GN65770N

GN65770N gn65770n
404D-22 2008/04/01
The information given within this parts book was correct at the time of printing and is subject to change without
notice. Always refer to your local Perkins outlet for the latest information. Only fully trained personnel should car-
ry out servicing of engines. Before working on any engine always refer to the correct user service and maintenance
manual.
Always refer to your local Perkins outlet before purchasing any parts
Subject to any existing rights of third parties, the information given in this document is the property of Perkins En-
gines Limited and should not be copied, in whole or part, without the prior written consent of the Company.
Contents
1. Introduction Pg. 4
2. How To Use Your Parts Book Pg. 4
3. Engine Breakdown Pg. 5
4. Symbol Descriptions Pg. 9
5. Parts Lists & Illustrations Pg. 11
6. Parts Index Pg. 128

Introduction
The build list of your engine, found on the front page of this parts book, provides a unique
reference to the components fitted to your engine; therefore this parts book is only applicable to
this particular engine
Always quote your build list and engine serial number when contacting your Perkins outlet.
How to use your Parts Book
This parts book has been designed to provide you with all the information you need to identify
parts to service your engine. There are several features within the book to make it easy to find
the parts you require.
Front Page
This lists your build list number and the date of publication of this book
Symbol Descriptions
Provides a quick reference guide to the symbols used within the book.
Engine Breakdown
Use this to identify all the major sections of your engine and the relevant pages within the book.
Parts Lists & Illustrations

This section shows each major section of your engine broken down into individual part numbers
along with an associated illustration for identifying the parts you require.
The illustrations used in this parts book are representational only and should only be used for
identification purposes.
For fitting instructions please refer to your engine Service Manual.
Parts Index
Using either the part number or description of the part you require this section will help you
locate the page within the Parts Lists & Illustrations section where the part appears.
Engine Breakdown
Section Page Section Page
Level 1 - Service 11 Relief Valve 37

AAAAAAGN ACPG0004
Level 2 - Repair 13 Timing Case 39

AAAAAAGN ADPG0016
Level 3 - Overhaul 15 Timing Case 41

AAAAAAGN ADPG0016
Cylinder Block 17 Timing Case 43

ACPG0004 ADPG0016
Cylinder Block 19 Timing Case 45

ACPG0004 ADPG0016
Crankshaft, Pistons & Connecting Rods 21 Timing Case 47

ACPG0004 ADPG0016
Crankshaft, Pistons & Connecting Rods 23 Camshaft & Gears 49

ACPG0004 ADPG0016
Rear End Oil Seal 25 Fuel Injection Pump 51

ACPG0004 AFPG0016
Cylinder Head 27 High Pressure Fuel Pipes 53

ACPG0004 AFPG0016
Cylinder Head 29 Atomisers 55

ACPG0004 AFPG0016
Rocker Shaft Assembly 31 Fuel Leak-Off Pipe 57

ACPG0004 AFPG0016
Oil Pump 33 Flywheel Housing 59

ACPG0004 CDPG0001
Pipes 35 Flywheel & Starter Ring 61

ACPG0004 DDPG0000
Page 5
Engine Breakdown
Section Page Section Page
Starter Motor 63 Fan 89

EDPG0001 MDPG0003
Pulleys 65 Fan Drive 91

FBPG0001 MEPG0017
Sump 67 Alternator 93
GBPG0001 NDPG0002
Dipstick & Filler Tube 69 Drive Belt & Tensioner 95

GBPG0001 NEPG0001
Dipstick & Filler Tube 71 Front End Drive Output 97

GBPG0001 QCPG0001
Sump 73 Cylinder Head Cover 99

GCPG0001 TBPG0002
Filler 75 Cylinder Head Cover 101

HBPG0000 TBPG0002
Oil Filter 77 Feed Pipes 103

JBPG0000 TBPG0002
Oil Filter 79 Exhaust Manifold 105

JCPG0000 UBPG0002
Front End Drive Input 81 Exhaust Manifold 107

KBPG0001N UDPG5503
Water Pump 83 Lift Pump 109

LBPG0003 VBPG0006
Thermostat & Housing 85 Fuel Filter 111

LBPG0003 VBPG0006
Water Outlet & Inlet 87

LDPG0001
Page 6
Engine Breakdown
Section Page
Pipework & Connections 113

VBPG0006
Cold Start System 115

WDPG0000
Engine Lifting Eyes 117

XBPG0000
Throttle & Stop Controls 119

ZAPG0002
Instrumentation 121
ZJPG0000
Instrumentation 123
ZLPG0002
Electrical Wiring & Fittings 125

ZPPG0001
Fuel Pre-Lift Pump 127

ZVPG0001
Page 7
Engine Breakdown
Page 8
Symbols and Notes
Symbol Description
A From Engine Number
B Upto Engine Number
C Repairs and Replaces
D See Appropriate Section - Reference Number
E Alternative
F Order
G Remanufactured Part
H New for Old Part
I Number of Teeth
J Thickness
K Bottom
L Top
M Left Hand
N Right Hand
O Reference for Detailed Breakdown
P Other Service Options Available
Q Cylinder Number
R See History Section
Page 9
Level 1 - Service Plate A
AAAAAAGN
Recommended stocking and service lists

Perkins provides Recommended stocking and service lists, for Distributor use when
recommending parts stocks for Dealers, preferred customers (eg fleets) etc. These lists
are based on agreed workshop capability and are at three distinct levels:
Level 1 - Service
The Level 1 workshop has the ability to perform basic non-intrusive maintenance on
Perkins engines.
Listes recommandées pour le stock et la maintenance
Perkins fournit des listes recommandées pour le stock et la maintenance afin d'aider le
Distributeur dans ses conseils aux Agents, aux clients habituels, etc.. Ces listes sont
basées sur le niveau technique des Ateliers avec trois niveaux distincts :
Niveau 1- Maintenance
L'atelier de niveau 1 est capable d'executer l'entretien de base des moteurs Perkins (sans
demontage).
Empfohlene Lagerbestands- und Servicelisten
Perkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche die
Vertragshändler verwenden können, um Händlern und Kunden (z.B. Fuhrparks) einen
bestimmten Ersatzteilbestand zu empfehlen. Diese Listen basieren auf den vereinbarten
Werkstattfähigkeiten, welche in die folgenden drei Stufen unterteilt werden:
Stufe 1 - Service
Werkstätten der Stufe 1 können grundlegende und einfache Wartungsarbeiten an
Perkins-Motoren ohne Spezialwerkzeug durchführen.
Listas de servicio y de stock recomendadas
Perkins proporciona Listas de servicio y de stock recomendadas, para que las use el
Distribuidor al recomendar stocks de repuestos a los Distribuidores, a los clientes
preferidos (por ejemplo, flotas), etc. Estas listas se basan en capacidad del taller
acordada y se dividen en tres niveles diferentes:
Nivel 1 - Servicio
El taller del Nivel 1 puede llevar a cabo un mantenimiento no intrusivo en los motores
Perkins.
Elenco parti consigliate ad uso stock ed assistenza
Perkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza;
ciò per soddisfare le richieste dei dealers, clienti preferenziali ecc. Questi elenchi tengono
in considerazione la capacità operativa concordata con l’officina e sono distinti in tre livelli
Livello 1 - Assistenza
Il livello 1 prevede che l’officina sia in grado di operare in maniera basilare sui motori
Perkins.
Page 10
Level 1 - Service Plate A
AAAAAAGN
Item Part No. References Qty. Description Notes
1 1 LEVEL 1 - SERVICE
Page 11
Level 2 - Repair Plate A
AAAAAAGN

Perkins provides Recommended stocking and service lists, for Distributor use when
recommending parts stocks for Dealers, preferred customers (eg fleets) etc. These lists are
based on agreed workshop capability and are at three distinct levels:
Level 2 - Repair
The Level 2 workshop has the ability to perform maintenance service,and inspection service on
Perkins engines.
Perkins fournit des listes recommandées pour le stock et la maintenance afin d'aider le
Distributeur dans ses conseils aux Agents, aux clients habituels, etc.. Ces listes sont basées sur
le niveau technique des Ateliers avec trois niveaux distincts :
Niveau 2 - Maintenance & reparation
L'atelier de niveau 2 est capable d’executer toutes les opérations d'entretien, la reparation des
composants externes (demarreur, alternateur,etc) et le diagnostic pour les problèmes touchant à
l'electronique
Perkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche die Vertragshändler
verwenden können, um Händlern und Kunden (z.B. Fuhrparks) einen bestimmten
Ersatzteilbestand zu empfehlen. Diese Listen basieren auf den vereinbarten
Werkstattfähigkeiten, welche in die folgenden drei Stufen unterteilt werden:
Stufe 2 - Reparatur
Werkstätten der Stufe 2 können Instandsetzungs- und Inspektionsarbeiten an Perkins-Motoren
durchführen.
Perkins proporciona Listas de servicio y de stock recomendadas, para que las use el
Distribuidor al recomendar stocks de repuestos a los Distribuidores, a los clientes preferidos
(por ejemplo, flotas), etc. Estas listas se basan en capacidad del taller acordada y se dividen en
tres niveles diferentes:
Nivel 2 - Reparación
El taller de Nivel 2 puede llevar a cabo el servicio de mantenimiento y el servicio de inspección
en los motores Perkins.
Perkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza; ciò per
soddisfare le richieste dei dealers, clienti preferenziali ecc. Questi elenchi tengono in
considerazione la capacità operativa concordata con l’officina e sono distinti in tre livelli :
Livello 2 - Riparazione
Nel livello 2 l’officina è in grado di svolgere la manutenzione e di fare controlli di
assistenza sui motori Perkins.
Page 12
Level 2 - Repair Plate A
AAAAAAGN
1 1 LEVEL 2 - REPAIR
Page 13
Level 3 - Overhaul Plate A
AAAAAAGN

Perkins provides Recommended stocking and service lists, for Distributor use when recommending parts
stocks for Dealers, preferred customers (eg fleets) etc. These lists are based on agreed workshop capability
and are at three distinct levels:
Level 3 - Overhaul.
The Level 3 workshop has the ability to perform complete service work on Perkins engines. Can repair and
fully overhaul engine, including engine test. Can perform all levels of electronics diagnosis and application
related faults.
Perkins fournit des listes recommandées pour le stock et la maintenance afin d'aider le Distributeur dans ses
conseils aux Agents, aux clients habituels, etc.. Ces listes sont basées sur le niveau technique des Ateliers
avec trois niveaux distincts :
Niveau 3 - Maintenance, reparation & refection
L' atelier de niveau 3 est capable de couvrir toutes les opérations d'entretien des moteurs Perkins. Il peut
aussi réparer et entièrement refaire des moteurs ainsi que les tester. Il est capable d'effectuer un diagnostic
pour les problèmes touchant à l'electronique et aux applications.
Perkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche die Vertragshändler verwenden
können, um Händlern und Kunden (z.B. Fuhrparks) einen bestimmten Ersatzteilbestand zu empfehlen. Diese
Listen basieren auf den vereinbarten Werkstattfähigkeiten, welche in die folgenden drei Stufen unterteilt
werden:
Stufe 3 - Überholung
Werkstätten der Stufe 3 können umfassende Servicearbeiten an Perkins-Motoren durchführen. Sie können
Motoren reparieren und komplett überholen und außerdem Motorprüfungen durchführen. Sie können
umfassende elektronische Diagnoseprüfungen durchführen und anwendungsspezifische Störungen
untersuchen.
Perkins proporciona Listas de servicio y de stock recomendadas, para que las use el Distribuidor al
recomendar stocks de repuestos a los Distribuidores, a los clientes preferidos (por ejemplo, flotas), etc. Estas
listas se basan en capacidad del taller acordada y se dividen en tres niveles diferentes:
Nivel 3 - Reparación general
El taller de Nivel 3 puede llevar a cabo un trabajo de servicio completo en los motores Perkins. Puede
reparar y reacondicionar completamente un motor, incluyendo probar el motor. Puede llevar a cabo todos los
niveles de diagnóstico electrónico y las fallas relacionadas con la aplicación.
Perkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza; ciò per soddisfare le
richieste dei dealers, clienti preferenziali ecc. Questi elenchi tengono in considerazione la capacità operativa
concordata con l’officina e sono distinti in tre livelli :
Livello 3 - Revisione
Nel livello 3 l’officina è in grado di svolgere lavori di assistenza completi sui motori Perkins. E’ in grado di
riparare e svolgere una revisione completa del motore, incluso le prove. Può anche effettuare diagnosi sull’
elettronica a tutti i livelli e sui relativi difetti nelle applicazioni.
Page 14
Level 3 - Overhaul Plate A
AAAAAAGN
1 1 LEVEL 3 - OVERHAUL
Page 15
Cylinder Block Plate A
ACPG0004
14
22 13
18 19
8
20
6
3
2
11
12
17 16
7 4 21
15
10
Page 16
Cylinder Block Plate A
ACPG0004
1 1 CYLINDER BLOCK (A)

2 198466940 4 PLUG
3 198466010 3 PLUG
4 198466020 2 PLUG
5 064210025 2 PLUG
6 064210040 3 PLUG
7 064210040 1 PLUG
8 064210040 1 PLUG
9 198466920 3 PLUG
10 198517222 P 1 BUSH
11 042309017 1 NEEDLE BEARING
12 042309018 1 NEEDLE BEARING
13 040106203 1 BALL BEARING
14 064100045 1 PLUG
15 165296220 1 SHAFT
16 012110635 1 STUD
17 012110660 1 STUD
18 010109441 3 STUD
19 030500612 2 DOWEL
20 030500616 2 DOWEL
21 030501025 2 DOWEL
22 030309005 2 PIN
Service Options
10 198517226 J (-)0.25MM 1 BUSH
10 198517229 J (-)0.50MM 1 BUSH
Footnotes
(A) SERVICE BY COMPLETE ENGINE
Page 17
Cylinder Block Plate B
ACPG0004
Page 18
Cylinder Block Plate B
ACPG0004
1 165996590 1 GASKET - TIMING CASE

2 011310612 2 SCREW
History
a.
4 U65166580 1 PLATE
Page 19
Crankshaft, Pistons & Connecting Rods Plate A
ACPG0004
33
1 5
4
7
6
3 30
26
27
24
20
29
21
18
28
14
23
15
12
31
22
8
17
9
25
16
11
19
10
32
13
Page 20
Crankshaft, Pistons & Connecting Rods Plate A
ACPG0004
1 115256990 1 CRANKSHAFT ASSEMBLY

2 F 115256990 1 CRANKSHAFT ASSEMBLY
3 115276270 1 CRANKSHAFT GEAR
4 030509020 1 KEY
5 199266210 1 THRUST WASHER
8 110156360 Q 1 1 HOLDER
9 F 110156360 1 CAP
10 F 110156360 1 CAP
11 030500612 2 DOWEL
12 010109406 2 SCREW
13 011511070 1 SCREW
14 110156370 Q 2 1 HOLDER
15 F 110156370 1 CAP
16 F 110156370 1 CAP
17 030500612 2 DOWEL
18 010109406 2 SCREW
19 011511070 1 SCREW
20 110156380 Q 3 1 HOLDER
21 F 110156380 1 CAP
22 F 110156380 1 CAP
23 030500612 2 DOWEL
24 010109406 2 SCREW
25 011511070 1 SCREW
26 110156390 Q 4 1 HOLDER
27 F 110156390 1 CAP
28 F 110156390 1 CAP
29 030500612 2 DOWEL
30 010109406 2 SCREW
31 010700860 2 BOLT
32 U5MB0025 P 1 MAIN BEARING KIT
33 U5ME0030 1 BIG END BEARING KIT
Service Options
32 U5MB0025A J (-) 0.25MM 1 MAIN BEARING KIT
Page 21
Crankshaft, Pistons & Connecting Rods Plate B
ACPG0004
3 2
12
8
10
11
Page 22
Crankshaft, Pistons & Connecting Rods Plate B
ACPG0004
1 115017491 4 PISTON AND RING KIT

2 F 115017491 1 PISTON
3 115107970 1 PISTON RING KIT
4 115026330 4 CON ROD ASSEMBLY
5 F 115026330 1 ROD
6 F 115026330 1 CAP
7 198517265 1 SMALL END BUSH
8 115176140 2 CON ROD BOLT
9 020109120 2 CON ROD NUT
10 115326220 4 GUDGEON PIN
11 036500028 4 CIRCLIP
12 036500028 4 CIRCLIP
Page 23
Rear End Oil Seal Plate A
ACPG0004
Page 24
Rear End Oil Seal Plate A
ACPG0004
1 050209083 1 SEAL - REAR END OIL (A,B)
Footnotes
(A) SEE SERVICE BULLETIN NO.195

(B) ALSO ORDER WEAR SLEEVE - 29990037
Page 25
Cylinder Head Plate A
ACPG0004
22
21
1
20
2 4
14
19
13
18
7
12
17
11
8
16
10
15
Page 26
Cylinder Head Plate A
ACPG0004
1 111011030 1 CYLINDER HEAD ASSEMBLY

2 F 111011030 1 CYLINDER HEAD
3 064210010 3 PLUG
4 064210018 7 CAP
5 064210025 3 PLUG
6 064210025 3 PLUG
7 064210030 1 CAP
8 064210030 1 CAP
9 120166380 4 INTAKE VALVE
10 TPN646 4 VALVE SEAT INSERT
11 120406070 4 SEAL - VALVE STEM (A)
12 198216700 4 VALVE SPRING
13 120186080 4 CAP
14 120226070 4 VALVE COLLET
15 120176380 4 EXHAUST VALVE
16 TPN645 4 VALVE SEAT INSERT
17 120406050 4 SEAL - VALVE STEM (B)
18 198216700 4 VALVE SPRING
19 120186080 4 CAP
20 120226070 4 VALVE COLLET
21 120216041 4 VALVE SPRING CAP
22 120216041 4 VALVE SPRING CAP
Footnotes
(A) INLET
(B) EXHAUST
Page 27
Cylinder Head Plate B
ACPG0004
Page 28
Cylinder Head Plate B
ACPG0004
1 P 1 GASKET - CYLINDER HEAD

2 111136480 14 SCREW
3 111136490 4 SCREW
4 012110655 2 STUD
5 012110860 2 STUD
Service Options
1 111147711 J 1.2MM 1 GASKET - CYLINDER HEAD
1 111147721 J 1.3MM 1 GASKET - CYLINDER HEAD
Page 29
Rocker Shaft Assembly Plate A
ACPG0004
7
8
10
3
9
5 6
16
15
14
12
2
11
13
Page 30
Rocker Shaft Assembly Plate A
ACPG0004
1 120036821 1 ROCKER BOX

2 F 120036821 1 ROCKER BOX
3 120316201 1 ROCKER SHAFT
4 052109076 1 SEAL - O RING
5 120356131 4 ROCKER ARM ASSEMBLY INLET
6 120356141 4 ROCKER ARM ASSEMBLY EXHAUST
7 198217170 3 ROCKER SHAFT SPRING
8 199486220 8 ADJUSTING SCREW
9 020109076 8 NUT
10 199280300 6 WASHER
11 120996130 1 SEAL - ROCKER BOX
12 120456310 8 PUSHROD
13 120116160 8 TAPPET
14 012109044 4 STUD
15 023100010 4 NUT
16 011310635 2 SCREW
Page 31
Oil Pump Plate A
ACPG0004
14
1
5
3
6
10
11
12
Page 32
Oil Pump Plate A
ACPG0004
1 165026270 1 IDLER GEAR

2 F 165026270 1 IDLER GEAR
3 F 165026270 1 ROTOR
4 F 165026270 1 ROTOR
5 198517290 3 BUSH
6 030509018 3 DOWEL
7 198217760 1 SPRING
8 140116220 1 COVER
9 P 1 SHIM
10 198216720 1 SPRING
11 199236540 1 COLLAR
12 036800010 1 CIRCLIP
Service Options
9 199286150 J (+)0.10MM 1 SHIM
9 199286160 J (+)0.15MM 1 SHIM
9 199286170 J (+)0.20MM 1 SHIM
9 199286180 J (+)0.50MM 1 SHIM
Page 33
Pipes Plate A
ACPG0004
Page 34
Pipes Plate A
ACPG0004
1 140607020 1 OIL PIPE

2 198486780 1 BOLT
3 140996260 1 WASHER
4 140996260 1 WASHER
Page 35
Relief Valve Plate A
ACPG0004
Page 36
Relief Valve Plate A
ACPG0004
1 140036220 1 RELIEF VALVE

2 052109078 1 SEAL - O RING
Page 37
Timing Case Plate A
ADPG0016
Page 38
Timing Case Plate A
ADPG0016
1 1 TIMING CASE (A)

2 165996630 1 GASKET - TIMING CASE
3 011310640 7 SCREW
4 011310660 4 SCREW
5 023100006 1 NUT
Footnotes
(A) SEE FOLLOWING PARTS LIST FOR SERVICE COMPONENTS
Page 39
Timing Case Plate B
ADPG0016
Page 40
Timing Case Plate B
ADPG0016
1 165106870 1 TIMING CASE

2 030300414 1 PIN
3 198636160 1 SEAL - FRONT END OIL
History
a.
052300850 1 SEAL - O RING
110416290 1 BEARING HOLDER ASSEMBLY
Page 41
Timing Case Plate C
ADPG0016
10
7
6 9
5
1
12
11
13
Page 42
Timing Case Plate C
ADPG0016
1 125616120 1 BRACKET
2 165996640 1 GASKET
3 125156262 R a. 1 ARM
4 198217870 1 SPRING
5 052100070 1 SEAL - O RING
6 198217750 1 SPRING
7 023100008 1 NUT
8 2315C039 1 SCREW
9 2648A120 1 NUT
10 26420462 1 ANTI-TAMPER CAP
11 2315C039 1 SCREW
12 2318A207 1 NUT
13 011310614 4 SCREW
History
a.
3 125156261 1 ARM
Page 43
Timing Case Plate D
ADPG0016
11
1
10
Page 44
Timing Case Plate D
ADPG0016
1 125046613 R a. 1 CONTROL LEVER

2 125116221 1 SHAFT
3 025100008 1 WASHER
4 131046560 1 SPEED SENSOR
5 020800010 1 NUT
6 125306151 R b. 1 CONTROL LEVER
7 125116211 1 SHAFT
8 024500006 1 NUT
9 025100006 1 WASHER
10 198217880 1 SPRING
11 031100004 1 PIN
History
a.
1 125046612 1 CONTROL LEVER
b.
6 125306150 1 CONTROL LEVER
Page 45
Timing Case Plate E
ADPG0016
1
3
5
8
10
12
11
Page 46
Timing Case Plate E
ADPG0016
1 131046650 1 SCREW
2 F 131046650 1 BOLT
3 020109177 1 NUT
4 025100010 1 WASHER
5 198217910 1 SPRING
6 198346160 1 RING
8 131466251 1 BOLT
9 020109239 1 NUT
10 025100006 1 WASHER
11 064210012 1 CAP
Page 47
Camshaft & Gears Plate A
ADPG0016
Page 48
Camshaft & Gears Plate A
ADPG0016
1 120026950 1 CAMSHAFT
2 F 120026950 1 CAMSHAFT
3 034100508 1 WOODRUFF KEY
4 120016240 1 CAMSHAFT GEAR
5 040109057 1 BALL BEARING
6 199216320 1 SPACER
7 125256240 1 SLIDER
8 199566750 1 PLATE
9 011310612 1 SCREW
Page 49
Fuel Injection Pump Plate A
AFPG0016
Page 50
Fuel Injection Pump Plate A
AFPG0016
1 131010080 1 FUEL INJECTION PUMP

2 P 1 SHIM
3 010800820 2 SCREW
4 010700820 1 SCREW
5 027100008 1 WASHER
6 023100008 3 NUT
Service Options
2 131437490 J (+) 0.2MM 1 SHIM
2 131437730 J (+) 0.25MM 1 SHIM
2 131437500 J (+) 0.3MM 1 SHIM
2 131437760 J (+) 0.35MM 1 SHIM
2 131437510 J (+) 0.4MM 1 SHIM
2 131437520 J (+) 0.5MM 1 SHIM
2 131437530 J (+) 0.5MM 1 SHIM (A)
Footnotes
(A) FLAT
Page 51
High Pressure Fuel Pipes Plate A
AFPG0016
7
1
Page 52
High Pressure Fuel Pipes Plate A
AFPG0016
1 131507520 Q 1 1 FUEL INJECTION PIPE

5 199106021 3 CLAMP
6 199106021 3 CLAMP
7 010110625 3 SCREW
8 023100006 3 NUT
Page 53
Atomisers Plate A
AFPG0016
Page 54
Atomisers Plate A
AFPG0016
1 131406440 4 INJECTOR
2 131426230 1 SEAL - INJECTOR
3 131426200 4 SEAL - INJECTOR
Page 55
Fuel Leak-Off Pipe Plate A
AFPG0016
Page 56
Flywheel Housing Plate A
CDPG0001
2
7
6
5
Page 58
Flywheel Housing Plate A
CDPG0001
1 110367570 1 BACKPLATE
2 011510816 10 SCREW
3 011511220 2 SCREW
4 010111030 2 BOLT
5 020900010 2 NUT
6 026200010 2 WASHER
7 027100010 2 WASHER
Page 59
Flywheel & Starter Ring Plate A
DDPG0000
Page 60
Flywheel & Starter Ring Plate A
DDPG0000
1 010109341 6 BOLT
Page 61
Starter Motor Plate A
EDPG0001
Page 62
Starter Motor Plate A
EDPG0001
1 185086600 1 STARTER MOTOR
Page 63
Pulleys Plate A
FBPG0001
Page 64
Pulleys Plate A
FBPG0001
1 145336620 1 WATER PUMP PULLEY
Page 65
Sump Plate A
GBPG0001
5 4
6
Page 66
Sump Plate A
GBPG0001
1 110708390 1 SUMP
2 110996920 1 GASKET - SUMP
3 010109235 30 SCREW
4 140406680 A U713161N 1 STRAINER
5 140987020 A U713161N 1 PIPE - OIL SUCTION
6 052109076 1 SEAL - O RING
7 011310612 2 SCREW
Page 67
Dipstick & Filler Tube Plate A
GBPG0001
Page 68
Dipstick & Filler Tube Plate A
GBPG0001
1 198416690 1 DIPSTICK
2 110756490 1 DIPSTICK TUBE
3 010109235 1 SCREW
4 052100100 2 SEAL - O RING
Page 69
Dipstick & Filler Tube Plate B
GBPG0001
Page 70
Dipstick & Filler Tube Plate B
GBPG0001
1 198436290 1 PLUG
2 052100100 1 SEAL - O RING
3 052100100 1 SEAL - O RING
4 011310612 1 SCREW
Page 71
Sump Plate A
GCPG0001
Page 72
Sump Plate A
GCPG0001
1 198736310 1 VALVE
2 025100016 1 WASHER
3 010109238 1 SCREW
4 025100016 1 WASHER
Page 73
Filler Plate A
HBPG0000
Page 74
Filler Plate A
HBPG0000
1 198436350 1 OIL FILLER CAP

2 052100400 1 SEAL - O RING
3 398430080 1 OIL FILLER CAP
4 052100280 1 SEAL - O RING
Page 75
Oil Filter Plate A
JBPG0000
Page 76
Oil Filter Plate A
JBPG0000
1 140517050 1 OIL FILTER
Page 77
Oil Filter Plate A
JCPG0000
Page 78
Oil Filter Plate A
JCPG0000
1 140546020 1 CONNECTION
Page 79
Front End Drive Input Plate A
KBPG0001N
Page 80
Front End Drive Input Plate A
KBPG0001N
1 U15397401 R a. 1 CRANKSHAFT PULLEY

2 020109086 1 NUT
3 034100508 1 WOODRUFF KEY
History
a.
1 115397400 1 CRANKSHAFT PULLEY
Page 81
Water Pump Plate A
LBPG0003
2
7
6
3
Page 82
Water Pump Plate A
LBPG0003
1 145010060 1 WATER PUMP

2 145996921 1 GASKET
3 145537300 1 HOSE
4 2481877 1 HOSE CLIP
5 2481877 1 HOSE CLIP
6 011310635 4 SCREW
7 023100006 1 NUT
Page 83
Thermostat & Housing Plate A
LBPG0003
6
3
Page 84
Thermostat & Housing Plate A
LBPG0003
1 145046110 1 THERMOSTAT HOUSING

2 145206230 1 THERMOSTAT
3 145996930 1 GASKET - THERMOSTAT HSG
4 011310655 2 BOLT
5 023100006 2 NUT
6 064500030 1 PLUG
7 064500060 1 PLUG
Page 85
Water Outlet & Inlet Plate A
LDPG0001
Page 86
Water Outlet & Inlet Plate A
LDPG0001
2 145996051 1 GASKET - THERMOSTAT HSG
3 011510825 2 SCREW
Page 87
Fan Plate A
MDPG0003
Page 88
Fan Plate A
MDPG0003
1 145306730 1 FAN
Page 89
Fan Drive Plate A
MEPG0017
Page 90
Fan Drive Plate A
MEPG0017
1 145386390 1 PLATE
2 011310620 4 SCREW
Page 91
Alternator Plate A
NDPG0002
9
8
11
10 5
1
3
6
12
4
Page 92
Alternator Plate A
NDPG0002
1 TPN766 1 ALTERNATOR
2 F TPN766 1 ALTERNATOR
3 3113E031 1 ALTERNATOR PULLEY
4 TPN744 1 ALTERNATOR BRACKET
5 2314H022 1 SCREW
6 011510820 3 SCREW
7 185727130 1 LEVER
8 011510825 1 SCREW
9 026100008 1 WASHER
10 011510825 1 SCREW
11 026109017 1 WASHER
12 023100008 1 NUT
Page 93
Drive Belt & Tensioner Plate A
NEPG0001
Page 94
Drive Belt & Tensioner Plate A
NEPG0001
1 080109107 1 BELT
Page 95
Front End Drive Output Plate A
QCPG0001
9
2
Page 96
Front End Drive Output Plate A
QCPG0001
1 U65166580 1 PLATE
2 110416290 1 BEARING HOLDER ASSEMBLY
3 U65206791 1 COVER
4 052300850 1 SEAL - O RING
5 052300850 1 SEAL - O RING
6 U65206791 1 COVER
7 052300850 1 SEAL - O RING
8 2314J017 2 SCREW
9 2318A604 2 NUT
Page 97
Cylinder Head Cover Plate A
TBPG0002
9
4
10
11
Page 98
Cylinder Head Cover Plate A
TBPG0002
1 111217411 1 CYLINDER HEAD COVER

2 111996401 1 GASKET - CYL. HEAD COVER
3 110566080 1 BREATHER VALVE
4 011100408 4 METRIC BOLT
5 110666210 1 RETAINING PLATE
6 110666060 1 GAUZE
7 015600406 6 SCREW
8 011310640 2 SCREW
9 011310660 3 SCREW
10 024600010 4 NUT
11 140996270 4 WASHER
Page 99
Cylinder Head Cover Plate B
TBPG0002
Page 100
Cylinder Head Cover Plate B
TBPG0002
1 135566570 1 PIPE - AIR

2 135996950 1 GASKET
3 011310620 2 SCREW
Page 101
Feed Pipes Plate A
TBPG0002
Page 102
Feed Pipes Plate A
TBPG0002
1 165206810 1 COVER
2 3688A035 1 GASKET
3 010109600 2 SCREW
Page 103
Exhaust Manifold Plate A
UBPG0002
6
5
Page 104
UBPG0002
1 135617150 1 EXHAUST MANIFOLD

2 135996780 1 GASKET - EXHAUST MANIFOLD
3 011510860 4 SCREW
4 010310880 2 SCREW
5 023100008 2 NUT
6 027100008 2 WASHER
Page 105
UDPG5503
Page 106
UDPG5503
1 314990013 1 GASKET - EXHAUST

2 011510825 1 SCREW
Page 107
Lift Pump Plate A
VBPG0006
Page 108
Lift Pump Plate A
VBPG0006
1 130506351 1 LIFT PUMP

2 2415A070 1 SEAL - O RING
3 2314F003 2 SCREW
Page 109
Fuel Filter Plate A
VBPG0006
10
2 11
Page 110
Fuel Filter Plate A
VBPG0006
1 130316190 1 FUEL FILTER HEAD

2 130366120 1 FUEL FILTER
3 130976260 1 BRACKET
4 130976250 1 STAY
5 010111035 2 BOLT
6 026200010 2 WASHER
7 020900010 2 NUT
8 027100010 2 WASHER
9 010310820 2 BOLT
10 023100008 2 NUT
11 011510816 2 SCREW
Page 111
Pipework & Connections Plate A
VBPG0006
2
1
12
13
10 11
Page 112
Pipework & Connections Plate A
VBPG0006
1 TPN673 1 FUEL PIPE

2 2411156 1 WASHER
3 068209227 1 FUEL PIPE
4 067100015 1 CLIP
5 067100015 1 CLIP
7 TPN731 1 BANJO BOLT
8 2411156 1 WASHER
9 2411156 1 WASHER
10 068209126 1 HOSE
11 067100015 1 CLIP
12 067100015 1 CLIP
13 1 FUEL FILTER HEAD
Page 113
Cold Start System Plate A
WDPG0000
5
6
Page 114
Cold Start System Plate A
WDPG0000
1 185366190 4 GLOWPLUG
2 F 185366190 1 GLOWPLUG
3 F 185366190 1 NUT
4 185376150 1 BAR
5 020100004 1 NUT
6 027100004 1 WASHER
Page 115
Engine Lifting Eyes Plate A
XBPG0000
Page 116
Engine Lifting Eyes Plate A
XBPG0000
1 195816100 1 LIFTING EYE

2 011510820 1 SCREW
3 026100008 1 WASHER
4 195816100 1 LIFTING EYE
Page 117
Throttle & Stop Controls Plate A
ZAPG0002
Page 118
Throttle & Stop Controls Plate A
ZAPG0002
1 U25416480 1 CONTROL LEVER

2 185206450 1 SOLENOID
3 025100016 1 WASHER
Page 119
Instrumentation Plate A
ZJPG0000
Page 120
ZJPG0000
1 198486871 1 BANJO BOLT

2 140996260 1 WASHER
3 140996260 1 WASHER
4 064400010 1 PLUG
5 1 ROCKER BOX ASSEMBLY
Page 121
ZLPG0002
Page 122
ZLPG0002
1 385720500 1 WATER TEMPERATURE SENSOR
Page 123
Electrical Wiring & Fittings Plate A
ZPPG0001
Page 124
Electrical Wiring & Fittings Plate A
ZPPG0001
1 20195 1 CONNECTION KIT

2 F 20195 3 CONNECTION
Page 125
Fuel Pre-Lift Pump Plate A
ZVPG0001
Page 126
Fuel Pre-Lift Pump Plate A
ZVPG0001
1 130306380 1 PRE-FUEL FILTER ASSY

2 F 130306380 1 FUEL FILTER HEAD
3 26560182 1 FUEL FILTER BOWL
5 26560183 3 DRAIN PLUG
4 130306360 1 FUEL FILTER
6 26560184 1 SEAL - O RING
Page 127
Parts Index
Page 128
Parts Index
Description Part No. Page Description Part No. Page
ADJUSTING SCREW 199486220 31 198486780 35
ALTERNATOR TPN766 93 198487450 57
ALTERNATOR TPN744 93 BRACKET 125616120 43

BRACKET
130976260 111
ALTERNATOR 3113E031 93
PULLEY BREATHER VALVE 110566080 99
ANTI-TAMPER CAP 131276440 47 BUSH 198517222 17
131466270 47 198517226 17
26420462 43 198517229 17
ARM 125156261 43 198517290 33
125156262 43 CAMSHAFT 120026950 49
BACKPLATE 110367570 59 CAMSHAFT GEAR 120016240 49
BALL BEARING 040106203 17 CAP 064210012 47
040109057 49 064210018 27
BANJO BOLT 198486871 121 064210030 27, 27
TPN731 113 120186080 27, 27
BAR 185376150 115 CIRCLIP 036500028 23, 23
BEARING HOLDER 110416290 41, 97 036800010 33

ASSEMBLY
CLAMP 199106021 53, 53
BELT 080109107 95
CLIP 067100015 113, 113,
BIG END BEARING U5ME0030 21 113, 113
KIT
COLLAR 199236540 33
BOLT 010109341 61
CON ROD 115026330 23
010111030 59 ASSEMBLY
010111035 111 CON ROD BOLT 115176140 23
010310820 111 CON ROD NUT 020109120 23
010700860 21 CONNECTION 131246240 113
011310655 85 140546020 79
131466251 47 145226320 87
Page 129
Parts Index
CONNECTION KIT 20195 125 FAN 145306730 89
CONTROL LEVER 125046612 45 FUEL FILTER 130306360 127
125046613 45 130366120 111
125306150 45 FUEL FILTER BOWL 26560182 127
125306151 45 FUEL FILTER HEAD 130316190 111
U25416480 119 FUEL INJECTION 131507520 53

PIPE
COVER 140116220 33
131507530 53
165206810 103
131507540 53
U65206791 97, 97
131507550 53
CRANKSHAFT 115256990 21
ASSEMBLY FUEL INJECTION 131010080 51
PUMP
CRANKSHAFT 115276270 21
GEAR FUEL PIPE 068209227 113
CRANKSHAFT 115397400 81 TPN673 113

PULLEY
GASKET 135996950 101
U15397401 81
145996921 83
CYLINDER HEAD 111011030 27
ASSEMBLY 165996640 43
CYLINDER HEAD 111217411 99 3688A035 103

COVER
GASKET - CYL. 111996401 99
DIPSTICK 198416690 69 HEAD COVER
DIPSTICK TUBE 110756490 69 GASKET - 111147711 29

CYLINDER HEAD
DOWEL 030500612 17, 21,
21, 21, 21 111147721 29
030500616 17 GASKET - 314990013 107

EXHAUST
030501025 17
GASKET - 135996780 105
030509018 33 EXHAUST
MANIFOLD
DRAIN PLUG 26560183 127
GASKET - SUMP 110996920 67
EXHAUST 135617150 105
MANIFOLD GASKET - 145996051 87
THERMOSTAT HSG
EXHAUST VALVE 120176380 27
Page 130
Parts Index
145996930 85 020109086 81
GASKET - TIMING 165996590 19 020109177 47

CASE
020109239 47
165996630 39
020800010 45
GAUZE 110666060 99
020900010 59, 111
GLOWPLUG 185366190 115
023100006 39, 53,
GUDGEON PIN 115326220 23 83, 85
HOLDER 110156360 21 023100008 43, 51,

93, 105,
110156370 21 111
110156380 21 023100010 31
110156390 21 024500006 45
HOSE 068209126 113 024600010 99
145537300 83 2318A207 43
HOSE CLIP 2481877 83, 83 2318A604 97
IDLER GEAR 165026270 33 2648A120 43
INJECTOR 131406440 55 OIL FILLER CAP 198436350 75
INTAKE VALVE 120166380 27 398430080 75
KEY 030509020 21 OIL FILTER 140517050 77
LEVER 185727130 93 OIL PIPE 140607020 35
LIFT PUMP 130506351 109 PIN 030300414 41
LIFTING EYE 195816100 117, 117 030309005 17
MAIN BEARING KIT U5MB0025 21 031100004 45
U5MB0025A 21 PIPE - AIR 135566570 101
METRIC BOLT 011100408 99 PIPE - FUEL INJ U31607080 57
LEAK OFF
NEEDLE BEARING 042309017 17
PIPE - OIL SUCTION 140987020 67
042309018 17
PISTON AND RING 115017491 23
NUT 020100004 115
KIT
020109076 31
PISTON RING KIT 115107970 23
Page 131
Parts Index
PLATE 145386390 91 010109238 73
199566750 49 010109406 21, 21,

21, 21
U65166580 19, 97
010109600 103
PLUG 064100045 17
010110625 53
064210010 27
010310880 105
064210025 17, 27, 27
010700820 51
064210040 17, 17, 17
010800820 51
064400010 121
011310612 19, 49,
064500030 85 67, 71
064500060 85 011310614 43
198436290 71 011310620 91, 101
198466010 17 011310635 31, 83
198466020 17 011310640 39, 99
198466920 17 011310660 39, 99
198466940 17 011510816 59, 111
PRE-FUEL FILTER 130306380 127 011510820 93, 117
ASSY
011510825 87, 93,
PUSHROD 120456310 31 93, 107
RELIEF VALVE 140036220 37 011510860 105
RETAINING PLATE 110666210 99 011511070 21, 21, 21
RING 198346160 47 011511220 59
ROCKER ARM 120356131 31 015600406 99
ASSEMBLY
111136480 29
120356141 31
111136490 29
ROCKER BOX 120036821 31
131046650 47
ROCKER SHAFT 120316201 31
2314F003 109
ROCKER SHAFT 198217170 31
SPRING 2314H022 93
SCREW 010109235 67, 69 2314J017 97
Page 132
Parts Index
2315C039 43, 43 131437730 51
SEAL - FRONT END 198636160 41 131437760 51

OIL
199286150 33
SEAL - INJECTOR 131426200 55
199286160 33
131426230 55
199286170 33
SEAL - O RING 052100070 43
199286180 33
052100100 69, 71, 71
SLIDER 125256240 49
052100280 75
SMALL END BUSH 198517265 23
052100400 75
SOLENOID 185206450 119
052109076 31, 67
SPACER 199216320 49
052109078 37
SPEED SENSOR 131046560 45
052300850 41, 97,
97, 97 SPRING 198216720 33
2415A070 109 198217750 43
26560184 127 198217760 33
SEAL - REAR END 050209083 25 198217870 43

OIL
198217880 45
SEAL - ROCKER 120996130 31
198217910 47
BOX
STARTER MOTOR 185086600 63
SEAL - VALVE 120406050 27
STEM STAY 130976250 111
120406070 27 STRAINER 140406680 67
SHAFT 125116211 45 STUD 010109441 17
125116221 45 012109044 31
165296220 17 012110635 17
SHIM 131437490 51 012110655 29
131437500 51 012110660 17
131437510 51 012110860 29
131437520 51 SUMP 110708390 67
131437530 51
Page 133
Parts Index
TAPPET 120116160 31 140996260 35, 35,

121, 121
THERMOSTAT 145206230 85
140996270 99
THERMOSTAT 145046110 85
HOUSING 199280300 31
THRUST WASHER 199266200 21, 21 2411156 113, 113,

113
199266210 21
WATER PUMP 145010060 83
199266270 33
WATER PUMP 145336620 65
TIMING CASE 165106870 41 PULLEY
VALVE 198736310 73 WATER 385720500 123
TEMPERATURE
VALVE COLLET 120226070 27, 27
SENSOR
VALVE SEAT TPN645 27
WOODRUFF KEY 034100508 49, 81
INSERT
TPN646 27
VALVE SPRING 198216700 27, 27
VALVE SPRING CAP 120216041 27, 27
WASHER 025100006 45, 47
025100008 45, 57, 57
025100010 47
025100016 73, 73,

119
026100008 93, 117
026109017 93
026200010 59, 111
027100004 115
027100008 51, 105
027100010 59, 111
Page 134

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2. How To Use Your Parts Book Pg. 4

3. Engine Breakdown Pg. 5

4. Symbol Descriptions Pg. 9

5. Parts Lists & Illustrations Pg. 11

6. Parts Index Pg. 128

How to use your Parts Book

Parts Lists & Illustrations

For fitting instructions please refer to your engine Service Manual.

Section Page Section Page

Level 1 - Service 11 Relief Valve 37

Level 2 - Repair 13 Timing Case 39

Level 3 - Overhaul 15 Timing Case 41

Cylinder Block 17 Timing Case 43

Cylinder Block 19 Timing Case 45

Crankshaft, Pistons & Connecting Rods 21 Timing Case 47

Crankshaft, Pistons & Connecting Rods 23 Camshaft & Gears 49

Rear End Oil Seal 25 Fuel Injection Pump 51

Cylinder Head 27 High Pressure Fuel Pipes 53

Cylinder Head 29 Atomisers 55

Rocker Shaft Assembly 31 Fuel Leak-Off Pipe 57

Oil Pump 33 Flywheel Housing 59

Pipes 35 Flywheel & Starter Ring 61

Section Page Section Page

Starter Motor 63 Fan 89

Pulleys 65 Fan Drive 91

Dipstick & Filler Tube 69 Drive Belt & Tensioner 95

Dipstick & Filler Tube 71 Front End Drive Output 97

Sump 73 Cylinder Head Cover 99

Filler 75 Cylinder Head Cover 101

Oil Filter 77 Feed Pipes 103

Oil Filter 79 Exhaust Manifold 105

Front End Drive Input 81 Exhaust Manifold 107

Water Pump 83 Lift Pump 109

Thermostat & Housing 85 Fuel Filter 111

Water Outlet & Inlet 87

Pipework & Connections 113

Cold Start System 115

Engine Lifting Eyes 117

Throttle & Stop Controls 119

Electrical Wiring & Fittings 125

Fuel Pre-Lift Pump 127

A From Engine Number

B Upto Engine Number

C Repairs and Replaces

D See Appropriate Section - Reference Number

H New for Old Part

O Reference for Detailed Breakdown

P Other Service Options Available

R See History Section

Recommended stocking and service lists

Item Part No. References Qty. Description Notes

Recommended stocking and service lists

Item Part No. References Qty. Description Notes

Recommended stocking and service lists

Item Part No. References Qty. Description Notes

Item Part No. References Qty. Description Notes

1 1 CYLINDER BLOCK (A)

(A) SERVICE BY COMPLETE ENGINE

Item Part No. References Qty. Description Notes

1 165996590 1 GASKET - TIMING CASE

Item Part No. References Qty. Description Notes

1 115256990 1 CRANKSHAFT ASSEMBLY

Item Part No. References Qty. Description Notes