AND s 3500B Specification

Page 1

Speciﬁcations

RENR5077-11

July 2010

3500B an

M8A1-Up (Engine) S2A1-Up M8B1-Up (Engine) S2B1-Up (Engine) S2D1-U S2E1-Up (Engine) S2F1-Up (Engine) B5G1MRG1-Up (Engine) PAG1-Up (Engine) S2G1MKH1-Up (Engine) S2H1-Up (Engine) S2J1 S2K1-Up (Engine) S2L1-Up (Engine) S2M1 S2N1-Up (Engine) S2P1-Up (Engine) S2R S2S1-Up (Engine) S2T1-Up (Engine) S2W S2X1-Up (Engine)

(Engine)

p (Engine)

Up (Engine)

-Up (Engine)

1-Up (Engine)

d 3500C Marine Engines

S2Y1-Up (Engine) S2Z1-Up

(Engine)

SAFETY.CAT.COM

Page 2

i03991620

Important Safety Information

Most accidents 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 neces

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operat 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 heed

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

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

A non-exh on the product and in this publication.

that involve product operation, maintenance and repair are caused by failure to observe

sary training, skills and tools to perform these functions properly.

e or perform any lubrication, maintenance or repair on this product, until you have

ed, bodily injury or death could occur to you or to other persons.

! Become Alert! Your Safety is Involved.

austive list of operations that may cause product damage are identiﬁed by “NOTICE” labels

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warn not use this product in any manner different from that considered by this manual without ﬁrst satisfying yourself that you have considered all safety rules and precautions applicable to the operat applicable to the worksite. If a tool, procedure, work method or operating technique that is not speciﬁcally recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for the operation, lubrication, maintenance or repair procedures that you intend to use.

The information, speciﬁcations, and illustrations in this publication are on the basis of information that was av 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

ings in this publication and on the product are, therefore, not all inclusive. You must

ion of the product in the location of use, including site-speciﬁc rules and precautions

others. You should also ensure that the product will not be damaged or become unsafe by

ailable at the time that the publication was written. The speciﬁcations, torques, pressures,

any job. Cat dealers have the most current information available.

When replacement parts are required for this product Caterpillar recommends using Cat re-

cement parts or parts with equivalent speci-

pla ﬁcations including, but not limited to, physical dimensions, type, strength and material.

Failure to heed this warning can lead to premature failures, product damage, personal injury or

ath.

In the United States, the maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner's choosing.

Page 3

RENR5077-11 3

Table of Contents

Speciﬁcations Section

Engine Design ....................................................... 5

Engine Design ....................................................... 6

Engine Design ....................................................... 7

Fuel Filter (Primary) ................................................ 8

Fuel Filter Base ...................................................... 9

Fuel Filter ............................................................. 10

Fuel Pressure Regulator ................................ ...... 10

Fuel Transfer Pump .............................................. 11

Fuel Injector Mechanism ....................................... 12

Fuel Injector .......................................................... 14

Camshaft ............................................................. 15

Camshaft ............................................................. 16

Camshaft ............................................................. 17

Camshaft ............................................................. 18

Camshaft ............................................................. 19

Camshaft ............................................................. 20

Valve Mechanism ................................................. 21

Cylinder Head ...................................................... 22

Cylinder Head Valves ........................................... 24

Turbocharger ........................................................ 26

Turbocharger ........................................................ 27

Turbocharger ........................................................ 28

Turbocharger ........................................................ 29

Turbocharger ........................................................ 30

Turbocharger ........................................................ 31

Turbocharger Support ........................................... 32

Accumulator ......................................................... 33

Exhaust Bypass V alve ......................................... 33

Exhaust Bypass V alve ......................................... 34

Exhaust Manifold ................................................. 35

Exhaust Manifold ................................................. 36

Exhaust Manifold ................................................. 38

Exhaust Manifold ................................................. 39

Exhaust Flange .................................................... 40

Air Cleaner ........................................................... 41

Air Cleaner Adapter .............................................. 41

Air Cleaner Adapter .............................................. 42

Engine Air Cleaner Service Indicator .................... 42

Air Inlet and Exhaust Lines ................................... 43

Air Inlet and Exhaust Lines ................................... 44

Air Inlet and Exhaust Lines ................................... 47

Air Inlet and Exhaust Lines ................................... 49

Air Shutoff ............................................................. 51

Air Shutoff ............................................................. 52

Engine Oil Pump .................................................. 53

Engine Oil Pump .................................................. 55

Engine Oil Pump .................................................. 57

Engine Oil Pump .................................................. 59

Engine Oil Scavenge Pump ................................. 61

Engine Oil Cooler Bypass and Cooling Jet Sequence

Valves ................................................................. 63

Engine Oil Cooler Bypass and Cooling Jet Sequence

Valves ................................................................. 64

Engine Oil Filter ................................................... 66

Engine Oil Filter ................................................... 67

Engine Oil Lin Engine Oil Lines (Front Mounted Engine Oil

Filter) ................................................................... 70

Duplex Engin

Engine Oil Filter Base .......................................... 73

Crankcase Breather ............................................. 73

Crankcase B

Crankcase Breather ............................................. 76

Engine Oil Pan ..................................................... 76

Engine Oil P

Engine Oil Pan ..................................................... 80

Water Temperature Regulator .............................. 82

Water Line

Engine Oil Sump Pump ........................................ 85

Water Pump ......................................................... 86

Auxiliary

Cooling System Pressure Cap ............................. 89

Cylinder Block ...................................................... 90

Cylinder

Cylinder Block ...................................................... 93

Cylinder Liner ....................................................... 95

Piston an

Piston and Rings (One-Piece Piston) ................... 97

Piston and Rings (Two-Piece Piston) ................... 99

Piston a

Connecting Rod ................................................. 102

Connecting Rod and Main Bearing Journals ...... 104

Cranksh

Crankshaft ......................................................... 106

Crankshaft Wear Sleeves and Seals ................. 108

Housin

Housing (Front) .................................................... 110

Gear Group (Front) (Reverse Rotation) ............... 111

Gear G

Gear Group (Front) ... ........................................... 115

Gear Group (Front) ... ........................................... 116

Gear G

Balancer Group (Front) ....................................... 119

Accessory Drive ................................................. 120

Acce

Accessory Drive (Lower Left Hand) .................... 123

Accessory Drive (Lower Left Hand) .................... 124

Acce

Accessory Drive (Upper Right Hand) .................. 128

Accessory Drive (Upper Right Hand) .................. 130

Acc Accessory Drive (Upper Left Hand, Reverse

Fly

Flywheel Housing .............................................. 134

Flywheel Housing .............................................. 135

Fl Engine Mount (Front) (Hydraulic Pump Drive or PTO

Vibration Damper ............................................... 140

Vibration Damper ............................................... 141

Vibration Damper Guard .................................... 143

g (Front) ................................................... 109

ssory Drive ................................................. 122

ssory Drive (Upper Right Hand) .................. 126

essory Drive (Upper Left Hand) .................... 131

Rotation) ........................................................... 132

wheel ............................................................. 133

exible Coupling ................................................ 137

Clutch) ............................................................... 138

gine Trunnion .................................................. 139

ibration Damper ............................................... 142

es ................................................... 69

e Oil Filters ..................................... 71

reather ............................................. 75

an ..................................................... 78

s ........................................................... 83

Water Pump .......................................... 87

Block ...................................................... 91

d Rings (One-Piece Piston) ................... 95

nd Rings (Two-Piece Piston) ................. 101

aft ......................................................... 105

roup (Front) (Reverse Rotation) ............... 113

roup (Rear) ............................................... 117

Page 4

4 RENR5077-11 Table of Contents

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

Stub Shaft (Fro

Stub Shaft (Front) ............................................... 145

Auxiliary Drive Pulley ......................................... 146

Auxiliary Dri

Belt Tension Chart ............................................. 148

Belt Tension Chart ............................................. 149

Alternator a

Alternator Mounting ........................................... 151

Electric Starting Motor ....................................... 152

Air Startin Air Starting Motor Pressure Regulating Valve ... 154

Jacket Water Heater .......................................... 155

Engine Harn

Coolant Level Switch ......................................... 158

Coolant Temperature Switch ............................... 158

Fuel Press

Magnetic Switch ................................................. 159

Coolant Level Sensor ......................................... 160

Engine Oil

Engine Oil Pressure Sensor ............................... 161

Turbocharger Inlet Pressure Sensor ................... 161

Turbocha

Turbocharger Outlet Pressure Sensor ................ 163

Aftercooler Coolant Temperature Sensor ........... 163

Engine Co

Turbocharger Exhaust Temperature Sensor ....... 164

Engine Speed/Timing Sensor ............................. 164

Engine S

Engine Speed/Timing Sensor ............................. 166

Engine S

Crankcase Pressure Sensor ............................... 168

Atmospheric Pressure Sensor ............................ 168

Atmosp

Atmospheric Pressure Sensor ............................ 169

Engine Speed Sensor ......................................... 170

Engin

heric Pressure Sensor ............................ 169

e Speed Sensor ......................................... 170

nt) ............................................... 144

ve Shaft . ......................................... 147

nd Regulator .................................... 150

g Motor ............................................... 153

ess (Rigid Wiring Harness) ............. 155

ure Sensor ........................................ 159

Pressure Sensor ............................... 160

rger Outlet Pressure Sensor ................ 162

olant Temperature Sensor .................. 163

peed/Timing Sensor ............................. 165

peed/Timing Sensor ............................. 167

Index

Index ................................................................... 172

Section

Page 5

RENR5077-11 5

Speciﬁcations Section

Engine Design

SMCS Code: 1000

S/N: M8A1-Up

S/N: S2A1-Up

S/N: M8B1-Up

S/N: S2B1-Up

S/N: S2D1-Up

S/N: S2E1-Up

S/N: S2F1-Up

i01939435

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

Valve lash

Inlet ......................................... 0.50 mm (

0.020 inch)

Exhaust ................................... 1.00 mm (0.040 inch)

Note: The front end of the engine is opposite the ﬂywheel end of the engine. The left and the right side of the engin

e are determined from the ﬂywheel end. The number 1 cylinder is the front cylinder on the right side. The number 2 cylinder is the front cylinder on the left s

Engine Des

ide.

i01939560

ign

SMCS Code: 1000

S/N: S2G1-Up

S/N: S2H1

-Up

S/N: S2K1-Up

S/N: S2L1-Up

Illustration 1

Cylinder and valve location

(A) Inlet valves (B) Exhaust valves

g00293348

Number and arrangement of

cylinders .............................................. 60 degree V-8

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

Displacement .............................. 34.5 L (2105 cu in)

Bore ............................................. 170 mm (6.7 inch)

Stroke .......................................... 190 mm (7.5 inch)

Compression ratio .............................................. 14:1

Combustion ........................................ Direct injection

When the crankshaft is viewed from the ﬂywheel end the crankshaft rotates in the following

direction. ....................................... Counterclockwise

Firing order (injection sequence)

Standard rotation CCW ............... 1, 2, 7, 3, 4, 5, 6, 8

S/N: S2M

Illustration 2

inder and valve location

Cyl

(A) Inlet valves (B) Exhaust valves

1-Up

g00293349

Number and arrangement of

cylinders ............................................ 60 degree V-12

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

splacement .............................. 51.8 L (3158 cu in)

Bore ............................................. 170 mm (6.7 inch)

Stroke .......................................... 190 mm (7.5 inch)

ompression ratio .............................................. 14:1

Combustion ........................................ Direct injection

Page 6

6 RENR5077-11 Speciﬁcations Section

When the crankshaft is viewed from the ﬂywheel end the cranksh

aft rotates in the following

direction. ....................................... Counterclockwise

Firing order (

injection sequence)

Standard rotation

CCW ...................... 1, 12, 9, 4

, 5, 8, 11, 2, 3, 10, 7, 6

Reverse rotation

CW ......................... 1, 4, 9, 8,

5, 2, 11, 10, 3, 6, 7, 12

Val v e lash

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

Exhaust ................................... 1.

00 mm (0.040 inch)

Note: The front end of the engine is opposite the ﬂywheel en

d of the engine. The left and the right side of the engine are determined from the ﬂywheel end. The number 1 cylinder is the front cylinder on the right sid

e. The number 2 cylinder is the front cylinder

on the left side.

i01443411

Engine Design

SMCS Cod

S/N: MRG1-Up

e: 1000

Bore ............................................. 170 mm (6.7 inch)

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

Compression r

atio ........................................... 15.5:1

Combustion ........................................ Direct injection

When the crankshaft is viewed from the ﬂywheel end the crankshaft rotates in the following direction.

....................................... Counterclockwise

Firing order (injection sequence)

Standard rotation

CCW ...................... 1, 12, 9, 4, 5, 8, 11, 2, 3, 10, 7, 6

Reverse rotation

CW ......................... 1, 4, 9, 8, 5, 2, 11, 10, 3, 6, 7, 12

Valve lash

Inlet ......................................... 0.5

0 mm (0.020 inch)

Exhaust ................................... 1.00 mm (0.040 inch)

Note: The front end of the engine is opposite the ﬂywheel end of the engine. The left and the right side of the en

gine are determined from the ﬂywheel end. The number 1 cylinder is the front cylinder on the right side. The number 2 cylinder is the front cylinder on the le

ft side.

S/N: MKH1-Up

S/N: S2

J1-Up

S/N: S2N1-Up

lustration 3

Cylinder and valve location

(A) Inlet valves (B) Exhaust valves

umber and arrangement of

g00293349

cylinders ............................................ 60 degree V-12

alves per cylinder .................................................. 4

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

Page 7

RENR5077-11 7

Speciﬁcations Section

Engine Design

SMCS Code: 100

S/N: S2P1-Up

S/N: S2R1-Up

S/N: S2S1-Up

S/N: S2W1-Up

S/N: S2Y1-Up

i01939608

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

Exhaust ................................... 1.00 mm (0.040 inch)

Note: The fron

t end of the engine is opposite the ﬂywheel end of the engine. The left and the right side of the engine are determined from the ﬂywheel end. The number 1 c

ylinder is the front cylinder on the right side. The number 2 cylinder is the front cylinder on the left side.

i01939644

Engine Design

SMCS Code: 1000

S/N: B5G1-

S/N: PAG1-U p

S/N: S2T1-Up

S/N: S2X1

S/N: S2Z1-Up

-Up

285

Illustration 4

Cylinder and valve location

et valves

(A) Inl

aust valves

(B) Exh

g00294

Number and arrangement of

ders ............................................ 60 degree V-16

cylin

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

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

............................................. 170 mm (6.7 inch)

Bore

Stroke .......................................... 190 mm (7.5 inch)

Compression ratio .............................................. 14:1

bustion ........................................ Direct injection

Com

When the crankshaft is viewed from the ﬂywheel

the crankshaft rotates in the following

end

direction. ....................................... Counterclockwise

ring order (injection sequence)

Standard rotation

W .. 1, 2, 5, 6, 3, 4, 9, 10, 15, 16, 11, 12, 13, 14, 7, 8

Reverse rotation

W.. 1,6,5,4,3,10,9,16,15,12,11,14,13,8,7,2

stration 5

Illu

Cylinder and valve location

(A) Inlet valves (B) E xhaust valves

ber and arrangement of

Num

g00294285

cylinders ............................................ 60 degree V-16

ves per cylinder .................................................. 4

Val

Displacement .............................. 78.0 L (4760 cu in)

Bore ............................................. 170 mm (6.7 inch)

roke .......................................... 215 mm (8.5 inch)

Compression ratio ........................................... 15.5:1

Combustion ........................................ Direct injection

Val v e lash

hen the crankshaft is viewed from the ﬂywheel

W end the crankshaft rotates in the following

direction. ....................................... Counterclockwise

Page 8

8 RENR5077-11 Speciﬁcations Section

Firing order (injection sequence)

Standard rotation CCW .. 1, 2, 5, 6, 3, 4, 9, 10, 15, 16, 11, 12, 13, 14, 7, 8

Reverse rotation CW .. 1, 6, 5, 4, 3, 10, 9, 16, 15, 12, 11, 14, 13, 8, 7, 2

Val v e lash

Inlet ......................................... 0.50 m

Exhaust ................................... 1.00 mm (0.040 inch)

Note: The front end of the engine is opposite the ﬂywheel end of the engine. The left and the right side of the engi The number 1 cylinder is the front cylinder on the right side. The number 2 cylinder is the front cylinder on the left

Fuel Filt

SMCS Code: 1260

Part No.: 8N-6435 S/N: M8A1-Up

Part No.: 8N-6435 S/N: S2A1-Up

Part No.: 8N-6435 S/N: M8B1-Up

ne are determined from the ﬂywheel end.

side.

er (Primary)

m (0.020 inch)

i03657840

Part No.: 8N-6435 S/N: S2K1-Up

Part No.: 8N-6435 S/N: S2L1-Up

Part No.: 8N-6435 S/N: S2M1-Up

Part No.: 8N-6435 S/N: S2N1-Up

Part No.: 8N-6435 S/N: S2P1-U

Part No.: 8N-6435 S/N: S2R1-U

Part No.: 8N-6435 S/N: S2S1-

Part No.: 8N-6435 S/N: S2T1-

Part No.: 8N-6435 S/N: S2W1

Part No.: 8N-6435 S/N: S2X

Part No.: S/N: S2Y

Part No.: 8N-6435 S/N: S2Z

-Up

1-Up

8N-6435

1-Up

Part No.: 8N-6435 S/N: S2B1-Up

Part No.: 8N-6435 S/N: S2D1-Up

Part No.: 8N-6435 S/N: S2E1-Up

Part No.: 8N-6435 S/N: S2F1-Up

Part No.: 8N-6435 S/N: MRG1-Up

Part No.: 8N-6435 S/N: PAG1-Up

Part No.: 8N-6435 S/N: S2G1-Up

Part No.: 8N-6435 S/N: MKH1-Up

Part No.: 8N-6435 S/N: S2H1-Up

Part No.: 8N-6435 S/N: S2J1-Up

Illustration 6

Torque for the nut ..... 25 ± 5 N·m (221 ± 44 lb in)

(1)

(2) Lubricate the bore and the shaft of the O-ring

al lightly with the clean engine oil.

(3) 7S -9323 Spring

Length under test force ... 27.94 mm (1.100 inch)

Test force ............... 27.7 to 32.3 N (6.2 to 7.3 lb)

ree length after test ...... 42.67 mm (1.680 inch)

Outside diameter ............ 17.32 mm (0.682 inch)

g01561538

Page 9

RENR5077-11 9

Speciﬁcations Section

Fuel Filter Base

SMCS Code: 126

Part No.: 8N-3481 S/N: S2A1-Up

Part No.: 8N-3481 S/N: S2B1-Up

Part No.: 8N-3481 S/N: S2D1-U

Part No.: 8N-3481 S/N: S2E1-U

Part No.: 8N-3481 S/N: S2F1-

Part No.: 8N-3481 S/N: B5G1-

Part No.: 8N-3481 S/N: MRG1

Part No.: 8N-3481 S/N: PAG

1-Up

Part No.: 8N-3481 S/N: S2G

1-Up

Part No.: 8N-3481 S/N: MKH

1-Up

-Up

i03083460

Part No.: 8N-3481 S/N: S2X1-Up

Part No.: 8N-3481 S/N: S2Y1-Up

Part No.: 8N-3481 S/N: S2Z1-Up

Illustration 7

example

Typical

g01563177

(A) Length for applying 154-9731 Thread Lock

Compoun

d on the tapered end of the taperlock

stud ................. 10.0 ± 1.5 mm (0.39 ± 0.06 inch)

(1) Tor

que for the taperlock stud ............. 68 ± 7 N·m

(50±5lbft)

Part No.: 8N-3481 S/N: S2

H1-Up

Part No.: 8N-3481

2J1-Up

S/N: S

Part No.: 8N-3481

2K1-Up

S/N: S

Part No.: 8N-3481

2L1-Up

S/N: S

Part No.: 8N-3481

S2M1-Up

S/N:

Part No.: 8N-3481

S2N1-Up

S/N:

Part No.: 8N-3481

: S2P1-Up

S/N

Part No.: 8N-3481

: S2R1-Up

S/N

Part No.: 8N-3481

N: S2S1-Up

Part No.: 8N-3481

N: S2T1-Up

Part No.: 8N-3481

/N: S2W1-Up

i03609520

Fuel Filter

SMCS Code: 1261

Part No.: 335-5612 S/N: M8A1-Up

Part No.: 115-7842, 7W-9741 S/N: S2A1-Up

Part No.: 335-5612 S/N: M8B1-Up

Part No.: 115-7842, 7W-9741 S/N: S2B1-Up

Part No.: 115-7842, 7W-9741 S/N: S2D1-Up

Part No.: 115-7842, 7W-9741 S/N: S2E1-Up

Part No.: 7W-9741 S/N: S2F1-Up

Part No.: 7W-9741 S/N: B5G1-Up

Part No.: 7W-9741 S/N: MRG1-Up

Page 10

10 RENR5077-11 Speciﬁcations Section

Part No.: 7W-9741 S/N: PAG1-Up

Part No.: 115-7842, 7W-9741 S/N: S2G1-Up

Part No.: 7W-9741 S/N: MKH1-Up

Part No.: 115-7842, 7W-9741 S/N: S2H1-Up

Part No.: 115-7842, 7W-9741 S/N: S2J1-U

Part No.: 115-7842, 7W-9741 S/N: S2K1-U

Part No.: 115-7842, 7W-9741 S/N: S2L1-

Part No.: 7W-9741 S/N: S2M1-

Part No.: 115-7842, 7W-9741 S/N: S2N1

-Up

Part No.: 115-7842, 7W-9741 S/N: S2P

1-Up

Part No.: 115-7842, 7W-9741 S/N: S2R

1-Up

Part No.: 115-7842, 7W-9741 S/N: S2S

1-Up

Part No.: 115-7842, 7W-9741 S/N: S2

T1-Up

Part No.: 115-7842, 7W-9741

2W1-Up

S/N: S

Part No.: 115-7842, 7W-9741

2X1-Up

S/N: S

Illustration 8

Typical examp le

(1) Manual valve assembly (3) Fuel ﬁlter element

g01934499

Note: Lightly lubricate the bore of the O-ring seals with the lubricant that is being sealed or an approved equivalent.

(2) 1N -2895 Spring

Length under test force ... 20.75 mm (0.817 inch)

Test force ....................................... 222 N (50 lb)

Free length after test ..... 62.48 mm (2.460 inch)

Outside diameter ................ 88.9 mm (3.50 inch)

i02723705

Fuel Pressure Regulator

SMCS C

Part No.: 114-5477

ode: 1277

Part No.: 7W-9741

2Y1-Up

S/N: S

Part No.: S/N:

115-7842, 7W-9741

S2Z1-Up

lustration 9

Typical examp le

(1) Fuel manifold adapter (3) Valve plunger

2) 9N-4053 Spring

(

Length under test force ....... 28.5 mm (1.12 inch)

est force .................... 40.8 ± 2.1 N (9.2 ± 0.5 lb)

T Free length after test force .. 57.2 mm (2.25 inch)

g01366239

Page 11

RENR5077-11 11

Speciﬁcations Section

Outside diameter ............ 15.24 mm (0.600 inch)

Fuel Transfer Pump

SMCS Code: 1256

Part No.: 313-7770 S/N: M8A1-Up

Part No.: 8N-6151 S/N: S2A1-Up

Part No.: 313-7770 S/N: M8B1-Up

Part No.: 8N-6151 S/N: S2B1-Up

Part No.: 8N-6151 S/N: S2D1-Up

Part No.: 8N-6151 S/N: S2E1-Up

Part No.: 8N-6151 S/N: S2F1-Up

i03229222

Part No.: 8N-6151 S/N: S2S1-Up

Part No.: 8N-6151 S/N: S2T1-Up

Part No.: 8N-6151 S/N: S2W1-Up

Part No.: 8N-6151 S/N: S2X1-Up

Part No.: 8N-6151 S/N:

S2Y1-U

Part No.: 8N-6151 S/N: S2Z1-U

Part No.: 8N-6151 S/N: B5G1-Up

Part No.: 8N-6151 S/N: MRG1-Up

Part No.: 8N-6151 S/N: PAG1-Up

Part No.: 8N-6151 S/N: S2G1-Up

Part No.: 8N-6151 S/N: MKH1-Up

Part No.: 8N-6151 S/N: S2H1-Up

Part No.: 8N-6151 S/N: S2J1-Up

Part No.: 8N-6151 S/N: S2K1-Up

Part No.: 8N-6151 S/N: S2L1-Up

Part No.: 8N-6151 S/N: S2M1-Up

Part No.: 8N-6151 S/N: S2N1-Up

Part No.: 8N-6151 S/N: S2P1-Up

Illustration 10

(3) Chec k valve

g01641861

When the fuel transfer pump group is viewed from the drive end, the drive gear rotates in the clockwise direction.

Minimum output .................... 21 L/min (5.5 US gpm)

Minimum output is attained under the following conditions:

Pump pressure ............................... 415 kPa (60 psi)

Pump speed ............................................... 2400 rpm

Part No.: 8N-6151 S/N: S2R1-Up

Minimum cracking pressure of bypass

valve ............................................... 620 kPa (90 psi)

Page 12

12 RENR5077-11 Speciﬁcations Section

Maximum pressure of fully open bypass

valve ............................................. 965 kPa (1

(1) Dimensions for terminal bushing

Inside diameter of the terminal bushing for gear

shaft ............................ 12.783 mm (0.5033 inch)

Installation

depth of terminal

bushing ............. 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

(2) Dimensio

ns for drive shaft assembly

Diameter of the shaft ........ 12.700 to 12.675 mm

(0.5000to0

.4990 inch)

Diameter of the gear ............ 29.801 ± 0.006 mm

(1.1733 ± 0.0002 inch)

Length of th

e gear ............... 25.347 ± 0.008 mm

(0.9979 ± 0.0003 inch)

(4) Dimens

ions for idler gear assembly

Diameter of the gear ............ 29.801 ± 0.006 mm

(1.1733 ±

0.0002 inch)

Length of the gear ............... 25.347 ± 0.008 mm

(0.9979 ± 0.0003 inch)

Fuel Injector Mechanism

SMCS Code: 1102; 1290

Part No.: 332-9690 S/N: M8A1-Up

Part No.: 224-9869 S/N: S2A1-Up

Part No.: 332-9690 S/N: M8B1-Up

40 psi)

i03601019

Part No.: 224-9869 S/N: S2H1-Up

Part No.: 224-9869 S/N: S2J1-Up

Part No.: 224-9869 S/N: S2K1-Up

Part No.: 224-9869 S/N: S2L1-Up

Part No.: 224-9869 S/N: S2M1-U

Part No.: 224-9869 S/N: S2N1-U

Part No.: 224-9869 S/N: S2P1-

Part No.: 224-9869 S/N: S2R1-

Part No.: 224-9869 S/N: S2S1

-Up

Part No.: 224-9869 S/N: S2T

1-Up

Part No.: 224-9869 S/N: S2W

1-Up

Part No.: 224-9869 S/N: S2X

1-Up

Part No.: 224-9869 S/N: S2

Y1-Up

Part No.: 224-9869

2Z1-Up

S/N: S

Part No.: 224-9869 S/N: S2B1-Up

Part No.: 224-9869 S/N: S2D1-Up

Part No.: 224-9869 S/N: S2E1-Up

Part No.: 224-9869 S/N: S2F1-Up

Part No.: 224-9869 S/N: B5G1-Up

Part No.: 224-9869 S/N: MRG1-Up

Part No.: 224-9869 S/N: PAG1-Up

Part No.: 224-9869 S/N: S2G1-Up

Part No.: 224-9869 S/N: MKH1-Up

Illustration 11

(3) Timing pin

g01441231

Page 13

RENR5077-11 13

Speciﬁcations Section

(A) Bore in the sleeve bearing for the rocker arm

shaft after ins

tallation ........... 45.077 ± 0.015 mm

(1.7747 ± 0.0006 inch)

(1) Torque for

the nut .... 120 ± 15 N·m (88 ± 11 lb ft)

(B) Diameter of the rocker arm

shaft ................ ..................... 45.000

± 0.013 mm

(1.7716 ± 0.0005 inch)

(2) 100-387

8 Injector Spring

Length under test force ... 85.00 mm (3.346 inch)

Test force .......................... 3

00±25N(67±6lb)

Free length after test ...... 87.65 mm (3.451 inch)

Outside diameter ............ 43.85 mm (1.726 inch)

Diameter o

f the unit injector lifter

assembly ............................. 34.950 ± 0.010 mm

(1.3760 ± 0.0004 inch)

Bore in th

e head for the unit injector lifter

assembly ............................. 35.000 ± 0.025 mm

(1.3779 ± 0.0010 inch)

Part No.: 250-1300 S/N: M8A1-Up

Part No.: 256-3663 S/N: S2A1-Up

Part No.: 250-1300 S/N: M8B1-Up

Part No.: 256-3663 S/N: S2B1-Up

Part No.: 256-3663 S/N: S2D1-U

Part No.: 256-3663 S/N: S2E1-U

Part No.: 256-3663 S/N: S2F1-

Part No.: 248-8695, 256-3663 S/N: B5G1-

Part No.: 248-8695, 256-3663 S/N: MRG1

-Up

Part No.: 256-3663 S/N: PAG

1-Up

Illustration 12

g01925693

(4) Lubricate the bore of the O-ring seal lightly with

clean engine oil.

Note: Start tightening the retainer nuts of the cap assembly by hand so that the terminal studs are not cross threaded.

(5) Torque for the retainer nuts of the cap

assembly ............................... 2.500 ± 0.025 N·m

(22.127 ± 0.221 lb in)

(6) Apply 5P-3413 Pipe Sealant to the threads of

the bolts, if the bolts are removed after initial installation.

i02895694

Fuel Injector

SMCS Code: 1290

Part No.: 256-3663 S/N: S2G

1-Up

Part No.: 248-8695, 256-3663 S/N: MKH

1-Up

Part No.: 256-3663 S/N: S2

H1-Up

Part No.: 256-3663

2J1-Up

S/N: S

Part No.: 256-3663

2K1-Up

S/N: S

Part No.: 256-3663

2L1-Up

S/N: S

Part No.: 256-3663

S2M1-Up

S/N:

Part No.: 256-3663

S2N1-Up

S/N:

Part No.: 256-3663

: S2P1-Up

S/N

Part No.: 256-3663

S2R1-Up

S/N

Part No.: 256-3663

N: S2S1-Up

Part No.: 256-3663

N: S2T1-Up

Part No.: 256-3663

/N: S2W1-Up

Page 14

14 RENR5077-11 Speciﬁcations Section

Part No.: 256-3663 S/N: S2X1-Up

Part No.: 256-3663 S/N: S2Y1-Up

Part No.: 256-3663 S/N: S2Z1-Up

Part No.: 106-4586, 106-4595 S/N: S2A1-Up

Part No.: 106-4586, 106-4595 S/N: S2B1-Up

Part No.: 106-4586, 106-4595 S/N: S2D1-Up

Part No.: 106-4586, 106-4595 S/N: S2E1-Up

Part No.: 106-4586 S/N: S2F1-U

Part No.: 106-4595 S/N: B5G1-U

Part No.: 106-4586, 106-4595 S/N: MRG1-

Part No.: 106-4595 S/N: PAG1-

Part No.: 106-4586, 106-4595 S/N: S2G1

-Up

Part No.: 106-4586, 106-4595 S/N: MKH

1-Up

Illustration 13

g01441567

Note: Prior to installation of the fuel injector group, lubricate the bore in the cylinder head with 1P-0808 Multipurpose Grease. Use the clamp to press the injector into the bore. Do not tap on the top surface of the injector.

(1) Torque for the bolt .......... 65 ± 7 N·m (48 ± 5 lb ft)

(A) Timing dimension .................... 64.34 ± 0.20 mm

(2.533 ± 0.008 inch)

Note: Before assembly, lubricate the bore and the threads of valve assembly (2) with 1P-0808 Multipurpose Grease.

(2) Valve assembly

Torque for valve assembly ............. 165 ± 10 N·m

(120 ± 7 lb ft)

Torque for terminal nuts ................. 2.4 ± 0.2 N·m

(21±2lbin)

(3) Torque for unit injector nozzle ........ 310 ± 20 N·m

(230 ± 15 lb ft)

i02874925

Camshaft

Part No.: 106-4586, 106-4595 S/N: S2H

1-Up

Part No.: 106-4586, 106-4595 S/N: S2J

1-Up

Part No.: 106-4586, 106-4595 S/N: S2

K1-Up

Part No.: 106-4586, 106-4595

2L1-Up

S/N: S

Part No.: 106-4586, 106-4595

2M1-Up

S/N: S

Part No.: 106-4586, 106-4595

2N1-Up

S/N: S

Part No.: 106-4586, 106-4595

S2P1-Up

S/N:

Part No.: 106-4586, 106-4595

S2R1-Up

S/N:

Part No.: 106-4586, 106-4595

: S2S1-Up

S/N

Part No.: 106-4586, 106-4595

: S2T1-Up

S/N

Part No.: 106-4586, 106-4595

N: S2W1-Up

Part No.: 106-4586, 106-4595

N: S2X1-Up

SMCS Code: 1210

Part No.: 106-4586, 106-4595

/N: S2Y1-Up

Page 15

RENR5077-11 15

Speciﬁcations Section

Part No.: 106-4586 S/N: S2Z1-Up

Illustration 14

(1) Left hand camshaft assembly (2) Right hand camshaft assembly

g01430676

(A) Thickness of the groove in a new camshaft

assembly .. 8.75 ± 0.05 mm (0.344 ± 0.002 inch)

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

(D) Thickness of a new thrust

washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)

(E) Journal surface

Diameter of bearing journals for a new camshaft .. 91.88 ± 0.02 mm (3.617 ± 0.001 inch) Bore in camshaft bearing after

installation ................................ 92.00 ± 0.06 mm

(3.622 ± 0.002 inch)

Note: End play for a new camshaft assembly is

0.15 to 0.35 mm (0.006 to 0.014 inch).

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

Illustration 15

g01381515

Use the following procedure in order to determine the camshaft lobe lift:

1. Measure camshaft lobe height (H).

2. Measure base circle (J).

3. Subtract the base circle (J) from the camshaft lobe

height (H). The difference is the actual camshaft lobe lift.

(G) Speciﬁed camshaft lobe lift

Inlet lobe ................. 12.7500 mm (0.50197 inch)

Injector lobe ............ 13.7313 mm (0.54060 inch)

Exhaust lobe ........... 13.2499 mm (0.52165 inch)

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

rear right hand camshaft and the front left hand

camshaft ......... 22.0 ± 0.5 mm (0.87 ± 0.02 inch)

Page 16

16 RENR5077-11 Speciﬁcations Section

i01390111

Camshaft

SMCS Code: 121

Part No.: 143-8726 S/N: S2A1-Up

Part No.: 333-8957 S/N: M8B1-Up

Part No.: 143-8726 S/N: S2D1-U

Illustration 16

lexample

Typica

(1) Pin

The pin extends from the camshaft by the

following distance: ....................... 12.0 ± 0.5 mm

± 0.02 inch)

(0.47

(2) New washer

g00289972

Illustration 17

g00290053

(6) Camshaft lobe height

In order to determine the height, use the procedure that follows:

1. Measure camshaft lobe height (6).

2. Measure base circle (8).

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

height (Step 1). The difference is the actual lobe lift.

4. Speciﬁed camshaft lobe lift (7)

Inlet lobe ...................... 13.250 mm (0.5217 inch)

Injector lobe ................. 13.731 mm (0.5406 inch)

Exhaust lobe ................ 13.250 mm (0.5217 inch)

Thickness of a new washer ....... 8.50 ± 0.05 mm

(0.335 ± 0.002 inch)

kness of the groove in a new

Thic camshaft ... 8.75 ± 0.05 mm (0.344 ± 0.002 inch)

End play for new camshafts ..... 0.15 to 0.35 mm

06 to 0.014 inch)

(0.0

(3) LH camshaft

(4) RH camshaft

Journal surface

(5)

Diameter of surface (journals) for new camshaft

arings .. 91.88 ± 0.02 mm (3.617 ± 0.001 inch)

be Bore in bearings for camshafts after

assembly ................................. 92.00 ± 0.06 mm

.622 ± 0.002 inch)

Page 17

RENR5077-11 17

Speciﬁcations Section

i02990771

Camshaft

SMCS Code: 121

Part No.: 332-7923 S/N: M8A1-Up

Part No.: 106-4582 S/N: S2B1-Up

Part No.: 106-4582 S/N: S2E1-U

Part No.: 106-4582 S/N: S2F1-U

Illustration 18

t hand camshaft assembly

(1) Lef

ht hand camshaft assembly

(2) Rig

g01515757

(A) Thickness of the groove for thrust washer in a

new ca

mshaft assembly ............ 8.75 ± 0.05 mm

(0.344 ± 0.002 inch)

tension of the dowel from the camshaft

(B) Ex

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

Illustration 19

g01460128

(E) Speciﬁed camshaft lobe lift

Inlet lobe ................. 12.7500 mm (0.50197 inch)

Injector lobe ............ 13.7313 mm (0.54060 inch)

Exhaust lobe ........... 13.2500 mm (0.52165 inch)

Use the following procedure in order to determine the actual camshaft lobe lift:

1. Measure camshaft lobe height (F).

2. Measure base circle (G).

3. Subtract the base circle (G) from the camshaft

lobe height (F). The difference is the actual camshaft lobe lift.

hickness of a new thrust

washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)

imensions for the journal surface

(D) D

Diameter of bearing journal ..... 91.88 ± 0.02 mm

617 ± 0.001 inch)

(3. Bore in camshaft bearing after

installation ................................ 92.00 ± 0.06 mm

622 ± 0.002 inch)

(3.

Note: End play for a new camshaft assembly is

15 to 0.35 mm (0.006 to 0.014 inch).

Page 18

18 RENR5077-11 Speciﬁcations Section

Camshaft

SMCS Code: 121

Part No.: 143-8727 S/N: S2G1-Up

Part No.: 143-8727 S/N: S2K1-Up

Part No.: 163-1419 S/N: S2N1-U

Part No.: 143-8728 S/N: S2P1-U

Part No.: 163-1451 S/N: S2T1-

Part No.: 143-8728 S/N: S2W1-

Part No.: 163-1451 S/N: S2Z1

-Up

i03021227

Bore in camshaft bearing after

installation ................................ 9

2.00 ± 0.06 mm

(3.622 ± 0.002 inch)

Note: End play

for a new camshaft assembly is

0.15 to 0.35 mm (0.006 to 0.014 inch).

(3) Torque fo

r 16 bolts ......... 55 ± 7 N·m (41 ± 5 lb ft)

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

rear right h

and camshaft and the front left hand

camshaft ......... 22.0 ± 0.5 mm (0.87 ± 0.02 inch)

Illustration 20

(1) Left hand camshaft assembly (2) Right hand camshaft assembly

g01381231

(A) Thickness of the groove in a new camshaft

assembly .. 8.75 ± 0.05 mm (0.344 ± 0.002 inch)

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

(D) Thickness of a new thrust

washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)

(E) Dimensions for the journal surface

Illustration 21

g01447245

Use the following procedure in order to determine the actual camshaft lobe lift:

1. Measure camshaft lobe height (H).

2. Measure base circle (J).

3. Subtract the base circle (J) from the camshaft lobe

height (H). The difference is the actual camshaft lobe lift.

(G) Speciﬁed camshaft lobe lift

Inlet lobe ..................... 13.250 mm (0.5217 inch)

Injector lobe ................ 13.731 mm (0.5406 inch)

Exhaust lobe ............... 13.250 mm (0.5217 inch)

Diameter of bearing journal ..... 91.88 ± 0.02 mm

(3.617 ± 0.001 inch)

Page 19

RENR5077-11 19

Speciﬁcations Section

Camshaft

SMCS Code: 121

Part No.: 281-7848 S/N: B5G1-Up

Part No.: 281-7848 S/N: MRG1-Up

Part No.: 281-7848 S/N: PAG1-U

Part No.: 281-7849 S/N: MKH1-U

i03021222

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

rear right hand

camshaft and the front left hand

camshaft ......... 22.0 ± 0.5 mm (0.87 ± 0.02 inch)

Illustration 23

g01447245

Illustration 22

(1) Left hand camshaft assembly (2) Right hand camshaft assembly

g01381231

(A) Thickness of the groove in a new camshaft

assembly .. 8.75 ± 0.05 mm (0.344 ± 0.002 inch)

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

(D) Thickness of a new thrust

washer ...... 8.40 ± 0.05 mm (0.331 ± 0.002 inch)

(E) Dimensions for the journal surface

Diameter of bearing journal ..... 91.88 ± 0.02 mm

(3.617 ± 0.001 inch) Bore in camshaft bearing after

installation ................................ 92.00 ± 0.06 mm

(3.622 ± 0.002 inch)

Use the following procedure in order to determine the actual camshaft lobe lift:

1. Measure camshaft lobe height (H).

2. Measure base circle (J).

3. Subtract the base circle (J) from the camshaft lobe

height (H). The difference is the actual camshaft lobe lift.

(G) Speciﬁed camshaft lobe lift

Inlet lobe .................. 12.7300 mm (0.50118 inch)

Injector lobe .............. 13.7313 mm (0.5406 inch)

Exhaust lobe ........... 13.1000 mm (0.51575 inch)

Note: End play for a new camshaft assembly is

0.15 to 0.35 mm (0.006 to 0.014 inch).

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

Page 20

20 RENR5077-11 Speciﬁcations Section

i03295700

Camshaft

SMCS Code: 121

Part No.: 231-9123 S/N: B5G1-Up

Part No.: 231-9123 S/N: PAG1-Up

Illustration 25

g01447245

Use the following procedure in order to determine the actual camshaft lobe lift:

1. Measure camshaft lobe height (H).

2. Measure base circle (J).

Illustration 24

(1) Left hand camshaft assembly (2) Right hand camshaft assembly

g01381231

(A) Thickness of the groove in a new camshaft

assembly .. 8.75 ± 0.05 mm (0.344 ± 0.002 inch)

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

(D) Thickness of a new thrust

washer ...... 8.50 ± 0.05 mm (0.335 ± 0.002 inch)

(E) Dimensions for the journal surface

Diameter of bearing journal ..... 91.88 ± 0.02 mm

(3.617 ± 0.001 inch) Bore in camshaft bearing after

installation ................................ 92.00 ± 0.06 mm

(3.622 ± 0.002 inch)

Note: End play for a new camshaft assembly is

0.15 to 0.35 mm (0.006 to 0.014 inch).

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

3. Subtract the base circle (J) from the camshaft lobe height (H). The difference is the actual camshaft lobe lift.

(G) Speciﬁed camshaft lobe lift

Inlet lobe ..................... 12.730 mm (0.5012 inch)

Injector lobe ............ 13.7313 mm (0.54060 inch)

Exhaust lobe ............... 13.100 mm (0.5157 inch)

i03577164

Valve Mecha nism

SMCS Code: 11 0 2

Part No.: 332-9690 S/N: M8A1-Up

Part No.: 224-9869 S/N: S2A1-Up

Part No.: 332-9690 S/N: M8B1-Up

Part No.: 224-9869 S/N: S2B1-Up

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

rear right hand camshaft and the front left hand

camshaft ......... 22.0 ± 0.5 mm (0.87 ± 0.02 inch)

Part No.: 224-9869 S/N: S2D1-Up

Part No.: 224-9869 S/N: S2E1-Up

Page 21

RENR5077-11 21

Speciﬁcations Section

Part No.: 224-9869 S/N: S2F1-Up

Part No.: 224-9869 S/N: B5G1-Up

Part No.: 224-9869 S/N: MRG1-Up

Part No.: 224-9869 S/N: PAG1-Up

Part No.: 224-9869 S/N: S2G1-U

Part No.: 224-9869 S/N: MKH1-U

Part No.: 224-9869 S/N: S2H1-

Part No.: 224-9869 S/N: S2J1-

Part No.: 224-9869 S/N: S2K1

-Up

Part No.: 224-9869 S/N: S2L

1-Up

Part No.: 224-9869 S/N: S2M

1-Up

Part No.: 224-9869 S/N: S2N

1-Up

Part No.: 224-9869 S/N: S2

P1-Up

Part No.: 224-9869

2R1-Up

S/N: S

Part No.: 224-9869

2S1-Up

S/N: S

Part No.: 224-9869

2T1-Up

S/N: S

Part No.: 224-9869

S2W1-Up

S/N:

Part No.: 224-9869

S2X1-Up

S/N:

Part No.: 224-9869

: S2Y1-Up

S/N

Part No.: 224-9869

: S2Z1-Up

S/N

Illustr

ation 26

g01905795

Refer to Guideline for Reusable Parts and Salvage Operati

ons, SEBF8172, “Visual Inspection of the

7N-4782 Lifter Guide Spring − 3500 Family of Engines” for lifter guide spring (2).

(1) Torque for two jam nuts ................... 70 ± 15 N·m

(52 ± 11 lb ft)

(A) Diameter of the rocker arm shaft

assembly ............................. 45.000 ± 0.013 mm

16 ± 0.0005 inch)

(1.77

(B) Dimensions for the valve lash

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

Exhaust ............................. 1.00 mm (0.039 inch)

assembly after installation ... 45.077 ± 0.015 mm

7747 ± 0.0006 inch)

(1.

(D) Dimensions for the valve lifter assembly

Diameter of the valve lifter

assembly ............................. 29.900 ± 0.010 mm

.1772 ± 0.0004 inch)

(1 Bore in the head for the valve lifter

assembly ............................. 30.000 ± 0.025 mm

.1811 ± 0.0010 inch)

Page 22

22 RENR5077-11 Speciﬁcations Section

Cylinder Head

SMCS Code: 110

Part No.: 332-9694 S/N: M8A1-Up

Part No.: 101-0830 S/N: S2A1-Up

Part No.: 332-9694 S/N: M8B1-U

Part No.: 101-0830 S/N: S2B1-U

Part No.: 101-0830 S/N: S2D1-

Part No.: 101-0830 S/N: S2E1-

Part No.: 101-0830 S/N: S2F1

-Up

Part No.: 101-0830 S/N: B5G

1-Up

i03076672

Part No.: 101-0830 S/N: S2T1-Up

Part No.: 101-0830 S/N: S2W1-Up

Part No.: 101-0830 S/N: S2X1-Up

Part No.: 101-0830 S/N: S2Y1-Up

Part No.: 101-0830 S/N: S2Z1-U

Part No.: 101-0830 S/N: MRG

1-Up

Part No.: 101-0830 S/N: PAG

1-Up

Part No.: 101-0830 S/N: S2

G1-Up

Part No.: 101-0830 S/N: M

KH1-Up

Part No.: 101-0830

2H1-Up

S/N: S

Part No.: 101-0830

2J1-Up

S/N: S

Part No.: 101-0830

S2K1-Up

S/N:

Part No.: 101-0830

S2L1-Up

S/N:

Part No.: 101-0830

: S2M1-Up

S/N

Part No.: 101-0830

: S2N1-Up

S/N

Illustration 27

lexample

Typica

(1) Loc ating pad

g01429899

NOTICE Thepipeplugatlocation(2)isinstalledinthecylinder head for engines with dry exhaust manifolds. If the pipe plug is not installed into the water passage, the coolant will leak and engine damage will result. For engines with dry exhaust manifolds, make sure that thepipeplugisinstalled.

Part No.: 101-0830

N: S2P1-Up

Part No.: 101-0830

N: S2R1-Up

Part No.: 101-0830

/N: S2S1-Up

Page 23

RENR5077-11 23

Speciﬁcations Section

Illustration 28

Typical example

Top vie w

g01611158

(3) Before assembly, lubricate the thread of the pipe

plug.

Use the following procedure to tighten the bolts of the cylinder head that is shown in Illustration 28:

Note: Before assembly, coat the threads of the bolt with clean engine oil.

1. Tighten the bolt 1 through bolt 8 in the numerical sequence to 30 ± 5 N·m (22 ± 4 lb ft).

2. Tighten the bolt 1 through bolt 8 in the numerical sequence to 200 ± 15 N·m (150 ± 11 lb ft).

3. Again tighten the bolt 1 through bolt 8 in the numerical sequence to 200 ± 15 N·m (150 ± 11 lb ft).

4. Turn the bolt 1 through bolt 8 in the numerical sequence to an additional rotation of 180 ± 5 degrees.

Note: Tighten the bolts (4) only after the cylinder head bolts have been given ﬁnal torque.

(4) Torque for two bolts ..... 55 ± 10 N·m (41 ± 7 lb ft)

Illustration 29

Typical examp le

g01413732

(A) Height of the new cylinder

head ...... 142.00 ± 0.15 mm (5.591 ± 0.006 inch)

Note: Before assembly, apply 6V-6640 Sealant to the bore of the ten cup plugs.

(B) Installation depth of two cup plugs from the top

surface of the cylinder head .......... 9.0 ± 0.5 mm

(0.35 ± 0.02 inch)

(D) Installation depth of eight cup plugs from the top

surface of the cylinder head .......... 1.0 ± 0.5 mm

(0.04 ± 0.02 inch)

i03080402

Cylinder Head Valves

SMCS Code: 11 0 5

Part No.: 332-9694 S/N: M8A1-Up

Part No.: 101-0830 S/N: S2A1-Up

Part No.: 332-9694 S/N: M8B1-Up

Part No.: 101-0830 S/N: S2B1-Up

Part No.: 101-0830 S/N: S2D1-Up

Part No.: 101-0830 S/N: S2E1-Up

Part No.: 101-0830 S/N: S2F1-Up

Page 24

24 RENR5077-11 Speciﬁcations Section

Part No.: 101-0830 S/N: B5G1-Up

Part No.: 101-0830 S/N: MRG1-Up

Part No.: 101-0830 S/N: PAG1-Up

Part No.: 101-0830 S/N: S2G1-Up

Part No.: 101-0830 S/N: MKH1-U

Part No.: 101-0830 S/N: S2H1-U

Part No.: 101-0830 S/N: S2J1-

Part No.: 101-0830 S/N: S2K1-

Part No.: 101-0830 S/N: S2L1

-Up

Part No.: 101-0830 S/N: S2M

Part No.: 101-0830 S/N: S2N

Part No.: 101-0830 S/N: S2P

Part No.: 101-0830 S/N: S2

Part No.: 101-0830 S/N: S

Part No.: 101-0830 S/N:

Part No.: 101-0830, 335-6220 S/N

1-Up

R1-Up

2S1-Up

2T1-Up

2W1-Up

S2X1-Up

S2Y1-Up

: S2Z1-Up

Page 25

RENR5077-11 25

Speciﬁcations Section

ation 3 0

Illustr

Typical example

Note: Before assembly, coat the inlet valve stems and the exhaust valve stems with clean engine oil.

(A) Height from the top of the cylinder head to the

top of the valve guides ................. 26.0 ± 1.0 mm

± 0.04 inch)

(1.02

(1) 316-5976 Spring

Quantity ............................................................ 4

Length under test force ... 60.29 mm (2.374 inch)

orce .................. 460 ± 23 N (103.4 ± 5.2 lb)

Te s t f

Free length after test .......... 74.8 mm (2.94 inch)

Outside diameter ............. 43.47 mm (1.711 inch)

(2) 316-5977 Spring

tity ............................................................ 4

Quan

Length under test force ....... 57.5 mm (2.26 inch)

Test force ............. 248.0 ± 12.4 N (55.8 ± 2.8 lb)

e length after test .......... 71.4 mm (2.81 inch)

Fre

Outside diameter ................ 30.7 mm (1.21 inch)

Install the valve stem seal to the inlet valves.

(3)

(4) Install the washer to the exhaust valves.

g01566713

Diameter of the exhaust valve

stem ..................................... 12.464 ± 0.025 mm

7 ± 0.0010 inch)

(0.490

Inlet .. 60.508 ± 0.025 mm (2.3822 ± 0.0010 inch)

Exhaust ................................ 60.000 ± 0.025 mm

22 ± 0.0010 inch)

(2.36

(5) Valve guide

Bore of the inlet valve guide after

installation .............................. 9.487 ± 0.025 mm

735 ± 0.0010 inch)

(0.3 Bore of the exhaust valve guide after

installation ............................ 12.619 ± 0.025 mm

968 ± 0.0010 inch)

(0.4

(D) Valve face angles

Inlet ................................... 19.40 ± 0.25 degrees

Exhaust ............................. 44.40 ± 0.25 degrees

(E) Diameter of the valve head ..... 56.00 ± 0.15 mm

(2.205 ± 0.006 inch)

(B) Dimension for the valves

ameter of the inlet valve

Di stem .. 9.441 ± 0.010 mm (0.3717 ± 0.0004 inch)

Page 26

26 RENR5077-11 Speciﬁcations Section

i03670347

Turbo charger

Illustration 31

Typical example

(F) Diameter of the valve seat inserts

Inlet .. 60.627 ± 0.015 mm (2.3869 ± 0.0006 inch)

Exhaust ................................. 60.119 ± 0.015 mm

(2.3669 ± 0.0006 inch)

g01441032

SMCS Code: 105

Part No.: 333-2233 S/N: M8A1-Up

Part No.: 145-7993 S/N: S2A1-Up

Part No.: 333-8955 S/N: M8B1-U

Part No.: 145-7995 S/N: S2B1-U

Part No.: 145-7995 S/N: S2E1-

Part No.: 145-7995 S/N: S2G1-

Part No.: 145-7995 S/N: S2K1

-Up

(G) Angle of the face of the valve seat inserts

Inlet ................................... 20.00 ± 0.25 degrees

Exhaust ............................. 45.00 ± 0.25 degrees

(H) Depth of bore in the cylinder head for the valve

seat insert ................................ 16.00 ± 0.15 mm

(0.630 ± 0.006 inch)

(J) Outside diameter of the face of the valve seat

insert .................................... 53.6 mm (2.11 inch)

Illustration 32

g01616117

Note: Before assembly, lubricate the threads and the bearing surfaces of the bolts with 4C-5599 Anti-Seize Compound.

(1) Torque for the bolts ........ 54 ± 5 N·m (40 ± 4 lb ft)

Page 27

RENR5077-11 27

Speciﬁcations Section

3. Again, tighten the clamp assemblies to 14 ± 3 N·m (124±27lbin).

i03414341

Turbo charger

SMCS Code: 1052

Part No.: 173-7676 S/N: S2H1-Up

Part No.: 173-7676 S/N: S2L1-Up

Part No.: 259-8431 S/N: S2M1-Up

Part No.: 165-6678 S/N: S2T1-Up

Illustration 33

Rear view

g01619282

Before assembly, lubricate the threads and the bearing surfaces of the bolts with 4C-5599 Anti-Seize Compound.

Use the following procedure in order to tighten the bolts of the half ﬂange (2).

1. Tighten bolts 3 in any sequence to 54 ± 5 N·m (40±4lbft).

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

Illustration 35

g01616117

Note: Before assembly, lubricate the threads and the bearing surface of the bolts with 4C-5599 Anti-Seize Compound.

(1) Torque for the bolts to the exhaust

manifold ......................... 54 ± 5 N·m (40 ± 4 lb ft)

Illustration 34

g01538253

Use the following procedure to tighten the clamp assembly (5) and turbine clamp assembly (6):

1. Tighten the clamp assemblies to 14 ± 3 N·m (124±27lbin).

2. Gently tap around the clamp assemblies with a soft faced hammer.

Page 28

28 RENR5077-11 Speciﬁcations Section

i03411202

Turbo charger

Illustr

ation 36

g01770114

Use the following procedure in order to tighten the bolts fo

r the half ﬂange (2):

SMCS Code: 105

Part No.: 159-8828 S/N: S2H1-Up

Part No.: 159-8828 S/N: S2J1-Up

Part No.: 176-3231 S/N: S2M1-U

Part No.: 159-8828 S/N: S2R1-U

Part No.: 159-8828 S/N: S2S1-

Part No.: 159-8828, 250-6111 S/N: S2Z1-

1. Tighten bolts (3) in any sequence to 54 ± 5 N·m (40±4l

bft).

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

lb ft).

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

Illustration 37

g01616117

Note: Before assembly, lubricate the threads and the bearing surface of the bolts with 4C-5599 Anti-Seize Compound.

(1) Torque for the bolts ........ 54 ± 5 N·m (40 ± 4 lb ft)

Page 29

RENR5077-11 29

Speciﬁcations Section

i03035044

Turbo charger

Illustr

ation 38

g01753233

Use the following procedure in order to tighten the bolts fo

r the half ﬂange (2):

SMCS Code: 105

Part No.: 167-1762 S/N: S2H1-Up

Part No.: 167-1762 S/N: S2J1-Up

Part No.: 167-1762 S/N: S2R1-U

Part No.: 167-1762 S/N: S2S1-U

Part No.: 167-1762 S/N: S2Z1-

1. Tighten bolts (3) in any sequence to 54 ± 5 N·m (40±4l

bft).

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

lb ft).

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

Illustration 39

g01538593

Note: Before assembly, apply 4C-5599 Anti-Seize Compound to the threads and to the bearing surface of the bolts.

(1) Torque for 20 bolts ......... 54 ± 5 N·m (40 ± 4 lb ft)

Page 30

30 RENR5077-11 Speciﬁcations Section

Torque ............................ 40 ± 5 N·m (30 ± 4 lb ft)

(2) Bolt

Illustration 40

g01538619

(2) Torque for four bolts ....... 54 ± 5 N·m (40 ± 4 lb ft)

(3) Torque for eight bolts for the turbine

housing .......................... 40 ± 2 N·m (30 ± 1 lb ft)

(4) Torque for eight bolts for the compressor

housing. ......................... 40 ± 2 N·m (30 ± 1 lb ft)

Torque ............................ 65 ± 5 N·

m (48 ± 4 lb ft)

(3) Clamp

Tighten each clamp in two places.

Torque ............................ 60 ± 5 N·m (44 ± 4 lb ft)

Turbo charger

SMCS Code: 1052

Part No.: 4P-2581 S/N: S2R1-Up

i01909990

Turboc harger

SMCS Code: 1052

Part No.: 238-7771 S/N: B5G1-Up

Part No.: 238-7774 S/N: MRG1-Up

Part No.: 238-7772 S/N: MKH1-Up

Illustration 41

i02051385

g01052152

Illustration 42

g00976451

(1) Bolt

(2) Washers

(3) Nut

Lubricate the bearing surfaces of bolt (1), wa shers (2), and nut (3) and lubricate the threads of the bolt and the nut with 4C-5597 Anti-Seize Compound.

(4) Bolt

Torque .......................... 55 ± 10 N·m (41 ± 7 lb ft)

(5) Lock

After assembly, bend the short end of the lock against the bolt head. Bend the long end of the lock around the turbine clamp. Do not reuse an opened lock.

(1) Bolt

(6) Washer

Page 31

RENR5077-11 31

Speciﬁcations Section

Lubricate the bearing surfaces of washer (6) with 4C-5597 Anti-S

eize Compound.

(7) Bolt

Lubricate the bolt's bearing surfaces and threads with 4C-5597 Anti-Seize Compound.

Torque .......................... 45 ± 10 N·m (33 ± 7 lb ft)

(8) Bolt

Torque .......................... 55 ± 1

0N·m(41±7lbft)

i03140083

Turboc harger

SMCS Code: 1052

Part No.: 159-8829 S/N: S2R1-Up

Part No.: 159-8829 S/N: S2S1-Up

Part No.: 159-8829 S/N: S2X1-Up

i03149240

Turbo charger

SMCS Code: 105

Part No.: 238-7769 S/N: PAG1-U p

Illustration 44

Rear v ie

(1) Torque for two clamp assemblies ...... 60 ± 5 N·m

g01619692

(44±4lb

ft)

Illustration 43

Rear view

(1) Torque for four V-band clamp

assemblies ..................... 60 ± 5 N·m (44 ± 4 lb ft)

(2) Torque for 12 bolts ......... 40 ± 5 N·m (30 ± 4 lb ft)

(3) Torque for 18 bolts ......... 65 ± 5 N·m (48 ± 4 lb ft)

g01616497

Page 32

32 RENR5077-11 Speciﬁcations Section

i03119342

Turboc harger Support

SMCS Code: 105

Part No.: 139-0600 S/N: S2G1-Up

Part No.: 139-0600 S/N: S2H1-Up

Part No.: 139-0600 S/N: S2P1-U

Part No.: 139-0600 S/N: S2R1-U

Part No.: 139-0600 S/N: S2Z1-

Illustration 45

(1) Torque for 21 bolts ... 120 ± 20 N·m (90 ± 15 lb ft)

(2) Torque for 10 bolts .. 135 ± 20 N·m (100 ± 15 lb ft)

g01595655

Page 33

RENR5077-11 33

Speciﬁcations Section

Accumulator

SMCS Code: 132

S/N: S2Y1-Up

i02835300

Exhaust Bypass Valve

SMCS Code: 105

Part No.: 165-4406 S/N: PAG1-U p

Part No.: 165-4406, 282-3015 S/N: MKH1-Up

Illustration 47

i03341711

g01414647

Illustration 46

(1) Accumulator assembly

Charging medium ............................ Dry nitrogen

Internal volume of compartment for

gas .......................................... 3786 mL (231 in

Charged pressure ..................... 138 kPa (20 psi)

Service pressure ....................... 138 kPa (20 psi)

Bursting pressure ............. 34500 kPa (5000 psi)

g01433346

(1) Torq

ue for the locknut .................. 12.5 ± 1.0 N·m

(110 ± 9 lb in)

(2) 7E -

4677 Spring

Free length ........................ 115.3 mm (4.54 inch)

e diameter ............ 82.55 mm (3.250 inch)

)

Outsid

(3) 7E -4676 Spring

Free length ........................ 115.3 mm (4.54 inch)

Outside diameter ............ 62.48 mm (2.460 inch)

(4) Torque for the nut ..... 14 ± 3 N·m (125 ± 27 lb in)

orque for the ﬁve screws .............. 6.5 ± 1.0 N·m

(5) T

(60±9lbin)

efore assembly, lubricate the threads and the

(6) B

bearing surfaces of the setscrew with 4C-5599 Anti-Seize Compound.

Page 34

34 RENR5077-11 Speciﬁcations Section

i03341316

Exhaust Bypass Valve

ation 48

Illustr

(7) E xhaust bypass valve (8) Locknut (9) Gasket

g01717353

1. Clean the stud, the locknut, and the base of the locknut prior to assembly.

2. Apply 2P-2333 High Temperature Sealer to the threads of the stud that extend through the ﬂange

exhaust bypass valve and to the bottom of

of the thematingfaceofeachlocknut.

3. Tight

en two diagonal locknuts.

Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft)

SMCS Code: 105

Part No.: 259-1436 S/N: B5G1-Up

Part No.: 259-1436 S/N: PAG1-U p

Illustration 49

(1) Torq

ue for the locknut .................. 12.5 ± 1.0 N·m

g01414647

(110 ± 9 lb in)

(2) 25 9

-1435 Spring

Free length .......................... 127 mm (5.00 inch)

e diameter ............ 82.55 mm (3.250 inch)

Outsid

(3) 25 9-1434 Spring

Free length .......................... 127 mm (5.00 inch)

Outside diameter ............ 62.48 mm (2.460 inch)

(4) Torque for the nut ..... 14 ± 3 N·m (125 ± 27 lb in)

orque for the ﬁve screws .............. 6.5 ± 1.0 N·m

(5) T

(60±9lbin)

4. Tighten the remaining locknuts.

ue ............................. 25 ± 6 N·m (18 ± 4 lb ft)

Tor q

5. Tighten all four locknuts again.

Torque ............................. 47 ± 9 N·m (35 ± 7 lb ft)

efore assembly, lubricate the threads and the

(6) B

bearing surfaces of the setscrew with 4C-5599 Anti-Seize Compound.

Page 35

RENR5077-11 35

Speciﬁcations Section

i03697281

Exhaust Manifold

ation 50

Illustr

(7) E xhaust bypass valve (8) Locknut (9) Gasket

g01717353

1. Clean the stud, the locknut, and the base of the locknut prior to assembly.

2. Apply 2P-2333 High Temperature Sealer to the threads of the stud that extend through the ﬂange

exhaust bypass valve and to the bottom of

of the thematingfaceofeachlocknut.

SMCS Code: 105

Part No.: 334-7032 S/N: M8A1-Up

Part No.: 334-7032 S/N: M8B1-Up

Illustration 51

g01988413

Note: Before assembly, lubricate the threads and the bearing surfaces of the bolts with 4C-5599 Anti-Seize Compound.

(1) Torque for the bolts ........ 65 ± 5 N·m (48 ± 4 lb ft)

3. Tight

en two diagonal locknuts.

Torque ............................. 25 ± 6 N·m (18 ± 4 lb ft)

4. Tighten the remaining locknuts.

ue ............................. 25 ± 6 N·m (18 ± 4 lb ft)

Tor q

5. Tighten all four locknuts again.

Torque ............................. 47 ± 9 N·m (35 ± 7 lb ft)

Page 36

36 RENR5077-11 Speciﬁcations Section

Exhaust Manifold

SMCS Code: 105

Part No.: 123-0324 S/N: S2A1-Up

Part No.: 123-0324 S/N: S2B1-Up

Part No.: 123-0324 S/N: S2D1-U

Part No.: 123-0324 S/N: S2E1-U

Part No.: 123-0324 S/N: S2F1-

i03114083

Exhaust Manifold

SMCS Code: 105

Part No.: 129-5488, 161-2502 S/N: S2A1-Up

Part No.: 129-5488, 161-2502 S/N: S2B1-Up

Part No.: 129-5488, 161-2502 S/N: S2D1-U

Part No.: 129-5488, 161-2502 S/N: S2E1-U

Part No.: 129-5488, 161-2502 S/N: S2F1-

Part No.: 129-5488, 161-2502 S/N: S2G1-

Part No.: 129-5488, 161-2502 S/N: S2H1

-Up

Part No.: 129-5488, 161-2502 S/N: S2J

1-Up

i03114039

Illustration 52

ew of engine

Top vi

g01592399

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

ds of the bolts and to the face of the washers.

threa Tighten diagonally opposite bolts simultaneously.

orque for the bolts ........ 55 ± 5 N·m (41 ± 4 lb ft)

(1) T

Part No.: 129-5488, 161-2502 S/N: S2K

1-Up

Part No.: 129-5488, 161-2502 S/N: S2L

1-Up

Part No.: 129-5488, 161-2502 S/N: S2

M1-Up

Part No.: 129-5488, 161-2502

2N1-Up

S/N: S

Part No.: 129-5488, 161-2502

2P1-Up

S/N: S

Part No.: 129-5488, 161-2502

2R1-Up

S/N: S

Part No.: 129-5488

1759

167-

, 161-2502, 161-2503,

S/N: S2S1-Up

No.: 129-5488, 161-2502, 167-1759

Part S/N: S2T1-Up

tNo.:129-5488, 161-2502

Par S/N: S2W1-Up

tNo.:129-5 488, 161-2502, 161-2503

Par S/N: S2X1-Up

Illustration 53

g01592401

Note: Apply 4C-5599 Anti-Seize Compound to the threads of the bolts and to the face of the washers.

(2) Torque for the bolts ........ 65 ± 5 N·m (48 ± 4 lb ft)

rt No.: 129-5488, 161-2502, 161-2503

Pa S/N: S2Y1-Up

rt No.: 129-5488, 161-2502, 167-1759

Pa S/N: S2Z1-Up

Page 37

RENR5077-11 37

Speciﬁcations Section

Illustration 54

Typical example

Top view of engine

Illustration 55

Rear view of engine

g01592366

g01592373

Note: Apply 4C-5599 Anti-Seize Compound to the threads of the bolts and to the face of the washers. Tighten diagonally opposite bolts simultaneously.

(1) Torque for the bolts ........ 55 ± 5 N·m (41 ± 4 lb ft)

Page 38

38 RENR5077-11 Speciﬁcations Section

i02051171

Exhaust Manifold

SMCS Code: 105

Part No.: 238-9120 S/N: PAG1-Up

Part No.: 239-0731 S/N: MKH1-Up

Illustration 56

(1) Clamp

Torque ............................ 25 ± 6 N·m (18 ± 4 lb ft)

(2) Bolt

Lubricate the washer face and the thread with 5P-3931 Anti-Seize Compound before assembly. Tighten diagonally opposite bolts simultaneously.

Torque ............................ 55 ± 5 N·m (41 ± 4 lb ft)

(3) Bolt

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

(4) Bolt

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

(5) Stud

g01052090

Torque ............................ 35 ± 5 N·m (26 ± 4 lb ft)

(6) Bolt

Torque ............................ 55 ± 5 N·m (41 ± 4 lb ft)

Page 39

RENR5077-11 39

Speciﬁcations Section

i03695742

Exhaust Manifold

SMCS Code: 105

Part No.: 240-0745 S/N: B5G1-Up

Part No.: 239-0732 S/N: MRG1-Up

Illustration 57

Typical example

(1) Before assembly, lubricate the threads and the

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

Note: Before assembly, lubricate the threads and the bearing surfaces of the clamps with 4C-5599 Anti-Seize Compound.

(2) Torque for the clamps ........................ 25 ± 6 N·m

(221±53lbin)

(3) Before assembly, lubricate the threads and the

bearing surfaces of the locknuts with 4C-5599 Anti-Seize Compound.

Note: Before assembly, lubricate the threads and the bearing surfaces of the bolts with 4C-5599 Anti-Seize Compound. Tighten diagonally opposite bolts simultaneously.

(4) Torque for the bolts ........ 55 ± 5 N·m (41 ± 4 lb ft)

i02953003

g01987274

Part No.: 7N-6962 S/N: M8A1-Up

Part No.: 7N-6962 S/N: S2A1-Up

Part No.: 7N-6962 S/N: M8B1-Up

Part No.: 7N-6962 S/N: S2B1-Up

Part No.: 7N-6962 S/N: S2D1-Up

Part No.: 7N-6962 S/N: S2E1-Up

Part No.: 7N-6962 S/N: S2F1-Up

Part No.: 7N-6962 S/N: S2G1-Up

Part No.: 7N-6962 S/N: S2H1-Up

Exhaust Flange

SMCS Code: 1061

Part No.: 7N-6962 S/N: S2J1-Up

Page 40

40 RENR5077-11 Speciﬁcations Section

Part No.: 7N-6962 S/N: S2K1-Up

Part No.: 7N-6962 S/N: S2L1-Up

Part No.: 7N-6962 S/N: S2M1-Up

Part No.: 7N-6962 S/N: S2N1-Up

Part No.: 7N-6962 S/N: S2P1-U

Part No.: 7N-6962 S/N: S2R1-U

Part No.: 7N-6962 S/N: S2S1-

Part No.: 7N-6962 S/N: S2T1-

Part No.: 7N-6962 S/N: S2W1

-Up

Part No.: 7N-6962 S/N: S2X

1-Up

Exhaust Flange

SMCS Code: 106

Part No.: 103-6668 S/N: PAG1-U p

Part No.: 103-6668 S/N: MKH1-Up

Part No.: 103-6668 S/N: S2J1-U

Part No.: 103-6668 S/N: S2K1-U

Part No.: 103-6668 S/N: S2P1-

Part No.: 103-6668 S/N: S2R1-

Part No.: 103-6668 S/N: S2S1

-Up

Part No.: 103-6668 S/N: S2T

1-Up

i02836282

Part No.: 7N-6962 S/N: S2Y

Illustration 58

Typ

1-Up

g01468407

ical exam ple

(1) Apply 4C-5599 Anti-Seize Compound to the

eads of 12 bolts.

thr

Part No.: 103-6668 S/N: S2W

1-Up

Part No.: 103-6668 S/N: S2X

1-Up

Part No.: 103-6668 S/N: S2

Y1-Up

Part No.: 103-6668

2Z1-Up

S/N: S

Illustration 59

pical example

g01414164

(1) Apply 4C-5599 Anti-Seize Compound to the

reads of the 16 bolts.

Page 41

RENR5077-11 41

Speciﬁcations Section

Air Cleaner

SMCS Code: 105

Part No.: 5N-8728 S/N: S2A1-Up

i01659336

i02954024

Air Cleaner Adapter

SMCS Code: 105

Part No.: 7W-9828 S/N: M8A1-Up

Part No.: 7W-9828 S/N: S2A1-Up

Part No.: 7W-9828 S/N: M8B1-U

Part No.: 7W-9828 S/N: S2B1-U

Part No.: 7W-9828 S/N: S2D1-

Part No.: 7W-9828 S/N: S2E1-

Part No.: 7W-9828 S/N: S2F1

-Up

Part No.: 7W-9828 S/N: S2G

1-Up

Illustration 60

g00856159

(1) Washer

In order to align the precleaner with the air cleaner, use the 8T-4896 Hard Washers as spacers for the air cleaner.

(2) Bolt

Torque .............................. 12 ± 4 N·m (9 ± 3 lb ft)

(3) Washer

In order to align the precleaner with the air cleaner, use the 8T-4122 Hard Washers as spacers for the precleaner.

Part No.: 7W-9828 S/N: S2K

1-Up

Part No.: 7W-9828 S/N: S2N

1-Up

Part No.: 7W-9828 S/N: S2

P1-Up

Part No.: 7W-9828

2R1-Up

S/N: S

Part No.: 7W-9828

2W1-Up

S/N: S

Part No.: 7W-9828

2Z1-Up

S/N: S

Illustration 61

1) Torque for 48 locknuts ....................... 12 ± 4 N·m

(

g01469799

(105 ± 35 lb in)

Page 42

42 RENR5077-11 Speciﬁcations Section

Air C lean er Adapte r

SMCS Code: 105

Part No.: 4P-2013 S/N: MRG1-Up

Part No.: 4P-2013 S/N: S2G1-Up

Part No.: 4P-2013 S/N: S2H1-U

Part No.: 4P-2013 S/N: S2J1-U

Part No.: 4P-2013 S/N: S2L1-

Part No.: 4P-2013 S/N: S2M1-

Part No.: 4P-2013 S/N: S2R1

-Up

Part No.: 4P-2013 S/N: S2S

1-Up

i02954022

Engine Air Cleaner Service Indicator

SMCS Code: 7452

Part No.: 213 S/N: S2A1-Up

Part No.: 213 S/N: S2B1-Up

Part No.: 21 S/N: S2G1-Up

Part No.: 21 S/N: S2H1-Up

Part No.: 2 S/N: S2P1-Up

Part No.: 2 S/N: S2R1-Up

Part No.: S/N: S2Z1-Up

-1412, 7N-6782

3-1412, 7N-6782

13-1412, 7N-6782

213-1412, 7N-6782

i02894887

Part No.: 4P-2013 S/N: S2T

1-Up

Part No.: 4P-2013 S/N: S2X

1-Up

Part No.: 4P-2013 S/N: S2

Illustration 62

Z1-Up

g01469798

) Torque for 28 locknuts ....................... 12 ± 4 N·m

(105±35lbin)

Illustration 63

Rear view of engine

(1) A ir cleaner

g01440984

Note: Install the air ﬁlter change indicator group with the ﬁlter side toward the air cleaner.

(2) Torque for the two air ﬁlter change indicator

groups ....................... 2.0 ± 0.7 N·m (18 ± 6 lb in)

Page 43

RENR5077-11 43

Speciﬁcations Section

i03688471

Air Inlet and Exhaust Lines

SMCS Code: 105

8; 1061

Part No.: 334-4668 S/N: M8A1-Up

Part No.: 334-4668 S/N: M8B1-Up

Illustration 65

g01983494

Illustration 64

g01983493

(1) Before assembly, lubricate the bore of the O-ring

seals lightly with 5P-3975 Rubber Lubricant.

Illustration 66

Bolt tightening sequence

g01983495

(2) Torque for the bolts .. 120 ± 20 N·m (89 ± 15 lb ft)

Note: Before assembly, lubricate the threads of the plugs with 4C-5599 Anti-Seize Compound.

(3) Torque for the plugs .. 25 ± 5 N·m (221 ± 44 lb in)

(4) Use the following procedure in order to tighten

the bolts of the aftercooler assembly:

1. Assemble the seals to the aftercooler core.

2. Temporarily secure the bottom seal to the

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

3. Assemble the aftercooler with seals to the inlet manifold.

4. Inspect the bottom seal in order to ensure that the seal is seating correctly in the recess.

Page 44

44 RENR5077-11 Speciﬁcations Section

5. Install the aftercooler cover.

6. Inspect the upper seal in order to ensure that the

seal is seating correctly in the recess.

7. Install the cover bolts. Hand tighten the cover bolts.

8. Tighten the bolts in the numerical sequence to 24 ± 6 N·m (212 ± 53 lb in). Refer to Illustration 66.

9. Again, tighten the bolts in the numerical sequence to 47 ± 9 N·m (35 ± 7 lb ft). Refer to Illustration 66.

10. Remove the tape.

i03295780

Air Inlet

SMCS Code: 1058; 1061

Part No.: 173-2947 S/N: S2A1-Up

Part No.: 173-2947 S/N: S2B1-Up

and Exhaust Lines

Part No.: 173-2947 S/N: S2T1-Up

Part No.: 173-2947 S/N: S2W1-Up

Part No.: 173-2947 S/N: S2X1-Up

Part No.: 173-2947 S/N: S2Y1-Up

Part No.: 173-2947 S/N: S2Z1-U

Part No.: 173-2947 S/N: S2D1-Up

Part No.: 173-2947 S/N: S2E1-Up

Part No.: 173-2947 S/N: S2F1-Up

Part No.: 173-2947 S/N: S2G1-Up

Part No.: 173-2947 S/N: S2H1-Up

Part No.: 162-5718, 173-2947 S/N: S2J1-Up

Part No.: 173-2947 S/N: S2K1-Up

Part No.: 173-2947 S/N: S2L1-Up

Part No.: 173-2947 S/N: S2M1-Up

Part No.: 162-5718, 173-2947 S/N: S2N1-Up

Part No.: 173-2947 S/N: S2P1-Up

Part No.: 173-2947 S/N: S2R1-Up

Part No.: 173-2947 S/N: S2S1-Up

Page 45

RENR5077-11 45

Speciﬁcations Section

Illustration 67

Right side view

(1) Lubricate the bore for the O-ring seals with

glycerin or an approved equivalent.

g01679613

Page 46

46 RENR5077-11 Speciﬁcations Section

Illustration 68

Bolt tightening sequence

g01614754

(2) Use the following procedure in order to tighten

the bolts of the aftercooler assembly:

1. Assemble the seals to the aftercooler core.

2. Temporarily secure the bottom seal to the

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

3. Assemble the aftercooler with seals to the inlet manifold.

4. Inspect the bottom seal in order to ensure that the seal is seating correctly in the recess.

5. Install the aftercooler cover.

6. Inspect the upper seal in order to ensure that the

seal is seating correctly in the recess.

7. Install the cover bolts. Hand tighten the cover bolts.

8. Tighten the bolts in the numerical sequence to 24 N·m (18 lb ft).

9. Again, tighten the bolts in the numerical sequence to 47 N·m (35 lb ft).

10. Remove the tape.

Note: Lubricate the threads of the plugs with

4C-5599 Anti-Seize Compound before assembly.

(3) Torque for three plugs .... 20 ± 5 N·m (15 ± 4 lb ft)

Page 47

RENR5077-11 47

Speciﬁcations Section

i03690160

Air Inlet and Exhaust Lines

SMCS Code: 105

8; 1061

Part No.: 107-0860 S/N: S2A1-Up

Part No.: 107-0860 S/N: S2B1-Up

Part No.: 107-0860 S/N: S2D1-U

Part No.: 107-0860 S/N: S2E1-U

Part No.: 107-0860 S/N: S2F1-

Illustration 69

Right side view of engine

g01984493

Page 48

48 RENR5077-11 Speciﬁcations Section

Illustration 70

Bolt tightening sequence

g01614673

(1) Before assembly, lubricate the bore of the O-ring

seals lightly with 5P-3975 Rubber Lubricant.

(2) Use the following procedure in order to tighten

the bolts of the aftercooler assembly:

1. Assemble the seals to the aftercooler core.

2. Temporarily secure the bottom seal to the

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

3. Assemble the aftercooler with seals to the inlet manifold.

4. Inspect the bottom seal in order to ensure that the seal is seating correctly in the recess.

5. Install the aftercooler cover.

6. Inspect the upper seal in order to ensure that the

seal is seating correctly in the recess.

7. Install the cover bolts. Hand tighten the cover bolts.

8. Tighten the bolts in the numerical sequence to 24 ± 6 N·m (212 ± 53 lb in). Refer to Illustration 70.

9. Again, tighten the bolts in the numerical sequence to 24 ± 6 N·m (212 ± 53 lb in). Refer to Illustration

70.

10. Remove the tape.

Note: Before assembly, lubricate the threads of the

plugs with 4C-5599 Anti-Seize Compound.

(3) Torque for the plugs .. 20 ± 5 N·m (177 ± 44 lb in)

(4) Torque for the bolts .. 120 ± 20 N·m (89 ± 15 lb ft)

Page 49

RENR5077-11 49

Speciﬁcations Section

i03137489

Air Inlet and Exhaust Lines

SMCS Code: 105

8; 1061

Part No.: 144-2885 S/N: S2P1-Up

Part No.: 107-0862 S/N: S2R1-Up

Part No.: 107-0862 S/N: S2S1-U

Part No.: 144-2885 S/N: S2W1-U

Illustration 71

Right side view of engine

Illustration 72

View A-A

g01614614

(1) Lubricate the bore for the O-ring seals with

glycerin or an approved equivalent.

g01614613

Page 50

50 RENR5077-11 Speciﬁcations Section

Illustration 73

Bolt tightening s equence

(2) Use the following procedure in order to tighten

the bolts of the aftercooler assembly:

1. Assemble the seals to the aftercooler core.

2. Temporarily secure the bottom seal to the

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

3. Assemble the aftercooler with seals to the inlet manifold.

4. Inspect the bottom seal in order to ensure that the seal is seating correctly in the recess.

5. Install the aftercooler cover.

6. Inspect the upper seal in order to ensure that the

seal is seating correctly in the recess.

7. Install the cover bolts. Hand tighten the cover bolts.

g01614616

Illustration 74

View B-B

Lubricate the threads of the plugs with

Note:

g01614

4C-5599 Anti-Seize Compound before assembly.

rque for two plugs ...... 20 ± 5 N·m (15 ± 4 lb ft)

(4) To

623

8. Tighten the bolts in the numerical sequence to 24 N·m (18 lb ft).

9. Again, tighten the bolts in the numerical sequence to 47 N·m (35 lb ft).

10. Remove the tape.

(3) Torque for the bolts .. 120 ± 20 N·m (90 ± 15 lb ft)

Page 51

RENR5077-11 51

Speciﬁcations Section

i03688482

Air Shutoff

SMCS Code: 107

Part No.: 335-1898 S/N: M8A1-Up

Part No.: 335-1898 S/N: M8B1-Up

Illustration 75

(1) Air shutoff group

Maximum operating temperature of the

valve .......................................... 204 °C (399 °F)

Maximum operating pressure of the

valve ......................................... 300 kPa (44 psi)

Note: Before you assemble the limit switch assembly (2) in the shutoff valve, apply 4C-5599 Anti-Seize Compound to the threads of the plug.

(2) Torque for the limit switch assembly ..... 16.3 N·m

(12.0lbft)

Illustration 76

g01983517

g01927222

Page 52

52 RENR5077-11 Speciﬁcations Section

Note: Apply 4C-5599 Anti-Seize Compound to the threads of the b

olts (3) and to the threads of the bolts

(7).

(3) Torque for

the bolts ......... 7 ± 1 N·m (62 ± 9 lb in)

(4) Apply 4C-5599 Anti-Seize Compound to the

shaftofthea

ir shutoff assembly.

Note: Before assembly, apply 4C-9614 Silicone Sealant bet

ween the body (5) and the cover (6).

(7) Torque for the bolts ........................ 9.5 ± 1.5 N·m

(84.1 ± 13.3

lb in)

(9) Solenoid assembly

Operating voltage .......................... 18 to 32 VDC

Resistance at 25 °C

(77 °F) ................................ 1.4

85 to 1.815 Ohms

Torque for the bolts (8) .................. 9.5 ± 1.5 N·m

(84.1 ± 13.3 lb in)

i03601965

Air Shutoff

Part No.: 214-5543 S/N: S2P1-Up

Part No.: 214-5543 S/N: S2S1-Up

Part No.: 214-5543 S/N: S2T1-Up

Part No.: 214-5543 S/N: S2W1-Up

Part No.: 214-5543 S/N: S2Z1-U

SMCS Code: 1078

Part No.: 214-5543 S/N: S2A1-Up

Part No.: 214-5543 S/N: S2B1-Up

Part No.: 214-5543 S/N: S2D1-Up

Part No.: 214-5543 S/N: S2E1-Up

Part No.: 214-5543 S/N: S2F1-Up

Part No.: 214-5543 S/N: S2G1-Up

Part No.: 214-5543, 274-5749 S/N: S2H1-Up

Part No.: 214-5543 S/N: S2J1-Up

Part No.: 214-5543 S/N: S2K1-Up

Part No.: 214-5543 S/N: S2L1-Up

Illustration 77

Rear v iew

g01927221

(1) Air shutoff group

Maximum operating temperature of the

valve .......................................... 204 °C (399 °F)

Maximum operating pressure of the

valve ......................................... 300 kPa (44 psi)

Note: Before you assemble the limit switch assembly (2) in the shutoff valve, apply 4C-5599 Anti-Seize Compound to the threads of the plug.

(2) Torque for the limit switch assembly ..... 16.3 N·m

(12.0 lb ft)

Part No.: 214-5543 S/N: S2M1-Up

Part No.: 214-5543 S/N: S2N1-Up

Page 53

RENR5077-11 53

Speciﬁcations Section

Part No.: 106-9872 S/N: S2F1-Up

Part No.: 106-9872 S/N: B5G1-Up

Part No.: 106-9872 S/N: MRG1-Up

Part No.: 106-9872 S/N: PAG1-U p

Part No.: 106-9872 S/N: S2G1-U

Part No.: 106-9872 S/N: MKH1-U

Part No.: 106-9872 S/N: S2H1-

Part No.: 106-9872

Illustration 78

g01927222

Note: Apply 4C-5599 Anti-Seize Compound to the threads of the bolts (3) and to the threads of the bolts (7).

S/N: S2J1-

Part No.: 106-9872 S/N: S2K1

Part No.: 106-9872 S/N: S2L

-Up

1-Up

(3) Torque for the bolts ......... 7 ± 1 N·m (62 ± 9 lb in)

(4) Apply 4C-5599 Anti-Seize Compound to the

shaft of the air shutoff assembly.

Note: Before assembly, apply 4C-9614 Silicone Sealant between the body (5) and the cover (6).

(7) Torque for the bolts ........................ 9.5 ± 1.5 N·m

(84.1 ± 13.3 lb in)

(9) Solenoid assembly

Operating voltage .......................... 18 to 32 VDC

Resistance at 25 °C

(77 °F) ................................ 1.485 to 1.815 Ohms

Torque for the bolts (8) .................. 9.5 ± 1.5 N·m

(84.1 ± 13.3 lb in)

i03557502

Engine Oil Pump

SMCS Code: 1304

Part No.: 106-9872 S/N: S2A1-Up

Part No.: 106-9872 S/N: S2M

1-Up

Part No.: 106-9872 S/N: S2N

1-Up

Part No.: 106-9872 S/N: S2

P1-Up

Part No.: 106-9872

2R1-Up

S/N: S

Part No.: 106-9872

2S1-Up

S/N: S

Part No.: 106-9872

2T1-Up

S/N: S

Part No.: 106-9872

S2W1-Up

S/N:

Part No.: 106-9872

S2X1-Up

S/N:

Part No.: 106-9872

: S2Y1-Up

S/N

Part No.: 106-9872

: S2Z1-Up

S/N

Part No.: 106-9872 S/N: S2B1-Up

Part No.: 106-9872 S/N: S2D1-Up

Part No.: 106-9872 S/N: S2E1-Up

Page 54

54 RENR5077-11 Speciﬁcations Section

Diameter of new shaft .......... 31.742 ± 0.008 mm

(1.2497 ± 0.000

3 inch) Bore in the sleeve bearing for the new

shaft ...................................... 31.811 ± 0.013 mm

(1.2524 ± 0.00

05 inch)

(D) Extension of the hollow dowel from the oil pump

cover ................. 6.0 ± 0.

5 mm (0.24 ± 0.02 inch)

(E) Distance from the end of the pump shaft

assembly to

the gear face ........... 34.0 ± 0.5 mm

(1.34 ± 0.02 inch)

Illustration 79

g01554195

Note: The rotation of the drive gear is clockwise when you view the engine oil pump from the drive end.

Note: Before you install the pump, lubricate the moving parts with clean engine oil. Rotate the pump by hand in order to ensure that the pump rotates freely.

(1) 107-7175 Spring

Length under test force ..................... 107.16 mm

(4.219 inch)

Test force ............ 555.6 ± 20.0 N (124.9 ± 4.5 lb)

Free length after test ........ 144.5 mm (5.69 inch)

Outside diameter ............ 27.00 mm (1.063 inch)

(F) Dimensi

ons for the pump drive shaft

Diameter of new pump drive

shaft ..................................... 31.7

42 ± 0.008 mm

(1.2497 ± 0.0003 inch) Bore in the sleeve bearing for the pump drive shaft afte

r assembly ............. 31.811 ± 0.013 mm

(1.2524 ± 0.0005 inch)

(G) Dista

nce from the gear face to the pump drive

shaft assembly ............................. 47.0 ± 0.5 mm

(1.85 ± 0.02 inch)

(H) Installation depth of the sleeve bearing in the

pump cover ....... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

(J) Installation depth of the sleeve bearing in the oil

pump body assembly ..................... 1.5 ± 0.5 mm

(0.06 ± 0

.02 inch)

Illustration 80

(B) Dimension for the gears

Length of new gear ............. 110.000 ± 0.015 mm

(4.3307 ± 0.0006 inch) Depth of the bore in the oil pump body for new

gear ....... 110.15 ± 0.02 mm (4.337 ± 0.001 inch)

g01883030

Illustration 81

g01554196

Page 55

RENR5077-11 55

Speciﬁcations Section

i03602902

Engine Oil P ump

Illustration 82

g01554197

(K) Position of the bearing joints from the centerline

through the bearing bores ........ 45 ± 15 degrees

SMCS Code: 130

Part No.: 7W-0053 S/N: M8A1-Up

Part No.: 7N-8715 S/N: S2A1-Up

Part No.: 7W-0053 S/N: M8B1-U

Part No.: 7N-8715 S/N: S2B1-U

Part No.: 7N-8715 S/N: S2D1-

Part No.: 7N-8715 S/N: S2E1-

Illustration 83

(2) Pump cover

g01881373

(L) Extension of the hollow dowel from the oil pump

cover ................. 6.0 ± 1.0 mm (0.24 ± 0.04 inch)

Bench test speciﬁcations

Unrestricted ﬂow rate per minute at 1000

rpm ....................................... 410 L (108 US gal)

Pump pressure at 300 rpm with fully blocked

outlet ..................... 570 to 630 kPa (83 to 91 psi)

Illustration 84

The rotation of the drive gear is clockwise when

Note:

g01554195

you view the engine oil pump from the drive end.

: Before you install the pump, lubricate the

Note

moving parts with clean engine oil. Rotate the pump by hand in order to ensure that the pump rotates

ly.

free

(1) 2S -2760 Spring

Length under test force .. 117.14 mm (4.612 inch)

Test force ........................ 499 ± 24 N (112 ± 5 lb)

roximate free length after test .... 152.91 mm

App

(6.020 inch)

Outside diameter ............ 27.00 mm (1.063 inch)

Page 56

56 RENR5077-11 Speciﬁcations Section

Illustration 85

g01890213

(2) Before assembly, lubricate the O-ring seal lightly

with 5P-3975 Rubber Lubricant.

(B) Dimensions for the gears

Length of new gear .............. 54.000 ± 0.015 mm

(2.1260 ± 0.0006 inch) Depth of the bore in the oil pump body for the new gear .. 54.15 ± 0.02 mm (2.132 ± 0.001 inch)

Diameter of the new shaft .... 31.742 ± 0.008 mm

(1.2497 ± 0.0003 inch) Boreinthesleevebearingforthenewshaftafter

assembly .............................. 3 1.811 ± 0.013 mm

(1.2524 ± 0.0005 inch)

(D) Extension of the hollow dowel from the pump

cover ................. 6.0 ± 0.5 mm (0.24 ± 0.02 inch)

(E) Distance from the end of the idler shaft to the

gear face ......... 34.0 ± 0.5 mm (1.34 ± 0.02 inch)

(F) Dimensions for the pump drive shaft

Illustration 86

Illustration 87

g01554196

g01554197

(K) Position of bearing joints from the centerline

through the bearing bores ........ 45 ± 15 degrees

Diameter of new shaft .......... 31.742 ± 0.008 mm

(1.2497 ± 0.0003 inch) Boreinthesleevebearingforthenewshaftafter

assembly .............................. 3 1.811 ± 0.013 mm

(1.2524 ± 0.0005 inch)

(G) Distance from the end of the shaft to the gear

face ................. 47.0 ± 0.5 mm (1.85 ± 0.02 inch)

(H) Installation depth of the sleeve bearing in the

pump cover ....... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

(J) Installation depth of the sleeve bearing in the oil

pump body assembly ..................... 1.5 ± 0.5 mm

(0.06 ± 0.02 inch)

Page 57

RENR5077-11 57

Speciﬁcations Section

Part No.: 8N-6152 S/N: S2J1-Up

Part No.: 8N-6152 S/N: S2K1-Up

Part No.: 8N-6152 S/N: S2L1-Up

Part No.: 8N-6152 S/N: S2M1-Up

Part No.: 8N-6152 S/N: S2N1-U

Part No.: 8N-6152 S/N: S2P1-U

Part No.: 8N-6152 S/N: S2R1-

Part No.: 8N-6152

-Up

Illustration 88

(3) Pump cover

g01927801

S/N: S2S1-

Part No.: 8N-6152 S/N: S2T1

(L) Extension of the hollow dowel from the oil pump

cover ................. 6.0 ± 1.0 mm (0.24 ± 0.04 inch)

Bench test speciﬁcations

Unrestricted ﬂow rate at 700 rpm ........... 135.0 L

(35.7 US gal) Pump pressure at 300 rpm with fully blocked

outlet ..................... 570 to 630 kPa (83 to 91 psi)

i03560066

Engine Oil Pump

SMCS Code: 1304

Part No.: 8N-6152 S/N: S2A1-Up

Part No.: 8N-6152 S/N: S2B1-Up

Part No.: 8N-6152 S/N: S2D1-Up

Part No.: 8N-6152 S/N: S2E1-Up

Part No.: 8N-6152 S/N: S2F1-Up

Part No.: 8N-6152 S/N: S2G1-Up

Part No.: 8N-6152 S/N: MKH1-Up

Part No.: 8N-6152 S/N: S2W

1-Up

Part No.: 8N-6152 S/N: S2X

1-Up

Part No.: 8N-6152 S/N: S2Y

1-Up

Part No.: 8N-6152 S/N: S2

Illustration 89

Z1-Up

g01554195

te: The rotation of the drive gear is clockwise when

you view the engine oil pump from the drive end.

te: Before you install the pump, lubricate the

moving parts with clean engine oil. Rotate the pump by hand in order to ensure that the pump rotates

reely.

Part No.: 8N-6152 S/N: S2H1-Up

(1) 2S -2760 Spring

Length under test force .. 117.14 mm (4.612 inch)

Test force .................. 499 ± 24 N (112.2 ± 5.4 lb)

Page 58

58 RENR5077-11 Speciﬁcations Section

Approximate free length after test .... 152.91 mm

(6.020 inch)

Outside diameter ..................... 27 mm (1.1 inch)

Illustration 90

g01890213

(J) Installation depth of the sleeve bearing in the oil

pump body assem

bly ..................... 1.5 ± 0.5 mm

(0.06 ± 0.02 inch)

Illustration 91

g01883675

(2) Before assembly, lubricate the O-ring seal lightly

with 5P-3975 Rubber Lubricant.

(B) Dimensions for the gears

Length of new gear .............. 84.000 ± 0.015 mm

(3.3071 ± 0.0006 inch) Depth of the bore in the oil pump body for the new gear .. 84.15 ± 0.02 mm (3.313 ± 0.001 inch)

Diameter of new shaft .......... 31.742 ± 0.008 mm

(1.2497 ± 0.0003 inch) Boreinthesleevebearingforthenewshaftafter

assembly .............................. 3 1.811 ± 0.013 mm

(1.2524 ± 0.0005 inch)

(D) Extension of hollow dowel from the oil pump

cover ................. 6.0 ± 1.0 mm (0.24 ± 0.04 inch)

(E) Distance from the end of the idler shaft to the

gear face ......... 34.0 ± 0.5 mm (1.34 ± 0.02 inch)

(F) Dimensions for the pump drive shaft

Diameter of new shaft .......... 31.742 ± 0.008 mm

(1.2497 ± 0.0003 inch) Boreinthesleevebearingforthenewshaftafter

assembly .............................. 3 1.811 ± 0.013 mm

(1.2524 ± 0.0005 inch)

Illustration 92

g01883677

(K) Position of bearing joints from the centerline

through the bearing bores ........ 45 ± 15 degrees

(G) Distance from the end of the shaft to the gear

face ................. 47.0 ± 0.5 mm (1.85 ± 0.02 inch)

(H) Installation depth of the sleeve bearing in the

pump cover ....... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

Page 59

RENR5077-11 59

Speciﬁcations Section

i02941571

Engine Oil P ump

ation 93

Illustr

(3) Pump cover

g01883017

SMCS Code: 130

Part No.: 244-8985 S/N: MRG1-Up

Part No.: 244-8985 S/N: MKH1-Up

Illustration 94

(1) Lubr

icate the bore of the O-ring seal lightly with 5P-3975 Rubber Lubricant immediately before assembly of the engine oil pump.

g01459732

(L) Extension of the hollow dowel from the oil pump

cover ................. 6.0 ± 0.5 mm (0.24 ± 0.02 inch)

Bench test speciﬁcations

Unrest

ricted ﬂow rate at 700 rpm ....... 220 L/min

(58.1 US gpm)

Pump pressure at 300 rpm with fully blocked

t .................... 570 to 630 kPa (83 to 91 psi )

outle

Illustration 95

(2) 2S -2760 Spring

Length under test force .. 117.14 mm (4.612 inch)

Test force .................. 499 ± 24 N (112.2 ± 5.4 lb)

Approximate free length after test .... 152.91 mm

(6.020 inch)

Outside diameter ............ 27.00 mm (1.063 inch)

g01459725

Page 60

60 RENR5077-11 Speciﬁcations Section

Illustration 96

g01459726

(B) Dimensions for the gears

Length of new gear .............. 84.000 ± 0.015 mm

(3.3071 ± 0.0006 inch) Depth of the bore in the oil pump body for the new gear .. 84.15 ± 0.02 mm (3.313 ± 0.001 inch)

Diameter of new shaft .......... 31.742 ± 0.008 mm

(1.2497 ± 0.0003 inch) Bore in the sleeve bearing for the new

shaft ................ ...................... 31.811 ± 0.013 mm

(1.2524 ± 0.0005 inch)

(D) Extension of the hollow dowel from the oil pump

cover ................. 6.0 ± 0.5 mm (0.24 ± 0.02 inch)

(E) Distance from the end of the pump shaft

assembly to the gear face ........... 34.0 ± 0.5 mm

(1.34 ± 0.02 inch)

(F) Dimensions for the pump drive shaft

Diameter of new pump drive

shaft ..................................... 31.742 ± 0.008 mm

(1.2497 ± 0.0003 inch) Bore in the sleeve bearing for the pump drive

shaft ................ ...................... 31.811 ± 0.013 mm

(1.2524 ± 0.0005 inch)

(G) Distance from the end of the pump drive shaft

assembly to the gear face ........... 47.0 ± 0.5 mm

(1.85 ± 0.02 inch)

(H) Installation depth of the sleeve bearing in the

pump cover ....... 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

Illustr

ation 97

g01502139

(K) Extension of the dowel from the oil pump

cover ................. 6.

Illustration 98

0 ± 1.0 mm (0.24 ± 0.04 inch)

g01459731

(L) Position of the bearing joints from the centerline

through the bearing bores ........ 45 ± 15 degrees

Bench test speciﬁcations

(J) Installation depth of the sleeve bearing in the oil

pump body assembly. .................... 1.5 ± 0.5 mm

(0.06 ± 0.02 inch)

Unrestricted ﬂow rate at 700 rpm ....... 220 L/min

(58 US gpm)

Page 61

RENR5077-11 61

Speciﬁcations Section

Pump pressure at 300 rpm with fully blocked

outlet ................. 710 to 77

0kPa(105to110psi)

Note: Before you install the pump, lubricate the moving parts w

ith clean engine oil. Rotate the pump by hand in order to ensure that the pump rotates freely.

i02394919

Engine Oil Scavenge Pump

SMCS Code: 1312

Part No.: 8N-9164 S/N: M8A1-Up

Part No.: 8N-9164 S/N: M8B1-Up

Illustration 99

NOTICE

Before operation, the pump must be lubricated with

ean engine oil and the pump must turn freely by hand

cl or damage to parts can be the result.

en the oil scavenge pump is viewed from

Wh thedriveendthedriverotatesinthefollowing

direction. ....................................... Counterclockwise

(1) Length of new gears

N-9164 Pump Group ........ 84.000 ± 0.015 mm

(3.3071 ± 0.0006 inch)

1W-8508 Pump Group ....... 110.000 ± 0.015 mm

3307 ± 0.0006 inch)

(4.

144-8267 Pump Group .... 145.000 ± 0.015 mm

(5.7087 ± 0.0006 inch)

Depth of bores for new gears

-9164 Pump Group ........ 84.150 ± 0.020 mm

(3.3130 ± 0.0008 inch)

1W-8508 Pump Group ....... 110.150 ± 0.020 mm

4.3366 ± 0.0008 inch)

(

144-8267 Pump Group .... 145.150 ± 0.020 mm

(5.7146 ± 0.0008 inch)

g00

118286

Page 62

62 RENR5077-11 Speciﬁcations Section

(2) Diameter of new gear shafts .. 31.742 ± 0.008 mm

(1.2497 ± 0.000

3 inch)

Bore in bearings for new gear shafts after

assembly .................................... 31.8

37 ± 0.070 mm

(1.2534 ± 0.0028 inch)

(3) Distance

from the end of the shafts to the gear

faces ............... 34.0 ± 0.5 mm (1.34 ± 0.02 inch)

(4) The bear

ings are installed in the pump body at

the following depth: ........................ 1.5 ± 0.5 mm

(0.06 ± 0.02 inch)

(5) Bolt

Note: Befo

re installing a gear onto the shaft, clean the shaft and clean the gear's bore with isopropyl alcohol.

1. Tap on gear in order to seat the taper on the shaft.

2. Tighten t

he bolt to the following torque:

Torque for bolt ........... 100 ± 20 N·m (75 ± 15 lb ft)

Repeat this procedure until the torque does not change.

Illustration 100

Typical example

g00118287

Page 63

RENR5077-11 63

Speciﬁcations Section

Illustration 101

g00118288

(6) Position of bearing joints from the centerline

through the bearing bores ........ 45 ± 15 degrees

(7) The bearings are installed in the cover at the

following depth: .. 1.5 ± 0.5 mm (0.06 ± 0.02 inch)

(8) The dowels extend from the cover at the following

distance: ........... 6.4 ± 0.5 mm (0.25 ± 0.02 inch)

i03686767

Engine Oi l Cooler Bypass and Cooling Jet Seq uence Valves

SMCS Code: 1314; 1331

Part No S/N: M8A1-Up

Part N S/N: M8B1-Up

.: 335-3154, 335-3155

o.: 335-3154, 335-3155

Illustration 102

(1) Lubricate the bore of the O-ring seals lightly with

the clean engine oil.

g01982413

(2) Torque for the plug ... 100 ± 15 N·m (74 ± 11 lb ft)

Page 64

64 RENR5077-11 Speciﬁcations Section

Note: The oil cooler bypass valve must open with a pressure diffe

(3) 2W-1635 Spring for oil cooler bypass valve

Length under test force ..... 102.0 mm (4.02 inch)

Test force ........................ 518 ± 26 N (116 ± 6 lb)

Free length af

Outside diameter ........ 37.251 mm (1.4666 inch)

Note: The coo to open at a pressure difference of 130 ± 30 kPa (18.9±4.4psi).

Note: The cooling jet sequence valves must be fully open at a pressure difference of 200 ± 30 kPa (29.0 ± 4.4

(4) 6B-9202 Spring for the cooling jet sequence

valve

Length under test force ....... 68.3 mm (2.69 inch)

Te s t f or c

Free length after test ......... 112.7 mm (4.44 inch)

Outside diameter ............ 24.60 mm (0.969 inch)

rence of 180 ± 20 kPa (26.1 ± 2.9 psi).

ter test ........ 143.4 mm (5.65 inch)

ling jet sequence valves must start

psi).

e ............... 85 to 100 N (19.0 to 22.4 lb)

i03139927

Engine Oi l Cooler Bypass and Cooling Jet Seq uence Valves

SMCS Code: 1314; 1331

Part No.: 115-7860 S/N: S2A1-Up

Part No.: 115-7860 S/N: S2J1-Up

Part No.: 115-7860 S/N: S2K1-Up

Part No.: 115-7860 S/N: S2L1-Up

Part No.: 115-7860 S/N: S2M1-Up

Part No.: 115-7860 S/N: S2N1-U

Part No.: 115-7860 S/N: S2P1-U

Part No.: 115-7860 S/N: S2R1-

Part No.: 115-7860 S/N: S2S1-

Part No.: 115-7860 S/N: S2T1

Part No.: 115-7860 S/N: S2W

Part No.: 115-7860 S/N: S2X

Part No.: 115-7860 S/N: S2Y

Part No.: 115-7860 S/N: S2

-Up

1-Up

Z1-Up

Part No.: 115-7860 S/N: S2B1-Up

Part No.: 115-7860 S/N: S2D1-Up

Part No.: 115-7860 S/N: S2E1-Up

Part No.: 115-7860 S/N: S2F1-Up

Part No.: 115-7860 S/N: B5G1-Up

Part No.: 115-7860 S/N: MRG1-Up

Part No.: 115-7860 S/N: PAG1-Up

Part No.: 115-7860 S/N: S2G1-Up

Part No.: 115-7860 S/N: MKH1-Up

Part No.: 115-7860 S/N: S2H1-Up

Page 65

RENR5077-11 65

Speciﬁcations Section

Illustration 103

Right side view

Typical example

Illustration 104

Front view

Typical example

g01616353

Use the following tightening sequence for the clamp bolts:

1. Snugly tighten the clamp assembly (3) to the tube

(4).

2. Tighten two bolts (2) of the clamp assembly to the

elbow(10)to47±9N·m(35±7lbft).

g01616336

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

Note: The cooling jet sequence valves must be fully open at a pressure difference of 200 ± 30 kPa (29.0 ± 4.5 psi).

(5) 6B -9202 Spring for the cooling jet sequence

valve

Quantity ............................................................ 2

Length under test force ....... 68.3 mm (2.69 inch)

Test force ..................... 85 to 102 N (19 to 23 lb)

Free length after test ......... 112.7 mm (4.44 inch)

Outside diameter ............ 24.60 mm (0.969 inch)

Note: The oil cooler bypass valve must open with a pressure difference of 180 ± 20 kPa (26 ± 3 psi).

(6) 2W -1635 Spring for oil cooler bypass valve

Length under test force ..... 102.0 mm (4.02 inch)

Test force .................. 518 ± 26 N (115.0 ± 5.8 lb)

Free length after test ........ 143.4 mm (5.65 inch)

Outside diameter ........ 37.251 mm (1.4666 inch)

(7) Lubricate the bore of the O-ring seals lightly with

the clean engine oil.

(8) Lubricate the bore of two O-ring plugs lightly with

the clean engine oil.

(9) Torque for the plug ... 100 ± 15 N·m (75 ± 11 lb ft)

3. Tighten two bolts (1) of the clamp assembly to the

tube(4)to47±9N·m(35±7lbft).

Page 66

66 RENR5077-11 Speciﬁcations Section

i03670352

Engine Oil Filter

SMCS Code: 131

Part No.: 112-4921

Illustration 105

Front view

(1) Lubricate the bore of the O-ring seals lightly with

clean engine oil.

(2) 2W-1635 Spring

Length under test force ..... 102.0 mm (4.02 inch)

g01445657

Test force ........................ 518 ± 26 N (116 ± 6 lb)

Free length after test ........ 143.4 mm (5.65 inch)

Outside diameter ........ 37.251 mm (1.4666 inch)

Note: The bypass valve (3) must move freely in the bore.

Page 67

RENR5077-11 67

Speciﬁcations Section

(3) Bypass valve

Start to open pressure ..................... 287 ± 7 kPa

(41.6 ± 1.0 psi)

Fully open pre

(4) Torque for

ssure ......................... 480 ± 7 kPa

(69.6 ± 1.0 psi)

the bolts ........ 55 ± 7 N·m (41 ± 5 lb ft)

Engine Oil Filter

SMCS Code: 1318

Part No.: 242-6278 S/N: M8A1-Up

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2A1-Up

Part No.: 242-6278 S/N: M8B1-Up

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2B1-Up

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2D1-Up

i03742181

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2P1-Up

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2R1-Up

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2S1-Up

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2T1-Up

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2W1-U

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2X1-U

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2Y1-

Part No.: 115-7841, 147-3172, 242-6278,

4W-6874

S/N: S2Z1-Up

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2E1-Up

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2F1-Up

Part No.: 242-6278 S/N: B5G1-Up

Part No.: 242-6278 S/N: MRG1-Up

Part No.: 242-6278 S/N: PAG1-Up

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2G1-Up

Part No.: 242-6278 S/N: MKH1-Up

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2H1-Up

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2J1-Up

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2K1-Up

Part No.: 115-7841, S/N: S2L1-Up

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2M1-Up

Part No.: 115-7841, 242-6278, 4W-6874 S/N: S2N1-Up

242-6278, 4W-6874

Page 68

68 RENR5077-11 Speciﬁcations Section

Illustration 106

Front view

(1) Lubricate the bore of the O-ring seals lightly with

clean engine oil.

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

(3) 2W-1635 Spring

Length under test force ..... 102.0 mm (4.02 inch)

Test force ........................ 518 ± 26 N (117 ± 6 lb)

Free length after test force ................. 143.4 mm

(5.65 inch)

Outside diameter ........ 37.251 mm (1.4666 inch)

Note: Bypass valve (4) must move freely in the bore.

(4) Bypass valve

Start to open pressure: .. 287 ± 7 kPa (42 ± 1 psi)

Fully open pressure: ..... 480 ± 7 kPa (70 ± 1 psi)

g01417897

Page 69

RENR5077-11 69

Speciﬁcations Section

Engine Oil Lines

SMCS Code: 130

Part No.: 335-3157 S/N: M8A1-Up

Part No.: 335-3157 S/N: M8B1-Up

i03686744

i01906041

Engine Oil Lines (Front Mounted Engine Oil Filter)

SMCS Code: 1307

Part No.: 242-6279 S/N: M8A1-Up

Part No.: 107-7180, 242-6279 S/N: S2A1-Up

Part No.: 242-6279 S/N: M8B1-Up

Part No.: 107-7180, 242-6279 S/N: S2B1-Up

Part No.: 107-7180, 242-6279 S/N: S2D1-Up

Part No.: 107-7180, 242-6279 S/N: S2E1-Up

Part No.: 107-7180, 242-6279 S/N: S2F1-Up

Illustration 107

Typical example

(1) Lubricate the bore of the O-ring seals lightly with

the clean engine oil.

Use the following tightening sequence to tighten the bolts of the clamp assembly (2):

1. Snugly tighten the clamp assembly to the tube .

2. Tighten the bolts of the clamp assembly to the

elbowto47±9N·m(35±7lbft).

3. Tighten the bolts of the clamp assembly to the

tube to 47 ± 9 N·m (35 ± 7 lb ft).

g01982333

Part No.: 107-7180, 242-6279 S/N: B5G1-Up

Part No.: 107-7180, 242-6279 S/N: MRG1-Up

Part No.: 107-7180, 242-6279 S/N: PAG1-U p

Part No.: 107-7180, 242-6279 S/N: S2G1-Up

Part No.: 107-7180, 242-6279 S/N: MKH1-Up

Part No.: 107-7180, 242-6279 S/N: S2H1-Up

Part No.: 107-7180, 242-6279 S/N: S2J1-Up

Part No.: 107-7180, 242-6279 S/N: S2K1-Up

Part No.: 107-7180, 242-6279 S/N: S2L1-Up

Part No.: 107-7180, 242-6279 S/N: S2M1-Up

Part No.: S/N: S2N1-Up

107-7180, 242-6279

Part No.: 107-7180, 242-6279 S/N: S2P1-Up

Part No.: 107-7180, 242-6279 S/N: S2R1-Up

Page 70

70 RENR5077-11 Speciﬁcations Section

Part No.: 107-7180, 242-6279 S/N: S2S1-Up

Part No.: 107-7180, 242-6279 S/N: S2T1-Up

Part No.: 107-7180, 242-6279 S/N: S2W1-Up

Part No.: 107-7180, 242-6279 S/N: S2X1-Up

Part No.: 107-7180, 242-6279 S/N: S2Y1-U

Part No.: 107-7180, 242-6279 S/N: S2Z1-U

(1) Clamp bolts

Torque ............................ 47 ± 9 N·m (35 ± 7 lb ft)

Tightening se

quence for the clamp bolts

1. Snugly tighten the clamp assembly to the tube.

2. Tighten the clamp assembly to the elbow.

3. Tighten the c

lamp assembly to the tube.

(2) O-rings

Lubricate the O-rings with clean engine oil prior to assembly.

i03694821

Duplex Engine Oil Filt ers

SMCS Code: 1318

Part No.: 120-4501 S/N: M8A1-Up

Part No.: 120-4501 S/N: S2A1-Up

Illustration 108

Right side view

g00992667

Part No.: 120-4501 S/N: M8B1-Up

Part No.: 120-4501 S/N: S2B1-Up

Part No.: 120-4501 S/N: S2D1-Up

Part No.: 120-4501 S/N: S2E1-Up

Part No.: 120-4501 S/N: S2F1-Up

Part No.: 120-4501 S/N: B5G1-Up

Part No.: 120-4501 S/N: MRG1-Up

Part No.: 120-4501 S/N: PAG1-U p

Part No.: 120-4501 S/N: S2G1-Up

Part No.: 120-4501 S/N: MKH1-Up

Illustration 109

Front view (typical example)

g00992788

Part No.: 120-4501 S/N: S2H1-Up

Part No.: 120-4501 S/N: S2J1-Up

Part No.: 120-4501 S/N: S2K1-Up

Page 71

RENR5077-11 71

Speciﬁcations Section

Part No.: 120-4501 S/N: S2L1-Up

Part No.: 120-4501 S/N: S2M1-Up

Part No.: 120-4501 S/N: S2N1-Up

Part No.: 120-4501 S/N: S2P1-Up

Part No.: 120-4501 S/N: S2R1-U

Part No.: 120-4501 S/N: S2S1-U

Part No.: 120-4501 S/N: S2T1-

Part No.: 120-4501 S/N: S2W1-

Part No.: 120-4501 S/N: S2X1

-Up

Part No.: 120-4501 S/N: S2Y

Part No.: 120-4501, 4W-9968 S/N: S2Z

1-Up

Page 72

72 RENR5077-11 Speciﬁcations Section

Illustration 110

Front view

(2) Lever (3) Lever

(5) Tie rod (6) Ball plunger assembly

Note: Refer to Testing and Adjusting, “Duplex Oil Filter - Adjust” for correct adjustment procedures of the ﬂuid control valve group (10).

(1) Lightly lubricate the O-ring seals with clean

engine oil.

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

(8) 2W-1635 Spring

Length under test force ..... 102.0 mm (4.02 inch)

Test force ........................ 518 ± 26 N (116 ± 6 lb)

Free length after test ........ 143.4 mm (5.65 inch)

Outside diameter ........ 37.251 mm (1.4666 inch)

g02002813

(7) Bracket (11) Cover

Note: The bypass valve (9) must move freely in the bore. The bypass valve must start to open at 287 ± 7 kPa (42 ± 1 psi). The bypass valve must be fully open at 480 ± 7 kPa (70 ± 1 psi).

Page 73

RENR5077-11 73

Speciﬁcations Section

Engine Oil Filter Base

SMCS Code: 130

Part No.: 151-9270, 8N-2001

i02947466

Part No.: 124-5513 S/N: S2G1-Up

Part No.: 124-5513 S/N: MKH1-Up

Part No.: 124-5513 S/N: S2H1-Up

Part No.: 124-5513 S/N: S2J1-Up

Part No.: 124-5513 S/N: S2K1-U

Part No.: 124-5513 S/N: S2L1-U

Part No.: 124-5513 S/N: S2N1-

Part No.: 124-5513, 247-4696 S/N: S2P1-

Part No.: 124-5513, 247-4696 S/N: S2R1

-Up

Part No.: 124-5513, 247-4696 S/N: S2S

1-Up

Illustration 111

Typical example

g01460980

(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)

(1) Torque for the hollow stud ............... 80 ± 14 N·m

(60 ± 10 lb ft)

i02895692

Crankcase Breather

SMCS Code: 1317

Part No.: 124-5513 S/N: S2A1-Up

Part No.: 124-5513 S/N: S2B1-Up

Part No.: 124-5513 S/N: S2D1-Up

Part No.: 124-5513 S/N: S2E1-Up

Part No.: 124-5513, 247-4696 S/N: S2T

1-Up

Part No.: 124-5513, 247-4696 S/N: S2W

1-Up

Part No.: 124-5513, 247-4696

X1-Up

S/N:

Part No.: 124-5513, 247-4696

2Y1-Up

S/N: S

Part No.: 247-4696

2Z1-Up

S/N: S

Part No.: 124-5513 S/N: B5G1-Up

Part No.: 124-5513 S/N: MRG1-Up

Part No.: 124-5513 S/N: PAG1-Up

Page 74

74 RENR5077-11 Speciﬁcations Section

Illustration 112

(2) Breather assembly (4) Cover assembly

(1) Lubricate the bore of the four O-ring seals lightly

with clean engine oil.

(3) Torque for the six hose clamps ...... 3.0 ± 0.5 N·m

(27±4lbin)

g01441554

Page 75

RENR5077-11 75

Speciﬁcations Section

i03137363

Crankcase Breather

SMCS Code: 131

Part No.: 101-0838 S/N: M8A1-Up

Part No.: 101-0838 S/N: S2A1-Up

Part No.: 101-0838 S/N: M8B1-U

Part No.: 101-0838 S/N: S2B1-U

Part No.: 101-0838 S/N: S2D1-

Part No.: 101-0838 S/N: S2E1-

Part No.: 101-0838 S/N: S2F1

-Up

Illustration 113

(3) Breather assembly (4) Cover assembly

(1) Lubricate the bore of two O-ring seals lightly with

clean engine oil.

(2) Torque for three hose clamps ........ 3.0 ± 0.5 N·m

(27±4lbin)

g01614413

Page 76

76 RENR5077-11 Speciﬁcations Section

Crankcase Breather

SMCS Code: 131

Part No.: 247-4696 S/N: S2P1-Up

Part No.: 247-4696 S/N: S2R1-Up

Part No.: 247-4696 S/N: S2S1-U

Part No.: 247-4696 S/N: S2T1-U

Part No.: 247-4696 S/N: S2W1-

Part No.: 247-4696 S/N: S2X1-

Part No.: 247-4696 S/N: S2Y1

Part No.: 247-4696 S/N: S2Z

-Up

1-Up

i03117145

Part No.: 8N-6164 S/N: S2A1-Up

Part No.: 8N-6164 S/N: S2B1-Up

Part No.: 8N-6164 S/N: S2D1-Up

Part No.: 8N-6164 S/N: S2E1-Up

Part No.: 8N-6164 S/N: S2F1-U

Part No.: 8N-6164 S/N: MRG1-U

Part No.: 8N-6164 S/N: PAG1-

Part No.: 8N-6164 S/N: S2G1-

Part No.: 8N-6164 S/N: MKH1

Part No.: 8N-6164 S/N: S2H

-Up

1-Up

Illustration 114

(1) Lubricate the bore for the seal with clean engine

oil.

(2) Torque for the hose clamps ........... 3.0 ± 0.5 N·m

g01594054

(27±4lbin)

i02948560

Engine Oil Pan

Part No.: 8N-6164 S/N: S2J

Part No.: 8N-6164 S/N: S2K

Part No.: 8N-6164 S/N: S2

Part No.: 8N-6164 S/N: S

Part No.: 8N-6164 S/N:

Part No.: 8N-6164 S/N

Part No.: 8N-6164

N: S2X1-Up

Part No.: 8N-6164

N: S2Y1-Up

1-Up

L1-Up

2M1-Up

2N1-Up

2P1-Up

S2R1-Up

S2S1-Up

: S2T1-Up

: S2W1-Up

SMCS Code: 1302

Page 77

RENR5077-11 77

Speciﬁcations Section

Illustration 115

Illustration 116

Use the following procedure in order to tighten the bolts of the plate:

1. Tighten ﬁve bolts (12) to standard torque.

2. Tighten bolt (1) through bolt (10) in a numerical

sequence that is shown in Illustration 115 to standard torque.

g01462912

g01462767

(14) As required, apply 4C-9614 Silicone Sealant,

Permatex No. 2 or 138-8436 Liquid Gasket on the sealing surface of the oil pan prior to assembly. The sealing surfaces are the following areas:

Connecting joint of the ﬂywheel housing (17) and

•

the rear of the cylinder block

(11) As required, apply 4C-9614 Silicone Sealant,

Permatex No. 2 or 138-8436 Liquid Gasket to the six joints of the gasket prior to assembly.

(13) Lubricate the bore of nine O-ring seals lightly

with the lubricant that is being sealed or an approved equivalent.

Connecting joint of the front accessory drive

•

housing (18) and the front of the cylinder block

(15) As required, apply 4C-9614 Silicone Sealant,

Permatex No. 2 or 138-8436 Liquid Gasket to the sealing surface of the integral seal prior to assembly.

Page 78

78 RENR5077-11 Speciﬁcations Section

(16) As required, apply 4C-9509 Wicking Sealant to

theopentopend of the oil pan.

(19) Torque fo

(20) Torque f

r the oil drain plug ......... 145 ± 15 N·m

or the oil drain plug ............. 55 ± 7 N·m

of the bolt holes after assembly

(105 ± 11 lb ft)

(41±5lbft)

i03139780

Engine Oil Pan

SMCS Code: 1302

Part No.: 8N-7706 S/N: S2A1-Up

Part No.: 8N-7706 S/N: S2B1-Up

Part No.: 8N-7706 S/N: S2D1-Up

Part No.: 8N-7706 S/N: S2E1-Up

Part No.: 8N-7706 S/N: S2S1-Up

Part No.: 8N-7706 S/N: S2T1-Up

Part No.: 8N-7706 S/N: S2W1-Up

Part No.: 8N-7706 S/N: S2X1-Up

Part No.: 8N-7706 S/N: S2Y1-U

Part No.: 8N-7706 S/N: S2Z1-U

Part No.: 8N-7706 S/N: S2F1-Up

Part No.: 8N-7706 S/N: MRG1-Up

Part No.: 8N-7706 S/N: PAG1-Up

Part No.: 8N-7706 S/N: S2G1-Up

Part No.: 8N-7706 S/N: MKH1-Up

Part No.: 8N-7706 S/N: S2H1-Up

Part No.: 8N-7706 S/N: S2J1-Up

Part No.: 8N-7706 S/N: S2K1-Up

Part No.: 8N-7706 S/N: S2L1-Up

Part No.: 8N-7706 S/N: S2M1-Up

Part No.: 8N-7706 S/N: S2N1-Up

Part No.: 8N-7706 S/N: S2P1-Up

Part No.: 8N-7706 S/N: S2R1-Up

Page 79

RENR5077-11 79

Speciﬁcations Section

Illustration 117

Use the following procedure in order to tighten the bolts of the plate:

1. Tighten ﬁve bolts (11) to a standard torque.

2. Tighten bolt 1 through bolt 10 in a numerical

sequence that is shown in Illustration 117 to a standard torque.

(12) As required, apply 8T-9014 Silicone Sealant,

Permatex No. 2 or 138-8436 Liquid Gasket to the joints of the gasket prior to assembly.

(13) Lubricate the bore of nine O-ring seals lightly

with the lubricant that is being sealed.

(14) As required, apply 8T-9014 Silicone Sealant,

Permatex No. 2 or 138 -8436 Liquid Gasket on the sealing surface of the oil pan prior to assembly. The sealing surfaces are the following areas:

Connecting joint of the ﬂywheel housing (17) and

•

the rear of the cylinder block

Connecting joint of the front accessory drive

•

housing (18) and the front of the cylinder block

g01616154

(15) As required, apply 4C-9509 Wicking Sealant to

the open top end of the bolt holes after assembly of the oil pan.

(16) As required, apply 8T-9014 Silicone Sealant,

Permatex No. 2 or 138-8436 Liquid Gasket to the sealing surface of the integral seal prior to assembly.

(19) Torque for the oil drain plug ......... 145 ± 15 N·m

(105 ± 11 lb ft)

(20) Torque for the oil drain plug ............. 55 ± 7 N·m

(41±5lbft)

i03139762

Engine Oil Pan

SMCS Code: 1302

Part No.: 335-3170, 7C-6887 S/N: M8A1-Up

Part No.: 7C-6887, 7C-7178, 7C-7185 S/N: S2A1-Up

Page 80

80 RENR5077-11 Speciﬁcations Section

Part No.: 335-3170, 7C-6887 S/N: M8B1-Up

Part No.: 7C-6887, 7C-7178, 7C-7185, 7C-9938 S/N: S2B1-Up

Part No.: 7C-6887, 7C-7178, 7C-7185, 7C-9938 S/N: S2D1-Up

Part No.: 7C-6887, 7C-7178, 7C-7185, 7C-9938 S/N: S2E1-Up

Part No.: 7C-6887, 7C-7185, 7C-9938 S/N: S2F1-U

Part No.: 7C-7178 S/N: B5G1-U

Part No.: 7C-7178, 7C-9938 S/N: MRG1-

Part No.: 7C-7178, 7C-9938 S/N: PAG1-

Part No.: 7C-7178, 7C-9938 S/N: S2G1

Part No.: 7C-7178, 7C-9938 S/N: MKH

-Up

1-Up

Part No.: 7C-7178 S/N: S2Z1-Up

Part No.: 7C-7178, 7C-9938 S/N: S2H

Part No.: 7C-7178, 7C-9938 S/N: S2J

Part No.: 7C-7178, 7C-9938 S/N: S2

Part No.: 7C-7178 S/N: S

Part No.: 7C-9938 S/N: S

Part No.: 7C-7178, 7C-9938 S/N: S

Part No.: 7C-7178, 7C-9938 S/N:

Part No.: 7C-7178, 7C-9938 S/N

1-Up

K1-Up

, 7C-9938

2L1-Up

2M1-Up

2N1-Up

S2P1-Up

S2R1-Up

: S2S1-Up

: S2T1-Up

Part No.: 7C-7178, 7C-9938

N: S2W1-Up

Part No.: 7C-7178, 7C-9938

N: S2X1-Up

Part No.: 7C-7178, 7C-9938

/N: S2Y1-Up

Page 81

RENR5077-11 81

Speciﬁcations Section

Illustration 118

Typical example

(1) Before assembly, apply 1P-0808 Multipurpose

Grease in order to lubricate the bores of the O-ring seals.

(2) As required, apply 8T-9014 Silicone Sealant

or 138-8436 Liquid Gasket to the joints of the gasket.

(4) Torque for two oil drain plugs ......... 145 ± 15 N·m

(105 ± 11 lb ft)

In order to prevent stress on the tube assembly (6), use the following tightening procedure during assembly:

1. Tightentwobolts(5)to47±9N·m(35±7lbft).

2. Tightentwobolts(3)to47±9N·m(35±7lbft).

g01448462

i01957454

Water Temperature Regulator

SMCS Code: 1355

Part No.: 248-5513 S/N: M8A1-Up

Part No.: 248-5513, 4W-4794 S/N: S2A1-Up

Part No.: 248-5513 S/N: M8B1-Up

Part No.: 248-5513, 4W-4794 S/N: S2B1-Up

Part No.: 248-5513, 4W-4794 S/N: S2D1-Up

Page 82

82 RENR5077-11 Speciﬁcations Section

Part No.: 248-5513, 4W-4794 S/N: S2E1-Up

Part No.: 248-5513, 4W-4794 S/N: S2F1-Up

Part No.: 248-5513, 4W-4794 S/N: B5G1-Up

Part No.: 248-5513, 4W-4794 S/N: MRG1-Up

Part No.: 248-5513, 4W-4794 S/N: PAG1-U

Part No.: 248-5513, 4W-4794 S/N: S2G1-U

Part No.: 248-5513, 4W-4794 S/N: MKH1-

Part No.: 248-5513, 4W-4794 S/N: S2H1-

Part No.: 248-5513, 4W-4794 S/N: S2J1

Part No.: 248-5513, 4W-4794 S/N: S2K

Part No.: 248-5513, 4W-4794 S/N: S2L

Part No.: 248-5513, 4W-4794 S/N: S2M

Part No.: 248-5513, 4W-4794 S/N: S2

Part No.: 248-5513, 4W-4794 S/N: S

Part No.: 248-5513, 4W-4794

S2T1-Up

S/N:

Part No.: 248-5513, 4W-4794

S2W1-Up

S/N:

Part No.: 248-5513, 4W-4794

: S2X1-Up

S/N

Part No.: 248-5513, 4W-4794

: S2Y1-Up

S/N

Part No.: 248-5513, 4W-4794

N: S2Z1-Up

-Up

1-Up

N1-Up

2P1-Up

2R1-Up

2S1-Up

Illustration 119

Fully open temperature ...................... 92 °C (197 °F)

Minimum opening distance at 92 °C

(197 °F) ..................................... 10.4 mm (0.41 inch)

Water Li

SMCS Code: 1380

Part No.: 335-1845 S/N: M8A1-Up

Part No.: 249-2846, 278-7527 S/N: S2A1-Up

Part No.: 335-1845 S/N: M8B1-Up

Part No.: 249-2846, 278-7527 S/N: S2B1-Up

Part No.: 249-2846, 278-7527 S/N: S2D1-Up

Part No.: 249-2846, 278-7527 S/N: S2E1-Up

Part No.: 249-2846, 278-7527 S/N: S2F1-Up

Part No.: 249-2846, 278-7527 S/N: B5G1-Up

Part No.: 249-2846 S/N: MRG1-Up

Part No.: 249-2846, 278-7527 S/N: S2G1-Up

Part No.: 249-2846, 278-7527 S/N: MKH1-Up

nes

g00286978

i02636978

Part No.: 249-2846, 278-7527 S/N: S2H1-Up

Part No.: 249-2846, 278-7527 S/N: S2J1-Up

Page 83

RENR5077-11 83

Speciﬁcations Section

Part No.: 249-2846, 278-7527 S/N: S2K1-Up

Part No.: 249-2846, 278-7527 S/N: S2L1-Up

Part No.: 249-2846, 278-7527 S/N: S2M1-Up

Part No.: 249-2846, 278-7527 S/N: S2N1-Up

Part No.: 249-2846, 278-7527 S/N: S2P1-U

Part No.: 249-2846, 278-7527 S/N: S2R1-U

Part No.: 249-2846, 278-7527 S/N: S2S1-

Part No.: 249-2846, 278-7527 S/N: S2T1-

Part No.: 249-2846, 278-7527 S/N: S2W1

-Up

Part No.: 249-2846, 278-7527 S/N: S2X

Part No.: 249-2846, 278-7527 S/N: S2Y

Part No.: 249-2846, 278-7527 S/N: S2Z

1-Up

Page 84

84 RENR5077-11 Speciﬁcations Section

Illustration 120

Zinc rod

Illustration 121

Typical example of zinc rod assembly

g01322268

1. Apply 9S-3263 Thread Lock Compound to

shoulder (2) of a new zinc rod (1). Do not apply sealant to threads (3) of the rod.

2. Lightly lubricate the bores for the zinc rods and

the plugs with liquid soap.

g01322263

Torqueforthezincrod..2.25±.25N·m(20±2lbin)

Page 85

RENR5077-11 85

Speciﬁcations Section

Engine Oil Sump Pump

SMCS Code: 132

Part No.: 7W-9703 S/N: M8A1-Up

Part No.: 7W-9703 S/N: M8B1-Up

i02843386

Water Pump

SMCS Code: 136

Part No.: 334-7865 S/N: M8A1-Up

Part No.: 212-8177 S/N: S2A1-Up

Part No.: 334-7865 S/N: M8B1-U

Part No.: 212-8177 S/N: S2B1-U

Part No.: 212-8177 S/N: S2D1-

Part No.: 212-8177 S/N: S2E1-

Part No.: 212-8177 S/N: S2F1

-Up

Part No.: 212-8177 S/N: B5G

1-Up

i03700561

Illustration 122

(1) S ump pum p group

g01434049

Use the following procedure to install the oil pickup assembly (2):

Note: Coat the threads of the oil pickup assembly with 5P-3413 Pipe Sealant prior to assembly.

1. Keep nut (3) held against the oil pickup assembly

and hand tighten the nut until the O-ring seal contacts the oil pan.

2. Unscrew the oil pickup assembly until the word

“UP” is at the 12 o'clock position.

Part No.: 212-8177 S/N: MRG

1-Up

Part No.: 212-8177 S/N: PAG

1-Up

Part No.: 212-8177 S/N: S2

G1-Up

Part No.: 212-8177 S/N: M

KH1-Up

Part No.: 212-8177

2H1-Up

S/N: S

Part No.: 212-8177

2J1-Up

S/N: S

Part No.: 212-8177

S2L1-Up

S/N:

Part No.: 212-8177

S2M1-Up

S/N:

Part No.: 212-8177

: S2N1-Up

S/N

Part No.: 212-8177

: S2P1-Up

S/N

3. Hold the oil pickup assembly in position and

tightenthenuttoatorqueof150±15N·m (110±11lbft).

Part No.: 212-8177

N: S2R1-Up

Part No.: 212-8177

N: S2S1-Up

Part No.: 212-8177

/N: S2T1-Up

Page 86

86 RENR5077-11 Speciﬁcations Section

Part No.: 212-8177 S/N: S2W1-Up

Part No.: 212-8177 S/N: S2X1-Up

Part No.: 212-8177 S/N: S2Y1-Up

Part No.: 212-8177 S/N: S2Z1-Up

Illustration 123

(2) Ring assem bly (3) Water pum p seal group

(1) Do not lubricate the sealing lip of the lip type seal.

(4) Lubricate the bore of the O-ring seals with

glycerin or an approved equivalent.

(5) Lubricate the shaft with a thin ﬁlm of clean engine

oil before pressing the impeller onto the shaft. The end of the shaft must be ﬂushwiththeface of the impeller within 0.15 mm (0.006 inch).

(B) Bore of the impeller for new

shaft ..................................... 25.342 ± 0.013 mm

(0.9977 ± 0.0005 inch)

washer ...... 8.75 ± 0.05 mm (0.344 ± 0.002 inch)

(D) Thickness of new thrust washer ............. 8.5 mm

(0.33 inch)

g01991398

(E) Clearance between the impeller and the

cover .................................. 0.5000 ± 0.4925 mm

(0.01968 ± 0.01939 inch)

(6) Torque for the taperlock studs ........... 35 ± 5 N·m

(26±4lbft)

(7) Torque for the full nuts .......... ............. 27 ± 4 N·m

(239 ± 35 lb in)

Minimum leakage per minute for the lip type seal at 138 kPa (20 psi) of air pressure is less than 24 cc (1.5 cu in).

Minimum leakage per minute for the water pump seal assembly at 138 kPa (20 psi) of air pressure is less than 20 cc (1.2 cu in).

Page 87

RENR5077-11 87

Speciﬁcations Section

Auxiliary Water Pump

SMCS Code: 137

Part No.: 334-8471 S/N: M8A1-Up

Part No.: 9Y-8175 S/N: S2A1-Up

Part No.: 334-8471 S/N: M8B1-U

Part No.: 9Y-8175 S/N: S2B1-U

Part No.: 9Y-8175 S/N: S2D1-

Part No.: 9Y-8175 S/N: S2E1-

Part No.: 9Y-8175 S/N: S2F1

Part No.: 9Y-8175 S/N: B5G

-Up

1-Up

i03780690

Part No.: 9Y-8175 S/N: S2T1-Up

Part No.: 9Y-8175 S/N: S2W1-Up

Part No.: 9Y-8175 S/N: S2X1-Up

Part No.: 9Y-8175 S/N: S2Y1-Up

Part No.: 9Y-8175 S/N: S2Z1-U

Part No.: 9Y-8175 S/N: MRG

Part No.: 9Y-8175 S/N: PAG

Part No.: 9Y-8175 S/N: S2

Part No.: 9Y-8175 S/N: M

Part No.: 9Y-8175 S/N: S

Part No.: 9Y-8175 S/N:

Part No.: 9Y-8175

: S2M1-Up

S/N

Part No.: 9Y-8175

: S2N1-Up

S/N

1-Up

G1-Up

KH1-Up

2H1-Up

2J1-Up

S2K1-Up

S2L1-Up

Part No.: 9Y-8175

N: S2P1-Up

Part No.: 9Y-8175

N: S2R1-Up

Part No.: 9Y-8175

/N: S2S1-Up

Page 88

88 RENR5077-11 Speciﬁcations Section

Illustration 124

Typical example

(A) Width of groove in the shaft for thrust

washer ...... 6.25 ± 0.05 mm (0.246 ± 0.002 inch)

(B) Thickness of the new thrust

washer ................................... 6.000 ± 0.025 mm

(0.2362 ± 0.0010 inch)

Bore in the sleeve bearing for auxiliary drive

shaft ..................................... 75.000 ± 0.055 mm

(2.9528 ± 0.0022 inch) Diameter of new auxiliary drive shaft (not

shown) ................................. 74.900 ± 0.015 mm

(2.9488 ± 0.0006 inch)

(D) Dimensions for the impeller

Bore diameter of the impeller

........ 19.000 ± 0.013 mm (0.7480 ± 0.0005 inch)

Diameter in the shaft for

impeller ............................. 19.050 to 19.063 mm

(0.7500 to 0.7505 inch)

g01486033

(E) Installation depth of the sleeve bearing in the

water pump housing ..................... 1.5 ± 0.5 mm

(0.06 ± 0.02 inch)

Note: Do not lubricate the sealing lip of the lip type seal (1).

Minimum leakage per minute for the lip type seal at 138 kPa (20 psi) of air pressure is less than 24 cc (1.5 cu in).

(3) Use the following procedure in order to assemble

the water pump seal assembly.

1. Lubricate the outside diameter of ceramic ring and rubber seal (2) with clean water or with 207-1600 Rubber Lubricant.

2. Orient the polished face of the ceramic ring toward water pump seal assembly.

3. Use the installation tool and hand pressure to seat the ceramic ring and the rubber seal into the water pump housing.

Page 89

RENR5077-11 89

Speciﬁcations Section

4. Remove spring (4) from the water pump seal assembly.

5. Lubricate the inside diameter of the water pump seal assembly

with clean water or with 207-1600

Rubber Lubricant.

6. Use the seal i

nstallation tool and hand pressure to install the water pump seal assembly onto the shaft until the face of the water pump seal assembly ma

kes light contact with the face of the

ceramic ring and rubber seal.

7. Install spr

ing (4) onto the water pump seal

assembly.

Assembled

length of the spring .. 17.45 ± 0.79 mm

(0.687 ± 0.031 inch)

Load on spr

ing at assembled

length ....................... 40.03 ± 4.45 N (9.0 ± 1.0 lb)

Minimum l

eakage per minute for the water pump seal assembly at 138 kPa (20 psi) of air pressure is less than 20 cc (1.2 cu in).

(6) Lubricate the shaft with a thin ﬁlm of clean engine

oil before pressing the impeller (5) onto the shaft. The end o

f the shaft must be ﬂushwiththeface

of the impeller within 0.15 mm (0.006 inch).

i01704040

Cooling System Pressure Cap

SMCS Code: 138

Part No.: 4N-3311

2; 1392

(7) Lubr

icate the bore of the O-ring seal lightly with

sealant that is being sealed.

(8) Lub

ricate the bore of the O-ring seal with clean

engine oil, glycerin or clean water.

Illustration 125

g00877286

Pressure that opens the cap relief valve ........ 48 kPa

(7 psi)

Maximum vacuum that opens the suction

valve ..................................................... 7 kPa (1 psi)

Page 90

90 RENR5077-11 Speciﬁcations Section

Cylinder Block

SMCS Code: 120

Part No.: 350-5225 S/N: M8A1-Up

Part No.: 350-5225 S/N: M8B1-Up

i03686680

(A) Extension of dowels from the surface of the

cylinder block

.. 20.0 ± 0.5 mm (0.79 ± 0.02 inch)

(B) Thickness of the spacer plates ......... 12.363 mm

(0.4867 inch)

For the correct method of determining height of the liner, refer to Testing And Adjusting, “Cylinder Liner Projection

”.

(D) Thickness of gasket between the cylinder block

and spacer p

lates ................. 0.194 to 0.218 mm

(0.0076 to 0.0086 inch)

(E) Extens

ion of dowels from the surface of the

cylinder block .. 21.0 ± 0.5 mm (0.83 ± 0.02 inch)

(F) Bore in

the block for the camshaft

bearings ............................... 98.000 ± 0.020 mm

(3.8583 ± 0.0008 inch)

(G) Oil holes must be positioned from horizontal at

the following angle. ..................... 20 ± 5 degrees

Note: All centerlines through oil holes in the camshaft bearings (G) and the camshaft bearing junctions (2) must be i

n the position that is shown for each side of

the cylinder block.

Illustration 126

Front view of cylinder block

(2) Cam shaft bearing junction

Illustration 127

Right side view

g01993533

g01993594

(1) Torque for the plugs .. 100 ± 15 N·m (74 ± 11 lb ft)

(H) Main

bearing cap width

Width of main bearing ........ 340.030 ± 0.015 mm

70 ± 0.0006 inch)

(13.38 Width of cylinder block for main bearing

cap ..................................... 339.985 ± 0.015 mm

852 ± 0.0006 inch)

(13.3 Tight press ﬁt between the sides of the main

bearing cap and the cylinder block ..... 0.075 mm

30 inch)

(0.00 Loose press ﬁt between the sides of the main

bearing cap and the cylinder block ..... 0.015 mm

006 inch)

(0.0

(J) New dimension from centerline of crankshaft

ing bore to the top of the block .. 586.00 mm

bear

(23.071 inch)

Bore in the block for the main bearings

(K)

Standard, original new

e .................................... 169.742 ± 0.020 mm

siz

(6.6827 ± 0.0008 inch)

0.63 mm (0.025 inch) larger than original

ze .................................... 170.372 ± 0.020 mm

(6.7076 ± 0.0008 inch)

) New dimension from centerline of crankshaft

bearing bore to bottom of block (pan

rails) .............................. 230.00 mm (9.055 inch)

(3) Main bearing cap

Page 91

RENR5077-11 91

Speciﬁcations Section

Usethefollowingproceduretotightenthemain bearing cap bol

1. Install main bearing caps with the part number and FRONT towa cap has a number. Each cap must be installed in the same position as the correct number on the side of the cy

2. Before assembly, apply clean engine oil to the threads of t

3. Tighten the bolts in the numerical sequence (4, 5, 6, 7) to 19 Illustration 127 for the tightening sequence.

4. Again, tig (4, 5, 6, 7) to an angle of 180 ± 5 degrees. Refer to Illustration 127 for the tightening sequence.

(M) Extension of dowels from the surface of the

cylinder block .... 6.0 ± 0.5 mm (0.24 ± 0.02 inch)

(N) Extension of dowels from the surface of the

cylinder block .. 19.0 ± 0.5 mm (0.75 ± 0.02 inch)

(P) Extension of dowels from the surface of the

cylinder block .. 40.0 ± 0.5 mm (1.58 ± 0.02 inch)

ts:

rd the front of the block. Each

linder block pan rail.

he bolts.

0 ± 14 N·m (140 ± 10 lb ft). Refer to

hten the bolts in the numerical sequence

i03152764

Cylinder Block

SMCS Code: 1201

Part No.: 240-6651, 240-6653 S/N: S2A1-Up

Part No.: 240-6651, 240-6653 S/N: S2B1-Up

Part No.: 240-6651, 240-6653 S/N: S2H1-Up

Part No.: 240-6651, 240-6653 S/N: S2J1-Up

Part No.: 240-6651, 240-6653 S/N: S2K1-Up

Part No.: 240-6651, 240-6653 S/N: S2L1-Up

Part No.: 240-6651 S/N: S2M1-U

Part No.: 240-6651, 240-6653 S/N: S2N1-U

Part No.: 240-6651, 240-6653 S/N: S2P1-

Part No.: 240-6651 S/N: S2R1-

Part No.: 240-6651, 240-6653 S/N: S2S1

Part No.: 122-5954, 240-6651, 240-6653 S/N: S2T

Part No.: 240-6651, 240-6653 S/N: S2W

Part No.: 122-5954, 240-6651, 240-6653 S/N: S2X

Part No.: 240-6651, 240-6653 S/N: S2

Part No.: 122-5954, 240-6651 S/N: S

, 240-6653

-Up

1-Up

Y1-Up

2Z1-Up

Part No.: 240-6651, 240-6653 S/N: S2D1-Up

Part No.: 240-6651, 240-6653 S/N: S2E1-Up

Part No.: 240-6651 S/N: S2F1-Up

Part No.: 240-6653 S/N: B5G1-Up

Part No.: 240-6651, 240-6653 S/N: MRG1-Up

Part No.: 240-6653 S/N: PAG1-Up

Part No.: 240-6651, 240-6653 S/N: S2G1-Up

Part No.: 240-6651, 240-6653 S/N: MKH1-Up

Page 92

92 RENR5077-11 Speciﬁcations Section

(1) Torque for four plugs ...................... 100 ± 15 N·m

(75 ± 11 lb ft)

(2) Lubricate the bore of the O-ring seals lightly with

the lubricant

that is being sealed.

(D) Height of the cylinder liner

For the correct method of determining the height of the cylinder liner, refer to Testing And Adjusting, “Cylinder L

iner Projection”.

(E) Bore in the block for the camshaft

bearings ............................... 98

.000 ± 0.020 mm

(3.8583 ± 0.0008 inch)

ation 128

Illustr

Front view

g01417382

(F) The oil

holes in the camshaft bearings must be positioned from horizontal at the following

angle: .......................................... 20 ± 5 degrees

Note: All centerlines through the oil holes in the camshaft bearings (F) and the camshaft bearing joints (3

) must be in the position that is shown for

each side of the cylinder block.

(G) New di

mension from centerline of crankshaft

bearing bore to the top of the block ....... 586 mm

(23.1 inch)

(H) New dimension from centerline of crankshaft

bearing bore to bottom of block (pan

rails) ....................................... 2

30 mm (9.1 inch)

(J) Bore in the block for the main bearings

Standard, original new

size .................................... 169.742 ± 0.020 mm

27 ± 0.0008 inch)

(6.68

0.63 mm (0.025 inch) larger than original

size .................................... 170.372 ± 0.020 mm

75 ± 0.0008 inch)

(6.70

(K) Dimension for crankshaft main bearing cap

stration 129

Illu

Right side view

g01434393

Note: During assembly, the bottom of spacer plates, top of cylinder block and both sides of plate gasket

t be free of fuel, oil, water, gasket adhesives,

mus assembly compounds and any other contaminants.

Thickness of the spacer plate .......... 12.313 mm

(A)

(0.4848 inch)

) Thickness of the plate gasket

between the cylinder block and spacer

plate ...................................... 0.194 to 0.218 mm

.0076 to 0.0086 inch)

ylinder block .. 21.0 ± 0.5 mm (0.83 ± 0.02 inch)

Width of crankshaft main bearing

cap ..................................... 340.030 ± 0.015 mm

3870 ± 0.0006 inch)

(13. Width of cylinder block for crankshaft main

bearing cap ........................ 339.985 ± 0.015 mm

.3852 ± 0.0006 inch)

(13 Tight press ﬁ t between the sides of the crankshaft main bearing cap and the cylinder

ck ............................. 0.075 mm (0.0030 inch)

blo Loose press ﬁt between the sides of the crankshaft main bearing cap and the cylinder

ock ............................. 0.015 mm (0.0006 inch)

(4) Main bearing cap

Use the following procedure to tighten the crankshaft main bearing cap bolts:

Page 93

RENR5077-11 93

Speciﬁcations Section

1. Install main bearing caps with the part number and “FRONT” tow

ard the front of the block. Each cap has a number. Each cap must be installed in the same position as the correct number on the side of the cyl

inder block pan rail.

2. Before assembly, apply clean engine oil on the threads of th

ebolts.

3. Tighten bolt (5) through bolt (8) in the numerical sequence th

atisshowninIllustration128toa

torque of 190 ± 14 N·m (140 ± 10 lb ft).

4. Tighten bol

t (5) through bolt (8) again in the numerical sequence to a rotation of 180 ± 5 degrees.

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

cylinder block .... 6.0 ± 0.5 mm (0.24 ± 0.02 inch)

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

cylinder block .... 6.0 ± 0.5 mm (0.24 ± 0.02 inch)

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

cylinder block .. 19.0 ± 0.5 mm (0.75 ± 0.02 inch)

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

cylinder block .. 40.0 ± 0.5 mm (1.57 ± 0.02 inch)

Cylinder Block

SMCS Code: 120

Part No.: 237-7957 S/N: S2A1-Up

Part No.: 237-7957 S/N: S2B1-Up

Part No.: 237-7957 S/N: S2D1-U

Part No.: 237-7957 S/N: S2E1-U

Part No.: 237-7957 S/N: S2F1-

i02674259

Illustration 130

Front view of cylinder block

(1) Camshaft bearing junction

g01343555

Page 94

94 RENR5077-11 Speciﬁcations Section

Width of cylinder block for main bearing

cap ..................................... 339.985 ± 0.

015 mm

(13.3852 ± 0.0006 inch) Tight press ﬁt between the sides of the main bearing cap an

d the cylinder block ..... 0.075 mm

(0.0030 inch) Loose press ﬁt between the sides of the main bearing cap a

nd the cylinder block ..... 0.015 mm

(0.0006 inch)

Illustration 131

g01343968

(A) Thickness of spacer plates ............... 12.313 mm

(0.4848 inch)

(B) Thickness of gasket between the cylinder block

and spacer plates ................. 0.194 to 0.218 mm

(0.0076 to 0.0086 inch)

distance. ......... 20.0 ± 0.5 mm (0.79 ± 0.02 inch)

(2) Torque for plugs ....... 100 ± 15 N·m (75 ± 11 lb ft)

(D) Height of Cylinder liner

For the correct method of determining height of the liner, refer to Testing And Adjusting, “Cylinder Liner Projection”.

(E) Bore in the block for the camshaft

bearings ............................... 98.000 ± 0.020 mm

(3.8583 ± 0.0008 inch)

(F) Oil holes must be positioned from horizontal at

the following angle. ..................... 20 ± 5 degrees

Note: All centerlines through oil holes in the camshaft bearings (F) and the camshaft bearing junctions (1) must be in the position that is shown for each side of the cylinder block.

(G) New dimension from centerline of crankshaft

bearing bore to the top of the block .. 586.00 mm

(23.071 inch)

(H) Main bearing cap width

Width of main bearing ........ 340.030 ± 0.015 mm

(13.3870 ± 0.0006 inch)

(J) Boreint

he block for the main bearings

Standard, original new

size .................................... 169.74

2 ± 0.020 mm

(6.6827 ± 0.0008 inch)

0.63 mm (0.025 inch) larger than original

size .................................... 170.3

72 ± 0.020 mm

(6.7076 ± 0.0008 inch)

(K) New dim

ension from centerline of crankshaft bearing bore to bottom of block (pan

rails) .............................. 230.00 mm (9.055 inch)

(3) Main bearing cap

Use the fo

llowing procedure to tighten the main

bearing cap bolts:

1. Install

main bearing caps with the part number and FRONT toward the front of the block. Each cap has a number. Each cap must be installed in the same

position as the correct number on the

side of the cylinder block pan rail.

2. Put cle

an engine oil on the bolts before assembly.

3. Tighten the bolts in the numerical sequence (4, 5, o the following torque.

6, 7) t

Torque for bolts ....... 190 ± 14 N·m (140 ± 10 lb ft)

4. Tighten the bolts again in the numerical sequence

to the following rotation.

Angle for bolts ............................ 180 ± 5 degrees

he dowel extends from the rear face of the block

(L) T

by the following distance. .............. 6.0 ± 0.5 mm

(0.24 ± 0.02 inch)

(M) The dowels extend from the front face of the

block by the following distance. ..... 6.0 ± 0.5 mm

24 ± 0.02 inch)

(0.

(N) The dowels extend from the rear face of the

ock by the following distance. ... 19.0 ± 0.5 mm

(0.75 ± 0.02 inch)

) The dowels extend from the front face of the

block by the following distance. ... 40.0 ± 0.5 mm

(1.58 ± 0.02 inch)

Page 95

RENR5077-11 95

Speciﬁcations Section

i02871050

Cylinder Liner

SMCS Code: 121

Part No.: 211-7826

tion 132

Illustra

(A) Bore in new cylinder liner .. 170.025 ± 0.025 mm

(B) Thickness of ﬂange (1) on cylinder

liner ......... 12

g01399536

(6.6939

.65 ± 0.02 mm (0.498 ± 0.001 inch)

± 0.0010 inch)

Piston and Rings (One-Piece Piston)

SMCS Code: 1214

Part No.: 332 S/N: M8A1-Up

Part No.: 332 S/N: M8B1-Up

-7924

i02872093

Use the liner again with any used piston or any new in the following range. Use a FLEX-HONE

ﬁrst. ..................................... 170.000 to 170.152 mm

Use the liner again with the original piston if the in the following range. Use a FLEX-HONE

ﬁrst. ..................................... 170.000 to 170.229 mm

Use the following procedure to install the cylinder line

1. Apply liquid soap on the cylinder block liner bore

2. Dip

3. Imm

4. Im

Note: Refer to Reuse And Salvage Guidelines,

SEBF8049, “Visual Inspection of the Piston” for more

nformation. Also, refer to Guideline For Reusable

i Parts And Salvage Operations, SEBF8068, “Cylinder Liners” for more information.

piston if all the measurements are

9to6.6989inch)

(6.692

measurements of the upper bore are

29 to 6.7019 inch)

(6.69

aces and the rubber seals that are on the

surf lower end of the cylinder liner.

the ﬁller band (2) completely in clean engine

oil for a moment.

ediately install the ﬁller band in the groove

that is under the ﬂange.

mediately install the cylinder liner into the cylinder block before the expansion of the ﬁller band.

Illustration 133

Note: Refer to Guideline for Reusable Parts for information on the pistons, the piston pins, and the retaining rings.

This piston has a square top piston ring. Use the 246-1176 Piston Ring Groove Gauge Gp for measuring the top piston ring groove.

This piston has a keystone type of intermediate piston ring. Use the 1U-6431 Piston Ring Groove Gauge Gp for measuring the intermediate piston ring groove. For correct use of the piston ring groove gauge group, refer to the instruction card that is with the piston ring groove gauge group.

Note: Prior to the installation of the piston rings, the ring grooves must be completely lubricated with clean engine oil. After assembly, the mating surfaces of the rings to the cylinder liner must be completely lubricated with clean engine oil.

g01430242

TopPistonRing(1)

Installthetoppistonringwiththe“UP-1”sidetoward the top of the piston.

Page 96

96 RENR5077-11 Speciﬁcations Section

When the new top piston ring is installed in a cylinder liner with a bor clearance between the ends of the piston ring is the

following value. ............................ 0.625 ± 0.125 mm

Thickness of new top piston ring ................ 3.88 mm

esizeof170mm(6.7inch),the

(0.0246 ± 0.00

49 inch)

(0.153 inch)

Intermediat

Install the intermediate piston ring with the “UP-2” side toward

When the new intermediate piston ring is installed in a cylinder l the clearance between the ends of the piston ring is

the following value. .......................... 1.00 ± 0.15 mm

Thickness of new intermediate piston

ring ...................................... 3.78

Oil Contr

The ends of the oil control piston ring should be a distanc the oil control piston ring is assembled. The white colored portion of the piston ring must be visible at the ring

Width of groove in new piston for the oil control piston

ring ......... 4.

Thickness of new oil control piston

ring ................ 3

When the new oil control piston ring is installed in a cylin the clearance between the ends of the piston ring is

the following value. ...................... 0.5 mm to 0.8 mm

Note: After the piston rings have been installed, rota degrees from each other.

e of 180 degrees from the ring end gap when

end gap.

derlinerwithaboresizeof170mm(6.7inch),

te the piston rings so that the end gaps are 120

e Piston Ring (2)

the top of the piston.

iner with a bore size of 170 mm (6.7 inch),

(0.039 ± 0.

5 mm (0.1490 inch)

006 inch)

ol Piston Ring (3)

04 mm to 4.07 mm (0.159 to 0.160 inch)

.97 to 3.99 mm (0.156 to 0.157 inch)

to 0.03 inch)

(0.02

Illustration 134

Note: Prior to assembly of the piston pin, the piston pin, the piston pin bore, the connecting rod eye, and the connecting rod pin bearing must be completely lubricated with clean engine oil.

g01446562

Piston Pin Bore (4)

(B) Angle of bushing locator on far side .. 45 degrees

pin .................................... 70.0705 ± 0.0075 mm

(2.75867 ± 0.00030 inch)

Piston Pin (5)

Dimensions for piston pin

Outside diameter of piston pin ... 69.930 ± 0.005 mm (2.7531 ± 0.0002 inch)

Inside diameter of piston pin ........ 30.5 ± 0.5 mm

(1.20 ± 0.02 inch)

Length of piston pin ........... 102.0 + 0.0 - 0.3 mm

(4.02 + 0.00 - 0.01)

Note: The 263-8955 Piston Pin is not interchangeable with the former 197-0560 Piston Pin.

Pin Retainer (6)

Assemble the pin retainer with the opening above section A-A.

Refer to Table 1 for the part numbers of the tools that areusedinservicingthepiston.

Page 97

RENR5077-11 97

Speciﬁcations Section

Table 1

Service Tools

Pt. No. Description

271-0498 Expander Ring

1P-1861 Retaining Ring Pliers

1U-7616

246-1176

1U-6431

(1)

Only for the top ring groove

(2)

Only for the intermediate ring groove

Piston Ring Compressor Gp

Piston Ring Groove Gauge Gp

Piston and Rings (One-Piece Piston )

SMCS Code: 1214

Part No. S/N: S2A1-Up

Part No. S/N: S2B1-Up

: 223-6363

(1)

(2)

i03661131

Part No.: 223-6363 S/N: S2N1-Up

Part No.: 223-6363 S/N: S2P1-Up

Part No.: 223-6363 S/N: S2R1-Up

Part No.: 223-6363 S/N: S2S1-Up

Part No.: 223-6363 S/N: S2T1-U

Part No.: 223-6363 S/N:

S2W1-U

Part No.: 223-6363 S/N: S2X1-

Part No.: 223-6363 S/N: S2Y1-

Part No.: 223-6363 S/N: S2Z1

-Up

Part No

.: 223-6363

S/N: S2D1-Up

Part No

.: 223-6363

S/N: S2E1-Up

o.: 223-6363

Part N S/N: S2F1-Up

o.: 223-6363

Part N S/N: B5G1-Up

No.: 223-6363

Part S/N: MRG1-Up

No.: 223-6363

Part S/N: PAG1-Up

tNo.:223-6363

Par S/N: S2G1-Up

tNo.:223-6363

Par S/N: MKH1-Up

rt No.: 223-6363

Pa S/N: S2H1-Up

rt No.: 223-6363

Pa S/N: S2J1-Up

art No.: 223-6363

P S/N: S2K1-Up

art No.: 223-6363

P S/N: S2L1-Up

art No.: 223-6363

P S/N: S2M1-Up

Illustration 135

g01430242

Use the 246-1176 Piston Ring Groove Gauge Gp for measuring the top ring groove.

Use the 1U-6431 Piston Ring Groove Gauge Gp for measuring the intermediate ring groove. Refer to the instruction card that is with the gauge group.

TopPistonRing(1)

Installthetoppistonringwiththe“UP-1”sidetoward the top of the piston.

Whenthenewtoppistonringisinstalledinacylinder liner with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the

Page 98

98 RENR5077-11 Speciﬁcations Section

following value. ............................ 0.625 ± 0.125 mm

(0.0246 ± 0.004

Thickness of new top piston ring ................ 3.88 mm

9 inch)

(0.153 inch)

Intermediate

Install the intermediate piston ring with the “UP-2” side toward t

When the new intermediate piston ring is installed in a cylinder l the clearance between the ends of the piston ring is

the following value. .......................... 1.00 ± 0.15 mm

Thickness of new intermediate piston

ring ...................................... 3.785

he top of the piston.

iner with a bore size of 170 mm (6.7 inch),

Oil Contr

Orient the ends of the oil ring spring to 180 degrees from the g ring must be visible at the ring end gap.

Width of

ring ......... 4.04 mm to 4.07 mm (0.159 to 0.160 inch)

Thickne

ring .......... 3.980 ± 0.010 mm (0.1567 ± 0.0004 inch)

When th cylinderlinerwithaboresizeof170mm(6.7inch), the clearance between the ends of the piston ring is the fo

Note:

rotate the piston rings so that the end gaps are 120 degrees from each other.

ap. The white colored portion of the piston

groove in new piston for the oil control piston

ss of new oil control piston

e new oil control piston ring is installed in a

llowing value. ............................. 0.5 to 0.8 mm

After the piston rings have been installed,

Piston R ing (2)

(0.039 ± 0.0

mm (0.1490 inch)

ol Piston Ring (3)

(0.02to0.03inch)

06 inch)

Illustration 136

Note: Prior to assembly of the piston pin, the piston pin, the piston pin bore, the connecting rod eye, and the connecting rod pin bearing must be completely lubricated with clean engine oil.

g01446562

Piston Pin Bore (4)

Note: Measure the pin bore in two places. Take

one measurement within the minor diameter. Move laterally and take another measurement within the minor diameter. Take the measurements close to the center of the pin bore. Do not take the measurements on the outside edges.

(B) Angle of bushing locator on far side .. 45 degrees

pin ..................................... 70.060 to 70.075 mm

(2.7583 to 2.7562 inch)

Piston Pin (5)

Outside diameter ....................... 69.962 ± 0.005 mm

(2.7544 ± 0.0002 inch)

Inside diameter ..... 30.5 ± 0.5 mm (1.20 ± 0.02 inch)

Length ......... 101.85 ± 0.15 mm (4.010 ± 0.006 inch)

Note: The 197-0560 Piston Pin is not interchangeable with other pistons and connecting rods.

Pin Retainer (6)

Assemble the retainer with the opening above line A-A.

Page 99

RENR5077-11 99

Speciﬁcations Section

Refer to Table 2 for the part numbers of the tools that areusedinserv

Table 2

Pt. No. Description

6V-4020 Piston Ring Expander Gp

6V-4023 Handle As

6V-4024

1P-1861 Retaining Ring Pliers

1U-7616 Piston Ring Compressor G p

246-1176 Piston Ring Groove Gauge Gp

1U-6431

(1)

Only for the top ring groove

(2)

Only for the intermediate ring groove

icing the piston.

Service Tools

Guide Ring

Piston Ring Groove Gauge Gp

(1)

(2)

i03132941

Piston and Rings (Two-Piece Piston)

Part No.: 101-0829 S/N: S2R1-Up

Part No.: 101-0829 S/N: S2S1-Up

Part No.: 101-0829 S/N: S2T1-Up

Part No.: 101-0829 S/N: S2W1-Up

Part No.: 101-0829 S/N: S2X1-U

Part No.: 101-0829 S/N: S2Y1-U

Part No.: 101-0829 S/N: S2Z1-

SMCS Code: 1214

Part No.: 101-0829 S/N: S2A1-Up

Part No.: 101-0829 S/N: S2B1-Up

Part No.: 101-0829 S/N: S2D1-Up

Part No.: 101-0829 S/N: S2E1-Up

Part No.: 101-0829 S/N: S2F1-Up

Part No.: 101-0829 S/N: S2G1-Up

Part No.: 101-0829 S/N: S2H1-Up

Part No.: 101-0829 S/N: S2J1-Up

Part No.: 101-0829 S/N: S2K1-Up

Part No.: 101-0829 S/N: S2L1-Up

Part No.: 101-0829 S/N: S2M1-Up

Part No.: 101-0829 S/N: S2N1-Up

Illustration 137

g01611477

This piston has a Keystone top and Keystone intermediate rings. The 1U-6431 Piston Ring Groove Gauge is necessary for measuring the ring grooves in Keystone pistons. For correct use of the gauge group, see the instruction card that is with the gauge group.

TopPistonRing(1)

Install the top ring with the “Up-1” side toward the top of the piston.

Thickness of new top piston ring ................ 3.91 mm

(0.154 inch)

Whenthepistonringisinstalledinacylinderliner withaboresizeof170mm(6.7inch),theclearance between the ends of the piston ring is the following

value. ...... 0.625 ± 0.125 mm (0.0246 ± 0.0049 inch)

Part No.: 101-0829 S/N: S2P1-Up

The increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch)

Page 100

100 RENR5077-11 Speciﬁcations Section

increase in the cylinder liner bore size is the following

value. ...................................... 0.08 mm (

Intermediate

Install the intermediate ring with the “Up-2” side toward the top

Thickness of new intermediate piston

ring ...................................... 3.785 mm

When the piston is installed in a cylinder liner with aboresizeo between the ends of the piston ring is the following

value. .............. 1.00 ± 0.15 mm (0.039 ± 0.006 inch)

The increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch) increase i

value. ...................................... 0.08 mm (0.003 inch)

n the cylinder liner bore size is the following

Piston R ing (2)

of the piston.

f 170 mm (6.7 inch), the clearance

0.003 inch)

(0.1490 inch)

Oil Control Piston Ring (3)

Width of g

ring .......... 5.050 ± 0.010 mm (0.1988 ± 0.0004 inch)

roove in piston for the new piston

Piston Pin (5)

Measure the piston pin diameter on each end in a vertical and horizontal direction.

Inside diameter of the piston pin ........ 35.0 ± 0.5 mm

(1.38 ± 0.02 inch)

Outside diameter of the piston

pin ......... 69.962 ± 0.005 mm (2.7544 ± 0.0002 inch)

Length of the piston pin ............... 133.00 ± 0.13 mm

(5.236 ± 0.005 inch)

Pin Retainer (6)

Assemble the retainer with the opening toward the top of the piston.

Thickne

Clearan

ring ........ 0.067 to 0.125 mm (0.0026 to 0.0049 inch)

When th with a bore size of 170 mm (6.7 inch), the clearance between the ends of the piston ring is the following value

The increase in the clearance between the ends of the increase in the cylinder liner bore size is the following

value. ...................................... 0.08 mm (0.003 inch)

Install the oil control ring so that the gap in the spring is 180 degrees away from the gap in the ring. The whit gap.

Afte the rings so that the end gaps are separated by 120 degrees. The ring gap for the oil ring must be aligned in t

ss of new piston ring ....... 4.954 ± 0.019 mm

(0.1950 ± 0.0007 inch)

ce between groove and new piston

e piston ring is installed in a cylinder liner

. .............. 0.70 ± 0.19 mm (0.028 ± 0.007 inch)

piston ring for each 0.03 mm (0.001 inch)

e portion of the spring must be visible at the ring

r all of the piston rings have been installed, rotate

he plane of the pin bore.

ton Pin Bore (4)

Pis

Measure the piston pin bore in the bushings in two

aces for each bushing in a vertical direction.

Bore diameter in the crown assembly for piston

n ......... 70.035 ± 0.005 mm (2.7573 ± 0.0002 inch)

Bore diameter in the piston skirts for piston

in ......... 69.983 ± 0.005 mm (2.7552 ± 0.0002 inch)