Renr1270 14 01 All

RENR1270-14
March 2006
Specifications
3126B and 3126E Truck Engines
BKD1-Up (Engine)
G3E1-Up (Engine)
DPF1-Up (Engine)
1AJ1-Up (Engine)
8YL1-Up (Engine)
CKM1-Up (Engine)
CRP1-Up (Engine)
7AS1-Up (Engine)
8SZ1-Up (Engine)
9SZ1-Up (Engine)
i01658146
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this

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

ture failures, product damage, personal injury or
death.
RENR1270-14 3
Table of Contents
Table of Contents Crankshaft Pulley .................................................

Crankshaft Pulley .................................................
46
47
Belt Tension Chart ............................................... 47
Belt Tensioner ....................................................... 49
Specifications Section Belt Tensioner ....................................................... 50
Belt Tensioner ....................................................... 50
Engine Design ....................................................... 4
Belt Tensioner ....................................................... 51
Fuel Transfer Pump (Fuel Transfer Pump and High
Belt Tensioner ....................................................... 51
Pressure Oil Pump) ............................................... 4
Belt Tensioner ....................................................... 52
Fuel Filter Base ...................................................... 5
Belt Tightener ....................................................... 52
Fuel Filter Base ...................................................... 6
Fan Drive ............................................................. 52
Injection Actuation Pressure Control Valve ............. 6
Fan Drive ............................................................. 53
Unit Injector ............................................................. 7
Alternator and Regulator ...................................... 54
Valve Rocker Arms, Lifters, and Bridges ............... 7
Electric Starting Motor ......................................... 55
Valve Mechanism Cover ........................................ 8
Valve Mechanism Cover ........................................ 9
Cylinder Head Valves ............................................. 9
Cylinder Head ...................................................... 10
Turbocharger ........................................................ 11
Turbocharger ....................................................... 13
Coolant Temperature Sensor ............................... 60
Air Inlet Elbow ....................................................... 14
Injection Actuation Pressure Sensor ..................... 60
Exhaust Manifold ................................................. 14
Engine Oil Pressure Sensor ................................. 61
Exhaust Elbow ..................................................... 15
Engine Oil Pressure Sensor ................................. 61
Camshaft ............................................................. 16
Engine Oil Temperature Sensor ............................ 62
Engine Oil Filter Base .......................................... 17
Engine Oil Pump .................................................. 18
Boost Pressure Sensor ......................................... 63
Engine Oil Pan ..................................................... 18
Engine Oil Pan ..................................................... 19
Crankcase Breather ............................................. 19
Atmospheric Pressure Sensor (If Equipped) ........ 64
Crankcase Breather ............................................. 20
Atmospheric Pressure Sensor (If Equipped) ........ 65
Water Temperature Regulator .............................. 20
Atmospheric Pressure Sensor .............................. 65
Water Temperature Regulator .............................. 21
Inlet Air Temperature Sensor ................................ 65
Water Pump ......................................................... 21
Water Pump ......................................................... 22
Water Pump ......................................................... 22
Speed/Timing Sensor .......................................... 66
Water Pump ......................................................... 23
Electronic Control Wiring Group ........................... 67
Water Pump ......................................................... 23
Electronic Control Wiring Group ........................... 67
Water Pump ......................................................... 24
Air Inlet Heater ...................................................... 68
Cylinder Block Cover Group ................................ 24
Air Compressor (Midland Air Compressors) ......... 68
Cylinder Block ...................................................... 25
Crankshaft ........................................................... 27
Crankshaft Seals ................................................. 27
Air Compressor (Bendix Tu-Flo Air
Crankshaft Seals ................................................. 28
Compressors) ..................................................... 70
Rear Seal Carrier (If Equipped) ............................ 30
Air Compressor (Bendix Tu-Flo Air
Vibration Damper ................................................. 30
Compressors) ..................................................... 71
Connecting Rod Bearing Journal ......................... 31
Main Bearing Journal ............................................ 31
Connecting Rod ................................................... 31 Index Section
Connecting Rod ................................................... 32
Piston and Rings .................................................. 33 Index ..................................................................... 73
Piston and Rings .................................................. 35
Piston and Rings .................................................. 36
Front Housing and Covers ................................... 37
Gear Group (Front) ............................................... 39
Gear Group (Front) ............................................... 40
Flywheel ............................................................... 41
Flywheel ............................................................... 42
Flywheel ............................................................... 42
Flywheel Housing ................................................ 43
Engine to Transmission Adapter (If Equipped) ..... 45
Engine to Transmission Adapter (If Equipped) ..... 45
4 RENR1270-14
Specifications Section
Specifications Section i02510030
Fuel Transfer Pump

i02399532 (Fuel Transfer Pump and High
Engine Design Pressure Oil Pump)
SMCS Code: 1201 SMCS Code: 1256
Part No.: 134-0467
g01198472
Illustration 1
Cylinder And Valve Location g01256595
Illustration 2
(A) Exhaust valve.
(B) Inlet valve. (1) Tighten the bolt to the following
torque. ............... 108.8 ± 13.6 N·m (80 ± 10 lb ft)
Bore .............................................. 110 mm (4.3 inch)
(2) Tighten the plug to the following
Stroke .......................................... 127 mm (5.0 inch) torque. ...................... 6.0 ± 0.7 N·m (53 ± 6 lb in)
Displacement ................................ 7.25 L (442 cu in) (3) Injection actuation pressure control valve
(IAPCV)
Number of cylinders ................................................ 6
(4) Tighten the bolt to the following
Cylinder arrangement ..................................... In-line torque. ... 24.5 ± 2.5 N·m (18.0702 ± 1.8439 lb ft)
Valves per cylinder .................................................. 3 (5) Tighten the valve to the following
torque. ........................... 50 ± 5 N·m (37 ± 4 lb ft)
In order to check the engine valve lash setting, the
engine must be cold and the engine must be stopped. Note: Lubricate the seals prior to assembly. The
Engine valve lash settings coil and the valve assembly must be assembled as
a matched set.
Inlet ........... 0.38 ± 0.08 mm (0.015 ± 0.003 inch)
Exhaust ..... 0.64 ± 0.08 mm (0.025 ± 0.003 inch)
(6) Tighten the inlet of the oil pump to the following
torque. ........................... 26 ± 3 N·m (19 ± 2 lb ft)
Type of combustion ........................... Direct Injection
(7) Tighten the plug to following
Firing Order ................................... 1 - 5 - 3 - 6 - 2 - 4
torque. .............. 10.75 ± 1.25 N·m (95 ± 11 lb in)
The crankshaft rotation is viewed from the
(8) Tighten the outlet of the fuel pump to the following
flywheel end of the engine. Crankshaft
torque. ..................... 17.5 ± 2 N·m (13 ± 1.5 lb ft)
rotation ........................................... counterclockwise
(9) Tighten the outlet of the oil pump to the following
Note: The front end of the engine is opposite of the
torque. ........................... 23 ± 2 N·m (17 ± 1 lb ft)
flywheel end of the engine. The left side of the engine
and the right side of the engine are viewed from the
(10) Tighten the inlet of the fuel pump to the following
flywheel end of the engine. The number one cylinder
torque. ..................... 17.5 ± 2 N·m (13 ± 1.5 lb ft)
is the front cylinder.
RENR1270-14 5
i02453381
Fuel Filter Base

SMCS Code: 1261; 1262
Part No.: 141-5138
S/N: BKD1-Up
Part No.: 141-5138
S/N: DPF1-Up
Part No.: 141-5138
S/N: CKM1-Up
Part No.: 141-5138
g01256603
Illustration 3 S/N: CRP1-Up
(11) Tighten the nut on the tube assembly to the Part No.: 141-5138
following torque. ............ 37 ± 4 N·m (27 ± 3 lb ft) S/N: 7AS1-Up
Part No.: 141-5138
(12) Tighten the locknut at the cylinder head to the S/N: 8SZ1-Up
following torque. ............ 48 ± 5 N·m (35 ± 7 lb ft)
(13) Connection of tube assembly to pump outlet

Tighten the nut on the tube assembly to the
following torque. ............ 37 ± 4 N·m (27 ± 3 lb ft)
Tighten the locknut at the pump outlet to the
following torque. ......... 23 ± 2 N·m (17 ± 1.5 lb ft)
g01224377
Illustration 4
(1) Put 4C-9507 Retaining Compound on the

tapered end of the stud to the following
distance. ........... 7.6 ± 1.5 mm (0.30 ± 0.06 inch)
Torque for stud ..................... 68 ± 7 N·m (50 ± 5 lb ft)

6 RENR1270-14
i02453478 i02271778
Fuel Filter Base Injection Actuation Pressure

SMCS Code: 1261; 1262
Control Valve
Part No.: 119-2978, 120-0201 SMCS Code: 5051
S/N: G3E1-Up
Part No.: 122-5053
Part No.: 120-0201
S/N: 1AJ1-Up
Part No.: 120-0201
S/N: 8YL1-Up
Part No.: 119-2978, 120-0201
S/N: CRP1-Up
Part No.: 119-2978, 120-0201
S/N: 8SZ1-Up
Part No.: 120-0201
S/N: 9SZ1-Up
g01138133
Illustration 6
(1) Install the injection actuation pressure control

valve. Tighten the valve to the following
torque. ........................... 50 ± 5 N·m (37 ± 4 lb ft)
(2) Tighten the nut to the following

torque. .................... 5.5 ± 1.5 N·m (50 ± 13 lb in)
(3) Spacer
i02273191
Unit Injector
SMCS Code: 1290
Part No.: 188-1320, 196-4229
S/N: BKD1-Up
g01224405
Illustration 5 Part No.: 198-6005
S/N: G3E1-Up
(1) Put 4C-9507 Retaining Compound on the
tapered end of the stud to the following Part No.: 218-8634
distance. ........... 7.6 ± 1.5 mm (0.30 ± 0.06 inch) S/N: DPF1-Up
Part No.: 196-1401, 218-4109
Torque for stud ..................... 68 ± 7 N·m (50 ± 5 lb ft)
S/N: 1AJ1-Up
Part No.: 188-1320, 196-1401, 196-4229
S/N: 8YL1-Up
Part No.: 196-1401, 198-6005
S/N: CKM1-Up
Part No.: 198-6005
S/N: CRP1-Up
RENR1270-14 7
Part No.: 188-1320, 196-1401, 196-4229, i02310236

218-4109
S/N: 7AS1-Up Valve Rocker Arms, Lifters,
Part No.: 196-1401, 196-4229, 218-4109
and Bridges
S/N: 8SZ1-Up
SMCS Code: 1102; 1121; 1209
Part No.: 188-1320, 196-1401, 196-4229
S/N: 9SZ1-Up Part No.: 135-2969
g01157132
Illustration 8
(1) Valve rocker arm assembly

Bore in the rocker arm for the shaft
(new) .................................... 21.548 ± 0.013 mm
(0.8483 ± 0.0005 inch)
g01138493 Diameter of the rocker arm shaft
Illustration 7
(new) .................................... 21.500 ± 0.013 mm
(0.8465 ± 0.0005 inch)
(1) Lubricate the bore slightly. Use the lubricant that
is being sealed.
(2) Tighten the locknut to the following
torque. ........................... 30 ± 7 N·m (22 ± 5 lb ft)
(2) Tighten the bolt to the following
torque. ............................ 6 ± 1 N·m (55 ± 9 lb in)
(3) Valve lash
(3) Position oil deflector (3). Inlet valves ................................. 0.38 ± 0.08 mm
(0.015 ± 0.003 inch)
(4) Tighten the bolt to the following Exhaust valves .......................... 0.64 ± 0.08 mm
torque. ...................... 12 ± 3 N·m (105 ± 27 lb in) (0.0252 ± 0.003 inch)
(4) Lifter assembly

Bore in the lifter arm for the shaft
(new) .................................... 15.670 ± 0.013 mm
(0.6169 ± 0.0005 inch)
Diameter of shaft (new) ....... 15.620 ± 0.018 mm
(0.6150 ± 0.0007 inch)
8 RENR1270-14
i02454802
Valve Mechanism Cover

SMCS Code: 1107
Part No.: 141-8269
S/N: BKD1-Up
Part No.: 141-8269
S/N: DPF1-Up
Part No.: 141-8269
S/N: 1AJ1-Up
Part No.: 141-8269
g01157133
Illustration 9 S/N: 8YL1-Up
View A-A
Part No.: 141-8269
S/N: CKM1-Up
(5) The lifter group must be installed with the oil
holes in the shaft, as shown. Part No.: 141-8269
S/N: CRP1-Up
(6) Apply 9S-3263 Thread Lock Compound. Tighten
the bolts that are shown above in a numerical Part No.: 141-8269
sequence to the following torque. ...... 13 ± 3 N·m S/N: 7AS1-Up
(10 ± 2 lb ft)
Part No.: 141-8269
S/N: 8SZ1-Up
Part No.: 141-8269
S/N: 9SZ1-Up
g01225153
Illustration 10
Tighten the bolts in a numerical sequence to the

following torque. .................. 9 ± 3 N·m (80 ± 27 lb in)
RENR1270-14 9
i02456283 Note: The inlet and exhaust valve stems must be

coated with engine oil prior to installation in the
Valve Mechanism Cover cylinder head.
SMCS Code: 1107 Note: The tips of the inlet and exhaust valves must
be coated with 8T-2998 Lubricant. The lubricant
Part No.: 141-8285
must be applied after assembly of the retainer.
S/N: G3E1-Up
(1) Exhaust valve
(2) Inlet valve
(3) 137-6718 Spring for exhaust valve

Free length ..................... 92.08 mm (3.625 inch)
Assembled length ........... 80.27 mm (3.160 inch)
Load at assembled length ................. 662 ± 33 N
(150 ± 7 lb)
Minimum operating length .................. 66.27 mm
(2.609 inch)
Load at minimum operating length .. 1445 ± 58 N
(325 ± 13 lb)
g01225803
Illustration 11
(4) 140-6188 Spring for inlet valve
Tighten the bolts in a numerical sequence to the Free length ......................... 67.5 mm (2.66 inch)
following torque. .................. 9 ± 3 N·m (80 ± 27 lb in) Assembled length ............... 60.4 mm (2.38 inch)
Load at assembled length .............. 302.5 ± 18 N
(68 ± 4 lb)
i02455765
Minimum operating length .. 46.4 mm (1.83 inch)
Cylinder Head Valves Load at minimum operating length .. 898.5 ± 36 N
(200 ± 8 lb)
SMCS Code: 1105
(5) Height to the top of the valve guides
Part No.: 227-5954
Inlet valves ............................... 23.00 ± 0.50 mm
(0.906 ± 0.020 inch)
Exhaust valves ........................ 17.80 ± 0.50 mm
(0.701 ± 0.020 inch)
Diameter of inlet valve
guide .................................... 13.030 ± 0.008 mm
(0.5130 ± 0.0003 inch)
Diameter of exhaust valve
guide .................................... 16.000 ± 0.008 mm
(0.6299 ± 0.0003 inch)
Note: Install the valve guide from the spring side of

the cylinder head.
Note: Assemble the valve guide. Seat the seal

against the top of the valve guide.
(6) Valve stem diameter (new)

Inlet valves ............................. 8.000 ± 0.008 mm
(0.3150 ± 0.0003 inch)
Exhaust valve ........................ 9.441 ± 0.010 mm
(0.3717 ± 0.0004 inch)
After installation into the cylinder head, the valve

guide bore is the following value.
Diameter of the valve guide bore (new)

g01138576
Illustration 12
10 RENR1270-14
Inlet valve .............................. 8.072 ± 0.013 mm Inlet valve ......................... 30.25 ± 0.25 degrees
(0.3178 ± 0.0005 inch) Exhaust valve ..................... 45.5 ± 0.25 degrees
Exhaust valve .......................... 10.29 ± 0.08 mm
(0.405 ± 0.003 inch) (11) Depth of the bore in the head for the valve seat
insert ....... 10.00 ± 0.05 mm (0.394 ± 0.002 inch)
(7) Diameter of the valve head
(12) Outside diameter of the seating face of the
Inlet valve ................................ 40.00 ± 0.13 mm valve seat insert
(1.575 ± 0.005 inch)
Exhaust valve .......................... 43.00 ± 0.13 mm Inlet valve ................... 37.351 mm (1.4705 inch)
(1.693 ± 0.005 inch) Exhaust valve ............. 40.800 mm (1.6063 inch)
(8) Angle of the valve faces Note: Do not reuse the valve seat inserts if the
outside diameter of the valve seat insert is larger
Inlet valve ......................... 60.25 ± 0.25 degrees than the specified value.
Exhaust valve ................... 45.00 ± 0.25 degrees
i02456009
Cylinder Head
SMCS Code: 1100
Part No.: 133-3742
g01225627
Illustration 13
g01138617
Illustration 14
(9) Diameter of the valve seat inserts
(1) Large bolts
Inlet valve ............................ 42.000 ± 0.013 mm
(1.6535 ± 0.0005 inch) (2) Small bolts
Exhaust valve ...................... 46.000 ± 0.013 mm
(1.8110 ± 0.0005 inch) Note: Lubricate the following components with
6V-4876 Lubricant: the bolt threads, the underside
Diameter of the bore in cylinder head for the valve of the bolt heads, and the washers.
seat insert
Tighten the cylinder head bolts according to the
Bore diameter following procedure:
Inlet valve ............................ 41.931 ± 0.013 mm 1. Tighten bolt (1) through bolt (14) in a numerical
(1.6508 ± 0.0005 inch) sequence to a torque of 300 ± 15 N·m
Exhaust valve ...................... 45.931 ± 0.013 mm (220 ± 11 lb ft).
(1.8083 ± 0.0005 inch)
2. Loosen bolt (1) through bolt (14) until the washers
Note: The valve seat insert must be shrunk by are loose under the bolt heads.
reduced temperature before the valve seat insert is
installed in the head. 3. Tighten bolt (1) through bolt (14) in a numerical
sequence to a torque of 130 ± 15 N·m
(10) Angle of the valve seat inserts (95 ± 11 lb ft).
RENR1270-14 11
4. Again tighten bolt (1) through bolt (14) in a i02456927

numerical sequence to a torque of 130 ± 15 N·m
(95 ± 11 lb ft). Turbocharger
5. Turn bolt (1) through bolt (14) in a numerical SMCS Code: 1052
sequence for an additional 90° (1/4 turn).
Part No.: 136-0613
S/N: G3E1-Up
6. Tighten bolt (15) through bolt (20) in a numerical
sequence to a torque of 55 ± 7 N·m (41 ± 5 lb ft). Part No.: 199-6064
S/N: DPF1-Up
(3) The installation depth of the cup plug is measured
from the face of the cylinder head to the top edge Part No.: 136-0613
of the plug. Depth of installation .. 1.25 ± 0.25 mm S/N: 1AJ1-Up
(0.049 ± 0.001 inch)
Part No.: 136-0613
S/N: 8YL1-Up
Part No.: 199-6064
S/N: CKM1-Up
Part No.: 136-0613
S/N: CRP1-Up
Part No.: 136-0613
S/N: 7AS1-Up
Part No.: 136-0613
S/N: 8SZ1-Up
Part No.: 136-0613
g01138623 S/N: 9SZ1-Up
Illustration 15
(4) Unit injector sleeve
Refer to Special Instruction, SEHS9120 for

information on replacing unit injector sleeves.
(5) Height of a new 133-3742 Cylinder Head

Gp ......... 158.00 ± 0.15 mm (6.221 ± 0.006 inch)
g01226340
Illustration 16
Typical example of turbocharger with a wastegate
12 RENR1270-14
4. Tighten the bolts for the compressor clamp to a

torque of 13.6 ± 1.1 N·m (10 ± 1 lb ft).
5. Tighten the bolts for the outlet plate to a torque of

21.6 ± 1.1 N·m (16 ± 1 lb ft).
Note: Put clean engine oil in the oil inlet of the

turbocharger after assembly or before installation.
This will provide lubrication during start-up and during
storage.
g01226342
Illustration 17
Typical example of turbocharger without a wastegate
(1) Stud
Apply 5P-3931 Anti-Seize Compound to the studs.
The 136-0613 Turbocharger Gp and the 199-6064

Turbocharger Gp are secured to the exhaust manifold
with the 3E-8017 Locknut. Tighten the 3E-8017
Locknut to the following torque. ............... 54 ± 5 N·m
(40 ± 4 lb ft)
Note: The 3E-8017 Locknut has a special thread

form that is identifiable from a standard thread. This
thread form is called a Spiralock thread.
(2) Exhaust inlet
(3) Exhaust outlet
(4) Air inlet
(5) Wastegate
Opening pressure of the wastegate ........ 155.14 kPa

(23 psi)
Use the following procedure to install the band

clamps to hold the cartridge to the compressor
housing:
1. Tighten the compressor clamps to a torque of

10.17 ± 0.7 N·m (90 ± 6 lb in).
2. Tap lightly around the circumference of the clamp.
3. Tighten the clamps again. Tighten the clamps to a

torque of 10.17 ± 0.7 N·m (90 ± 6 lb in).
RENR1270-14 13
i02457214
Turbocharger
SMCS Code: 1052
Part No.: 136-0610, 136-0611
S/N: BKD1-Up
Part No.: 136-0611
S/N: G3E1-Up
Part No.: 136-0611
S/N: DPF1-Up
Part No.: 136-0610, 136-0611
S/N: 8YL1-Up
Part No.: 136-0610, 136-0611
S/N: CKM1-Up
Part No.: 136-0611
S/N: CRP1-Up
g01226342
Illustration 19
Part No.: 136-0610, 136-0611
Typical example of turbocharger without a wastegate
S/N: 7AS1-Up
Part No.: 136-0610 (1) Stud
S/N: 8SZ1-Up
Apply 5P-3931 Anti-Seize Compound to the studs.
Part No.: 136-0610, 136-0611
S/N: 9SZ1-Up The 136-0610 Turbocharger Gp and the 136-0611
Turbocharger Gp are secured to the exhaust manifold
with the 3E-8017 Locknut. Tighten the 3E-8017
Locknut to the following torque. ............... 54 ± 5 N·m
(40 ± 4 lb ft)
Note: The 3E-8017 Locknut has a special thread

form that is identifiable from a standard thread. This
thread form is called a Spiralock thread.
(2) Exhaust inlet
(3) Exhaust outlet
(4) Air inlet
(5) Wastegate
Opening pressure of the wastegate ........ 148.04 kPa

(21 psi)
Use the following procedure to install the band

Illustration 18
g01226340 clamps to hold the cartridge to the compressor
housing:
Typical example of turbocharger with a wastegate
1. Tighten the compressor clamps to a torque of

10.17 ± 0.7 N·m (90 ± 6 lb in).
2. Tap lightly around the circumference of the clamp.
3. Tighten the clamps again. Tighten the clamps to a

torque of 10.17 ± 0.7 N·m (90 ± 6 lb in).
4. Tighten the bolts for the compressor clamp to a

torque of 13.6 ± 1.1 N·m (10 ± 1 lb ft).
14 RENR1270-14
5. Tighten the bolts for the outlet plate to a torque of (1) Apply 1U-8846 Gasket Sealant to the face of
21.6 ± 1.1 N·m (16 ± 1 lb ft). the elbow and spread the sealant uniformly. The
elbow must be assembled and the elbow must
Note: Put clean engine oil in the oil inlet of the be tightened within ten minutes.
turbocharger after assembly or before installation.
This will provide lubrication during start-up and during
i01675931
storage.
Exhaust Manifold
i02444902
SMCS Code: 1059
Air Inlet Elbow
Part No.: 127-3466, 148-7227, 164-0219,
SMCS Code: 1071 164-0225
S/N: BKD1-Up
Part No.: 137-5182, 151-0854
S/N: BKD1-Up Part No.: 127-3466
S/N: G3E1-Up
Part No.: 151-0854
S/N: G3E1-Up Part No.: 127-3466, 164-0219
S/N: DPF1-Up
Part No.: 151-0854
S/N: DPF1-Up Part No.: 127-3466
S/N: 1AJ1-Up
Part No.: 151-7141
S/N: 1AJ1-Up Part No.: 127-3466, 148-7227, 164-0219,
164-0225
Part No.: 137-5182, 151-0854, 151-7141 S/N: 8YL1-Up
S/N: 8YL1-Up
Part No.: 127-3466, 148-7227, 164-0219,
Part No.: 151-0854 164-0225
S/N: CKM1-Up S/N: CKM1-Up
Part No.: 137-5182, 151-0854 Part No.: 127-3466, 148-7227
S/N: CRP1-Up S/N: CRP1-Up
Part No.: 151-0854 Part No.: 127-3466, 148-7227, 164-0219,
S/N: 7AS1-Up 164-0225
S/N: 7AS1-Up
Part No.: 137-5182, 151-0854
S/N: 8SZ1-Up Part No.: 127-3466, 148-7227, 164-0219,
164-0225
Part No.: 137-5182, 151-0854, 151-7141 S/N: 8SZ1-Up
S/N: 9SZ1-Up
Part No.: 127-3466, 148-7227, 164-0219,
164-0225
S/N: 9SZ1-Up
NOTICE
Excessive use of sealant can cause damage to com-
ponents.
To avoid component damage use only the amount of

sealant necessary for the application.
Use the following procedure during assembly of the

three-piece exhaust manifold to the cylinder block.
g01221697
Illustration 20 1. Mounting surfaces should be clean, and dry. In
Typical example of a air inlet elbow addition, mounting surfaces should be free of any
other foreign matter.
RENR1270-14 15
2. Apply 2P-2333 High Temperature Sealer to the i02457521

outside diameter of the male ends of the exhaust
manifold. Do not apply the sealer at the tip of the Exhaust Elbow
male ends. Remove any excess sealer from the
assembled joint. SMCS Code: 1061
Part No.: 126-7856, 126-7857
S/N: BKD1-Up
Part No.: 126-7857
S/N: 1AJ1-Up
Part No.: 126-7856, 126-7857
S/N: 8YL1-Up
g00291084
Three-piece exhaust manifold S/N: CKM1-Up
Typical example
Part No.: 126-7856, 126-7857
3. Apply 5P-3931 Anti-Seize Compound to the S/N: CRP1-Up
threads of bolt (1) through bolt (12). Part No.: 126-7856, 126-7857
S/N: 7AS1-Up
sequence. Part No.: 126-7857
S/N: 8SZ1-Up
Tighten the bolts to the following
torque. .............................. 4 ± 1 N·m (35 ± 9 lb in) Part No.: 126-7856, 126-7857
S/N: 9SZ1-Up
sequence.
Tighten the bolts to the following

torque. ............................. 45 ± 5 N·m (33 ± 4 lb ft)
6. Lock the tabs and bend the tabs (13) over the flat
of the bolt heads.
7. Tighten the studs (14) to a torque of 35 ± 5 N·m

(26 ± 4 lb ft).
Note: Prior to starting or running the engine, allow

the sealant in the exhaust manifold joints to air dry
for 24 hours.
g01226588
Illustration 22
Typical example of an exhaust elbow
(1) Tighten the nut for the clamp to the following

torque. ............................. 12 ± 4 N·m (9 ± 3 lb ft)
16 RENR1270-14
i02458104 (4) Exhaust lobe

Camshaft (5) Distance between the shoulder of the camshaft
and the shoulder of the gear
SMCS Code: 1210
Total distance .. 4.83 ± 0.05 mm (0.190 ± 0.002 inch)
Part No.: 205-1324
S/N: BKD1-Up
Part No.: 205-1324
S/N: G3E1-Up
Part No.: 205-1324
S/N: DPF1-Up
Part No.: 205-1324
S/N: 1AJ1-Up
Part No.: 205-1324
S/N: 8YL1-Up
Part No.: 205-1324
S/N: CKM1-Up
g00939444
Illustration 24
Part No.: 205-1324
S/N: CRP1-Up (6) Camshaft lobe lift
Part No.: 117-9939 Specified camshaft lobe lift (6)
S/N: 7AS1-Up
Exhaust lobe ................. 7.707 mm (0.3034 inch)
Part No.: 205-1324 Inlet lobe ....................... 7.970 mm (0.3138 inch)
S/N: 8SZ1-Up
Part No.: 205-1324 To find the lobe lift, use the procedure that follows:
S/N: 9SZ1-Up
1. Measure the camshaft lobe height (7).
2. Measure the base circle (8).
3. Subtract the base circle that is found in Step 2

from the lobe height that is found in Step 1. The
difference is the actual camshaft lobe lift (6).
Maximum permissible difference between actual

lobe lift and the specified lobe lift of a new
camshaft .............................. ± 0.10 mm (0.004 inch)
g01115468
Illustration 23
(1) New thrust washer thickness ................ 4.70 mm

(0.185 inch)
End play of a new camshaft ............. 0.13 ± 0.08 mm

(0.005 ± 0.003 inch)
(2) Diameter of the camshaft

journals ................................ 65.126 ± 0.013 mm
(2.5640 ± 0.0005 inch)
(3) Inlet lobe

RENR1270-14 17
i02458437 Two-Piece Body

Engine Oil Filter Base
SMCS Code: 1306
Part No.: 117-4074
S/N: BKD1-Up
Part No.: 117-4074
S/N: G3E1-Up
Part No.: 117-4074
S/N: DPF1-Up
Part No.: 117-4074
S/N: 1AJ1-Up
Part No.: 117-4074, 201-9775
S/N: 8YL1-Up
Part No.: 117-4074
S/N: CKM1-Up
Part No.: 117-4074 g01156511
S/N: CRP1-Up Illustration 26
Part No.: 117-4074 (1) The bypass valve spring is located in the filter
S/N: 7AS1-Up bypass valve:
Part No.: 117-4074 Outside diameter ................. 11.0 mm (0.43 inch)
S/N: 8SZ1-Up Free length .............................. 58.50 ± 0.50 mm
(2.303 ± 0.020 inch)
Part No.: 117-4074, 201-9775 Assembled length ............. 43.18 mm (1.70 inch)
S/N: 9SZ1-Up Load at assembled length ......... 43.7 N (9.82 lb)
One-Piece Body (2) The oil filter bypass valves must open at the
following pressure. ......................... 125 ± 30 kPa
(18.1 ± 4.4 psi)
(3) Prior to installing the stud into the engine oil filter
base, apply 9S-3263 Thread Lock Compound to
the base end of the stud. Length ... 7.5 ± 1.5 mm
(0.30 ± 0.06 inch)
Tighten the stud to the following torque. .. 68 ± 7 N·m

(50 ± 5 lb ft)
(4) Use clean engine oil to lubricate the oil filter’s

seal. Tighten the filter until the seal contacts the
base. Hand tighten the filter for an additional 3/4
turn (270 degrees).
g01156510
Illustration 25
18 RENR1270-14
i01582205 Outside diameter ................ 13.0 mm (0.51 inch)

Free length ..................... 64.98 mm (2.558 inch)
Engine Oil Pump Assembled length ............... 54.5 mm (2.15 inch)
Load at assembled length ............. 51.99 ± 1.9 N
SMCS Code: 1304 (12 ± 0.4 lb)
Part No.: 189-8777
(5) Relief valve plunger
Diameter of the plunger ....... 17.000 ± 0.013 mm
(0.6693 ± 0.0005 inch)
Bore in the pump body for the
plunger ................................. 17.100 ± 0.025 mm
(0.6732 ± 0.0010 inch)
i02459175
Engine Oil Pan

SMCS Code: 1302
Part No.: 122-8936
S/N: BKD1-Up
Part No.: 122-8936
S/N: DPF1-Up
Part No.: 122-8936
S/N: 1AJ1-Up
g00292581
Section view through pump gears S/N: 8YL1-Up
Typical example
Part No.: 122-8936
S/N: CKM1-Up
Part No.: 122-8936
S/N: CRP1-Up
Part No.: 122-8936
S/N: 7AS1-Up
g00292582 Part No.: 122-8936

Illustration 28
S/N: 8SZ1-Up
The section view is of the bypass valve that is located in the pump
assembly. Part No.: 122-8936
S/N: 9SZ1-Up
(1) Distance between the front face of the gear and
the housing .............................. 43.00 ± 0.25 mm
(1.693 ± 0.010 inch)
(2) Length of the gears .................. 33.00 ± 0.03 mm

(1.299 ± 0.001 inch)
Depth of the bores for the gears .... 33.13 ± 0.02 mm

(1.304 ± 0.001 inch)
(3) Diameter of the gear shafts .. 15.600 ± 0.005 mm

(0.6142 ± 0.0002 inch)
Bores in the pump bodies for the gear

shafts .... 15.641 ± 0.008 mm (0.6158 ± 0.0003 inch)
g01227231
Illustration 29
(4) 105-1805 Spring for relief valve
RENR1270-14 19
(1) Tighten the plug to the following (3) Tighten the plug to the following
torque. ........................... 25 ± 5 N·m (18 ± 4 lb ft) torque. ........................... 35 ± 5 N·m (26 ± 4 lb ft)
Apply 230-6262 Sealant to four areas on the sealing Apply 230-6262 Sealant to the four corners on the
surface of the oil pan. The areas are marked location sealing surface of the oil pan. The sealing area must
(Y). The areas are at the corners of the oil pan in the be free of oil and debris. The sealant must be applied
following locations: in the form of a bead with a consistent cross section
of 5 mm (0.20 inch). The parts must be assembled
• Connecting joint of the front housing and the front within 5 minutes of the application of the sealant.
of the cylinder block
i02274130
• Connecting joint of the flywheel housing and the
rear of the cylinder block Crankcase Breather
Use the following procedure to tighten the bolts for SMCS Code: 1317
the oil pan.
Part No.: 128-2682
Tighten four bolts (X). S/N: BKD1-Up
Start with bolt (Z) and tighten all remaining bolts in a Part No.: 128-2682
counterclockwise sequence. S/N: G3E1-Up
Part No.: 128-2682
Tighten the bolts to the following torque. .. 31 ± 3 N·m
(23 ± 2 lb ft) S/N: DPF1-Up
Part No.: 128-2682
Start again with bolt (Z) and tighten all remaining S/N: 8YL1-Up
bolts in a counterclockwise sequence.
Part No.: 128-2682
Tighten the bolts to the following torque. .. 31 ± 3 N·m S/N: CKM1-Up
(23 ± 2 lb ft)
Part No.: 128-2682
S/N: CRP1-Up
i02459230
Part No.: 128-2682
Engine Oil Pan S/N: 7AS1-Up
SMCS Code: 1302 Part No.: 128-2682

S/N: 8SZ1-Up
Part No.: 164-0216
S/N: G3E1-Up Part No.: 128-2682
S/N: 9SZ1-Up
g01227259
Illustration 30
g01138835
Illustration 31
(1) Tighten the plug to the following Typical example
torque. ........................... 25 ± 5 N·m (18 ± 4 lb ft)
(1) Tighten bolt (1) that holds the breather cap to the
(2) Tighten the plug to the following following torque. ........... 7 ± 2 N·m (60 ± 18 lb in)
torque. ........................... 50 ± 7 N·m (37 ± 5 lb ft)
20 RENR1270-14
i02459585 i02445046
Crankcase Breather Water Temperature Regulator

Part No.: 156-0233 Part No.: 119-3075
S/N: BKD1-Up S/N: BKD1-Up
Part No.: 156-0233 Part No.: 119-3075
S/N: G3E1-Up S/N: G3E1-Up
Part No.: 156-0233 Part No.: 119-3075
S/N: 1AJ1-Up S/N: DPF1-Up
Part No.: 156-0233 S/N: 8YL1-Up
S/N: 8YL1-Up
Part No.: 119-3075
Part No.: 156-0233 S/N: CKM1-Up
S/N: CKM1-Up
Part No.: 119-3075
Part No.: 156-0233 S/N: CRP1-Up
S/N: CRP1-Up
Part No.: 119-3075
Part No.: 156-0233 S/N: 7AS1-Up
S/N: 7AS1-Up
Part No.: 119-3075
Part No.: 156-0233 S/N: 8SZ1-Up
S/N: 8SZ1-Up
Part No.: 119-3075
Part No.: 156-0233 S/N: 9SZ1-Up
S/N: 9SZ1-Up
g01227421
Illustration 32
(1) Tighten the bolt that holds the breather cap to the
following torque. ........... 7 ± 2 N·m (62 ± 18 lb in)
g01221772
Illustration 33
Start to open temperature of the water temperature

regulator ................ 78 °C to 83 °C (172 °F to 181 °F)
Fully open temperature of the water temperature

regulator ............................................. 94 °C (201 °F)
(1) Closed dimension of the water temperature

regulator ......... 30.5 ± 0.5 mm (1.20 ± 0.02 inch)
RENR1270-14 21
(2) Minimum stroke of the water temperature i02460137

regulator at fully open temperature ....... 8.75 mm
(0.345 inch) Water Pump
SMCS Code: 1361
i02459754
Part No.: 159-3141, 159-3145
Water Temperature Regulator S/N: BKD1-Up
SMCS Code: 1355 Part No.: 159-3141, 159-3145

S/N: G3E1-Up
Part No.: 115-4223
Part No.: 159-3141, 159-3145
S/N: DPF1-Up
Part No.: 159-3145
S/N: 1AJ1-Up
Part No.: 159-3141, 159-3145
S/N: 8YL1-Up
Part No.: 159-3141, 159-3145
S/N: CKM1-Up
Part No.: 159-3141, 159-3145
S/N: CRP1-Up
Part No.: 159-3141, 159-3145
S/N: 7AS1-Up
Part No.: 159-3141, 159-3145
S/N: 8SZ1-Up
Part No.: 159-3141, 159-3145
S/N: 9SZ1-Up
g01115619
Illustration 34
Start to open temperature of the water temperature

regulator ............... 86 °C to 89 °C (187 °C to 160 °F)
Fully open temperature of the water temperature

regulator ............................................. 97 °C (206 °F)
(1) Closed dimension of the water temperature

regulator ......... 29.5 ± 0.5 mm (1.16 ± 0.02 inch)
(2) Minimum stroke of the water temperature

regulator at fully open temperature ....... 8.00 mm
(0.315 inch)
g01227834
Illustration 35
22 RENR1270-14
(1) Clearance between the impeller and the (3) Height of seal ........................... 12.83 ± 0.13 mm
housing ..... 0.75 ± 0.25 mm (0.030 ± 0.010 inch) (0.505 ± 0.005 inch)
(2) Seal (4) Dimension from the front face of the pulley to the
face of the housing ....................... 103 ± 0.3 mm
(3) Height of seal ........................... 12.83 ± 0.13 mm (4.1 ± 0.01 inch)
(0.505 ± 0.005 inch)
i02397369
(4) Dimension from the front face of the pulley to the
face of the housing .................... 103.8 ± 0.3 mm
(4.09 ± 0.01 inch)
Water Pump
SMCS Code: 1361
i02460154
Part No.: 159-3145
Water Pump
SMCS Code: 1361
Part No.: 151-3087, 236-4420
S/N: BKD1-Up
Part No.: 151-3087, 236-4420
S/N: 8YL1-Up
Part No.: 151-3087, 236-4420
S/N: CKM1-Up
Part No.: 151-3087, 236-4420
S/N: CRP1-Up
Part No.: 151-3087, 236-4420
S/N: 7AS1-Up
Part No.: 151-3087, 236-4420
S/N: 9SZ1-Up
g01197373
Illustration 37
The impeller cover is not shown.
(1) Clearance between the impeller and the

housing ..... 0.75 ± 0.25 mm (0.030 ± 0.010 inch)
(2) Seal
(3) Height of seal ........................... 12.83 ± 0.13 mm

(0.505 ± 0.005 inch)
(4) The filter should not extend beyond the surface

of the housing.
g01227793
Illustration 36
(1) Clearance between the impeller and the face of the housing .................... 103.8 ± 0.3 mm
housing ..... 0.75 ± 0.25 mm (0.030 ± 0.010 inch) (4.09 ± 0.01 inch)
(2) Seal
RENR1270-14 23
i02460221 (5) Distance from the front of the water pump pulley
to the face of the housing .. 122.8 mm (4.83 inch)
Water Pump
SMCS Code: 1361 i02459918
Part No.: 160-8175, 187-8992 Water Pump

S/N: BKD1-Up
SMCS Code: 1361
Part No.: 160-8175, 187-8992
S/N: 8YL1-Up Part No.: 227-4301
S/N: BKD1-Up
Part No.: 160-8175, 187-8992
S/N: CKM1-Up Part No.: 227-4301
S/N: 8YL1-Up
Part No.: 160-8175, 187-8992
S/N: CRP1-Up Part No.: 227-4301
S/N: CKM1-Up
Part No.: 160-8175, 187-8992
S/N: 9SZ1-Up Part No.: 227-4301
S/N: 9SZ1-Up
g01227793
Illustration 39
(1) Clearance between the impeller and the

housing ..... 0.75 ± 0.25 mm (0.030 ± 0.010 inch)
g01182799 (2) Seal

Illustration 38
(3) Height of seal ........................... 12.19 ± 0.13 mm
(1) Clearance between the impeller and the (0.48 ± 0.005 inch)
housing ..... 0.75 ± 0.25 mm (0.030 ± 0.010 inch)
(2) Water pump shaft face of the housing ....................... 103 ± 0.3 mm
(4.1 ± 0.01 inch)
Note: Refer to Disassembly and Assembly for the
complete procedure for installing the shaft and seal.
(3) The bearing must be flush with the edge of the

housing.
(4) Working height of the installed

seal ......... 12.83 ± 0.13 mm (0.505 ± 0.005 inch)
24 RENR1270-14
i02370457 (4) Working height of the installed

seal ......... 12.19 ± 0.13 mm (0.480 ± 0.005 inch)
Water Pump
(5) Distance from the front of the water pump pulley
SMCS Code: 1361 to the face of the housing ...... 122.79 ± 0.30 mm
(4.834 ± 0.012 inch)
Part No.: 227-4300
S/N: BKD1-Up
i02462091
Part No.: 227-4300
S/N: 8YL1-Up Cylinder Block Cover Group
Part No.: 227-4300
SMCS Code: 1201
S/N: CKM1-Up
Part No.: 118-0432, 140-3573, 142-0369,
Part No.: 227-4300
143-4926, 193-4712, 197-9591, 222-5947
S/N: CRP1-Up
S/N: BKD1-Up
Part No.: 227-4300
Part No.: 222-5947, 262-4305
S/N: 9SZ1-Up
S/N: G3E1-Up
Part No.: 142-0369, 193-4712, 210-5596,
210-5598, 210-5599, 211-9089, 211-9100,
211-9101, 222-5947
S/N: DPF1-Up
Part No.: 142-0369, 143-4926, 222-5947
S/N: 1AJ1-Up
Part No.: 118-0432, 140-3573, 142-0369,
143-4926, 151-7126, 193-4712, 197-9591,
210-5596, 210-5598, 210-5599, 211-9089,
211-9100, 211-9101, 222-5947
S/N: 8YL1-Up
Part No.: 118-0432, 140-3573, 142-0369,
143-4926, 193-4712, 197-9591, 222-5947
S/N: CKM1-Up
Part No.: 118-0432, 140-3573, 142-0369,
143-4926, 193-4712, 197-9591, 210-5596,
210-5598, 210-5599, 211-9089, 211-9100,
211-9101, 222-5947
S/N: CRP1-Up
Part No.: 118-0432, 140-3573, 142-0369,
143-4926, 222-5947
S/N: 7AS1-Up
g01182799 Part No.: 118-0432, 142-0369, 222-5947

Illustration 40
S/N: 8SZ1-Up
(1) Clearance between the impeller and the Part No.: 118-0432, 140-3573, 142-0369,
housing ..... 0.75 ± 0.25 mm (0.030 ± 0.010 inch) 143-4926, 151-7126, 193-4712, 197-9591,
210-5596, 210-5598, 210-5599, 211-9089,
(2) Water pump shaft 211-9100, 211-9101, 222-5947
S/N: 9SZ1-Up
Note: Refer to Disassembly and Assembly for the
complete procedure for installing the shaft and seal.
(3) The bearing must be flush with the edge of the

housing.
RENR1270-14 25
(7) Distance for sleeve (3) from the cylinder block

face ................... 5.0 ± 0.5 mm (0.20 ± 0.02 inch)
g01188203
Illustration 41
Left side view of engine (typical example)
g00938462
Illustration 43
(1) Cylinder block
Tighten bolts (1 through 8 on each cover) in the
(2) Gasket numerical sequence that is shown in Illustration 43.
Gasket (2) is molded. In order to prevent fluid

i02462470
leakage, install the gasket so that the bead, that is
molded into the surface of the gasket, is facing the
side cover (5).
Cylinder Block
SMCS Code: 1201
(3) Six sleeves must be installed in location (X).
Part No.: 129-1165
(4) Cover assembly
Clean the face of the cover with solvent. Apply

8C-8422 Sealant to the gasket surface that is on the
cover. Spread the sealant uniformly on the face of the
cover and around the bolt holes. The cover must be
installed and tightened within ten minutes.
(5) Side cover
(6) Eight spacers must be installed in location (Y).

Some applications utilize twelve spacers. If
your application has twelve spacers, install the
spacers along the bottom row of bolts for each
of the side cover. g01116572
Illustration 44
(1) Installation depth of the cup plug from the block

face to the top edge of the plug. .. 1.25 ± 0.25 mm
(0.049 ± 0.010 inch)
g01138968
Illustration 42
View A-A
Installation of the sleeves
26 RENR1270-14
Note: The front camshaft bearing is installed with

the bearing oil hole in alignment with the oil hole in
the cylinder block and bearing joint (6) in the position
that is shown.
(8) Bearing cap

Width of the main bearing cap ........ 159.995 mm
(6.2990 inch)
Width of the cylinder block for the main
bearing ................... 160.018 mm to 159.977 mm
(6.2999 inch to 6.2983 inch)
(9) Distance from the centerline of the crankshaft

bore to the pan rail ......... 110.00 mm (4.331 inch)
g01116575
Illustration 45
View F-F (10) Bore in the cylinder block for the seven main
bearings ............................... 95.000 ± 0.013 mm
(2) Location of the bearing oil hole (3.7402 ± 0.0005 inch)
(3) Bore diameters in the cylinder block for (11) Location of the sequence number for the bearing
all camshaft bearings except the front cap
bearing ................................. 69.000 ± 0.038 mm
(2.7165 ± 0.0015 inch) (12) Main bearing cap bolts
Install the bearing caps with the sequence number to

the right. The order is 1 through 7 (front to rear).
1. Apply 4C-5593 Anti-Seize Compound to the bolt

threads (16) and face of the washers.
2. Tighten bolts (12) on each bearing cap.
Tighten to the following torque. ........... 54 ± 7 N·m

(40 ± 5 lb ft)
3. Tighten bolts (12) on each bearing cap again.
Tighten the bolts by another one quarter of a

turn. ............................................. 90 ± 5 degrees
Note: Additional information on reconditioning

procedures can be ordered. Refer to the following
documents:
g01116577 Guideline For Reusable Parts And Salvage

Illustration 46
Operations, SEBF8192, “Specifications and Salvage
View A-A for Cylinder Blocks on 3114, 3116, 3126 and 3126B
Engines”
(4) Bore diameter in the cylinder block for the front
camshaft bearing ................. 70.000 ± 0.025 mm Guideline For Reusable Parts And Salvage
(2.7559 ± 0.0010 inch) Operations, SEBF8261, “Installing a 7C-6208
Cylinder Sleeve in 3114 and 3116 Engines and a
(5) Distance from the centerline of the crankshaft 107-7604 Cylinder Sleeve in 3126 Engines”
bore to the top surface of the cylinder
block ................................ 322 mm (12.677 inch)
(6) Location of the joint for the front camshaft bearing
(7) Front camshaft bearing oil hole

RENR1270-14 27
i02209974 i02424747
Crankshaft Crankshaft Seals

SMCS Code: 1202 SMCS Code: 1160; 1161
Part No.: 113-6087 Part No.: 122-8929
Part No.: 151-6301 Part No.: 122-8929
Part No.: 212-3658 Part No.: 122-8929
S/N: DPF1-Up S/N: DPF1-Up
Part No.: 113-6087 Part No.: 122-8929
S/N: 1AJ1-Up S/N: 1AJ1-Up
Part No.: 113-6087 Part No.: 122-8929, 5R-8845
S/N: 8YL1-Up S/N: 8YL1-Up
Part No.: 113-6087 Part No.: 122-8929
Part No.: 151-6301 Part No.: 122-8929
Part No.: 113-6087 Part No.: 122-8929, 5R-8845
S/N: 7AS1-Up S/N: 7AS1-Up
Part No.: 113-6087, 151-6301 Part No.: 122-8929
S/N: 8SZ1-Up S/N: 8SZ1-Up
Part No.: 113-6087 Part No.: 122-8929, 5R-8845
Note: For the complete procedure on removing and

installing the crankshaft seals, refer to Disassembly
and Assembly.
Front Crankshaft Seal
g01115711
Illustration 47
(1) Crankshaft end play .................. 0.07 to 0.32 mm

(0.003 to 0.013 inch)
g01211763
Illustration 48
(1) Front crankshaft seal
Install the front seal. Ensure that the front face of the
seal is 2.5 ± 0.5 mm (0.10 ± 0.02 inch) from the front
housing (3).
(2) Crankshaft seal excluder

28 RENR1270-14
Prior to installing the crankshaft seal excluder onto

the crankshaft pulley (4), lubricate the inside diameter
sparingly with liquid soap.
Note: The front crankshaft seal and the crankshaft

seal excluder are serviced separately.
g01133079
Illustration 51
(6a) Single lip seal that is used for dry applications
(6b) Double lip seal that is used for wet applications
(9) Wear sleeve
Use the correct seal for your application.

g01133077
Illustration 49
The wear sleeve (9) must not be removed from the
The shipping sleeve (5) must not be removed prior seal at any time. If the wear sleeve is removed
to the installation of the seal. If the shipping sleeve from the seal, the seal should not be used.
has been removed prior to installation of the seal,
the seal should not be used. i02463065
Install the front seal (1) in the housing. Remove the Crankshaft Seals
shipping sleeve (5). Install the pulley (4).
SMCS Code: 1160; 1161
Rear Crankshaft Seal Part No.: 115-4210
S/N: 8SZ1-Up
Note: For the complete procedure on removing and

installing the crankshaft seals, refer to Disassembly
and Assembly.
Front Crankshaft Seal
g01133078
Illustration 50
(6) Rear crankshaft seal
Install the rear crankshaft seal into the carrier

housing or the flywheel housing (7). After installation
of the seal, ensure that the rear face of the seal is
15.4 ± 0.5 mm (0.61 ± 0.02 inch) from the rear face g01211763
of the engine block (8). Illustration 52
(1) Front crankshaft seal

RENR1270-14 29
Install the front seal. Ensure that the front face of the
seal is 2.5 ± 0.5 mm (0.10 ± 0.02 inch) from the front
housing (3).
(2) Crankshaft seal excluder
Prior to installing the crankshaft seal excluder onto

the crankshaft pulley (4), lubricate the inside diameter
sparingly with liquid soap.
Note: The front crankshaft seal and the crankshaft

seal excluder are serviced separately.
g01133079
Illustration 55
(6a) Single lip seal that is used for dry applications
(6b) Double lip seal that is used for wet applications
(9) Wear sleeve
Use the correct seal for your application.
The wear sleeve (9) must not be removed from the

seal at any time. If the wear sleeve is removed
from the seal, the seal should not be used.
g01133077
Illustration 53
The shipping sleeve (5) must not be removed prior

to the installation of the seal. If the shipping sleeve
has been removed prior to installation of the seal,
the seal should not be used.
Install the front seal (1) in the housing. Remove the

shipping sleeve (5). Install the pulley (4).
Rear Crankshaft Seal
g01133078
Illustration 54
(6) Rear crankshaft seal
Install the rear crankshaft seal into the carrier

housing or the flywheel housing (7). After installation
of the seal, ensure that the rear face of the seal is
16.0 ± 0.5 mm (0.63 ± 0.02 inch) from the rear face
of the engine block (8).
30 RENR1270-14
i02463213 i02463878
Rear Seal Carrier Vibration Damper

(If Equipped) SMCS Code: 1205
SMCS Code: 1161 Part No.: 111-7245, 183-4498, 189-0255
S/N: BKD1-Up
Part No.: 132-3844
S/N: BKD1-Up Part No.: 111-7245, 183-4498, 189-0255
S/N: 8YL1-Up
Part No.: 132-3844
S/N: G3E1-Up Part No.: 111-7245, 183-4498, 189-0255
S/N: CKM1-Up
Part No.: 132-3844
S/N: 8YL1-Up Part No.: 111-7245, 183-4498, 189-0255
S/N: CRP1-Up
Part No.: 132-3844
S/N: 7AS1-Up
Part No.: 132-3844
S/N: CRP1-Up Part No.: 111-7245, 183-4498, 189-0255
S/N: 9SZ1-Up
Part No.: 132-3844
S/N: 7AS1-Up
Part No.: 132-3844
S/N: 8SZ1-Up
Part No.: 132-3844
S/N: 9SZ1-Up
g01229331
Illustration 57
Typical example
(1) Damper assembly
(2) Tighten the bolts to the following

torque. ................... 200 ± 25 N·m (148 ± 18 lb ft)
g01156562
Illustration 56
(1) Apply 230-6262 Sealant to the joint face of the

seal carrier. Spread the liquid gasket uniformly
on the joint face. The seal carrier must be
assembled and tightened to the cylinder block
within ten minutes.
(2) Apply 9S-3263 Thread Lock Compound to the

threads of the eight bolts.
RENR1270-14 31
i01135341 Part No.: 213-3193

S/N: 1AJ1-Up
Connecting Rod Bearing
Part No.: 161-8420
Journal S/N: 8YL89883-Up
SMCS Code: 1202; 1219; 1225 Part No.: 213-3193
S/N: CKM1-Up
Part No.: 222-3900
Part No.: 213-3193
Table 1
S/N: CRP1-Up
Diameter Of Crankshaft Journal (Bearing Surface)
For Connecting Rod Bearings Part No.: 213-3193
S/N: 7AS1-Up
70.000 ± 0.020 mm
Original Size Journal
(2.7559 ± 0.0008 inch) Part No.: 213-3193
S/N: 8SZ1-Up
Undersize Journal 69.750 ± 0.020 mm
0.25 mm (0.010 inch) (2.7461 ± 0.0008 inch) Part No.: 213-3193
S/N: 9SZ1-Up
0.50 mm (0.020 inch) (2.7362 ± 0.0008 inch)
Clearance between bearing and new

journal ... 0.053 to 0.155 mm (0.0021 to 0.0061 inch)
i01135346
Main Bearing Journal

SMCS Code: 1202; 1203
Part No.: 222-3900
Table 2
Diameter Of Crankshaft Journal (Bearing

Surface) For Main Bearings
90.000 ± 0.020 mm
Original Size Journal
(3.5433 ± 0.0008 inch)

0.25 mm (0.010 inch) (3.5335 ± 0.0008 inch)

0.50 mm (0.020 inch) (3.5236 ± 0.0008 inch)
Clearance between bearing and new

journal ... 0.071 to 0.173 mm (0.0028 to 0.0068 inch)
i02496948
Connecting Rod
g01133091
Illustration 58
SMCS Code: 1218
Part No.: 213-3193 Note: Handle the fractured connecting rod with care.
S/N: BKD1-Up Use a soft jawed vise in order to hold the connecting
rod while loosening the connecting rod cap bolts. Use
Part No.: 213-3193 a soft faced hammer in order to tap the connecting
S/N: G3E1-Up rod cap, if necessary.
Part No.: 213-3193

S/N: DPF1-Up
32 RENR1270-14
The connecting rod small end must be heated from i02427715

175 to 260 °C (347 to 500 °F) before the installation
of the piston pin bearing. Connecting Rod
The bearing joint for the piston pin bearing (A) must SMCS Code: 1218
be positioned at 12 ± 5 degrees (B) above the
Part No.: 2W-9128
centerline on either side.
S/N: BKD1-Up
Apply heat only within length (C) of the connecting Part No.: 2W-9128
rod. .................................. 75 ± 5 mm (3.0 ± 0.2 inch) S/N: G3E1-Up
(1) Bore size for the piston pin after the installation Part No.: 2W-9128
of the bearing S/N: DPF1-Up
Bore in the piston pin Part No.: 2W-9128
bearing ................................. 40.028 ± 0.008 mm S/N: 1AJ1-Up
(1.5759 ± 0.0003 inch)
Part No.: 140-7390
(2) Bore size for the piston pin bearing S/N: 8YL1-89882
Bore in the connecting rod for the piston pin Part No.: 2W-9128
bearing ................................. 43.191 ± 0.013 mm S/N: CKM1-Up
(1.7004 ± 0.0005 inch) Part No.: 2W-9128
S/N: CRP1-Up
(3) Distance between the center of the connecting
rod bores ............................... 200 mm (7.9 inch) Part No.: 2W-9128
S/N: 7AS1-Up
(4) Connecting rod bolts .................... 65.0 ± 0.5 mm
(2.56 ± 0.02 inch) Part No.: 2W-9128
S/N: 8SZ1-Up
Note: Use the following procedure to tighten the
Part No.: 2W-9128
connecting rod bolts before measuring the crankshaft
bore. Check the dimensions of the crankshaft bore S/N: 9SZ1-Up
only after the tightening procedure has been followed.
(5) Bore in the connecting rod for the

bearing for the crankshaft connecting rod
journal .................................. 75.000 ± 0.013 mm
(2.9527 ± .0005 inch)
Use the instructions that follow in order to tighten the

connecting rod cap bolts:
1. Before installing the rod cap, clean the mating

surfaces of the connecting rod with compressed
air or a steel brush. Ensure that there are no loose
particles that remain from the process that is used
to fracture the rod.
Note: Lubricate the seating faces of the rod cap bolts

with 4C-5593 Anti-Seize Compound or engine oil
before installing the bolts.
2. Install new connecting rod cap bolts (4).
Tighten each of the cap bolts to the following

torque. ............................. 70 ± 5 N·m (50 ± 4 lb ft)
3. Place an index mark on each connecting rod

cap bolt and tighten each of the cap bolts for an
additional 120 ± 5 degrees (1/3 of a turn). g00594371
Illustration 59
RENR1270-14 33
Note: The connecting rod must be heated for the i02466458

installation of the piston pin bearing. Do not use a
torch. Piston and Rings
The connecting rod may be heated from SMCS Code: 1214; 1215
175° to 260 °C (347 °F to 500 °F) for the installation
Part No.: 227-5958
of the piston pin bearing.
S/N: 1AJ1-Up
Length (A) is the maximum distance for heating the
connecting rod . .............. 75 ± 5 mm (3.0 ± 0.2 inch) Two-Piece Articulated Piston
The bearing joint must be at angle (B) which is 12.0 ±
5.0 degrees above the centerline.
(1) Bore size

Bore in the connecting rod for the piston pin
bearing ................................. 43.191 ± 0.013 mm
(1.7004 ± 0.0005 inch)
Bore in the bearing for the piston
pin ... 40.028 ± 0.008 mm (1.5759 ± 0.0003 inch)
(2) Distance between the center of the

bearings ........................ 200.00 mm (7.874 inch)
g01139038
(3) Location for the etched cylinder numbers on the Illustration 60
rod and the cap after assembly
(1) Crown assembly
Note: Etch the cylinder number on the connecting rod
and the cap in this location (3). Mark the numbers on Top Ring and Intermediate Ring
the same side of the connecting rod as the bearing
retainer notch. (2) The top ring has the mark “UP-1”.
(4) Connecting rod bolts Install the piston ring with the side marked “UP-1”
toward the top of the piston. The colored stripe faces
(5) Bore in the connecting rod for the to the right of the ring end gap.
bearing for the crankshaft connecting rod
journal .................................. 75.000 ± 0.013 mm The ends of the piston ring have a clearance when
(2.9527 ± 0.0005 inch) the piston ring is installed in a cylinder with a specific
bore size.
Tighten the connecting rod bolts. Use the instructions
that follow: Cylinder bore size ............ 110.025 mm (4.3317 inch)
1. Before installing the connecting rod bolts (4), Clearance ....... 0.40 ± 0.10 mm (0.016 ± 0.004 inch)
lubricate the bolt threads and the seating faces of
the caps with engine oil. The piston ring has an increase in clearance for each
0.03 mm (0.001 inch) increase in the cylinder liner
2. Install the connecting rod bolts (4). bore.
Tighten each nut to the following Increase .................................. 0.09 mm (0.004 inch)
torque. ............................. 54 ± 7 N·m (40 ± 5 lb ft)
(3) The intermediate ring has the mark “UP-2”.
3. Put an alignment mark on the cap and the nut.
Install the piston ring with the side marked “UP-2”
4. Tighten each nut for an additional 60 ± 5 degrees toward the top of the piston. The colored stripe faces
(1/6 of a turn). to the right of the piston ring end gap.
Thickness of the new piston ring .. 2.980 ± 0.010 mm

(0.1173 ± 0.0004 inch)
The ends of the piston ring have a clearance when

the piston ring is installed in a cylinder with a specific
bore size.
34 RENR1270-14
Cylinder bore size ............ 110.025 mm (4.3317 inch) Piston pin bore diameter that is in the crown
assembly ............................. 40.031 ± 0.007 mm
Clearance .................................... 0.825 ± 0.125 mm (1.5760 ± 0.0003 inch)
(0.0325 ± 0.0049 inch) Piston pin bore diameter that is in the piston
skirt .. 40.020 ± 0.008 mm (1.5756 ± 0.0003 inch)
The intermediate piston ring has an increase in Piston pin diameter .............. 39.993 ± 0.005 mm
clearance for each 0.03 mm (.001 inch) increase in (1.5745 ± 0.0002 inch)
the cylinder liner bore. Length of piston pin ................. 89.95 ± 0.15 mm
(3.541 ± 0.006 inch)
Increase .................................. 0.09 mm (0.004 inch)
Thoroughly lubricate the piston pin with clean engine
Oil Control Ring oil prior to assembly.
(4) The oil control piston ring has a spring that is (7) Connecting rod
installed with the ring. The gap in the spring
should be a distance of 180 degrees from the Note: Install the rod and piston group in the engine
ring end gap when the oil control piston ring is with the part number to the rear of the engine. The
assembled. The light green colored portion of the rear of the engine is the flywheel end of the engine.
spring must be visible at the ring end gap. Lubricate the rod and piston group with clean engine
oil before you insert the rod and piston group into
Width of the groove in a new piston for the oil control the block.
piston ring .................................... 4.041 ± 0.013 mm
(0.1591 ± 0.0005 inch)

(0.1569 ± 0.0004 inch)
Clearance between the oil groove and the oil control

piston ring .................................... 0.033 ± 0.079 mm
(0.0013 ± 0.0031 inch)
The ends of the oil control piston ring have a

clearance when the ring is installed in a cylinder with
a specific bore size.
Cylinder bore size ............ 110.025 mm (4.3317 inch)
Clearance ....... 0.45 ± 0.15 mm (0.018 ± 0.006 inch)
The oil control piston ring has an increase in

clearance for each 0.03 mm (0.001 inch) increase
in the cylinder liner bore.
Increase .................................. 0.09 mm (0.004 inch)
After the piston rings have been installed, rotate the

piston rings so that the end gaps are 120 degrees
from each other.
(5) Piston skirt
Lubricate the entire piston in zone (A) prior to

assembly into the cylinder block. Use clean engine
oil.
Piston Pin Bore

(6) Piston pin
RENR1270-14 35
i02466476 The ends of the piston ring have a clearance when

Piston and Rings bore size.
SMCS Code: 1214; 1215 Cylinder bore size ............ 110.025 mm (4.3317 inch)
Part No.: 161-8420
S/N: BKD1-Up
Part No.: 161-8420 The piston ring has an increase in clearance for each
S/N: G3E1-Up 0.03 mm (0.001 inch) increase in the cylinder liner
bore.
Part No.: 212-3660
S/N: DPF1-Up Increase .................................. 0.09 mm (0.004 inch)
Part No.: 161-8420 (3) The intermediate ring has the mark “UP-2”.
S/N: 1AJ1-Up
Part No.: 161-8420, 227-5948 Install the piston ring with the side marked “UP-2”
S/N: 8YL1-Up toward the top of the piston. The colored stripe faces
to the right of the piston ring end gap.
Part No.: 161-8420, 227-5948
S/N: CKM1-Up Thickness of the new piston ring .. 2.980 ± 0.013 mm
(0.1173 ± 0.0005 inch)
Part No.: 161-8420
S/N: CRP1-Up The ends of the piston ring have a clearance when
Part No.: 161-8420
bore size.
S/N: 7AS1-Up
Part No.: 161-8420 Cylinder bore size ............ 110.025 mm (4.3317 inch)
S/N: 8SZ1-Up
Clearance .................................... 0.825 ± 0.125 mm
Part No.: 161-8420, 227-5948 (0.0325 ± 0.0049 inch)
S/N: 9SZ1-Up
The intermediate piston ring has an increase in
clearance for each 0.03 mm (.001 inch) increase in
Two-Piece Articulated Piston the cylinder liner bore.
Increase .................................. 0.09 mm (0.004 inch)
Oil Control Ring

(4) The oil control piston ring has a spring that is
should be a distance of 180 degrees from the
ring end gap when the oil control piston ring is
assembled. The light green colored portion of the
spring must be visible at the ring end gap.
Width of the groove in a new piston for the oil control

piston ring .................................... 4.041 ± 0.013 mm
g01139038
Illustration 61 (0.1591 ± 0.0005 inch)
(1) Crown assembly Thickness of the new piston ring .. 3.985 ± 0.010 mm
(0.1569 ± 0.0004 inch)
Top Ring and Intermediate Ring
Clearance between the oil groove and the oil control
(2) The top ring has the mark “UP-1”. piston ring .................................... 0.033 ± 0.079 mm
(0.0013 ± 0.0031 inch)
toward the top of the piston. The colored stripe faces The ends of the oil control piston ring have a
to the right of the ring end gap. clearance when the ring is installed in a cylinder with

36 RENR1270-14
Clearance ....... 0.45 ± 0.15 mm (0.018 ± 0.006 inch) i02466545
The oil control piston ring has an increase in Piston and Rings
in the cylinder liner bore. SMCS Code: 1214; 1215
Part No.: 177-7500
Increase .................................. 0.09 mm (0.004 inch)
S/N: BKD1-Up
After the piston rings have been installed, rotate the Part No.: 177-7500
piston rings so that the end gaps are 120 degrees S/N: 8YL1-Up
from each other.
Part No.: 177-7500
(5) Piston skirt S/N: CKM1-Up
Lubricate the entire piston in zone (A) prior to Part No.: 177-7500
assembly into the cylinder block. Use clean engine S/N: 9SZ1-Up
oil.
One-Piece Aluminum Piston
Piston Pin Bore
(6) Piston pin
Piston pin bore diameter that is in the crown
assembly ............................. 40.031 ± 0.007 mm
(1.5760 ± 0.0003 inch)
Piston pin bore diameter that is in the piston
skirt .. 40.020 ± 0.008 mm (1.5756 ± 0.0003 inch)
Piston pin diameter .............. 39.993 ± 0.005 mm
(1.5745 ± 0.0002 inch)
Length of piston pin ................. 89.95 ± 0.15 mm
(3.541 ± 0.006 inch)

g01139054
oil prior to assembly. Illustration 62
(7) Connecting rod (1) Piston body assembly
Note: Install the rod and piston group in the engine Lubricate the entire piston in zone (A) prior to
with the part number to the rear of the engine. The assembly into the cylinder block. Use clean engine
rear of the engine is the flywheel end of the engine. oil.
Lubricate the rod and piston group with clean engine
oil before you insert the rod and piston group into Top Ring and Intermediate Ring
the block.
(2) The top ring has the mark “UP-1”.

to the right of the ring end gap.
The ends of the piston ring have a clearance when

bore size.
The piston ring has an increase in clearance for each

0.03 mm (0.001 inch) increase in the cylinder liner
bore.
RENR1270-14 37
Increase .................................. 0.09 mm (0.004 inch) Length of piston pin ................. 89.95 ± 0.15 mm
(3.541 ± 0.006 inch)
(3) The intermediate ring has the mark “UP-2”.
Install the piston ring with the side marked “UP-2” oil prior to assembly.
to the right of the piston ring end gap. (6) Connecting rod
Thickness of the new piston ring ... 2.98 ± 0.013 mm Note: Assemble the rod and piston group with the
(0.1173 ± 0.0005 inch) marking “front” on the piston body in the opposite
direction of the part number on the rod assembly.
The ends of the piston ring have a clearance when Install the rod and piston group in the engine with the
the piston ring is installed in a cylinder with a specific part number on the rod assembly to the rear of the
bore size. engine. The rear of the engine is the flywheel end of
the engine. Lubricate the rod and piston group with
Cylinder bore size ............ 110.025 mm (4.3317 inch) clean engine oil before you insert the rod and piston
group into the block.
Clearance .................................... 0.825 ± 0.125 mm
(0.0325 ± 0.0049 inch)
i02467367
The intermediate piston ring has an increase in

Front Housing and Covers
in the cylinder liner bore. SMCS Code: 1162; 1166
Increase .................................. 0.09 mm (0.004 inch) Part No.: 133-5055, 165-4446
Oil Control Ring

(4) The oil control piston ring has a spring that is
should be a distance of 180 degrees from the
ring end gap when the oil control piston ring is
assembled. The light green colored portion of the
spring must be visible at the ring end gap.

(0.1569 ± 0.0004 inch)
The ends of the oil control piston ring have a

clearance when the ring is installed in a cylinder with
Cylinder bore size ................ 110.03 mm (4.332 inch)
The oil control piston ring has an increase in

in the cylinder liner bore.
Increase .................................. 0.09 mm (0.004 inch)
After the piston rings have been installed, rotate the

g01116434
piston rings so that the end gaps are 120 degrees Illustration 63
from each other.
Piston Pin Bore

(5) Piston pin
Piston pin diameter .............. 39.993 ± 0.005 mm
(1.5745 ± 0.0002 inch)
38 RENR1270-14
g01230505
Illustration 64
Apply 8C-8422 Sealant to the front housing sealing

surfaces before assembling the front housing to the
cylinder block. The front housing must be assembled
and tightened to the cylinder block within ten minutes.
(1) Cylinder Block
(2) Front housing
(3) Bolts (X) .............................. 50.0 mm (1.97 inch)
(4) Bolts (Y) .............................. 20.0 mm (0.79 inch)
(5) Front housing cover

serrations of the studs before installation.
RENR1270-14 39
i02467615
Gear Group (Front)

SMCS Code: 1206
Part No.: 205-1321
g01133392
Illustration 65
(1) Camshaft idler gear (4) Align the timing marks on the camshaft idler gear
(1) with the holes on the camshaft (2) and the
Distance between the front of the bearing face and crankshaft gear (5).
the front of the gear face (B) ............ 1.08 ± 0.25 mm
(0.043 ± 0.010 inch) (5) Crankshaft gear
Diameter of new shaft (A) .......... 79.146 ± 0.013 mm (6) Oil pump drive gear
(3.1160 ± 0.0005 inch)
(2) Camshaft gear threads of the oil pump idler gear bolt. Tighten
the bolt to the following torque. ........ 70 ± 15 N·m
(3) Tighten the bolts of the camshaft idler gear to the (50 ± 11 lb ft)
following torque. ........ 70 ± 15 N·m (50 ± 11 lb ft)
40 RENR1270-14
(8) Oil pump idler gear
Distance between the rear of the bearing face and

the rear of the gear face (C) ........... 0.75 ± 0.25 mm
(0.030 ± 0.010 inch)
Diameter of new shaft (D) .......... 28.644 ± 0.013 mm

(1.1277 ± 0.0005 inch)
i02231565
Gear Group (Front)

SMCS Code: 1206
Part No.: 101-4540
g01133392
Illustration 66
(1) Camshaft idler gear

RENR1270-14 41
Distance between the front of the bearing face and i02468606

the front of the gear face (B) ............ 0.40 ± 0.25 mm
(0.016 ± 0.010 inch) Flywheel
Diameter of new shaft (A) ............ 80.00 ± 0.013 mm SMCS Code: 1156
(3.1496 ± 0.0005 inch)
Part No.: 100-6578, 122-8933, 188-7119
S/N: BKD1-Up
(2) Camshaft gear
Part No.: 256-7187
(3) Tighten the bolts of the camshaft idler gear to the S/N: G3E1-Up
following torque. ........ 70 ± 15 N·m (50 ± 11 lb ft)
Part No.: 122-8933, 188-7119
(4) Align the timing marks on the camshaft idler gear S/N: DPF1-Up
(1) with the holes on the camshaft (2) and the
crankshaft gear (5). Part No.: 100-6578, 122-8933, 161-0206,
188-7119
(5) Crankshaft gear S/N: 8YL1-Up
Part No.: 100-6578, 122-8933, 188-7119
(6) Oil pump drive gear S/N: CKM1-Up
(7) Apply 9S-3263 Thread Lock Compound to the Part No.: 100-6578, 122-8933, 188-7119,
threads of the oil pump idler gear bolt. Tighten 256-7187
the bolt to the following torque. ........ 70 ± 15 N·m S/N: CRP1-Up
(50 ± 11 lb ft)
Part No.: 100-6578, 122-8933, 161-0206
(8) Oil pump idler gear S/N: 7AS1-Up
Part No.: 122-8933, 161-0206
Distance between the rear of the bearing face and
S/N: 8SZ1-Up
the rear of the gear face (C) ........... 0.75 ± 0.25 mm
(0.030 ± 0.010 inch) Part No.: 100-6578, 122-8933, 161-0206,
188-7119
Diameter of new shaft (D) .......... 28.644 ± 0.013 mm S/N: 9SZ1-Up
(1.1277 ± 0.0005 inch)
g01139170
Illustration 67
Typical example
Note: Refer to Systems Operation/Testing and

Adjusting for the correct method of inspecting the
flywheel.
(1) Bolt
42 RENR1270-14
(2) Ring gear Note: Refer to Systems Operation/Testing and

(3) Spring pin flywheel.
The following instructions should be used during (1) Bolt

installation of the ring gear:
Tighten bolts (1) that hold the flywheel to the
1. Press spring pin (3) into the crankshaft before crankshaft to the following torque. .. 120 ± 20 N·m
assembling the flywheel to the crankshaft. Check (90 ± 15 lb ft)
the distance from the face of the crankshaft to the
end of spring pin (3). (2) Ring gear
Distance ............ 11.0 ± 1.0 mm (0.43 ± 0.04 inch) i02468985
2. Tighten bolts (1) that hold the flywheel to the Flywheel

crankshaft.
SMCS Code: 1156
Tighten to the following torque. ....... 120 ± 20 N·m
(90 ± 15 lb ft) Part No.: 207-8050
S/N: BKD1-Up
i02468771 Part No.: 207-8050

S/N: 8YL1-Up
Flywheel
Part No.: 207-8050
SMCS Code: 1156 S/N: CKM1-Up
Part No.: 198-1204 Part No.: 207-8050

S/N: G3E1-Up S/N: CRP1-Up
Part No.: 7E-0519 Part No.: 207-8050

S/N: 8YL1-Up S/N: 9SZ1-Up
Part No.: 7E-0519, 9Y-7506

S/N: 8SZ1-Up
Part No.: 7E-0519
S/N: 9SZ1-Up
g01231233
Illustration 69

flywheel.
g01231100
Illustration 68
(1) Bolt
Typical example
(2) Ring gear
RENR1270-14 43
(3) Spring pin i02469380
The following instructions should be used during Flywheel Housing

installation of the ring gear:
SMCS Code: 1157
1. Press spring pin (3) into the crankshaft before
Part No.: 117-0515, 122-8934, 129-1175
assembling the flywheel to the crankshaft. Check
S/N: BKD1-Up
the distance from the face of the crankshaft to the
end of spring pin (3). Part No.: 122-8934
S/N: G3E1-Up
Distance ............ 11.0 ± 1.0 mm (0.43 ± 0.04 inch)
Part No.: 122-8934, 129-1175
2. Tighten bolts (1) that hold the flywheel to the S/N: DPF1-Up
crankshaft.
Part No.: 122-8934
Tighten to the following torque. ....... 120 ± 20 N·m S/N: 1AJ1-Up
(90 ± 15 lb ft) Part No.: 117-0515, 122-8934, 129-1175,
159-3970, 237-9630
S/N: 8YL1-Up
Part No.: 117-0515, 122-8934, 129-1175
S/N: CKM1-Up
Part No.: 117-0515, 122-8934, 129-1175
S/N: CRP1-Up
Part No.: 117-0515, 122-8934, 129-1175
S/N: 7AS1-Up
Part No.: 117-0515, 122-8934, 197-5210
S/N: 8SZ1-Up
Part No.: 117-0515, 122-8934, 129-1175,
159-3970, 237-9630
S/N: 9SZ1-Up
g01231611
Illustration 70
Typical example

flywheel housing.
44 RENR1270-14
(1) Sealing surface i02469585
Apply 8C-8422 Sealant to all of the sealing surfaces Flywheel Housing

(2) of the flywheel housing . The flywheel housing
must be assembled and tightened to the block within SMCS Code: 1157
ten minutes.
Part No.: 200-4502
S/N: G3E1-Up
i02469635
Part No.: 200-4502
Flywheel Housing S/N: CRP1-Up
SMCS Code: 1157

Part No.: 132-2104
S/N: BKD1-Up
Part No.: 132-2104
S/N: 8YL1-Up
Part No.: 132-2104
S/N: CKM1-Up
Part No.: 132-2104
S/N: CRP1-Up
Part No.: 132-2104
S/N: 8SZ1-Up
Part No.: 132-2104
S/N: 9SZ1-Up
g01231751
Illustration 72

flywheel housing.
(1) Plug
Tighten the three plugs (1) to the following

torque. ................................... 4 ± 1 N·m (35 ± 9 lb in)
(2) Sealing surface
Apply 8C-8422 Sealant to all of the sealing surfaces

(2) of the flywheel housing. The flywheel housing
must be assembled and tightened to the block within
ten minutes.
g01231698
Illustration 71

flywheel housing.
(1) plug
Tighten the two plugs (1) to the following

torque. ................................... 4 ± 1 N·m (35 ± 9 lb in)
RENR1270-14 45
i02470977 i02309148
Engine to Transmission Engine to Transmission

Adapter Adapter
(If Equipped) (If Equipped)
Part No.: 107-2781 Part No.: 100-4029, 117-0508, 117-3440,
S/N: BKD1-Up 133-5003, 161-9214
S/N: BKD1-Up
Part No.: 107-2781
S/N: 8YL1-Up S/N: G3E1-Up
Part No.: 107-2781 Part No.: 100-4029, 117-0508, 133-5003
S/N: CKM1-Up S/N: DPF1-Up
Part No.: 107-2781 S/N: 1AJ1-Up
S/N: CRP1-Up
Part No.: 100-4029, 117-0508, 117-3440,
Part No.: 107-2781 133-5003, 161-9214, 263-4019, 263-4021
S/N: 7AS1-Up S/N: 8YL1-Up
Part No.: 107-2781 Part No.: 100-4029, 117-0508, 117-3440,
S/N: 9SZ1-Up 133-5003, 161-9214
S/N: CKM1-Up
Part No.: 100-4029, 117-0508, 117-3440,
133-5003, 161-9214
S/N: CRP1-Up
Part No.: 100-4029, 117-0508, 117-3440,
133-5003, 161-9214
S/N: 7AS1-Up
S/N: 8SZ1-Up
Part No.: 100-4029, 117-0508, 117-3440,
133-5003, 161-9214, 263-4019, 263-4021
S/N: 9SZ1-Up
g01232551
Illustration 73

torque. ............................ 4 ± 1 N·m (35 ± 9 lb in)
(2) Adapter
(3) Crankshaft
g01156615
Illustration 74
(1) Crankshaft
46 RENR1270-14
(2) Flywheel assembly i02471394
(3) Hub Crankshaft Pulley

(4) Flex plate SMCS Code: 1205
Part No.: 118-2090, 119-0066, 122-8931,
4P-4452
torque. ..................... 120 ± 20 N·m (90 ± 15 lb ft) S/N: BKD1-Up
Part No.: 118-2090, 122-8931
S/N: G3E1-Up
Part No.: 118-2090
S/N: DPF1-Up
Part No.: 118-2090, 119-0066, 122-8931
S/N: 1AJ1-Up
Part No.: 118-2090, 119-0066, 122-8931,
4P-4452
S/N: 8YL1-Up
Part No.: 118-2090, 119-0066, 122-8931,
4P-4452
S/N: CKM1-Up
Part No.: 118-2090, 119-0066, 122-8931,
4P-4452
S/N: CRP1-Up
Part No.: 118-2090, 119-0066, 122-8931,
4P-4452
S/N: 7AS1-Up
Part No.: 118-2090, 119-0066, 122-8931,
4P-4452
S/N: 8SZ1-Up
Part No.: 118-2090, 119-0066, 122-8931,
4P-4452
S/N: 9SZ1-Up
g01135859
Illustration 75
Typical example

torque. ................... 200 ± 25 N·m (150 ± 18 lb ft)
RENR1270-14 47
i02471408 i01617888
Crankshaft Pulley Belt Tension Chart

Part No.: 4W-5429 Part No.: 7N-9693
S/N: BKD1-Up
Note: Do not use the belt tension charts for belts with
Part No.: 4W-5429 tensioners that are spring loaded.
S/N: 8YL1-Up
Part No.: 4W-5429
S/N: CKM1-Up
Part No.: 4W-5429
S/N: CRP1-Up
Part No.: 4W-5429
S/N: 7AS1-Up
Part No.: 4W-5429
S/N: 8SZ1-Up
Part No.: 4W-5429
S/N: 9SZ1-Up
g01232434
Illustration 76

torque. ................... 190 ± 30 N·m (140 ± 22 lb ft)
(2) Washer
(3) Pulley
48 RENR1270-14
Table 3
Belt Tension Chart
Kent-Moore Gauge
Gauge Reading
Numbers
Size of
Width of Belt Number
Belt Belt Tension Belt Tension Number of the
of the Old
“Initial”(1) “Used”(2)(3) New Gauge
Gauge
534 ± 111 N
3/8 10.72 mm (0.422 inch) 400 ± 22 N (90 ± 5 lb) BT-33-97 BT 3397
(120 ± 25 lb)
578 ± 111 N
1/2 13.89 mm (0.547 Inch) 445 ± 44 N (100 ± 10 lb) BT-33-97 BT 3397
(130 ± 25 lb)
712 ± 111 N BT-33-
5V 15.88 mm (0.626 Inch) 445 ± 44 N (100 ± 10 lb) BT 3372C
(160 ± 25 lb) 72C
712 ± 111 N BT-33-
11/16 17.48 mm (0.688 Inch) 445 ± 44 N (100 ± 10 lb) BT 3372C
(160 ± 25 lb) 72C
712 ± 111 N BT-33-
3/4 19.05 mm (0.750 Inch) 445 ± 44 N (100 ± 10 lb) BT 3372C
(160 ± 25 lb) 72C
712 ± 111 N
15/16 23.83 mm (0.938 Inch) 445 ± 44 N (100 ± 10 lb) BT-33-77 BT 3372C
(160 ± 25 lb)
1068 ± 111 N BT-33-
8PK 27.82 mm (1.095 inch) 890 ± 44 N (200 ± 10 lb) BT 33109
(240 ± 25 lb) 109
801 ± 111 N BT-33-
6PK 20.94 mm (0.824 Inch) 667 ± 44 N (150 ± 10 lb) BT 33109
(180 ± 25 lb) 109
Measure the tension of the belt that is farthest from the engine.
(1) Belt tension “Initial” is for a new belt.
(2) Belt tension “Used” is for a belt that has operated for 30 minutes or more of operation at the rated speed.
(3) If a belt falls below the “Used” belt tension, the belt should be tightened again to the high side of the “Used” belt tension.
RENR1270-14 49
Table 4
For DAYCO Supplied Belts Only
Belt Tension Belt Tension
Size of Belt
“Initial”(1) “Used”(2)(4)
.380 (V-Belt) 623 ± 22 N (140 ± 5 lb) 245 - 534 N (100 ± 5 lb)
.440 (V-Belt) 667 ± 22 N (150 ± 5 lb) 245 - 534 N (100 ± 5 lb)
.500 (V-Belt) 712 ± 22 N (160 ± 5 lb) 245 - 534 N (100 ± 5 lb)
.600 (V-Belt) 779 ± 22 N (175 ± 5 lb) 245 - 534 N (100 ± 5 lb)
.660 (V-Belt) 890 ± 22 N (200 ± 5 lb) 245 - 534 N (100 ± 5 lb)
.790 (V-Belt) 890 ± 22 N (200 ± 5 lb) 245 - 534 N (100 ± 5 lb)
4 - RIB PVK 623 ± 22 N (140 ± 5 lb) 267 - 445 N (90 ± 5 lb)
5 - RIB PVK 779 ± 22 N (175 ± 5 lb) 334 - 556 N (100 ± 5 lb)
6 - RIB PVK 934 ± 22 N (210 ± 5 lb) 400 - 667 N (130 ± 5 lb)
8 - RIB PVK 1157 ± 22 N (260 ± 5 lb) 534 - 890 N (180 ± 5 lb)
10 - RIB PVK 1557 ± 22 N (350 ± 5 lb) 667 - 1112 N (230 ± 5 lb)
12 - RIB PVK 1869 ± 22 N (420 ± 5 lb) 800 - 1335 N (270 ± 5 lb)
15 - RIB PVK 2336 ± 22 N (525 ± 5 lb) 1000 - 1669 N (350 ± 5 lb)
(1) Belt tension “Initial” is for a new belt.
(2) Belt tension “Used” is for a belt that has operated for 30 minutes or more of operation at the rated speed.
(4) If a belt falls below the “Used” belt tension, the belt should be tightened again to the “Initial” belt tension.
i02471966
Belt Tensioner
SMCS Code: 1358
Part No.: 135-2151
g01156636
Illustration 77
(1) Minimum travel ................................. 71 degrees
(2) The torque for the spring is 14.1 ± 1.7 N·m

(10 ± 1 lb ft) at 25 degrees from the released
position.
50 RENR1270-14
i02473321 i02431963
Belt Tensioner Belt Tensioner

Part No.: 200-2290 Part No.: 220-1210
Part No.: 200-2290 Part No.: 220-1210
Part No.: 200-2290 Part No.: 220-1210
S/N: CKM1-Up S/N: CRP1-Up
Part No.: 200-2290 Part No.: 220-1210
S/N: CRP1-Up S/N: 9SZ1-Up
Part No.: 200-2290
S/N: 9SZ1-Up
g01103389
Illustration 79
g01233637
(1) Limited travel .................. 52 degrees (minimum)
Illustration 78
(2) Spring force at assembly 59.9 ± 6.0 N·m
(1) Spring force at assembly 59.9 ± 6.0 N·m (44 ± 4 lb ft) at 35 degrees from the free arm stop
(44 ± 4 lb ft) at 36 degrees from the free arm stop

RENR1270-14 51
i02471973 i02472057
Belt Tensioner Belt Tensioner

Part No.: 135-2142 Part No.: 196-4195
Part No.: 135-2142 Part No.: 196-4195
Part No.: 135-2142 Part No.: 196-4195
Part No.: 135-2142 Part No.: 196-4195
Part No.: 135-2142 Part No.: 196-4195
g01232850 g01232917
Illustration 80 Illustration 81
(1) Minimum travel ................................. 71 degrees (1) Minimum travel ................................. 71 degrees
(2) The torque for the spring is 42.9 ± 4.18 N·m (2) The torque for the spring is 27.0 ± 2.8 N·m
(32 ± 3 lb ft) at 36 degrees from the released (20 ± 2 lb ft) at 36 degrees from the released
position. position.
52 RENR1270-14
i02473481 (1) Distance from the back of the plate assembly to

the middle of the pulley ................ 26.0 ± 0.3 mm
Belt Tensioner (1.02 ± 0.01 inch)
SMCS Code: 1358 (2) Distance from the back of the plate assembly to
the back of the pulley ............. 16 mm (0.63 inch)
Part No.: 200-2292
S/N: BKD1-Up
(3) Plate assembly
(4) Pulley

pulley bore before assembly.
i02309792
Fan Drive
SMCS Code: 1359
S/N: G3E1-Up
g01233791 S/N: DPF1-Up

Illustration 82
S/N: 1AJ1-Up
(2) Spring force at assembly 59.9 ± 6.0 N·m

(44 ± 4 lb ft) at 35 degrees from the free arm stop
i02472595
Belt Tightener
SMCS Code: 1358
Part No.: 115-4204
g01156570
Illustration 83
g01156884
Illustration 84
RENR1270-14 53
(1) Use the grease fitting to fill the bearing cavity with i02473652
30 grams (1.05 ounces) of 2S-3230 Bearing
Lubricant. Apply the grease to the bearing cavity Fan Drive
after installing fan drive bearings.
SMCS Code: 1359
(2) Bracket
Part No.: 162-7760
S/N: BKD1-Up
(3) Bearing assembly
Part No.: 162-7760
(4) Bolt S/N: 8YL1-Up
(5) Bolt Part No.: 162-7760

S/N: CKM1-Up
(6) Support
Part No.: 162-7760
Assembly procedure for the bracket S/N: CRP1-Up
Part No.: 162-7760
1. Tighten bolt (4) by hand into the housing. S/N: 7AS1-Up
2. Tighten bolt (5) by hand into the bracket (2). Part No.: 162-7760, 7C-0044
S/N: 8SZ1-Up
3. Tighten bolts (4) and (5).
Part No.: 162-7760, 7C-0044
Tighten the bolts to the following S/N: 9SZ1-Up
torque. ........................... 55 ± 10 N·m (40 ± 7 lb ft)
g01234006
Illustration 85
54 RENR1270-14
(1) Use the grease fitting to fill the bearing cavity with Amperage ..................................................... 95 Amp
30 grams (1.05 ounces) of 8T-1807 Bearing
Lubricant. Apply the grease to the bearing cavity Note: Load the battery with a carbon pile 4C-4911
after installing fan drive bearings. Battery Load Tester in order to get the maximum
alternator output.
(2) Bearing assembly
Polarity ............................................ Negative ground
(3) Bracket
Rotation .................................................... Clockwise
(4) Bolt
The minimum full load current at 5000 rpm is the
(5) Bolt following value: ............................................. 95 Amp
(6) Support The minimum full load current at 2000 rpm is the
following value: ............................................. 28 Amp
Assembly procedure for the bracket
Output voltage .......................................... 28 ± 1.0 V
1. Tighten bolt (4) by hand into the housing.
(1) Positive terminal nut
2. Tighten bolt (5) by hand into the bracket (2).
Tighten the positive terminal nut to the following
3. Tighten bolts (4) and (5). torque: .......... 18.2 ± 2.4 N·m (161.1 ± 21.2 lb in)
Tighten the bolts to the following (2) Ground bolt

torque. ........................... 55 ± 10 N·m (40 ± 7 lb ft)
Tighten the ground bolt to the following
torque: ...................... 4.4 ± 1.0 N·m (39 ± 9 lb in)
i02400049
(3) Regulator
Alternator and Regulator
Voltage setting ............................. No adjustment
SMCS Code: 1405; 1410 Permissible voltage range .................. 27 to 29 V
Part No.: 197-8820 (4) Shaft nut

S/N: CRP1-Up
Tighten the shaft nut to the following
Part No.: 197-8820 torque: ....................... 127 ± 10 N·m (94 ± 7 lb ft)
S/N: 8SZ1-Up
g01199166
Illustration 86
Voltage ............................................................... 24 V
RENR1270-14 55
i02304907 No load conditions at 25 °C (77 °F)

Electric Starting Motor Speed ...................................... 7018 ± 1517 rpm
Current .................................... 125.5 ± 27.5 amp
SMCS Code: 1453 Voltage ......................................................... 11 V
Part No.: 6V-4238 (1) Tighten the nut on the battery terminal to the
S/N: BKD1-Up following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)
Part No.: 6V-4238
(2) Tighten the ground terminal to the following
S/N: 8YL1-Up
torque. ..................... 30.5 ± 3.5 N·m (22 ± 3 lb ft)
Part No.: 6V-4238
S/N: CKM1-Up (3) Tighten the nut to the following
torque. .................. 2.25 ± 0.25 N·m (20 ± 2 lb in)
Part No.: 6V-4238
S/N: CRP1-Up (4) Tighten the nut on the switch terminal to the
following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in)
Part No.: 6V-4238
S/N: 7AS1-Up (5) Tighten the nut on the motor terminal to the
Part No.: 6V-4238 following torque. ........... 8 ± 3 N·m (71 ± 27 lb in)
S/N: 8SZ1-Up
(6) Tighten the nut on the motor frame terminal to
Part No.: 6V-4238 the following torque. ..... 8 ± 3 N·m (71 ± 27 lb in)
S/N: 9SZ1-Up
Solenoid
Current draw at 12 V and 25 °C (77 °F)

Pull-in windings ................................. 89 ± 5 amp
Hold-in windings ............... 23 ± 2 amp maximum
g00282688
Illustration 87
Typical example
g00489813
Illustration 88
Typical solenoid connections
When the electric starting motor is viewed from

the drive end, the motor rotates in the following
direction. ................................................... Clockwise
56 RENR1270-14
i02309875
Electric Starting Motor

SMCS Code: 1453
Part No.: 207-1516
S/N: BKD1-Up
Part No.: 207-1516, 266-7229
S/N: G3E1-Up
Part No.: 207-1516
S/N: 1AJ1-Up
Part No.: 207-1516
g01156917
S/N: 8YL1-Up Illustration 90
Part No.: 207-1516
S/N: CKM1-Up
Part No.: 207-1516, 266-7229 the drive end, the motor rotates in the following
S/N: CRP1-Up direction. ................................................... Clockwise
Part No.: 207-1516 No load conditions at 25 °C (77 °F)

S/N: 7AS1-Up
Speed ...................................... 7200 ± 1250 rpm
Part No.: 207-1516, 207-1517 Current ...................................... 82.5 ± 17.5 amp
S/N: 8SZ1-Up Voltage ......................................................... 23 V
Part No.: 207-1516 (1) Tighten the nut on the battery terminal to the
S/N: 9SZ1-Up following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)

torque. ..................... 30.5 ± 3.5 N·m (22 ± 3 lb ft)

torque. .................. 2.25 ± 0.25 N·m (20 ± 2 lb in)
(4) Tighten the nut on the switch terminal to the

(5) Tighten the nut on the motor terminal to the

following torque. ...... 14.7 ± 3.4 N·m (11 ± 3 lb ft)

g01156902 the following torque. ..... 8 ± 3 N·m (71 ± 27 lb in)
Illustration 89
Typical example Solenoid

Pull-in windings ....................................... 57 amp
Hold-in windings ..................................... 13 amp
RENR1270-14 57
i02474436 Current ....................................... 147 ± 27.5 amp

Voltage ......................................................... 11 V
(1) Tighten the nut on the battery terminal to the
SMCS Code: 1453 following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)
Part No.: 207-1508, 207-1510, 207-1513
S/N: BKD1-Up
torque. ..................... 30.5 ± 3.5 N·m (22 ± 3 lb ft)
Part No.: 207-1508, 207-1510, 207-1513
S/N: 8YL1-Up (3) Tighten the nut to the following
torque. .................. 2.25 ± 0.25 N·m (20 ± 2 lb in)
Part No.: 207-1508, 207-1510, 207-1513
S/N: CKM1-Up (4) Tighten the nut on the switch terminal to the
Part No.: 207-1508, 207-1510, 207-1513
S/N: CRP1-Up (5) Tighten the nut on the motor terminal to the
Part No.: 207-1508, 207-1510 following torque. ........... 8 ± 3 N·m (71 ± 27 lb in)
S/N: 7AS1-Up
Part No.: 207-1508, 207-1510 the following torque. ..... 8 ± 3 N·m (71 ± 27 lb in)
S/N: 8SZ1-Up
Solenoid
Part No.: 207-1508, 207-1510, 207-1513
S/N: 9SZ1-Up Current draw at 10 V and 25 °C (77 °F)
Hold-in windings ..................... 19 amp maximum
g01156902
Illustration 91
g01156903
Illustration 92

No load conditions at 25 °C (77 °F)

Speed ...................................... 7018 ± 1517 rpm
58 RENR1270-14
i02309883 Speed ........................................ 3628 ± 413 rpm

Current ............................................ 90 ± 16 amp
Electric Starting Motor Voltage ......................................................... 23 V
SMCS Code: 1453 (1) Tighten the nut on the battery terminal to the
Part No.: 130-0875
S/N: BKD1-Up
Part No.: 130-0875 torque. ..................... 30.5 ± 3.5 N·m (22 ± 3 lb ft)
S/N: 8YL1-Up
Part No.: 130-0875 torque. .................. 2.25 ± 0.25 N·m (20 ± 2 lb in)
S/N: CKM1-Up
Part No.: 130-0875 following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in)
S/N: CRP1-Up
Part No.: 103-0875 (5) Tighten the nut on the motor terminal to the
S/N: 7AS1-Up following torque. ...... 14.7 ± 3.4 N·m (11 ± 3 lb ft)
Part No.: 130-0875 (6) Tighten the nut on the motor frame terminal to
S/N: 9SZ1-Up the following torque. ..... 8 ± 3 N·m (71 ± 27 lb in)
Solenoid

Hold-in windings ....................... 6 amp maximum
g01156902
Illustration 93
Typical example
g01156917
Illustration 94


RENR1270-14 59
i02474619 Current ....................................... 147 ± 27.5 amp

Voltage ......................................................... 11 V
(1) Tighten the nut on the battery terminal to the
SMCS Code: 1453 following torque. ...... 30.5 ± 3.5 N·m (22 ± 3 lb ft)
Part No.: 207-1514
S/N: BKD1-Up
torque. ..................... 30.5 ± 3.5 N·m (22 ± 3 lb ft)
Part No.: 207-1514
S/N: 8YL1-Up (3) Tighten the nut to the following
torque. .................. 2.25 ± 0.25 N·m (20 ± 2 lb in)
Part No.: 207-1514
S/N: CKM1-Up (4) Tighten the nut on the motor terminal to the
following torque. ........... 8 ± 3 N·m (71 ± 27 lb in)
Part No.: 207-1514
S/N: CRP1-Up (5) Tighten the nut on the motor frame terminal to
Part No.: 207-1514 the following torque. ..... 8 ± 3 N·m (71 ± 27 lb in)
S/N: 7AS1-Up
Solenoid
Part No.: 207-1514
S/N: 8SZ1-Up Current draw at 10 V and 25 °C (77 °F)
Part No.: 207-1514 Pull-in windings ....................................... 74 amp

S/N: 9SZ1-Up Hold-in windings ..................... 19 amp maximum
i02474663

SMCS Code: 1453
Part No.: 204-9742
S/N: CRP1-Up
g01234827
Illustration 95
g01234869
Illustration 97
g01234836
Illustration 96


Speed ...................................... 7018 ± 1517 rpm
60 RENR1270-14
i01135887
Coolant Temperature Sensor

SMCS Code: 1906
Part No.: 130-9811, 197-8392
g01156917
Illustration 98

g00294228
Illustration 99
Typical example
Speed ...................................... 7200 ± 1250 rpm
Current ...................................... 82.5 ± 17.5 amp (1) Sensor assembly
Voltage ......................................................... 23 V
Tighten the sensor assembly to the following
(1) Tighten the nut on the battery terminal to the torque. .................................. 20 ± 5 N·m (15 ± 4 lb ft)
i02274781
torque. ..................... 30.5 ± 3.5 N·m (22 ± 3 lb ft) Injection Actuation Pressure
(3) Tighten the nut to the following Sensor
torque. .................. 2.25 ± 0.25 N·m (20 ± 2 lb in)
SMCS Code: 1925
following torque. ... 2.25 ± 0.25 N·m (20 ± 2 lb in) Part No.: 224-4536
(5) Tighten the nut on the motor terminal to the


the following torque. ..... 8 ± 3 N·m (71 ± 27 lb in)
Solenoid

Hold-in windings ..................................... 13 amp
g01139325
Illustration 100
(1) Sensor assembly

torque. .................................. 20 ± 2 N·m (15 ± 1 lb ft)
(2) Plug
RENR1270-14 61
i02030238 Install the sensor so that the pressure port is lower

than the wire end. Mount the sensor as close to
Engine Oil Pressure Sensor vertical as possible.
SMCS Code: 1924
i02475387
Part No.: 194-6725
S/N: BKD1-Up Engine Oil Pressure Sensor
Part No.: 194-6725 SMCS Code: 1924
S/N: G3E1-Up
Part No.: 197-8394
Part No.: 194-6725 S/N: BKD1-Up
S/N: DPF1-Up
Part No.: 197-8394
Part No.: 194-6725 S/N: G3E1-Up
S/N: 8YL1-Up
Part No.: 197-8394
Part No.: 194-6725 S/N: DPF1-Up
S/N: CKM1-Up
Part No.: 197-8394
Part No.: 194-6725 S/N: 8YL1-Up
S/N: CRP1-Up
Part No.: 197-8394
Part No.: 194-6725 S/N: CKM1-Up
S/N: 7AS1-Up
Part No.: 197-8394
Part No.: 194-6725 S/N: CRP1-Up
S/N: 9SZ1-Up
Part No.: 197-8394
S/N: 7AS1-Up
Part No.: 197-8394
S/N: 9SZ1-Up
g01046769
Illustration 101
Typical example
(1) Sensor assembly
(2) Plug with socket A, socket B, and socket C
(3) Port fitting

Torque ........................ 10 ± 2 N·m (90 ± 18 lb in)
Operating temperature ........................ −40 to 125 °C Illustration 102

g01235437
(−40 to 257 °F)
(1) Sensor
Maximum input pressure (absolute
pressure) ..................................... 1135 kPa (165 psi) Torque ........................ 10 ± 2 N·m (90 ± 18 lb in)
Input supply voltage ............................. 5 ± 0.25 VDC (2) O-ring seal
Maximum supply current ................................. 20 mA Input supply voltage ............................. 5 ± 0.25 VDC
62 RENR1270-14
Install the sensor so that the pressure port is lower i01428683

than the connector end. Mount the sensor as close to
vertical as possible. Engine Oil Temperature Sensor
SMCS Code: 1929
i01606911
Part No.: 130-9811
Engine Oil Temperature Sensor S/N: 1AJ1-Up

S/N: 8YL1-Up
Part No.: 191-6587
S/N: 1AJ1-Up Part No.: 130-9811
S/N: 7AS1-Up
Part No.: 130-9811
S/N: 8SZ1-Up
Part No.: 130-9811
S/N: 9SZ1-Up
g00726046
Illustration 103
(1) Sensor assembly

torque. .................................. 48 ± 5 N·m (35 ± 4 lb ft)
g00294228
Illustration 104
(2) Plug
(1) Sensor assembly

torque. .................................. 20 ± 3 N·m (15 ± 2 lb ft)
RENR1270-14 63
i02475980 i02475880
Boost Pressure Sensor Boost Pressure Sensor

Part No.: 183-4760 Part No.: 194-6723
Part No.: 183-4760 Part No.: 194-6723
Part No.: 183-4760 Part No.: 194-6723
Part No.: 183-4760 Part No.: 194-6723
Part No.: 161-1704, 183-4760 Part No.: 194-6723, 239-3478
Part No.: 183-4760 Part No.: 194-6723
Part No.: 183-4760 Part No.: 194-6723
Part No.: 183-4760 Part No.: 194-6723
Part No.: 183-4760 Part No.: 194-6723
Part No.: 161-1704, 183-4760 Part No.: 194-6723, 239-3478
g01236087 g01235798
Illustration 105 Illustration 106
(1) Sensor assembly (1) Sensor assembly
Tighten the sensor assembly to the following Tighten the sensor assembly to the following
torque. ............................... 10 ± 2 N·m (90 ± 18 lb in) torque. ............................... 10 ± 2 N·m (90 ± 18 lb in)
Install the sensor so that the pressure port is lower

than the connector end. Mount the sensor as close to
vertical as possible.
64 RENR1270-14
i00675169 i02476246
Boost Pressure Sensor Atmospheric Pressure Sensor

SMCS Code: 1917
(If Equipped)
Part No.: 161-9927, 194-6722 SMCS Code: 1923
S/N: BKD1-Up
Part No.: 161-1703
S/N: G3E1-Up S/N: BKD1-Up
Part No.: 161-9927, 194-6722 Part No.: 161-1703

Part No.: 194-6722 Part No.: 161-1703

Part No.: 161-9927, 194-6722, 194-6724 Part No.: 161-1703

Part No.: 161-9927, 194-6722 Part No.: 161-1703

Part No.: 161-9927, 194-6722 Part No.: 161-1703

Part No.: 161-9927, 194-6722, 194-6724 Part No.: 161-1703

Part No.: 161-9927 Part No.: 161-1703

Part No.: 161-9927, 194-6722, 194-6724

S/N: 9SZ1-Up
g01236069
Illustration 108
(1) Sensor assembly

g00293962
Illustration 107
Typical example Tighten the sensor assembly to the following
torque. ............................... 10 ± 2 N·m (90 ± 18 lb in)
(1) Sensor assembly
Install the sensor so that the pressure port is lower
Tighten the sensor assembly to the following than the connector end. Mount the sensor as close to
torque. ............................... 10 ± 2 N·m (90 ± 18 lb in) vertical as possible.
(2) Port fitting

RENR1270-14 65
i01161328 i02305501
Atmospheric Pressure Sensor Atmospheric Pressure Sensor

(If Equipped) SMCS Code: 1923
S/N: 8YL1-Up
Part No.: 194-6722
S/N: BKD1-Up Part No.: 274-6717
S/N: 9SZ1-Up
Part No.: 194-6722
S/N: DPF1-Up
Part No.: 194-6722
S/N: 1AJ1-Up
Part No.: 194-6722
S/N: 8YL1-Up
Part No.: 194-6722
S/N: CKM1-Up
Part No.: 194-6722
S/N: CRP1-Up
Part No.: 194-6722
S/N: 7AS1-Up g01154731
Illustration 110
Part No.: 194-6722
S/N: 9SZ1-Up (1) Tighten the sensor to the following
torque. ........................ 10 ± 2 N·m (90 ± 18 lb in)
i02174714
Inlet Air Temperature Sensor

SMCS Code: 1921
Part No.: 130-9811
g00293963
Illustration 109
Typical example
(1) Sensor assembly

torque. ............................... 10 ± 2 N·m (90 ± 18 lb in)
(2) Plug g01089060

Illustration 111
(1) Tighten the sensor assembly to the following

torque: ........................... 20 ± 5 N·m (15 ± 4 lb ft)
66 RENR1270-14
i02476836 Tighten the sensor assembly to the following

torque. ................................. 6 ± 1 N·m (50 ± 10 lb in)
(2) Plug
SMCS Code: 1921
Part No.: 256-6453 i02307203
S/N: 8YL1-Up
Speed/Timing Sensor
Part No.: 256-6453
S/N: 9SZ1-Up SMCS Code: 1907; 1912
Part No.: 169-3300, 245-4630
g01089060
Illustration 112
g01155565
(1) Tighten the sensor assembly to the following Illustration 114
torque: ........................... 20 ± 3 N·m (15 ± 2 lb ft) (1) Bolt
(2) Sensor
(3) Flange
i00789088
Note: The sensors must be replaced as a pair.
1. Seat both sensors to the sensor’s flanges before
SMCS Code: 1921 tightening the bolt to the bracket.
Part No.: 145-7028
S/N: 8YL1-Up 2. Torque the bolt (1) to 28 ± 7 N·m (21 ± 5 lb ft).
Part No.: 145-7028

i02477340
S/N: 9SZ1-Up
Electronic Control Wiring
Group
SMCS Code: 1408
Part No.: 135-5991, 141-5145, 145-7040,
160-5200, 177-0345, 187-3327
S/N: BKD1-Up
Part No.: 145-7040, 160-5200
S/N: G3E1-Up
Part No.: 135-5991, 141-5145, 160-5200,
187-3327
S/N: DPF1-Up
g00367352
Illustration 113
Part No.: 145-7040
(1) Sensor Assembly S/N: 1AJ1-Up
RENR1270-14 67
Part No.: 135-5991, 141-5145, 145-7040, i02477376

160-5200, 172-1634, 177-0345, 187-3327,
211-7896 Electronic Control Wiring
S/N: 8YL1-Up Group
Part No.: 135-5991, 141-5145, 145-7040,
SMCS Code: 1408
160-5200, 177-0345, 187-3327, 211-7896
S/N: 8YL1-Up
Part No.: 135-5991, 141-5145, 145-7040,
160-5200, 177-0345, 187-3327, 211-7896, Part No.: 180-5169
239-5927 S/N: CKM1-Up
S/N: CRP1-Up
Part No.: 180-5169
Part No.: 126-5457, 135-5991, 141-5145, S/N: CRP1-Up
145-7040, 160-5200, 177-0345
S/N: 7AS1-Up Part No.: 180-5169
S/N: 9SZ1-Up
Part No.: 141-5145, 145-7040
S/N: 8SZ1-Up
Part No.: 135-5991, 141-5145, 145-7040,
160-5200, 172-1634, 177-0345, 187-3327,
211-7896
S/N: 9SZ1-Up
g01237194
Illustration 116
Typical example
(1) Tighten the nut to the following torque. .. 6 ± 1 N·m

(55 ± 9 lb in)
g00938439
Illustration 115
Typical Example
(1) Tighten the nuts for the magnetic switch assembly

to the following torque. .. 6 ± .5 N·m (55 ± 4 lb in)
(2) Tighten the nut to the following torque. .. 6 ± 1 N·m

(55 ± 9 lb in)
68 RENR1270-14
i02477424 Note: During assembly of the air inlet heater to the

inlet manifold and the air inlet elbow, clean the air
Air Inlet Heater inlet heater’s joint faces with solvent. Apply 4C-9500
Quick Cure Primer to the joint faces. Allow the primer
SMCS Code: 1090 to air dry for a minimum of three to five minutes.
Apply 8C-8422 Sealant to the joint face and spread
Part No.: 109-3000, 155-4911, 159-3537
the gasket maker uniformly. The heater must be
S/N: BKD1-Up
assembled and tightened within ten minutes.
Part No.: 109-3000, 155-4911, 159-3537
S/N: G3E1-Up
i02478146
Part No.: 109-3000, 155-4911

S/N: DPF1-Up
Air Compressor
Part No.: 109-3000, 155-4911, 159-3537
(Midland Air Compressors)
S/N: 1AJ1-Up SMCS Code: 1803
Part No.: 109-3000, 155-4911, 159-3537 Part No.: 143-7348
Part No.: 109-3000, 155-4911, 159-3537 Part No.: 143-7348
S/N: CKM1-Up S/N: 7AS1-Up
Part No.: 109-3000, 155-4911, 159-3537 Part No.: 143-7348
S/N: CRP1-Up S/N: 9SZ1-Up
Part No.: 109-3000, 155-4911, 159-3537
S/N: 7AS1-Up
Part No.: 109-3000, 155-4911, 159-3537
S/N: 8SZ1-Up
Part No.: 109-3000, 155-4911, 159-3537
S/N: 9SZ1-Up
g01237730
Illustration 118
(1) Air compressor
(2) Nut
Perform the following steps in order to properly

tighten the nut:
g00292365
Illustration 117
Section view of the air inlet heater 1. Tighten the nut to a torque of 160 ± 15 N·m
(120 ± 11 lb ft).
(1) Air inlet heater
2. Use a soft faced hammer and a 213-3530 Socket
(2) Tighten the nuts to the following and tap the gear one time. Tighten the nut to a
torque. ......................... 7.8 ± 1 N·m (70 ± 9 lb in) torque of 160 ± 15 N·m (120 ± 11 lb ft).
(3) Gear
(4) Bolt
RENR1270-14 69
Tighten the bolt that holds the air compressor line on (4) Bolt
engines that are equipped with this hose assembly.
Tighten the bolt to the following torque. .. 55 ± 10 N·m Tighten the bolt that holds the air compressor line on
(41 ± 7 lb ft) engines that are equipped with this hose assembly.
Tighten the bolt to the following torque. ... 28 ± 7 N·m
Use the following procedure to mount the air (21 ± 5 lb ft)
compressor.
Use the following procedure to mount the air
1. Install two bolts (A) and tighten the bolts to a compressor.
torque of 100 ± 20 N·m (75 ± 15 lb ft).
1. Install two bolts (A) and tighten the bolts to a
2. Install the following four bolts finger tight: (B) and torque of 100 ± 20 N·m (75 ± 15 lb ft).
(C).
2. Install the following four bolts finger tight: (B), (C),
3. Tighten two bolts (B) to a torque of 55 ± 10 N·m and (D).
(41 ± 7 lb ft).
3. Tighten one bolt (B) to a torque of 50 ± 10 N·m
4. Tighten two bolts (C) to a torque of 55 ± 10 N·m (37 ± 7 lb ft).
(40 ± 7 lb ft).
4. Tighten two bolts (C) to a torque of 55 ± 10 N·m
(40 ± 7 lb ft).
i02478063
Air Compressor 5. Tighten one bolt (D) to a torque of 28 ± 7 N·m

(21 ± 5 lb ft).
(Midland Air Compressors)
SMCS Code: 1803
Part No.: 123-6357, 148-7235
S/N: 7AS1-Up
g01237622
Illustration 119
(1) Air compressor
(2) Nut

tighten the nut:
1. Tighten the nut to a torque of 160 ± 15 N·m

(120 ± 11 lb ft).

and tap the gear one time. Tighten the nut to a
torque of 160 ± 15 N·m (120 ± 11 lb ft).
(3) Gear
70 RENR1270-14
i02477940 Tighten the bolt that holds the air compressor line on
engines that are equipped with this hose assembly.
Air Compressor Tighten the bolt to the following torque. ... 28 ± 7 N·m
(Midland Air Compressors) (21 ± 5 lb ft)
SMCS Code: 1803 Use the following procedure to mount the air
compressor.
Part No.: 161-0220
S/N: BKD1-Up 1. Install two bolts (A) and tighten the bolts to a
torque of 100 ± 20 N·m (75 ± 15 lb ft).
Part No.: 161-0220
S/N: 8YL1-Up 2. Install the following four bolts finger tight: (B), (C),
and (D).
Part No.: 161-0220
S/N: CKM1-Up
3. Tighten one bolt (B) to a torque of 50 ± 10 N·m
Part No.: 161-0220 (37 ± 7 lb ft).
S/N: CRP1-Up
Part No.: 161-0220 (40 ± 7 lb ft).
S/N: 7AS1-Up
5. Tighten one bolt (D) to a torque of 28 ± 7 N·m
Part No.: 161-0220 (21 ± 5 lb ft).
S/N: 9SZ1-Up
i02478704
Air Compressor
(Bendix Tu-Flo Air
Compressors)
SMCS Code: 1803
Part No.: 148-7223
S/N: 8YL1-Up
Part No.: 122-1714, 125-9564, 143-7351,
148-7223
g01237622 S/N: 7AS1-Up
Illustration 120
Part No.: 148-7223
(1) Air compressor S/N: 9SZ1-Up
(2) Nut

tighten the nut:
1. Tighten the nut to a torque of 170 ± 15 N·m

(125 ± 11 lb ft).

torque of 170 ± 15 N·m (125 ± 11 lb ft).

g01156957
torque of 170 ± 15 N·m (125 ± 11 lb ft). Illustration 121
(3) Gear (1) Air compressor
(4) Bolt (2) Nut

RENR1270-14 71
Perform the following steps in order to properly Part No.: 114-9086, 120-7400, 126-1517,
tighten the nut: 126-8216, 148-7222, 156-9646, 164-9605,
175-2389, 175-2390, 190-4111, 193-4702,
1. Tighten the nut (2) to a torque of 160 ± 15 N·m 195-9252, 200-1203
(120 ± 11 lb ft). S/N: CRP1-Up
2. Use a soft faced hammer and a 213-3530 Socket Part No.: 114-9086, 120-7400, 126-1517,
and tap the gear one time. Tighten the nut (2) to a 126-8216, 148-7222, 156-9646, 164-9605,
torque of 160 ± 15 N·m (120 ± 11 lb ft). 168-8638, 175-2389, 175-2390
S/N: 7AS1-Up
(3) Gear Part No.: 114-9086, 120-7400, 148-7222,
156-9646, 164-9605, 195-9252
(4) Bolt
S/N: 8SZ1-Up
Tighten the bolt that holds the air compressor line on Part No.: 114-9086, 120-7400, 126-1517,
engines that are equipped with this hose assembly. 126-8216, 148-7222, 156-9646, 164-9605,
Tighten the bolt to the following torque. ... 30 ± 7 N·m 168-8638, 175-2389, 175-2390, 190-4111,
(22 ± 5 lb ft) 193-4702, 195-9252, 197-9660, 200-1205
S/N: 9SZ1-Up
compressor.

torque of 100 ± 20 N·m (75 ± 15 lb ft).
2. Install the four bolts (B) and (C) finger tight.
3. Tighten two bolts (B) to a torque of 60 ± 12 N·m

(44 ± 8 lb ft).

(44 ± 8 lb ft).
i02309950 g01156957
Illustration 122
Air Compressor
(1) Air compressor
(Bendix Tu-Flo Air
Compressors) (2) Nut
SMCS Code: 1803 Perform the following steps in order to properly

tighten the nut:
Part No.: 114-9086, 120-7400, 126-1517,
126-8216, 148-7222, 156-9646, 164-9605, 1. Tighten the nut (2) to a torque of 170 ± 15 N·m
168-8638, 175-2389, 175-2390, 190-4111, (125 ± 11 lb ft).
193-4702, 195-9252, 197-9660, 200-1205
S/N: BKD1-Up 2. Use a soft faced hammer and a 213-3530 Socket
and tap the gear one time. Tighten the nut (2) to a
Part No.: 126-8216, 148-7222, 164-9605 torque of 170 ± 15 N·m (125 ± 11 lb ft).
S/N: DPF1-Up
Part No.: 114-9086, 120-7400, 126-1517, and tap the gear one time. Tighten the nut (2) to a
126-8216, 148-7222, 156-9646, 164-9605, torque of 170 ± 15 N·m (125 ± 11 lb ft).
168-8638, 175-2389, 175-2390, 190-4111,
193-4702, 195-9252, 197-9660, 200-1205 (3) Gear
S/N: 8YL1-Up
Part No.: 114-9086, 120-7400, 126-1517, (4) Bolt
126-8216, 148-7222, 156-9646, 164-9605,
168-0281, 175-2389, 175-2390, 190-4111, Tighten the bolt that holds the air compressor line on
193-4702, 195-9252, 197-9660, 200-1205 engines that are equipped with this hose assembly.
S/N: CKM1-Up Tighten the bolt to the following torque. ... 30 ± 7 N·m
(22 ± 5 lb ft)
72 RENR1270-14

compressor.

torque of 100 ± 20 N·m (75 ± 15 lb ft).
2. Install the four bolts (B) and (C) finger tight.
3. Tighten two bolts (B) to a torque of 60 ± 12 N·m

(44 ± 8 lb ft).

(44 ± 8 lb ft).
RENR1270-14 73
Index Section
Index
A Front Housing and Covers..................................... 37
Fuel Filter Base ................................................... 5–6
Air Compressor (Bendix Tu-Flo Air Fuel Transfer Pump (Fuel Transfer Pump and High
Compressors) ................................................ 70–71 Pressure Oil Pump) ............................................... 4
Air Compressor (Midland Air Compressors).... 68–70
Air Inlet Elbow........................................................ 14
Air Inlet Heater....................................................... 68 G
Alternator and Regulator ....................................... 54
Atmospheric Pressure Sensor............................... 65 Gear Group (Front).......................................... 39–40
Atmospheric Pressure Sensor (If Equipped) ... 64–65
I
B
Important Safety Information ................................... 2
Belt Tension Chart ................................................. 47 Injection Actuation Pressure Control Valve ............. 6
Belt Tensioner.................................................. 49–52 Injection Actuation Pressure Sensor ..................... 60
Belt Tightener ........................................................ 52 Inlet Air Temperature Sensor........................... 65–66
Boost Pressure Sensor.................................... 63–64
M
C
Main Bearing Journal............................................. 31
Camshaft ............................................................... 16
Connecting Rod............................................... 31–32
Connecting Rod Bearing Journal........................... 31 P
Coolant Temperature Sensor................................. 60
Crankcase Breather......................................... 19–20 Piston and Rings ....................................... 33, 35–36
Crankshaft ............................................................ 27 One-Piece Aluminum Piston .............................. 36
Crankshaft Pulley ............................................ 46–47 Two-Piece Articulated Piston ....................... 33, 35
Crankshaft Seals ............................................. 27–28
Front Crankshaft Seal .................................. 27–28
Rear Crankshaft Seal................................... 28–29 R
Cylinder Block........................................................ 25
Cylinder Block Cover Group .................................. 24 Rear Seal Carrier (If Equipped) ............................. 30
Cylinder Head........................................................ 10
Cylinder Head Valves .............................................. 9
S
E Specifications Section ............................................. 4

Speed/Timing Sensor ............................................ 66
Electric Starting Motor ..................................... 55–59
Electronic Control Wiring Group ............................ 67
Engine Design ......................................................... 4 T
Engine Oil Filter Base............................................ 17
One-Piece Body................................................. 17 Table of Contents..................................................... 3
Two-Piece Body ................................................. 17 Turbocharger .................................................... 11, 13
Engine Oil Pan................................................. 18–19
Engine Oil Pressure Sensor .................................. 61
Engine Oil Pump.................................................... 18 U
Engine to Transmission Adapter (If Equipped) ...... 45 Unit Injector ............................................................. 7
Exhaust Elbow....................................................... 15
Exhaust Manifold ................................................... 14
V
F Valve Mechanism Cover...................................... 8–9

Valve Rocker Arms, Lifters, and Bridges ................. 7
Fan Drive ......................................................... 52–53 Vibration Damper................................................... 30
Flywheel .......................................................... 41–42
Flywheel Housing ............................................ 43–44
74 RENR1270-14
Index Section
Water Pump..................................................... 21–24

Water Temperature Regulator ......................... 20–21
RENR1270-14 75
Index Section
©2006 Caterpillar
All Rights Reserved Printed in U.S.A.

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RENR1270-14

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Crankshaft Pulley .................................................

Specifications Section i02510030

Fuel Transfer Pump

Fuel Filter Base

(13) Connection of tube assembly to pump outlet

(1) Put 4C-9507 Retaining Compound on the

Torque for stud ..................... 68 ± 7 N·m (50 ± 5 lb ft)

Fuel Filter Base Injection Actuation Pressure

(1) Install the injection actuation pressure control

(2) Tighten the nut to the following

Part No.: 188-1320, 196-1401, 196-4229, i02310236

(1) Valve rocker arm assembly

(4) Lifter assembly

Valve Mechanism Cover

Tighten the bolts in a numerical sequence to the

i02456283 Note: The inlet and exhaust valve stems must be

(2) Inlet valve

(3) 137-6718 Spring for exhaust valve

Note: Install the valve guide from the spring side of

Note: Assemble the valve guide. Seat the seal

(6) Valve stem diameter (new)

After installation into the cylinder head, the valve

Diameter of the valve guide bore (new)

4. Again tighten bolt (1) through bolt (14) in a i02456927

(4) Unit injector sleeve

Refer to Special Instruction, SEHS9120 for

(5) Height of a new 133-3742 Cylinder Head

4. Tighten the bolts for the compressor clamp to a

5. Tighten the bolts for the outlet plate to a torque of

Note: Put clean engine oil in the oil inlet of the

Apply 5P-3931 Anti-Seize Compound to the studs.

The 136-0613 Turbocharger Gp and the 199-6064

Note: The 3E-8017 Locknut has a special thread

(2) Exhaust inlet

(3) Exhaust outlet

(4) Air inlet

Opening pressure of the wastegate ........ 155.14 kPa

Use the following procedure to install the band

1. Tighten the compressor clamps to a torque of

2. Tap lightly around the circumference of the clamp.

3. Tighten the clamps again. Tighten the clamps to a

Note: The 3E-8017 Locknut has a special thread

(2) Exhaust inlet

(3) Exhaust outlet

(4) Air inlet

Opening pressure of the wastegate ........ 148.04 kPa

Use the following procedure to install the band

1. Tighten the compressor clamps to a torque of

2. Tap lightly around the circumference of the clamp.

3. Tighten the clamps again. Tighten the clamps to a

4. Tighten the bolts for the compressor clamp to a

To avoid component damage use only the amount of

Use the following procedure during assembly of the

2. Apply 2P-2333 High Temperature Sealer to the i02457521

Tighten the bolts to the following

7. Tighten the studs (14) to a torque of 35 ± 5 N·m

Note: Prior to starting or running the engine, allow

(1) Tighten the nut for the clamp to the following