Uenr0996 03 00 - Manuals Service Modules - Specifications

UENR0996-03 (en-us)
January 2019
Specifications
C15 and C18 Engines for Caterpillar
Built Machines
NJH 1-UP (Machine)
L4D 1-UP (Machine)
L4E 1-UP (Machine)
L4F 1-UP (Machine)
ECM 1-UP (Machine)
3F6 1-UP (Machine)
3F7 1-UP (Machine)
TWG 1-UP (Machine)
PUBLICATIONS.CAT.COM
i06558969
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, including human factors
that can affect safety. 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 verify
that you are authorized to perform this work, and 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.
A non-exhaustive list of 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. You must not
use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that you are authorized to perform this work, and that the
product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair
procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
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. Cat dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
UENR0996-03 3
Table of Contents
Table of Contents Cylinder Head Valves ..........................................93

Cylinder Head ....................................................95
Cylinder Head .................................................. 101
Specifications Section Cylinder Head .................................................. 104
Cylinder Head .................................................. 107
Fuel Filter Base ....................................................7 Cylinder Head .................................................. 111
Fuel Filter Base ..................................................10 Compression Brake........................................... 123
Fuel Filter Base .................................................. 11 Compression Brake (If Equipped) ....................... 126
Fuel Filter Base ..................................................12 Compression Brake........................................... 128
Fuel Filter Base ..................................................13 Turbocharger .................................................... 131
Fuel Filter Base (Primary) ....................................14 Turbocharger .................................................... 131
Electronic Unit Injector.........................................19 Turbocharger .................................................... 135
Electronic Unit Injector Mechanism ......................23 Turbocharger .................................................... 144
Electronic Unit Injector Rocker Arm ......................34 Turbocharger .................................................... 158
Valve Mechanism ...............................................41 Turbocharger .................................................... 171
Valve Rocker Arm ...............................................51 Turbocharger .................................................... 181
Valve Rocker Arm ...............................................52 Turbocharger .................................................... 183
Valve Rocker Arm ...............................................53 Exhaust Gas Valve (NRS) .................................. 183
Valve Rocker Arm ...............................................54 Exhaust Gas Valve (NRS) .................................. 185
Valve Rocker Arm ...............................................55 Exhaust Manifold .............................................. 187
Valve Rocker Arm ...............................................56 Exhaust Manifold .............................................. 188
Valve Mechanism Cover .....................................57 Exhaust Manifold .............................................. 189
Cylinder Head Valves ..........................................78 Exhaust Manifold .............................................. 209
Cylinder Head Valves ..........................................85 Exhaust Manifold Shield ................................... 215
Cylinder Head Valves ..........................................87 Mounting Straps................................................ 216
Cylinder Head Valves ..........................................89 Camshaft ......................................................... 216
Cylinder Head Valves ..........................................91 Camshaft ......................................................... 217
Camshaft ......................................................... 219
4 UENR0996-03
Table of Contents
Camshaft ......................................................... 221 Water Pump ..................................................... 321

Camshaft ......................................................... 223 Water Pump (Separate Circuit Water Pump)........ 323
Camshaft ......................................................... 224 Cylinder Block .................................................. 323
Engine Oil Filter Base ....................................... 233 Cylinder Block .................................................. 341
Engine Oil Filter Base ....................................... 236 Cylinder Liner ................................................... 344
Engine Oil Filter Base ....................................... 243 Crankshaft ....................................................... 351
Engine Oil Pump .............................................. 253 Crankshaft ....................................................... 359
Engine Oil Pan ................................................. 262 Crankshaft Seals .............................................. 366
Engine Oil Pan ................................................. 268 Vibration Damper and Pulley ............................. 373
Engine Oil Pan ................................................. 274 Connecting Rod Bearing Journal ....................... 376
Engine Oil Pan ................................................. 283 Main Bearing Journal......................................... 379
Engine Oil Pan ................................................. 289 Connecting Rod ............................................... 381
Engine Oil Pan ................................................. 300 Piston and Rings .............................................. 389
Water Temperature Regulator ........................... 304 Piston and Rings .............................................. 394
Water Pump ..................................................... 305 Piston and Rings .............................................. 396
Water Pump ..................................................... 315 Piston Cooling Jet ............................................. 411
Water Pump ..................................................... 316 Housing (Front)................................................. 413
UENR0996-03 5
Table of Contents
Housing (Front)................................................. 420 Electric Starting Motor ...................................... 510

Gear Group (Front)............................................ 429 Electric Starting Motor ...................................... 516
Flywheel .......................................................... 450 Electric Starting Motor ...................................... 525
Flywheel .......................................................... 459 Coolant Temperature Sensor ............................. 539
Flywheel .......................................................... 464 Fuel Temperature Sensor .................................. 544
Flywheel .......................................................... 465 Fuel Temperature Sensor .................................. 545
Flywheel .......................................................... 466 Engine Oil Pressure Sensor ............................... 546
Flywheel Housing ............................................. 471 Engine Oil Pressure Sensor ............................... 552
Flywheel Housing ............................................. 472 Boost Pressure Sensor...................................... 552
Flywheel Housing ............................................. 475 Atmospheric Pressure Sensor............................ 556
Flywheel Housing ............................................. 483 Inlet Air Temperature Sensor ............................. 560
Flywheel Housing ............................................. 487 Pressure Sensor (ARD Combustion Air).............. 563
Flywheel Housing ............................................. 488 Pressure Sensor (DPF Inlet) .............................. 564
Flywheel Housing ............................................. 491 Pressure Sensor (NOx Reduction System).......... 565
Flywheel Housing ............................................. 493 Temperature Sensor (NOx Reduction System) .... 565
Flywheel Housing ............................................. 494 Soot Antenna.................................................... 566
Flywheel Housing ............................................. 495 Temperature Sensor (DPF Inlet, Flame Detect) ... 568
Flywheel Housing ............................................. 498 Speed/Timing Sensor ....................................... 568
Belt Tensioner................................................... 501 Speed/Timing Sensor ....................................... 571
Belt Tensioner (Alternator and Compressor) ........ 503 Speed/Timing Sensor ....................................... 576
Belt Tensioner................................................... 509
Belt Tensioner................................................... 510
6 UENR0996-03
Table of Contents
Index Section
Index................................................................ 583
UENR0996-03 7
Specifications Section
i04372697
Fuel Filter Base

SMCS Code: 1261; 1262
S/N: NJH1–Up
S/N: ECM1–Up
Illustration 1 g02546020
(A) Length 11 mm (0.4 inch)
Table 1
Specifications for 213-0064 Base As
Item Qty Part Specification Description
Apply red Loctite 271 to a length of (A) to the threads.

1 1 9S-4167 Hollow Stud
Torque to 70 ± 15 N·m (52 ± 11 lb ft).
8 UENR0996-03
i04374369
Fuel Filter Base

SMCS Code: 1261; 1262
S/N: NJH1–Up
S/N: ECM1–Up
Table 2
Specifications for 237-9308 Base As and 237-9310 Base As
A - - Dimension from the surface of the base to the end of the hollow stud is 25.5 ± 1.0 mm
(1.00 ± 0.04 inch).
1 1 9S-4167 Hollow Stud Apply red Loctite 271 on the tapered end of the hollow stud before assembly into the base
assembly.
Torque to 70 ± 15 N·m (52 ± 11 lb ft).
UENR0996-03 9
i04405496
Fuel Filter Base

SMCS Code: 1261; 1262
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 237-9314
S/N: L4D1–Up
Part No.: 237-9314
S/N: L4E1–Up
Part No.: 237-9314
S/N: L4F1–Up
S/N: NJH1–Up
S/N: ECM1–Up
(1) Base
Table 3
Specifications for 237-9314 Base As
Dimension from the surface of the base to the end of the hollow stud is 25.5 ± 1.0 mm
A - -
(1.00 ± 0.04 inch).
Before assembly, apply red Loctite 271 to the threads on the tapered end of the hollow stud.
Torque to 70 ± 15 N·m (52 ± 11 lb ft).
10 UENR0996-03
i04405525
Fuel Filter Base

SMCS Code: 1261; 1262
S/N: NJH1–Up
S/N: ECM1–Up
(1) Base
Table 4
Specifications for 237-9307 Fuel Filter Base As
Dimension from the surface of the base to the end of the hollow stud is 39.5 ± 1.0 mm
A - -
(1.56 ± 0.04 inch).
Before assembly, apply red Loctite 271 to the threads on the tapered end of the stud.
2 1 237-9323 Stud
Torque to 70 ± 15 N·m (52 ± 11 lb ft).
UENR0996-03 11
i04406141
Fuel Filter Base

SMCS Code: 1261; 1262
S/N: NJH1–Up
S/N: ECM1–Up
Typical example
Table 5
Specifications for 162-7838 Fuel Filter Base As and 1N-3789 Filter Base As
Length for applying red Loctite 271 on the tapered end of the hollow stud is 7.6 ± 0.8 mm
(0.30 ± 0.03 inch).
Torque to 70 ± 15 N·m (52 ± 11 lb ft).
12 UENR0996-03
i04481309
Fuel Filter Base

SMCS Code: 1261; 1262
S/N: NJH1–Up
S/N: ECM1–Up
Table 6
Specification for 349-4571 Fuel Filter Base
1 1 234-5013 Temperature Sensor Gp Torque to 20 ± 3 N·m (177 ± 27 lb in).
2 1 325-8634 Pressure Sensor Gp Torque fuel pressure sensor (pre-filter) to 10 ± 2 N·m (89 ± 18 lb in).
3 1 325-8634 Pressure Sensor Gp Torque fuel pressure sensor (post-filter) to 10 ± 2 N·m (89 ± 18 lb in).
4 - - Lubricate seal lightly with the fluid that is being sealed.
5 2 308-9679 Fuel Filter Torque to 35 ± 3 N·m (26 ± 2 lb ft).

UENR0996-03 13
i04553610
Fuel Filter Base

SMCS Code: 1261; 1262
S/N: NJH1–Up
S/N: ECM1–Up
Typical example
Table 7
Specification for 237-9313 Base As, 237-9311 Base As and 237-9309 Base As
Item Qty Part Specification description
Dimension from the surface of the base (1) to the end of the stud is
A - -
39.5 ± 1.0 mm (1.56 ± 0.04 inch).
Before assembly, apply red Loctite 271 to the threads on the tapered end of the
2 1 237-9323 Stud stud.
Torque to 70 ± 15 N·m (52 ± 11 lb ft).
14 UENR0996-03
i04953944
Fuel Filter Base

(Primary)
SMCS Code: 1261; 1262
S/N: NJH1–Up
S/N: ECM1–Up
Table 8
Specification for 247-6050 Fuel Priming Pump Gp
1 1 9S-8002 O-Ring Plug Torque to 11 ± 2 N·m (97 ± 18 lb in).
2 2 179-7267 Plug Torque to 95 ± 10 N·m (70 ± 7 lb ft).
Length under test force is 20.21 mm (0.796 inch).

3 2 162-2222 Spring Test force is 1.01 ± 0.05 N (0.23 ± 0.01 lb).
Free length after test is 31.75 mm (1.250 inch).
Length (B) for applying red Loctite 271 on the tapered end of the hollow stud is
4 1 9S-4167 Hollow Stud 11.0 ± 0.5 mm (0.43 ± 0.02 inch).
Torque to 70 ± 15 N·m (52 ± 11 lb ft).
UENR0996-03 15
i05593411
Fuel Filter Base

SMCS Code: 1261; 1262
Part No.: 348-7307

S/N: 3F61–Up
Part No.: 348-7307
S/N: 3F71–Up
S/N: NJH1–Up
Table 9
Specifications for 348-7307 Fuel Filter Base As
Apply red Loctite 271 to the threads on the tapered end to a length of
Torque to 70 ± 15 N·m (52 ± 11 lb ft).
16 UENR0996-03
i06165189
Fuel Filter Base

SMCS Code: 1261; 1262
S/N: NJH1–Up
S/N: ECM1–Up
Typical example
Table 10
Specifications for 190-8970 Fuel Priming Pump Gp, 217-8339 Fuel Priming Pump As, and 235-8724 Fuel Transfer
Pump Gp
1 2 6D-5801 Locknut Torque to 1.7 ± 0.4 N·m (15.0 ± 3.5 lb in).
2 2 179-7267 Plug Torque to 95 ± 10 N·m (70 ± 7 lb ft).
3 1 9S-8002 O-Ring Plug Torque to 11 ± 2 N·m (97 ± 18 lb in).
(continued)
UENR0996-03 17
(Table 10, contd)

Specifications for 190-8970 Fuel Priming Pump Gp, 217-8339 Fuel Priming Pump As, and 235-8724 Fuel Transfer
Pump Gp

Apply red Loctite 263 to the threads to the length (D) of 11.0 ± 0.5 mm
5 1 9S-4167 Hollow Stud (0.43 ± 0.02 inch).
Torque to 70 ± 15 N·m (52 ± 11 lb ft).
18 UENR0996-03
i06638118
Fuel Filter Base

SMCS Code: 1261; 1262
Part No.: 343-8126

S/N: 3F61–Up
Part No.: 343-8126
S/N: 3F71–Up
Part No.: 343-8126
S/N: L4D1–Up
Part No.: 343-8126
S/N: L4E1–Up
Part No.: 343-8126
S/N: L4F1–Up
Part No.: 343-8126
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
(3) Fuel filter base assembly

UENR0996-03 19
Table 11
Specification for 343-8126 Fuel Filter Base
1 1 234-5013 Temperature Sensor Gp Final installation torque is 20 ± 3 N·m (177 ± 27 lb in).
Final installation torque is 10 ± 2 N·m (89 ± 18 lb in).

2 1 325-8634 Pressure Sensor Gp
Operating voltage is 5.00 ± 0.25 VDC.
Lubricate the seal and the bore lightly with the lubricant that is being sealed.
4 2 1R-0749 Fuel Filter
Torque to 35 ± 3 N·m (26 ± 2 lb ft).
Table 12
Before assembly, apply red Loctite 263 on the tapered end of the hollow stud to a length of
Torque to 70 ± 15 N·m (52 ± 11 lb ft).
Distance between the sealing surface of the base to the end of the hollow stud (5) is
A - -
24.7 mm (0.97 inch).
i02152525
Electronic Unit Injector

SMCS Code: 1290
S/N: NJH1–Up
S/N: ECM1–Up
20 UENR0996-03
(1) Lubricate the seals and the bore with a 50 percent

mix of 8T-2998 Lubricant and engine oil.
(2) Bolt torque . . . . . . . . . .55 ± 10 N·m ((40 ± 7 lb ft))

UENR0996-03 21
i05297468

SMCS Code: 1290
S/N: NJH1–Up
S/N: ECM1–Up
Typical example
Table 13
Specification for 381-6298 Fuel Injection Pump Gp and 372-6468 Fuel Injection Pump Gp
1 1 8S-9191 Bolt Torque to 55 ± 10 N·m (41 ± 7 lb ft).
Before assembly, lubricate the O-ring seals and the bore with a 50 percent mix of
2 - -
green 8T-2998 Lubricant and clean engine oil.
22 UENR0996-03
i05761294

SMCS Code: 1290
S/N: NJH1–Up
S/N: ECM1–Up
Table 14
Specification for 235-1402 Fuel Injection Pump Gp
Before assembly, lubricate the O-ring seals and the bore with a 50 percent mix of
2 - -
green 8T-2998 Lubricant and clean engine oil.
UENR0996-03 23
i06936472

SMCS Code: 1290
S/N: NJH1–Up
S/N: ECM1–Up
Table 15
1 1 8T-0644 Bolt Torque to 70 ± 15 N·m (52 ± 11 lb ft).
i02685980

Mechanism
SMCS Code: 1290
S/N: NJH1–Up
S/N: ECM1–Up
24 UENR0996-03
(2) Rocker arm
(3) Rocker arm shaft
(4) Lifter group shaft
(5) Unit injector lifter assembly
Use the following procedure for adjusting the unit

injector:
1. Loosen the locknut (1).
2. Turn the adjustment screw clockwise. Stop turning
the adjustment screw when contact is made with
the unit injector.
3. Turn the adjustment screw clockwise.
Turn . . . . . . . . . . . . . . . . . 180 degrees (1/2 of a turn)

4. Hold the adjustment screw. Tighten the locknut (1).
Tighten the locknut to the following torque.

. . . . . . . . . . . . . . . . . . . . . .55 ± 10 N·m ((41 ± 7 lb ft))
UENR0996-03 25
i04403749

Mechanism
SMCS Code: 1290
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 235-1402
S/N: L4D1–Up
Part No.: 235-1402
S/N: L4E1–Up
Part No.: 235-1402
S/N: L4F1–Up
S/N: NJH1–Up
S/N: ECM1–Up
(3) Spacer (4) Unit injector clamp
Table 16
Specification for the 190-0009 Fuel Pump and Valve Mechanism, 148-7482 Fuel Pump and Valve Mechanism, 128-8510 Fuel In-
jector Gp, 130-9701 Fuel Injection Pump Gp, 153-2875 Fuel Injector Gp, 235-1401 Fuel Injection Pump Gp, 297-1027 Fuel Injec-
tion Pump Gp, 252-5786 Fuel Injection Pump Gp, 253-8352 Fuel Injection Pump Gp, 261-0048 Fuel Injection Pump Gp and
235-1402 Fuel Injection Pump Gp
Before installation of the unit injector, lubricate the O-ring seals (5) with a 50/50 mixture of clean engine oil and 8T-2998 Lubricant.
1 1 - Torque the locknut to 100 ± 10 N·m (74 ± 7 lb ft).
2 1 - Use the following procedure to tighten the bolt:
(continued)
26 UENR0996-03
(Table 16, contd)

1. Tighten the bolt to 55 ± 10 N·m (41 ± 7 lb ft).
2. Loosen the bolt until the bolt is finger tight.
3. Again, tighten the bolt to 55 ± 10 N·m (41 ± 7 lb ft).
A - - Adjust the unit injector height to 78.0 ± 0.2 mm (3.07 ± 0.01 inch).
UENR0996-03 27
i04406189

Mechanism
SMCS Code: 1290
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 266-3699
S/N: L4D1–Up
Part No.: 266-3699
S/N: L4E1–Up
Part No.: 266-3699
S/N: L4F1–Up
S/N: NJH1–Up
S/N: ECM1–Up
(4) Spacer (5) Clamp
Table 17
Specification for 266-3699 Fuel Pump and Valve Mechanism
Before installation of the unit injector, lubricate the O-ring seals (6) with a 50/50 mixture of clean engine oil and 8T-2998 Lubricant.
1 - - Torque to 2.50 ± 0.25 N·m (22.13 ± 2.21 lb in).
196-5070 Jam
2 1 Torque to 100 ± 10 N·m (74 ± 7 lb ft).
Nut
3 - Use the following procedure to tighten the bolt:
(continued)
28 UENR0996-03
(Table 17, contd)

The unit injector height is measured from the timing seat. Adjust the unit injector height to
A - -
78.0 ± 0.2 mm (3.07 ± 0.01 inch).
Refer to Testing and Adjusting, “Electronic Unit Injector - Adjust” for the correct procedure for setting the lash on the electronic unit injector.
UENR0996-03 29
i05546069

Mechanism
SMCS Code: 1290
S/N: NJH1–Up
S/N: ECM1–Up
Table 18
2 1 230-3775 O-Ring Seal Lubricate the seal lightly with a 50/50 mixture of green 8T-2998 Lubricant and engine oil.
30 UENR0996-03
371-8891 Fuel Injector Gp
Table 19

5 4 283-8654 Screw Torque to 1.1 ± 0.1 N·m (9.7 ± 0.9 lb in).
Lubricate the threads with Vactra No. 2 MSDS 5380.

6 1 365-3386 Unit Injector Nozzle Torque to 12 N·m (106 lb in) and start tracking turn angle to reach final turn angle of 43 ± 2
degrees. Final case torque to reach 100 ± 20 N·m (74 ± 15 lb ft).

7 1 254-4379 Nozzle Spring Test force is 239.5 ± 10.0 N (53.8 ± 2.2 lb).
UENR0996-03 31
298-5517 Actuator As
Table 20
Before assembly, apply green Loctite 290 to the threads.

8 1 421-5853 Flat Head Screw
Torque to 2.9 ± 0.7 N·m (25.7 ± 6.2 lb in).

9 1 269-3183 Solenoid Spring Test force is 70.8 N (15.9 lb).
10 1 254-4376 Spacer Select the spacer to provide spring force of 80.0 ± 1.0 N (18.0 ± 0.2 lb).
11 1 298-5534 Nut Torque to 1.1 ± 0.1 N·m (9.7 ± 0.9 lb in).

32 UENR0996-03
i05546170

Mechanism
SMCS Code: 1290
S/N: NJH1–Up
S/N: ECM1–Up
Table 21
A - - Adjust the unit injector height to 78.0 ± 0.2 mm (3.07 ± 0.01 inch).
UENR0996-03 33
i06111998

Mechanism
SMCS Code: 1290
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 22
Specification for 260-9631 Fuel Pump and Valve Mechanism and 255-8001 Fuel Pump and Valve Mechanism
1 1 - Tighten the cap nut to 2.50 ± 0.25 N·m (22.13 ± 2.21 lb in).
2 1 - Tighten the locknut to 100 ± 10 N·m (74 ± 7 lb ft).
Use the following procedure in order to tighten the bolt:
3 1 - 1. Tighten the bolt to 55 ± 10 N·m (41 ± 7 lb ft).

34 UENR0996-03
i04375854
Electronic Unit Injector Rocker

Arm
SMCS Code: 1123
S/N: NJH1–Up
S/N: ECM1–Up
Table 23
Specification for the 207-5248 Rocker Arm As, 278-1932 Arm As, 278-1365 Rocker Arm As, 278-1363 Rocker Arm As,
243-2466 Rocker Arm As
Bushing must not extend beyond either face of the rocker arm.
A - 207-9576 Bushing
Bore of the new bushing after installation is 40.065 ± 0.015 mm (1.5774 ± 0.0006 inch).
UENR0996-03 35
i04842435

Arm
SMCS Code: 1123
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 322-9168
S/N: L4D1–Up
Part No.: 322-9168
S/N: L4E1–Up
Part No.: 322-9168
S/N: L4F1–Up
Part No.: 322-9168
S/N: TWG1–Up
S/N: NJH1–Up
Table 24
Specification for 322-9168 Rocker Arm As
After installation, bore (A) in the bushing for the rocker arm shaft is 40.065 ± 0.015 mm
1 1 207-9576 Bushing (1.5774 ± 0.0006 inch).
36 UENR0996-03
i05389132

Arm
SMCS Code: 1123
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 278-1363
S/N: L4D1–Up
Part No.: 278-1363
S/N: L4E1–Up
Part No.: 278-1363
S/N: L4F1–Up
Part No.: 278-1363
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Typical example
Table 25
Specification for 278-1365 Rocker Arm As, 243-2465 Rocker Arm, and 278-1363 Rocker Arm As
A - 207-9576 Bushing
Bore of the new bushing after installation is 40.065 ± 0.015 mm (1.5774 ± 0.0006 inch).
UENR0996-03 37
i05548510

Arm
SMCS Code: 1123
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 26
Specification for 437-3881 Rocker Arm
1 1 207-9576 Bushing (1.5774 ± 0.0006 inch).
38 UENR0996-03
i05576929

Arm
SMCS Code: 1123
S/N: NJH1–Up
S/N: ECM1–Up
Table 27
1 1 322-5765 Bearing (1.3406 ± 0.0006 inch).
UENR0996-03 39
i05755911

Arm
SMCS Code: 1123
S/N: NJH1–Up
S/N: ECM1–Up
Typical example
Table 28
Specification for 437-3878 Rocker Arm, and 437-3862 Rocker Arm
1 1 207-9576 Bushing (1.5774 ± 0.0006 inch).
i06544886

Arm
SMCS Code: 1123
S/N: NJH1–Up
S/N: ECM1–Up
40 UENR0996-03
(1) Maximum free running torque of the adjustment

screw . . . . . . . . . . . . . . . . . . . . . . . . 0.4 N·m ((4 lb in))
(2) Torque for the hex thin nut . . . . . . . . 55 ± 10 N·m

((41 ± 7 lb ft))
(A) Oil passage angle . . . . . . . . . . . . . . . . 13 degrees
Note: Opening diameter for the oil hole must be

2.3 mm (0.09 inch) minimum after the assembly of
the bearing.
(B) Bearing bore diameter . . . . . 34.050 ± 0.015 mm

((1.3405 ± 0.0006 inch))
Bore in the rocker arm for the bearing

. . . . . . . 37.000 ± 0.020 mm ((1.4567 ± 0.0008 inch))
Note: The bearing in the rocker arm must not extend

beyond either face of the rocker arm.
(C) Oil passage angle . . . . . . . . . . . . . . . . 20 degrees

Note: The diameter for the oil hole opening must be
2.3 mm (0.09 inch) minimum after the assembly of
the bearing.
UENR0996-03 41
i04375750
Valve Mechanism
SMCS Code: 1102
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 343-4437, 343-4438
S/N: L4D1–Up
Part No.: 343-4437, 343-4438
S/N: L4E1–Up
Part No.: 343-4437, 343-4438
S/N: L4F1–Up
Part No.: 343-4437, 343-4438
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
(1) Rocker arm (7) Valve bridge

(5) Camshaft (3) Adjusting screw
Table 29
Specification for 148-7482 Fuel Pump and Valve Mechanism, 343-4437 Fuel Pump and Valve Mechanism, 343-4438 Fuel Pump
and Valve Mechanism and 266-3699 Fuel Pump and Valve Mechanism.
2 1 276-5317 Nut Torque to 30 ± 7 N·m (265 ± 60 lb in)
307-8322 Rocker Lubricate with clean engine oil before assembly.

4 1
Shaft Assembly Diameter of a new rocker shaft assembly is 40.000 ± 0.010 mm (1.5748 ± 0.0004 inch).
(continued)
42 UENR0996-03
(Table 29, contd)

Bore in the rocker arm for rocker shaft assembly is 40.065 ± 0.015 mm (1.5774 ± 0.0006 inch).
Valve lash setting:

6 - - Inlet valve is 0.38 ± 0.08 mm (0.015 ± 0.003 inch).
Exhaust valve is0.76 ± 0.08 mm (0.030 ± 0.003 inch).
For engines that are equipped with variable valve actuators, refer to Specifications , “Variable valve Actuator” for information on installation of
the rocker arm assembly.
For engines that are equipped with CAT Compression Brakes, refer to Specifications , “CAT Compression Brake” for the correct procedure on
installation of the rocker arm assembly.
i04575980
Valve Mechanism
SMCS Code: 1102
S/N: NJH1–Up
S/N: ECM1–Up
Torque for the jam nuts (2 ) after setting the valve

lash . . . . . . . . . . . . . . . . . . . .30 ± 7 N·m ((22 ± 5 lb ft))
(1) Inlet rocker arm bore for shaft

. . . . . . . 34.075 ± 0.015 mm ((1.3415 ± 0.0006 inch))
(3) Exhaust rocker arm bore for shaft

. . . . . . . 34.075 ± 0.015 mm ((1.3415 ± 0.0006 inch))
UENR0996-03 43
i04845169
Valve Mechanism
SMCS Code: 1102
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 265-7878
S/N: L4D1–Up
Part No.: 265-7878
S/N: L4E1–Up
Part No.: 265-7878
S/N: L4F1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 30
1 1 276-5317 Nut Torque to 30 ± 7 N·m (266 ± 62 lb in).
Refer to Testing and Adjusting, “Engine Valve Lash - Inspect/Adjust” for the correct proce-
- - -
dure on setting the engine valve lash.
Valve lash dimensions:

- - - Inlet valve is 0.38 ± 0.08 mm (0.015 ± 0.003 inch).
Exhaust valve is 0.81 ± 0.08 mm (0.032 ± 0.003 inch).
44 UENR0996-03
Top view of engine
Table 31
2 1 196-5070 Jam Nut Torque to 100 ± 10 N·m (74 ± 7 lb ft).

UENR0996-03 45
i04845289
Valve Mechanism
SMCS Code: 1102
S/N: NJH1–Up
S/N: ECM1–Up
Table 32
Specification for 326-1959 Valve Mechanism Gp

Exhaust valve is 0.76 ± 0.08 mm (0.030 ± 0.003 inch).
Torque to 30 ± 7 N·m (266 ± 62 lb in).

1 - 2Y-5829 Nut
After you tighten the nut, recheck the valve lash setting.
46 UENR0996-03
i05336175
Valve Mechanism
SMCS Code: 1102
S/N: NJH1–Up
S/N: ECM1–Up
(1) Rocker arm (5) Camshaft

(3) Adjusting screw (7) Valve bridge
Table 33
Specification for 190-0009 Fuel Pump and Valve Mechanism, 224-5136 Fuel Pump and Valve Mechanism, and 235-0382 Fuel
Pump and Valve Mechanism
2 1 276-5317 Nut Torque for the nuts 30 ± 7 N·m (265 ± 60 lb in)
307-8322 Rocker Diameter of a new rocker shaft assembly is 40.000 ± 0.010 mm (1.5748 ± 0.0004 inch).
4 1
Shaft Assembly Bore in the rocker arm for rocker shaft is 40.065 ± 0.015 mm (1.5774 ± 0.0006 inch).
Valve lash setting:

6 - - Inlet valve is 0.38 ± 0.08 mm (0.015 ± 0.003 inch).
Exhaust valve is0.76 ± 0.08 mm (0.030 ± 0.003 inch).
For engines that are equipped with variable valve actuators, refer to Specifications, “Variable valve Actuator” for information on installation of
the rocker arm assembly.
For engines that are equipped with CAT Compression Brakes, refer to Specifications, “CAT Compression Brake” for the correct procedure on
installation of the rocker arm assembly.
UENR0996-03 47
i06633384
Valve Mechanism
SMCS Code: 1102
S/N: NJH1–Up
S/N: ECM1–Up
Table 34
1 1 3S-2713 Full Nut Torque to 30 ± 7 N·m (266 ± 62 lb in).
Refer to Testing and Adjusting, “Engine Valve Lash - Inspect/Adjust” for the correct proce-
- - -
dure on setting the engine valve lash.

Exhaust valve is 0.76 ± 0.08 mm (0.030± 0.003 inch).
48 UENR0996-03
Top view of engine
Table 35
2 1 196-5070 Jam Nut Torque to 100 ± 10 N·m (74 ± 7 lb ft).

UENR0996-03 49
i06633459
Valve Mechanism
SMCS Code: 1102
S/N: NJH1–Up
S/N: ECM1–Up
Table 36
Specification for 346-8685 Valve Mechanism Gp

Inlet valve lash is 0.38 ± 0.08 mm (0.015 ± 0.003 inch).
A - -
Exhaust valve lash is 0.64 ± 0.08 mm (0.025 ± 0.003 inch).
1 12 - Torque to 30 ± 7 N·m (266 ± 62 lb in).
Diameter of the rocker arm shaft is 21.500 ± 0.013 mm (0.8465 ± 0.0005 inch).
2 1 274-5874 Rocker Arm Shaft Bore in the rocker arm for the rocker arm shaft is 21.548 ± 0.013 mm
(0.8483 ± 0.0005 inch).
50 UENR0996-03
Right side view
Table 37

Before installation of the valve lifter assembly, lubricate the bore of the valve lifter assembly and the lobes of the camshaft with a 50/50 mixture
of clean engine oil and 8T-2998 Lubricant.
Bore in the 453-5999 Lifter Body for the roller pin is 12.668 ± 0.006 mm
(0.4987 ± 0.0002 inch).
3 12 453-5998 Valve Lifter As
Diameter of the 453-6000 Roller Pin is 12.694 ± 0.006 mm
(0.4998 ± 0.0002 inch).
UENR0996-03 51
i04845329
Valve Rocker Arm

SMCS Code: 1123
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 320-2794
S/N: L4D1–Up
Part No.: 320-2794
S/N: L4E1–Up
Part No.: 320-2794
S/N: L4F1–Up
Part No.: 320-2794
S/N: TWG1–Up
S/N: NJH1–Up
Table 38
Bore (A) in the valve rocker arm for the rocker arm shaft is 40.065 ± 0.015 mm
271-3962 Valve Rocker (1.5774 ± 0.0006 inch).
1 1
Arm Bushing must not extend beyond either face of the rocker arm.
2 1 207-5245 Pin Pin must not extend beyond either face of the valve rocker arm.
52 UENR0996-03
i05548469
Valve Rocker Arm

SMCS Code: 1123
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 39
1 1 203-8823 Arm (1.5774 ± 0.0006 inch).
UENR0996-03 53
i05757314
Valve Rocker Arm

SMCS Code: 1123
S/N: NJH1–Up
S/N: ECM1–Up
Table 40
1 1 203-8823 Arm (1.5774 ± 0.0006 inch).
54 UENR0996-03
i06633317
Valve Rocker Arm

SMCS Code: 1123
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 41
1 1 274-4491 Arm Adjustment Screw The free running torque must not exceed 0.4 N·m (3.5 lb in)
2 1 271-3962 Valve Rocker Arm (1.5774 ± 0.0006 inch).
3 1 276-5317 Nut Torque to 6 ± 3 N·m (53 ± 27 lb in)
UENR0996-03 55
i06633376
Valve Rocker Arm

SMCS Code: 1123
S/N: NJH1–Up
S/N: ECM1–Up
Table 42

260-7524 Valve Adjust-
1 1 The free running torque must not exceed 0.4 N·m (3.5 lb in).
ment Screw
2 1 2Y-5829 Nut Torque to 7 ± 3 N·m (62 ± 27 lb in).
Bore in the valve rocker arm for the rocker arm shaft is 21.548 ± 0.013 mm
3 1 344-8704 Rocker Arm As (0.8483 ± 0.0005 inch).
56 UENR0996-03
i07597244
Valve Rocker Arm

SMCS Code: 1123
S/N: NJH1–Up
S/N: ECM1–Up
Table 43

260-7524 Valve Ad-
1 1 The free running torque must not exceed 0.4 N·m (3.5 lb in).
justment Screw
2 1 2Y-5829 Nut Torque to 7 ± 3 N·m (62 ± 27 lb in).
255-8670 Rocker
3 1 Bore in the valve rocker arm for the rocker arm shaft is 21.548 ± 0.013 mm (0.8483 ± 0.0005 inch).
Arm
UENR0996-03 57
i04381654
Valve Mechanism Cover

SMCS Code: 1107
S/N: NJH1–Up
S/N: ECM1–Up
Typical example
Tightening sequence for the valve covers
58 UENR0996-03
Tightening sequence for the valve cover base
Table 44
Specification for the 248-5588 Valve Mechanism Cover Gp
Tighten the bolts for the valve cover in the numerical sequence that is shown in Illustration 49
1 6 243-1159 Fastener to 18 ± 3 N·m (159 ± 27 lb in).
Tighten 15 bolts for the valve cover base in the numerical sequence that is shown in Illustra-
2 15 -
tion 50 .
UENR0996-03 59
Table 45
Orient the connector for the solenoid valve group in the position that is shown in Illustration 51 .
3 - -
Torque the nut to 10.0 ± 1.5 N·m (88.5 ± 13.3 lb in).
4 - - Torque the solenoid valve group to 50 ± 5 N·m (37 ± 4 lb ft).

60 UENR0996-03
i04407570

SMCS Code: 1107
S/N: NJH1–Up
S/N: ECM1–Up
Tightening sequence for valve cover
UENR0996-03 61
Tightening sequence for valve cover base
Table 46
Specification for 239-5820 Valve Mechanism Cover Gp
1 6 243-1159 Fastener Torque to 18 ± 3 N·m (159 ± 27 lb in) in the numerical sequence as shown in Illustration 53 .
2 1 272-2583 O-Ring Seal Lubricate the joint surfaces and the O-ring seal with the clean engine oil.
3 14 9L-8925 Bolt Tighten the bolts for the valve cover base in the numerical sequence that is shown in Illustration
4 1 122-1472 Bolt 54 .
Apply blue Loctite 242 to the threads of the bolts that fasten the wiring for the electronic unit in-
- - -
jectors to the valve cover base.
- - - Orient the connector for the solenoid valve group in the position that is shown in Illustration 55 .
5 - - Torque the nut to 10.0 ± 1.5 N·m (90 ± 13 lb in).
6 - - Torque the solenoid valve group to 50 ± 5 N·m (37 ± 4 lb ft).

62 UENR0996-03
i04407623

SMCS Code: 1107
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 187-1328
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 63
Table 47
Specification for 187-1328 Valve Mechanism Cover Gp and 239-4113 Valve Mechanism Cover Gp
2 14 9L-8925 Bolt
Tighten the bolts in the numerical sequence as shown in Illustration 58 .
3 1 122-1472 Bolt
Apply blue Loctite 242 to the threads of the bolts that fasten the wiring for the electronic unit in-
- - -
jectors to the valve cover base.
64 UENR0996-03
i04412879

SMCS Code: 1107
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 65
Table 48
2 1 272-2583 O-Ring Seal Lubricate the joint surfaces and the seals with the clean engine oil.
3 14 9L-8925 Bolt
4 1 122-1472 Bolt
Apply blue Loctite 242 to the threads of the bolts that fasten the wiring for the electronic unit
- - -
injectors to the valve cover base.
66 UENR0996-03
i04412886

SMCS Code: 1107
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 67
Table 49
2 1 272-2583 O-Ring Seal Lubricate the joint surfaces and the seals with the clean engine oil.
3 14 9L-8925 Bolt
4 1 122-1472 Bolt
Apply blue Loctite 242 to the threads of the bolts that fasten the wiring for the electronic unit injectors to the valve cover base.
68 UENR0996-03
i04464691

SMCS Code: 1107
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 325-3918
S/N: L4D1–Up
Part No.: 325-3918
S/N: L4E1–Up
Part No.: 325-3918
S/N: L4F1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Tightening sequence for valve cover and valve cover base
UENR0996-03 69
Table 50
Specifications for 278-5662 Valve Cover and Injection Harness Base Gp, 286-7168 Valve Mechanism Cover Gp, and 239-5223
Valve Mechanism Cover Gp
- - - Apply blue Loctite 242 to the threads of the bolts.
Tighten the bolts in the numerical sequence as shown in Illustration 66 to 18 ± 3 N·m

- - -
(160 ± 27 lb in).
70 UENR0996-03
i04483689

SMCS Code: 1107
S/N: NJH1–Up
S/N: ECM1–Up
Table 51
A 1 - Orientation for the breather cap is 11° ± 5°.
227-4531 Engine Oil Filler Hand tighten the engine oil filter cap assembly until the O-ring seal seats fully on
1 1
Cap As the valve mechanism cover.
Tighten the bolt 1 through bolt 10 in a numerical sequence that is shown in Illustration 67 to standard torque.
Table 52
(continued)
UENR0996-03 71
(Table 52, contd)

2 1 2N-8109 Clamp Torque to 4.5 ± 0.5 N·m (39.8 ± 4.4 lb in).
3 1 365-5169 Adapter Torque to 15 ± 3 N·m (133 ± 27 lb in).
4 1 6V-3831 O-Ring Seal Lightly lubricate the bore of the O-ring seal with clean engine oil.
72 UENR0996-03
i05297642

SMCS Code: 1107
S/N: NJH1–Up
S/N: ECM1–Up
Top view of engine
Typical example
Table 53
Specification for 170-6525 Valve Mechanism Cover Gp and 187-1327 Valve Mechanism Cover Gp
Tighten the bolts in the numerical sequence 1,2,3,4,5, and 6 to 18 ± 3 N·m

1 - 243-1159 Fastener (159 ± 27 lb in)refer to Illustration 70 .
UENR0996-03 73
i05543370

SMCS Code: 1107
S/N: NJH1–Up
S/N: ECM1–Up
74 UENR0996-03
Tightening sequence
UENR0996-03 75
Table 54
Specification for 419-4591 Valve Cover and Injection Harness Base Gp
1 3 161-7419 Stud Tighten the bolts and studs in numerical order as shown in Illustration 72 .
Use the following tightening sequence:
2 12 9L-8925 Bolt 1. Use multi spindle torquing tool.

2. Avoid bolts (2) at locations 6, 1 & 7 in multi spindle station.
3. Add studs (1) at locations 6, 1 & 7 after multi spindle station.
76 UENR0996-03
i05543429

SMCS Code: 1107
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 77
Tightening sequence
Table 55
Specification for 349-5296 Valve Cover Base Gp
1 15 9L-8925 Bolt Tighten the bolts as per tightening sequence shown in Illustration 74 .
78 UENR0996-03
i05572649

SMCS Code: 1107
S/N: NJH1–Up
S/N: ECM1–Up
Table 56
1 1 368-8036 Breather As Torque to 30.0 ± 7.5 N·m (265.5 ± 66.4 lb in). Reorient the breather outlet by hand.
227-4531 Engine Oil Filler Hand tighten the engine oil filter cap assembly until the O-ring seal seats fully on the
2 1
Cap As valve mechanism cover.
Tighten the bolt 1 through bolt 10 in a numerical sequence that is shown in Illustration 1 to standard torque.
i04166497
Cylinder Head Valves

SMCS Code: 1105
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 79
(D) Diameter of the valve head

. . . . . . . . 44.50 ± 0.13 mm ((1.752 ± 0.005 inch))
(E) Minimum valve lip thickness
. . . . . . . . . 3.50 ± 0.20 mm ((0.138 ± 0.008 inch))
(2) 224-4441 Spring
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Length under test force . . . . . . . . . . . . 50.47 mm
((1.987 inch))
Test force . . . . . . . . . 160 ± 13 N ((36.0 ± 2.9 lb))
Approximate free length after test . . . . . 64.1 mm
((2.52 inch))
Outside diameter . . . . . 23.24 mm ((0.915 inch))
Note: Apply clean engine oil to the inlet valve stems

and to the exhaust valve stems prior to installation in
the cylinder head.
(A) Height to the step in the valve guide

. . . . . . . . . . . . . . . 20.0 ± 0.5 mm ((0.79 ± 0.02 inch))
Exhaust valve
(3) Exhaust valve
(F) Valve stem diameter . . . . . 9.441 ± 0.008 mm

((0.3717 ± 0.0003 inch))
Minimum valve stem diameter . . . . . . . 9.309 mm
((0.3665 inch))
(G) Valve face angle . . . . . . 45.75 ± 0.25 degrees
(H) Diameter of the valve head
. . . . . . . . 41.50 ± 0.13 mm ((1.634 ± 0.005 inch))
(J) Minimum valve lip thickness
. . . . . . . . . 3.50 ± 0.20 mm ((0.138 ± 0.008 inch))
Inlet valve (4) 214-0586 Spring
(1) Inlet valve Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(B) Valve stem diameter . . . . . 9.441 ± 0.008 mm ((2.085 inch))
((0.3717 ± 0.0003 inch)) Test force . . . . . . . . . 320 ± 31 N ((71.9 ± 7.0 lb))
Minimum valve stem diameter . . . . . . . 9.309 mm Approximate free length after test . . . . . 62.7 mm
((0.3665 inch)) ((2.47 inch))
(C) Valve face angle . . . . . . 60.75 ± 0.25 degrees Outside diameter . . . . . 34.00 mm ((1.339 inch))
80 UENR0996-03
Note: Apply clean engine oil to the valve guide bore

before installing the valve guides.
(5) Valve guide
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Bore of the installed valve guide
. . . . . 9.508 ± 0.013 mm ((0.3743 ± 0.0005 inch))
Maximum recommended diameter of the valve
guide bore . . . . . . . . . . 9.544 mm ((0.3757 inch))
Note: Do not use a combination of a valve and a
valve guide that has a difference of 0.13 mm
(0.005 inch) or more.
(6) Inlet valve insert
Angle of the valve insert . . . 30.75 ± 0.25 degrees

Diameter of the valve insert
. . . . 45.525 ± 0.013 mm ((1.7923 ± 0.0005 inch))
Bore in the cylinder head for the valve insert
. . . . 45.461 ± 0.015 mm ((1.7898 ± 0.0006 inch))
(7) Exhaust valve insert

. . . . 42.390 ± 0.015 mm ((1.6689 ± 0.0006 inch))
. . . . 42.320 ± 0.015 mm ((1.6661 ± 0.0006 inch))
UENR0996-03 81
i04389429

SMCS Code: 1105
S/N: NJH1–Up
S/N: ECM1–Up
Table 57
Specification for 331-2477 Cylinder Head Gp
Apply clean engine oil to the stem prior to installation.

Diameter (B) is 9.441 ± 0.008 mm (0.3717 ± 0.0003 inch)
1 12 252-7802 Inlet Valve
Face angle (D) is 60.75 ± 0.25 degrees
Valve head diameter (F) is 44.50 ± 0.13 mm (1.752 ± 0.005 inch)
Apply clean engine oil to the stem prior to installation.

Diameter (C) is 9.441 ± 0.008 mm (0.3717 ± 0.0003 inch)
2 12 248-1467 Exhaust Valve
Face angle (E) is 45.75 ± 0.25 degrees
Valve head diameter (G) is 41.50 ± 0.13 mm (1.634 ± 0.005 inch)
Length under test force is 50.47 mm (1.987 inch)

3 24 224-4441 Spring Test force is 160 ± 13 N (36 ± 3 lb)
Approximate free length after test is 64.1 mm (2.52 inch)
(continued)
82 UENR0996-03
(Table 57, contd)

Length under test force is 52.95 mm (2.085 inch)
4 24 332-2152 Spring Test force is 320 ± 31 N (72 ± 7 lb)
Approximate free length after test is 62.7 mm (2.47 inch)
Apply clean engine oil to the bore prior to installation.

5 24 268-2953 Valve Guide Bore is 9.508 ± 0.013 mm (0.3743 ± 0.0005 inch)
Height (A) to the step is 20.0 ± 0.5 mm (0.79 ± 0.02 inch)
Insert angle is 29.75 ± 0.25 degrees

6 12 260-4855 Valve Seat Insert Diameter is 45.525 ± 0.013 mm (1.7923 ± 0.0005 inch)
Bore in the cylinder head is 45.461 ± 0.015 mm (1.7898 ± 0.0006 inch)
Insert angle is 44.75 ± 0.25 degrees

7 12 224-1270 Valve Seat Insert Diameter is 42.390 ± 0.015 mm (1.6689 ± 0.0006 inch)
Bore in the cylinder head is 42.320 ± 0.015 mm (1.6661 ± 0.0006 inch)
UENR0996-03 83
i04485689

SMCS Code: 1105
S/N: NJH1–Up
S/N: ECM1–Up
Table 58
Before assembly of cylinder head valves, coat the valve guide inside diameter
with clean engine oil.
Diameter of valve head is 41.50 ± 0.13 mm (1.634 ± 0.005 inch).
Face angle is 29.50 ± 0.25 degrees.
Before assembly of cylinder head valves, coat the valve guide inside diameter
with clean engine oil.
Diameter of valve head is 37.50 ± 0.13 mm (1.476 ± 0.005 inch).

3 24 349-5307 Spring
Test force is 465.0 ± 23.3 N (104.5 ± 5.2 lb).
(continued)
84 UENR0996-03
(Table 58, contd)

Approximate free length after test is 77.9 mm (3.07 inch).
Before assembly of valve guide, coat the cylinder head bore for valve guide with clean engine oil.
Install the valve guide from the spring side of the cylinder head. Check the inside
diameter of the valve guide for distortion after installation into the cylinder head.
5 24 255-8665 Valve Guide
Outside diameter is 13.030 ± 0.008 mm (0.5130 ± 0.0003 inch).
Inside diameter is 8.072 ± 0.013 mm (0.3178 ± 0.0005 inch).
After assembly of the valve guide into the cylinder head, install the seal onto the top of the valve guide.
A - Diameter of valve stem is 8.000 ± 0.010 mm (0.3150 ± 0.0004 inch).
Typical Example
Table 59
Depth of the bore in the cylinder head for the inlet valve seat insert is
9.30 ± 0.05 mm (0.366 ± 0.002 inch).
B - -
Depth of the bore in the cylinder head for the exhaust valve seat insert is
10.40 ± 0.05 mm (0.409 ± 0.002 inch).
Diameter of the inlet 255-8666 Valve Seat Insert is 42.560 ± 0.013 mm

(1.6756 ± 0.0005 inch).
C 24 -
Bore in cylinder head for the inlet valve seat insert is 42.500 ± 0.015 mm
(1.6732 ± 0.0006 inch).
(continued)
UENR0996-03 85
(Table 59, contd)

Diameter of the exhaust 262-2959 Valve Seat Insert is 39.060 ± 0.013 mm
(1.5378 ± 0.0005 inch).
Bore in cylinder head for the exhaust valve seat insert is 39.000 ± 0.015 mm
(1.5354 ± 0.0006 inch).
i05297857

SMCS Code: 1105
S/N: NJH1–Up
S/N: ECM1–Up
Inlet valve
(1) Inlet valve
(B) Valve stem diameter . . . . . 9.441 ± 0.008 mm

((0.3717 ± 0.0003 inch))
(C) Valve face angle . . . . . . 60.75 ± 0.25 degrees
(D) Diameter of the valve head
Illustration 82 g01445699 . . . . . . . . 44.50 ± 0.13 mm ((1.752 ± 0.005 inch))
(E) Valve lip thickness . . . . . . . . .3.50 ± 0.20 mm
Note: Before installation of valves into the cylinder
((0.138 ± 0.008 inch))
head, lubricate the inlet valve stem and the exhaust
valve stem with clean engine oil. (2) 224-4441 Spring
(A) Height to the step in the valve guide Length under test force . . . . . . . . . . . . 50.47 mm
. . . . . . . . . . . . . . . 20.0 ± 0.5 mm ((0.79 ± 0.02 inch)) ((1.987 inch))
Test force . . . . . . . . . 160 ± 13 N ((36.0 ± 2.9 lb))
((2.52 inch))
86 UENR0996-03

. . . . 45.525 ± 0.013 mm ((1.7923 ± 0.0005 inch))
. . . . 45.461 ± 0.015 mm ((1.7898 ± 0.0006 inch))
(7) Exhaust valve insert

. . . . 42.390 ± 0.015 mm ((1.6689 ± 0.0006 inch))
. . . . 42.320 ± 0.015 mm ((1.6661 ± 0.0006 inch))
Exhaust valve
(3) Exhaust valve
(F) Valve stem diameter . . . . . 9.441 ± 0.008 mm

((0.3717 ± 0.0003 inch))
(G) Valve face angle . . . . . . 45.75 ± 0.25 degrees
(H) Diameter of the valve head
. . . . . . . . 41.50 ± 0.13 mm ((1.634 ± 0.005 inch))
(J) Valve lip thickness . . . . . . . . . .3.25 ± 0.10 mm
((0.128 ± 0.004 inch))
(4) 332-2152 Spring

((2.085 inch))
Test force . . . . . . . . . 320 ± 31 N ((71.9 ± 7.0 lb))
((2.47 inch))
Outside diameter . . . . . . . .34.0 mm ((1.34 inch))
Note: Before installing the valve guides, apply clean

engine oil to the valve guide bore.
(5) Valve guide
Bore of the installed valve guide

. . . . . 9.508 ± 0.013 mm ((0.3743 ± 0.0005 inch))
Maximum recommended diameter of the valve
guide bore . . . . . . . . . . 9.544 mm ((0.3757 inch))
Note: Do not use a combination of a valve and a
valve guide that has a difference of 0.13 mm
(0.005 inch) or more.
(6) Inlet valve insert

UENR0996-03 87
i05300990

SMCS Code: 1105
S/N: NJH1–Up
S/N: ECM1–Up
Table 60

1 24 247-9908 Spring Test force is 320 ± 25 N (72 ± 6 lb).

Height from top of the cylinder head to the top of the valve guides is 35.0 ± 0.5 mm
A - -
(1.38 ± 0.02 inch).
Apply clean engine oil to the bore before assembly.

Bore in the valve guide for the valves is 9.502 ± 0.013 mm (0.3741 ± 0.00051 inch).
Apply clean engine oil to the valve stems prior to installation in the cylinder head.
Stem diameter is 9.441 ± 0.010 mm (0.3717 ± 0.0004 inch).
Valve head diameter is 41.81 ± 0.13 mm (1.646 ± 0.005 inch).
(continued)
88 UENR0996-03
(Table 60, contd)

6 12 226-5561 Valve Seat Insert Bore in the cylinder head for valve seat insert is 42.774 ± 0.025 mm
(1.6840 ± 0.0010 inch).
Depth of bore in the cylinder head for seat insert is 13.90 ± 0.05 mm (0.547 ± 0.002 inch).

7 12 280-3979 Valve Seat Insert
Bore in the cylinder head for seat insert is 47.950 ± 0.025 mm (1.8878 ± 0.0010 inch).
UENR0996-03 89
i06638110

SMCS Code: 1105
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 61


A - -
(1.38 ± 0.02 inch).

Bore in the valve guide for valves is 9.502 ± 0.013 mm (0.3741 ± 0.0005 inch).
(continued)
90 UENR0996-03
(Table 61, contd)



Bore in the cylinder head for valve seat insert is 42.774 ± 0.025 mm
6 12 300-3565 Valve Seat Insert
(1.6840 ± 0.0010 inch).
Depth of bore in the cylinder head for seat insert is 13.90 ± 0.05 mm
(0.547 ± 0.002 inch).

7 12 280-3979 Valve Seat Insert Bore in the cylinder head for seat insert is 47.950 ± 0.025 mm (1.8878 ± 0.0010 inch).
Depth of bore in the cylinder head for seat insert is 14.00 ± 0.05 mm
(0.551 ± 0.002 inch).
UENR0996-03 91
i07517372

SMCS Code: 1105
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 223-9250
S/N: L4D1–Up
Part No.: 223-9250
S/N: L4E1–Up
Part No.: 223-9250
S/N: L4F1–Up
Part No.: 223-9250
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Typical example
Table 62


(continued)
92 UENR0996-03
(Table 62, contd)

A - -
(1.38 ± 0.02 inch).


300-3565 Valve Seat Outside diameter is 42.850 ± 0.013 mm (1.6870 ± 0.0005 inch).
6 12
Insert Bore in the cylinder head for valve seat insert is 42.774 ± 0.025 mm (1.6840 ± 0.0010 inch).

7 12
Insert Bore in the cylinder head for seat insert is 47.950 ± 0.025 mm (1.8878 ± 0.0010 inch).
UENR0996-03 93
i07526179

SMCS Code: 1105
S/N: NJH1–Up
S/N: ECM1–Up
Typical example
Table 63


A - -
(1.38 ± 0.02 inch).

(continued)
94 UENR0996-03
(Table 63, contd)

6 12
Insert Bore in the cylinder head for valve seat insert is 42.774 ± 0.025 mm (1.6840 ± 0.0010 inch).

7 12
Insert Bore in the cylinder head for seat insert is 47.950 ± 0.025 mm (1.8878 ± 0.0010 inch).
UENR0996-03 95
i04562833
Cylinder Head
SMCS Code: 1100
S/N: NJH1–Up
S/N: ECM1–Up
Table 64
Specification for 274-1953 Cylinder Head Gp and 235-2974 Cylinder Head Gp
The following bolts are 194 mm (7.6 inch) long: bolt 1 through bolt 10, 15, 17, 19, 21, 23, and 25
The following bolts are 215.9 mm (8.5 inch) long: bolt 11 through bolt 14, 16, 18, 20, 22, 24, and 26
Apply 6V-4876 Lubricant to the bolt threads and both sides of the hard washers.
Use the following procedure to tighten the bolts of the cylinder head:
Tighten the bolt 1 through bolt 26 in a numerical sequence to 270 ± 15 N·m (200 ± 11 lb ft).
- - -
Again, tighten the bolt 1 through bolt 26 in a numerical sequence to 450 ± 15 N·m (330 ± 11 lb ft).
The flatness of the cylinder head should be within a total of 0.13 mm (0.005 inch). Also, the flat-
ness of the cylinder head should be within a maximum of 0.05 mm (0.002 inch) for any 150 mm
(6.0 inch) span.
96 UENR0996-03
Table 65
Cylinder head thickness:

A - - Thickness of a new cylinder head is 120.00 ± 0.15 mm (4.724 ± 0.006 inch)
Minimum thickness of a used cylinder head is 119.50 mm (4.705 inch)
UENR0996-03 97
(1) Sleeve bearing joint (3) Oil holes

(2) Oil gallery (4) Sleeve bearing
NOTICE
Camshaft bearings must be installed into their correct
position. Failure to do so will result in engine
damage.
98 UENR0996-03
Table 66
B - - Orientation of the sleeve bearing joint is 20 ± 5 degrees above horizontal
C - - Bore for camshaft sleeve bearing is 90.985 ± 0.020 mm (3.5821 ± 0.0008 inch)
UENR0996-03 99
Table 67
The depth of installation of the sleeve bearings is important. Install sleeve bearings to the following
depths:
Dimension (D): 8.0 ± 0.5 mm (0.31 ± 0.02 inch)
Dimension (E): 178.1 ± 0.5 mm (7.01 ± 0.02 inch)
4 7 216-5582 Bushing Dimension (F): 349.5 ± 0.5 mm (13.76 ± 0.02 inch)
Dimension (G): 521.0 ± 0.5 mm (20.51 ± 0.02 inch)
Dimension (H): 692.4 ± 0.5 mm (27.26 ± 0.02 inch)
Dimension (J): 863.8 ± 0.5 mm (34.01 ± 0.02 inch)
Dimension (K): 1035.3 ± 0.5 mm (40.76 ± 0.02 inch)
100 UENR0996-03
Table 68
Before assembly, apply 4C-9506 Retaining Compound to press fit diameter of the lower end of
5 - - six injector sleeves.
Press the injector sleeve to the bottom of the face (6).
V - - Installation depth for the cup plugs is 4.25 ± 0.25 mm (0.167 ± 0.010 inch)
W - - Installation depth for the cup plugs is 1.25 ± 0.25 mm (0.049 ± 0.010 inch)
UENR0996-03 101
i04849288
Cylinder Head
SMCS Code: 1100
S/N: NJH1–Up
S/N: ECM1–Up
Table 69
Specification for 223-7263 Cylinder Head
Use the following procedure in order to tighten the bolts of the cylinder head:
The following bolts are 194 mm (7.6 inch) long: Bolt 1 through bolt 10, 15, 17, 19, 21, 23, and 25.
The following bolts are 215.9 mm (8.50 inch) long: Bolt 11 through bolt 14, 16, 18, 20, 22, 24, and
1 16 124-1855 Bolt 26.
1. Apply 6V-4876 Lubricant to the bolt threads and both sides of the hard washers.
2. Tighten the bolt 1 through bolt 26 in a numerical sequence to 270 ± 15 N·m (199 ± 11 lb ft).
3. Tighten the bolt 1 through bolt 26 in a numerical sequence to 450 ± 15 N·m (332 ± 11 lb ft).
4. Again, tighten the bolt 1 through bolt 26 in a numerical sequence to 450 ± 15 N·m
2 10 124-1854 Bolt (332 ± 11 lb ft).
102 UENR0996-03
Top view
Table 70
Before assembly, apply High Strength or High Temperature Anaerobic Flange Sealant to the
3 20 3B-0645 Cup Plug surfaces.
Installation depth is 1.25 ± 0.25 mm (0.050 ± 0.010 inch).
Before assembly, apply green Loctite 620 to press fit diameter of the lower end of injector
5 6 263-4920 Injector Sleeve sleeves.
Press the injector sleeve until the injector sleeve bottoms of the face (6).
UENR0996-03 103
Section A-A
Table 71
Refer Illustration 97 for installation depth of the camshaft bushing:

Dimension (H) is 8.0 ± 0.5 mm (0.31 ± 0.02 inch).
Dimension (J) is 178.1 ± 0.5 mm (7.01 ± 0.02 inch).
Dimension (K) is 349.5 ± 0.5 mm (13.76 ± 0.02 inch).
- 7 216-5582 Bushing
Dimension (L) is 521.0 ± 0.5 mm (20.51 ± 0.02 inch).
Dimension (M) is 692.4 ± 0.5 mm (27.26 ± 0.02 inch).
Dimension (N) is 863.8 ± 0.5 mm (34.01 ± 0.02 inch).
Dimension (P) is 1035.3 ± 0.5 mm (40.76 ± 0.02 inch).
Table 72
R - - Bore for camshaft bushing is 90.985 ± 0.020 mm (3.5821 ± 0.0008 inch).
S - - Orientation of the bushing joint is 20 ± 5 degrees above horizontal.
- - - New cylinder head thickness is 120.00 ± 0.15 mm (4.724 ± 0.006 inch).

104 UENR0996-03
i05303625
Cylinder Head
SMCS Code: 1100
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 73
Use the following procedure in order to tighten the cylinder head bolts. Refer to Illustration 99 for
the tightening sequence:
1 16 124-1855 Bolt The following bolts are 194 mm (7.6 inch) long: Bolt 1 through bolt 10, 15, 17, 19, 21, 23, and 25.
The following bolts are 215.9 mm (8.50 inch) long: Bolt 11 through bolt 14, 16, 18, 20, 22, 24, and
26.
1. Apply 6V-4876 Lubricant to the bolt threads and both sides of the hard washers.
2. Tighten bolt 1 through bolt 26 in a numerical sequence to 270 ± 15 N·m (199 ± 11 lb ft).
2 10 124-1854 Bolt 4. Again, tighten bolt 1 through bolt 26 in a numerical sequence to 450 ± 15 N·m (332 ± 11 lb ft).
UENR0996-03 105

Top view
Table 74
Before assembly, apply Loctite 11358 to the bores for the cup plug.
3 20 3B-0645 Cup Plug
4 - 3B-0623 Cup Plug Before assembly, apply Loctite 11358 to the bores for the cup plug.
Before assembly, lubricate the bore lightly with 15W-40 clean engine oil immediately prior to
5 12 166-2904 O-Ring Seal
assembly.
Before assembly, apply green Loctite 620 to press fit diameter of the lower end of injector
6 6 263-4920 Injector Sleeve sleeves.
Press the injector sleeve until the injector sleeve bottoms the face (7).
106 UENR0996-03

Section A-A
Table 75
Refer Illustration 101 for Install the camshaft bushing at the following dimension:
- 7 216-5582 Bushing
Dimension (L) is 521.0 ± 0.5 mm (20.51 ± 0.02 inch).
Dimension (M) is 692.4 ± 0.5 mm (27.26 ± 0.02 inch).
Dimension (N) is 863.8 ± 0.5 mm (34.01 ± 0.02 inch).
Dimension (P) is 1035.3 ± 0.5 mm (40.76 ± 0.02 inch).
Table 76
R - - Bore for camshaft bushing is 90.985 ± 0.020 mm (3.5821 ± 0.0008 inch).
S - - Orientation of the bushing joint is 20 ± 5 degrees above horizontal.
- - - New cylinder head thickness is 120.00 ± 0.15 mm (4.724 ± 0.006 inch).

UENR0996-03 107
i06059660
Cylinder Head
SMCS Code: 1100
S/N: NJH1–Up
S/N: ECM1–Up

Bolt tightening sequence
Note: Examine bolts (1) for wear or for damage.

Refer to Reuse And Salvage Guidelines, SEBF8301,
“Inspection and Reuse of Critical Fasteners Used in
All Engines”. Replace with new bolts (1), if
necessary.
Table 77
(continued)
108 UENR0996-03
(Table 77, contd)
Use the following procedure in order to tighten the cylinder head bolts:
Refer to the Illustration 103 for cylinder head bolt tightening sequence.
290-6884 Cylinder Head Lightly lubricate the threads of the bolts with clean engine oil before assembly.
1 26
Fastener Gp 1. Tighten bolt 1 through bolt 26 in a numerical sequence to 160 ± 15 N·m (118 ± 11 lb ft).
2. Again, tighten bolt 1 through bolt 26 in a numerical sequence to 160 ± 15 N·m
(118 ± 11 lb ft).
3. Place a mark on bolt 1 through bolt 26. Tighten bolt 1 through bolt 26 in a numerical se-
quence to an angle of 90 degrees (1/4 turn).
4. Loosen bolt 1 through bolt 26 until the washers are loose under the bolt heads.
6. Again, tighten bolt 1 through bolt 26 in a numerical sequence to 160 ± 15 N·m
(118 ± 11 lb ft).
2 6 9X-6000 Bolt 7. Place a mark on bolt 1 through bolt 26. Tighten bolt 1 through bolt 26 in a numerical se-
quence to an angle of 90 degrees (1/4 turn).
- - - Height of the new cylinder head is 163.00 ± 0.15 mm (6.417 ± 0.006 inch).
UENR0996-03 109
Table 78
3 5 8M-5860 Cup Plug Before installation, apply Loctite 11358 to the bores for the cup plugs.
4 6 3B-0623 Cup Plug Before installation, apply Loctite 11358 to the bores for the cup plugs.
7 6 310-7258 O-Ring Seal Before assembly, apply clean engine oil to the bores.
8 6 310-7259 O-Ring Seal Before assembly, apply clean engine oil to the bores.
Before assembly, apply green Loctite 620 on the outside surface of the in-
9 6 325-6575 Injector Sleeve
jector sleeve to a distance (H).
(continued)
110 UENR0996-03
(Table 78, contd)

E - - Installation depth for cup plug (3) is 1.25 ± 0.25 mm (0.049 ± 0.010 inch).
F - - Installation depth for cup plug (4) is 3.75 ± 0.50 mm (0.148 ± 0.020 inch).
G - - Installation depth for cup plug (5) is 1.00 ± 0.50 mm (0.039 ± 0.020 inch).
UENR0996-03 111
i06753533
Cylinder Head
SMCS Code: 1100
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 274-1953
S/N: L4D1–Up
Part No.: 274-1953
S/N: L4E1–Up
Part No.: 274-1953
S/N: L4F1–Up
Part No.: 345-2206
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
112 UENR0996-03
Table 79
Specification for 263-5054 Cylinder Head Gp and 223-7263 Cylinder Head

Apply black Loctite Graphite-50 to the bolt threads and both sides of the hard washers.
Use the following procedure to tighten the bolts of the cylinder head:
- - -
The flatness of the cylinder head should be within a total of 0.13 mm (0.005 inch). Also, the flat-
ness of the cylinder head should be within a maximum of 0.05 mm (0.002 inch) for any 150 mm
(6.0 inch) span.
Table 80

Cylinder head thickness:
A - - Thickness of a new cylinder head is 120.00 ± 0.15 mm (4.724 ± 0.006 inch)
Minimum thickness of a used cylinder head is 119.50 mm (4.705 inch)
UENR0996-03 113
(1) Sleeve bearing joint (3) Oil holes

(2) Oil gallery (4) Sleeve bearing
NOTICE
damage.
114 UENR0996-03
Table 81
B - - Orientation of the sleeve bearing joint is 20 ± 5 degrees above horizontal
C - - Bore for camshaft sleeve bearing is 90.985 ± 0.020 mm (3.5821 ± 0.0008 inch)
UENR0996-03 115
Table 82

The depth of installation of the sleeve bearings is important. Install sleeve bearings to the following
depths:
Dimension (D): 8.0 ± 0.5 mm (0.31 ± 0.02 inch)
Dimension (E): 178.1 ± 0.5 mm (7.01 ± 0.02 inch)
4 7 216-5582 Bushing Dimension (F): 349.5 ± 0.5 mm (13.76 ± 0.02 inch)
Dimension (G): 521.0 ± 0.5 mm (20.51 ± 0.02 inch)
Dimension (H): 692.4 ± 0.5 mm (27.26 ± 0.02 inch)
Dimension (J): 863.8 ± 0.5 mm (34.01 ± 0.02 inch)
Dimension (K): 1035.3 ± 0.5 mm (40.76 ± 0.02 inch)
116 UENR0996-03
Table 83

Before assembly, apply 4C-9506 Retaining Compound to press fit diameter of the lower end of
5 - - six injector sleeves.
Press the injector sleeve to the bottom of the face (6).
V - - Installation depth for the cup plugs is 1.25 ± 0.25 mm (0.050 ± 0.010 inch)
UENR0996-03 117
i06803367
Cylinder Head
SMCS Code: 1100
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Top view of cylinder head
Table 84

Before assembly, lubricate the threads of the bolts and both sides of the washers with
4C-5593 Thread Lubricant.
Use the following procedure to tighten the bolts:
- 26 242-1811 Bolt
1. Torque bolt 1 through bolt 26 in a numerical sequence to 170 ± 10 N·m
(125 ± 7 lb ft) as shown in Illustration 111 .
2. Torque again bolt 1 through bolt 26 in a numerical sequence to 170 ± 10 N·m
3. Turn bolt 1 through bolt 26 in a numerical sequence to an extra 120 ± 5 degrees as
shown in Illustration 111 .
4. Loosen bolt 1 through bolt 26 to 0 N.m (0 lb ft).
5. Torque bolt 1 through bolt 26 in a numerical sequence to 170 ± 10 N·m
- 8 210-4460 Bolt 6. Torque again bolt 1 through bolt 26 in a numerical sequence to 170 ± 10 N·m
7. Turn bolt 1 through bolt 26 in a numerical sequence to an extra 120 ± 5 degrees as
8. Torque bolt 27 through 34 in a numerical sequence to 55 ± 10 N·m (41 ± 7 lb ft) as
Top gasket face of cylinder block, cylinder liners, and bottom gasket face of cylinder head must be free of oil, fuel, water, and other contami-
nants before assembly.
118 UENR0996-03

Top view of cylinder head
UENR0996-03 119
Table 85

Installation depth (M) is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).
- 35 3B-0623 Cup Plug
Installation depth (N) is 3.0 ± 1.0 mm (0.12 ± 0.04 inch).
Apply Loctite 11358 to the bores for the cup plugs prior to the installation.
120 UENR0996-03
i07502984
Cylinder Head
SMCS Code: 1100
S/N: NJH1–Up
S/N: ECM1–Up

Tightening Sequence
Table 86
6I-4025 Cylinder
16 Head Fastener Gp Use the following procedure to tighten the bolts of the cylinder head:
-
10 106-5673 Cylinder Tighten the bolt 1 through bolt 26 in a numerical sequence to 270 ± 15 N·m (200 ± 11 lb ft).
Head Fastener Gp
UENR0996-03 121
Table 87
A - - Thickness of a new cylinder head is 120.00 ± 0.15 mm (4.724 ± 0.006 inch).

122 UENR0996-03
Table 88
Camshaft bushing must be installed into the correct position. Failure to do so will result in engine damage.
B - - Orientation of the bushing joint is 20 ± 5 degrees above horizontal.
C - - Bore for camshaft bushing is 90.985 ± 0.020 mm (3.5821 ± 0.0008 inch).

UENR0996-03 123
Table 89
The installation depth of bushing is important. Install bushing to the following

depths:
Dimension (D) is 8.0 ± 0.5 mm (0.31 ± 0.02 inch).
Dimension (E) is 178.1 ± 0.5 mm (7.01 ± 0.02 inch).
216-5582 Bushing Dimension (F) is 349.5 ± 0.5 mm (13.76 ± 0.02 inch).

1 7
Dimension (G) is 521.0 ± 0.5 mm (20.51 ± 0.02 inch).
i03875003 S/N: NJH1–Up
Compression Brake
SMCS Code: 1119; 1129
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 322-8542
S/N: L4D1–Up
Part No.: 322-8542
S/N: L4E1–Up
Part No.: 322-8542
S/N: L4F1–Up
Part No.: 322-8542
S/N: TWG1–Up
124 UENR0996-03
Illustration 118 g01525616 Illustration 119 g01525613

Top view Right side view
Note: Refer to Testing and Adjusting, “CAT

Compression Brake Lash - Adjust” in order to obtain
the correct procedure for setting the lash on the
compression brake.
(1) Use the following procedure to tighten the
locknuts:
1. Set the lash for the CAT compression brake to
0.686 ± 0.050 mm (0.0270 ± 0.0020 inch).
2. Tighten the locknut on the adjustment screw to
15 ± 3 N·m (11 ± 2 lb ft).
Use the following procedure to tighten the nine studs
(2) :
1. Tighten the studs in the numerical sequence that is
shown in Illustration 119 to 50 ± 5 N·m
(37 ± 4 lb ft).
2. Turn the studs to an additional 45 ± 5 degrees.
(3) Torque for three taperlock studs . . . . 65 ± 10 N·m

((48 ± 7 lb ft))
UENR0996-03 125

Tightening sequence for CAT compression brake
Use the following steps in order to install the housing

for the CAT compression brake onto the cylinder
head:
1. Place the housing over the mounting studs. Finger
tighten the mounting stud nuts and the mounting
bolt.
2. Torque the CAT compression brake to the cylinder
head by using the numerical sequence that is
3. Torque the CAT compression brake again by using
the same numerical sequence.
126 UENR0996-03
i04381891
Compression Brake
(If Equipped)
SMCS Code: 1119; 1129
S/N: NJH1–Up
S/N: ECM1–Up

Top view

Right side view
Table 90
Specification for 233-7245 Valve Actuator Gp, and 276-0034 Valve Actuator Gp
(continued)
UENR0996-03 127
(Table 90, contd)

Use the following procedure to tighten the locknuts:
1. Set the lash for the CAT compression brake to 0.686 ± 0.050 mm
1 6 235-1088 Nut
(0.0270 ± 0.0020 inch).
2. Tighten the locknut on the adjustment screw to 15 ± 3 N·m (133 ± 27 lb in).
Use the following procedure to tighten the studs:

1. Tighten the studs in a numerical sequence as shown in Illustration 122 to
2 9 304-9553 Stud
50 ± 5 N·m (37 ± 4 lb ft).
2. Turn the studs to an additional 45 ± 5 degrees.
3 3 8T-7062 Taperlock Stud Torque to 65 ± 10 N·m (48 ± 7 lb ft).
Refer to Testing and Adjusting, “CAT Compression Brake Lash - Adjust” in order to obtain the correct procedure for setting the lash on the com-
pression brake.

Tightening sequence for CAT compression brake
Table 91
Specification for 233-7245 Valve Actuator Gp, and 276-0034 Valve Actuator Gp
Use the following steps in order to install the housing for the CAT compression brake on the cylinder head:
1. Place the housing over the mounting studs. Finger tighten the mounting stud nuts and the mounting bolt.
2. Tighten the CAT compression brake to the cylinder head by using the numerical sequence that is shown in Illustration 123 .
3. Again tighten the CAT compression brake by using the same numerical sequence.
128 UENR0996-03
i05198186
Compression Brake
SMCS Code: 1119; 1129
S/N: NJH1–Up
S/N: ECM1–Up

Tightening Sequence
Table 92
Specification for 304-3851 Valve Actuator Gp and 304-3850 Valve Actuator Gp
Refer to Testing and Adjusting, “Compression Brake Lash - Adjust”, in order to obtain the
- - - correct procedure for setting the lash on the compression brake.
Lash setting is 0.9 ± 0.2 mm (0.03 ± 0.01 inch).
1 11 208-9300 Tighten bolt (1) through bolt (11) in the numerical sequence to 55 ± 10 N·m (41 ± 7 lb ft).
Table 93
Specification for 304-3851 Valve Actuator Gp
12 - 8C-6437 Nut Torque to 50 ± 10 N·m (37 ± 7 lb ft).

UENR0996-03 129

Section B-B
Table 94
13 - 8C-6437 Nut Torque to 50 ± 10 N·m (37 ± 7 lb ft).

Section A-A
Table 95
14 6 230-9425 Check Valve Gp Torque to 25 ± 6 N·m (221 ± 53 lb in).

130 UENR0996-03

Section C-C
Table 96
15 1 277-8537 Quill Torque to 40 ± 5 N·m (30 ± 4 lb ft).

View D-D
Table 97
16 2 236-5958 Bolt Torque to 6 ± 1 N·m (53 ± 9 lb in).

UENR0996-03 131
i03563140 i03916090
Turbocharger Turbocharger
SMCS Code: 1052 SMCS Code: 1052
S/N: NJH1–Up S/N: NJH1–Up

S/N: ECM1–Up S/N: ECM1–Up

Typical example Typical example
(1) Torque for the compressor clamp assembly Note: Before assembly, lubricate the threads and the
. . . . . . . . . . . . . . . . .13.5 ± 1 N·m ((119.5 ± 8.9 lb in)) bearing surface of the locknuts with 4C-5599 Anti-
Seize Compound.
Use the following procedure to tighten the turbine
clamp assembly (2) : (1) Torque for locknuts . . . .55 ± 5 N·m ((41 ± 4 lb ft))
1. Tighten the turbine clamp assembly to 18.1 N·m (2) Torque for the compressor clamp assembly
(160.2 lb in). . . . . . . . . . . . . . . 13.6 ± 1.2 N·m ((120.4 ± 10.6 lb in))
2. Loosen the turbine clamp assembly to 5.6 N·m Use the following procedure to tighten the turbine
(49.6 lb in). clamp assembly (3) :
3. Again, tighten the turbine clamp assembly to 1. Tighten the turbine clamp assembly to 18.1 N·m
13.5 ± 1 N·m (119.5 ± 8.9 lb in). (160.2 lb in).
Wastegate setting . . . . . . . . . . . . . . . 151.7 ± 3.4 kPa 2. Loosen the turbine clamp assembly to 5.6 N·m
((22.0 ± 0.5 psi)) (49.6 lb in).
3. Again, tighten the turbine clamp assembly to
13.6 ± 1.2 N·m (120.4 ± 10.6 lb in).
Wastegate setting . . . . . . . . . . . . . . . 165.5 ± 3.4 kPa

((24.0 ± 0.5 psi))
132 UENR0996-03
i03918731 i03920895
Turbocharger Turbocharger


Typical example Typical example
Note: Before assembly, lubricate the threads and the Note: Before assembly, lubricate the threads and the
bearing surface of the locknuts with 4C-5599 Anti- bearing surface of the locknuts with 4C-5599 Anti-
Seize Compound. Seize Compound.
(1) Torque for locknuts . . . .55 ± 5 N·m ((41 ± 4 lb ft)) (1) Torque for locknuts . . . .55 ± 5 N·m ((41 ± 4 lb ft))
(2) Torque for the compressor clamp assembly (2) Torque for the compressor clamp assembly
. . . . . . . . . . . . . . 13.6 ± 1.2 N·m ((120.4 ± 10.6 lb in)) . . . . . . . . . . . . . . 13.6 ± 1.2 N·m ((120.4 ± 10.6 lb in))
Use the following procedure to tighten the turbine Use the following procedure to tighten the turbine
clamp assembly (3) : clamp assembly (3) :
1. Tighten the turbine clamp assembly to 18.1 N·m 1. Tighten the turbine clamp assembly to 18.1 N·m
(160.2 lb in). (160.2 lb in).
2. Loosen the turbine clamp assembly to 5.6 N·m 2. Loosen the turbine clamp assembly to 5.6 N·m
(49.6 lb in). (49.6 lb in).
3. Again, tighten the turbine clamp assembly to 3. Again, tighten the turbine clamp assembly to
13.6 ± 1.2 N·m (120.4 ± 10.6 lb in). 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in).
Wastegate setting . . . . . . . . . . . . . . . 158.6 ± 3.4 kPa Wastegate setting . . . . . . . . . . . . . . . 125.5 ± 3.4 kPa
((23.0 ± 0.5 psi)) ((18.2 ± 0.5 psi))
UENR0996-03 133
i04408745
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
134 UENR0996-03
Table 98
Specification for 239-5953 Turbocharger Gp and 260-3601 Turbocharger Gp
Use the following procedure to tighten the turbine clamp assembly:

1. Torque to 18.1 N·m (160.2 lb in).
1 1 9N-2038 Turbine Clamp As
2. Loosen to 1 to 2 turns.
3. Again, torque to 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in).
2 - - Opening pressure of the wastegate is 142.0 ± 3.5 kPa (20.6 ± 0.5 psi).
3 - 7W-2297 Clamp As Torque to 13.5 ± 1.0 N·m (119.5 ± 9.0 lb in).
Before assembly, apply Loctite C5A copper anti-size to the threads.

4 4 375-2467 Flange Locknut
Torque to 70 ± 5 N·m (52 ± 4 lb ft).
UENR0996-03 135
i04411173
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
136 UENR0996-03
Table 99
Specification for 262-0974 Turbocharger Gp

1. Torque to 18.1 N·m (160.2 lb in).
2. Loosen to 5.6 N·m (49.6 lb in).
(continued)
UENR0996-03 137
(Table 99, contd)

Before assembly, apply Loctite C5A copper anti-size to the threads of the
4 4 2N-2765 High Temperature Bolt locknuts.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
138 UENR0996-03
i04458230
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 139
Table 100

1. Torque to 18.1 N·m (160.2 lb in).
Before assembly, apply Loctite C5A copper anti-size to the threads of the locknuts.
4 4 2N-2765 High Temperature Bolt
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
140 UENR0996-03
i04458276
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 141
Table 101

1. Torque to 18.1 N·m (160.2 lb in).
3 - 7W-2297 Clamp As Torque for the clamp assembly is 13.5 ± 1.2 N·m (119.5 ± 10.6 lb in).

Torque to 55 ± 5 N·m (41 ± 4 lb ft).
142 UENR0996-03
i04458454
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 143
Table 102

1. Torque to 18.1 N·m (160.2 lb in).
3 - 268-2960 Clamp As Torque to 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in).

Torque to 55 ± 5 N·m (41 ± 4 lb ft).
144 UENR0996-03
i04458476
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 145
Table 103

1. Torque to 18.1 N·m (160.2 lb in).
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
146 UENR0996-03
i04458479
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 147
Table 104
(continued)
148 UENR0996-03
(Table 104, contd)

1. Torque to 18.1 N·m (160.2 lb in).

Torque to 55 N·m (41 lb ft).
UENR0996-03 149
i04461810
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
150 UENR0996-03
Table 105

1. Torque to 18.1 N·m (160.2 lb in).

Torque to 70 ± 5 N·m (52 ± 4 lb ft).
UENR0996-03 151
i04461833
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
152 UENR0996-03
Table 106

1. Torque to 18.1 N·m (160.2 lb in).

4 4 2N-2766 Locknut
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
UENR0996-03 153
i04461838
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
154 UENR0996-03
Table 107
Specifications for 296-7642 Turbocharger Gp

1. Tighten to 18.1 N·m (160.2 lb in).
3. Again, tighten to 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in).
3 1 268-2960 Clamp As Torque to 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in)
Before assembly, apply Loctite C5A copper anti-seize to the threads.

4 4 -
Torque the nuts to 55 ± 5 N·m (41 ± 4 lb ft).
UENR0996-03 155
i04461851
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
156 UENR0996-03
Table 108

1. Torque to 18.1 N·m (160.2 lb in).
(continued)
UENR0996-03 157
(Table 108, contd)

4 4 2N-2766 Locknut locknuts.
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
158 UENR0996-03
i04555824
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 159
Table 109

1. Torque to 18.1 N·m (160.2 lb in).
3 - 268-2960 Clamp As Torque to 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in)

Torque to 70 ± 5 N·m (52 ± 4 lb ft).
160 UENR0996-03
i04852075
Turbocharger
SMCS Code: 1052
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 345-9009
S/N: L4D1–Up
Part No.: 345-9009
S/N: L4E1–Up
Part No.: 345-9009
S/N: L4F1–Up
S/N: NJH1–Up

Right side view
Table 110
Before assembly, lubricate the threads and bearing surfaces with Loctite C5A Copper
1 4 375-2467 Flange Locknut Anti-Seize.
Torque to 70 ± 5 N·m (52 ± 4 lb ft).
239-5858 Compressor Clamp

2 1 Tighten the compressor clamp assembly to 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in).
Assembly
Use the following procedure in order to tighten the turbine clamp assembly:
1. Tighten to 18.0 ± 1.6 N·m (159.3 ± 14.2 lb in).
2. Loosen by 1 to 2 turns.
3.Again, tighten to 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in).
UENR0996-03 161
i04912342
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
162 UENR0996-03
Table 111
Specification for 220-6060 Turbocharger Gp, 260-3602 Turbocharger Gp, and 246-6624 Turbocharger Gp

1. Tighten to 18 ± 1.6 N·m (159 ± 14 lb in).
2. Loosen to one to two full turns.
3. Again, tighten to 13.6 ± 1.2 N·m (120 ± 10 lb in).
3 - 268-2960 Clamp As Torque to 13.6 ± 1.2 N·m (120 ± 10 lb in)
Torque to 70 ± 5 N·m (52 ± 4 lb ft).
UENR0996-03 163
i05296451
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Rear view of engine
Table 112
Specification for 374-8294 Turbocharger Gp, 374-8295 Turbocharger Gp, 374-8296 Turbocharger Gp, and 374-8297 Turbo-
charger Gp
Before assembly, lubricate the threads and bearing surfaces with Loctite C5A
375-2467 Flange Locknut copper Anti-Seize.
1 4
Torque to 70 ± 5 N·m (52 ± 4 lb ft).
Tighten the compressor clamp assembly to 13.6 ± 1.2 N·m

- - -
(120.4 ± 10.6 lb in).
Use the following procedure in order to tighten the clamp assembly:
1. Tighten the turbine clamp assembly to 18 N·m (159 lb in).

- - -
2. Loosen by turbine clamp assembly 1 to 2 turns.
3. Again, tighten to the turbine clamp assembly to 13.6 ± 1.2 N·m
(120.4 ± 10.6 lb in).
164 UENR0996-03
i05350411
Turbocharger
SMCS Code: 1052
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 230-7911
S/N: L4D1–Up
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 165
Table 113

1. Torque to 18.0 ± 1.6 N·m (159.3 ± 14.2 lb in).
2. Loosen 1 to 2 turns.
(continued)
166 UENR0996-03
(Table 113, contd)

4 4 2N-2766 Locknut locknuts.
Torque to 70 ± 5 N·m (52 ± 4 lb ft).
UENR0996-03 167
i05543509
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Table 114
Specification for 364-4498 Turbocharger Gp, and 364-4501 Turbocharger Gp

1 1 Torque to 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in)
Assembly
(continued)
168 UENR0996-03
(Table 114, contd)

Use the following procedure to tighten the band clamp:
2 1 361-7980 Band Clamp 1. Tighten the clamp to 18.0 ± 1.6 N·m (159.3 ± 14.2 lb in).
2. Loosen the clamp one to two turns.
3. Again tighten the clamp to 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in).
3 4 375-2467 Flange Locknut Copper Anti-Seize.
Torque to 70 ± 5 N·m (52 ± 4 lb ft).
UENR0996-03 169
i05543550
Turbocharger
SMCS Code: 1052
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
170 UENR0996-03
Table 115
1 1 7W-2297 Clamp As Torque to 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in)
2 1 9N-2038 Turbine Clamp As 1. Tighten the clamp to 18.0 ± 1.6 N·m (159.3 ± 14.2 lb in).
Torque to 70 ± 5 N·m (52 ± 4 lb ft).
UENR0996-03 171
i05543590
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
Table 116
2 1 9N-2038 Turbine Clamp As 1. Tighten the clamp to 18.1 N·m (160.2 lb in).
Torque to 70 ± 5 N·m (52 ± 4 lb ft).
172 UENR0996-03
i05578809
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
Table 117

Torque to 70 ± 5 N·m (52 ± 4 lb ft).
2 1 4W-9977 Clamp As Torque to 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in).

1. Torque to 18 N·m (159 lb in).
3 1 243-2504 Turbine Clamp As
2. Loosen to 1 to 2 turns .
UENR0996-03 173
i05755769
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Table 118

1 1 Torque to 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in)
Assembly
(continued)
174 UENR0996-03
(Table 118, contd)

2 1 361-7980 Band Clamp 1. Tighten the clamp to 18.0 ± 1.6 N·m (159.3 ± 14.2 lb in).
Torque to 70 ± 5 N·m (52 ± 4 lb ft).
UENR0996-03 175
i05755785
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Table 119
Torque to 70 ± 5 N·m (52 ± 4 lb ft).
176 UENR0996-03

392-7914 Turbocharger Gp
Table 120
2 - 268-2960 Clamp As Torque to 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in)
UENR0996-03 177
i05758198
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
Table 121

1 1 Torque to 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in).
Assembly
Before assembly, lubricate the threads and bearing surfaces with Loctite C5A copper
2 4 9X-6620 Locknut anti-seize.
Torque to 70 ± 5 N·m (52 ± 4 lb ft).
Use the following procedure in order to tighten the turbine clamp assembly:
(1.) Tighten the band clamp to 18.0 ± 1.6 N·m (159.3 ± 14.2 lb in).
3 1 243-2504 Turbine Clamp As
(2.) Loosen the band clamp by one to two turns.
(3.) Again, tighten the band clamp to 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in).
178 UENR0996-03
i05808596
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
Table 122

Torque to 70 ± 5 N·m (52 ± 4 lb ft).
UENR0996-03 179
Table 123
Tighten the compressor clamp assembly to 13.6 ± 1.2 N·m

2 1 -
(120.4 ± 10.6 lb in).

1. Tighten to 18.1 N·m (160.2 lb in).
3 1 -
3. Again, tighten to 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in).
i06606858
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
(1) Torque for the compressor clamp assembly

. . . . . . . . . . . . . . . . .13.5 ± 1 N·m ((119.5 ± 8.9 lb in))
180 UENR0996-03
Use the following procedure to tighten the turbine

clamp assembly (2) :
1. Tighten the turbine clamp assembly to 18.1 N·m
(160.2 lb in).
2. Loosen the turbine clamp assembly to 5.6 N·m
(49.6 lb in).
3. Again, tighten the turbine clamp assembly to
13.5 ± 1 N·m (119.5 ± 8.9 lb in).
Wastegate setting . . . . . . . . . . . . . . . 151.7 ± 3.4 kPa

((22.0 ± 0.5 psi))
UENR0996-03 181
i06633431
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
Table 124

1. Torque to 18.1 N·m (160.2 lb in).
1 - -
2 - - Torque to 13.6 ± 1.2 N·m (120.4 ± 10.6 lb in).

182 UENR0996-03
Table 125

Torque to 70 ± 5 N·m (52 ± 4 lb ft).
UENR0996-03 183
i06860333
Turbocharger
SMCS Code: 1052
S/N: NJH1–Up
S/N: ECM1–Up
Table 126

Torque to 70 ± 5 N·m (52 ± 4 lb ft).
i03920091
Exhaust Gas Valve (NRS)

SMCS Code: 3139; 5137; 5479
S/N: NJH1–Up
S/N: ECM1–Up
184 UENR0996-03
(1) Torque for the nut . . . . .20 ± 2.5 N·m ((15 ± 2lb ft))
(2) Torque for the valve . . . .50 ± 5 N·m ((37 ± 4 lb ft))

UENR0996-03 185
i05301094
Exhaust Gas Valve (NRS)

SMCS Code: 3139; 5137; 5479
S/N: NJH1–Up
S/N: ECM1–Up
Table 127
Specification for 337-7323 Exhaust Gas Valve Gp (NRS)
1 1 338-1913 Rotary Actuator Lubricate the rotary actuator housing with 5P-3975 Rubber Lubricant.
186 UENR0996-03
Table 128
2 1 342-0636 Solenoid Valve Gp Torque to 50 ± 5 N·m (37 ± 4 lb ft).
3 1 198-2914 Nut Torque to 20.0 ± 2.5 N·m (177.0 ± 22.1 lb in).
4 1 316-1438 Cartridge As Torque to 35 ± 3 N·m (26 ± 2 lb ft).

UENR0996-03 187
340-7208 Exhaust Gas Valve Gp

(NRS)
Table 129
Specification for 340-7208 Exhaust Gas Valve Gp (NRS)
5 1 342-1679 Throttle Shaft Lubricate with 5P-3975 Rubber Lubricant.
6 2 342-1682 Screw Torque to 3.5 ± 0.5 N·m (31.0 ± 4.4 lb in).
i02905350
Exhaust Manifold
SMCS Code: 1059
S/N: NJH1–Up
S/N: ECM1–Up
188 UENR0996-03
i03922646
Exhaust Manifold
SMCS Code: 1059
S/N: NJH1–Up
S/N: ECM1–Up
(1) Apply 4C-5599 Anti-Seize Compound to the

threads of the locknuts and the bearing surface of the
locknuts and the washers before assembly.
(2) Install the gasket with the tab downward, as
shown.
(3) Torque for the four taperlock studs . . . 35 ± 5 N·m

((26 ± 4 lb ft)) Illustration 183 g02151874
(4) Torque for the 12 taperlock studs . . . . 35 ± 5 N·m Note: Before you apply sealant, the male end and
((26 ± 4 lb ft)) the female end of the exhaust manifold must be free
from the following substance:dirt, rust, grease and oil.
Apply a thin coat of 3M sealer EC - 1137 to the
outside diameter and inside diameter of the exhaust
manifolds. Remove excess sealer from the
assembled joint.
(2) Torque for taperlock studs . . . . . . . . . . 38 ± 5 N·m

((28 ± 4 lb ft))
Note: Use assembly spacers at positions 11, 7 and 9
to align the exhaust manifolds. Remove the assembly
spacers before final assembly.
Note: Before assembly, lubricate the threads and the
bearing surface of the locknuts with 4C-5599 Anti-
Seize Compound.
(3) Tighten the locknut (1) through locknut (12) in the
numerical sequence that is shown in Illustration 183
to 55 ± 5 N·m (41 ± 4 lb ft).
UENR0996-03 189
i03929890
Exhaust Manifold
SMCS Code: 1059
S/N: NJH1–Up
S/N: ECM1–Up
Note: Before you apply sealant, the male end and

the female end of the exhaust manifold must be free
from the following substance:dirt, rust, grease and oil.
Apply a thin coat of 3M sealer EC - 1137 to the
outside diameter and inside diameter of the exhaust
manifolds. Remove excess sealer from the
assembled joint.
(2) Torque for taperlock studs . . . . . . . . . . 35 ± 5 N·m

((26 ± 4 lb ft))
Note: Use assembly spacers at positions 11, 7 and 9
to align the exhaust manifolds. Remove the assembly
spacers before final assembly.
Note: Before assembly, lubricate the threads and the
bearing surface of the locknuts with 4C-5599 Anti-
Seize Compound.
(3) Tighten the locknut (1) through locknut (12) in the
numerical sequence that is shown in Illustration 184
to 55 ± 5 N·m (41 ± 4 lb ft).
190 UENR0996-03
i04383978
Exhaust Manifold
SMCS Code: 1059
S/N: NJH1–Up
S/N: ECM1–Up

Tightening sequence for the locknuts
Table 130
Specification for 237-4291 Exhaust Manifold Gp
106-1792 Taperlock
1 11 Torque to 35 ± 5 N·m (26 ± 4 lb ft)
Stud
(continued)
UENR0996-03 191
(Table 130, contd)

4S-6137 Taperlock
1
Stud
- - Before use apply sealer, the ends of the exhaust manifolds should be clean and free from dirt, rust, grease, and oil.
102-8608 Exhaust Before assembly, apply 2P-2333 High Temperature Sealer to the outer diameter of the male
2 2
Manifold ends of the exhaust manifold. Remove excess sealer from the assembled joint.
263-8511 Exhaust Before assembly, apply 2P-2333 High Temperature Sealer to the inner diameter of the female
3 1
Manifold ends of the exhaust manifold. Remove excess sealer from the assembled joint.
Before assembly, apply 4C-5599 Anti-Seize Compound to the threads.
Refer to Illustration 186 in order to tighten the locknut 1 through locknut 12 to 50 ± 5 N·m
4 12 2N-2766 Locknut
(37 ± 4 lb ft).
Do not reuse.
192 UENR0996-03
i04390173
Exhaust Manifold
SMCS Code: 1059
S/N: NJH1–Up
S/N: ECM1–Up

Tightening sequence
UENR0996-03 193
Table 131
Before assembly, apply 4C-5599 Anti-Seize Compound to the threads and bearing
surfaces.
1 12 9X-6620 Locknut
Torque to 55 ± 5 N·m (41 ± 4 lb ft).
Refer to Illustration 188 for the locknut tightening sequence.
Torque tool speed should not exceed 100 rpm.

2 12 116-3715 Taperlock Stud
Torque to 35 ± 5 N·m (26 ± 4 lb ft).
Assemble the bellows assembly with the “Flow Arrow” toward the NOx Reduction
System (NRS) cooler.
3 1 324-9290 Bellows As The total maximum misalignment of the bellows assembly allowed between the NRS
cooler and the exhaust manifold elbow is 1.5 mm (0.06 inch) lateral and 1.5 mm
(0.06 inch) axial.
Before assembly, apply thin coat of 2P-2333 High Temperature Sealer to the outside
5 1 231-9030 Exhaust Manifold diameter of the male end of the exhaust manifold.
Remove the excess sealer from the assembled joints.
6 6 283-2238 Gasket Install the gasket with tab down as shown in Illustration 187 .
Before assembly, apply thin coat of 2P-2333 High Temperature Sealer to the inside
7 1 350-4502 Exhaust Manifold diameter of the female end of the exhaust manifold.
Torque tool speed should not exceed 100 rpm.

Torque to 35 ± 5 N·m (26 ± 4 lb ft).
Before assembly, apply thin coat of 2P-2333 High Temperature Sealer to the outside
9 1 350-4503 Exhaust Manifold diameter of the male end of the exhaust manifold.
A - - Angle of the V-band clamp is 45 ± 10 degrees.

194 UENR0996-03
i04406771
Exhaust Manifold
SMCS Code: 1059
S/N: NJH1–Up
S/N: ECM1–Up
Table 132
150-1916 Exhaust Before you apply sealant, the male end and the female end of the exhaust manifold must be free
1 1
Manifold from the following substance: dirt, rust, grease, and oil. Apply a thin coat of 3M sealer EC - 1137
133-3359 Exhaust to the outside diameter and inside diameter of the exhaust manifolds. Remove excess sealer from
2 2 the assembled joint.
Manifold
UENR0996-03 195

Tightening sequence
Table 133
106-1792 Taperlock
3 12 Torque to 35 ± 5 N·m (26 ± 4 lb ft)
Stud
Apply Loctite C5A copper anti-seize to the threads.
4 12 2N-2766 Locknut Tighten the locknuts in the numerical sequence that is shown in Illustration 191 to 50 ± 5 N·m
(37 ± 4 lb ft).
196 UENR0996-03
i04407588
Exhaust Manifold
SMCS Code: 1059
S/N: NJH1–Up
S/N: ECM1–Up

Right side view

Tightening sequence
Table 134
146-9445 Exhaust Before you apply sealant, the male end and the female end of the exhaust manifold must be free
1 1
Manifold from the following substance: dirt, rust, grease, and oil. Apply a thin coat of 3M sealer EC - 1137
133-3359 Exhaust to the outside diameter and inside diameter of the exhaust manifolds. Remove excess sealer
2 2 from the assembled joint.
Manifold
3 1 106-1793 Taperlock Stud Torque to 35 ± 5 N·m (26 ± 4 lb ft).
Apply Loctite C5A copper anti-seize to the threads..

5 12 2N-2766 Locknut Tighten the locknuts in the numerical sequence that is shown in Illustration 193 to 50 ± 5 N·m
(37 ± 4 lb ft).
UENR0996-03 197
i04491809
Exhaust Manifold
SMCS Code: 1059
S/N: NJH1–Up
S/N: ECM1–Up
Table 135
Specification for 343-0583 Exhaust Manifold Gp, 343-0584 Exhaust Manifold Gp, and 343-0585 Exhaust Manifold Gp
Before assembly, apply a thin coat of 2P-2333 High Temperature Sealer to

1 2 - the outside diameter of the male end of the exhaust manifold. Remove excess
high temperature sealer from the assembled joint.
2 2 9N-5085 Clamp Torque the clamp nuts to 7.5 ± 1.0 N·m (66.4 ± 8.9 lb in).
Install the gaskets for the exhaust manifold with the tabs toward the cylinder
4 6 161-3411 Gasket
block.
198 UENR0996-03

View A-A

Tightening sequence
Table 136
Specification for 343-0583 Exhaust Manifold Gp, 343-0584 Exhaust Manifold Gp, and 343-0585 Exhaust Manifold Gp
Before assembly, lubricate the threads and bearing surfaces of the locknuts with
Loctite C5A copper anti-seize.
5 12 9X-6620 Locknut
Tighten the locknut in the numerical sequence as shown in the Illustration 196 to
55 ± 5 N·m (41 ± 4 lb ft).

UENR0996-03 199
i04555856
Exhaust Manifold
SMCS Code: 1059
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up

Right side view
Table 137
1 1 336-7595 Exhaust Manifold Before you apply sealant, the male end and the female end of the exhaust
manifold must be free from the following substance: dirt, rust, grease, and
oil. Apply a thin coat of 3M sealer EC - 1137 to the outside diameter and
2 2 133-3359 Exhaust Manifold inside diameter of the exhaust manifolds. Remove excess sealer from the
assembled joint.
200 UENR0996-03

Tightening sequence
Table 138
357-0351 Taper-
3 4 Torque to 35 ± 5 N·m (26 ± 4 lb ft).
lock Stud
106-1792 Taper-
4 12 Torque to 35 ± 5 N·m (26 ± 4 lb ft).
lock Stud
Apply Loctite C5A copper anti-seize to the threads and to the bearing surfaces.
Tighten the locknuts in the numerical sequence that is shown in Illustration 199 to 20 ± 3 N·m
5 12 2N-2766 Locknut (177 ± 27 lb in).
Again tighten the locknuts in the numerical sequence that is shown in Illustration 199 to 50 ± 5 N·m
(37 ± 4 lb ft)
UENR0996-03 201
i05296392
Exhaust Manifold
SMCS Code: 1059
S/N: NJH1–Up
S/N: ECM1–Up

Top view of engine

Tightening sequence
Table 139
(continued)
202 UENR0996-03
(Table 139, contd)

Before assembly, apply thin coat of 2P-2333 High Temperature Sealer to
1 1 133-3359 Exhaust Manifold the OD of Male end manifold and ID of female end manifold. Remove ex-
cess sealer from the assembled joint.
Before assembly, Apply Loctite C5A copper anti-seize to the threads and to
the bearing surfaces.
1. Tighten the locknuts in the numerical sequence to 20 ± 3 N·m
(177 ± 27 lb in) is shown in Illustration 201 .
2. Again tighten the locknuts in the numerical sequence to 50 ± 5 N·m
(37 ± 4 lb ft) is shown in Illustration 201 .
4 2 6V-5843 Bolt Torque to 25 ± 7 N·m (221 ± 62 lb in).



UENR0996-03 203
i05296435
Exhaust Manifold
SMCS Code: 1059
S/N: NJH1–Up
S/N: ECM1–Up

Top view of engine

Tightening sequence
Table 140
(continued)
204 UENR0996-03
(Table 140, contd)

Before assembly, apply thin coat of 2P-2333 High Temperature Sealer to the
1 1 133-3359 Exhaust Manifold OD of Male end manifold and ID of female end manifold .Remove excess seal-
er from the assembled joint.
Before assembly, Apply Loctite C5A copper anti-seize to the threads and to the
bearing surfaces.
Tighten the locknuts in the numerical sequence to 20 ± 3 N·m (177 ± 27 lb in)

that is shown in Illustration to 203 .
Again tighten the locknuts in the numerical sequence to 50 ± 5 N·m
(37 ± 4 lb ft)that is shown in Illustration to 203 .
UENR0996-03 205
i05755869
Exhaust Manifold
SMCS Code: 1059
S/N: NJH1–Up
S/N: ECM1–Up

Tightening sequence
206 UENR0996-03
Table 141

Torque to 35 ± 5 N·m (26 ± 4 lb ft).
Before assembly, apply Loctite C5A copper anti-seize to the threads and to the
bearing surfaces.
1. Tighten the locknuts in the numerical sequence to 20 ± 3 N·m (177 ± 27 lb in) is

Torque to 35 ± 5 N·m (26 ± 4 lb ft).
Before assembly, apply thin coat of 2P-2333 High Temperature Sealer to the OD
4 1 336-1468 Exhaust Manifold of Male end manifold and ID of female end manifold. Remove excess sealer from
the assembled joint.
Assemble the bellows assembly with the “Flow Arrow” towards the NOx Reduction
8 1 324-9290 Bellows As
System (NRS) cooler.
UENR0996-03 207
i05755882
Exhaust Manifold
SMCS Code: 1059
S/N: NJH1–Up
S/N: ECM1–Up

Top view

Tightening sequence
Table 142

Torque to 35 ± 5 N·m (26 ± 4 lb ft).
Before assembly, apply Loctite C5A copper anti-seize to the threads and to the bear-
ing surfaces.
2. Again tighten the locknuts in the numerical sequence to 50 ± 5 N·m (37 ± 4 lb ft) is
Torque to 35 ± 5 N·m (26 ± 4 lb ft).
208 UENR0996-03

Right side view
Table 143
Before assembly, apply thin coat of 2P-2333 High Temperature Sealer to the OD of
4 2 133-3359 Exhaust Manifold Male end manifold and ID of female end manifold. Remove excess sealer from the
assembled joint.
Before assembly, apply thin coat of 2P-2333 High Temperature Sealer to the OD of
5 1 380-8545 Exhaust Manifold Male end manifold and ID of female end manifold. Remove excess sealer from the
assembled joint.
UENR0996-03 209
i05755898
Exhaust Manifold
SMCS Code: 1059
S/N: NJH1–Up
S/N: ECM1–Up

Top view

Tightening sequence
Table 144
(continued)
210 UENR0996-03
(Table 144, contd)

Torque to 35 ± 5 N·m (26 ± 4 lb ft).
Before assembly, apply Loctite C5A copper anti-seize to the threads and to the
bearing surfaces.

Right side view
Table 145

Torque to 35 ± 5 N·m (26 ± 4 lb ft).
UENR0996-03 211
i06633289
Exhaust Manifold
SMCS Code: 1059
S/N: NJH1–Up
S/N: ECM1–Up

Top view of engine

Tightening sequence
212 UENR0996-03
Table 146




UENR0996-03 213
i06860315
Exhaust Manifold
SMCS Code: 1059
S/N: NJH1–Up
S/N: ECM1–Up

Top view of engine

Tightening sequence
214 UENR0996-03
Table 147


UENR0996-03 215
i04854169
Exhaust Manifold Shield

SMCS Code: 1067
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 289-0630
S/N: L4D1–Up
Part No.: 289-0630
S/N: L4E1–Up
Part No.: 289-0630
S/N: L4F1–Up
S/N: NJH1–Up
S/N: ECM1–Up

Right side view of engine
Table 148
Specification for 289-0630 Manifold Shield

216 UENR0996-03
i05198070
Mounting Straps
SMCS Code: 7553
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 342-6381
S/N: L4D1–Up
Part No.: 342-6381
S/N: L4E1–Up
Part No.: 342-6381
S/N: L4F1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 149
Specification for 345-1799 Mounting Strap Gp
Before assembly, lubricate the threads with Loctite C5A copper anti seize compound
1 4 358-3679 Strap
Torque to 15 to 18 N·m (133 to 159 lb in).
i03563404
Camshaft
SMCS Code: 1210
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 217
3. Subtract the base circle (C) from the camshaft lobe

height (B). The difference is the actual camshaft
lobe lift.
i03875030
Camshaft
SMCS Code: 1210
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 318-2352
S/N: L4D1–Up
Part No.: 318-2352
S/N: L4E1–Up
Part No.: 318-2352
S/N: L4F1–Up
Illustration 218 g01350428 Part No.: 318-2352
Top view of engine S/N: TWG1–Up
(1) Diameter of camshaft bearing journal S/N: NJH1–Up

. . . . . . . 77.850 ± 0.025 mm ((3.0650 ± 0.0010 inch)) Note: Before installation of the camshaft, ensure that
the camshaft and the camshaft bearings are clean.
(2) Torque for the bolts . . . .35 ± 8 N·m ((26 ± 6 lb ft))
lubricate the camshaft lobes with a 50/50 mixture of
Rotation of injector lobe for camshaft at zero lift . . 74 8T-2998 Lubricant and clean engine oil. Apply a
thin coat of clean engine oil on the camshaft
to 180 degrees
bearings.

(A) Specified camshaft lobe lift (1) Exhaust lobe
(2) Injector lobe
Exhaust lobe . . . . . . . . 9.417 mm ((0.3707 inch)) (3) Inlet lobe
Inlet lobe . . . . . . . . . . 12.607 mm ((0.4963 inch)) (4) Front of camshaft
Injector lobe . . . . . . . 12.703 mm ((0.5001 inch))
(A) Diameter of camshaft journals . . . . . . . 84.85 mm
Use the following procedure in order to determine the ((3.341 inch))
actual camshaft lobe lift:
1. Measure the camshaft lobe height (B).
2. Measure the base circle (C).
218 UENR0996-03
Use the following procedure in order to determine the

actual lobe lift :
1. Measure the camshaft lobe height (C).
2. Measure the base circle (D).
3. Subtract the base circle (D) from the lobe height
(C). The difference is the actual lobe lift .
(B) Specified camshaft lobe lift
Exhaust lobe . . . . . . . . 8.515 mm ((0.3352 inch))

Injector lobe . . . . . . . 10.913 mm ((0.4296 inch))
Inlet lobe . . . . . . . . . . . 9.431 mm ((0.3713 inch))
The maximum permissible difference between the
actual lobe lift in Step 3 and the specified lobe lift is
0.13 mm (0.005 inch).
UENR0996-03 219
i04383994
Camshaft
SMCS Code: 1210
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
(4) Front of camshaft
Table 150
Specification for 243-0551 Camshaft Gp
A - - Diameter of camshaft bearing journal is 84.850 ± 0.020 mm (3.3405 ± 0.0008 inch).
- - - Lubricate the camshaft bearings with clean engine oil before you install the camshaft.
- - - Lubricate the camshaft lobes with a 50/50 mixture of 8T-2998 Lubricant and clean engine oil.
1 - - Maximum exhaust lobe lift at zero degrees is 8.51521 mm (0.33524 inch).
2 - - Maximum injector lobe lift at zero degrees is 10.33845 mm (0.40702 inch).
3 - - Maximum inlet lobe lift at zero degrees is 9.431116 mm (0.37130 inch).
Use the following procedure to find the actual lobe lift (B):
- - -
(continued)
220 UENR0996-03
(Table 150, contd)
- - - 2. Measure the base circle (D).
3. Subtract the base circle measurement in Step 2 from the camshaft lobe height in Step 1. The dif-
- - -
ference is the actual lobe lift (B).
The maximum permissible difference between the actual lobe lift in Step 3 and the specified cam-
- - -
shaft lobe lift of a new camshaft is ± 0.10 mm (± 0.0034 inch).
Table 151
5 3 119-0036 Flat Head Screw Torque to 13 ± 3 N·m (115 ± 27 lb in).

UENR0996-03 221
i04384022
Camshaft
SMCS Code: 1210
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Table 152
- - -
(continued)
222 UENR0996-03
(Table 152, contd)

- - -
- - -
Table 153

UENR0996-03 223
i04392976
Camshaft
SMCS Code: 1210
S/N: NJH1–Up
S/N: ECM1–Up
Table 154
Specification for 348-9715 Camshaft
- - -
- - -
ference is the actual lobe lift.
- - -
224 UENR0996-03
i04395674
Camshaft
SMCS Code: 1210
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 155
(continued)
UENR0996-03 225
(Table 155, contd)

2. Measure the base circle (D).
3. Subtract the base circle measurement in Step 2 from the camshaft lobe height in Step 1. The difference is the actual lobe lift (B).
4. The maximum permissible difference between the actual lobe lift in Step 3 and the specified camshaft lobe lift of a new camshaft is
± 0.100 mm (± 0.0034 inch).
Lubricate the camshaft bearings with clean engine oil before install the camshaft.
Lubricate the camshaft lobes with a 50/50 mixture of 8T-2998 Lubricant and clean engine oil.

Rear view of engine
Table 156

226 UENR0996-03
i04397369
Camshaft
SMCS Code: 1210
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Table 157
- - -
(continued)
UENR0996-03 227
(Table 157, contd)
- - -
- - -
Table 158

228 UENR0996-03
i04854229
Camshaft
SMCS Code: 1210
S/N: NJH1–Up
S/N: ECM1–Up

Table 159
Before installation of the camshaft, lubricate the cam bearings with clean engine
oil.
2 1 348-2587 Camshaft
Lubricate the camshaft lobes with a 50/50 mixture of 8T-2998 Lubricant and
clean engine oil
A - - Diameter of camshaft journals is 84.85 ± 0.02 mm (3.341 ± 0.001 inch).

UENR0996-03 229
Table 160
Use the following procedure in order to determine the actual camshaft lobe lift (B):
1. Measure camshaft lobe height (C).
3. Subtract the base circle (D) from the camshaft lobe height (C). The difference is the actual
camshaft lobe lift.
Specified camshaft lobe lift for:
Inlet lobe is 9.431 mm (0.3713 inch).

B - -
Exhaust lobe is 8.515 mm (0.3352 inch).
Injector lobe is 10.908 mm (0.4294 inch).

230 UENR0996-03
i05198752
Camshaft
SMCS Code: 1210
S/N: NJH1–Up
S/N: ECM1–Up
Table 161
Thickness of a new thrust washer is 4.7 mm (0.19 inch).

1 1 107-7694 Thrust Plate Distance between the shoulder of the camshaft and the shoulder of the gear is
4.83 ± 0.05 mm (0.190 ± 0.002 inch).

UENR0996-03 231
Table 162
Use the following procedure in order to determine the actual camshaft lobe lift:
- - - 2. Measure base circle (D).
3. Subtract the base circle (D) from the camshaft lobe height (C). The differ-
ence is the actual camshaft lobe lift.
B - - Inlet lobe is 9.366 mm (0.3687 inch).
232 UENR0996-03
i06633316
Camshaft
SMCS Code: 1210
S/N: NJH1–Up
S/N: ECM1–Up

Table 163
A - - Diameter of camshaft journals is 84.85 ± 0.02 mm (3.341 ± 0.001 inch).
Before installation of the camshaft, lubricate the cam bearings with clean engine
oil.
2 1 348-2587 Camshaft
Lubricate the camshaft lobes with a 50/50 mixture of 8T-2998 Lubricant and
clean engine oil.
UENR0996-03 233
Table 164

Use the following procedure to determine the actual camshaft lobe lift (B):
3. Subtract the base circle (D) from the camshaft lobe height (C). The difference is the actual
camshaft lobe lift.
Inlet lobe is 9.431 mm (0.3713 inch).

B - -
Injector lobe is 10.908 mm (0.4294 inch).
i02921010
Engine Oil Filter Base

SMCS Code: 1306
S/N: NJH1–Up
S/N: ECM1–Up

Section A-A
Oil filter bypass

Right side view
234 UENR0996-03
Test force . . . . . . . . . . . . . . . . . . 92.52 N ((21 lb))

Free length after test . . . . . . . . . . . . . 124.71 mm
((4.910 inch))

Section D-D
Illustration 239 g01350925 High pressure relief valve
Section B-B
Oil cooler bypass (4) 1A-2170 Retainer Spring
(1) Torque for the three plugs . . . . . . . . 100 ± 15 N·m Length under test force . . .21.4 mm ((0.84 inch))
((75 ± 11 lb ft)) Test force . . . . . . 184.6 to 215.7 N ((41 to 48 lb))
Free length after test . . . . . . . 31 mm ((1.2 inch))
(2) 4N-8150 Spring Outside diameter . . . . . . . . . . . 19.66 ± 0.20 mm
((0.774 ± 0.008 inch))
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Length under test force . . . . . . . . . . . . 55.24 mm Opening pressure for the engine oil filter bypass
((2.175 inch)) valve . . . . . . . . . . . . . . . . . . . . . . . . .204 kPa ((30 psi))
Test force . . . . 75.619 ± 5.800 N ((17.0 ± 1.3 lb))
Free length after test . . . . . . . . . . . . . 93.726 mm Closing pressure for the engine oil filter bypass valve
((3.6900 inch)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 kPa ((19 psi))
Illustration 240 g01350927 Right side view

Section C-C
(5) Torque for the hollow stud . . . . . . . . . . 68 ± 7 N·m
Pump bypass valve
((50 ± 5 lb ft))
(3) 2N-6005 Spring (6) Torque for the filter base stud . . . . . . . 68 ± 7 N·m
Length under test force . . . . . . . . . . . . 96.52 mm ((50 ± 5 lb ft))
((3.800 inch))
UENR0996-03 235

Section E-E
(7) Apply 6V-6640 Sealant to the bores of the cup
(G) Length for applying 154-9731 Thread Lock plugs prior to assembly.
Compound to the threads of the hollow stud
. . . . . . . . . . . . . . . 10.5 ± 1.5 mm ((0.41 ± 0.06 inch))

Section F-F
236 UENR0996-03
i03001185

SMCS Code: 1306
S/N: NJH1–Up
S/N: ECM1–Up

Section A-A
(D) Apply 154-9731 Thread Lock Compound to the

threads of the hollow stud to the following length.
. . . . . . . . . . . . . . . 10.5 ± 1.5 mm ((0.41 ± 0.06 inch))

Engine oil filter base

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

((50 ± 5 lb ft))

Section B-B
UENR0996-03 237
i03094842

SMCS Code: 1306
S/N: NJH1–Up
S/N: ECM1–Up

Section C-C
(3) Apply 6V-6640 Sealant to the bores of the cup

plugs prior to assembly.
(A) Length for applying 154-9731 Thread Lock

Compound to the threads of the hollow stud
. . . . . . . . . . . . . . . . . . . . . . . . . .10.0 mm ((0.39 inch))
(1) Torque for the hollow stud . . . . . . . . . 80 ± 15 N·m

((60 ± 11 lb ft))
238 UENR0996-03
i03870040 Outside diameter . . . . . . . .20.6 mm ((0.81 inch))
Engine Oil Filter Base The oil cooler bypass valve and the oil filter bypass
valve must open with a pressure difference of
SMCS Code: 1306 240 ± 20 kPa (35.0 ± 3.0 psi).
S/N: 3F61–Up (2) Torque for 148-8406 Plug As
S/N: 3F71–Up . . . . . . . . . . . . . . . 203.5 ± 13.5 N·m ((150 ± 10 lb ft))
Part No.: 342-9677 (3) Torque for the hollow stud . . . . . . . . . . 68 ± 7 N·m
S/N: L4D1–Up ((50 ± 5 lb ft))
Part No.: 342-9677 (4) Torque for 183-7262 Plug As

S/N: L4E1–Up . . . . . . . . . . . . . . . 215.5 ± 15.5 N·m ((159 ± 11 lb ft))
Part No.: 342-9677 (5) Use clean unused engine oil to lubricate the oil
S/N: L4F1–Up filter seal. Tighten one turn after the seal has made
contact with the base.
Part No.: 342-9677
S/N: TWG1–Up Note: Apply 6V-6640 Sealant to the top
11.0 ± 2.0 mm (0.43 ± 0.08 inch) of the hollow stud
S/N: NJH1–Up
threads.

Engine oil filter base
(1) 4N-8150 Spring
Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
((2.1750 inch))
Test force . . . . . . .75.619 ± 5.8 N ((17 ± 1.30 lb))
((3.6810 inch))
UENR0996-03 239
i04006730

SMCS Code: 1306
S/N: NJH1–Up
S/N: ECM1–Up
(1) 4N-8150 Spring

((2.175 inch))
Test force . . . . . . . . . . . . . . . . . 75.619 ± 5.800 N
((17.000 ± 1.304 lb))
((3.6900 inch))
Note: Apply red Loctite 271 to the tapered end

threads of the hollow stud for a length of
10.5 ± 1.5 mm (0.41 ± 0.06 inch).

((50 ± 5 lb ft))
(3) Torque for the plugs . . . . . . . . . . . . . 100 ± 15 N·m

((74 ± 11 lb ft))
The nominal opening pressure of the bypass valves

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .204 kPa ((30 psi))
240 UENR0996-03
i04411252

SMCS Code: 1306
S/N: NJH1–Up
S/N: ECM1–Up
Table 165
Specification for 121-2471 Oil Filter Base Gp
1 2 4N-8150 Spring Test force is 75.619 ± 5.800 N (17.000 ± 1.304 lb).
Apply red Loctite 271 to the tapered end threads of the hollow stud for a length of
10.5 ± 1.5 mm (0.41 ± 0.06 inch).
2 1 2P-4304 Hollow Stud
Torque to 68 ± 7 N·m (50 ± 5 lb ft).
3 2 319-6234 Plug As Torque to 100 ± 15 N·m (74 ± 11 lb ft).

UENR0996-03 241
i04412875

SMCS Code: 1306
S/N: NJH1–Up
S/N: ECM1–Up
Table 166
Apply red Loctite 271 to the tapered end threads of the hollow stud for a length of
10.5 ± 1.5 mm (0.41 ± 0.06 inch).
2 1 2P-4304 Hollow Stud
Torque to 68 ± 7 N·m (50 ± 5 lb ft).

242 UENR0996-03
i04412889

SMCS Code: 1306
S/N: NJH1–Up
S/N: ECM1–Up
Table 167
Specification for 2P-4301 Base As
Apply red Loctite 271 on the tapered end of the hollow stud to the dimension 10.2 ± 1.5 mm
A - -
(0.40 ± 0.06 inch).
2P-4304 Hollow
2 1 Torque to 80 ± 14 N·m (59 ± 10 lb ft).
Stud
UENR0996-03 243
i04464761

SMCS Code: 1306
S/N: NJH1–Up
S/N: ECM1–Up
244 UENR0996-03
Table 168
Specifications for 227-5372 Engine Oil Filter Gp
(continued)
UENR0996-03 245
(Table 168, contd)

Orient the elbow as shown.

2 1 319-6220 Elbow As
Torque to 70 ± 10 N·m (52 ± 7 lb ft).
Lubricate the bore lightly with glycerin or approved

3 2 6V-3908 O-Ring Seal
equivalent.
4 1 102-5828 Cover Torque to 70 ± 10 N·m (52 ± 7 lb ft).
Apply red Loctite 271 to the tapered end of the hollow stud
5 1 2P-4304 Hollow Stud to the length of 7.6 mm (0.30 inch).
Torque to 85 ± 14 N·m (63 ± 10 lb ft).
Apply red Loctite 271 to the tapered end of the hollow stud
6 1 2P-4304 Hollow Stud to the length (D) of 10 mm (0.4 inch).
Torque to 68 ± 7 N·m (50 ± 5 lb ft).
246 UENR0996-03
i04498870

SMCS Code: 1306
S/N: NJH1–Up
S/N: ECM1–Up
Table 169
1 1 242-3864 Spring Test force is 43.7 N (9.8 lb).
Free length after test is 58.50 ± 0.50 mm (2.303 ± 0.020 inch).

UENR0996-03 247
Table 170
Tighten the 359-5999 Base bolts in a numerical sequence as shown in

- - -
the Illustration 259 to the standard torque.
248 UENR0996-03
i04498909

SMCS Code: 1306
S/N: NJH1–Up
S/N: ECM1–Up

Bolt tightening sequence for oil filter base
Table 171
Specification for 363-7616 Engine Oil Filter Gp
1 1 1R-1808 Engine Oil Filter Apply clean lubricating oil to the gasket of the engine oil filter.
Tighten the 209-7291 Oil Filter Base As bolts in a numerical sequence

- - -
as shown in the Illustration 260 to the standard torque.
UENR0996-03 249
Table 172
2 2 242-3864 Spring Test force is 43.7 N (9.8 lb).
Free length after test is 58.50 ± 0.50 mm (2.303 ± 0.020 inch).
3 1 2P-4304 Hollow Stud Torque to 68 ± 7 N·m (50 ± 5 lb ft).
Length for applying red Loctite 271 to the threads of the hollow stud is
A - -
10.0 ± 1.5 mm (0.39 ± 0.06 inch).
250 UENR0996-03
i04556068

SMCS Code: 1306
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 173
Specification for the 176-4109 Engine Oil Filter Gp 268-6625 Engine Oil Filter Gp
Apply red Loctite 271 on the tapered end of the hollow stud to a distance of
B - -
10.5 ± 1.5 mm (0.41 ± 0.06 inch).
1 2 2P-4304 Hollow Stud Torque to 68 ± 7 N·m (50 ± 5 lb ft).
3 2 4N-8150 Spring Test force is 75.619 ± 5.800 N (17.000± 1.304 ).
4 - - Apply clean lubricating oil to the filter gasket.

UENR0996-03 251
i05198136

SMCS Code: 1306
S/N: NJH1–Up
S/N: ECM1–Up
Table 174

Free length after test is 93.726 mm (3.6900 inch)
2 1 1R-1808 Engine Oil Filter Lubricate the seal with 309-6932 Hydraulic Oil.
252 UENR0996-03

362-3515 Oil Filter Base As
Table 175
Length for applying red Loctite 271 to the threads of the taperlock stud is
B 20.0 ± 0.8 mm (0.79 ± 0.03 inch).
1 362-5032 Taperlock Stud
3 Torque to 68 ± 7 N·m (50 ± 5 lb ft).
UENR0996-03 253
i05307629

SMCS Code: 1306
S/N: NJH1–Up
S/N: ECM1–Up
Table 176
Specification for 362-3515 Oil Filter Base As
Before assembly, apply red Loctite 271 on the tapered end of the stud to a
- - -
length of (C) 20.0 ± 0.8 mm (0.79 ± 0.03 inch ) .
i03096860
Engine Oil Pump

SMCS Code: 1304
S/N: NJH1–Up
S/N: ECM1–Up
254 UENR0996-03
(3) Oil pump drive gear may be heated to a maximum

temperature of 316 °C (601 °F) for installation in the
shaft.

(4) O-ring seal
NOTICE
Before operating the engine, the oil pump must be lu-
bricated with clean engine oil. The oil pump must turn
freely by hand. Damage to the drive gear and internal
pump damage can occur if the oil pump is not lubri-
cated with clean engine oil.
Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAE 30
Oil temperature . . . . . . . . . . . . . . . . . 50 °C ((122 °F))
Pump speed . . . . . . . . . . . . . . . . . . . . . . . . .3000 rpm
Oil pressure . . . . . . . . . . . . . . . . . . .359 kPa ((52 psi))
Minimum oil flow . . . . . . . . . 185 L/min ((49 US gpm))
(1) Gear
Length of the new gear . . . . 50.000 ± 0.025 mm

((1.9685 ± 0.0010 inch))
Depth of bore in oil pump body for the gear
. . . . . . . . . . . . . . . . . . . . 50.13 mm ((1.974 inch))
Note: Gears may be heated to a maximum
temperature of 316 °C (601 °F) for installation in the
shaft.
(2) Oil pump shaft assembly
Diameter of the shaft . . . . . . 18.000 ± 0.005 mm

((0.7087 ± 0.0002 inch))
Bore in oil pump body for the shaft
. . . . 18.050 ± 0.010 mm ((0.7106 ± 0.0004 inch))
UENR0996-03 255
i04380864
Engine Oil Pump

SMCS Code: 1304
S/N: NJH1–Up
S/N: ECM1–Up
NOTICE
Before operation, the pump must be lubricated with
clean engine oil and the pump must turn freely by
hand or damage to parts can be the result.
Table 177
Specification for the 161-4113 Engine Oil Pump Gp
127-6356 Pump
1 1 Flush 8S-6511 Bushing with the face of the pump cover.
Cover
2 1 2S-2760 Spring Test force is 499 ± 24 N (112 ± 5 lb).
4N-5273 Pump Diameter of pump drive shaft is 22.217 ± 0.005 mm (0.8747 ± 0.0002 inch).
A 1
Drive Shaft Bore in oil pump cover for bushing for pump drive shaft is 25.400 ± 0.013 mm (1.0000 ± 0.0005 inch).
(continued)
256 UENR0996-03
(Table 177, contd)

Length of the gear is 79.375 ± 0.025 mm (3.1250 ± 0.0010 inch).
B 1 1W-7240 Gear
Depth of bore is 79.502 ± 0.020 mm (3.1300 ± 0.0008 inch).
Install the bushings so that the bushings are even with the outside of the oil pump body.
3 1 -
Angle from the centerline of the oil pump body to the bushing joint of the bushing is 30 ± 15 degrees.
D 1 8M-8489 Dowel Installation depth of the dowel in the oil pump is 6.4 ± 0.5 mm (0.25 ± 0.02 inch).
E 1 - Installation depth of the bushing in the oil pump housing is 0.30 ± 0.25 mm (0.012 ± 0.010 inch)
UENR0996-03 257
i04394126
Engine Oil Pump

SMCS Code: 1304
S/N: NJH1–Up
S/N: ECM1–Up
NOTICE
Before operating the engine, the oil pump must be lu-
bricated with clean engine oil. The oil pump must turn
freely by hand. Damage to the drive gear and internal
pump damage can occur if the oil pump is not lubri-
cated with clean engine oil.
Table 178
Specification for 361-5604 Engine Oil Pump Gp and 338-0996 Engine Oil Pump Gp
- - - Pump performance:
- - - Oil type is SAE 30.
- - - Oil temperature is 50 °C (122 °F).
- - - Pump speed is 3000 rpm.
- - - Oil pressure is 359 kPa (52 psi).
- - O-ring seals Lubricate lightly with the lubricant that is being sealed.
Length is 67.500 ± 0.025 mm (2.6575 ± 0.0010 inch).

2 2 224-3402 Gear
Depth of the bore in oil pump body for the gear is 67.63 mm (2.663 inch).
In order to install the oil pump gears on the shafts, the oil pump gears must first be heated. Do not heat the oil
- -
pump gears above the temperature of 316 °C (600 °F).
Diameter is 18.000 ± 0.005 mm (0.7087 ± 0.0002 inch).

3 1 224-3404 Shaft Diameter of the bore in oil pump body for the shaft is 18.050 ± 0.010 mm
(0.7106 ± 0.0004 inch).
(continued)
258 UENR0996-03
(Table 178, contd)

Diameter is 18.000 ± 0.005 mm (0.7087 ± 0.0002 inch)
4 1 224-3403 Shaft Diameter of the bore in oil pump body for the shaft is 18.050 ± 0.010 mm
(0.7106 ± 0.0004 inch).
In order to install the oil pump drive gear on the shaft, the oil pump drive gear must first
5 1 Oil pump drive gear be heated. Do not heat the oil pump drive gear above the temperature of 316 °C
(600 °F).
UENR0996-03 259
i04556553
Engine Oil Pump

SMCS Code: 1304
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 198-1508
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
NOTICE
Before operation, the pump must be lubricated with
clean engine oil and the pump must turn freely by
hand or damage to parts can be the result.
260 UENR0996-03
Table 179
Specification for 198-1508 Engine Oil Pump Gp

1 1 2S-2760 Spring Test force is 499 ± 24 N (112.2 ± 5.4 lb).
2 1 202-3572 Drive Shaft As Diameter of shaft is 22.217 ± 0.005 mm (0.8747 ± 0.0002 inch).
3 1 145-8503 Idler Shaft Assembly Diameter of shaft is 22.217 ± 0.005 mm (0.8747 ± 0.0002 inch).
Bore of the bushing after installation is 20.361 ± 0.008 mm (0.8016 ± 0.0003 inch)
Installation depth is 1.52 mm (0.060 inch)
4 2 4N-5274 Bushing
Position of the bearing joint from the centerline through the bearing bore is 30 ± 15
degrees.
Length is 65.07 ± 0.05 mm (2.562 ± 0.002 inch).

B 1 7W-7141 Pump Gear
Depth of bore for the pump gear is 65.197 ± 0.020 mm (2.5668 ± 0.0008 inch).
Length is 79.375 ± 0.025 mm (3.1250 ± 0.0010 inch)

C 1 1W-7240 Gear
Depth of bore for the gear is 79.502 ± 0.02 mm (3.1299 ± 0.0008 inch)
Table 180
Position of the bearing joint from the centerline through the bearing bore is 30 ±
E - -
15 degrees.
F 2 7N-2156 Bushing Installation depth is 0.30 ± 0.25 mm (0.012 ± 0.010 inch).
Dimensions to install the dowels from the bottom surface of the oil pump body is
G 2 8M-8489 Dowel 6.4 ± 0.5 mm (0.25 ± 0.02 inch).
UENR0996-03 261
i04854350
Engine Oil Pump

SMCS Code: 1304
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 161-4113
S/N: L4D1–Up
Part No.: 161-4113
S/N: L4E1–Up
Part No.: 161-4113
S/N: L4F1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 181

2 1 2S-2760 Spring Test force is 499 ± 24 N (112 ± 5 lb).
(continued)
262 UENR0996-03
(Table 181, contd)

4N-5273 Pump Drive Length is 157.5 ± 0.8 mm (6.20 ± 0.03 inch).
3 1
Shaft Bore in oil pump cover for bushing for pump drive shaft is 25.400 ± 0.013 mm
(1.0000 ± 0.0005 inch).

4N-5271 Pump Drive Length is 139.7 ± 0.8 mm (5.50 ± 0.03 inch).
4 1
Shaft Bore in oil pump cover for bushing for pump drive shaft is 25.400 ± 0.013 mm
(1.0000 ± 0.0005 inch).
Length is 79.375 ± 0.025 mm (3.1250 ± 0.0010 inch).

5 2 1W-7240 Gear
Depth of bore in the oil pump body is 79.502 ± 0.020 mm (3.1300 ± 0.0008 inch).
6 1 127-6356 Pump Cover Flush 8S-6511 Bushing (7) with the face of the pump cover.

(1) 235-1587 Body
Table 182
8 2 8M-8489 Dowel Installation depth of the dowel in the oil pump (A) is 6.4 ± 0.5 mm (0.25 ± 0.02 inch).
Install the bushings so that the bushings are even with the outside of the oil pump body.
Angle from the centerline of the oil pump body to the bushing joint of the bushing is 30 ± 15
9 2 7N-2156 Bushing
degrees.
Installation depth (C) is 0.30 ± 0.25 mm (0.012 ± 0.010 inch).
i02694853
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 263

Right Side View
(1) Oil pan
(2) Bolts
(3) Torque for the two drain plugs . . . . . . 70 ± 15 N·m

((50 ± 11 lb ft))
(4) Torque for the two plugs . . . . . . . . . . 70 ± 15 N·m

((50 ± 11 lb ft))
264 UENR0996-03
i04372772
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up
Table 183
Specification for 233-4890 Oil Pan Gp and 235-3406 Oil Pan Gp
5P-5846 O-Ring
1 1 Lubricate the bore lightly with the lubricant that is being sealed.
Seal
5P-8068 O-Ring
Seal
9X-6451 Drain
4 3 Torque to 70 ± 15 N·m (50 ± 11 lb ft).
Plug
UENR0996-03 265
i04395698
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up

Right side view
Table 184
Specification for 109-3285 Oil Pan Gp
353-5065 Oil Pan Apply ultra blue Loctite 587 on the top across the entire length of joints of the oil pan gasket as shown
1 2
Gasket in Illustration 276 .
5P-5846 O-Ring
Seal
5P-8068 O-Ring
Seal
206-7331 Drain
4 1 Torque to 70 ± 15 N·m (50 ± 11 lb ft).
Plug
266 UENR0996-03
Table 185
Use the following procedure during assembly of engine oil pan:
Note: The sealing surfaces of the oil pan shall be free of oil, debris, gasket material, or any other sealant.
Note: The oil pan must be assembled and tightened to the cylinder block within10 minutes of applying sealant.
1. Apply 3 to 5 mm (0.1 to 0.2 inch) of ultra blue Loctite 587 to the following locations:
Connecting joint of the front housing and the front of the cylinder block.
Connecting joint of the flywheel housing and the rear of the cylinder block.
2. Tighten bolt 1 through bolt 40 in the numerical sequence as shown in Illustration 277 to 40 ± 5 N·m (30 ± 4 lb ft)
2. Again, tighten bolt 1 through bolt 40 in the numerical sequence as shown in Illustration 277 to 47 ± 5 N·m (35 ± 4 lb ft)
UENR0996-03 267
i04447151
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up

Top view
Table 186
1 1 109-0072 O-Ring Seal Lubricate the bore lightly with lubricate that is being sealed.
3 3 9X-6451 Drain Plug Torque to 70 ± 15 N·m (50 ± 11 lb ft).

268 UENR0996-03
i04447170
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up

Top view
Table 187
1 1 5P-5846 O-Ring Seal Lubricate the bore lightly with lubricate that is being sealed.
UENR0996-03 269
i04447209
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up

Top view
Table 188
3 - - Apply ultra blue Loctite blue RTV silicone sealant to the joints of the gasket.

270 UENR0996-03
i04556578
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up

Top view
Table 189
Apply ultra blue Loctite blue RTV silicone sealant on the top across the entire length of
1 2 353-5065 Oil Pan Gasket
joints of the oil pan gasket.
2 1 4P-0519 Drain Adapter Torque to 70 ± 15 N·m (52 ± 11 lb ft).

UENR0996-03 271
Table 190
- - - Use the following procedure during assembly of engine oil pan:
- - - The sealing surfaces of the oil pan shall be free of oil, debris, gasket material, or any other sealant.
- - - The oil pan must be assembled and tightened to the cylinder block within 10 minutes of applying sealant.
1. Apply 3 to 5 mm (0.1 to 0.2 inch) ultra blue Loctite blue RTV silicone sealant to the following locations:
- - - Connecting joint of the flywheel housing and the rear of the cylinder block.
Apply bead of sealant to the gasket or to the housing face. At the T-joint location the bead should cover
the entire span.
2. Tighten bolt 1 through bolt 40 in the numerical sequence as shown in Illustration 282 to 40 ± 5 N·m
(30 ± 4 lb ft).
4 40 2P-3205 Bolt
3. Again, tighten bolt 1 through bolt 40 in the numerical sequence as shown in Illustration 282 to
47 ± 5 N·m (35 ± 4 lb ft).
272 UENR0996-03
i04556594
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up
Table 191
Apply ultra blue Loctite blue RTV silicone sealant across the entire length of the joint to the top of the
1 1 -
joint between the oil pans.
109-5839 Drain Lubricate the threads with clean engine oil before assembly.
2 1
Plug Torque to 96 ± 15 N·m (71 ± 11 lb ft).
3 15 0S-1588 Bolt Use the following procedure to tighten the bolts :
(continued)
UENR0996-03 273
(Table 191, contd)

Tighten the bolts in the numerical sequence that is shown in Illustration 283 to 45 ± 5 N·m
(33 ± 4 lb ft).
After few minutes, again tighten the bolts in the numerical sequence that is shown in Illustration 283 to
45 ± 5 N·m (33 ± 4 lb ft).
Table 192
213-0677 Liquid Lev-

4 1 Torque to 70 ± 15 N·m (52 ± 11 lb ft).
el Switch
274 UENR0996-03
i04556611
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up
Table 193
1 1 213-0677 Liquid Level Switch Torque to 70 ± 15 N·m (52 ± 11 lb ft).
Before assembly, lubricate the threads with clean engine oil.

2 1 109-5839 Drain Plug
Torque to 96 ± 15 N·m (71 ± 11 lb ft).
UENR0996-03 275
Table 194
- - - The oil pan must be assembled and tightened to the cylinder block within 10 minutes of applying sealant.
1. Apply 3 to 5 mm (0.1 to 0.2 inch) ultra blue Loctite blue RTV silicone sealant to the following locations:
- - - Connecting joint of the flywheel housing and the rear of the cylinder block.
the entire span.
(30 ± 4 lb ft).
3 40 0S-1571 Bolt
47 ± 5 N·m (35 ± 4 lb ft).
276 UENR0996-03
i04556617
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up
Table 195
The sealing surfaces should be free from contaminants. Apply ultra blue Loctite blue RTV silicone sealant to the cylinder block across the entire
span of the T-shaped joints. The engine oil pan must be assembled within 10 minutes of the application of the sealant.

UENR0996-03 277
Table 196
1. Tighten bolt 1 through bolt 40 in the numerical sequence as shown in Illustration 288 to
40 ± 5 N·m (30 ± 4 lb ft).
6 39 3B-1915 Bolt
2. Again, tighten bolt 1 through bolt 40 in the numerical sequence as shown in Illustration
288 to 47 ± 5 N·m (35 ± 4 lb ft).
278 UENR0996-03
i04556649
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up
Table 197
Specification for 7W-0158 Oil Pan Gp

UENR0996-03 279
Table 198
Specification for 7W-0158 Oil Pan Gp
- The oil pan must be assembled and tightened to the cylinder block within 10 minutes of applying
- -
sealant.
1. Apply 3 to 5 mm (0.1 to 0.2 inch) ultra blue Loctite blue RTV silicone sealant to the following
locations:
- - -
Apply bead of sealant to the gasket or to the housing face. At the T-joint location the bead should
cover the entire span.
40 ± 5 N·m (30 ± 4 lb ft).
3 39 3B-1915 Bolt
47 ± 5 N·m (35 ± 4 lb ft).
280 UENR0996-03
i04556656
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up
Table 199

UENR0996-03 281
Table 200
- The oil pan must be assembled and tightened to the cylinder block within 10 minutes of applying
- -
sealant.
1. Apply 3 to 5 mm (0.1 to 0.2 inch) ultra blue Loctite blue RTV silicone sealant to the following
locations:
- - -
the entire span.
(30 ± 4 lb ft).
3 31 3B-1915 Bolt
47 ± 5 N·m (35 ± 4 lb ft).
282 UENR0996-03
i04753210
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up
Table 201
Assembly torque is 24 to 30 N·m (212 to 266 lb in).

1 1 351-0283 Shutoff Valve Gp
Stem torque is 2 to 3 N·m (18 to 27 lb in).
UENR0996-03 283
i04758104
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up

Table 202
3 1 3E-7427 Adapter Torque to 70 ± 15 N·m (52 ± 11 lb ft).

284 UENR0996-03
i04758244
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up

Table 203


UENR0996-03 285
i05296461
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up

Top view of engine

Table 204
1 1 5P-5846 O-Ring Seal Lubricate the bore lightly with the lubricant that is being sealed.
3 3 206-7331 Drain Plug Torque to 70 ± 15 N·m (52 ± 11 lb ft).

286 UENR0996-03

Tightening sequence

Retightening sequence
Table 205
The sealing surfaces of the oil pan shall be free of oil, debris, gasket material, or any other sealant.
4 40 2P-3205 Bolt
The oil pan must be assembled and tightened to the cylinder block within 10 minutes of applying
sealant.
(continued)
UENR0996-03 287
(Table 205, contd)

2. Tighten bolt 1 through bolt 40 in the numerical sequence as shown in Illustration 298 40 ± 5 N·m
(30 ± 4 lb ft).
3. Again, tighten bolt 1 through bolt 40 in the numerical sequence as shown in Illustration299
47 ± 5 N·m (35 ± 4 lb ft).
288 UENR0996-03
i05296466
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up

Top view of engine

Table 206
2 - - Apply ultra blue Loctite 587 on the top across the entire length of joints .

UENR0996-03 289
i05296484
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up

Table 207

290 UENR0996-03

Tightening procedure

Retightening procedure
Table 208
3 40 2P-3205 Bolt
The oil pan must be assembled and tightened to the cylinder block within10 minutes of applying
sealant.
(continued)
UENR0996-03 291
(Table 208, contd)

1. Apply 3 to 5 mm (0.1 ± 0.2 inch) of ultra blue Loctite 587 to the following locations:
2. Tighten bolt 1 through bolt 40 in the numerical sequence to 40 ± 5 N·m (30 ± 4 lb ft) as shown in Il-
lustration 303 .
3. Again, tighten bolt 1 through bolt 40 in the numerical sequence to 47 ± 5 N·m (35 ± 4 lb ft) as
292 UENR0996-03
i05299589
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up

Top view

Right side view
UENR0996-03 293
Table 209
1 1 5P-5846 O-Ring Seal Before assembly, lightly lubricate the bore with the lubricant that is being sealed.

Tightening sequence

Retightening sequence
294 UENR0996-03
Table 210
The oil pan must be assembled and tightened to the cylinder block within 10 minutes of applying
sealant.
4 40 2P-3205 Bolt Connecting joint of the front housing and the front of the cylinder block.
2. Tighten bolt 1 through bolt 40 in the numerical sequence as shown in Illustration 307 40 ± 5 N·m
(30 ± 4 lb ft).
3. Again, tighten bolt 1 through bolt 40 in the numerical sequence as shown in Illustration 308
47 ± 5 N·m (35 ± 4 lb ft).
UENR0996-03 295
i05299629
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up

Top view

Right side view
296 UENR0996-03
Table 211
Apply 3 to 5 mm (0.1 to 0.2 inch) ultra blue Loctite blue RTV silicone sealant to the
following locations:
- - -
Apply bead of sealant to the gasket or to the housing face. At the T-joint location the
bead should cover the entire span.
UENR0996-03 297
i05543650
Engine Oil Pan

SMCS Code: 1302
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
298 UENR0996-03
Table 212

UENR0996-03 299
i05543713
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Table 213
Specification for 379-0064 Oil Pan Gp, 379-9144 Oil Pan Gp, and 277-8461 Oil Pan Gp
300 UENR0996-03
i05578830
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up
Table 214

UENR0996-03 301
i05579532
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Table 215
Specification for 348-8371 Oil Pan Gp, and 381-6727 Oil Pan Gp
The sealing surfaces of the oil pan shall be free of oil, debris, gasket material that is protruding, or any other sealant. The oil pan must be as-
sembled and tightened to the cylinder block within 10 minutes of applying sealant.
Apply Loctite blue RTV silicone to a bead of 5 mm (0.2 inch) at two places (2) on the
- - -
connecting joint of the front housing (1) and the front of the cylinder block.
- - -
connecting joint of the flywheel housing (3) and the rear of the cylinder block.
302 UENR0996-03
i06068092
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Table 216
Specification for 353-5704 Oil Pan Gp , 187-3075 Oil Pan Gp , 286-1952 Oil Pan Gp , and 165-4459 Oil Pan Gp
The sealing surfaces of the oil pan shall be free of oil, debris, gasket material that is protruding, or any other sealant. The oil pan must be as-
sembled and tightened to the cylinder block within 10 minutes of applying sealant.
- - -
connecting joint of the front housing and the front of the cylinder block.
- - -
connecting joint of the flywheel housing and the rear of the cylinder block.
UENR0996-03 303
i07255513
Engine Oil Pan

SMCS Code: 1302
S/N: NJH1–Up
S/N: ECM1–Up
Table 217


304 UENR0996-03
i04907651
Water Temperature Regulator

SMCS Code: 1355
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 248-5513
S/N: L4D1–Up
Part No.: 248-5513
S/N: L4E1–Up
Part No.: 248-5513
S/N: L4F1–Up
Part No.: 248-5513
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 218
Specification for 248-5513 Temperature Regulator
A - - Minimum opening distance at fully open temperature is 10.4 mm (0.41 inch).
- - - Opening temperature is 81 to 84 °C (178 to 183 °F).
- - - Fully open temperature is 92 °C (198 °F).
Leakage at the seat and sleeve shall not exceed minimum 10.0 cc (0.6 cubic inch) at 207 kPa
- - -
(30 psi).
Force required to separate valve from seat is 165 ± 9 N (37 ± 2 lb), measured at temperature 75 °C
- - -
(167 °F).
UENR0996-03 305
i02801653 Note: A negative offset is toward the housing.
Water Pump (4) Press the gear until the gear is flush with the
bearing.
SMCS Code: 1361
S/N: NJH1–Up
S/N: ECM1–Up
Note: With an installation tool, press the seal group

onto the water pump shaft until the stationary cup is
fully seated inside the pump housing.
(1) Seal group
Maximum leakage at the side for water at

140 kPa (20 psi) should not exceed the following
value. . . . . . . . . . . . . . . . .10 ml/min ((0.3 oz/min))
Maximum leakage at the side for oil at 140 kPa
(20 psi) should not exceed the following value.
. . . . . . . . . . . . . . . . . . . . .24 ml/min ((0.8 oz/min))
(2) By using an installation tool, install the lip type

seal with the primary lip toward the gear. Press the lip
type seal with a press until the lip type seal is flush
with the face inside the housing, as shown. Do not
install the lip type seal by hand.
(3) The pump impeller should be pressed onto the

shaft within the following tolerance.
. . . . . . . . . −0.25 to 0.00 mm ((−0.010 to 0.000 inch))
306 UENR0996-03
i03001211
Water Pump
SMCS Code: 1361
S/N: NJH1–Up
S/N: ECM1–Up
Note: Orient the cup plug (9) at ± 10 degrees, as

shown.
(9) Maximum installation depth of the cup plug

. . . . . . . . . . . . . . . . . . . . . . . . 1.25 mm ((0.049 inch))

(2) Seal group
(4) Water pump gear
(5) Ball bearing
(6) Impeller
(7) Water pump shaft
(8) Bolt
(1) Lubricate the bore of the O-ring seal with the

lubricant that is being sealed.
(3) Do not lubricate the lip of the lip type seal.
(A) Distance between the pump flange and the

impeller hub . . 8.40 ± 0.25 mm ((0.331 ± 0.010 inch))
UENR0996-03 307
i04392855
Water Pump
SMCS Code: 1361
S/N: NJH1–Up
S/N: ECM1–Up
Table 219
Specification for 361-5607 Water Pump Gp and 332-0984 Water Pump Gp
1 1 6V-7350 O-Ring Seal Lubricate the bore lightly with 5P-3975 Rubber Lubricant before assembly.
2 - - Lubricate the top oil passage with 15 mL (0.5 oz) of engine oil.
308 UENR0996-03
Table 220
3 1 225-7003 O-Ring Seal Lubricate the bore lightly with 5P-3975 Rubber Lubricant before assembly.
4 1 8C-3100 Lip Type Seal Do not lubricate.

UENR0996-03 309
Table 221
Distance between end of the pump housing to water pump shaft is 8.40 ± 0.25 mm
C - -
(0.331 ± 0.010 inch).
E - - Distance from pump housing to water pump seal is 10.92 ± 0.13 mm (0.430 ± 0.005 inch).
Maximum installation depth of the cup plug is 1.25 mm (0.049 inch).

5 1 203-3831 Cup Plug
Orient the cup plug weep hole at ± 10 degrees from vertical, as shown in Illustration 323 .
310 UENR0996-03
i04441929
Water Pump
SMCS Code: 1361
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 314-5155
S/N: L4D1–Up
Part No.: 314-5155
S/N: L4E1–Up
Part No.: 314-5155
S/N: L4F1–Up
Part No.: 314-5155
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 222
Specification for 314-5155 Water Pump Gp
1 1 246-3129 Pump Impeller Pump impeller should be flush with the shaft within −0.25 to 0.00 mm (−0.010 to 0.000 inch).
Install the lip type seal with the primary lip toward the water pump drive gear. Press the oil seal
2 1 153-1256 Lip Type Seal with a press until the oil seal is flush with face of housing as shown. Do not install the lip type
seal by hand.
3 1 276-4756 Seal Gp Press the seal group onto the shaft until the cup is fully seated inside the pump housing.
4 1 195-0319 Gear Press the gear until the gear is flush with the bearing.
Maximum installation depth of the cup plug from the machined surface is 0.5 mm (0.02 inch).
5 1 203-3831 Cup Plug
Orient the cup plug as shown, within ±10 degrees.
UENR0996-03 311
i04442296
Water Pump
SMCS Code: 1361
S/N: NJH1–Up
S/N: ECM1–Up
Table 223
244-1645 Seal With an installation tool, press the seal group onto the water pump shaft until the stationary cup is fully
1 1
Gp seated inside the pump housing.
By using an installation tool, install the lip type seal with the primary lip toward the gear. Press the lip type
153-1256 Lip
2 1 seal with a press until the lip type seal is flush with the face inside the housing. Do not install the lip type
Type Seal
seal by hand.
246-3129 Pump The pump impeller should be pressed onto the shaft within the −0.25 to 0.00 mm (−0.010 to 0.000 inch)
3 1
Impeller tolerance.
312 UENR0996-03
i04557743
Water Pump
SMCS Code: 1361
S/N: NJH1–Up
S/N: ECM1–Up
Table 224
Specification for the 174-5986 Water Pump Gp, 161-0969 Water Pump Gp, and 100-9347 Water Pump Gp
1 1 9M-3786 O-Ring Seal Lubricate the bore of the O-ring seal lightly with 5P-3975 Rubber Lubricant.
With an installation tool, press the water pump seal onto the water pump shaft until
3 1 349-2654 Water Pump Seal
the stationary cup is fully seated inside the pump housing.
By using an installation tool, install the lip type seal with the primary lip toward water
4 1 153-1256 Lip Type Seal pump drive gear. Press the lip type seal with a press until the lip type seal is flush
with the face inside the housing. Do not install the lip type seal by hand.
Diameter of the water pump shaft at the carbon seal assembly seat area is
A 1 135-4928 Water Pump Shaft
19.100 ± 0.010 mm (0.7520 ± 0.0004 inch).
UENR0996-03 313
i04856910
Water Pump
SMCS Code: 1361
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 225
2 1 153-1256 Lip Type Seal with a press until the oil seal is flush with face of housing as shown in the Illustration 327 .
Use installation tool. Do not install the lip type seal by hand.
352-2002 Water Pump

3 1 Press the water pump gear until the water pump gear is flush with the bearing (4).
Gear
Press the water pump seal assembly onto the shaft until the cup is fully seated inside the pump
336-2212 Water Pump
5 1 housing. Use installation tool.
Seal As
Installation height (B) is 9.90 ± 0.38 mm (0.390 ± 0.015 inch).
6 1 203-3831 Cup Plug
Orient the cup plug as shown in the Illustration 327 , within ±10 degrees.
314 UENR0996-03
i04856993
Water Pump
SMCS Code: 1361
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 280-7374
S/N: L4D1–Up
Part No.: 280-7374
S/N: L4E1–Up
Part No.: 280-7374
S/N: L4F1–Up
Part No.: 280-7374
S/N: TWG1–Up
S/N: NJH1–Up
Table 226
Use installation tool for installation. Do not install the lip type seal by hand.
3 1 195-0319 Gear Press the gear until the gear is flush with the bearing (4).
Press the water pump seal assembly onto the shaft until the stationary cup is fully seated inside
5 1 276-4756 Seal Gp the pump housing. Use installation tool for installation.
Installation height (B) is 13.67 ± 0.38 mm (0.538 ± 0.015 inch).
UENR0996-03 315
i05246969
Water Pump
SMCS Code: 1361
S/N: NJH1–Up
S/N: ECM1–Up
Table 227
1 1 9M-3786 O-Ring Seal Lubricate the bore lightly with 5P-3975 Rubber Lubricant.
349-2654 Water Pump With an installation tool, press the water pump seal onto the water pump shaft until the station-
3 1
Seal ary cup is fully seated in the pump housing.
By using an installation tool, install the lip type seal with the primary lip toward water pump drive
4 1 153-1256 Lip Type Seal gear. Press the lip type seal until the lip type seal is flush with the face inside the housing. Use
press to install the lip the seal, do not install the lip type seal by hand.
135-4928 Water Pump Diameter of the water pump shaft at the carbon seal assembly seat area is 19.100 ± 0.010 mm
A 1 (0.7520 ± 0.0004 inch).
Shaft
316 UENR0996-03
i05295509
Water Pump
SMCS Code: 1361
S/N: NJH1–Up
S/N: ECM1–Up

366-0168 Water Pump Gp
Table 228
Pump impeller should be flush with the shaft within −0.25 to 0.00 mm
1 1 246-3129 Pump Impeller
(−0.010 to 0.000 inch).
Install the lip type seal with the primary lip toward the water pump drive gear. Press
2 1 153-1256 Lip Type Seal the oil seal with a press until the oil seal is flush with face of housing as shown. Do
not install the lip type seal by hand.
Press the seal group onto the shaft until the cup is fully seated inside the pump
3 1 336-2212 Water Pump Seal As
housing.
4 1 361-8234 Water Pump Gear Press the gear until the gear is flush with the bearing.
Maximum installation depth of the cup plug from the machined surface is 0.5 mm
5 1 203-3831 Cup Plug
(0.02 inch). Orient the cup plug as shown, within ±10 degrees.
Diameter of shaft over impeller end is 25.400 to 25.413 mm

6 - 246-3130 Water Pump Shaft
(1.0000 to 1.0005 inch).
UENR0996-03 317
i05388348
Water Pump
SMCS Code: 1361
S/N: NJH1–Up
S/N: ECM1–Up
Table 229
Specification for 276-4755 Water Pump Gp, and 336-2213 Water Pump Gp
Pump impeller should be flush with the shaft within −0.25 to 0.00 mm
1 1 246-3129 Pump Impeller
(−0.010 to 0.000 inch).
Install the lip type seal with the primary lip toward the water pump drive gear. Press the oil
2 1 153-1256 Lip Type Seal seal with a press until the oil seal is flush with face of housing as shown. Do not install the
lip type seal by hand.
3 1 276-4756 Seal Gp Press the seal group onto the shaft until the cup is fully seated inside the pump housing.
318 UENR0996-03
i05546149
Water Pump
SMCS Code: 1361
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 319
Table 230
1 1 371-6782 Pump Impeller Installation depth of impeller (B) is 11.71 ± 0.20 mm (0.461 ± 0.008 inch).
352-2002 Water Pump

3 1 Press the water pump gear until the water pump gear is flush with the bearing (2).
Gear
(continued)
320 UENR0996-03
(Table 230, contd)

4 1 203-3831 Cup Plug
Orient the cup plug as shown in the Illustration 332 , within ±10 degrees.
Use installation tool. Do not install the lip type seal by hand.
Press the water pump seal assembly onto the shaft until the cup is fully seated inside the pump
336-2212 Water Pump
6 1 housing. Use installation tool.
Seal As
Installation height (D) is 9.90 ± 0.38 mm (0.390 ± 0.015 inch).
UENR0996-03 321
i06058972
Water Pump
SMCS Code: 1361
S/N: NJH1–Up
S/N: ECM1–Up
Table 231
1 1 5F-3999 O-Ring Seal Lubricate bore of the O-ring seal lightly with 5P-3975 Rubber Lubricant.
3 1 397-1832 Shaft As During installation, flush shaft assembly with the housing.
Distance from the 261-3423 Impeller (2) to the face of the housing is
A - -
9.00 ± 0.25 mm (0.354 ± 0.0010 inch).
B 1 350-5417 Seal Operating height is 10.92 ± 0.13 mm (0.430 ± 0.0051inch).
Distance from the front face of the 203-6098 Hub (4) to the face of the housing
C - -
is 155.8 ± 0.3 mm (6.13 ± 0.01 inch).
322 UENR0996-03

Front view of engine
Table 232
During installation, flush plug with the housing and orient the plug as show in the
5 1 177-1058 Plug
Illustration 334 .
UENR0996-03 323
i06615890
Water Pump
(Separate Circuit Water Pump)
SMCS Code: 1361
S/N: NJH1–Up
S/N: ECM1–Up
Table 233
1 - Installation height 10.92 ± 0.013 mm (0.43 ± 0.0005 inch)
Distance between impeller on shaft to mount-

2 - 23.28 ± 0.25 mm (0.92 ± 0.0098 inch)
ing face of the inlet
i04664259
Cylinder Block
SMCS Code: 1201
S/N: NJH1–Up
S/N: ECM1–Up
The flatness of the top contact surface of the cylinder
block must be within 0.05 mm (0.002 inch) for any
150 mm (5.9 inch) section of the surface.
Bore diameter in the cylinder block for the cylinder

liner:
324 UENR0996-03
(A) . . . . 151.50 ± 0.03 mm ((5.965 ± 0.001 inch)) 1. Orient the main bearing cap correctly. The part
(B) . . . . 149.80 ± 0.30 mm ((5.898 ± 0.012 inch)) number on the main bearing cap must face to the
(C) . . . . 148.00 ± 0.03 mm ((5.827 ± 0.001 inch)) right and to the front face of the block. Also, the
(D) . . . . 141.90 ± 0.05 mm ((5.587 ± 0.002 inch)) tab slots that are in the block and the main bearing
caps must be adjacent.
Note: The main bearing caps are marked with

identification numbers 1 through 7. Install the main
bearing caps into the correct positions.
2. Lubricate the main bearing cap bolts. Use SAE

30W oil or molybdenum grease to lubricate the
threads and the washer face.
3. Tighten the main bearing cap bolts to 150 ± 5 N·m
(110 ± 4 lb ft).
4. Rotate each main bearing cap bolt in the clockwise
direction for additional 60 ± 5 degrees.

Front view
(2) Bolt for the piston cooling jet
Install the camshaft bearings into the cylinder block

(E) Diameter of the camshaft bore
at the location that is specified. The distance that is
. . . . . . . 85.000 ± 0.015 mm ((3.3465 ± 0.0006 inch))
listed below is measured from the front face of the
(F) Distance from the centerline of the crankshaft cylinder block.
bore to the top surface of the cylinder block
(K) . . . . . . . . . . . . . . . 972.50 mm ((38.287 inch))
. . . . . . . . . . . . . . . . . . . . . 387.00 mm ((15.236 inch))
(L) . . . . . . . . . . . . . . . 816.50 mm ((32.146 inch))
(G) Bore in the cylinder block for the main bearing (M) . . . . . . . . . . . . . . . 660.50 mm ((26.004 inch))
. . . . . . 116.000 ± 0.013 mm ((4.5669 ± 0.0005 inch)) (N) . . . . . . . . . . . . . . . 504.50 mm ((19.862 inch))
(P) . . . . . . . . . . . . . . . 348.50 mm ((13.720 inch))
(H) Distance from the centerline of the crankshaft to (R) . . . . . . . . . . . . . . . . 192.50 mm ((7.579 inch))
the bottom surface of the cylinder block . . 120.0 mm (S) . . . . . . . . . . . . . . . . . 36.50 mm ((1.437 inch))
((4.72 inch))
NOTICE
(J) Dimensions of main bearing cap Camshaft bearings must be installed into their correct
Width of the main bearing cap damage.
. . . 178.000 ± 0.020 mm ((7.0079 ± 0.0008 inch))
Width in cylinder block for the main bearing cap
. . . 178.000 ± 0.023 mm ((7.0079 ± 0.0009 inch))
(1) Apply Loctite 574 to the bore of three cup plugs.
Use the following procedure in order to tighten the
main bearing cap bolts (3) :
UENR0996-03 325

(4) Bearing joint
(5) Oil hole
(T) Bearing oil hole is located at the 45 degrees angle

from vertical. All seven bearings have the same
angle.
326 UENR0996-03
i05272237
Cylinder Block
SMCS Code: 1201
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 223-9252
S/N: L4D1–Up
Part No.: 223-9252
S/N: L4E1–Up
Part No.: 223-9252
S/N: L4F1–Up
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 327
Table 234
Specifications for 223-9252 Cylinder Block Gp
The bottom of spacer plate (2), the top of cylinder block, and both surfaces of gasket
(1) must be free of fuel, oil, water, adhesives, assembly compounds or any other con-
1 1 227-1204 Gasket
taminants during assembly.
Thickness of the gasket is 0.20 ± 0.02 mm (0.008 ± 0.001 inch).
Apply green Loctite 609 to the dowel before installation.

A 1 4N-1650 Dowel Extension of dowel above the top surface of the cylinder block is 18.5 ± 0.5 mm
(0.73 ± 0.02 inch).
2 1 6I-4421 Spacer Plate Maximum thickness of the spacer plate is 8.585 ± 0.025 mm (0.3380 ± 0.0010 inch).
(continued)
328 UENR0996-03
(Table 234, contd)

Extension of dowel above the top surface of the cylinder block is 16.0 ± 0.5 mm
B 1 1S-9540 Dowel (0.63 ± 0.02 inch).

C 1 6I-1055 Dowel Extension of dowel above the top surface of the cylinder block is 20.0 ± 0.5 mm
(0.79 ± 0.02 inch).
Extension of the dowel beyond the end of the cylinder block is 19.1 ± 0.5 mm
E 2 4N-0683 Dowel (0.75 ± 0.02 inch).
F 2 266-6038 Dowel (1.37 ± 0.12 inch).
3 - - Lubricate the bore of the O-ring seal with the fluid that is being sealed.
H - - Installation depth of the plug is 2.0 ± 2.0 mm (0.08 ± 0.08 inch).
Table 235
Item Qty Parts Specification Description
Thoroughly lubricate the full inner diameter of the cylinder liner with clean engine
4 1 197-9322 Cylinder Block Liner
oil.
5 - - Lubricate the bore of the O-ring seal with the fluid that is being sealed.
Dimension from the centerline of the crankshaft bearing bore to the top of a new
cylinder block is 425.45 mm (16.750 inch)
J - - Minimum dimension for brake applications should be 425.45 mm (16.750 inch)
Minimum dimension for NON-brake applications should be 425.02 mm
(16.733 inch)
(continued)
UENR0996-03 329
(Table 235, contd)

Bore in the cylinder block for the main bearings is 129.891 ± 0.013 mm
K - -
(5.1138 ± 0.0005 inch)
Width of the main bearing cap 215.9 mm (8.50 inch)

L - - Width of the cylinder block for the main bearing cap 215.900 ± 0.020 mm
(8.5000 ± 0.0008 inch)
Dimension from the centerline of the crankshaft bearing bore to the bottom of
M - -
cylinder block pan rails is 165.1 mm (6.50 inch)
Use the following procedure in order to tighten the main bearing cap bolts:
1. Apply clean engine oil to the threads of the bolts.
2. Tighten the bolts that are in the tab end to 258 ± 14 N·m (190 ± 10 lb ft).
3. Tighten the bolts that are opposite to the tab end to 258 ± 14 N·m
(190 ± 10 lb ft).
6 14 3P-1323 Bearing Cap Bolt
4. Again, tighten the bolts that are opposite to the tab end to an additional angle
of 120 ± 5 degrees.
4. Again, tighten the bolts that are in the tab end to an additional angle of 120 ± 5
degrees.
Repeat the procedure for each bolt.
The total flatness of the top contact surface of the cylinder block must be within 0.10 mm (0.004 inch). The flatness must also be within
0.05 mm (0.002 inch) for any 150 mm (5.9 inch) section of the surface.
330 UENR0996-03
i05303812
Cylinder Block
SMCS Code: 1201
S/N: NJH1–Up
S/N: ECM1–Up
Table 236
Specifications for 358-6883 Cylinder Block Gp
The bottom of spacer plate (2), the top of cylinder block, and both surfaces of gasket (1) must be
1 1 227-1204 Gasket free of fuel, oil, water, adhesives, assembly compounds or any other contaminants during
assembly.

(0.73 ± 0.02 inch).
B 1 1S-9540 Dowel (0.63 ± 0.02 inch).

(0.79 ± 0.02 inch).
D 4 4N-0683 Dowel Extension of the dowel beyond the end of the cylinder block is 19.1 ± 0.5 mm (0.75 ± 0.02 inch).
UENR0996-03 331
Table 237
Before assembly, lubricate the cylinder block bore surfaces and rubber seals with
3 6 155-0809 Liner Seal 5P-3975 Rubber Lubricant prior to inserting liners.
Before assembly, lubricate the cylinder block bore surfaces and rubber seals with
4 12 155-2793 Liner Seal 5P-3975 Rubber Lubricant prior to inserting liners.

5 14 3P-1323 Bearing Cap Bolt (190 ± 10 lb ft).
4. Again, tighten the bolts that are opposite to the tab end to an additional angle of
120 ± 5 degrees.
4. Again, tighten the bolts that are in the tab end to an additional angle of 120 ± 5
degrees.
Dimension from the centerline of the crankshaft bearing bore to the top of a new
E - -
cylinder block is 425.45 mm (16.750 inch).
F - -
(5.1138 ± 0.0005 inch).
Width of the main bearing cap 215.9 mm (8.50 inch)

G - - Width of the cylinder block for the main bearing cap 215.900 ± 0.020 mm
(8.5000 ± 0.0008 inch).
Dimension from the centerline of the crankshaft bearing bore to the bottom of cylin-
H - -
der block pan rails is 165.1 mm (6.50 inch).
332 UENR0996-03
i06038778
Cylinder Block
SMCS Code: 1201
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 333
Table 238
Specifications for 240-7271 Cylinder Block Gp and 361-5592 Cylinder Block Gp
1 6 437-1409 Liner Seal Before assembly, apply 5P-3975 Rubber Lubricant.
Bore diameter in the cylinder block for cylinder block liner:
2 6 197-9330 Cylinder Block Liner Dimension (B) is 151.50 ± 0.03 mm (5.965 ± 0.001 inch).
Dimension (C) is 149.80 ± 0.30 mm (5.898 ± 0.012 inch).
(continued)
334 UENR0996-03
(Table 238, contd)

Dimension (E) is 141.90 ± 0.15 mm (5.587 ± 0.111 inch).
The flatness of the top contact surface of the cylinder block must be within 0.05 mm
- - -
(0.002 inch) for any 150 mm (5.9 inch) section of the surface.
Before assembly, apply High Strength or High Temperature Anaerobic Flange Seal-
3 5 4F-5695 Cup Plug ant to the bores.
Table 239
F - - Bore for camshaft bearing is 85.000 ± 0.015 mm (3.3465 ± 0.0006 inch).
Distance from the centerline of the crankshaft bore to the top surface of the cylinder block is
G - -
387.00 mm (15.236 inch).
4 3 3B-0623 Cup Plug bores.
H - - Bore in the cylinder block for the main bearing is 116.000 ± 0.013 mm (4.5669 ± 0.0005 inch).
Distance from the centerline of the crankshaft bore to the bottom surface of the cylinder block
J - -
is 120.0 mm (4.72 inch).
Width in the cylinder block for main bearing cap is 177.96 mm (7.006 inch).
K 7 207-8572 Bearing Cap
Width of the bearing cap (L) is 178.0 mm (7.01 inch).
5 14 223-6546 Bolt Refer to the Disassembly and Assembly manual for the installation procedure.
UENR0996-03 335
Table 240
Install the camshaft bearings into the cylinder block at the location specified. The distance that is listed below is measured from the
-
front face of the cylinder block.
- - - Dimension (M) is 970.5 ± 0.5 mm (38.21 ± 0.02 inch).
- - - Dimension (N) is 816.5 ± 0.5 mm (32.15 ± 0.02 inch).
- - - Dimension (P) is 660.5 ± 0.5 mm (26.00 ± 0.02 inch).
- - - Dimension (R) is 504.5 ± 0.5 mm (19.86 ± 0.02 inch).
- - - Dimension (S) is 348.5 ± 0.5 mm (13.72 ± 0.02 inch).
- - - Dimension (T) is 192.5 ± 0.5 mm (7.58 ± 0.02 inch).
- - - Dimension (U) is 36.5 ± 0.5 mm (1.44 ± 0.02 inch).
NOTICE
damage.
Table 241
Bearing oil hole (6) is located at the 45 ± 5 degrees angle from vertical. All seven bearings have
V - -
the same angle.
336 UENR0996-03
i06071159
Cylinder Block
SMCS Code: 1201
S/N: NJH1–Up
S/N: ECM1–Up

Table 242
Specification for 277-7261 Cylinder Block Gp and 425-3527 Cylinder Block Gp
Extension of sleeve from the top deck of the cylinder block is 14.0 ± 0.5 mm
1 2 1W-8407 Sleeve (0.55 ± 0.02 inch).
2 2 6V-3538 Dowel Extension of the new dowel is 8.0 ± 0.5 mm (0.31 ± 0.02 inch).
3 2 7N-5683 Dowel Extension of the new dowel is 12.0 ± 0.5 mm (0.47 ± 0.02 inch).
Before assembly, apply high temperature anaerobic flange sealant to the

4 4 4F-5695 Cup Plug
bores for the cup plug before assembly.
Installation depth for the cup plug (4) is 1.25 ± 0.25 mm

B - -
(0.049 ± 0.010 inch).
UENR0996-03 337

Front view
Table 243
Before assembly, apply 5P-3975 Rubber Lubricant to the liner seal, and
5 6 167-0024 Liner Seal
immediately install the cylinder liner into the cylinder block.

6 2 0L-1026 Cup Plug
bores for the cup plug at both the ends.

7 2 3B-0623 Cup Plug
bores of the cup plug at both the ends.

E - -
(0.049 ± 0.010 inch).

F - -
(0.049 ± 0.010 inch).
338 UENR0996-03

Rear view
Table 244

8 1 0S-0519 Cup Plug
bores for the cup plug at both the ends.

H - -
(0.049 ± 0.010 inch).
UENR0996-03 339
Table 245
Before installation, bore in the cylinder block for the new cylinder is
J - -
123.59 ± 0.15 mm (4.866 ± 0.006 inch).
New dimension from centerline of the crankshaft bore to the top surface of the
K - -
cylinder block is 361.5 mm (14.23 inch).
Width of the main bearing cap is 175.000 ± 0.020 mm (6.8897 ± 0.0008 inch).
L 7 212-7002 Bearing Cap Width in the cylinder block for the main bearing cap is 175.000 ± 0.018 mm
(6.8897 ± 0.0007 inch).
New dimension from centerline of the crankshaft bore to the pan rail is 110 mm
M - -
(4.3 inch).
Bore in the cylinder block for the seven main bearings is 112.000 ± 0.013 mm
N - -
(4.4094 ± 0.0005 inch).
1. Install main bearing caps with the part number to the right and towards the
front face of the block.
9 14 175-0454 Bolt 2. Apply molybdenum or SAE 30 oil to the threads of the bolts and faces of the
washers.
3. Tighten bolts to 95 ± 5 N·m (70 ± 4 lb ft).
4. Again tighten bolts simultaneously on each bearing cap to a turn angle of 90
± 5 degrees.
340 UENR0996-03
Table 246
Bore in the cylinder block for the bushing is 70.000 ± 0.038 mm

10 1 203-6090 Bushing
(2.7559 ± 0.0015 inch).
Bore in the cylinder block for the bushing is 70.000 ± 0.025 mm

11 1 216-5586 Bushing
(2.7559 ± 0.0010 inch).
Except for the front camshaft bearing (11), locate oil hole in each camshaft
bearing so that oil hole is located at the top of the bore.
- - -
Align oil hole in the front camshaft bearing (11) with the oil hole in the cylin-
der block.
The camshaft bearings are installed into the cylinder block at the following positions:
Distance from front face of cylinder block is 816.5 ± 0.8 mm

P - -
(32.15 ± 0.03 inch).

R (21.12 ± 0.03 inch).

S (11.59 ± 0.03 inch).

T (0.020 ± 0.010 inch).
UENR0996-03 341
i06836904
Cylinder Block
SMCS Code: 1201
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 261-0191
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
342 UENR0996-03
Table 247
Specification for 261-0191 Cylinder Block Gp

The bottom of spacer plate (2), the top of cylinder block, and both surfaces of gasket (1)
must be free of fuel, oil, water, adhesives, assembly compounds or any other contami-
1 1 227-1204 Gasket
nants during assembly.
Thickness of the gasket is 0.20 ± 0.02 mm (0.008 ± 0.001 inch).

(0.73 ± 0.02 inch).
(continued)
UENR0996-03 343
(Table 247, contd)

Specification for 261-0191 Cylinder Block Gp

B 1 1S-9540 Dowel (0.63 ± 0.02 inch).

(0.79 ± 0.02 inch).
E 2 4N-0683 Dowel (0.75 ± 0.02 inch).
3 - - Lubricate the bore of the O-ring seal lightly with the fluid that is being sealed.
G - - Installation depth of the plug 2.0 ± 2.0 mm (0.08 ± 0.08 inch)
Table 248

Thoroughly lubricate the full inner diameter of the cylinder liner with clean en-
4 1 516-9693 Cylinder Block Liner
gine oil.
5 - - Lubricate the bore of the O-ring seal lightly with the fluid that is being sealed.
Dimension from the centerline of the crankshaft bearing bore to the top of a
H - -
new cylinder block is 425.45 mm (16.750 inch).
J - -
(5.1138 ± 0.0005 inch).
(continued)
344 UENR0996-03
(Table 248, contd)

Width of the main bearing cap is 215.9 mm (8.50 inch).
K - - Width of the cylinder block for the main bearing cap is 215.900 ± 0.020 mm
(8.5000 ± 0.0008 inch).
Dimension from the centerline of the crankshaft bearing bore to the bottom of
L - -
cylinder block pan rails is 165.1 mm (6.50 inch).
Use the following procedure to tighten the main bearing cap bolts:
(190 ± 10 lb ft).
6 14 3P-1323 Bearing Cap Bolts
4. Again, tighten the bolts that are opposite to the tab end to an extra angle of
120 ± 5 degrees.
4. Again, tighten the bolts that are in the tab end to an extra angle of 120 ± 5
degrees.
The total flatness of the top contact surface of the cylinder block must be within 0.10 mm (0.004 inch). The flatness must also be within
0.05 mm (0.002 inch) for any 150 mm (5.9 inch) section of the surface.
i02840286 Dimension (D) . . . . . . . . . . . . . 141.38 ± 0.08 mm

((5.566 ± 0.003 inch))
Cylinder Liner
SMCS Code: 1216
S/N: NJH1–Up
S/N: ECM1–Up
Note: Apply 5P-3975 Rubber Lubricant to the

cylinder liner seals prior to assembly.
(A) Bore diameter for the cylinder liner

. . . . . . 130.025 ± 0.025 mm ((5.1191 ± 0.0010 inch))
Outside diameters of the cylinder liner
Dimension (B) . . . . . . . . . . . . . 151.42 ± 0.05 mm

((5.961 ± 0.002 inch))
Dimension (C) . . . . . . . . . . . . . 147.90 ± 0.03 mm
((5.823 ± 0.001 inch))
UENR0996-03 345
i04379736
Cylinder Liner
SMCS Code: 1216
S/N: NJH1–Up
S/N: ECM1–Up

Outside diameter of the cylinder liners
(1) Cylinder block liner (2) Liner seal
Table 249
Specification for 197-9330 Cylinder Block Liner
A - - Diameter is 151.42 ± 0.05 mm (5.961 ± 0.002 inch).
B - - Diameter is 147.90 ± 0.03 mm (5.823 ± 0.001 inch).
C - - Diameter is 141.38 ± 0.08 mm (5.566 ± 0.003 inch).
- - - Apply 5P-3975 Rubber Lubricant to the cylinder liner seals before assembly.
346 UENR0996-03
i04384050
Cylinder Liner
SMCS Code: 1216
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 250
Specification for the 197-9322 Cylinder Block Liner, 238-2700 Cylinder Block Liner, and 2W-6000 Cylinder Block Liner
A - - New cylinder liner bore is 137.185 ± 0.025 mm (5.4010 ± 0.0010 inch).
Flange Thickness is 8.890 ± 0.020 mm (0.3500 ± 0.0008 inch).

B - -
Minimum thickness is 8.870 mm (0.3492 inch).
Use the following procedure to install the cylinder liner:

1. Put liquid soap on the cylinder block liner bore surfaces and the rubber seals that are on the lower end of the cylinder liner.
2. Dip the filler band (1) completely in clean engine oil.
3. Immediately install the filler band (1) in the groove that is under the cylinder liner flange.
4. Install the cylinder liner into the cylinder block before the expansion of the filler band.
Refer to Guideline For Reusable Parts and Salvage Operations, SEBF8068, “Cylinder Liners” for more information. Also, refer to Reuse And
Salvage Guidelines, SEBF8049, “Visual Inspection of the Piston” for more information.
UENR0996-03 347
i04399232
Cylinder Liner
SMCS Code: 1216
S/N: NJH1–Up
S/N: ECM1–Up
Table 251
Specification for the 253-8766 Cylinder Block Liner, 215-2985 Cylinder Block Liner, 322-1126 Cylinder Block Liner, and
304-9856 Cylinder Block Liner
A - - New liner bore is 145.000 ± 0.025 mm (5.7086 ± 0.0010 inch).
Thickness of flange on liner is 8.890 ± 0.020 mm (0.3500 ± 0.0008 inch).

B - -
The minimum thickness of the part that can be used again is 8.870 mm (0.3492 inch).
Use the following procedure for installing the cylinder liner into the cylinder block:
1. Apply 5P-3975 Rubber Lubricant on the surfaces of the cylinder liner bore. Apply 5P-3975 Rubber Lubricant on the rubber seals on the
lower part of the cylinder liner.
2. Put filler band (1) completely in clean engine oil for a moment.
3. Install the filler band in the groove under the liner flange without delay.
4. Install the liner in the bore immediately, before the filler band expands.
Refer to Guideline For Reusable Parts, SEBF8068, “Cylinder Liners” for more information. Also, refer to Testing and Adjusting, “Cylinder Liner
Projection - Inspect” for the procedure for inspecting the projection of the cylinder liners.
348 UENR0996-03
i04539349
Cylinder Liner
SMCS Code: 1216
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 197-9322
S/N: L4D1–Up
Part No.: 197-9322
S/N: L4E1–Up
Part No.: 197-9322
S/N: L4F1–Up
Part No.: 197-9322
S/N: TWG1–Up
S/N: NJH1–Up
Table 252
A - - Bore of the new cylinder liner is 137.185 ± 0.025 mm (5.4010 ± 0.0010 inch).
B - - Dimensions for flange (1) is 8.89 ± 0.02 mm (0.350 ± 0.001 inch).
Use the following procedure to install the cylinder liner:

1. Apply liquid soap on the cylinder block liner bore surfaces and the rubber seals that are on the lower end of
the cylinder liner.
- - -
2. Dip the filler band (2) completely in clean engine oil.
3. Immediately install the filler band in the groove that is under the flange.
4. Install the cylinder liner into the cylinder block before the expansion of the filler band..
UENR0996-03 349
i05391826
Cylinder Liner
SMCS Code: 1216
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 322-1126
S/N: L4D1–Up
Part No.: 322-1126
S/N: L4E1–Up
Part No.: 322-1126
S/N: L4F1–Up
Part No.: 322-1126
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 253
Specification for the 253-8766 Cylinder Block Liner, 215-2985 Cylinder Block Liner, and 322-1126 Cylinder Block Liner
A - - New liner bore is 145.000 ± 0.025 mm (5.7086 ± 0.0010 inch).
Thickness of flange on liner is 8.890 ± 0.020 mm (0.3500 ± 0.0008 inch).

B - -
The minimum thickness of the part that can be used again is 8.870 mm (0.3492 inch).
Use the following procedure for installing the cylinder liner into the cylinder block:
1. Apply 5P-3975 Rubber Lubricant on the surfaces of the cylinder liner bore. Apply 5P-3975 Rubber Lubricant on the rubber seals on the
lower part of the cylinder liner.
2. Put filler band (1) completely in clean engine oil for a moment.
3. Install the filler band in the groove under the liner flange without delay.
4. Install the liner in the bore immediately, before the filler band expands.
Refer to Guideline For Reusable Parts, SEBF8068, “Cylinder Liners” for more information. Also, refer to Testing and Adjusting, “Cylinder Liner
Projection - Inspect” for the procedure for inspecting the projection of the cylinder liners.
350 UENR0996-03
i06059178
Cylinder Liner
SMCS Code: 1216
S/N: NJH1–Up
S/N: ECM1–Up
Table 254
A - - Diameter is 128.95 ± 0.03 mm (5.077 ± 0.001 inch).
B - - Diameter is 127 ± 0.38 mm (4.999 ± 0.015 inch)147.90 ± 0.03 mm (5.823 ± 0.001 inch).
C - - Diameter is 128.85 ± 0.05 mm (5.073 ± 0.002 inch).
D - - Diameter is 128.85 ± 0.05 mm (5.073 ± 0.002 inch).
E Diameter is 128.15 ± 0.05 mm (5.045 ± 0.002 inch).
F Diameter is 122.75 ± 0.2 mm (4.833 ± 0.008 inch).
- - - Bore diameter for the cylinder liner 115.025 ± 0.025 mm (4.529 ± 0.001 inch).
UENR0996-03 351
i03812236
Crankshaft
SMCS Code: 1202
S/N: NJH1–Up
S/N: ECM1–Up

(1) Main bearing journals
(2) Connecting rod bearing journals
The thrust plate should be used only on the center

main bearing journals.
(A) Dimensions for crankshaft gear
Average diameter after assembly

. . . . . . . 136.20 ± 0.11 mm ((5.362 ± 0.004 inch))
Maximum diameter after assembly . . 136.36 mm
((5.368 inch))
(C) Height from top of the dowel (3) to the surface of

the crankshaft . . . . 8.0 ± 0.5 mm ((0.31 ± 0.02 inch))
Note: After the crankshaft is assembled into the
block, the crankshaft end play should be a maximum
of 0.50 mm (0.020 inch) and a minimum of 0.10 mm
(0.004 inch).
Note: The gap between the crankshaft gear and the
crankshaft should not exceed 0.10 mm (0.004 inch).
352 UENR0996-03
i04375769
Crankshaft
SMCS Code: 1202
S/N: NJH1–Up
S/N: ECM1–Up
(1) Main bearing journal (2) Connecting rod bearing journal (3) Crankshaft gear
Table 255
Specifications for 221-9360 Crankshaft, 189-4918 Crankshaft, and 337-0201 Crankshaft.
Protrusion of the dowel from the face of the crankshaft is 6.4 mm

A 1 4N-0684 Dowel (0.25 inch).
Protrusion of the dowel from the surface of the crankshaft is 4.1 ± 0.5 mm
B 1 7S-5005 Dowel (0.16 ± 0.02 inch).
End play of the crankshaft is 0.11 to 0.57 mm (0.004 to 0.022 inch).

-
The maximum permissible end play with used bearings is 0.89 mm (0.035 inch).
UENR0996-03 353
i04393050
Crankshaft
SMCS Code: 1202
S/N: NJH1–Up
S/N: ECM1–Up
(2) Connecting rod bearing journal (3) Main bearing journal
Table 256
Specification for 361-5593 Crankshaft Gp
1 2 246-3144 Thrust Plate The thrust plate should be used only on the center main bearing journals.
The gap between the crankshaft gear and the crankshaft should not exceed 0.10 mm
A - -
(0.004 inch).
Average diameter of crankshaft gear is 136.25 ± 0.11 mm (5.364 ± 0.004 inch).

B - -
Maximum diameter of crankshaft gear after assembly is 136.38 mm (5.369 inch).
Height from top of the dowel (4) to the surface of the crankshaft is 8.0 ± 0.5 mm
D - -
(0.31 ± 0.02 inch).
After the crankshaft is assembled into the cylinder block, the crankshaft end play should
- - -
be between maximum of 0.50 mm (0.020 inch) and minimum of 0.10 mm (0.004 inch).
354 UENR0996-03
i04857852
Crankshaft
SMCS Code: 1202
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 257
The thrust plate should be used only on the center main bearing journals.
1 2 253-1752 Thrust Plate
Install the thrust plate with surface stamped with “BLOCK SIDE” towards block.
Install the upper main bearing half with grooves and holes in the block, and the lower main
2 7 211-0592 Main Bearing
bearing half in the bearing cap.
After assembly, average diameter (A) of crankshaft gear is 221.67 ± 0.13 mm

3 1 352-2001 Crankshaft Gear (8.72715 ± 0.00512 inch).
The gap between the crankshaft gear and the crankshaft should not exceed 0.10 mm
B - -
(0.004 inch).
After the crankshaft is assembled into the cylinder block, the crankshaft end play should be
- - -
between maximum of 0.57 mm (0.0224 inch) and minimum of 0.11 mm (0.004 inch).
UENR0996-03 355
Table 258
4 1 7S-5005 Dowel Protrusion of the dowel after installation (C) is 4.1 ± 0.5 mm (0.16 ± 0.02 inch).
5 1 4N-0684 Dowel Maximum protrusion of the new dowel is 6.4 mm (0.25 inch).
356 UENR0996-03
i05297805
Crankshaft
SMCS Code: 1202
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Table 259
Specification for 366-0230 Crankshaft Gp and 366-6114 Crankshaft Gp
Thrust plates should be used only on center main bearing.

After assembly, end play of the crankshaft is 0.11 to 0.57 mm (0.004 ± 0.022 inch).
UENR0996-03 357
Table 260
A 1 4N-0684 Dowel Maximum extension of the dowel from the face of the crankshaft is 6.4 mm (0.25 inch).
Extension of the dowel from the surface of the crankshaft is 4.1 ± 0.5 mm
B 1 7S-5005 Dowel (0.16 ± 0.02 inch).
i05447630
Crankshaft
SMCS Code: 1202
S/N: NJH1–Up
S/N: ECM1–Up

The thrust plate should be used only on the center

main bearing journals.
(A) Dimensions for crankshaft gear

358 UENR0996-03
Average diameter after assembly

. . . . . . . 136.20 ± 0.11 mm ((5.362 ± 0.004 inch))
Maximum diameter after assembly . . 136.36 mm
((5.368 inch))
(C) Height from top of the dowel to the surface of the

crankshaft . . . . . . . 8.0 ± 0.5 mm ((0.31 ± 0.02 inch))
Note: Crankshaft end play after assembly into

cylinder block is 0.1 mm (0.004 inch) min to 0.5 mm
(0.02 inch) max.
Note: The gap between the crankshaft gear and the
crankshaft should not exceed 0.10 mm (0.004 inch).
UENR0996-03 359
i05546257
Crankshaft
SMCS Code: 1202
S/N: NJH1–Up
S/N: ECM1–Up
Table 261

After assembly, end play of the crankshaft is 0.11 to 0.57 mm (0.004 to 0.022 inch).
360 UENR0996-03
Table 262
Extension of the dowel from the surface of the crankshaft is 4.1 ± 0.5 mm
B 1 7S-5005 Dowel (0.16 ± 0.02 inch).
UENR0996-03 361
i05587715
Crankshaft
SMCS Code: 1202
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 223-9731
S/N: L4D1–Up
Part No.: 223-9731
S/N: L4E1–Up
Part No.: 223-9731
S/N: L4F1–Up
S/N: NJH1–Up
Table 263
Specification for 223-9731 Crankshaft Gp and 160-3912 Crankshaft Gp
Refer to Specifications, “Connecting Rod Bearing Journal” and Specifications, “Main Bearing Journal” for more information about the crankshaft
journals.
For the correct procedure on measuring for a bent crankshaft, refer to the Guideline for Reusable Parts and Salvage Operations, SEBF8054,
“Procedure to Measure and Straighten Bent Crankshafts”.
A 1 4N-0684 Dowel Protrusion of the dowel from the face of the crankshaft is 6.4 mm (0.25 inch).
B 1 7S-5005 Dowel Protrusion of the dowel from the surface of the crankshaft is 4.1 ± 0.5 mm (0.16 ± 0.02 inch).
Average diameter of the crankshaft gear after assembly is 220.35 ± 0.15 mm

160-5120 Crankshaft (8.675 ± 0.006 inch).
C 1
Gear Maximum diameter of the crankshaft gear after assembly is 220.57 mm (8.684 inch).
Thrust plates to be used only on center main bearing.

- 2 253-1752 Thrust Plate End play of the crankshaft is 0.11 to 0.57 mm (0.004 to 0.022 inch)
The maximum permissible end play with used bearings is 0.89 mm (0.035 inch)
362 UENR0996-03
i06059265
Crankshaft
SMCS Code: 1202
S/N: NJH1–Up
S/N: ECM1–Up

Table 264
Average diameter of gear after assembly (A) is 113.76 ± 0.12 mm

(4.479 ± 0.005 inch).
2 1 282-7955 Crankshaft Gear
Maximum diameter of gear after assembly is 113.90 mm (4.484 inch).
Crankshaft end play after assembly into cylinder block is 0.21 to 0.60 mm (0.008 to 0.024 inch).
UENR0996-03 363
i06062433
Crankshaft
SMCS Code: 1202
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 189-4917
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 265
Refer to Specifications, “Connecting Rod and Main Bearing Journals” for more information about the crankshaft journals.
For the correct procedure of measuring for a bent crankshaft, refer to the Guideline for Reusable Parts and Salvage Operations, SEBF8054,
“Procedure to Measure and Straighten Bent Crankshafts”.
1 2 253-1752 Thrust Plate Install the thrust plates on the center main bearing journal of the crankshaft only.
A 1 4N-0684 Dowel Maximum protrusion of the dowel from the face of the crankshaft is 6.4 mm (0.25 inch).
2 Average diameter of the crankshaft gear after assembly is 220.34 ± 0.19 mm

1 223-9135 Crankshaft Gear (8.675 ± 0.007 inch).
B Maximum diameter of the crankshaft gear after assembly is 220.56 mm (8.683 inch).
The measurement for end play with thrust washers installed are listed below. The end play must fall on or between the measurements
that are listed below.
D
Minimum : 0.11 mm (0.004 inch)
Maximum : 0.57 mm (0.022 inch)
364 UENR0996-03

View C-C
Table 266
E 1 7S-5005 Dowel Protrusion of the dowel from the surface of the crankshaft is 4.1 ± 0.5 mm (0.16 ± 0.02 inch).
UENR0996-03 365
i06633321
Crankshaft
SMCS Code: 1202
S/N: NJH1–Up
S/N: ECM1–Up
Table 267

After assembly, end play of the crankshaft is 0.11 to 0.57 mm (0.004 to 0.022 inch).
366 UENR0996-03
Table 268
B 1 7S-5005 Dowel Extension of the dowel from the surface of the crankshaft is 4.1 ± 0.5 mm (0.16 ± 0.02 inch).
i03552560
Crankshaft Seals
SMCS Code: 1160; 1161
S/N: NJH1–Up
S/N: ECM1–Up

Tightening sequence for the crankshaft seal group
UENR0996-03 367

Section A-A
Note: During assembly, the front face of the

crankshaft seal and the rear face of the cylinder block
must be free of oil, fuel, water, dirt, assembly
compounds and any other contaminants.
(1) Apply 8T-9022 Silicone Gasket in order to fill the
space at the cylinder block, the crankshaft seal and
the flywheel housing.
368 UENR0996-03
i04375725
Crankshaft Seals
SMCS Code: 1160; 1161
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 319-7401
S/N: L4D1–Up
Part No.: 319-7401
S/N: L4E1–Up
Part No.: 319-7401
S/N: L4F1–Up
Part No.: 319-7401
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
(2) Front end of the crankshaft (4) Rear end of the crankshaft
UENR0996-03 369
Table 269
Specification for 142-5867 Crankshaft Seal, and 142-5868 Crankshaft Seal
Do not separate the seal from the sleeve. Replace the seal if the seal is separated from
the sleeve.
1 1 142-5867 Crankshaft Seal The sleeve of the front crankshaft seal should be flush with front face of crankshaft.
The seal driver should not contact the crankshaft seal inside diameter
177.80 ± 0.25 mm (7.000 ± 0.010 inch).
Do not separate the seal from the sleeve. Replace the seal if the seal is separated from
the sleeve.
Installation depth of the rear crankshaft seal is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).
3 1 142-5868 Crankshaft Seal The seal driver should not contact the crankshaft seal inside diameter
177.80 ± 0.25 mm (7.000 ± 0.010 inch).
The assembled installation depth should be checked with the crankshaft at maximum
rearward position.
i04394025
Crankshaft Seals
SMCS Code: 1160; 1161
S/N: NJH1–Up
S/N: ECM1–Up
226-4755 Crankshaft Seal Gp
(1) Crankshaft seal group (2) Ring seal (3) Crankshaft

370 UENR0996-03
Table 270
226-4755 Crankshaft Seal Install dry.

1 1
Gp Tighten bolts in numerical sequence as shown in Illustration 383 .
UENR0996-03 371
116-1091 Crankshaft Seal Gp
(4) Crankshaft seal group (5) O-ring seal (6) Crankshaft
Table 271
116-1091 Crankshaft Seal Install dry.

4 1
Gp Tighten bolts in numerical sequence as shown in Illustration 385 .
Front face of the crankshaft seal and the rear face of the cylinder block must be free of oil, water, dirt, assembly compounds, and contaminants
during assembly.
Apply, 8T-9022 Silicone Gasket in order to fill the space at the cylinder block, the crankshaft seal, and the flywheel housing.
372 UENR0996-03
i04535374
Crankshaft Seals
SMCS Code: 1160; 1161
S/N: NJH1–Up
S/N: ECM1–Up
(2) Front housing (4) O-ring seal

(3) Front crankshaft seal (5) Bolt

Detail A
Table 272
Specification for 296-1486 Crankshaft Seal Gp and 295-2351 Crankshaft Seal Gp
(continued)
UENR0996-03 373
(Table 272, contd)

The crankshaft seal excluder can be installed with the front seal for use in appli-
cations that operate in harsh environments. If the extruder is used on your appli-
1 1 4R-9999 Crankshaft Seal Excluder
cation, lubricate the inside diameter of the crankshaft seal excluder with liquid
soap prior to assembly to the crankshaft pulley.
Refer to Disassembly and Assembly for the complete procedure that is used for information that relates to the removal and the installation of
the front and the rear crankshaft seals.

Detail B
(7) Rear crankshaft seal group with dust lip
Table 273
Specification for 296-1486 Crankshaft Seal Gp and 295-2351 Crankshaft Seal Gp
The rear crankshaft seal group (6) is a double lipped seal that is used for wet flywheel hous-
- - -
ing applications.
i02359492
Vibration Damper and Pulley

SMCS Code: 1205
S/N: NJH1–Up
S/N: ECM1–Up
374 UENR0996-03
i04137369

SMCS Code: 1205
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 170-1757
S/N: L4D1–Up
Part No.: 170-1757
S/N: L4E1–Up
Part No.: 170-1757
S/N: L4F1–Up
S/N: NJH1–Up
S/N: ECM1–Up
(1) Bolts
(2) Pulley
(3) Damper assembly
Apply anti-seize compound to (1) bolts prior to
assembly.

(2) Damper
(3) Pulley
(1) Before assembly, apply molybdenum disulfide or

a graphite-based lubricant to the threads of the bolts.
UENR0996-03 375
i05298352

SMCS Code: 1205
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Table 274
Specification for 345-8397 Damper and Pulley Gp and 354-2423 Damper and Pulley Gp
1 6 1B-7538 Bolt Torque to 270 ± 40 N·m (199 ± 30 lb ft).

376 UENR0996-03
i05615109

SMCS Code: 1205
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Table 275
Specification for 354-2417 Damper and Pulley Gp, 354-2424 Damper and Pulley Gp and 354-2425 Damper and Pulley Gp
Use the following procedure to tighten the bolt:
1. Before assembly, lubricate the threads with molybdenum disulfide graphite base
1 6 148-2871 Bolt
lubricant.
3. Turn additional turn angle of 180 ± 5 degrees.
i03001867 Part No.: 223-9731

S/N: L4F1–Up
Connecting Rod Bearing Part No.: 223-9731
Journal S/N: TWG1–Up
SMCS Code: 1202; 1219; 1225 S/N: NJH1–Up
S/N: 3F61–Up S/N: ECM1–Up

Refer to Guideline For Reusable Parts, SEBF8009,
S/N: 3F71–Up “Main and Connecting Rod Bearings” and Guideline
For Reusable Parts, SEBF8041, “Specifications for
Part No.: 223-9731 Crankshaft in Caterpillar Engines”.
S/N: L4D1–Up
Part No.: 223-9731
S/N: L4E1–Up
UENR0996-03 377
Table 276
Connecting Rod Bearing Journal
97.000 ± 0.020 mm
Original Size Journal
(3.8189 ± 0.0008 inch)
Undersize Journal 0.63 mm

96.37 mm (3.794 inch)
(0.025 inch)
Undersize Journal 1.27 mm

95.73 mm (3.769 inch)
(0.050 inch)
Clearance between the new bearing and the journal

. . . . . . . . . . . . . . . . . . . . . . . . 0.062 mm to 0.160 mm
((0.0024 inch to 0.0063 inch))
Maximum permissible clearance between the bearing

and the journal . . . . . . . . . . . . 0.20 mm ((0.008 inch))
378 UENR0996-03
i04393017

SMCS Code: 1202; 1219; 1225
S/N: NJH1–Up
S/N: ECM1–Up
Table 277
Specification for 312-4593 Crankshaft
A - - Diameter of new connecting rod bearing journal is 89.000 ± 0.020 mm (3.5040 ± 0.0008 inch).
Clearance between a new bearing and a new journal is 0.050 ± 0.155 mm (0.0020 ± 0.0061 inch)
i04860933

SMCS Code: 1202; 1219; 1225
S/N: NJH1–Up
S/N: ECM1–Up
Table 278
Specification for 195-0312 Crankshaft and 195-0314 Crankshaft
Refer to Guideline For Reusable Parts, SEBF8009, “Main and Connecting Rod Bearings” and
- - -
Guideline For Reusable Parts, SEBF8041, “Crankshaft Measurements”.
- - - Original size of connecting rod bearing journal is 97.000 ± 0.020 mm (3.8189 ± 0.0008 inch).
- - - For undersize journal of 0.63 mm (0.025 inch) is 96.370 ± 0.020 mm (3.7941 ± 0.0008 inch).
Clearance between the new bearing and the journal is 0.062 mm to 0.160 mm
- - -
(0.0024 inch to 0.0063 inch).
- - - Maximum permissible clearance between the bearing and the journal is 0.20 mm (0.008 inch).
UENR0996-03 379
i06619588 Table 279

Connecting Rod Bearing
Original size journal 80.000 ± 0.020 mm
Journal (3.1496 ± 0.0008 inch)
SMCS Code: 1202; 1219; 1225

For additional information, refer to Reuse And
S/N: NJH1–Up Salvage Guidelines.
S/N: ECM1–Up
i07104883

SMCS Code: 1202; 1219; 1225
S/N: NJH1–Up
S/N: ECM1–Up
Table 280
Original size journal 89.000 ± 0.020 mm (3.5039 ± 0.0008 inch)
Undersize journal
88.492 ± 0.020 mm (3.4839 ± 0.0008 inch)
0.508 mm (0.0200 inch)
Undersize journal
88.238 ± .020 mm (3.4739 ± 0.0008 inch)
0.762 mm (0.0300 inch)
(Table 281, contd)

Clearance between a new bearing and a new journal Undersize journal 107.490 ± 0.020 mm
. . . . . . . 0.062 to 0.132 mm ((0.0024 to 0.0052 inch)) 0.510 mm (0.0201 inch) (4.2319 ± 0.0008 inch)
Undersize journal 107.240 ± 0.020 mm

i02845841
0.760 mm (0.0299 inch) (4.2220 ± 0.0008 inch)
Main Bearing Journal

Clearance between a new bearing and a new journal
SMCS Code: 1202; 1203 . . . . . . . 0.081 to 0.181 mm ((0.0032 to 0.0071 inch))
Table 282
S/N: NJH1–Up
Main Bearing Bore
S/N: ECM1–Up
Main bearing bore (original size) 116.000 ± 0.013 mm
Table 281 (4.5669 ± 0.0005 inch)
Oversize bore in block 116.510 ± 0.013 mm
Original size journal 108.000 ± 0.020 mm 0.510 mm (0.0201 inch) (4.5870 ± 0.0005 inch)
(4.2520 ± 0.0008 inch)
(continued)
i04379811

SMCS Code: 1202; 1203
S/N: NJH1–Up
S/N: ECM1–Up
380 UENR0996-03
Table 283
Specification for the 221-9360 Crankshaft, 189-4918 Crankshaft, and 337-0201 Crankshaft
Main bearing journal original size is 120.650 ± 0.020 mm (4.7500 ± 0.0008 inch).
Diameter of 0.63 mm (0.025 inch) undersize main bearing journal is 120.015 ± 0.020 mm
(4.7250 ± 0.0008 inch).
Diameter of 1.27 mm (0.050 inch) undersize main bearing journal size is 119.380 ± 0.020 mm
(4.7000 ± 0.0008 inch).
- - - Clearance between new bearing and new journal of Main bearing cap with two bolts is
0.076 to 0.186 mm (0.0030 to 0.0073 inch).
Clearance between new bearing and new journal of Main bearing cap with four bolts is
0.071 to 0.178 mm (0.0028 to 0.0070 inch).
Original size of the main bearing bore in the block is 129.891 ± 0.013 mm (5.1138 ± 0.0005 inch).
Diameter of 0.63 mm (0.025 inch) oversize main bearing bore in the block is 130.521 ± 0.013 mm
(5.1387 ± 0.0005 inch).
i04860949

SMCS Code: 1202; 1203
S/N: NJH1–Up
S/N: ECM1–Up
Table 284
Specification for 195-0312 Crankshaft
Refer to Guideline For Reusable Parts And Salvage Operations, SEBF8009, “Main and Connect-
- - - ing Rod Bearings” and Guideline For Reusable Parts and Salvage Operations, SEBF8041,
“Specifications for Crankshaft in Caterpillar Engines”.
- - - Original size of main Bearing Journals is 120.650 ± 0.020 mm (4.7500 ± 0.0008 inch).
Clearance between the new bearing and the journal is 0.076 to 0.186 mm
- - -
(0.0030 to 0.0073 inch).
i07317148 S/N: L4F1–Up
Main Bearing Journal Part No.: 223-9731

S/N: TWG1–Up
SMCS Code: 1202; 1203 S/N: NJH1–Up
S/N: 3F61–Up S/N: ECM1–Up
S/N: 3F71–Up
Connecting Rod Bearing Journals
Part No.: 223-9731 Refer to Guideline For Reusable Parts And Salvage
S/N: L4D1–Up Operations, SEBF8009, “Main and Connecting Rod
Bearings”.
Part No.: 223-9731
S/N: L4E1–Up
Part No.: 223-9731
UENR0996-03 381
Refer to Guideline For Reusable Parts and Salvage i02818273

Operations, SEBF8041, “Specifications for
Crankshaft in Caterpillar Engines” for 3500 Engines. Connecting Rod
Refer to Guideline For Reusable Parts and Salvage SMCS Code: 1218
Operations, SEBF9217, “Specifications for
Crankshaft in Caterpillar Engines” for C7-C32 S/N: NJH1–Up
Engines.
S/N: ECM1–Up
Clearance between new bearing and new journal
. . . . . . . 0.070 to 0.178 mm ((0.0028 to 0.0070 inch))
Main Bearing Journals

Table 285
Main Bearing Journals
120.650 ± 0.020 mm
Original Size Journal
(4.7500 ± 0.0008 inch)
Undersize Journal 0.63 mm 120.015 ± 0.020 mm

(0.025 inch) (4.7250 ± 0.0008 inch)
Undersize Journal 1.27 mm 119.380 ± 0.020 mm

(0.050 inch) (4.7000 ± 0.0008 inch)
Main bearing cap with two bolts

. . . . 0.076 to 0.186 mm ((0.0030 to 0.0073 inch))
Main bearing cap with four bolts

. . . . 0.071 to 0.178 mm ((0.0028 to 0.0070 inch))
Table 286
Main Bearing Bore
Original Size of the Bore In the 129.891 ± 0.013 mm

Block (5.1138 ± 0.0005 inch)
Oversize Bore 0.63 mm 130.526 ± 0.013 mm

(0.025 inch) (5.1388 ± 0.0005 inch)
(1) Etch the cylinder number on the connecting rod

and the cap in this location. Mark the connecting rod
and the cap with a number 1 through 6. Mark the
numbers on the same side of the connecting rod as
the bearing retainer notch.
Note: Install the connecting rod in the engine with the
part number to the rear of the engine.
Note: If you replace a connecting rod make sure that

you do not combine fractured connecting rods with
machined connecting rods. Refer to Special
Instruction, REHS3801, “Combining Machined
Connecting Rods and Fractured Connecting Rods on
C13 Engines” for more instruction.
382 UENR0996-03
(2) Tighten the connecting rod bolts. Use the

instructions that follow.
1. Tighten the connecting rod bolts.
Tighten the connecting rod bolts to the following

torque. . . . . . . . . . . . . . . . .130 ± 7 N·m ((95 ± 5 lb ft))
2. Tighten each connecting rod bolt for an additional
amount.
Rotate each connecting rod bolt in the clockwise

direction. . . . . . . . . . . . 60 ± 5 degrees (1/6 of a turn)
(A) Bore in the connecting rod for the piston pin

bearing . . . . . . . . . . . . . . . . . . . . . 57.810 ± 0.013 mm
((2.2759 ± 0.0005 inch))
(B) Bore in the bearing for the piston pin

. . . . . . . 53.205 ± 0.008 mm ((2.0947 ± 0.0003 inch))
Diameter of the piston pin . . . . . . 53.155 ± 0.005 mm

((2.0927 ± 0.0002 inch))
Thoroughly lubricate the piston pin with clean engine
oil prior to assembly of the piston and connecting rod.
(C) Location of the bearing joint from the horizontal

centerline of the pin bore . . . . . . . . 12.5 ± 5 degrees
(D) Bore in the connecting rod for the crankshaft

bearing . . . . . . . . . . . . . . . . . . . . . 93.800 ± 0.013 mm
((3.6929 ± 0.0005 inch))
(E) Distance between the center of the bearings

. . . . . . . . . . . . . . . . . . . . . . . . 247.5 mm ((9.74 inch))
Note: The connecting rod must be heated for the
installation of the piston pin bearing. Do not use a
torch.
(F) The connecting rod may be heated from

175 °C to 260 °C (347 °F to 500 °F) for the
installation of the piston pin bearing. Maximum
distance for heating the connecting rod . . . . . . 88 mm
((3.5 inch))
UENR0996-03 383
i04394063
Connecting Rod
SMCS Code: 1218
S/N: NJH1–Up
S/N: ECM1–Up
Table 287
Specification for 292-0483 Connecting Rod
Length (A) may be heated to 175 °C to 260 °C (347 °F to 468 °F) to assemble the
small end connecting rod bearing.
Bore in the connecting rod for connecting rod bearing is 57.810 ± 0.013 mm
(2.2760 ± 0.0005 inch).
115-2972 Connecting
1 1 Bore in the connecting rod bearing after assembly is 53.205 ± 0.008 mm
Rod Bearing
(2.0947 ± 0.0003 inch).
Thoroughly lubricate the piston pin with clean engine oil prior to assembly of the pis-
ton and connecting rod.
Diameter of the piston pin is 53.155 ± 0.005 mm (2.0927 ± 0.0002 inch).
292-0484 Connecting Bore in the large end of connecting rod for the connecting rod bearing is
2 1 93.800 ± 0.013 mm (3.6929 ± 0.0005 inch).
Rod Bearing
(continued)
384 UENR0996-03
(Table 287, contd)

Use the following procedure to tighten the bolts:
1. Lubricate the bolts with clean engine oil before assembly.
3 2 115-2973 Bolt
2. Tighten each bolt to 130 ± 7 N·m (96 ± 5 lb ft).
3. Tighten each bolts to an additional 60 ± 5 degrees.
- - - Distance (B) between center of the bearings is 239 mm (9.4 inch).

UENR0996-03 385
i04509211
Connecting Rod
SMCS Code: 1218
S/N: NJH1–Up
S/N: ECM1–Up
Table 288
Handle the fractured connecting rod with care. Use a soft jawed vise in order to hold the connecting rod when you are loosening the connecting
rod cap bolts. Use a soft faced hammer in order to tap the connecting rod cap, if necessary.
Bore in the connecting rod for the 256-9656 Bushing is 54.630 ± 0.013 mm
A - -
(2.1508 ± 0.0005 inch).
Bore in the bushing for the piston pin is 50.035 ± 0.008 mm

B 1 256-9656 Bushing
(1.9699 ± 0.0003 inch).
The connecting rod must be heated for the installation of the sleeve bearing. Do not use a torch.
The connecting rod may be heated from 175 to 260 °C (347 to 500 °F) for the in-
C - - stallation of the bushing. Maximum distance for heating the connecting rod is
85 mm (3.3 inch).
Thoroughly lubricate the piston pin with clean engine oil prior to assembly of the
- - -
piston and connecting rod.
(continued)
386 UENR0996-03
(Table 288, contd)

1 - - The bearing joint must be within ± 5 degrees of either location.
D - - Distance between the center of the bushings is 217 mm (8.5 inch).
Bore in the connecting rod for the crankshaft bearing is 85.000 ± 0.013 mm
F - -
(3.3465 ± 0.0005 inch).

View E-E
Table 289
Etch the cylinder number on the connecting rod and the cap in this location. Mark
2 - - the connecting rod and the cap with a number 1 through 6. Mark the numbers on
the same side of the connecting rod as the bearing retainer notch (4).
Install the rod and piston group in the engine with the part number of the forging for the rod assembly to the rear of the engine. The rear of the
engine is the flywheel end of the engine. Lubricate the rod and piston group with clean engine oil before you insert the rod and piston group into
the block.
Use the following procedure in order to tighten the bolts:
3 2 160-8197 Bolt 1. Tighten the bolts to 50 ± 5 N·m (37 ± 4 lb ft).
2. Again tighten the bolts to a torque angle of 90 ± 5 degrees.
i04690696
Connecting Rod
SMCS Code: 1218
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 387
(D) Distance between the center of the bearings

. . . . . . . . . . . . . . . . . . . . . . . . . . . 239 mm ((9.4 inch))
(E) Bore in the connecting rod for the crankshaft

bearing . . . . . . . . . . . . . . . . . . . . . 93.800 ± 0.013 mm
((3.6929 ± 0.0005 inch))
Note: If you replace a connecting rod, make sure that

you do not combine fractured connecting rods with
machined connecting rods. Refer to Special
Instruction, REHS3801, “Combining Machined
Connecting Rods and Fractured Connecting Rods on
C13 Engines” for more instruction.
(A) Dimensions for the piston pin
Bore in the connecting rod for the piston pin

bearing . . . . . . . . . . . . . . . . . 57.810 ± 0.013 mm
((2.2759 ± 0.0005 inch))
Bore in the bearing for the piston pin
. . . . 53.205 ± 0.008 mm ((2.0947 ± 0.0003 inch))
Diameter of the piston pin . . 53.155 ± 0.005 mm
((2.0927 ± 0.0002 inch))
(B) Location of the bearing joint from the horizontal

centerline of the pin bore . . . . . . . . 12.5 ± 5 degrees
Note: The connecting rod must be heated for the

installation of the piston pin bearing. Do not use a
torch.
(C) The connecting rod may be heated from

175 °C to 260 °C (347 °F to 500 °F) for the
installation of the piston pin bearing. Maximum
distance for heating the connecting rod . . . . . . 88 mm
((3.5 inch))
388 UENR0996-03
i05393058
Connecting Rod
SMCS Code: 1218
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 224-3245
S/N: L4D1–Up
Part No.: 224-3245
S/N: L4E1–Up
Part No.: 224-3245
S/N: L4F1–Up
Part No.: 224-3245
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 290
Specification for 283-7669 Piston and Rod Gp, and 224-3245 Rod As
(continued)
UENR0996-03 389
(Table 290, contd)

A - - Location of the bearing joint from the horizontal centerline of the pin bore is ± 5 degrees.
Inside diameter of connecting rod for bearing for the piston pin is 64.592 ± 0.013 mm
B - -
(2.5430 ± 0.0005 inch).
C - - Bore diameter of bearing for the piston pin is 60.035 ± 0.008 mm (2.3636 ± 0.0003 inch).
Maximum length for heating the connecting rod during the installation of bearing for piston pin is
93.0 mm (3.66 inch).
D - -
Temperature for heating the connecting rod is 175 to 260 °C (347 to 500 °F).
Note : Apply heat to the connecting rod prior to installation of bearing for piston pin.
Distance between the center of the bore for the bearing for piston pin and the center of the bore for
E - -
the crankshaft journal is 270.76 mm (10.660 inch).
Inside diameter of connecting rod for the bearing for crankshaft journal is 103.200 ± 0.013 mm
F - -
(4.0630 ± 0.0005 inch).
G - - Bore in the bearing for crankshaft is 97.088 ± 0.016 mm (3.8224 ± 0.0006 inch).
Use the following procedure in order to tighten the bolts for the rod cap. Refer Illustration 399 for
tightening sequence.
1. Before assembly, lubricate the threads of the bolts and the seating face of the bolt heads with
clean engine oil.
1 4 213-3217 Bolt 2. Tighten bolt 1 and bolt 3 to 70 ± 4 N·m (52 ± 3 lb ft).
3. Tighten bolt 2 and bolt 4 to 70 ± 4 N·m (52 ± 3 lb ft).
4. Tighten bolt 2 and bolt 4 by an additional angle of 60 ± 5 degrees.
5. Again tighten bolt 1 and bolt 3 to 70 ± 4 N·m (52 ± 3 lb ft).
6. Tighten bolt 1 and bolt 3 by an additional angle of 60 ± 5 degrees.
i02690465 Lubricate the entire piston to 360° in zone (A) prior to

assembly into the cylinder block. Use clean engine
Piston and Rings oil.
SMCS Code: 1214; 1215 Note: Install the top piston ring with the side marked
“UP-1” toward the top of the piston.
S/N: NJH1–Up
(2) Top piston ring groove
S/N: ECM1–Up
The ends of the piston ring have a clearance
when the piston ring is installed in a cylinder liner
with a bore of 130.000 mm (5.1181 inch).
Clearance . . . . . . . . . . . . . . . . . . .0.40 ± 0.10 mm
((0.016 ± 0.004 inch))
The top 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))
Note: Install the intermediate piston ring with the side
marked “UP-2” toward the top of the piston.
(3) Intermediate piston ring groove
Width of groove in new piston for intermediate

piston ring . . . . . . . . . . . . . . . . 3.053 ± 0.013 mm
((0.1202 ± 0.0005 inch))
Thickness of new intermediate piston ring
. . . . . 2.980 ± 0.010 mm ((0.1173 ± 0.0004 inch))
(1) The piston is symmetrical with a center crater.

390 UENR0996-03
The ends of the piston ring have a clearance i02961800

with a bore of 130.000 mm (5.1181 inch). Piston and Rings
Clearance . . . . . . . . . . . . . . . . 1.000 ± 0.125 mm
((0.0393 ± 0.0049 inch)) SMCS Code: 1214; 1215
The intermediate piston ring has an increase in S/N: NJH1–Up
clearance for each 0.03 mm (0.001 inch)
increase in the cylinder liner bore. Increase S/N: ECM1–Up
. . . . . . . . . . . . . . . . . . . . . 0.09 mm ((0.004 inch))
Note: The ends of the oil control piston ring should
be a distance of 180 degrees from the ring end gap
when the oil control piston ring is assembled. The
white colored portion of the piston ring must be
visible at the ring end gap.
(4) Oil control ring groove
Width of groove in new piston for oil control

piston ring . . . . . . . . . . . . . . . . 4.052 ± 0.012 mm
((0.1595 ± 0.0005 inch))
Thickness of new oil control piston ring
. . . . . 3.980 ± 0.010 mm ((0.1567 ± 0.0004 inch))
The ends of the piston ring have a clearance
with a bore of 130.000 mm (5.1181 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) Illustration 401 g01481993
increase in the cylinder liner bore. Increase
. . . . . . . . . . . . . . . . . . . . . 0.09 mm ((0.004 inch)) (1) The piston is symmetrical with a center crater.
Note: After the piston rings have been installed, Lubricate the entire piston to 360 degrees in zone (A)
rotate the piston rings so that the end gaps are 120 prior to assembly into the cylinder block. Use clean
degrees from each other. engine oil.
(B) Piston pin bore diameter . . . . 53.250 ± 0.010 mm Top Piston Ring (2)
((2.0965 ± 0.0004 inch))
Note: Install the top piston ring with the side marked
Note: Thoroughly lubricate the piston pin with clean “UP-1” toward the top of the piston.
engine oil prior to assembly.
Thickness of the new top piston ring . . . . . . . 4.0 mm
((0.16 inch))
Clearance between the ends of the piston ring in a

cylinder liner bore of 130.000 mm (5.1181 inch)
. . . . . . . . . . . . 0.40 ± 0.10 mm ((0.016 ± 0.004 inch))
Increase in the clearance between the ends of the

piston ring for each 0.03 mm (0.001 inch) increase in
the cylinder liner bore . . . . . . 0.09 mm ((0.004 inch))
Intermediate Piston Ring (3)

marked “UP-2” toward the top of the piston.
Width of groove in new piston for intermediate piston

ring . . . . . 3.053 ± 0.013 mm ((0.1202 ± 0.0005 inch))
UENR0996-03 391
Thickness of the new intermediate piston ring S/N: L4F1–Up

. . . . . . . . 2.980 ± 0.010 mm ((0.1173 ± 0.0004 inch))
Part No.: 316-6617
Clearance between the ends of the piston ring in a S/N: TWG1–Up
cylinder liner bore of 130.000 mm (5.1181 inch) S/N: NJH1–Up
. . . . . . . . 1.000 ± 0.125 mm ((0.0393 ± 0.0049 inch))
Refer to Reuse And Salvage Guidelines, SEBF8049,
Increase in the clearance between the ends of the “Visual Inspection of the Piston” and Reuse And
piston ring for each 0.03 mm (0.001 inch) increase in Salvage Guidelines, SEBF8051, “Inspection and
Measuring Procedures for Piston Pins”.
Oil Control Ring (4)

white colored portion of the piston ring must be
visible at the ring end gap.
Width of groove in new piston for oil control piston

ring . . . . . 4.052 ± 0.012 mm ((0.1595 ± 0.0005 inch))
Thickness of the new oil control ring

. . . . . . . . 3.980 ± 0.010 mm ((0.1567 ± 0.0004 inch))

. . . . . . . . . . . . 0.45 ± 0.15 mm ((0.018 ± 0.006 inch))
Increase in the clearance between the ends of the oil

control ring for each 0.03 mm (0.001 inch) increase
in the cylinder liner bore . . . . 0.09 mm ((0.004 inch)) Illustration 402 g01516394
Piston and rod
Note: After the piston rings have been installed,
(1) Piston crown assembly
rotate the piston rings so that the end gaps are 120 (5) Piston skirt
degrees from each other.
Thoroughly lubricate the outer surface of the entire
Piston Pin (5) piston and the piston rings with clean engine oil
before installation in the cylinder block.
Note: Thoroughly lubricate the piston pin with clean
engine oil prior to assembly. Top Piston Ring (2)
Piston pin bore diameter . . . . . . . 53.220 ± 0.010 mm Install the piston ring with the side marked “UP-1”
toward the top of the piston. The blue color stripe and
((2.0952 ± 0.0004 inch)) the yellow color stripe must be to the right of the ring
end gap.
i02991923
Thickness of new top piston ring . . . . . . . . . 3.83 mm
Piston and Rings ((0.151 inch))
SMCS Code: 1214; 1215 Clearance between the ends of the piston ring in a
S/N: 3F61–Up . . . . . . . . . . . . 0.35 ± 0.05 mm ((0.014 ± 0.002 inch))
S/N: 3F71–Up
Part No.: 316-6617 piston ring for each 0.03 mm (0.001 inch) increase in
S/N: L4D1–Up the cylinder liner bore . . . . . . 0.08 mm ((0.003 inch))
Part No.: 316-6617
S/N: L4E1–Up
Part No.: 316-6617
392 UENR0996-03
Intermediate piston ring (3) Note: Thoroughly lubricate the piston pin with clean
engine oil before assembly.
Install the piston ring with the side marked “UP-2”
toward the top of the piston. The violet color stripe
must be to the right of the ring end gap. i03552482
Width of groove in new piston for the intermediate Piston and Rings
piston ring . . . . . . . . . . . . . . . . . . . 3.070 ± 0.010 mm
((0.1209 ± 0.0004 inch)) SMCS Code: 1214; 1215
Thickness of new intermediate piston ring S/N: NJH1–Up

. . . . . . . . 3.005 ± 0.015 mm ((0.1183 ± 0.0006 inch)) S/N: ECM1–Up
Clearance between the ends of the piston ring in a Steel Piston
. . . . . . . . . . . . .0.70 ± 0.10 mm ((0.028± 0.004 inch))

Oil control ring (4)

The spring ends of the piston ring should be
assembled 180 degrees from the ring end gap. The
blue color stripe can be to the right or to the left of the
ring end gap.
Width of groove in new piston for the oil control piston

ring . . . . . . . . . 4.03 ± 0.01 mm ((0.159 ± 0.001 inch))
Thickness of new oil control piston ring
(6) Connecting rod
. . . . . . . . . . . . 3.98 ± 0.01 mm ((0.157 ± 0.001 inch))
Clearance between the groove and the new oil (A) Height of the tall piston . . . . . . 105.00 ± 0.10 mm
control piston ring . . . . . . . . . . . . . . . .0.05 ± 0.02 mm ((4.134 ± 0.004 inch))
((0.002 ± 0.001 inch)) Note: Before assembly, lubricate the entire piston
body assembly (1) to 360 degrees on zone (A) with
Clearance between the ends of the piston ring in a the clean engine oil.
. . . . . . . . . . . . 0.45 ± 0.15 mm ((0.018 ± 0.006 inch))
Top Piston Ring (2)
Increase in the clearance between the ends of the Note: Install the top piston ring with the side marked
piston ring for each 0.03 mm (0.001 inch) increase in “UP-1” toward the top of the piston. The green
the cylinder liner bore . . . . . . 0.08 mm ((0.003 inch)) colored stripe faces to the right of the ring end gap.
Note: After all of the piston rings have been installed, Thickness of the new top piston ring . . . . . . 3.95 mm
rotate the piston rings so that the end gaps are ((0.156 inch))
separated by 120 degrees.
Piston Pin (6) cylinder liner bore of 130 mm (5.1 inch)
. . . . . . . . . . . . 0.51 ± 0.05 mm ((0.020 ± 0.002 inch))
Diameter of new piston pin . . . . . 59.975 ± 0.005 mm
((2.3612 ± 0.0002 inch)) Increase in the clearance between the ends of the
Length of the piston pin . . . . . . . . . . 89.80 ± 0.15 mm the cylinder liner bore . . . . . . 0.09 mm ((0.004 inch))
((3.535 ± 0.006 inch))
Bore in the body of the piston for the piston pin

. . .60.0925 ± 0.0075 mm ((2.36580 ± 0.00030 inch))
UENR0996-03 393

marked “UP-2” toward the top of the piston. The
violet and the orange colored stripe faces to the right
of the piston ring end gap.
Thickness of the new intermediate piston ring

. . . . . . . . . . . . 2.98 ± 0.01 mm ((0.117 ± 0.001 inch))

cylinder liner bore of 130 mm (5.1 inch)
. . . . . . . . . . . . . 1.00 ± 0.10 mm ((0.39 ± 0.004 inch))

Oil Control Piston Ring (4)

green colored stripe can be to the right of the ring end
gap or to the left of the ring end gap.
Thickness of the new oil control piston ring

. . . . . . . . . . . 3.98 ± 0.01 mm ((0.157 ± 0.0004 inch))
Clearance between the ends of the piston ring in

. . . . . . . . . . . . 0.45 ± 0.15 mm ((0.018 ± 0.006 inch))

rotate the piston rings so that the end gaps are 120
Piston Pin (5)

Note: Before assembly, thoroughly lubricate the
piston pin with clean engine oil.
Outside diameter . . . . . . . . . . . . . 53.155 ± 0.005 mm

((2.0927 ± 0.0002 inch))
Inside diameter . . . . . . . . . . . . . . . . 23.00 ± 0.25 mm

((0.906 ± 0.010 inch))
Length . . . . . 92.00 ± 0.15 mm ((3.622 ± 0.006 inch))
Bore diameter for the piston pin

. . . . . . . 53.250 ± 0.010 mm ((2.0965 ± 0.0004 inch))
394 UENR0996-03
i04380849
Piston and Rings

SMCS Code: 1214; 1215
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 291
Specification for the 229-2863 Piston and Rod Gp, and 252-0652 Piston and Rod Gp
Install the top piston ring with the side marked “UP-1” toward the top of the piston. Orient the col-
ored faces to the right of the end gaps of the piston ring.
Clearance between the ends of the top piston ring in a cylinder liner bore of 137.16 mm
247-6130 Top Pis- (5.400 inch) is 0.40 ± 0.10 mm (0.016 ± 0.004 inch).
1 1
ton Ring
Increase in the clearance between the ends of the top piston ring for each 0.03 mm (0.001 inch)
increase in the cylinder liner bore is 0.08 mm (0.003 inch).
Thickness of new top piston ring is 3.81 mm (0.150 inch).
164-4187 Piston Install the intermediate piston ring with the side marked “UP-2” toward the top of the piston. Orient
2 1
Ring the colored faces to the right of the end gaps of the piston ring.
(continued)
UENR0996-03 395
(Table 291, contd)

Clearance between the ends of the intermediate piston ring in a cylinder liner bore of 137.16 mm
(5.400 inch) is 0.770 ± 0.125 mm (0.0303 ± 0.0049 inch)
Increase in the clearance between the ends of the intermediate piston ring for each 0.03 mm
(0.001 inch) increase in the cylinder liner bore is 0.08 mm (0.003 inch)
Thickness of new intermediate piston ring is 3.08 mm (1.121 inch)
The spring ends of the oil control ring should be placed 180 degrees from the ring end gap. The
colored stripe in the spring coil must be visible at the ring end gap.
Clearance between the groove and the new oil control piston ring in a cylinder liner bore of
306-4014 Piston 137.16 mm (5.400 inch) is 0.45 ± 0.15 mm (0.018 ± 0.006 inch)
3 1
Ring
Increase in the clearance between the ends of the oil control piston ring for each 0.03 mm
Thickness of new oil control piston ring is 3.980 ± 0.010 mm (0.1567 ± 0.0004 inch)
Lubricate the piston pin with clean engine oil before the piston pin is inserted into the piston body
assembly and the connecting rod (6).
Diameter of the new piston pin is 59.975 ± 0.005 mm (2.3612 ± 0.0002 inch)
180-7350 Piston
4 1
Pin Length of the new piston pin is 89.80 ± 0.15 mm (3.535 ± 0.006 inch)
Bore in the piston assembly for the piston pin is 60.095 ± 0.010 mm (2.3659 ± 0.0004 inch)
Install the retainer ring (5) with the gap at the bottom of the piston. Refer to Illustration 404
7 1 151-5925 Bolt Torque to 40 ± 8 N·m (30 ± 6 lb ft)
Thoroughly lubricate the entire piston in zone (A) with clean engine oil prior to assembly into the cylinder block.
After the piston rings have been installed, rotate the piston rings so that the end gaps are placed at 120 degrees distance from each other.
396 UENR0996-03
i04380852
Piston and Rings

SMCS Code: 1214; 1215
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Table 292
Specification for the 234-6136 Piston and Rod Gp, and 220-1441 Piston and Rod Gp
Install the top piston ring with the side marked “UP-1” toward the top of the piston. The
purple colored stripe faces to the right of the piston ring end gap.
Thickness of new top piston ring is 3.845 mm (0.1514 inch)

1 1 223-9159 Top Piston Ring Clearance between the ends of the piston ring in a cylinder liner bore of 144.975 mm
(5.7077 inch) is 0.40 ± 0.10 mm (0.016 ± 0.004 inch)
Increase in the clearance between the ends of the piston ring for each 0.03 mm
Install the intermediate piston ring with the side marked “UP-2” toward the top of the pis-
238-2707 Piston Ring ton. The white-colored stripe faces to the right of the piston ring end gap.
2 1
(continued)
UENR0996-03 397
(Table 292, contd)

Clearance between the ends of the piston ring in a cylinder liner bore of 144.975 mm
(5.7077 inch) is 0.600 ± 0.125 mm (0.0236 ± 0.0049 inch)
The spring ends of the oil control ring should be assembled 180 degrees from the ring
end gap. The colored faces to the right or left of the piston ring end gap.
Width of groove in new piston for oil control piston ring is 3.020 ± 0.010 mm
(0.1189 ± 0.0004 inch)
3 1 246-5659 Piston Ring
Clearance between groove and oil control piston ring is 0.04 mm (0.002 inch)
(5.7077 inch) is 0.55 ± 0.15 mm (0.022 ± 0.006 inch)
Thoroughly lubricate the piston pin with clean engine oil before the piston is inserted into
the piston body and the connecting rod (6).
Diameter of the bore in the finished bearing that is installed into the piston skirt for the
piston pin is 60.0925 ± 0.0075 mm (2.36584 ± 0.00030 inch)
4 1 180-7350 Piston Pin
Diameter of the new piston pin is 59.975 ± 0.005 mm (2.3612 ± 0.0002 inch)
Length of the piston pin is 89.80 ± 0.15 mm (3.535 ± 0.006 inch)
Install the retainer ring (5) with the gap at the bottom of the piston. Refer to Illustration
405 .
Thoroughly lubricate the entire piston in zone (A) with clean engine oil prior to assembly into the cylinder block
398 UENR0996-03
i05298620
Piston and Rings

SMCS Code: 1214; 1215
S/N: NJH1–Up
S/N: ECM1–Up
Table 293
Specification for 342-6368 Piston and Rod Gp
Install the top piston ring with the side marked “UP-1” toward the top of the piston. Orient
the colored faces to the right of the end gaps of the piston ring.
1 1 310-4188 Piston Ring Clearance between the ends of the top piston ring is 0.35 ± 0.05 mm
(0.014 ± 0.002 inch).
ton. Orient the colored faces to the right of the end gaps of the piston ring.
Clearance between the ends of the intermediate piston ring is 0.15 ± 0.10 mm
(0.006 ± 0.004 inch).
Thickness of new intermediate piston ring is 3.005 ± 0.15 mm (0.118 ± 0.006 inch).
Width in the piston body for piston ring is 3.070 ± 0.013 mm (0.1209 ± 0.0005 inch).
The spring ends of the oil control ring should be placed 180 degrees from the ring end
gap. The colored stripe in the spring coil must be visible at the ring end gap.
Clearance between the groove and the new oil control piston ring is 0.45 ± 0.15 mm
(0.018 ± 0.006 inch).
Thickness of new oil control piston ring is 3.980 ± 0.010 mm (0.1567 ± 0.0004 inch).
Width in the piston body for piston ring is 4.030 ± 0.013 mm (0.1587 ± 0.0005 inch).
(continued)
UENR0996-03 399
(Table 293, contd)

Lubricate the piston pin with clean engine oil before the piston pin is inserted into the pis-
ton body assembly and the connecting rod .
Diameter of the new piston pin is 59.975 ± 0.005 mm (2.3612 ± 0.0002 inch).
4 1 180-7350 Piston Pin
Length of the new piston pin is 89.80 ± 0.15 mm (3.535 ± 0.006 inch).
Bore in the piston assembly for the piston pin is 60.095 ± 0.010 mm
(2.3660 ± 0.0004 inch).
Install the retainer ring with the opening towards top of the piston. Refer to Illustration
5 2 250-2940 Pin Retainer
406 .
400 UENR0996-03
i05299572
Piston and Rings

SMCS Code: 1214; 1215
S/N: NJH1–Up
S/N: ECM1–Up
Table 294
Install the top piston ring with the side marked “UP-1” toward the top of the piston. Orient
1 1 340-9400 Top Piston Ring Clearance between the ends of the top piston ring is 0.40 ± 0.05 mm
(0.016 ± 0.002 inch).
ton. Orient the colored faces to the right of the end gaps of the piston ring.
2 1 238-2707 Piston Ring Clearance between the ends of the intermediate piston ring is 0.600 ± 0.125 mm
(0.0236 ± 0.0050 inch).
Thickness of new intermediate piston ring is 2.94 mm (0.116 inch).
The spring ends of the oil control ring should be placed 180 degrees from the ring end
gap. The colored stripe in the spring coil must be visible at the ring end gap.
Clearance between the groove and the new oil control piston ring is 0.45 ± 0.15 mm
(0.018 ± 0.006 inch).
Width in the piston body for piston ring is 3.020 ± 0.010 mm (0.1190 ± 0.0004 inch) .
(continued)
UENR0996-03 401
(Table 294, contd)

Lubricate the piston pin with clean engine oil before the piston pin is inserted into the pis-
ton body assembly and the connecting rod .
4 1 180-7350 Piston Pin
Length of the new piston pin is 89.80 ± 0.15 mm (3.535 ± 0.006 inch).
Bore in the piston assembly for the piston pin is 60.125 ± 0.005 mm
(2.3671 ± 0.0002 inch).
5 2 250-2940 Pin Retainer Install the retainer ring with the opening towards top of the piston. .
402 UENR0996-03
i05578870
Piston and Rings

SMCS Code: 1214; 1215
S/N: NJH1–Up
S/N: ECM1–Up

384-3698 Piston Body As (5)
Table 295
Install with side marked “UP-1” toward top of the piston. The colored stripe faces to the
right of the piston ring end gap.
1 1 434-9020 Piston Ring Thickness of new top piston ring is 3.93 mm (0.155 inch).
Clearance of the ends when assembled in a new cylinder liner of bore

130.025 ± 0.025 mm (5.1191 ± 0.0010 inch) is 0.51 ± 0.05 mm (0.020 ± 0.002 inch).
Install with side marked “UP-2” toward top of the piston. The colored stripe faces to the
right of the piston ring end gap.
Thickness of new piston ring is 2.980 ± 0.010 mm (0.1173 ± 0.0004 inch)

2 1 331-6025 Piston Ring Width (A) of the groove in the piston for piston is 3.0525 ± 0.0125 mm
(0.12018 ± 0.00049 inch).

130.025 ± 0.025 mm (5.1191 ± 0.0010 inch) is 1.00 ± 0.10 mm (0.039 ± 0.004 inch).
The ends of the spring coil should be placed 180 degrees from the end gap of the oil con-
trol piston rings. The colored stripe in the spring coil must be visible at the oil control pis-
3 1 265-1113 Piston Ring ton ring end gap.
(continued)
UENR0996-03 403
(Table 295, contd)

Width (B) of the groove in the piston is 4.052 ± 0.012 mm (0.1595 ± 0.0005 inch).

130.025 ± 0.025 mm (5.1191 ± 0.0010 inch) is 0.45 ± 0.15 mm (0.018 ± 0.006 inch).
After installing the piston rings, rotate the piston rings so that the end gaps are placed at 120 degrees distance from each other.
-
Lubricate the entire piston to 360 degrees in zone (C) prior to assembly into the cylinder block. Use clean engine oil.
Thoroughly lubricate the piston pin with clean engine oil prior to assembly.

4 1 197-9327 Piston Pin Length is 92.00 ± 0.15 mm (3.622 ± 0.006 inch).
Bore (D) in the piston body (5) for the piston pin is 53.250 ± 0.010 mm
(2.0965 ± 0.0004 inch).
i05640637 Clearance between the ends of the piston ring in a

Piston and Rings . . . . . . . . . . . . 0.35 ± 0.05 mm ((0.014 ± 0.002 inch))
SMCS Code: 1214; 1215 Increase in the clearance between the ends of the
S/N: NJH1–Up the cylinder liner bore . . . . . . 0.09 mm ((0.004 inch))
S/N: ECM1–Up
Steel Piston Note: Install the intermediate piston ring with the side
marked “UP-2” toward the top of the piston. The
colored stripe faces to the right of the piston ring end
gap.
Thickness of the new intermediate piston ring

. . . . . . . . 2.980 ± 0.010 mm ((0.1173 ± 0.0004 inch))

. . . . . . . . . . . . . . .0.7 ± 0.1 mm ((0.028± 0.004 inch))

Illustration 409 g01375031 Oil Control Piston Ring (4)

(6) Connecting rod
(A) Height of the tall piston . . . . . . 105.00 ± 0.10 mm be a distance of 180 degrees from the ring end gap
((4.134 ± 0.004 inch)) when the oil control piston ring is assembled. The
green colored stripe can be to the right of the ring end
Note: Before assembly, lubricate the entire piston gap or to the left of the ring end gap.
body assembly (1) to 360 degrees on zone (A) with
the clean engine oil. Thickness of the new oil control piston ring
. . . . . . . . 3.980 ± 0.010 mm ((0.1567 ± 0.0004 inch))
Top Piston Ring (2) Clearance between the ends of the piston ring in
Note: Install the top piston ring with the side marked cylinder liner bore of 130 mm (5.1 inch)
“UP-1” toward the top of the piston. The blue colored . . . . . . . . . . . . 0.45 ± 0.15 mm ((0.018 ± 0.006 inch))
stripe faces to the right of the ring end gap.
Thickness of the new top piston ring . . . . . . 3.93 mm piston ring for each 0.03 mm (0.001 inch) increase in
((0.155 inch)) the cylinder liner bore . . . . . . 0.09 mm ((0.004 inch))
404 UENR0996-03

rotate the piston rings so that the end gaps are 120
Piston Pin (5)

Note: Before assembly, thoroughly lubricate the
piston pin with clean engine oil.
Outside diameter . . . . . . . . . . . . . 53.155 ± 0.005 mm

((2.0927 ± 0.0002 inch))
Inside diameter . . . . . . . . . . . . . . . . 23.00 ± 0.25 mm

((0.906 ± 0.010 inch))
Length . . . . . 92.00 ± 0.15 mm ((3.622 ± 0.006 inch))
Bore diameter for the piston pin

. . . . . . . 53.250 ± 0.010 mm ((2.0965 ± 0.0004 inch))
UENR0996-03 405
i06860320
Piston and Rings

SMCS Code: 1214; 1215
S/N: NJH1–Up
S/N: ECM1–Up
Table 296
Specification for the 477-3845 Piston and Rod Gp

Install the top piston ring with the side marked “UP-1” toward the top of the piston. Orient the col-
ored faces to the right of the end gaps of the piston ring.
Clearance between the ends of the top piston ring in a cylinder liner bore of 137.16 mm
247-6130 Top Pis- (5.400 inch) is 0.40 ± 0.10 mm (0.016 ± 0.004 inch).
1 1
ton Ring
Increase in the clearance between the ends of the top piston ring for each 0.03 mm (0.001 inch)
increase in the cylinder liner bore is 0.08 mm (0.003 inch).
Install the intermediate piston ring with the side marked “UP-2” toward the top of the piston. Orient
Clearance between the ends of the intermediate piston ring in a cylinder liner bore of 137.16 mm
164-4187 Piston (5.400 inch) is 0.770 ± 0.125 mm (0.0303 ± 0.0049 inch)
2 1
Ring
Increase in the clearance between the ends of the intermediate piston ring for each 0.03 mm
306-4014 Piston The spring ends of the oil control ring should be placed 180 degrees from the ring end gap. The
3 1
Ring colored stripe in the spring coil must be visible at the ring end gap.
(continued)
406 UENR0996-03
(Table 296, contd)

Specification for the 477-3845 Piston and Rod Gp

Clearance between the groove and the new oil control piston ring in a cylinder liner bore of
137.16 mm (5.400 inch) is 0.45 ± 0.15 mm (0.018 ± 0.006 inch)
Increase in the clearance between the ends of the oil control piston ring for each 0.03 mm
Lubricate the piston pin with clean engine oil before the piston pin is inserted into the piston body
assembly and the connecting rod.
180-7350 Piston Diameter of the new piston pin is 59.975 ± 0.005 mm (2.3612 ± 0.0002 inch)
4 1
Pin
Length of the new piston pin is 89.80 ± 0.15 mm (3.535 ± 0.006 inch)
Bore in the piston assembly for the piston pin is 60.095 ± 0.010 mm (2.3659 ± 0.0004 inch)
250-2940 Pin
5 2 Install the retainer ring with the opening towards the bottom of the piston. Refer to Illustration 410
Retainer
UENR0996-03 407
i05579430
Piston and Rings

SMCS Code: 1214; 1215
S/N: NJH1–Up
S/N: ECM1–Up
Table 297
Install the rod and piston group in the engine with the part number of the forging for the rod assembly to the rear of the engine. The rear of the
engine is the flywheel end of the engine. Lubricate the rod and piston group with clean engine oil before you insert the rod and piston group into
the block.
Install the top piston ring with the side marked “UP-1” toward the top of the piston.
The blue colored stripe faces to the right of the ring end gap.
When the new top piston ring is installed in a cylinder liner bore with bore size of
115.025 ± 0.250 mm (4.5285± 0.0098 inch), the clearance between the ends of
the piston ring is 0.40 ± 0.10 mm (0.016 ± 0.004 inch).
Thickness is 3.5 mm (0.14 inch).
Install the intermediate piston ring with the side marked “UP-2” toward the top of
the piston. The white-colored stripe faces to the right of the piston ring end gap.
2 1 467-1177 Piston Ring When the new intermediate piston ring is installed in a cylinder liner bore with bore
size of 115.025 ± 0.250 mm(4.5285± 0.0098 inch), the clearance between the
ends of the piston ring is 0.90 ± 0.12 mm (0.035 ± 0.005 inch).
(continued)
408 UENR0996-03
(Table 297, contd)

Width of groove in new piston body assembly for intermediate piston ring is
3.080 ± 0.010 mm (0.1213 ± 0.0004 inch).
Thickness is 2.980 ± 0.010 mm (0.1173 ± 0.0004 inch).
The oil control piston ring has a spring that is installed with the ring. The gap in the
spring should be a distance of 180 degrees from the ring end gap when the oil
control piston ring is assembled. The orange colored portion can be to the right or
to the left of the ring end gap.
When the new oil control piston ring is installed in a cylinder liner bore with bore
3 1 262-2891 Piston Ring size of 115.025 ± 0.250 mm(4.5285± 0.0098 inch), the clearance between the
ends of the piston ring is 0.45 ± 0.15 mm (0.018 ± 0.006 inch).
Width of groove in new piston body assembly for oil control piston ring is
4.050 ± 0.010 mm (0.1594 ± 0.0004 inch).
After the piston rings have been installed, rotate the piston rings so that the end gaps are 120 degrees from each other.
Thoroughly lubricate the entire piston prior to assembly into the cylinder block with clean engine oil.
Thoroughly lubricate the piston pin with clean engine oil prior to assembly.

4 1 524-5566 Piston Pin
The inside diameter is 23.4 ± 0.3 mm (0.92 ± 0.01 inch).
Length is 90.85 ± 0.20 mm (3.577 ± 0.008 inch).

UENR0996-03 409
i07512102
Piston and Rings

SMCS Code: 1214; 1215
S/N: NJH1–Up
S/N: ECM1–Up
Table 298
Install the top piston ring with the side marked “UP-1” toward the top of the piston. The colored
stripe faces to the right of the piston ring end gap.

1 1 223-9159 Top Piston Ring Clearance between the ends of the piston ring in a cylinder liner bore of 144.975 mm
(5.7077 inch) is 0.40 ± 0.10 mm (0.016 ± 0.004 inch).
Increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch) in-
crease in the cylinder liner bore is 0.08 mm (0.003 inch).
Install the intermediate piston ring with the side marked “UP-2” toward the top of the piston. The
colored stripe faces to the right of the piston ring end gap.
2 1 238-2707 Piston Ring Thickness of new intermediate piston ring is 2.94 mm (0.116 inch).
(5.7077 inch) is 0.600 ± 0.125 mm (0.0236 ± 0.0049 inch).
(continued)
410 UENR0996-03
(Table 298, contd)

The spring ends of the oil control ring should be assembled 180 degrees from the ring end gap.
The colored faces to the right or left of the piston ring end gap.
Width of groove in new piston for oil control piston ring is 3.020 ± 0.010 mm
(0.1189 ± 0.0004 inch).
3 1 246-5659 Piston Ring Thickness of new oil control piston ring is 2.980 ± 0.010 mm (0.1173 ± 0.0004 inch).
(5.7077 inch) is 0.55 ± 0.15 mm (0.022 ± 0.006 inch).
Thoroughly lubricate the piston pin with clean engine oil before the piston is inserted into the pis-
ton body and the connecting rod.
Diameter of the bore in the finished bearing that is installed into the piston skirt for the piston pin
is 60.125 ± 0.005 mm (2.3671 ± 0.00020 inch).
4 1 524-5565 Piston Pin
Length of the piston pin is 89.80 ± 0.15 mm (3.535 ± 0.006 inch).
Install the retainer ring (5) with the gap at the bottom of the piston. Refer to Illustration 412 .
Use the following procedure to tighten the rod bolts:

1. Before assembly, lubricate the rod bolts with engine oil.
6 2 213-3217 Bolt 2. Tighten the bolt to 70 ± 4 N·m (52 ± 3 lb ft).
3. Again, tighten the bolt to 70 ± 4 N·m (52 ± 3 lb ft) to an addition angle of 60 degrees ± 5
degrees.
Use the following procedure to tighten the rod bolts:

1. Before assembly, lubricate the rod bolts with engine oil.
7 2 213-3217 Bolt
2. Tighten the bolt to 70 ± 4 N·m (52 ± 3 lb ft) to an additional angle of 60 degrees ± 5 degrees.
Thoroughly lubricate the entire piston in zone (A) with clean engine oil prior to assembly into the cylinder block
UENR0996-03 411
i04863970
Piston Cooling Jet

SMCS Code: 1331
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 276-4637
S/N: L4D1–Up
Part No.: 276-4637
S/N: L4E1–Up
Part No.: 276-4637
S/N: L4F1–Up
Part No.: 276-4637
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 299
Specification for 276-4637 Oil Jet Tube As
1 - - Tighten the bolt to 40 ± 8 N·m (30 ± 6 lb ft).

412 UENR0996-03
Table 300
2 - - Diameter of the oil jet tube assembly is 1.83 mm (0.072 inch).
- - - Use compressed air in order to check the oil jet tube assembly for plugging.
Visually inspect the oil jet tube assembly for damage or distortion. If there is any damage
- - -
or distortion, replace the oil jet tube assembly.
Note: The proper orientation of the oil jet tube assembly is essential to ensure correct cool-
ing and lubrication of the piston. When you remove the oil jet tube assemblies from the en-
- - -
gine, be sure to handle the oil jet tube assemblies in a manner that the jets will not become
damaged.
UENR0996-03 413
Table 301
Dimension (A) is 53.27 ± 0.25 mm (2.097 ± 0.010 inch).
Dimension (B) is 3.15 ± 0.25 mm (0.124 ± 0.0010 inch).

- - -
Dimension (C) is 63.37 ± 0.25 mm (2.495 ± 0.010 inch).
i02941567 S/N: ECM1–Up
Housing (Front)
SMCS Code: 1151
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 353-2789
S/N: L4D1–Up
Part No.: 353-2789
S/N: L4E1–Up
Part No.: 353-2789
S/N: L4F1–Up
Part No.: 353-2789
S/N: TWG1–Up
S/N: NJH1–Up
414 UENR0996-03

Right side view
(3) During assembly, the rear face of the housing and

the front face of the cylinder block must be free of oil,
fuel, water, dirt, assembly compounds and any other
contaminants.
Note: After assembly, trim the gasket and flush the

gasket with the face of the housing.
Note: Apply 8T-9022 Silicone Gasket in order to fill

the space at the connecting joint of the front plate, oil
pan gasket, and cylinder block.
Typical example
Note: Apply 155-0695 Thread Lock Compound to

the threads of stud (1) prior to installation.
(2) Use the following procedure in order to tighten the
bolts that fasten the plate to the cylinder block.
1. Tighten the eight locking bolts to 55 ± 10 N·m
(41 ± 7 lb ft).
2. Again tighten the eight locking bolts to 55 N·m
(41 lb ft).
UENR0996-03 415
Note: Tighten the 12 button head screws (4) only

after tightening the two nuts (5).
(4) Torque for the 12 button head screws

. . . . . . . . . . . . . . . . . . . . . . .21 ± 3 N·m ((15 ± 2 lb ft))
416 UENR0996-03
i04415033
Housing (Front)
SMCS Code: 1151
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Table 302
Specification for 175-1483 Front Housing, and 241-0478 Front Housing Gp
1 - 3E-8044 Stud Before assembly, apply red Loctite 271 to the threads.
Use the following procedure in order to tighten the bolts that fasten the plate to the cylinder block.
2 - - Tighten the eight locking bolts to 55 ± 10 N·m (41 ± 7 lb ft).
Again, tighten the eight locking bolts to 55 N·m (41 lb ft).

UENR0996-03 417

Right side view
Table 303
During assembly, the rear face of the housing and the front face of the cylinder block must be free
of oil, fuel, water, dirt, assembly compounds, and any other contaminants.
3 - - Apply ultra blue Loctite 587 in order to fill the space at the connecting joint of the front plate, oil
After assembly, trim the gasket and flush the gasket with the face of the housing.
418 UENR0996-03
Table 304
Tighten the 12 button head screws (4) only after tightening the two nuts (5).
4 - -
Tighten the 12 button head screws to 21 ± 3 N·m (185 ± 25 lb in)
UENR0996-03 419
i04864154
Housing (Front)
SMCS Code: 1151
S/N: NJH1–Up
S/N: ECM1–Up
Table 305
Specification for 218-7272 Front Housing Gp
During assembly, the rear face of the housing and the front face of the cylinder block
- - -
must be free of oil, fuel, water, dirt, assembly compounds, and any other contaminants.
Apply ultra blue Loctite 587 in order to fill the space at the connecting joint of the front
- - -
housing, engine oil pan, and cylinder block.
Use the following bolts for mounting the front housing group:
1 17 6V-2317 Bolt
M8 X 1.25 X 30 mm.
2 9 6V-5219 Bolt M8 X 1.25 X 40 mm.
3 1 3E-8016 Self-Locking Bolt M8 X 1.25 X 25 mm.

420 UENR0996-03
i05300914
Housing (Front)
SMCS Code: 1151
S/N: NJH1–Up
S/N: ECM1–Up
Table 306
During assembly, front and rear faces of front plate, the rear face of the housing and the front face of the cylinder block must be free of oil, fuel,
water, dirt, assembly compounds, and any other contaminants.
Use the following procedure in order to tighten the bolts :
1 8 5P-4255 Locking Bolt Tighten bolt to 55 ± 10 N·m (41 ± 7lb ft).
Again, tighten bolt to 55 ± 10 N·m (41 ± 7lb ft).
(continued)
UENR0996-03 421
(Table 306, contd)

2 1 155-9524 Integral Seal
3 1 166-9144 Gasket
Apply ultra blue Loctite 587 in order to fill the space at the connecting joint of the front
4 - -
plate, oil pan gasket, and cylinder block.
5 - - Apply ultra blue Loctite 587 to bottom of seal joint immediately prior to seal installation.

353-2621 Front Housing
Table 307
6 1 3E-8044 Stud Before installing, apply red Loctite 271 to interference stud threads.
422 UENR0996-03
i05546351
Housing (Front)
SMCS Code: 1151
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Table 308
Specification for 175-1483 Front Housing, 248-2609 Front Housing Gp, 353-2595 Front Housing, and 353-2790 Front Housing
Gp
1 - 3E-8044 Stud Before assembly, apply red Loctite 271 to the threads.
2 - - Tighten the eight locking bolts to 55 ± 10 N·m (41 ± 7 lb ft).
Again tighten the eight locking bolts to 55 N·m (41 lb ft).

UENR0996-03 423

Right side view
Table 309
3 - - After assembly, trim the gasket and flush the gasket with the face of the housing.
Apply ultra blue Loctite 587 in order to fill the space at the connecting joint of the front plate, oil
424 UENR0996-03
Table 310
4 - -
UENR0996-03 425
i05578849
Housing (Front)
SMCS Code: 1151
S/N: NJH1–Up
S/N: ECM1–Up
Table 311
Use the following bolts for mounting the front housing group:
1 17 6V-2317 Bolt
M8 X 1.25 X 30 mm.
2 9 6V-5219 Bolt M8 X 1.25 X 40 mm.
3 1 3E-8016 Self-Locking Bolt M8 X 1.25 X 25 mm.
During assembly, the rear face of the housing and the front face of the cylinder block must be free of oil, fuel, water, dirt, assembly compounds,
and any other contaminants.
Apply ultra blue Loctite 587 in order to fill the space at the connecting joint of the front housing, engine oil pan, and cylinder block.
426 UENR0996-03
i06885798
Housing (Front)
SMCS Code: 1151
S/N: NJH1–Up
S/N: ECM1–Up
Table 312
Specification for 341-8964 Front Housing Gp and 225-3903 Front Housing Gp
1 - Stud Before assembly, apply red Loctite 271 to the threads.
5P-4255 Locking
2 8 Tighten to 55 ± 10 N·m (41 ± 7 lb ft).
Bolt
Again, tighten to 55 ± 10 N·m (41 ± 7 lb ft).
UENR0996-03 427

Right side view
Table 313
3 - - Apply ultra blue Loctite 587 in order to fill the space at the connecting joint of the front plate, oil
428 UENR0996-03
Table 314
4 - -
UENR0996-03 429
i04393454
Gear Group (Front)

SMCS Code: 1206
S/N: NJH1–Up
S/N: ECM1–Up
(6) Tapped holes for accessory drive
Table 315
Specification for 361-5599 Front Gear Gp
363-5182 Camshaft Number of teeth is 96.

1 1
Drive Gear Bore of the gear is 58.900 ± 0.013 mm (2.3189 ± 0.0005 inch).
Align the timing marks on the idler gear to the timing marks on the camshaft gear and the
2 - -
marks on the crankshaft gear.
Number of teeth is 72.

Bore of the gear for bearing is 74.452 ± 0.015 mm (2.9312 ± 0.0006 inch).
3 1 361-5600 Idler Gear As
Bore of the bearing after installation is 69.205 ± 0.013 mm (2.7246 ± 0.0005 inch).
The bearing is recessed from the back of the gear is 1.00 ± 0.25 mm (0.039 ± 0.010 inch).
4 1 360-0444 Gear As Number of teeth is 64.
(continued)
430 UENR0996-03
(Table 315, contd)

361-5595 Crankshaft Number of teeth is 48

5 1
Gear Bore of the gear is 96.900 ± 0.020 mm (3.8150 ± 0.0008 inch).
UENR0996-03 431
i04393483
Gear Group (Front)

SMCS Code: 1206
S/N: NJH1–Up
S/N: ECM1–Up
(6) Tapped holes for accessory drive
Table 316

1 1 222-3907 Gear
Bore of the gear is 58.900 ± 0.013 mm (2.3189 ± 0.0005 inch).
Align the timing marks on the idler gear to the timing marks on the camshaft gear and the
2 - -
marks on the crankshaft gear.

3 1 222-3905 Gear As
4 1 222-3902 Gear As Number of teeth is 64.
(continued)
432 UENR0996-03
(Table 316, contd)

187-8972 Crankshaft Number of teeth is 48.

5 1
Gear Bore of the gear is 96.900 ± 0.020 mm (3.8150 ± 0.0008 inch).
UENR0996-03 433
i04512069
Gear Group (Front)

SMCS Code: 1206
S/N: NJH1–Up
S/N: ECM1–Up
(6) Oil pump idler gear (7) Bolt (8) Oil pump idler gear
Table 317
A 1 200-4495 Idler Shaft Diameter is 74.000 ± 0.013 mm (2.9134 ± 0.0005 inch).
Bore of the bushing after installation is 74.075 ± 0.013 mm

B 1 296-5413 Bushing (2.9163 ± 0.0005 inch)
3 2 6V-5843 Bolt Torque to 70 ± 15 N·m (52 ± 11 lb ft).
Align the timing marks on the camshaft idler gear (2) with the holes on the
4 - -
camshaft gear (1) and the crankshaft gear (5).
434 UENR0996-03
i05206414
Gear Group (Front)

SMCS Code: 1206
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 208-9490
S/N: L4D1–Up
Part No.: 208-9490
S/N: L4E1–Up
Part No.: 208-9490
S/N: L4F1–Up
Part No.: 208-9490
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
(1) Water pump drive gear (7) Gear assembly (11) Oil pump drive gear
(5) Gear assembly (8) Gear for the fuel transfer pump
(6) Air compressor drive gear (if equipped) (10) Crankshaft gear
Note: Refer to the following procedure when any bolt 2. Clean the bolt, the nut and/or the stud with a wire
or any nut is loosened for service: brush.
1. Remove the bolt or the nut. 3. Apply blue Loctite 242 to the threads of the bolts,
nuts and/or studs before assembly.
UENR0996-03 435
4. A new bolt with a previously applied thread lock is

acceptable for use.
5. Tighten the bolts, the nuts and/or the studs to the
standard torque.
Note: Refer to Testing and Adjusting, “Gear Group

(Front) - Time” for the backlash adjustment
procedure.
Table 318
Specifications for 208-9490 Front Gear Gp, 207-0449 Front Gear Gp, and 248-6767 Front Gear Gp
Before tightening the bolts for the stub shaft, set distance (A) between the centers of
A - - camshaft gear (3) and gear assembly (5) with a gauge in order to obtain the gear back-
lash of 0.3556 ± 0.254 mm (0.0140 ± 0.010 inch) .

Torque sequence for the stub shaft for cluster gear
Table 319
Tighten five bolts for the stub shaft of the cluster gear assembly to the standard torque in
2 1 197-4971 Stub Shaft
the following sequence. Refer to Illustration 436 - 1, 3, 4, 5, 2, 1, 2, 3, 4, 5, 1
436 UENR0996-03

Torque sequence for the camshaft gear
Table 320
Align the timing mark on the camshaft gear with the timing mark on the front housing
4 -
when the No. 1 piston is at top center.
Align the timing mark on the crankshaft gear with the timing mark on the cluster gear
9 -
assembly.
(continued)
UENR0996-03 437
(Table 320, contd)

Lightly lubricate O-ring seal (12) with 50/50 mixture of 8T-2998 Lubricant and clean en-
gine oil.
13 1 031-3185 Bolt
Tightening sequence for bolts (13) 1, 4, 2, 5, 3, 6, 1, 4
Torque bolts (13) to 240 ± 40 N·m (177 ± 30 lb ft)
14 - - Install the oil groove of the thrust plate toward the face of gear assembly (7).
15 - - Install the oil groove of the thrust plate toward the face of gear assembly (5).
16 - - Install the oil groove of the thrust plate toward the face of cluster gear assembly (2).
i05241337
Gear Group (Front)

SMCS Code: 1206
S/N: NJH1–Up
S/N: ECM1–Up

Stub shaft for cluster gear
(2) Cluster gear

Apply 9S-3263 Thread Lock Compound to the
five bolts for the stub shaft.
Tighten the five bolts for the stub shaft in the
following sequence. See Illustration 440 for the
numbering of the bolts. . . 1, 3, 4, 5, 2, 1, 2, 3, 4,
5, 1
four bolts that fasten the cluster gear to the stub
shaft.
Tighten the four bolts that fasten the cluster gear
to the stub shaft to the following torque.
. . . . . . . . . . . . . . . . . . . .30 ± 7 N·m ((22 ± 5 lb ft))
(1) Water pump drive gear

438 UENR0996-03
Lightly lubricate the O-ring seal on the outside of

the camshaft sealing plate with a 50/50 mixture
of 8T-2998 Lubricant and clean engine oil.
three bolts for the camshaft sealing plate.
Tighten the three camshaft sealing plate bolts to
the following torque. See Illustration 441 .
. . . . . . . . . . . . . . . . . . . . . 12 ± 3 N·m ((9 ± 2 lb ft))
Tighten the camshaft bolts in the following
sequence. See Illustration 442 for the numbering
of the bolts. . . . . . . . . . . . . . . . 1, 4, 2, 5, 3, 6, 1, 4
Tighten the six camshaft gear bolts to the
following torque. . . . . . . . . . . . . . . . 240 ± 40 N·m
((175 ± 30 lb ft))
(5) Adjustable idler gear

Install the plate with the oil groove toward the
gear face. Apply 9S-3263 Thread Lock
Compound to the three bolts that fasten the
adjustable idler gear to the stub shaft.
Tighten the three bolts for the adjustable idler
gear to the stub shaft to the following torque.
. . . . . . . . . . . . . . . . . . . .30 ± 7 N·m ((22 ± 5 lb ft))
Refer to Testing and Adjusting, “Gear Group
procedure.
Illustration 441 g01248404 Backlash between the camshaft gear and the
(3) Camshaft gear adjustable idler gear . . . . . . . 0.3556 ± 0.254 mm
(12) Camshaft retainer bolts ((0.0140 ± 0.010 inch))
(13) Seals
(14) Camshaft gear bolts
one bolt and five studs for the stub shaft.
Tighten the one bolt and five nuts for the stub
shaft to the following torque. . . . . . . 55 ± 10 N·m
((41 ± 7 lb ft))
(6) Air compressor gear (if equipped)
(7) Idler gear

one bolt and five studs for the stub shaft.
Tighten the one bolt and five nuts for the stub
shaft to the following torque. . . . . . . 55 ± 10 N·m
((41 ± 7 lb ft))
Illustration 442 g00593987 three bolts that fasten the idler gear to the stub
Torque sequence for the camshaft gear shaft.
Tighten the three bolts that fasten the idler gear
(4) Align the timing mark on the camshaft gear with to the stub shaft to the following torque.
the timing mark on the front housing when the No. 1 . . . . . . . . . . . . . . . . . . . .30 ± 7 N·m ((22 ± 5 lb ft))
piston is at top center.
(8) Gear for the fuel transfer pump drive
(3) Camshaft gear
(9) Align the timing mark on the crankshaft gear with
the timing mark on the cluster gear.
(10) Crankshaft gear
(11) Oil pump drive gear
UENR0996-03 439
i05244022
Gear Group (Front)

SMCS Code: 1206
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 282-0671
S/N: L4D1–Up
Part No.: 282-0671
S/N: L4E1–Up
Part No.: 282-0671 Illustration 444 g00537659
S/N: L4F1–Up Stub shaft for cluster gear
S/N: NJH1–Up
(2) Cluster gear
S/N: ECM1–Up
threads of five bolts for the stub shaft.
Tighten the five bolts for the stub shaft in the
numerical sequence. See Illustration 444 for the
numbering of the bolts. . . 1, 3, 4, 5, 2, 1, 2, 3, 4,
5, 1
Torque for the stub shaft . . . . . . . . . . 47 ± 9 N·m
((35 ± 7 lb ft))
threads of four bolts that fasten the cluster gear's
thrust plate to the stub shaft.
Torque for four bolts that fasten the cluster gear's
thrust plate to the stub shaft . . . . . . . 25 ± 6 N·m
((18 ± 4 lb ft))

(1) Water pump gear
(6) Air compressor gear (if equipped)
(8) Gear for the fuel transfer pump gear
(10) Crankshaft gear
440 UENR0996-03
(4) Align the timing mark on the camshaft gear with

the timing mark on the front housing when the No. 1
piston is at top center.
(5) Adjustable idler gear

Compound to the threads of three bolts that
fasten the adjustable idler gear to the stub shaft.
Tighten the three bolts for the adjustable idler
gear to the stub shaft to the following torque.
. . . . . . . . . . . . . . . . . . . .30 ± 7 N·m ((22 ± 5 lb ft))
Refer to Testing and Adjusting, “Gear Group
procedure.
Backlash between the camshaft gear and the
adjustable idler gear . . . . . . . −.3556 ± 0.254 mm
((0.0140 ± 0.010 inch))
threads of one bolt and five studs for the stub
shaft.
Tighten one bolt and five nuts for the stub shaft to
the following torque. . . . . . . . . . . . . . 55 ± 10 N·m
((41 ± 7 lb ft))
(7) Idler gear

threads of one bolt and five studs for the stub
shaft.
Tighten one bolt and five nuts for the stub shaft to
the following torque. . . . . . . . . . . . . . 55 ± 10 N·m
((41 ± 7 lb ft))
Compound to the threads of three bolts that
fasten the idler gear to the stub shaft.
Tighten the three bolts that fasten the idler gear
to the stub shaft to the following torque.
. . . . . . . . . . . . . . . . . . . .30 ± 7 N·m ((22 ± 5 lb ft))
(9) Align the timing mark on the crankshaft gear with
Illustration 446 g00593987 the timing mark on the cluster gear.
Torque sequence for the camshaft gear
(11) Torque for the bolt of the oil pump drive gear
. . . . . . . . . . . . . . . . . . . . . .55 ± 10 N·m ((41 ± 7 lb ft))
(3) Camshaft gear
Lightly lubricate the O-ring seal on the outside of
the plate with a 50/50 mixture of 8T-2998
Lubricant and clean engine oil. Apply 9S-3263
Thread Lock Compound to the threads of three
bolts for the plate.
Torque for three plate bolts (12) . . . . 12 ± 3 N·m
((105 ± 25 lb in))
Tightening sequence for the bolts (13) that is
shown in Illustration 446 . . . . 1, 4, 2, 5, 3, 6, 1, 4
Torque for six bolts (13) . . . . . . . . . 240 ± 40 N·m
((175 ± 30 lb ft))
UENR0996-03 441
i05546652
Gear Group (Front)

SMCS Code: 1206
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
442 UENR0996-03

Cam gear tightening sequence
UENR0996-03 443
Table 321
Tighten the bolt in a numerical sequence 1,4,2,5,3,6,1,4 as shown in Illustration 448 to

1 6 031-3185 Bolt 240 ± 40 N·m (177 ± 30 lb ft).
Before tightening the bolts for the stub shaft, set distance (B) between the centers of
B - - camshaft gear and gear assembly with a gauge in order to obtain the gear backlash of
0.216 ± 0.114 mm (0.0085 ± 0.0045 inch).
3 2 5P-4142 Locking Bolt Torque to 55 ± 10 N·m (41 ± 7 lb ft).
Refer to the following procedure when nut is loosened for service:
1. Remove the nut.

4 10 9S-8752 Full Nut
2. Clean the nut with a wire brush.
3. Apply blue Loctite 242 to the threads before assembly.
4. Tighten nut to 55 ± 10 N·m (41 ± 7 lb ft).
Refer to the following procedure when any bolt is loosened for service:
1. Remove the bolt.

5 10 126-1756 Locking Bolt 2. Clean bolt with a wire brush.
A new bolt with a previously applied thread lock is acceptable for use.
4. Tighten bolt to 30 ± 7 N·m (266 ± 62 lb in).
Install the oil groove of the thrust plate toward the face of gear assembly.
6 2 6I-3624 Thrust Plate

444 UENR0996-03

Stub shaft tightening sequence
Table 322
8 1 102-5861 Thrust Plate Thickness is 5.000 ± 0.025 mm (0.1968 ± 0.0009 inch).
(continued)
UENR0996-03 445
(Table 322, contd)

Before assembly, lubricate the bore lightly with 50/50 mixture of 8T-2998 Lubricant and
9 1 117-8801 O-Ring Seal
clean engine oil.
After installation, bore in the 128-2661 Bushing is 63.566 ± 0.013 mm

10 1 352-9728 Gear As (2.5026 ± 0.0005 inch).
Tighten the bolt in a numerical sequence 1, 3, 4, 5, 2, 1, 2, 3, 4, 5, 1 as shown in the Illus-

tration 450 to 55 ± 10 N·m (41 ± 7 lb ft).
11 5 2J-3118 Locking Bolt 1. Remove the bolt.

2. Clean bolt with a wire brush.
4. Tighten bolt to 55 ± 10 N·m (41 ± 7 lb ft).
13 1 197-4971 Stub Shaft Lubricate the gear journals, bearing bores and thrust faces with engine oil.
Lubricate the gear journals, bearing bores and thrust faces with engine oil.
Outside diameter of the 130-4698 Bushing is 56.030 ± 0.013 mm
14 1 130-4701 Gear As (2.2059 ± 0.0005 inch).
Thickness of the bushing is 2.500 ± 0.013 mm (0.0984 ± 0.0005 inch).
15 1 151-5966 Stub Shaft As Diameter is 50.800 ± 0.013 mm (2.0000 ± 0.0005 inch).
Extension of 6I-3623 Dowel is 4.5 ± 0.5 mm (0.18 ± 0.02 inch).
Outside diameter of the 101-8468 Bushing is 56.030 ± 0.013 mm
16 1 6I-3625 Gear As (2.2059 ± 0.0005 inch).
Thickness of the bushing is 2.500 ± 0.013 mm (0.0984 ± 0.0005 inch).
17 1 158-3416 Stub Shaft
446 UENR0996-03
i07548890
Gear Group (Front)

SMCS Code: 1206
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 447
Table 323

Tighten the bolt in a numerical sequence 1,4,2,5,3,6,1,4 as shown in Illustration 452
1 6 031-3185 Bolt to 240 ± 40 N·m (177 ± 30 lb ft).
Before tightening the bolts for the stub shaft, set distance (B) between the centers of
B - - camshaft gear and gear assembly with a gauge in order to obtain the gear backlash
of 0.216 ± 0.114 mm (0.0085 ± 0.0045 inch).
C 1 6V-3677 Dowel Extension of the new dowel is 12.5 ± 0.5 mm (0.49 ± 0.02 inch).
(continued)
448 UENR0996-03
(Table 323, contd)

Extension of 103-0126 Dowel from rear face of the camshaft gear is 8.0 ± 0.5 mm
2 1 361-8240 Camshaft Gear (0.31 ± 0.02 inch).
4 1 102-5861 Thrust Plate Thickness is 5.000 ± 0.025 mm (0.1968 ± 0.0009 inch).
Before assembly, lubricate the bore lightly with 50/50 mixture of 8T-2998 Lubricant
5 1 117-8801 O-Ring Seal
and clean engine oil.
After installation, bore in the 417-4618 Bushing for the stubshaft is

6 1 417-4617 Idler Gear As 50.857 ± 0.013 mm (2.0022 ± 0.0005 inch).
Installation depth of the bushing is 2.5 ± 0.5 mm (0.09 ± 0.02 inch).

7 1 151-5966 Stub Shaft As
Extension of 6I-3623 Dowel is 4.5 ± 0.5 mm (0.18 ± 0.02 inch).
After installation, Bore in the 417-4616 Bushing is 50.857 ± 0.013 mm

8 1 417-4615 Idler Gear As (2.0022 ± 0.0005 inch).
Installation depth of the bushing is 1.5 ± 0.5 mm (0.06 ± 0.02 inch).
9 1 158-3416 Stub Shaft Diameter is 50.800 ± 0.013 mm (2.0000 ± 0.0005 inch).

Section D-D
UENR0996-03 449
Table 324
After installation, bore in the 128-2661 Bushing is 63.566 ± 0.013 mm

361-8233 Cluster Gear
10 1 (2.5026 ± 0.0005 inch).
Assembly
11 1 197-4971 Stub Shaft Diameter of the new stub shaft is 63.500 ± 0.013 mm (2.5000 ± 0.0005 inch).
Tighten the bolt in a numerical sequence 1, 3, 4, 5, 2, 1, 2, 3, 4, 5, 1 as shown in the Illus-

12 5 2J-3118 Locking Bolt
tration 454 to 55 ± 10 N·m (41 ± 7 lb ft).

450 UENR0996-03
Table 325
15 2 6I-3624 Thrust Plate
16 2 5P-4142 Locking Bolt Torque to 55 ± 10 N·m (41 ± 7 lb ft).
Refer to the following procedure when nut is loosened for service:
1. Remove the nut.

17 10 9S-8752 Full Nut
2. Clean the nut with a wire brush.
4. Tighten nut to 55 ± 10 N·m (41 ± 7 lb ft).
1. Remove the bolt.

18 10 126-1756 Locking Bolt 2. Clean bolt with a wire brush.
4. Tighten bolt to 30 ± 7 N·m (266 ± 62 lb in).
i02867219 S/N: TWG1–Up

S/N: NJH1–Up
Flywheel
SMCS Code: 1156
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 207-7307
UENR0996-03 451
i02934295
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up

(2) Ring gear
Note: Refer to the System Operation, Testing &

Adjusting, “Flywheel Runout” for the correct method
of flywheel inspection.
(1) Apply engine oil, molybdenum disulfide, or a

graphite based lubricant to the threads of the bolts.
Tighten the bolts to the following torque. Illustration 457 g01113518
. . . . . . . . . . . . . . . . . . 270 ± 40 N·m ((200 ± 30 lb ft)) (1) Ring gear
(2) Washer
Note: Refer to System Operation, Testing and

Adjusting for the correct method of inspecting the
flywheel.
(3) Torque for eight bolts . . . . . . . . . . . . 300 ± 40 N·m

((220 ± 30 lb ft))
452 UENR0996-03
i02960983 i02970260
Flywheel Flywheel


(1) Flywheel gear
Note: Refer to System Operation, Testing and
Note: Refer to System Operation, Testing and Adjusting for the correct method of inspecting the
Adjusting for the correct method of inspecting the flywheel.
flywheel.
(1) Apply 4C-4030 Thread Lock Compound to the
(2) Torque for eight locking bolts . . . . . 300 ± 40 N·m threads of 16 bolts.
((220 ± 30 lb ft))
UENR0996-03 453
i02993765
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
(2) Flywheel Gear
Note: Refer to Testing and Adjusting for the correct

method of inspecting the flywheel.
(1) Torque for eight bolts . . . . . . . . . . . . 300 ± 40 N·m

((220 ± 30 lb ft))
454 UENR0996-03
i04377606
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up
Table 326
Specification for 319-8165 Flywheel Gp
1 8 9X-2021 Locking Bolt Torque to 300 ± 40 N·m (221 ± 30 lb ft).

UENR0996-03 455
i04388288
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up
Table 327
Specification for the 107-3825 Flywheel Gp and 113-7060 Flywheel Gp
Before assembly, apply engine oil, molybdenum disulfide, or a graphite-based lubricant to the
1 12 0S-1576 Bolt threads.
Torque to 270 ± 40 N·m (200 ± 30 lb ft).
Note: Refer to the System Operation, Testing & Adjusting, “Flywheel Runout” for the correct method of flywheel inspection
456 UENR0996-03
i04388298
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up
Table 328
Specification for the 122-1227 Flywheel Gp
Torque to 270 ± 40 N·m (200 ± 30 lb ft).
Note: Refer to the System Operation, Testing & Adjusting, “Flywheel Runout” for the correct method of flywheel inspection.
UENR0996-03 457
i04388312
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up
Note:
Table 329
Specification for the 154-6189 Flywheel Gp
1 12 5B-0841 Bolt threads.
Torque to 270 ± 40 N·m (200 ± 30 lb ft).
458 UENR0996-03
i04388317
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up
Table 330
Specification for the 7N-3060 Flywheel Gp
Torque to 270 ± 40 N·m (200 ± 30 lb ft).
UENR0996-03 459
i04388467
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up
Table 331
Torque to 270 ± 40 N·m (200 ± 30 lb ft).
460 UENR0996-03
i04392972
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up
Table 332
1 12 1B-7538 Bolt threads.
Torque to 270 ± 40 N·m (200 ± 30 lb ft).
UENR0996-03 461
i04437951
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up
Table 333
Specification for 6N-9259 Flywheel Gp
Before assembly, lubricate the threads with engine oil, Molybdenum Disulfide or Graphite base lubri-
1 12 0S-1577 Bolt cant .
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
462 UENR0996-03
i04438117
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up
Table 334
Specification for 4P-6817 Flywheel Gp
Before assembly, lubricate the threads with engine oil, Molybdenum Disulfide or Graphite base
1 12 0S-1577 Bolt lubricant.
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
UENR0996-03 463
i04440053
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up
Table 335
Specification for 7N-9651 Flywheel Gp
Before assembly, lubricate the threads with engine oil, Molybdenum Disulfide or Graphite base
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
464 UENR0996-03
i04440110
Flywheel
SMCS Code: 1156
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 219-4438
S/N: L4D1–Up
Part No.: 219-4438
S/N: L4F1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 336
Before assembly, lubricate the bolt threads with engine oil, Molybdenum Disulfide or Graphite base
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
UENR0996-03 465
i04461735
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up
Table 337
Specifications for 159-9019 Flywheel Gp
Before assembly, apply clean engine oil molybdenum disulfide or graphite base lu-
1 12 0S-1602 Bolt brication to the threads.
Torque to 270 ± 40 N·m (200 ± 30 lb ft)
466 UENR0996-03
i04512253
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up
(2) Flywheel gear
Table 338
1 8 9X-2057 Bolt Torque to 300 ± 40 N·m (221 ± 30 lb ft).

UENR0996-03 467
i04560181
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up
Table 339
Before assembly, lubricate the threads with engine oil, molybdenum disulfide, or graphite base
1 12 0V-0523 Bolt lubricant.
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
468 UENR0996-03
i04560191
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up
Table 340
Before assembly, lubricate the threads with engine oil, molybdenum disulfide, or graphite base
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
UENR0996-03 469
i05299632
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up
Table 341
Before assembly, lubricate the bolt threads with engine oil, Molybdenum Disulfide, or Graphite base
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
470 UENR0996-03
i05302369
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up
Table 342
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
UENR0996-03 471
i05815529
Flywheel
SMCS Code: 1156
S/N: NJH1–Up
S/N: ECM1–Up
Table 343

Before assembly, lubricate the threads with engine oil, Molybdenum Disulfide or graphite base
1 12 5L-2683 Bolt lubricant.
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
i02489827
Flywheel Housing
SMCS Code: 1157
S/N: NJH1–Up
S/N: ECM1–Up
472 UENR0996-03
i02960981
Flywheel Housing
SMCS Code: 1157
S/N: NJH1–Up
S/N: ECM1–Up

(1) Flywheel housing (rear view)
Note: Remove excessive oil, fuel and water from the

front face of the flywheel housing and the rear face of
the cylinder block.
(1) Apply 1U-8846 Gasket Sealant to all of the
sealing surfaces of the flywheel housing . The
flywheel housing must be assembled and tightened
to the block within ten minutes.

Right side view
(2) Apply 1U-8846 Gasket Sealant on the gasket

surface of the flywheel housing. Assemble the
flywheel housing to the cylinder block and tighten
within ten minutes of applying the sealant.
UENR0996-03 473
i02970361
Flywheel Housing
SMCS Code: 1157
S/N: NJH1–Up
S/N: ECM1–Up
(2) Apply a continuous bead of 1U-8846 Gasket

Sealant to entire joint face. The flywheel housing
must be assembled and tightened to the block within
ten minutes.
For bolt 1 through bolt 10, use M14 X 2 X 60 mm

bolts.
For bolt 11 and bolt 12, use M12 X 1.75 X 100 mm
bolts.
Tighten the bolt 1 through bolt 12 in the numerical
sequence that is shown in Illustration 482 to standard
torque.
(1) Apply 5P-3413 Pipe sealant to the pipe plug.
Tighten the pipe plug barely below the front face of
the flywheel housing.
474 UENR0996-03
i04379729
Flywheel Housing
SMCS Code: 1157
S/N: NJH1–Up
S/N: ECM1–Up
Table 344
Specification for 344-2905 Flywheel Housing Gp and 264-4643 Flywheel Housing Gp
Apply 8C-8422 Sealant continuously and evenly over the entire surface as shown in Illustration 484 .
1 - -
Assemble the housing to the engine within 10 minutes of sealant application.
UENR0996-03 475
i04416069
Flywheel Housing
SMCS Code: 1157
S/N: NJH1–Up
S/N: ECM1–Up
476 UENR0996-03

Bolt tightening sequence
UENR0996-03 477
Table 345
Specification for 223-4738 Flywheel Housing Gp
Before installation of the flywheel housing, inspect the front face of the flywheel housing and the rear face of the cylinder block. The compo-
nents must be free of the following substances: oil, fuel, water, gasket adhesive, assembly compounds, and any other foreign material.
To seal the joint between the flywheel housing and the cylinder block, apply ultra blue Loctite 587 to the mating surface of the flywheel housing.
Use the following procedure to tighten the flywheel housing bolts:
1 9 5J-5793 Bolt 1. Tighten bolt 1 through bolt 9 in a numerical sequence as shown in Illustration 486 to
100 ± 20 N·m (75 ± 15 lb ft).
2 5 165-3931 Bolt 2. Tighten bolt 10 through bolt 24 in a numerical sequence as shown in Illustration 486 to
3 9 165-3929 Bolt 40 ± 10 N·m (30 ± 7 lb ft).
3. Again, tighten bolt 1 through bolt 9 in a numerical sequence as shown in Illustration 486 to
135 ± 20 N·m (100 ± 15 lb ft).
4 1 165-3925 Bolt 4. Again, tighten bolt 10 through bolt 24 in a numerical sequence as shown in Illustration 486
to 55 ± 10 N·m (41 ± 7 lb ft).
5 2 1P-1669 Seal Plug Torque to 9.5 ± 1.5 N·m (84.1 ± 13.3 lb in).
478 UENR0996-03
i04451969
Flywheel Housing
SMCS Code: 1157
S/N: NJH1–Up
S/N: ECM1–Up
Table 346
Specification for 7E-8996 Flywheel Housing Gp
Before installation of the flywheel housing, inspect the following components for any foreign materials: The front face of the flywheel housing,
the two sides of the flywheel housing gasket and the rear face of the cylinder block. These components must be free of the following substan-
ces: oil, fuel, water, gasket adhesive, assembly compounds, and any other foreign material. Apply ultra blue Loctite 587 as a continuous film on
entire joint face.
1 8 9K-7290 Bolt Use the following procedure to tighten the flywheel housing bolts:
1.Tighten the bolt 1 through bolt 9 to 100 ± 20 N·m (75 ± 15 lb ft) in the numerical sequence.
2 1 5J-5793 Bolt
2. Tighten the bolt 10 through bolt 22 to 40 ± 10 N·m (30 ± 7 lb ft) in the numerical sequence.
3 6 165-3932 Bolt 3. Again, tighten the bolt 1 through bolt 9 to 135 ± 20 N·m (100 ± 15 lb ft) in the numerical
sequence.
5 6 165-3930 Bolt sequence.
UENR0996-03 479
i04461733
Flywheel Housing
SMCS Code: 1157
S/N: NJH1–Up
S/N: ECM1–Up
480 UENR0996-03

UENR0996-03 481
Table 347
Specifications for 134-2809 Flywheel Housing Gp
During assembly, inspect the following components for any foreign materials: the front face of the flywheel housing, the two sides of the fly-
wheel housing gasket and the rear face of the cylinder block. These components must be free of the following substances: oil, fuel, water, adhe-
sive, assembly compounds, and any foreign materials. Apply ultra blue Loctite 587 to fill the space between the cylinder block, the flywheel
housing, and the oil pan. The components must be assembled within 10 minutes of applying the sealant.
1 9 7K-6058 Bolt Use the following tightening procedure to tighten the bolts for the flywheel housing:
1. Tighten bolt 1 to bolt 9 in a numerical sequence as shown in Illustration 489 to
100 ± 20 N·m (75 ± 15 lb ft).
2 8 165-3929 Bolt 40 ± 10 N·m (30 ± 7 lb ft).
3. Again, tighten bolt 1 to bolt 9 in a numerical sequence as shown in Illustration 489 to
135 ± 20 N·m (100 ± 15 lb ft).
55 ± 10 N·m (41 ± 7 lb ft).
3 7 165-3933 Bolt
4 3 4B-4043 Bolt Torque to 115 ± 20 N·m (85 ± 15 lb ft).

482 UENR0996-03
i04464871
Flywheel Housing
SMCS Code: 1157
S/N: NJH1–Up
S/N: ECM1–Up
Table 348
During assembly, front face of the flywheel housing and rear face of the cylinder block must be free of oil, fuel, water, and assembly
compounds.
Apply ultra blue Loctite 587 to fill the space between the cylinder block, the flywheel housing, and the oil pan. The components must be as-
sembled within 10 minutes of applying the sealant.
Use the following tightening procedure to tighten the bolts for the flywheel housing:
1 9 7K-6058 Bolt
1. Tighten bolt 1 to bolt 9 in a numerical sequence as shown in Illustration to
100 ± 20 N·m (75 ± 15 lb ft).
2. Tighten bolt 10 to bolts 24 in a numerical sequence as shown in Illustration to
40 ± 10 N·m (30 ± 7 lb ft)
3. Again, tighten bolt 1 to bolt 9 in a numerical sequence as shown in Illustration
to 135 ± 20 N·m (100 ± 15 lb ft).
2 10 165-3929 Bolt
4. Again, tighten bolt 10 to bolts 24 in a numerical sequence as shown in Illus-
tration to 55 ± 10 N·m (41 ± 7 lb ft)
3 5 165-3933 Bolt
4 3 0S-1566 Bolt Torque to 115 ± 20 N·m (85 ± 15 lb ft)

UENR0996-03 483
i04515630
Flywheel Housing
SMCS Code: 1157
S/N: NJH1–Up
S/N: ECM1–Up
Table 349
Apply blue Loctite high flex GM on the gasket surface of the flywheel hous-
1 - - ing. Assemble the flywheel housing to the cylinder block and tighten within
10 minutes of applying the sealant.
484 UENR0996-03
i04560211
Flywheel Housing
SMCS Code: 1157
S/N: NJH1–Up
S/N: ECM1–Up
Table 350
ces: oil, fuel, water, gasket adhesive, assembly compounds, and any other foreign material. Apply ultra blue Loctite 587 to seal the joints be-
tween the engine oil pan, cylinder block, and the flywheel housing.
1 6 223-4903 Bolt Use the following procedure to tighten the flywheel housing bolts:
1.Tighten bolt 1 through bolt 9 in the numerical sequence as shown in Illustration 492 to
2 1 165-3932 Bolt
100 ± 20 N·m (75 ± 15 lb ft) in the numerical sequence.
3 1 5J-5793 Bolt 2. Tighten bolt 10 through bolt 23 in the numerical sequence as shown in Illustration 492 to
4 7 165-3930 Bolt 3. Again, tighten bolt 1 through bolt 9 in the numerical sequence as shown in Illustration 492
to 135 ± 20 N·m (100 ± 15 lb ft) in the numerical sequence.
5 8 338-4562 Bolt 4. Again, tighten bolt 10 through bolt 23 in the numerical sequence as shown in Illustration
492 to 55 ± 10 N·m (41 ± 7 lb ft) in the numerical sequence.
UENR0996-03 485
i04560224
Flywheel Housing
SMCS Code: 1157
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 220-6368
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 351
tween the cylinder block, engine oil pan, and the flywheel housing.
(continued)
486 UENR0996-03
(Table 351, contd)

1 6 223-4903 Bolt Use the following procedure to tighten the bolts for the flywheel housing:
2 1 165-3932 Bolt
3 1 5J-5793 Bolt 2. Tighten bolt 10 through bolt 23 in the numerical sequence as shown in Illustration 493 to
4 7 165-3930 Bolt 3. Again, tighten bolt 1 through bolt 9 in the numerical sequence as shown in Illustration 493
5 8 5J-5794 Bolt 4. Again, tighten bolt 10 through bolt 23 in the numerical sequence as shown in Illustration
UENR0996-03 487
i04560867
Flywheel Housing
SMCS Code: 1157
S/N: NJH1–Up
S/N: ECM1–Up
Table 352
ces: oil, fuel, water, gasket adhesive, assembly compounds, and any other foreign material. Apply ultra blue Loctite 587 to fill the joints of the
cylinder block, flywheel housing, and engine oil pan.
1 1 5J-5793 Bolt
Use the following procedure to tighten the bolts of the flywheel housing:
2 8 9K-7290 Bolt 100 ± 20 N·m (75 ± 15 lb ft).
3 6 165-3930 Bolt 40 ± 10 N·m (30 ± 7 lb ft).
135 ± 20 N·m (100 ± 15 lb ft).
4 2 165-3936 Bolt 4. Again, tighten bolt 10 through bolt 22 in the numerical sequence as shown in Illustration 494 to
55 ± 10 N·m (41 ± 7 lb ft).
5 5 165-3932 Bolt
488 UENR0996-03
i04560871
Flywheel Housing
SMCS Code: 1157
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 489
Table 353
During assembly, the front face of the flywheel housing and the rear face of the cylinder block must be free of following substances: Oil, fuel,
water, gasket adhesive, assembly compounds, and any other foreign material. Apply ultra blue Loctite 587 to seal the joints between the cylin-
der block, the flywheel housing, and the oil pan joint.
(continued)
490 UENR0996-03
(Table 353, contd)
1 5 165-3931 Bolt Use the following procedure to tighten the bolts of the flywheel housing:
2 8 165-3929 Bolt 2. Tighten bolt 10 through bolt 24 in the numerical sequence as shown in Illustration 496 to
3 2 165-3934 Bolt
4 9 5J-5793 Bolt
5 1 7X-7731 Pipe Plug The pipe plug must not protrude above the surface after assembly.
6 3 5F-0304 Plug Torque to 35 ± 14 N·m (26 ± 10 lb ft).

UENR0996-03 491
i04560873
Flywheel Housing
SMCS Code: 1157
S/N: NJH1–Up
S/N: ECM1–Up
492 UENR0996-03
Table 354
Front face of the flywheel housing and rear face of the cylinder block must be free of oil, fuel, water, gasket adhesive, and any other contami-
nants during assembly. Apply ultra blue Loctite 587 to seal the joints between the cylinder block, flywheel housing, and engine oil pan.
Before assembly, apply ultra blue Loctite 587 to the locations (4). After assembly, apply ultra blue Loctite 587 to the locations (5).
(continued)
UENR0996-03 493
(Table 354, contd)
Use the following procedure to tighten the bolts of the flywheel housing:
1 8 165-3929 Bolt 1.Tighten bolt 1 through bolt 9 in the numerical sequence as shown in the Illustration 498 to
100 ± 20 N·m (75 ± 15 lb ft)
2. Tighten bolt 10 through bolt 24 in the numerical sequence as shown in the Illustration
2 7 165-3931 Bolt 3. Again, tighten bolt 1 through bolt 9 in the numerical sequence as shown in the Illustration
4. Again, tighten bolt 10 through bolt 24 in the numerical sequence as shown in the Illustra-
tion 498 to 55 ± 10 N·m (41 ± 7 lb ft) in the numerical sequence.
3 9 5J-5793 Bolt
i04694689
Flywheel Housing
SMCS Code: 1157
S/N: NJH1–Up
S/N: ECM1–Up
Note: During assembly, inspect the following

components for any foreign materials: the front face
of the flywheel housing and the rear face of the
cylinder block. These components must be free of
the following substances: oil, fuel, water, sealant,
assembly compounds and any other foreign material.
Apply 6ml of Loctite High Flex sealant as a
continuous film on entire joint face.
1. Apply Loctite 7649 and then apply Loctite 620 to

the threads of the bolts prior to assembly. In a
numerical sequence, tighten bolt 1 through bolt 12.
Torque for the 12 bolts . . . . . . . . . . . . . 100 ± 20 N·m

((75 ± 15 lb ft))
494 UENR0996-03
i05546260
Flywheel Housing
SMCS Code: 1157
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 355
tween the engine oil pan, cylinder block, and the flywheel housing.
2 1 165-3932 Bolt
3 1 5J-5793 Bolt 100 ± 20 N·m (75 ± 15 lb ft) in the numerical sequence.
4 7 165-3930 Bolt 40 ± 10 N·m (30 ± 7 lb ft) in the numerical sequence.
5 8 5J-5794 Bolt 4. Again, tighten bolt 10 through bolt 23 in the numerical sequence as shown in Illustration
UENR0996-03 495
i05757268
Flywheel Housing
SMCS Code: 1157
S/N: NJH1–Up
S/N: ECM1–Up
496 UENR0996-03

UENR0996-03 497
Table 356
During assembly, inspect the following components for any foreign materials: the front face of the flywheel housing, the two sides of the fly-
wheel housing gasket and the rear face of the cylinder block. These components must be free of the following substances: oil, fuel, water, adhe-
sive, assembly compounds, and any foreign materials. Apply ultra blue Loctite 587 to fill the space between the cylinder block, the flywheel
housing, and the oil pan. The components must be assembled within 10 minutes of applying the sealant.
1 10 418-4204 Bolt Use the following tightening procedure to tighten the bolts for the flywheel housing:

100 ± 20 N·m (75 ± 15 lb ft).
2 5 165-3933 Bolt 40 ± 10 N·m (30 ± 7 lb ft).
3. Again, tighten bolt 1 to bolt 9 in a numerical sequence as shown in Illustration 502 to
135 ± 20 N·m (100 ± 15 lb ft).
3 9 7K-6058 Bolt 55 ± 10 N·m (41 ± 7 lb ft).

498 UENR0996-03
i05799745
Flywheel Housing
SMCS Code: 1157
S/N: NJH1–Up
S/N: ECM1–Up
Table 357
1.Tighten the bolt 1 through bolt 9 to 100 ± 20 N·m (75 ± 15 lb ft) in the numerical sequence.
2 6 165-3932 Bolt
2. Tighten the bolt 10 through bolt 22 to 40 ± 10 N·m (30 ± 7 lb ft) in the numerical sequence.
sequence.
4 1 5J-5793 Bolt 4. Again, tighten the bolt 10 through bolt 22 to 55 ± 10 N·m (41 ± 7 lb ft) in the numerical
5 8 9K-7290 Bolt sequence.
i05814530
Flywheel Housing
SMCS Code: 1157
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 499
Torque for the bolts . . . . . .40 ± 10 N·m ((30 ± 7 lb ft))

3. In a numerical sequence, again tighten bolt 1
through bolt 9.
Torque for the bolts . . 135 ± 20 N·m ((100 ± 15 lb ft))

4. In a numerical sequence, again tighten bolt 10
through bolt 23.
Torque for the bolts . . . . . .55 ± 10 N·m ((40 ± 7 lb ft))
(2) The maximum permissible change from an exact

vertical face at four points . . . 0.38 mm ((0.015 inch))

components for any foreign materials: front face of
the flywheel housing, two sides of the flywheel
housing seals and rear face of the cylinder block.
These components must be free of the following
substances: oil, fuel, water, gasket adhesive,
assembly compounds and any other foreign material.
Apply Loctite 587 Blue High Performance RTV
Silicon Gasket Maker to fill the space between the
following components: flywheel housing, cylinder
block and engine oil pan. Apply Loctite 587 Blue High
Performance RTV Silicon Gasket Maker to the
bottom of the joint of the flywheel housing prior to
installation.
(1) To tighten the flywheel housing bolts, use the
procedure that follows:
1. In a numerical sequence tighten bolt 1 through bolt
9.
Torque for bolts . . . . . . .100 ± 20 N·m ((74 ± 15 lb ft))

2. In a numerical sequence, tighten bolt 10 through
bolt 23.
500 UENR0996-03
i06289069 Torque for the ten bolts . . .40 ± 10 N·m ((30 ± 7 lb ft))
4. In a numerical sequence, from bolt 1 through bolt
Flywheel Housing 9, remove one bolt at a time. Apply Loctite 7649
SMCS Code: 1157 and then apply Loctite 263 to the threads of the
bolts prior to assembly.
S/N: NJH1–Up
Torque for the bolts . . 135 ± 20 N·m ((100 ± 15 lb ft))
S/N: ECM1–Up
5. In a numerical sequence, from bolt 10 through bolt
24, remove one bolt at a time. Apply Loctite 7649
and then apply Loctite 263 to the threads of the
bolts prior to assembly.
Torque for the 15 bolts . . .55 ± 10 N·m ((40 ± 7 lb ft))

Typical example

components for any foreign materials: the front face
of the flywheel housing, the two sides of the flywheel
housing gasket and the rear face of the cylinder
block. These components must be free of the
following substances: oil, fuel, water, gasket
adhesive, assembly compounds and any other
foreign material. Apply Loctite 587 Blue RTV Silicone
to the space between the cylinder block, the flywheel
housing, and the oil pan. Install the oil pan gasket
and the oil pan.
(1) Tighten the bolts, as follows:
1. Install washers to bolts and in a numerical
sequence, tighten bolt 1 through bolt 9.
Torque for the nine bolts . . . . . . . . . . . . 100 ± 20 N·m

((75 ± 15 lb ft))
2. Install washers to bolts and in a numerical
sequence, tighten bolt 10 through bolt 14.
Torque for the five bolts . . .40 ± 10 N·m ((30 ± 7 lb ft))

3. Install washers and spacers to bolts and in a
numerical sequence, tighten bolt 15 through bolt
24.
UENR0996-03 501
i03569156 i03920972
Belt Tensioner Belt Tensioner



Typical example
(3) Mounting bracket (1) Tensioner is in the free position when the belt is
not on the tensioner. Required torque for rotating the
(1) Torque for bolts . . . . . . .50 ± 5 N·m ((37 ± 4 lb ft)) tensioner to an angle of 30 degrees from the free
position . . . . . . . . . 50.8 ± 5.1 N·m ((37.5 ± 3.8 lb ft))
(2) The tensioner is in the free position when the belt
is not on the tensioner. Required torque for rotating
the tensioner to a 30 degrees angle from the free
position . . . . . . . . . . . . .58.8 ± 5.9 N·m ((43 ± 4 lb ft))
502 UENR0996-03
i04375218
Belt Tensioner
SMCS Code: 1358
S/N: NJH1–Up
S/N: ECM1–Up
Table 358
Specifications for 190-0649 Belt Tensioner
A - - Minimum limited travel is 71 degrees.
Spring torque at assembly is 42.9 ± 4.3 N·m (31.6 ± 3.2 lb ft) at 36 degrees
1 - -
from the free arm position.
UENR0996-03 503
i04394074
Belt Tensioner
(Alternator and Compressor)
SMCS Code: 1358
S/N: NJH1–Up
S/N: ECM1–Up
Table 359
Specification for 350-0223 Belt Tensioner
Belt tensioner is in the free position when the belt is not on the tensioner. Required torque
1 - - for rotating the tensioner to a 30 degree angle from the free position is 58.8 ± 5.9 N·m
(43.0 ± 4.0 lb ft).
2 - - Torque bolt to 50 ± 5 N·m (37 ± 4 lb ft).

504 UENR0996-03
Table 360
Specification for 350-0223 Belt Tensioner
3 1 - Torque bolt to 41 ± 8 N·m (30 ± 6 lb ft).

UENR0996-03 505
i04428699
Belt Tensioner
SMCS Code: 1358
S/N: NJH1–Up
S/N: ECM1–Up
Table 361
Assembly spring torque is 14.1 ± 1.7 N·m (124.8 ± 15.1 lb in) at 25 degrees from the free arm
1 - -
position.
506 UENR0996-03
i04428712
Belt Tensioner
SMCS Code: 1358
S/N: NJH1–Up
S/N: ECM1–Up
Table 362
1 - - Assembly spring torque is 56.5 ± 5.6 N·m (42 ± 4 lb ft) at 30 degrees from the free arm position.
UENR0996-03 507
i04428730
Belt Tensioner
SMCS Code: 1358
S/N: NJH1–Up
S/N: ECM1–Up
Table 363
1 - - Assembly spring torque is 62.1 ± 6.2 N·m (45.8 ± 4.6 lb ft) at 30 degrees from the free arm position.
508 UENR0996-03
i04515729
Belt Tensioner
SMCS Code: 1358
S/N: NJH1–Up
S/N: ECM1–Up
Table 364
Specification for 347-7963
Spring force at assembly is 56.5 ± 5.7 N·m (500.0 ± 50.0 lb in) at 30 degrees
1 - -
from the free arm position.
- - - Minimum arm travel is 51 degrees.
- - - Recommended mounting bolt torque is 50 ± 5 N·m (37 ± 4 lb ft)
- - - Pulley bolt torque is 41 ± 8 N·m (30 ± 6 lb ft)

UENR0996-03 509
i04793219
Belt Tensioner
SMCS Code: 1358
S/N: NJH1–Up
S/N: ECM1–Up
Table 365
Assembly spring torque is 23.7 ± 2.4 N·m (209.8 ± 21.2 lb in) at 35 degrees from the free arm
1 - -
position.
- - - Recommended mounting bolt torque is 50 ± 5 N·m (37 ± 4 lb ft).

510 UENR0996-03
i05325427
Belt Tensioner
SMCS Code: 1358
S/N: NJH1–Up
S/N: ECM1–Up
Table 366
Specification for 369-6649 Belt Tightener Gp
1 - - Tighten the adjustment bolt according to the Specifications, “Belt Tension Chart”.
2 - - Tighten the jam nut to 200 ± 25 N·m (148 ± 18 lb ft).
A - - Distance between the hard washer and pulley assembly is 22.0 mm (0.87 inch).
i02787418
Electric Starting Motor

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 511
Note: The switch terminal must be insulated with

heat shrink tubing. Do not use molded terminals.
(4) Final installation torque for the switch terminal nut

. . . . . . . . . . . . . . . . . . 2.25 ± 0.25 N·m ((20 ± 2 lb in))
(5) Final installation torque for the motor terminal nut

. . . . . . . . . . . . . . . . . 30.5 ± 3.5 N·m ((270 ± 30 lb in))
(6) Final installation torque for the motor frame

terminal nut . . . . . . . . . . . . 8 ± 3 N·m ((70 ± 27 lb in))
Solenoid assembly
Current consumption at 20V and 25 °C (77 °F)

Pull-in windings . . . . . . . . . . . . . . . . . . . . 57 Amp
Hold-in windings . . . . . . . . . . . . . . . . . . . . 16 Amp
Maximum rated current . . . . . . . . . . . . . 850 Amp

View A-A
When the electric starting motor is viewed from the

pinion end, the motor rotates in the following
direction. . . . . . . . . . . . . . . . . . . . . . . . . . . . Clockwise
No load conditions at 25 °C (77 °F)
Speed . . . . . . . . . . . . . . . . . . . . 7643 ± 1683 rpm

Current draw . . . . . . . . . . . . . . . . 76.5 ± 14.5 Amp
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23V
(B) Clearance between the pinion and the housing

. . . . . . . . . . . . . . . . . . . . . . . . . . .9.1 mm ((0.36 inch))
(1) Final installation torque for the ground terminal

nut . . . . . . . . . . . . . . 30.5 ± 3.5 N·m ((270 ± 30 lb in))

nut . . . . . . . . . . . . . . . 2.25 ± 0.25 N·m ((20 ± 2 lb in))
Note: A maximum of three cable terminals or wire
terminals may be used with the battery terminal nut
(3). A maximum of two of the cable terminals may be
equal to or greater than 0 AWG.
(3) Final installation torque for the battery terminal

nut . . . . . . . . . . . . . . 30.5 ± 3.5 N·m ((270 ± 30 lb in))
512 UENR0996-03
i02942994 Note: A maximum of three cable terminals or wire

terminals may be used with the battery terminal nut.
Electric Starting Motor A maximum of two of the terminals may be equal to
or greater than 0 AWG.
SMCS Code: 1453
(5) Final installation torque for the battery terminal
S/N: NJH1–Up nut . . . . . . . . . . . . . . 30.5 ± 3.5 N·m ((270 ± 30 lb in))
S/N: ECM1–Up (6) Final installation torque for the motor frame
terminal nut . . . . . . . 30.5 ± 3.5 N·m ((270 ± 30 lb in))
Solenoid assembly
Current consumption at 20V and 25 °C (77 °F)
Pull-in windings . . . . . . . . . . . . . . 49.3 ± 3.3 Amp

Hold-in windings . . . . . . . . . . . . . . . . . . . 6.8 Amp

Speed . . . . . . . . . . . . . . . . . . . . 6950 ± 1650 rpm

Current draw . . . . . . . . . . . . . . . . . . 115 ± 25 Amp
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 VDC
(B) Clearance between the pinion and the housing is

the following value. . . . . . . . . . . .9.1 mm ((0.36 inch))

nut . . . . . . . . . . . . . . 30.5 ± 3.5 N·m ((270 ± 30 lb in))

. . . . . . . . . . . . . . . . . . 2.25 ± 0.25 N·m ((20 ± 2 lb in))


. . . . . . . . . . . . . . . . . . 2.25 ± 0.25 N·m ((20 ± 2 lb in))

. . . . . . . . . . . . . . . . . 30.5 ± 3.5 N·m ((270 ± 30 lb in))
UENR0996-03 513
i02995124 No load conditions at 25 °C (77 °F)
Electric Starting Motor Speed . . . . . . . . . . . . . . . . . . . . 6900 ± 1800 rpm

Current draw . . . . . . . . . . . . . . . 127.5 ± 27.5 Amp
SMCS Code: 1453 Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 V
S/N: 3F61–Up (B) Clearance between the pinion and the housing
S/N: 3F71–Up . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1 mm ((0.36 inch))
Part No.: 207-1532 (1) Final installation torque for the ground terminal
S/N: L4D1–Up nut . . . . . . . . . . . . . . 30.5 ± 3.5 N·m ((270 ± 30 lb in))
Part No.: 207-1532 (2) Final installation torque for the ground terminal
S/N: L4E1–Up nut . . . . . . . . . . . . . . . 2.25 ± 0.25 N·m ((20 ± 2 lb in))
Part No.: 207-1532 Note: A maximum of three cable terminals or wire
S/N: L4F1–Up terminals may be used with the battery terminal nut
(3). A maximum of two of the cable terminals may be
Part No.: 207-1532
equal to or greater than 0 AWG.
S/N: TWG1–Up
S/N: NJH1–Up (3) Final installation torque for the battery terminal
nut . . . . . . . . . . . . . . 30.5 ± 3.5 N·m ((270 ± 30 lb in))

. . . . . . . . . . . . . . . . . . 2.25 ± 0.25 N·m ((20 ± 2 lb in))

. . . . . . . . . . . . . . . . . 30.5 ± 3.5 N·m ((270 ± 30 lb in))
(6) Final installation torque for the motor frame

terminal nut . . . . . . . . . . . . 8 ± 3 N·m ((70 ± 27 lb in))
Solenoid assembly
Illustration 520 g01392303 Current consumption at 10 V and 25 °C (77 °F)
Pull-in current . . . . . . . . . . . . . . . . 92.5 ± 7.5 Amp

Hold-in current . . . . . . . . . . . . . . . . . . . . . 23 Amp
Maximum rated current . . . . . . . . . . . . 1600 Amp

View A-A

514 UENR0996-03
i04392884

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
Table 367
Specification for the 237-1962 Electric Starting Motor Gp
B - - Clearance between the pinion and the housing is 9.1 mm (0.36 inch).
1 2 6V-8188 Nut Ground terminal. Torque to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).
2 2 4B-2049 Nut Torque to 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in).
3 1 6V-8188 Nut Motor terminal. Torque to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).
(continued)
UENR0996-03 515
(Table 367, contd)

Battery terminal. A maximum of three cable terminals or wire terminals may be used with the bat-
tery terminal nut. A maximum of two of the cable terminals may be equal to or greater than 0 AWG.
4 1 6V-8188 Nut
Torque to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).
5 - - Motor frame terminal. Torque to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).
Pull-in current at 20 V and 25° C (77° F) is 49.3 ± 3.3 Amp.

- - -
Hold-in current at 20 V and 25° C (77° F) is 6.8 Amp max.
When the electric starting motor is viewed from the pinion end, the motor rotates in the clockwise
- - -
direction.
No load conditions at 25 °C (77 °F):
Speed is 6950 ± 1650 rpm.

- - -
Current draw is 115 ± 25 Amp.
Voltage is 23 VDC.
516 UENR0996-03
i04392923

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
Table 368
B - - The clearance between the pinion and the housing is 9.1 mm (0.36 inch).
1 2 6V-8188 Nut Torque to 30.5 ± 3.5 N·m (270 ± 31 lb in).
Current consumption at 20V and 25 °C (77 °F):

250-8279 Solenoid
2 1 1. For Pull-in current is 57 Amp
Kit
2. For Hold-in current is 16 Amp max
A maximum of three cable terminals or wire terminals may be used with the battery terminal nut
5 1 6V-8188 Nut (5). A maximum of two of the terminals may be equal to or greater than 0 AWG.
Torque to 30.5 ± 3.5 N·m (270 ± 30 lb in).
7 - - Torque to 8 ± 3 N·m (71 ± 27 lb in).
direction.
- - -
1. Speed is 7643 ± 1683 rpm
2. Current draw is 76.5 ± 14.5 Amp
3. Voltage is 23 V
UENR0996-03 517
i04392953

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
Table 369
Specification for the 207-1549 Electric Starting Motor Gp, 207-1562 Electric Starting Motor Gp, and 207-1557 Electric Starting
Motor Gp

2 1 - 1. For Pull-in current is 57 Amp
2. For Hold-in current is 16 Amp max
3 1 6V-8188 Nut Torque to 30.5 ± 3.5 N·m (269.9 ± 30.9 lb in).
A maximum of three cable terminals or wire terminals may be used with the battery terminal nut (5).
5 1 6V-8188 Nut A maximum of two of the terminals may be equal to or greater than 0 AWG.
Torque to 30.5 ± 3.5 N·m (270 ± 30 lb in).
The switch terminal must be insulated with heat shrink tubing. Do not use molded terminals.
6 1 6V-8378 Nut
Torque to 2.25 ± 0.25 N·m (20 ± 2 lb in).
7 - - Torque to 8 ± 3 N·m (71 ± 27 lb in).
direction.
- - -
1. Speed is 7643 ± 1683 rpm
3. Voltage is 23 VDC
518 UENR0996-03
i04394629

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
Table 370
Specification for 348-7651 Electric Starting Motor Gp
The switch terminal must be insulated with heat shrinkable tubing. Do not use molded
2 1 4B-2049 Nut terminals.
Torque to 3.4 ± 1.2 N·m (30.1 ± 10.6 lb in).
A maximum of three cable terminals or wire terminals may be used with the battery termi-
4 1 6V-8188 Nut nal nut. A maximum of two of the terminals may be equal to or greater than 0 AWG.
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
- - - System voltage is 24 V.
No load performance at 25 °C (77 °F):

Speed 6950 ± 1650 rpm
- - -
Current 115 ± 25 amp.
Voltage 23 V
Mount the electric starting motor in a position that places the solenoid assembly no less than the 15 degrees above the horizontal.
When the electric starting motor is viewed from the pinion end, the motor rotates in the clockwise direction.
UENR0996-03 519
i04419669

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
Table 371
Specification for 6V-0889 Electric Starting Motor Gp and 6V-0513 Electric Starting Motor Gp
The switch terminal must be insulated with heat shrinkable tubing. Do not use
3 1 4B-2049 Nut molded terminals.
Torque to 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in).
A maximum of three cable terminals or wire terminals may be used with the
battery terminal nut. A maximum of two of the cable terminals may be equal to
5 1 6V-8188 Nut
or greater than 0 AWG.
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
Pull-in current at 20 V and 25 °C (77 °F) is 49.3 ± 3.3 Amp.

- - -
Hold-in current at 20 V and 25 °C (77 °F) is 6.8 Amp max.
When the electric starting motor is viewed from the pinion end, the motor ro-
- - -
tates in the clockwise direction.
520 UENR0996-03
i04432829

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
Table 372

338-3453 Starting Mo-
1 1 1. For pull-in windings is 49.3 ± 3.3 amp
tor Solenoid
2. For hold-in windings is 6.8 amp
2 2 6V-8188 Nut Ground terminal. Torque to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).
3 1 4B-2049 Nut Switch terminal. Torque to 2.25 ± 0.25 N·m (20.00 ± 2.00 lb in).
Switch terminal. Torque to 2.25 ± 0.25 N·m (20.00 ± 2.00 lb in).

4 1 4B-2049 Nut
Note:The switch terminal must be insulated with heat shrink tubing. Do not use molded terminals.
5 1 6V-8188 Nut Motor terminal. Torque to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).
Battery terminal. A maximum of three cable terminals or wire terminals may be used with the bat-
tery terminal nut. A maximum of two of the cable terminals may be equal to or greater than 0 AWG.
6 1 6V-8188 Nut
Torque to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).
7 - - Motor frame terminal. Torque to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).
- - -
direction.
(continued)
UENR0996-03 521
(Table 372, contd)

No load performance at 25 °C (77 °F):

- - -
Current draw is 115 ± 25 amp.
Voltage is 23 VDC.
522 UENR0996-03
i04561232

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
Table 373
Current consumption at 20 V and 25 °C (77 °F):

1. For pull-in windings is 57 amp
2 1 -
2. For hold-in windings is 16 amp
3. Maximum rated current is 850 amp
A maximum of three cable terminals or wire terminals may be used with the battery terminal nut. A
4 1 6V-8188 Nut maximum of two of the terminals may be equal to or greater than 0 AWG.
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
5 1 6V-8378 Nut
Torque to 20.6 ± 0.8 N·m (182.3 ± 7.1 lb in).
7 - - Torque to 8 ± 3 N·m (71 ± 27 lb in).
direction.
- - -
1. Speed is 7643 ± 1683 rpm
2. Current draw is 76.5 ± 14.5 amp
3. Voltage is 23 V
UENR0996-03 523
i04870252

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
Table 374
Battery terminal:
Maximum number of cable or wire terminals between the nuts should be 3.
1 - -
A maximum of two cable terminals can be larger than 0 AWG.
Final installation torque for the nut on the battery terminal is 24 ± 2 N·m (212 ± 18 lb in).
2 - - Final installation torque for the solenoid mounting nuts is 8.75 ± 1.05 N·m (77.44 ± 9.29 lb in).
Switch terminal:
Connect switch terminal to start relay switch.
3 - -
No other additional connection is required.
Final installation torque for the nut on the switch terminal is 2.15 ± 0.25 mm (0.08 ± 0.01 inch).
4 - - Final installation torque for the nut on the ground terminal is 24 ± 2 N·m (212 ± 18 lb in).
A - - Distance when pinion engaged is 69.9 mm (2.75 inch).
B - - Distance when pinion disengaged is 47.5 ± 2.2 mm (1.87 ± 0.09 inch).
Direction of rotation from the pinion end is Clockwise.

- - - Operation voltage is 24 VDC.
Operating temperature range is −32 to +120° C (−26 to 248° F).
No load performance at 20° C (68° F):

- - -
Current is 142 ± 30 amp.
Voltage is 24 VDC.
524 UENR0996-03
i04882274

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
Table 375

2 1 - 1. For Pull-in current is 57 amp
2. For Hold-in current is 16 amp
5 1 6V-8188 Nut maximum of two of the terminals may be equal to or greater than 0 AWG.
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
6 1 6V-8378 Nut
Torque to 2.6 ± 0.8 N·m (23.0 ± 7.0 lb in).
7 - - Torque to 8 ± 3 N·m (71 ± 27 lb in).
direction.
- - -
1. Speed is 7643 ± 1683 rpm
2. Current draw is 76.5 ± 14.5 amp
3. Voltage is 23 VDC
UENR0996-03 525
i04947034

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
Table 376
When the electric starting motor is viewed from the pinion end, the motor rotates in clockwise direction.

1 1 338-3453 Starting Motor Solenoid Pull-in winding is 49.3 ± 3.3 amp.
Maximum hold-in winding is 6.8 amp.
2 2 6V-8188 Nut Torque the ground terminal nut to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).
526 UENR0996-03

View A-A
Table 377
The switch terminal must be insulated with heat shrink tubing. Do not use molded
3 1 - terminals.
Torque to 3.4 ± 1.2 N·m (30.1 ± 10.6 lb in).
4 1 - Torque the ground terminal nut to 3.4 ± 1.2 N·m (30.1 ± 10.6 lb in).
A maximum of three cable terminals or wire terminals may be used between the battery
terminal nut (4). A maximum of two of the cable terminals may be equal to or greater
5 1 6V-8188 Nut than 0 AWG.
Torque the battery terminal nut to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).
6 1 6V-8188 Nut Torque the motor terminal nut to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).
7 1 - Torque the motor frame terminal nut to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).

- - -
Current draw is 115 ± 25 amp.
Voltage is 23 VDC.
UENR0996-03 527
i05300949

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
Table 378
Battery terminal.
A maximum of three cable terminals or wire terminals may be used with the battery
1 - - terminal nut. A maximum of two of the cable terminals may be equal to or greater
than 0 AWG.
Final Installation torque is 24 ± 2 N·m (212 ± 18 lb in).
2 - - Final Installation torque is 8.75 ± 1.05 N·m (77.44 ± 9.29 lb in).
Ground (Low side).

3 - -
Final Installation torque is 2.15 ± 0.25 N·m (19.03 ± 2.21 lb in).
Start relay terminal ground (High side).

4 - -
Final Installation torque is 2.15 ± 0.25 N·m (19.03 ± 2.21 lb in).
Ground terminal.
5 - -
Final Installation torque is 24 ± 2 N·m (212 ± 18 lb in).
When the electric starting motor is viewed from the pinion end, the motor rotates in
- - -
the clockwise direction.

- - -
Voltage is 24 VDC.
528 UENR0996-03
i05301030

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
Table 379
Ground terminal.
1 1 4B-2049 Nut
Torque to 3.4 ± 1.2 N·m (30.1 ± 10.6 lb in).
Switch terminal.
2 1 4B-2049 Nut The switch terminal must be insulated with heat shrinkable tubing. Do not use molded terminals.
Torque to 3.4 ± 1.2 N·m (30.1 ± 10.6 lb in).
Ground terminal.
3 1 6V-8188 Nut
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
Motor terminal.
4 1 6V-8188 Nut
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
Battery terminal.
5 1 6V-8188 Nut
maximum of two of the cable terminals may be equal to or greater than 0 AWG.
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
Motor frame terminal.

6 1 6V-8188 Nut
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
- - - Pull-in current at 20 V and 25 °C (77 °F) is 49.3 ± 3.3 Amp.
(continued)
UENR0996-03 529
(Table 379, contd)

- - -
direction.

- - -
Voltage is 23 VDC.
530 UENR0996-03
i05302721

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
Table 380
1 2 6V-8188 Nut Ground terminal. Torque to 30.5 ± 3.5 N·m (269.9± 30.9 lb in).
2 1 6V-8188 Nut Motor Terminal. Torque to 30.5 ± 3.5 N·m (270 ± 31 lb in).
3 1 6V-8378 Nut Ground Terminal. Torque to 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in).
Battery Terminal. Torque to 30.5 ± 3.5 N·m (269.9± 30.9 lb in) .
5 1 6V-8378 Nut Switch terminal. Torque to 2.25 ± 0.25 N·m (20 ± 2 lb in).
6 - - Motor frame terminal. Torque to 8 ± 3 N·m (71 ± 27 lb in).
direction.
Performance at no load conditions 25 °C (77 °F)
- - -
1. Speed is 6900± 1800 rpm
3. Voltage is 11 V
UENR0996-03 531
i05306414

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
Table 381
Specification for 352-9765 Electric Starting Motor Gp and 150-8867 Electric Starting Motor Gp
1 2 6V-8188 Nut Final installation torque to 30.5 ± 3.5 N·m (269.9 ± 30.9 lb in).
2 1 4B-2049 Nut Final installation torque to 3.4 ± 1.2 N·m (30.1 ± 10.6 lb in).
Switch terminal.
The switch terminal must be insulated with heat shrinkable tubing. Do
3 1 4B-2049 Nut
not use molded terminals.
Final installation torque to 3.4 ± 1.2 N·m (30.1 ± 10.6 lb in).
Ground terminal.
4 1 6V-8188 Nut
Final installation torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
Battery terminal.
A maximum of three cable terminals or wire terminals may be used
5 1 6V-8188 Nut with the battery terminal nut. A maximum of two of the cable terminals
may be equal to or greater than 0 AWG.
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
Motor frame terminal.

6 - -
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
Pull-in current at 10 V and 20° C (68° F) is 82.0 to 94.2 Amp.

- - -
Hold-in current at 10 V and 20° C (68° F) is 16.4 Amp max.
When the electric starting motor is viewed from the pinion end, the
- - -
motor rotates in the clockwise direction.
Speed is 4600 to 7100 rpm.

- - -
Current is 210 to 305 Amp.
Voltage is 11 VDC.
532 UENR0996-03
i05313015

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Table 382
Specification for 207-1520 Electric Starting Motor Gp and 207-1537 Electric Starting Motor Gp
Ground terminal.
1 1 6V-8188 Nut
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
Battery terminal.
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
2 1 6V-8188 Nut A maximum of three cable terminals or wire terminals may be used with the battery
terminal nut. A maximum of two of the terminals may be equal to or greater than 0
AWG.
Ground terminal.
3 1 6V-8378 Nut
Torque to 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in).
Switch terminal.
4 1 6V-8378 Nut
Torque to 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in).
5 1 5S-7349 Bolt Torque to 8 ± 3 N·m (71 ± 27 lb in).
Battery terminal.
6 1 6V-8188 Nut
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
(continued)
UENR0996-03 533
(Table 382, contd)

No load performance at 25° C (77° F):
Speed 6900 ± 1800 rpm.
Current 127.5 ± 27.5 amp.
Voltage 11 V.
- - -
534 UENR0996-03
i05657860

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
Table 383
1 - Screw Torque to 8.75 ± 1.05 N·m (77.44 ± 9.29 lb in).
2 - Nut Torque to 2.60 ± 0.80 N·m (23.01 ± 7.08 lb in).
3 - Bolt Final installation torque to 2.25 ± 0.25 N·m (19.91 ± 2.21 lb in).
4 - Nut Final installation torque to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).
UENR0996-03 535
i06568226

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
Table 384

250-8279 Solenoid 1. For Pull-in windings is 57 Amp
2 1
Kit 2. For Hold-in windings is 16 Amp
3. Maximum rated current is 850 Amp
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
5 1 6V-8378 Nut
Torque to 2.6 ± 0.8 N·m (23.0 ± 7.1 lb in).
7 - - Torque to 8 ± 3 N·m (71 ± 27 lb in).
direction.
- - -
1. Speed is 7643 ± 1683 rpm
3. Voltage is 23 V
536 UENR0996-03
i04941072

SMCS Code: 1453
S/N: NJH1–Up
S/N: ECM1–Up
Table 385
1 - - Final installation torque to 8.75 ± 1.05 N·m (77.44 ± 9.29 lb in).
3 - - Torque to 2.6 ± 0.8 N·m (23.0 ± 7.1 lb in).
Torque to 2.6 ± 0.8 N·m (23.0 ± 7.1 lb in).

4 - -
5 - - Torque to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).
6 - - Torque to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).
7 - - Torque to 30.5 ± 3.5 N·m (270.0 ± 31.0 lb in).

UENR0996-03 537
i07258768

SMCS Code: 1453
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 386
2 1 Torque to 3.4 ± 1.2 N·m (30.1 ± 10.6 lb in).
4B-2049 Nut The switch terminal must be insulated with heat shrinkable tubing. Do not use
3 1 molded terminals.
Torque to 3.4 ± 1.2 N·m (30.1 ± 10.6 lb in).
A maximum of three cable terminals or wire terminals may be used with the battery
terminal nut. A maximum of two of the cable terminals may be equal to or greater
4 1 6V-8188 Nut
than 0 AWG.
Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
6 1 Motor Frame Terminal Torque to 30.5 ± 3.5 N·m (269.9 ± 31.0 lb in).
Pull-in current at 20 V and 25 °C (77 °F) is 49.3 ± 3.3 Amp.

- - -
(continued)
538 UENR0996-03
(Table 386, contd)

- - -

- - -
Voltage is 23 VDC.
UENR0996-03 539
i04405418
Coolant Temperature Sensor

SMCS Code: 1906
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 256-6453
S/N: L4D1–Up
Part No.: 256-6453
S/N: L4E1–Up
Part No.: 256-6453
S/N: L4F1–Up
Part No.: 256-6453
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 387
Specification for 264-4297 Temperature Sensor and 256-6453 Temperature Sensor
1 1 - Torque to temperature sensor 20 ± 3 N·m (177 ± 27 lb in).
- - - Output type is Passive.

540 UENR0996-03
i04448859

SMCS Code: 1906
S/N: NJH1–Up
S/N: ECM1–Up
Table 388
Specification for 130-9811 Temperature Sensor Gp, 274-7396 Temperature Sensor Gp, 197-8392 Temperature Sensor Gp, and
256-6453 Temperature Sensor
Torque to 20 ± 3 N·m (175 ± 25 lb in).

1 1 -
Output type is passive.
UENR0996-03 541
i04974669

SMCS Code: 1906
S/N: NJH1–Up
S/N: ECM1–Up

Typical example
Table 389
Specification for 234-5012 Temperature Sensor Gp and 234-5013 Temperature Sensor Gp
1 1 256-6453 Temperature Sensor Final installation torque is 20 ± 3 N·m (177 ± 27 lb in).

542 UENR0996-03
i07192182

SMCS Code: 1906
S/N: NJH1–Up
S/N: ECM1–Up
Table 390
1 1 238-0112 Temperature Sensor Gp Final installation torque is 20 ± 3 N·m (177 ± 27 lb in)
Output type of the temperature sensor is passive.

UENR0996-03 543
i07527488

SMCS Code: 1906
Part No.: 256-6454

S/N: 3F61–Up
Part No.: 256-6454
S/N: 3F71–Up
S/N: NJH1–Up

Typical example
(1) Tighten the temperature sensor to the following

torque.. . . . . . . . . . . . . . . . . . . . . . 20 N·m ((177 lb in))
544 UENR0996-03
i04390215
Fuel Temperature Sensor

SMCS Code: 1922
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 256-6453
S/N: L4D1–Up
Part No.: 256-6453
S/N: L4E1–Up
Part No.: 256-6453
S/N: L4F1–Up
Part No.: 256-6453
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 391
Specification for the 264-4297 Temperature Sensorand 256-6453 Temperature Sensor
Torque to 20 ± 3 N·m (15 ± 2 lb ft).

1 - -
Output type is Passive.
UENR0996-03 545
i04974693
Fuel Temperature Sensor

SMCS Code: 1922
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 234-5013
S/N: L4D1–Up
Part No.: 234-5013
S/N: L4E1–Up
Part No.: 234-5013
S/N: L4F1–Up
Part No.: 234-5013
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 392
Specification for 234-5013 Temperature Sensor Gp
1 1 - Final installation torque for temperature sensor is 20 ± 3 N·m (177 ± 27 lb in).

546 UENR0996-03
i04397599
Engine Oil Pressure Sensor

SMCS Code: 1924
S/N: NJH1–Up
S/N: ECM1–Up
Table 393
Specification for 274-6719 Pressure Sensor Gp, 299-3222 Pressure Sensor Gp, 248-2167 Pressure Sensor Gp, 276-9067 Pres-
sure Sensor Gp, and 293-5535 Pressure Sensor Gp
1 - - Torque to 10 ± 2 N·m (89 ± 18 lb in).
- - - Operating voltage is 5.0 ± 0.5 VDC.

UENR0996-03 547
i04402163

SMCS Code: 1924
S/N: NJH1–Up
S/N: ECM1–Up
Table 394
Specification for the 161-1705 Engine Oil Pressure Sensor
Torque the pressure sensor to 10 ± 2 N·m (90 ± 18 lb in).
Prior to installing the pressure sensor onto the engine, apply 5P-3413 Pipe
1 - -
Sealant to the first three threads of the sensor.
548 UENR0996-03
i04518649

SMCS Code: 1924
S/N: 3F61–Up
S/N: 3F71–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 395
Specification for 293-5535 Pressure Sensor Gp
1 - - Torque to 10 ± 2 N·m (89 ± 18 lb in).

UENR0996-03 549
i04753349

SMCS Code: 1924
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 299-3222
S/N: L4D1–Up
Part No.: 299-3222
S/N: L4E1–Up
Part No.: 299-3222
S/N: L4F1–Up
Part No.: 299-3222
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 396
Specification for the 194-6725 Pressure Sensor Gp, 161-9931 Pressure Sensor Gp, 163-8523 Pressure Sensor Gp, 299-3222
Pressure Sensor Gp, 161-9926 Pressure Sensor Gp, 239-2396 Pressure Sensor Gp, 239-3478 Pressure Sensor Gp, and 3E-8652
Pressure Sensor Gp
Torque to 10 ± 2 N·m (90 ± 18 lb in).

1 1 -
550 UENR0996-03
i05391885

SMCS Code: 1924
S/N: NJH1–Up
S/N: ECM1–Up
Table 397
Specification for the 276-9067 Pressure Sensor Gp
274-6719 Pressure Sensor Torque to 10 ± 2 N·m (89 ± 18 lb in).

1 1
Gp Operating voltage is 5.0 ± 0.5 VDC.
UENR0996-03 551
i05663014

SMCS Code: 1924
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 293-5535
S/N: L4D1–Up
Part No.: 293-5535
S/N: L4E1–Up
Part No.: 293-5535
S/N: L4F1–Up
Part No.: 293-5535
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
(1) Final installation torque for the pressure sensor

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

((−40 to 257 °F))
Operating voltage . . . . . . . . . . . . . . . . . 5.0 ± 0.5 VDC

552 UENR0996-03
i07398027

SMCS Code: 1924
S/N: NJH1–Up
S/N: ECM1–Up
Table 398

Torque to 10 ± 2 N·m (89 ± 18 lb in).
274-6719 Pres-
1 1 Operating voltage is 5.00 ± 0.5 VDC.
sure Sensor Gp
Operating temperature is −40 °C to 125 °C (−40 °F to 257 °F).
i03874763
Boost Pressure Sensor

SMCS Code: 1917
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 325-7472
S/N: L4D1–Up
Part No.: 325-7472
S/N: L4E1–Up
Part No.: 325-7472 Illustration 556 g01951827
S/N: L4F1–Up
(1) Final installation torque for the pressure sensor
Part No.: 325-7472
S/N: TWG1–Up group . . . . . . . . . . . . . . . . 10 ± 2 N·m ((89 ± 18 lb in))
S/N: NJH1–Up Operating temperature . . . . . . . . . . . . . −40 to 125 °C

((−40 to 257 °F))
S/N: ECM1–Up
Operating voltage . . . . . . . . . . . . . . . . 5.0 ± 0.25 VDC
Maximum supply current . . . . . . . . . . . . . . . . . 10 mA

UENR0996-03 553
Maximum operating pressure (absolute pressure)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .600 kPa ((87 psi))
Voltage (output signal) . . Supply voltage X (pin (kPa)

X slope) + intercept
Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.00141093
Intercept . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05343915
Note: Install the pressure sensor group so that the
inlet pressure port is lower than the connector end.
Mount the pressure sensor group as close to vertical
as possible.
Table 399
Wiring Table
Pin Circuit
1 Vs
2 GND
3 SIG
554 UENR0996-03
i04423464

SMCS Code: 1917
S/N: NJH1–Up
S/N: ECM1–Up
Table 400
Torque to 10 ± 2 N·m (90 ± 18 lb in).

1 1 -
UENR0996-03 555
i07198740

SMCS Code: 1917
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 332-0296
S/N: L4D1–Up
Part No.: 332-0296
S/N: L4E1–Up
Part No.: 332-0296
S/N: L4F1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 401
1 1 - Final installation torque is 16 ± 3 N.m (142 ± 27 lb in).
- - - Operating voltage is 5.00 ± 0.25 VDC

556 UENR0996-03
i04385589
Atmospheric Pressure Sensor

SMCS Code: 1923
S/N: NJH1–Up
S/N: ECM1–Up
Table 402
Specification for the 194-6722 Pressure Sensor Gp, 194-6724 Pressure Sensor Gp, 194-6725 Pressure Sensor Gp,163-8530
Pressure Sensor Gp, and 239-3478 Pressure Sensor Gp
Torque to 10 ± 2 N·m (90 ± 18 lb in).

1 1 -
UENR0996-03 557
i04397550

SMCS Code: 1923
S/N: NJH1–Up
S/N: ECM1–Up
Table 403
Specification for 274-6717 Pressure Sensor, 248-2162 Pressure Sensor Gp, 276-6793 Pressure Sensor Gp, 306-6834 Pressure
Sensor Gp, 296-8060 Pressure Sensor Gp
1 - - Torque to 10 ± 2 N·m (89 ± 18 lb in).

558 UENR0996-03
i04423449

SMCS Code: 1923
S/N: NJH1–Up
S/N: ECM1–Up
Table 404
Torque to 10 ± 2 N·m (90 ± 18 lb in).

1 1 -
UENR0996-03 559
i07321090

SMCS Code: 1923
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 331-1134
S/N: L4D1–Up
Part No.: 331-1134
S/N: L4E1–Up
Part No.: 331-1134
S/N: L4F1–Up
Part No.: 331-1134
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 405
1 1 320-3063 Pressure Sensor Gp Torque to 13 ± 3 N·m (115 ± 27 lb in).
- - - Operating temperature is −40 °C to 125 °C (−40 °F to 257 °F).

560 UENR0996-03
i04390246
Inlet Air Temperature Sensor

SMCS Code: 1921
S/N: NJH1–Up
S/N: ECM1–Up
Table 406
Torque to 20 ± 5 N·m (177 ± 44 lb in).

1 1 130-9811 Temperature Sensor Gp
UENR0996-03 561
i04390275

SMCS Code: 1921
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 256-6453
S/N: L4D1–Up
Part No.: 256-6453
S/N: L4E1–Up
Part No.: 256-6453
S/N: L4F1–Up
Part No.: 256-6453
S/N: TWG1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 407
Specification for the 264-4297 Temperature Sensor and 256-6453 Temperature Sensor
Torque to 20 ± 3 N·m (15 ± 2 lb ft).

1 1 -
562 UENR0996-03
i04423438

SMCS Code: 1921
S/N: NJH1–Up
S/N: ECM1–Up
Table 408
234-5013 Temperature Torque to 20 ± 3 N·m (177 ± 27 lb in).

1 1
Sensor Gp Output type is passive.
UENR0996-03 563
i07597350
Pressure Sensor (ARD

Combustion Air)
SMCS Code: 1439
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 320-3062
S/N: L4D1–Up
Part No.: 320-3062
S/N: L4E1–Up
Part No.: 320-3062
S/N: L4F1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 409
1 1 320-3062 Pressure Sensor Gp Torque to 16 ± 3 N.m (142 ± 27 lb in).

564 UENR0996-03
i07597361
Pressure Sensor (DPF Inlet)

SMCS Code: 1439-PXS
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 330-6719
S/N: L4D1–Up
Part No.: 330-6719
S/N: L4E1–Up
Part No.: 330-6719
S/N: L4F1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 410
1 1 330-6719 Pressure Sensor Gp Torque to 13 ± 3 N.m (115 ± 27 lb in).

UENR0996-03 565
i03875093 i03875095
Pressure Sensor (NOx Temperature Sensor (NOx

Reduction System) Reduction System)
S/N: 3F61–Up S/N: 3F61–Up

S/N: 3F71–Up S/N: 3F71–Up
Part No.: 328-9038 Part No.: 320-0574
S/N: L4D1–Up S/N: L4D1–Up
Part No.: 328-9038 Part No.: 320-0574
S/N: L4E1–Up S/N: L4E1–Up
Part No.: 328-9038 Part No.: 320-0574
S/N: L4F1–Up S/N: L4F1–Up

Absolute pressure sensor
(1) Final installation torque for the temperature
Operating voltage . . . . . . . . . . . . . . . . . 5.0 ± 0.5 VDC sensor group . . . . . . . . . . . .45 ± 5 N·m ((33 ± 4 lb ft))
Operating temperature . . . . . . . . . . . . . −40 to 125 °C Output type . . . . . . . . . . . . Analog/ Powered passive

((−40 to 257 °F))
Operating voltage . . . . . . . . . . . . . . . . 5.0 ± 0.25 VDC
566 UENR0996-03
i04521824
Soot Antenna
SMCS Code: 108F-NS; 1335-SOT
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 349-7695
S/N: L4D1–Up
Part No.: 349-7695
S/N: L4E1–Up
Part No.: 349-7695
S/N: L4F1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 411
Specification for 349-7695 Soot Antenna Gp
1 - - Torque to 45 ± 5 N·m (33 ± 4 lb ft).
2 - - Tighten the mating connector to 1.2 ± 0.2 N·m (10.6 ± 1.8 lb in).
UENR0996-03 567
Note: Before installing the antenna into the Diesel

Particulate Filter (DPF), apply the anti-seize
compound to the threads of the antenna. Also apply
the anti-seize compound to the threads that the
antenna will be installed into. Use Never Seez®
Bostik "Pure Nickel Special" anti-seize compound.
This anti-seize compound can be ordered from the
following companies.
P & C Industrial Products
734-426-1400
Manufactures Warehouse Supply
847-632-1340
Table 412
Never Seez® Bostik "Pure Nickel Special" anti-seize
compound
Stock Number Description Amount
NSN -165 Flat top 1 lb
NSN -8 Flat top 8 lb
NSBT - 8N Brush top 8 oz
NSBT - 16N Brush top 1 lb
NSN - 42B Pail 42 lb

NSN - 130B Drum 130 lb
NSN - 425B Drum 425 lb
568 UENR0996-03
i04522024
Temperature Sensor (DPF Inlet,

Flame Detect)
SMCS Code: 1439
S/N: 3F61–Up
S/N: 3F71–Up
Part No.: 341-4176
S/N: L4D1–Up
Part No.: 341-4176
S/N: L4E1–Up
Part No.: 341-4176
S/N: L4F1–Up
S/N: NJH1–Up
S/N: ECM1–Up
Table 413
1 - - Torque to 45 ± 5 N·m (33 ± 4 lb ft).
- - - Output type is analog.
i03870354 Part No.: 300-9805

S/N: L4E1–Up
Speed/Timing Sensor Part No.: 300-9805
SMCS Code: 1907; 1912 S/N: L4F1–Up
Part No.: 300-9805
S/N: 3F61–Up
S/N: TWG1–Up
S/N: 3F71–Up
S/N: NJH1–Up
Part No.: 300-9805 S/N: ECM1–Up
S/N: L4D1–Up
UENR0996-03 569
Primary Speed/Timing Sensor Output type . . . . . . . . . . . . . . . . . . . . . . . . . . . .Analog
(1) Torque for the bolt . . . . .28 ± 7 N·m ((21 ± 5 lb ft))
Note: Ensure that the speed sensor group (1) is

seated before the bolt (2) is tightened.
Note: Ensure that the bracket (3) is installed in the
orientation that is shown.

((−40 to 216 °F))
Output type . . . . . . . . . . . . . . . . . . . . . . . . . . . .Analog

((−40 to 216 °F))
(2) Torque for the bolt . . . . .28 ± 7 N·m ((21 ± 5 lb ft))
Secondary Speed/Timing Sensor
Note: Ensure that the speed sensor group (2) is

seated before the bolt (1) is tightened.
Note: Ensure that the bracket (3) is installed in the
orientation that is shown.

((−40 to 216 °F))
570 UENR0996-03
i04389496
Speed/Timing Sensor
SMCS Code: 1907; 1912
S/N: NJH1–Up
S/N: ECM1–Up
Table 414
Specification for 191-8303 Speed Sensor Gp
133-0260 Ensure that the bracket is installed in the correct orientation. Refer to Illustration 574 for the orientation
1 1
Bracket of the bracket.
2 1 - Torque to 28 ± 7 N·m (248 ± 62 lb in).

UENR0996-03 571
i04389514
Speed/Timing Sensor
SMCS Code: 1907; 1912
S/N: NJH1–Up
S/N: ECM1–Up
Table 415
133-0261 Ensure that the bracket is installed in the correct orientation. Refer to Illustration 575 for the orientation
1 1
Bracket of the bracket.
2 1 - Torque to 28 ± 7 N·m (248 ± 62 lb in).
i04390432
Speed/Timing Sensor
SMCS Code: 1907; 1912
S/N: NJH1–Up
S/N: ECM1–Up
572 UENR0996-03
Primary Speed/Timing Sensor

(Crankcase)
Table 416
Specification for 300-9805 Speed Sensor Gp (PRIMARY, TIMING)
Lubricate the bore with the lubricant that is being sealed.

2 1 279-9828 Speed Sensor Gp
Ensure that the sensor is seated before the bolt is tightened.
UENR0996-03 573

(Camshaft)
Table 417
Specification for 300-9806 Speed Sensor Gp (SECONDARY, TIMING)
1 1 8T-4970 Bolt Torque to 28 ± 7 N·m (248 ± 62 lb in).
Lubricate the bore with the lubricant that is being sealed.

2 1 279-9829 Speed Sensor Gp
Ensure that the sensor is seated before the bolt is tightened.
574 UENR0996-03
i04403689
Speed/Timing Sensor
SMCS Code: 1907; 1912
S/N: NJH1–Up
S/N: ECM1–Up
Table 418
1 2 264-7786 Bracket Ensure that the bracket is installed in the orientation, as shown. Refer to Illustration 578 .
2 - - Torque for the bolt is 28 ± 7 N·m (21 ± 5 lb ft).
Lubricate the O-ring seal lightly with the lubricant that is being sealed.
Ensure that the sensor (3) is seated before the bolt (2) is tightened.
Note:
Note:
UENR0996-03 575
i04403707
Speed/Timing Sensor
SMCS Code: 1907; 1912
S/N: NJH1–Up
S/N: ECM1–Up
Table 419
2 - - Torque the bolt to 28 ± 7 N·m (248 ± 62 lb in).
Lubricate the O-ring seal lightly with the lubricant that is being sealed.
576 UENR0996-03
i04421189
Speed/Timing Sensor
SMCS Code: 1907; 1912
S/N: NJH1–Up
S/N: ECM1–Up
Table 420
- - - Lubricate the O-ring seal lightly with the lubricant that is being sealed.
Ensure that the bracket is installed in the correct orientation. Refer to Illustration 580 for the orienta-
1 1 133-0261 Bracket
tion of the bracket.
2 1 - Torque the M8 bolt to 28 ± 7 N·m (248 ± 62 lb in).
192-1562 Speed
3 1 Ensure that the sensor is seated before the bolt (2) is tightened.
Sensor
UENR0996-03 577
i04522028
Speed/Timing Sensor
SMCS Code: 1907; 1912
S/N: NJH1–Up
S/N: ECM1–Up
(2) Low output speed sensor group (4) High output speed sensor group
Table 421
Specifications for 236-6221 Speed Sensor Gp
Locate each sensor to the sensor support before tightening the bolt.
1 1 -
Torque the bolt for the mounting bracket (3) to 28 ± 7 N·m (248 ± 62 lb in).
The speed sensor group must be replaced as a pair. Each sensor has a different
- - -
part number.
- - - Output type of the speed sensor group is analog.
i05261235
Speed/Timing Sensor
SMCS Code: 1907; 1912
S/N: NJH1–Up
S/N: ECM1–Up
578 UENR0996-03
Camshaft Position Sensor
Table 422
Ensure that the bracket is installed in the orientation as shown in Illustration 582
1 - -
.
2 - - Operating temperature of the sensor is −40° C to 120° C (−40° F to 248° F).
- - - Lubricate the seal for the speed sensor with clean engine oil before installation.
- - - Ensure that the speed sensor is seated before the bolt is tightened.
UENR0996-03 579
Crankshaft Position Sensor
Table 423
Ensure that the bracket is installed in the orientation as shown in Illustration 583
1 - -
.
2 - - Operating temperature of the sensor is −40° C to 120° C (−40° F to 248° F).
- - - Lubricate the seal for the speed sensor with clean engine oil before installation.
- - - Ensure that the speed sensor is seated before the bolt is tightened.
i05393010
Speed/Timing Sensor
SMCS Code: 1907; 1912
S/N: NJH1–Up
S/N: ECM1–Up
580 UENR0996-03
Table 424
Specification for 279-9828 Speed Sensor Gp, and 284-3163 Speed Sensor Gp
Torque for the bolt is 28 ± 7 N·m (248 ± 62 lb in).

2 - -
i05393037
Speed/Timing Sensor
SMCS Code: 1907; 1912
S/N: NJH1–Up
S/N: ECM1–Up
UENR0996-03 581
Table 425

3 - -
582 UENR0996-03
Table 426

6 - -
UENR0996-03 583
Index Section
Index
A H
Atmospheric Pressure Sensor.....................556–559 Housing (Front).....413, 416, 419–420, 422, 425–426
B I
Belt Tensioner.............................501–502, 505–510 Important Safety Information ..................................2
Belt Tensioner (Alternator and Compressor) ........ 503 Inlet Air Temperature Sensor.......................560–562
Boost Pressure Sensor....................... 552, 554–555
M
C
Main Bearing Journal..................................379–380
Camshaft......216–217, 219, 221, 223–224, 226, 228, Connecting Rod Bearing Journals ................... 380
230, 232 Main Bearing Journals.................................... 381
Compression Brake....................................123, 128 Mounting Straps................................................ 216
Compression Brake (If Equipped) ....................... 126
Connecting Rod ...................381, 383, 385–386, 388
Connecting Rod Bearing Journal ......... 376, 378–379 P
Coolant Temperature Sensor ......................539–543 Piston and Rings ......... 389–392, 394, 396, 398, 400,
Crankshaft.... 351–354, 356–357, 359, 361–363, 365 402–403, 405, 407, 409
Crankshaft Seals......................... 366, 368–369, 372 Intermediate piston ring (3) ............................. 392
116-1091 Crankshaft Seal Gp....................... 371 Intermediate Piston Ring (3) ............ 390, 393, 403
226-4755 Crankshaft Seal Gp....................... 369 Oil Control Piston Ring (4) .......................393, 403
Cylinder Block.............. 323, 326, 330, 332, 336, 341 Oil control ring (4) .......................................... 392
Cylinder Head ..........95, 101, 104, 107, 111, 117, 120 Oil Control Ring (4) ........................................ 391
Cylinder Head Valves ....78, 81, 83, 85, 87, 89, 91, 93 Piston Pin (5).................................. 391, 393, 404
Cylinder Liner ............................................344–350 Piston Pin (6)................................................. 392
Steel Piston ............................................392, 403
E Top Piston Ring (2) ......................... 390–392, 403
Piston Cooling Jet ............................................. 411
Electric Starting Motor .........510, 512–514, 516–520, Pressure Sensor (ARD Combustion Air).............. 563
522–525, 527–528, 530–532, 534–537 Pressure Sensor (DPF Inlet) .............................. 564
Electronic Unit Injector..............................19, 21–23 Pressure Sensor (NOx Reduction System).......... 565
Electronic Unit Injector Mechanism..... 23, 25, 27, 29,
32–33
Electronic Unit Injector Rocker Arm ................ 34–39 S
Engine Oil Filter Base ..........233, 236–243, 246, 248, Soot Antenna.................................................... 566
250–251, 253 Specifications Section ...........................................7
Engine Oil Pan..... 262, 264–265, 267–270, 272, 274, Speed/Timing Sensor ..........568, 570–571, 574–577,
276, 278, 280, 282–285, 288–289, 292, 295, 297, 579–580
299–303 Camshaft Position Sensor .............................. 578
Engine Oil Pressure Sensor ........................546–552 Crankshaft Position Sensor ............................ 579
Engine Oil Pump ..................253, 255, 257, 259, 261 Primary Speed/Timing Sensor ......... 569, 580–581
Exhaust Gas Valve (NRS) ...........................183, 185 Primary Speed/Timing Sensor (Crankcase) ..... 572
340-7208 Exhaust Gas Valve Gp (NRS) ........ 187 Secondary Speed/Timing Sensor .............569, 582
Exhaust Manifold ........ 187–190, 192, 194, 196–197, Secondary Speed/Timing Sensor (Camshaft)... 573
199, 201, 203, 205, 207, 209, 211, 213
Exhaust Manifold Shield .................................... 215
T
F Table of Contents ..................................................3
Temperature Sensor (DPF Inlet, Flame Detect) ... 568
Flywheel....................................................450–471 Temperature Sensor (NOx Reduction System) .... 565
Flywheel Housing........ 471–475, 478–479, 482–485, Turbocharger ....... 131–133, 135, 138, 140, 142, 144,
487–488, 491, 493–495, 498, 500 146, 149, 151, 153, 155, 158, 160–161, 163–164,
Fuel Filter Base...............................7–13, 15–16, 18 167, 169, 171–173, 175, 177–179, 181, 183
Fuel Filter Base (Primary) ....................................14
Fuel Temperature Sensor ...........................544–545
V
G Valve Mechanism ..........................41–43, 45–47, 49
Valve Mechanism Cover .... 57, 60, 62, 64, 66, 68, 70,
Gear Group (Front)...... 429, 431, 433–434, 437, 439, 72–73, 76, 78
441, 446 Valve Rocker Arm ......................................... 51–56
584 UENR0996-03
Index Section
Vibration Damper and Pulley.......................373–376
W
Water Pump........................ 305–307, 310–318, 321
Water Pump (Separate Circuit Water Pump)........ 323
Water Temperature Regulator ............................ 304
UENR0996 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2019 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.
586 January 2019

Uenr0996 03 00 - Manuals Service Modules - Specifications

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Uenr0996 03 00 - Manuals Service Modules - Specifications

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UENR0996-03 (en-us)

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When replacement parts are required for this

Table of Contents Cylinder Head Valves ..........................................93

Camshaft ......................................................... 221 Water Pump ..................................................... 321

Housing (Front)................................................. 420 Electric Starting Motor ...................................... 510

Fuel Filter Base

(A) Length 11 mm (0.4 inch)

Item Qty Part Specification Description

Apply red Loctite 271 to a length of (A) to the threads.

Fuel Filter Base

Item Qty Part Specification Description

Fuel Filter Base

Item Qty Part Specification Description

Fuel Filter Base

Item Qty Part Specification Description

Fuel Filter Base

Item Qty Part Specification Description

Fuel Filter Base

Item Qty Part Specification Description

1 1 234-5013 Temperature Sensor Gp Torque to 20 ± 3 N·m (177 ± 27 lb in).

4 - - Lubricate seal lightly with the fluid that is being sealed.

5 2 308-9679 Fuel Filter Torque to 35 ± 3 N·m (26 ± 2 lb ft).

Fuel Filter Base

Item Qty Part Specification description

Fuel Filter Base

Item Qty Part Specification Description

1 1 9S-8002 O-Ring Plug Torque to 11 ± 2 N·m (97 ± 18 lb in).

2 2 179-7267 Plug Torque to 95 ± 10 N·m (70 ± 7 lb ft).

Length under test force is 20.21 mm (0.796 inch).

Fuel Filter Base

Part No.: 348-7307

Item Qty Part Specification Description

Fuel Filter Base

Item Qty Part Specification Description

1 2 6D-5801 Locknut Torque to 1.7 ± 0.4 N·m (15.0 ± 3.5 lb in).

2 2 179-7267 Plug Torque to 95 ± 10 N·m (70 ± 7 lb ft).

3 1 9S-8002 O-Ring Plug Torque to 11 ± 2 N·m (97 ± 18 lb in).

(Table 10, contd)

Item Qty Part Specification Description

Fuel Filter Base

Part No.: 343-8126

(3) Fuel filter base assembly

Item Qty Part Specification Description

1 1 234-5013 Temperature Sensor Gp Final installation torque is 20 ± 3 N·m (177 ± 27 lb in).

Final installation torque is 10 ± 2 N·m (89 ± 18 lb in).

Electronic Unit Injector

(1) Lubricate the seals and the bore with a 50 percent

(2) Bolt torque . . . . . . . . . .55 ± 10 N·m ((40 ± 7 lb ft))

Electronic Unit Injector

Item Qty Part Specification Description

1 1 8S-9191 Bolt Torque to 55 ± 10 N·m (41 ± 7 lb ft).

Electronic Unit Injector

Item Qty Part Specification Description

1 1 8S-9191 Bolt Torque to 55 ± 10 N·m (41 ± 7 lb ft).

Electronic Unit Injector

Item Qty Part Specification Description

1 1 8T-0644 Bolt Torque to 70 ± 15 N·m (52 ± 11 lb ft).

Electronic Unit Injector

Use the following procedure for adjusting the unit

Turn . . . . . . . . . . . . . . . . . 180 degrees (1/2 of a turn)

Tighten the locknut to the following torque.