PDF Caterpillar 3516 Compress

RENR5057-04
February
February 2013
Specifications
3500B
500B Ge
Gene
nerrator
tor Se
Sett Engin
gines
GD3 1-U
1-Up
p (Ge
(Gener
nerato
ator
r ZAR 1-Up
1-Up (Ge
(Gener
nerato
ator
r
Set) Set)
YBB 1-Up ZBR 1-Up
1-Up (Ge
(Gener
nerato
ator
r
(Generato
(Gen eratorr Set) Set)
YBC 1-Up Y
YAT
AT 1-Up (Generator
(Generato
ZAD 1-U
1-Up
p (Ge
(Gener
nerato
ator
r YBT 1-Up (Generator
Set) Set)
JDE 1-U
1-Up
p (Ge
(Gener
nerato
ator
r Y
YAW
AW 1-Up
Set) (Generato
(Gen eratorr Set)
ZAH 1-U
1-Up
p (Ge
(Gener
nerato
ator
r YBW 1-Up
Set) (Generato
(Gen eratorr Set)
ZAJ 1-Up
1-Up (Ge
(Gener
nerato
ator
r JCY 1-U
1-Up
p (Ge
(Gener
nerato
ator
r
Set) Set)
YAM
YAM 1-Up Y
YA
AY 1-Up (Generator
(Generato
YAN
YAN 1-Up (Generator Y
YAZ
AZ 1-Up (Generator
Set) Set)
YAP
YAP 1-Up (Generator
Set)
ZAP 1-U
1-Up
p (Ge
(Gener
nerato
ator
r
Set)
ZBP 1-U
1-Up
p (Ge
(Gener
nerato
ator
r
Set)
PBR 1-U
1-Up
p
(Generato
(Gen eratorr Set)
PDR 1-U
1-Up
p
(Generato
(Gen eratorr Set)
YAR
YAR 1-Up (Generator
Set)
SAFETY.CAT.COM

i05086812
Important
Important Safety
Safety Infor
Informati
matio
on
Most accidents
accidents that involve prod
product
uct operat
operation,
ion, maint
maintenan
enance
ce and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing
recognizing potentially hazardous
situations
situations before an accident occu
occurs.
rs. A perso
person
n must be alert to potent
potential
ial hazard
hazards,s, including huma
human n factors
that can affect safety.
safety. This person
person should also have the necessa
necessary ry training, skills and tools to perfor
performm these
functions properly
properly..
Imprope
Impr operr operat
operation
ion,, lub
lubric
ricatio
ation,
n, mai
mainte
ntenan
nance
ce or repair
repair of thi
this
s produc
productt can be dan
danger
gerou
ous
s and cou
could
ld
resu
result
lt in in
inju
jury
ry or de
deat
ath.
h.
Do no
nott op
oper
eratate
e or perf
perfor
orm
m an
any
y lubr
lubrica
icatio
tion,
n, ma
maininte
tena
nanc
ncee or repa
repair
ir on this
this pr
prod
oduc
uct,
t, unti
untill you
you veri
verify
fy
that
that you
you ar
are
e autho
authoririze
zed
d to perf
perfor
ormm this
this work
work,, an
andd have
have read
read and
and unde
undersrsto
tood
od th
the
e oper
operat
atio ion,
n,
lubrication
lubrication,, mainten
maintenanc
ancee and repair
repair informa
information.
tion.
Safety precautio
precautions
ns and warning
warnings s are provided
provided in this manual and on the product.
product. If these hazard warnings
warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified

identified by the “Safety Alert Symbol” and followed
followed by a “Signal Wor
Word”
d” such as
“DANGER”, “WARNING”
“DANGER”, “WARNING” or “CAUTION”
“CAUTION”.. The Safety Alert “WARNIN
“WARNING” G” label is shown below
below..
The meaning
meaning of this safety alert symbol
symbol is as follows:
Attentio
Attention!
n! Become
Become Ale
Alert!
rt! Your Safety
Safety is Involve
Involved.
d.
The message that appears under the warnin

message
presented. warning
g explains
explains the hazard and can be either written or pictoriall
pictorially
y
A non-exhaustive list of operations that may cause product damage are identified by NOTICE labels on “ ”
the product
product and in this publica
publication.
tion.
Caterp
Cat erpilla
illarr cannot
cannot antanticip
icipate
ate eve
everyry pos
possibsible
le cir
circum
cumsta stance
nce tha
thatt might
might involv
involve ea p pote
otenti
ntial
al hazard
hazard..
The
The wa
warnrning
ingss in this
this pu
publi
blica
catio
tionn and
and on th thee prod
producuctt ar
are,
e, ther
theref
efor
ore,
e, not
not all
all incl
inclus
usiv
ive.
e. You mumustst no
nott
use
use thi
this
s pr
prod
oduc
uctt in any
any ma
mannnner
er diffe
differe
rent
nt fr
from
om ththat
at co
consnsid
ider
ered
ed by this
this ma
manu nual
al wit
witho
hout
ut first
first satis
satisfy
fyin
ing
g
yo
your
urseself
lf that
that you
you have
have cons
considider
ered
ed all
all sa
safefety
ty rule
ruless an
and d prec
precau
auti
tion
ons s appl
applicicab
ablele to the
the oper
operatation
ion of th
the
e
produc
pro ductt in the locatio
locationn of use,
use, includ
including
ing sit
site-s
e-spec
pecifific
ic rules
rules and pre
precau
caution
tions s app
applica
licable
ble to the
work
wo rksit
site.
e. If a too
tool,
l, proc
proced
edur
ure,
e, work
work memethothodd or oper
operat atin
ing
g tech
techni
niqu
que e that
that is no
nott spec
specifiifica
callly
reco
recomme
mmend ndeded by CaCater
terpi
pill
llar
ar is usused
ed,, you
you mumustst satis
satisfyfy your
yourse
self
lf that
that it is safe
safe foforr you
you and
and for other
others.
s.
You should also ensure that you are authorized to perform this work, and that the product will not be
damage
dam aged d or become
become uns unsafe
afe by the operat
operationion,, lub
lubric
ricati
ation
on,, mai
mainte
ntenan
nancece or rep
repair
air pro
proced
cedure
uress that
you
you in
inte
tend
nd to use.
use.
The information,
information, specificatio
specifications,
ns, and illustrations
illustrations in this publication
publication are on the basis of infor
information
mation that was
available
availa ble at the time that the publica
publication
tion was written. The specification
specifications,
s, torque
torques,
s, press
pressures,
ures,
measurements, adjustments, illustrations, and other items can change at any any time. These ch
changes
anges can
affectt the service that
affec that is given to the produ
product.
ct. Obtain the
the complete
complete and most curr
current
ent information
information before y
you
ou
start any job.
job. Cat dealers
dealers have
have the most
most current
current information
information availa
available.
ble.
When rep
When replac
laceme
ement
nt parts
parts are requir
required
ed for this
product Caterpillar recommends using Cat re-
placement
placem ent parts or parts with equivalent
equivalent speci-
fications including, but not limited to, physical
dimensi
dime nsions
ons,, typ
type,
e, streng
strength
th and materia
material.
l.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury
or death.
death.
In the
the Un
Unite
ited
d Sta
States
tes,, th
the
e maint
mainten
enan
ance
ce,, repl
replac
acem
emenent,
t, or repa
repair
ir of the
the em
emisissi
sion
on cont
contro
roll devi
device
ces
s and
and
sy
syst
stem
emss ma
may y be perf
perfor
ormed
med by any
any repa
repairir esta
establ
blish
ishme
mentnt or ind
indivivid
idua
uall of the
the ow
owne
ner'
r's
s choo
choosising
ng..

RENR5057 3
Table of Contents
Tab
able
le of Cont
Conten
ents
ts Exhaust Flange........................ ....................... 89
Exhaust Flange........................ ....................... 91
Exhaust Flange........................ ....................... 93
Specificati
Specifications
ons Section
Section
Air Cleaner...........................
Cleaner ........................... ........................... 94
Engine Design ......................... ......................... 6 Engine Air Cleaner Service Indicator....Indicator....... ... ....... 95
Engine Design ......................... ......................... 6 Air Lines.............................
Lines ............................. ............................. 96
Engine Design ......................... ......................... 7 Air Inlet and Exhaust Lines ............... .............. 97
Air Inlet and Exhaust Lines .............. ............. 100
Engine Design ......................... ......................... 7 Air Inlet and Exhaust Lines .............. ............. 102
Engine Design ......................... ......................... 8
Engine Design ......................... ......................... 8 Air Inlet and Exhaust Lines .............. ............. 105
Fuel Filter (Primary)............
(Primary)................. ........
... ...............
....................
..... 10 Air Inlet and Exhaust Lines .............. ............. 108
Fuel Filter............................ .............................11 Air Inlet and Exhaust Lines .............. .............. 111
Fuel Filter............................
Filter... ......................... ............................ 13 Air Shutoff ........................... ...........................113
Fuel Filter............................
Filter... ......................... ............................ 14 Air Shutoff ........................... ...........................115
Fuel Pressure
Pressure Regulator.....
Regulator........................
..... ...............
................. 15 Air Shutoff ........................... ...........................117
Fuel Transfer Pump ..............
...................
....... ...............
....................
..... 17 Air Shutoff ........................... .......................... 120
Fuel Priming Pump ..............
.....................
....... .................
....................
... 20 Prelube
Prelub e Pump.................
Pump........................
....... ..............
...................
.........
.... 122
Fuel Injector
Injector Mechanism
Mechanism ............
................
.... ................
................ 21 Prelube
Prelub e Pump.................
Pump........................
....... ..............
...................
.........
.... 124
Fuel Injector
Injector Mechanism
Mechanism ............
................
.... ................
................ 23 Prelube
Prelub e Pump (Air)(Air) .............
...................
........ ...................
................... 126
Fuel Injector
Injector ..............
.....................
............
..... .............
...................
.............
....... 25 Prelube
Prelub e Pump.................
Pump........................
....... ..............
...................
.........
.... 127
Fuel Injector
Injector ..............
.....................
............
..... .............
...................
.............
....... 27 Engine Oil Pump............
Pump...................
..........
... ..............
.....................
....... 129
Fuel Injector
Injector ..............
.....................
............
..... .............
...................
.............
....... 28 Engine Oil Pump............
Pump...................
..........
... ..............
.....................
....... 132
Camshaft
Camsha ft ..............
.....................
..............
....... ..............
.....................
..............
....... 30 Engine Oil Pump............
Pump...................
..........
... ..............
.....................
....... 137
Camshaft
Camsha ft ..............
.....................
..............
....... ..............
.....................
..............
....... 33 Engine Oil Cooler
Cooler Bypass and and Cooling
Cooling Jet
Camshaft
Camsha ft ..............
.....................
..............
....... ..............
.....................
..............
....... 35 Sequence
Seque nce Valves.................
alves....................... ..............
...................
....... 143
Camshaft
Camsha ft ..............
.....................
..............
....... ..............
.....................
..............
....... 37 Engine Oil Cooler
Cooler Bypass and and Cooling
Cooling Jet
Valve Mechanism ............................................ 39 Sequence
Seque nce Valves.................
alves....................... ..............
...................
....... 146
Valve Mechanism ............................................ 41 Engine Oil Filter ...................... ...................... 148
Cylinder
Cylind er Head...............
Head.......................
..........
.. ..............
.....................
..........
... 43 Engine Oil Filter ...................... ...................... 150
Cylinder
Head.......................
..........
.. ..............
.....................
..........
Cylinder
Head.......................
..........
.. ..............
.....................
..........
Cylinder
Cylind er Head Valves
Valves ......
..............
.............
..... ..................
.................. 53 Engine Oil Lines...................... ...................... 156
Cylinder
Cylind er Head Valves
Valves ......
..............
.............
..... ..................
.................. 56 Engine Oil Lines...................... ...................... 159
Turbochar
Turbochargerger Oil Lines ............
..................
...... ..............
.................
... 59 Duplex Engine Oil Filters...............
Filters ............... ............... 162
Turbochar
Turbocharger
ger Oil Lines ............
..................
...... ..............
.................
... 61 Engine Oil Cooler..................... ..................... 164
Turbocharger ......................... ......................... 62
Turbocharger......................... Crankcase Breather....
Crankcase Breather..........
...........
.........
.... ............
...................
....... 165
Turbocharger.........................
Turbocharger ......................... ......................... 65 Crankcase
Crankca se Breather....
Breather..........
...........
.........
.... ............
...................
....... 167
Turbocharger.........................
Breather..........
...........
.........
.... ............
...................
....... 168
Turbocharger.........................
Breather..........
...........
.........
.... ............
...................
....... 169
Turbocharger.........................
Breather..........
...........
.........
.... ............
...................
....... 170
Turbocharger.........................
Turbocharger ......................... ......................... 72 Engine Oil Pan...............
Pan....................
........
... ..............
...................
.........
.... 172
Turbocharger.........................
Pan....................
........
... ..............
...................
.........
.... 174
Turbocharger.........................
Pan....................
........
... ..............
...................
.........
.... 176
Exhaust Manifold...................... ...................... 78 Engine Oil Pan...............
Pan....................
........
... ..............
...................
.........
.... 179
Pan....................
........
... ..............
...................
.........
.... 182
Pan....................
........
... ..............
...................
.........
.... 185
Pan....................
........
... ..............
...................
.........
.... 187
Engine Oil Pan...............
Pan....................
........
... ..............
...................
.........
.... 188
Pan....................
........
... ..............
...................
.........
.... 190
Exhaust Manifold...................... ...................... 85
Exhaust Manifold...................... ...................... 87 Waterr Temperature
Wate emperature Regulator
Regulator ...........
........... ...........
........... 193
Waterr Temperature
Wate emperature Regulator
Regulator ...........
........... ...........
........... 195

4 RENR5057
Table of Contents
Water Lines.......................... ......................... 196 Flywheel ........................... ............................ 313

Thermostatic Valve
Valve .................... ................... 197 Flywheell Housing
Flywhee Housing ..............
.....................
....... ..............
...................
....... 315
Fan Drive ........................... ........................... 200 Flywheell Housing
Flywhee Housing Cover.......
Cover..............
.........
.. .............
...............
.. 319
Fan Drive ........................... ........................... 202 Generator
Genera tor Coupling
Coupling ..............
...................
..... ................
...................
... 320
Radiator............................ ............................ 203 Generator
Genera tor Coupling
Coupling ..............
...................
..... ................
...................
... 322
Radiator............................ ............................ 204 Flexible
Flexibl e Coupling
Coupling........
.............
...........
........
.. ..............
.....................
....... 323
Radiator............................ ............................ 205 Flexible
Flexibl e Coupling
Coupling........
.............
...........
........
.. ..............
.....................
....... 325
Engine
Engin e Oil Sump Pump ..............
................
.. .............
................
... 206 Vibration
Vibra tion Damper...........
Damper.................
..........
.... ..............
.....................
....... 326
Water Pump......................... ......................... 207 Vibration
Damper.................
..........
.... ..............
.....................
....... 328
Water Pump......................... ......................... 209 Vibration
Damper.................
..........
.... ..............
.....................
....... 330
Water Pump......................... ..........................211 Vibration
Damper.................
..........
.... ..............
.....................
....... 332
Auxiliary Water Pump .................. ................. 215 Vibration
Damper.................
..........
.... ..............
.....................
....... 334
Damper.................
..........
.... ..............
.....................
....... 336
Auxiliary Water Pump (Sea Water) ....... ....... 220 Vibration
Vibra tion Damper Guard..........
Guard................
...... ...............
............... 337
Guard................
...... ...............
............... 339
Cooling
Coolin g System Pressure
Pressure Cap ...........
........... ..........
.......... 225 Vibration
Guard................
...... ...............
............... 340
Cylinder Block........................
Block............. ........... ....................... 228 Vibration
Guard................
...... ...............
............... 341
Cylinder Block........................
Block............. ........... ....................... 233 Stub Shaft (Front) ..................... .................... 342
Cylinder Block........................
Block............. ........... ....................... 236 Stub Shaft (Front) ..................... .................... 345
Cylinder Block........................
Block............. ........... ....................... 240 Auxiliary Drive Pulley .................. .................. 346
Cylinder Liner........................ ........................ 243 Auxiliary Drive Pulley .................. .................. 347
Piston and Rings
Rings (One-Piece
(One-Piece Piston) Piston) ..... ..... 246 Auxiliary Drive Pulley .................. .................. 348
Piston and Rings
Rings (One-Piece
(One-Piece Piston) Piston) ..... ..... 249 Auxiliary Drive Shaft ................... .................. 349
Piston and Rings
Rings (Two-Pie
(Two-Piece ce Piston)
Piston) ..... ..... 252 Belt Tension
Tension Chart .................... .................... 350
Piston and Rings
Rings (Two-Pie
(Two-Piece ce Piston)
Piston) ..... ..... 255 Alternator and Regulator................ ............... 352
Connecting
Connec ting Rod...................
Rod......................... ..............
.....................
......... 258 Alternator and Regulator................ ............... 354
Connecting
Connec ting Rod...................
Rod......................... ..............
.....................
Connecting
Connec ting Rod...................
Rod......................... ..............
.....................
Connecting
Connec ting Rod...................
Rod......................... ..............
.....................
......... 267 Alternator Mounting ................... ................... 359
Connec
Con nectin
ting
g Rod an and d Main Bear Bearinging Journa
Journals ls 269 Alternator Mounting ................... ................... 361
Crankshaft .......................... .......................... 271 Electric
Electric Starting
Starting Motor ..............
.................
... ..............
.................
... 363
Electric Starting
.................
... ..............
.................
... 365
Electric Starting
.................
... ..............
.................
... 368
Electric Starting
.................
... ..............
.................
... 370
Electric Starting
.................
... ..............
.................
... 372
Crankshaft .......................... .......................... 277 Air Starting Motor.....................
Motor... .................. ..................... 373
Crankshaft
Crankshaft Wear Sleeves
Sleeves and Seals...... ...... 279 Air Starting Motor Pressure Regulating Valve 376
Cover Group (Front Housing)
Housing) ............
............ ...........
........... 282
282 Coolantt Level Switch
Coolan Switch .............
..................
..... .............
..................
..... 378
Housing (Front)....................... ...................... 284 Coolantt Temperature
Coolan emperature Switch ....... ............
..... ............
............ 380
Housing (Front)....................... ...................... 286 Fuel Pressure Sensor............
Sensor..................
...... ..............
.................
... 381
Gear Group (Front)
(Front) ..............
....................
...... ...............
...................
.... 287 Fuel Pressure Sensor............
Sensor..................
...... ..............
.................
... 384
Gear Group (Front)
(Front) ..............
....................
...... ...............
...................
.... 290 Prelube
Prelub e Pressure
Pressure Switch ..............
................ ...............
............... 386
386
Gear Group (Rear).......
(Rear)..............
............
....... .............
...................
........ 292 Coolantt Level Sensor ............
Coolan ..................
...... ................
.................. 388
(Rear)..............
............
....... .............
...................
........ 294 Coolantt Level Sensor ............
Coolan ..................
...... ................
.................. 391
(Rear)..............
............
....... .............
...................
........ 296 Engine Oil Pressure
Pressure Sensor ............
.............. ............
............ 393
(Rear)..............
............
....... .............
...................
........ 299 Engine Oil Pressure
Pressure Sensor ............
.............. ............
............ 394
Balancer
Balancer Group (Front).........
(Front)..............
........
... .............
................
... 301 Engine Oil Temperature
Temperature Sensor ......... .......... 396
Accessory Drive (Lower Left Hand) ....... ....... 302 Engine Oil Temperature
Temperature Sensor ......... .......... 399
Accessory Drive (Upper Right Hand) ............ 305 Turbo
Turbocha
charge
rgerr Inlet
Inlet Pressur
Pressure e Sensor
Sensor...... ........ ....
......
.. 400
Accessory Drive (Upper Right Hand) ............ 308 Turbo
Turbocha
charge
rgerr Inlet
Inlet Pressur
Pressure e Sensor
Sensor...... ........ ....
......
.. 402
Accessory Drive (Upper Right Hand) ...... ......311 Turbochar
Tur bocharger
ger Outlet Pressure
Pressure Sensor.....
Sensor..... ..... ..... 405

RENR5057 5
Table of Contents
Turbocharger
Turbochar ger Outlet Pressure
Pressure Sensor.....
Sensor..... ..... 406
Aftercooler Coolant Temperature Sensor ... .. 408
Engine
Engin e Coolant
Coolant Temperature
emperature Sensor ...... ..... 409
Engine
Engin e Coolant
Coolant Temperature
emperature Sensor ...... ..... 412
Turbochar
Turbocharger
ger Exhaus
Exhaustt Temperature
emperature Sensor 413
Turbochar
Turbocharger
ger Exhaus
Exhaustt Temperature
emperature Sensor 416
Engine Speed/Timing Sensor............ ........... 417
Engine Speed/Timing Sensor............ ........... 418
Crankcase
Crankc ase Pressure
Pressure Sensor...........
Sensor............. .. ............
............ 420
Crankcase
Crankc ase Pressure
Pressure Sensor...........
Sensor............. .. ............
............ 422
Atmospheric Pressure Sensor...........
Sensor..... ...... ...........
... ........ 423
Atmospheric Pressure Sensor...........
Sensor..... ...... ...........
... ........ 425
Engine Speed Sensor.................. ................. 426
Engine Speed Sensor.................. ................. 428
Thermocouple........................ ....................... 431
Index
Index Sectio
Section
n
Index............................... .............................. 434

6 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Specifica
Specifications
tions Sect
Section
ion i01430869
i01430864
Engine
Engine Design
Design
SMCS
SMCS Code:
Code: 1000
Engine
Engine Design
Design
S/N: YBB1–Up
SMCS
SMCS Code:
Code: 1000
S/N: ZAH1–Up
S/N: ZAD1–Up
S/N: YAM1–Up
S/N: YAY1–Up
Illustration 1 g00293348
Cylinder and valve location
(A) Inlet valves
valves Illustration 2 g00293349
(B) Exhaust valves Cylinder and valve location
(A) Inlet valves
Number and ar
Number arrangem
rangement
ent of cylinders
cylinders ....60 degree
degree V (B) Exhaust valves
−8
Number and
and arrange
arrangement
ment of cylinde
cylinders
rs ....60 degree V
Valves per cylinder ........................................
.................................... ................
............ 4 −12
Displacement...................
Displacement..... ............................. 34.5 L (2105 cu
cu in) Valves per cylinder ....................
.................................
.........................
...................
....... 4
Bore ....................
.........................
.........................
.......................170
...170 mm (6.7 inch) Displacement.................
Displacement.. .......................
................
........ 51.8 L (3158 cu in)
Stroke .............................................190 mm (7.5 inch) Bore .........
...................
................................
.......................
........
..... 170 mm (6.7 inch)
Compression ratio .........................

............. .........................
.......................
.......... 14:1 Stroke ....................
.................. ................
....................
...........
..... 190 mm (7.5 inch)
Combustion ..........................................Direct injection Compression ratio ....................
.................................
....................
...............
........ 14:1
When the crankshaft
crankshaft is viewed from the flywheel end, Combustion ..........................................Direct injection
the crankshaft
crankshaft rotates in the following direction direction::
.........................................................Counterclockwise When the crankshaf
crankshaftt is viewed fro fromm the flywh
flywheel
eel end,
the cranksh
crankshaft aft rotates in the the fol
following
lowing directi
direction:
on:
Fir
Firing
ing order
order (injec
(injection
tion seq
sequen
uence)
ce)
.........................................................Counterclockwise
Standard
Standard rotatio
rotation
n CCW ..................
..................1,
1, 2, 7, 3, 4, 5, 6, 8 Firing order (injec
(injection
tion seque
sequence)
nce)
Valve lash
Standard rotatio
Standard rotation
n CCW .........1, 12, 9, 4, 5, 8, 11,
11, 2, 3,
Inlet ....................
.......................................
........................0.50
.....0.50 mm (0.020 inch) 10, 7, 6
Valve lash
Exhaust..............
Exhaust....................
................
..................1.00
........1.00 mm (0.040 inch)
Note: The front end of the engine is opposite the Inlet ........................................
................................ ............
.... 0.50 mm (0.020 inch)
flywheel end of the engine. The left side and the right
Exhaust......................................1.00 mm (0.040 inch)
side of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder on the
right side.
side. The number 2 cylind
cylinder
er is the front cylinder
cylinder
on the left side.

RENR5057 7
Specificatio
Specifications
ns Sectio
Section
n
Note: The front end of the engine is opposite the Reverse rotat
Reverse rotation
ion CW ....
....1,
1, 4, 9, 8, 5, 2,
2, 1
11,
1, 10, 3, 6
6,, 7,
flywheel end of the engine. The left side and the right 12
side of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder on the Valve lash
right side.
side. The number 2 cylind
cylinder
er is the front cylinder
cylinder
on the left side. Inlet ........................................
................................ ............
.... 0.50 mm (0.020 inch)
Exhaust......................................1.00 mm (0.040 inch)

i01443411
Note: The front end of the engine is opposite the
Engine
Engine Design
Design flywheel end of the engine. The left and the right side
of the engine are
are determin
determined
ed from the flywheel
flywheel end.
SMCS
SMCS Code:
Code: 1000
The number 1 cylinder is the front cylin
cylinder
der on the right
side. The number
number 2 cylinder is the front cylinder
cylinder on
S/N: YBC1–Up
the left side.
S/N: ZAJ1–Up
i05220884
S/N: YAN1–Up
S/N: YAZ1–Up Engine
Engine Design
Design
SMCS
SMCS Code:
Code: 1000
S/N: GD31–Up
(A) Inlet valves
valves
(B) Exhaust valves Illustration 4 g03337471
Numberr and a
Numbe arrange
rrangement
ment of cy
cylinder
linders
s .......60 degree
(A) Inlet valves
V-12 (B) Exhaust valves
.................................... ................
............ 4
Number and
and arrang
arrangement
ement of cylinders
cylinders .......60 degree
Displacement...................
cu in) V-16
Bore ....................
.........................
.........................
.......................170
...170 mm (6.7 inch) Valves per cylinder ....................
.................................
.........................
...................
....... 4
Stroke .............................................215 mm (8.5 inch) Displacement.................

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

............. .........................
....................
....... 15.5:1 Bore .........
...................
................................
.......................
........
..... 170 mm (6.7 inch)
Combustion ..........................................Direct injection Stroke ....................

.................. ................
....................
...........
..... 190 mm (7.5 inch)
When the crankshaft

crankshaft is viewed from the flywheel end Combustion ..........................................Direct injection
the crankshaft
crankshaft rotates in the following direction direction..
When the crankshaf
crankshaftt is viewed fro
from
m the flywh
flywheel
eel end,
Fir
Firing
ing order
order (injec
(injection
tion seq
sequen
uence)
ce) the crankshaft
cranksh aft rotates in the the fol
following
lowing directi
direction.
on.
Standard rotatio
Standard rotation
n CCW .........1, 12, 9, 4, 5, 8, 11,
11, 2, 3, Firing order (injec
(injection
tion seque
sequence)
nce)
10, 7, 6
Standard rotatio
Standard rotation
n CCW .........1,
.........1, 2, 5, 6, 3, 4, 9, 10, 15,
16, 11, 12, 13, 14, 7, 8

8 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Special
Special Firing order
order (inject
(injection
ion sequence)
sequence) Bore .........
...................
................................
.......................
........
..... 170 mm (6.7 inch)
Reverse rotation
Reverse rotation CW ....1, 6, 5, 4, 3, 10, 9, 16,
16, 15, 12, Stroke ....................
.................. ................
....................
...........
..... 190 mm (7.5 inch)
11, 14, 13, 8, 7, 2
Compression ratio ....................
.................................
....................
...............
........ 14:1
Valve lash
Combustion ..........................................Direct injection
Inlet ....................
.......................................
........................0.50
.....0.50 mm (0.020 inch)
When the crankshaf
crankshaftt is viewed fro
from
m the flywh
flywheel
eel end,
Exhaust..............
Exhaust....................
................
..................1.00
........1.00 mm (0.040 inch)
the crankshaft
cranksh aft rotates in the the fol
following
lowing directi
direction:
on:
flywheel end of the engine. The left and the right side Firing order (injec
(injection
tion seque
sequence)
nce)
of the engine are determined
determined from the flywheel end end..
The number
number 1 cylinder is the front cylind
cylinder
er on the right Standard rotatio
Standard rotation
n CCW .........1,
.........1, 2, 5, 6, 3, 4, 9, 10, 15,
side. The number
number 2 cylinder is the front cyli
cylinder
nder on 16, 11, 12, 13, 14, 7, 8
the left side.
Valve lash
i01430901
Inlet ........................................
................................ ............
.... 0.50 mm (0.020 inch)
Engine
Engine Design
Design Exhaust......................................1.00 mm (0.040 inch)
SMCS
SMCS Code:
Code: 1000
S/N: YAP1–Up flywheel end of the engine. The left side and the right
side of the engine
engine are determ
determined
ined from the flywheel
flywheel
S/N: ZAP1–Up end. side.
right The number
nThe
umber 1 cylinde
cylinder
numbe
number r is theisfront
r 2 cylinder the cylind
cylinder
er on the
front cylinder
S/N: ZBP1–Up on the left side.
S/N: PBR1–Up
i01430926
S/N: PDR1–Up
S/N: YAT1–Up Engine
Engine Design
Design
S/N: YBT1–Up SMCS
SMCS Code:
Code: 1000
S/N: JCY1–Up S/N: JDE1–Up

S/N: YAR1–Up
S/N: ZAR1–Up
S/N: ZBR1–Up
S/N: YAW1–Up
S/N: YBW1–Up
(A) Inlet valve
valve
(B) Exhaust valve
Numberr and ar
Numbe arrangem
rangement
ent of cylinders
cylinders ....60 degree
degree V
−16

.................................... ................
............ 4 Illustration 6 g00294285
Displacement...................
cu in) (A) Inlet valve
(B) Exhaust valv
valve
e

RENR5057 9
Specificatio
Specifications
ns Sectio
Section
n
Number and a
Number arrange
rrangement
ment of cy
cylinder
linders
s .......60 degree
V-16

.................................... ................
............ 4
Displacement...................
Displacement..... ................................
............. ... 78 L (4760 cu
cu in)
Bore ....................
.........................
.........................
.......................170
...170 mm (6.7 inch)
Stroke .............................................215 mm (8.5 inch)

............. .........................
....................
....... 15.5:1
Combustion ..........................................Direct injection
When the crankshaft

crankshaft is viewed from the flywheel end,
the crankshaft
crankshaft rotates in the following direction direction::
Fir
Firing
ing order
order (injec
(injection
tion seq
sequen
uence)
ce)
Standard rotatio
Standard rotation
n CCW .........1,
.........1, 2, 5, 6, 3, 4, 9, 10, 15,
16, 11, 12, 13, 14, 7, 8
Valve lash
Inlet ....................
.......................................
........................0.50
.....0.50 mm (0.020 inch)
Exhaust..............
Exhaust....................
................
..................1.00
........1.00 mm (0.040 inch)

flywheel end of the engine. The left and the right side
of the engine are determined
determined from the flywheel end end..
The number
number 1 cylinder is the front cylind
cylinder
er on the right
side. The number
number 2 cylinder is the front cyli
cylinder
nder on
the left side.

10 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
i04888422
Fuell Filter
Fue Filter (Pr
(Prima
imary)
ry)
SMCS
SMCS Code:
Code: 1260
Part
Part No.:
No.: 387-0485
S/N: JDE1–Up
Part
Part No.:
No.:
387-0485
S/N: JCY1–Up
Table 1
Specification
Specification for 387-0485 Primar
Primary
y Fue
Fuell Fil
FilterGp
terGp
Item Qty Part Specification Description

Specification
1 1 7N-1628 Nut Torqu

orque
e to 25 ± 5 N·m (221 ± 44 lb in).
2 1 2J-0157 O-R
O-RingSeal
ingSeal Lub
Lubric
ricatethe
atethe bor
bore
e of the O-r
O-ring
ing sea
seall and
and the shaft
shaft lightl
lightly
y with
with clean
clean eng
engine
ine oil.
oil.
Length under
Length under test forc
forcee is 27.9
27.94
4 mm (1.100 inch).
inch).
3 1 7S-9323 Spring Test for
force
ce 27.7 to 32
32.3
.3 N (6.2 to 7.3 lb).
lb).
Free lengt
length
h after
after test is 42.6
42.677 mm (1.680 inch).
inch).

RENR5057 11
Specificatio
Specifications
ns Sectio
Section
n
i04713909
Fuel
Fuel Filt
Filter
er
SMCS
SMC Code: 1261
S Code:
Part
Part No.:
No.: 7W-9741
S/N: ZAD1–Up
Part
Part No.:
No.: 7W-9741
S/N: ZAH1–Up
Part
Part No.:
No.: 7W-9741
S/N: ZAJ1–Up
Part
Part No.:
No.: 7W-9741
S/N: YAM1–Up
Part
Part No.:
No.: 7W-9741
S/N: YAN1–Up
Part
Part No.:
No.: 7W-9741
S/N: YAP1–Up
Part
Part No.:
No.: 7W-9741
S/N: ZAP1–Up
Part
Part No.:
No.:
7W-9741
S/N: ZBP1–Up
Part
Part No.:
No.: 7W-9741
S/N: PBR1–Up
Part
Part No.:
No.: 7W-9741
S/N: PDR1–Up
Part
Part No.:
No.: 7W-9741
S/N: YAR1–Up
Part
Part No.:
No.: 7W-9741
S/N: ZAR1–Up
Part
Part No.:
No.: 7W-9741
S/N: ZBR1–Up
Part
Part No.:
No.: 7W-9741
S/N: YAT1–Up
Part
Part No.:
No.: 7W-9741
S/N: YBT1–Up
Part
Part No.:
No.:7W-9741
S/N: YAW1–Up
Part
Part No.:
No.:7W-9741
S/N: YBW1–Up
Part
Part No.:
No.: 7W-9741
S/N: YAY1–Up
Part
Part No.:
No.: 7W-9741
S/N: YAZ1–Up

12 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Table 2
Specification
Specification for 7W-9741 Fue
Fuell Fil
FilterGp
terGp
Item Qty Part Specification description

Specification
1 1 6V-4589 O-R
O-Ring
ing Sea
Seall Lightl
Lightly
y lubric
lubricat
ate
e the bor
bore
e with
with the lubric
lubricantthat
antthat is being
being sea
sealed
led..
2 1 8L-2786 O-R
O-Ring
ing Sea
Seall Lightl
Lightly
y lubric
lubricat
ate
e the bor
bore
e with
with the lubric
lubricantthat
antthat is being
being sea
sealed
led..
3 5 6V-5048 O-R
O-Ring
ing Sea
Seall Lightl
Lightly
y lubric
lubricat
ate
e the bor
bore
e with
with the lubric
lubricantthat
antthat is being
being sea
sealed
led..
4 2 5D-5957 O-R
O-Ring
ing Sea
Seall Lightl
Lightly
y lubric
lubricat
ate
e the bor
bore
e with
with the lubric
lubricantthat
antthat is being
being sea
sealed
led..
5 1 6V-5049 O-R
O-Ring
ing Sea
Seall Lightl
Lightly
y lubric
lubricat
ate
e the bor
bore
e with
with the lubric
lubricantthat
antthat is being
being sea
sealed
led..
Length
force
e is 20.7
20.75
5 mm (0.817 inch).
inch).
6 1 1N-2895 Spring Test fo

force
rce is 222 N (50 lb).
lb).
Free lengt
length
h after
after test is 62.48
62.48 mm (2.460 inch).
inch).

RENR5057 13
Specificatio
Specifications
ns Sectio
Section
n
i04938315
Fuel
Fuel Filt
Filter
er
SMCS
SMC Code: 1261
S Code:
Part
Part No.:
No.: 377-5898
S/N: YBB1–Up
Part
Part No.:
No.: 377-5898
S/N: YBC1–Up
Part
Part No.:
No.: 377-5898
S/N: JDE1–Up
Part
Part No.:
No.: 377-5898
S/N: JCY1–Up
Table 3
Specification
Specification for 377-5898 Fue
Fuell Fil
FilterGp
terGp

Specification
1 4 5D-5957 O-R
O-RingSeal
ingSeal Lub
Lubric
ricatethe
atethe bor
bore
e lightl
lightly
y with
with clean
clean eng
engine
ine oil.
oil.
Length
Leng th under
under test forc
forcee is 20.7
20.75
5 mm (0.817 inch).
inch).
force
rce is 222 N (50 lb)lb)..
Free lengt
lengthh after
after test is 62.48
62.48 mm (2.460 inch).
inch).

14 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
i04716709
Fuel
Fuel Filt
Filter
er
SMCS
SMC Code: 1261
S Code:
Part
Part No.:
No.: 112-4922
S/N: GD31–Up
Table 4
Specification
Fuell Fil
FilterGp
terGp
Item Qty Part Specification description

Specification
1 2 5D-5957 O-R
O-Ring
ing Sea
Seall Lightl
Lightly
y lubric
lubricat
ate
e the bor
bore
e with
with the clean
clean eng
engine
ine oil.
oil.
Length
force
e is 20.7
20.75
5 mm (0.817 inch).
inch).

force
rce is 222 N (50 lb).
lb).
Free lengt
length
h after
after test is 62.48
62.48 mm (2.460 inch).
inch).

RENR5057 15
Specificatio
Specifications
ns Sectio
Section
n
i04369549
Fuell Pressu
Fue Pressure
re Regula
Regulator
tor
SMCS
SMCS Code:
Code: 1277
Part
Part No.:
No.: 114-5477
S/N: YBB1–Up
Part
Part No.:
No.:
114-5477
S/N: YBC1–Up
Part
Part No.:
No.: 114-5477
S/N: ZAD1–Up
Part
Part No.:
No.: 114-5477
S/N: ZAH1–Up
Part
Part No.:
No.: 114-5477
S/N: ZAJ1–Up
Part
Part No.:
No.: 114-5477
S/N: YAM1–Up
Part
Part No.:
No.: 114-5477
S/N: YAN1–Up
Part
Part No.:
No.: 114-5477
S/N: YAP1–Up
Part
Part No.:
No.: 114-5477
S/N: ZAP1–Up
Part
Part No.:
No.: 114-5477
S/N: ZBP1–Up
Part
Part No.:
No.: 114-5477
S/N: PBR1–Up
Part
Part No.:
No.: 114-5477
S/N: PDR1–Up
Part
Part No.:
No.: 114-5477
S/N: YAR1–Up
Part
Part No.:
No.: 114-5477
S/N: ZAR1–Up
Part
Part No.:
No.: 114-5477
S/N: ZBR1–Up
Part
Part No.:
No.: 114-5477
S/N: YAT1–Up
Part
Part No.:
No.: 114-5477
S/N: YBT1–Up
Part
Part No.:
No.:114-5477
S/N: YAW1–Up
Part
Part No.:
No.:114-5477
S/N: YBW1–Up
Part
Part No.:
No.: 114-5477
S/N: YAY1–Up
Part
Part No.:
No.: 114-5477
S/N: YAZ1–Up

16 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
(2) Valv
Valve
e plunger
Table 5
Specification
Specification for 114-5477 Va
Valve
lve Plung
Plunger
er

Specification
Length under
force e is 28.4
28.4 mm (1.12
(1.12 inch).
inch).
1 1 9N-4053 Spring Test fforce
orce is 40.79
40.79 ± 2.05 N (9.1 (9.17
7 ± 0.46 lb).
Free
Free length
length aft
after
er tes
testt forc
forcee is 57.15
57.15 mm (2.
(2.250inch)
250inch)..

RENR5057 17
Specificatio
Specifications
ns Sectio
Section
n
i05196360
Fuel
Fuel Trans
ransfe
ferr Pu
Pump
mp

18 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
SMCS
SMCS Code:
Code: 1256 S/N: YAY1–Up
Part
Part No.:
No.: 8N-6151 Part
Par No.: 8N-6151
t No.:
S/N: GD31–Up S/N: YAZ1–Up
Part
Part No.:
No.: 313-7770
S/N: YBB1–Up
Part
Part No.:
No.: 313-7770
S/N: YBC1–Up
Part
Part No.:
No.: 8N-6151
S/N: ZAD1–Up
Part
Part No.:
No.: 313-7770
S/N: JDE1–Up
Part
Part No.:
No.: 8N-6151
S/N: ZAH1–Up
Part
Part No.:
No.: 8N-6151
S/N: ZAJ1–Up
Part
Part No.:
No.: 8N-6151
S/N: YAM1–Up
Part
Part No.:
No.: 8N-6151
S/N: YAN1–Up
Part
Part No.:
No.: 8N-6151
S/N: YAP1–Up
Part
Part No.:
No.: 8N-6151
S/N: ZAP1–Up
Part
Part No.:
No.: 8N-6151
S/N: ZBP1–Up
Part
Part No.:
No.: 8N-6151
S/N: PBR1–Up
Part
Part No.:
No.: 8N-6151
S/N: PDR1–Up
Part
Part No.:
No.: 8N-6151
S/N: YAR1–Up
Part
Part No.:
No.: 8N-6151
S/N: ZAR1–Up
Part
Part No.:
No.: 8N-6151
S/N: ZBR1–Up
Part
Part No.:
No.: 8N-6151
S/N: YAT1–Up
Part
Part No.:
No.: 8N-6151
S/N: YBT1–Up
Part
Part No.:
No.:8N-6151
S/N: YAW1–Up
Part
Part No.:
No.:
8N-6151
S/N: YBW1–Up
Part
Part No.:
No.: 313-7770
S/N: JCY1–Up
Part
Part No.:
No.: 8N-6151

RENR5057 19
Specificatio
Specifications
ns Sectio
Section
n
Table 6
Specification
Specification for 8N-6151 Fue
Fuell Transfe
ransferr Pump
Pump Gp, 332-7928 Fue
Fuell Transfe
ransferr Pump
Pump Gp, 313-7770 Fuel
Fuel Transfe
ransferr Pum
Pump
p Gp and
377-5900 Fuel Tran
ransfe
sferr Pum
Pump p Gp

Specification
Before
Befo re installat
installation,inside
ion,inside diamet
diameter
er of the termi
terminal
nal bush
bushing
ing for gear shaf
shaftt is
1 4 7C-2870 Terminal Bushing 12.783 mm (0.5033
12.783 (0.5033 inch
inch).
).
Installat
Installation
ion depth
depth of terminal
terminal bushi
bushing
ng is 1.5 ± 0.5
0.5 mm (0.06
(0.06 ± 0.02 in
inch).
ch).
Diameter
Diameter of the gear is 29.8
29.801
01 ± 0.006
0.006 mm (1.1733
(1.1733 ± 0.000
0.00022 inch).
inch).
2 1 268-1903 Driv
Drive
e Shaft As
Length
Length of tthe
he gear is 25.34
25.347
7 ± 0.008
0.008 mm (0.9979
(0.9979 ± 0.
0.0003
0003 inch)
inch)..
Diam
Diameter
eter of the idler gear assembly
assembly is 29.8
29.801
01 ± 0.006
0.006 mm (1.1733
(1.1733 ± 0.00
0.0002
02 inch).
inch).
3 1 1W-4003 Idler Gear As
As
Length of tthe
Length he gear is 25.34
25.347
7 ± 0.008
0.008 mm (0.9979
(0.9979 ± 0.
0.0003
0003 inch)
inch)..

20 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
i04488609
Fuel
Fuel Prim
Primin
ing
g Pump
Pump
SMCS
SMCS Code:
Code: 1258
Part
Part No.:
No.: 7N-8599
S/N: GD31–Up
Table 7
Specification
Specification for 7N-8599 Fue
Fuell Pri
Primin
ming
g Pum
Pump
p Gp

Specification
7X-2501 Bolt(1)
1 1 Torque to 12 ± 3 N·m (106 ± 2
27
7 lb in).
8T-4971 Bolt(2)
6V-8918 Bolt(1)
2 1 Torque to 15 ± 3 N·m (133 ± 2
27
7 lb in).
8T-7547 Bolt(2)
(1) Use if inch bolt is required
(2) Use if metric bolt is required

RENR5057 21
Specificatio
Specifications
ns Sectio
Section
n
i05182335
Fuell Inject
Fue Injector
or Mechan
Mechanism
ism
SMCS
SMCS Code:
Code: 1102; 1290
Part
Part No.:
No.: 224-9869
S/N: GD31–Up
Part
Part No.:
No.: 224-9869
S/N: ZAD1–Up
Part
Part No.:
No.: 224-9869
S/N: ZAH1–Up
Part
Part No.:
No.: 224-9869
S/N: ZAJ1–Up
Part
Part No.:
No.: 224-9869
S/N: YAM1–Up
Part
Part No.:
No.: 224-9869
S/N: YAN1–Up
Part
Part No.:
No.: 224-9869
S/N: YAP1–Up
Part
Part No.:
No.: 224-9869
S/N: ZAP1–Up
Part
Part No.:
No.: 224-9869
S/N: ZBP1–Up
Part
Part No.:
No.: 224-9869
S/N: PBR1–Up
Part
Part No.:
No.: 224-9869
S/N: PDR1–Up
Part
Part No.:
No.: 224-9869
S/N: YAR1–Up
Part
Part No.:
No.: 224-9869
S/N: ZAR1–Up
Part
Part No.:
No.: 224-9869
S/N: ZBR1–Up
Part
Part No.:
No.: 224-9869
S/N: YAT1–Up
Part
Part No.:
No.: 224-9869
S/N: YBT1–Up
Part
Part No.:
No.:224-9869
S/N: YAW1–Up
Part
Part No.:
No.:224-9869
S/N: YBW1–Up
Part
Part No.:
No.: 224-9869
S/N: YAY1–Up
Part
Part No.:
No.: 224-9869
S/N: YAZ1–Up

22 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Table 8
Specification
Specification for 224-9869 Val
Valve
ve Mechanis
Mechanism
m Gp, 332-9690 Valv
Valve
e Mech
Mechanis
anism
m Gp, and 357-9219 Val
Valve
ve Mech
Mechanis
anism
m Gp

Specification
1 1 317-1121 Jam Nut Torque to 120 ± 15 N·m (89 ± 11 lb ft).
2 1 6J-2245 O-Ri
O-Ring
ng Seal
Seal Lubr
Lubric
icat
ate
e th
the
e bore
bore light
lightly
ly wi
with
th clea
clean
n engi
engine
ne oil.
oil.
Start tighteningthe
Start tighteningthe retainernuts of the cap asse
assembly
mbly by hand so that the term
termi-
i-
nal studs are not cross threaded.
3 1 7E-6508 Cap As
Tighten the retainer
retainer nuts of tthe
he cap assembly
assembly to 2.50 ± 0.25 N·m
(22.13 ± 2.21 lb in).

(22.13
Length
Lengt h under
under test forc
force e is 85.0
85.00
0 mm (3.346 inch).
inch).
4 1 100-3878 Injec
Injector
tor Spring
Spring Test fo
force
rce is 300 ± 25 N (67 ± 6 lb).
Free
Free length
length after
after tes
testt is 87.65mm (3.
(3.451inch)
451inch)..
Apply black Loctite

Loctite gaskgasket
et maker
maker #2 to the thre
threads
ads of the bolt
bolt,, if the bolt
bolts
s are
5 2 334-1626 Bolt
removed after
removed after initial
initial insta
installati
llatio
on.
n.
Bore of the bush

bushing
ing for the rock
rocker
er arm shaft
shaft after
after assembly
assembly is
B 1 230-2620 Bushing
45.077 ± 0.015 mm (1.7747 ± 0.0006
45.077 0.0006 inch).
inch).
C 1 234-2273 Rocker Arm Sh
Shaft
aft Diam
Diameter
eter is 45.0
45.000
00 ± 0.013 mm (1.7716±
(1.7716± 0.0005
0.0005 inch)
inch)
Diameter
Diam eter is 34.95
34.950
0 ± 0.010
0.010 mm (1.3760
(1.3760 ± 0.0004
0.0004 inch).
inch).
D 1 282-7944 Injec
Injector
tor Lift
Lifter
er As Bore in the cylinder
cylinder head for th
the
e unit injector
injector lifte
lifterr asse
assembly
mbly is
35.000
35.00 0 ± 0.025 mm (1.3779 ± 0.0010
0.0010 inch).
inch).

RENR5057 23
Specificatio
Specifications
ns Sectio
Section
n
i04913393
Fuell Inject
Fue Injector
or Mechan
Mechanism
ism
SMCS
SMCS Code:
Code: 1102; 1290
Part
Part No.:
No.: 370-9889
S/N: YBB1–Up
Part
Part No.:
No.: 370-9889
S/N: YBC1–Up
Part
Part No.:
No.: 370-9889
S/N: JDE1–Up
Part
Part No.:
No.: 370-9889
S/N: JCY1–Up
Top view
Table 9
Specification
Specification for 370-9889 Valve Mechanis
Mechanism
m Gp

Specification
1 2 3J-9196 Jam Nut Torque to 70 ± 15 N·m (52 ± 11 lb ft).
Torque to 2.50 ± 0.25

0.25 N·m (22.13
(22.13 ± 2.21 lb in).
2 2 7E-6507 Reta
Retainer
iner Nut Start tightening the retainernuts of the cap aassembly
ssembly by hand so that the terminal
studs are not cross threaded.

Length forcee is 85.00 mm (3.346
(3.346 inch
inch).
).
4 1 100-3878 Injec
Injector
tor Spring
Spring Test force is 300 ± 25 N (67 ± 6 lb).
Free lengt
length
h after
after test is 87.65 mm (3.451 inch).
inch).
5 1 5P-7530 O-R
O-Ring
ing Se
Seal
al Lub
Lubric
ricatethe
atethe bor
bore
e lightl
lightly
y with
with the lubric
lubricantthat
antthat is bei
being
ng sea
sealed
led..
6 2 334-1626 Bolt If the bolt is remo

removed
ved for service,
service, apply black Loct
Loctite
ite Gask
Gasket
et Make
Makerr to the thre
threads.
ads.

24 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Table 10
Item Qty Part Specification

Specification Description
9 1 234-2273 Rocker Arm Shaft Diameter

Diameter is 45.000
45.000 ± 0.013 mm (1.7717
(1.7717 ± 0.00
0.0005
05 inch).
inch).
If the bolt is removed

removed for serv
service,
ice, apply black Loct
Loctite
ite Gask
Gasket
et Make
Makerr to the
10 2 0L-2070 Bolt
threads.
11 1 6J-2245 O-R
O-RingSeal
ingSeal Lubric
Lubricatethe
atethe bor
bore
e lightl
lightly
y with
with the lubric
lubricantthat
antthat is bei
being
ng sea
sealed
led..
Bore of the bushing

bushing in the injec
injector
tor rock
rocker
er arm assembly
assembly (7) is
B - -
45.077
45.077 ± 0.015
0.015 mm (1.7747 ± 0.0006
0.0006 inch)
inch)..
Bore of the bushing

bushing in the valv
valve
e rock
rocker
er arm assembly
assembly (8) is 45.0
45.077
77 ± 0.015
0.015 mm
C - -
(1.7747
(1.7747 ± 0.00
0.0006
06 inch).
inch).

RENR5057 25
Specificatio
Specifications
ns Sectio
Section
n
i05213812
Fuell Inject
Fue Injector
or
SMCS
SMCS Code:
Code: 1290
Part
Part No.:
No.: 256-3663
S/N: GD31–Up
Part
Part No.:
No.: 256-3663
S/N: ZAD1–Up
Part
Part No.:
No.: 256-3663
S/N: ZAH1–Up
Part
Part No.:
No.: 231-784
231-7845,
5, 256-366
256-3663
3
S/N: ZAJ1–Up
Part
Part No.:
No.: 256-3663
S/N: YAM1–Up
Part
Part No.:
No.: 231-7845, 256-366
231-7845, 256-3663
3
S/N: YAN1–Up
Part
Part No.:
No.: 256-3663
S/N: YAP1–Up
Part
Part No.:
No.: 256-3663
S/N: ZAP1–Up
Part
Part No.:
No.: 256-3663
S/N: ZBP1–Up
Part
Part No.:
No.: 256-3663
S/N: PBR1–Up
Part
Part No.:
No.: 256-3663
S/N: PDR1–Up
Part
Part No.:
No.: 256-3663
S/N: YAR1–Up
Part
Part No.:
No.: 231-7845, 256-366
231-7845, 256-3663
3
S/N: ZAR1–Up
Part
Part No.:
No.: 256-3663
S/N: YAT1–Up
Part
Part No.:
No.: 256-3663
S/N: YBT1–Up
Part
Part No.:
No.: 231-784
231-7845,
5, 256-366
256-3663
3
S/N: YAW1–Up
Part
Part No.:
No.: 256-3663
S/N: YAY1–Up
Part
Part No.:
No.: 256-3663
S/N: YAZ1–Up

26 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Table 11
Specification
Specification for 256-3663 FueFuell Inj
Inject
ectionPump
ionPump Gp, 252-0064 Fue Fuell Inj
Inject
ectionPump
ionPump Gp, 253-2636 Fue
Fuell Inject
InjectionPump
ionPump Gp,
254-1417 Fue
Fuell
Inject
InjectionPump
Inject
ectionPump
Inject
ectionPump
ionPump Gp, 282-5076 Fuel Inje
Injection
ction
Pump
Pump Gp, 147-0625 Fue
Fuell Inj
Inject
ectionPump
Inject
ectionPump
ionPump Gp, 274-0053 Fuel Inj Inject
ectionPump
ionPump Gp, and 282-6903
Fuell Inject
Fue InjectionPump
ionPump Gp
Item Qty Part Specification Descrip

tion
Prior to installatio
installation
n of the fuel injector
injector grou
group,
p, lubr
lubricatethe
icatethe bore in the cylinder
cylinder head with 1P-0808 Multipurpos
Multipurpose
e Grease. Use the clamp to press
the injector into the bore.
bore. Do not tap on tthe
he top surface
surface of the injecto
injectorr.
A - - Tim
Timing
ing dimensio
dimension
n is 64.34 ± 0.20 mm (2.533
(2.533 ± 0.008
0.008 inch)
1 1 7F-8698 Bolt Torqu

orque
e to 65 ± 7 N·m (48 ± 5 lb ft).

RENR5057 27
Specificatio
Specifications
ns Sectio
Section
n
i04938316
Fuell Inject
Fue Injector
or
SMCS
SMCS Code:
Code: 1290
Part
Part No.:
No.: 384-4705
S/N: YBB1–Up
Part
Part No.:
No.: 384-4705
S/N: JCY1–Up
Table 12
Specification
Fuell Inj
Inject
ectionPump
ionPump Gp

tion
installation
injector grou
group,
p, lubr
lubricatethe
cylinder head with 1P-0808 Mult
Multipurp
ipurpos
ose
e Greas
Grease.
e. Use injector clam
clamp
p (3)
to press the injector into the bore. Do not tap on the top surface
surface of the injector
injector..
Use the following

following procedurein
procedurein orderto tighttighten
en the fuel inject
injection
ion valv
valve
e assembl
assembly:
y:
Before assembly,
assembly, lubricate the bore and the threads with 1P-0808 Multipurpose
361-9354 Fuel Injection Va
Valve
lve Grease.
1 1
Assembly 1. Tighten
Tighten the valve
valve assembly
assembly to 35 N·m (26 lb ft) ft)..
2. Turn
Turn to reach
reach the fina
finall turn angle of 19 ± 1 degrees
degrees..
3. Again,
Again, tighten
tighten to 1
115
15 to 290 N·m (85 to 214 lb ft ft).
).

orque
e to 65 ± 7 N·m (48 ± 5 lb ft).
A - - Timing
Timing dimensionis
dimensionis 64.3
64.34
4 ± 0.20 mm (2.533
(2.533 ± 0.008
0.008 inch)
Use the following

following proc
procedurein
edurein orderto tight
tighten
en the unit injec
injector
tor nozz
nozzle:
le:
1. Tighten
Tighten the unit injecto
injectorr nozz
nozzle
le to 30 N·m (266 lb in).
3 1 230-9456 Unit Injector
Injector Nozzle
Nozzle
2. Turn
Turn to reach
reach the fina
degrees..
3. Again,
Again, tighten
tighten to 180 to 340 N·mN·m (133 to 251
251 lb ft).

28 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
i04938348
Fuell Inject
Fue Injector
or
SMCS
SMCS Code:
Code: 1290
Part
Part No.:
No.: 383-4050
S/N: YBC1–Up
Part
Part No.:
No.: 383-4050
S/N: JDE1–Up
Part
Part No.:
No.: 159-8832
S/N: ZBR1–Up
Part
Part No.:
No.:159-8832
S/N: YBW1–Up
Typical example

RENR5057 29
Specificatio
Specifications
ns Sectio
Section
n
Table 13
Specification
Fuell Inj
Inject
ectionPump
ionPump Gp and 159-8832 Fue
Fuell Inj
Inject
ectionPump
ionPump Gp

tion
installation
injector grou
group,
p, lubr
lubricatethe
cylinder head with 1P-0808 Mult
Multipurp
ipurpos
ose
e Greas
Grease.
e. Use injector clam
clamp
p (3)
to press the injector into the bore. Do not tap on the top surface
surface of the injector
injector..
Use the following

following procedurein
procedurein orderto tight
tighten
en the fuel inject
injection
ion valv
valve
e assembl
assembly:
y:
Before assembly,
assembly, lubricate the bore and the threads with 1P-0808 Multipurpose
361-9354 Fuel Injection Va
Valve
lve Grease.
1 1
Assembly 1. Tighten
Tighten the valve
valve assembly
assembly to 35 N·m (26 lb ft) ft)..
2. Turn
Turn to reach
reach the fina
degrees..
3. Again,
Again, tighten
tighten to 1
115
15 to 290 N·m (85 to 214 lb ft ft).
).

orque
e to 65 ± 7 N·m (48 ± 5 lb ft).
A - - Timing
Timing dimensionis
dimensionis 64.3
64.34
4 ± 0.20 mm (2.533
(2.533 ± 0.008
0.008 inch)
Use the following

following proc
procedurein
edurein orderto tight
tighten
en the unit injec
injector
tor nozz
nozzle:
le:
1. Tighten
Tighten the unit injecto
injectorr nozz
nozzle
le to 30 N·m (266 lb in).
3 1 229-0187 Unit Injector
Injector Nozzle
Nozzle
2. Turn
Turn to reach
reach the fina
degrees..
3. Again,
Again, tighten
tighten to 180 to 340 N·mN·m (133 to 251
251 lb ft).

30 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
i04407569
Camshaft
SMCS
SMCS Code:
Code: 1210
Part
Part No.:
No.: 106-4595
S/N: GD31–Up
Part
Part No.:
No.:
106-4586
S/N: ZAD1–Up
Part
Part No.:
No.: 106-4586
S/N: ZAH1–Up
Part
Part No.:
No.: 106-4586
S/N: ZAJ1–Up
Part
Part No.:
No.: 106-4586
S/N: YAM1–Up
Part
Part No.:
No.: 106-4586
S/N: YAN1–Up
Part
Part No.:
No.: 106-4586, 106-459
106-4586, 106-4595
5
S/N: YAP1–Up
Part
Part No.:
No.: 106-458
106-4586,
6, 106-459
106-4595
5
S/N: ZAP1–Up
Part
Part No.:
No.: 106-4595
S/N: ZBP1–Up
Part
Part No.:
No.: 106-458
106-4586,
6, 106-459
106-4595
5
S/N: PBR1–Up
Part
Part No.:
No.: 106-458
106-4586,
6, 106-459
106-4595
5
S/N: YAR1–Up
Part
Part No.:
No.: 106-458
106-4586,
6, 106-459
106-4595
5
S/N: ZAR1–Up
Part
Part No.:
No.: 106-4595
S/N: ZBR1–Up
Part
Part No.:
No.: 106-458
106-4586,
6, 106-459
106-4595
5
S/N: YAT1–Up
Part
Part No.:
No.: 106-4595
S/N: YBT1–Up
Part
Part No.:
No.: 106-458
106-4586,
6, 106-459
106-4595
5
S/N: YAW1–Up
Part
Part No.:
No.:106-4595
S/N: YBW1–Up
Part
Part No.:
No.: 106-4586
S/N: YAY1–Up
Part
Part No.:
No.: 106-4586
S/N: YAZ1–Up

RENR5057 31
Specificatio
Specifications
ns Sectio
Section
n
(1)
(1) Left
Left-h
-ha
and ca
cam
msh
shaf
aftt asse
assemb
mbly
ly (2)
(2) Ri
Righ
ght-
t-ha
handca
ndcam
msh
shaf
aftt asse
assemb
mbly
ly
Table 14
Specification
Specification for 106-4595 Cams
Camsha
haft
ft Gp and 106-4586 Cams
Camshaft
haft Gp

Thickness of the groove in a new camshaft assembly is 8.75 ± 0.05 mm

A - -
(0.344
(0.344 ± 0.002
0.002 inch
inch).
).
C 1 5B-5821 Dowel Exte

Extension
nsion of the dowel is 12.0 ± 0.5 mm (0.47 ± 0.02 inch).
inch).
D 2 7N-3218 Thrust Washer Thick

Thicknes
ness
s of a new
new thrust
thrust wash
washer
er is 8.
8.50
50 ± 0.05 mm (0.335
(0.335 ± 0.
0.002
002 inch)
inch)..
Diameter of bearing journals for a new cam

Diameter camshaft
shaft is 91
91.88
.88 ± 0.02 mm
(3.617
(3.617 ± 0.001
0.001 inch
inch).
).
E - -
Bore in camshaf
camshaftt bearing
bearing after
after installat
installation
ion is 92.
92.00
00 ± 0.06 mm
(3.622 ± 0.002
(3.622 0.002 inch
inch).
).
- - - End play for a new cams

camshaf
haftt assembly
assembly is 0.15 to 0.35 mm (0.006
(0.006 to 0.014
0.014 inch).
inch).
3 16 5P-0076 Bolt Torque to 55 ± 7 N·m (41 ± 5 lb ft).
F 1 4N-1650 Dowel Exte

Extension
nsion of the dowel is 22.0 ± 0.5 mm (0.87 ± 0.02 inch).
inch).

32 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Table 15
Specification
Camsha
haft
Camshaft
haft Gp

Specification
Use the following

following procedure in order to determ
determine
ine the camsh
camshaft
aft lobe lift:
1. Measure
Measure cams
camshaft
haft lobe heig
height
ht (H).
- - -
2. Measure
Measure base cir
circle
cle (J).
3. Subtract
Subtract the base circle
circle (J) fro
from
m the cams
camshaft
haft lobe heig
height
ht (H). The dif
differ
ference
ence
is the actual camshaft
camshaft lobe lift
lift..
Specified
Specified cams
camshaft
haft lobe lift:
lift:
Inlett lobe is 12.7500

Inle 12.7500 mm (0.50197
(0.50197 inch)
inch)..
G - -
Injector
Injector lobe iis
s 13.7313
13.7313 mm (0.54060
(0.54060 inch)
inch)..
Exhaust
Exhaust lobe is 13.
13.2499
2499 mm (0.52165
(0.52165 inch)
inch)..

RENR5057 33
Specificatio
Specifications
ns Sectio
Section
n
i05206168
Camshaft
SMCS
SMCS Code:
Code: 1210
Part
Part No.:
No.: 106-4582
S/N: ZAD1–Up
(1)
(1) Left
Left-h
-ha
and ca
cam
msh
shaf
aftt asse
assemb
mbly
ly (2)
(2) Ri
Righ
ght-
t-ha
handca
ndcam
msh
shaf
aftt asse
assemb
mbly
ly
Table 16
Specification
Camsha
haft
Camshaft
haft Gp

Specification
Thickness
Thicknes s of the groove
groove in a new camshaft
camshaft asse
assembly
mbly is 8.75 ± 0.05 mm
A - -
(0.344
(0.344 ± 0.002
0.002 inch)
inch)..
B 2 5B-5821 Dowel Exte

Extension
nsion of the dowe
dowell is 12.0 ± 0.5 mm (0.47 ± 0.02 inch).
inch).
C 2 7N-3218 Thrust Washer Thick

Thicknes
ness
s of
of a n
new
ew thrus
thrustt washer
washer is 8.50 ± 0.05 mm (0.335 ± 0
0.002
.002 inch).
inch).
Diameterr of bearing journals for a new cam

Diamete camshaft
shaft is 91.88 ± 0.02 mm
(3.617 ± 0.001
(3.617 0.001 inch)
inch)..
D - -
Bore in c
camsh
amshaft
aft bearing
bearing after
after insta
installati
llation
on is 92.00
92.00 ± 0.06
0.06 mm
mm (3.62
(3.622
2 ± 0.
0.002
002 inch
inch).
).

34 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Table 17

Specification
Use the following

following proc
procedurein
edurein order to determinethe
determinethe cams
camshaft
haft lobe lift
lift::
1. Measure
Measure camshaft
camshaft lobe height (F).
- - -
2. Measure
Measure base cir
circle
cle (G).
3. Subtract
Subtract the bas
base
e circle (G) from the camsha
camshaft
ft lobe he
height
ight (F). The dif
differe
ference
nce is
the actual camshaft
camshaft lobe lift.
Specified
Specified cams
camshaft
haft lobe lift:
Inlett lobe is 12
Inle 12.750
.7500
0 mm (0.50197
(0.50197 inch)
inch)..
E - -
Injector
Injector lobe iis
s 13.7313
13.7313 mm (0.54060
(0.54060 inch)
inch)..
Exhaust
Exhaust lobe is 13.
13.2499
2499 mm (0.52165
(0.52165 inch
inch).
).

RENR5057 35
Specificatio
Specifications
ns Sectio
Section
n
i04939143
Camshaft
SMCS
SMCS Code:
Code: 1210
Part
Part No.:
No.: 382-3100
S/N: YBB1–Up
Part
Part No.:
No.:
382-3100
S/N: YBC1–Up
Part
Part No.:
No.: 380-2698
S/N: JDE1–Up
Part
Part No.:
No.: 380-2698
S/N: JCY1–Up
(1)
(1) Left
Left-h
-ha
and ca
cam
msh
shaf
aftt asse
assemb
mbly
ly (2)
(2) Ri
Righ
ght-
t-ha
handca
ndcam
msh
shaf
aftt asse
assemb
mbly
ly
Table 18
Specification
Camshaft
haft Gpand 382-3100 Cams
Camshaft
haft Gp
Item Qty Part Specification Descripti

on
Thickness of the groove in the new camshaft assemb

assembly
ly for the thrust washer is
A - -
8.75 ± 0.05 mm (0.344
(0.344 ± 0.002
0.002 inch).
inch).
C 2 5B-5821 Dowel Extension

Extension of the dowel is 12.0 ± 0.5 mm (0.47 ± 0.02 inch).
inch).
D 2 7N-3218 Thrust Washer Thicknes

Thickness
s of the new thrus
thrustt washer
washer is 8.
8.50
50 ± 0.05 mm (0.335
(0.335 ± 0.
0.002
002 inch
inch).
).
Diameterof bearing journ

Diameterof journals
als for a new cam
camshaf
shaftt is 91.88 ± 0.02 mm
(3.617
(3.617 ± 0.001
0.001 inch
inch).
).
E - -
Bore in c
camsh
amshaft
aft bearing
bearing afte
afterr installat
installation
ion is 92.00
92.00 ± 0.06
0.06 mm (3.622
(3.622 ± 0.002
0.002 inch)
inch)..
F 2 4N-1650 Dowel Extension

inch).

36 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Table 19

Use the following

following procedure in order to determ
determine
ine the camsh
camshaft
aft lobe lift:
1. Measure
Measure cams
camshaft
haft lobe heig
height
ht (H).
- - -
2. Measure
Measure base cir
circle
cle (J).
3. Subtract
circle (J) fro
from
m the cams
camshaft
haft lobe heig
height
ht (H). The dif
differ
ference
ence
is the actual camshaft
camshaft lobe lift
lift..
Specified
Specified cams
camshaft
haft lobe lift:
lift:
Inlett lobe is 12.7500

Inle 12.7500 mm (0.50197
(0.50197 inch)
inch)..
G - -
Injector
Injector lobe iis
s 13.7313
13.7313 mm (0.54060
(0.54060 inch)
inch)..
Exhaust
Exhaust lobe is 13.
13.2499
2499 mm (0.52165
(0.52165 inch)
inch)..

RENR5057 37
Specificatio
Specifications
ns Sectio
Section
n
i04936960
Camshaft
SMCS
SMCS Code:
Code: 1210
Part
Part No.:
No.: 231-9123
S/N: PBR1–Up
Part
Part No.:
No.:
231-9123
S/N: PDR1–Up
Part
Part No.:
No.: 231-9123
S/N: YAT1–Up
Part
Part No.:
No.: 231-9123
S/N: YBT1–Up
(1)
(1) Left
Left-h
-ha
and ca
cam
msh
shaf
aftt asse
assemb
mbly
ly (2)
(2) Ri
Righ
ght-
t-ha
handca
ndcam
msh
shaf
aftt asse
assemb
mbly
ly
Table 20
Camshaft
haft Gp
Item Qty Part Specification Descripti

on
Thickness of the groove in a new camsha

camshaft
ft assembly for the thrust washer is
A - -
8.75 ± 0.05 mm (0.344
(0.344 ± 0.002
0.002 inch).
inch).
C 2 5B-5821 Dowel Extension

inch).
D 2 7N-3218 Thrust Washer Thicknes

Thickness
s of a new
new thrus
thrustt wash
washer
er is 8.
8.50
50 ± 0.05 mm (0.335
(0.335 ± 0.
0.002
002 inch)
inch)..
Diameterof bearing journ

Diameterof journals
als for a new cam
camshaf
shaftt is 91.88 ± 0.02 mm
(3.617
(3.617 ± 0.001
0.001 inch
inch).
).
E - -
Bore in c
camsh
amshaft
aft bearing
bearing afte
afterr installat
installation
ion is 92.00
92.00 ± 0.06
0.06 mm (3.622
(3.622 ± 0.002
0.002 inch)
inch)..
- - - End play for a new cams

camshaf
haftt assembly
assembly is 0.15 to 0.35 mm (0.006
(0.006 to 0.014 inch).
inch).
F 2 4N-1650 Dowel Extension

inch).

38 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Table 21

Specification Descripti
Description
on
Use the following procedure in order to determ

determine
ine the camshaft lobe lift:
1. Measure
Measure cams
camshaft
haft lobe heig
height
ht (H).
- - -
2. Measure
Measure base cir
circle
cle (J).
3. Subtract
circle (J) from the cams
camshaftlobe
haftlobe height (H). The diff
differen
erence
ce is the actual cams
camshaf
haftt
lobe lift.
Specified
Specified cams
camshaft
haft lobe lift:
Inlet lobe is
is 12.73
12.73 mm (0.501
(0.501 inch).
inch).
G - -
Exhaust
Exhaust lobe is 13
13.10
.10 mm (0.516
(0.516 inch
inch).
).
Injector
Injector lobe is 13.73
13.73 mm (0.541
(0.541 inch
inch).
).

RENR5057 39
Specificatio
Specifications
ns Sectio
Section
n
i05182336
Valve Mechanis
Mechanism
m
SMCS
SMC Code: 1102
S Code:
Part
Part No.:
No.: 224-9869
S/N: GD31–Up
Part
Part No.:
No.:
224-9869
S/N: ZAD1–Up
Part
Part No.:
No.: 224-9869
S/N: ZAH1–Up
Part
Part No.:
No.: 224-9869
S/N: ZAJ1–Up
Part
Part No.:
No.: 224-9869
S/N: YAM1–Up
Part
Part No.:
No.: 224-9869
S/N: YAN1–Up
Part
Part No.:
No.: 224-9869
S/N: YAP1–Up
Part
Part No.:
No.: 224-9869
S/N: ZAP1–Up
Part
Part No.:
No.: 224-9869
S/N: ZBP1–Up
Part
Part No.:
No.: 224-9869
S/N: PBR1–Up
Part
Part No.:
No.: 224-9869
S/N: PDR1–Up
Part
Part No.:
No.: 224-9869
S/N: YAR1–Up
Part
Part No.:
No.: 224-9869
S/N: ZAR1–Up
Part
Part No.:
No.: 224-9869
S/N: ZBR1–Up
Part
Part No.:
No.: 224-9869
S/N: YAT1–Up
Part
Part No.:
No.: 224-9869
S/N: YBT1–Up
Part
Part No.:
No.:224-9869
S/N: YAW1–Up
Part
Part No.:
No.:224-9869
S/N: YBW1–Up
Part
Part No.:
No.: 224-9869
S/N: YAY1–Up
Part
Part No.:
No.: 224-9869
S/N: YAZ1–Up

40 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Table 22
Specific
Specificatio
ation
n for the 224-9869 Val
Valve
ve Mechanis
Mechanism
m Gp 332-9690 Val
Valve
ve Mechanis
Mechanism
m Gp 281-6160 Va
Valve
lve Mechanis
Mechanism
m Gp 286-5723 Valve
Mechan
Mech anism
ism Gp 308-5356 Va
Valve
lve Mechanis
Mechanismm Gp 357-9219 Valv
Valve
e Mechanis
Mechanism
m Gp

1 2 3J-9196 Jam Nut Torque the jam nuts to 70 ± 15 N·m (52 ± 11 lb ft).
Diameter
Diam eter of the
the rocker
rocker arm shaft
shaft assembly
assembly is 45.
45.000
000 ± 0.0
0.013
13 mm
A 1 230-2633 Shaft As
(1.7716 ± 0.0
(1.7716 0.0005
005 inch)
Dimension for the valve lash:
B - - Inlet valve
valve 0.50 mm (0.020
(0.020 inch)
Exhaust
Exha ust valve 1.00
1.00 mm (0.04
(0.040
0 inch)
inch)..
Bore in the bush

bushing
ing for the rock
rocker
er arm shaft
shaft assembly
assembly afte
afterr installat
installation
ion is
C 1 230-2620 Bushing
45.077
45.07 7 ± 0.015
0.015 mm (1.7747 ± 0.0006
0.0006 inch).
inch).
Diameter of the valve

Diameter valve lif
lifter
ter asse
assembl
mblyy is 29.900
29.900 ± 0.010 mm (1.1772
(1.1772 ± 0.00
0.0004
04 inch).
inch).
D 2 263-6672 Lifte
Lifterr Body Bore in
in the cylind
cylinder
er head for
for valve lifte
lifterr asse
assembly
mbly is 30.
30.000
000 ± 0.02
0.025
5 mm
(1.1811
(1.1811 ± 0.0010 inch).

RENR5057 41
Specificatio
Specifications
ns Sectio
Section
n
i04449469
Valve Mechanis
Mechanism
m
SMCS
SMC Code: 1102
S Code:
Part
Part No.:
No.: 370-9889
S/N: YBB1–Up
Part
Part No.:
No.: 370-9889
S/N: YBC1–Up
Part
Part No.:
No.: 370-9889
S/N: JDE1–Up
Part
Part No.:
No.: 370-9889
S/N: JCY1–Up
Top view
Table 23
Specification
Mechanism
m Gp

Specification
1 2 3J-9196 Jam Nut Torque to 70 ± 15 N·m (52 ± 11 lb ft).
Torque to 2.50 ± 0.25

0.25 N·m (22.13
(22.13 ± 2.21 lb in).
2 2 7E-6507 Reta
Retainer
iner Nut Start tightening the retainernuts of the cap aassembly
ssembly by hand so that the terminal
studs are not cross threaded.
4 1 5P-7530 O-R
O-Ring
ing Se
Seal
al Lub
Lubric
ricatethe
atethe bor
bore
e lightl
lightly
y with
with the lubric
lubricantthat
antthat is bei
being
ng sea
sealed
led..
5 2 334-1626 Bolt If the bolt is remo

removed
ved for service,
service, apply black Loct
Loctite
ite Gask
Gasket
et Make
Makerr to the thre
threads.
ads.

42 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Table 24
Specification
Mechanism
m Gp

Specification
8 1 234-2273 Rocker Arm Shaft Diameter

Diameter is 45.000
45.000 ± 0.013 mm (1.7717
(1.7717 ± 0.00
0.0005
05 inch).
inch).
If the bolt is removed

removed for serv
service,
ice, apply black Loct
Loctite
ite Gask
Gasket
et Make
Makerr to the
9 2 0L-2070 Bolt
threads.
10 1 6J-2245 O-R
O-RingSeal
ingSeal Lubric
Lubricatethe
atethe bor
bore
e lightl
lightly
y with
with the lubric
lubricantthat
antthat is bei
being
ng sea
sealed
led..
Bore of the
the bus
bushing
hing in the injec
injector
tor rock
rocker
er arm assembly
assembly (6) is
B - -
45.077
45.077 ± 0.015
0.015 mm (1.7747 ± 0.0006
0.0006 inch)
inch)..
Bore of the bushing

bushing in the valv
valve
e rock
rocker
er arm assembly
assembly (7) is 45.0
45.077
77 ± 0.015
0.015 mm
C - -
(1.7747
(1.7747 ± 0.00
0.0006
06 inch).
inch).

RENR5057 43
Specificatio
Specifications
ns Sectio
Section
n
i04721894
Cylind
Cylinder
er Head
Head
SMCS
SMCS Code:
Code: 1100
Part
Part No.:
No.: 101-0830
S/N: GD31–Up
Part
Part No.:
No.: 101-0830
S/N: ZAD1–Up
Part
Part No.:
No.: 101-0830
S/N: ZAH1–Up
Part
Part No.:
No.: 101-0830
S/N: ZAJ1–Up
Part
Part No.:
No.: 101-0830
S/N: YAM1–Up
Part
Part No.:
No.: 101-0830
S/N: YAN1–Up
Part
Part No.:
No.: 101-0830
S/N: YAP1–Up
Part
Part No.:
No.: 101-0830
S/N: ZAP1–Up
Part
Part No.:
No.: 101-0830
S/N: ZBP1–Up
Part
Part No.:
No.: 101-0830
S/N: PBR1–Up
Part
Part No.:
No.: 101-0830
S/N: PDR1–Up
Part
Part No.:
No.: 101-0830
S/N: YAR1–Up
Part
Part No.:
No.: 101-0830
S/N: ZAR1–Up
Part
Part No.:
No.: 101-0830
S/N: ZBR1–Up
Part
Part No.:
No.: 101-0830
S/N: YAT1–Up
Part
Part No.:
No.: 101-0830
S/N: YBT1–Up
Part
Part No.:
No.:101-0830
S/N: YAW1–Up
Part
Part No.:
No.:101-0830
S/N: YBW1–Up
Part
Part No.:
No.: 101-0830
S/N: YAY1–Up
Part
Part No.:
No.: 101-0830
S/N: YAZ1–Up

44 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Table 25
Specification
Specification for 285-3086 Cyli
Cylinde
nderr Head
Head Gp, and 101-0830 Cylind
Cylinder
er Hea
Head
d Gp

Specification
During
During installati
installation,
on, shru
shrunk
nk the valve seat insert with reduc
reduced
ed temp
temperatu
erature
re
1 2 130-2607 Valve Seat Insert (Reference
(Referen ce temp
temperat
erature
ure : −60° C (−76° F)) and res
resss the insert into th
the
e cylin-
der heads counterbore.
During
During installati
installation,
on, shru
shrunk
nk the valve seat insert with reduc
reduced
ed temp
temperatu
erature
re
2 2 130-2608 Valve Seat Insert (Reference
(Referen ce temp
temperat
erature
ure : −60° C (−76° F)) and res
resss the insert into th
the
e cylin-
der heads counterbore.
3 5 3B-0623 Cup Plu

Plug
g Apply
Apply Loctit
Loctite
e 11358
1358 to the bor
bores
es for the cup plugs
plugs prior
prior to the instal
installat
latio
ion.
n.
4 5 3B-0645 Cup Plu

Plug
g Apply
Apply Loctit
Loctite
e 11358
1358 to the bor
bores
es for the cup plugs
plugs prior
prior to the instal
installat
latio
ion.
n.
D - - Installat
Installatio
ion
n depth
depth for cup plug is 9.0 ± 0.5 mm (0.35
(0.35 ± 0.02 inch).
inch).
E - - Installat
Installatio
ion
n depth
depth for cup plug is 1.0 ± 0.5 mm (0.04
(0.04 ± 0.02 inch).
inch).

RENR5057 45
Specificatio
Specifications
ns Sectio
Section
n
Table 26

Specification
5 1 5B-7890 Pip
Pipe
e Plu
Plug
g Bef
Before
ore assemb
assembly
ly,, lubric
lubricatethe
atethe thr
thread
eads
s with
with Loc
Loctit
tite
e C5A CopperAnti-
CopperAnti-Sei
Seize
ze .
131-0420 Cylinder Head Fasten- Use the following

following procedureto
procedureto tightighten
ten the bolts for the cylinder
cylinder head
head::
6 6
er Gp 1. Before assembly,
assembly, apply clean eng engine
ine oil to the threads of the bolts.
2. Tighten
Tighten bolt 1 through
through bolt 8 in the numerical
numerical seque
sequence nce as shown in Illu
Illus-
s-
131-0421 Cylinder Head Fasten- tration
tration 32 to a to torque
rque of 30 ± 5 N·m (22 ± 4 lb ft ft).
).
7 2
er Gp 3. Again,
Again, tighte
tighten n bolt 1 through
through bolt 8 in the numerical
numerical sequ sequence
ence as shown in
Illustration
Illustratio n 32 to a torqu
torque e of 200 ± 15 N·m (148 ± 11 11 lb ft).
4. Again, retighte
retightenn bolt 1 throughbolt 8 in the numeric
numerical al sequ
sequence
ence as shown
in Illustration
Illustration 32 to a torque of 200 ± 15 N·m (148 ± 1 11
1 lb ft).
5. Turn
Turn bolt 1 through
through bolt 8 in the numnumerica
ericall sequ
sequence
ence to an angle of 180 ± 5
8 2 5B-0213 Bolt degrees as shown in Illustrat
Illustration
ion 32 .
6. Tighten
Tighten two bolts
bolts (8) only aft
after
er bolt 1 throu
throughgh bolt 8 have been given given the fi-
nal torque.
7. Tighten
Tighten two bolts
bolts (8) to 55 ± 10 N·m (41 ± 7 lb ft) ft)..

46 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
i04938343
Cylind
Cylinder
er Head
Head
SMCS
SMCS Code:
Code: 1100
Part
Part No.:
No.: 380-5795
S/N: YBB1–Up
Part
Part No.:
No.: 380-5795
S/N: YBC1–Up
Part
Part No.:
No.: 380-5795
S/N: JDE1–Up
Part
Part No.:
No.: 380-5795
S/N: JCY1–Up

RENR5057 47
Specificatio
Specifications
ns Sectio
Section
n
Table 27
Specification
Specification for 380-5795 Cyl
Cylind
inder
er Head
Head Gp

Specification
During
During installati
installation,
on, shrunk
shrunk the valve seat insert with reduce
reduced
d temp
temper
eratur
ature
e (Ref
(Referenc
erence
e
1 2 130-2607 Valve Seat Insert
temperature: −60° C (−76° F)) and ress the insert into the cylinder heads cocounterbore
unterbore..
Durin
During
g installati
installation,
on, shrunk
shrunk the valve seat inser
insertt with reduced
reduced temp
temper
eratur
ature
e (Ref
(Referenc
erence
e
temperature: −60° C (−76° F)) and ress the insert into the cylinder heads co counterbore
unterbore..
Before assembly,
assembly, apply high strength or high temperatureAnaerobic Flange Sealant to
3 5 3B-0645 Cup Plug
the bores.
Before assembly,
assembly, apply high strength or high temperatureAnaerobic Flange Sealant to
4 1 3B-0623 Cup Plug
the bores.
Before assembly,
assembly, apply high strstrength
ength or high temperatureAnaerobic Flange Sealant to
5 2 3B-0623 Cup Plug the bores.
Installat
Installation
ion depth (E) is 1.0 ± 0.5 mm (0.04 ± 0.02 inch).
inch).
Before assembly,
assembly, apply high strstrength
ength or high temperatureAnaerobic Flange Sealant to
6 2 3B-0623 Cup Plug the bores.
Installat
Installation
ion depth (D) is 9.0 ± 0.5 mm (0.35 ± 0.02 inch).
inch).

48 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Table 28

Specification
131-0420 Cylinder Head Fas- Use the followi

following
ng procedurein
procedurein orde
orderr to tight
tighten
en the bolts
bolts for the cylinder
cylinder head:
7 6
tener
tener Gp Referr Illus
Refe Illustrat
tration
ion 34 for bolt tigh
tightenin
teningg seque
sequence.
nce.
1. Before assembly,
assembly, apply clean engine
engine oil to the threads of the bolts.
131-0421 Cylinder Head Fas- 2. Tighten
Tighten bolt 1 through
through bolt 8 in the num
numeric
erical
al sequ
sequence
ence to 30 ± 5 N·m (22 ± 4 lb ft).
8 2
tener
tener Gp 3. Again,
Again, tighten
tighten bolt 1 through
numerica
ericall seque
sequence
nce to 200 ± 15 N·m
(148 ± 11 lb ft).
4. Again,
Again, retightenbolt
retightenbolt 1 through bolt 8 in the num numeric
ericalal sequ
sequence
ence to 200 ± 15 N·m
(148 ± 11 lb ft).
9 2 5B-0213 Bolt
5. Turn
Turn bolt 1 through
numerica
ericall seque
sequence
nce to an angle of 180 ± 5 degree
degrees s.
6. Tighten
Tighten two bolts
bolts (9) only after
after bolt 1 through
through bolt 8 have been givengiven the final torq
torque.
ue.
7. Tighten
Tighten two bolts
bolts (9)
(9) to 55 ± 10 N·
N·m
m (41 ± 7 lb ft)ft)..

RENR5057 49
Specificatio
Specifications
ns Sectio
Section
n
i04372705
Cylind
Cylinder
er Head
Head
SMCS
SMCS Code:
Code: 1100
Part
Part No.:
No.: 274-8568
S/N: PBR1–Up
Typical example
(1)Locatingpad
(1)Locatingpad
NOTICE
The pipe plug at locati
location
on (2) is install
installed
ed in the cylinder
head for engines with dry exhaust manifolds. If the
pipe plug is not installed into the water passage, the
coolant will leak and engine damage will result. For
engines with dry exhaust manifolds, make sure that
the pipe plug is installed.
Typical example (top view)
(3) Pipe p
plug
lug

50 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Table 29
Specification Cylinder
nder Head Gp, 299-3521 Cylinde
Cylinderr Head Gp, 332-9693 Cyli
Cylinder
nder Head Gp, 274-8568 Cyli
Cylinder
nder Head
Gp, 317-2441 Cyli
Cylinder
Cylinder
nder Head Gp, 285-3086 CylCylind
inder
er Head
Cylinder
er Hea
Head
d Gp

Specification
Before assembly,
assembly, lubricate the threads of the pipe plug.with 5P-3931 Anti-Seize
3 1 5B-7890 Pipe Plug
Compound.
A 1 - Heigh
Heightt of the new cylinder
cylinder head is 142.
142.00
00 ± 0.15 mm (5.591
(5.591 ± 0.00
0.006
6 inch).
inch).
Apply Anaerobic Flange Sealant to the bores of the cup plugs before assemb
assembly.
ly.
B 2 3b-0623 Cup Plug Installation
Installation depth of plugs from
from the top sur
surface
face of the cylin
cylinder
der head is
9.0 ± 0.5 mm
mm (0.3
(0.35
5 ± 0.02 inch)
inch)
Apply Anaerobic Flange Sealant to the bores of the cup plugs before assemb
assembly.
ly.
D 2 3b-0623 Cup Plug Installation
Installation depth of plugs from
from the top sur
surface
face of the cylin
cylinder
der head is
1.0 ± 0.5 mm
mm (0.0
(0.04
4 ± 0.02 inch)
inch)
Boltt Tight
Bol Tighteni
ening
ng Pro
Proced
cedure
ure
The cylind
cylinder
er head
head bol
boltt tighteni
tightening
ng proced
procedure
ure
de
depe
pend
ndss on wh
whicich
h cy
cylin
linde
derr head
head ga
gask
sket
et is used
used..
Refer to one of the following bolt tightening
procedures
procedures based on your cylinder head gasket.
Bolt Ti
Bolt Tigh
ghte
teni
ning
ng wi
with
th th
the
e 110-6991
Cylind
Cylinder
er Head
Head Gasket
Gasket
Use the following procedure
procedure when the 110-6991
Cylinder Head Gasket is installed.

RENR5057 51
Specificatio
Specifications
ns Sectio
Section
n
Table 30
Cylinder
Cylinder
nder Head
Gp, 317-2441 Cyli
Cylinder
Cylinder
inder
er Head
Cylinder
er Hea
Head
d Gp

Specification
131-0420 CylinderHead Fas- 1. Coat the threads

threads of the bolts with clean engin engine e oil.
6
ten
tener
er Gp 2. Tig
Tighten
hten bolt (1) (1) thro
through
ugh bolt (8(8)) in the nu
numeric
merical al seque
sequence nce to 30 ± 5 N·m
(22 ± 4 lb ft).
131-0421 CylinderHead Fas- 3. Tighten
Tighten bolt (1) (1) thro
through
ugh bolt (8(8)) in the nu
numeric
merical al seque
sequence nce to 200 ± 15 NN·m
·m
2
ten
tener
er Gp (150 ± 11 lb ft)
ft)..
4. Again tighten
tighten bolt (1) through
through bolt (8) in the numeric
numerical al sequ
sequence
ence to
-
200 ± 15 N·m (150 ± 1 11
1 lb ft).
5. Turn
Turn bolt (1) through
through bolt (8(8)) in the num
numerica
ericall sequ
sequence
ence to an additionalrota-
additionalrota-
2 5B-0213 Bolt tion of 180 ± 5 degrees.
Tighten
Tigh ten bolts (9)
(9) and (1 (10)
0) only a after
fter bolt (1)
(1) thro
through
ugh bolt ((8) 8) have be
been
en give
given
n the
final torq
torque.
ue.
6. Tighten
Tighten bolts (9) and (10) (10) to 55 ± 10 N·m (40 ± 7 lb ft) ft)..
Bolt Ti
Bolt Tigh
ghte
teni
ning
ng wi
with
th th
the
e 362-8264
Cylind
Cylinder
er Head
Head Gasket
Gasket
Use the following procedure
procedure when the 362-8264
Cylinder Head Gasket is installed.

52 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Table 31
Cylinder
Cylinder
nder Head
Gp, 317-2441 Cyli
Cylinder
Cylinder
inder
er Head
Cylinder
er Hea
Head
d Gp

Specification
131-0420 Cylin
Cylinder
der Head Fas- 1. Coat the threads
threads of the bolts with clean engin enginee oil.
6
ten
tener
er Gp 2. Ti
Tighte
ghten
n bolt (1)
(1) throu
through
gh bolt ((8)
8) in the nnumer
umerical
ical sequ
sequence
ence to a torque
torque of
30 ± 5 N·m (22 ± 4 lb ft) ft)..
131-0421 Cylin
Cylinder
der Head Fas- 3. Tighten
Tighten bolt (1)
(1) throu
through
gh bolt (8(8)) in the num
numeric
erical
al sequ
sequence
N·m
2
ten
tener
er Gp (75 ± 11 lb ft).
4. Tighten
Tighten bolt (1)
(1) throu
through
numeric
erical
al sequ
sequence
N·m
(330 ± 11 lb ft).
-
5. Loosen
Loosen bolt ((1)1) throu
through
gh bolt ((8)
8) in the num
numeric
erical
al sequ
sequence
ence for an angle o
off 90
± 5 degrees.
2 5B-0213 Bolt 6. Tighten
Tighten bolt (1)
(1) throu
through
numeric
erical
al sequ
sequence
N·m
(360 ± 11 lb ft).
Tig
Tighten
hten bolts
bolts (9) and (1 (10)
0) only a after
fter bolt (1) thro
through
ugh bolt (8) have been given fi-
nal torque.
7. Tighten
Tighten bolts (9)
(9) and (1
(10)0) to 55 ± 10 N·m (40 ± 7 lb ft) ft)..

RENR5057 53
Specificatio
Specifications
ns Sectio
Section
n
i04728230
Cylind
Cylinder
er Head
Head Valves
alves
SMCS
SMCS Code:
Code: 1105
Part
Part No.:
No.: 317-2440
S/N: GD31–Up
Part
Part No.:
No.: 317-2440
S/N: ZAD1–Up
Part
Part No.:
No.: 317-2440
S/N: ZAH1–Up
Part
Part No.:
No.: 317-2440
S/N: ZAJ1–Up
Part
Part No.:
No.: 317-2440
S/N: YAM1–Up
Part
Part No.:
No.: 317-2440
S/N: YAN1–Up
Part
Part No.:
No.: 317-2440
S/N: YAP1–Up
Part
Part No.:
No.: 317-2440
S/N: ZAP1–Up
Part
Part No.:
No.: 317-2440
S/N: ZBP1–Up
Part
Part No.:
No.: 317-2440
S/N: PBR1–Up
Part
Part No.:
No.: 317-2440
S/N: PDR1–Up
Part
Part No.:
No.: 317-2440
S/N: YAR1–Up
Part
Part No.:
No.: 317-2440
S/N: ZAR1–Up
Part
Part No.:
No.: 317-2440
S/N: ZBR1–Up
Part
Part No.:
No.: 317-2440
S/N: YAT1–Up
Part
Part No.:
No.: 317-2440
S/N: YBT1–Up
Part
Part No.:
No.:317-2440
S/N: YAW1–Up
Part
Part No.:
No.:317-2440
S/N: YBW1–Up
Part
Part No.:
No.: 317-2440
S/N: YAY1–Up
Part
Part No.:
No.: 317-2440
S/N: YAZ1–Up

54 RENR5057
Specificatio
Specifications
ns Sectio
Section
n

RENR5057 55
Specificatio
Specifications
ns Sectio
Section
n
Table 32
Specification
Cylinde
nderr Head
Cylinder
er Hea
Head
d Gp

Specification

Length forcee is 60.2
60.29
9 mm (2.374
(2.374 inch
inch).
).
1 4 316-5976 Spring Test fo
force
rce is 460
460 ± 23 N (103 ± 5 lb).
Free lengt
length
h after
after test is 74.8
74.8 mm (2.94
(2.94 inch).
inch).
Length
Lengt h under test force
force is 57.5
57.5 mm (2.2
(2.26
6 inch
inch).
).
2 4 316-5977 Spring Test for
force
ce is 248.0
248.0 ± 12.4 N (55.
(55.8
8 ± 2.8 lb).
Free lengt
lengthh after
after test is 71.4
71.4 mm (2.81
(2.81 inch).
inch).
Install the valve

valve stem
stem se
seal
al to the inlet valves.
3 2 316-5980 V
Valve
alve Stem Seal
Before assembly,
assembly, coat with
with engine oil.
4 2 316-5981 Wa
Washe
sherr Ins
Instal
talll the washer
washer to the exhaus
exhaustt valves
valves..
Heightt from the top of the cylinder

Heigh cylinder head to the top of the va
valve
lve guides
guides is
A - -
26.0 ± 1.0 mm
mm (1.0
(1.02
2 ± 0.04 inc
inch).
h).
Bore of the exhaust

exhaust valve
valve guide afte
afterr insta
installati
llation
on is 12.619 ± 0.025 mm
5 2 197-6995 Valve Guide
(0.4968
(0.4968 ± 0.001
0.0010
0 inch).
inch).
Bore of tthe
he inlet
inlet valv
valve
e gu
guide
ide afte
afterr installatio
installation
n is 9.
9.487
487 ± 0.
0.025
025 mm
(0.3735 ± 0.001
(0.3735 0.0010 0 inch).
inch).
Before assembly,
assembly, coat the exha
exhaust
ust valve st
stems
ems with clean engine oil.
Stem diameter
diameter (B) is 12.464
12.464 ± 0.025
0.025 mm (0.4907
(0.4907 ± 0.
0.0010
0010 inch)
inch)..
7 2 194-4897 Exhaus
Exhaustt Valve
Valve diam
diameter
eter (D) is 56.00
56.00 ± 0.15
0.15 mm (2.205
(2.205 ± 0.006
0.006 inch).
inch).
Face angle is 44.40
44.40 ± 0.25 degrees.
Before assembl
Before assembly y, coat the inlet valv
valve
e stems with clean engi
engine
ne oil.
Stem
Stem diamet
diameter
er (C)is 9.4
9.441
41 ± 0.01
0.0100 mm (0.
(0.371
37177 ± 0.00
0.0004
04 inch).
inch).
8 2 210-2542 Inlet Valve
Valve diamet
diameter
er (E) is 56.00
56.00 ± 0.15 m mmm (2.2
(2.205
05 ± 0.006
0.006 inch).
inch).
Face angle is 19.40
19.40 ± 0.25 degrees.
Diameter of exhaust
exhaust valve seseat
at insert is 60.119
60.119 ± 0.015 mm
(2.3669 ± 0.000
(2.3669 0.0006 6 inch).
inch).
Bore in the
the cy
cylinde
linderr head is 60
60.000
.000 ± 0.025
0.025 mm (2.3622
(2.3622 ± 0.
0.0010
0010 inch)
inch)..
Face angle is 45.00
45.00 ± 0.25 degrees.
Diameterof
Diam eterof inlet valve seat inser
insertt is 60
60.627
.627 ± 0.015
0.015 mm (2.3869
(2.3869 ± 0.0
0.0006
006 inch)
inch)..
10 2 130-2607 Valve Seat Insert Bore in the
the cy
cylinde
linderr head is 60
60.508
.508 ± 0.025
0.025 mm (2.3822
(2.3822 ± 0.
0.0010
0010 inch)
inch)..
Face angle is 20.00
20.00 ± 0.25 degrees.

56 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
i04935314
Cylind
Cylinder
er Head
Head Valves
alves
SMCS
SMCS Code:
Code: 1105
Part
Part No.:
No.: 380-5795
S/N: YBB1–Up
Part
Part No.:
No.: 380-5795
S/N: YBC1–Up
Part
Part No.:
No.: 380-5795
S/N: JDE1–Up
Part
Part No.:
No.: 380-5795
S/N: JCY1–Up

RENR5057 57
Specificatio
Specifications
ns Sectio
Section
n
Table 33
Specification
Specification for 380-5795 Cyl
Cylind
inder
er Head
Head Gp

Specification

Length forcee is 60.2
60.29
9 mm (2.374
(2.374 inch
inch).
).
1 4 316-5976 Spring Test fo
force
rce is 460
460 ± 23 N (103 ± 5 lb).
Free lengt
length
h after
after test is 74.8
74.8 mm (2.94
(2.94 inch).
inch).
Length
Lengt h under test force
force is 57.5
57.5 mm (2.2
(2.26
6 inch
inch).
).
2 4 316-5977 Spring Test for
force
ce is 248.0
248.0 ± 12.4 N (55.
(55.8
8 ± 2.8 lb).
Free lengt
lengthh after
after test is 71.4
71.4 mm (2.81
(2.81 inch).
inch).
3 2 316-5980 V
Valve
alve Stem
Stem Seal Install
Install the valve
valve stem
stem seal
seal to the in
inlet
let valve
valves.
s.
Heigh
Heightt from the top of the cylin
cylinder
der head to the top of the valv
valve
e guide
guides
s is
B - -
26.0 ± 1.0 mm
mm (1.0
(1.02
2 ± 0.04 inc
inch).
h).
Bore of the exhaust

exhaust valve
valve guide afte
afterr insta
installati
llation
on is 12.619 ± 0.025 mm
(0.4968
(0.4968 ± 0.001
0.0010
0 inch).
inch).
Bore of tthe
he inlet
inlet valv
valve
e gu
guide
ide afte
afterr installatio
installation
n is 9.
9.487
487 ± 0.
0.025
025 mm
(0.3735
(0.3735 ± 0.001
0.0010 0 inch).
inch).
Diameter of exhaust
exhaust valve seseat
at insert is 60.119
60.119 ± 0.015 mm
(2.3669 ± 0.000
(2.3669 0.0006 6 inch).
inch).
Bore in the
the cy
cylinde
linderr head is 60
60.000
.000 ± 0.025
0.025 mm (2.3622
(2.3622 ± 0.
0.0010
0010 inch)
inch)..
Face angle is 45.00
45.00 ± 0.25 degrees.
Diameterof
Diam eterof inlet valve seat inser
insertt is 60
60.627
.627 ± 0.015
0.015 mm (2.3869
(2.3869 ± 0.0
0.0006
006 inch)
inch)..
7 2 130-2607 Valve Seat Insert Bore in the
the cy
cylinde
linderr head is 60
60.508
.508 ± 0.025
0.025 mm (2.3822
(2.3822 ± 0.
0.0010
0010 inch)
inch)..
Face angle is 20.00
20.00 ± 0.25 degrees.

58 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Table 34

Specification
Before assembly,
assembly, coat the exha
exhaust
ust valve st
stems
ems with clean engine oil.
Stem diamet
Stem diameter
er (C)is 12.
12.464±
464± 0.0
0.025
25 mm (0.
(0.490
49077 ± 0.00
0.0010
10 inch).
inch).
8 2 194-4897 Exhaus
Exhaustt Valve
Valve diamet
diameter
er (E) is 56.00
56.00 ± 0.15 m
mmm (2.2
(2.205
05 ± 0.006
0.006 inch).
inch).
Face angle is 45.60
45.60 ± 0.25 degrees.
Before assembl
Before assemblyy, coat the inlet valv
valve
e stems with clean engi
engine
ne oil.
Stem
Stem diamet
diameter
er (D)is 9.4
9.441
41 ± 0.01
0.0100 mm (0.
(0.371
37177 ± 0.00
0.0004
04 inch).
inch).
9 2 210-2542 Inlet Valve
Valve diam
diameter
eter (F) is 56.
56.00
00 ± 0.15
0.15 mm (2.205
(2.205 ± 0.006
0.006 inch).
inch).
Face angle is 19.40

19.40 ± 0.25 degrees.
10 2 316-5981 Wa
Washe
sherr Ins
Instal
talll the washer
washer to the exhaus
exhaustt valves
valves..

RENR5057 59
Specificatio
Specifications
ns Sectio
Section
n
i04758986
Turb
urboch
ocharg
arger
er Oil Lines
Lines
SMCS
SMCS Code:
Code: 1052; 1307
Part
Part No.:
No.: 111-3424
S/N: GD31–Up
Typical example
Front view of en
engine
gine
Typical example
Rear view of engine

60 RENR5057
Specificatio
Specifications
ns Sectio
Section
n
Table 35
Specification
Specification for 111-3424 Turboc
urbocharg
harger
er Oil Lines Gp, 101-1255 Turb
urboch
ocha
arge
rgerr OilLines Gp, and 272-6983 Turboc
urbocharge
hargerr Oil Lines
Gp

Befo
Before
re assembl
assembly
y, apply Loct
Loctite
ite C5A Copper
Copper Anti
Anti-Seiz
-Seize
e to the threa
threads
ds and the beari
bearing
ng surfaces
surfaces
1 - -
of bolts.
Befo
Before
re assembl
assembly
y, lightly
lightly lubricate
lubricate the bore for the O-ring
O-ring seals with the lubri
lubricant
cant that is being
2 - - sealed.

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The hazards are identified

The message that appears under the warnin

Failure to heed this warning can lead to prema-

Water Lines.......................... ......................... 196 Flywheel ........................... ............................ 313

Index............................... .............................. 434

Compression ratio .........................

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

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

Compression ratio .........................

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

When the crankshaft

S/N: JCY1–Up S/N: JDE1–Up

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

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

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

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

When the crankshaft

Note: The front end of the engine is opposite the

Item Qty Part Specification Description

1 1 7N-1628 Nut Torqu

Item Qty Part Specification description

6 1 1N-2895 Spring Test fo

Item Qty Part Specification Description

Item Qty Part Specification description

2 1 1N-2895 Spring Test fo

Item Qty Part Specification Description

Item Qty Part Specification Description

Item Qty Part Specification Description

Item Qty Part Specification Description

1 1 317-1121 Jam Nut Torque to 120 ± 15 N·m (89 ± 11 lb ft).

(22.13 ± 2.21 lb in).

Apply black Loctite

Bore of the bush

Item Qty Part Specification Description

1 2 3J-9196 Jam Nut Torque to 70 ± 15 N·m (52 ± 11 lb ft).

Torque to 2.50 ± 0.25

3 1 317-1121 Jam Nut Torque to 120 ± 15 N·m (89 ± 11 lb ft).

Length under test forc

6 2 334-1626 Bolt If the bolt is remo

Item Qty Part Specification

9 1 234-2273 Rocker Arm Shaft Diameter

If the bolt is removed

Bore of the bushing

Bore of the bushing

Item Qty Part Specification Descrip

1 1 7F-8698 Bolt Torqu

Item Qty Part Specification Descrip

Use the following

2 1 7F-8698 Bolt Torqu

Use the following

Item Qty Part Specification Descrip

Use the following

2 1 7F-8698 Bolt Torqu

Use the following

Item Qty Part Specification Description

Thickness of the groove in a new camshaft assembly is 8.75 ± 0.05 mm

C 1 5B-5821 Dowel Exte

D 2 7N-3218 Thrust Washer Thick

Diameter of bearing journals for a new cam

- - - End play for a new cams

3 16 5P-0076 Bolt Torque to 55 ± 7 N·m (41 ± 5 lb ft).

F 1 4N-1650 Dowel Exte

Item Qty Part Specification Description