mm
(0.183 ± 0.001 inch)
Part No.: 4N-0963 Thickness of the groove in the new
S/N: 87Z1-Up camshaft ... 4.83 ± 0.05 mm (0.190 ± 0.002 inch)
Part No.: 4N-0963 End play of camshaft ................ 0.10 to 0.25 mm
S/N: 87Z1-Up (0.004 to 0.010 inch)
Refer to Guideline For Reusable Parts and Salvage

Operations, SEBF8146, “Visual Inspection of
Camshafts” and Guideline For Reuse and Salvage
Guidelines, SEBF8097, “Measurement of the
Camshaft” for information that relates to the
reusability of camshafts.
SENR1017-04 75
Part No.: 108-1547

S/N: BBB1-Up
Part No.: 185-7909
S/N: BEC1-Up
Part No.: 108-1547
S/N: 1JD1-Up
Part No.: 185-7909
S/N: 1JD1-Up
Part No.: 185-7909
S/N: 2YD1-Up
Part No.: 108-1547
S/N: 2YD1-Up
Part No.: 108-1547
S/N: CEH1-Up
Part No.: 108-1547
S/N: 6XJ1-Up
g01380522
Illustration 90
Part No.: 185-7909
(E) Camshaft lobe lift S/N: 7XJ1-Up
Part No.: 185-7909
Specified camshaft lobe lift S/N: 7XJ1-Up
Exhaust lobe ................. 8.783 mm (0.3458 inch) Part No.: 185-7909
Inlet lobe ....................... 8.100 mm (0.3189 inch) S/N: NBJ1-Up
In order to determine the height, use the following Part No.: 185-7909
procedure: S/N: 7KK1-Up
1. Measure camshaft lobe height (D). Part No.: 185-7909

S/N: AAK1-Up
2. Measure base circle (F).
Part No.: 108-1547, 185-7909
S/N: ABK1-Up
3. Subtract the base circle (F) from the lobe height
(D). The difference is the actual camshaft lobe lift. Part No.: 185-7909
S/N: ASK1-Up
i02910167 Part No.: 108-1547
Camshaft Bearings S/N: AWK1-Up
Part No.: 185-7909
SMCS Code: 1211 S/N: 7TL1-Up
Part No.: 185-7909 Part No.: 108-1547
S/N: AAA1-Up S/N: 7TL1-Up
Part No.: 108-1547 Part No.: 185-7909
S/N: BCA1-Up S/N: 8BL1-Up
Part No.: 185-7909 Part No.: 108-1547
S/N: BDA1-Up S/N: 8BL1-Up
Part No.: 108-1547 Part No.: 108-1547
S/N: 1AB1-Up S/N: ACL1-Up
Part No.: 108-1547 Part No.: 185-7909
S/N: 1FB1-Up S/N: 7GN1-Up
Part No.: 108-1547 Part No.: 185-7909
S/N: 1NB1-Up S/N: 8HN1-Up
76 SENR1017-04
Part No.: 185-7909 Part No.: 185-7909

S/N: BBN1-Up S/N: BCR1-Up
Part No.: 108-1547 Part No.: 108-1547
S/N: 2ZR1-Up S/N: CLR1-Up
Part No.: 185-7909 Part No.: 108-1547
S/N: 3KR1-Up S/N: 2PS1-Up
Part No.: 108-1547 Part No.: 108-1547
S/N: 3KR1-Up S/N: 5SS1-Up
Part No.: 185-7909 Part No.: 108-1547
S/N: 4FR1-Up S/N: 6YS1-Up
Part No.: 185-7909 Part No.: 185-7909
Part No.: 185-7909 Part No.: 185-7909
Part No.: 185-7909 Part No.: 108-1547
Part No.: 185-7909 Part No.: 185-7909
Part No.: 185-7909 Part No.: 108-1547
S/N: 5HR1-Up S/N: AAT1-Up
Part No.: 108-1547 Part No.: 185-7909
S/N: 5TR1-Up S/N: AKT1-Up
Part No.: 108-1547, 185-7909 Part No.: 108-1547
Part No.: 108-1547 Part No.: 108-1547
Part No.: 185-7909 Part No.: 108-1547
Part No.: 108-1547, 185-7909 Part No.: 108-1547
Part No.: 185-7909 Part No.: 185-7909
Part No.: 185-7909 Part No.: 185-7909
Part No.: 108-1547, 185-7909 Part No.: 185-7909
Part No.: 108-1547 Part No.: 185-7909
Part No.: 185-7909 Part No.: 108-1547
S/N: 7ER1-Up S/N: BLW1-Up
Part No.: 108-1547 Part No.: 108-1547
Part No.: 108-1547, 185-7909 Part No.: 185-7909
Part No.: 108-1547, 185-7909 Part No.: 185-7909
SENR1017-04 77
Part No.: 108-1547 Camshaft Bearing Position

S/N: 99X1-Up
Part No.: 108-1547
S/N: 53Y1-Up
Part No.: 108-1547
S/N: 1YZ1-Up
Part No.: 108-1547
S/N: 1ZZ1-Up
Part No.: 185-7909
S/N: 2KZ1-Up
Part No.: 108-1547
S/N: BKZ1-Up
g01448121
Illustration 92
The camshaft bearings are installed from the front

face of the cylinder block to the following distance.
Dimension (B) ............................ 7.40 ± 0.50 mm
(0.291 ± 0.020 inch)
Dimension (C) ......................... 211.30 ± 0.50 mm
(8.319 ± 0.020 inch)
Dimension (D) ........................ 395.50 ± 0.50 mm
(15.571 ± 0.020 inch)
Dimension (E) ........................ 579.60 ± 0.50 mm
(22.819 ± 0.020 inch)
Dimension (F) ........................ 763.80 ± 0.50 mm
g01448119
(30.071 ± 0.020 inch)
Illustration 91 Dimension (G) ....................... 947.90 ± 0.50 mm
(37.319 ± 0.020 inch)
(1) Install the camshaft bearings with the oil holes in Dimension (H) ....................... 1144.30 ± 0.50 mm
the horizontal position. (45.051 ± 0.020 inch)
Note: Two different camshaft bearings are used.

Install the wider camshaft bearings in the two outer i03250840
bores. Install the narrow camshaft bearings in the
inner bores. Engine Oil Lines
(A) Bore in the camshaft bearings after installation SMCS Code: 1307
Outer bearings ..................... 69.969 ± 0.048 mm Part No.: 4N-8160

(2.7547 ± 0.0019 inch) S/N: 1AB1-Up
Inner bearings ...................... 69.982 ± 0.061 mm Part No.: 4N-8160
(2.7552 ± 0.0024 inch) S/N: 1FB1-Up
Diameter of camshaft journals ... 69.850 ± 0.013 mm Part No.: 4N-8160
(2.7500 ± 0.0005 inch) S/N: 1NB1-Up
Part No.: 212-1447, 7C-4485
S/N: 2YD1-Up
Part No.: 124-9445
S/N: 8YG1-Up
78 SENR1017-04
Part No.: 9Y-3771 Part No.: 4N-8160

S/N: 3BJ1-Up S/N: 86Z1-Up
S/N: 7MJ1-Up S/N: 86Z1-Up
S/N: 7XJ1-Up S/N: 87Z1-Up
Part No.: 7C-4485 Part No.: 4N-8160
S/N: 3SK1-Up S/N: 87Z1-Up
Part No.: 124-9445 Part No.: 6N-1114
S/N: 3TK1-Up S/N: 89Z1-Up
S/N: 7HK1-Up S/N: 89Z1-Up
Part No.: 124-9445 Part No.: 6N-1114
S/N: 2ZR1-Up S/N: 90Z1-Up
Part No.: 7C-4485 Part No.: 6N-1114
Part No.: 212-1447, 7C-4485 Part No.: 6N-1114
Part No.: 6N-1114
S/N: 4YR1-Up
Part No.: 124-9445
S/N: 7BR1-Up
Part No.: 124-9445
S/N: 7FR1-Up
Part No.: 124-9445
S/N: 8GS1-Up
Part No.: 212-1447, 7C-4485
S/N: AKT1-Up
Part No.: 4N-8160
S/N: 24W1-Up
Part No.: 4N-8160
S/N: 25W1-Up
Part No.: 4N-8160
S/N: 26W1-Up g01651880
Illustration 93
Part No.: 6N-1114 Typical example
S/N: 63W1-Up Top view
Part No.: 6N-1114

S/N: 64W1-Up (1) Lubricate the O-ring seals lightly with clean
engine oil before assembly.
Part No.: 9Y-3771
S/N: 01X1-Up
i02385184
Part No.: 9Y-3771
S/N: 01X1-Up
Engine Oil Lines
Part No.: 4N-8160 SMCS Code: 1307
S/N: 99X1-Up
Part No.: 122-1790
Part No.: 6N-1114 S/N: BDA1-Up
S/N: 49Z1-Up
SENR1017-04 79
Part No.: 122-1790 Part No.: 122-1790

S/N: BEC1-Up S/N: 2KZ1-Up
Part No.: 122-1790
S/N: 7XJ1-Up
Part No.: 122-1790
S/N: NBJ1-Up
Part No.: 122-1790
S/N: ASK1-Up
Part No.: 122-1790
S/N: BBN1-Up
Part No.: 122-1790
S/N: 4FR1-Up
Part No.: 122-1790 g01189707
Illustration 94
S/N: 4YR1-Up
Part No.: 122-1790 (1) Lubricate the bores and the O-Ring seals lightly
S/N: 4YR1-Up with engine oil.
Part No.: 122-1790

S/N: 4YR1-Up i02847540
Part No.: 122-1790 Engine Oil Filter Base

S/N: 4YR1-Up
SMCS Code: 1306
Part No.: 122-1790
S/N: 5HR1-Up Part No.: 4N-2357
S/N: AAA1-Up
Part No.: 122-1790
S/N: 5YR1-Up Part No.: 4N-2357
S/N: BDA1-Up
Part No.: 122-1790
S/N: 1AB1-Up
Part No.: 122-1790
S/N: 6PR1-Up Part No.: 4N-2357
S/N: 1FB1-Up
Part No.: 122-1790
S/N: 6TR1-Up Part No.: 4N-2357
S/N: 1NB1-Up
Part No.: 122-1790
S/N: 7ER1-Up Part No.: 4N-2357
S/N: BEC1-Up
Part No.: 122-1790
S/N: CEH1-Up
Part No.: 122-1790
S/N: BCR1-Up Part No.: 4N-1409
S/N: 3BJ1-Up
Part No.: 122-1790
S/N: 7CS1-Up Part No.: 4N-1409, 4N-2357
S/N: 7XJ1-Up
Part No.: 122-1790
S/N: 8AS1-Up Part No.: 4N-1409
S/N: 7XJ1-Up
Part No.: 122-1790
S/N: 9YS1-Up Part No.: 4N-2357
S/N: NBJ1-Up
Part No.: 122-1790
S/N: 63W1-Up Part No.: 4N-2357
S/N: 7HK1-Up
Part No.: 122-1790
S/N: 64W1-Up Part No.: 4N-2357
S/N: AAK1-Up
80 SENR1017-04

S/N: ASK1-Up S/N: AXT1-Up
S/N: AWK1-Up S/N: 24W1-Up
S/N: 7GN1-Up S/N: 25W1-Up
S/N: 8HN1-Up S/N: 26W1-Up
S/N: BBN1-Up S/N: 63W1-Up
Part No.: 4N-2357 Part No.: 4N-1409, 4N-2357
S/N: 5HR1-Up S/N: 01X1-Up
S/N: 7BR1-Up S/N: 87Z1-Up
S/N: 7ER1-Up S/N: 89Z1-Up
S/N: BCR1-Up S/N: 91Z1-Up
Part No.: 4N-2357
S/N: CLR1-Up
Part No.: 4N-2357
S/N: 2PS1-Up
Part No.: 4N-2357
S/N: 7CS1-Up
Part No.: 4N-2357
S/N: 8AS1-Up
Part No.: 4N-2357
S/N: 9YS1-Up
Part No.: 4N-2357
S/N: AAT1-Up
SENR1017-04 81
Part No.: 9Y-1911

S/N: 1FB1-Up
Part No.: 9Y-1911
S/N: BBB1-Up
Part No.: 9Y-1911
S/N: 8YG1-Up
Part No.: 9Y-1911
S/N: 3TK1-Up
Part No.: 9Y-1911
S/N: 2ZR1-Up
Part No.: 9Y-1911
g01419688
Illustration 95 S/N: 4YR1-Up
(1) Oil filter base assembly
(2) Fluid sampling valve Part No.: 9Y-1911
(3) Oil supply line (unfiltered oil) S/N: 7BR1-Up
(5) Oil cooler bypass valves
(6) Oil return line (filtered oil) Part No.: 9Y-1911
S/N: 2PS1-Up
(4) Lightly lubricate the bore and the O-ring seals for
the cooler bypass tube with clean engine oil. Part No.: 9Y-1911
S/N: 8GS1-Up
(7) Lubricate the seal of the engine oil filter element Part No.: 9Y-1911
assembly with clean engine oil. S/N: 25W1-Up
Part No.: 9Y-1911
S/N: 26W1-Up
Part No.: 9Y-1911
S/N: 01X1-Up
Part No.: 9Y-1911
S/N: 99X1-Up
Part No.: 9Y-1911
S/N: 91Z1-Up
g01419678
Illustration 96
(A) Length for applying 154-9731 Thread Lock

Compound to the threads of the hollow
stud ................. 10.2 ± 1.5 mm (0.40 ± 0.06 inch)
(8) Torque for the hollow stud ............... 80 ± 14 N·m

(60 ± 10 lb ft)
i03096982
Engine Oil Filter Base

SMCS Code: 1306
Part No.: 9Y-1911
S/N: BCA1-Up
g01577739
Part No.: 9Y-1911 Illustration 97
S/N: 1AB1-Up (3) Engine oil filter
(1) 4N-8150 Spring

82 SENR1017-04
Length under test force ... 55.24 mm (2.175 inch) i03259961

Test force .......... 75.619 ± 5.800 N (17.0 ± 1.3 lb)
Free length after test .. 93.726 mm (3.6900 inch) Engine Oil Filter Base
Outside diameter ................ 20.6 mm (0.81 inch)
SMCS Code: 1306
(2) Pressure difference for the oil filter bypass valve
Part No.: 128-0948
to open ........................ 255 ± 21 kPa (37 ± 3 psi)
S/N: 2YD1-Up
Part No.: 127-4327
S/N: 7TL1-Up
Part No.: 127-4327
S/N: 8BL1-Up
Part No.: 127-4327
S/N: 8BL1-Up
Part No.: 127-4327
S/N: ACL1-Up
Part No.: 128-0948
S/N: 3KR1-Up
g01577740
Illustration 98
Section A-A
(B) Length for applying 154-9731 Thread Lock

Compound on the hollow stud .. 10 mm (0.4 inch)
(4) Torque for two hollow studs ............. 80 ± 15 N·m

(60 ± 11 lb ft)
g01661933
Illustration 99
Typical example
(1) Lubricate the bore of two O-ring seals lightly with

the lubricant that is being sealed.
i03291361
Engine Oil Filter Bypass Valve

SMCS Code: 1318
Part No.: 9M-0853
S/N: AAA1-Up
Part No.: 9M-0853
S/N: BCA1-Up
Part No.: 9M-0853
S/N: BDA1-Up
SENR1017-04 83
Part No.: 9M-0853 Part No.: 9M-0853

S/N: 1AB1-Up S/N: 2ZR1-Up
S/N: 1NB1-Up S/N: 4FR1-Up
S/N: BBB1-Up S/N: 4YR1-Up
S/N: BEC1-Up S/N: 5HR1-Up
S/N: 1JD1-Up S/N: 5TR1-Up
S/N: 2YD1-Up S/N: 5YR1-Up
S/N: CEH1-Up S/N: 6JR1-Up
S/N: 7XJ1-Up S/N: 6PR1-Up
S/N: 3TK1-Up S/N: 7BR1-Up
S/N: 7KK1-Up S/N: 7ER1-Up
S/N: AAK1-Up S/N: 7FR1-Up
S/N: ABK1-Up S/N: 7KR1-Up
S/N: AWK1-Up S/N: CLR1-Up
S/N: 7TL1-Up S/N: 2PS1-Up
S/N: 8BL1-Up S/N: 5SS1-Up
S/N: ACL1-Up S/N: 6YS1-Up
S/N: BBN1-Up S/N: 8GS1-Up
84 SENR1017-04
Part No.: 9M-0853

S/N: 9XS1-Up
Part No.: 9M-0853
S/N: 9YS1-Up
Part No.: 9M-0853
S/N: AAT1-Up
Part No.: 9M-0853
S/N: AKT1-Up
Part No.: 9M-0853
S/N: AXT1-Up
Part No.: 9M-0853
S/N: 24W1-Up
Part No.: 9M-0853
S/N: 25W1-Up
Part No.: 9M-0853
S/N: 26W1-Up
Part No.: 9M-0853
S/N: 63W1-Up
Part No.: 9M-0853
S/N: 64W1-Up
Part No.: 9M-0853
S/N: BLW1-Up
Part No.: 9M-0853
S/N: 01X1-Up
Part No.: 9M-0853
S/N: 99X1-Up g01427693
Illustration 100
Part No.: 9M-0853 Typical example
S/N: 53Y1-Up Right side view of engine
Part No.: 9M-0853 (1) Valve plunger

S/N: 1YZ1-Up
Note: Check the valve and the valve seat for
Part No.: 9M-0853 abnormal contact patterns.
S/N: 1ZZ1-Up
(2) 9F-6304 Spring
Part No.: 9M-0853
S/N: 2KZ1-Up Length under test force ... 53.98 mm (2.125 inch)
Test force ............. 145 to 160 N (32.3 to 35.7 lb)
Part No.: 9M-0853 Free length after test .... 105.56 mm (4.156 inch)
S/N: BKZ1-Up Outside diameter ............ 20.65 mm (0.813 inch)
i03298121
Prelubrication Oil Pump

SMCS Code: 1319
Part No.: 3N-0592
S/N: AAA1-Up
Part No.: 3N-0592
S/N: BCA1-Up
Part No.: 3N-0592
S/N: BDA1-Up
SENR1017-04 85

86 SENR1017-04

SENR1017-04 87
Part No.: 3N-0592 Part No.: 9M-0853

S/N: BKZ1-Up S/N: 7XJ1-Up
Part No.: 9M-0853
S/N: NBJ1-Up
Part No.: 9M-0853
S/N: 3TK1-Up
Part No.: 9M-0853
S/N: 7KK1-Up
Part No.: 9M-0853
S/N: AAK1-Up
Part No.: 9M-0853
S/N: ABK1-Up
g01681953 Part No.: 9M-0853

Illustration 101
S/N: ASK1-Up
Typical example
Part No.: 9M-0853
Pump specifications: S/N: AWK1-Up
Rate of flow per minute at 1150 rpm and at 172.4 kPa Part No.: 9M-0853
(25 psi) pressure .......................... 56.8 L (15 US gal) S/N: 7TL1-Up
Part No.: 9M-0853
i02865988 S/N: 8BL1-Up
Engine Oil Bypass Valve Part No.: 9M-0853

S/N: ACL1-Up
SMCS Code: 1306-BV
Part No.: 9M-0853
Part No.: 9M-0853 S/N: 7GN1-Up
S/N: AAA1-Up
Part No.: 9M-0853
Part No.: 9M-0853 S/N: 8HN1-Up
S/N: BCA1-Up
Part No.: 9M-0853
Part No.: 9M-0853 S/N: BBN1-Up
S/N: BDA1-Up
Part No.: 9M-0853
Part No.: 9M-0853 S/N: 2ZR1-Up
S/N: 1AB1-Up
88 SENR1017-04

S/N: 3KR1-Up S/N: 9YS1-Up
S/N: 4FR1-Up S/N: AAT1-Up
S/N: 5HR1-Up S/N: AXT1-Up
S/N: 6TR1-Up S/N: BLW1-Up
S/N: 7FR1-Up S/N: 53Y1-Up
S/N: BCR1-Up S/N: 1ZZ1-Up
S/N: CLR1-Up S/N: 2KZ1-Up
S/N: 2PS1-Up S/N: BKZ1-Up
Part No.: 9M-0853
S/N: 5SS1-Up
Part No.: 9M-0853
S/N: 6YS1-Up
Part No.: 9M-0853
S/N: 7CS1-Up
Part No.: 9M-0853
S/N: 8AS1-Up
Part No.: 9M-0853
S/N: 8GS1-Up
Part No.: 9M-0853
S/N: 9XS1-Up
SENR1017-04 89
i02857775
Engine Oil Pan

SMCS Code: 1302
Part No.: 129-5236
S/N: AAA1-Up
Part No.: 119-8582
S/N: 2YD1-Up
Part No.: 119-8582
S/N: 3KR1-Up
Part No.: 119-8582
S/N: AKT1-Up
g01427693
Illustration 102
Typical example
Right side view of engine
Note: Check the valve and the valve seat for

abnormal contact patterns.
(1) The 9M-0853 Valve Plunger is for the oil filter

bypass valve.
g01433353
Illustration 103
(2) The 9F-6304 Spring is for the oil filter bypass
valve. (3) After assembly, trim off excess gasket material
from outside of assembled joint.
Length under test force ... 53.98 mm (2.125 inch)
Test force ............. 145 to 160 N (32.3 to 35.7 lb) Note: Lubricate the threads of the drain plug lightly
Free length after test .... 105.56 mm (4.156 inch) with clean engine oil before assembly.
(4) Torque for the drain plug .................. 70 ± 10 N·m
(50 ± 7 lb ft)
Bolts (1) are 3/8-16 X 2 3/4 inches.

90 SENR1017-04
The remaining oil pan bolts are 3/8-16 X 1 1/4 inches.
i03127921
Engine Oil Pan

SMCS Code: 1302
Part No.: 298-5143
S/N: NBJ1-Up
Part No.: 4N-2647
S/N: 67K1-Up
Part No.: 4N-2647
S/N: 4YR1-Up Illustration 104
g01606339
Left side view

Part No.: 4N-2647
S/N: 4YR1-Up
Part No.: 4N-2647
S/N: 4YR1-Up
Part No.: 4N-2647
S/N: 5XR1-Up
Part No.: 4N-2647
S/N: 5YR1-Up
Part No.: 4N-2647
S/N: 6PR1-Up
Part No.: 4N-2647
S/N: 6TR1-Up g01606333
Illustration 105
Part No.: 4N-2647 Right side view
S/N: 7KR1-Up
(1) Torque for three pipe plugs .............. 80 ± 10 N·m
Part No.: 4N-2647 (60 ± 7 lb ft)
S/N: 64W1-Up
Part No.: 132-3627
S/N: 42X1-Up
Part No.: 4N-2647
S/N: 89Z1-Up
Part No.: 4N-2647
S/N: 89Z1-Up
Part No.: 4N-2647
S/N: 90Z1-Up
Part No.: 4N-2647
S/N: 90Z1-Up
Part No.: 4N-2647
S/N: 91Z1-Up
Part No.: 4N-2647
S/N: 91Z1-Up
SENR1017-04 91
i02145562 Part No.: 132-3627

S/N: 7XJ1-Up
Engine Oil Pan
Part No.: 132-3627
SMCS Code: 1302 S/N: ASK1-Up
Part No.: 4N-1733 Part No.: 132-3627
S/N: 3BJ1-Up S/N: 5HR1-Up
Part No.: 4N-1733 Part No.: 132-3627
S/N: 01X1-Up S/N: 6KR1-Up
Part No.: 4N-1733 Part No.: 132-3627
S/N: 01X1-Up S/N: 7ER1-Up
Part No.: 4N-1733 Part No.: 132-3627
S/N: 86Z1-Up S/N: 7CS1-Up
Part No.: 4N-1733 Part No.: 132-3627
S/N: 86Z1-Up S/N: 8AS1-Up
Part No.: 4N-1733 Part No.: 132-3627
S/N: 87Z1-Up S/N: 9YS1-Up
Part No.: 4N-1733 Part No.: 132-3627
S/N: 87Z1-Up S/N: 63W1-Up
Part No.: 132-3627
S/N: 64W1-Up
Part No.: 132-3627
S/N: 01X1-Up
Part No.: 132-3627
S/N: 49Z1-Up
g00274390
Illustration 106
Typical Example
(1) Tighten three plugs on the engine oil pan to the

following torque. .......... 80 ± 10 N·m (60 ± 7 lb ft)
i03250601
g01651693
Engine Oil Pan Illustration 107
Right side view
SMCS Code: 1302
Part No.: 132-3627
S/N: BDA1-Up
Part No.: 132-3627
S/N: BEC1-Up
Part No.: 132-3627
S/N: 3BJ1-Up
Part No.: 132-3627
S/N: 7MJ1-Up
92 SENR1017-04
i03250612
Engine Oil Pan

SMCS Code: 1302
Part No.: 7W-6381
S/N: 1JD1-Up
Part No.: 7W-6381
S/N: 1JD1-Up
Part No.: 7C-5017
S/N: 2YD1-Up
Part No.: 7C-5017
g01651717
Illustration 108 S/N: 2YD1-Up
Left side view
Part No.: 7W-6381
S/N: 6XJ1-Up
(1) Torque for three pipe plugs .............. 80 ± 10 N·m
(60 ± 7 lb ft) Part No.: 7C-5017
S/N: 3SK1-Up
Part No.: 7W-6381
S/N: ABK1-Up
Part No.: 7W-6381
S/N: 7TL1-Up
Part No.: 7W-6381
S/N: 8BL1-Up
Part No.: 7W-6381
S/N: 8BL1-Up
Part No.: 7W-6381
S/N: ACL1-Up
Part No.: 7C-5017, 7W-6381
S/N: 3KR1-Up
Part No.: 7C-5017
S/N: 3KR1-Up
Part No.: 7C-5017, 7W-6381
S/N: 53Y1-Up
g01651728
Illustration 109
(1) After the assembly of the oil pan, remove the

excess sealant and trim the excess gasket
material.
SENR1017-04 93
(1) Torque for the drain adapter ............ 70 ± 10 N·m Part No.: 2N-8220, 9Y-2989
(50 ± 7 lb ft) S/N: 8BL1-Up
Part No.: 2N-8220, 9Y-2989
i03259900 S/N: ACL1-Up
Crankcase Breather Part No.: 2N-8220, 9Y-2989
S/N: 3KR1-Up
SMCS Code: 1317
Part No.: 2N-8220, 9Y-2989
Part No.: 2N-8220, 9Y-2989 S/N: 4YR1-Up
S/N: 1AB1-Up
Part No.: 2N-8220, 9Y-2989
Part No.: 2N-8220, 9Y-2989 S/N: 7BR1-Up
S/N: 1FB1-Up
Part No.: 2N-8220, 9Y-2989
Part No.: 2N-8220, 9Y-2989 S/N: 7FR1-Up
S/N: 1NB1-Up
Part No.: 2N-8220
S/N: 1JD1-Up
Part No.: 2N-8220
Part No.: 2N-8220, 9Y-2989 S/N: 25W1-Up
S/N: 1JD1-Up
Part No.: 2N-8220
Part No.: 2N-8220, 9Y-2989 S/N: 26W1-Up
S/N: 2YD1-Up
Part No.: 9Y-2989
S/N: 2YD1-Up
Part No.: 2N-8220, 9Y-2989
Part No.: 9Y-2989 S/N: 63W1-Up
S/N: 8YG1-Up
Part No.: 9Y-2989
S/N: 3BJ1-Up
Part No.: 2N-8220
Part No.: 2N-8220, 9Y-2989 S/N: 64W1-Up
S/N: 6XJ1-Up
Part No.: 2N-8220, 9Y-2989
S/N: 7MJ1-Up
Part No.: 2N-8220, 9Y-2989
Part No.: 9Y-2989 S/N: 01X1-Up
S/N: 7XJ1-Up
Part No.: 9Y-2989
Part No.: 2N-8220, 9Y-2989 S/N: 01X1-Up
S/N: 7XJ1-Up
Part No.: 9Y-2989
Part No.: 9Y-2989 S/N: 01X1-Up
S/N: 3SK1-Up
Part No.: 2N-8220
Part No.: 2N-8220 S/N: 99X1-Up
S/N: 3TK1-Up
Part No.: 2N-8220
Part No.: 9Y-2989 S/N: 53Y1-Up
S/N: 7HK1-Up
Part No.: 9Y-2989
Part No.: 2N-8220, 9Y-2989 S/N: 49Z1-Up
S/N: 7KK1-Up
Part No.: 9Y-2989
Part No.: 2N-8220, 9Y-2989 S/N: 86Z1-Up
S/N: ABK1-Up
Part No.: 9Y-2989
Part No.: 2N-8220, 9Y-2989 S/N: 86Z1-Up
S/N: 7TL1-Up
Part No.: 9Y-2989
Part No.: 9Y-2989 S/N: 87Z1-Up
S/N: 8BL1-Up
94 SENR1017-04
Part No.: 9Y-2989 Part No.: 9Y-2989

S/N: 87Z1-Up S/N: 7HK1-Up
S/N: 89Z1-Up S/N: 8BL1-Up
S/N: 91Z1-Up S/N: 01X1-Up
Part No.: 9Y-2989
S/N: 49Z1-Up
Part No.: 9Y-2989
S/N: 86Z1-Up
Part No.: 9Y-2989
S/N: 87Z1-Up
Part No.: 9Y-2989
S/N: 89Z1-Up
Part No.: 9Y-2989
S/N: 90Z1-Up
Part No.: 9Y-2989
S/N: 91Z1-Up
g01661881
Illustration 110
(1) Lubricate the bore of the O-ring seal lightly with

(2) Torque for the clamp .. 4.5 ± 0.5 N·m (40 ± 4 lb in)
i02790171
Crankcase Breather Illustration 111

g01026542
Typical example
SMCS Code: 1317
(1) Breather assembly
Part No.: 2N-8220
S/N: 1JD1-Up (2) O-ring seal ................... Lubricate the bore lightly
with a thin coat of clean engine oil.
Part No.: 2N-8220
S/N: 2YD1-Up (3) Torque for the clamp .. 4.5 ± 0.5 N·m (40 ± 4 lb in)
Part No.: 9Y-2989
S/N: 3BJ1-Up
Part No.: 9Y-2989
S/N: 7XJ1-Up
SENR1017-04 95
i02863790 Part No.: 9N-3668

S/N: 6KR1-Up
Coolant Conditioner Base
Part No.: 9N-3668
SMCS Code: 1352 S/N: 6PR1-Up
S/N: 1AB1-Up S/N: 6TR1-Up
S/N: 1FB1-Up S/N: 7BR1-Up
S/N: 1NB1-Up S/N: 7ER1-Up
S/N: 1JD1-Up S/N: 7FR1-Up
S/N: 2YD1-Up S/N: 7KR1-Up
S/N: 6XJ1-Up S/N: 2PS1-Up
S/N: 7XJ1-Up S/N: 5SS1-Up
S/N: 3TK1-Up S/N: 6YS1-Up
S/N: 7KK1-Up S/N: 7CS1-Up
S/N: 7TL1-Up S/N: 8AS1-Up
S/N: 8BL1-Up S/N: 8GS1-Up
S/N: 7GN1-Up S/N: 24W1-Up
S/N: 8HN1-Up S/N: 25W1-Up
S/N: 2ZR1-Up S/N: 26W1-Up
S/N: 4YR1-Up S/N: BLW1-Up
S/N: 5YR1-Up S/N: 53Y1-Up
S/N: 6JR1-Up S/N: 1YZ1-Up
96 SENR1017-04
Part No.: 9N-3668 Part No.: 248-5513

S/N: 1ZZ1-Up S/N: 2YD1-Up
Part No.: 9N-3668 Part No.: 248-5513
S/N: 2KZ1-Up S/N: 2YD1-Up
Part No.: 9N-3668 Part No.: 248-5513
S/N: BKZ1-Up S/N: 8YG1-Up
Part No.: 248-5513
S/N: CEH1-Up
Part No.: 248-5513
S/N: 3BJ1-Up
Part No.: 248-5513
S/N: 6XJ1-Up
Part No.: 248-5513
S/N: 7MJ1-Up
Part No.: 248-5513
S/N: 7XJ1-Up
g01426451 Part No.: 248-5513

Illustration 112
S/N: 7XJ1-Up
Note: Apply 154-9731 Thread Lock Compound to Part No.: 248-5513
the top half of the taperlock stud before assembly. S/N: NBJ1-Up
(1) Torque for the taperlock stud ........... 70 ± 15 N·m Part No.: 248-5513
(50 ± 11 lb ft) S/N: 3SK1-Up
Part No.: 248-5513
i03295643 S/N: 3TK1-Up
Water Temperature Regulator Part No.: 248-5513
S/N: 67K1-Up
SMCS Code: 1355
Part No.: 248-5513
Part No.: 248-5513 S/N: 7HK1-Up
S/N: AAA1-Up
Part No.: 248-5513
Part No.: 248-5513 S/N: 7KK1-Up
S/N: BCA1-Up
Part No.: 248-5513
S/N: BDA1-Up
Part No.: 248-5513
Part No.: 248-5513 S/N: ABK1-Up
S/N: 1AB1-Up
Part No.: 248-5513
Part No.: 248-5513 S/N: ASK1-Up
S/N: 1FB1-Up
Part No.: 248-5513
Part No.: 248-5513 S/N: AWK1-Up
S/N: 1NB1-Up
Part No.: 248-5513
Part No.: 248-5513 S/N: 7TL1-Up
S/N: BBB1-Up
Part No.: 248-5513
Part No.: 248-5513 S/N: 7TL1-Up
S/N: BEC1-Up
Part No.: 248-5513
Part No.: 248-5513 S/N: 8BL1-Up
S/N: 1JD1-Up
Part No.: 248-5513
Part No.: 248-5513 S/N: 8BL1-Up
S/N: 1JD1-Up
SENR1017-04 97
Part No.: 248-5513 Part No.: 248-5513

Part No.: 248-5513 Part No.: 248-5513
Part No.: 248-5513 Part No.: 248-5513
Part No.: 248-5513 Part No.: 248-5513
S/N: 2ZR1-Up Part No.: 248-5513
S/N: 7KR1-Up
Part No.: 248-5513
S/N: 3KR1-Up Part No.: 248-5513
S/N: BCR1-Up
Part No.: 248-5513
S/N: 3KR1-Up Part No.: 248-5513
S/N: CLR1-Up
Part No.: 248-5513
S/N: 4FR1-Up Part No.: 248-5513
S/N: 2PS1-Up
Part No.: 248-5513
S/N: 4YR1-Up Part No.: 248-5513
S/N: 5SS1-Up
Part No.: 248-5513
S/N: 4YR1-Up Part No.: 248-5513
S/N: 6YS1-Up
Part No.: 248-5513
S/N: 4YR1-Up Part No.: 248-5513
S/N: 7CS1-Up
Part No.: 248-5513
S/N: 4YR1-Up Part No.: 248-5513
S/N: 8AS1-Up
Part No.: 248-5513
S/N: 5HR1-Up Part No.: 248-5513
S/N: 8GS1-Up
Part No.: 248-5513
S/N: 5TR1-Up Part No.: 248-5513
S/N: 9XS1-Up
Part No.: 248-5513
S/N: 5XR1-Up Part No.: 248-5513
S/N: 9YS1-Up
Part No.: 248-5513
S/N: 5YR1-Up Part No.: 248-5513
S/N: AAT1-Up
Part No.: 248-5513
S/N: 5YR1-Up Part No.: 248-5513
S/N: AKT1-Up
Part No.: 248-5513
S/N: 6JR1-Up Part No.: 248-5513
S/N: AXT1-Up
Part No.: 248-5513
S/N: 6KR1-Up Part No.: 248-5513
S/N: 24W1-Up
Part No.: 248-5513
S/N: 6PR1-Up Part No.: 248-5513
S/N: 25W1-Up
Part No.: 248-5513
S/N: 6PR1-Up Part No.: 248-5513
S/N: 26W1-Up
Part No.: 248-5513
S/N: 6TR1-Up Part No.: 248-5513
S/N: 50W1-Up
Part No.: 248-5513
S/N: 6TR1-Up Part No.: 248-5513
S/N: 63W1-Up
98 SENR1017-04
Part No.: 248-5513 Part No.: 248-5513

Part No.: 248-5513 Part No.: 248-5513
Part No.: 248-5513
S/N: 64W1-Up
Part No.: 248-5513
S/N: BLW1-Up
Part No.: 248-5513
S/N: 01X1-Up
Part No.: 248-5513
S/N: 01X1-Up
Part No.: 248-5513
S/N: 01X1-Up
Part No.: 248-5513
S/N: 42X1-Up
Part No.: 248-5513
S/N: 99X1-Up
Part No.: 248-5513
S/N: 53Y1-Up g01449799
Illustration 113
Part No.: 248-5513
S/N: 1YZ1-Up Start to open temperature ....................... 81 to 84 °C
(178 to 183 °F)
Part No.: 248-5513
S/N: 1ZZ1-Up Fully open temperature ...................... 92 °C (198 °F)
Part No.: 248-5513
(A) Minimum opening distance at fully open
S/N: 2KZ1-Up
temperature ........................ 10.4 mm (0.41 inch)
Part No.: 248-5513
S/N: 49Z1-Up Maximum opening time from closed position at
79 °C (174 °F) to fully open position at 94 °C
Part No.: 248-5513 (201 °F) ...................................................... 3 minutes
S/N: 86Z1-Up
Maximum closing time from fully open position
Part No.: 248-5513 at 94 °C (201 °F) to closed position at 79 °C
S/N: 86Z1-Up (174 °F) ...................................................... 6 minutes
Part No.: 248-5513
S/N: 87Z1-Up i02798334
Part No.: 248-5513 Water Pump

S/N: 87Z1-Up
SMCS Code: 1361
Part No.: 248-5513
S/N: 89Z1-Up Part No.: 4N-5837
S/N: AAA1-Up
Part No.: 248-5513
S/N: BCA1-Up
Part No.: 248-5513
S/N: BDA1-Up
Part No.: 248-5513
S/N: 1AB1-Up
Part No.: 248-5513
S/N: 1FB1-Up
SENR1017-04 99

Part No.: 4N-1951, 4N-5837 Part No.: 4N-1951
Part No.: 4N-1951, 4N-5837 Part No.: 4N-1951, 4N-5837
100 SENR1017-04

SENR1017-04 101
Part No.: 4N-5837 Side with oil ............................... 24 cc (1.5 cu in)

S/N: 89Z1-Up
Part No.: 4N-5837 i01949695
S/N: 89Z1-Up
Cylinder Block
Part No.: 4N-5837
Part No.: 4N-5837 Part No.: 1W-5082
S/N: BKZ1-Up S/N: 1JD1-Up
Part No.: 4N-1201
S/N: 2YD1-Up
Part No.: 4N-1201
S/N: 2YD1-Up
Part No.: 1W-5082
S/N: 8YG1-Up
Part No.: 1W-5082
S/N: 3BJ1-Up
Part No.: 4N-1201
S/N: 7MJ1-Up
Part No.: 4N-1201
S/N: 7XJ1-Up
Part No.: 4N-1201
S/N: 7XJ1-Up
Part No.: 4N-1201
g01398145
S/N: 3SK1-Up
Illustration 114
Part No.: 1W-5082
Note: Do not install the lip type seal (1) by hand. Use S/N: 3TK1-Up
the installation tool and a press to install the lip type
seal. Make sure that the primary lip is toward the Part No.: 4N-1201
water pump drive gear. Press the lip type seal until S/N: 7HK1-Up
the lip type seal is flush into the counterbore. Part No.: 4N-1201
S/N: 7KK1-Up
Note: Use the installation tool to install the seal
group (2). Press the seal group onto the shaft until Part No.: 1W-5082
the stationary cup of the seal group is fully seated in S/N: 7TL1-Up
the pump housing.
Part No.: 1W-5082
(3) Torque for the bolt .......... 39 ± 3 N·m (29 ± 2 lb ft) S/N: 8BL1-Up
(A) Diameter of the water pump Part No.: 4N-1201

shaft ..................................... 19.100 ± 0.010 mm S/N: 5HR1-Up
(0.7520 ± 0.0004 inch) Part No.: 1W-5082
S/N: 7FR1-Up
Maximum air leakage per minute with an air pressure
test of 140 kPa (20 psi) Part No.: 1W-5082
S/N: 24W1-Up
Water side .................................. 10 cc (0.6 cu in)
102 SENR1017-04
Part No.: 1W-5082

S/N: 25W1-Up
Part No.: 1W-5082
S/N: 26W1-Up
Part No.: 1W-5082
S/N: 50W1-Up
Part No.: 4N-1201
S/N: 63W1-Up
Part No.: 4N-1201
S/N: 63W1-Up
Part No.: 4N-1201
S/N: 64W1-Up
Part No.: 4N-1201
S/N: 64W1-Up
Part No.: 1W-5082
S/N: 01X1-Up
g01014592
Illustration 115
Part No.: 1W-5082
Cylinder block
S/N: 01X1-Up
Typical example
Part No.: 1W-5082
S/N: 01X1-Up (1) Apply 6V-6640 Sealant to the outside diameter
of the cup plugs before installation into the
Part No.: 4N-1201 cylinder block.
S/N: 42X1-Up
Part No.: 1W-5082 (2) Apply 5P-3413 Pipe Sealant to the threads of
S/N: 99X1-Up the plugs before installation into the front and
rear of the cylinder block.
Part No.: 4N-1201
S/N: 49Z1-Up (3) The dowels extend from the top deck of the
cylinder block. .. 18.5 ± 0.5 mm (0.73 ± 0.02 inch)
Part No.: 1W-5082
S/N: 86Z1-Up (4) Tighten the studs into the front of the cylinder
block to the following torque. ............. 35 ± 5 N·m
Part No.: 1W-5082 (26.0 ± 4.0 lb ft)
S/N: 86Z1-Up
Part No.: 1W-5082 (5) The dowels project from the front of the cylinder
S/N: 87Z1-Up block and from the rear of the cylinder block.
Distance .......... 19.0 ± 0.5 mm (0.75 ± 0.02 inch)
Part No.: 1W-5082
S/N: 87Z1-Up (6) Main bearing caps
Part No.: 4N-1201 Width of the main bearing
S/N: 89Z1-Up caps ................................... 215.900 ± 0.025 mm
(8.5000 ± 0.0010 inch)
Part No.: 4N-1201 The width of the slot that is machined into
S/N: 89Z1-Up the cylinder block for the main bearing
caps ................................... 215.900 ± 0.013 mm
Part No.: 4N-1201
(8.5000 ± 0.0005 inch)
S/N: 90Z1-Up
Part No.: 4N-1201 (7) Apply 5P-3413 Pipe Sealant on the threads of
S/N: 90Z1-Up the plugs before installation into the front and the
rear of the cylinder block. Tighten the plugs to the
Part No.: 4N-1201 following torque. ........ 80 ± 15 N·m (60 ± 10 lb ft)
S/N: 91Z1-Up
(8) Use the procedure that follows in order to install
Part No.: 4N-1201 the main bearing caps.
S/N: 91Z1-Up
SENR1017-04 103
g00285128
Illustration 116
Index marks for the tightening procedure
1. Lubricate the threads of the bolts with engine oil

prior to installation.
2. First, tighten the bolts that are on the bearing tab Illustration 117
g01014946
side of the cap.
Front face of cylinder block
Torque for bolts .. 258 ± 14 N·m (190.0 ± 10.0 lb ft) Typical example
3. Tighten the bolts on the opposite side of the (A) Thickness of a new cylinder head
bearing tab. gasket .................................... 0.208 ± 0.025 mm
(0.0082 ± 0.0010 inch)
Torque for bolts .. 258 ± 14 N·m (190.0 ± 10.0 lb ft)
(B) Thickness of the cylinder head spacer
4. Use a paint stick in order to place an index mark plate .. 8.585 ± 0.025 mm (0.3380 ± 0.0010 inch)
on each bolt and each cap. Refer to Illustration
116. (C) The size of the bore in the cylinder block for the
camshaft bearings ............... 76.835 ± 0.018 mm
5. Tighten the bolts that are on the opposite side of (3.0250 ± 0.0007 inch)
the bearing tab for an additional amount.
(D) The size of the bore in cylinder block for the main
Turn the bolt clockwise from the index mark. bearings
Angle .......................................... 120 ± 5 degrees
Standard size bearings ...... 129.891 ± 0.013 mm
(5.1138 ± 0.0005 inch)
6. Tighten the bolts that are on the bearing tab side
0.64 mm (0.025 inch) larger than the standard
of the cap for an additional amount.
size .................................... 130.526 ± 0.013 mm
(5.1388 ± 0.0005 inch)
Turn the bolt clockwise from the index mark.
Angle .......................................... 120 ± 5 degrees
104 SENR1017-04
Part No.: 117-9514

S/N: 2YD1-Up
Part No.: 124-7507
S/N: CEH1-Up
Part No.: 124-7507
S/N: 6XJ1-Up
Part No.: 117-9514
S/N: 7XJ1-Up
Part No.: 117-9514
S/N: NBJ1-Up
Part No.: 117-9514
S/N: 7KK1-Up
Part No.: 117-9514
S/N: AAK1-Up
Part No.: 124-7507
S/N: ABK1-Up
g01015335
Illustration 118
Part No.: 117-9514
(E) The distance from the centerline of the crankshaft S/N: ASK1-Up
bearing bore to the top deck of the cylinder Part No.: 124-7507
block ... 419.10 ± 0.15 mm (16.500 ± 0.006 inch) S/N: AWK1-Up
(F) The distance from the centerline of the crankshaft Part No.: 124-7507
bearing bore to the pan rail .... 165.10 ± 0.10 mm S/N: 7TL1-Up
(6.500 ± 0.004 inch)
Part No.: 124-7507
S/N: 8BL1-Up
i02819533
Part No.: 124-7507
Cylinder Block S/N: ACL1-Up

S/N: 7GN1-Up
Part No.: 117-9514
S/N: 8HN1-Up
Part No.: 124-7507
S/N: BBN1-Up
Part No.: 117-9514
S/N: BDA1-Up Part No.: 124-7507
S/N: 2ZR1-Up
Part No.: 124-7507
S/N: 1AB1-Up Part No.: 117-9514, 124-7507
S/N: 3KR1-Up
Part No.: 124-7507
S/N: 1FB1-Up Part No.: 117-9514
S/N: 4FR1-Up
Part No.: 124-7507
S/N: 1NB1-Up Part No.: 117-9514
S/N: 4YR1-Up
Part No.: 124-7507
S/N: BBB1-Up Part No.: 117-9514
S/N: 5HR1-Up
Part No.: 117-9514
S/N: BEC1-Up Part No.: 124-7507
S/N: 5TR1-Up
Part No.: 124-7507
S/N: 1JD1-Up Part No.: 117-9514, 124-7507
S/N: 5YR1-Up
SENR1017-04 105
Part No.: 124-7507 Part No.: 124-7507

Part No.: 117-9514 Part No.: 117-9514
Part No.: 117-9514, 124-7507 Part No.: 117-9514
Part No.: 124-7507 Part No.: 124-7507
Part No.: 124-7507 Part No.: 124-7507
Part No.: 117-9514 Part No.: 124-7507
Part No.: 124-7507 Part No.: 124-7507
Part No.: 117-9514, 124-7507 Part No.: 124-7507
Part No.: 117-9514 Part No.: 124-7507
Part No.: 124-7507 Part No.: 117-9514
Part No.: 124-7507 Part No.: 124-7507
Part No.: 124-7507
S/N: 5SS1-Up
Part No.: 124-7507
S/N: 6YS1-Up
Part No.: 117-9514
S/N: 7CS1-Up
Part No.: 117-9514
S/N: 8AS1-Up
Part No.: 117-9509
S/N: 8GS1-Up
Part No.: 124-7507
S/N: 9XS1-Up
Part No.: 117-9514
S/N: 9YS1-Up
Part No.: 117-9514
S/N: AAT1-Up
Part No.: 117-9514
S/N: AKT1-Up
Part No.: 124-7507
S/N: AXT1-Up
g01406987
Part No.: 124-7507 Illustration 119
S/N: 24W1-Up Typical example
Part No.: 124-7507 Front view of the engine

S/N: 25W1-Up
106 SENR1017-04
Note: The top face of the cylinder block, both sides (7) Apply 6V-6640 Sealant on the cup plug.
of plate gasket (2) and bottom surface of spacer plate
(1) must be free of fuel, oil, water, gasket adhesives, (G) Extension of dowels from the rear face of the
assembly compounds and any other contaminants cylinder block and from the front face of the
during assembly. cylinder block .. 19.0 ± 0.5 mm (0.75 ± 0.02 inch)
(3) Torque for three taperlock studs ........ 27 ± 4 N·m

(20 ± 3 lb ft)
(A) Thickness of the spacer

plates ..................................... 8.585 ± 0.025 mm
(0.3380 ± 0.0010 inch)
(B) Thickness of plate gasket that is between cylinder

block and spacer plate ........... 0.208 ± 0.025 mm
(0.0082 ± 0.0010 inch)
(C) Extension of the dowels on the left bank and right

bank from the cylinder block ....... 18.5 ± 0.5 mm
(0.73 ± 0.02 inch)
g01406653
Illustration 121
Note: Apply 5P-3413 Pipe Sealant on the threads of Section F-F
the taperlock plugs (4) before assembly. (8) Oil jet tube assembly
(4) Torque for the three taperlock plugs .. 80 ± 15 N·m (9) Torque for the special bolts ................ 25 ± 7 N·m
(60 ± 11 lb ft) (18 ± 5 lb ft)
(D) Bore in cylinder block for main Note: The main bearing caps (5) must be installed
bearing ............................... 129.891 ± 0.013 mm with the identifying marks toward the front of the
(5.1138 ± 0.0005 inch) engine. The number of the main bearing cap (5) must
also match the cast number on the left side of each
(E) Dimensions for crankshaft bearing cap main bearing saddle.
The width of the slot for the main bearing
caps ................................... 215.900 ± 0.013 mm Use the following procedure to install the main
(8.5000 ± 0.0005 inch) bearing caps:
Width of main bearing cap .. 215.900 ± 0.025 mm

(8.5000 ± 0.0010 inch)
g01407019
Illustration 122
Marks for tightening main bearings
1. Apply clean engine oil on the threads of the main

bearing cap bolts (6). Loosely install the main
bearing cap bolts (6).
2. Tighten the main bearing cap bolts (6) first on the

main bearing tab side of the main bearing cap (5)
g01406651 to 258 ± 14 N·m (190 ± 10 lb ft).
Illustration 120
Right side view of the engine
SENR1017-04 107
3. Tighten the main bearing cap bolts (6) that are Part No.: 117-9512
opposite the main bearing tab side of the main S/N: AAA1-Up
bearing cap (5) to 258 ± 14 N·m (190 ± 10 lb ft).
Part No.: 117-9512
4. Put a mark on each main bearing cap bolt (6) and S/N: BDA1-Up
each main bearing cap (5). See Illustration 122.
Part No.: 117-9512
S/N: BEC1-Up
5. Tighten the main bearing cap bolts (6) that are
placed opposite the main bearing tab side of the Part No.: 117-9512
main bearing cap (5) from the mark by angle (H) S/N: 2YD1-Up
of 120 ± 5 degrees.
Part No.: 117-9512
6. Tighten the main bearing cap bolts (6) that are S/N: 7XJ1-Up
placed on the main bearing tab side of the main
bearing cap (5) from the mark by angle (H) of 120 Part No.: 117-9512
± 5 degrees. S/N: NBJ1-Up
Part No.: 117-9512
S/N: 67K1-Up
Part No.: 117-9512
S/N: AAK1-Up
Part No.: 117-9512
S/N: ASK1-Up
Part No.: 117-9512
S/N: 7GN1-Up
Part No.: 117-9512
S/N: 8HN1-Up
Part No.: 117-9512
S/N: BBN1-Up
Part No.: 117-9512
S/N: 3KR1-Up
Part No.: 117-9512
S/N: 3KR1-Up
g01406997
Illustration 123
Part No.: 117-9512
(J) Bores in the block for the camshaft sleeve S/N: 4FR1-Up
bearings. .............................. 76.835 ± 0.018 mm Part No.: 117-9512
(3.0250 ± 0.0007 inch) S/N: 4YR1-Up
(K) The distance from the centerline of the Part No.: 117-9512
crankshaft bearing bore to the top of the cylinder S/N: 4YR1-Up
block ... 419.10 ± 0.15 mm (16.500 ± 0.006 inch)
Part No.: 117-9512
Minimum distance from the centerline of the S/N: 4YR1-Up
crankshaft bearing bore to the top of the cylinder
block (top deck) ................ 418.67 mm (16.483 inch) Part No.: 117-9512
S/N: 4YR1-Up
(L) The distance from the centerline of the crankshaft Part No.: 117-9512
bearing bore to the bottom of the cylinder block S/N: 5TR1-Up
.............. 165.10 ± 0.10 mm (6.500 ± 0.004 inch)
Part No.: 117-9512
S/N: 5XR1-Up
i02602045
Part No.: 117-9512
Cylinder Block S/N: 5YR1-Up
S/N: 5YR1-Up
108 SENR1017-04
Part No.: 117-9512

S/N: 6KR1-Up
Part No.: 117-9512
S/N: 6PR1-Up
Part No.: 117-9512
S/N: 6PR1-Up
Part No.: 117-9512
S/N: 6TR1-Up
Part No.: 117-9512
S/N: 6TR1-Up
Part No.: 117-9512
S/N: 7ER1-Up
Part No.: 117-9512
S/N: 7KR1-Up
Part No.: 117-9512
S/N: 7KR1-Up
g01302411
Illustration 124
Part No.: 117-9512
S/N: BCR1-Up (1) Tighten the three studs that hold the water pump
Part No.: 117-9512 to the following torque. ...................... 35 ± 5 N·m
S/N: 7CS1-Up (25.8 ± 3.7 lb ft)
Part No.: 117-9512 (2) There are two plugs on the front of the cylinder
S/N: 8AS1-Up block. There are two plugs on the rear of the
cylinder block. Put 5P-3413 Pipe Sealant on the
Part No.: 117-9512 threads of the plugs before assembly.
S/N: 9YS1-Up
(3) The dowels extend from the cylinder block.
Part No.: 117-9512
Distance .......... 18.5 ± 0.5 mm (0.73 ± 0.02 inch)
S/N: AKT1-Up
Part No.: 117-9512 (4) The gasket that is between the cylinder
S/N: 63W1-Up block and the top plates is the following
thickness. ............................... 0.208 ± 0.025 mm
Part No.: 117-9512 (.0082 ± .0010 inch)
S/N: 64W1-Up
(5) Thickness of the top plates .... 8.585 ± 0.025 mm
Part No.: 117-9512 (.3380 ± .0010 inch)
S/N: 2KZ1-Up
(6) Refer to the Systems Operation, Testing and
Adjusting Manual, “Cylinder Liner Projection”
for the correct procedure for the cylinder liner
projection.
(7) The camshaft bearing bore is the following

value. ................................... 76.835 ± 0.018 mm
(3.0250 ± .0007 inch)
(8) Put 5P-3413 Pipe Sealant on the threads of

the plugs before assembly. Tighten the plug that
is in the front of the block and tighten the plug
that is in the rear of the block to the following
torque. ....................... 80 ± 15 N·m (60 ± 10 lb ft)
(9) Bore in cylinder block for main bearings

New bearings that are standard
size .................................... 129.891 ± 0.013 mm
(5.1138 ± 0.0005 inch)
SENR1017-04 109
Bearings that are 0.64 mm (.025 inch) larger than

the standard size ............... 130.526 ± 0.013 mm
(5.1388 ± 0.0005 inch)
(10) There are two dowels that are in the front of the
cylinder block. There are two dowels that are in
the rear of the cylinder block. The dowels project
from the cylinder block. Distance .. 19.0 ± 0.5 mm
(.75 ± .02 inch)
(11) The width of the slot for the main bearing caps
is the following value. ........ 215.900 ± 0.013 mm
(8.5000 ± .0005 inch)
Width of main bearing cap ....... 215.900 ± 0.013 mm

(8.5000 ± .0005 inch)
Clearance between slot and main bearing cap

Tight ................................ 0.025 mm (.0010 inch)
Loose .............................. 0.025 mm (.0010 inch)
g00366557
Illustration 125
(12) Tighten the bolts that hold the piston cooling jets
to the following torque. ...................... 25 ± 7 N·m
(14) The distance from the centerline of the
(18.5 ± 5 lb ft)
crankshaft bearing bore to the top of the cylinder
block is the following value. ... 419.10 ± 0.15 mm
(13) Use the procedure that follows to install the
(16.500 ± .006 inch)
main bearing caps.
(15) The distance from the centerline of the
1. Install the main bearing caps with the arrows
crankshaft bearing bore to the bottom
toward the front of the engine. Each main bearing
of the cylinder block is the following
cap is numbered on the bottom. Main bearing
value. ...... 165.10 ± 0.10 mm (6.500 ± .004 inch)
caps must be installed in the same position before
removal. A corresponding number is on the left
side of the cylinder block pan rail.
2. Put 4C-5593 Anti-Seize Compound on the

threads of the main bearing cap bolts.
3. Tighten the bolts on the left side.
Torque for bolts ....... 258 ± 14 N·m (190 ± 10 lb ft)
4. Tighten the bolts on the right side.
Torque for bolts ....... 258 ± 14 N·m (190 ± 10 lb ft)
5. Place a mark on each cap and each bolt.
6. Additionally tighten the bolts on the right side.
Distance ..................................... 120 ± 5 degrees
7. Additionally tighten the bolts on the left side.

g01302483
Illustration 126
Distance ..................................... 120 ± 5 degrees
(16) Two plugs are located on the top right side of
the cylinder block. One plug is in the front and
one plug is in the rear. Use 4C-9500 Quick Cure
Primer and 4C-9507 Retaining Compound in the
plug bores before assembly.
110 SENR1017-04
(17) Plug. Use 4C-9500 Quick Cure Primer and i02996025

4C-9507 Retaining Compound in the plug bore
before assembly. Crankshaft
(18) Tighten the studs to the following SMCS Code: 1202
torque. ........................... 35 ± 5 N·m (26 ± 4 lb ft)
Part No.: 4N-0922
S/N: AAA1-Up
i02811418
Part No.: 4N-0922
Cylinder Liner S/N: BDA1-Up
Part No.: 4N-0922
SMCS Code: 1216
S/N: BEC1-Up
Part No.: 197-9322
Part No.: 4N-0922
S/N: 2YD1-Up
Part No.: 4N-0922
S/N: 2YD1-Up
Part No.: 4N-0922
S/N: 7MJ1-Up
Part No.: 4N-0922
S/N: 7XJ1-Up
Part No.: 4N-0922
S/N: 7XJ1-Up
Part No.: 4N-0922
g01402328 S/N: NBJ1-Up
Illustration 127
Part No.: 4N-0922
(A) Bore in new cylinder liner .. 137.185 ± 0.025 mm S/N: 3SK1-Up
(5.4010 ± 0.0010 inch)
Part No.: 4N-0922
(B) Dimensions for flange (1) S/N: 67K1-Up
Thickness of flange on cylinder Part No.: 4N-0922

liner ........... 8.89 ± 0.02 mm (0.350 ± 0.001 inch) S/N: 7HK1-Up
Minimum thickness ....... 8.870 mm (0.3492 inch)
Part No.: 4N-0922
Use the following procedure to install the cylinder S/N: 7KK1-Up
liner: Part No.: 4N-0922
S/N: AAK1-Up
1. Apply liquid soap on the cylinder block liner bore
surfaces and the rubber seals that are on the Part No.: 4N-0922
lower end of the cylinder liner. S/N: ASK1-Up
2. Dip the filler band (2) completely in clean engine Part No.: 4N-0922
oil. S/N: 7GN1-Up
Part No.: 4N-0922
3. Immediately install the filler band in the groove
S/N: 8HN1-Up
that is under the flange.
Part No.: 4N-0922
4. Install the cylinder liner into the cylinder block S/N: BBN1-Up
before the expansion of the filler band.
Part No.: 4N-0922
Note: Refer to Reuse And Salvage Guidelines, S/N: 3KR1-Up
SEBF8049, “Visual Inspection of the Piston” for more
information. Also, refer to Guideline For Reusable Part No.: 4N-0922
Parts and Salvage Operations, SEBF8068, “Cylinder S/N: 3KR1-Up
Liners” for more information. Part No.: 4N-0922
S/N: 4FR1-Up
SENR1017-04 111

S/N: 5XR1-Up S/N: 99X1-Up
S/N: 7ER1-Up S/N: 91Z1-Up
Part No.: 4N-0922 Note: For the correct procedure on measuring for
S/N: 7KR1-Up a bent crankshaft, refer to Guideline for Reusable
Parts, SEBF8054, “Procedure to Measure and
Part No.: 4N-0922
Straighten Bent Crankshafts”.
S/N: 7KR1-Up
Part No.: 4N-0922
S/N: BCR1-Up
Part No.: 4N-0922
S/N: 7CS1-Up
Part No.: 4N-0922
S/N: 8AS1-Up
Part No.: 4N-0922
S/N: 8GS1-Up
Part No.: 4N-0922
S/N: 9YS1-Up
Part No.: 4N-0922
S/N: AAT1-Up
Part No.: 4N-0922
S/N: AKT1-Up
112 SENR1017-04
g01519152
Illustration 128
(A) Maximum protrusion of pin from the rear side of i02995980

the crankshaft face ............... 8.4 mm (0.33 inch)
Crankshaft
(1) Thrust plate
SMCS Code: 1202
Thickness of the new thrust plate
.................. 5.74 ± 0.04 mm (0.226 ± 0.002 inch) Part No.: 1W-5010
End play for the crankshaft with new thrust S/N: BCA1-Up
plates ...... 0.10 to 0.60 mm (0.004 to 0.024 inch)
Part No.: 1W-5010
Maximum permissible end play with used thrust S/N: 1AB1-Up
plates ................................ 0.89 mm (0.035 inch)
Part No.: 1W-5010
Note: The thrust plates are used only on the center S/N: 1FB1-Up
main bearing.
Part No.: 1W-5010
(B) Protrusion of the dowel from the crankshaft S/N: 1NB1-Up
surface .............. 4.1 ± 0.5 mm (0.16 ± 0.02 inch)
Part No.: 1W-5010
(2) Connecting rod bearing journal S/N: BBB1-Up
Part No.: 1W-5010
Refer to Specifications, “Connecting Rod and Main S/N: 1JD1-Up
Bearing Journals” for more information.
Part No.: 1W-5010
(3) Main bearing journal S/N: 1JD1-Up
Refer to Specifications, “Connecting Rod and Main Part No.: 1W-5010

Bearing Journals” for more information. S/N: 8YG1-Up
(4) Install the crankshaft gear with the timing mark Part No.: 1W-5010
S/N: CEH1-Up
“V” on the outside of the crankshaft.
Part No.: 1W-5010
Note: Refer to Special Instruction, SMHS8508, S/N: 3BJ1-Up
“Special Handling Information and Installation
Instructions for Crankshaft Seal Groups That Have Part No.: 1W-5010
Hydrodynamic Grooves In the Sealing Lip”. S/N: 6XJ1-Up
Part No.: 1W-5010
S/N: 3TK1-Up
Part No.: 1W-5010
S/N: ABK1-Up
SENR1017-04 113

S/N: 7TL1-Up S/N: 26W1-Up
S/N: 7TL1-Up S/N: 50W1-Up
S/N: 8BL1-Up S/N: BLW1-Up
S/N: 8BL1-Up S/N: 01X1-Up
S/N: ACL1-Up S/N: 01X1-Up
S/N: 2ZR1-Up S/N: 01X1-Up
S/N: 5TR1-Up S/N: 1YZ1-Up
S/N: 5YR1-Up S/N: 1ZZ1-Up
S/N: 7BR1-Up S/N: 87Z1-Up
S/N: 7FR1-Up S/N: BKZ1-Up
Part No.: 1W-5010
S/N: 7KR1-Up
Part No.: 1W-5010
S/N: CLR1-Up
Part No.: 1W-5010
S/N: 2PS1-Up
Part No.: 1W-5010
S/N: 5SS1-Up
Part No.: 1W-5010
S/N: 6YS1-Up
Part No.: 1W-5010
S/N: 9XS1-Up
Part No.: 1W-5010
S/N: AXT1-Up
Part No.: 1W-5010
S/N: 24W1-Up
114 SENR1017-04
g01519075
Illustration 129
Note: For the correct procedure on measuring for a Note: Refer to Special Instruction, SMHS8508,
bent crankshaft, refer to Guideline for Reusable Parts “Special Handling Information and Installation
and Salvage Operations, SEBF8054, “Procedure to Instructions for Crankshaft Seal Groups That Have
Measure and Straighten Bent Crankshafts”. Hydrodynamic Grooves In the Sealing Lip”.
(A) Maximum protrusion of the dowel from the

i02866012
crankshaft face ..................... 8.4 mm (0.33 inch)
(1) Thrust plate

Vibration Damper
Thickness of the new thrust plate SMCS Code: 1205
.................. 5.74 ± 0.04 mm (0.226 ± 0.002 inch) Part No.: 6N-2229
End play for the crankshaft with new thrust plates S/N: AAA1-Up
................ 0.10 to 0.60 mm (0.004 to 0.024 inch)
Part No.: 6N-2229
Note: The thrust plates are only on the center main S/N: BCA1-Up
bearing.
Part No.: 6N-2229
(2) Minimum torque for pipe plug ... 23 N·m (17 lb ft) S/N: BDA1-Up
(B) Protrusion of the dowel from the crankshaft Part No.: 6N-2229
surface .............. 4.1 ± 0.5 mm (0.16 ± 0.02 inch) S/N: BBB1-Up
Part No.: 6N-2229
(3) Connecting rod bearing journal S/N: BEC1-Up
Refer to Specifications, “Connecting Rod and Main Part No.: 6N-2229
Bearing Journals” for more information. S/N: 2YD1-Up
(4) Main bearing journal Part No.: 6N-2229

S/N: 2YD1-Up
Refer to Specifications, “Connecting Rod and Main
Part No.: 6N-2229
Bearing Journals” for more information.
S/N: 7MJ1-Up
Note: Install the crankshaft gear with the timing mark Part No.: 6N-2229
“V” toward the outside of the crankshaft. S/N: 7XJ1-Up
(5) Maximum permissible temperature of the Part No.: 6N-2229

crankshaft gear for installation on the S/N: 7XJ1-Up
crankshaft .................................. 233 °C (451 °F)
SENR1017-04 115

S/N: 3SK1-Up S/N: 6TR1-Up
S/N: 7HK1-Up S/N: 7FR1-Up
S/N: 7KK1-Up S/N: 7KR1-Up
S/N: 3KR1-Up S/N: AKT1-Up
S/N: 5XR1-Up S/N: 42X1-Up
116 SENR1017-04

S/N: 90Z1-Up S/N: 8YG1-Up
S/N: 91Z1-Up S/N: 3TK1-Up
S/N: 91Z1-Up S/N: ABK1-Up
Part No.: 116-6566, 4W-5973
S/N: 7TL1-Up
Part No.: 116-6566, 4W-5973
S/N: 8BL1-Up
Part No.: 116-6566
S/N: 8BL1-Up
Part No.: 116-6566, 4W-5973
S/N: ACL1-Up
Part No.: 1W-0998
S/N: 2ZR1-Up
Part No.: 116-6566
S/N: 3KR1-Up
Part No.: 1W-0998
S/N: 5TR1-Up
Part No.: 1W-0998
g01427717 S/N: 6JR1-Up
Illustration 130
(1) Damper adapter Part No.: 1W-0998
(2) Damper S/N: 7BR1-Up
(3) Torque for 12 bolts .. 135 ± 20 N·m (100 ± 15 lb ft) Part No.: 1W-0998
S/N: 7FR1-Up
i03201104 Part No.: 1W-0998

S/N: 5SS1-Up
Vibration Damper
Part No.: 1W-0998
SMCS Code: 1205 S/N: 6YS1-Up

S/N: BCA1-Up S/N: 8GS1-Up
Part No.: 1W-0998, 4N-1560 Part No.: 1W-0998

S/N: 1AB1-Up S/N: 9XS1-Up
Part No.: 1W-0998, 4N-1560 Part No.: 1W-0998, 4N-1560

S/N: 1FB1-Up S/N: 24W1-Up
Part No.: 1W-0998, 4N-1560 Part No.: 1W-0998, 4N-1560

S/N: 1NB1-Up S/N: 25W1-Up
Part No.: 1W-0998 Part No.: 1W-0998, 4N-1560

S/N: BBB1-Up S/N: 26W1-Up
Part No.: 1W-0998, 4W-5973 Part No.: 1W-0998

SENR1017-04 117
Part No.: 1W-0998 i03201020

S/N: BLW1-Up
Vibration Damper
Part No.: 1W-0998, 4N-1560
S/N: 01X1-Up SMCS Code: 1205
Part No.: 1W-0998, 4N-1560 Part No.: 4P-5893
S/N: 99X1-Up S/N: 1AB1-Up
Part No.: 116-6566, 4W-5973 Part No.: 4P-5893
S/N: 53Y1-Up S/N: 1FB1-Up
Part No.: 1W-0998 Part No.: 4P-5893
S/N: 1YZ1-Up S/N: 1NB1-Up
S/N: 1ZZ1-Up S/N: BBB1-Up
S/N: BKZ1-Up S/N: AWK1-Up
Part No.: 4P-5893
NOTICE S/N: 5YR1-Up
Thoroughly inspect the viscous damper for signs of
leakage or for signs of a dented (damaged) case. Part No.: 4P-5893
Either of these conditions can cause the weight to S/N: 6PR1-Up
make contact with the case. This can affect the vis-
cous damper's operation. Part No.: 4P-5893
S/N: 6TR1-Up
Part No.: 4P-5893
S/N: 7KR1-Up
Part No.: 4P-5893
S/N: CLR1-Up
Part No.: 4P-5893
S/N: 2PS1-Up
Part No.: 4P-5893
S/N: AXT1-Up
Part No.: 4P-5893
S/N: 25W1-Up
Part No.: 4P-5893
S/N: 26W1-Up
Part No.: 4P-5893
S/N: 99X1-Up
Part No.: 4P-5893
Illustration 131
g01633414 S/N: 86Z1-Up
Typical example Part No.: 4P-5893
(1) Damper adapter S/N: 86Z1-Up
(3) Damper
Part No.: 4P-5893
(2) Before assembly, lubricate the threads of six S/N: 87Z1-Up
bolts with clean engine oil, molybdenum disulfide
or graphite base lubricant. Part No.: 4P-5893
S/N: 87Z1-Up
118 SENR1017-04
Part No.: 4N-0922

NOTICE S/N: BEC1-Up
Thoroughly inspect the viscous damper for signs of
Part No.: 1W-5010
leakage or for signs of a dented (damaged) case.
Either of these conditions can cause the weight to S/N: 1JD1-Up
make contact with the case. This can affect the vis- Part No.: 1W-5010
cous damper's operation. S/N: 1JD1-Up
Part No.: 4N-0922
S/N: 2YD1-Up
Part No.: 1W-5010
S/N: 8YG1-Up
Part No.: 1W-5010
S/N: CEH1-Up
Part No.: 1W-5010
S/N: 3BJ1-Up
Part No.: 1W-5010
S/N: 6XJ1-Up
Part No.: 4N-0922
S/N: 7XJ1-Up
Part No.: 4N-0922
S/N: NBJ1-Up
Part No.: 4N-0922
S/N: 7KK1-Up
g01074376
Illustration 132
(2) Damper
Part No.: 4N-0922
(3) Damper adapter S/N: AAK1-Up
Part No.: 1W-5010
(1) Before assembly, lubricate the threads of six
bolts with clean engine oil, molybdenum disulfide S/N: ABK1-Up
or graphite base lubricant. Part No.: 4N-0922
S/N: ASK1-Up
i02739840
Part No.: 1W-5010
Connecting Rod and Main S/N: AWK1-Up
Bearing Journals Part No.: 1W-5010

S/N: 7TL1-Up
SMCS Code: 1230
Part No.: 1W-5010
Part No.: 4N-0922 S/N: 8BL1-Up
S/N: AAA1-Up
Part No.: 1W-5010
Part No.: 1W-5010 S/N: 8BL1-Up
S/N: BCA1-Up
Part No.: 1W-5010
Part No.: 4N-0922 S/N: ACL1-Up
S/N: BDA1-Up
Part No.: 4N-0922
Part No.: 1W-5010 S/N: 7GN1-Up
S/N: 1AB1-Up
Part No.: 4N-0922
Part No.: 1W-5010 S/N: 8HN1-Up
S/N: 1FB1-Up
Part No.: 4N-0922
Part No.: 1W-5010 S/N: BBN1-Up
S/N: 1NB1-Up
Part No.: 1W-5010
Part No.: 1W-5010 S/N: 2ZR1-Up
S/N: BBB1-Up
SENR1017-04 119
Part No.: 1W-5010, 4N-0922 Part No.: 4N-0922

S/N: 4FR1-Up S/N: AKT1-Up
S/N: 5HR1-Up S/N: 24W1-Up
Part No.: 1W-5010, 4N-0922 Part No.: 4N-0922
Part No.: 1W-5010 Part No.: 4N-0922
S/N: BCR1-Up S/N: 1YZ1-Up
S/N: CLR1-Up S/N: 1ZZ1-Up
S/N: 2PS1-Up S/N: 2KZ1-Up
S/N: 5SS1-Up S/N: 86Z1-Up
S/N: 7CS1-Up S/N: BKZ1-Up
Part No.: 4N-0922 Refer to the Guideline for Reusable Parts for more
S/N: 8AS1-Up information.
Part No.: 1W-5010
S/N: 9XS1-Up
Part No.: 4N-0922
S/N: 9YS1-Up
120 SENR1017-04
Connecting Rod Bearing Journals i03201461
Table 1 Connecting Rod

Diameter of Crankshaft Journal (Bearing
Surface) For Connecting Rod
SMCS Code: 1218
Original Size 97.028 ± 0.020 mm Part No.: 160-8178

(3.8200 ± 0.0008 inch)
Clearance between new bearing and new

journal ... 0.070 to 0.178 mm (0.0028 to 0.0070 inch)
Main Bearing Journals

Table 2
Diameter of Crankshaft Journal (Bearing

Surface) for Main Bearings
Original Size 120.650 ± 0.020 mm
(4.7500 ± 0.0008 inch)
Undersize Journal 120.015 ± 0.020 mm
0.63 mm (0.025 inch) (4.7250 ± 0.0008 inch)
Undersize Journal 119.380 ± 0.020 mm
1.27 mm (0.050 inch) (4.7000 ± 0.0008 inch)
Main bearing cap with two bolts

g01385501
Clearance between new bearing and new Illustration 133
journal ................................... 0.076 to 0.186 mm
(0.0030 to 0.0073 inch) (A) Diameter of the connecting rod's bore for the
piston pin's bearing .............. 55.436 ± 0.013 mm
Main bearing cap with four bolts (2.1825 ± 0.0005 inch)
Clearance between new bearing and new (B) Diameter of the connecting rod's bearing for the
journal ................................... 0.071 to 0.178 mm crankshaft journal .............. 103.500 ± 0.013 mm
(0.0028 to 0.0070 inch) (4.0748 ± 0.0005 inch)
(C) Distance between the center of the bore for the

bearing for piston pin and the center of the bore
for the crankshaft journal .................. 261.62 mm
(10.300 inch)
(D) Dimensions for piston pin and bearing

Bore of bearing for the piston
pin ... 50.830 ± 0.008 mm (2.0012 ± 0.0003 inch)
Average roughness of the finished bearing ... 0.8
Diameter of piston pin .......... 50.795 ± 0.005 mm
(1.9998 ± 0.0002 inch)
(E) Inside diameter of connecting rod

for the crankshaft main bearing
journal ................................ 97.119 to 97.175 mm
(3.8236 to 3.8258 inch)
Clearance between the new bearing and the

crankshaft ................................... 0.070 to 0.178 mm
(0.0028 to 0.0070 inch)
SENR1017-04 121
g01375328 g01375363
Position of the piston pin bearing
(1) Use the following procedure to tighten the
(F) Maximum angle of the bearing's joint from the connecting rod nut :
horizontal centerline ........................ ± 5 degrees
1. Before assembly, lubricate the threads of the bolts
(G) Maximum angle of the bearing's joint from the and the seating face of the bolt heads with clean
horizontal centerline ........................ ± 5 degrees engine oil.
Note: Do not use a torch to heat the connecting rod. 2. Tighten the connecting rod nuts to 82 ± 8 N·m
(60 ± 6 lb ft).
(H) Maximum length for heating the connecting
rod during installation of bearing for the piston 3. After torquing the connecting rod nuts, tighten
pin ............................................ 89 mm (3.5 inch) each nut for an additional angle (J) of 120 ± 5
degrees.
Allowable temperature for heating of the connecting
rod .............................. 175 to 260 °C (350 to 500 °F)
i02750532
Piston and Rings

SMCS Code: 1214; 1215
Part No.: 109-2823
S/N: AAA1-Up
Part No.: 109-2823
S/N: BCA1-Up
Part No.: 109-2823
S/N: BDA1-Up
Part No.: 109-2823
S/N: 1AB1-Up
g01385471
Illustration 135
View A-A Part No.: 109-2823
S/N: 1FB1-Up
Note: Install surface (2) of the connecting rod next Part No.: 109-2823
to the crank pin thrust surface. Refer to Illustration
S/N: 1NB1-Up
135. Surface (3) of the connecting rod is now next to
surface (3) of the adjacent rod on the common crank Part No.: 109-2823
pin. S/N: BBB1-Up
Part No.: 109-2823
S/N: BEC1-Up
Part No.: 109-2823
S/N: 1JD1-Up
Part No.: 2W-9054
S/N: 1JD1-Up
122 SENR1017-04
Part No.: 2W-9054 Part No.: 109-2823

Part No.: 2W-9054 Part No.: 109-2823
S/N: 8YG1-Up S/N: 4FR1-Up
Part No.: 109-2823 Part No.: 109-2823
S/N: CEH1-Up S/N: 4YR1-Up
Part No.: 2W-9054 Part No.: 109-2823
S/N: 3BJ1-Up S/N: 5HR1-Up
Part No.: 2W-9054 Part No.: 109-2823
S/N: 7MJ1-Up S/N: 5TR1-Up
Part No.: 2W-9054 Part No.: 109-2823
Part No.: 109-2823 Part No.: 109-2823
S/N: 7XJ1-Up S/N: 6JR1-Up
Part No.: 109-2823 Part No.: 109-2823
S/N: NBJ1-Up S/N: 6KR1-Up
Part No.: 2W-9054 Part No.: 109-2823
S/N: 3SK1-Up S/N: 6PR1-Up
Part No.: 2W-9054 Part No.: 109-2823
Part No.: 109-2823 Part No.: 109-2823
S/N: 7KK1-Up S/N: 7BR1-Up
Part No.: 109-2823 Part No.: 109-2823
S/N: AAK1-Up S/N: 7ER1-Up
Part No.: 109-2823 Part No.: 109-2823
S/N: ABK1-Up S/N: 7FR1-Up
Part No.: 109-2823 Part No.: 109-2823
Part No.: 109-2823 Part No.: 109-2823
S/N: AWK1-Up S/N: CLR1-Up
Part No.: 2W-9054 Part No.: 109-2823
Part No.: 109-2823 Part No.: 109-2823
Part No.: 2W-9054 Part No.: 109-2823
S/N: 8BL1-Up S/N: 6YS1-Up
Part No.: 109-2823 Part No.: 109-2823
S/N: ACL1-Up S/N: 7CS1-Up
Part No.: 109-2823 Part No.: 109-2823
S/N: 7GN1-Up S/N: 8AS1-Up
Part No.: 109-2823 Part No.: 109-2823
S/N: 8HN1-Up S/N: 9XS1-Up
Part No.: 109-2823 Part No.: 109-2823
Part No.: 109-2823 Part No.: 109-2823
S/N: 2ZR1-Up S/N: AAT1-Up
SENR1017-04 123
Part No.: 109-2823 Part No.: 2W-9054

Part No.: 109-2823 Part No.: 2W-9054
Part No.: 2W-9054 Part No.: 109-2823
Part No.: 2W-9054
S/N: 63W1-Up
Part No.: 109-2823
S/N: 63W1-Up
Part No.: 109-2823
S/N: 64W1-Up
Part No.: 2W-9054
S/N: 64W1-Up
Part No.: 109-2823
S/N: BLW1-Up
Part No.: 109-2823
S/N: 01X1-Up
Part No.: 2W-9054
S/N: 01X1-Up
Part No.: 2W-9054
S/N: 01X1-Up g01377415
Illustration 137
Part No.: 109-2823
S/N: 1YZ1-Up Note: Refer to Guideline for Reusable Parts for
information on the pistons, the piston pins, and the
Part No.: 109-2823 retaining rings.
S/N: 1ZZ1-Up
Note: Lubricate the piston body assembly with clean
Part No.: 109-2823
engine oil around the zone (A) and the top of the
S/N: 2KZ1-Up
piston body assembly prior to assembly into the
Part No.: 2W-9054 cylinder block.
S/N: 49Z1-Up
Part No.: 2W-9054
Top Piston Ring
S/N: 86Z1-Up
The 1U-6431 Piston Ring Groove Gauge Gp is
Part No.: 2W-9054 used for measuring the ring grooves in keystone
S/N: 86Z1-Up style pistons. Refer to the Special Instruction that is
supplied with the piston ring groove gauge.
Part No.: 2W-9054
S/N: 87Z1-Up (1) Top piston ring
Part No.: 2W-9054 Install the top piston ring with “UP-1” mark toward
S/N: 87Z1-Up the top of the piston.
Part No.: 2W-9054
S/N: 89Z1-Up There is a clearance between the ends of the top
piston ring. When the top piston ring is installed in a
Part No.: 2W-9054 cylinder liner with a bore of 137.16 mm (5.400 inch),
S/N: 89Z1-Up the clearance is the following value. .. 0.55 ± 0.15 mm
(0.022 ± 0.006 inch)
Part No.: 2W-9054
S/N: 90Z1-Up There is an increase in the clearance between the
ends of the top piston rings for each 0.030 mm
Part No.: 2W-9054 (0.0012 inch) increase in the cylinder liner bore.
S/N: 90Z1-Up Increase .................................. 0.08 mm (0.003 inch)
124 SENR1017-04
Intermediate Piston Ring Diameter of the bore in the piston for the piston
pin ... 50.800 ± 0.005 mm (2.0000 ± 0.0002 inch)
The 1U-6431 Piston Ring Groove Gauge Gp is Diameter of the new piston
used for measuring the ring grooves in keystone pin ... 50.795 ± 0.005 mm (1.9998 ± 0.0002 inch)
style pistons. Refer to the Special Instruction that is
supplied with the piston ring groove gauge.
i02948371
(2) Intermediate piston ring Piston and Rings

Install the intermediate piston ring with “UP-2” mark SMCS Code: 1214; 1215
toward the top of the piston.
Part No.: 192-8808
There is a clearance between the ends of the S/N: AAA1-Up
intermediate piston ring. When the piston ring is
installed in a cylinder liner with a bore of 137.16 mm Part No.: 192-8809
(5.400 inch), the clearance is the following S/N: BCA1-Up
value. ...... 1.080 ± 0.190 mm (0.0425 ± 0.0075 inch)
Part No.: 192-8809
S/N: BDA1-Up
There is an increase in the clearance between
the ends of the piston rings for each 0.030 mm Part No.: 192-8808, 192-8809
(0.0012 inch) increase in the cylinder liner bore. S/N: 1AB1-Up
Increase .................................. 0.08 mm (0.003 inch)
Part No.: 192-8808, 192-8809
S/N: 1FB1-Up
Oil Control Piston Ring
Part No.: 192-8808, 192-8809
(3) Oil control piston ring S/N: 1NB1-Up
Note: The spring ends of the oil control piston ring Part No.: 192-8809
should be assembled 180 degrees from the ring end S/N: BBB1-Up
gap.
Part No.: 192-8808, 192-8809
The 5P-3519 Piston Ring Groove Gauge Gp is S/N: BEC1-Up
available for checking the ring grooves with straight
Part No.: 192-8808, 192-8809
sides. Refer to the Guideline for Reusable Parts for
S/N: 1JD1-Up
instructions on using the piston ring groove gauge.
Part No.: 192-8808
Width of groove in new piston for oil control piston S/N: 2YD1-Up
ring .......... 3.190 ± 0.010 mm (0.1256 ± 0.0004 inch)
Part No.: 192-8809
Thickness of new oil control piston S/N: CEH1-Up
ring .......... 3.137 ± 0.013 mm (0.1235 ± 0.0005 inch)
Part No.: 192-8809
There is a clearance between the ends of the oil S/N: 6XJ1-Up
control piston ring. When the oil control piston Part No.: 192-8808, 192-8809
ring is installed in a cylinder liner with a bore of S/N: 7XJ1-Up
137.16 mm (5.400 inch), the clearance is the
following value. ................................ 0.57 ± 0.19 mm Part No.: 192-8808
(0.022 ± 0.008 inch) S/N: NBJ1-Up
There is an increase in the clearance between the Part No.: 192-8808

ends of the oil control piston rings for each 0.030 mm S/N: 3TK1-Up
(0.0012 inch) increase in the cylinder liner bore.
Increase .................................. 0.08 mm (0.003 inch) Part No.: 192-8808
S/N: 67K1-Up
Piston Pin Part No.: 192-8808, 192-8809

S/N: 7KK1-Up
Note: Lubricate the piston pin with clean engine oil
before assembly. Part No.: 192-8808
S/N: AAK1-Up
(4) Piston pin Part No.: 192-8809
S/N: ABK1-Up
SENR1017-04 125
Part No.: 192-8809 Part No.: 192-8808

S/N: ASK1-Up S/N: 6TR1-Up
Part No.: 192-8809 Part No.: 192-8808
S/N: AWK1-Up S/N: 6TR1-Up
Part No.: 192-8808, 192-8809 Part No.: 192-8808
S/N: 7TL1-Up S/N: 7BR1-Up
Part No.: 192-8808 Part No.: 192-8808, 192-8809
S/N: 8BL1-Up S/N: 7ER1-Up
Part No.: 192-8809 Part No.: 192-8808
S/N: ACL1-Up S/N: 7FR1-Up
Part No.: 192-8809 Part No.: 192-8808
Part No.: 192-8808, 192-8809 Part No.: 192-8808
Part No.: 192-8808 Part No.: 192-8809
Part No.: 192-8808 Part No.: 192-8809
Part No.: 192-8808, 192-8809 Part No.: 192-8808, 192-8809
Part No.: 192-8808 Part No.: 192-8808
Part No.: 192-8808 Part No.: 192-8808
Part No.: 192-8808 Part No.: 192-8808, 192-8809
Part No.: 192-8808 Part No.: 192-8808, 192-8809
Part No.: 192-8808 Part No.: 192-8808
Part No.: 192-8808 Part No.: 192-8808
Part No.: 192-8808 Part No.: 192-8808
S/N: 5XR1-Up S/N: AAT1-Up
Part No.: 192-8808 Part No.: 192-8809
Part No.: 192-8808 Part No.: 192-8809
Part No.: 192-8808 Part No.: 192-8808, 192-8809
Part No.: 192-8808 Part No.: 192-8808, 192-8809
Part No.: 192-8808 Part No.: 192-8808, 192-8809
Part No.: 192-8808 Part No.: 192-8808, 192-8809
126 SENR1017-04
Part No.: 192-8808, 192-8809 liner with a bore of 137.16 mm (5.400 inch), the
S/N: 64W1-Up clearance is the following value. ...... 0.40 ± 0.10 mm
(0.016 ± 0.004 inch)
Part No.: 192-8808
S/N: BLW1-Up There is an increase in the clearance between
the ends of the piston rings for each 0.030 mm
Part No.: 192-8808, 192-8809
S/N: 01X1-Up
Increase .................................. 0.08 mm (0.003 inch)
Part No.: 192-8808
S/N: 42X1-Up Intermediate Piston Ring
Part No.: 192-8808, 192-8809
The 1U-6431 Piston Ring Groove Gauge is used for
S/N: 99X1-Up
measuring the ring grooves in keystone style pistons.
Part No.: 192-8808, 192-8809 Refer to the Special Instruction that is supplied with
S/N: 53Y1-Up the Piston Ring Groove Gauge.
Part No.: 192-8808 (2) Intermediate piston ring

S/N: 1YZ1-Up
Install the piston ring with “UP-2” mark toward the
Part No.: 192-8808 top of the piston.
S/N: 1ZZ1-Up
Part No.: 192-8808, 192-8809 Width of groove in new piston forintermediate piston
S/N: 2KZ1-Up ring .......... 2.050 ± 0.010 mm (0.0807 ± 0.0004 inch)
Part No.: 192-8808 Thickness of new piston ring ....... 1.980 ± 0.010 mm
S/N: BKZ1-Up (0.0780 ± 0.0004 inch)
Clearance between groove and new piston

ring ............ 0.05 to 0.09 mm (0.0020 to 0.0035 inch)
There is a clearance between the ends of the piston

ring. When the piston ring is installed in a cylinder
liner with a bore of 137.16 mm (5.400 inch), the
clearance is the following value. .. 0.675 ± 0.125 mm
(0.0266 ± 0.0049 inch)

Increase .................................. 0.08 mm (0.003 inch)
g01462430
Illustration 138
Oil Control Ring
Typical example
(3) Oil control ring
Note: Refer to Guideline for Reusable Parts for
information on the pistons, the piston pins, and the The spring ends of the oil control ring should be
retaining rings. assembled 180 degrees from the ring end gap.
Top Piston Ring The 5P-3519 Piston Ring Groove Gauge is available
for checking the ring grooves with straight sides.
The 1U-6431 Piston Ring Groove Gauge is used for Refer to the Guideline for Reusable Parts for
measuring the ring grooves in keystone style pistons. instructions on using the Piston Ring Groove Gauge.
Refer to the Special Instruction that is supplied with
the Piston Ring Groove Gauge. Width of groove in new piston for oil control
ring ........... 3.030 ± 0.010 mm (0.1193 ± 0.0004 inch)
(1) Top piston ring
Thickness of new piston ring ....... 2.980 ± 0.010 mm
Install the piston ring with “UP-1” mark toward the (0.1173 ± 0.0004 inch)
top of the piston.
Clearance between groove and new piston
There is a clearance between the ends of the piston ring ........ 0.030 to 0.070 mm (0.0012 to 0.0028 inch)
ring. When the piston ring is installed in a cylinder
SENR1017-04 127
There is a clearance between the ends of the piston Part No.: 126-7280
ring. When the piston ring is installed in a cylinder S/N: 67K1-Up
liner with a bore of 137.16 mm (5.400 inch), the
clearance is the following value. ...... 0.55 ± 0.15 mm Part No.: 126-7280, 137-8142
(0.022 ± 0.006 inch) S/N: 7KK1-Up
Part No.: 126-7280, 137-8142
S/N: AAK1-Up
(0.0012 inch) increase in the cylinder liner bore. Part No.: 126-7280, 137-8142
Increase .................................. 0.08 mm (0.003 inch) S/N: ASK1-Up
Part No.: 126-7280
Piston Pin Bore S/N: AWK1-Up
(4) Piston pin bore Part No.: 126-7280, 137-8142
S/N: 7GN1-Up
Bore in piston for pin .................. 50.858 ± 0.008 mm
(2.0023 ± 0.0003 inch) Part No.: 126-7280, 137-8142
S/N: 8HN1-Up
Diameter of the new piston pin .. 50.795 ± 0.005 mm
(1.9998 ± 0.0002 inch) Part No.: 126-7280
S/N: BBN1-Up
Clearance between the piston pin and the bore in the Part No.: 126-7280
piston ...... 0.05 to 0.076 mm (0.0020 to 0.0030 inch) S/N: 2ZR1-Up
Part No.: 126-7280
i03200844
S/N: 4FR1-Up
Housing (Front) Part No.: 126-7280
S/N: 4YR1-Up
SMCS Code: 1151
Part No.: 126-7280
Part No.: 126-7280, 137-8142 S/N: 4YR1-Up
S/N: AAA1-Up
Part No.: 126-7280
Part No.: 126-7280 S/N: 4YR1-Up
S/N: BCA1-Up
Part No.: 126-7280
Part No.: 126-7280, 137-8142 S/N: 4YR1-Up
S/N: BDA1-Up
Part No.: 126-7280, 137-8142
Part No.: 126-7280 S/N: 5HR1-Up
S/N: 1AB1-Up
Part No.: 126-7280, 137-8142
Part No.: 126-7280 S/N: 5TR1-Up
S/N: 1FB1-Up
Part No.: 126-7280
Part No.: 126-7280 S/N: 5XR1-Up
S/N: 1NB1-Up
Part No.: 126-7280
Part No.: 126-7280, 137-8142 S/N: 5YR1-Up
S/N: BBB1-Up
Part No.: 126-7280
Part No.: 126-7280, 137-8142 S/N: 5YR1-Up
S/N: BEC1-Up
Part No.: 126-7280, 137-8142
Part No.: 126-7280 S/N: 6JR1-Up
S/N: CEH1-Up
Part No.: 126-7280, 137-8142
Part No.: 126-7280, 137-8142 S/N: 6KR1-Up
S/N: 7XJ1-Up
Part No.: 126-7280
Part No.: 126-7280, 137-8142 S/N: 6PR1-Up
S/N: NBJ1-Up
Part No.: 126-7280
Part No.: 126-7280 S/N: 6PR1-Up
S/N: 3TK1-Up
128 SENR1017-04
Part No.: 126-7280 Part No.: 126-7280, 137-8142

Part No.: 126-7280 Part No.: 126-7280
Part No.: 126-7280 Part No.: 126-7280, 137-8142
Part No.: 126-7280, 137-8142 Part No.: 126-7280
Part No.: 126-7280 Part No.: 126-7280
Part No.: 126-7280 Part No.: 126-7280
Part No.: 126-7280 Part No.: 126-7280
S/N: 7KR1-Up S/N: 1ZZ1-Up
Part No.: 126-7280 Part No.: 126-7280
S/N: BCR1-Up S/N: 2KZ1-Up
Part No.: 126-7280 Part No.: 126-7280
S/N: CLR1-Up S/N: BKZ1-Up
Part No.: 126-7280
S/N: 2PS1-Up
Part No.: 126-7280, 137-8142
S/N: 5SS1-Up
Part No.: 126-7280, 137-8142
S/N: 6YS1-Up
Part No.: 126-7280, 137-8142
S/N: 7CS1-Up
Part No.: 126-7280, 137-8142
S/N: 8AS1-Up
Part No.: 126-7280
S/N: 8GS1-Up
Part No.: 126-7280, 137-8142
S/N: 9XS1-Up
Part No.: 126-7280, 137-8142
S/N: 9YS1-Up g01140255
Illustration 139
Part No.: 126-7280, 137-8142 (1) Studs
S/N: AAT1-Up
(2) Apply a layer of sealant between the cylinder
Part No.: 126-7280 block, the front housing, and the oil pan in order
S/N: AXT1-Up to fill the space.
Part No.: 126-7280
S/N: 24W1-Up
Part No.: 126-7280
S/N: 25W1-Up
Part No.: 126-7280
S/N: 26W1-Up
Part No.: 126-7280, 137-8142
S/N: 63W1-Up
SENR1017-04 129
3. Tighten bolt 1 and bolt 2 again to a torque of

47 ± 9 N·m (35 ± 7 lb ft).
i02748519
Housing (Front)
SMCS Code: 1151
Part No.: 4N-5226
S/N: 1JD1-Up
Part No.: 4N-5226
S/N: 2YD1-Up
Part No.: 4N-5226
S/N: 8YG1-Up
Part No.: 4N-5226
S/N: 3BJ1-Up
Part No.: 4N-5226
Illustration 140
g01632995 S/N: 7MJ1-Up
Part No.: 4N-5226
Note: Lubricate the O-ring of speed sensor group
S/N: 7XJ1-Up
lightly with clean engine oil.
Part No.: 4N-5226
(3) Torque for two speed sensor group ... 40 ± 5 N·m S/N: 3SK1-Up
(30 ± 4 lb ft)
Part No.: 4N-5226
Note: The rear face of the front housing and the S/N: 7HK1-Up
front face of the cylinder block must be free of
contaminants during assembly. The gasket for the Part No.: 4N-5226
front housing must be free of contaminants during S/N: 50W1-Up
assembly. Part No.: 4N-5226
S/N: 63W1-Up
(4) The gasket for the front housing must be trimmed
after assembly with the face so that the gasket Part No.: 4N-5226
is flush. S/N: 64W1-Up
Part No.: 4N-5226
S/N: 01X1-Up
Part No.: 4N-5226
S/N: 01X1-Up
Part No.: 4N-5226
S/N: 49Z1-Up
Part No.: 4N-5226
S/N: 86Z1-Up
Part No.: 4N-5226
S/N: 86Z1-Up
Illustration 141
g01140263 Part No.: 4N-5226
S/N: 87Z1-Up
Use the following procedure to tighten the support
Part No.: 4N-5226
for the housing.
S/N: 87Z1-Up
1. Tighten bolt 1 and bolt 2 to a torque of 5 ± 3 N·m Part No.: 4N-5226
(45 ± 27 lb in). S/N: 89Z1-Up
2. Tighten bolt 3 through bolt 6 to a torque of Part No.: 4N-5226
47 ± 9 N·m (35 ± 7 lb ft). S/N: 89Z1-Up
130 SENR1017-04
Part No.: 4N-5226 i03200977

S/N: 90Z1-Up
Housing (Front)
Part No.: 4N-5226
Part No.: 4N-5226 Part No.: 127-3514
Part No.: 4N-5226 Part No.: 127-3514
Part No.: 127-3514
S/N: 6XJ1-Up
Part No.: 127-3514
S/N: ABK1-Up
Part No.: 127-3514
S/N: 7TL1-Up
Part No.: 127-3514
S/N: 8BL1-Up
Part No.: 127-3514
S/N: ACL1-Up
Part No.: 127-3514
S/N: 3KR1-Up
Part No.: 127-3514
S/N: 3KR1-Up
Part No.: 127-3514
S/N: 53Y1-Up
g01022142
Illustration 142
(1) Install the taperlock studs into the front housing

to following depth. ........................ 28.5 ± 1.5 mm
(1.12 ± 0.06 inch)
Note: Remove all old sealant and gasket material

after disassembling the front housing. The rear face
of the front housing and the front face of the cylinder
block must be free of oil, fuel, water, dirt and any
other contaminants during assembly.
(2) The cylinder block gasket for the front housing

must be trimmed after assembly. Trim the excess
cylinder block gasket from the bottom of the front
housing after assembly. Illustration 143
g01633113
(3) Apply a layer of 4C-9612 Silicone Sealant (1) Apply 154-9731 Thread Lock Compound to the
between the cylinder block, the front housing, threads of stud.
and the oil pan.
(2) Before assembly, apply 4C-9614 Silicone
Sealant between the cylinder block, the front
housing, and the oil pan in order to fill the space.
SENR1017-04 131
i03200902
Housing (Front)
SMCS Code: 1151
Part No.: 166-5427
S/N: 2YD1-Up
Part No.: 166-5427
S/N: 3KR1-Up
Part No.: 166-5427
S/N: AKT1-Up
g01633175
Illustration 144
Note: Lubricate the O-ring for the speed sensor

group lightly with clean engine oil.
(3) Torque for two speed sensor group ... 40 ± 5 N·m

(30 ± 4 lb ft) g01633079
Illustration 145
Note: The rear face of the front housing and the front
face of the cylinder block must be free of oil, fuel, (1) Before assembly, apply 154-9731 Thread Lock
water, assembly compounds and other contaminants Compound to the threads of two studs.
during assembly. The gasket for the front housing
must be free of contaminants during assembly. (2) Apply 4C-9614 Silicone Sealant between the
cylinder block, the front housing, and the oil pan
(4) The gasket for the front housing must be trimmed in order to fill the space.
after assembly with the face so that the gasket
is flush.
132 SENR1017-04
i03200925
Housing (Front)
SMCS Code: 1151
Part No.: 127-5561
S/N: ABK1-Up
Part No.: 127-5561
S/N: 7TL1-Up
Part No.: 127-5561
S/N: 8BL1-Up
Part No.: 127-5561
S/N: ACL1-Up
Part No.: 127-5561
S/N: 3KR1-Up
g01633080
Illustration 146
Note: Lubricate the O-ring for the speed sensor

group lightly with clean engine oil.
(3) Torque for two speed sensor groups .. 40 ± 5 N·m

(30 ± 4 lb ft)
Note: The rear face of the front housing and the front
face of the cylinder block must be free of oil, fuel,
water, assembly compounds and other contaminants
during assembly. The gasket for the front housing
g01633113
must be free of contaminants during assembly. Illustration 147
(4) The gasket for the front housing must be trimmed (1) Before assembly, apply 154-9731 Thread Lock
after assembly with the face so that the gasket Compound to the threads of the stud.
is flush.
(2) Apply 4C-9614 Silicone Sealant between the
cylinder block, the front housing, and the oil pan
in order to fill the space.
SENR1017-04 133
Part No.: 126-7281

S/N: BBB1-Up
Part No.: 127-3516
S/N: BEC1-Up
Part No.: 126-7281
S/N: 1JD1-Up
Part No.: 127-3516
S/N: 2YD1-Up
Part No.: 126-7281
S/N: CEH1-Up
Part No.: 126-7281
S/N: 6XJ1-Up
Part No.: 127-3516
S/N: 7XJ1-Up
Part No.: 126-7281
S/N: 3TK1-Up
Part No.: 127-3516
S/N: 7KK1-Up
Part No.: 127-3516
S/N: AAK1-Up
g01633102 Part No.: 126-7281

Illustration 148
S/N: ABK1-Up
Note: The rear face of the front housing and the front Part No.: 127-3516
face of the cylinder block must be free of oil, fuel, S/N: ASK1-Up
water, assembly compounds and other contaminants
during assembly. The gasket for the front housing Part No.: 126-7281
must be free of contaminants during assembly. S/N: AWK1-Up
(3) The gasket for the front housing must be trimmed Part No.: 126-7281
after assembly with the face so that the gasket S/N: 7TL1-Up
is flush. Part No.: 126-7281
S/N: 7TL1-Up
i03248389
Part No.: 126-7281
Gear Group (Front) S/N: 8BL1-Up
Part No.: 126-7281
SMCS Code: 1206 S/N: ACL1-Up
Part No.: 127-3516 Part No.: 127-3516
S/N: AAA1-Up S/N: 7GN1-Up
Part No.: 126-7281 Part No.: 127-3516
S/N: BCA1-Up S/N: 8HN1-Up
Part No.: 127-3516 Part No.: 127-3516
S/N: BDA1-Up S/N: BBN1-Up
Part No.: 126-7281 Part No.: 126-7281
S/N: 1AB1-Up S/N: 2ZR1-Up
Part No.: 126-7281 Part No.: 127-3516
Part No.: 126-7281 Part No.: 126-7281, 127-3516
134 SENR1017-04
Part No.: 127-3516 Part No.: 127-3516

Part No.: 127-3516 Part No.: 127-3516
Part No.: 127-3516 Part No.: 126-7281
S/N: 5HR1-Up S/N: AXT1-Up
Part No.: 126-7281 Part No.: 126-7281
Part No.: 126-7281, 127-3516 Part No.: 126-7281
Part No.: 126-7281 Part No.: 126-7281
Part No.: 127-3516 Part No.: 127-3516
Part No.: 126-7281, 127-3516 Part No.: 127-3516
Part No.: 126-7281, 127-3516 Part No.: 126-7281
Part No.: 126-7281 Part No.: 126-7281
Part No.: 127-3516 Part No.: 126-7281
Part No.: 126-7281 Part No.: 126-7281
Part No.: 126-7281, 127-3516 Part No.: 126-7281
Part No.: 127-3516 Part No.: 126-7281
Part No.: 126-7281 Part No.: 127-3516
Part No.: 126-7281 Part No.: 126-7281
Part No.: 126-7281
S/N: 5SS1-Up
Part No.: 126-7281
S/N: 6YS1-Up
Part No.: 127-3516
S/N: 7CS1-Up
Part No.: 127-3516
S/N: 8AS1-Up
Part No.: 126-7281
S/N: 8GS1-Up
Part No.: 126-7281, 127-3516
S/N: 9XS1-Up
Part No.: 127-3516
S/N: 9YS1-Up
SENR1017-04 135
g01649933 g01649935
(1) With the no. 1 piston in the top dead center (TDC) (2) Torque for four bolts ....................... 135 ± 20 N·m
position, align the timing marks. (100 ± 15 lb ft)
Note: Lubricate the shaft, the bearing bore, and the

thrust faces of the thrust plates with clean engine oil.
(3) Install the thrust plate with the oil groove side
toward idler gear assembly.
(4) Torque for five bolts ..... 55 ± 10 N·m (41 ± 7 lb ft)
(5) Lubricate the shaft, the bearing bore, and the

thrust faces of the drive idler shaft with clean
engine oil.
(6) Lubricate the shaft, the bearing bore, and the

thrust faces of the idler gear assembly with clean
engine oil.
Note: Before assembly, apply 5P-3413 Pipe Sealant

to the threads of the bolt.
(7) Torque for the bolt ........ 55 ± 10 N·m (41 ± 7 lb ft)
(8) Torque for the bolt ........ 55 ± 10 N·m (41 ± 7 lb ft)

136 SENR1017-04
i02910340
Gear Group (Front)

SMCS Code: 1206
Part No.: 126-7282
S/N: NBJ1-Up
Part No.: 126-7282
S/N: 67K1-Up
Part No.: 126-7282
S/N: 4YR1-Up
Part No.: 126-7282
S/N: 4YR1-Up
Part No.: 126-7282
S/N: 4YR1-Up
Part No.: 126-7282
S/N: 5XR1-Up
Part No.: 126-7282
S/N: 5YR1-Up
Part No.: 126-7282
S/N: 6PR1-Up
Part No.: 126-7282 g01034262
Illustration 151
S/N: 6TR1-Up
()
Part No.: 126-7282 (4) Pump drive gear
(6) Camshaft gear
S/N: 7KR1-Up
(7) Accessory drive gear
(8) Crankshaft gear
Part No.: 126-7282 (9) Oil pump drive gear
S/N: 42X1-Up (11) Idler gear
(12) Water pump drive gear
(1) Bolt
Tighten the bolts to the following
torque. ................... 135 ± 20 N·m (100 ± 15 lb ft)
(2) Bolt
Tighten the bolt to the following
torque. ......................... 55 ± 10 N·m (41 ± 7 lb ft)
(3) Bolt
Tighten the bolts to the following
torque. ......................... 55 ± 10 N·m (41 ± 7 lb ft)
(5) Align the timing mark on the pump drive gear (4)
to the timing mark on the camshaft gear (6).
(10) Align the timing mark on the crankshaft gear (8)

to the timing mark on the idler gear (11).
i02820420
Gear Group (Front)

SMCS Code: 1206
SENR1017-04 137
Part No.: 4N-6341

S/N: 2YD1-Up
Part No.: 4N-6341
S/N: 7MJ1-Up
Part No.: 4N-6341
S/N: 7XJ1-Up
Part No.: 4N-6341
S/N: 3SK1-Up
Part No.: 4N-6341
S/N: 7HK1-Up
Part No.: 4N-6341
S/N: 63W1-Up
Part No.: 4N-6341
S/N: 64W1-Up
Part No.: 4N-6341
S/N: 49Z1-Up
Part No.: 4N-6341
S/N: 89Z1-Up
Part No.: 4N-6341
S/N: 89Z1-Up
Part No.: 4N-6341
S/N: 90Z1-Up
Part No.: 4N-6341
S/N: 90Z1-Up
Part No.: 4N-6341
S/N: 91Z1-Up g01407416
Illustration 152
Part No.: 4N-6341 (1) Pump drive gear
S/N: 91Z1-Up (3) Water pump drive gear
(10) Oil pump idler gear
(13) Oil pump drive gear
138 SENR1017-04
Note: Apply 5P-3413 Pipe Sealant for the threads

of bolt (12).
(12) Torque for bolt ............ 55 ± 10 N·m (41 ± 7 lb ft)
(14) Torque for bolt ............ 55 ± 10 N·m (41 ± 7 lb ft)
i02748537
Gear Group (Front)

SMCS Code: 1206
Part No.: 7N-2840
S/N: 1JD1-Up
Part No.: 7N-2840
S/N: 8YG1-Up
Part No.: 7N-2840
S/N: 3BJ1-Up
Illustration 153
g01407417 Part No.: 7N-2840
Timing marks S/N: 8BL1-Up
Part No.: 7N-2840
The timing marks on camshaft gear (2), on camshaft
S/N: 50W1-Up
idler gear (7), on idler gear (8), and on crankshaft
gear (9) must be visible from the front of the engine. Part No.: 7N-2840
Illustration 153 shows the correct alignment of the S/N: 01X1-Up
timing marks when the number one piston is in the
top center position. Part No.: 7N-2840
S/N: 01X1-Up
For assembly, lubricate the drive idler shaft, the
bearing's bore, and the faces of thrust plate (5) with Part No.: 7N-2840
clean engine oil. Install the thrust plate with the oil S/N: 86Z1-Up
groove side toward the drive idler gear. Part No.: 7N-2840
S/N: 86Z1-Up
(A) Diameter of new drive idler
shaft ..................................... 63.500 ± 0.013 mm Part No.: 7N-2840
(2.5000 ± 0.0005 inch) S/N: 87Z1-Up
Bearing bore for the drive idler shaft after Part No.: 7N-2840
assembly .................................... 63.566 ± 0.013 mm S/N: 87Z1-Up
(2.5026 ± 0.0005 inch)
(6) Torque for the five locking bolts ....... 55 ± 10 N·m

(41 ± 7 lb ft)
For assembly, install the thrust plate (11) with the oil
groove side toward the idler gear.
(B) Diameter of new oil pump idler

shaft ..................................... 34.943 ± 0.013 mm
(1.3757 ± 0.0005 inch)
Bore in bearing after assembly .. 35.034 ± 0.038 mm

(1.3793 ± 0.0015 inch)
(C) Extension of spring pin from the front of the oil

pump idler shaft .................... 3.0 mm (0.12 inch)
(D) Extension of dowel from the bottom of the oil

pump idler shaft .................... 4.8 mm (0.19 inch)
SENR1017-04 139
i03250499
Gear Group (Rear)

SMCS Code: 1204; 1206
Part No.: 129-1338
S/N: AAA1-Up
Part No.: 4P-3581
S/N: BCA1-Up
Part No.: 4P-3581
S/N: 1AB1-Up
Part No.: 4P-3581
S/N: 1FB1-Up
Part No.: 4P-3581
S/N: 1NB1-Up
Part No.: 4P-3581
S/N: BBB1-Up
Part No.: 112-3441, 4P-3581
S/N: 1JD1-Up
Part No.: 8N-0614
S/N: 2YD1-Up
g01376985 Part No.: 8N-0614

Illustration 154
S/N: 2YD1-Up
(1) Fuel pump drive gear and timing advance unit
(3) Water pump drive gear Part No.: 4P-3581
S/N: 8YG1-Up
(7) Oil pump drive gear
Part No.: 4P-3581
(2) Camshaft gear S/N: CEH1-Up
Note: Align the “V” timing marks prior to installation. Part No.: 4P-3581
S/N: 6XJ1-Up
(5) Idler gear assembly
Part No.: 8N-0614
(B) Diameter of new drive idler S/N: 3SK1-Up
shaft ............................... 63.500 ± 0.013 mm
(2.5000 ± 0.0005 inch) Part No.: 6I-1970
Bore in sleeve bearing after S/N: 3TK1-Up
assembly ............................. 63.592 ± 0.013 mm Part No.: 4P-3582
(2.5036 ± 0.0005 inch) S/N: 7HK1-Up
(C) Installation depth of the sleeve
bearing ................................ 0.38 ± 0.25 mm Part No.: 6I-1419
(0.015 ± 0.010 inch) S/N: 7KK1-Up
Note: Align the “V” timing marks prior to installation. Part No.: 129-1338
S/N: AAK1-Up
(6) Crankshaft gear
Part No.: 4P-3581
Note: Align the “V” timing marks prior to installation. S/N: ABK1-Up
Part No.: 4P-3581
(8) Torque for the bolt ........ 55 ± 10 N·m (41 ± 7 lb ft) S/N: AWK1-Up
(9) Torque for locking bolts .................... 55 ± 10 N·m Part No.: 4P-3581
(41 ± 7 lb ft) S/N: 7TL1-Up
(10) Install the thrust plate with the oil groove side Part No.: 112-3441
toward the idler gear assembly. S/N: 7TL1-Up
140 SENR1017-04
Part No.: 112-3441, 4P-3581 Part No.: 6I-1970

S/N: 8BL1-Up S/N: 8GS1-Up
Part No.: 112-3441 Part No.: 4P-3581
S/N: 8BL1-Up S/N: 9XS1-Up
Part No.: 112-3441, 4P-3581 Part No.: 129-1338
S/N: ACL1-Up S/N: AAT1-Up
Part No.: 129-1338 Part No.: 8N-0614
S/N: 7GN1-Up S/N: AKT1-Up
Part No.: 129-1338 Part No.: 4P-3581
S/N: 8HN1-Up S/N: AXT1-Up
Part No.: 4P-3582 Part No.: 4P-3581
S/N: BBN1-Up S/N: 24W1-Up
S/N: 2ZR1-Up S/N: 25W1-Up
Part No.: 8N-0614 Part No.: 4P-3581
Part No.: 8N-0614 Part No.: 5R-4412
Part No.: 4P-3581 Part No.: 112-3441, 4P-3581
S/N: 6JR1-Up S/N: 53Y1-Up
S/N: 6PR1-Up S/N: 1YZ1-Up
S/N: 6TR1-Up S/N: 1ZZ1-Up
Part No.: 4P-3581, 5R-4412 Part No.: 4P-3582
S/N: 7BR1-Up S/N: 2KZ1-Up
Part No.: 4P-3581, 5R-4412 Part No.: 4P-3581
S/N: 7FR1-Up S/N: BKZ1-Up
Part No.: 4P-3581
S/N: 7KR1-Up
Part No.: 4P-3582
S/N: BCR1-Up
Part No.: 4P-3581
S/N: CLR1-Up
Part No.: 4P-3581
S/N: 2PS1-Up
Part No.: 4P-3581
S/N: 5SS1-Up
Part No.: 4P-3581
S/N: 6YS1-Up
SENR1017-04 141
Part No.: 4N-3825

S/N: 1NB1-Up
Part No.: 4N-3825
S/N: BBB1-Up
Part No.: 4N-3825
S/N: BEC1-Up
Part No.: 4N-3825
S/N: 1JD1-Up
Part No.: 4N-3825
S/N: 1JD1-Up
Part No.: 4N-3825
S/N: CEH1-Up
Part No.: 4N-3825
S/N: 3BJ1-Up
Part No.: 4N-3825
S/N: 6XJ1-Up
Part No.: 4N-3825
S/N: 7XJ1-Up
Part No.: 4N-3825
S/N: 7XJ1-Up
Part No.: 4N-3825
S/N: NBJ1-Up
Part No.: 4N-3825
S/N: 67K1-Up
Part No.: 4N-3825
g01651553 S/N: ABK1-Up
Illustration 155
Part No.: 4N-3825
(1) Lubricate the bore of the O-ring seals lightly with S/N: ASK1-Up
Part No.: 4N-3825
(2) Torque for the bearing locknut ....... 406 ± 68 N·m S/N: AWK1-Up
(300 ± 50 lb ft)
Part No.: 4N-3825
S/N: 7TL1-Up
Note: Bend the tab on the lockwashers (3) that aligns
with the slot in the bearing locknuts. Part No.: 4N-3825
S/N: 8BL1-Up
i03248743
Part No.: 4N-3825
Gear Group (Rear) S/N: ACL1-Up
Part No.: 4N-3825
SMCS Code: 1204; 1206 S/N: BBN1-Up
S/N: BCA1-Up S/N: 3KR1-Up
S/N: 1FB1-Up S/N: 4YR1-Up
142 SENR1017-04

S/N: 5HR1-Up S/N: 9YS1-Up
S/N: 5TR1-Up S/N: AXT1-Up
S/N: 5XR1-Up S/N: 24W1-Up
S/N: CLR1-Up S/N: 86Z1-Up
S/N: 2PS1-Up S/N: 87Z1-Up
S/N: 5SS1-Up S/N: 87Z1-Up
S/N: 7CS1-Up S/N: 89Z1-Up
S/N: 8AS1-Up S/N: 90Z1-Up
SENR1017-04 143
Part No.: 4N-3825 Part No.: 136-7907

Part No.: 4N-3825 Part No.: 136-7907, 6N-2415
S/N: 91Z1-Up S/N: 5HR1-Up
Part No.: 4N-3825 Part No.: 136-7907, 6N-2415
S/N: 91Z1-Up S/N: 5TR1-Up
Part No.: 136-7907, 6N-2415
S/N: 6JR1-Up
Part No.: 136-7907, 6N-2415
S/N: 6KR1-Up
Part No.: 136-7907, 6N-2415
S/N: 7ER1-Up
Part No.: 136-7907
S/N: 2PS1-Up
Part No.: 136-7907
S/N: 5SS1-Up
g01650417 Part No.: 136-7907

Illustration 156
S/N: 6YS1-Up
(1) Torque for four bolts ....... 27 ± 4 N·m (20 ± 3 lb ft) Part No.: 136-7907, 6N-2415
S/N: 7CS1-Up
i03258110 Part No.: 136-7907
Gear Group (Rear) S/N: 8AS1-Up
Part No.: 136-7907
SMCS Code: 1204; 1206 S/N: 9XS1-Up
Part No.: 136-7907 Part No.: 136-7907, 6N-2415
S/N: BCA1-Up S/N: 9YS1-Up
Part No.: 136-7907 Part No.: 136-7907
S/N: BDA1-Up S/N: 25W1-Up
Part No.: 136-7907 Part No.: 136-7907
S/N: 1AB1-Up S/N: 26W1-Up
Part No.: 136-7907 Part No.: 136-7907, 6N-2415
S/N: 1FB1-Up S/N: 63W1-Up
Part No.: 136-7907 Part No.: 136-7907, 6N-2415
S/N: BBB1-Up S/N: 63W1-Up
Part No.: 136-7907, 6N-2415 Part No.: 136-7907, 6N-2415
S/N: BEC1-Up S/N: 64W1-Up
Part No.: 6N-2415 Part No.: 136-7907, 6N-2415
S/N: 3BJ1-Up S/N: 64W1-Up
Part No.: 6N-0195 Part No.: 136-7907, 6N-2415
S/N: 7MJ1-Up S/N: 01X1-Up
Part No.: 6N-2415 Part No.: 136-7907, 6N-2415
Part No.: 136-7907, 6N-2415 Part No.: 136-7907
Part No.: 136-7907 Part No.: 6N-0195
S/N: NBJ1-Up S/N: 49Z1-Up
144 SENR1017-04
Part No.: 7N-9574

S/N: 53Y1-Up
Part No.: 9Y-1191
S/N: 1YZ1-Up
Part No.: 9Y-1191
S/N: 1ZZ1-Up
Part No.: 9Y-1191
S/N: BKZ1-Up
g01659393
Illustration 157
Typical example
(1) Before assembly, lubricate the O-ring seal lightly

with clean engine oil or glycerin.
(2) Lubricate the sealing lip of the lip type seal lightly
with the lubricant that is being sealed.
(3) Torque for the taperlock stud ............. 27 ± 4 N·m

(20 ± 3 lb ft) Illustration 158
g01651655
Rear view
i03250560
Gear Group (Rear)

SMCS Code: 1204; 1206
Part No.: 7N-9574
S/N: 1JD1-Up
Part No.: 7N-9574
S/N: 1JD1-Up
Part No.: 7N-9574
S/N: 6XJ1-Up
Part No.: 7N-9574
S/N: 7TL1-Up
Part No.: 7N-9574
S/N: 8BL1-Up
Part No.: 9Y-1191
S/N: BLW1-Up
g01651654
Illustration 159
SENR1017-04 145
(1) Lubricate the bore of the O-ring seals lightly with (1) Torque for 12 bolts .. 270 ± 40 N·m (200 ± 30 lb ft)
i03211789
(2) The number one piston is at the top center
position (TC). Align the timing marks on the
balancer gear and the crankshaft gear.
Flywheel
SMCS Code: 1156
i03211601
Part No.: 128-9728
Flywheel S/N: AAA1-Up
Part No.: 128-9728
SMCS Code: 1156 S/N: AAK1-Up
Part No.: 9Y-1569
Part No.: 128-9728
S/N: 7KK1-Up S/N: 7GN1-Up
Part No.: 9Y-1569
Part No.: 128-9728
S/N: 5TR1-Up S/N: 8HN1-Up
Part No.: 9Y-1569
Part No.: 128-9728
S/N: BLW1-Up S/N: AAT1-Up
Part No.: 9Y-1569
S/N: 1YZ1-Up
Part No.: 9Y-1569
S/N: 1ZZ1-Up
Part No.: 9Y-1569
S/N: BKZ1-Up
g01637982
Illustration 161
Note: Before assembly, lubricate the threads of the

bolts with clean engine oil, molybdenum disulfide or
a graphite base lubricant.
(1) Torque for 12 bolts .. 270 ± 40 N·m (200 ± 30 lb ft)

g01637637
Illustration 160

146 SENR1017-04
i03211540 i03211841
Flywheel Flywheel
SMCS Code: 1156 SMCS Code: 1156
S/N: 1AB1-Up S/N: 67K1-Up
S/N: 1NB1-Up S/N: 4YR1-Up
S/N: AWK1-Up S/N: 4YR1-Up
S/N: CLR1-Up S/N: 4YR1-Up
S/N: 2PS1-Up S/N: 5XR1-Up
S/N: AXT1-Up S/N: 5YR1-Up
S/N: 24W1-Up S/N: 5YR1-Up
S/N: 25W1-Up S/N: 6PR1-Up
S/N: 26W1-Up S/N: 6PR1-Up
S/N: 99X1-Up S/N: 6TR1-Up
Part No.: 8N-0953
S/N: 6TR1-Up
Part No.: 8N-0953
S/N: 7KR1-Up
Part No.: 8N-0953
S/N: 7KR1-Up
Part No.: 8N-0953
S/N: 49Z1-Up
Part No.: 8N-0953
S/N: 89Z1-Up
Part No.: 8N-0953
S/N: 89Z1-Up
Part No.: 8N-0953
S/N: 90Z1-Up
Part No.: 8N-0953
g01637622 S/N: 90Z1-Up
Illustration 162
Part No.: 8N-0953
Note: Before assembly, lubricate the threads of the S/N: 91Z1-Up
a graphite base lubricant. Part No.: 8N-0953
S/N: 91Z1-Up
SENR1017-04 147
i03211640
Flywheel
SMCS Code: 1156
Part No.: 7E-1734
S/N: 5YR1-Up
Part No.: 7E-1734
S/N: 6PR1-Up
Part No.: 7E-1734
S/N: 6TR1-Up
Part No.: 7E-1734
S/N: 7KR1-Up
Part No.: 7E-1734
S/N: 86Z1-Up
Part No.: 7E-1734
S/N: 86Z1-Up
Part No.: 7E-1734
S/N: 87Z1-Up
Part No.: 7E-1734
S/N: 87Z1-Up
g01638114
Illustration 163

g01637642
Illustration 164


148 SENR1017-04
i03211860 Part No.: 2W-6533

S/N: BCA1-Up
Flywheel
Part No.: 2W-6533
SMCS Code: 1156 S/N: BBB1-Up
S/N: 3TK1-Up S/N: 2YD1-Up
Part No.: 126-7287, 4N-0739 Part No.: 2W-6533
S/N: 7BR1-Up S/N: 5TR1-Up
Part No.: 126-7287, 4N-0739 Part No.: 2W-6533
S/N: 7FR1-Up S/N: 6JR1-Up
S/N: 8GS1-Up S/N: 5SS1-Up
S/N: 50W1-Up S/N: 6YS1-Up
S/N: 91Z1-Up S/N: 9XS1-Up
Part No.: 2W-6533
S/N: 50W1-Up
Part No.: 2W-6533
S/N: 01X1-Up
Part No.: 2W-6533
S/N: 01X1-Up
Part No.: 6N-0990
S/N: 49Z1-Up
g01638139
Illustration 165

i03210713
Flywheel Illustration 166

g01637225
SMCS Code: 1156 Typical example

SENR1017-04 149
Note: Before assembly, lubricate the threads of the i03211581

a graphite base lubricant. Flywheel
Use the following procedure to tighten the bolts (1): SMCS Code: 1156
Part No.: 4P-3669
1. Tighten the bolts in a crisscross pattern to
S/N: 8YG1-Up
100 ± 5 N·m (75 ± 4 lb ft).
Part No.: 2W-6533
2. Again, tighten the bolts to an additional 180 ± 5 S/N: 3BJ1-Up
degrees.
Part No.: 4P-3669
Note: Replace all the 12 bolts at time of service. S/N: 7MJ1-Up
Part No.: 4P-3669
S/N: 7HK1-Up
Part No.: 4P-3669
S/N: BBN1-Up
Part No.: 4P-3669
S/N: 2ZR1-Up
Part No.: 4P-3669
S/N: 4FR1-Up
Part No.: 173-8349
S/N: 7FR1-Up
Part No.: 4P-3669
S/N: BCR1-Up
Part No.: 4P-3669
S/N: 2KZ1-Up
g01637632
Illustration 167
150 SENR1017-04

i03211709
Flywheel
SMCS Code: 1156
Part No.: 4N-7734
S/N: BDA1-Up
Part No.: 4N-7734
S/N: BEC1-Up
Part No.: 4N-7734
S/N: 7XJ1-Up
Part No.: 4N-7734
S/N: 7XJ1-Up
Part No.: 4N-7734
S/N: NBJ1-Up
Part No.: 4N-7734
S/N: ASK1-Up
g01637796
Illustration 168
Part No.: 4N-7734
S/N: 5HR1-Up Note: Before assembly, lubricate the threads of the
Part No.: 4N-7734 bolts with clean engine oil, molybdenum disulfide or
S/N: 6KR1-Up a graphite base lubricant.
Part No.: 4N-7734 (1) Torque for 12 bolts .. 270 ± 40 N·m (200 ± 30 lb ft)
S/N: 7ER1-Up
Part No.: 4N-7734 i03211560
S/N: 7CS1-Up
Flywheel
Part No.: 4N-7734
S/N: 8AS1-Up SMCS Code: 1156
Part No.: 4N-7734 Part No.: 107-3752, 2W-8025

S/N: 63W1-Up S/N: 1JD1-Up

S/N: 63W1-Up S/N: 1JD1-Up
Part No.: 4N-7734 Part No.: 107-3752

S/N: 64W1-Up S/N: 2YD1-Up
Part No.: 4N-7734 Part No.: 107-3752, 2W-8025

S/N: 64W1-Up S/N: 6XJ1-Up
Part No.: 4N-7734 Part No.: 107-3752

S/N: 42X1-Up S/N: ABK1-Up
Part No.: 107-3752, 2W-8025
S/N: 7TL1-Up
Part No.: 107-3752
S/N: 8BL1-Up
Part No.: 107-3752
S/N: 8BL1-Up
SENR1017-04 151
Part No.: 107-3752 i03211784

S/N: ACL1-Up
Flywheel
Part No.: 107-3752
S/N: 3KR1-Up SMCS Code: 1156
Part No.: 107-3752 Part No.: 6N-1350
S/N: AKT1-Up S/N: 2YD1-Up
Part No.: 107-3752, 2W-8025 Part No.: 6N-1350
S/N: 53Y1-Up S/N: 2YD1-Up
Part No.: 6N-1350
S/N: 3SK1-Up
Part No.: 6N-1350
S/N: 3KR1-Up
Part No.: 6N-1350
S/N: 3KR1-Up
Part No.: 6N-1350
S/N: AKT1-Up
g01637625
Illustration 169
Typical example

g01637975
Illustration 170

i03213262
Flywheel Housing
SMCS Code: 1157
152 SENR1017-04
Part No.: 128-2982, 153-3050, 157-3562

S/N: 1JD1-Up
Part No.: 128-2982, 157-3562
S/N: 2YD1-Up
Part No.: 153-3050, 157-3562
S/N: 6XJ1-Up
Part No.: 6I-4665
S/N: 3TK1-Up
Part No.: 130-0926
S/N: 7KK1-Up
Part No.: 153-3050, 157-3562
S/N: ABK1-Up
Part No.: 128-2982, 153-3050, 157-3562
S/N: 7TL1-Up
Part No.: 128-2982, 157-3562
S/N: 8BL1-Up
Part No.: 128-2982, 157-3562
S/N: ACL1-Up
Part No.: 128-2982
S/N: 3KR1-Up
Part No.: 128-2982, 157-3562 g01640055
Illustration 171
S/N: 3KR1-Up
Rear view
Part No.: 148-6753
S/N: 5TR1-Up Note: Before installation of the flywheel housing,
inspect the front face of the flywheel housing and
Part No.: 273-4183 the rear face of the cylinder block. The components
S/N: 7BR1-Up must be free of the following substances: oil, fuel,
Part No.: 273-4183 water, gasket adhesive, assembly compounds and
S/N: 7FR1-Up any other foreign material
Part No.: 6I-4665 Use the following procedure to tighten the bolts for
S/N: 8GS1-Up the flywheel housing group:
Part No.: 128-2982 1. Tighten the bolt 1 through bolt 21 in the numerical
S/N: AKT1-Up sequence that is shown in Illustration171 to
40 ± 10 N·m (30 ± 7 lb ft).
Part No.: 273-4183
S/N: 50W1-Up 2. Again, tighten the bolt 1 through bolt 8 in the
Part No.: 148-6753 numerical sequence that is shown in Illustration
S/N: BLW1-Up 171 to 135 ± 20 N·m (100 ± 15 lb ft).
Part No.: 128-2982, 153-3050, 157-3562 3. Again, tighten the bolt 9 through bolt 21 in the
S/N: 53Y1-Up numerical sequence that is shown in Illustration
171 to 55 ± 10 N·m (41 ± 7 lb ft).
Part No.: 148-6753
S/N: 1YZ1-Up
Part No.: 148-6753
S/N: 1ZZ1-Up
Part No.: 273-4183
S/N: 91Z1-Up
Part No.: 148-6753
S/N: BKZ1-Up
SENR1017-04 153
i03235501
Flywheel Housing
SMCS Code: 1157
Part No.: 4P-3010
S/N: AAA1-Up
Part No.: 141-8917
S/N: 8YG1-Up
Part No.: 141-8917
S/N: 7HK1-Up
Part No.: 4P-3010
S/N: AAK1-Up
Part No.: 4P-3010
S/N: 7GN1-Up
Part No.: 4P-3010
S/N: 8HN1-Up
Part No.: 141-8917
S/N: BBN1-Up
Part No.: 141-8917
S/N: 2ZR1-Up
Part No.: 141-8917
S/N: 4FR1-Up
Part No.: 141-8917
S/N: BCR1-Up
Part No.: 4P-3010
S/N: AAT1-Up
Part No.: 141-8917
S/N: 2KZ1-Up
g01640115
Illustration 172
Front view
(1) Before assembly, apply 4C-4030 Thread Lock

Compound to the threads of the bolts.
(2) Apply a continuous bead of 4C-9612 Silicone

Sealant immediately prior to assembling the
flywheel housing. After assembly of the flywheel
housing, remove excess silicone sealant from the
flange with a straight edge.
(3) Apply 4C-9612 Silicone Sealant to the T-shaped

joints immediately prior to the installation of the
gasket for the oil pan. The application of the
silicone sealant should cover the entire width of
the T-shaped joints, as shown.
154 SENR1017-04
g01643633
Illustration 173
Rear view
Use the following procedure to tighten the bolts for

the flywheel housing group:
1. Tighten the bolt 1 through bolt 21 in the numerical

40 ± 7 N·m (30 ± 5 lb ft).
2. Again, tighten the bolt 1 through bolt 8 in the

numerical sequence that is shown in Illustration
173 to 135 ± 15 N·m (100 ± 11 lb ft).

173 to 55 ± 7 N·m (41 ± 5 lb ft).
g01643603
Illustration 174
Front view


gasket for the pan. The application of the silicone
sealant should cover the entire width of the
T-shaped joints, as shown.
SENR1017-04 155
i03213042
Flywheel Housing
SMCS Code: 1157
Part No.: 7C-3617
S/N: 1AB1-Up
Part No.: 7C-3617
S/N: 1FB1-Up
Part No.: 7C-3617
S/N: 1NB1-Up
Part No.: 7C-3617
S/N: CEH1-Up
Part No.: 7C-3617
S/N: AWK1-Up
Part No.: 7C-3617
S/N: 5YR1-Up
Part No.: 7C-3617
S/N: 6PR1-Up
Part No.: 7C-3617
S/N: 7KR1-Up
Part No.: 7C-3617 g01639853
Illustration 175
S/N: CLR1-Up
Part No.: 7C-3617 Note: Before installation of the flywheel housing,
S/N: AXT1-Up inspect the front face of the flywheel housing and
the rear face of the cylinder block. The components
Part No.: 7C-3617 must be free of the following substances: oil, fuel,
S/N: 24W1-Up water, gasket adhesive, assembly compounds and
any other foreign material
Part No.: 7C-3617
S/N: 25W1-Up (1) Before assembly, apply 155-9731 Thread Lock
Part No.: 7C-3617 Compound to the threads of the stud and both
S/N: 26W1-Up sides of gasket.
Part No.: 7C-3617 (2) Torque for two plugs .. 55 ± 14 N·m (41 ± 10 lb ft)
S/N: 99X1-Up
Part No.: 7C-3617 the flywheel housing group:
S/N: 86Z1-Up
Part No.: 7C-3617
sequence that is shown in Illustration175 to
S/N: 86Z1-Up
40 ± 10 N·m (30 ± 7 lb ft).
Part No.: 7C-3617
S/N: 87Z1-Up 2. Again, tighten the bolt 1 through bolt 8 in the
Part No.: 7C-3617 175 to 135 ± 20 N·m (100 ± 15 lb ft).
S/N: 87Z1-Up
175 to 55 ± 10 N·m (41 ± 7 lb ft).
156 SENR1017-04


i03235680
Flywheel Housing
SMCS Code: 1157
Part No.: 7W-4380
S/N: 4YR1-Up
Illustration 176
g01639773 Part No.: 7W-4380
S/N: 4YR1-Up
Part No.: 161-8380, 7W-4380
S/N: 4YR1-Up
Part No.: 7W-4380
S/N: 4YR1-Up
Part No.: 7W-4380
S/N: 5XR1-Up
Part No.: 161-8380, 7W-4380
S/N: 5YR1-Up
Part No.: 7W-4380
S/N: 5YR1-Up
Part No.: 7W-4380
S/N: 6PR1-Up
Part No.: 161-8380, 7W-4380
S/N: 6PR1-Up
Part No.: 161-8380, 7W-4380
S/N: 6TR1-Up
Part No.: 7W-4380
S/N: 6TR1-Up
Part No.: 161-8380, 7W-4380
S/N: 7KR1-Up
Part No.: 7W-4380
S/N: 7KR1-Up
Part No.: 7W-4380
S/N: 89Z1-Up
Illustration 177
g01639793 Part No.: 7W-4380
S/N: 89Z1-Up
View A-A
Part No.: 7W-4380
(3) The plug must not protrude above the surface S/N: 90Z1-Up
after assembly.
SENR1017-04 157
Part No.: 7W-4380 Note: Before installation of the flywheel housing,

S/N: 90Z1-Up inspect the front face of the flywheel housing and
Part No.: 7W-4380 must be free of the following substances: oil, fuel,
S/N: 91Z1-Up water, gasket adhesive, assembly compounds and
Part No.: 7W-4380
S/N: 91Z1-Up
(1) Before assembly, apply 4C-4030 Thread Lock
Compound to the threads of the bolts .
(2) Torque for two plugs .. 55 ± 14 N·m (41 ± 10 lb ft)

1. Tighten the bolt 1 and bolt 21 in the numerical

sequence that is shown in Illustration178 to
40 ± 10 N·m (30 ± 7 lb ft).

178 to 135 ± 20 N·m (100 ± 15 lb ft).

178 to 55 ± 10 N·m (41 ± 7 lb ft).
g01643713
Illustration 178
g01643695
Illustration 180
g01643714
Illustration 179
158 SENR1017-04
i03213560
Flywheel Housing
SMCS Code: 1157
Part No.: 129-5244
S/N: BCA1-Up
Part No.: 129-5244
S/N: BBB1-Up
Part No.: 129-5244
S/N: 5TR1-Up
Part No.: 129-5244
S/N: 6JR1-Up
Part No.: 129-5244
S/N: 5SS1-Up
Part No.: 129-5244
S/N: 6YS1-Up
Part No.: 129-5244
S/N: 9XS1-Up
Part No.: 129-5244
S/N: 01X1-Up
g01643715
Illustration 181
View A-A


the T-shaped joints, as shown. Illustration 182
g00838785
Note: Before installation of the flywheel housing,

inspect the front face of the flywheel housing and
must be free of the following substances: oil, fuel,
water, gasket adhesive, assembly compounds and


40 ± 10 N·m (30 ± 7 lb ft).
SENR1017-04 159

182 to 135 ± 20 N·m (100 ± 15 lb ft).

182 to 55 ± 10 N·m (41 ± 7 lb ft).
g01640875
Illustration 183
g01640879
Illustration 184
View A-A


i03214661
Flywheel Housing
SMCS Code: 1157
160 SENR1017-04
Part No.: 129-6829

S/N: BDA1-Up
Part No.: 129-6829
S/N: BEC1-Up
Part No.: 4N-7733
S/N: 3BJ1-Up
Part No.: 4N-7733
S/N: 7MJ1-Up
Part No.: 129-6829, 4N-7733
S/N: 7XJ1-Up
Part No.: 129-6829
S/N: NBJ1-Up
Part No.: 4N-7733
S/N: 3SK1-Up
Part No.: 129-6829
S/N: ASK1-Up
g00838584
Illustration 185
Part No.: 129-6829
S/N: 5HR1-Up Note: Before installation of the flywheel housing,
Part No.: 129-6829 inspect the front face of the flywheel housing and
S/N: 6KR1-Up the rear face of the cylinder block. The components
must be free of the following substances: oil, fuel,
Part No.: 129-6829 water, gasket adhesive, assembly compounds and
S/N: 7ER1-Up any other foreign material
Part No.: 129-6829 Use the following procedure to tighten the bolts for
S/N: 7CS1-Up the flywheel housing group:
Part No.: 129-6829
S/N: 8AS1-Up
Part No.: 129-6829 40 ± 10 N·m (30 ± 7 lb ft).
S/N: 9YS1-Up
Part No.: 129-6829, 4N-7733 numerical sequence that is shown in Illustration
S/N: 63W1-Up 185 to 135 ± 20 N·m (100 ± 15 lb ft).
Part No.: 4N-7733 3. Again, tighten the bolt 8 through bolt 18 in the
S/N: 63W1-Up numerical sequence that is shown in Illustration
Part No.: 129-6829, 4N-7733 185 to 55 ± 10 N·m (41 ± 7 lb ft).
S/N: 64W1-Up
Part No.: 4N-7733
S/N: 64W1-Up
Part No.: 4N-7733
S/N: 01X1-Up
Part No.: 4N-7733
S/N: 01X1-Up
Part No.: 129-6829
S/N: 42X1-Up
Part No.: 4N-7733
S/N: 49Z1-Up
SENR1017-04 161
g01640911
Illustration 186
g01640912
Illustration 187
View A-A


i02580056
Belt Tension Chart

SMCS Code: 1357
162 SENR1017-04

S/N: AAA1-Up S/N: 8HN1-Up
S/N: BCA1-Up S/N: BBN1-Up
S/N: BDA1-Up S/N: 2ZR1-Up
S/N: 1NB1-Up S/N: 5HR1-Up
S/N: BBB1-Up S/N: 5TR1-Up
S/N: BEC1-Up S/N: 5YR1-Up
S/N: 1JD1-Up S/N: 6JR1-Up
S/N: CEH1-Up S/N: 6PR1-Up
S/N: NBJ1-Up S/N: 7BR1-Up
S/N: 3TK1-Up S/N: 7ER1-Up
S/N: 7KK1-Up S/N: 7FR1-Up
S/N: ABK1-Up S/N: BCR1-Up
S/N: ASK1-Up S/N: CLR1-Up
S/N: AWK1-Up S/N: 2PS1-Up
S/N: 7TL1-Up S/N: 5SS1-Up
S/N: 8BL1-Up S/N: 6YS1-Up
S/N: ACL1-Up S/N: 7CS1-Up
S/N: 7GN1-Up S/N: 8AS1-Up
SENR1017-04 163
Part No.: 7N-9693

S/N: 8GS1-Up
Part No.: 7N-9693
S/N: 9XS1-Up
Part No.: 7N-9693
S/N: 9YS1-Up
Part No.: 7N-9693
S/N: AAT1-Up
Part No.: 7N-9693
S/N: AKT1-Up
Part No.: 7N-9693
S/N: AXT1-Up
Part No.: 7N-9693
S/N: 24W1-Up
Part No.: 7N-9693
S/N: 25W1-Up
Part No.: 7N-9693
S/N: 26W1-Up
Part No.: 7N-9693
S/N: 99X1-Up
Part No.: 7N-9693
S/N: 53Y1-Up
Note: Do not use the belt tension charts for belts with
tensioners that are spring loaded.
Table 3
Belt Tension Chart

Kent-Moore Gauge
Gauge Reading
Size Numbers
of Width of Belt Number Number of
Belt Belt Tension Belt Tension
of the Old the New
“Initial”(1) “Used”(2)(3)
Gauge Gauge
3/8 10.72 mm (0.422 inch) 534 ± 111 N (120 ± 25 lb) 400 ± 22 N (90 ± 5 lb) BT-33-97 BT 3397
1/2 13.89 mm (0.547 Inch) 578 ± 111 N (130 ± 25 lb) 445 ± 44 N (100 ± 10 lb) BT-33-97 BT 3397
5V 15.88 mm (0.626 Inch) 712 ± 111 N (160 ± 25 lb) 445 ± 44 N (100 ± 10 lb) BT-33-72C BT 3372C
11/16 17.48 mm (0.688 Inch) 712 ± 111 N (160 ± 25 lb) 445 ± 44 N (100 ± 10 lb) BT-33-72C BT 3372C
3/4 19.05 mm (0.750 Inch) 712 ± 111 N (160 ± 25 lb) 445 ± 44 N (100 ± 10 lb) BT-33-72C BT 3372C
15/16 23.83 mm (0.938 Inch) 712 ± 111 N (160 ± 25 lb) 445 ± 44 N (100 ± 10 lb) BT-33-77 BT 3372C
8PK 27.82 mm (1.095 inch) 1068 ± 111 N (240 ± 25 lb) 890 ± 44 N (200 ± 10 lb) BT-33-109 BT 33109
6PK 20.94 mm (0.824 Inch) 801 ± 111 N (180 ± 25 lb) 667 ± 44 N (150 ± 10 lb) BT-33-109 BT 33109
Measure the tension of the belt that is farthest from the engine.
(1) Belt tension “Initial” 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.
164 SENR1017-04
Table 4
DAYCO Supplied Belts Only
Belt Tension Belt Tension
Size of Belt
“Initial” “Used”(4)
0.380 (V-Belt) 623 ± 22 N (140 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
0.440 (V-Belt) 667 ± 22 N (150 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
0.500 (V-Belt) 712 ± 22 N (160 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
0.600 (V-Belt) 779 ± 22 N (175 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
0.660 (V-Belt) 890 ± 22 N (200 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
0.790 (V-Belt) 890 ± 22 N (200 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
4 - RIB PVK 623 ± 22 N (140 ± 5 lb) 400 ± 22 N (90 ± 5 lb)
5 - RIB PVK 779 ± 22 N (175 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
6 - RIB PVK 934 ± 22 N (210 ± 5 lb) 578 ± 22 N (130 ± 5 lb)
8 - RIB PVK 1157 ± 22 N (260 ± 5 lb) 800 ± 22 N (180 ± 5 lb)
10 - RIB PVK 1557 ± 22 N (350 ± 5 lb) 1023 ± 22 N (230 ± 5 lb)
12 - RIB PVK 1869 ± 22 N (420 ± 5 lb) 1200 ± 22 N (270 ± 5 lb)
15 - RIB PVK 2336 ± 22 N (525 ± 5 lb) 1557 ± 22 N (350 ± 5 lb)
(4) If a belt falls below the “Used” belt tension, the belt should be tightened again to the “Initial” belt tension.
i02839270 Part No.: 9X-7803

S/N: 7GN1-Up
Alternator and Regulator
Part No.: 9X-7803
SMCS Code: 1405; 1410 S/N: 8HN1-Up
Part No.: 9X-7803 Part No.: 9X-7803
S/N: AAA1-Up S/N: BBN1-Up
S/N: 2YD1-Up S/N: 2ZR1-Up
S/N: 3TK1-Up S/N: 4FR1-Up
S/N: AAK1-Up S/N: 5TR1-Up
S/N: ABK1-Up S/N: 6JR1-Up
S/N: 8BL1-Up S/N: 7KR1-Up
S/N: ACL1-Up S/N: BCR1-Up
SENR1017-04 165
Part No.: 9X-7803 Minimum full load current at 5000 rpm ......... 94 Amp
S/N: 8GS1-Up
Minimum full load current at 2000 rpm ........... 9 Amp
Part No.: 9X-7803
S/N: AAT1-Up Output voltage ............................................. 28 ± 1 V
Part No.: 9X-7803
(1) (B-) terminal. Final installation torque for the
S/N: 01X1-Up
bolt ............................ 6.2 ± 0.6 N·m (55 ± 5 lb in)
Part No.: 9X-7803
S/N: 01X1-Up (2) Final installation torque for the
locknut ......................... 102 ± 7 N·m (75 ± 5 lb ft)
Part No.: 9X-7803
S/N: 01X1-Up (3) (B+) terminal. Final installation torque for the
nut ............................. 7.1 ± 0.8 N·m (65 ± 7 lb in)
Part No.: 9X-7803
S/N: 53Y1-Up (4) Voltage regulator assembly
Part No.: 9X-7803 Voltage setting ............................. No adjustment
S/N: 2KZ1-Up Permissible voltage range .................. 27 to 29 V
i03263711

SMCS Code: 1405; 1410
Part No.: 7N-9720
S/N: BCA1-Up
Part No.: 7N-9720
S/N: BDA1-Up
Part No.: 7N-9720
S/N: 1AB1-Up
g01416051
Illustration 188
Part No.: 7N-9720
S/N: 1FB1-Up
Part No.: 7N-9720
S/N: 1NB1-Up
Part No.: 7N-9720
S/N: BBB1-Up
Part No.: 7N-9720
S/N: BEC1-Up
Part No.: 7N-9720
S/N: 1JD1-Up
Part No.: 7N-9720
Illustration 189
g01275266 S/N: 1JD1-Up
Part No.: 7N-9720
Voltage ............................................................... 24 V S/N: 2YD1-Up
Amperage ................................................... 100 Amp Part No.: 7N-9720
S/N: 2YD1-Up
Note: Load the battery with a carbon pile 4C-4911
Battery Load Tester in order to get the maximum Part No.: 7N-9720
alternator output. S/N: CEH1-Up
Part No.: 7N-9720
Polarity ............................................ Negative ground
S/N: 6XJ1-Up
Rotation ............................................ Either direction Part No.: 7N-9720
S/N: 7XJ1-Up
166 SENR1017-04

S/N: 7XJ1-Up S/N: 9XS1-Up
S/N: NBJ1-Up S/N: 9YS1-Up
S/N: 6JR1-Up S/N: 99X1-Up
Part No.: 7N-9720
S/N: 6PR1-Up
Part No.: 7N-9720
S/N: 6TR1-Up
Part No.: 7N-9720
S/N: 7BR1-Up
Part No.: 7N-9720
S/N: 7ER1-Up
Part No.: 7N-9720
S/N: 7FR1-Up
Part No.: 7N-9720
S/N: 7KR1-Up
Part No.: 7N-9720
S/N: 2PS1-Up
Part No.: 7N-9720
S/N: 5SS1-Up g01663735
Illustration 190
Part No.: 7N-9720
S/N: 6YS1-Up
Part No.: 7N-9720
S/N: 7CS1-Up
Part No.: 7N-9720
S/N: 8AS1-Up
SENR1017-04 167
Part No.: 100-5046

S/N: BDA1-Up
Part No.: 100-5046
S/N: 1AB1-Up
Part No.: 100-5046
S/N: 1FB1-Up
Part No.: 100-5046
S/N: 1NB1-Up
Part No.: 100-5046
S/N: BBB1-Up
Part No.: 100-5046
S/N: BEC1-Up
Part No.: 100-5046
S/N: 1JD1-Up
Part No.: 100-5046
S/N: 2YD1-Up
g01663794
Illustration 191
Part No.: 100-5046
Voltage ............................................................... 24 V S/N: 7XJ1-Up
Part No.: 100-5046
Amperage ..................................................... 35 Amp S/N: 4YR1-Up
Note: Load the battery with a carbon pile 4C-4911 Part No.: 100-5046
Battery Load Tester in order to get the maximum S/N: 5HR1-Up
alternator output.
Part No.: 100-5046
Polarity ............................................ Negative ground S/N: 5TR1-Up
Part No.: 100-5046
Rotation .................................................... Clockwise
S/N: 5YR1-Up
Minimum full load current at 5000 rpm ......... 35 Amp Part No.: 100-5046
S/N: 6JR1-Up
Minimum full load current at 1500 rpm ......... 12 Amp
Part No.: 100-5046
Output voltage ....................................... 27.5 ± 1.0 V S/N: 6KR1-Up
(1) Final installation torque for the Part No.: 100-5046

locknut ......................... 102 ± 7 N·m (75 ± 5 lb ft) S/N: 6TR1-Up
Part No.: 100-5046
(2) (B+) terminal. Final installation torque for the S/N: 7BR1-Up
nut ............................ 13.5 ± 1.3 N·m (10 ± 1 lb ft)
Part No.: 100-5046
Voltage regulator assembly S/N: 7ER1-Up
Voltage setting ................................... No adjustment Part No.: 100-5046

S/N: 7FR1-Up
Permissible voltage range ........................ 27 to 29 V
Part No.: 100-5046
S/N: 2PS1-Up
i03263345
Part No.: 100-5046
Alternator and Regulator S/N: 5SS1-Up
SMCS Code: 1405; 1410 Part No.: 100-5046

S/N: 6YS1-Up
Part No.: 100-5046
S/N: 7CS1-Up
168 SENR1017-04
Part No.: 100-5046

S/N: 8AS1-Up
Part No.: 100-5046
S/N: 9XS1-Up
Part No.: 100-5046
S/N: 9YS1-Up
Part No.: 100-5046
S/N: 24W1-Up
Part No.: 100-5046
S/N: 25W1-Up
Part No.: 100-5046
S/N: 26W1-Up
Part No.: 100-5046
S/N: 63W1-Up
Part No.: 100-5046
S/N: 64W1-Up
g01663736
Illustration 193
Part No.: 100-5046
S/N: 01X1-Up Voltage ............................................................... 24 V
Part No.: 100-5046
S/N: 99X1-Up Amperage ..................................................... 50 Amp
Part No.: 100-5046 Note: Load the battery with a carbon pile 4C-4911
S/N: 53Y1-Up Battery Load Tester in order to get the maximum
alternator output.
Rotation ............................................ Either direction
Minimum full load current at 1500 rpm ...... 14.5 Amp
Output voltage ....................................... 27.5 ± 1.0 V

locknut ......................... 102 ± 7 N·m (75 ± 5 lb ft)
(2) (B+) terminal. Final installation torque for the

nut ............................ 13.5 ± 1.3 N·m (10 ± 1 lb ft)
(3) (B−) terminal. Final installation torque for the

nut ......................... 2.25 ± 0.25 N·m (20 ± 2 lb in)
g01663735 Voltage regulator assembly

Illustration 192
Voltage setting ................................... No adjustment
i02836311

SMCS Code: 1405; 1410
SENR1017-04 169
Part No.: 3T-6352 Part No.: 3T-6352

S/N: BCA1-Up S/N: 2PS1-Up
S/N: BDA1-Up S/N: 5SS1-Up
S/N: 1AB1-Up S/N: 6YS1-Up
S/N: 1FB1-Up S/N: 7CS1-Up
S/N: 1NB1-Up S/N: 8AS1-Up
S/N: BBB1-Up S/N: 9XS1-Up
S/N: BEC1-Up S/N: 9YS1-Up
S/N: CEH1-Up S/N: 26W1-Up
S/N: 5TR1-Up S/N: 53Y1-Up
Part No.: 3T-6352
S/N: 5YR1-Up
Part No.: 3T-6352
S/N: 6JR1-Up
Part No.: 3T-6352
S/N: 6KR1-Up
Part No.: 3T-6352
S/N: 6PR1-Up
Part No.: 3T-6352
S/N: 6TR1-Up
Part No.: 3T-6352 g01107198
Illustration 194
S/N: 7BR1-Up
Part No.: 3T-6352
S/N: 7ER1-Up
Part No.: 3T-6352
S/N: 7KR1-Up
170 SENR1017-04
Part No.: 100-5045

S/N: BCA1-Up
Part No.: 100-5045
S/N: BDA1-Up
Part No.: 100-5045
S/N: 1AB1-Up
Part No.: 100-5045
S/N: 1FB1-Up
Part No.: 100-5045
S/N: 1NB1-Up
Part No.: 100-5045
g01107209
Illustration 195 S/N: BBB1-Up
Battery Load Tester in order to get the maximum S/N: BEC1-Up
alternator output. Part No.: 100-5045
S/N: 1JD1-Up
Voltage ............................................................... 24 V
Part No.: 100-5045
Amperage ..................................................... 35 Amp S/N: 2YD1-Up
Polarity ............................................ Negative ground Part No.: 100-5045

S/N: 7XJ1-Up
Part No.: 100-5045
Minimum full load current at 5000 rpm ......... 35 Amp S/N: NBJ1-Up
Part No.: 100-5045
Minimum full load current at 1500 rpm ......... 11 Amp S/N: 4YR1-Up
Output voltage ............................................. 28 ± 1 V Part No.: 100-5045
S/N: 5HR1-Up
Note: Torque the bolt (1) before you tighten the
mounting bolt of the alternator. Part No.: 100-5045
S/N: 5TR1-Up
(1) Torque for bolt .......... 88.4 ± 6.8 N·m (65 ± 5 lb ft)
Part No.: 100-5045
S/N: 5YR1-Up
(2) Final installation torque for flange
nut ................................ 102 ± 7 N·m (75 ± 5 lb ft) Part No.: 100-5045
S/N: 6JR1-Up
Note: Use a 7/16 ring terminal for (B+) terminal.
Part No.: 100-5045
(3) (B+) terminal. Final installation torque for S/N: 6KR1-Up
nut ............................. 6.2 ± 0.6 N·m (55 ± 5 lb in)
Part No.: 100-5045
(4) (B-) terminal. Final installation torque for S/N: 6TR1-Up
nut ......................... 2.25 ± 0.25 N·m (20 ± 2 lb in) Part No.: 100-5045
S/N: 7BR1-Up
(5) Voltage regulator assembly
Part No.: 100-5045
Voltage setting ............................. No adjustment S/N: 7ER1-Up
Permissible voltage range .................. 27 to 29 V
Part No.: 100-5045
S/N: 7FR1-Up
i03262416
Part No.: 100-5045
Alternator and Regulator S/N: 2PS1-Up
SMCS Code: 1405; 1410 Part No.: 100-5045
S/N: 5SS1-Up
SENR1017-04 171
Part No.: 100-5045

S/N: 6YS1-Up
Part No.: 100-5045
S/N: 7CS1-Up
Part No.: 100-5045
S/N: 8AS1-Up
Part No.: 100-5045
S/N: 9XS1-Up
Part No.: 100-5045
S/N: 9YS1-Up
Part No.: 100-5045
S/N: 24W1-Up
Part No.: 100-5045
S/N: 25W1-Up
Part No.: 100-5045
S/N: 26W1-Up
Part No.: 100-5045
S/N: 63W1-Up
Part No.: 100-5045
S/N: 64W1-Up
Part No.: 100-5045 g01663673
Illustration 197
S/N: 01X1-Up
Part No.: 100-5045 Voltage ............................................................... 24 V
S/N: 99X1-Up
Amperage ..................................................... 50 Amp
Part No.: 100-5045
S/N: 53Y1-Up Note: Load the battery with a carbon pile 4C-4911
Battery Load Tester in order to get the maximum
alternator output.
Output voltage ....................................... 28.0 ± 1.0 V

locknut ......................... 102 ± 7 N·m (75 ± 5 lb ft)

nut ............................ 13.5 ± 1.3 N·m (10 ± 1 lb ft)

nut ............................. 4.4 ± 1.0 N·m (40 ± 9 lb in)
g01663674
Illustration 196
Voltage regulator assembly

172 SENR1017-04
i03267060 Part No.: 9G-4574

S/N: 6TR1-Up
Part No.: 9G-4574
SMCS Code: 1405; 1410 S/N: 7BR1-Up
Part No.: 9G-4574 Part No.: 9G-4574
S/N: BCA1-Up S/N: 7ER1-Up
S/N: BDA1-Up S/N: 7FR1-Up
S/N: 1FB1-Up S/N: 2PS1-Up
S/N: 1NB1-Up S/N: 5SS1-Up
S/N: BBB1-Up S/N: 6YS1-Up
S/N: BEC1-Up S/N: 7CS1-Up
S/N: 1JD1-Up S/N: 8AS1-Up
S/N: 2YD1-Up S/N: 9XS1-Up
S/N: CEH1-Up S/N: 9YS1-Up
Part No.: 9G-4574
S/N: 6JR1-Up
Part No.: 9G-4574
S/N: 6KR1-Up
Part No.: 9G-4574
S/N: 6PR1-Up
SENR1017-04 173
Output voltage ....................................... 28.0 ± 1.0 V

locknut ......................... 102 ± 7 N·m (75 ± 5 lb ft)

nut ............................ 13.5 ± 1.3 N·m (10 ± 1 lb ft)

nut ............................. 4.4 ± 1.0 N·m (40 ± 9 lb in)
Voltage regulator assembly
g01663674
Illustration 198
i03295689

SMCS Code: 1405; 1410
Part No.: 112-5041
S/N: BCA1-Up
Part No.: 112-5041
S/N: BDA1-Up
Part No.: 112-5041
S/N: 1AB1-Up
Part No.: 112-5041
S/N: 1FB1-Up
Part No.: 112-5041
S/N: 1NB1-Up
Part No.: 112-5041
S/N: BBB1-Up
Part No.: 112-5041
S/N: BEC1-Up
Part No.: 112-5041
S/N: 1JD1-Up
Part No.: 112-5041
Illustration 199
g01678395 S/N: 2YD1-Up
Part No.: 112-5041
Voltage ............................................................... 24 V
S/N: CEH1-Up
Amperage ..................................................... 35 Amp Part No.: 112-5041
S/N: 7XJ1-Up
Battery Load Tester in order to get the maximum Part No.: 112-5041
alternator output. S/N: 4YR1-Up
Polarity ............................................ Negative ground Part No.: 112-5041

S/N: 5HR1-Up
174 SENR1017-04
Part No.: 112-5041

S/N: 5TR1-Up
Part No.: 112-5041
S/N: 5YR1-Up
Part No.: 112-5041
S/N: 6JR1-Up
Part No.: 112-5041
S/N: 6KR1-Up
Part No.: 112-5041
S/N: 6PR1-Up
Part No.: 112-5041
S/N: 6TR1-Up
Part No.: 112-5041
S/N: 7BR1-Up
Part No.: 112-5041
S/N: 7ER1-Up
g01679497
Illustration 200
Part No.: 112-5041
S/N: 7KR1-Up
Part No.: 112-5041
S/N: 2PS1-Up
Part No.: 112-5041
S/N: 5SS1-Up
Part No.: 112-5041
S/N: 6YS1-Up
Part No.: 112-5041
S/N: 7CS1-Up
Part No.: 112-5041
S/N: 8AS1-Up
S/N: 9XS1-Up
Part No.: 112-5041
S/N: 9YS1-Up
Part No.: 112-5041
g01679493
S/N: 24W1-Up Illustration 201
Part No.: 112-5041 Voltage ............................................................... 24 V

S/N: 25W1-Up
Amperage ..................................................... 50 Amp
Part No.: 112-5041
S/N: 63W1-Up
Part No.: 112-5041 Battery Load Tester in order to get the maximum
S/N: 64W1-Up alternator output.
Part No.: 112-5041 Polarity ............................................ Negative ground

S/N: 01X1-Up
Part No.: 112-5041
S/N: 99X1-Up Minimum full load current at 5000 rpm ......... 47 Amp
Part No.: 112-5041
S/N: 53Y1-Up Minimum full load current at 1500 rpm ......... 18 Amp
Output voltage ....................................... 28.0 ± 1.0 V

SENR1017-04 175
(1) Final installation torque for the Part No.: 169-3345

locknut ......................... 102 ± 7 N·m (75 ± 5 lb ft) S/N: 6PR1-Up
(2) (B-) terminal. Final installation torque for the Part No.: 169-3345
screw ........................ 6.2 ± 0.6 N·m (55 ± 5 lb in) S/N: 6TR1-Up
Part No.: 169-3345
S/N: 7ER1-Up
nut ............................ 13.5 ± 1.3 N·m (10 ± 1 lb ft)
Part No.: 169-3345
Voltage regulator assembly S/N: 7KR1-Up
Voltage setting ................................... No adjustment Part No.: 169-3345

S/N: 5SS1-Up
Part No.: 169-3345
S/N: 6YS1-Up
i02906659
Part No.: 169-3345
Alternator and Regulator S/N: 7CS1-Up
SMCS Code: 1405; 1410 Part No.: 169-3345

S/N: 8AS1-Up
Part No.: 169-3345
S/N: 9XS1-Up
Part No.: 169-3345
S/N: BDA1-Up Part No.: 169-3345
S/N: 24W1-Up
Part No.: 169-3345
S/N: BBB1-Up Part No.: 169-3345
S/N: 25W1-Up
Part No.: 169-3345
S/N: BEC1-Up Part No.: 169-3345
S/N: 26W1-Up
Part No.: 169-3345
S/N: CEH1-Up Part No.: 169-3345
S/N: 63W1-Up
Part No.: 169-3345
S/N: 7XJ1-Up Part No.: 169-3345
S/N: 64W1-Up
Part No.: 169-3345
S/N: NBJ1-Up Part No.: 169-3345
S/N: 01X1-Up
Part No.: 169-3345
S/N: ASK1-Up
Part No.: 169-3345
S/N: 4FR1-Up
Part No.: 169-3345
S/N: 4YR1-Up
Part No.: 169-3345
S/N: 5HR1-Up
Part No.: 169-3345
S/N: 5TR1-Up
Part No.: 169-3345
S/N: 5YR1-Up
Part No.: 169-3345
S/N: 6JR1-Up
Part No.: 169-3345
S/N: 6KR1-Up
g01449471
Illustration 202
176 SENR1017-04
Voltage setting ............................. No adjustment

i02825634

SMCS Code: 1405; 1410
Part No.: 3E-7577
S/N: AWK1-Up
Part No.: 3E-7577
S/N: AXT1-Up
Part No.: 3E-7577
S/N: BLW1-Up
Part No.: 3E-7577
S/N: 1YZ1-Up
Part No.: 3E-7577
S/N: 1ZZ1-Up
Part No.: 3E-7577
S/N: BKZ1-Up
g01449475
Illustration 203
Voltage ............................................................... 24 V
Amperage ..................................................... 50 Amp

alternator output.

g01409463
Rotation .................................................... Clockwise Illustration 204
Minimum full load current at 5000 rpm ......... 50 Amp (1) Final installation torque for the
locknut ......................... 102 ± 7 N·m (75 ± 5 lb ft)
Output voltage ............................................. 28 ± 1 V

locknut ....................... 127 ± 10 N·m (95 ± 7 lb ft)

bolt ............................ 4.4 ± 1.0 N·m (39 ± 9 lb in)
(3) The peak voltage for (R) terminal must not be

less than the output voltage for (B+) terminal.

nut ....................... 18.2 ± 2.4 N·m (160 ± 21 lb in)
Note: Use a 7/16 ring terminal for (B+) terminal.

SENR1017-04 177
Part No.: 169-3345

S/N: 3BJ1-Up
Part No.: 169-3345
S/N: 7MJ1-Up
Part No.: 169-3345
S/N: 3SK1-Up
Part No.: 169-3345
S/N: 67K1-Up
Part No.: 169-3345
S/N: 7HK1-Up
Part No.: 169-3345
S/N: 3KR1-Up
Part No.: 169-3345
S/N: 5XR1-Up
Part No.: 169-3345
S/N: 5YR1-Up
g01409464
Illustration 205
Part No.: 169-3345
Voltage ............................................................... 24 V S/N: 6PR1-Up
Part No.: 169-3345
Amperage ..................................................... 75 Amp S/N: 6TR1-Up
Battery Load Tester in order to get the maximum S/N: 7KR1-Up
alternator output.
Part No.: 169-3345
Polarity ............................................ Negative ground S/N: 01X1-Up
Part No.: 169-3345
S/N: 42X1-Up
Minimum full load current at 5000 rpm ......... 67 Amp Part No.: 169-3345
S/N: 49Z1-Up
Part No.: 169-3345
Output voltage ............................................. 28 ± 1 V S/N: 86Z1-Up
(2) (B-) terminal. Final installation torque for the Part No.: 169-3345
screw ........................ 6.2 ± 0.6 N·m (55 ± 5 lb in) S/N: 86Z1-Up
Part No.: 169-3345
(3) (B+) terminal. Final installation torque for the S/N: 87Z1-Up
stud ..................... 13.5 ± 1.3 N·m (120 ± 12 lb in)
Part No.: 169-3345
(4) Voltage regulator assembly S/N: 87Z1-Up
Voltage setting ............................. No adjustment Part No.: 169-3345
Permissible voltage range .................. 27 to 29 V S/N: 89Z1-Up
(5) The peak voltage for (R) terminal must not be Part No.: 169-3345
less than the output voltage for (B+) terminal. S/N: 89Z1-Up
Part No.: 169-3345
i01424067 S/N: 90Z1-Up
Alternator and Regulator Part No.: 169-3345

S/N: 91Z1-Up
SMCS Code: 1405; 1410
Part No.: 169-3345
Part No.: 169-3345 S/N: 91Z1-Up
S/N: 8YG1-Up
178 SENR1017-04
114-2401 Alternator Gp (4) Regulator

169-3345 Alternator Gp
g00115456
Illustration 206
g00752048
Illustration 208
g00115457
Illustration 207

alternator output.
g00752049
Illustration 209
Polarity ........................................... Negative Ground
Rotation ............................................ Either Direction Battery Load Tester in order to get the maximum
alternator output.
Polarity ........................................... Negative Ground
Rotation .................................................... Clockwise
Output voltage ....................................... 27.5 ± 1.0 V
(1) Bolt
Tighten the bolt on the ground terminal to the
following torque. ....... 6.2 ± 0.6 N·m (55 ± 5 lb in) Output voltage .......................................... 28 ± 1.0 V
(2) Nut (1) Nut
Tighten the nut on the output shaft of the Tighten the nut on the positive terminal to the
alternator to the following torque. .... 102 ± 7 N·m following torque. ...... 18.2 ± 2.4 N·m (13 ± 2 lb ft)
(75 ± 5 lb ft)
(2) Nut
(3) Nut
Tighten the nut on the output shaft of the
Tighten the nut on the positive terminal to the alternator to the following torque. .. 127 ± 10 N·m
following torque. ....... 7.1 ± 0.8 N·m (5 ± 0.6 lb ft) (94 ± 7 lb ft)
SENR1017-04 179
(3) Nut
Tighten the nut on the ground terminal to the
following torque. ....... 4.4 ± 1.0 N·m (39 ± 9 lb in)
(4) Regulator
i03262040

SMCS Code: 1405; 1410
Part No.: 114-2401
S/N: 1JD1-Up
Part No.: 114-2401
S/N: 2YD1-Up
Part No.: 114-2401
S/N: 6XJ1-Up
Part No.: 114-2401
S/N: ABK1-Up
Part No.: 114-2401
S/N: 7TL1-Up Illustration 211
g01663613
Part No.: 114-2401

S/N: 8BL1-Up Voltage ............................................................... 24 V
Part No.: 114-2401 Amperage ..................................................... 75 Amp

S/N: ACL1-Up
Part No.: 114-2401 Battery Load Tester in order to get the maximum
S/N: 3KR1-Up alternator output.
Part No.: 114-2401 Polarity ............................................ Negative ground
S/N: 53Y1-Up
Output voltage ....................................... 27.5 ± 1.0 V

bolt ............................ 6.2 ± 0.6 N·m (55 ± 5 lb in)

locknut ......................... 102 ± 7 N·m (75 ± 5 lb ft)

nut .............................. 7.1 ± 0.8 N·m (60 ± 7 lb ft)

g01663614
Illustration 210
180 SENR1017-04
i01038402 Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072

S/N: 3TK1-Up
Alternator Mounting
Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072
SMCS Code: 1405 S/N: 67K1-Up
Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072 Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072
S/N: AAA1-Up S/N: 7HK1-Up
SENR1017-04 181
182 SENR1017-04
Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072

S/N: 1ZZ1-Up
Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072
S/N: 2KZ1-Up
Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072
S/N: 49Z1-Up
Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072
S/N: 86Z1-Up
Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072
S/N: 86Z1-Up
Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072
g00511202
S/N: 87Z1-Up Illustration 213
Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072 7W-4071 Alternator Mounting

S/N: 87Z1-Up
Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072 (1) Tighten the shaft nut for the alternator pulley to
S/N: 89Z1-Up the following torque. ...... 61 ± 7 N·m (45 ± 5 lb ft)
Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072

i02225023
S/N: 89Z1-Up
Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072
Electric Starting Motor
S/N: 90Z1-Up
SMCS Code: 1453
Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072
Part No.: 237-1962, 6V-0890
S/N: 90Z1-Up
S/N: AAA1-Up
Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072
Part No.: 237-1962, 6V-0890
S/N: 91Z1-Up
S/N: BCA1-Up
Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072
Part No.: 237-1962, 6V-0890
S/N: 91Z1-Up
S/N: BDA1-Up
Part No.: 129-8138, 1W-1806, 7W-4071, 7W-4072
Part No.: 237-1962, 6V-0890
S/N: BKZ1-Up
S/N: 1AB1-Up
Part No.: 237-1962, 6V-0890
S/N: 1FB1-Up
Part No.: 237-1962, 6V-0890
S/N: 1NB1-Up
Part No.: 237-1962, 6V-0890
S/N: BBB1-Up
Part No.: 237-1962, 6V-0890
S/N: BEC1-Up
Part No.: 237-1962, 6V-0890
S/N: 2YD1-Up
g00511202
Illustration 212 Part No.: 6V-0890
S/N: 8YG1-Up
1W-1806 Alternator Mounting
Part No.: 237-1962, 6V-0890
7W-4072 Alternator Mounting S/N: CEH1-Up
Part No.: 6V-0890
129-8138 Alternator Mounting S/N: 3BJ1-Up
(1) Tighten the shaft nut for the alternator pulley to Part No.: 237-1962, 6V-0890
the following torque. .... 102 ± 7 N·m (75 ± 5 lb ft) S/N: 6XJ1-Up
SENR1017-04 183
Part No.: 6V-0890 Part No.: 237-1962, 6V-0890

S/N: 7MJ1-Up S/N: 6JR1-Up
Part No.: 237-1962, 6V-0890 Part No.: 237-1962, 6V-0890
Part No.: 237-1962, 6V-0890 Part No.: 6V-0890
S/N: NBJ1-Up S/N: 6PR1-Up
Part No.: 237-1962, 6V-0890 Part No.: 237-1962, 6V-0890
S/N: 3TK1-Up S/N: 6PR1-Up
Part No.: 6V-0890 Part No.: 237-1962, 6V-0890
Part No.: 237-1962, 6V-0890 Part No.: 6V-0890
S/N: 7KK1-Up S/N: 6TR1-Up
Part No.: 237-1962, 6V-0890 Part No.: 237-1962, 6V-0890
S/N: AAK1-Up S/N: 7BR1-Up
Part No.: 237-1962, 6V-0890 Part No.: 237-1962, 6V-0890
S/N: ASK1-Up S/N: 7ER1-Up
Part No.: 237-1962, 6V-0890 Part No.: 237-1962, 6V-0890
S/N: AWK1-Up S/N: 7FR1-Up
Part No.: 237-1962, 6V-0890 Part No.: 237-1962, 6V-0890
S/N: 7GN1-Up S/N: 7KR1-Up
Part No.: 237-1962, 6V-0890 Part No.: 6V-0890
S/N: 8HN1-Up S/N: 7KR1-Up
Part No.: 237-1962, 6V-0890 Part No.: 237-1962, 6V-0890
Part No.: 6V-0890 Part No.: 237-1962, 6V-0890
Part No.: 237-1962, 6V-0890 Part No.: 237-1962, 6V-0890
Part No.: 237-1962, 6V-0890 Part No.: 237-1962, 6V-0890
S/N: 4FR1-Up S/N: 5SS1-Up
Part No.: 6V-0890 Part No.: 237-1962, 6V-0890
Part No.: 237-1962, 6V-0890 Part No.: 237-1962, 6V-0890
Part No.: 6V-0890 Part No.: 237-1962, 6V-0890
Part No.: 237-1962, 6V-0890 Part No.: 237-1962, 6V-0890
Part No.: 237-1962, 6V-0890 Part No.: 237-1962, 6V-0890
Part No.: 6V-0890 Part No.: 237-1962, 6V-0890
Part No.: 6V-0890 Part No.: 237-1962, 6V-0890
Part No.: 237-1962, 6V-0890 Part No.: 237-1962, 6V-0890
184 SENR1017-04
Part No.: 237-1962, 6V-0890 Part No.: 6V-0890

Part No.: 237-1962, 6V-0890 Part No.: 6V-0890
Part No.: 237-1962, 6V-0890 Part No.: 6V-0890
Part No.: 237-1962, 6V-0890 Part No.: 237-1962, 6V-0890
Part No.: 237-1962, 6V-0890
S/N: 63W1-Up
Part No.: 237-1962, 6V-0890
S/N: 63W1-Up
Part No.: 237-1962, 6V-0890
S/N: 64W1-Up
Part No.: 237-1962, 6V-0890
S/N: 64W1-Up
Part No.: 237-1962, 6V-0890
S/N: BLW1-Up
Part No.: 237-1962, 6V-0890 g01122292
Illustration 214
S/N: 01X1-Up
Part No.: 237-1962, 6V-0890
S/N: 01X1-Up
Part No.: 237-1962, 6V-0890
S/N: 01X1-Up
Part No.: 237-1962, 6V-0890
S/N: 99X1-Up
Part No.: 237-1962, 6V-0890
S/N: 1YZ1-Up
Part No.: 237-1962, 6V-0890
S/N: 1ZZ1-Up
g01122294
Part No.: 237-1962, 6V-0890 Illustration 215
S/N: 2KZ1-Up Typical solenoid connections
Part No.: 6V-0890 When the electric starting motor is viewed from
S/N: 86Z1-Up the pinion end, the motor rotates in the following
Part No.: 6V-0890 direction. ................................................... Clockwise
S/N: 86Z1-Up
No load conditions at 25 °C (77 °F)
Part No.: 6V-0890
S/N: 87Z1-Up Speed ...................................... 6950 ± 1650 rpm
Current draw .................................. 115 ± 25 amp
Part No.: 6V-0890 Voltage ......................................................... 23 V
S/N: 87Z1-Up
(1) Tighten the nut on the ground terminal to the
Part No.: 6V-0890 following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)
S/N: 89Z1-Up
(2) Three wires are the maximum between the nuts.
Part No.: 6V-0890
Tighten the nut on the battery terminal to the
S/N: 89Z1-Up
following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)
Part No.: 6V-0890
S/N: 90Z1-Up (3) Tighten the ground terminal to the following
torque. .................. 2.25 ± 0.25 N·m (20 ± 2 lb in)
SENR1017-04 185
(4) Tighten the nut on the switch terminal to the Part No.: 9X-4452
following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in) S/N: 5TR1-Up
(5) Tighten the nut on the motor terminal to the Part No.: 9X-4452
following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft) S/N: 5YR1-Up
Part No.: 9X-4452
(6) Tighten the nut on the motor frame terminal to the
S/N: 6JR1-Up
Part No.: 9X-4452
Solenoid S/N: 6KR1-Up
Current draw at 20 V and 25 °C (77 °F) Part No.: 9X-4452
S/N: 6PR1-Up
Pull-in windings ........................... 49.3 ± 3.3 Amp
Part No.: 9X-4452
Hold-in windings ................... 6.8 Amp maximum S/N: 6TR1-Up
Part No.: 9X-4452
i02877675 S/N: 7BR1-Up
Electric Starting Motor Part No.: 9X-4452
S/N: 7ER1-Up
SMCS Code: 1453
Part No.: 9X-4452
Part No.: 9X-4452 S/N: 7FR1-Up
S/N: BCA1-Up
Part No.: 9X-4452
Part No.: 9X-4452 S/N: 7KR1-Up
S/N: BDA1-Up
Part No.: 9X-4452
Part No.: 9X-4452 S/N: CLR1-Up
S/N: 1AB1-Up
Part No.: 9X-4452
Part No.: 9X-4452 S/N: 2PS1-Up
S/N: 1FB1-Up
Part No.: 9X-4452
Part No.: 9X-4452 S/N: 5SS1-Up
S/N: 1NB1-Up
Part No.: 9X-4452
Part No.: 9X-4452 S/N: 6YS1-Up
S/N: BBB1-Up
Part No.: 9X-4452
Part No.: 9X-4452 S/N: 7CS1-Up
S/N: BEC1-Up
Part No.: 9X-4452
Part No.: 9X-4452 S/N: 8AS1-Up
S/N: CEH1-Up
Part No.: 9X-4452
Part No.: 9X-4452 S/N: 9XS1-Up
S/N: 7XJ1-Up
Part No.: 9X-4452
Part No.: 9X-4452 S/N: 9YS1-Up
S/N: NBJ1-Up
Part No.: 9X-4452
Part No.: 9X-4452 S/N: AXT1-Up
S/N: 3TK1-Up
Part No.: 9X-4452
Part No.: 9X-4452 S/N: 24W1-Up
S/N: ASK1-Up
Part No.: 9X-4452
S/N: AWK1-Up
Part No.: 9X-4452
S/N: 4YR1-Up
Part No.: 9X-4452
S/N: 5HR1-Up
186 SENR1017-04
Part No.: 9X-4452 Speed .................................. 3300 rpm minimum

S/N: 64W1-Up Current draw .......................... 80 Amp maximum
Voltage ...................................................... 23.5 V
Part No.: 9X-4452
S/N: BLW1-Up (1) Battery terminal
Part No.: 9X-4452 Three wires are the maximum that may fit
S/N: 01X1-Up between the nuts.
Part No.: 9X-4452 Tighten the nut on the ground terminal to the
S/N: 99X1-Up following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)
Part No.: 9X-4452 (2) Nut

S/N: 1YZ1-Up
Tighten the nut to the following
Part No.: 9X-4452 torque. ...................... 1.5 ± 0.5 N·m (13 ± 4 lb in)
S/N: 1ZZ1-Up
(3) Ground Terminal
Part No.: 9X-4452
S/N: BKZ1-Up Tighten the nut on the ground terminal to the
(4) Nut
Tighten the nut on the switch terminal to the
following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in)
(5) Nut
Tighten the nut on the motor terminal to the
(6) Nut
Tighten the nut on the motor frame terminal to the
g01432181 following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)
Illustration 216
Solenoid
Current draw at 24 V and 25 °C (77 °F)

Pull-in windings ..................................... 103 Amp
Hold-in windings ..................................... 19 Amp
i02877737

SMCS Code: 1453
Part No.: 7T-0794
S/N: BCA1-Up
Part No.: 7T-0794
S/N: BDA1-Up
Part No.: 7T-0794
S/N: 1AB1-Up
g01432182
Illustration 217
Part No.: 7T-0794
When the electric starting motor is viewed from S/N: 1FB1-Up
the pinion end, the motor rotates in the following
direction. ................................................... Clockwise Part No.: 7T-0794
S/N: 1NB1-Up
No load conditions at 25 °C (77 °F)
SENR1017-04 187

S/N: BBB1-Up S/N: 7CS1-Up
S/N: BEC1-Up S/N: 8AS1-Up
S/N: CEH1-Up S/N: 9XS1-Up
S/N: 7XJ1-Up S/N: 9YS1-Up
S/N: NBJ1-Up S/N: AXT1-Up
S/N: 3TK1-Up S/N: 24W1-Up
S/N: ASK1-Up S/N: 25W1-Up
S/N: 6JR1-Up S/N: 99X1-Up
S/N: 6PR1-Up S/N: 1ZZ1-Up
S/N: 6TR1-Up S/N: BKZ1-Up
Part No.: 7T-0794
S/N: 7BR1-Up
Part No.: 7T-0794
S/N: 7ER1-Up
Part No.: 7T-0794
S/N: 7FR1-Up
Part No.: 7T-0794
S/N: CLR1-Up
Part No.: 7T-0794
S/N: 2PS1-Up
Part No.: 7T-0794
S/N: 5SS1-Up
Part No.: 7T-0794
S/N: 6YS1-Up
188 SENR1017-04
Part No.: 8C-3644

S/N: BCA1-Up
Part No.: 8C-3644
S/N: BDA1-Up
Part No.: 8C-3644
S/N: 1AB1-Up
Part No.: 8C-3644
S/N: 1FB1-Up
Part No.: 8C-3644
S/N: 1NB1-Up
Part No.: 8C-3644
S/N: BBB1-Up
Part No.: 8C-3644
S/N: BEC1-Up
Part No.: 8C-3644
S/N: CEH1-Up
Part No.: 8C-3644
S/N: 7XJ1-Up
Part No.: 8C-3644
S/N: NBJ1-Up
g01432202 Part No.: 8C-3644

Illustration 218
S/N: 3TK1-Up
When the electric starting motor is viewed from Part No.: 8C-3644
the pinion end, the motor rotates in the following S/N: ASK1-Up
direction. ................................................... Clockwise
Part No.: 8C-3644
No load conditions at 25 °C (77 °F) S/N: AWK1-Up
Speed .................................. 5500 rpm minimum Part No.: 8C-3644

Current draw ........................ 140 Amp maximum S/N: 4YR1-Up
Voltage ......................................................... 24 V
Part No.: 8C-3644
(1) Large terminal nuts S/N: 5HR1-Up
Tighten the large terminal nuts to the following Part No.: 8C-3644
torque. ..................... 30.5 ± 3.5 N·m (22 ± 3 lb ft) S/N: 5TR1-Up
Part No.: 8C-3644
(2) Small terminal nuts S/N: 5YR1-Up
Tighten the small terminal nuts to the following Part No.: 8C-3644
torque. .................. 2.25 ± 0.25 N·m (20 ± 2 lb in) S/N: 6JR1-Up
Solenoid Part No.: 8C-3644
S/N: 6KR1-Up
Part No.: 8C-3644
Pull-in windings ....................................... 51 Amp S/N: 6PR1-Up
Hold-in windings ....................................... 7 Amp Part No.: 8C-3644
S/N: 6TR1-Up
i02877757 Part No.: 8C-3644
S/N: 7BR1-Up
Part No.: 8C-3644
SMCS Code: 1453 S/N: 7ER1-Up
SENR1017-04 189
Part No.: 8C-3644

S/N: 7FR1-Up
Part No.: 8C-3644
S/N: 7KR1-Up
Part No.: 8C-3644
S/N: CLR1-Up
Part No.: 8C-3644
S/N: 2PS1-Up
Part No.: 8C-3644
S/N: 5SS1-Up
Part No.: 8C-3644
g01432214
S/N: 6YS1-Up Illustration 219
Part No.: 8C-3644

S/N: 7CS1-Up
Part No.: 8C-3644
S/N: 8AS1-Up
Part No.: 8C-3644
S/N: 9XS1-Up
Part No.: 8C-3644
S/N: 9YS1-Up
Part No.: 8C-3644
S/N: AXT1-Up
Part No.: 8C-3644 Illustration 220
g01432215
S/N: 24W1-Up
Part No.: 8C-3644 When the electric starting motor is viewed from
S/N: 25W1-Up the pinion end, the motor rotates in the following
Part No.: 8C-3644
S/N: 26W1-Up No load conditions at 25 °C (77 °F)
Part No.: 8C-3644 Speed ...................................... 7643 ± 1683 rpm
S/N: 63W1-Up Current draw ............................... 67.5 ± 7.5 Amp
Voltage ......................................................... 23 V
Part No.: 8C-3644
S/N: 64W1-Up (1) Ground terminal
Part No.: 8C-3644 Tighten the nut on the ground terminal to the
S/N: BLW1-Up following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)
Part No.: 8C-3644
(2) Nut
S/N: 01X1-Up
Tighten the nut on the ground terminal to the
Part No.: 8C-3644
following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in)
S/N: 99X1-Up
Part No.: 8C-3644 (3) Battery terminal
S/N: 1YZ1-Up
Three wires are the maximum that may fit
Part No.: 8C-3644 between the nuts.
S/N: BKZ1-Up Tighten the nut on the battery terminal to the
(4) Switch terminal

190 SENR1017-04
The switch terminal must be insulated with heat Part No.: 4N-0959
shrink tubing. S/N: 50W1-Up
Tighten the nut on the switch terminal to the Part No.: 7N-1509
following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in) S/N: 42X1-Up
(5) Nut Part No.: 7N-7049
S/N: 53Y1-Up
Tighten the nut on the motor terminal to the
following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft) Part No.: 7N-1509
S/N: 49Z1-Up
(6) Nut
Tighten the nut on the motor frame terminal to the
following torque. ........... 8 ± 3 N·m (71 ± 27 lb in)
Solenoid

Pull-in windings ........................... 56.5 ± 4.6 Amp
Hold-in windings .................................. 14.6 Amp
i02787417

SMCS Code: 1453
Part No.: 7N-7049
S/N: 1JD1-Up
Part No.: 7N-7049 g01394255
Illustration 221
S/N: 1JD1-Up
Part No.: 7N-7049 When the electric starting motor is viewed from
S/N: 2YD1-Up the pinion end, the motor rotates in the following
Part No.: 7N-1059
S/N: 7XJ1-Up No load conditions at 25 °C (77 °F)
Part No.: 7N-7049 Speed ...................................... 6950 ± 1650 rpm
S/N: 3SK1-Up Current draw ................................. 115 ± 25 Amp
Voltage .................................................... 23 VDC
Part No.: 4N-4439
S/N: 67K1-Up (B) The clearance between the pinion and the
Part No.: 6V-0928 housing is the following value. ................ 9.1 mm
S/N: ABK1-Up (0.36 inch)
Part No.: 7N-7049 (1) Final installation torque for the ground terminal
S/N: 7TL1-Up nut ....................... 30.5 ± 3.5 N·m (270 ± 30 lb in)
Part No.: 6V-0928 (2) Final installation torque for the ground terminal
S/N: 7TL1-Up nut ......................... 2.25 ± 0.25 N·m (20 ± 2 lb in)
Part No.: 7N-7049
Note: The switch terminal must be insulated with
S/N: 8BL1-Up
heat shrink tubing. Do not use molded terminals.
Part No.: 6V-0928
S/N: 8BL1-Up (3) Final installation torque for the switch terminal
nut ......................... 2.25 ± 0.25 N·m (20 ± 2 lb in)
Part No.: 6V-0928
S/N: ACL1-Up (4) Final installation torque for the motor terminal
nut ....................... 30.5 ± 3.5 N·m (270 ± 30 lb in)
Part No.: 6V-0928
S/N: 3KR1-Up
SENR1017-04 191
Note: A maximum of three cable terminals or wire i03258194

terminals may be used with the battery terminal nut.
A maximum of two of the terminals may be equal to Magnetic Pickup
or greater than 0 AWG.
SMCS Code: 1905; 1907
(5) Final installation torque for the battery terminal
Part No.: 100-4505, 109-3633
nut ....................... 30.5 ± 3.5 N·m (270 ± 30 lb in)
S/N: 1JD1-Up
(6) Final installation torque for the motor frame Part No.: 100-4505, 109-3633
terminal nut ......... 30.5 ± 3.5 N·m (270 ± 30 lb in) S/N: 2YD1-Up
Solenoid Part No.: 100-4505, 109-3633
S/N: 6XJ1-Up
Current consumption at 20V and 25 °C (77 °F)
Part No.: 109-3633
Pull-in windings ........................... 49.3 ± 3.3 Amp S/N: 3SK1-Up
Hold-in windings ............................ 6.8 Amp max
Part No.: 100-4505, 109-3633
S/N: 3TK1-Up
Part No.: 113-5276
S/N: 7KK1-Up
Part No.: 113-5276
S/N: ABK1-Up
Part No.: 113-5276
S/N: 7TL1-Up
Part No.: 113-5276
S/N: 8BL1-Up
Part No.: 113-5276
S/N: 8BL1-Up
Part No.: 113-5276
S/N: ACL1-Up
Part No.: 100-4505
S/N: 8GS1-Up
g01418609
Illustration 222
Typical example
While the engine is stopped, install the magnetic

pickup. Once the magnetic pickup is in contact
with the gear tooth of the flywheel or the pump
drive gear, back out the magnetic pickup by
turning the pickup assembly in a counterclockwise
direction. ............................................ 1/2 ± 1/10 turn
192 SENR1017-04
(A) Clearance between magnetic pickup and flywheel (A) Clearance between magnetic pickup and flywheel
ring gear .. 0.69 ± 0.14 mm (0.027 ± 0.006 inch) ring gear .. 0.71 ± 0.14 mm (0.028 ± 0.006 inch)
(1) Torque for the locknut .... 25 ± 5 N·m (18 ± 4 lb ft) (1) Torque for the locknut .... 25 ± 5 N·m (18 ± 4 lb ft)
i03258161 i02870347
Magnetic Pickup Coolant Temperature Sensor

SMCS Code: 1905; 1907 SMCS Code: 1906
Part No.: 128-5109 Part No.: 106-0735
S/N: 1JD1-Up S/N: AAA1-Up
Part No.: 128-5109, 191-6506 Part No.: 106-0735
S/N: 2YD1-Up S/N: BCA1-Up
Part No.: 128-5109 Part No.: 106-0735
S/N: 6XJ1-Up S/N: BDA1-Up
Part No.: 128-5109 Part No.: 106-0735
S/N: ABK1-Up S/N: 1AB1-Up
Part No.: 128-5109 Part No.: 106-0735
S/N: 8BL1-Up S/N: 1FB1-Up
Part No.: 128-5109 Part No.: 106-0735
S/N: ACL1-Up S/N: 1NB1-Up
Part No.: 128-5109, 191-6506 Part No.: 106-0735
S/N: 3KR1-Up S/N: BBB1-Up
Part No.: 128-5109 Part No.: 106-0735
S/N: 3KR1-Up S/N: BEC1-Up
Part No.: 191-6506 Part No.: 106-0735
S/N: AKT1-Up S/N: 1JD1-Up
Part No.: 128-5109 Part No.: 106-0735
S/N: 53Y1-Up S/N: 1JD1-Up
Part No.: 106-0735
S/N: 2YD1-Up
Part No.: 106-0735
S/N: 2YD1-Up
Part No.: 106-0735
S/N: 8YG1-Up
Part No.: 106-0735
S/N: CEH1-Up
Part No.: 106-0735
S/N: 3BJ1-Up
g01418609 Part No.: 106-0735

Illustration 223
S/N: 6XJ1-Up
Typical example
Part No.: 106-0735
While the engine is stopped, install the magnetic S/N: 7MJ1-Up
pickup. Once the magnetic pickup is in contact with
the gear tooth, or the flywheel face, back out the Part No.: 106-0735
magnetic pickup by turning the pickup assembly in a S/N: 7XJ1-Up
counterclockwise direction. ................ 1/2 ± 1/10 turn
Part No.: 106-0735
S/N: 7XJ1-Up
SENR1017-04 193
Part No.: 106-0735 Part No.: 106-0735

Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
S/N: 3TK1-Up S/N: 5HR1-Up
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
S/N: 7KK1-Up S/N: 5YR1-Up
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
S/N: AWK1-Up S/N: 6PR1-Up
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
S/N: 7TL1-Up S/N: 6TR1-Up
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
S/N: 8BL1-Up S/N: 7BR1-Up
Part No.: 106-0735 Part No.: 106-0735
S/N: ACL1-Up S/N: 7ER1-Up
Part No.: 106-0735 Part No.: 106-0735
S/N: 7GN1-Up S/N: 7FR1-Up
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
194 SENR1017-04
Part No.: 106-0735 Part No.: 106-0735

Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735 Part No.: 106-0735
Part No.: 106-0735
S/N: 64W1-Up
Part No.: 106-0735
S/N: 64W1-Up
Part No.: 106-0735
S/N: BLW1-Up
Part No.: 106-0735
S/N: 01X1-Up
Part No.: 106-0735
S/N: 01X1-Up
Part No.: 106-0735 g01429733
Illustration 224
S/N: 01X1-Up
Typical example
Part No.: 106-0735 (2) Plug
S/N: 42X1-Up
(1) Final installation torque .. 20 ± 3 N·m (15 ± 2 lb ft)
Part No.: 106-0735
S/N: 99X1-Up
Operating voltage ......................... 4.75 to 8.50 Volts
Part No.: 106-0735
S/N: 53Y1-Up Output type .................................................... Analog
Part No.: 106-0735

S/N: 1YZ1-Up
SENR1017-04 195
i02845077 i02847523
Coolant Temperature Sensor Coolant Temperature Sensor

Part No.: 264-4297 Part No.: 130-9811
S/N: BBB1-Up S/N: 1FB1-Up
Part No.: 264-4297 Part No.: 130-9811
S/N: 2YD1-Up S/N: BBB1-Up
Part No.: 264-4297 Part No.: 130-9811
S/N: CEH1-Up S/N: 2YD1-Up
Part No.: 264-4297 Part No.: 130-9811
S/N: 6XJ1-Up S/N: CEH1-Up
Part No.: 264-4297 Part No.: 130-9811
S/N: 3KR1-Up S/N: 6XJ1-Up
Part No.: 264-4297 Part No.: 130-9811
S/N: 4FR1-Up S/N: 3KR1-Up
Part No.: 264-4297 Part No.: 130-9811
S/N: 5YR1-Up S/N: 4FR1-Up
Part No.: 264-4297 Part No.: 130-9811
S/N: 6PR1-Up S/N: 5YR1-Up
Part No.: 264-4297 Part No.: 130-9811
S/N: 6TR1-Up S/N: 6PR1-Up
Part No.: 264-4297 Part No.: 130-9811
S/N: 7KR1-Up S/N: 6TR1-Up
Part No.: 264-4297 Part No.: 130-9811
S/N: 26W1-Up S/N: 7KR1-Up
Part No.: 130-9811
S/N: 26W1-Up
g01089060
Illustration 225
(1) Final installation torque for the temperature g01391967

sensor group .................. 20 ± 3 N·m (15 ± 2 lb ft) Illustration 226
Output type ................................................... Passive (1) Final installation torque for the temperature
sensor group .................. 20 ± 5 N·m (15 ± 4 lb ft)
Operating temperature ........................ −40 to 150 °C
(−40 to 302 °F) Output type ................................................... Passive

(−40 to 302 °F)
196 SENR1017-04
i02905347 Part No.: 171-8708, 171-8710

S/N: 1JD1-Up
Coolant Temperature Sensor
Part No.: 171-8708
SMCS Code: 1906 S/N: 1JD1-Up
Part No.: 145-7028 Part No.: 171-8708
Part No.: 145-7028 Part No.: 171-8708, 171-8710
S/N: 3KR1-Up S/N: 2YD1-Up
Part No.: 171-8708
S/N: 8YG1-Up
Part No.: 171-8708
S/N: CEH1-Up
Part No.: 171-8708
S/N: 3BJ1-Up
Part No.: 171-8708, 171-8710
S/N: 6XJ1-Up
Part No.: 171-8708
S/N: 7MJ1-Up
g01446063 Part No.: 171-8708, 171-8710, 171-8711

Illustration 227
S/N: 7XJ1-Up
(1) Final installation torque for the temperature Part No.: 171-8708
sensor group ................... 6 ± 1 N·m (55 ± 9 lb in) S/N: 7XJ1-Up
Output type ................................................... Passive Part No.: 171-8708

S/N: NBJ1-Up
(−40 to 302 °F) Part No.: 171-8708
S/N: 3SK1-Up
i03076541 Part No.: 171-8708

S/N: 3TK1-Up
Coolant Flow Switch Part No.: 171-8708
Part No.: 171-8708 Part No.: 171-8708

Part No.: 171-8708 Part No.: 171-8708, 171-8710

Part No.: 171-8708 Part No.: 171-8708

Part No.: 171-8708, 171-8710 Part No.: 171-8708

Part No.: 171-8708, 171-8710, 171-8711 Part No.: 171-8708

Part No.: 171-8708, 171-8710 Part No.: 171-8708

Part No.: 171-8708 Part No.: 171-8708, 171-8710

Part No.: 171-8708 Part No.: 171-8708

SENR1017-04 197
Part No.: 171-8708 Part No.: 171-8708

Part No.: 171-8708, 171-8710 Part No.: 171-8708, 171-8710
Part No.: 171-8708 Part No.: 171-8708
Part No.: 171-8708 Part No.: 171-8708
Part No.: 171-8708 Part No.: 171-8708
Part No.: 171-8708 Part No.: 171-8708
Part No.: 171-8708 Part No.: 171-8708
Part No.: 171-8708 Part No.: 171-8708
Part No.: 171-8708 Part No.: 171-8708, 171-8710
Part No.: 171-8708 Part No.: 171-8708
Part No.: 171-8708 Part No.: 171-8708
Part No.: 171-8708 Part No.: 171-8708, 171-8710
Part No.: 171-8708 Part No.: 171-8708
Part No.: 171-8708, 171-8710 Part No.: 171-8708
Part No.: 171-8708 Part No.: 171-8708
Part No.: 171-8708 Part No.: 171-8708
Part No.: 171-8708 Part No.: 171-8708
Part No.: 171-8708 Part No.: 171-8708
Part No.: 171-8708 Part No.: 171-8708
Part No.: 171-8708 Part No.: 171-8708, 171-8710
Part No.: 171-8708 Part No.: 171-8708, 171-8710
Part No.: 171-8708 Part No.: 171-8708, 171-8710
Part No.: 171-8708 Part No.: 171-8708
198 SENR1017-04
Part No.: 171-8708 Part No.: 171-8708

Part No.: 171-8708, 171-8710, 171-8711 Part No.: 171-8708
Part No.: 171-8708
S/N: 64W1-Up
Part No.: 171-8708
S/N: BLW1-Up
Part No.: 171-8708
S/N: 01X1-Up
Part No.: 171-8708, 171-8710
S/N: 01X1-Up
Part No.: 171-8708
S/N: 01X1-Up
Part No.: 171-8708 g01560115
Illustration 228
S/N: 42X1-Up
Typical example
Part No.: 171-8708, 171-8710
S/N: 99X1-Up Note: Test the flow switch with the paddle in the
vertical position and the force (1) on the rivet head
Part No.: 171-8708, 171-8710 (2).
S/N: 53Y1-Up
Part No.: 171-8708 Actuation force ................................. 0.362 ± 0.029 N
(0.0814 ± 0.0065 lb)
S/N: 1YZ1-Up
Part No.: 171-8708 Minimum deactuation force ........ 0.303 N (0.0681 lb)
S/N: 1ZZ1-Up
Part No.: 171-8708 (−40 to 250 °F)
S/N: 2KZ1-Up
Contact position ................................. Normally open
Part No.: 171-8708
S/N: 49Z1-Up Note: When the switch is installed in the engine
Part No.: 171-8708 cooling system, there is not enough force from the
S/N: 86Z1-Up flow of coolant at engine cranking speed in order to
activate the switch. When the engine is running at
Part No.: 171-8708 low idle, the flow of coolant has enough force in order
S/N: 86Z1-Up to activate the switch.
Part No.: 171-8708

S/N: 87Z1-Up i01670593
Part No.: 171-8708 Jacket Water Heater

S/N: 87Z1-Up
SMCS Code: 1383
Part No.: 171-8708
S/N: 89Z1-Up Part No.: 6T-3764
S/N: AAA1-Up
Part No.: 171-8708
S/N: BCA1-Up
Part No.: 171-8708
S/N: BDA1-Up
Part No.: 171-8708
S/N: 1FB1-Up
Part No.: 171-8708
S/N: BBB1-Up
SENR1017-04 199

S/N: BEC1-Up S/N: 6KR1-Up
Part No.: 6T-3764, 9X-1292 Part No.: 6T-3764
S/N: 2YD1-Up S/N: 7BR1-Up
S/N: 6XJ1-Up S/N: 7ER1-Up
S/N: NBJ1-Up S/N: BCR1-Up
S/N: 7KK1-Up S/N: 6YS1-Up
S/N: AAK1-Up S/N: 7CS1-Up
S/N: ABK1-Up S/N: 8AS1-Up
S/N: ASK1-Up S/N: AAT1-Up
S/N: 7TL1-Up S/N: AKT1-Up
S/N: 8BL1-Up S/N: 2KZ1-Up
Part No.: 6T-3764
S/N: 8BL1-Up
Part No.: 6T-3764
S/N: ACL1-Up
Part No.: 6T-3764
S/N: BBN1-Up
Part No.: 6T-3764
S/N: 2ZR1-Up
Part No.: 6T-3764
S/N: 3KR1-Up
Part No.: 6T-3764 g00117937
Illustration 229
S/N: 3KR1-Up
Part No.: 6T-3764 Power ...................................................... 1500 Watts
S/N: 4FR1-Up
Voltage ............................................................. 240 V
Part No.: 6T-3764
S/N: 5TR1-Up Current ......................................................... 6.3 Amp
Part No.: 6T-3764
S/N: 5YR1-Up i01668452
Part No.: 6T-3764 Jacket Water Heater

S/N: 6JR1-Up
SMCS Code: 1383
200 SENR1017-04

S/N: BCA1-Up S/N: 3KR1-Up
S/N: BDA1-Up S/N: 4FR1-Up
S/N: 1NB1-Up S/N: 4YR1-Up
S/N: BBB1-Up S/N: 5HR1-Up
S/N: BEC1-Up S/N: 5TR1-Up
S/N: 1JD1-Up S/N: 5XR1-Up
S/N: 6XJ1-Up S/N: 6JR1-Up
S/N: 3SK1-Up S/N: 6PR1-Up
S/N: 7KK1-Up S/N: 6TR1-Up
S/N: ABK1-Up S/N: 6TR1-Up
S/N: ASK1-Up S/N: 7BR1-Up
S/N: AWK1-Up S/N: 7ER1-Up
S/N: 7TL1-Up S/N: 7FR1-Up
S/N: ACL1-Up S/N: 7KR1-Up
SENR1017-04 201
Part No.: 9G-6655

S/N: 2PS1-Up
Part No.: 9G-6655
S/N: 5SS1-Up
Part No.: 9G-6655
S/N: 6YS1-Up
Part No.: 9G-6655
S/N: 7CS1-Up
Part No.: 9G-6655
S/N: 8AS1-Up
Part No.: 9G-6655
g00117937
S/N: AKT1-Up Illustration 230
Part No.: 9G-6655 Power ...................................................... 1500 Watts

S/N: AXT1-Up
Part No.: 9G-6655 Voltage ............................................................. 120 V
S/N: 24W1-Up
Current ....................................................... 12.5 Amp
Part No.: 9G-6655
S/N: 25W1-Up
i02877832
Part No.: 9G-6655
S/N: 26W1-Up
Fuel Temperature Sensor
Part No.: 9G-6655 SMCS Code: 1922
S/N: 63W1-Up
Part No.: 102-2240
Part No.: 9G-6655 S/N: AAA1-Up
S/N: 64W1-Up
Part No.: 102-2240
Part No.: 9G-6655 S/N: BCA1-Up
S/N: 01X1-Up
Part No.: 102-2240
Part No.: 9G-6655 S/N: BDA1-Up
S/N: 99X1-Up
Part No.: 102-2240
Part No.: 9G-6655 S/N: 1AB1-Up
S/N: 53Y1-Up
Part No.: 102-2240
Part No.: 9G-6655 S/N: 1FB1-Up
S/N: 86Z1-Up
Part No.: 102-2240
Part No.: 9G-6655 S/N: 1NB1-Up
S/N: 86Z1-Up
Part No.: 102-2240
Part No.: 9G-6655 S/N: BBB1-Up
S/N: 87Z1-Up
Part No.: 102-2240
Part No.: 9G-6655 S/N: BEC1-Up
S/N: 87Z1-Up
Part No.: 102-2240
Part No.: 9G-6655 S/N: 1JD1-Up
S/N: 90Z1-Up
Part No.: 102-2240
Part No.: 9G-6655 S/N: 2YD1-Up
S/N: 90Z1-Up
Part No.: 102-2240
Part No.: 9G-6655 S/N: 2YD1-Up
S/N: 91Z1-Up
Part No.: 102-2240
Part No.: 9G-6655 S/N: 8YG1-Up
S/N: 91Z1-Up
202 SENR1017-04
Part No.: 102-2240 Part No.: 102-2240

S/N: CEH1-Up S/N: 2ZR1-Up
Part No.: 102-2240 Part No.: 102-2240
S/N: 3BJ1-Up S/N: 3KR1-Up
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
S/N: 7MJ1-Up S/N: 4YR1-Up
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
S/N: 3SK1-Up S/N: 5HR1-Up
Part No.: 102-2240 Part No.: 102-2240
S/N: 67K1-Up S/N: 5TR1-Up
Part No.: 102-2240 Part No.: 102-2240
S/N: 7HK1-Up S/N: 5YR1-Up
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
S/N: AAK1-Up S/N: 6JR1-Up
Part No.: 102-2240 Part No.: 102-2240
S/N: ABK1-Up S/N: 6KR1-Up
Part No.: 102-2240 Part No.: 102-2240
S/N: ASK1-Up S/N: 6PR1-Up
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
S/N: 8BL1-Up S/N: 7ER1-Up
Part No.: 102-2240 Part No.: 102-2240
S/N: ACL1-Up S/N: 7FR1-Up
Part No.: 102-2240 Part No.: 102-2240
S/N: 7GN1-Up S/N: 7KR1-Up
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
SENR1017-04 203
Part No.: 102-2240 Part No.: 102-2240

Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
S/N: 5SS1-Up S/N: 53Y1-Up
Part No.: 102-2240 Part No.: 102-2240
S/N: 6YS1-Up S/N: 1YZ1-Up
Part No.: 102-2240 Part No.: 102-2240
S/N: 7CS1-Up S/N: 1ZZ1-Up
Part No.: 102-2240 Part No.: 102-2240
S/N: 8AS1-Up S/N: 2KZ1-Up
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240 Part No.: 102-2240
Part No.: 102-2240
S/N: 26W1-Up
Part No.: 102-2240
S/N: 50W1-Up
Part No.: 102-2240
S/N: 63W1-Up
Part No.: 102-2240
S/N: 63W1-Up
Part No.: 102-2240
S/N: 64W1-Up
Part No.: 102-2240 g01432247
Illustration 231
S/N: BLW1-Up
(2) Receptacle
Part No.: 102-2240
S/N: 01X1-Up (1) Sensor assembly
Part No.: 102-2240 Tighten the sensor assembly to the following
S/N: 01X1-Up torque. ........................... 20 ± 3 N·m (15 ± 2 lb ft)
Part No.: 102-2240
S/N: 01X1-Up
204 SENR1017-04
i03163504 i02845081
Fuel Temperature Sensor Fuel Temperature Sensor

Part No.: 130-9811 Part No.: 264-4297
S/N: 1FB1-Up S/N: 1FB1-Up
Part No.: 130-9811 Part No.: 264-4297
S/N: BBB1-Up S/N: BBB1-Up
Part No.: 130-9811 Part No.: 264-4297
Part No.: 130-9811 Part No.: 264-4297
S/N: CEH1-Up S/N: CEH1-Up
Part No.: 130-9811 Part No.: 264-4297
S/N: 6XJ1-Up S/N: 6XJ1-Up
Part No.: 130-9811 Part No.: 264-4297
S/N: 3KR1-Up S/N: 4FR1-Up
Part No.: 130-9811 Part No.: 264-4297
S/N: 4FR1-Up S/N: 5YR1-Up
Part No.: 130-9811 Part No.: 264-4297
S/N: 5YR1-Up S/N: 6PR1-Up
Part No.: 130-9811 Part No.: 264-4297
S/N: 6PR1-Up S/N: 6TR1-Up
Part No.: 130-9811 Part No.: 264-4297
S/N: 6TR1-Up S/N: 7KR1-Up
Part No.: 130-9811 Part No.: 264-4297
Part No.: 130-9811
S/N: 26W1-Up
g01089060
Illustration 233
g01391967
(1) Final installation torque for the temperature
Illustration 232 sensor group .................. 20 ± 3 N·m (15 ± 2 lb ft)
(1) Final installation torque for the temperature Output type ................................................... Passive
sensor ............................ 20 ± 5 N·m (15 ± 4 lb ft)
Output type ................................................... Passive (−40 to 302 °F)
(−40 to 302 °F)
SENR1017-04 205
i03250162 i02911292
Fuel Temperature Sensor Fuel Temperature Sensor

Part No.: 191-6587 Part No.: 145-7028
S/N: CEH1-Up S/N: 2YD1-Up
Part No.: 145-7028
S/N: 2YD1-Up
Part No.: 145-7028
S/N: 3KR1-Up
Part No.: 145-7028
S/N: 3KR1-Up
g01125504
Illustration 234
(2) Connector plug assembly

Output type ................................................... Passive

g01448886
Operating temperature ........................ −50 to 150 °C Illustration 235
(−58 to 302 °F)
sensor group ................... 6 ± 1 N·m (55 ± 9 lb in)

(−40 to 302 °F)
i03250121
Injection Actuation Pressure

Sensor
SMCS Code: 1925
Part No.: 194-6722, 194-6724, 194-6725
S/N: AAA1-Up
Part No.: 194-6722, 194-6724, 194-6725
S/N: BCA1-Up
Part No.: 194-6722, 194-6724, 194-6725
S/N: BDA1-Up
Part No.: 194-6722, 194-6724, 194-6725
S/N: 1AB1-Up
Part No.: 194-6722, 194-6724, 194-6725
S/N: 1FB1-Up
206 SENR1017-04
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6724
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722
Part No.: 194-6722 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722 Part No.: 194-6722
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722 Part No.: 194-6722
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722
Part No.: 194-6722 Part No.: 194-6722
Part No.: 194-6722 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
SENR1017-04 207
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722 Part No.: 194-6722
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722
208 SENR1017-04
Part No.: 194-6722 Part No.: 194-6722, 194-6724, 194-6725

Part No.: 194-6722 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722 Part No.: 194-6725
Part No.: 194-6722 Part No.: 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
S/N: BKZ1-Up S/N: 2YD1-Up
Part No.: 194-6725
S/N: 8YG1-Up
Part No.: 194-6722, 194-6724, 194-6725
S/N: CEH1-Up
Part No.: 194-6725
S/N: 3BJ1-Up
Part No.: 194-6722, 194-6724, 194-6725
S/N: 6XJ1-Up
Part No.: 194-6725
S/N: 7MJ1-Up
g01068621 Part No.: 194-6722, 194-6724, 194-6725

Illustration 236
S/N: 7XJ1-Up
(1) Final installation torque for the pressure sensor Part No.: 194-6725
group .......................... 10 ± 2 N·m (90 ± 18 lb in) S/N: 7XJ1-Up
Operating temperature ........................ −40 to 125 °C Part No.: 194-6722, 194-6724, 194-6725
(−40 to 257 °F) S/N: NBJ1-Up
Operating voltage ........................... 5.00 ± 0.25 VDC Part No.: 194-6725

S/N: 3SK1-Up
i02845092 Part No.: 194-6725

S/N: 3TK1-Up
Engine Oil Pressure Sensor Part No.: 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6725

Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6725 Part No.: 194-6722, 194-6724, 194-6725

SENR1017-04 209
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6725

Part No.: 194-6725 Part No.: 194-6725
Part No.: 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
210 SENR1017-04
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6725

Part No.: 194-6725 Part No.: 194-6725
Part No.: 194-6725 Part No.: 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6724, 194-6725
Part No.: 194-6725
S/N: 64W1-Up
Part No.: 194-6724, 194-6725
S/N: BLW1-Up
Part No.: 194-6722, 194-6724, 194-6725
S/N: 01X1-Up
Part No.: 194-6725
S/N: 01X1-Up
Part No.: 194-6725
S/N: 01X1-Up
Part No.: 194-6725 g01068621
Illustration 237
S/N: 42X1-Up
Part No.: 194-6722, 194-6724, 194-6725 (1) Final installation torque for the pressure sensor
S/N: 99X1-Up group .......................... 10 ± 2 N·m (90 ± 18 lb in)
Part No.: 194-6722, 194-6724, 194-6725 Operating temperature ........................ −40 to 125 °C
S/N: 53Y1-Up (−40 to 257 °F)
Part No.: 194-6724, 194-6725 Operating voltage ........................... 5.00 ± 0.25 VDC
S/N: 1YZ1-Up
Part No.: 194-6724, 194-6725 i02030238
S/N: 1ZZ1-Up
Part No.: 194-6722, 194-6724, 194-6725
Engine Oil Pressure Sensor
S/N: 2KZ1-Up SMCS Code: 1924
Part No.: 194-6725 Part No.: 103-6092
S/N: 49Z1-Up S/N: AAA1-Up
Part No.: 194-6725 Part No.: 103-6092
S/N: 86Z1-Up S/N: BCA1-Up
Part No.: 194-6725 Part No.: 103-6092
Part No.: 194-6725 Part No.: 103-6092
Part No.: 194-6725 Part No.: 103-6092
Part No.: 194-6725 Part No.: 103-6092
Part No.: 194-6725 Part No.: 103-6092
SENR1017-04 211
Part No.: 103-6092 Part No.: 103-6092

S/N: BEC1-Up S/N: 5HR1-Up
Part No.: 103-6092 Part No.: 103-6092
Part No.: 103-6092 Part No.: 103-6092
Part No.: 103-6092 Part No.: 103-6092
S/N: CEH1-Up S/N: 6JR1-Up
Part No.: 103-6092 Part No.: 103-6092
Part No.: 103-6092 Part No.: 103-6092
Part No.: 103-6092 Part No.: 103-6092
Part No.: 103-6092 Part No.: 103-6092
S/N: 3TK1-Up S/N: 7BR1-Up
Part No.: 103-6092 Part No.: 103-6092
S/N: 7KK1-Up S/N: 7ER1-Up
Part No.: 103-6092 Part No.: 103-6092
S/N: ABK1-Up S/N: 7FR1-Up
Part No.: 103-6092 Part No.: 103-6092
Part No.: 103-6092 Part No.: 103-6092
S/N: AWK1-Up S/N: BCR1-Up
Part No.: 103-6092 Part No.: 103-6092
S/N: 7TL1-Up S/N: CLR1-Up
Part No.: 103-6092 Part No.: 103-6092
Part No.: 103-6092 Part No.: 103-6092
Part No.: 103-6092 Part No.: 103-6092
S/N: ACL1-Up S/N: 6YS1-Up
Part No.: 103-6092 Part No.: 103-6092
Part No.: 103-6092 Part No.: 103-6092
Part No.: 103-6092 Part No.: 103-6092
S/N: BBN1-Up S/N: 8GS1-Up
Part No.: 103-6092 Part No.: 103-6092
S/N: 2ZR1-Up S/N: 9XS1-Up
Part No.: 103-6092 Part No.: 103-6092
S/N: 3KR1-Up S/N: 9YS1-Up
Part No.: 103-6092 Part No.: 103-6092
Part No.: 103-6092 Part No.: 103-6092
212 SENR1017-04
Part No.: 103-6092 Operating temperature ........................ −40 to 125 °C

S/N: AXT1-Up (−40 to 257 °F)
Part No.: 103-6092 Maximum input pressure (absolute
S/N: 24W1-Up pressure) ..................................... 1135 kPa (165 psi)
Part No.: 103-6092
Input supply voltage ............................. 5 ± 0.25 VDC
S/N: 25W1-Up
Part No.: 103-6092 Maximum supply current ................................. 20 mA
S/N: 26W1-Up
Install the sensor so that the pressure port is lower
Part No.: 103-6092 than the wire end. Mount the sensor as close to
S/N: 63W1-Up vertical as possible.
Part No.: 103-6092
S/N: 64W1-Up
Part No.: 103-6092
S/N: BLW1-Up
Part No.: 103-6092
S/N: 01X1-Up
Part No.: 103-6092
S/N: 99X1-Up
Part No.: 103-6092
S/N: 53Y1-Up
Part No.: 103-6092
S/N: 1YZ1-Up
Part No.: 103-6092
S/N: 1ZZ1-Up
Part No.: 103-6092
S/N: 2KZ1-Up
Part No.: 103-6092
S/N: BKZ1-Up
g01046769
Illustration 238
Typical example
(1) Sensor assembly
(2) Plug with socket A, socket B, and socket C
(3) Port fitting

Torque ........................ 10 ± 2 N·m (90 ± 18 lb in)
SENR1017-04 213
i02935129 i02704601
Engine Oil Temperature Sensor Engine Oil Temperature Sensor

Part No.: 264-4297 Part No.: 130-9811
Part No.: 264-4297 Part No.: 130-9811
Part No.: 264-4297 Part No.: 130-9811
Part No.: 264-4297 Part No.: 130-9811
S/N: CEH1-Up S/N: CEH1-Up
Part No.: 264-4297 Part No.: 130-9811
S/N: 6XJ1-Up S/N: 6XJ1-Up
Part No.: 264-4297 Part No.: 130-9811
S/N: 4FR1-Up S/N: 3KR1-Up
Part No.: 264-4297 Part No.: 130-9811
S/N: 5YR1-Up S/N: 4FR1-Up
Part No.: 264-4297 Part No.: 130-9811
S/N: 6PR1-Up S/N: 5YR1-Up
Part No.: 264-4297 Part No.: 130-9811
S/N: 6TR1-Up S/N: 6PR1-Up
Part No.: 264-4297 Part No.: 130-9811
S/N: 7KR1-Up S/N: 6TR1-Up
Part No.: 264-4297 Part No.: 130-9811
S/N: 26W1-Up S/N: 7KR1-Up
Part No.: 130-9811
S/N: 26W1-Up
g01089060
Illustration 239
(1) Final installation torque for the temperature g00294228

sensor group .................. 20 ± 3 N·m (15 ± 2 lb ft) Illustration 240
Output type ................................................... Passive (1) Final installation torque for temperature
sensor ............................ 20 ± 5 N·m (15 ± 4 lb ft)
(−40 to 302 °F) Operating voltage ..................................... 5 ± 0.25 V

214 SENR1017-04
i02847502 Part No.: 102-2240

S/N: 8BL1-Up
Engine Oil Temperature Sensor
Part No.: 102-2240
SMCS Code: 1929 S/N: 4YR1-Up
Part No.: 191-6587 Part No.: 102-2240
Part No.: 102-2240
S/N: 4YR1-Up
Part No.: 102-2240
S/N: 5YR1-Up
Part No.: 102-2240
S/N: 6PR1-Up
Part No.: 102-2240
S/N: 6TR1-Up
Part No.: 102-2240
S/N: 7KR1-Up
g01125504 Part No.: 102-2240

Illustration 241
S/N: 8GS1-Up
(2) Connector plug assembly
Part No.: 102-2240
(1) Final installation torque for the temperature S/N: 50W1-Up
Part No.: 102-2240
Output type ................................................... Passive S/N: 63W1-Up
Part No.: 102-2240
S/N: 64W1-Up
(−58 to 302 °F)
Part No.: 102-2240
S/N: 01X1-Up
i03129524
Part No.: 102-2240

Engine Oil Temperature Sensor S/N: 01X1-Up
S/N: 42X1-Up
Part No.: 102-2240
S/N: 2YD1-Up Part No.: 102-2240
S/N: 49Z1-Up
Part No.: 102-2240
S/N: 8YG1-Up Part No.: 102-2240
S/N: 89Z1-Up
Part No.: 102-2240
S/N: 3BJ1-Up Part No.: 102-2240
S/N: 89Z1-Up
Part No.: 102-2240
S/N: 7MJ1-Up Part No.: 102-2240
S/N: 90Z1-Up
Part No.: 102-2240
S/N: 7XJ1-Up Part No.: 102-2240
S/N: 90Z1-Up
Part No.: 102-2240
S/N: 3SK1-Up Part No.: 102-2240
S/N: 91Z1-Up
Part No.: 102-2240
S/N: 67K1-Up Part No.: 102-2240
S/N: 91Z1-Up
Part No.: 102-2240
S/N: 7HK1-Up
SENR1017-04 215
i02992049
Engine Oil Temperature Sensor

(If Equipped)
SMCS Code: 1929
Part No.: 134-2252
S/N: ABK1-Up
Part No.: 134-2252
S/N: 7TL1-Up
Part No.: 134-2252
S/N: 7TL1-Up
g01445314
Illustration 242
Part No.: 134-2252
S/N: 8BL1-Up
sensor group .................. 20 ± 3 N·m (15 ± 2 lb ft) Part No.: 134-2252
S/N: 8BL1-Up
(−40 to 248 °F) Part No.: 134-2252
S/N: ACL1-Up
Operating voltage .......................... 4.75 to 8.50 VDC
Part No.: 134-2252
Output type .................................................... Analog S/N: 3KR1-Up
Part No.: 134-2252
i02841021 S/N: 3KR1-Up
Engine Oil Temperature Sensor Part No.: 134-2252

S/N: AKT1-Up
SMCS Code: 1929
Part No.: 145-7028
S/N: 2YD1-Up
Part No.: 145-7028
S/N: 3KR1-Up
g01258081 g01516494
(1) Final installation torque for the temperature (1) Final installation torque for the temperature
sensor group ................... 6 ± 1 N·m (55 ± 9 lb in) sensor group .................. 20 ± 3 N·m (15 ± 2 lb ft)
Output type ................................................... Passive Operating temperature ........................ −40 to 120 °C

(−40 to 248 °F)
(−40 to 302 °F) Output type ...................................................... PWM
i02845102
Atmospheric Pressure Sensor

SMCS Code: 1923
216 SENR1017-04
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 161-9925

Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6724
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 161-9925
Part No.: 161-9925 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6724 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 161-9925 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 161-9925 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 161-9925 Part No.: 161-9925
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 161-9925 Part No.: 161-9925
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 161-9925
Part No.: 194-6724 Part No.: 161-9925
Part No.: 194-6724 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 161-9925 Part No.: 194-6722, 194-6724, 194-6725
SENR1017-04 217
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
S/N: 5TR1-Up S/N: AAT1-Up
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 161-9925 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 161-9925 Part No.: 194-6724
Part No.: 161-9925 Part No.: 161-9925
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 161-9925
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 161-9925 Part No.: 161-9925
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 161-9925
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 161-9925
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6724, 194-6725
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 194-6724, 194-6725
Part No.: 161-9925 Part No.: 194-6722, 194-6724, 194-6725
Part No.: 194-6724, 194-6725 Part No.: 161-9925
Part No.: 194-6722, 194-6724, 194-6725 Part No.: 161-9925
218 SENR1017-04
Part No.: 161-9925 Part No.: 107-8618

Part No.: 161-9925 Part No.: 107-8618
Part No.: 161-9925 Part No.: 107-8618
Part No.: 161-9925 Part No.: 107-8618
Part No.: 194-6724 Part No.: 107-8618
Part No.: 161-9925 Part No.: 107-8618
Part No.: 161-9925 Part No.: 107-8618
Part No.: 161-9925 Part No.: 107-8618
Part No.: 161-9925 Part No.: 107-8618
Part No.: 194-6724, 194-6725 Part No.: 107-8618
S/N: BKZ1-Up S/N: AAK1-Up
Part No.: 107-8618
S/N: ABK1-Up
Part No.: 107-8618
S/N: ASK1-Up
Part No.: 107-8618
S/N: AWK1-Up
Part No.: 107-8618
S/N: 7TL1-Up
Part No.: 107-8618
S/N: 8BL1-Up
g01392045 Part No.: 107-8618

Illustration 245
S/N: ACL1-Up
(1) Final installation torque for the pressure sensor Part No.: 107-8618
group .......................... 10 ± 2 N·m (90 ± 18 lb in) S/N: 7GN1-Up
Operating voltage ........................... 5.00 ± 0.25 VDC Part No.: 107-8618

S/N: 8HN1-Up
(−40 to 257 °F) Part No.: 107-8618
S/N: BBN1-Up
i03267361 Part No.: 107-8618

S/N: 2ZR1-Up
Inlet Air Temperature Sensor Part No.: 107-8618
SMCS Code: 1921 S/N: 3KR1-Up
Part No.: 107-8618 Part No.: 107-8618

S/N: AAA1-Up S/N: 4FR1-Up
Part No.: 107-8618 Part No.: 107-8618

S/N: BCA1-Up S/N: 7ER1-Up
SENR1017-04 219
Part No.: 107-8618 (1) Final installation torque for the temperature
S/N: BCR1-Up sensor group .................. 15 ± 3 N·m (11 ± 2 lb ft)
Part No.: 107-8618 Operating voltage .......................... 4.75 to 8.50 VDC
S/N: CLR1-Up
Part No.: 107-8618
(−40 to 248 °F)
S/N: 2PS1-Up
Part No.: 107-8618
i02851357
S/N: 7CS1-Up
Part No.: 107-8618
Inlet Air Temperature Sensor
S/N: 8AS1-Up
SMCS Code: 1921
Part No.: 107-8618
Part No.: 130-9811
S/N: AAT1-Up
S/N: 1FB1-Up
Part No.: 107-8618
Part No.: 130-9811
S/N: AKT1-Up
S/N: BBB1-Up
Part No.: 107-8618
Part No.: 130-9811
S/N: AXT1-Up
S/N: 2YD1-Up
Part No.: 107-8618
Part No.: 130-9811
S/N: 24W1-Up
S/N: CEH1-Up
Part No.: 107-8618
Part No.: 130-9811
S/N: 25W1-Up
S/N: 6XJ1-Up
Part No.: 107-8618
Part No.: 130-9811
S/N: 26W1-Up
S/N: 3KR1-Up
Part No.: 107-8618
Part No.: 130-9811
S/N: 63W1-Up
S/N: 4FR1-Up
Part No.: 107-8618
Part No.: 130-9811
S/N: 64W1-Up
S/N: 5YR1-Up
Part No.: 107-8618
Part No.: 130-9811
S/N: 01X1-Up
S/N: 6PR1-Up
Part No.: 107-8618
Part No.: 130-9811
S/N: 99X1-Up
S/N: 6TR1-Up
Part No.: 107-8618
Part No.: 130-9811
S/N: 53Y1-Up
S/N: 7KR1-Up
Part No.: 107-8618
Part No.: 130-9811
S/N: 2KZ1-Up
S/N: 26W1-Up
g01665855
Illustration 246 g01089060
Illustration 247
220 SENR1017-04
(1) Final installation torque for the temperature (1) Final installation torque for temperature sensor
sensor group .................. 20 ± 5 N·m (15 ± 4 lb ft) group ............................. 20 ± 3 N·m (15 ± 2 lb ft)
Output type ................................................... Passive Output type ................................................... Passive
Operating temperature ........................ −40 to 150 °C Operating temperature ........................ −40 to 150 °C
(−40 to 302 °F) (−40 to 302 °F)
i02847505 i02993681
Inlet Air Temperature Sensor Inlet Air Temperature Sensor

Part No.: 264-4297 Part No.: 264-4297
Part No.: 264-4297 Part No.: 264-4297
Part No.: 264-4297 Part No.: 264-4297
S/N: 2YD1-Up S/N: CEH1-Up
Part No.: 264-4297 Part No.: 264-4297
S/N: CEH1-Up S/N: 6XJ1-Up
Part No.: 264-4297 Part No.: 264-4297
Part No.: 264-4297 Part No.: 264-4297
S/N: 3KR1-Up S/N: 4FR1-Up
Part No.: 264-4297 Part No.: 264-4297
S/N: 4FR1-Up S/N: 5YR1-Up
Part No.: 264-4297 Part No.: 264-4297
S/N: 5YR1-Up S/N: 6PR1-Up
Part No.: 264-4297 Part No.: 264-4297
S/N: 6PR1-Up S/N: 7KR1-Up
Part No.: 264-4297
S/N: 6TR1-Up
Part No.: 264-4297
S/N: 7KR1-Up
Part No.: 264-4297
S/N: 26W1-Up
g01068415
Illustration 249

Operating temperature ......................... −40 to 150°C

Illustration 248
g01089060 (−40 to 302 °F)
SENR1017-04 221
i03250163 Output type ................................................... Passive

Inlet Air Temperature Sensor Operating temperature ........................ −40 to 150 °C
(−40 to 302 °F)
SMCS Code: 1921
Part No.: 191-6587 i02847453
S/N: CEH1-Up
Turbocharger Outlet Pressure
Sensor
SMCS Code: 1917
Part No.: 161-9926, 194-6722, 194-6724,
194-6725
S/N: AAA1-Up
Part No.: 161-9926, 194-6722, 194-6724,
194-6725
S/N: BCA1-Up
Part No.: 161-9926, 194-6722, 194-6724,
194-6725
Illustration 250
g01125504 S/N: BDA1-Up
(2) Connector plug assembly Part No.: 161-9926, 194-6722, 194-6724,
194-6725
(1) Final installation torque for the temperature S/N: 1AB1-Up
Part No.: 161-9926, 194-6722, 194-6724,
Output type ................................................... Passive 194-6725
S/N: 1FB1-Up
(−58 to 302 °F) Part No.: 161-9926, 194-6722, 194-6725,
194-9924
S/N: 1NB1-Up
i02905318
Part No.: 161-9926, 194-6722, 194-6724,
Inlet Air Temperature Sensor 194-6725
S/N: BBB1-Up
SMCS Code: 1921
Part No.: 161-9926, 194-6722, 194-6724,
Part No.: 145-7028 194-6725
S/N: 2YD1-Up S/N: BEC1-Up
Part No.: 145-7028 Part No.: 161-9926, 194-6722, 194-6724,
S/N: 3KR1-Up 194-6725
S/N: 1JD1-Up
Part No.: 194-6724
S/N: 1JD1-Up
Part No.: 194-6724
S/N: 2YD1-Up
Part No.: 161-9926, 194-6722, 194-6724,
194-6725
S/N: 2YD1-Up
Part No.: 194-6724
S/N: 8YG1-Up
Part No.: 161-9926, 194-6722, 194-6724,
Illustration 251
g01446063 194-6725
S/N: CEH1-Up
sensor group ................... 6 ± 1 N·m (55 ± 9 lb in)
222 SENR1017-04
Part No.: 194-6724 Part No.: 161-9926, 194-6722, 194-6724,

S/N: 3BJ1-Up 194-6725
S/N: ACL1-Up
Part No.: 161-9926, 194-6722, 194-6724,
194-6725 Part No.: 161-9926, 194-6722, 194-6724,
S/N: 6XJ1-Up 194-6725
S/N: 7GN1-Up
Part No.: 194-6724
S/N: 7MJ1-Up Part No.: 161-9926, 194-6722, 194-6724,
194-6725
Part No.: 161-9926, 194-6722, 194-6724, S/N: 8HN1-Up
194-6725
S/N: 7XJ1-Up Part No.: 161-9926, 194-6722, 194-6724,
194-6725
Part No.: 194-6724 S/N: BBN1-Up
S/N: 7XJ1-Up
Part No.: 161-9926, 194-6722, 194-6724,
Part No.: 161-9926, 194-6722, 194-6724, 194-6725
194-6725 S/N: 2ZR1-Up
S/N: NBJ1-Up
Part No.: 161-9926, 194-6722, 194-6724,
Part No.: 194-6724 194-6725
S/N: 3SK1-Up S/N: 3KR1-Up
Part No.: 194-6724 Part No.: 194-6724
S/N: 3TK1-Up S/N: 3KR1-Up
Part No.: 161-9926 Part No.: 161-9926, 194-6722, 194-6724,
S/N: 67K1-Up 194-6725
S/N: 4FR1-Up
Part No.: 194-6724
S/N: 7HK1-Up Part No.: 194-6724
S/N: 4YR1-Up
Part No.: 161-9926, 194-6722, 194-6724,
194-6725 Part No.: 194-6724
Part No.: 161-9926, 194-6722, 194-6724, Part No.: 194-6724
194-6725 S/N: 4YR1-Up
S/N: AAK1-Up
Part No.: 161-9926, 194-6722, 194-6724,
Part No.: 161-9926, 194-6722, 194-6724, 194-6725
194-6725 S/N: 4YR1-Up
S/N: ABK1-Up
Part No.: 161-9926, 194-6722, 194-6724,
Part No.: 161-9926, 194-6722, 194-6724, 194-6725
194-6725 S/N: 5HR1-Up
S/N: ASK1-Up
Part No.: 161-9926, 194-6722, 194-6724,
Part No.: 194-6722, 194-6724, 194-6725 194-6725
S/N: AWK1-Up S/N: 5TR1-Up
Part No.: 161-9926, 194-6722, 194-6723, Part No.: 161-9926, 194-6722, 194-6724,
194-6725 194-6725
S/N: 7TL1-Up S/N: 5YR1-Up
Part No.: 194-6724 Part No.: 194-6724
S/N: 7TL1-Up S/N: 5YR1-Up
Part No.: 161-9926 Part No.: 161-9926, 194-6722, 194-6724,
S/N: 8BL1-Up 194-6725
Part No.: 161-9926, 194-6722, 194-6724, S/N: 6JR1-Up
194-6725 Part No.: 161-9926, 194-6722, 194-6724,
S/N: 8BL1-Up 194-6725
S/N: 6KR1-Up
SENR1017-04 223
Part No.: 161-9926, 194-6722, 194-6724, Part No.: 161-9926, 194-6722, 194-6724,
194-6725 194-6725
S/N: 6PR1-Up S/N: AAT1-Up
Part No.: 194-6724 Part No.: 161-9926, 194-6722, 194-6724,
S/N: 6PR1-Up 194-6725
S/N: AKT1-Up
Part No.: 194-6724
S/N: 6TR1-Up Part No.: 161-9926, 194-6722, 194-6724,
194-6725
Part No.: 161-9926, 194-6722, 194-6724, S/N: AXT1-Up
194-6725
S/N: 6TR1-Up Part No.: 161-9926, 194-6722, 194-6724,
194-6725
Part No.: 161-9926, 194-6722, 194-6724, S/N: 24W1-Up
194-6725
S/N: 7BR1-Up Part No.: 161-9926, 194-6722, 194-6724,
194-6725
Part No.: 161-9926, 194-6722, 194-6724, S/N: 25W1-Up
194-6725
S/N: 7ER1-Up Part No.: 161-9926, 194-6722, 194-6724,
194-6725
Part No.: 161-9926, 194-6722, 194-6724, S/N: 26W1-Up
194-6725
S/N: 7FR1-Up Part No.: 194-6724
S/N: 50W1-Up
Part No.: 161-9926, 194-6722, 194-6724,
194-6725 Part No.: 194-6724
Part No.: 194-6724 Part No.: 161-9926, 194-6722, 194-6724,
S/N: 7KR1-Up 194-6725
S/N: 63W1-Up
Part No.: 194-6722, 194-6724, 194-6725
S/N: BCR1-Up Part No.: 161-9926, 194-6722, 194-6724,
194-6725
Part No.: 161-9926, 194-6722, 194-6724, S/N: 64W1-Up
194-6725
S/N: CLR1-Up Part No.: 194-6724
S/N: 64W1-Up
Part No.: 161-9926, 194-6722, 194-6724,
194-6725 Part No.: 194-6722, 194-6724, 194-6725
S/N: 2PS1-Up S/N: BLW1-Up
Part No.: 161-9926, 194-6722, 194-6724, Part No.: 161-9926
194-6725 S/N: 01X1-Up
S/N: 5SS1-Up
Part No.: 194-6724
Part No.: 161-9926, 194-6722, 194-6724, S/N: 01X1-Up
194-6725
S/N: 6YS1-Up Part No.: 194-6724
S/N: 01X1-Up
Part No.: 161-9926, 194-6722, 194-6724,
194-6725 Part No.: 194-6724
S/N: 7CS1-Up S/N: 42X1-Up
Part No.: 161-9926, 194-6722, 194-6724, Part No.: 161-9926, 194-6722, 194-6724,
194-6725 194-6725
S/N: 8AS1-Up S/N: 99X1-Up
Part No.: 194-6724 Part No.: 161-9926, 194-6722, 194-6724,

S/N: 8GS1-Up 194-6725
S/N: 53Y1-Up
Part No.: 161-9926, 194-6725
S/N: 9XS1-Up Part No.: 194-6724, 194-6725
S/N: 1YZ1-Up
Part No.: 161-9926, 194-6722, 194-6725
S/N: 9YS1-Up
224 SENR1017-04
Part No.: 194-6724, 194-6725 i03267107

S/N: 1ZZ1-Up
Speed/Timing Sensor
Part No.: 161-9926, 194-6722, 194-6724,
194-6725 SMCS Code: 1907; 1912
S/N: 2KZ1-Up
Part No.: 129-6628
Part No.: 194-6724 S/N: AAA1-Up
S/N: 49Z1-Up
Part No.: 129-6628
Part No.: 194-6724 S/N: BCA1-Up
S/N: 86Z1-Up
Part No.: 129-6628
Part No.: 194-6724 S/N: BDA1-Up
S/N: 86Z1-Up
Part No.: 129-6628
Part No.: 194-6724 S/N: 1AB1-Up
S/N: 87Z1-Up
Part No.: 129-6628
Part No.: 194-6724 S/N: 1FB1-Up
S/N: 87Z1-Up
Part No.: 129-6628
Part No.: 194-6724 S/N: 1NB1-Up
S/N: 89Z1-Up
Part No.: 129-6628
Part No.: 194-6724 S/N: BBB1-Up
S/N: 89Z1-Up
Part No.: 129-6628
Part No.: 194-6724 S/N: BEC1-Up
S/N: 90Z1-Up
Part No.: 129-6628
Part No.: 194-6724 S/N: 1JD1-Up
S/N: 90Z1-Up
Part No.: 129-6628
Part No.: 194-6724 S/N: 1JD1-Up
S/N: 91Z1-Up
Part No.: 129-6628
Part No.: 194-6724 S/N: 2YD1-Up
S/N: 91Z1-Up
Part No.: 129-6628
Part No.: 194-6724, 194-6725 S/N: 2YD1-Up
S/N: BKZ1-Up
Part No.: 129-6628
S/N: 8YG1-Up
Part No.: 129-6628
S/N: CEH1-Up
Part No.: 129-6628
S/N: 3BJ1-Up
Part No.: 129-6628
S/N: 6XJ1-Up
Part No.: 129-6628
S/N: 7MJ1-Up
Part No.: 129-6628
g01046622 S/N: 7XJ1-Up
Illustration 252
Part No.: 129-6628
(1) Final installation torque for the pressure sensor S/N: 7XJ1-Up
group .......................... 10 ± 2 N·m (90 ± 18 lb in)
Part No.: 129-6628
Operating temperature ........................ −40 to 125 °C S/N: NBJ1-Up
(−40 to 257 °F)
Part No.: 129-6628
Operating voltage ........................... 5.00 ± 0.25 VDC S/N: 3SK1-Up
SENR1017-04 225
Part No.: 129-6628 Part No.: 129-6628

Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
226 SENR1017-04
Part No.: 129-6628 Part No.: 129-6628

Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628 Part No.: 129-6628
Part No.: 129-6628
S/N: 64W1-Up
Part No.: 129-6628
S/N: BLW1-Up
Part No.: 129-6628
S/N: 01X1-Up
Part No.: 129-6628
S/N: 01X1-Up
Part No.: 129-6628
S/N: 01X1-Up
Part No.: 129-6628 g01665553
Illustration 253
S/N: 42X1-Up
Part No.: 129-6628 Note: Before assembly, apply 4C-5599 Anti-Seize
S/N: 99X1-Up Compound on the threads of the speed sensor group.
Part No.: 129-6628 (1) Final installation torque for the speed sensor
S/N: 53Y1-Up group ............................. 45 ± 5 N·m (33 ± 4 lb ft)
Part No.: 129-6628 Operating temperature ........................ −40 to 121 °C
S/N: 1YZ1-Up (−40 to 250 °F)
Part No.: 129-6628
S/N: 1ZZ1-Up Operating voltage ..................................... 12 to 14 V
Part No.: 129-6628

S/N: 2KZ1-Up
SENR1017-04 227
Index Section
Index
A Fuel Temperature Sensor ............................ 203–205
Fuel Transfer Pump................................................. 8
Aftercooler ............................................................. 62
Alternator and Regulator ............................ 165–166,
168–169, 171–172, 174–177, 179 G
114-2401 Alternator Gp ................................. 178
169-3345 Alternator Gp ................................. 178 Gear Group (Front).............................. 134, 136–138
Alternator Mounting ............................................. 182 Gear Group (Rear) .............................. 140, 143–144
Atmospheric Pressure Sensor............................. 218
H
B
Housing (Front).................................... 128, 130–132
Belt Tension Chart ............................................... 163 Hydraulic Pump Drive............................................ 19
C I
Camshaft ................................................... 70, 73–74 Important Safety Information ................................... 2

Camshaft Bearings ................................................ 77 Injection Actuation Pressure Control Valve ........... 26
Camshaft Bearing Position ................................ 77 Injection Actuation Pressure Sensor ................... 208
Connecting Rod................................................... 120 Inlet Air Temperature Sensor....................... 219–221
Connecting Rod and Main Bearing Journals ........ 119
Connecting Rod Bearing Journals ................... 120
Main Bearing Journals ..................................... 120 J
Coolant Conditioner Base...................................... 96
Coolant Flow Switch ............................................ 198 Jacket Water Heater.................................... 199, 201
Coolant Temperature Sensor....................... 194–196
Crankcase Breather............................................... 94
Crankshaft ................................................... 111, 113 M
Cylinder Block...................................... 102, 105, 108
Cylinder Head...................................... 47, 50, 52, 54 Magnetic Pickup .......................................... 191–192
Cylinder Head Valves ...................................... 43, 46
Cylinder Liner ....................................................... 110
P
E Piston and Rings ......................................... 123, 126

Intermediate Piston Ring.......................... 124, 126
Electric Starting Motor ......... 184, 186–187, 189–190 Oil Control Piston Ring..................................... 124
Engine Design ......................................................... 5 Oil Control Ring................................................ 126
3408E Engines..................................................... 5 Piston Pin......................................................... 124
3412E Engines..................................................... 5 Piston Pin Bore ................................................ 127
Engine Oil Bypass Valve ....................................... 88 Top Piston Ring........................................ 123, 126
Engine Oil Filter Base...................................... 80–82 Prelubrication Oil Pump......................................... 87
Engine Oil Filter Bypass Valve .............................. 84
Engine Oil Lines .............................................. 78–79
Engine Oil Pan................................................. 89–92 S
Engine Oil Pressure Sensor ........................ 210, 212
Engine Oil Temperature Sensor .................. 213–215 Specifications Section ............................................. 5
Engine Oil Temperature Sensor (If Equipped)..... 215 Speed/Timing Sensor .......................................... 226
Ether Starting Aid ............................................ 15–16
Exhaust Manifold ....................................... 63, 65–69
T
F Table of Contents..................................................... 3
Turbocharger ....................................... 56–57, 59–60
Flywheel ...................................................... 145–151 Turbocharger Outlet Pressure Sensor................. 224
Flywheel Housing ........ 152–153, 155, 157–158, 160
Fuel Filter (Primary)............................................... 13
Fuel Filter Base ............................................ 9, 11–12
U
Unit Injector ........................................................... 28

Unit Injector Hydraulic Pump ................................. 22
Unit Injector Wiring ................................................ 31
Valve Mechanism Cover.................................. 39–41

Valve Rocker Arms, Lifters, and Bridges ......... 34–35
Type 1 ................................................................ 36
Type 2 ................................................................ 37
Vibration Damper.......................................... 116–118
Water Pump......................................................... 101

Water Temperature Regulator ............................... 98
©2008 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.

Senr1017!04!00 Manuals Service Modules Specifications

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Senr1017!04!00 Manuals Service Modules Specifications

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SENR1017-04

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Crankcase Breather ............................................. 94

Electric Starting Motor ....................................... 189

Specifications Section 3412E Engines

(A) Inlet Valves

(B) Exhaust Valves

Bore ........................................ 137.2 mm (5.40 inch)

Stroke ..................................... 152.4 mm (6.00 inch)

Part No.: 149-1950 Part No.: 149-1950

Part No.: 149-1950 Part No.: 149-1950

Part No.: 149-1950 Part No.: 127-0291

g01137694 Part No.: 127-0291

Part No.: 127-0291 Part No.: 127-0291

Part No.: 6N-2946

Part No.: 6N-2946 Fuel Filter Base

(1) Install the check valve to the bottom of the seat.

i03285121 (B) Distance from the sealing surface of the base to

Part No.: 1W-3892 Fuel Filter Base

(1) Apply 154-9731 Thread Lock Compound to the

(A) Length for applying 154-9731 Thread Lock

Part No.: 8H-7204

Fuel Filter (Primary)

Part No.: 7T-3148, 8E-5662 Part No.: 128-6799, 134-1441, 220-1701,

Ether Starting Aid

Part No.: 125-3428 Part No.: 125-3431

Part No.: 125-3428 Part No.: 125-3428

Part No.: 125-3431

Use the following procedure to tighten the bolts of the

1. Tighten four bolts (5) to a torque of 5 ± 3 N·m

2. Install the pin (6) and tighten the pin to a torque of

3. Again tighten four bolts (5) to a torque of

Unit Injector Hydraulic Pump

Part No.: 126-7292 Part No.: 126-7292

Part No.: 126-7292 Part No.: 126-7292

Part No.: 126-7292

(2) Torque for four bolts ................... 7.45 ± 0.65 N·m

(3) Torque for the plug ..................... 7.45 ± 0.65 N·m

(4) Remove the plug on top of the pump. Fill the

Note: Lubricate the bore of the O-ring seal lightly

(5) Torque for the pressure sensor

Note: Lubricate the bore of the O-ring seal lightly

(6) Torque for the temperature sensor

Part No.: 107-0677 Part No.: 107-0677

Part No.: 107-0677 Part No.: 107-0677

Part No.: 107-0677 Part No.: 206-2630

g01138133 Part No.: 206-2630

Unit Injector Part No.: 206-2630

Part No.: 209-2785 Part No.: 206-2630

Part No.: 209-2785 Part No.: 206-2630

Part No.: 109-0401

Part No.: 109-0401 Part No.: 109-0401

Part No.: 109-0401 Part No.: 109-0401

Part No.: 108-1551

SMCS Code: 1102; 1121; 1209 Part No.: 108-1551

Part No.: 108-1551 Part No.: 108-1551, 108-1874

Part No.: 108-1874

(1) Refer to Specifications, “Cylinder Head” for

Note: Tighten cylinder head bolts (1) before you

Diameter of the valve lifter Part No.: 4N-4298

Type 1 Diameter of the valve lifter bore that is in the cylinder