Specifications PDF

RENR2387-15
April 2009
Specifications
C18 Marine and Auxiliary Marine
Generator Set Engines
WKB1-Up (Engine)
PLE1-Up (Engine)
CKH1-Up (Engine)
C1J1-Up (Engine)
J2K1-Up (Engine)
CYN1-Up (Engine)
GEN1-Up (Engine)
P1N1-Up (Engine)
P2N1-Up (Engine)
T2P1-Up (Engine)
GES1-Up (Engine)
MGS1-Up (Generator Set)
KJT1-Up (Engine)
JKX1-Up (Engine)
NAX1-Up (Engine)
NAY1-Up (Engine)
GPN1-Up (Engine)
SAFETY.CAT.COM
i01658146
Important Safety Information

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

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

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

ture failures, product damage, personal injury or
death.
RENR2387-15 3
Table of Contents
Table of Contents Alternator and Regulator ......................................

Coolant Temperature Sensor ...............................
63
64
Coolant Temperature Sensor ............................... 64
Coolant Temperature Sensor ............................... 65
Specifications Section Coolant Level Sensor ........................................... 65
Fuel Temperature Sensor ..................................... 65
Engine Design ....................................................... 4
Fuel Temperature Sensor ..................................... 66
Fuel Transfer Pump ............................................... 4
Fuel Pressure Sensor .......................................... 66
Fuel Transfer Pump ............................................... 5
Engine Oil Pressure Sensor ................................. 66
Fuel Filter Base ...................................................... 6
Boost Pressure Sensor ......................................... 66
Fuel Filter Base ...................................................... 7
Atmospheric Pressure Sensor .............................. 67
Fuel Filter Base ...................................................... 8
Inlet Air Temperature Sensor ................................ 67
Electronic Unit Injector Mechanism ....................... 8
Inlet Air Temperature Sensor ................................ 68
Electronic Unit Injector Rocker Arm ........................ 9
Speed/Timing Sensor .......................................... 69
Valve Mechanism ................................................. 10
Tachometer .......................................................... 70
Valve Mechanism Cover ...................................... 10
Tachometer Calibration Chart ............................... 70
Cylinder Head Valves ............................................ 11
Circuit Breakers ................................................... 71
Cylinder Head ...................................................... 13
Circuit Breakers ................................................... 72
Turbocharger ........................................................ 16
Turbocharger ........................................................ 17
Exhaust Manifold ................................................. 18 Index Section
Exhaust Manifold ................................................. 20
Camshaft ............................................................. 21 Index ..................................................................... 73
Camshaft ............................................................. 22
Camshaft ............................................................. 23
Engine Oil Filter Base .......................................... 24
Engine Oil Pump .................................................. 27
Engine Oil Pump .................................................. 28
Engine Oil Pan ..................................................... 29
Engine Oil Pan ..................................................... 30
Engine Oil Pan ..................................................... 31
Engine Oil Pan ..................................................... 31
Water Temperature Regulator .............................. 32
Water Pump ......................................................... 33
Auxiliary Water Pump .......................................... 34
Auxiliary Water Pump .......................................... 35
Heat Exchanger .................................................... 37
Heat Exchanger .................................................... 38
Cylinder Block ...................................................... 39
Cylinder Liner ....................................................... 41
Crankshaft ........................................................... 42
Vibration Damper and Pulley ............................... 43
Connecting Rod Bearing Journal ......................... 45
Main Bearing Journal ............................................ 46
Connecting Rod ................................................... 47
Piston and Rings .................................................. 48
Housing (Front) ..................................................... 49
Front Housing and Covers ................................... 50
Gear Group (Front) ............................................... 51
Gear Group (Front) ............................................... 53
Flywheel ............................................................... 55
Flywheel ............................................................... 55
Flywheel ............................................................... 56
Flywheel Housing ................................................ 56
Flywheel Housing ................................................ 57
Belt Tension Chart ............................................... 58
Alternator and Regulator ...................................... 60
4 RENR2387-15
Specifications Section
Specifications Section Part No.: 295-9260

S/N: WKB1-Up
i03526822
Part No.: 295-9260
S/N: PLE1-Up
Engine Design Part No.: 295-9260
SMCS Code: 1201 S/N: CKH1-Up
Part No.: 295-9260
C18 S/N: C1J1-Up
Part No.: 295-9260
S/N: J2K1-Up
Part No.: 295-9260
S/N: CYN1-Up
Part No.: 295-9260
S/N: GEN1-Up
Part No.: 295-9260
S/N: P1N1-Up
Part No.: 295-9260
S/N: P2N1-Up
Illustration 1
g01611394 Part No.: 295-9260
S/N: T2P1-Up
(A) Inlet
(B) Exhaust Part No.: 295-9260
(1) Flywheel end of engine
(2) Cylinder number
S/N: GES1-Up
Part No.: 295-9260
Bore ........................................... 145 mm (5.71 inch) S/N: KJT1-Up
Stroke ........................................ 183 mm (7.20 inch) Part No.: 295-9260
S/N: NAX1-Up
Displacement ............................... 18.1 L (1105 cu in)
Part No.: 295-9260
Cylinder arrangement ................... In-line six cylinder S/N: NAY1-Up
Valves per cylinder .................................................. 4 Part No.: 295-9260

S/N: MGS1-Up; GPN1-Up
Inlet valve lash ................................. 0.38 ± 0.08 mm
(0.015 ± 0.003 inch)
Exhaust valve lash ........................... 0.76 ± 0.08 mm

(0.030 ± 0.003 inch)
Firing order (injection sequence) ........ 1, 5, 3, 6, 2, 4
Crankshaft rotation from the flywheel

end ................................................ Counterclockwise
Note: The front end of the engine is opposite the

flywheel end. The left side and the right side of the
engine are viewed from the flywheel end. The No. 1
cylinder is the front cylinder. g01412636
Illustration 2
(1) Weep hole
i03001161 (2) Pressure regulating valve
(3) Inlet port
Fuel Transfer Pump (4) Outlet port
SMCS Code: 1256 When the fuel transfer pump is using diesel fuel, the
fuel transfer pump has the following specifications:
RENR2387-15 5
1. Run the pump at 2940 rpm. The full bypass Part No.: 290-8866, 292-5906
pressure should be 716 to 786 kPa (104 to 114 psi). S/N: KJT1-Up
2. Run the pump at 840 rpm. The flow at 550 kPa Part No.: 290-8866, 292-5906
(80 psi) must be 3.0 L/min (0.8 US gpm). S/N: NAX1-Up
Part No.: 290-8866, 292-5906
3. Run the pump at 2940 rpm. The flow at 650 kPa
S/N: NAY1-Up
(94 psi) must be 4.5 L/min (1.19 US gpm).
Part No.: 290-8866, 292-5906
4. Run the pump at 120 rpm. Keep the inlet open to S/N: MGS1-Up; GPN1-Up
the atmosphere for 10 seconds. Block the inlet.
The pump must maintain the vacuum of 30 kPa
(4.5 psi) minimum in 30 seconds.
5. Run the pump at 840 rpm. Keep the inlet open to

the atmosphere for 10 seconds. Block the inlet.
The pump must maintain the vacuum of 45 kPa
(6.5 psi) minimum in 30 seconds.
6. Run the pump at 120 rpm with a blocked inlet for

30 seconds. The pump inlet must have a suction
lift of 60.9 kPa (9 psi) minimum.
When the pump is viewed from the drive end, the

rotation of the pump is counterclockwise.
i02647766
Fuel Transfer Pump

SMCS Code: 1256
g01328715
Illustration 3
Part No.: 290-8866, 292-5906
S/N: WKB1-Up
Part No.: 290-8866, 292-5906
S/N: PLE1-Up
Part No.: 290-8866, 292-5906
S/N: CKH1-Up
Part No.: 290-8866, 292-5906
S/N: C1J1-Up
Part No.: 290-8866, 292-5906
S/N: J2K1-Up
Part No.: 290-8866, 292-5906
S/N: CYN1-Up
Part No.: 290-8866, 292-5906
S/N: GEN1-Up
Part No.: 290-8866
S/N: P1N1-Up
Part No.: 290-8866, 292-5906 Illustration 4
g01328716
S/N: P2N1-Up
(1) Pressure regulating valve
Part No.: 290-8866, 292-5906
S/N: T2P1-Up (2) Inlet port
Part No.: 290-8866, 292-5906
S/N: GES1-Up (3) Weep hole
(4) Outlet port

6 RENR2387-15
When the fuel transfer pump is using diesel fuel, the i02650012
fuel transfer pump has the following specifications.
Fuel Filter Base
Run the pump at 2940 rpm. The full bypass pressure
should be the following value. ........... 716 to 786 kPa SMCS Code: 1261; 1262
(104 to 114 psi)
Part No.: 8H-7204
S/N: WKB1-Up
Run the pump at 840 rpm. The flow at 550 kPa
(80 psi) must be 3.0 L/min (0.8 US gpm). Part No.: 8H-7204
S/N: PLE1-Up
Run the pump at 2940 rpm. The flow at 650 kPa
(94 psi) must be 4.5 L/min (1.19 US gpm). Part No.: 8H-7204
S/N: CKH1-Up
When the pump is viewed from the drive end the
rotation of the pump is counterclockwise. Part No.: 8H-7204
S/N: C1J1-Up
Part No.: 8H-7204
S/N: J2K1-Up
Part No.: 8H-7204
S/N: CYN1-Up
Part No.: 8H-7204
S/N: GEN1-Up
Part No.: 8H-7204
S/N: T2P1-Up
Part No.: 8H-7204
S/N: GES1-Up
Part No.: 8H-7204
S/N: KJT1-Up
Part No.: 8H-7204
S/N: JKX1-Up
Part No.: 8H-7204
g01328708
Illustration 5 S/N: MGS1-Up; GPN1-Up
Cover opposite the fuel transfer pump
(5) Apply 154-9731 Thread Lock Compound to the

threads of the studs.
(6) Tighten the nuts to the following

torque. ........................... 30 ± 5 N·m (22 ± 4 lb ft)
g01330431
Illustration 6
(1) Torque for nut ................ 25 ± 4 N·m (18 ± 3 lb ft)

RENR2387-15 7
i02699060
Fuel Filter Base

SMCS Code: 1261; 1262
Part No.: 127-0291
S/N: WKB1-Up
Part No.: 127-0291
S/N: PLE1-Up
Part No.: 127-0291
S/N: CKH1-Up
Part No.: 127-0291
S/N: C1J1-Up
Part No.: 127-0291
S/N: J2K1-Up
Part No.: 127-0291
S/N: CYN1-Up
g01365334
Illustration 8
Part No.: 127-0291
Section A-A
S/N: GEN1-Up
Part No.: 127-0291 (A) Apply 154-9731 Thread Lock Compound on the
S/N: T2P1-Up tapered end of the hollow stud to the following
distance. ........... 7.7 ± 0.8 mm (0.30 ± 0.03 inch)
Part No.: 127-0291
S/N: GES1-Up (B) Distance from the sealing surface of the filter base
to the end of the hollow stud ........ 24.6 ± 1.3 mm
Part No.: 127-0291 (0.97 ± 0.05 inch)
S/N: KJT1-Up
Part No.: 127-0291 (1) Torque for the hollow stud ............... 70 ± 15 N·m
S/N: MGS1-Up; GPN1-Up (50 ± 11 lb ft)
i03288121
Fuel Filter Base

SMCS Code: 1261; 1262
Part No.: 6N-6259
S/N: WKB1-Up
Part No.: 6N-6259
S/N: PLE1-Up
Part No.: 6N-6259
S/N: CKH1-Up
Part No.: 6N-6259
S/N: C1J1-Up
Part No.: 6N-6259
S/N: J2K1-Up
Part No.: 6N-6259
g01330577
Illustration 7 S/N: CYN1-Up
Fuel filter base
Part No.: 6N-6259
S/N: GEN1-Up
Part No.: 6N-6259
S/N: P1N1-Up
8 RENR2387-15
Part No.: 6N-6259 distance. ........................................ 7.6 ± 0.8 mm

S/N: P2N1-Up (0.30 ± 0.03 inch)
Part No.: 6N-6259 (B) Distance from the sealing surface of the filter
S/N: T2P1-Up base to the end of the hollow stud .. 25 ± 1.6 mm
(0.98 ± 0.06 inch)
Part No.: 6N-6259
S/N: GES1-Up
(1) Torque for hollow studs .............. 68.0 ± 13.5 N·m
Part No.: 6N-6259 (50 ± 10 lb ft)
S/N: KJT1-Up
Part No.: 6N-6259 i03086662
S/N: NAX1-Up
Electronic Unit Injector
Part No.: 6N-6259
S/N: NAY1-Up
Mechanism
Part No.: 6N-6259 SMCS Code: 1290
S/N: MGS1-Up; GPN1-Up Part No.: 190-0009
g01330386
Illustration 9
Fuel filter base
g01568313
Illustration 11
(4) Spacer
(5) Unit injector clamp
Note: Before installation of the unit injector, lubricate

two O-ring seals (6) with a 50/50 mixture of clean
engine oil and 8T-2998 Lubricant.
Note: Refer to Testing and Adjusting, “Electronic Unit

Injector - Adjust” for the correct procedure for setting
the lash on the electronic unit injector.
(1) Torque for the cap nut ................ 2.50 ± 0.25 N·m
(22 ± 2 lb in)
(A) Adjust the unit injector height to the following

g01365315
dimension. ...... 78.0 ± 0.2 mm (3.07 ± 0.01 inch)
Illustration 10
Section A-A (2) Torque for the locknut for the adjustment screw
................................... 100 ± 10 N·m (75 ± 7 lb ft)
(A) Apply 154-9731 Thread Lock Compound on the
tapered end of the hollow stud to the following Use the following procedure to tighten the bolt (3):
RENR2387-15 9
1. Tighten the bolt to 55 ± 10 N·m (41 ± 7 lb ft).
2. Loosen the bolt until the bolt is finger tight.
3. Again, tighten the bolt to 55 ± 10 N·m (41 ± 7 lb ft).
i02794899
Electronic Unit Injector Rocker

Arm
SMCS Code: 1123
Part No.: 203-8824
g01401981
Illustration 13
View A-A
Typical example
(3) Bearing joint
(B) Bore
New parts ............................ 40.065 ± 0.015 mm
(1.5774 ± 0.0006 inch)
Maximum dimension for worn parts .. 40.193 mm
(1.5824 inch)
(C) Bearing for the rocker arm and the pin must not
extend beyond either face of the rocker arm.
g01395736
Illustration 12
Typical example
(1) Shaft assembly
(2) Rocker arm
10 RENR2387-15
i03016667 Note: Refer to Testing and Adjusting, “Engine Valve

Lash - Inspect/Adjust” for the correct procedure on
Valve Mechanism setting the engine valve lash.
SMCS Code: 1102
i01765227
Part No.: 190-0009
Valve Mechanism Cover
SMCS Code: 1107
Part No.: 187-3316, 250-9990
S/N: WKB1-Up
Part No.: 187-3316
S/N: PLE1-Up
Part No.: 187-3316
S/N: CKH1-Up
Part No.: 187-3316, 250-9990
S/N: C1J1-Up
Part No.: 187-3316, 250-9990
S/N: J2K1-Up
Part No.: 187-3316, 250-9990
S/N: GEN1-Up
Part No.: 187-3316, 250-9990
Illustration 14
g01246863 S/N: P1N1-Up
(1) Rocker arm Part No.: 187-3316, 250-9990
(4) Camshaft
(6) Valve bridge
S/N: P2N1-Up
Part No.: 187-3316, 250-9990
(2) Torque for the adjustment nuts .......... 30 ± 7 N·m S/N: T2P1-Up
(22 ± 5 lb ft)
Part No.: 187-3316, 250-9990
(3) Rocker shaft S/N: GES1-Up
Diameter of a new rocker Part No.: 187-3316, 250-9990
shaft ..................................... 40.000 ± 0.010 mm S/N: KJT1-Up
(1.5748 ± 0.0004 inch)
Bore in the rocker arm for rocker Part No.: 187-3316
shaft ..................................... 40.065 ± 0.015 mm S/N: JKX1-Up
(1.5774 ± 0.0006 inch)
Part No.: 187-3316, 250-9990
Maximum dimension for the bore of the rocker
S/N: NAX1-Up
arm for the rocker arm shaft ............. 40.193 mm
(1.5824 inch) Part No.: 187-3316, 250-9990
S/N: NAY1-Up
Note: For engines that are equipped with variable
valve actuators, refer to Specifications, “Variable Part No.: 187-3316, 250-9990, 276-7321
valve Actuator” for information on installation of the S/N: MGS1-Up; GPN1-Up
rocker arm assembly.
Note: For engines that are equipped with CAT

Compression Brakes, refer to Specifications, “CAT
Compression Brake” for the correct procedure on
installation of the rocker arm assembly.
(5) Location for checking the valve lash

Inlet valves ................................. 0.38 ± 0.08 mm
(0.015 ± 0.003 inch)
Exhaust valves .......................... 0.76 ± 0.08 mm
(0.030 ± 0.003 inch)
RENR2387-15 11
Part No.: 223-9250

S/N: CKH1-Up
Part No.: 223-9250
S/N: C1J1-Up
Part No.: 223-9250
S/N: J2K1-Up
Part No.: 223-9250
S/N: CYN1-Up
Part No.: 223-9250
S/N: GEN1-Up
Part No.: 223-9250
g00903076
Illustration 15 S/N: P1N1-Up
Valve mechanism cover
Part No.: 223-9250
S/N: P2N1-Up
Part No.: 223-9250
S/N: T2P1-Up
Part No.: 223-9250
S/N: GES1-Up
Part No.: 223-9250
S/N: KJT1-Up
Part No.: 312-8347
S/N: JKX1-Up
Part No.: 223-9250
S/N: NAX1-Up
Part No.: 223-9250
S/N: NAY1-Up
Part No.: 223-9250
g00285630
Illustration 16
Tightening Sequence For Valve Cover And Base
Note: Apply 4C-4030 Thread Lock Compound to

the bolts that fasten the wiring for the electronic unit
injectors to the valve cover base.
(1) Torque for bolts .............. 18 ± 3 N·m (13 ± 2 lb ft)
Note: The valve cover seal and the cover base seal
are cut to size at assembly. Coat seal joints with
3S-6252 Sealant.
i02997793
Cylinder Head Valves

SMCS Code: 1105
Part No.: 223-9250
S/N: WKB1-Up g01397685
Illustration 17
Part No.: 223-9250
S/N: PLE1-Up Note: Apply clean engine oil to the valve stems prior
to installation in the cylinder head.
12 RENR2387-15
(1) 247-9908 Spring Inlet ........... 4.00 ± 0.20 mm (0.158 ± 0.008 inch)
Exhaust ..... 3.56 ± 0.20 mm (0.140 ± 0.008 inch)
Length under test force ... 67.12 mm (2.643 inch)
Test force .................... 320 ± 25 N (71.9 ± 5.6 lb) Note: Refer to Reuse And Salvage Guidelines,
Approximate free length after test ...... 76.70 mm SEBF8034 for additional information for the valves
(3.020 inch) and the valve springs.
Outside diameter ................ 36.3 mm (1.43 inch)
(H) Overall length of valve
(2) 211-3122 Spring
Inlet ....... 202.00 ± 0.45 mm (7.953 ± 0.018 inch)
Length under test force ... 60.14 mm (2.368 inch) Exhaust .. 202.06 ± 0.45 mm (7.955 ± 0.018 inch)
Test force .................... 150 ± 12 N (33.7 ± 2.7 lb)
Approximate free length after test ...... 71.70 mm
(2.823 inch)
Outside diameter ............ 25.17 mm (0.991 inch)
(A) Height to top of valve guide ..... 35.00 ± 0.50 mm

(1.378 ± 0.020 inch)
(B) Bore of installed new valve

guide .. 9.502 ± 0.013 mm (0.3741 ± 0.0005 inch)
Note: Do not use a combination of a valve and

a valve guide that has a difference of 0.13 mm
(0.005 inch) or more.
(C) Dimension for valve recess Illustration 19

g01401267
Inlet .......... 2.20 to 2.80 mm (0.087 to 0.110 inch)

(J) Width of the valve seat
Exhaust ... 1.20 to 1.80 mm (0.047 to 0.071 inch)
Inlet ............................... 2.377 mm (0.0936 inch)
Exhaust ......................... 1.508 mm (0.0594 inch)
(K) Depth of bore in the cylinder head for the valve

seat insert
Inlet ......... 14.00 ± 0.05 mm (0.551 ± 0.002 inch)
Exhaust ... 13.90 ± 0.05 mm (0.547 ± 0.002 inch)
(L) Inside diameter of valve seat insert

Inlet ......... 41.00 ± 0.50 mm (1.614 ± 0.020 inch)
Exhaust ... 36.50 ± 0.50 mm (1.437 ± 0.020 inch)
(M) Angle of valve seat face

g01401264
Illustration 18
Inlet ................................... 30.25 ± 0.25 degrees
Exhaust ............................. 45.25 ± 0.25 degrees
(D) Dimension for valve face angle
Inlet ................................... 60.75 ± 0.25 degrees (N) Outside diameter of valve seat insert
Exhaust ............................. 45.75 ± 0.25 degrees
Inlet .. 48.025 ± 0.013 mm (1.8907 ± 0.0005 inch)
Exhaust ................................ 42.840 ± 0.013 mm
(E) Dimension for valve stem diameter
(1.6866 ± 0.0005 inch)
New valve stem diameter ...... 9.427 ± 0.010 mm Diameter of the bore in the cylinder head for the
(0.3711 ± 0.0004 inch)
valve seat insert
Minimum recommended valve stem
diameter ........................ 9.309 mm (0.3665 inch) Inlet .. 47.950 ± 0.025 mm (1.8878 ± 0.0010 inch)
Exhaust ................................ 42.774 ± 0.025 mm
(F) Diameter of valve head (1.6840 ± 0.0010 inch)
Inlet ......... 47.00 ± 0.13 mm (1.850 ± 0.005 inch)

Exhaust ... 41.81 ± 0.13 mm (1.646 ± 0.005 inch)
(G) Dimension for valve lip thickness

RENR2387-15 13
i02873801
Cylinder Head
SMCS Code: 1100
Part No.: 272-9707
S/N: WKB1-Up
Part No.: 272-9707
S/N: PLE1-Up
Part No.: 272-9707
S/N: CKH1-Up
Part No.: 272-9707
S/N: C1J1-Up
Part No.: 272-9707
S/N: J2K1-Up
Part No.: 272-9707
S/N: CYN1-Up
Part No.: 272-9707
S/N: GEN1-Up
Part No.: 234-9216
S/N: P1N1-Up
Part No.: 234-9216
S/N: P2N1-Up
Part No.: 272-9707
S/N: T2P1-Up
Part No.: 272-9707
S/N: GES1-Up
Part No.: 272-9707
S/N: KJT1-Up
Part No.: 312-1183
S/N: JKX1-Up
Part No.: 234-9216
S/N: NAX1-Up
Part No.: 234-9216
S/N: NAY1-Up
Part No.: 272-9707
14 RENR2387-15
g01430706
Illustration 20
Cylinder head
The following bolts are 216 mm (8.5 inch) long: 11, Note: The flatness of the cylinder head should be
12, 13, 14, 16, 18, 20, 22, 24, and 26. The following within a total of 0.13 mm (0.005 inch). Also, the
bolts are 198.8 ± 1.0 mm (7.83 ± 0.04 inch) long: 2, flatness of the cylinder head should be within a
8, and 10. The rest of the bolts are 194 mm (7.6 inch) maximum of 0.05 mm (0.002 inch) for any 150 mm
long. (5.9 inch) span.
Apply 6V-4876 Lubricant to the bolt threads and

both sides of the washers. Tighten the bolts in the
following step sequence:
1. In a numerical sequence, tighten bolts 1 through

26.
Torque for bolts ............................... 270 ± 15 N·m

(200 ± 11 lb ft)
2. In a numerical sequence, tighten bolts 1 through

26.

(330 ± 11 lb ft)
3. In a numerical sequence, again tighten bolts 1

through 26.

(330 ± 11 lb ft) g01430707
Illustration 21
(A) Cylinder Head Thickness

RENR2387-15 15
Thickness of a new cylinder Orientation of bearing joint

head ....................................... 120.00 ± 0.15 mm (B) ..................................... 20° ± 5° above horizontal
(4.724 ± 0.006 inch)
Minimum thickness of a used cylinder
head ................................................... 119.50 mm
(4.705 inch)
g01430714
Illustration 24
The depth of installation of the camshaft bearings is

very important. Install bearings (30) to the following
depths:
Installation depth for camshaft bearings (30)

C ....................... 8.0 ± 0.5 mm (0.32 ± 0.02 inch)
D ................... 178.1 ± 0.5 mm (7.01 ± 0.02 inch)
E ................. 349.5 ± 0.5 mm (13.76 ± 0.02 inch)
g01430709
Illustration 22 F ................. 521.0 ± 0.5 mm (20.51 ± 0.02 inch)
(27) Oil gallery G ................. 692.4 ± 0.5 mm (27.26 ± 0.02 inch)
(28) Bearing joint H ................. 863.8 ± 0.5 mm (34.01 ± 0.02 inch)
(29) Oil holes I ................. 1035.3 ± 0.5 mm (40.76 ± 0.02 inch)
(30) Camshaft bearing
NOTICE
Camshaft bearings must be installed into their correct
position. Failure to do so will result in engine damage.
g01430712
Illustration 23
(28) Bearing joint
(29) Oil holes
16 RENR2387-15
i02946141
Turbocharger
SMCS Code: 1052
Part No.: 201-7252
S/N: PLE1-Up
Part No.: 201-7252
S/N: CKH1-Up
Part No.: 201-7252
S/N: CYN1-Up
Part No.: 201-7252
S/N: GEN1-Up
Part No.: 201-7252
S/N: P2N1-Up
Part No.: 201-7252
S/N: GES1-Up
g01460237
Illustration 26
Part No.: 201-7252
Typical example
S/N: KJT1-Up
Part No.: 278-2399, 278-2400 Use the following procedure to tighten the compressor
S/N: JKX1-Up clamp assembly (2) and the turbine clamp assembly
(3) for the turbocharger group:
Part No.: 201-7252
S/N: NAY1-Up 1. Tighten the clamp assemblies to 14.0 ± 1.0 N·m
(125 ± 9 lb in).
Part No.: 201-7252
S/N: MGS1-Up; GPN1-Up 2. Lightly tap around the clamp assemblies with a
soft faced hammer.
3. Again, tighten the clamp assemblies to

14.0 ± 1.0 N·m (125 ± 9 lb in).
i02946038
Turbocharger
SMCS Code: 1052
Part No.: 241-9421, 245-4791
S/N: WKB1-Up
Part No.: 201-7251
S/N: PLE1-Up
Part No.: 201-7251
S/N: CKH1-Up
Part No.: 241-9421, 245-4791
g01460889
S/N: C1J1-Up
Illustration 25
Typical example Part No.: 301-4315
Rear view of engine
S/N: J2K1-Up
Part No.: 201-7251, 241-9421, 245-4791
(1) Apply 4C-5599 Anti-Seize Compound to the S/N: CYN1-Up
threads and the bearing surface of four locknuts
before assembly. Part No.: 201-7251, 241-9421, 245-4791
S/N: GEN1-Up
RENR2387-15 17
Part No.: 241-9421

S/N: P1N1-Up
Part No.: 201-7251
S/N: P2N1-Up
Part No.: 301-4315
S/N: T2P1-Up
Part No.: 201-7251
S/N: GES1-Up
Part No.: 201-7251
S/N: KJT1-Up
Part No.: 241-9421
S/N: NAX1-Up
Part No.: 201-7251
S/N: NAY1-Up
Part No.: 201-7251, 241-9421, 245-4791
g01460233
Illustration 28
Typical example
Use the following procedure to tighten the compressor

clamp assembly (2) and the turbine clamp assembly
(3) for the turbocharger group:
1. Tighten the clamp assemblies to 14.0 ± 1.0 N·m

(125 ± 9 lb in).
2. Lightly tap around the clamp assemblies with a

soft faced hammer.
3. Again, tighten the clamp assemblies to

14.0 ± 1.0 N·m (125 ± 9 lb in).
i03560842
Exhaust Manifold
g01460208
SMCS Code: 1059
Illustration 27
Typical example Part No.: 126-5052, 201-2087, 257-7662
Right side view of engine
S/N: WKB1-Up
Part No.: 126-5052, 201-2087
(1) Apply 4C-5599 Anti-Seize Compound to the S/N: CKH1-Up
threads and the bearing surface of four locknuts
before assembly. Part No.: 126-5052, 201-2087, 257-7662
S/N: C1J1-Up
Part No.: 126-5052, 201-2087
S/N: J2K1-Up
Part No.: 126-5052, 201-2087, 257-7662
S/N: CYN1-Up
Part No.: 126-5052, 201-2087, 257-7662
S/N: GEN1-Up
Part No.: 126-5052, 257-7662
S/N: P1N1-Up
18 RENR2387-15
Part No.: 201-2087

S/N: P2N1-Up
Part No.: 126-5052, 201-2087
S/N: T2P1-Up
Part No.: 126-5052, 201-2087
S/N: GES1-Up
Part No.: 126-5052, 201-2087
S/N: KJT1-Up
Part No.: 126-5052, 257-7662
S/N: NAX1-Up
Part No.: 201-2087
S/N: NAY1-Up
Part No.: 126-5052, 201-2087, 257-7662
g01883654
Illustration 29
Typical example
RENR2387-15 19
g00592627
Illustration 30
Tightening sequence
Note: Before assembly, apply 4C-5599 Anti-Seize

Compound to the threads and to the bearing surfaces
of the locknuts (1).
(1) Tighten the locknut 1 through locknut 12 in the

numerical sequence that is shown in Illustration
30 to the torque of 38 ± 5 N·m (28 ± 4 lb ft).
(2) Lightly lubricate the bore of the O-ring seals

at each end of the exhaust manifold with the
glycerin.

of the taperlock studs (3).
(3) Torque for the taperlock studs ........... 27 ± 4 N·m

(239 ± 35 lb in)
20 RENR2387-15
i03561201
Exhaust Manifold
SMCS Code: 1059
Part No.: 310-5809, 320-7495
S/N: JKX1-Up
g01884033
Illustration 31
Typical example
(2) Tighten the locknut 1 through 12 in the numerical

sequence that is shown in Illustration 32 to the
torque of 38 ± 5 N·m (28 ± 4 lb ft).
(3) Lightly lubricate the bore of the O-ring seals

at each end of the exhaust manifold with the
glycerin.

of the taperlock studs (4).

(239 ± 35 lb in)
g00592627
Illustration 32
Tightening sequence

(26 ± 4 lb ft)

of the locknuts (2).
RENR2387-15 21
i02947452
Camshaft
SMCS Code: 1210
Part No.: 201-0566
S/N: PLE1-Up
Part No.: 201-0566
S/N: CKH1-Up
Part No.: 201-0566
S/N: CYN1-Up
Part No.: 201-0566
S/N: GEN1-Up
Part No.: 201-0566
S/N: P2N1-Up
Part No.: 201-0566
S/N: NAY1-Up
g01460981
Illustration 34
Part No.: 201-0566
S/N: MGS1-Up; GPN1-Up (B) Specified camshaft lobe lift
Exhaust lobe ................. 8.515 mm (0.3352 inch)
Inlet lobe ....................... 9.702 mm (0.3820 inch)
Injector lobe ................. 10.445 mm (0.4112 inch)
Use the following procedure to find the actual

camshaft lobe lift:
1. Measure the camshaft lobe height (C).
2. Measure the base circle (D).
3. Subtract the base circle measurement in Step

2 from the camshaft lobe height in Step 1. The
difference is the actual camshaft lobe lift.
The maximum permissible difference between the

actual camshaft lobe lift in Step 3 and the specified
camshaft lobe lift of a new camshaft is ± 0.10 mm
(0.004 inch).
g01460979
Illustration 33
(1) Exhaust lobe
(2) Injector lobe
(3) Inlet lobe
Note: Lubricate the camshaft lobes with a 50/50

mixture of clean engine oil and 8T-2998 Lubricant
before installation.
Note: Lubricate the camshaft bearings with clean

engine oil prior to installing the camshaft.
(A) Diameter of the camshaft

journal .................................. 84.850 ± 0.020 mm
(3.3405 ± 0.0008 inch)
(4) Torque for three flat head screws ...... 13 ± 3 N·m

(115 ± 27 lb in)
22 RENR2387-15
i02650563 (4) Bearing journal

Camshaft Diameter of the bearing
journals ... 84.85 ± 0.02 mm (3.341 ± 0.001 inch)
SMCS Code: 1210
Part No.: 130-9710 engine oil prior to installing the camshaft.
S/N: WKB1-Up
(5) Front of camshaft
Part No.: 130-9710
S/N: PLE1-Up
Part No.: 130-9710
S/N: CKH1-Up
Part No.: 130-9710
S/N: C1J1-Up
Part No.: 130-9710, 299-1446
S/N: J2K1-Up
Part No.: 130-9710
S/N: CYN1-Up
Part No.: 130-9710
S/N: GEN1-Up
g01331010
Illustration 36
Part No.: 130-9710, 299-1446
S/N: T2P1-Up (A) Camshaft lobe lift
Part No.: 299-1446 Specified camshaft lobe lift
S/N: GES1-Up
Part No.: 299-1446 Inlet lobe ....................... 9.702 mm (0.3820 inch)
S/N: KJT1-Up Injector lobe ................. 10.445 mm (0.4112 inch)
Part No.: 299-1446 (B) Camshaft lobe height

S/N: JKX1-Up
(C) Base circle
Part No.: 130-9710
S/N: MGS1-Up; GPN1-Up To find the lobe lift, use the procedure that follows:
1. Measure camshaft lobe height (B).
2. Measure base circle (C).
3. Subtract the base circle measurement (Step 2)

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

lobe lift (Step 3) and the specified lobe lift of a new
camshaft ................................... 0.1 mm (0.004 inch)
g01096494
Illustration 35
(1) Exhaust lobe
(2) Injector lobe
(3) Inlet lobe
Note: Prior to installation, lubricate the camshaft

lobes with a 50/50 mixture of 8T-2998 Lubricant and
clean engine oil.
RENR2387-15 23
i03561803
Camshaft
SMCS Code: 1210
Part No.: 243-0551
S/N: WKB1-Up
Part No.: 243-0551
S/N: PLE1-Up
Part No.: 243-0551
S/N: C1J1-Up
Part No.: 243-0551
g01331009
Illustration 37 S/N: CYN1-Up
(6) Screw Part No.: 243-0551

S/N: GEN1-Up
Tighten the screws that fasten the cover to the
cylinder head to the following torque. .. 13 ± 3 N·m Part No.: 243-0551
(10 ± 2 lb ft) S/N: P1N1-Up
Part No.: 243-0551
S/N: T2P1-Up
Part No.: 243-0551
S/N: GES1-Up
Part No.: 243-0551
S/N: KJT1-Up
Part No.: 243-0551
S/N: NAX1-Up
Part No.: 243-0551
g01373752
Illustration 38
(1) Exhaust lobe
(2) Injector lobe
(3) Inlet lobe
(4) Front of camshaft

engine oil before you install the camshaft.
Note: Lubricate the camshaft lobes with a 50/50

mixture of 8T-2998 Lubricant and clean engine oil.
(A) Diameter of the bearing

journal ..... 84.85 ± 0.02 mm (3.341 ± 0.001 inch)
24 RENR2387-15
g01373758 g01356516
Illustration 39 Illustration 40
(B) Specified camshaft lobe lift (5) Torque for the flat head screws ......... 13 ± 3 N·m
(115 ± 27 lb in)
Inlet lobe ....................... 9.431 mm (0.3713 inch)
Injector lobe ................ 10.338 mm (0.4070 inch) i02493629
Use the following procedure in order to determine Engine Oil Filter Base
the actual lobe lift:
SMCS Code: 1306
1. Measure the camshaft lobe height (C). Part No.: 2P-4301
2. Measure the base circle (D).
3. Subtract the base circle (D) from the camshaft

lobe height (C). The difference is the actual
camshaft lobe lift (B).
Maximum permissible difference between the actual

lobe lift that was found in Step 3 and the specified
lobe lift of a new camshaft ...... 0.10 mm (0.004 inch)
g01246731
Illustration 41
Engine oil filter base
RENR2387-15 25
(1) Engine oil filter bypass valve i03016023
The oil filter bypass valve must open at the Engine Oil Filter Base
following pressure: ...... 255 ± 21 kPa (37 ± 3 psi)
SMCS Code: 1306
(2) 4N-8150 Spring
Part No.: 172-6059
4N-8150 Spring S/N: WKB1-Up
Length under test force ... 55.25 mm (2.175 inch) Part No.: 172-6059
Test force ........................ 75 ± 6 N (17.0 ± 1.3 lb) S/N: PLE1-Up
Free length after test .......... 93.7 mm (3.69 inch)
Outside diameter ................ 20.6 mm (0.81 inch) Part No.: 172-6059
S/N: CKH1-Up
(3) Engine oil cooler bypass valve
Part No.: 172-6059
The oil cooler bypass valve must open at the S/N: C1J1-Up
following pressure: ...... 255 ± 21 kPa (37 ± 3 psi)
Part No.: 172-6059
(4) Apply clean engine oil to the gasket of the engine S/N: J2K1-Up
oil filter. Install the filter until the filter contacts the
Part No.: 172-6059
base. Tighten the filter for an additional 3/4 of a
turn (270 degrees). S/N: CYN1-Up
Part No.: 172-6059
S/N: P1N1-Up
Part No.: 172-6059
S/N: P2N1-Up
Part No.: 172-6059
S/N: T2P1-Up
Part No.: 172-6059
S/N: GES1-Up
Part No.: 172-6059
S/N: KJT1-Up
Part No.: 172-6059
S/N: JKX1-Up
Part No.: 172-6059
S/N: NAX1-Up
Part No.: 172-6059
S/N: NAY1-Up
g01246732
Illustration 42
Part No.: 172-6059
Section A-A
(B) Apply 154-9731 Thread Lock Compound
to the threads of the stud to the following
length. ............. 10.2 ± 1.5 mm (0.40 ± 0.06 inch)
(5) Tighten the stud (3) to the following

torque. ....................... 80 ± 14 N·m (59 ± 10 lb ft)
g01356539
Illustration 43
26 RENR2387-15
(A) Apply 154-9731 Thread Lock Compound on the i02685936

tapered end of the hollow stud to the following
dimension. ...... 10.5 ± 1.5 mm (0.41 ± 0.06 inch) Engine Oil Filter Base
(1) Torque for two hollow studs ............... 68 ± 7 N·m SMCS Code: 1306
(50 ± 5 lb ft)
S/N: PLE1-Up
Part No.: 295-5551
S/N: J2K1-Up
Part No.: 295-5551
S/N: T2P1-Up
Part No.: 295-5551
S/N: JKX1-Up
g01356551
Illustration 44
(2) Torque for the two O-ring plugs ..... 100 ± 15 N·m
(75 ± 11 lb ft)
(3) 4N-8150 Spring

Quantity ............................................................ 2
g01246471
Test force .......... 75.619 ± 5.800 N (17.0 ± 1.3 lb) Illustration 45
Free length after test .. 93.726 mm (3.6900 inch)
Outside diameter ................ 20.6 mm (0.81 inch) (1) The engine oil filter bypass valve must open at
the following pressure. ................... 255 ± 20 kPa
The nominal opening pressure of the oil filter bypass (37 ± 3 psi)
valve 247 kPa (36 psi)
(2) 4N-8150 Spring
Test force ........................ 75 ± 6 N (17.0 ± 1.3 lb)
Free length after test .......... 93.7 mm (3.69 inch)
Outside diameter ................ 20.6 mm (0.81 inch)
(3) The engine oil cooler bypass valve must open at

the following pressure. ................... 255 ± 20 kPa
(37 ± 3 psi)
RENR2387-15 27
i02994920
Engine Oil Pump

SMCS Code: 1304
Part No.: 161-4113
S/N: WKB1-Up
Part No.: 161-4113
S/N: PLE1-Up
Part No.: 161-4113
S/N: CKH1-Up
Part No.: 161-4113
S/N: C1J1-Up
Part No.: 161-4113
S/N: J2K1-Up
Part No.: 161-4113
S/N: CYN1-Up
Part No.: 161-4113
S/N: GEN1-Up
Part No.: 161-4113
S/N: T2P1-Up
g01246473 Part No.: 161-4113

Illustration 46
S/N: GES1-Up
Part No.: 161-4113
S/N: KJT1-Up
Part No.: 161-4113
S/N: JKX1-Up
Part No.: 161-4113
g01246474
Illustration 47
Section A-A
(B) Apply 154-9731 Thread Lock Compound to

the threads of the hollow studs to the following
length. ............. 10.5 ± 1.5 mm (0.41 ± 0.06 inch)
(4) Tighten the hollow studs (4) to the following

torque. ........................... 68 ± 7 N·m (50 ± 5 lb ft)
g01356570
Illustration 48
28 RENR2387-15
(F) Installation depth of the sleeve bearing in the oil

NOTICE pump housing ............................ 0.30 ± 0.25 mm
Before operation, the pump must be lubricated with (0.012 ± 0.010 inch)
clean engine oil and the pump must turn freely by hand
or damage to parts can be the result.
i02690454
(A) Diameter of pump drive Engine Oil Pump

shaft ..................................... 22.217 ± 0.005 mm
(0.8747 ± 0.0002 inch) SMCS Code: 1304
Part No.: 226-1191
Diameter of bore in oil pump cover for
shaft ...... 25.400 ± 0.013 mm (1.0000 ± 0.0005 inch)
(B) Length of gear ..................... 79.375 ± 0.025 mm

(3.1250 ± 0.0010 inch)
Depth of bore for gear ................ 79.502 ± 0.020 mm

(3.1300 ± 0.0008 inch)
(1) 2S-2760 Spring

Length under test force .. 117.14 mm (4.612 inch)
Test force ........................ 499 ± 24 N (110 ± 5 lb)
Approximate free length after test .... 152.91 mm
(6.020 inch)
Outside diameter ............ 27.00 mm (1.063 inch)
g01331011
Illustration 50
NOTICE
Before operation, the pump must be lubricated with
clean engine oil and the pump must turn freely by hand
or damage to parts can be the result.
(A) Diameter of shafts ............... 22.217 ± 0.005 mm

(0.8747 ± 0.0002 inch)
Diameter of bores in cover for

shafts .... 22.258 ± 0.008 mm (0.8763 ± 0.0003 inch)
(B) Length of gears ................... 79.375 ± 0.025 mm

g01520597
(3.1250 ± 0.0010 inch)
Illustration 49
Oil pump body Depth of bores for gears ............ 79.502 ± 0.020 mm
(3.1300 ± 0.0008 inch)
Note: Install the sleeve bearings so the bearings are
even with the outside of the oil pump body. (1) 236-6733 Spring
(D) Angle from the centerline of the oil pump body to Length under test force ... 82.87 mm (3.263 inch)
the bearing joint of the sleeve bearings for the Test load ...................... 709 ± 35 N (160 ± 7.9 lb)
pump shaft ................................ 30 ± 15 degrees Free length after test ............. 130 mm (5.1 inch)
Outside diameter ..................... 27 mm (1.1 inch)
(E) Installation depth of the dowel in the oil
pump ................. 6.4 ± 0.5 mm (0.25 ± 0.02 inch)
RENR2387-15 29
g01331012 g01623601
Pump body View A-A
(2) Install the bearings so the bearings are even with (2) Torque for the pipe plug ................... 82 ± 10 N·m
the outside of the pump body. (60 ± 7 lb ft)
(C) Position of bearing joint from the centerline

through bearing bores .............. 30 ± 15 degrees
i03022662
Engine Oil Pan

SMCS Code: 1302
Part No.: 198-4620
S/N: PLE1-Up
Part No.: 198-4620
S/N: CKH1-Up
g01331014
Illustration 54
Right side view
(3) Torque for 24 bolts ......... 38 ± 6 N·m (28 ± 4 lb ft)
(4) Torque for the drain plug .................. 70 ± 15 N·m

(50 ± 11 lb ft)
i02952779
Engine Oil Pan

SMCS Code: 1302
g01331015 Part No.: 228-0880, 302-5449, 322-8954

Illustration 52
S/N: WKB1-Up
Top view
Part No.: 228-0880, 302-5449, 322-8954
(1) Lubricate the bore for the O-ring seals with the S/N: PLE1-Up
lubricant that is being sealed.
Part No.: 228-0880, 302-5449, 322-8954
S/N: CKH1-Up
Part No.: 228-0880, 302-5449, 322-8954
S/N: C1J1-Up
Part No.: 228-0880, 302-5449, 322-8954
S/N: J2K1-Up
30 RENR2387-15
Part No.: 228-0880, 302-5449, 322-8954

S/N: CYN1-Up
Part No.: 228-0880, 302-5449, 322-8954
S/N: GEN1-Up
Part No.: 228-0880, 302-5449, 322-8954
S/N: P1N1-Up
Part No.: 228-0880, 302-5449, 322-8954
S/N: P2N1-Up
Part No.: 228-0880, 302-5449, 322-8954
S/N: T2P1-Up
Part No.: 228-0880, 302-5449, 322-8954
g01468027
S/N: GES1-Up Illustration 56
Right side view
Part No.: 228-0880, 302-5449, 322-8954
S/N: KJT1-Up
(2) Torque for three pipe plugs .............. 82 ± 10 N·m
Part No.: 228-0880, 302-5449, 322-8954 (60 ± 7 lb ft)
S/N: NAX1-Up
(3) Torque for drain plug .. 70 ± 15 N·m (50 ± 11 lb ft)
Part No.: 228-0880, 302-5449, 322-8954
S/N: NAY1-Up
Part No.: 228-0880, 302-5449, 322-8954
g01468007
Illustration 55
Top view
(1) Apply 8T-9022 Silicone Gasket on the top

across the entire length of joints of the gasket as
shown figure 55.
RENR2387-15 31
i02876838 i03563240
Engine Oil Pan Engine Oil Pan

SMCS Code: 1302 SMCS Code: 1302
Part No.: 126-9140 Part No.: 228-1644
S/N: WKB1-Up S/N: WKB1-Up
Part No.: 126-9140 Part No.: 228-1644
S/N: PLE1-Up S/N: PLE1-Up
Part No.: 126-9140 Part No.: 228-1644
S/N: CKH1-Up S/N: CKH1-Up
Part No.: 126-9140 Part No.: 228-1644
S/N: C1J1-Up S/N: C1J1-Up
Part No.: 126-9140 Part No.: 228-1644
S/N: CYN1-Up S/N: J2K1-Up
Part No.: 126-9140 Part No.: 228-1644
S/N: GEN1-Up S/N: CYN1-Up
Part No.: 126-9140 Part No.: 228-1644
S/N: MGS1-Up; GPN1-Up S/N: GEN1-Up
Part No.: 228-1644
S/N: T2P1-Up
Part No.: 228-1644
S/N: GES1-Up
Part No.: 228-1644
S/N: KJT1-Up
Part No.: 228-1644
S/N: JKX1-Up
Part No.: 228-1644
g01431600
Illustration 57 g01891333
Illustration 58
(1) Torque for pipe plug ..... 82 ± 10 N·m (60 ± 7 lb ft) Top view
(2) Torque for the oil pan bolts .............. 55 ± 10 N·m (1) Lubricate the bores of the O-ring seals lightly with
(41 ± 7 lb ft) the lubricant that is being sealed.
(3) Front face of block
(4) Torque for drain plug .. 70 ± 15 N·m (52 ± 11 lb ft)

32 RENR2387-15
i03563503
Water Temperature Regulator

SMCS Code: 1355
Part No.: 248-5513
g01331013
Illustration 59
Section A-A
(2) Torque for the pipe plug ................... 82 ± 10 N·m

(60 ± 7 lb ft)
g01449799
Illustration 61
Start to open temperature ....................... 81 to 84 °C

(178 to 183 °F)
Fully open temperature ...................... 92 °C (198 °F)

g01885635
Illustration 60 (A) Minimum opening distance at fully open
Right side view temperature ........................ 10.4 mm (0.41 inch)
(3) Apply 8T-9022 Silicone Gasket on the top

across the entire length of joints of the gasket.
(4) Torque for the drain plug .................. 70 ± 15 N·m

(52 ± 11 lb ft)
RENR2387-15 33
i03433984
Water Pump
SMCS Code: 1361
Part No.: 174-5986
g01784653
Illustration 62
(1) Lubricate the bore of the O-ring seals with

glycerin or approved equivalent.
(2) Torque for the bolt .......... 39 ± 3 N·m (29 ± 2 lb ft)
(A) Diameter of the water pump shaft at the carbon

seal assembly seat area ...... 19.100 ± 0.010 mm
(0.7520 ± 0.0004 inch)
Note: With an installation tool, press the seal group

onto the water pump shaft until the stationary cup is
fully seated inside the pump housing.
(3) Seal group

Maximum leakage at the side of water at 140 kPa
(20 psi) ............................. 10 ml/min (0.3 oz/min)
Maximum leakage at the side of oil at 140 kPa
(20 psi) ............................. 24 ml/min (0.8 oz/min)
(4) By using an installation tool, install the lip type

seal with the primary lip toward the gear. Press
the lip type seal with a press until the lip type
seal is flush with the face inside the housing, as
shown. Do not install the lip type seal by hand.
34 RENR2387-15
i02494989
Auxiliary Water Pump

SMCS Code: 1371
Part No.: 207-6998, 207-7001
S/N: WKB1-Up
Part No.: 207-6998, 207-7001
S/N: PLE1-Up
Part No.: 207-6998, 207-7001
S/N: CKH1-Up
Part No.: 207-6998, 207-7001
S/N: C1J1-Up
Part No.: 207-6998, 207-7001
S/N: CYN1-Up
Part No.: 207-6998, 207-7001
S/N: GEN1-Up
Part No.: 207-6998, 207-7001
g01046049
Illustration 63
Auxiliary water pump
(1) Tighten the bolts to the following (6) Tighten the impeller to the following
torque. ..................... 21.5 ± 2.5 N·m (16 ± 2 lb ft) torque. ................... 103 ± 13 N·m (76 ± 103 lb ft)
(2) Tighten the plug to the following (7) Tighten the impeller to the following
torque. ............................ 9 ± 1 N·m (80 ± 9 lb in) torque. .................................... 103 N·m (76 lb ft)
(3) Tighten the bolts to the following (8) Tighten the bolts to the following
torque. ............................ 6 ± 1 N·m (53 ± 9 lb in) torque. ................ 1.9 ± 0.2 N·m (16.8 ± 1.8 lb in)
(4) Tighten the bolts for the housing to the following

torque. ............................ 6 ± 1 N·m (53 ± 9 lb in)
(5) Tighten bolts to the following torque. ... 6 ± 1 N·m

(53 ± 9 lb in)
RENR2387-15 35
Part No.: 194-2450, 276-5906

S/N: P2N1-Up
Part No.: 194-2450, 276-5906
S/N: T2P1-Up
Part No.: 194-2450, 276-5906
S/N: GES1-Up
Part No.: 194-2450, 276-5906
S/N: KJT1-Up
Part No.: 307-8939
S/N: JKX1-Up
Part No.: 194-2450, 276-5906
S/N: NAX1-Up
Part No.: 194-2450, 276-5906
S/N: NAY1-Up
Part No.: 194-2450, 276-5906
g01040579
Illustration 64
(9) The distance of the impeller below ring

(10) .......... 0.11 to 0.16 mm (0.004 to 0.006 inch)
(10) Ring
i02872740
Auxiliary Water Pump

SMCS Code: 1371
Part No.: 194-2450, 276-5906
S/N: WKB1-Up g01430420
Illustration 65
Part No.: 194-2450, 276-5906 Auxiliary water pump
S/N: PLE1-Up
(1) Torque for clamps ..................... 20 N·m (15 lb ft)
Part No.: 194-2450, 276-5906
S/N: CKH1-Up (2) Apply 155-0695 Thread Lock Compound to
Part No.: 194-2450, 276-5906 the threads of the stud. Tighten the nut to the
S/N: C1J1-Up following torque. ............ 40 ± 5 N·m (30 ± 4 lb ft)
Part No.: 194-2450, 276-5906

S/N: J2K1-Up
Part No.: 194-2450, 276-5906
S/N: CYN1-Up
Part No.: 194-2450, 276-5906
S/N: GEN1-Up
Part No.: 194-2450, 276-5906
S/N: P1N1-Up
36 RENR2387-15
g01430421 g01430425
Top view of auxiliary water pump Front view of auxiliary water pump
(3) Tighten the three bolts for the housing to the (8) Torque for four bolts ..................... 21.5 ± 2.5 N·m
following torque. ........... 6 ± 1 N·m (50 ± 10 lb in) (16 ± 2 lb ft)
(9) Tighten the four bolts for the housing to the

following torque. ........... 6 ± 1 N·m (50 ± 10 lb in)
g01430424
Illustration 67
Section A-A
(4) Torque for three bolts .... 6 ± 1 N·m (50 ± 10 lb in)
(5) Tighten the impeller to the following

torque. ..................... 103 ± 13 N·m (80 ± 10 lb ft)
(6) Torque for plug .............. 9 ± 1 N·m (80 ± 10 lb in)
(7) Tighten the impeller to the following

torque. ..................... 103 ± 13 N·m (80 ± 10 lb ft)
RENR2387-15 37
i03362921 Use the following procedure to tighten the bolts:

Heat Exchanger 1. Install guide studs in locations (5) and (6). Use
three incremental steps to hand tighten bolt (1)
SMCS Code: 1379 through bolt (4).
Part No.: 200-7102, 201-6758
2. Remove the guide studs from locations (5) and (6).
S/N: WKB1-Up
Part No.: 200-7102, 201-6758 3. Install the spacers in locations (5) and (6).
S/N: PLE1-Up
4. Tighten bolt (1) through bolt (10) in numerical
Part No.: 200-7102, 201-6758 order.
S/N: CKH1-Up
Torque ........................... 108 ± 7 N·m (80 ± 5 lb ft)
Part No.: 200-7102, 201-6758
S/N: C1J1-Up
Part No.: 200-7102, 201-6758
S/N: J2K1-Up
Part No.: 200-7102, 201-6758
S/N: CYN1-Up
Part No.: 200-7102, 201-6758
S/N: GEN1-Up
Part No.: 200-7102, 201-6758
S/N: P1N1-Up
Part No.: 200-7102, 201-6758
S/N: P2N1-Up
Part No.: 200-7102, 201-6758
S/N: T2P1-Up
Part No.: 200-7102, 201-6758
S/N: GES1-Up
Part No.: 200-7102, 201-6758
S/N: KJT1-Up
Part No.: 200-7102, 201-6758
S/N: NAX1-Up
Part No.: 200-7102, 201-6758
S/N: NAY1-Up
Part No.: 200-7102, 201-6758
g00903274
Illustration 69
38 RENR2387-15
i02690439 Use the following procedure to tighten the bolts:

Heat Exchanger 1. Install guide studs in locations (5) and (6). Use
three incremental steps to hand tighten bolt (1)
SMCS Code: 1379 through bolt (4).
Part No.: 200-7102, 201-6758
2. Remove the guide studs from locations (5) and (6).
S/N: WKB1-Up
Part No.: 200-7102, 201-6758 3. Install the spacers in locations (5) and (6).
S/N: PLE1-Up
4. Tighten bolt (1) through bolt (10) in numerical
Part No.: 200-7102, 201-6758 order.
S/N: CKH1-Up
Torque ..................... 215 ± 40 N·m (160 ± 30 lb ft)
Part No.: 200-7102, 201-6758
S/N: C1J1-Up
i03289191
Part No.: 200-7102, 201-6758
S/N: J2K1-Up Cylinder Block
Part No.: 200-7102, 201-6758 SMCS Code: 1201
S/N: CYN1-Up
Part No.: 223-9253, 261-0191
Part No.: 200-7102, 201-6758 S/N: WKB1-Up
S/N: GEN1-Up
Part No.: 223-9253, 261-0191
Part No.: 200-7102, 201-6758 S/N: PLE1-Up
S/N: P1N1-Up
Part No.: 223-9253, 261-0191
Part No.: 200-7102, 201-6758 S/N: CKH1-Up
S/N: P2N1-Up
Part No.: 223-9253, 261-0191
Part No.: 200-7102, 201-6758 S/N: C1J1-Up
S/N: T2P1-Up
Part No.: 261-0191
Part No.: 200-7102, 201-6758 S/N: J2K1-Up
S/N: KJT1-Up
Part No.: 223-9253, 261-0191
Part No.: 290-3991 S/N: CYN1-Up
S/N: JKX1-Up
Part No.: 223-9253, 261-0191
Part No.: 200-7102, 201-6758 S/N: GEN1-Up
S/N: NAX1-Up
Part No.: 223-9253, 261-0191
Part No.: 200-7102, 201-6758 S/N: P1N1-Up
S/N: NAY1-Up
Part No.: 223-9253, 261-0191
Part No.: 200-7102, 201-6758 S/N: P2N1-Up
Part No.: 261-0191
S/N: T2P1-Up
Part No.: 261-0191
S/N: GES1-Up
Part No.: 261-0191
S/N: KJT1-Up
Part No.: 312-1182
S/N: JKX1-Up
Part No.: 223-9253, 261-0191
S/N: NAX1-Up
Part No.: 223-9253, 261-0191
Illustration 70
g00903274 S/N: NAY1-Up
RENR2387-15 39
Part No.: 261-0191

g01628113
Illustration 71
Right side view
Note: The bottom of the spacer plate (2), the top (C) Extension of dowel above the top surface of the
of the cylinder block, and both surfaces of the cylinder block .. 20.0 ± 0.5 mm (0.79 ± 0.02 inch)
gasket (1) must be free of fuel, oil, water, adhesives,
assembly compounds or any other contaminants (E) Extension of the dowel beyond the end of the
during assembly. cylinder block .. 19.1 ± 0.5 mm (0.75 ± 0.02 inch)
Note: Apply 4C-4032 Bearing Mount Compound to

the dowel before installation.
(A) Extension of dowel above the top surface of the

cylinder block .. 18.5 ± 0.5 mm (0.73 ± 0.02 inch)
(1) Thickness of the gasket ............. 0.20 ± 0.02 mm

(0.008 ± 0.001 inch)
(2) Thickness of the spacer plate .. 8.585 ± 0.025 mm

(0.3380 ± 0.0010 inch)
Projection of cylinder liner above the spacer

plate ...... 0.025 to 0.152 mm (0.0010 to 0.0060 inch)
g01628133
Illustration 72
(3) Torque for the cylinder block plug View D-D
group ..................... 145 ± 13 N·m (105 ± 10 lb ft)
(B) Extension of dowel above the top surface of the

cylinder block .. 16.0 ± 0.5 mm (0.63 ± 0.02 inch)
Note: Apply 4C-4032 Bearing Mount Compound to

the dowel before installation.
40 RENR2387-15
g01628135
Illustration 73
Section F-F
(4) Lubricate the O-ring seals and the bore with

clean engine oil.
(G) Installation depth of the plug ......... 2.0 ± 2.0 mm

(0.08 ± 0.08 inch)
g01628178
Illustration 74
Front view of engine
Note: The total flatness of the top contact surface

of the cylinder block must be within 0.10 mm
(0.004 inch). The flatness must also be within
0.05 mm (0.002 inch) for any 150.0 mm (5.91 inch)
section of the surface.
(H) Dimension from the centerline of the crankshaft

bearing bore to the top of the cylinder block
New ............................ 425.45 mm (16.750 inch)
Minimum ..................... 425.02 mm (16.733 inch)
(J) Bore in the cylinder block for the main

bearings ............................. 129.891 ± 0.013 mm
(5.1138 ± 0.0005 inch)
(K) New dimension from the centerline of the

crankshaft bearing bore to the bottom of the
cylinder block pan rails .. 165.10 mm (6.500 inch)
(L) Width of the main bearing cap ........ 215.900 mm

(8.5000 inch)
Width of the cylinder block for the main bearing

cap ...... 215.900 ± 0.020 mm (8.5000 ± 0.0008 inch)
RENR2387-15 41
i02684335
Cylinder Liner
SMCS Code: 1216
Part No.: 215-2985, 253-8766
S/N: WKB1-Up
g01628190
Illustration 75 Part No.: 215-2985, 253-8766
Torque-turn tightening method for main bearing cap bolts S/N: PLE1-Up
Use the following procedure in order to tighten the Part No.: 215-2985, 253-8766
main bearing cap bolts (5): S/N: CKH1-Up
Part No.: 215-2985, 253-8766
1. Apply clean engine oil to the threads of the bolts. S/N: C1J1-Up
2. Tighten the bolt (7) first on the bearing tab side of Part No.: 253-8766
the cap to 258 ± 14 N·m (190 ± 10 lb ft). S/N: J2K1-Up
3. Tighten the bolt (6) on the opposite end to the tab Part No.: 215-2985, 253-8766
end of the cap to 258 ± 14 N·m (190 ± 10 lb ft). S/N: CYN1-Up
Part No.: 215-2986, 253-8766
4. Put a mark on each bolt and each cap.
S/N: GEN1-Up
5. Tighten the bolt (6) on the opposite end to the tab Part No.: 215-2985, 253-8766
end of the cap from the mark to angle (M) of 120 ± S/N: P1N1-Up
5 degrees (2 flats).
Part No.: 215-2985, 253-8766
6. Tighten the bolt (7) on the bearing tab side of the S/N: P2N1-Up
cap from the mark to angle (M) of 120 ± 5 degrees
(2 flats). Part No.: 253-8766
S/N: T2P1-Up
Part No.: 253-8766
S/N: GES1-Up
Part No.: 253-8766
S/N: KJT1-Up
Part No.: 304-9856
S/N: JKX1-Up
Part No.: 215-2985, 253-8766
S/N: NAX1-Up
Part No.: 215-2985, 253-8766
S/N: NAY1-Up
g01628196
Illustration 76 Part No.: 253-8766
Right side view S/N: MGS1-Up; GPN1-Up
(8) Straight thread O-ring plug
Note: To prevent damage to the piston cooling

jets during service, the piston cooling jets must be
removed.
(9) Minimum permissible clearance between

the piston, the piston cooling jet, and the
crankshaft ......................... 0.63 mm (0.025 inch)
42 RENR2387-15
i03565042
Crankshaft
SMCS Code: 1202
Part No.: 189-4917
g01348803
Illustration 77
(1) Filler band
Use the following procedure for installing the cylinder

liner into the cylinder block:
1. Apply 5P-3975 Rubber Lubricant on the surfaces Illustration 78

g01520659
of the cylinder liner bore. Apply 5P-3975 Rubber
(1) Main bearing journal
Lubricant on the rubber seals on the lower part of (3) Connecting rod bearing journal
the cylinder liner.
Note: For the correct procedure on measuring for
2. Put filler band (1) completely in clean engine oil a bent crankshaft, refer to the Reuse And Salvage
for a moment. Guidelines, SEBF8054, “Procedure to Measure and
Straighten Crankshafts”.
3. Install the filler band in the groove under the liner
flange without delay. (A) Maximum protrusion of the dowel from the face
of the crankshaft ................... 6.4 mm (0.25 inch)
4. Install the liner in the bore immediately, before the
filler band expands. (B) Crankshaft end play ................. 0.15 to 0.55 mm
(0.006 to 0.022 inch)
(A) Bore in new liner ............... 145.000 ± 0.025 mm
(5.7086 ± 0.0010 inch) (2) Installation depth of the metal face of the
rear crankshaft seal from the end of the
(B) Thickness of flange on liner .. 8.890 ± 0.020 mm crankshaft .. 6.52 ± 0.13 mm (0.257 ± 0.005 inch)
(0.3500 ± 0.0008 inch)
Note: The seal group can not be used once the
The minimum thickness of the part that can be used seal has been separated from the wear sleeve.
again is the following value. ...................... 8.870 mm The seal driver can not contact the seal inside a
(0.3492 inch) 177.80 ± 0.25 mm (7.000 ± 0.010 inch) diameter.
Note: Refer to Guideline For Reusable Parts, (4) Install the thrust plates on the center main
SEBF8068, “Cylinder Liners” for more information. bearing journal of the crankshaft only.
Also, refer to Testing and Adjusting, “Cylinder Liner
Projection - Inspect” for the procedure for inspecting
the projection of the cylinder liners.
g01520666
Illustration 79
RENR2387-15 43
Refer to Specifications, “Connecting Rod Bearing i03565360

Journal” and Specifications, “Main Bearing Journal”
for more information about the crankshaft journals. Vibration Damper and Pulley
(5) Maximum permissible temperature of the gear for SMCS Code: 1205
installation on the crankshaft ..... 233 °C (451 °F)
Part No.: 209-3600
S/N: WKB1-Up
Note: The timing mark “V” is toward the outside
of the crankshaft when the gear is installed on the Part No.: 209-3600
crankshaft. S/N: PLE1-Up
(C) Protrusion of the dowel from the surface of the Part No.: 209-3600
crankshaft ......... 4.1 ± 0.5 mm (0.16 ± 0.02 inch) S/N: CKH1-Up
(6) Installation depth of the metal face of the Part No.: 209-3600
front crankshaft seal from the end of the S/N: C1J1-Up
crankshaft .. 5.40 ± 0.13 mm (0.213 ± 0.005 inch) Part No.: 209-3600
S/N: J2K1-Up
Note: The seal group can not be used once the
seal has been separated from the wear sleeve. Part No.: 209-3600, 247-8489
The seal driver can not contact the seal inside a S/N: CYN1-Up
177.80 ± 0.25 mm (7.000 ± 0.010 inch) diameter.
Part No.: 209-3600, 247-8489
Note: Refer to Special Instruction, “Special S/N: GEN1-Up
Handling Information and Installation Instructions for
Part No.: 209-3600
Crankshaft Seal Groups That Have Hydrodynamic
Grooves In the Sealing Lip” for the correct procedure S/N: T2P1-Up
on the installation of the front seal group and the rear Part No.: 247-8489
seal group. S/N: GES1-Up
Part No.: 247-8489
S/N: KJT1-Up
Part No.: 324-7482
S/N: JKX1-Up
Part No.: 209-3600, 247-8489
g01886893
Illustration 80
44 RENR2387-15
(1) Before assembly, lubricate the threads of the

bolts with molybdenum disulfide or graphite base
lubricant.
(2) Torque for the taperlock studs ......... 65 ± 10 N·m

(48 ± 7 lb ft)
(3) Torque for the full nuts ................... 135 ± 20 N·m

(100 ± 15 lb ft)
i03565602
Vibration Damper and Pulley

SMCS Code: 1205
Part No.: 209-2786
S/N: WKB1-Up
Part No.: 209-2786
S/N: PLE1-Up
g01887204
Part No.: 209-2786 Illustration 81
S/N: CKH1-Up
(1) Before assembly, lubricate the threads of the
Part No.: 209-2786 bolts with molybdenum disulfide or graphite base
S/N: C1J1-Up lubricant.
Part No.: 209-2786 (2) Torque for the taperlock studs ......... 65 ± 10 N·m
S/N: J2K1-Up (48 ± 7 lb ft)
Part No.: 209-2786, 247-8490
(3) Torque for the full nuts ................... 135 ± 20 N·m
S/N: CYN1-Up
(100 ± 15 lb ft)
Part No.: 209-2786, 247-8490
S/N: GEN1-Up
Part No.: 209-2786
S/N: P1N1-Up
Part No.: 209-2786
S/N: P2N1-Up
Part No.: 209-2786
S/N: T2P1-Up
Part No.: 247-8490
S/N: GES1-Up
Part No.: 247-8490
S/N: KJT1-Up
Part No.: 324-7481
S/N: JKX1-Up
Part No.: 209-2786
S/N: NAX1-Up
Part No.: 209-2786
S/N: NAY1-Up
Part No.: 209-2786, 247-8490
RENR2387-15 45
i03565193 (3) Torque for the full nuts ................... 135 ± 20 N·m
(100 ± 15 lb ft)
Vibration Damper and Pulley
SMCS Code: 1205 i03001867
Part No.: 209-3603 Connecting Rod Bearing

S/N: WKB1-Up
Journal
Part No.: 209-3603
S/N: PLE1-Up SMCS Code: 1202; 1219; 1225
Part No.: 209-3603 Part No.: 224-3245

S/N: CKH1-Up
Refer to Guideline For Reusable Parts, SEBF8009,
Part No.: 209-3603 “Main and Connecting Rod Bearings” and Guideline
S/N: C1J1-Up For Reusable Parts, SEBF8041, “Specifications for
Crankshaft in Caterpillar Engines”.
Part No.: 209-3603, 247-8491
S/N: CYN1-Up Table 1
Part No.: 209-3603, 247-8491 Connecting Rod Bearing Journal

S/N: GEN1-Up 97.000 ± 0.020 mm
Original Size Journal
(3.8189 ± 0.0008 inch)
Part No.: 247-8491
S/N: GES1-Up Undersize Journal
96.37 mm (3.794 inch)
0.63 mm (0.025 inch)
Part No.: 247-8491
S/N: KJT1-Up Undersize Journal
95.73 mm (3.769 inch)
1.27 mm (0.050 inch)
Part No.: 209-3603, 247-8491
S/N: MGS1-Up; GPN1-Up Clearance between the new bearing and the
journal .................................. 0.062 mm to 0.160 mm
(0.0024 inch to 0.0063 inch)
Maximum permissible clearance between the bearing

and the journal ........................ 0.20 mm (0.008 inch)
g01886851
Illustration 82
Note: Before assembly, lubricate the threads of the

bolts (1) with molybdenum disulfide or graphite base
lubricant.
(1) Torque for the bolts ........................ 270 ± 25 N·m

(199 ± 18 lb ft)
(2) Torque for the taperlock studs ......... 65 ± 10 N·m

(48 ± 7 lb ft)
46 RENR2387-15
i02776201 Table 2
Main Bearing Journal Main Bearing Journals

120.650 ± 0.020 mm
SMCS Code: 1202; 1203 Original Size Journal
(4.7500 ± 0.0008 inch)
Part No.: 189-4918 Undersize Journal 120.015 ± 0.020 mm

S/N: WKB1-Up 0.63 mm (0.025 inch) (4.7250 ± 0.0008 inch)
Undersize Journal 119.380 ± 0.020 mm
Part No.: 189-4918 1.27 mm (0.050 inch) (4.7000 ± 0.0008 inch)
S/N: PLE1-Up
Part No.: 195-0314 Main bearing cap with two bolts
S/N: CKH1-Up
Clearance between new bearing and new
Part No.: 195-0314 journal ................................... 0.076 to 0.186 mm
S/N: C1J1-Up (0.0030 to 0.0073 inch)
Part No.: 195-0314 Main bearing cap with four bolts
S/N: J2K1-Up
Clearance between new bearing and new
Part No.: 195-0314 journal ................................... 0.071 to 0.178 mm
S/N: CYN1-Up (0.0028 to 0.0070 inch)
Part No.: 195-0314
Table 3
S/N: GEN1-Up
Main Bearing Bore
Part No.: 189-4918
S/N: P1N1-Up Original Size of the Bore 129.891 ± 0.013 mm
In the Block (5.1138 ± 0.0005 inch)
Part No.: 189-4918 Oversize Bore 0.63 mm 130.526 ± 0.013 mm
S/N: P2N1-Up (0.025 inch) (5.1388 ± 0.0005 inch)
Part No.: 189-4918
S/N: T2P1-Up
Part No.: 195-0314
S/N: GES1-Up
Part No.: 195-0314
S/N: KJT1-Up
Part No.: 195-0314
S/N: JKX1-Up
Part No.: 195-0314
S/N: NAX1-Up
Part No.: 195-0314
S/N: NAY1-Up
Part No.: 195-0314
Refer to Guideline For Reusable Parts And Salvage

Operations, SEBF8009, “Main and Connecting Rod
Bearings” and Guideline For Reusable Parts and
Salvage Operations, SEBF8041, “Specifications for
Crankshaft in Caterpillar Engines”.
RENR2387-15 47
i02992079 (F) Bore in the connecting rod for the crankshaft

bearing ............................... 103.200 ± 0.013 mm
Connecting Rod (4.0630 ± 0.0005 inch)
SMCS Code: 1218 (G) Bore in bearing for
crankshaft ............................ 97.088 ± 0.016 mm
Part No.: 224-3245
(3.8224 ± 0.0006 inch)
g01517217
Illustration 84
Use the following procedure to tighten the connecting

rod bolts:
1. Before assembly, lubricate the threads of the bolt

and the seating faces of the caps with the clean
engine oil.
2. Torque the bolt (1) and the bolt (3) to 70 ± 4 N·m

(50 ± 3 lb ft).
Illustration 83
g01516583 3. Torque the bolt (2) and the bolt (4) to 70 ± 4 N·m
(50 ± 3 lb ft).
(A) Bore in the connecting rod for the piston pin
bearing ................................. 64.592 ± 0.013 mm 4. Rotate the bolt (2) and the bolt (4) for an additional
(2.5430 ± 0.0005 inch) 60 ± 5 degrees.
(B) Location of the bearing joint from the horizontal 5. Again, tighten the bolt (1) and the bolt (3) to
centerline of the pin bore ................ ± 5 degrees 70 ± 4 N·m (50 ± 3 lb ft).
(C) The connecting rod may be heated from 6. Rotate the bolt (1) and the bolt (3) for an additional
175 to 260 °C (347 to 500 °F) for the installation 60 ± 5 degrees.
of the piston pin bearing. Maximum distance for
heating the connecting rod ...... 93 mm (3.7 inch) i03567861
(D) Bore in the bearing for the piston Piston and Rings
pin ... 60.035 ± 0.008 mm (2.3636 ± 0.0003 inch)
SMCS Code: 1214; 1215
Diameter of the piston pin .......... 59.975 ± 0.005 mm
(2.3612 ± 0.0002 inch) Part No.: 235-6393, 235-6394
S/N: WKB1-Up
(E) Distance between the center of the Part No.: 235-6393, 235-6394
bearings ...................... 270.76 mm (10.660 inch) S/N: PLE1-Up
48 RENR2387-15
Part No.: 235-6393, 235-6394

S/N: CKH1-Up
Part No.: 235-6393, 235-6394
S/N: C1J1-Up
Part No.: 235-6394
S/N: J2K1-Up
Part No.: 235-6393, 235-6394
S/N: CYN1-Up
Part No.: 235-6393, 235-6394
S/N: GEN1-Up
Part No.: 235-6394
S/N: P1N1-Up
Part No.: 235-6393
S/N: P2N1-Up
Part No.: 235-6394
S/N: T2P1-Up
Part No.: 235-6394
S/N: GES1-Up
Part No.: 235-6394
S/N: KJT1-Up
Part No.: 324-5618
S/N: JKX1-Up
Part No.: 235-6394
S/N: NAX1-Up
Part No.: 235-6393
S/N: NAY1-Up g01890513
Illustration 85
Part No.: 235-6364, 235-6393
S/N: MGS1-Up; GPN1-Up Refer to Reuse and Salvage Guidelines, “Visual
Inspection of the Piston” and Reuse and Salvage
Guidelines, “Inspection and Measuring Procedures
for Piston Pins”.
Note: Lubricate the entire piston to 360 degrees with

clean engine oil prior to assembly into the cylinder
block.
Top Piston Ring (1)

Install the piston ring with “UP-1” mark toward the top
of the piston. The purple colored stripe faces to the
right of the top piston ring end gap.
Thickness of new top piston ring .............. 3.845 mm

(0.1514 inch)
Clearance between the ends of the top piston

ring in a cylinder liner with a bore of 145 mm
(5.7 inch) ......... 0.40 ± 0.10 mm (0.016 ± 0.004 inch)
Increase in the clearance between the ends of the top

piston ring for each 0.030 mm (0.0012 inch) increase
in the cylinder liner bore .......... 0.08 mm (0.003 inch)
RENR2387-15 49
Intermediate Piston Ring (2) Clearance between the piston pin and the bore in the
piston .... 0.033 to 0.046 mm (0.0013 to 0.0018 inch)
Install the piston ring with “UP-2” mark toward the top
of the piston. The colored stripe faces to the right of Pin Retainer (5)
the intermediate piston ring end gap.
Width of the new pin retainer .......... 1.93 to 2.00 mm
Thickness of new intermediate piston ring .. 2.94 mm (0.076 to 0.079 inch)
(0.116 inch)
Width of groove in the new piston for the pin
Clearance between the ends of the intermediate retainer ............ 2.25 ± 0.10 mm (0.089 ± 0.004 inch)
piston ring in a cylinder liner with a bore of 145 mm
(5.7 inch) .. 0.600 ± 0.125 mm (0.0236 ± 0.0049 inch)
i03293167
Increase in the clearance between the ends of
the intermediate piston ring for each 0.030 mm Housing (Front)
(0.0012 inch) increase in the cylinder liner
bore ......................................... 0.08 mm (0.003 inch) SMCS Code: 1151
Part No.: 206-1211
Oil Control Piston Ring (3) S/N: WKB1-Up
The spring ends of the oil control ring should be Part No.: 206-1211
assembled 180 degrees from the ring end gap. The S/N: PLE1-Up
green colored portion of the oil control piston ring
Part No.: 206-1211
must be visible at the piston ring end gap.
S/N: CKH1-Up
Thickness of new oil control piston Part No.: 206-1211
ring ........... 2.980 ± 0.010 mm (0.1173 ± 0.0004 inch) S/N: C1J1-Up
Width of groove in new piston for the oil control piston Part No.: 291-4880
ring ........... 3.020 ± 0.010 mm (0.1189 ± 0.0004 inch) S/N: J2K1-Up
Clearance between groove and new oil control piston Part No.: 206-1211
ring .......................................... 0.04 mm (0.002 inch) S/N: CYN1-Up
Part No.: 206-1211
Clearance between the ends of the oil control S/N: GEN1-Up
piston ring in a cylinder liner with a bore of 145 mm
(5.7 inch) ......... 0.55 ± 0.15 mm (0.022 ± 0.006 inch) Part No.: 206-1211
S/N: P1N1-Up
Increase in the clearance between the ends of the oil
control piston ring for each 0.030 mm (0.0012 inch) Part No.: 206-1211
increase in the cylinder liner bore ............... 0.08 mm S/N: P2N1-Up
(0.003 inch)
Part No.: 291-4880
Note: After the piston rings have been installed, S/N: T2P1-Up
rotate the piston rings so that the end gaps are 120 Part No.: 291-4880
degrees from each other. S/N: GES1-Up
Piston Pin (4) Part No.: 291-4880

S/N: KJT1-Up
Note: Thoroughly lubricate the piston pin with clean Part No.: 291-4880
engine oil before you insert the piston pin into the S/N: JKX1-Up
piston body assembly and the connecting rod.
Part No.: 206-1211
Diameter of the new piston pin .. 59.975 ± 0.005 mm S/N: NAX1-Up
(2.3612 ± 0.0002 inch)
Part No.: 206-1211
Length of the new piston pin .......... 89.80 ± 0.15 mm S/N: NAY1-Up
(3.535 ± 0.006 inch)
Part No.: 206-1211
Bore in the body of the piston for the piston
pin .. 60.0925 ± 0.0075 mm (2.36584 ± 0.00030 inch)
50 RENR2387-15
Note: Apply 8T-9022 Silicone Gasket in order to fill

the space at the connecting joint of the front plate, oil
pan gasket, and cylinder block.
i02145580
Front Housing and Covers

SMCS Code: 1162; 1166
Part No.: 159-6159
g01203086
Illustration 86
Front housing
g01088946
Illustration 88
(1) Button head screws

Tighten the twelve button head screws only after
tightening the two nuts (2).
g01050293
Illustration 87 Tighten the button head screws to the following
Typical example of View A-A, View B-B, and View C-C torque. ........................... 21 ± 3 N·m (15 ± 2 lb ft)
(3) Sealing washer
(4) Plate
(5) Washer
(1) Bolts
Use the following procedure in order to tighten the

bolts that fasten the plate to the cylinder block.
1. Use hand tools to tighten the bolts.
Tighten the bolts to the following

torque. ............................. 55 ± 5 N·m (40 ± 4 lb ft)
2. Use hand tools to tighten the bolts again.

g00550805
Illustration 89
Tighten the bolts to the following View A-A
torque. ............................. 55 ± 5 N·m (40 ± 4 lb ft)
(2) Stud and nut
(2) Brake stud
Apply 155-0695 Thread Lock Compound to the
Apply 155-0695 Thread Lock Compound to the threads of the stud that engage the front housing.
serrations of brake stud (2) prior to installation.
RENR2387-15 51
i02760885
Gear Group (Front)

SMCS Code: 1206
Part No.: 207-0449
S/N: WKB1-Up
Part No.: 207-0449
S/N: PLE1-Up
Part No.: 207-0449
S/N: CKH1-Up
Part No.: 207-0449
S/N: C1J1-Up
Part No.: 207-0449
S/N: CYN1-Up
Part No.: 207-0449
S/N: GEN1-Up
Part No.: 207-0449
S/N: P1N1-Up
Part No.: 207-0449
S/N: P2N1-Up
Part No.: 207-0449 g01384968
Illustration 90
S/N: NAX1-Up
(1) Water pump drive gear
Part No.: 207-0449 (5) Gear assembly
(6) Air compressor drive gear (if equipped)
S/N: NAY1-Up
(7) Gear assembly
(8) Gear for the fuel transfer pump
Part No.: 207-0449 (10) Crankshaft gear
S/N: MGS1-Up; GPN1-Up (11) Oil pump drive gear
Note: Refer to the following procedure when any bolt

or any nut is loosened for service:
1. Remove the bolt or the nut.
2. Clean the bolt, the nut and/or the stud with a wire
brush.
3. Apply 9S-3263 Thread Lock Compound to the

threads of the bolts, nuts and/or studs before
assembly.
Note: A new bolt with a previously applied thread

lock is acceptable for use.
4. Tighten the bolts, the nuts and/or the studs to the

standard torque.
Note: Refer to Testing and Adjusting, “Gear

Group (Front) - Time” for the backlash adjustment
procedure.
Note: Before tightening the bolts for the stub shaft,

set distance (A) between the centers of camshaft
gear (3) and gear assembly (5) with a gauge in order
to obtain the gear backlash.
52 RENR2387-15
Backlash between the gears ......... 0.216 ± 0.114 mm

(0.0085 ± 0.0045 inch)
g00593987
Illustration 93
Torque sequence for the camshaft gear
g00537659
Illustration 91
Torque sequence for the stub shaft Note: Lightly lubricate O-ring seal (12) with 50/50
mixture of 8T-2998 Lubricant and clean engine oil.
(2) Tighten the five bolts for the stub shaft of the
cluster gear assembly to the standard torque (3) Camshaft gear
in the following sequence. Refer to Illustration
Tightening sequence for bolts
91. ............................. 1, 3, 4, 5, 2, 1, 2, 3, 4, 5, 1
(13) ....................................... 1, 4, 2, 5, 3, 6, 1, 4
Torque for bolts (13) ...................... 240 ± 40 N·m
(175 ± 30 lb ft)
(4) Align the timing mark on the camshaft gear with

the timing mark on the front housing when the
No. 1 piston is at top center.
(9) Align the timing mark on the crankshaft gear with

the timing mark on the cluster gear assembly.
(14) Install the oil groove of the thrust plate toward

the face of gear assembly (7).

the face of gear assembly (5).

the face of cluster gear assembly (2).
g01382103
Illustration 92
RENR2387-15 53
i02393955
Gear Group (Front)

SMCS Code: 1206
Part No.: 283-5149
S/N: J2K1-Up
Part No.: 283-5149
S/N: GES1-Up
Part No.: 283-5149
S/N: KJT1-Up
Part No.: 283-5149
g00537659
S/N: JKX1-Up Illustration 95
Stub shaft for cluster gear
(2) Cluster gear

Apply 9S-3263 Thread Lock Compound to the
five bolts for the stub shaft.
Tighten the five bolts for the stub
shaft in the following sequence. See
Illustration 95 for the numbering of the
bolts. ......................... 1, 3, 4, 5, 2, 1, 2, 3, 4, 5, 1
four bolts that fasten the cluster gear to the stub
shaft.
Tighten the four bolts that fasten the cluster
gear to the stub shaft to the following
torque. ......................... 55 ± 10 N·m (41 ± 7 lb ft)
g01090281
Illustration 94
(1) Water pump drive gear

54 RENR2387-15
Tighten the camshaft bolts in the following

sequence. See Illustration 97 for the numbering
of the bolts. ........................... 1, 4, 2, 5, 3, 6, 1, 4
Tighten the six camshaft gear bolts to the
following torque. .... 240 ± 40 N·m (177 ± 30 lb ft)
(4) Align the timing mark on the camshaft gear with

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

Install the plate with the oil groove toward
the gear face. Apply 9S-3263 Thread Lock
Compound to the three bolts that fasten the
adjustable idler gear to the stub shaft.
Tighten the three bolts for the adjustable
idler gear to the stub shaft to the following
torque. ......................... 55 ± 10 N·m (41 ± 7 lb ft)
Refer to Testing and Adjusting, “Gear Group
(Front) - Time” for the backlash adjustment
procedure.
Backlash between the camshaft gear and the
adjustable idler gear ............... 0.216 ± 0.114 mm
(0.0085 ± 0.0045 inch)
g01090280
Illustration 96 one bolt and five studs for the stub shaft.
(3) Camshaft gear Tighten the one bolt and five nuts for the stub
(12) Bolts for the sealing plate for the camshaft
(13) Seals
shaft to the following torque. ............ 55 ± 10 N·m
(14) Camshaft gear bolts (41 ± 7 lb ft)
(6) Air compressor gear (if equipped)
(7) Idler gear

one bolt and five studs for the stub shaft.
Tighten the one bolt and five nuts for the stub
shaft to the following torque. ............ 55 ± 10 N·m
(41 ± 7 lb ft)
three bolts that fasten the idler gear to the stub
shaft.
Tighten the three bolts that fasten the
g00593987
Illustration 97 idler gear to the stub shaft to the following
Bolt locations for the camshaft gear torque. ......................... 55 ± 10 N·m (41 ± 7 lb ft)
(3) Camshaft gear (8) Gear for the fuel transfer pump drive
Lightly lubricate the O-ring seal on the outside of (9) Align the timing mark on the crankshaft gear with
the camshaft sealing plate with a 50/50 mixture of the timing mark on the cluster gear.
8T-2998 Lubricant and clean engine oil. Apply
9S-3263 Thread Lock Compound to the three (10) Crankshaft gear
bolts for the camshaft sealing plate.
Tighten the three camshaft sealing plate (11) Oil pump drive gear
bolts to the following torque. See Illustration
96. .................................... 12 ± 3 N·m (9 ± 2 lb ft) Tighten the bolt for the oil pump drive gear to the
following torque. .......... 55 ± 10 N·m (41 ± 7 lb ft)
RENR2387-15 55
i02989859 Note: Use the following procedure to tighten the

twelve bolts in a circular pattern. The circular
Flywheel pattern can be in a clockwise direction or in a
counterclockwise direction.
SMCS Code: 1156
1. Torque for 12 bolts (3) to 100 ± 5 N·m (75 ± 4 lb ft)
Part No.: 9Y-7571
S/N: WKB1-Up
2. Turn the bolts by an additional 90 ± 5 degrees.
Part No.: 9Y-7571
S/N: C1J1-Up Note: Replace the bolts at service.
Part No.: 9Y-7571

S/N: J2K1-Up i02867219
Part No.: 9Y-7571 Flywheel

S/N: CYN1-Up
SMCS Code: 1156
Part No.: 9Y-7571
S/N: GEN1-Up Part No.: 7N-3060
Part No.: 9Y-7571

S/N: T2P1-Up
Part No.: 9Y-7571
S/N: GES1-Up
Part No.: 9Y-7571
S/N: KJT1-Up
Part No.: 9Y-7571
g01222011
Illustration 99
(2) Ring gear
Note: Refer to the System Operation, Testing &

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

a graphite based lubricant to the threads of
the bolts. Tighten the bolts to the following
torque. ................... 270 ± 40 N·m (200 ± 30 lb ft)
g01090276
Illustration 98
(1) Flywheel
(2) Flywheel gear
Note: Before assembly, lubricate the threads of the

bolts (3) with molybdenum disulfide or base lubricant.
56 RENR2387-15
i03293175 Part No.: 198-1295

S/N: C1J1-Up
Flywheel
Part No.: 198-1295
SMCS Code: 1156 S/N: J2K1-Up
Part No.: 214-9521 Part No.: 198-1295
S/N: PLE1-Up S/N: CYN1-Up
Part No.: 214-9521 Part No.: 198-1295
S/N: CKH1-Up S/N: GEN1-Up
Part No.: 198-1295
S/N: P1N1-Up
Part No.: 198-1295
S/N: P2N1-Up
Part No.: 198-1295
S/N: T2P1-Up
Part No.: 198-1295
S/N: JKX1-Up
Part No.: 198-1295
S/N: NAX1-Up
Part No.: 198-1295
S/N: NAY1-Up
Part No.: 198-1295
g01248855
Illustration 100
(1) Flywheel
(3) Flywheel ring gear
Note: Refer to Systems Operation/Testing and

Adjusting for the correct method of inspecting the
flywheel.
(2) Bolts
Lubricate the threads of the bolts with molybdenum

disulfide before assembling the flywheel.
Tighten the bolts to the following

torque. .......................... 300 ± 40 N·m (220 ± 30 lb ft)
i02685927
Flywheel Housing
SMCS Code: 1157
Part No.: 198-1295
S/N: WKB1-Up
Part No.: 198-1295
g01248904
S/N: PLE1-Up Illustration 101
Part No.: 198-1295

S/N: CKH1-Up
RENR2387-15 57
Note: During assembly, inspect the following i03566497

components for any foreign materials: the front
face of the flywheel housing, the two sides of the Flywheel Housing
flywheel housing gasket and the rear face of the
cylinder block. These components must be free of SMCS Code: 1157
the following substances: oil, fuel, water, gasket
Part No.: 178-8579
adhesive, assembly compounds, and any other
S/N: PLE1-Up
foreign material. Apply a small amount of 8T-9022
Silicone Gasket in order to fill the space between the Part No.: 178-8579
cylinder block, the flywheel housing, and the oil pan S/N: C1J1-Up
before installing the oil pan gasket and the oil pan.
Part No.: 178-8579
Use the following procedure to tighten the flywheel S/N: J2K1-Up
housing bolts:
Part No.: 178-8579
1. Tighten bolt (1) through bolt (9) to 100 ± 20 N·m S/N: CYN1-Up
(75 ± 15 lb ft). Part No.: 178-8579
S/N: GEN1-Up
2. Tighten bolt (10) through bolt (24) to 40 ± 10 N·m
(30 ± 7 lb ft). Part No.: 178-8579
S/N: T2P1-Up
(100 ± 15 lb ft). Part No.: 178-8579
S/N: GES1-Up
Part No.: 178-8579
(41 ± 7 lb ft).
S/N: KJT1-Up
Part No.: 178-8579
g01248956
Illustration 102
(25) Torque for the plug ... 35 ± 14 N·m (26 ± 10 lb ft)
g01889193
Illustration 103
Rear view
58 RENR2387-15
Note: The front face of the flywheel housing group

and the rear face of the cylinder block must be
free of oil, fuel, water, dirt, assembly compounds
and any other contaminants during assembly. The
gasket for the flywheel housing group must be free
of contaminants during assembly.
Note: Apply a small amount of 8T-9022 Silicone

Gasket in order to fill the space between the cylinder
block, the flywheel housing, and the oil pan before
installing the oil pan gasket and the oil pan.
Use the following procedure to tighten the bolts for

the flywheel housing group:
1. Tighten the bolt (1) through bolt (9) in the

numerical sequence that is shown in Illustration
103 to 100 ± 20 N·m (74 ± 15 lb ft). These bolts
are 1/2-13 X 2 inches.
2. Tighten bolt (10) through bolt (16) in the numerical

sequence that is shown in Illustration 103 to
40 ± 10 N·m (30 ± 7 lb ft). These bolts are 3/8-16
X 1 3/4 inches.

40 ± 10 N·m (30 ± 7 lb ft). These bolts are 3/8-16
X 1 1/2 inches.

135 ± 20 N·m (100 ± 15 lb ft).

55 ± 10 N·m (41 ± 7 lb ft).

55 ± 10 N·m (41 ± 7 lb ft).
i03288322
Belt Tension Chart

SMCS Code: 1357
Part No.: 7N-9693
Note: Do not use the belt tension charts for belts with
tensioners that are spring loaded.
RENR2387-15 59
Table 4
Belt Tension Chart
Kent-Moore Gauge
Gauge Reading
Numbers
Size of
Width of Belt Number
Belt Belt Tension Belt Tension Number of the
of the Old
“Initial”(1) “Used”(2)(3) New Gauge
Gauge
534 ± 111 N
3/8 10.72 mm (0.422 inch) 400 ± 22 N (90 ± 5 lb) BT-33-97 BT 3397
(120 ± 25 lb)
578 ± 111 N
1/2 13.89 mm (0.547 Inch) 445 ± 44 N (100 ± 10 lb) BT-33-97 BT 3397
(130 ± 25 lb)
712 ± 111 N BT-33-
5V 15.88 mm (0.626 Inch) 445 ± 44 N (100 ± 10 lb) BT 3372C
(160 ± 25 lb) 72C
712 ± 111 N BT-33-
11/16 17.48 mm (0.688 Inch) 445 ± 44 N (100 ± 10 lb) BT 3372C
(160 ± 25 lb) 72C
712 ± 111 N BT-33-
3/4 19.05 mm (0.750 Inch) 445 ± 44 N (100 ± 10 lb) BT 3372C
(160 ± 25 lb) 72C
712 ± 111 N
15/16 23.83 mm (0.938 Inch) 445 ± 44 N (100 ± 10 lb) BT-33-77 BT 3372C
(160 ± 25 lb)
1068 ± 111 N BT-33-
8PK 27.82 mm (1.095 inch) 890 ± 44 N (200 ± 10 lb) BT 33109
(240 ± 25 lb) 109
801 ± 111 N BT-33-
6PK 20.94 mm (0.824 Inch) 667 ± 44 N (150 ± 10 lb) BT 33109
(180 ± 25 lb) 109
Measure the tension of the belt that is farthest from the engine.
(1) Belt tension “Initial” is for a new belt.
(2) Belt tension “Used” is for a belt that has operated for 30 minutes or more of operation at the rated speed.
(3) If a belt falls below the “Used” belt tension, the belt should be tightened again to the high side of the “Used” belt tension.
Table 5
For DAYCO Supplied Belts Only

Belt Tension Belt Tension
Size of Belt
“Initial”(1) “Used”(2)(4)
.380 (V-Belt) 623 ± 22 N (140 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
.440 (V-Belt) 667 ± 22 N (150 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
.500 (V-Belt) 712 ± 22 N (160 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
.600 (V-Belt) 779 ± 22 N (175 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
.660 (V-Belt) 890 ± 22 N (200 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
.790 (V-Belt) 890 ± 22 N (200 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
4 - RIB PVK 623 ± 22 N (140 ± 5 lb) 400 ± 22 N (90 ± 5 lb)
5 - RIB PVK 779 ± 22 N (175 ± 5 lb) 445 ± 22 N (100 ± 5 lb)
6 - RIB PVK 934 ± 22 N (210 ± 5 lb) 578 ± 22 N (130 ± 5 lb)
8 - RIB PVK 1157 ± 22 N (260 ± 5 lb) 800 ± 22 N (180 ± 5 lb)
10 - RIB PVK 1557 ± 22 N (350 ± 5 lb) 1023 ± 22 N (230 ± 5 lb)
12 - RIB PVK 1869 ± 22 N (420 ± 5 lb) 1200 ± 22 N (270 ± 5 lb)
15 - RIB PVK 2336 ± 22 N (525 ± 5 lb) 1557 ± 22 N (350 ± 5 lb)
(1) Belt tension “Initial” is for a new belt.
(2) Belt tension “Used” is for a belt that has operated for 30 minutes or more of operation at the rated speed.
(4) If a belt falls below the “Used” belt tension, the belt should be tightened again to the “Initial” belt tension.
60 RENR2387-15
i02685929
Alternator and Regulator

SMCS Code: 1405; 1410
Part No.: 8C-6163
S/N: WKB1-Up
Part No.: 8C-6163
S/N: PLE1-Up
Part No.: 8C-6163
S/N: CKH1-Up
Part No.: 8C-6163
S/N: C1J1-Up
Part No.: 8C-6163
S/N: CYN1-Up
Part No.: 8C-6163
S/N: GEN1-Up
g01249723
Illustration 105
Part No.: 8C-6163
S/N: MGS1-Up; GPN1-Up Note: Load the battery with a carbon pile 4C-4911
Battery Load Tester in order to get the maximum
alternator output.
Polarity ............................................ Negative ground
Rotation ............................................ Either direction
Minimum full load current at 5000 rpm ......... 96 Amp
Output voltage ....................................... 14.0 ± 0.5 V
(1) Torque for the locknut .. 102 ± 7 N·m (75 ± 5 lb ft)
(2) Torque for output terminal nuts ...... 7.1 ± 0.8 N·m
(65 ± 7 lb in)
(3) 3E-5451 Voltage Regulator As
Voltage setting ................................... No adjustment

g01249721
Illustration 104
Permissible voltage range .................. 13.5 to 14.5 V
Voltage rating ..................................................... 24 V
i02825050

SMCS Code: 1405; 1410
Part No.: 4N-3986
S/N: WKB1-Up
Part No.: 4N-3986
S/N: PLE1-Up
RENR2387-15 61
Part No.: 4N-3986

S/N: CKH1-Up
Part No.: 4N-3986
S/N: C1J1-Up
Part No.: 4N-3986
S/N: J2K1-Up
Part No.: 4N-3986
S/N: CYN1-Up
Part No.: 4N-3986
S/N: GEN1-Up
Part No.: 4N-3986
S/N: P2N1-Up
Part No.: 4N-3986
S/N: T2P1-Up
Part No.: 4N-3986
S/N: GES1-Up
g01408818
Illustration 107
Part No.: 4N-3986
S/N: KJT1-Up Note: Load the battery with a carbon pile 4C-4911
Part No.: 4N-3986 Battery Load Tester in order to get the maximum
S/N: JKX1-Up alternator output.
Part No.: 4N-3986 Voltage ............................................................... 24 V

S/N: NAX1-Up
Amperage ..................................................... 60 Amp
Part No.: 4N-3986
S/N: NAY1-Up Polarity ............................................ Negative ground
Part No.: 4N-3986
Output voltage ............................................. 28 ± 1 V
(1) Final installation torque for locknut .. 102 ± 7 N·m

(75 ± 5 lb ft)
(2) Final installation torque for nuts ..... 7.1 ± 0.8 N·m
(65 ± 7 lb in)
(3) Voltage regulator assembly

Voltage setting ............................. No adjustment
Permissible voltage range .................. 27 to 29 V
g01074415
Illustration 106
62 RENR2387-15
i03194075

SMCS Code: 1405; 1410
Part No.: 6T-1396
S/N: WKB1-Up
Part No.: 6T-1396
S/N: PLE1-Up
Part No.: 6T-1396
S/N: CKH1-Up
Part No.: 6T-1396
S/N: C1J1-Up
Part No.: 6T-1396
S/N: CYN1-Up
Part No.: 6T-1396
S/N: GEN1-Up
g01627699
Illustration 109
Part No.: 6T-1396
S/N: MGS1-Up; GPN1-Up Note: Load the battery with a carbon pile 4C-4911
alternator output.
Voltage ............................................................... 12 V
Amperage ..................................................... 51 Amp
Polarity ............................................ Negative ground
Minimum full load current at 1500 rpm ...... 14.5 Amp
Output voltage ....................................... 13.8 ± 0.2 V
(1) Final installation torque for the nut .... 60 ± 7 N·m

(44 ± 5 lb ft)
Note: The peak voltage for (R) terminal must not be

g01249773
Illustration 108 less than the output voltage for (B+) terminal.
(2) (R) terminal. Final installation torque for two

nuts ....................... 2.25 ± 0.25 N·m (20 ± 2 lb in)
(3) (B+) terminal. Final installation torque for the

nut ............................. 4.1 ± 0.4 N·m (35 ± 4 lb in)
(4) (B-) terminal. Final installation torque for the

nut ......................... 2.25 ± 0.25 N·m (20 ± 2 lb in)
(5) Voltage regulator group

Voltage setting ............................. No adjustment
RENR2387-15 63
i02499698

SMCS Code: 1405; 1410
Part No.: 6T-1395
S/N: WKB1-Up
Part No.: 6T-1395
S/N: PLE1-Up
Part No.: 6T-1395
S/N: CKH1-Up
Part No.: 6T-1395
S/N: C1J1-Up
Part No.: 6T-1395
S/N: CYN1-Up
Part No.: 6T-1395
S/N: GEN1-Up
g01249774
Illustration 111
Part No.: 6T-1395
S/N: MGS1-Up; GPN1-Up 6T-1395 Alternator
Note: Load the battery with a carbon pile 4C-4911

alternator output.
Polarity ........................................... Negative Ground
Rotation ............................................ Either Direction
Output voltage .......................................... 28 ± 1.0 V
(1) Shaft nut torque ............. 60 ± 7 N·m (44 ± 5 lb ft)
(2) Torque for three terminal nuts .... 2.25 ± 0.25 N·m
(20 ± 2 lb in)
(3) Torque for the large terminal nut .... 4.1 ± 0.4 N·m
g01249773
Illustration 110 (36 ± 4 lb in)
(4) 134-8278 Regulator Kit
Voltage setting ................................... No Adjustment
Permissible voltage range ........................ 27 to 29 V
Voltage rating ..................................................... 24 V

64 RENR2387-15
i02870347 i02847523
Coolant Temperature Sensor Coolant Temperature Sensor

Part No.: 106-0735 Part No.: 130-9811
S/N: WKB1-Up
Part No.: 106-0735
S/N: PLE1-Up
Part No.: 106-0735
S/N: CKH1-Up
Part No.: 106-0735
S/N: C1J1-Up
Part No.: 106-0735
S/N: J2K1-Up
Part No.: 106-0735
S/N: CYN1-Up
g01391967
Illustration 113
Part No.: 106-0735
S/N: T2P1-Up (1) Final installation torque for the temperature
sensor group .................. 20 ± 5 N·m (15 ± 4 lb ft)
Output type ................................................... Passive
Operating temperature ........................ −40 to 150 °C

(−40 to 302 °F)
g01429733
Illustration 112
Typical example
(2) Plug
(1) Final installation torque .. 20 ± 3 N·m (15 ± 2 lb ft)
Operating voltage ......................... 4.75 to 8.50 Volts
Output type .................................................... Analog

RENR2387-15 65
i02845077 i02894836
Coolant Temperature Sensor Coolant Level Sensor

SMCS Code: 1906 SMCS Code: 7470-NS
Part No.: 264-4297 Part No.: 204-2518
S/N: J2K1-Up
Part No.: 264-4297
S/N: P1N1-Up
Part No.: 264-4297
S/N: P2N1-Up
Part No.: 264-4297
S/N: T2P1-Up
Part No.: 264-4297
S/N: GES1-Up
Part No.: 264-4297
S/N: KJT1-Up
g01440910
Illustration 115
Part No.: 264-4297
S/N: JKX1-Up (1) Final installation torque for the coolant level
Part No.: 264-4297 sensor group .................. 22 ± 3 N·m (16 ± 2 lb ft)
S/N: NAX1-Up
Part No.: 264-4297 (−40 to 257 °F)
S/N: NAY1-Up
Operating voltage .................................. 7 to 32 VDC
Part No.: 264-4297
i02839267
Fuel Temperature Sensor

SMCS Code: 1922
Part No.: 130-9811
g01089060
Illustration 114
(1) Final installation torque for the temperature


g01089060
Illustration 116
(−40 to 302 °F) (1) Final installation torque for the temperature
sensor ............................ 20 ± 5 N·m (15 ± 4 lb ft)

(−40 to 302 °F)
66 RENR2387-15
i02845081 i02847040
Fuel Temperature Sensor Engine Oil Pressure Sensor

Part No.: 264-4297 Part No.: 161-1705
g01089060 g01122320
(1) Final installation torque for the temperature Prior to installing the pressure sensor onto the
sensor group .................. 20 ± 3 N·m (15 ± 2 lb ft) engine, apply 5P-3413 Pipe Sealant to the first three
threads of the sensor.
(1) Final installation torque for the pressure
Operating temperature ........................ −40 to 150 °C sensor ......................... 10 ± 2 N·m (90 ± 18 lb in)
(−40 to 302 °F)
Operating voltage ........................... 5.00 ± 0.25 VDC
i02869400
Fuel Pressure Sensor (−40 to 257 °F)
SMCS Code: 1718 i02870383
Part No.: 161-1705 Boost Pressure Sensor

SMCS Code: 1917
Part No.: 218-3840
g01135892
Illustration 118
(1) Final installation torque for the pressure sensor

group .......................... 10 ± 2 N·m (90 ± 18 lb in)
g01429763
Illustration 120
Operating temperature ........................ −40 to 125 °C (2) Plug
(−40 to 257 °F)
(1) Final installation torque ...................... 10 ± 2 N·m
Operating voltage ........................... 5.00 ± 0.25 VDC (90 ± 18 lb in)
RENR2387-15 67
Operating voltage .......................... 4.75 to 5.25 VDC i03001907
Inlet Air Temperature Sensor

i02911305
SMCS Code: 1921
Atmospheric Pressure Sensor
S/N: PLE1-Up
SMCS Code: 1923
Part No.: 130-9811
Part No.: 161-9932 S/N: CKH1-Up
Part No.: 130-9811
S/N: C1J1-Up
Part No.: 130-9811
S/N: J2K1-Up
Part No.: 130-9811
S/N: CYN1-Up
Part No.: 130-9811
S/N: GEN1-Up
Part No.: 130-9811
S/N: P1N1-Up
Illustration 121
g01190345 Part No.: 130-9811
S/N: P2N1-Up
(1) Final installation torque for the pressure sensor Part No.: 130-9811
group .......................... 10 ± 2 N·m (90 ± 18 lb in) S/N: GES1-Up
Operating temperature ........................ −40 to 125 °C Part No.: 130-9811
(−40 to 257 °F) S/N: KJT1-Up
Operating voltage ........................... 5.00 ± 0.25 VDC Part No.: 130-9811

S/N: JKX1-Up
Part No.: 130-9811
S/N: NAX1-Up
Part No.: 130-9811
S/N: NAY1-Up
Part No.: 130-9811
g01068415
Illustration 122
(1) Final installation torque for the temperature

68 RENR2387-15
Operating temperature ........................ −40 to 150 °C i02847505

(−40 to 302 °F)
Inlet Air Temperature Sensor
SMCS Code: 1921
Part No.: 264-4297
S/N: PLE1-Up
Part No.: 264-4297
S/N: CKH1-Up
Part No.: 264-4297
S/N: C1J1-Up
Part No.: 264-4297
S/N: J2K1-Up
Part No.: 264-4297
S/N: CYN1-Up
Part No.: 264-4297
S/N: GEN1-Up
Part No.: 264-4297
S/N: P1N1-Up
Part No.: 264-4297
S/N: P2N1-Up
Part No.: 264-4297
S/N: GES1-Up
Part No.: 264-4297
S/N: KJT1-Up
Part No.: 264-4297
S/N: JKX1-Up
Part No.: 264-4297
S/N: NAX1-Up
Part No.: 264-4297
S/N: NAY1-Up
Part No.: 264-4297
g01089060
Illustration 123
(1) Final installation torque for temperature sensor

group ............................. 20 ± 3 N·m (15 ± 2 lb ft)
RENR2387-15 69
Output type ................................................... Passive Secondary Speed/Timing Sensor

(−40 to 302 °F)
i02993763
Speed/Timing Sensor
SMCS Code: 1907; 1912
Part No.: 188-7513, 189-9266
Primary Speed/Timing Sensor

g01520700
Illustration 125
Secondary speed/timing sensor
Note: Before installation, lubricate the O-ring with

fluid that is being sealed.
(1) Ensure that the bracket is installed in the

orientation that is shown.

(−40 to 302 °F)
Note: Ensure that the sensor is seated before bolt

Illustration 124
g01520699 (2) is tightened.
Primary speed/timing sensor
Note: Before installation, lubricate the O-ring with
fluid that is being sealed.
(1) Ensure that the bracket is installed in the

orientation that is shown.

(−40 to 302 °F)
Note: Ensure that the sensor is seated before bolt

(2) is tightened.

70 RENR2387-15
i03293250 Refer to the Specifications, “Tachometer Calibration

Chart”for calibration settings.
Tachometer
General specifications
SMCS Code: 7462
Operating temperature range .... −20° C to 85° C
Part No.: 197-7348 (−4° F to 185° F)
S/N: WKB1-Up Accuracy of tachometer ................. ± 0.5 percent
Input frequency range ................... 75 to 9000 Hz
Part No.: 197-7348
Time that is required for the update
S/N: PLE1-Up
(maximum) ......................................... 1.0 second
Part No.: 197-7348 Time that is required for the update
S/N: CKH1-Up (minimum) ........................................ 0.25 second
Part No.: 197-7348

S/N: C1J1-Up i03288363
Part No.: 197-7348 Tachometer Calibration Chart

S/N: J2K1-Up
SMCS Code: 7462
Part No.: 197-7348
S/N: CYN1-Up Part No.: 197-7348
S/N: WKB1-Up
Part No.: 197-7348
S/N: GEN1-Up Part No.: 197-7348
S/N: PLE1-Up
Part No.: 197-7348
S/N: T2P1-Up Part No.: 197-7348
S/N: CKH1-Up
Part No.: 197-7348
S/N: GES1-Up Part No.: 197-7348
S/N: C1J1-Up
Part No.: 197-7348
S/N: KJT1-Up Part No.: 197-7348
S/N: J2K1-Up
Part No.: 197-7348
S/N: JKX1-Up Part No.: 197-7348
S/N: CYN1-Up
Part No.: 197-7348
S/N: MGS1-Up; GPN1-Up Part No.: 197-7348
S/N: GEN1-Up
Part No.: 197-7348
S/N: T2P1-Up
Part No.: 197-7348
S/N: GES1-Up
Part No.: 197-7348
S/N: KJT1-Up
Part No.: 197-7348
S/N: JKX1-Up
Part No.: 197-7348
g01332706
Illustration 126
(1) Magnetic pickup terminals
(2) Tighten the two nuts to the following

torque. ........................ 0.9 ± 0.1 N·m (8 ± 1 lb in)
(3) To calibrate the tachometer, remove the

plug. Tighten the plug to the following
torque. ........................ 0.6 ± 0.1 N·m (5 ± 1 lb in)
RENR2387-15 71
g01674534
Illustration 127
i02870395 Part No.: 171-2209

S/N: P1N1-Up
Circuit Breakers
Part No.: 171-2209
SMCS Code: 1420 S/N: P2N1-Up
Part No.: 171-2205, 171-2209, 171-2213 Part No.: 171-2205, 171-2209, 171-2213
S/N: WKB1-Up S/N: T2P1-Up
Part No.: 171-2205, 171-2209, 171-2213 Part No.: 171-2205, 171-2209, 171-2213
S/N: PLE1-Up S/N: GES1-Up
Part No.: 171-2205, 171-2209, 171-2213 Part No.: 171-2205, 171-2209, 171-2213
S/N: CKH1-Up S/N: KJT1-Up
Part No.: 171-2205, 171-2209, 171-2213 Part No.: 171-2205, 171-2209, 171-2213
S/N: C1J1-Up S/N: JKX1-Up
Part No.: 171-2205, 171-2209, 171-2213 Part No.: 171-2209
S/N: J2K1-Up S/N: NAX1-Up
Part No.: 171-2205, 171-2209, 171-2213 Part No.: 171-2209
S/N: CYN1-Up S/N: NAY1-Up
Part No.: 171-2205, 171-2209, 171-2213 Part No.: 171-2205, 171-2209, 171-2213
S/N: GEN1-Up S/N: MGS1-Up; GPN1-Up
72 RENR2387-15
i02870411
Circuit Breakers
SMCS Code: 1420
Part No.: 6T-3645
S/N: WKB1-Up
Part No.: 6T-3645
S/N: PLE1-Up
Part No.: 6T-3645
S/N: CKH1-Up
Part No.: 6T-3645
g01429771
Illustration 128 S/N: C1J1-Up
(1) Final installation torque for the nuts ..... 7 ± 1 N·m Part No.: 6T-3645
(60 ± 9 lb in) S/N: J2K1-Up
Part No.: 6T-3645
S/N: CYN1-Up
Part No.: 6T-3645
S/N: GEN1-Up
Part No.: 6T-3645
S/N: T2P1-Up
Part No.: 6T-3645
S/N: GES1-Up
Part No.: 6T-3645
S/N: KJT1-Up
Part No.: 6T-3645
S/N: JKX1-Up
Part No.: 6T-3645
g01429776
Illustration 129
(1) Tighten the nuts to the following

torque. .................. 2.25 ± 0.25 N·m (20 ± 2 lb in)
RENR2387-15 73
Index Section
Index
A Housing (Front)...................................................... 49
Alternator and Regulator ................................. 60–63

Atmospheric Pressure Sensor............................... 67 I
Auxiliary Water Pump ...................................... 34–35
Important Safety Information ................................... 2
Inlet Air Temperature Sensor........................... 67–68
B
Belt Tension Chart ................................................. 58 M

Boost Pressure Sensor.......................................... 66
Main Bearing Journal............................................. 46
C
P
Camshaft ......................................................... 21–23
Circuit Breakers ............................................... 71–72 Piston and Rings ................................................... 48
Connecting Rod..................................................... 47 Intermediate Piston Ring (2) .............................. 49
Connecting Rod Bearing Journal........................... 45 Oil Control Piston Ring (3) ................................. 49
Coolant Level Sensor ............................................ 65 Pin Retainer (5).................................................. 49
Coolant Temperature Sensor........................... 64–65 Piston Pin (4) ..................................................... 49
Crankshaft ............................................................ 42 Top Piston Ring (1) ............................................ 48
Cylinder Block........................................................ 39
Cylinder Head........................................................ 13
Cylinder Head Valves ............................................. 11 S
Cylinder Liner ........................................................ 41
Specifications Section ............................................. 4
Speed/Timing Sensor ............................................ 69
E Primary Speed/Timing Sensor ........................... 69
Secondary Speed/Timing Sensor ...................... 69
Electronic Unit Injector Mechanism ......................... 8
Electronic Unit Injector Rocker Arm......................... 9
Engine Design ......................................................... 4 T
C18 ...................................................................... 4
Engine Oil Filter Base...................................... 24–26 Table of Contents..................................................... 3
Engine Oil Pan................................................. 29–31 Tachometer............................................................ 70
Engine Oil Pressure Sensor .................................. 66 Tachometer Calibration Chart................................ 70
Engine Oil Pump.............................................. 27–28 Turbocharger ................................................... 16–17
Exhaust Manifold ............................................. 18, 20
V
F
Valve Mechanism .................................................. 10
Flywheel .......................................................... 55–56 Valve Mechanism Cover........................................ 10
Flywheel Housing ............................................ 56–57 Vibration Damper and Pulley........................... 43–45
Front Housing and Covers..................................... 50
Fuel Filter Base ................................................... 6–8
Fuel Pressure Sensor............................................ 66 W
Fuel Temperature Sensor ................................ 65–66
Fuel Transfer Pump ............................................. 4–5 Water Pump........................................................... 33
Water Temperature Regulator ............................... 32
Gear Group (Front).......................................... 51, 53
Heat Exchanger............................................... 37–38

74 RENR2387-15
Index Section
RENR2387-15 75
Index Section
©2009 Caterpillar Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge Printed in U.S.A.
All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.

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RENR2387-15

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Alternator and Regulator ......................................

Specifications Section Part No.: 295-9260

Valves per cylinder .................................................. 4 Part No.: 295-9260

Exhaust valve lash ........................... 0.76 ± 0.08 mm

Firing order (injection sequence) ........ 1, 5, 3, 6, 2, 4

Crankshaft rotation from the flywheel

Note: The front end of the engine is opposite the

5. Run the pump at 840 rpm. Keep the inlet open to

6. Run the pump at 120 rpm with a blocked inlet for

When the pump is viewed from the drive end, the

Fuel Transfer Pump

(4) Outlet port

(5) Apply 154-9731 Thread Lock Compound to the

(6) Tighten the nuts to the following

(1) Torque for nut ................ 25 ± 4 N·m (18 ± 3 lb ft)

Fuel Filter Base

Fuel Filter Base

Part No.: 6N-6259 distance. ........................................ 7.6 ± 0.8 mm

Note: Before installation of the unit injector, lubricate

Note: Refer to Testing and Adjusting, “Electronic Unit

(A) Adjust the unit injector height to the following

1. Tighten the bolt to 55 ± 10 N·m (41 ± 7 lb ft).

2. Loosen the bolt until the bolt is finger tight.

3. Again, tighten the bolt to 55 ± 10 N·m (41 ± 7 lb ft).

Electronic Unit Injector Rocker

i03016667 Note: Refer to Testing and Adjusting, “Engine Valve

Note: For engines that are equipped with CAT

(5) Location for checking the valve lash

Part No.: 223-9250

Note: Apply 4C-4030 Thread Lock Compound to

(1) Torque for bolts .............. 18 ± 3 N·m (13 ± 2 lb ft)

Cylinder Head Valves

(A) Height to top of valve guide ..... 35.00 ± 0.50 mm

(B) Bore of installed new valve

Note: Do not use a combination of a valve and

(C) Dimension for valve recess Illustration 19

Inlet .......... 2.20 to 2.80 mm (0.087 to 0.110 inch)

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

(L) Inside diameter of valve seat insert

(M) Angle of valve seat face

Inlet ......... 47.00 ± 0.13 mm (1.850 ± 0.005 inch)

(G) Dimension for valve lip thickness

Apply 6V-4876 Lubricant to the bolt threads and

1. In a numerical sequence, tighten bolts 1 through

Torque for bolts ............................... 270 ± 15 N·m

2. In a numerical sequence, tighten bolts 1 through

Torque for bolts ............................... 450 ± 15 N·m

3. In a numerical sequence, again tighten bolts 1

Torque for bolts ............................... 450 ± 15 N·m

(A) Cylinder Head Thickness

Thickness of a new cylinder Orientation of bearing joint

The depth of installation of the camshaft bearings is

Installation depth for camshaft bearings (30)