G3600 Specifi RENR5907-06-01-ALL

RENR5907-06
August 2004
Specifications
G3600 Engines
BLB1-Up (Engine)
BKE1-Up (Engine)
BEN1-Up (Engine)
4ZS1-Up (Engine)
i01658146
Important Safety Information

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

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

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

ture failures, product damage, personal injury or
death.
RENR5907-06 3
Table of Contents
Table of Contents Connecting Rod and Main Bearing Journals ........ 72

Piston and Rings .................................................. 73
Cylinder Liner ....................................................... 74
Camshaft Bearings .............................................. 74
Specifications Section Camshaft Bearings .............................................. 75
Camshaft Bearing Position .................................. 76
Engine Design ....................................................... 4
Engine Design ....................................................... 4
Engine Design ....................................................... 5
Engine Design ....................................................... 5
Gear Group (Front) ............................................... 82
Air Lines (Air Choke) ............................................... 7
Housing (Front) ..................................................... 83
Air Lines (Air Choke) ............................................. 10
Gear Group (Rear) ................................................ 84
Gear Group (Rear) ................................................ 85
Housing (Rear) ..................................................... 88
Gas Engine Ignition (Bio-Gas Fuel) ...................... 16
Housing (Rear) ..................................................... 90
Gas Engine Ignition ............................................. 16
Vibration Damper (Single) .................................... 92
Electrohydraulic Actuator ...................................... 17
Vibration Damper (Dual) ....................................... 93
Engine Oil Lines (Electrohydraulic System) .......... 17
Vibration Damper (Single) .................................... 94
Electronic Control (Combustion Sensor) .............. 18
Flywheel ............................................................... 95
Fuel Control .......................................................... 18
Flywheel ............................................................... 96
Fuel Control .......................................................... 20
Flexible Coupling .................................................. 97
Fuel Lines ............................................................. 21
Fuel Lines ............................................................. 22
Camshaft ............................................................. 22
Manual Barring Group .......................................... 98
Camshaft ............................................................. 24
Engine Lifting Bracket ........................................... 98
Valve Mechanism ................................................. 26
Engine Lifting Bracket ........................................... 99
Cylinder Head, Valves, Valve Springs and Valve Seat
Engine Support .................................................... 99
Inserts ................................................................. 28
Belt Tension Chart ............................................... 99
Prechamber (Bio-Gas Fuel) .................................. 30
Alternator and Regulator .................................... 101
Prechamber .......................................................... 31
Alternator and Regulator .................................... 102
Prechamber .......................................................... 32
Air Starting Motor ............................................... 102
Turbocharger ....................................................... 33
Air Starting Motor ............................................... 103
Turbocharger ....................................................... 34
Air Starting Motor Pressure Regulating Valve ... 103
Exhaust Manifold ................................................. 35
Temperature Sensor ........................................... 103
Pressure Switch .................................................. 104
Pressure Switch (Electrohydraulic) ..................... 104
Pressure Switch .................................................. 104
Exhaust Bypass Valve ......................................... 40
Pressure Sensor ................................................. 105
Pressure Sensor ................................................. 105
Pressure Sensor ................................................. 105
Detonation Sensor .............................................. 106
Aftercooler ........................................................... 50
Prelube Pressure Switch .................................... 106
Aftercooler ........................................................... 50
Speed Sensor .................................................... 106
Aftercooler (Two-Stage) ........................................ 51
Speed Sensor .................................................... 107
Air Cleaner Adapter .............................................. 51
Prelube Pump ....................................................... 51
Engine Oil Pump .................................................. 52 Index Section
Engine Oil Pump .................................................. 53
Engine Oil Pump .................................................. 55 Index ................................................................... 108
Engine Oil Pump .................................................. 56
Engine Oil Pump .................................................. 58
Priority Valve ........................................................ 59
Engine Oil Filter ................................................... 59
Electrohydraulic Oil Filter ...................................... 59
Engine Oil Temperature Regulator ....................... 60
Crankcase Breather ............................................. 60
Water Pump ......................................................... 61
Water Temperature Regulator .............................. 63
Cylinder Block ...................................................... 64
Cylinder Block ...................................................... 66
Crankshaft ........................................................... 68
Crankshaft Seals ................................................. 70
Connecting Rod ................................................... 70
4 RENR5907-06
Specifications Section
Specifications Section When the crankshaft is viewed from the flywheel

end the crankshaft rotates in the following
direction. ....................................... Counterclockwise
i00763110
Note: The front end of the engine is opposite the
Engine Design flywheel end of the engine. The left and the right side
of the engine are determined from the flywheel end.
SMCS Code: 1000; 1201 The number 1 cylinder is the front cylinder.
S/N: 4ZS1-Up
i00939911
Engine Design
SMCS Code: 1000; 1201
S/N: BEN1-Up
g00283190
Illustration 1
Engine Design
(A) Inlet. (B) Gas admission. (C) Exhaust.
Number and arrangement of cylinders ........ In-line 6
Valves per cylinder Illustration 2

g00465539
Inlet valves ........................................................ 2 Engine Design

(A) Inlet. (B) Gas admission. (C) Exhaust.
Exhaust valves ................................................. 2
Number and arrangement of cylinders ........ In-line 8
Gas admission valve ........................................ 1
Valves per cylinder
Displacement ............................ 127.2 L (7762 cu in)
Inlet valves ........................................................ 2
Bore ............................................ 300 mm (11.8 inch)
Exhaust valves ................................................. 2
Stroke ......................................... 300 mm (11.8 inch)
Compression ratio ............................................. 9.2:1
Displacement ............................ 170 L (10,352 cu in)
Compression ratio ............................................... 11:1
Bore ............................................ 300 mm (11.8 inch)
Combustion .......................................... Spark Ignited
Stroke ......................................... 300 mm (11.8 inch)
Firing order
Compression ratio ............................................. 9.2:1
Standard rotation CCW .................... 1-5-3-6-2-4
Compression ratio ............................................... 11:1
Valve lash
Inlet ..................................... 0.50 mm (.020 inch)
Firing order
Exhaust ............................... 1.27 mm (.050 inch)
Standard rotation CCW .............. 1-6-2-5-8-3-7-4
Gas admission .................... 0.64 mm (.025 inch)
Valve lash
RENR5907-06 5
Inlet ..................................... 0.50 mm (.020 inch) Standard rotation

CCW ........................ 1-12-9-4-5-8-11-2-3-10-7-6
Exhaust ............................... 1.27 mm (.050 inch)
Valve lash
Gas admission .................... 0.64 mm (.025 inch)
Inlet valve ........................... 0.50 mm (.020 inch)
When the crankshaft is viewed from the flywheel
end the crankshaft rotates in the following Exhaust valve ..................... 1.27 mm (.050 inch)
Gas admission valve .......... 0.64 mm (.025 inch)
flywheel end of the engine. The left and the right side When the crankshaft is viewed from the flywheel
of the engine are determined from the flywheel end. end the crankshaft rotates in the following
The number 1 cylinder is the front cylinder. direction. ....................................... Counterclockwise

i02112524 flywheel end of the engine. The left and the right side
Engine Design The number 1 cylinder is the right front cylinder.
SMCS Code: 1000; 1201
i02112530
S/N: BKE1-Up
Engine Design
SMCS Code: 1000; 1201
S/N: BLB1-Up
g00471973
Illustration 3
Engine Design
(A) Inlet valves. (B) Gas admission valves. (C) Exhaust valves.
Number and arrangement of cylinders ... 50° Vee 12 Illustration 4

g00472128
Engine Design
Valves per cylinder
(A) Inlet valves. (B) Gas admission valves. (C) Exhaust valves.
Inlet valves ........................................................ 2
Number and arrangement of cylinders .... 50° Vee 16
Exhaust valves ................................................. 2
Gas admission valve ........................................ 1 Valves per cylinder
Inlet valves ........................................................ 2
Displacement ............................ 254.5 L (15,525 in 3 )
Exhaust valves ................................................. 2
Bore ............................................ 300 mm (11.8 inch)
Stroke ......................................... 300 mm (11.8 inch)
Displacement ............................ 339.3 L (20,700 in 3 )
Compression ratio ................................................ 9:1
Bore ............................................ 300 mm (11.8 inch)
Stroke ......................................... 300 mm (11.8 inch)
Firing order
Compression ratio ................................................ 9:1
6 RENR5907-06
Firing order
Standard rotation
CCW .... 1-2-5-6-3-4-9-10-15-16-11-12-13-14-7-8
Valve lash
Inlet valve ........................... 0.50 mm (.020 inch)
Exhaust valve ..................... 1.27 mm (.050 inch)
Gas admission valve .......... 0.64 mm (.025 inch)
When the crankshaft is viewed from the flywheel

end the crankshaft rotates in the following

flywheel end of the engine. The left and the right side
The number 1 cylinder is the right front cylinder.
RENR5907-06 7
i01747378
Air Lines
(Air Choke)
SMCS Code: 1058
S/N: BEN1-Up
S/N: 4ZS1-Up
g00894620
Illustration 5
Left side view of the air choke for G3606 Engines
8 RENR5907-06
g00894621
Illustration 6
Left side view of the air choke for G3608 Engines
(1) Choke plate Thickness of thrust washer ........ 6.00 ± 0.05 mm

(0.236 ± 0.002 inch)
(2) Shaft
(5) Bolt
Bore in housing for shaft
bearings ............................... 15.081 ± 0.009 mm (6) Locking nut
(.5937 ± .0004 inch)
Outside diameter of shaft (7) Adjusting bolt
bearings ............................... 15.120 ± 0.018 mm
(0.5953 ± 0.0007 inch) (8) Stop plate
(3) Bolt (9) Plate
(4) Thrust washer (10) Inlet port for the actuator
Width of groove in shaft for thrust
washer ...... 6.48 ± 0.10 mm (0.255 ± 0.004 inch) (11) Outlet port for the actuator
RENR5907-06 9
(12) Full nut 6. Assemble rod (13). Provide equal engagement

of the threads at both ends of the rod until the
Torque for full nut ... 200 ± 20 N·m (150 ± 15 lb ft) distance between the center bores of the rod ends
is approximately the specified length.
(13) Rod
7. Apply 4C-4030 Thread Lock Compound to the
Distance between the center bores of the rod
threads of clevis (14).
ends ................................. 25.36 cm (9.984 inch)
8. For final adjustment of the linkage, ensure that
(14) Clevis
the actuator does not try to force stop plate (8)
(15) Full nut past plate (9) when the choke plate is moved to
the fully open position.
Torque for full nuts ......... 25 ± 6 N·m (18 ± 4 lb ft)
a. Fully extend the actuator. Make sure that the
(16) Bolt choke plate is in the fully open position and that
stop plate (8) contacts plate (9).
(17) O-ring seal
b. Then reduce the length of rod (13) by 1/2 turn
(180 degrees).
This allows a clearance between stop plate (8)

and plate (9).
c. Make sure that the choke plate can achieve

the fully closed position. Tighten full nuts (15)
to the specified torque.
9. Apply 4C-5597 Anti-Seize Compound to the

threads and to the face of bolts (16).
10. Apply glycerin to O-ring seal (17).

g00894722
Illustration 7
(A) Angle for the lever in the fully closed

position ............................................. 20 degrees
(B) Angle for the lever in the fully open

Use the following procedure to assemble the air

choke:
1. Assemble choke plate (1) to shaft (2). Loosely

install bolts (3).
2. Install thrust washer (4) and tighten bolts (5).
3. To ensure that bolts (3) are properly seated in

shaft (2), fully close choke plate (1) and tighten
bolts (3).
4. Make sure that choke plate (1) is fully closed.

Loosen locking nut (6) and turn adjusting bolt
(7) until the bolt is seated against stop plate (8).
Tighten the bolt for an additional 1/4 turn (90
degrees) and then tighten the locking nut.
5. Assemble the actuator with inlet port (10) in the

upward position and with outlet port (11) in the
downward position. Tighten full nut (12) to the
specified torque.
10 RENR5907-06
i01748457
Air Lines
(Air Choke)
SMCS Code: 1058
Part No.: 210-5736
S/N: BLB1-Up
Part No.: 210-5736
S/N: BKE1-Up
g00897221
Illustration 10
Closed position
(1) Adjusting bolt
(2) Thrust washer

washer .. 6.53 ± 0.10 mm (0.2571 ± 0.0039 inch)
Thickness of thrust washer ........ 6.00 ± 0.05 mm
(0.236 ± 0.002 inch)
(3) Locking nut
(4) Plate
(5) Bolt
g00897609 (6) Stop plate

Illustration 8
Rear view (7) Housing
bearings ............................... 25.402 ± 0.010 mm
(1.0001 ± 0.0004 inch)
Outside diameter of shaft
bearings ................................ 25.529 ±0.020 mm
(1.0051 ± 0.0008 inch)
(8) Shaft
(9) Choke plate
(10) Bolt
g00897197
(11) Bearing
Illustration 9
Left view Install the bearings so the lubrication fitting is in an
accessible position.
RENR5907-06 11
Lubricate the bearings with 5P-0960 Molybdenum 1. Assemble choke plate (9) to shaft (8). Loosely
Grease. install bolts (10).
(12) O-ring 2. Install thrust washer (2) and tighten bolts (5).
Lubricate the O-ring with 1U-6396 O-Ring Assembly 3. To ensure that bolts (10) are properly seated in
Compound. shaft (8), fully close choke plate (9) and tighten
bolts (10).
(13) Bolt
Apply 4C-5598 High Temperature Anti-Seize to the Loosen locking nut (3) and turn adjusting bolt
threads and to the face of the bolts. (1) until the bolt is seated against stop plate (6).
(14) Nut degrees) and then tighten the locking nut.
Torque for nuts ............... 25 ± 6 N·m (18 ± 4 lb ft) 5. Assemble the actuator with inlet port (21) in
the upward position and with outlet port (22) in
(15) Rod the downward position. Tighten nut (18) to the
specified torque.
ends ................................ 121.6 mm (4.787 inch)
(16) Clevis
7. Assemble rod (15). Provide equal engagement
Apply 4C-4030 Thread Lock Compound to the
threads.
distance between the center bores of the rod ends
(17) Nut
Torque for nuts ............... 25 ± 6 N·m (18 ± 4 lb ft) 8. Assemble rod (19). Provide equal engagement
(18) Nut distance between the center bores of the rod ends
Torque for nut ........ 200 ± 20 N·m (150 ± 15 lb ft)
9. For final adjustment of the linkage, ensure that
(19) Rod the actuator does not try to force stop plate (6)
past plate (4) when the choke plate is moved to
Distance between the center bores of the rod the fully open position.
ends .............................. 340.1 mm (13.389 inch)
a. Fully extend the actuator. Make sure that the
(20) Actuator choke plate is in the fully open position and that
(21) Inlet port
(22) Outlet port (180 degrees).
(A) Angle This allows a clearance between stop plate (6)
Angle for the lever in the fully closed and plate (4).
(B) Angle the fully closed position. Tighten nuts (14) and
nuts (17) to the specified torque.
Angle for the lever in the fully closed
(C) Angle

choke:
12 RENR5907-06
i01755045
Air Lines
(Air Choke)
SMCS Code: 1058
Part No.: 206-6540
S/N: BKE1-Up
g00897965
Illustration 12
Top view
g00897955
Illustration 11
Rear view
g00897954
Illustration 13
Closed position
(1) Adjusting bolt
(2) Thrust washer

washer .. 6.53 ± 0.10 mm (0.2571 ± 0.0039 inch)
Thickness of thrust washer ........ 6.00 ± 0.05 mm
(0.236 ± 0.002 inch)
(3) Locking nut
(4) Plate
RENR5907-06 13
(5) Bolt (21) Inlet port
(6) Stop plate (22) Outlet port
(7) Housing (A) Angle

Bore in housing for shaft Angle for the lever in the fully closed
bearings ............................... 25.402 ± 0.010 mm position ............................................. 27 degrees
(1.0001 ± 0.0004 inch)
Outside diameter of shaft (B) Angle
bearings ................................ 25.529 ±0.020 mm
(1.0051 ± 0.0008 inch) Angle for the lever in the fully closed
(8) Shaft
(C) Angle
(9) Choke plate
(10) Bolt
(11) Bearing choke:
Install the bearings so the lubrication fitting is in an
accessible position. install bolts (10).
Lubricate the bearings with 5P-0960 Molybdenum
Grease.
(12) Bolt
shaft (8), fully close choke plate (9) and tighten
bolts (10).
Apply 155-0695 Thread Lock Compound to the
threads of the bolts prior to assembly.
(13) Bolt
(1) until the bolt is seated against stop plate (6).
Apply 4C-5599 Anti-Seize Compound to the threads degrees) and then tighten the locking nut.
and to the face of the bolts.
5. Assemble the actuator with inlet port (21) in
(14) Nut the upward position and with outlet port (22) in
Torque for nuts ............... 25 ± 6 N·m (18 ± 4 lb ft) the downward position. Tighten nut (18) to the
specified torque.
(15) Rod
Distance between the center bores of the rod threads of clevis (16).
ends .................................... 118 mm (4.646 inch)
(16) Clevis of the threads at both ends of the rod until the
Apply 4C-4030 Thread Lock Compound to the is approximately the specified length.
threads.
(17) Nut of the threads at both ends of the rod until the
Torque for nuts ............... 25 ± 6 N·m (18 ± 4 lb ft) is approximately the specified length.
(18) Nut 9. For final adjustment of the linkage, ensure that
the actuator does not try to force stop plate (6)
Torque for nut ........ 200 ± 20 N·m (150 ± 15 lb ft)
past plate (4) when the choke plate is moved to
(19) Rod the fully open position.
Distance between the center bores of the rod a. Fully extend the actuator. Make sure that the
ends ................................. 389 mm (15.315 inch) choke plate is in the fully open position and that
(20) Actuator
14 RENR5907-06

(180 degrees).
This allows a clearance between stop plate (6)

and plate (4).

the fully closed position. Tighten nuts (14) and
i01786425
Air Lines
(Air Choke)
SMCS Code: 1058
Part No.: 147-5090
S/N: BLB1-Up
g00913961
Illustration 15
Left view
g00913952
Illustration 14
Rear view
g00913967
Illustration 16
Closed position
(1) Adjusting bolt
(2) Thrust washer

washer .. 6.53 ± 0.10 mm (0.2571 ± 0.0039 inch)
RENR5907-06 15
Thickness of thrust washer ........ 6.00 ± 0.05 mm Torque for nut ........ 200 ± 20 N·m (150 ± 15 lb ft)
(0.236 ± 0.002 inch)
(19) Rod
(3) Locking nut
(4) Plate ends .............................. 544.7 mm (21.445 inch)
(5) Bolt (20) Actuator
(6) Stop plate (21) Inlet port
(7) Housing (22) Outlet port
Bore in housing for shaft (A) Angle

bearings ............................... 25.402 ± 0.010 mm
(1.0001 ± 0.0004 inch) Angle for the lever in the fully closed
Outside diameter of shaft position ............................................. 27 degrees
bearings ................................ 25.529 ±0.020 mm
(1.0051 ± 0.0008 inch) (B) Angle
(8) Shaft
position .......................................... 41.5 degrees
(9) Choke plate (C) Angle
(10) Bolt Angle for the lever in the fully closed
(11) Bearing
Install the bearings so the lubrication fitting is in an choke:
accessible position.
Lubricate the bearings with 5P-0960 Molybdenum install bolts (10).
Grease.
(12) O-ring
Lubricate the O-ring with 1U-6396 O-Ring Assembly shaft (8), fully close choke plate (9) and tighten
Compound. bolts (10).
(13) Bolt 4. Make sure that choke plate (9) is fully closed.
Apply 4C-5598 High Temperature Anti-Seize to the (1) until the bolt is seated against stop plate (6).
threads and to the face of the bolts. Tighten the bolt for an additional 1/4 turn (90
degrees) and then tighten the locking nut.
(14) Nut
5. Assemble the actuator with inlet port (21) in
Torque for nuts ............... 25 ± 6 N·m (18 ± 4 lb ft) the upward position and with outlet port (22) in
the downward position. Tighten nut (18) to the
(15) Rod
specified torque.
ends ................................ 121.6 mm (4.787 inch) 6. Apply 4C-4030 Thread Lock Compound to the
(16) Clevis
Apply 4C-4030 Thread Lock Compound to the of the threads at both ends of the rod until the
threads. distance between the center bores of the rod ends
(17) Nut
Torque for nuts ............... 25 ± 6 N·m (18 ± 4 lb ft) of the threads at both ends of the rod until the
(18) Nut is approximately the specified length.
16 RENR5907-06
9. For final adjustment of the linkage, ensure that Note: A new gasket should be used when a spark
the actuator does not try to force stop plate (6) plug is installed. Install the spark plug gasket with the
past plate (4) when the choke plate is moved to tangs toward the sealing face of the spark plug.
the fully open position.
Tighten the nuts for the connectors to the
a. Fully extend the actuator. Make sure that the transformers in a clockwise motion. Use 6V-0006
choke plate is in the fully open position and that Electrical Connector Pliers to tighten the nuts.
i01574790
(180 degrees). Gas Engine Ignition
This allows a clearance between stop plate (6) SMCS Code: 1550
and plate (4).

the fully closed position. Tighten nuts (14) and
i01882419
Gas Engine Ignition

(Bio-Gas Fuel)
SMCS Code: 1550
g00818389
Illustration 18
(1) Transformer assembly
(2) Seals
Lubricate the bore lightly with engine oil.
(3) Extension assembly
(4) Spark plug

Tighten the spark plug in the cylinder head to the
g00818389
Illustration 17 following torque. ............ 68 ± 4 N·m (50 ± 3 lb ft)
Spark plug gap .......................... 0.29 ± 0.04 mm
(1) Transformer assembly (0.011 ± 0.002 inch)
(2) Seals Note: A new gasket should be used when a spark

plug is installed. Install the spark plug gasket with the
Lubricate the bore lightly with engine oil. tangs toward the sealing face of the spark plug.
(3) Extension assembly Tighten the nuts for the connectors to the
transformers in a clockwise motion. Use 6V-0006
(4) Spark plug Electrical Connector Pliers to tighten the nuts.
Tighten the spark plug in the cylinder head to the
following torque. ............ 45 ± 5 N·m (33 ± 4 lb ft)
Spark plug gap .......................... 0.28 ± 0.05 mm
(0.011 ± 0.002 inch)
RENR5907-06 17
i01608517 i01856658
Electrohydraulic Actuator Engine Oil Lines

SMCS Code: 1716
(Electrohydraulic System)
SMCS Code: 1307
Part No.: 222-1306
S/N: BEN1-Up
g00833105
Illustration 19
(1) Piston assembly
(2) Housing
1. Insert the piston assembly into the housing.
Torque ....................... 125 ± 15 N·m (92 ± 11 lb ft)
(3) Plug
Torque .................................. 27 ± 5 N·m (20 ± 4 lb ft)
(4) Bolts
Finger tighten the bolts. Torque .............. 3 ± 0.2 N·m

(27 ± 2 lb in)
g00946695
Illustration 20
(1) Pressure relief valve
Operate the engine at rated speed and adjust the

hydraulic oil pressure to 1515 ± 35 kPa (220 ± 5 psi).
(2) Adapter

adapter’s threads.
18 RENR5907-06
i01749710 i01775035
Electronic Control Fuel Control

(Combustion Sensor) SMCS Code: 1550
SMCS Code: 1559 S/N: BEN1-Up
S/N: BLB1-Up Part No.: 231-6462
S/N: 4ZS1-Up
S/N: BKE1-Up
S/N: BEN1-Up
Part No.: 195-6245, 206-5459, 213-6286,
219-9926
S/N: 4ZS1-Up
g00898185
Illustration 22
g00895780
Illustration 21
(1) Connector
g00898432
Illustration 23
(2) Extension
(3) Combustion sensor

A new 108-3515 Gasket is used before each
installation of the combustion sensor.
Tighten the combustion sensor to the following
torque: ........................... 38 ± 2 N·m (28 ± 1 lb ft)
The combustion sensor must not exceed the
following resistance between the terminal post
and the center electrode. ........................ 5 ohms
The combustion sensor must pass a low voltage
continuity check between the terminal post and
the center electrode. ............................... 15 VDC
g00898466
Illustration 24
(1) Actuator
(2) Inlet port

RENR5907-06 19
(3) Bearing (D) Angle
Install the bearings so the lubrication fitting is in an Angle for the lever in the fully open
accessible position. position ............................................... 4 degrees
Lubricate the bearings with 5P-0960 Molybdenum Use the following procedure to assemble the linkage
Grease. for the fuel control valve:
(4) Fuel control valve 1. Assemble the actuator with inlet port (2) in the
upward position and with outlet port (5) in the
(5) Outlet port downward position. Tighten nut (8) to the specified
torque.
(6) Clevis
Apply 4C-4030 Thread Lock Compound to the threads of clevis (6).
threads.
(7) Rod of the threads at both ends of the rod until the
Distance between the center bores of the rod is approximately the specified length.
ends ................................ 235.4 mm (9.268 inch)
(8) Nut of the threads at both ends of the rod until the
Torque for nut ........ 200 ± 20 N·m (150 ± 15 lb ft) is approximately the specified length.
(9) Nut 5. A final adjustment of the linkage is required to
ensure that the actuator is not over rotating the
Torque for nuts ............... 25 ± 6 N·m (18 ± 4 lb ft)
valve stem when the fuel control valve is in the
closed position. The actuator must still close the
(10) Rod end
fuel control valve.
ends ..................................... 82 mm (3.228 inch) a. Fully extend the actuator and close the fuel
control valve.
(11) Nut
b. Rotate the clevis by 1/2 turn so that the clevis
Torque for nuts ............... 25 ± 6 N·m (18 ± 4 lb ft) moves away from the fuel control valve.
(12) Rod length c. Make sure that the metering valve will still
reach the full open position. Tighten nuts (9)
When the fuel control valve is in the closed and nut (11) to the specified torque.
position, the rod assembly is the following
length: ............................. 140.7 mm (5.539 inch)
(13) Rod length

When the fuel control valve is in the open
position, the rod assembly is the following
length: ............................. 159.7 mm (6.287 inch)
(A) Angle
position ............................................ 115 degrees
(B) Angle
Angle for the lever in the fully open
(C) Angle
20 RENR5907-06
i02096739
Fuel Control
SMCS Code: 1550
Part No.: 206-6541
S/N: BLB1-Up
Part No.: 206-6541
S/N: BKE1-Up
g01077941
Illustration 26
Assemble connecting rod (7) so that there is equal

thread engagement at each end. Adjust the rod to
the correct distance.
Distance (D) . ................ 234.2 mm (9.2205 inch)
Tighten rod end nuts (9). ................... 25 ± 6 N·m
(18 ± 4 lb ft)
Tighten end bolts (8). ..... 47 ± 9 N·m (35 ± 7 lb ft)
Tighten bolt (6). .............. 47 ± 9 N·m (35 ± 7 lb ft)
When the fuel valve is in the closed position, the

actuator lever is at angle (A) and the distance from
the clevis to the mounting plate is length (B).
(A) Angle of actuator lever with fuel valve
g00805470 closed. ................................................ 9 degrees
Illustration 25
(B) Distance from the clevis to the mounting
Top view plate. ............................. 138.8 mm (5.4646 inch)
(1) Actuator When the fuel valve is in the open position, the
Install actuator (1) so the inlet port and the outlet actuator lever is at angle (C) and the distance from
port are aligned. This is shown in illustration 25. the clevis to the mounting plate is length (E).
The ports on the actuator are stamped “Inlet” (2) (C) Angle of actuator lever with fuel valve
and “Outlet” (3). open. ................................................. 36 degrees
Torque for the nut on the actuator .. 200 ± 20 N·m (E) Distance from the clevis to the mounting
(148 ± 15 lb ft) plate. ............................... 90.9 mm (3.5787 inch)
(4) Bearings
Install bearings (4) so the lube fitting is
accessible. Lubricate the bearings with 5P-0960
Lithium complex grease.
Torque for bearing bolts. .................... 47 ± 9 N·m
(35 ± 7 lb ft)
RENR5907-06 21
i00763004
Fuel Lines
SMCS Code: 1550
S/N: BEN1-Up
S/N: 4ZS1-Up
g00806072
Illustration 27
Fuel control linkage
Assemble connecting rod (12) so that there is equal

thread engagement at each end. Adjust the rod to
the correct distance.
Distance (H). .................... 172 mm (6.7716 inch)
Tighten rod end nuts (13). ................. 25 ± 6 N·m g00284607
Illustration 28
(18 ± 4 lb ft)
Tighten end bolts (11). ... 47 ± 9 N·m (35 ± 7 lb ft)
(1) Fuel control linkage
Tighten bolt (10). ............ 47 ± 9 N·m (35 ± 7 lb ft)
(2) Tube assembly
When the fuel valve is in the closed position, the lever
is at angle (F) and the distance from the connecting
(3) Fuel control valve
rod to the fuel valve is length (J).
Angle (E). .......................................... 26 degrees (4) Fuel line
Length (J). .................... 140.7 mm (5.5394 inch)
When the fuel valve is in the open position, the lever

is at angle (G) and the distance from the connecting
rod to the fuel valve is length (K).
Angle (F). .......................................... 71 degrees
Length (K). .................... 159.7 mm (6.2874 inch)
A final adjustment of the linkage is required to ensure

that the actuator is not over rotating the valve stem
when the fuel valve is in the closed position. The
actuator must still close the fuel valve.
1. Fully extend the actuator and close the fuel valve.
2. Rotate the clevis by 1/2 turn so that the clevis

moves away from the metering valve.
3. Lock the linkage into position and ensure that the

metering valve will still reach the full open position.
g00284608
Illustration 29
(5) Needle valve

22 RENR5907-06
Note: Direction of arrow on the needle valve should (5) Needle valve
point toward the cylinder head.
Note: Direction of arrow on the needle valve should
Refer to the Testing and Adjusting for the procedure point toward the cylinder head.
to adjust the needle valves.
Refer to the Testing and Adjusting for the procedure
to adjust the needle valves.
i00941477
Fuel Lines i00918743
SMCS Code: 1550 Camshaft

S/N: BLB1-Up SMCS Code: 1210
S/N: BKE1-Up S/N: BEN1-Up
S/N: 4ZS1-Up
g00289767
Illustration 32
(1) Thickness of new thrust plate .. 15.00 ± 0.25 mm

(.591 ± .010 inch)
g00479970
Illustration 30
(2) Diameter of camshaft journal .. 173.80 ± 0.03 mm
(6.843 ± .001 inch)
(1) Fuel control linkage
Bore in camshaft bearing after
(2) Tube assembly installation ..... 174.00 ± 0.06 mm (6.850 ± .002 inch)
(3) Fuel control valve (3) Thickness of new plate ............. 11.80 ± 0.05 mm
(.465 ± .002 inch)
(4) Fuel line
(4) Timing bolt location
NOTICE
Correct cam segment relationship (timing) must be ob-
served at assembly. If the cam segments are out of
time, serious engine damage will occur.
g00480001
Illustration 31
RENR5907-06 23
g00289768 g00289771
Illustration 33 Illustration 35
Location Of Dowels On The Camshaft Bearing Journal Letter Designation Of G3606 Camshaft Journals
g00469453 g00469407
Location Of Dowels On The Camshaft Bearing Journal Letter Designation Of G3608Camshaft Journals
Note: The position of the single dowel in relation to (8) Camshaft bearing journal
the variable dowel determines the letter designation
of the cam journals. The single dowel is located on Install the camshaft bearing journals with the grooved
the same end as the locating groove. The variable end toward the front of the engine.
dowel is located on the end opposite the locating
groove. (9) Camshaft segments
(5) Locating groove Install the camshaft segments with the grooved
flange toward the rear of the engine.
(6) Location of the single dowel in the face of the
camshaft bearing journal (10) Tighten the bolts for the camshaft segment to
the following torque. ...................... 270 ± 40 N·m
Distance from the top of the dowel to the (200 ± 30 lb ft)
camshaft bearing journal ............... 7.0 ± 0.5 mm
(.28 ± .02 inch) (11) The camshaft must be assembled in an
assembly fixture or the camshaft must be
(7) Location of the variable dowel in the face of the assembled in the cylinder block.
camshaft bearing journal
Apply a force at the rear end of the camshaft (11).
Distance from the top of the dowel to the The rolling torque must be a maximum of the
camshaft bearing journal ............... 7.0 ± 0.5 mm following value. ......................... 22 N·m (16 lb ft)
(.28 ± .02 inch)
24 RENR5907-06
i01921213
Camshaft
SMCS Code: 1210
S/N: BLB1-Up
S/N: BKE1-Up
g00289772
Illustration 37
(12) Specified camshaft lobe lift
To find the specified camshaft lobe lift, use the

procedure that follows:
1. Measure the total height of the camshaft (13).

g00482459
Illustration 38
2. Measure base circle (14).
(1) Thickness of new thrust plate .. 15.00 ± 0.25 mm
3. Subtract base circle (14) from the total height (0.591 ± 0.010 inch)
of camshaft (13). The difference is the specified
camshaft lobe lift (12). (2) Camshaft journal
4. Specified camshaft lobe lift (12) for the camshaft Diameter ................................ 173.80 ± 0.03 mm
is the following value: (6.843 ± 0.001 inch)
Bore in camshaft bearing after
Exhaust lobe .................. 19.500 mm (.7677 inch) installation .............................. 174.00 ± 0.06 mm
(6.850 ± 0.002 inch)
Inlet lobe ........................ 19.500 mm (.7677 inch)
(3) Thickness of new plate ............. 11.80 ± 0.05 mm
Gas admission lobe ....... 10.001 mm (.3937 inch) (0.465 ± 0.002 inch)
(4) Timing bolt location
NOTICE
Correct cam segment relationship (timing) must be ob-
served at assembly. If the cam segments are out of
time, serious engine damage will occur.
RENR5907-06 25
g00289768 g00482541
Location of the dowels on the camshaft bearing journals Letter designation of G3612 camshaft journals
g00482542 g00482543
Location of the dowels on the camshaft bearing journals Letter designation of G3616 camshaft journals
Note: The position of the single dowel in relation to (8) Camshaft bearing journal
the variable dowel determines the letter designation
of the cam journals. The single dowel is located next Install the camshaft bearing journals with the grooved
to the locating groove. The variable dowel is on the end toward the front of the engine.
end opposite the locating groove.
(9) Camshaft segments
(5) Locating groove
Install the camshaft segments with the grooved
(6) Dowel flange toward the front of the engine.
Distance from the top of the dowel to the (10) Bolts
(0.28 ± 0.02 inch) Torque .................... 270 ± 40 N·m (200 ± 30 lb ft)
(7) Dowel (11) The camshaft must be assembled in an

assembly fixture or the camshaft must be
Distance from the top of the dowel to the assembled in the cylinder block.
(0.28 ± 0.02 inch) Apply a force at the rear end of the camshaft (11).
The rolling torque must be a maximum of the
following value. ......................... 28 N·m (21 lb ft)
26 RENR5907-06
i01532351
Valve Mechanism
SMCS Code: 1102; 1121; 1209
S/N: BLB1-Up
S/N: BKE1-Up
S/N: BEN1-Up
Part No.: 7C-0417
S/N: 4ZS1-Up
g00289772
Illustration 43
(12) Specified camshaft lobe lift
To find the specified camshaft lobe lift, use the

procedure that follows:
1. Measure the total height of the camshaft (13).
2. Measure base circle (14).
3. Subtract base circle (14) from the total height

of camshaft (13). The difference is the specified
camshaft lobe lift (12).
4. Specified camshaft lobe lift (12) for the camshaft

is the following value:
Exhaust lobe ................ 19.500 mm (0.7677 inch)

g00284769
Illustration 44
Inlet lobe ...................... 19.500 mm (0.7677 inch)
(1) Tighten the rocker arm adjustment screw
Gas admission lobe ..... 10.001 mm (0.3937 inch) locknut. .................. 200 ± 25 N·m (150 ± 18 lb ft)
(2) The diameter of the rocker arm shaft is the

following value. .................... 69.900 ± 0.015 mm
(2.7520 ± 0.0006 inch)
The bore in the bearings for the rocker arm shaft is

the following value. .................... 70.000 ± 0.015 mm
(2.7559 ± 0.0006 inch)
(3) Valve lash

Inlet valve ......................... 0.50 mm (0.020 inch)
Exhaust valve ................... 1.27 mm (0.050 inch)
Gas admission valve ........ 0.64 mm (0.025 inch)
(4) Tighten the bridge adjustment screw locknut to

the following torque. ...................... 100 ± 15 N·m
(75 ± 11 lb ft)
(5) Diameter of bridge dowel ..... 19.055 ± 0.003 mm

(0.7502 ± 0.0001 inch)
RENR5907-06 27
Diameter of bore in bridge ......... 19.162 ± 0.030 mm The bore in the adapter of the lifter for
(0.7544 ± 0.0012 inch) the gas admission valve is the following
value. .... 27.950 ± 0.020 mm (1.1004 ± 0.0008 inch)
Diameter of bore in plug for
dowel .... 19.017 ± 0.020 mm (0.7487 ± 0.0008 inch)
Diameter of plug ........................ 27.050 ± 0.008 mm

(1.0650 ± 0.0003 inch)
Diameter of bore in cylinder head for

plug ....... 27.000 ± 0.020 mm (1.0630 ± 0.0008 inch)
(6) Support assembly and the gas admission valve
(7) The guide springs must not be used again.

Always install new guide springs.
g00285522
Illustration 46
(12) Tighten the bolts to the following

torque. ................... 430 ± 60 N·m (320 ± 44 lb ft)
g00795499
Illustration 45
(8) Guides for the lifters
(9) The diameter of the inlet and exhaust valve lifter

is the following value. .......... 41.910 ± 0.010 mm
(1.6500 ± 0.0004 inch)
The valve guide bore of the inlet and exhaust valve

lifter is the following value. ......... 42.000 ± 0.020 mm
(1.6535 ± 0.0008 inch)
(10) The diameter of the adapter of the lifter

for the gas admission valve is the following
value. ................................... 56.070 ± 0.020 mm
(2.2075 ± 0.0008 inch)
The bore in the guide for the adapter is the following

value. .... 56.000 ± 0.020 mm (2.2047 ± 0.0008 inch)
(11) The diameter of the lifter for the gas admission

valve is the following value. .. 27.896 ± 0.013 mm
(1.0983 ± 0.0005 inch)
28 RENR5907-06
i01782843
Cylinder Head, Valves, Valve

Springs and Valve Seat Inserts
SMCS Code: 1101; 1103; 1104; 1105; 1108; 1123
S/N: BLB1-Up
S/N: BKE1-Up
S/N: BEN1-Up
Part No.: 7C-0440
S/N: 4ZS1-Up
g00911987
Illustration 47
(1) Assembled height of rocker arm support (4) 1W-1749 Spring inner spring for valve
dowels .............. 8.0 ± 1.0 mm (0.32 ± 0.04 inch)
Length under test force ....... 79.3 mm (3.12 inch)
(2) Inside diameter of assembled valve Test force .......................... 361 ± 36 N (80 ± 8 lb)
guides .................................. 16.031 ± 0.028 mm Free length after test ........ 107.0 mm (4.21 inch)
(0.6311 ± 0.0011 inch) Outside diameter ................ 47.9 mm (1.89 inch)
(3) Assembled height of bridge (5) 1W-1748 Spring outer spring for valve
dowels .......... 105.0 ± 2.0 mm (4.13 ± 0.08 inch) Length under test force ....... 84.9 mm (3.34 inch)
Test force ...................... 758 ± 76 N (170 ± 17 lb)
RENR5907-06 29
Free length after test ......... 114.0 mm (4.49 inch)

Outside diameter ................ 68.0 mm (2.68 inch)
(6) Assembled height of valve

guides ............. 20.0 ± 2.0 mm (0.79 ± 0.08 inch)
(7) Procedure to tighten the cylinder head nuts
1. Assemble the seals, the gasket and the washers

to the cylinder head. Tighten the nuts by hand.
2. Use the 4C-5850 Stud Tensioner Tool Group to

apply tension to all four studs at the same time.
Tension the studs to the following

value. ........... 40000 ± 1500 kPa (5800 ± 220 psi)
3. Tighten the nuts by hand.
4. Slowly release the pressure.
5. Repeat Step 2 through Step 4.
(8) Thickness of combustion gasket .... 4 ± 0.05 mm

(0.158 ± 0.002 inch)
Surfaces must be parallel within the following

dimension. .............................. 0.03 mm (0.001 inch)
g00912082
Illustration 48
(9) Angle of valve face Inlet and exhaust valves
Angle of the face of the inlet (10) Depth of bore for valve seat
valve ................................. 20.25 ± 0.10 degrees insert ....... 24.00 ± 0.15 mm (0.945 ± 0.006 inch)
Angle of the face of the exhaust
valve ................................. 20.25 ± 0.10 degrees (11) Diameter of valve stems
Diameter of inlet valve stem .. 15.980 ± 0.007 mm
(0.6291 ± 0.0003 inch)
Diameter of exhaust valve
stem .. 15.977 ± 0.01 mm (0.6290 ± 0.0004 inch)
Install the valve guide into the cylinder head.

The bore in the valve guide is the following
dimension. ................................. 16.031 ± 0.028 mm
(0.6311 ± 0.0011 inch)
Note: The inlet valve stems and the exhaust valve

stems should be coated with 8T-2998 Lubricant.
This should be prior to the installation in the cylinder
head.
(12) Diameter of valve seat inserts

Diameter of inlet valve seat
insert .................................... 97.195 ± 0.015 mm
(3.8266 ± 0.0006 inch)
Diameter of exhaust valve seat
insert .................................... 97.215 ± 0.015 mm
(3.8274 ± 0.0006 inch)
Bore in head for valve seat

inserts ... 97.000 ± 0.025 mm (3.8189 ± 0.0010 inch)
30 RENR5907-06
(13) Angle of face of valve seat (19) 7N-1903 Spring inner spring for valve
inserts ......................................... 20 ± 1 degrees
Contact is required between both the valve and the Test force .......................... 125 ± 12 N (28 ± 3 lb)
insert for the full 360 degrees. This should be a full Free length after test .......... 51.5 mm (2.03 inch)
face contact. The minimum width of the seat is the Outside diameter ................ 29.2 mm (1.15 inch)
following dimension. ................... 3.0 mm (0.12 inch)
(20) Inside diameter of the valve guide for the gas
(14) Maximum recess from the closed valve face to admission valve ..................... 9.502 ± 0.013 mm
the surface of the cylinder head ............. 2.0 mm (0.3741 ± 0.0005 inch)
(0.08 inch)
(21) Install the retainer and tighten the retainer to the
Maximum projection of the closed valve above the following torque. ...... 100 ± 15 N·m (75 ± 11 lb ft)
surface of the cylinder head .... 0.50 mm (0.020 inch)
(22) Diameter of the valve stem for the gas admission
(15) Outside diameter of the head of the inlet valve .. 9.441 ± 0.008 mm (0.3717 ± 0.0003 inch)
valve ....... 90.00 ± 0.20 mm (3.543 ± 0.008 inch)
(23) Angle of the face of the gas admission
Outside diameter of head of the exhaust valve ................................. 45.75 ± 0.25 degrees
valve ............. 90.00 ± 0.20 mm (3.543 ± 0.008 inch)
Angle of the support for the gas admission
(16) The minimum valve lip thickness that can be valve ......................................... 44.75 ± 0.5 degrees
used again is the following dimension. .. 5.40 mm
(0.213 inch) (24) Outside diameter of the head of the gas
admission valve ....................... 41.81 ± 0.13 mm
(1.646 ± 0.005 inch)
i02113596
Prechamber
(Bio-Gas Fuel)
SMCS Code: 1106
S/N: BLB1-172
S/N: BKE1-206
S/N: 4ZS1-282
g00912084
Illustration 49
Gas admission valve
(17) 7N-1904 Spring outer spring for valve

Test force .......................... 254 ± 25 N (57 ± 6 lb)
Free length after test .......... 62.5 mm (2.46 inch)
Outside diameter ................ 44.0 mm (1.73 inch) Illustration 50
g00983797
(18) Valve stem seal (1) Bolt
Note: To prevent contamination of the fuel supply, Diameter ........................................................ 3/8

install a valve stem seal on each gas admission
valve. 1. Seat the prechamber assembly into the bore of the
cylinder head by alternate tightening of the bolts.
RENR5907-06 31
2. Loosen the bolts once the prechamber assembly 2. Loosen the bolts once the prechamber assembly
is seated in the bore of the cylinder head. is seated in the bore of the cylinder head.
3. Alternate the tightening of one bolt to the other 3. Alternate the tightening of one bolt to the other
bolt. Tighten each bolt: bolt. Tighten the hold down bolts:
Torque ........................................ 25 N·m (18 lb ft) Torque .......................................... 5 N·m (44 lb in)
4. Tighten each bolt again: 4. Tighten hold down bolts by the following degrees:
Torque ........................................ 35 N·m (26 lb ft) Degrees of rotation .......................................... 60
5. Tighten each bolt again: 5. Tighten hold down bolts by the following additional
degrees:
Torque ........................................ 47 N·m (35 lb ft)
Degrees of rotation .......................................... 60
(2) Plug
6. Tighten hold down bolts by the following additional
Torque ........................................ 15 N·m (11 lb ft) degrees:
(3) O-rings Degrees of rotation .......................................... 60
Lubricate the O-ring with 5N-5561 Silicone Lubricant Note: The total degrees of turn from the initial torque
prior to assembly. of 5 N·m (44 lb in) is 180 ± 5 degrees. Inadequate
turning of the bolt may shorten the life of the bolt.
(4) Check valve Turning the bolt not far enough can lead to an
inadequate load on the gasket. This may result in
Torque ...................... 115 ± 15 N·m (85 ± 11 lb ft)
coolant leaks into the combustion chamber.
i02113591 (2) Plug
Prechamber Torque ........................................ 15 N·m (11 lb ft)
SMCS Code: 1106 (3) O-rings
S/N: BLB1-172 Lubricate the O-ring with 5N-5561 Silicone Lubricant

prior to assembly.
S/N: BKE1-206
S/N: BEN1-210 (4) Check valve
S/N: 4ZS1-282 Torque ...................... 115 ± 15 N·m (85 ± 11 lb ft)
g00911845
Illustration 51
(1) Bolt
Diameter ........................................................ 3/8
1. Seat the prechamber assembly into the bore of the

cylinder head by alternate tightening of the bolts.
32 RENR5907-06
i02113578 Note: The total degrees of turn from the initial torque
of 30 ± 5 N·m (22 ± 4 lb ft) is 120 ± 5 degrees.
Prechamber Inadequate turning of the bolt may shorten the life of
the bolt. Turning the bolt not far enough can lead to
SMCS Code: 1106 an inadequate load on the gasket. This may result in
coolant leaks into the combustion chamber.
S/N: BLB173-Up
S/N: BKE207-Up (2) Plug
S/N: BEN211-Up Torque ........................................ 15 N·m (11 lb ft)
S/N: 4ZS283-Up (3) O-rings
Lubricate the O-ring with 5N-5561 Silicone Lubricant

prior to assembly.
(4) Check valve

Tighten the check valve to the following
torque: ..................... 115 ± 15 N·m (85 ± 11 lb ft)
g00911858
Illustration 52
(1) Bolt
Diameter ........................................................ 1/2
1. Seat the prechamber assembly into the bore of

the cylinder head by alternate tightening of the
bolts. Tighten each bolt:
Torque ........................................ 30 N·m (22 lb ft)
2. Loosen the bolts once the prechamber assembly

is seated in the bore of the cylinder head.
3. Alternate the tightening of one bolt to the other

bolt.
Torque ............................. 30 ± 5 N·m (22 ± 4 lb ft)
4. Tighten each bolt by the following degrees:
5. Tighten each bolt by the following additional

degrees:
6. Tighten each bolt by the following additional

degrees:

RENR5907-06 33
i02106754
Turbocharger
SMCS Code: 1052
S/N: BKE1-Up
Part No.: 139-5840, 172-6405, 197-0667,
4P-6747
S/N: 4ZS1-Up
g00914711
Illustration 53
(1) Clamp torque: .............. 60 ± 12 N·m (44 ± 9 lb ft) (6) Axial clearance for the turbine
shaft .... 0.120 to 0.160 mm (.0047 to .0063 inch)
(2) Bolt torque: .................... 20 ± 4 N·m (15 ± 3 lb ft)
Axial clearance for reusable turbine
(3) Radial clearance for new turbine shaft .......... 0.120 to 0.210 mm (.0047 to .0083 inch)
Radial clearance for reusable turbine

shaft .......... 0.720 to 1.310 mm (.0283 to .0520 inch)
(4) Retaining bolt torque ..................... 220 ± 20 N·m

(162 ± 15 lb ft)
(5) Bolt torque: .................. 60 ± 12 N·m (44 ± 9 lb ft)

34 RENR5907-06
i01781133
Turbocharger
SMCS Code: 1052
S/N: BLB1-Up
Part No.: 106-9709, 111-5720, 4P-6746,
7C-0429
S/N: BEN1-Up
g00470523
Illustration 54
(1) Radial clearance for new turbine (3) Tighten the bolts to the following
shaft .... 0.440 to 0.600 mm (.0173 to .0236 inch) torque. ......................... 58 ± 12 N·m (43 ± 9 lb ft)
Radial clearance for reusable turbine (4) Tighten the bolts to the following
shaft .......... 0.440 to 0.870 mm (.0173 to .0343 inch) torque. ........................... 28 ± 7 N·m (21 ± 5 lb ft)
(2) Torque for impeller retaining bolt ..... 48 ± 12 N·m (5) Minimum outside diameter of turbine shaft
(35 ± 9 lb ft) (impeller end) ............. 33.480 mm (1.3181 inch)
Note: If there is a cap, then screw the cap up to Maximum inside diameter of turbine shaft bearing
the shoulder of the cartridge. Apply a mark on the (impeller end) ........................ 33.54 mm (1.320 inch)
cap and on the set of compressor wheels. Tighten
the cap an additional 10 mm (.39 inch) in a circular (6) Tighten the bolts to the following
measurement. torque. ........................... 17 ± 3 N·m (13 ± 2 lb ft)
RENR5907-06 35

torque. ........................... 28 ± 7 N·m (21 ± 5 lb ft)

torque. ......................... 58 ± 12 N·m (43 ± 9 lb ft)
(9) Axial clearance for the turbine

Axial clearance for a reusable turbine

shaft ........... 0.100 to 0.300 mm (.0040 to .0118 inch)
(10) Maximum width of seal ring groove .... 2.85 mm

(.112 inch)
(11) Minimum diameter of the impeller

hub ................................... 46.00 mm (1.811 inch)

torque. ........................... 17 ± 3 N·m (13 ± 2 lb ft)

torque. ......................... 58 ± 12 N·m (43 ± 9 lb ft)
(14) Tighten the mounting bolts for the turbocharger

to the following torque. .. 86 ± 5 N·m (64 ± 4 lb ft)
(15) Minimum outside diameter of turbine shaft

(turbine end) ............... 42.980 mm (1.6921 inch)
Maximum inside diameter of turbine shaft bearing

(turbine end) ......................... 43.06 mm (1.695 inch)
(16) Maximum width of seal ring groove in turbine

shaft .................................... 2.58 mm (.102 inch)
i01854767
Exhaust Manifold
SMCS Code: 1059
Part No.: 219-9932
S/N: 4ZS1-Up
g00945799
Illustration 55
(1) Exhaust manifold (2) Bellows

36 RENR5907-06
Use the following procedure to install the exhaust

manifolds and the bellows:
Note: To avoid damaging the bellows, assemble

and disassemble the exhaust manifold segments
individually. The bolts and nuts for the bellows may
be assembled from either side of the flanges.
1. Install the manifolds onto the cylinder heads.

Lubricate the bolt threads with 5P-3931
Anti-Seize Compound and hand tighten the bolts.
2. Install the bellows onto the manifolds. Lubricate

the threads of the bolts for the bellows with
5P-3931 Anti-Seize Compound. Tighten the bolts
for the bellows.
3. Tighten the bolts that attach the manifolds to the

cylinder heads.
4. Tighten the remaining bolts for the bellows.
(3) Adapter
Lubricate the adapter’s threads with 5P-3931
Anti-Seize Compound.
Torque .................... 200 ± 25 N·m (150 ± 18 lb ft)
(4) Pipe plug

Lubricate the plug threads with 5P-3931
Torque ...................... 130 ± 20 N·m (95 ± 15 lb ft)
(5) Bolt
Lubricate the bolt threads with 5P-3931 Anti-Seize

Compound.
(6) Adapter
Torque .................... 200 ± 25 N·m (150 ± 18 lb ft)
RENR5907-06 37
i01854748
Exhaust Manifold
SMCS Code: 1059
Part No.: 145-5658
S/N: 4ZS1-Up
g00945784
Illustration 56
(1) Exhaust manifold Lubricate the bolt threads with 5P-3931

(2) Bellows Torque .................... 240 ± 40 N·m (180 ± 30 lb ft)
Use the following procedure to install the exhaust (5) Pipe plug
Note: To avoid damaging the bellows, assemble Anti-Seize Compound.
Torque ...................... 130 ± 20 N·m (95 ± 15 lb ft)
be assembled from either side of the flanges. (6) Adapter
1. Install the manifolds onto the cylinder heads. Lubricate the adapter’s threads with 5P-3931
Lubricate the bolt threads with 5P-3931 Anti-Seize Compound.
Torque .................... 200 ± 25 N·m (150 ± 18 lb ft)
the threads of the bolts for the bellows with (7) Cap
5P-3931 Anti-Seize Compound. Tighten the bolts Torque .............................. 12 ± 3 N·m (9 ± 2 lb ft)
for the bellows.
(8) Adapter
Torque ........................... 50 ± 10 N·m (37 ± 7 lb ft)
3. Tighten the bolts that attach the manifolds to the Anti-Seize Compound.
cylinder heads. Torque .................... 200 ± 30 N·m (150 ± 22 lb ft)
Torque ........................... 50 ± 10 N·m (37 ± 7 lb ft)
(3) Pipe plug

Torque ...................... 130 ± 20 N·m (95 ± 15 lb ft)
(4) Bolt
38 RENR5907-06
i01854668
Exhaust Manifold
SMCS Code: 1059
Part No.: 228-6588
S/N: BEN1-Up
Part No.: 213-6463
S/N: 4ZS1-Up
g00945708
Illustration 57
(1) Exhaust manifold Lubricate the plug threads with 5P-3931

(2) Bellows Torque ...................... 130 ± 20 N·m (95 ± 15 lb ft)
Use the following procedure to install the exhaust (4) Bolt
Lubricate the bolt threads with 5P-3931
Note: To avoid damaging the bellows, assemble Anti-Seize Compound.
Torque .................... 240 ± 40 N·m (180 ± 30 lb ft)
be assembled from either side of the flanges. (5) Pipe plug
1. Install the manifolds onto the cylinder heads. Lubricate the plug threads with 5P-3931
Lubricate the bolt threads with 5P-3931 Anti-Seize Compound.
Torque ...................... 130 ± 20 N·m (95 ± 15 lb ft)
the threads of the bolts for the bellows with (6) Adapter
5P-3931 Anti-Seize Compound. Tighten the bolts Lubricate the adapter’s threads with 5P-3931
for the bellows. Anti-Seize Compound.
Torque ........................... 50 ± 10 N·m (37 ± 7 lb ft) Torque .................... 200 ± 25 N·m (150 ± 18 lb ft)
3. Tighten the bolts that attach the manifolds to the (7) Adapter
cylinder heads. Lubricate the adapter’s threads with 5P-3931
Torque .................... 200 ± 30 N·m (150 ± 22 lb ft)
Torque ........................... 50 ± 10 N·m (37 ± 7 lb ft)
(3) Pipe plug

RENR5907-06 39
i01781345
Exhaust Manifold
SMCS Code: 1059
S/N: BLB1-Up
Part No.: 213-6790
S/N: BKE1-Up
g00911002
Illustration 58
To avoid damaging the bellows, assemble and Tighten the adapters. ..................... 200 ± 25 N·m
disassemble the exhaust manifold segments (150 ± 18 lb ft)
individually. The bolts and nuts may be assembled
from either side of the flanges for the bellows. Use the (8) Adapter
following procedure to install the exhaust manifolds:
Tighten the caps. ....... 70 ± 15 N·m (52 ± 11 lb ft)
Note: Put 5P-3931 Anti-Seize Compound on all
threads prior to assembly.
(1) Exhaust manifold

Assemble the exhaust manifolds to the cylinder
heads. ..................... Tighten the bolts hand tight.
(2) Bellows
Assemble the bellows to the
exhaust manifolds and to the
turbochargers. ........ Tighten the bolts hand tight.
(3) Bolt
Tighten the bolts. ......... 55 ± 10 N·m (41 ± 7 lb ft)
(4) Bolt
Tighten the bolts. ... 135 ± 20 N·m (100 ± 15 lb ft)
(5) Bolts
Tighten the bolts. ... 135 ± 20 N·m (100 ± 15 lb ft)
(6) Adapter
Tighten the adapters. ..................... 200 ± 25 N·m
(150 ± 18 lb ft)
(7) Adapter
40 RENR5907-06
i02096906
Exhaust Bypass Valve

SMCS Code: 1057
S/N: 4ZS1-Up
g01069082
Illustration 59
(1) Put 5P-3931 Anti-Seize Compound on Diameter of shaft ................. 19.500 ± 0.013 mm
the threads of the bolts before assembly. (.7677 ± .0005 inch)
Torque .......................... 50 ± 10 N·m (37 ± 7 lb ft)
(4) Thrust washer
(2) Put 5P-3931 Anti-Seize Compound on
the threads of the bolts before assembly. Thickness ..... 6.00 ± 0.08 mm (.236 ± .003 inch)
Torque ...................... 120 ± 20 N·m (90 ± 15 lb ft)
(5) Adjustable rod
(3) Housing
(6) Assemble the cross shaft with the end that is
Bore in housing for shaft stamped “W/G END” toward the housing of the
bearings ............................... 25.875 ± 0.013 mm exhaust bypass valve.
(1.0187 ± .0005 inch)
Outside diameter of shaft (7) Put 5P-3931 Anti-Seize Compound on
bearings ............................... 25.898 ± 0.013 mm the threads of the bolts before assembly.
(1.0196 ± .0005 inch) Torque .......................... 50 ± 10 N·m (37 ± 7 lb ft)
Inside diameter of in-line shaft
bearings ...................... 19.806 mm (0.7798 inch) (8) Actuator
RENR5907-06 41
Torque of the nut for the actuator .. 200 ± 20 N·m Assemble the plate to the shaft. Assemble the levers
(147.5120 ± 14.7512 lb ft) to the shaft and to the cross shaft. Use the woodruff
keys to provide the proper orientation. Assemble
(9) Outlet port and adjust the upper connecting rod to the correct
distance.
(10) Inlet port
Distance between the rod ends of the upper
Note: Assemble the actuator so the inlet port and the connecting rod .... 349.2 ± 1.0 mm (13.75 ± .04 inch)
outlet port are aligned. This is shown in Illustration
59. The ports on the actuator are stamped“ Inlet” and When the adjustable rod for the exhaust bypass
“Outlet”. valve is in the closed position the levers should be at
angle (A). (A) Angle ................................ 75 degrees
(11) Put 5P-3931 Anti-Seize Compound on
the threads of the bolts before assembly. (18) Nut torque .................... 25 ± 6 N·m (18 ± 4 lb ft)
Torque .......................... 50 ± 10 N·m (37 ± 7 lb ft)
Assemble the lever on the cross shaft. The lever
(12) Put 5P-3931 Anti-Seize Compound on should be located on the same side as the actuator.
the threads of the bolts before assembly. Use the woodruff key to assemble the lever.
Torque ...................... 120 ± 20 N·m (90 ± 15 lb ft) Assemble the linkage on the actuator. Check the
distance between the rod end and the clevis when
(13) Put 5P-3931 Anti-Seize Compound on the actuator is in the extended position.
the threads of the bolts before assembly.
Torque .......................... 50 ± 10 N·m (37 ± 7 lb ft) Distance between the rod end and the
clevis .............................. 117 ± 1 mm (4.5 ± .04 inch)
(14) Plate and mounting bolts
Note: A final adjustment of the linkage is required.
(15) Shaft The adjustment of the linkage ensures that the plate
does not contact the housing. In the closed position,
(16) Mounting bolts torque. .. 14 ± 3 N·m (10 ± 2 lb ft) contact the housing with the plate. The actuator
should be fully extended. Shorten the length of the
upper connecting rod by 1 turn. Lock the connecting
rod in place.
When the adjustable rod for the actuator is in the

closed position the levers should be at angle (B). (B)
Angle .................................................... 36.4 degrees
g00914501
Illustration 60
Exhaust bypass valve linkage
Closed position
(17) Nut torque .................... 25 ± 6 N·m (18 ± 4 lb ft)

42 RENR5907-06
i01786961

SMCS Code: 1057
Part No.: 219-9930
S/N: BEN1-Up
g00914201
Illustration 61
RENR5907-06 43
g00914199
Illustration 62
(2) Plate
(3) Bolt
Tighten the bolt to the following
torque: ...................... 14 ± 3 N·m (124 ± 27 lb in)
(4) Bearing
(5) Shaft
(6) Bolt
Apply 5P-3931 Anti-Seize Compound to the threads

of the bolts prior to assembly.
(7) Cover
(8) Stop plate
(9) Thrust washer
(10) Spacer
(11) Cover
(12) Bolt
Illustration 63
g00914200 Apply 5P-3931 Anti-Seize Compound to the threads
Exhaust bypass valve linkage of the bolts prior to assembly.
Closed position
(13) Housing
(1) Shaft
44 RENR5907-06
Bore in housing for shaft Angle for the lever in the fully closed
bushings .............................. 25.845 ± 0.013 mm position .......................................... 44.3 degrees
(1.0175 ± 0.0005 inch)
Outside diameter of shaft Use the following procedure in order to assemble the
bushings .............................. 25.898 ± 0.013 mm exhaust bypass valve and the actuator linkage.
(1.0196 ± 0.0005 inch)
Inside diameter of in-line shaft 1. Assemble plate (2) of the exhaust bypass valve
bushings .............................. 19.806 ± 0.013 mm to shaft (5). Leave the mounting bolts loose.
(0.7798 ± 0.0005 inch) Assemble thrust washer (9) and stop plate (8).
Diameter of shaft ................. 19.500 ± 0.013 mm
(0.7677 ± 0.0005 inch) Thickness of thrust washer ......... 6.00 ± 0.08 mm
(0.2362 ± 0.0031 inch)
(14) Bolt
2. Install cover (7).
of the bolts prior to assembly. 3. Fully close plate (2) of the exhaust bypass valve.
Tighten mounting bolts (3) to the specified torque.
(15) Actuator
Bend the locking ends upward in order to secure
(16) Nut the bolts in position. Install spacer (10) and cover
(11) onto the shaft. Make sure that the shaft can
Torque for nuts ............... 25 ± 6 N·m (18 ± 4 lb ft) rotate freely.
(17) Rod 4. Install bearings (4) so the lube fitting is accessible.
Lubricate the bearings with 5P-0960 Lithium
ends ................................... 242 mm (9.528 inch) complex grease.
5. Install shaft (5) with the end that is stamped “W/G

(18) Rod
END” toward the housing of the exhaust bypass
Distance between the center bores of the rod valve.
ends ................................. 134.9 mm (5.311 inch)
6. Install actuator (15) so the inlet port (22) and outlet
(19) Nut port (24) are aligned. The ports on the actuator
are stamped “Inlet” and “Outlet”.
Torque for nuts ............... 25 ± 6 N·m (18 ± 4 lb ft)
(20) Clevis threads of clevis (20). Assemble the clevis on the
actuator.
threads. 8. Assemble the levers to the shaft of the exhaust
bypass valve to the cross shaft. Use the woodruff
(21) Nut keys in order to provide proper orientation.
Assemble rod (18) so that there is equal thread
Torque for nut ........ 200 ± 20 N·m (150 ± 15 lb ft) engagement at each end. Adjust the rod to the
specified length. Tighten nuts (19) to the specified
(22) Inlet port torque.
(23) Outlet port 9. Assemble the lever on the side of the cross shaft
that goes toward the actuator. Use the woodruff
(A) Angle key to assemble the lever. Assemble rod (17) so
Angle for the lever in the fully closed that there is equal thread engagement at each
position .......................................... 44.3 degrees end. Adjust the rod to the specified length. Tighten
nuts (16) to the specified torque. Assemble the
(B) Angle rod on the clevis.

(C) Angle
RENR5907-06 45
Note: A final adjustment of the linkage is required to

ensure that the plate does not contact the housing
when the plate is in the closed position. Fully extend
the actuator to the closed position. With the plate in
contact with the housing, shorten the length of the
connecting rod by 2/3 turn. Lock the connecting rod
in place.
i01773128

SMCS Code: 1057
Part No.: 210-5735
S/N: BLB1-Up
Part No.: 210-5735
S/N: BKE1-Up
g00906628
Illustration 64
46 RENR5907-06
g00906630
Illustration 65
(1) Bolts

(2) Bearing
(3) Shaft
(4) Bolt

(5) Cover
(6) Stop plate
(7) Thrust washer
(8) Spacer
(9) Cover
(10) Shaft
(11) Plate
g00906633
Illustration 66 (12) Bolt
Exhaust bypass valve linkage
Closed position
RENR5907-06 47
Tighten the bolt to the following (B) Angle

torque: ...................... 14 ± 3 N·m (124 ± 27 lb in)
(13) Bolt position ............................................. 45 degrees
Apply 5P-3931 Anti-Seize Compound to the threads (C) Angle

(14) Housing
Bore in housing for shaft Use the following procedure in order to assemble the
bushings .............................. 25.845 ± 0.013 mm exhaust bypass valve and the actuator linkage.
(1.0175 ± 0.0005 inch)
Outside diameter of shaft 1. Assemble plate (11)of the exhaust bypass valve
bushings .............................. 25.898 ± 0.013 mm to shaft (10). Leave the mounting bolts loose.
(1.0196 ± 0.0005 inch) Assemble thrust washer (7) and stop plate (6).
bushings .............................. 19.806 ± 0.013 mm Thickness of thrust washer ......... 6.00 ± 0.08 mm
(0.7798 ± 0.0005 inch) (0.2362 ± 0.0031 inch)
(0.7677 ± 0.0005 inch) 2. Install cover (5).
(15) Bolt 3. Fully close plate (11) of the exhaust bypass

valve. Tighten mounting bolts (12) to the specified
Apply 5P-3931 Anti-Seize Compound to the threads torque.
Bend the locking ends upward in order to secure
(16) Actuator the bolts in position. Install spacer (8) and cover
(9) onto shaft (10). Make sure that the shaft can
(17) Nut rotate freely.
Torque for nuts ............... 25 ± 6 N·m (18 ± 4 lb ft) 4. Install bearings (2) so the lube fitting is accessible.
Lubricate the bearings with 5P-0960 Lithium
(18) Rod complex grease.
Distance between the center bores of the rod 5. Install shaft (3) with the end that is stamped “W/G
ends ................................... 242 mm (9.528 inch) END” toward the housing of the exhaust bypass
valve.
(19) Rod
6. Install actuator (16) so the inlet port (23) and outlet
ends ................................. 134.9 mm (5.311 inch) port (24) are aligned. The ports on the actuator
are stamped “Inlet” and “Outlet”.
(20) Nut
Torque for nuts ............... 25 ± 6 N·m (18 ± 4 lb ft) threads of clevis (21). Assemble the clevis on the
actuator.
(21) Clevis
8. Assemble the levers to shaft (10) of the exhaust
Apply 4C-4030 Thread Lock Compound to the bypass valve and to shaft (3). Use the woodruff
threads. keys in order to provide proper orientation.
Assemble rod (19) so that there is equal thread
(22) Nut engagement at each end. Adjust the rod to the
specified length. Tighten nuts (20) to the specified
Torque for nut ........ 200 ± 20 N·m (150 ± 15 lb ft) torque.
(23) Inlet port 9. Assemble the lever on the side of the shaft that
goes toward the actuator. Use the woodruff key
(24) Outlet port to assemble the lever. Assemble rod (18) so that
there is equal thread engagement at each end.
(A) Angle Adjust the rod to the specified length. Tighten nuts
(17) to the specified torque. Assemble the rod on
Angle for the lever in the fully closed the clevis.
48 RENR5907-06

in place.
i01785352

SMCS Code: 1057
Part No.: 206-6539
S/N: BKE1-Up
g00803694
Illustration 67
Right side view
(1) Bolts Put 5P-3931 Anti-Seize Compound on the

threads of the bolts before assembly. Tighten the
bolts to the following torque. .......... 120 ± 20 N·m
(89 ± 15 lb ft)
RENR5907-06 49
(2) Tighten the nuts to the following 7. Install actuator (14) so the inlet port and outlet port
torque. ..................... 100 ± 20 N·m (74 ± 15 lb ft) (15) are aligned. The ports on the actuator are
stamped “Inlet” and “Outlet”.
(3) Housing
bushings .............................. 25.845 ± 0.013 mm
(1.0175 ± 0.0005 inch)
Outside diameter of shaft
bushings .............................. 25.898 ± 0.013 mm
(1.0196 ± 0.0005 inch)
bushings .............................. 19.806 ± 0.013 mm
(0.7798 ± 0.0005 inch)
(0.7677 ± 0.0005 inch)
Use the following procedure in order to assemble the

exhaust bypass valve and the actuator linkage.
1. Assemble the plate of the exhaust bypass valve

to the shaft. Leave the mounting bolts loose.
Assemble thrust washer (4) and axial stop (5).
Thickness of thrust washer ......... 6.00 ± 0.08 mm

(0.2362 ± 0.0031 inch)
Tighten the axial stop bolt to the following

torque. ............................. 47 ± 9 N·m (35 ± 7 lb ft)
2. Install cover (6).

g00913067
Illustration 68
Tighten the cover bolts to the following
Actuator and adjustable rod linkage
torque. ............................. 47 ± 9 N·m (35 ± 7 lb ft)
Closed position
3. Fully close the plate of exhaust bypass valve (9).
8. Assemble the levers to the shaft of the exhaust
Tighten mounting bolts (10) to the following bypass valve and to the cross shaft. Use
torque. ............................. 14 ± 3 N·m (10 ± 2 lb ft) the woodruff keys in order to provide proper
orientation. Assemble upper connecting rod (12)
Bend the locking ends upward in order to secure so that there is equal thread engagement at each
the bolts in position. Install spacer (7) and cover end. Adjust the rod to the correct distance.
assembly (8) onto the shaft. Make sure that the
shaft can rotate freely. The distance between the rod ends of
the upper connecting rod is the following
Tighten the bolts for the cover assembly to the value. ......... 640 ± 1 mm (25.1968 ± 0.0394 inch)
following torque. .............. 47 ± 9 N·m (35 ± 7 lb ft)
Tighten nuts (17) to the following
4. Put 5P-3931 Anti-Seize Compound on the torque. ............................. 25 ± 6 N·m (18 ± 4 lb ft)
threads of bolts (11) before assembly.
9. Assemble the lever on the side of the cross shaft
Tighten the bolts to the following that goes toward the actuator. Use the woodruff
torque. ........................... 50 ± 10 N·m (37 ± 7 lb ft) key to assemble the lever. Assemble the linkage
on the actuator. Check the distance between the
5. Install cross shaft (13) with the end that is stamped rod end and the clevis when the actuator is in the
“W/G END” toward the housing of the exhaust extended position.
bypass valve.
The distance between the rod end and the clevis
6. Install bearings (16) so the lube fitting is should be the following value. .......... 80.5 ± 1 mm
accessible. Lubricate the bearings with 5P-0960 (3.1693 ± 0.0394 inch)
Lithium complex grease.
When the adjustable rod for the actuator is in the
closed position the lever should be at angle (A).
50 RENR5907-06
Angle (A). ..................................... 45 degrees i01570178
When the adjustable rod is in the closed position Aftercooler

the levers should be at angle (B) and angle (C).
SMCS Code: 1063
Angle (B). ..................................... 45 degrees
Angle (C). ..................................... 45 degrees S/N: BLB1-Up
Part No.: 159-1528
S/N: BKE1-Up
in place.
i01746302
Aftercooler
SMCS Code: 1063
S/N: BEN1-Up
S/N: 4ZS1-Up g00479750
Illustration 70
(1) The aftercooler core must withstand the following

water pressure. ......................... 330 kPa (48 psi)
(2) Put a light coat of glycerin on all O-ring seals at

assembly.
(3) Put 9S-3263 Thread Lock Compound on the

threads of the bolts. Tighten the bolts that
hold the aftercooler to the cylinder head to the
following torque. .......... 50 ± 10 N·m (37 ± 7 lb ft)
g00284759
Illustration 69
Typical example
(1) The aftercooler core must withstand the following

water pressure. ......................... 330 kPa (48 psi)
(2) Put a light coat of glycerin on all O-ring seals at

assembly.
(3) Bolt
Torque ............................ 30 ± 7 N·m (22 ± 5 lb ft)
RENR5907-06 51
i01786171 i01956929
Aftercooler Air Cleaner Adapter

(Two-Stage) SMCS Code: 1051
SMCS Code: 1063
Part No.: 131-0525
S/N: BLB1-Up
g00289587
Illustration 72
(1) Assemble the two tandem clamps around the

hose.
g00913682
Illustration 71 Maximum torque on clamp bolts .. 10 N·m (7 lb ft)
(1) Gaskets
i01100343
Install the gaskets with the “FRONT” marking toward
the front of the engine. Prelube Pump
Apply 4C-9505 Gasket Sealant to the gasket joints. SMCS Code: 1319
(2) Bolts
Apply 4C-4030 Thread Lock Compound to the bolts

on both ends of the aftercooler.
(3) Plug
Apply 1U-6396 O-Ring Assembly Compound to the

O-rings for the plugs.
(4) Bolt
Torque for bolts ............ 50 ± 10 N·m (37 ± 7 lb ft)
g00288335
Illustration 73
(1) Inside diameter of idler gear bearing .. 19.126 mm

(0.7530 inch)
(2) Idler gear

Thickness of idler gear in the air driven
pump ................................. 31.775 to 31.801 mm
(1.2510 to 1.2520 inch)
52 RENR5907-06
Pump end clearance Maximum permissible temperature for installation of

the gear ............................................ 316 °C (601 °F)
Measure the clearance between the back of the
rotor and the machined surface in the bottom (3) Distance from the end of the idler shaft to the
housing. ................................ 0.013 to 0.076 mm gear face ....... 52.5 ± .5 mm (2.0669 ± 0.02 inch)
(0.0005 to 0.0030 inch)
The maximum permissible temperature for installation
(3) Outside diameter of the of the gear ........................................ 316 °C (601 °F)
rotor .................................. 85.509 to 85.547 mm
(3.3665 to 3.3680 inch) (4) Length of gears
(4) Idler pocket Drive Shaft ............................. 120.00 ± 0.02 mm
(4.724 ± 0.001 inch)
Depth of the idler pocket (air driven Idler Shaft .............................. 120.00 ± 0.02 mm
pump) ............................... 31.725 to 31.750 mm (4.724 ± 0.001 inch)
(1.2490 to 1.2500 inch)
(5) Diameter of idler shaft ......... 59.930 ± 0.010 mm
i02096952
(2.3594 ± 0.0004 inch)
Engine Oil Pump

SMCS Code: 1304
Part No.: 2W-5577
S/N: 4ZS1-Up
g00288421
Illustration 75
(6) Distance from the top of the dowels to the surface

of the cover ........... 12 ± 1 mm (0.47 ± 0.04 inch)
(7) Bore in bearing for idler shaft ... 60.115 ± .02 mm

(2.3667 ± 0.0008 inch)
(8) Depth of bearings in the cover ... 7.50 ± 0.25 mm

(0.295 ± 0.010 inch)
(9) Bore in bearing for drive shaft .. 60.115 ± .02 mm

(2.3667 ± 0.0008 inch)
(10) Align the oil holes in the bearings with the oil
holes in the cover.
g00288420
Illustration 74
(1) Diameter of new drive shaft .. 59.930 ± 0.010 mm

(2.3594 ± 0.0004 inch)
(2) Distance from the end of the drive shaft to the

gear face ....... 169.5 ± 0.5 mm (6.67 ± 0.02 inch)
RENR5907-06 53
(17) Install the dowel in this position for a clockwise

rotation of the engine.
i02097485
Engine Oil Pump

SMCS Code: 1304
Part No.: 2W-5584
S/N: 4ZS1-Up
g00288422
Illustration 76
(11) Bearings
To minimize the press fit, cool the bearings and
the bearing driver.
Temperature ............................ −75 °C (−103 °F)
(11) Depth of bearings in the
housing .............................. 12.30 ± 0.25 mm
(0.484 ± 0.010 inch)
(12) Bore in bearings in housing ... 60.126 ± .04 mm

(2.3672 ± 0.0016 inch)
(13) Align the oil hole in the bearing with the oil hole
in the housing.
(14) End clearance between the gears and the

housing: .. 0.14 to 0.26 mm (0.006 to 0.010 inch)
g00288420
Illustration 78

(2.3594 ± 0.0004 inch)

gear face ....... 169.5 ± 0.5 mm (6.67 ± 0.02 inch)

of the gear ........................................ 316 °C (601 °F)
(3) Distance from the end of the idler shaft to the

gear face ..... 52.5 ± 0.5 mm (2.0669 ± 0.02 inch)

of the gear ........................................ 316 °C (601 °F)
g00288423
Illustration 77
(4) Length of gears
(15) Oil pump cover assembly
Drive Shaft ............................... 95.00 ± 0.02 mm
Height of dowel ....... 8 ± 1 mm (0.32 ± 0.04 inch) (3.740 ± 0.001 inch)
Idler Shaft ................................ 95.00 ± 0.02 mm
(16) Install the dowel in this position for a (3.740 ± 0.001 inch)
counterclockwise rotation of the engine.
54 RENR5907-06
(5) Diameter of idler shaft ......... 59.930 ± 0.010 mm (13) Align the oil hole in the bearing with the oil hole
(2.3594 ± 0.0004 inch) in the housing.

housing ... 0.14 to 0.26 mm (0.006 to 0.010 inch)
g00288421
Illustration 79

(7) Bore in bearing for idler shaft .. 60.115 ± 0.02 mm

(2.3667 ± 0.0008 inch)
(8) Install the bearings in the cover to the following

depth: ........ 7.50 ± 0.25 mm (0.295 ± 0.010 inch) g00288423
Illustration 81
(9) Bore in bearing for drive shaft .. 60.115 ± 0.02 mm

(2.3667 ± 0.0008 inch) (15) Oil pump cover assembly
Height of dowel ....... 8 ± 1 mm (0.32 ± 0.04 inch)
holes in the cover. (16) Install the dowel in this position for a

g00288422
Illustration 80
(11) Bearings
the bearing driver.
Temperature ............................ −75 °C (−103 °F)
housing .............................. 12.30 ± 0.25 mm
(0.484 ± 0.010 inch)
(12) Bore in bearings in housing .. 60.126 ± 0.04 mm

(2.3672 ± 0.0016 inch)
RENR5907-06 55
i02097491 (5) Diameter of idler shaft ......... 59.930 ± 0.010 mm

(2.3594 ± 0.0004 inch)
Engine Oil Pump
SMCS Code: 1304
Part No.: 1W-0797
S/N: BKE1-Up
Part No.: 1W-0797
S/N: BEN1-Up
g00288421
Illustration 83


(2.3667 ± 0.0008 inch)

(0.295 ± 0.010 inch)

(2.3667 ± 0.0008 inch)
holes in the cover.
g00288420
Illustration 82

(2.3594 ± 0.0004 inch)

gear face ....... 169.5 ± 0.5 mm (6.67 ± 0.02 inch)

of the gear ........................................ 316 °C (601 °F) Illustration 84
g00288422
(3) Distance from the end of the idler shaft to the (11) Bearings
gear face ......... 52.5 ± 0.5 mm (2.07 ± 0.02 inch)
The maximum permissible temperature for installation the bearing driver.
of the gear ........................................ 316 °C (601 °F)
Temperature ............................ −75 °C (−103 °F)
(4) Length of gears
housing .............................. 12.30 ± 0.25 mm
Drive Shaft ............................. 140.00 ± 0.02 mm (0.484 ± 0.010 inch)
(5.512 ± 0.001 inch)
Drive Shaft ............................. 140.00 ± 0.02 mm (12) Bore in bearings in housing .. 60.126 ± 0.04 mm
(5.512 ± 0.001 inch) (2.3672 ± 0.0016 inch)
56 RENR5907-06
(13) Align the oil hole in the bearing with the oil hole i02097500
in the housing.
Engine Oil Pump
housing ... 0.14 to 0.26 mm (0.006 to 0.010 inch) SMCS Code: 1304
Part No.: 4W-0675
S/N: BLB1-Up
Part No.: 4W-0675
S/N: BKE1-Up
g00288423
Illustration 85

(16) Install the dowel in this position for a


g00288420
Illustration 86

(2.3594 ± 0.0004 inch)

gear face ....... 169.5 ± 0.5 mm (6.67 ± 0.02 inch)

of the gear ........................................ 316 °C (601 °F)

gear face ......... 51.0 ± 0.5 mm (2.01 ± 0.02 inch)

of the gear ........................................ 316 °C (601 °F)
(4) Length of gears

Drive Shaft ............................. 155.00 ± 0.02 mm
(6.102 ± 0.001 inch)
Idler Shaft .............................. 155.00 ± 0.02 mm
(6.102 ± 0.001 inch)
RENR5907-06 57
(5) Diameter of idler shaft ......... 59.930 ± 0.010 mm (13) Align the oil hole in the bearing with the oil hole
(2.3594 ± 0.0004 inch) in the housing.

housing .. 0.14 to 0.26 mm (0.006 to 0.010 inch)
g00288421
Illustration 87


(2.3667 ± 0.0008 inch)

(0.295 ± 0.010 inch) g00288423
Illustration 89

(2.3667 ± 0.0008 inch) (15) Oil pump cover assembly
holes in the cover. (16) Install the dowel in this position for a

g00288422
Illustration 88
(11) Bearings
the bearing driver.
Temperature ............................ −75 °C (−103 °F)
housing .............................. 12.30 ± 0.25 mm
(0.484 ± 0.010 inch)
(12) Bore in bearings in housing .. 60.126 ± 0.04 mm

(2.3672 ± 0.0016 inch)
58 RENR5907-06
i02097507
Engine Oil Pump

SMCS Code: 1304
Part No.: 7C-8539
S/N: BLB1-Up
g00288421
Illustration 91


(2.3667 ± 0.0008 inch)

(0.295 ± 0.010 inch)

(2.3667 ± 0.0008 inch)
holes in the cover.
g00288420
Illustration 90

(2.3594 ± 0.0004 inch)

gear face ....... 169.5 ± 0.5 mm (6.67 ± 0.02 inch)

of the gear .......................................... 316°C (601°F)
g00288422
Illustration 92
gear face ......... 51.0 ± 0.5 mm (2.01 ± 0.02 inch) (11) Bearings
The maximum permissible temperature for installation To minimize the press fit, cool the bearings and
of the gear ........................................ 316 °C (601 °F) the bearing driver.
Temperature ............................ −75 °C (−103 °F)
(4) Length of gears (11) Depth of bearings in the
housing .............................. 12.30 ± 0.25 mm
Drive Shaft ............................. 195.00 ± 0.02 mm (0.484 ± 0.010 inch)
(7.677 ± 0.001 inch)
Idler Shaft .............................. 195.00 ± 0.02 mm (12) Bore in bearings in housing .. 60.126 ± 0.04 mm
(7.677 ± 0.001 inch) (2.3672 ± 0.0016 inch)
(5) Diameter of idler shaft ......... 59.930 ± 0.010 mm
(2.3594 ± 0.0004 inch)
RENR5907-06 59
(13) Align the oil hole in the bearing with the oil hole Test force .......................... 435 ± 22 N (98 ± 5 lb)
in the housing. Free length after test ........ 203.8 mm (8.02 inch)
housing ... 0.14 to 0.26 mm (0.006 to 0.010 inch) (2) 2G-5664 Spring
Test force .................. 3426 ± 169 N (770 ± 38 lb)
Free length after test ........ 131.3 mm (5.17 inch)
i01089975
Engine Oil Filter

SMCS Code: 1318
g00288423
Illustration 93

Height of dowel ....... 8 ± 1 mm (0.32 ± 0.04 inch) g00284480
Illustration 95
(16) Install the dowel in this position for a
counterclockwise rotation of the engine. (1) Hex head on shaft flange ................... 25 ± 1 mm
(0.98 ± 0.04 inch)
rotation of the engine. (2) Put clean engine oil on the O-ring seals at
assembly.
i00642511
i01758342
Priority Valve Electrohydraulic Oil Filter
SMCS Code: 5137
SMCS Code: 1716-FI
g00287802
Illustration 94 g00899561
Illustration 96
(1) 1W-2240 Control Valve Spring
(1) Electrohydraulic oil filter
Length under test force ..... 164.0 mm (6.46 inch)
60 RENR5907-06
Tighten the electrohydraulic oil filter to the i01957022

following torque: .......................... 44.0 ± 3.5 mm
(1.73 ± 0.138 inch) Crankcase Breather
SMCS Code: 1317
i01571825
Engine Oil Temperature

Regulator
SMCS Code: 1330
S/N: BLB1-Up
S/N: BKE1-Up
S/N: BEN1-Up
Part No.: 120-9453
S/N: 4ZS1-Up
g00283754
Illustration 98
(1) Clamps
Torque ....................... 3.0 ± 0.5 N·m (27 ± 4 lb in)
(2) O-ring seals
Apply clean engine oil in the bores.
g00274459
Illustration 97
When the oil temperature regulator is completely

open, the temperature is the following value. .. 85 °C
(185°F)
Minimum opening distance at 85 °C

(185 °F) ..................................... 10.4 mm (0.41 inch)
RENR5907-06 61
i02112594
Water Pump
SMCS Code: 1361
g00287157
Illustration 99
(1) Diameter of the shaft at the seat area of the b. Put clean water on the seal assembly as the
carbon seal assembly ......... 44.450 ± 0.020 mm only lubrication for assembly. Do not get any
(1.7500 ± 0.0008 inch) grease or oil on the seal faces.
(2) Seal assembly c. Do not stretch the rubber of the seal assembly
at installation. If the seal is stretched, the
1. Ring and water seal service life is shortened.
a. Lubricate the housing bore with a light amount d. Use the 8T-3034 Water Pump Seal Driver and
of glycerin. hand pressure to install the seal assembly on
the pump shaft until the seal face makes light
b. Use the 8T-3034 Water Pump Seal Driver and contact with the smooth face of the ring.
hand pressure in order to install the water seal
(3) and the ring together in the pump housing Note: The seal assembly must rotate with the water
bore. Ensure that the polished face of the ring pump shaft. Do not use any lubricant (except clean
is toward the groove of the seal assembly. water) that will reduce the friction between the seal
and the shaft.
2. Seal assembly.
e. Install the carbon seal assembly spring.
a. Remove the spring from the seal.
(3) Seal. Put a light coat of glycerin on the seal and
in the housing bore at assembly.
62 RENR5907-06
(4) Diameter of the impeller shaft at the location of The shaft support bearing should be flush with the
the lip type seal .................... 49.200 ± 0.020 mm surface of the pump housing during installation.
(1.9370 ± 0.0008 inch)
(5) Diameter of impeller shaft .... 64.850 ± 0.020 mm

(2.5531 ± 0.0008 inch)
(6) Diameter of the impeller shaft at the support

end. ...................................... 88.878 ± 0.013 mm
(3.4991 ± 0.0005 inch)
(7) Put a light coat of glycerin on the O-ring seal

at assembly. Put a light coat of glycerin in the
housing bore at assembly.
(8) Put a light coat of glycerin on the seal at

assembly.
g01075929
Illustration 101
(9) Thickness of thrust washer ....... 11.85 ± 0.05 mm Positioning impeller shaft bearing
(0.467 ± 0.002 inch) View A-A
Width of groove in the impeller shaft for the thrust (13) Install the impeller shaft bearing (10) with
washer .......... 12.00 ± 0.05 mm (0.472 ± 0.002 inch) the bearing joint at a 5 degree angle from the
horizontal centerline of the pump housing.
End play for impeller shaft .............. 0.05 to 0.25 mm
(0.002 to 0.010 inch)
g01075947
Illustration 102
Positioning shaft support bearing
View B-B
(14) Install the shaft support bearing (12) with the

bearing joint at a 15 degree angle from the
vertical centerline of the pump housing.
g00287158
Illustration 100
(10) Bore in impeller shaft bearing .. 65.00 ± 0.06 mm

(2.559 ± 0.002 inch)
(11) Dimension of impeller shaft bearing from surface

of pump housing .......................... 92.5 ± 1.0 mm
(3.64 ± 0.04 inch)
(12) Bore in shaft support bearing .. 89.08 ± 0.06 mm

(3.507 ± 0.002 inch)
RENR5907-06 63
i01771230
Water Temperature Regulator

SMCS Code: 1355
g00274459
Illustration 103
Table 1
Part number Start to open temperature Fully open temperature Minimum opening distance
at fully open temperature
196-0427 20 °C (68 °F) 32 °C (90 °F) 10.4 mm (0.41 inch)
6I-4953 26 °C (79 °F) 37 °C (99 °F) 10.4 mm (0.41 inch)
6I-4952 45 °C (113 °F) 50 °C (122 °F) 10.4 mm (0.41 inch)
204-6707 42 °C (108 °F) 54 °C (129 °F) 10.4 mm (0.41 inch)
204-6708 47 °C (117 °F) 59 °C (138 °F) 10.4 mm (0.41 inch)
174-3504 81 °C (178 °F) 92 °C (198 °F) 10.4 mm (0.41 inch)
174-6584 87 °C (189 °F) 98 °C (208 °F) 10.4 mm (0.41 inch)
109-2327 98 °C (208 °F) 109 °C (228 °F) 10.4 mm (0.41 inch)
196-0431 102 °C (216 °F) 116 °C (241 °F) 10.4 mm (0.41 inch)
142-9675 108 °C (226 °F) 120 °C (248 °F) 9.5 mm (0.37 inch)
64 RENR5907-06
i00762501 5. Coat the upper half of each stud with 1.5 mm

(.06 inch) thick coating of 4C-4774 Water and
Cylinder Block Temperature Resistant Grease.
SMCS Code: 1201 (2) The dowels protrude from the front face
of the cylinder block at the following
S/N: BEN1-Up
distance. ............... 8.0 ± 1.0 mm (.32 ± .04 inch)
S/N: 4ZS1-Up
(3) The dowels protrude from the rear face
distance. ............. 20.0 ± 1.0 mm (.79 ± .04 inch)
(4) The dowels protrude from the front face

distance. ........... 55.0 ± 1.0 mm (2.17 ± .04 inch)
g00287638
Illustration 104
Right Side View
(1) Cylinder head studs
Install the cylinder head studs with the following

procedure: g00287639
Illustration 105
1. Coat the lower half of each stud with 1.5 mm Front View Of Cylinder Block
(.06 inch) thick coating of 4C-4774 Water and
Temperature Resistant Grease. (5) The dowels protrude above the cylinder block
face at the following distance. ....... 8.0 ± 1.0 mm
2. Thoroughly clean the top of the cylinder block. (.32 ± .04 inch)
3. Install the cylinder head studs. (6) The dowels protrude above the cylinder block
face at the following distance. ..... 60.0 ± 1.0 mm
Tighten the cylinder head studs to the following (2.36 ± .04 inch)
torque. ....................... 100 ± 20 N·m (75 ± 15 lb ft)
(7) Bore in the block for main
4. Apply a bead of sealant at the top of the block bearings ............................. 265.000 ± 0.020 mm
around each stud. This will ensure that the (10.4330 ± .0008 inch)
counterbore is filled with grease.
1.00 mm (.040 inch) oversize .. 266.000 ± 0.020 mm
(10.4724 ± .0008 inch)
RENR5907-06 65
2.00 mm (.080 inch) oversize .. 267.000 ± 0.020 mm Width of cylinder block for main bearing
(10.5118 ± .0008 inch) cap .............. 500.00 ± 0.05 mm (19.685 ± .002 inch)
(8) The center line of the crankshaft bearing bore to Clearance between the sides of the main bearing cap
the top surface of the cylinder block .. 946.00 mm and the cylinder block ..................... 0.03 to 0.13 mm
(37.244 inch) (.001 to .005 inch)
(9) Procedure for tightening the main bearings
1. Torque the studs in the cylinder block.
Torque for the studs .. 100 ± 20 N·m (75 ± 15 lb ft)
2. Assemble the main bearing cap and the washer.

Hand tighten the nut.
3. Tighten all side bolts by hand. Ensure that the

washer face and the side bolt threads have a
clean coating of 4C-5593 Anti-Seize Compound.
Ensure that all surfaces that contact the bearing
are free of 4C-5593 Anti-Seize Compound.
g00287640
Illustration 106
4. Start at the front face of the block. Main Bearing Cap
Tighten the side bolts on the side of the cap with (12) The dowel protrudes from the main bearing cap
the tab slot to the following torque. .. 215 ± 40 N·m at the following distance. ............. 10.0 ± 0.5 mm
(160 ± 30 lb ft) (.39 ± .02 inch)
5. Start at the front face of the block. Use the (13) Main bearing cap
4C-5850 Stud Tensioner Tool Group in order to
apply tension on the studs.
Apply tension on each pair of studs at the same

time to the following pressure. .. 65000 ± 2400 kPa
(9420 ± 348 psi)
6. Repeat Step 5.
(10) Tighten the side bolts according to the following

procedure.
1. Start at the front face of the block.
Tighten the side bolts on the side of the

cap opposite the tab slot to the following
torque. ..................... 215 ± 40 N·m (160 ± 30 lb ft)
Tighten the side bolts on the side of the cap with the
tab slot to the following torque. ... 1825 ± 175 N·m
(1340 ± 130 lb ft)
Tighten the side bolts on the side of the

torque. ............. 1825 ± 175 N·m (1340 ± 130 lb ft)
(11) Width of main bearing cap ... 499.95 ± 0.03 mm

(19.683 ± .001 inch)
66 RENR5907-06
i01543000 (2) Apply 8T-9014 Silicone Sealant to the covers

when the covers are installed to the block.
Cylinder Block
(3) The dowels protrude from the rear face
SMCS Code: 1201 of the cylinder block at the following
distance. ......... 20.0 ± 1.0 mm (0.79 ± 0.04 inch)
S/N: BLB1-Up
S/N: BKE1-Up (3) The dowels protrude from the front face
distance. ......... 20.0 ± 1.0 mm (0.79 ± 0.04 inch)
g00480025
Illustration 108
Front View Of Cylinder Block
(5) The dowels protrude above the cylinder block

g00584368 face at the following distance. ..... 60.0 ± 1.0 mm
Illustration 107
(2.36 ± 0.04 inch)
(1) Cylinder head studs Apply 4C-4774 Water and Temperature Resistant
Grease to the dowel before the head is assembled.
Use the following procedure in order to install the
cylinder head studs: (6) The dowels protrude above the cylinder block
face at the following distance. ....... 8.0 ± 1.0 mm
1. Coat the lower half of each stud with 1.5 mm (0.32 ± 0.04 inch)
(0.06 inch) thick coating of 4C-4774 Water and
Temperature Resistant Grease. (7) Procedure for tightening the main bearings
2. Thoroughly clean the top of the cylinder block. 1. Lubricate the stud threads with engine oil before
assembly.
3. Install the cylinder head studs.
2. Torque the studs in the cylinder block.
Tighten the cylinder head studs to the following
torque. ....................... 100 ± 20 N·m (75 ± 15 lb ft) Torque for the studs .. 100 ± 20 N·m (75 ± 15 lb ft)
4. Apply a bead of grease at the top of the block 3. Assemble the main bearing cap and the washer
around each stud. This will ensure that the with the part number toward the front of the engine
counterbore is filled with grease. block. Hand tighten the nut.
5. Coat the upper half of each stud with 1.5 mm
(0.06 inch) thick coating of 4C-4774 Water and
Temperature Resistant Grease.
RENR5907-06 67
4. Tighten all side bolts (9) by hand. Lubricate the

washer face and the threads with engine oil before
assembly.
Tighten the side bolts on the side of the cap with

the tab slot to the following torque. .. 215 ± 40 N·m
(160 ± 30 lb ft)
6. Start at the front face of the block. Use the

4C-5850 Stud Tensioner Tool Group in order to
apply tension on the studs.
Apply tension on each pair of studs at the same

time to the following pressure. .. 65000 ± 2400 kPa
(9400 ± 350 psi)
Tighten the nuts by hand and release the tension.
7. Repeat Step 6.
g00584867
Illustration 109
8. Start at the front face of the block. Rear view Of Cylinder Block
Tighten the side bolts on the side of the (10) The dowels protrude above the cylinder block
cap opposite the tab slot to the following face at the following distance. ....... 8.0 ± 1.0 mm
torque. ..................... 215 ± 40 N·m (160 ± 30 lb ft) (0.32 ± 0.04 inch)
9. Start at the front face of the block. (11) Width of main bearing cap ... 499.95 ± 0.03 mm
(19.683 ± 0.001 inch)
Tighten the side bolts on the side of the cap with the
tab slot to the following torque. ... 1825 ± 175 N·m Width of cylinder block for main bearing
(1340 ± 130 lb ft) cap ............ 500.00 ± 0.05 mm (19.685 ± 0.002 inch)
10. Start at the front face of the block. Clearance between the sides of the main bearing cap
and the cylinder block ..................... 0.03 to 0.13 mm
Tighten the side bolts on the side of the (0.001 to 0.005 inch)
torque. ............. 1825 ± 175 N·m (1340 ± 130 lb ft)
(8) Bore in the block for main

bearings ............................. 265.000 ± 0.020 mm
(10.4330 ± 0.0008 inch)
1.00 mm (0.040 inch) oversize .. 266.000 ± 0.020 mm

(10.4724 ± 0.0008 inch)
2.00 mm (0.080 inch) oversize .. 267.000 ± 0.020 mm

(10.5118 ± 0.0008 inch)
g00584890
Illustration 110
Main Bearing Cap
(12) The dowel protrudes from the main bearing cap

at the following distance. ............. 10.0 ± 0.5 mm
(0.39 ± 0.02 inch)
(13) Main bearing cap

68 RENR5907-06
i02112538
Crankshaft
SMCS Code: 1202
S/N: BLB1-Up
S/N: BKE1-Up
S/N: BEN1-Up
Part No.: 179-3572, 189-2500, 191-5424,
193-5846
S/N: 4ZS1-Up
g00290565
Illustration 112
Section A-A
Tighten the counterweight bolts according to the

following procedure.
1. Install the counterweight with the heavy side

toward the rod.

threads and seating surfaces of bolts (4) and (5).
3. Seat the counterweight by tightening bolt (4) first.

g00290564
Illustration 111 Torque ............... 1500 ± 100 N·m (1100 ± 75 lb ft)
Typical example
4. Tighten bolts (5).
(1) Thickness of thrust plates ........ 13.80 ± 0.05 mm
(0.543 ± 0.002 inch) Torque ............... 1500 ± 100 N·m (1100 ± 75 lb ft)
Install the thrust plates on the rear main bearing for 5. Loosen bolt (4) and bolts (5).
rear driven equipment. Install the thrust plates on the
front main bearing for front driven equipment. 6. Reseat the counterweight by tightening bolt (4)
first.
(2) Diameter of new connecting rod
journals .............................. 216.000 ± 0.025 mm Torque ..................... 320 ± 30 N·m (240 ± 22 lb ft)
(8.5039 ± 0.0010 inch)
7. Tighten bolts (5).
(3) Diameter of new main bearing
journals .............................. 250.000 ± 0.025 mm Torque ..................... 320 ± 30 N·m (240 ± 22 lb ft)
(9.8425 ± 0.0010 inch)
8. Check the torque on bolt (4).
Torque ..................... 320 ± 30 N·m (240 ± 22 lb ft)
9. Tighten bolt (4) first.
Tighten bolt (4) to the following required

amount. ...................................... 120 ± 5 degrees
Tighten bolts (5) to the following required

amount. ...................................... 120 ± 5 degrees
RENR5907-06 69
g00801223 g00290567
Detail A Section B-B
Crankshaft timing pin bracket
10. Insert locking pin (6) into Area (A) or Area (B).
(10) The dowel extends from the crankshaft timing pin
(A) Angle .......................................... 120 degrees bracket at the following distance. .. 5.0 ± 1.0 mm
(0.20 ± 0.04 inch)
(B) Angle .......................................... 120 degrees
Note: The angle of Area (A) is 120 degrees. The

angle of Area (B) is 120 degrees.
g00906201
Illustration 116
Detail of throw of crankshaft
g00290566 (11) The change in the dimension must not exceed

Illustration 114
the following value when the engine is at ambient
temperature. ................... 0.08 mm (0.0032 inch)
(7) Oil plugs of crankshaft
Torque .......................... 300 ± 40 N·m (221 ± 30 lb ft)
(8) Crankshaft timing pin bracket
(9) Crankshaft end play .................. 0.20 to 0.60 mm

(0.008 to 0.024 inch)
70 RENR5907-06
i01542690 (6) Position the sleeves on the adapters. Make sure

that the arrow on the outside diameter of the
Crankshaft Seals sleeve is pointing in the direction of the rotation
of the crankshaft. Assemble the sleeve onto the
SMCS Code: 1160; 1161 adapter. Make sure that the adapter bottoms out
against the shoulder.
i02185552
Connecting Rod
SMCS Code: 1218
g00304423
Illustration 117
g00287846
Illustration 118
(1) Crankshaft seals must be installed with the lip
of the seal toward the inside of the engine, as (1) Bore in connecting rod for piston pin
shown above. Make sure that the correct seal is bearing ............................... 130.000 ± 0.015 mm
installed on each end of the crankshaft. (5.1181 ± 0.0006 inch)
An SAE standard rotation engine will have crankshaft The piston pin bearing may be installed in the
seals that are installed in the following locations: connecting rod by using either of the following
methods:
• 190-2462 Seal Assembly on the front of the
engine 1. Lower the temperature of the piston pin bearing
before installing the piston pin bearing in the
• 190-2463 Seal Assembly on the rear of the connecting rod. This is the preferred method of
engine installation.
An SAE opposite rotation engine will have crankshaft Minimum temperature to cool piston pin
seals that are installed in the following locations: bearing ........................................ −90°C (−130°F)
• 190-2463 Seal Assembly on the front of the 2. Raise the temperature of the piston pin end of
engine the connecting rod before installing the bearing.
This must be for a minimum length of 250 mm
• 190-2462 Seal Assembly on the rear of the engine (10 inch). Raise the temperature evenly. Raise
the temperature thoroughly. This is the alternative
(2) Rear face of cylinder block method.
(3) Front face of cylinder block Note: Do not use a torch to heat the connecting rod.
(4) Apply 4C-4774 Water and Temperature Heat the connecting rod to the following
Resistant Grease to the bore of the adapter. Also, temperature. ............... 190° ± 15°C (374° ± 27°F)
apply the grease to the holes (66 mm (2.6 inch)
diameter) in the adapter. (2) Bore in piston pin bearing for new piston
pin .. 120.114 ± 0.008 mm (4.7289 ± 0.0003 inch)
(5) Apply clean engine oil to the O-ring seals at
assembly.
RENR5907-06 71
Diameter of new piston pin ....... 119.994 ± 0.006 mm

(4.7242 ± 0.0002 inch)
Tight fit between connecting rod and piston pin

bearing .. 0.120 to 0.180 mm (0.0047 to 0.0071 inch)
Note: Assemble the piston pin retainer so the word

“OUT” is visible.
g00775406
Illustration 120
This illustration identifies dimension (X) for the connecting rod bolt.
Do not reuse a connecting rod bolt if dimension (X) is

more than 329.00 mm (12.953 inch).
Tightening Procedure for

Illustration 119
g00287847
Connecting Rod Bolts
Positioning piston pin bearing
Note: Connecting rod bolt (1) and connecting rod
Note: The bearing junction and the locating hole are bolt (2) are on the same side of the connecting rod
180 degrees across from each other. The bearing as the tab slots for the connecting rod bearing.
junction and the locating hole must be assembled
within area (A). Area (A) is 90 ± 15 degrees from the
centerline through the connecting rod bores.
(3) Bore in bearing for

crankshaft ..................... 216.145 to 216.306 mm
(8.5096 to 8.5160 inch)
(4) Bore in connecting rod for

bearing ....... 225.000 + 0.025 mm to − 0.065 mm
(8.8582 + 0.0009 inch to − 0.0025 inch)
Total allowed runout ............ 0.066 mm (0.0026 inch)
Clearance between bearing and g00756010

crankshaft ................................... 0.171 to 0.282 mm Illustration 121
(0.0067 to 0.0111 inch) This illustration identifies the connecting rod bolts and nuts.
(5) Distance between center of Use 6V-4876 Lubricant to lubricate the following
bearings ...................... 600.00 mm (23.622 inch) parts: connecting rod bolt threads, the knurled shank
of the connecting rod bolts, and the seating face of
the nut.
Reuse Information for the
Connecting Rod Bolts 1. Tighten nuts (1), (2), (3), and (4).
Inspect connecting rod bolts at each service of the Torque ....................... 105 ± 20 N·m (75 ± 15 lb ft)
connecting rod bearings. There should be no fretting
on the shank of the connecting rod bolt. This includes 2. Tighten nut (1).
the knurled area of the connecting rod bolts. Ensure
that the connecting rod bolts meet the guidelines for Torque ..................... 340 ± 15 N·m (250 ± 10 lb ft)
reusable parts. Refer to Guidelines For Reusable
Parts, SEBF8063, “Visual Inspection Of Connecting 3. Tighten nut (4).
Rods”. Do not reuse the nuts.
Torque ..................... 340 ± 15 N·m (250 ± 10 lb ft)
72 RENR5907-06
4. Tighten nut (2). Torque ........................... 80 ± 10 N·m (59 ± 7 lb ft)
Torque ..................... 340 ± 15 N·m (250 ± 10 lb ft) 17. Place an index mark on nut (3). Align the index
mark on the socket with the mark on the nut. Place
5. Tighten nut (3). another index mark on the connecting rod that
aligns with the mark on the socket. This will serve
Torque ..................... 340 ± 15 N·m (250 ± 10 lb ft) as a reference for the degree of rotation. Rotate
nut (3) for 360 ± 5 degrees in a clockwise direction.
6. Without loosening the nut, tighten nut (1) again.
i02110239
Torque ..................... 340 ± 15 N·m (250 ± 10 lb ft)

Connecting Rod and Main
Bearing Journals
Torque ..................... 340 ± 15 N·m (250 ± 10 lb ft)
SMCS Code: 1230
Refer to Guidelines For Reusable Parts, SEBF8009,
Torque ..................... 340 ± 15 N·m (250 ± 10 lb ft) “Main And Connecting Rod Bearings” for more
information.
Connecting Rod Bearing Journals
Torque ..................... 340 ± 15 N·m (250 ± 10 lb ft)
Table 2
10. Loosen nut (1) and then tighten nut (1). Diameter Of Crankshaft Journal (Bearing Surface)
For Connecting Rod Bearings
Torque ........................... 80 ± 10 N·m (59 ± 7 lb ft)
Original Size Journal 216.000 ± 0.025 mm
(8.5039 ± 0.0010 inch)
11. Place an index mark on nut (1). Place another
index mark on the socket that is used to rotate the Undersize Journal 215.500 ± 0.025 mm
nut. The index mark on the socket must align with 0.50 mm (0.020 inch) (8.4843 ± 0.0010 inch)
the mark on the nut. Place another index mark Undersize Journal 215.000 ± 0.025 mm
on the connecting rod that aligns with the mark 1.00 mm (0.040 inch) (8.4646 ± 0.0010 inch)
on the socket. This will serve as a reference for
the degree of rotation. Rotate nut (1) for 360 ± 5
degrees in a clockwise direction. Clearance between bearing and new
journal .... 0.173 to 0.285 mm (0.0068 to 0.0112 inch)
12. Loosen nut (4) and then tighten nut (4).
Main Bearing Journals
Torque ........................... 80 ± 10 N·m (59 ± 7 lb ft)
Table 3
13. Place an index mark on nut (4). Align the index Diameter Of Crankshaft Journal (Bearing
mark on the socket with the mark on the nut. Place Surface) For Main Bearings
another index mark on the connecting rod that Original Size Journal 250.000 ± 0.025 mm
aligns with the mark on the socket. This will serve (9.8425 ± 0.0010 inch)
as a reference for the degree of rotation. Rotate
nut (4) for 360 ± 5 degrees in a clockwise direction. Undersize Journal 249.500 ± 0.025 mm
0.50 mm (.020 inch) (9.8228 ± 0.0010 inch)
14. Loosen nut (2) and then tighten nut (2). Undersize Journal 249.000 ± 0.025 mm
1.00 mm (0.040 inch) (9.8031 ± 0.0010 inch)
Torque ........................... 80 ± 10 N·m (59 ± 7 lb ft)
15. Place an index mark on nut (2). Align the index Clearance between bearing and new
mark on the socket with the mark on the nut. Place journal ... 0.265 to 0.385 mm (0.0104 to 0.0152 inch)
another index mark on the connecting rod that
aligns with the mark on the socket. This will serve
as a reference for the degree of rotation. Rotate
nut (2) for 360 ± 5 degrees in a clockwise direction.
16. Loosen nut (3) and then tighten nut (3).

RENR5907-06 73
i02110241
Piston and Rings

SMCS Code: 1214; 1215
g00290542
Illustration 122
Table 4
Piston and rings
Description (1) Top ring (2) Intermediate ring (3) Oil control ring
Width of groove in new piston 5.160 ± 0.010 mm 5.160 ± 0.010 mm 8.050 ± 0.500 mm
(0.2030 ± 0.0004 inch) (0.2030 ± 0.0004 inch) (0.3169 ± 0.0197 inch)
Width of piston ring 4.965 ± 0.025 mm 4.977 ± 0.012 mm 7.976 ± 0.011 mm
(0.1955 ± 0.0010 inch) (0.1959 ± 0.0005 inch) (0.3140 ± 0.0004)
Clearance between groove and piston ring 0.160 to 0.230 mm 0.161 to 0.205 mm 0.053 to 0.095 mm
(0.0063 to 0.0091 (0.0063 to 0.0081 inch) (0.0021 to 0.0037 inch)
inch)
End gap for the piston ring that is installed in 1.50 ± 0.20 mm 3.00 ± 0.20 mm 1.10 ± 0.20 mm
300 mm (11.8 inch) bore (0.059 ± 0.008 inch) (0.118 ± 0.008 inch) (0.043 ± 0.008 inch)
(3)
Installation “UP-1”(1) “UP-2”(2)
(1) The top ring must be installed with the “UP-1” mark toward the top of the piston.
(2) The intermediate ring must be installed with the “UP-2” mark toward the top of the piston.
(3) The oil control ring and the ring expander must be installed with the gaps 180 degrees across from each other. The white colored portion of
the ring expander must be visible through the oil control ring gap.
Bore in piston for pin .................... 120.20 ± 0.05 mm

(4.732 ± 0.002 inch)
Diameter of piston pin ............... 119.994 ± 0.006 mm

(4.7242 ± 0.0002 inch)
Clearance between piston pin and bore in

piston ................................... 0.015 mm to 0.047 mm
(0.0006 inch to 0.0019 inch)
74 RENR5907-06
i01544344 i00641074
Cylinder Liner Camshaft Bearings

SMCS Code: 1216 SMCS Code: 1211
S/N: BLB1-Up S/N: BEN1-Up
S/N: BKE1-Up S/N: 4ZS1-Up
S/N: BEN1-Up
Part No.: 7C-5044
S/N: 4ZS1-Up
g00288319
Illustration 123
(1) Groove for the Combustion gasket

Depth of groove ......................... 3.50 ± 0.15 mm
(0.138 ± 0.002 inch)
The dimension must not vary more than the
following value. ............. 0.020 mm (0.0008 inch)
g00287581
(2) Bore in new liner ................ 300.025 ± 0.025 mm Illustration 124
(11.8120 ± 0.0010 inch)
Note: Install the camshaft bearings with the bearing
Note: Measure the bore at four locations along joint toward the top face of the cylinder block.
the depth of the liner. Each location should be 90
degrees from each other. (1) Bore in camshaft bearings after
installation .............................. 174.00 ± 0.06 mm
(3) Flange (6.850 ± .002 inch)
Thickness of flange .................. 33.00 ± 0.03 mm Diameter of camshaft journals ..... 173.80 ± 0.03 mm
(1.299 ± 0.001 inch) (6.843 ± .001 inch)
The dimension must not vary more than the
following value. ............. 0.013 mm (0.0005 inch) Note: The camshaft bearing in the rear of the cylinder
block must be installed so that the engine timing pin
will pass freely through the cylinder block and the
bearing.
(2) Distance from the top surface of the

cylinder block to the center line of the oil
hole .......... 206.00 ± 0.50 mm (8.110 ± .020 inch)
RENR5907-06 75
i01130581
Camshaft Bearings
SMCS Code: 1211
S/N: BLB1-Up
S/N: BKE1-Up
g00480148
Illustration 125
Note: The left camshaft bearings and the right

camshaft bearings in the rear of the cylinder block
must be installed so that the engine timing pin
will pass freely through the cylinder block and the
bearing.
(1) Angle from the horizontal centerline to the

center of the timing pin hole in the rear camshaft
bearings ...................................... 25 ± 5 degrees
(2) Install the camshaft bearings with the bearing

joint toward the top face of the cylinder block.
(3) Bore in camshaft bearings after

installation .............................. 174.00 ± 0.06 mm
(6.850 ± 0.002 inch)
Diameter of the camshaft

journals ....... 173.80 ± 0.03 mm (6.843 ± 0.001 inch)
76 RENR5907-06
i00641062
Camshaft Bearing Position

SMCS Code: 1211
S/N: 4ZS1-Up
g00287545
Illustration 126
The camshaft bearings from the rear surface of the (E) ..................... 850.0 ± 1.5 mm (33.47 ± .06 inch)
cylinder block are the following dimensions:
(F) ..................... 440.0 ± 1.5 mm (17.32 ± .06 inch)
(A) ................... 2490.0 ± 1.5 mm (98.03 ± .06 inch)
(G) ......................... 30.0 ± 1.0 mm (1.18 ± .04 inch)
(B) ................... 2080.0 ± 1.5 mm (81.89 ± .06 inch)
(C) ................... 1670.0 ± 1.5 mm (65.75 ± .06 inch)
(D) ................... 1260.0 ± 1.5 mm (49.61 ± .06 inch)

RENR5907-06 77
i01426579

SMCS Code: 1211
S/N: BEN1-Up
g00467571
Illustration 127
The camshaft bearings from the rear surface of the

cylinder block are the following dimensions:
(A) ............... 3310.0 ± 1.5 mm (130.32 ± 0.06 inch)
(B) ................ 2900.0 ± 1.5 mm (114.17 ± 0.06 inch)
(C) ................. 2490.0 ± 1.5 mm (98.03 ± 0.06 inch)
(D) ................. 2080.0 ± 1.5 mm (81.89 ± 0.06 inch)
(E) ................. 1670.0 ± 1.5 mm (65.75 ± 0.06 inch)
(F) ................. 1260.0 ± 1.5 mm (49.61 ± 0.06 inch)
(G) ................... 850.0 ± 1.5 mm (33.47 ± 0.06 inch)
(H) ................... 440.0 ± 1.5 mm (17.32 ± 0.06 inch)
(J) ........................ 30.0 ± 1.0 mm (1.18 ± 0.04 inch)

78 RENR5907-06
i01130593

SMCS Code: 1211
S/N: BKE1-Up
g00480206
Illustration 128
Right Side View
The right camshaft bearings from the front surface of (E) ................... 919.0 ± 1.5 mm (36.18 ± 0.06 inch)
the cylinder block are the following dimensions:
(F) ................... 459.0 ± 1.5 mm (18.07 ± 0.06 inch)
(A) ............... 2759.0 ± 1.0 mm (108.62 ± 0.04 inch)
(G) ....... The front camshaft bearing should be flush
(B) ................. 2299.0 ± 1.5 mm (90.51 ± 0.06 inch) with the front surface of the cylinder block.
(C) ................. 1839.0 ± 1.5 mm (72.40 ± 0.06 inch)
(D) ................. 1379.0 ± 1.5 mm (54.29 ± 0.06 inch)

RENR5907-06 79
g00480207
Illustration 129
Left Side View
The left camshaft bearings from the front surface of

(H) ........ The rear camshaft bearing should be flush

with the rear surface of the cylinder block.
(I) ................... 2381.0 ± 1.5 mm (93.74 ± 0.06 inch)
(J) .................. 1921.0 ± 1.5 mm (75.63 ± 0.06 inch)
(K) ................. 1461.0 ± 1.5 mm (57.52 ± 0.06 inch)
(L) .................. 1001.0 ± 1.5 mm (39.41 ± 0.06 inch)
(M) ................... 541.0 ± 1.5 mm (21.30 ± 0.06 inch)
(N) ....................... 81.0 ± 1.0 mm (3.19 ± 0.04 inch)

80 RENR5907-06
i01130603

SMCS Code: 1211
S/N: BLB1-Up
g00480325
Illustration 130
Right Side View
The right camshaft bearings from the front surface of (H) ................... 459.0 ± 1.5 mm (18.07 ± 0.06 inch)
(I) ......... The front camshaft bearing should be flush
(A) ............... 3679.0 ± 1.0 mm (144.84 ± 0.04 inch) with the front surface of the cylinder block.
(B) ............... 3219.0 ± 1.5 mm (126.73 ± 0.06 inch)
(C) ............... 2759.0 ± 1.0 mm (108.62 ± 0.04 inch)
(D) ................. 2299.0 ± 1.5 mm (90.51 ± 0.06 inch)
(E) ................. 1839.0 ± 1.5 mm (72.40 ± 0.06 inch)
(F) ................. 1379.0 ± 1.5 mm (54.29 ± 0.06 inch)
(G) ................... 919.0 ± 1.5 mm (36.18 ± 0.06 inch)

RENR5907-06 81
g00480328
Illustration 131
Left Side View
The left camshaft bearings from the front surface of

(J) ......... The rear camshaft bearing should be flush

with the rear surface of the cylinder block.
(K) ............... 3301.0 ± 1.5 mm (129.96 ± 0.06 inch)
(L) ................. 2841.0 ± 1.5 mm (111.85 ± 0.06 inch)
(M) ................. 2381.0 ± 1.5 mm (93.74 ± 0.06 inch)
(N) ................. 1921.0 ± 1.5 mm (75.63 ± 0.06 inch)
(O) ................. 1461.0 ± 1.5 mm (57.52 ± 0.06 inch)
(P) ................. 1001.0 ± 1.5 mm (39.41 ± 0.06 inch)
(Q) ................... 541.0 ± 1.5 mm (21.30 ± 0.06 inch)
(R) ....................... 81.0 ± 1.0 mm (3.19 ± 0.04 inch)

82 RENR5907-06
i01972674
Gear Group (Front)

SMCS Code: 1206
g01024127
Illustration 132
Note: Lubricate all of the O-ring seals with clean

engine oil.
RENR5907-06 83
Thickness .................................. 9.45 ± 0.05 mm

(0.372 ± 0.0020 inch)
(5) Left idler shaft

Outer diameter ......................... 69.85 ± 0.02 mm
(2.750 ± 0.001 inch)
Position of the oil hole for engines with standard
rotation ................................................. 2 O’clock
Position of the oil hole for engines with reverse
rotation ................................................. 8 O’clock
(6) Right idler shaft

Outer diameter ......................... 69.85 ± 0.02 mm
(2.750 ± 0.001 inch)
Position of the oil hole for engines with standard
rotation ................................................. 5 O’clock
Position of the oil hole for engines with reverse
rotation ................................................ 11 O’clock
g01024336
(7) Crankshaft gear
Illustration 133
Cross section of the left idler gear and of the right idler gear Use a 4C-9797 Grease Tube to lubricate the bore of
the crankshaft gear.
(1) Left idler gear
Gear’s bore for bearing ............ 76.00 ± 0.02 mm i01131272
(2.992 ± 0.001 inch)
(8) Depth of the installed bearing in the gear’s Housing (Front)
bore .... 2.50 ± 0.50 mm (0.098 ± 0.020 inch)
(9) Pitch diameter ....... 301.02 mm (11.851 inch) SMCS Code: 1151; 1162
(10) Circular runout of the bearing bore
established by the axis of the gear’s pitch
diameter. ..................... 0.16 mm (0.006 inch)
(11) Inner diameter of bearing bore after
machining ...................... 69.950 ± 0.010 mm
(2.7539 ± 0.0004 inch)
(12) Maximum roughness of machined bearing
bore .................................... 0.8 micrometers
(2) Right idler gear

Gear’s bore for bearing ............ 76.00 ± 0.02 mm
(2.992 ± 0.001 inch)
(8) Depth of the installed bearing in the gear’s
bore .... 2.50 ± 0.50 mm (0.098 ± 0.020 inch)
(9) Pitch diameter ....... 296.59 mm (11.677 inch)
(10) Circular runout of the bearing bore
established by the axis of the gear’s pitch
diameter. ..................... 0.16 mm (0.006 inch)
(11) Inner diameter of bearing bore after
machining ...................... 69.950 ± 0.010 mm
(2.7539 ± 0.0004 inch)
(12) Maximum roughness of machined bearing
(3) Bearing
Outer diameter ..................... 76.091 ± 0.020 mm
(2.996 ± 0.001 inch) Illustration 134
g00288800
(4) Thrust washer

84 RENR5907-06
(1) The dowels at location (B) extend from Note: Use the manual barring group to rotate the
the surface of the housing at the following engine. The engine should be prelubed before
distance. ........... 6.0 ± 0.5 mm (0.24 ± 0.02 inch) rotating the crankshaft in order to perform service
work. Rotating the crankshaft before prelube may
(2) The dowels at location (A) extend from cause damage to the crankshaft bearings if the
the surface of the housing at the following mating surface is dry.
distance. ......... 10.0 ± 1.0 mm (0.40 ± 0.04 inch)
1. Rotate the engine to the Top Center Position of the
(3) The dowels at location (C) extend from compression stroke for the number one cylinder.
the surface of the housing at the following Install the crankshaft timing pin.
distance. ........... 4.0 ± 1.0 mm (0.16 ± 0.04 inch)
NOTICE
(4) Magnetic pickup If the crankshaft timing pin location is missed, do not
turn the flywheel in the opposite direction to install the
i01223335 crankshaft timing pin. If the crankshaft timing pin loca-
tion is missed, repeat Step 1.
Gear Group (Rear)
SMCS Code: 1204; 1206 2. Install the camshaft timing pin.
S/N: BEN1-Up 3. Put the camshaft drive gear (1) in position on

the camshaft (2). Apply 4C-5592 Anti-Seize
S/N: 4ZS1-Up Compound to the threads of bolt (3). Install the
plate and the bolt (3) hand tight.
Note: Make sure that the gear taper and the camshaft
taper are clean and dry. Make sure that the gear
taper and the camshaft taper are free of dirt, rust
and lubricants.
4. To prevent the crankshaft from turning, engage

the Manual barring group.
Tighten the locking guide to the following

torque. ..................... 270 ± 25 N·m (200 ± 18 lb ft)
5. Use a torque multiplier to tighten the camshaft

bolt.
Tighten the bolt to the following

torque. ............. 2000 ± 275 N·m (1480 ± 200 lb ft)
6. Strike the plate with a hammer in order to seat the

gear taper on the camshaft. Repeat Step 5.
7. Repeat Step 6 until there is no change in the bolt

torque.
8. Loosen the locking guide on the Manual barring

group. Verify the relation of the crankshaft to the
camshaft by installing the timing pins. If both
g00289173
Illustration 135 timing pins cannot be installed, loosen the bolt and
the camshaft drive gear. Repeat the procedure for
(1) Camshaft drive gear installing the camshaft drive gear.
(2) Camshaft (4) Tighten the mounting bolts for the idler gear to the
following torque. .... 270 ± 40 N·m (200 ± 30 lb ft)
(3) Bolt and plate that holds the camshaft drive gear
in position When the timing pin is engaged in the crankshaft, the
mounting bolts must be visible through the holes in
Procedure for installing the camshaft drive gear the idler gear.
RENR5907-06 85
(5) Small cluster idler gear

Backlash between the camshaft drive gear (1)
and the idler gear (5) ............ 0.269 to 0.434 mm
(0.0106 to 0.0171 inch)
(6) Idler shaft assembly

Outside diameter of shaft .. 105.840 ± 0.020 mm
(4.1669 ± 0.0008 inch)
Height to the top of the dowel in idler
shaft .................. 7.0 ± 0.5 mm (0.28 ± 0.02 inch)
(7) Thickness of new thrust washer .. 9.60 ± 0.05 mm

(0.378 ± 0.002 inch)
(8) Large cluster idler gear

Backlash between the idler gear (8) and the
crankshaft gear (9) ............... 0.304 to 0.504 mm
(0.0120 to 0.0198 inch)
(9) Crankshaft gear g01042492

Illustration 137
Bore in crankshaft gear ......... 235.10 ± 0.03 mm (2) Idler gears

(9.256 ± 0.001 inch)
Backlash between the camshaft drive gears and
(10) Crankshaft the idler gears ....................... 0.160 to 0.795 mm
(0.0063 to 0.0313 inch)
Diameter of crankshaft .......... 235.00 ± 0.03 mm Bore for bearing .......................... 150 ± 0.02 mm
(9.252 ± 0.001 inch) (5.905 ± 0.0008 inch)
(A) Base diameter. ..................... 160 ± 0.02 mm
i02016107 (6.299 ± 0.0008 inch)
(B) Depth of installed bearing in gear’s
Gear Group (Rear) bore ........... 3.0 ± 0.5 mm (0.118 ± 0.02 inch)
(C) Circular runout of the bearing bore
SMCS Code: 1204; 1206 established by the axis of the gear’s base
diameter. ................... 0.13 mm (0.0051 inch)
S/N: BLB1-Up (D) Inner diameter of bearing bore after
machining ..................... 150.002 ± .020 mm
S/N: BKE1-Up
(5.9056 ± 0.0008 inch)
(E) Maximum roughness of machined bearing
(3) Small cluster idler gear

Backlash between the idler gears and the small
cluster idler gear ................... 0.067 to 0.778 mm
(0.0026 to 0.0306 inch)
(4) Idler gear
(5) Torque for the bolts that connect the idler gear to
the small cluster idler gear ............. 135 ± 20 N·m
(100 ± 15 lb ft)
g00483155
Illustration 136 (6) Crankshaft gear
(1) Camshaft drive gears Backlash between the idler gear and the
crankshaft ............................. 0.216 to 0.949 mm
(0.0085 to 0.0374 inch)
86 RENR5907-06
Torque ..................... 160 ± 16 N·m (120 ± 12 lb ft)
3. Tighten each of the bolts for an additional 45 ±

5 degrees.
(8) Locking plate and bolts
(9) Bolt that holds the camshaft drive gear in position
Use the following procedure in order to install the

camshaft drive gears:
Note: Use the manual barring group to rotate the

engine. The engine must be prelubed before rotating
the crankshaft in order to perform service work.
Rotating the crankshaft before prelube may cause
damage to the crankshaft bearings if the mating
surface is dry.
1. Rotate the engine to the Top Center position of the

compression stroke for the number one cylinder.
Install the crankshaft timing pin.
NOTICE
If the crankshaft timing pin location is missed, do not
turn the flywheel in the opposite direction to install the
crankshaft timing pin. If the crankshaft timing pin loca-
Illustration 138
g00483156 tion is missed, repeat Step 1.
(7) Mounting bolts for the idler shafts 2. Install the camshaft timing pin.
Use the following procedure in order to tighten the 3. Put the camshaft drive gear (1) in position on the
mounting bolts for the idler shaft. camshaft. Install the plate and the bolt hand tight.
Note: Make sure that the gear taper and the camshaft
taper are clean and dry. Make sure that the gear
taper and the camshaft taper are free of dirt, rust
and lubricants.
4. To prevent the crankshaft from turning, engage the

manual barring group. Tighten the locking guide.
Torque ..................... 270 ± 25 N·m (200 ± 18 lb ft)

threads and to the seating face of the bolt. Use a
torque multiplier to tighten the camshaft bolt.
g00483157
Illustration 139 Torque ............. 2000 ± 275 N·m (1480 ± 200 lb ft)
1. Use the following sequence in order to tighten and 6. Strike the plate with a hammer in order to seat the
turn the bolts. gear taper on the camshaft. Repeat Step 5.
Two idler shafts with 8 bolt 7. Repeat Step 6 until there is no change in the bolt
patterns ........................................ 1-5-3-7-2-6-4-8 torque.
One idler shaft with 10 bolt
pattern ................................. 1-6-3-8-5-10-7-2-9-4
2. Tighten the bolts.

RENR5907-06 87
8. Loosen the locking guide on the manual barring (15) Install the bearing in idler gear (2) to the
group. Verify the relation of the crankshaft to the following depth. .. 3.0 ± 0.5 mm (0.12 ± 0.02 inch)
camshaft by installing the timing pins. If both
timing pins cannot be installed, loosen the bolt and (16) Bearing for the idler gear
the camshaft drive gear. Repeat the procedure for
installing the camshaft drive gear. Inside diameter of bearing for idler gear
(2) .. 150.002 ± 0.020 mm (5.9056 ± 0.0008 inch)
(10) Outside diameter of idler gear Bore in gear for bearing ..... 160.000 ± 0.020 mm
shaft ................................... 149.850 ± 0.020 mm (6.2992 ± 0.0008 inch)
(5.8996 ± 0.0008 inch)
(11) Thickness of idler gear thrust

washers .... 9.60 ± 0.05 mm (0.378 ± 0.002 inch)
(12) Idler gear shaft

Outside diameter of the shaft for the small cluster
idler gear ............................ 105.860 ± 0.020 mm
(4.1677 ± 0.0008 inch)
g00483159
Illustration 140
(13) Install the bearing in small cluster idler gear (3)

to the following depth. .................... 3.0 ± 0.5 mm
(0.12 ± 0.02 inch)
(14) Bearing for the small cluster idler gear

Outside diameter of bearing for small cluster idler
gear (3) ............................... 114.171 ± 0.026 mm
(4.4949 ± 0.0010 inch)
Bore in gear for bearing ...... 114.000 ± 0.020 mm
(4.4882 ± 0.0008 inch)
g00483240
Illustration 141
88 RENR5907-06
i02097583
Housing (Rear)
SMCS Code: 1157
S/N: BEN1-Up
S/N: 4ZS1-Up
g00900687
Illustration 142
(1) 1/2 inch Bolt Torque ...................... 125 ± 15 N·m (90 ± 11 lb ft)
Torque .................... 135 ± 20 N·m (100 ± 15 lb ft) Tighten the bolts for the rear housing in the following
sequence:
(2) 5/8 inch Bolt
1. Bolts (B)
Torque .................... 270 ± 40 N·m (200 ± 30 lb ft)
2. Bolts (C)
(3) Plug
3. Bolts (D)
RENR5907-06 89
4. Bolts (E)
5. Bolts (A)
Table 5
Installation Chart For The
Bolt Length
Rear Housing Bolts
Diameter Part mm
Bolt inch
inch Number
1A-1460
A 1/2 50.8 2.00
Bolt
2H-3756
B 5/8 228.6 9.00
Bolt
0S-1569
C 5/8 101.6 4.00
Bolt
1D-4599
D 5/8 177.8 7.00
Bolt
6V-9608
E 5/8 254.0 10.00
Bolt
90 RENR5907-06
i01957332
Housing (Rear)
SMCS Code: 1157
S/N: BLB1-Up
S/N: BKE1-Up
g00900032
Illustration 143
(1) Bolt (1/2 inch) Torque .................... 270 ± 40 N·m (200 ± 30 lb ft)
Torque .................... 135 ± 20 N·m (100 ± 15 lb ft) Tighten the bolts for the rear housing in the following
sequence with the turbocharger supports in position:
(2) Bolt (3/4 inch)
1. Tighten bolts (A) and tighten bolts (B) to the
Torque .................... 475 ± 20 N·m (350 ± 15 lb ft)
specified torque.
(3) Bolt (5/8 inch)
2. Tighten bolts (E) and tighten bolts (F) to the
specified torque.
RENR5907-06 91
3. Tighten bolts (C) and tighten bolt (D) to the

specified torque.
Table 6
Installation Chart For The
Bolt Length
Rear Housing Bolts
Diameter Part mm
Bolt inch
inch Number
4J-7945
A 3/4 292.1 11.50
Bolt(1)
5D-1972
B 3/4 298.5 11.75
Bolt(2)
1A-1460
C 1/2 50.8 2.00
Bolt
0S-1585
D 1/2 38.1 1.50
Bolt
6V-9608
E 5/8 254.0 10.00
Bolt
2H-3756
F 5/8 228.6 9.00
Bolt
(1) The bolts are contained in the mounting group for the
turbocharger.
(2) The bolts are contained in the mounting group for the gas lines.
92 RENR5907-06
i01957432
Vibration Damper
(Single)
SMCS Code: 1205
Part No.: 1W-0791
S/N: BLB1-Up
Part No.: 1W-0791
S/N: 4ZS1-Up
g00284764
Illustration 144
(1) Crankshaft (6) Bolts
(2) Crankshaft gear Torque .............. 1150 ± 150 N·m (840 ± 110 lb ft)
(3) Bolts (7) Adapter
Torque .............. 1300 ± 150 N·m (960 ± 110 lb ft) (8) Position the sleeve on the adapter so the arrow
on the sleeve is pointing in the direction of the
(4) Vibration damper crankshaft rotation.
(5) Align the dash mark with the dash mark on the Apply 4C-9507 Retaining Compound to the inner
crankshaft adapter (7). diameter of the sleeve.
RENR5907-06 93
(9) The lower bolt hole is offset. Align the dash marks
for the correct orientation.
i01957346
Vibration Damper
(Dual)
SMCS Code: 1205
S/N: BKE1-Up
S/N: BEN1-Up
g00467780
Illustration 145
(1) Dash mark (4) Bolts
(2) Center of inner damper Torque ............ 1350 ± 150 N·m (1000 ± 110 lb ft)
Align the center mark on the damper with the mark (5) Outer vibration damper
on the crankshaft.
(6) Inner vibration damper
(3) Center of outer damper
(7) Damper to crankshaft adapter
When the damper is installed the mark should be
rotated 36 degrees clockwise as the damper is (8) Crankshaft gear
viewed from the front of the engine.
(9) Crankshaft
94 RENR5907-06
Position the sleeve on the adapter so that the arrow

on the sleeve is pointing in the direction of the
crankshaft rotation.
(10) Lower bolt hole
The lower bolt hole is offset. Align the dash marks

for the correct orientation.
(11) Bolts
Torque ............ 1350 ± 150 N·m (1000 ± 110 lb ft)
i00651428
Vibration Damper
(Single)
SMCS Code: 1205
Part No.: 1W-0864
S/N: BLB1-Up
g00289513
Illustration 146
(1) Vibration damper
Install the vibration damper with the dash mark and

the number 1 piston at the top center position.

torque. ........... 1350 ± 150 N·m (1000 ± 110 lb ft)
RENR5907-06 95
i01854065
Flywheel
SMCS Code: 1156
S/N: BLB1-Up
S/N: BKE1-Up
S/N: 4ZS1-Up
g00530468
Illustration 147
Typical example
Refer to Testing And Adjusting, “Flywheel Runout” for

the correct method of flywheel inspection.
(1) Dash marks
Note: When the flywheel is installed, put the dash

mark on the flywheel near the pilot bore in alignment
with the dash mark on the crankshaft.
(2) Put 4C-5593 Anti-Seize Compound on the

washer face and the bolt threads. Tighten the
(590 ± 60 lb ft)
Tighten the bolts to an additional 90 degrees + 2 -

5 degrees.
(3) Install the ring gear on the flywheel with the

chamfer in the ring gear toward the engine.
96 RENR5907-06
i01957438
Flywheel
SMCS Code: 1156
Part No.: 6I-2075
S/N: BLB1-Up
Part No.: 6I-2075
S/N: BKE1-Up
Part No.: 6I-2074
S/N: BEN1-Up
Part No.: 6I-2074
S/N: 4ZS1-Up
g00287056
Illustration 148
Refer to Testing And Adjusting, “Flywheel Runout” for (3) Put 4C-5593 Anti-Seize Compound on the
the correct method of flywheel inspection. washer face and the bolt threads. Tighten the
(1) Dash marks (590 ± 60 lb ft)
Note: When the flywheel is installed, put the dash Tighten the bolts to an additional 90 degrees + 2 -
mark on the flywheel near the pilot bore in alignment 5 degrees.
with the dash mark on the crankshaft.
(4) Install the ring gear on the flywheel with the
(2) Bolts chamfer in the ring gear toward the engine.
Torque .............. 1150 ± 150 N·m (840 ± 110 lb ft)
RENR5907-06 97
i01765043 i01765416
Flexible Coupling Flexible Coupling

Part No.: 147-0074 Part No.: 150-0320
S/N: BEN1-Up S/N: BLB1-Up
Part No.: 147-0074 Part No.: 150-0320
S/N: 4ZS1-Up S/N: BKE1-Up
g00903004 g00903625
(1) Bolt (1) Bolt

Tighten the bolts to the following Tighten the bolts to the following
torque: ........... 1450 ± 150 N·m (1060 ± 110 lb ft) torque: ........... 1450 ± 150 N·m (1060 ± 110 lb ft)
(2) Spacer assembly (2) Spacer assembly
The bolts, nuts and washers that assemble the two The bolts, nuts and washers that assemble the two
halves of the spacer assembly (2) must be removed halves of the spacer assembly (2) must be removed
after the flexible coupling has been installed and prior after the flexible coupling has been installed and prior
to engine operation. to engine operation.
(3) Bolt (3) Bolt

Tighten the bolts to the following Tighten the bolts to the following
torque: ................... 913 ± 48 N·m (673 ± 35 lb ft) torque: ................. 1015 ± 55 N·m (749 ± 41 lb ft)
(4) Tighten the bolts to the following (4) Bolt

torque: ................... 265 ± 15 N·m (195 ± 11 lb ft)
Tighten the bolts to the following
torque: ................... 655 ± 35 N·m (483 ± 26 lb ft)
(5) Bolt
torque: ................... 370 ± 20 N·m (273 ± 15 lb ft)
(6) Bolt
torque: ................... 370 ± 20 N·m (273 ± 15 lb ft)
98 RENR5907-06
i01765235 i01957550
Flexible Coupling Manual Barring Group

Part No.: 147-0076
S/N: BLB1-Up
g00283576
Illustration 152
(1) Nut
Torque .................... 270 ± 25 N·m (200 ± 18 lb ft)
i00609985
Engine Lifting Bracket

g00903088
Illustration 151
SMCS Code: 1122
(1) Bolt S/N: BEN1-Up
Tighten the bolts to the following S/N: 4ZS1-Up
torque: ........... 1450 ± 150 N·m (1060 ± 110 lb ft)
(2) Spacer assembly
The bolts, nuts and washers that assemble the two

halves of the spacer assembly (2) must be removed
after the flexible coupling has been installed and prior
to engine operation.
(3) Bolt
torque: ................. 1015 ± 55 N·m (749 ± 41 lb ft)
(4) Bolt
g00284632
Tighten the bolts to the following Illustration 153
torque: ................. 1015 ± 55 N·m (749 ± 41 lb ft)
(1) Tighten the nuts to the following
(5) Bolt torque. ........... 2150 ± 250 N·m (1580 ± 185 lb ft)
Tighten the bolts to the following Apply 5P-3931 Anti-Seize Compound to nuts prior
torque: ................... 695 ± 35 N·m (513 ± 26 lb ft) to assembly.
RENR5907-06 99
i01958717
Engine Lifting Bracket

SMCS Code: 1122
S/N: BLB1-Up
S/N: BKE1-Up
g00943350
Illustration 156
Typical example 2
g00468227
Illustration 154
Position the bracket on the engine so that the hole in

the clevis is in a horizontal plane.
(1) Nuts
Apply 5P-3931 Anti-Seize Compound to nuts
prior to assembly.
g01018028
Illustration 157
Torque ............ 2150 ± 250 N·m (1580 ± 185 lb ft)
Side view
i01958175 (1) Bolts

Engine Support Torque ................ 1125 ± 100 N·m (820 ± 75 lb ft)
SMCS Code: 7060 (2) Dowel

Projection of the dowel beyond the surface of the
support
Dimension ............. 20 ± 1 mm (0.79 ± 0.04 inch)
i01617888
Belt Tension Chart

SMCS Code: 1357
Note: Do not use the belt tension charts for belts with
tensioners that are spring loaded.
g00943346
Illustration 155
Typical example 1
100 RENR5907-06
Table 7
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.
RENR5907-06 101
Table 8
For DAYCO Supplied Belts Only
Belt Tension Belt Tension
Size of Belt
“Initial”(1) “Used”(2)(4)
.380 (V-Belt) 623 ± 22 N (140 ± 5 lb) 245 - 534 N (100 ± 5 lb)
.440 (V-Belt) 667 ± 22 N (150 ± 5 lb) 245 - 534 N (100 ± 5 lb)
.500 (V-Belt) 712 ± 22 N (160 ± 5 lb) 245 - 534 N (100 ± 5 lb)
.600 (V-Belt) 779 ± 22 N (175 ± 5 lb) 245 - 534 N (100 ± 5 lb)
.660 (V-Belt) 890 ± 22 N (200 ± 5 lb) 245 - 534 N (100 ± 5 lb)
.790 (V-Belt) 890 ± 22 N (200 ± 5 lb) 245 - 534 N (100 ± 5 lb)
4 - RIB PVK 623 ± 22 N (140 ± 5 lb) 267 - 445 N (90 ± 5 lb)
5 - RIB PVK 779 ± 22 N (175 ± 5 lb) 334 - 556 N (100 ± 5 lb)
6 - RIB PVK 934 ± 22 N (210 ± 5 lb) 400 - 667 N (130 ± 5 lb)
8 - RIB PVK 1157 ± 22 N (260 ± 5 lb) 534 - 890 N (180 ± 5 lb)
10 - RIB PVK 1557 ± 22 N (350 ± 5 lb) 667 - 1112 N (230 ± 5 lb)
12 - RIB PVK 1869 ± 22 N (420 ± 5 lb) 800 - 1335 N (270 ± 5 lb)
15 - RIB PVK 2336 ± 22 N (525 ± 5 lb) 1000 - 1669 N (350 ± 5 lb)
(1) Belt tension “Initial” is for a new belt.
(2) Belt tension “Used” is for a belt that has operated for 30 minutes or more of operation at the rated speed.
(4) If a belt falls below the “Used” belt tension, the belt should be tightened again to the “Initial” belt tension.
i01967327
Alternator and Regulator

SMCS Code: 1405
Part No.: 6N-9294
g00278491
Illustration 159
Note: Load the battery with a carbon pile 4C-4911

Battery Load Tester in order to get the maximum
alternator output.
g00278489 Voltage ............................................................... 24 V

Illustration 158
Amperage ..................................................... 35 Amp
Polarity ............................................ Negative ground
Rotation ............................................ Either direction
The minimum full load current at 5000 rpm is the

following value. ............................................. 35 Amp

following value. ............................................. 11 Amp
102 RENR5907-06
Output voltage ............................................. 28 ± 1 V The minimum full load current at 2000 rpm is the
following value: ............................................... 9 Amp
(1) Shaft nut
Output voltage .......................................... 28 ± 1.0 V
Torque .......................... 102 ± 7 N·m (75 ± 5 lb ft)
(1) Positive terminal nut
(2) Positive terminal nut
Tighten the positive terminal nut to the following
Torque ....................... 6.2 ± 0.6 N·m (55 ± 5 lb in) torque: ...................... 6.2 ± 0.6 N·m (55 ± 5 lb in)
(3) Ground terminal nut (2) Field terminal nut
Torque ................... 2.25 ± 0.25 N·m (20 ± 2 lb in) Tighten the field terminal nut to the following
torque: .................. 2.25 ± 0.25 N·m (20 ± 2 lb in)
(4) Regulator
(3) Regulator
Voltage setting ............................. No adjustment
Permissible voltage range .................. 27 to 29 V Voltage setting ............................. No adjustment
Permissible voltage range .................. 27 to 29 V
i01768637
(4) Ground bolt
Alternator and Regulator Tighten the ground bolt to the following
SMCS Code: 1405 torque: ...................... 6.2 ± 0.6 N·m (55 ± 5 lb in)
Part No.: 200-8277 (5) Shaft nut

S/N: BLB1-Up
Tighten the shaft nut to the following
Part No.: 200-8277 torque: ......................... 102 ± 7 N·m (75 ± 5 lb ft)
S/N: BKE1-Up
i01599454
Air Starting Motor

SMCS Code: 1451
g00904521
Illustration 160
Voltage ............................................................... 24 V
Amperage ................................................... 100 Amp

g00828891
Illustration 161
Note: Load the battery with a carbon pile 4C-4911
Battery Load Tester in order to get the maximum (1) Inlet port
alternator output.
Recommended inlet pressure ... 620 kPa (90 psi)
Polarity ............................................ Negative ground
Rotation ............................................ Either direction

following value: ............................................. 90 Amp
RENR5907-06 103
i01958143 i01578541
Air Starting Motor Air Starting Motor Pressure

SMCS Code: 1451
Regulating Valve
SMCS Code: 1462
Part No.: 4W-2100
g00288167
Illustration 162
(1) Put 4C-5593 Anti-Seize Compound on the

threads of the bolts. These bolts hold the cover Illustration 163
g00287035
and the housing to the case.
(1) Adjusting screw
Tighten the bolts evenly in small increases.
Torque ....................................... 80 N·m (60 lb ft) (2) Inlet port
Inlet pressure ........................ 1724 kPa (250 psi)
(2) Bolts Maximum permissible pressure ........... 2758 kPa
Torque ....................................... 36 N·m (27 lb ft) (400 psi)
(3) Bolts (3) Outlet port
Torque ....................................... 78 N·m (60 lb ft) Minimum outlet pressure ........ 827 kPa (120 psi)
Maximum outlet pressure ....... 965 kPa (140 psi)
(4) Bolt
i02067507
Torque ...................................... 110 N·m (80 lb ft)
Temperature Sensor
(5) Tighten the nut until the clearance between the
rear end plate and the rotor is the following SMCS Code: 7400
value. ...... 0.03 to 0.08 mm (0.001 to 0.003 inch)
Part No.: 130-9811
Check the clearance again after the bolt for the clamp
nut is tightened.
(6) Bolt
Torque ..................................... 120 N·m (90 lb ft)
g01059361
Illustration 164
(1) Sensor assembly

104 RENR5907-06
Torque ............................ 20 ± 3 N·m (15 ± 2 lb ft) i01720050
Input supply voltage ............................. 5 VDC ± 0.25 Pressure Switch

(Electrohydraulic)
Maximum output current .................................. 10mA
SMCS Code: 7400
Operating temperature ........................ −40 to 125 °C
(−40 to 257 °F) Part No.: 140-9669
i01958151
Pressure Switch
SMCS Code: 7400
Part No.: 110-1168
g00289499
Illustration 166
Actuation pressure ...................... 1206 kPa (175 psi)
Deactuation pressure .. 700 ± 103 kPa (100 ± 15 psi)
Contact position (A) and

(C) ....... Normally closed below deactuation pressure
g00471391
Illustration 165
Contact position (A) and
(1) Pressure switch (B) ......... Normally open below deactuation pressure
Torque ............................ 22 ± 3 N·m (16 ± 2 lb ft) (1) Tighten the pressure switch to the following
torque. ........................... 82 ± 8 N·m (60 ± 6 lb ft)
Actuation pressure ............ 462 ± 41 kPa (67 ± 6 psi)
Deactuation pressure ........ 462 ± 41 kPa (67 ± 6 psi) i01783311
Contact position (B) and

Pressure Switch
(C) ....... Normally closed below deactuation pressure
SMCS Code: 7400
Contact position (A) and Part No.: 211-3504
(B) ......... Normally open below deactuation pressure
g00912402
Illustration 167
RENR5907-06 105
(1) Pressure switch i02065585
Actuation pressure ............. 508 ± 48 mm of H2O Pressure Sensor

(20 ± 2.3 inches of H2O)
SMCS Code: 7400-NS; 7450-NS
i01582114 Part No.: 149-5150
Pressure Sensor
Part No.: 207-6859
g01058984
Illustration 170
(1) Plug with socket A, socket B, and socket C
(2) Sensor assembly

g00821004
Illustration 168
(3) Port fitting
(1) Pressure sensor Torque .............................. 10 ± 2 N·m (7 ± 2 lb ft)
Maximum input pressure ....... ± 2 kPa (± 0.3 psi)
Torque ......................... 10 ± 2 N·m (89 ± 18 lb in) Input supply voltage ............................. 8 ± 0.25 VDC
Maximum supply current ................................. 12 mA

i01607863
Output type ........................... Pulse width modulated
Pressure Sensor
Output frequency ................................. 500 ± 100 Hz
Part No.: 163-8523
g00289576
Illustration 169
(1) Pressure sensor

Maximum pressure ............... 1135 kPa (165 psi)
Torque ......................... 10 ± 2 N·m (89 ± 18 lb in)
106 RENR5907-06
i02067024 Deactuation pressure (minimum) ............... 9 ± 3 kPa

(1.3 ± 0.4 psi)
Detonation Sensor
Contact position .......................................... Normally
SMCS Code: 7400 open below the deactuation pressure
Part No.: 195-2431
(1) Tighten the switch to the following
torque. ........................... 22 ± 3 N·m (16 ± 2 lb ft)
(2) Receptacle with pin A, pin B, and pin C
i02112539
Speed Sensor
SMCS Code: 7400
Part No.: 191-8305
g01059165
Illustration 171
(1) Plug with socket A. socket B, and socket C
(2) Torque ............................ 15 ± 3 N·m (11 ± 2 lb ft)
Input supply voltage ............................. 8 ± 0.25 VDC
Maximum supply current ................................. 30 mA
Output voltage ......................................... 4 ± 0.4 V ()
Operating temperature ........................ −40 to 121 °C

(−40 to 250 °F)
i01607724
Prelube Pressure Switch g01075831

Illustration 173
SMCS Code: 7400
(1) Sensor assembly
Part No.: 152-1959
Torque ............................ 25 ± 5 N·m (18 ± 4 lb ft)
Clearance between the sensor and the gear
tooth ................ 1.0 ± 0.4 mm (0.04 ± 0.016 inch)
g00820629
Illustration 172
Actuation pressure .............. 9 ± 3 kPa (1.3 ± 0.4 psi)

RENR5907-06 107
i01992347
Speed Sensor
SMCS Code: 7400
Part No.: 8L-4171
S/N: 4ZS1-Up
g01031789
Illustration 174
Thread the speed sensor into the threaded hole until

the tip contacts a tooth of the flywheel ring gear.
Unscrew the sensor for 1/2 of a turn (180 degrees).
Tighten the locknut.
(1) Speed sensor

Operating temperature ................. −60 to 150 °C
(−76 to 302 °F)
Torque for locknut .......... 25 ± 5 N·m (18 ± 4 lb ft)
Clearance between the speed sensor and the
flywheel ring gear ..................... 0.56 to 0.84 mm
(0.022 to 0.033 inch)
108 RENR5907-06
Index Section
Index
A F
Aftercooler ............................................................. 50 Flexible Coupling ............................................. 97–98

Aftercooler (Two-Stage)......................................... 51 Flywheel .......................................................... 95–96
Air Cleaner Adapter ............................................... 51 Fuel Control ..................................................... 18, 20
Air Lines (Air Choke) ............................. 7, 10, 12, 14 Fuel Lines ........................................................ 21–22
Air Starting Motor......................................... 102–103
Air Starting Motor Pressure Regulating Valve ..... 103
Alternator and Regulator ............................. 101–102 G
Gas Engine Ignition ............................................... 16

B Gas Engine Ignition (Bio-Gas Fuel)....................... 16
Gear Group (Front)................................................ 82
Belt Tension Chart ................................................. 99 Gear Group (Rear) .......................................... 84–85
C H
Camshaft ......................................................... 22, 24 Housing (Front)...................................................... 83

Camshaft Bearing Position ........................ 76–78, 80 Housing (Rear) ................................................ 88, 90
Camshaft Bearings .......................................... 74–75
Connecting Rod..................................................... 70
Reuse Information for the Connecting Rod I
Bolts ................................................................. 71
Tightening Procedure for Connecting Rod Important Safety Information ................................... 2
Bolts ................................................................. 71
Connecting Rod and Main Bearing Journals ......... 72
Crankcase Breather............................................... 60 M
Crankshaft ............................................................ 68
Crankshaft Seals ................................................... 70 Manual Barring Group ........................................... 98
Cylinder Block.................................................. 64, 66
Cylinder Head, Valves, Valve Springs and Valve Seat
Inserts .................................................................. 28 P
Cylinder Liner ........................................................ 74
Piston and Rings ................................................... 73
Prechamber ..................................................... 31–32
D Prechamber (Bio-Gas Fuel)................................... 30
Prelube Pressure Switch ..................................... 106
Detonation Sensor............................................... 106 Prelube Pump........................................................ 51
Pressure Sensor.................................................. 105
Pressure Switch................................................... 104
E Pressure Switch (Electrohydraulic)...................... 104
Priority Valve.......................................................... 59
Electrohydraulic Actuator....................................... 17
Electrohydraulic Oil Filter....................................... 59
Electronic Control (Combustion Sensor) ............... 18 S
Engine Design ..................................................... 4–5
Engine Lifting Bracket...................................... 98–99 Specifications Section ............................................. 4
Engine Oil Filter ..................................................... 59 Speed Sensor.............................................. 106–107
Engine Oil Lines (Electrohydraulic System) .......... 17
Engine Oil Pump............................ 52–53, 55–56, 58
Engine Oil Temperature Regulator ........................ 60 T
Engine Support...................................................... 99
Exhaust Bypass Valve ......................... 40, 42, 45, 48 Table of Contents..................................................... 3
Exhaust Manifold ....................................... 35, 37–39 Temperature Sensor ............................................ 103
Turbocharger ................................................... 33–34
RENR5907-06 109
Index Section
Valve Mechanism .................................................. 26

Vibration Damper (Dual)........................................ 93
Vibration Damper (Single) ............................... 92, 94
Water Pump........................................................... 61
Water Temperature Regulator ............................... 63
110 RENR5907-06
Index Section
RENR5907-06 111
Index Section
©2004 Caterpillar
All Rights Reserved Printed in U.S.A.

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RENR5907-06

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 Connecting Rod and Main Bearing Journals ........ 72

Specifications Section When the crankshaft is viewed from the flywheel

Number and arrangement of cylinders ........ In-line 6

Valves per cylinder Illustration 2

Inlet valves ........................................................ 2 Engine Design

Inlet ..................................... 0.50 mm (.020 inch) Standard rotation

Note: The front end of the engine is opposite the

Number and arrangement of cylinders ... 50° Vee 12 Illustration 4

Combustion .......................................... Spark Ignited

When the crankshaft is viewed from the flywheel

Note: The front end of the engine is opposite the

(1) Choke plate Thickness of thrust washer ........ 6.00 ± 0.05 mm

(12) Full nut 6. Assemble rod (13). Provide equal engagement

This allows a clearance between stop plate (8)

c. Make sure that the choke plate can achieve

9. Apply 4C-5597 Anti-Seize Compound to the

10. Apply glycerin to O-ring seal (17).

(A) Angle for the lever in the fully closed

(B) Angle for the lever in the fully open

Use the following procedure to assemble the air

1. Assemble choke plate (1) to shaft (2). Loosely

2. Install thrust washer (4) and tighten bolts (5).

3. To ensure that bolts (3) are properly seated in

4. Make sure that choke plate (1) is fully closed.

5. Assemble the actuator with inlet port (10) in the

(1) Adjusting bolt

(2) Thrust washer

(3) Locking nut

g00897609 (6) Stop plate

(9) Choke plate

Use the following procedure to assemble the air

(1) Adjusting bolt

(2) Thrust washer

(3) Locking nut

(5) Bolt (21) Inlet port

(6) Stop plate (22) Outlet port

(7) Housing (A) Angle

b. Then reduce the length of rod (15) by 1/2 turn

This allows a clearance between stop plate (6)

c. Make sure that the choke plate can achieve

(1) Adjusting bolt

(2) Thrust washer

(5) Bolt (20) Actuator

(6) Stop plate (21) Inlet port

(7) Housing (22) Outlet port

Bore in housing for shaft (A) Angle

c. Make sure that the choke plate can achieve

Gas Engine Ignition

(1) Transformer assembly

Lubricate the bore lightly with engine oil.

(3) Extension assembly

(4) Spark plug

(2) Seals Note: A new gasket should be used when a spark

Electrohydraulic Actuator Engine Oil Lines

(1) Piston assembly

1. Insert the piston assembly into the housing.

Torque ....................... 125 ± 15 N·m (92 ± 11 lb ft)

Torque .................................. 27 ± 5 N·m (20 ± 4 lb ft)

Finger tighten the bolts. Torque .............. 3 ± 0.2 N·m