001a HM02316 - 00 Engine Specifications

SENR9936-06
January 2008
Specifications
C27 and C32 Engines for Caterpillar
Built Machines
5301-Up (Machine)
2211-Up (Machine)
LWA1-Up (Machine)
GEB1-Up (Machine)
TPB1-Up (Machine)
H4C1-Up (Machine)
EED1-Up (Machine)
RJG1-Up (Machine)
Z9K1-Up (Machine)
JRP1-Up (Machine)
DLS1-Up (Machine)
BTW1-Up (Machine)
JNW1-Up (Machine)
BWX1-Up (Machine)
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 Caterpillar replacement parts or parts with equivalent
specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
SENR9936-06
Table of Contents
Specifications Section
Engine Design ....................................................... 4
Engine Design ....................................................... 4
Fuel Transfer Pump ............................................... 5
Fuel Filter Base ...................................................... 5
Fuel Filter Base ...................................................... 6
Electronic Unit Injector Mechanism ....................... 6
Electronic Unit Injector Rocker Arm ........................ 7
Electronic Unit Injector Wiring ................................. 7
Valve Mechanism ................................................... 8
Valve Mechanism ................................................... 9
Cylinder Head Valves ........................................... 10
Cylinder Head ....................................................... 11
Compression Brake .............................................. 13
Turbocharger ....................................................... 16
Turbocharger ....................................................... 18
Turbocharger ....................................................... 20
Turbocharger ....................................................... 21
Turbocharger ....................................................... 22
Exhaust Manifold ................................................. 24
Camshaft ............................................................. 31
Engine Oil Filter Base .......................................... 32
Engine Oil Filter Base .......................................... 33
Engine Oil Pump .................................................. 34
Engine Oil Pump .................................................. 36
Engine Oil Bypass Valve ...................................... 38
Engine Oil Bypass Valve ...................................... 39
Engine Oil Pan ..................................................... 40
Engine Oil Pan ..................................................... 41
Engine Oil Pan ..................................................... 42
Water Temperature Regulator .............................. 42
Water Pump ......................................................... 43
Cylinder Block ...................................................... 43
Cylinder Liner ....................................................... 45
Cylinder Liner ....................................................... 46
Crankshaft ........................................................... 47
Crankshaft Seals ................................................. 49
Vibration Damper ................................................. 49
Connecting Rod Bearing Journal ......................... 52
Main Bearing Journal ............................................ 52
Connecting Rod ................................................... 53
Piston and Rings .................................................. 55
Piston and Rings .................................................. 57
Housing (Front) ..................................................... 58
Housing (Rear) ..................................................... 59
Gear Group (Front) ............................................... 61
Gear Group (Rear) ................................................ 62
Gear Group (Rear) ................................................ 63
Gear Group (Rear) ................................................ 65
Gear Group (Rear) ................................................ 67
3
Table of Contents
Flywheel ...............................................................
Flywheel ...............................................................
Flywheel ...............................................................
Flywheel Housing ................................................
Coolant Temperature Sensor ...............................
Coolant Temperature Sensor ...............................
Coolant Flow Switch ............................................
Fuel Temperature Sensor .....................................
Fuel Temperature Sensor .....................................
Fuel Filter Pressure Differential Switch .................
Mass Air Flow Sensor ...........................................
Mass Air Flow Sensor ...........................................
Engine Oil Pressure Sensor .................................
Engine Oil Pressure Sensor .................................
Atmospheric Pressure Sensor ..............................
Inlet Manifold Temperature Sensor .......................
Turbocharger Inlet Pressure Sensor .....................
Turbocharger Inlet Pressure Sensor .....................
Speed/Timing Sensor ..........................................
68
69
70
70
72
73
75
77
78
79
79
80
81
81
82
83
83
84
84
85
85
86
86
87
87
Index Section
Index ..................................................................... 89
4
SENR9936-06
i02810716
Engine Design
SMCS Code: 1201
Note: The front of the engine is opposite of the

flywheel end of the engine. The left side and the right
side of the engine are viewed from the flywheel end
of the engine. The No. 1 cylinder is the front cylinder
on the left side. The No. 2 cylinder is the front cylinder
on the right side.
The crankshaft rotation is viewed from the flywheel
end of the engine.
S/N: EED1-Up
Crankshaft rotation ................. Counterclockwise
S/N: RJG1-Up
Note: Number one cylinder is the front cylinder

on the left side of the cylinder block. Number two
cylinder is the front cylinder on the right side of the
cylinder block.
S/N: DLS1-Up
S/N: BTW1-Up
S/N: JNW1-Up
Firing order ............ 1, 10, 9, 6, 5, 12, 11, 4, 3, 8, 7, 2
S/N: BWX1-Up
i02856750
Engine Design
SMCS Code: 1201
S/N: 5301-Up
S/N: 2211-Up
S/N: LWA1-Up
S/N: GEB1-Up
S/N: TPB1-Up
Illustration 1
g01113721
(A) Inlet valves

(B) Exhaust valves
Bore ........................................ 137.2 mm (5.40 inch)
S/N: H4C1-Up
S/N: Z9K1-Up
S/N: JRP1-Up
Stroke ..................................... 152.4 mm (6.00 inch)

Displacement ................................. 27 L (1648 cu in)
Compression ratio .............................................. 15:1
Cylinder arrangement ..................... 65 degrees V 12
Valves per cylinder .................................................. 4
Type of combustion ............................ Direct injection
Valve lash with engine stopped (cold)
Inlet ........... 0.38 0.08 mm (0.015 0.003 inch)
Exhaust ..... 0.76 0.08 mm (0.030 0.003 inch)
Illustration 2
g01113721
(A) Inlet valves

(B) Exhaust valves
Bore ............................................. 145 mm (5.7 inch)

Stroke .......................................... 162 mm (6.4 inch)
SENR9936-06
5
Displacement ................................. 32 L (1953 cu in)

Compression ratio .............................................. 15:1
Cylinder arrangement ...................... 65 degrees V12
Valves per cylinder .................................................. 4
Type of combustion ............................ Direct injection
Valve lash measurement
Inlet ................. 0.38 0.08 mm (0.015 0.003 inch)
Exhaust ........... 0.76 0.08 mm (0.030 0.003 inch)
Crankshaft rotation direction (view from the flywheel
end) ............................................... Counterclockwise
Firing order (injection
sequence) .............. 1, 10, 9, 6, 5, 12, 11, 4, 3, 8, 7, 2
The no. 1 cylinder is the front cylinder on the left side
of the cylinder block. The no. 2 cylinder is the front
cylinder on the right side of the cylinder block.
Note: The front of the engine is opposite of the
flywheel end of the engine. The left side of the engine
and the right side of the engine is viewed from the
flywheel end of the engine.
When the fuel transfer pump is using diesel fuel, the

fuel transfer pump has the following specifications:
Run the pump at 2940 rpm. The full bypass pressure
should be the following value. ........... 716 to 786 kPa
(104 to 114 psi)
Run the pump at 840 rpm. The flow at 550 kPa
(80 psi) must be 6.0 L/min (1.6 US gpm).
Run the pump at 2940 rpm. The flow at 650 kPa
(94 psi) must be 9.0 L/min (2.38 US gpm).
Run the pump at 120 rpm with the inlet open to the
atmosphere for 10 seconds. Block the inlet. The
pump must maintain vacuum of 30 kPa (4.5 psi)
minimum in 30 seconds.
Run the pump at 840 rpm with the inlet open to the
atmosphere for 10 seconds. Block the inlet. The
pump must maintain vacuum of 45 kPa (6.5 psi)
minimum in 30 seconds.
Run the pump at 120 rpm with a blocked inlet that is
full of fuel for 30 seconds. The pump inlet must have
a suction lift of 60.9 kPa (18 In Hg) minimum.
When the pump is viewed from the drive gear
end or the drive shaft, the rotation of the pump is
counterclockwise.
i02774886
i02774897
Fuel Transfer Pump
Fuel Filter Base
SMCS Code: 1256
SMCS Code: 1261; 1262
Part No.: 286-2531
Part No.: 237-9307
Illustration 3
(1)
(2)
(3)
(4)
g01391562
Pressure regulating valve

Weep hole
Inlet port
Outlet port
Note: Maximum inlet pressure to the pump shall not

exceed 69 kPa (10 psi).
Illustration 4
(1) Base
g01386907
6
SENR9936-06
(A) Apply 154-9731 Thread Lock Compound to the

threads on the taperlock end of the stud to the
following distance. ....................... 39.5 0.5 mm
(1.56 0.02 inch)
Part No.: 260-9631

S/N: GEB1-Up
(2) Torque for the stud ..... 70 15 Nm (50 11 lb ft)
Part No.: 255-8001, 260-9631

S/N: H4C1-Up
i02864490
Fuel Filter Base
Part No.: 260-9631

S/N: TPB1-Up
Part No.: 255-8001, 260-9631

S/N: EED1-Up
Part No.: 260-9631
S/N: RJG1-Up
SMCS Code: 1261; 1262

Part No.: 266-9459
S/N: LWA1-Up
Part No.: 255-8001, 260-9631

S/N: Z9K1-Up
Part No.: 266-9459

S/N: GEB1-Up
Part No.: 255-8001, 260-9631

S/N: JRP1-Up
Part No.: 266-9459

S/N: TPB1-Up
Part No.: 255-8001, 260-9631

S/N: DLS1-Up
Part No.: 266-9459

S/N: Z9K1-Up
Part No.: 260-9631

S/N: BTW1-Up
Part No.: 260-9631
S/N: JNW1-Up
Part No.: 260-9631
S/N: BWX1-Up
Illustration 5
g01426884
(A) Length for applying 154-9731 Thread Lock

Compound to the threads on the taperlock end of
the stud ........... 39.5 0.5 mm (1.56 0.02 inch)
(1) Torque for the stud ..... 70 15 Nm (50 11 lb ft)
i02792816
Electronic Unit Injector

Mechanism
Illustration 6
g01395719
SMCS Code: 1290
(4) Spacer
Part No.: 255-8001, 260-9631

S/N: 5301-Up
Note: Refer to Testing and Adjusting, Electronic Unit

Injector - Adjust for the correct procedure for setting
the lash on the electronic unit injector.
Part No.: 255-8001, 260-9631

S/N: 2211-Up
Part No.: 255-8001, 260-9631
S/N: LWA1-Up
Note: Before installation of the unit injector, lubricate

the top two O-ring seals (6) with a 50/50 mixture of
clean engine oil and 8T-2998 Lubricant.
SENR9936-06
7
(1) Torque for cap nut .. 2.50 0.25 Nm (22 2 lb in)

(2) Torque for nut ............ 100 10 Nm (75 7 lb ft)
(A) Adjust the unit injector height from the timing seat
to the following distance. ............. 78.0 0.2 mm
(3.07 0.01 inch)
Part No.: 223-6408, 249-8717

S/N: 2211-Up
Part No.: 223-6408, 249-8717
S/N: LWA1-Up
Part No.: 223-6408
S/N: GEB1-Up
Use the following procedure to tighten the bolt (3)

for clamp (5):
Part No.: 223-6408

S/N: TPB1-Up
1. Tighten the bolt for the clamp to 55 10 Nm

(41 7 lb ft).
Part No.: 223-6408, 249-8717

S/N: H4C1-Up
2. Loosen the bolt for the clamp until the bolt is finger
tight.
Part No.: 223-6408, 249-8717

S/N: EED1-Up
3. Tighten the bolt for the clamp again to 55 10 Nm

(41 7 lb ft).
i02796857
Electronic Unit Injector Rocker

Arm
SMCS Code: 1123
Part No.: 223-6408

S/N: RJG1-Up
Part No.: 223-6408, 249-8717
S/N: Z9K1-Up
Part No.: 223-6408, 249-8717
S/N: JRP1-Up
Part No.: 223-6408, 249-8717
S/N: DLS1-Up
Part No.: 223-6408
S/N: BTW1-Up
Part No.: 278-1363
Part No.: 223-6408

S/N: JNW1-Up
Part No.: 223-6408
S/N: BWX1-Up
Illustration 7
g01397096
Typical example
(1) Location of bearing joint
Note: The sleeve bearing and pin must not extend

beyond either face of the rocker arm.
(A) Dimension for bore of new sleeve bearing after
installation ............................ 40.065 0.015 mm
(1.5774 0.0006 inch)
i02864507
Electronic Unit Injector Wiring

SMCS Code: 1290
Part No.: 223-6408, 249-8717
S/N: 5301-Up
Illustration 8
Typical example
(1) Engine harness assembly and connector seal
g01075720
8
SENR9936-06
Note: Install the flat part of the connector seal against

the connector surface. The curved part of the seal
must be installed so that the seal is against the valve
mechanism cover base.
(2) Torque for the 24 retainer nuts that are on the 12
cap assemblies ..... 2.50 0.25 Nm (22 2 lb in)
Note: Orient connectors so wires are not contacting
metal surfaces.
Note: Refer to Testing and Adjusting, Engine Valve

Lash - Inspect/Adjust for the correct procedure on
setting the engine valve lash.
(5) Location for checking the valve lash
Inlet valves ................................. 0.38 0.08 mm
(0.015 0.003 inch)
Exhaust valves .......................... 0.76 0.08 mm
(0.030 0.003 inch)
i02897419
Valve Mechanism
SMCS Code: 1102
Part No.: 260-9631
Illustration 10
g01404154
Left side of engine
Illustration 9
g01442728
(1) Rocker arm

(4) Camshaft
(6) Valve bridge
Illustration 11
g01404155
Right side of engine
(2) Torque for the adjustment screw

locknut ........................... 30 7 Nm (22 5 lb ft)
(3) Rocker shaft assembly
Diameter of a new rocker arm
shaft ..................................... 40.000 0.010 mm
(1.5748 0.0004 inch)
Bore in a new bearing for rocker arm
shaft ..................................... 40.065 0.015 mm
(1.5774 0.0006 inch)
Maximum dimension for the bore in a worn
bearing for rocker arm shaft ............. 40.193 mm
(1.5824 inch)
Illustration 12
Tightening sequence
g01400354
SENR9936-06
9
Note: Tighten the bolts for the rocker arm group in the
sequence 9, 10, 8, 11, 9, 10. Refer to Illustration 12.
(7) Torque for bolts ........ 109 15 Nm (80 11 lb ft)
i02794903
Valve Mechanism
Diameter of a new rocker arm shaft

........ 40.000 0.010 mm (1.5748 0.0004 inch)
Bore in a new bearing for rocker arm
shaft ..................................... 40.065 0.015 mm
(1.5774 0.0006 inch)
Maximum dimension for the bore in a worn
bearing for rocker arm shaft ............. 40.193 mm
(1.5824 inch)
Note: Refer to Testing and Adjusting, Engine Valve
Lash - Inspect/Adjust for the correct procedure on
setting the engine valve lash.
SMCS Code: 1102

Part No.: 255-8001
S/N: 5301-Up
(5) Location for checking the valve lash
Part No.: 255-8001

S/N: 2211-Up
Inlet valves ................................. 0.38 0.08 mm

(0.015 0.003 inch)
Exhaust valves .......................... 0.76 0.08 mm
(0.030 0.003 inch)
Part No.: 255-8001

S/N: LWA1-Up
Part No.: 255-8001
S/N: H4C1-Up
Part No.: 255-8001
S/N: EED1-Up
Part No.: 255-8001
S/N: Z9K1-Up
Part No.: 255-8001
S/N: JRP1-Up
Part No.: 255-8001
S/N: DLS1-Up
Illustration 14
g01400357
Left side of engine
Illustration 15
g01400358
Right side of engine

Illustration 13
g01246863
(1) Rocker arm

(4) Camshaft
(6) Valve bridge
(2) Torque for the adjustment screw

locknut ........................... 30 7 Nm (22 5 lb ft)
(3) Rocker shaft assembly
(7) Torque for bolts ........ 109 15 Nm (80 11 lb ft)
10
SENR9936-06
i02838507
Cylinder Head Valves

SMCS Code: 1105
Inlet valve ................................ 47.00 0.13 mm

(1.850 0.005 inch)
Exhaust valve .......................... 41.81 0.13 mm
(1.646 0.005 inch)
Part No.: 284-8892
Illustration 17
g01415562
View of area D
Inlet valve seat insert
Illustration 16
g01415536
(1) Exhaust valve

(2) Inlet valve
Note: Lubricate inner diameter of valve guides with

clean engine oil immediately prior to valve installation
in the cylinder.
(3) 247-9908 Springs
Quantity .......................................................... 24
Length under test force ... 67.12 mm (2.643 inch)
Test force .................... 320 25 N (71.9 5.6 lb)
Approximate free length after test ...... 76.70 mm
(3.020 inch)
Outside diameter ................ 36.3 mm (1.43 inch)
(4) 211-3122 Springs
Illustration 18
g01415565
View of area E
Exhaust valve seat insert
(F) Angle of face of valve seat insert

Inlet valve ......................... 30.25 0.25 degrees
Exhaust valve ................... 45.25 0.25 degrees
Quantity .......................................................... 24
Test force .................... 150 12 N (33.7 2.7 lb)
Approximate free length after test ...... 71.70 mm
(2.823 inch)
Outside diameter ............ 25.17 mm (0.991 inch)
(A) Height to the step that is in the valve
guide ............... 35.0 0.5 mm (1.38 0.02 inch)
(B) New valve stem diameter ...... 9.427 0.010 mm
(0.3711 0.0004 inch)
(C) Diameter of valve head
Illustration 19
g01415570
SENR9936-06
11
(G) Depth of the bore in the cylinder head for the

valve seat insert
Inlet ......... 14.00 0.05 mm (0.551 0.002 inch)
Exhaust ... 13.90 0.05 mm (0.547 0.002 inch)
(H) Angle of valve face
Angle of the face of the inlet
valve ................................. 29.25 0.25 degrees
Angle of the face of the exhaust
valve ................................. 44.25 0.25 degrees
Note: Shrink the valve seat inserts by reducing the
temperature. Shrinking the valve seat inserts allows
placement into the counterbore.
(J) Valve seat insert
Diameter of valve seat insert (inlet
valve) ................................... 48.025 0.013 mm
(1.8907 0.0005 inch)
Bore in cylinder head for valve seat insert (inlet
valve) ................................... 47.950 0.025 mm
(1.8878 0.0010 inch)
Diameter of valve seat insert (exhaust
valve) ................................... 42.840 0.013 mm
(1.6866 0.0005 inch)
Bore in cylinder head for valve seat insert
(exhaust valve) .................... 42.774 0.025 mm
(1.6840 0.0010 inch)
i02846910
Cylinder Head
SMCS Code: 1100
Part No.: 284-8895
Illustration 20
Bolt tightening sequence
g01423291
12
SENR9936-06
The bolts that are marked X are 216 mm (8.5 inch)

long.
Bolts 27 through 39 are 150 mm (5.9 inch) long.
The remainder of the bolts are 194 mm (7.6 inch)
long.
Use the following procedure in order to tighten the
cylinder head bolts:
Note: Apply 4C-5592 Anti-Seize Compound to the
bolt threads and to both sides of the washers for bolt
1 through bolt 26 prior to assembly.
g01419267
1. Torque for bolt 1 through bolt 26 in a numerical

sequence to 270 15 Nm (200 11 lb ft)
Illustration 22

Note: Lubricate the bores for the cup plugs with

6V-6640 Sealant prior to installing the cup plugs.
3. Again torque the bolt 1 through bolt 26 in

a numerical sequence to 450 15 Nm
(330 11 lb ft).
(B) The cup plugs are measured from the face of the
cylinder head to the top edge of the plug. Depth
of installation .............................. 1.25 0.25 mm
(0.049 0.010 inch)

Note: Install the taperlock studs so that the letter Y
is showing.
Cylinder head face
NOTICE
Camshaft bearings must be installed into their correct
position. Failure to do so will result in engine damage.
(40) Torque for 24 taperlock studs .......... 35 5 Nm

(26 4 lb ft)
Illustration 23
g01419268
(C) Orientation of bearing

joint .................. 20 3 degrees below horizontal
Illustration 21
(41)
(42)
(43)
(44)
Oil gallery
Camshaft bearing
Oil holes
Typical location for cup plug
g01419264
SENR9936-06
Illustration 24
13
g01423293
The installation depth of the camshaft bearings (42)

is very important. Install the camshaft bearings to the
following depths:
Illustration 25
g01427660
Top view of engine
(D) ..................... 8.0 0.5 mm (0.31 0.02 inch)

(E) ................. 227.5 0.5 mm (8.96 0.02 inch)
(F) ................ 411.7 0.5 mm (16.21 0.02 inch)
(G) .............. 595.8 0.5 mm (23.46 0.02 inch)
(H) ............... 780.0 0.5 mm (30.71 0.02 inch)
(J) ............... 964.1 0.5 mm (37.96 0.02 inch)
(K) .............. 1140.3 0.5 mm (44.89 0.02 inch)
i02857841
Compression Brake
Illustration 26
SMCS Code: 1119; 1129
Tightening sequence for the rocker arm shaft
Part No.: 255-7955

S/N: 5301-Up
Right side view
Part No.: 255-7955

S/N: 2211-Up
Part No.: 255-7955
S/N: LWA1-Up
Part No.: 255-7955
S/N: H4C1-Up
g01431042
Use the following procedure to tighten the nine studs

(1):
1. Tighten the studs in the numerical sequence that is
shown in Illustration 26 to 50 5 Nm (37 4 lb ft).
2. Turn the studs to an additional 45 5 degrees.
Part No.: 255-7955

S/N: EED1-Up
Part No.: 255-7955
S/N: Z9K1-Up
Part No.: 255-7955
S/N: JRP1-Up
Part No.: 255-7955
S/N: DLS1-Up
NOTICE
Do not disassemble the Variable Valve Actuator.
There are no components of the Variable Valve
Actuator that are serviceable. If the Variable Valve
Actuator is disassembled, the warranty will be void.
Illustration 27
Tightening sequence for the rocker arm shaft
Left side view
g01431037
14
SENR9936-06
Use the following procedure to tighten the nine studs

(2):
1. Tighten the studs in the numerical sequence that is
shown in Illustration 27 to 50 5 Nm (37 4 lb ft).
2. Turn the studs to an additional 45 5 degrees.
Illustration 29
g01428104
Left side view of engine
(6) Torque for six taperlock studs .......... 65 10 Nm

(48 7 lb ft)
Illustration 28
g01427680
Right side view of engine
Illustration 30
Tightening sequence for the valve actuator group
g01428087
SENR9936-06
Illustration 31
15
g01436074

Tightening sequence for the valve actuator group
Use the following procedure to tighten the valve

actuator group:
1. In order to install the valve actuator group for the
compression brake to the cylinder head, place the
housing over the mounting studs. Finger tighten
the mounting stud nuts and the mounting bolt.
2. Tighten the nuts, the bolt and flange nuts of each
valve actuator group in the sequence 9, 12, 8, 10,
7, 13, 11, 9 to standard torque. Refer to Illustration
30 and Illustration 31.
3. Again tighten the nuts, the bolt and flange nuts of
each valve actuator group in the sequence 9, 12,
8, 10, 7, 13, 11, 9 to standard torque.
Illustration 32
g01427354
Typical example
Note: The lash setting for the exhaust valve to rocker

arm must be completed before the lash setting of the
compression brake. Refer to Testing and Adjusting,
Engine Valve Lash - Inspect/Adjust for procedural
information.
(14) Lash setting for compression
brake ......... 0.76 0.08 mm (0.030 0.003 inch)
(15) Torque for locknut ........ 15 3 Nm (11 2 lb ft)
Reference: Refer to Testing and Adjusting,
Compression Brake Lash - Adjust for procedural
information that is related to the adjustment of the
compression brake.
16
SENR9936-06
i02884389
Turbocharger
SMCS Code: 1052
Part No.: 290-4621
S/N: 5301-Up
Part No.: 290-4621
S/N: 2211-Up
Part No.: 290-4621
S/N: H4C1-Up
Part No.: 277-8418
S/N: EED1-Up
Part No.: 217-6570
S/N: RJG1-Up
Part No.: 277-8419
S/N: JRP1-Up
Part No.: 277-8418
S/N: DLS1-Up
Illustration 33
Typical example
Front view
(3) Spacer
(1) Apply 4C-5599 Anti-Seize Compound to the

threads of the six bolts before assembly.
(2) Torque for the eight locknuts ............. 55 9 Nm
(41 7 lb ft)
g01436068
SENR9936-06
Illustration 34
17
g01436065
Typical example
(4) Torque for the compressor clamp

assembly .............. 13.5 1.0 Nm (120 9 lb in)
Use the following procedure to tighten the turbine
clamp assembly (5):
1. Tighten the turbine clamp assembly to 18.1 Nm
(160 lb in).
2. Loosen the turbine clamp assembly to 5.6 Nm
(50 lb in).
3. Again tighten the turbine clamp assembly to
13.5 1.0 Nm (120 9 lb in).
18
SENR9936-06
i02844244
Turbocharger
SMCS Code: 1052
Part No.: 217-5689
S/N: RJG1-Up
Part No.: 217-5689
S/N: BTW1-Up
Part No.: 217-5689
S/N: BWX1-Up
Illustration 35
Front view of engine
g01434386
SENR9936-06
Illustration 36
Top view of engine
Note: The oil supply and the oil drain holes should
be in the vertical position with respect to the engine
when the turbocharger group (1) is attached to the
exhaust manifold.
Use the following procedure to tighten the compressor
clamp assembly and the turbine clamp assembly for
the turbocharger group:
1. Tighten the clamp assemblies to 14 1 Nm
(125 9 lb in).
2. Lightly tap around the clamp assemblies with a
soft faced hammer.
3. Again tighten the clamp assemblies to 14 1 Nm
(125 9 lb in).
Note: Apply 4C-5599 Anti-Seize Compound on the
threads of the six bolts (3).
(2) Torque for eight locknuts ................... 55 9 Nm
(41 7 lb ft)
19
g01434384
20
SENR9936-06
i02884391
Turbocharger
SMCS Code: 1052
Part No.: 245-9774
S/N: LWA1-Up
Part No.: 245-9774
S/N: Z9K1-Up
Illustration 37
Front view
(3) Spacer

threads of the six bolts before assembly.
(41 7 lb ft)
g01436070
SENR9936-06
21
i02884396
Turbocharger
SMCS Code: 1052
Part No.: 294-9711
S/N: JNW1-Up
Illustration 38
g01436069

assembly .............. 13.5 1.0 Nm (120 9 lb in)
clamp assembly (5):
(160 lb in).
Illustration 39
g01436082
Rear view

threads of the eight bolts before assembly.
(41 7 lb ft)

(50 lb in).
13.5 1.0 Nm (120 9 lb in).
Illustration 40
g01436083

assembly .............. 13.5 1.0 Nm (120 9 lb in)
22
SENR9936-06

clamp assembly (4):
(160 lb in).
(50 lb in).
13.5 1.0 Nm (120 9 lb in).
i02844349
Turbocharger
SMCS Code: 1052
Part No.: 292-8580
S/N: GEB1-Up
Part No.: 292-8580
S/N: TPB1-Up
Illustration 41
Front view

threads of the four bolts before assembly. These
bolts are 3/8-16 X 2 inches.
threads of the four bolts before assembly. These
bolts are 3/8-16 X 1 3/4 inches.
(41 7 lb ft)
g01436071
SENR9936-06
Illustration 42
23
g01435716
Turbocharger group
Note: The oil supply and the oil drain holes should
be in the vertical position with respect to the engine
when the turbocharger group is attached to the
exhaust manifold.
Use the following procedure to tighten the compressor
clamp assembly and the turbine clamp assembly for
the turbocharger group:
1. Tighten the clamp assemblies to 14 1 Nm
(125 9 lb in).
2. Lightly tap around the clamp assemblies with a
soft faced hammer.
3. Again tighten the clamp assemblies to 14 1 Nm
(125 9 lb in).
24
SENR9936-06
i02841625
Exhaust Manifold
SMCS Code: 1059
Part No.: 295-0647
S/N: 5301-Up
Part No.: 295-0647
S/N: 2211-Up
Part No.: 259-6926
S/N: EED1-Up
Part No.: 253-2633, 259-6926
S/N: JRP1-Up
Part No.: 259-6926
S/N: DLS1-Up
Part No.: 253-2633, 259-6926, 291-3026
S/N: BTW1-Up
Part No.: 253-2633, 259-6926, 291-3026
S/N: BWX1-Up
Illustration 43
Typical example
g01417453
SENR9936-06
25
(1) Install the gaskets so that the MANIFOLD SIDE

marking faces away from the cylinder head.
(2) Apply 4C-5599 Anti-Seize Compound on the
threads of the 24 locknuts before assembly.
Illustration 44
g01417476
Exhaust manifold
Tightening sequence for the exhaust manifold
Note: Use a centering tool in at least one oversize

hole per exhaust manifold section in order to align
the exhaust manifolds. Do not remove the centering
tool until removal is required to tighten the locknuts.
Use the following procedure to tighten the exhaust
manifold on the cylinder head:
1. Tighten locknuts 4 through 15 in a numerical
sequence to 20 3 Nm (15 2 lb ft).
2. Again tighten locknuts 4 through 15 in a numerical
two taperlock studs before assembly.
(3) Torque for two taperlock studs ........... 35 5 Nm
(26 4 lb ft)
(16) Torque for eight clamps ............... 8.5 1.0 Nm
(75 9 lb in)
26
SENR9936-06
i02843153
Exhaust Manifold
SMCS Code: 1059
Part No.: 217-6686
S/N: EED1-Up
Part No.: 217-6686
S/N: RJG1-Up
Part No.: 217-6686
S/N: BTW1-Up
Part No.: 217-6686
S/N: BWX1-Up
Illustration 45
Front view
(1) Apply 4C-5599 Anti-Seize Compound on the

g01417760
SENR9936-06
Illustration 46
27
g01417778
Exhaust manifold

(2) Coat the female ends of the two exhaust
manifolds with clean engine oil.
taperlock studs (3) before assembly.
(3) Torque for two taperlock studs ........... 35 5 Nm
(26 4 lb ft)
(4) Apply a thin coat of 2P-2333 High Temperature
Sealer to the outside diameter of the male ends
of the four exhaust manifolds prior to assembly.
Remove excess sealer from the assembled joint.
(5) Torque for 12 taperlock studs ............ 35 5 Nm
(26 4 lb ft)
28
SENR9936-06
i02866063
Exhaust Manifold
SMCS Code: 1059
Part No.: 251-1088
S/N: LWA1-Up
Part No.: 251-1088
S/N: H4C1-Up
Part No.: 251-1088
S/N: Z9K1-Up
Illustration 47
g01427800
Front view
(1) Install the 12 gaskets so that the MANIFOLD

SIDE marking faces away from the cylinder
head.
(2) Torque for the two taperlock studs ..... 35 5 Nm
(26 4 lb ft)
(3) Torque for the eight clamps ........... 8.5 1.0 Nm
(75 9 lb in)

Use the following procedure to tighten locknut 4
through locknut 15:
threads of the 24 locknuts.
SENR9936-06
29
1. Tighten the locknuts in a numerical sequence to

20 3 Nm (15 2 lb ft).
2. Again tighten the locknuts in a numerical sequence
to 38 5 Nm (28 4 lb ft).
i02843234
Exhaust Manifold
SMCS Code: 1059
Part No.: 283-1004
S/N: JNW1-Up
Illustration 48
g01417806
Orientation of clamps from front view of engine

(C) Orientation for the four clamps ... 78 2 degrees

(D) Orientation for the four clamps ... 90 2 degrees
(13) Torque for the eight clamps ......... 8.5 1.0 Nm
(75 9 lb in)

tools until removal is required to tighten the locknuts.
Use the following procedure to tighten the locknuts:
30
SENR9936-06

threads of locknuts and to the bearing surface of the
locknuts and the spacers and the washers before
assembly.
i02843368
Exhaust Manifold
SMCS Code: 1059
Part No.: 272-2953
S/N: GEB1-Up
Part No.: 272-2953
S/N: TPB1-Up
Illustration 50
g01417902

(1) Torque for 12 taperlock studs ............ 35 5 Nm
(26 4 lb ft)
(2) Torque for eight clamps ................. 8.5 1.0 Nm
(75 9 lb in)
i02840165
Illustration 49
Front view
g01432982
Camshaft
SMCS Code: 1210
Part No.: 260-9307
S/N: 5301-Up
Part No.: 260-9307
S/N: 2211-Up
Part No.: 260-9307
S/N: LWA1-Up
SENR9936-06
31
Part No.: 260-9307

S/N: GEB1-Up
(1) The end of the camshaft that is marked F must

be placed at the front of the engine. Lubricate the
camshaft bearings, the journals, and the lobes
with a 50/50 mixture of 8T-2998 Lubricant and
clean engine oil.
Part No.: 260-9307

S/N: TPB1-Up
Part No.: 260-9307
S/N: H4C1-Up
Part No.: 260-9306
S/N: EED1-Up
Part No.: 260-9306
S/N: RJG1-Up
Part No.: 260-9307
S/N: Z9K1-Up
Part No.: 260-9307
S/N: JRP1-Up
Part No.: 260-9306
S/N: DLS1-Up
Illustration 52
Part No.: 260-9306

S/N: BTW1-Up
(2) Exhaust lobe

(3) Injector lobe
(4) Inlet lobe
Part No.: 260-9306

S/N: JNW1-Up
(A) Diameter of camshaft journal .. 84.85 0.02 mm

(3.341 0.001 inch)
g01416694
Part No.: 260-9306

S/N: BWX1-Up
Illustration 53
g01416960
(B) Camshaft lobe lift

Use the following procedure in order to determine
the camshaft lobe lift:
1. Measure the camshaft lobe height (C).
2. Measure the base circle (D).
3. Subtract the base circle measurement in Step
2 from the camshaft lobe height in Step 1. The
difference is the actual camshaft lobe lift (B).
Illustration 51
g01427361
Specified camshaft lobe lift

Inlet lobe ....................... 9.619 mm (0.3787 inch)
Exhaust lobe ................. 8.515 mm (0.3352 inch)
Injector lobe (right bank) ................... 10.337 mm
(0.4070 inch)
32
Injector lobe (left bank) ..................... 10.338 mm

(0.4070 inch)
The maximum permissible difference between the
actual camshaft lobe lift in Step 3 and the specified
camshaft lobe lift is 0.13 mm (0.005 inch).
SENR9936-06
i02847540
Engine Oil Filter Base

SMCS Code: 1306
Part No.: 4N-2357
S/N: 5301-Up
Part No.: 4N-2357
S/N: 2211-Up
Part No.: 4N-2357
S/N: LWA1-Up
Part No.: 4N-2357
S/N: H4C1-Up
Part No.: 231-0211, 4N-2357
S/N: EED1-Up
Part No.: 4N-2357
S/N: Z9K1-Up
Part No.: 231-0211, 4N-2357
S/N: JRP1-Up
Part No.: 231-0211, 4N-2357
S/N: DLS1-Up
Part No.: 4N-2357
S/N: BTW1-Up
Part No.: 231-0211, 4N-2357
S/N: JNW1-Up
Part No.: 4N-2357
S/N: BWX1-Up
Illustration 54
(1)
(2)
(3)
(5)
(6)
g01419688
Oil filter base assembly

Fluid sampling valve
Oil supply line (unfiltered oil)
Oil cooler bypass valves
Oil return line (filtered oil)
(4) Lightly lubricate the bore and the O-ring seals for
the cooler bypass tube with clean engine oil.
(7) Lubricate the seal of the engine oil filter element
assembly with clean engine oil.
SENR9936-06
33
i02848619
Engine Oil Filter Base

SMCS Code: 1306
Part No.: 216-0819
S/N: GEB1-Up
Part No.: 216-0819
S/N: TPB1-Up
Part No.: 216-0819
S/N: RJG1-Up
Illustration 55
g01419678
(A) Length for applying 154-9731 Thread Lock

Compound to the threads of the hollow
stud ................. 10.2 1.5 mm (0.40 0.06 inch)
(8) Torque for the hollow stud ............... 80 14 Nm
(60 10 lb ft)
Illustration 56
g01432945
34
SENR9936-06
(D) Length for applying 154-9731 Thread Lock

Compound on the two taperlock studs ...... 8 mm
(0.3 inch)
(5) Torque for two taperlock studs ......... 80 15 Nm
(60 11 lb ft)
i02847457
Engine Oil Pump

SMCS Code: 1304
Part No.: 116-1980
S/N: 5301-Up
Part No.: 116-1980
S/N: 2211-Up
Part No.: 116-1980
S/N: LWA1-Up
Part No.: 116-1980
S/N: H4C1-Up
Part No.: 116-1980
S/N: EED1-Up
Illustration 57
g01432946
Front view of engine
(1) Lubricate the bore of the O-ring seal lightly with

lubricant that is being sealed.
Use the following procedure to tighten the bolts:
1. Torque bolts (4) to 47 9 Nm (35 7 lb ft).
Part No.: 116-1980

S/N: RJG1-Up
Part No.: 116-1980
S/N: Z9K1-Up
Part No.: 116-1980
S/N: JRP1-Up
Part No.: 116-1980
S/N: DLS1-Up
2. Torque bolts (2) to 5 3 Nm (45 27 lb in).
Part No.: 116-1980

S/N: BTW1-Up
3. Torque bolts (3) to 47 9 Nm (35 7 lb ft).
Part No.: 116-1980

S/N: JNW1-Up
4. Again torque bolts (2) to 47 9 Nm (35 7 lb ft).
Part No.: 116-1980

S/N: BWX1-Up
Illustration 58
Section C-C
g01420429
SENR9936-06
35
Illustration 60
g01419620
Oil pump body
(E) Extension of dowel from the oil pump

body .................. 6.4 0.5 mm (0.25 0.02 inch)
Illustration 59
g01419619
(F) Installation depth for sleeve bearing

.................. 0.30 0.25 mm (0.012 0.010 inch)
(A) Diameters of the shafts

Oil pump drive shaft for the pump drive shaft
assembly ............................. 22.217 0.005 mm
(0.8747 0.0002 inch)
Oil pump drive shaft for the idler shaft
assembly ............................. 22.217 0.005 mm
(0.8747 0.0002 inch)
(B) Dimensions for the gears
Length of new gears .......... 140.000 0.025 mm
(5.5118 0.0010 inch)
Depth of bores in oil pump body for new
gears .................................. 140.127 0.020 mm
(5.5168 0.0008 inch)
(1) 2S-2760 Spring
Length under test force .. 117.14 mm (4.612 inch)
Test force .................. 499 24 N (112.2 5.4 lb)
Approximate free length after test .... 152.91 mm
(6.020 inch)
Note: The 2S-2760 Spring is for the relief of oil
pressure.
Illustration 61
g01419634
Oil pump cover
(D) Position of bearing joint from the centerline

through bearing bores .............. 30 15 degrees
Note: The sleeve bearings should be installed so
that the edge of the bearing is flush with the outside
of the oil pump body. The sleeve bearings should
also be installed so that the edge of the bearing is
flush with face (2).
36
SENR9936-06
i02857697
Engine Oil Pump

SMCS Code: 1304
Part No.: 7C-1772
S/N: GEB1-Up
Part No.: 7C-1772
S/N: TPB1-Up
Part No.: 7C-1772
S/N: RJG1-Up
g01422622
Illustration 62
NOTICE
Before operation, the pump must be lubricated with
clean engine oil and the pump must turn freely by hand
or damage to parts can be the result.
(B) Diameter of a new shaft for the drive shaft
assembly ............................. 20.320 0.005 mm
(0.8000 0.0002 inch)
(C) Diameter of a new shaft for the idler shaft
assembly ............................. 20.320 0.005 mm
(0.8000 0.0002 inch)
(D) Dimensions for new pump gears
Length of pump gears .............. 65.07 0.05 mm
(2.562 0.002 inch)
Depth of bores for pump

gears .................................... 65.197 0.020 mm
(2.5667 0.0008 inch)
(E) Diameter of a new shaft for the drive shaft
assembly ............................. 22.217 0.005 mm
(0.8747 0.0002 inch)
(F) Diameter of a new shaft for the idler shaft
assembly ............................. 22.217 0.005 mm
(0.8747 0.0002 inch)
(G) Dimensions for new gears
Length of new gears ............ 79.375 0.025 mm
(3.1250 0.0010 inch)
SENR9936-06
37
Depth of bores for new

gears .................................... 79.502 0.020 mm
(3.1300 0.0008 inch)
Oil Pump Spacer Assembly (3)
(1) 236-6733 Spring

Test force .................. 709 35 N (159.4 7.9 lb)
Approximate free length after test ......... 130 mm
(5.1 inch)
Pump Body (2)
Illustration 64
g01423433
(K) Installation depth for the two sleeve

bearings ............................ 0.76 mm (0.030 inch)
(5) The two sleeve bearings should be located with
the oil holes on the horizontal centerline slots.
Oil Pump Body (4)

Illustration 63
g01423414
(H) Installation depth for the two sleeve

bearings ............................ 1.52 mm (0.060 inch)
(J) Position of bearing joint from the centerline
Illustration 65
g01423468
38
SENR9936-06
(L) Position of bearing joint from the centerline

(N) Projection of dowel from the surface of the oil
pump body ........ 6.4 0.5 mm (0.25 0.02 inch)
(P) Installation depth for the two sleeve
bearings .... 0.30 0.25 mm (0.012 0.010 inch)
i02865988
Engine Oil Bypass Valve

SMCS Code: 1306-BV
Part No.: 316-5686
S/N: 5301-Up
Part No.: 316-5686
S/N: 2211-Up
Part No.: 225-9619
S/N: LWA1-Up
Part No.: 225-9619
S/N: H4C1-Up
Part No.: 231-0211
S/N: EED1-Up
Part No.: 225-9619
S/N: Z9K1-Up
Part No.: 231-0211
S/N: JRP1-Up
Part No.: 231-0211
S/N: DLS1-Up
Part No.: 225-9619
S/N: BTW1-Up
Part No.: 231-0211
S/N: JNW1-Up
Part No.: 225-9619
S/N: BWX1-Up
Illustration 66
g01427693
Typical example
Note: Check the valve and the valve seat for

abnormal contact patterns.
(1) The 9M-0853 Valve Plunger is for the oil filter
bypass valve.
(2) The 9F-6304 Spring is for the oil filter bypass
valve.
Test force ............. 145 to 160 N (32.3 to 35.7 lb)
Free length after test .... 105.56 mm (4.156 inch)
SENR9936-06
39
i02865980
Engine Oil Bypass Valve

SMCS Code: 1306-BV
Part No.: 266-9446
S/N: GEB1-Up
Part No.: 266-9446
S/N: TPB1-Up
Part No.: 216-0810
S/N: RJG1-Up
Illustration 67
g01427688
Typical example
Right side view
Note: Check the valve and the valve seat for

abnormal contact patterns.
(1) The 9M-0853 Valve Plunger is for the oil filter
bypass valve.
(2) The 9F-6304 Spring is for the oil filter bypass
valve.
Test force ............. 145 to 160 N (32.3 to 35.7 lb)
Free length after test .... 105.56 mm (4.156 inch)
40
SENR9936-06
i02855050
Engine Oil Pan

SMCS Code: 1302
Part No.: 291-1432
S/N: 5301-Up
Part No.: 291-1432
S/N: 2211-Up
Part No.: 291-1432
S/N: H4C1-Up
Illustration 68
g01422063
Typical example
Right side view
Use the following procedure to tighten the bolts for

the oil pan:
1. Tighten the bolts in the numerical sequence to

47 9 Nm (35 7 lb ft).
SENR9936-06
41
2. Again tighten the bolts in the numerical sequence

to 47 9 Nm (35 7 lb ft).
(3) After assembly, trim off excess gasket material

from outside of assembled joint.
Note: Lubricate the threads of the drain plug lightly
with clean engine oil before assembly.
(4) Torque for the drain plug .................. 70 10 Nm
(50 7 lb ft)
Bolts (1) are 3/8-16 X 2 3/4 inches.
Illustration 69
g01427674
Detail of the oil pan gasket joint
(41) Apply sealant below the four ball and socket

joints of the oil pan gasket and over the four ball
and socket joints of the oil pan gasket.
i02857775
Engine Oil Pan

SMCS Code: 1302
Part No.: 119-8582
S/N: RJG1-Up
Illustration 70
g01433353
The remaining oil pan bolts are 3/8-16 X 1 1/4 inches.
42
SENR9936-06
i02879916
Engine Oil Pan
(3) After assembly, trim off excess gasket material

from outside of assembled joint.
SMCS Code: 1302
Part No.: 266-9450

S/N: GEB1-Up
Part No.: 266-9450

S/N: TPB1-Up
The remaining oil pan bolts are 3/8-16 X 1 1/4 inches.

i02799191
Water Temperature Regulator

SMCS Code: 1355
Part No.: 248-5513
Illustration 72
g01056598
Typical example
(1) Seal
(2) Water temperature regulator

Opening temperature ........................ 81 to 84 C
(178 to 183 F)
Fully open temperature ................ 92 C (198 F)
Minimum stroke at fully open
temperature ........................ 10.4 mm (0.41 inch)
i02798334
Water Pump
SMCS Code: 1361
Illustration 71
g01433751
Part No.: 230-4172

S/N: 5301-Up
Note: Lubricate the threads of the drain plug lightly

with clean engine oil before assembly.
Part No.: 230-4172

S/N: 2211-Up
(2) Torque for the drain plug .................. 70 10 Nm

(50 7 lb ft)
Part No.: 230-4172

S/N: LWA1-Up
Part No.: 230-4172
S/N: GEB1-Up
SENR9936-06
43
Part No.: 230-4172

S/N: TPB1-Up
(A) Diameter of the water pump

shaft ..................................... 19.100 0.010 mm
(0.7520 0.0004 inch)
Part No.: 230-4172

S/N: H4C1-Up
Maximum air leakage per minute with an air pressure

test of 140 kPa (20 psi)
Part No.: 4N-5837

S/N: EED1-Up
Water side .................................. 10 cc (0.6 cu in)

Side with oil ............................... 24 cc (1.5 cu in)
Part No.: 230-4172

S/N: RJG1-Up
i02899215
Part No.: 230-4172

S/N: Z9K1-Up
Cylinder Block
Part No.: 230-4172

S/N: JRP1-Up
SMCS Code: 1201

Part No.: 253-9882
S/N: 5301-Up
Part No.: 4N-5837

S/N: DLS1-Up
Part No.: 253-9882

S/N: 2211-Up
Part No.: 4N-5837

S/N: BTW1-Up
Part No.: 253-9882

S/N: LWA1-Up
Part No.: 4N-5837

S/N: JNW1-Up
Part No.: 253-9882

S/N: GEB1-Up
Part No.: 4N-5837

S/N: BWX1-Up
Part No.: 253-9882

S/N: TPB1-Up
Part No.: 253-9882
S/N: H4C1-Up
Part No.: 237-0842
S/N: EED1-Up
Part No.: 237-0842
S/N: RJG1-Up
Part No.: 253-9882
S/N: Z9K1-Up
Part No.: 253-9882
S/N: JRP1-Up
Part No.: 237-0842
S/N: DLS1-Up
Part No.: 237-0842
S/N: BTW1-Up
Illustration 73
g01398145
Note: Do not install the lip type seal (1) by hand. Use
the installation tool and a press to install the lip type
seal. Make sure that the primary lip is toward the
water pump drive gear. Press the lip type seal until
the lip type seal is flush into the counterbore.
Note: Use the installation tool to install the seal
group (2). Press the seal group onto the shaft until
the stationary cup of the seal group is fully seated in
the pump housing.
(3) Torque for the bolt .......... 39 3 Nm (29 2 lb ft)
Part No.: 237-0842

S/N: JNW1-Up
Part No.: 237-0842
S/N: BWX1-Up
44
SENR9936-06
(D) Bore in cylinder block for main

bearing ............................... 129.891 0.013 mm
(5.1138 0.0005 inch)
(E) Dimensions for main bearing cap
The width of the slot for the main bearing
caps ...... 236.00 0.05 mm (9.291 0.002 inch)
Width of main bearing cap .. 235.500 0.025 mm
(9.2716 0.0010 inch)
Illustration 75
g01403680
Right side of the engine

Illustration 74
g01443593
Front of the engine
Note: Apply 6V-6640 Sealant to the pipe threads

of stud (1). Tighten the stud with the coated pipe
threads into the cylinder block.
(4) Torque for three taperlock studs ........ 35 5 Nm
(26 4 lb ft)
Note: The top face of the cylinder block, both sides
of plate gasket (3) and bottom surface of spacer plate
(2) must be free of fuel, oil, water, gasket adhesives,
assembly compounds and any other contaminants
during assembly.
(F) Extension of dowels from the rear face of the

cylinder block and from the front face of the
cylinder block .. 19.0 0.5 mm (0.75 0.02 inch)
Note: The main bearing caps (7) must be installed
with the identifying marks toward the front of the
engine. The number of the main bearing cap (7) must
also match the cast number on the left side of each
main bearing saddle.
Use the following procedure to install the main
bearing caps:
(A) Thickness of the spacer

plates ..................................... 8.585 0.025 mm
(0.3380 0.0010 inch)
(B) Thickness of plate gasket that is between cylinder
block and spacer plate ........... 0.208 0.025 mm
(0.0082 0.0010 inch)
(C) Extension of the dowels on the left bank and right
bank from the cylinder block ....... 18.5 0.5 mm
(0.73 0.02 inch)
Note: Apply 5P-3413 Pipe Sealant on the threads of
the taperlock plugs (5) before assembly.
(5) Torque for the four taperlock plugs .. 80 15 Nm
(60 11 lb ft)
Illustration 76
Marks for tightening main bearings
g01398970
SENR9936-06
45
1. Apply clean engine oil on the threads of the main

bearing cap bolts (8). Loosely install the main
bearing cap bolts (8).
(J) The distance from the centerline of the crankshaft

bearing bore to the bottom of the cylinder block
.............. 165.10 0.10 mm (6.500 0.004 inch)
2. Apply clean engine oil on the threads of the side

bolts (6) and the washers. Loosely install the side
bolts and the washers.
i02788282
3. Tighten the main bearing cap bolts (8) first on the

main bearing tab side of the main bearing cap (7)
to 258 14 Nm (190 10 lb ft).
4. Tighten the main bearing cap bolts (8) that are
opposite the main bearing tab side of the main
bearing cap (7) to 258 14 Nm (190 10 lb ft).
5. Put a mark on each main bearing cap bolt (8) and
each main bearing cap (7). See Illustration 76.
placed opposite the main bearing tab side of the
main bearing cap (7) from the mark by angle (G)
of 120 5 degrees.
placed on the main bearing tab side of the main
bearing cap (7) from the mark by angle (G) of 120
5 degrees.
Cylinder Liner
SMCS Code: 1216
Part No.: 197-9322
S/N: EED1-Up
Part No.: 197-9322
S/N: RJG1-Up
Part No.: 197-9322
S/N: DLS1-Up
Part No.: 197-9322
S/N: BTW1-Up
Part No.: 197-9322
S/N: JNW1-Up
Part No.: 197-9322
S/N: BWX1-Up
8. Tighten the side bolts (6) that are opposite the

to 80 10 Nm (60 7 lb ft).
9. Tighten the side bolts (6) that are placed on the
to 80 10 Nm (60 7 lb ft).
Illustration 78
g01392812
(1) Filler band
(A) Bore in new cylinder liner .. 137.185 0.025 mm

(5.4010 0.0010 inch)
(B) Flange
Thickness .............................. 8.890 0.020 mm
(0.3500 0.0008 inch)
Minimum thickness ....... 8.870 mm (0.3492 inch)
Use the following procedure to install the cylinder
liner:
Illustration 77
g01398978
(H) The distance from the centerline of the

crankshaft bearing bore to the top of the cylinder
block ... 419.10 0.15 mm (16.500 0.006 inch)
1. Put liquid soap on the cylinder block liner bore

surfaces and the rubber seals that are on the
lower end of the cylinder liner.
2. Dip the filler band completely in clean engine oil.
46
SENR9936-06
3. Immediately install the filler band in the groove

that is under the cylinder liner flange.
4. Install the cylinder liner into the cylinder block
before the expansion of the filler band.
Note: Refer to Guideline For Reusable Parts and
Salvage Operations, SEBF8068, Cylinder Liners for
more information. Also, refer to Reuse And Salvage
Guidelines, SEBF8049, Visual Inspection of the
Piston for more information.
i02801040
Cylinder Liner
1. Apply liquid soap on the cylinder block liner bore

surfaces and the rubber seals that are on the
lower end of the cylinder liner.
2. Dip the filler band (2) completely in clean engine
oil.
4. Install the cylinder liner into the cylinder block

before the expansion of the filler band.
Part No.: 253-8766

S/N: 5301-Up
Note: Refer to Reuse And Salvage Guidelines,

SEBF8049, Visual Inspection of the Piston for more
information. Also, refer to Guideline For Reusable
Parts And Salvage Operations, SEBF8068, Cylinder
Liners for more information.
Part No.: 253-8766

S/N: 2211-Up
Part No.: 253-8766
S/N: LWA1-Up
Part No.: 253-8766
S/N: GEB1-Up
Part No.: 253-8766
S/N: TPB1-Up
Part No.: 253-8766
S/N: H4C1-Up
Part No.: 253-8766
S/N: Z9K1-Up
Part No.: 253-8766
S/N: JRP1-Up
g01399536
(A) Bore in new cylinder liner .. 145.000 0.025 mm

(5.7086 0.0010 inch)
(B) Dimensions for flange (1)
Use the following procedure to install the cylinder

liner:
3. Immediately install the filler band in the groove

that is under the flange.
SMCS Code: 1216
Illustration 79
Thickness of flange on cylinder

liner ........... 8.89 0.02 mm (0.350 0.001 inch)
Minimum thickness ....... 8.870 mm (0.3492 inch)
SENR9936-06
47
i02801044
Crankshaft
SMCS Code: 1202
Part No.: 224-3250
S/N: 5301-Up
Part No.: 224-3250
S/N: 2211-Up
Part No.: 224-3250
S/N: LWA1-Up
Part No.: 224-3250
S/N: GEB1-Up
Part No.: 224-3250
S/N: TPB1-Up
Part No.: 224-3250
S/N: H4C1-Up
Part No.: 225-6052
S/N: EED1-Up
Part No.: 225-6052
S/N: RJG1-Up
Part No.: 224-3250
S/N: Z9K1-Up
Part No.: 224-3250
S/N: JRP1-Up
Part No.: 225-6052
S/N: DLS1-Up
Part No.: 225-6052
S/N: BTW1-Up
Part No.: 225-6052
S/N: JNW1-Up
Part No.: 225-6052
S/N: BWX1-Up
Note: To measure a crankshaft that may be bent, a
procedure must be followed. Refer to the Guideline
For Reusable Parts And Salvage Operations,
SEBF8054, Procedure to Measure and Straighten
Bent Crankshafts for the correct procedure.
48
SENR9936-06
g01399550
Illustration 80
Typical example
(3) Main journal
(4) Rod journal
Note: Thrust plates (1) are used on the center main

bearing only.
Note: The seal and the sleeve can not be used if the
seal and the sleeve have been separated.
(A) Thickness of new thrust plate .... 5.74 0.04 mm

(0.226 0.002 inch)
Note: The sleeve must be flush with the front face of

the crankshaft within 0.13 mm (0.005 inch).
Note: Check assembled installation depth with the

crankshaft in any axial position.
(B) Assembled installation depth ... 4.68 to 5.28 mm
(0.184 0.208 inch)
(C) Maximum extension of dowel from the crankshaft
face ....................................... 8.4 mm (0.33 inch)
(E) End play
New crankshaft ......................... 0.10 to 0.60 mm
(0.004 to 0.024 inch)
Maximum end play with used bearings .. 0.89 mm
(0.035 inch)
(2) The crankshaft gear must be installed on the
crankshaft with the timing mark V on the outside
of the crankshaft.
(3), (4) Refer to the Specifications, Connecting Rod
and Main Bearing Journals for more information.
Illustration 81
g01399556
View D-D
Note: The seal and the sleeve should not be used if

the seal and the sleeve have been separated.
(5) The front crankshaft seal is installed on the
front of the crankshaft. The seal driver can not
contact the seal inside a 177.80 0.25 mm
(7.000 0.010 inch) diameter.
(F) Extension of the dowel from the surface of the

crankshaft ......... 4.1 0.5 mm (0.16 0.02 inch)
SENR9936-06
49
i02287333
i02866012
Crankshaft Seals
Vibration Damper
SMCS Code: 1160; 1161
SMCS Code: 1205
Part No.: 142-5867
Part No.: 6N-2229

S/N: EED1-Up
Part No.: 6N-2229
S/N: RJG1-Up
Part No.: 6N-2229
S/N: Z9K1-Up
Part No.: 6N-2229
S/N: JRP1-Up
Part No.: 6N-2229
S/N: DLS1-Up
Part No.: 6N-2229
S/N: BTW1-Up
Part No.: 6N-2229
S/N: BWX1-Up
Illustration 82
g01144821
(1) Front crankshaft seal

The front seal should be installed even with
the front of the crankshaft with the following
tolerance. ...................................... 0.13 to 0.13 mm
(0.005 to 0.005 inch)
The seal driver should not contact the seal within the
following diameter. ....................... 177.80 0.25 mm
(7.000 0.010 inch)
Illustration 83
(2) Rear crankshaft seal
(1) Damper adapter

(2) Damper
Install the rear seal to the following distance from the

end of the crankshaft. .......................... 1.5 0.5 mm
(0.06 0.02 inch)
The seal driver should not contact the seal within the
following diameter. ....................... 177.80 0.25 mm
(7.000 0.010 inch)
Note: Do not separate the seal from the sleeve.
Replace the seal if the seal is separated from the
sleeve.
Note: The assembled installation depth may be
checked with the crankshaft in any axial position.
g01427717
(3) Torque for 12 bolts .. 135 20 Nm (100 15 lb ft)
50
SENR9936-06
i02866018
i02856619
Vibration Damper
Vibration Damper
SMCS Code: 1205
SMCS Code: 1205
Part No.: 259-3105

S/N: JRP1-Up
Part No.: 263-5259

S/N: BTW1-Up
Part No.: 263-5259
S/N: JNW1-Up
Part No.: 263-5259
S/N: BWX1-Up
Illustration 84
g01427740
(1) Damper
(2) Damper adapter

Illustration 85
g01248941
(1) Damper
(2) Crankshaft pulley
SENR9936-06
51
i02866033
i02866067
Vibration Damper
Vibration Damper
SMCS Code: 1205
SMCS Code: 1205
Part No.: 257-8730

S/N: 5301-Up
Part No.: 298-3542

S/N: GEB1-Up
Part No.: 257-8730

S/N: 2211-Up
Part No.: 298-3542

S/N: TPB1-Up
Part No.: 257-8730

S/N: LWA1-Up
Part No.: 257-8730
S/N: H4C1-Up
Part No.: 257-8730
S/N: Z9K1-Up
Illustration 87
g01427778
(1) Dampers
(3) Damper adapter
Illustration 86
g01427752
(1) Damper adapter

(2) Dampers
52
SENR9936-06
i02776231
i02776201
Connecting Rod Bearing

Journal
Main Bearing Journal
SMCS Code: 1202; 1219; 1225
Part No.: 219-4454

S/N: 5301-Up
Part No.: 219-4454

S/N: 5301-Up
Part No.: 219-4454

S/N: 2211-Up
Part No.: 219-4454

S/N: 2211-Up
Part No.: 219-4454

S/N: LWA1-Up
Part No.: 219-4454

S/N: LWA1-Up
Part No.: 219-4454

S/N: GEB1-Up
Part No.: 219-4454

S/N: GEB1-Up
Part No.: 219-4454

S/N: TPB1-Up
Part No.: 219-4454

S/N: TPB1-Up
Part No.: 219-4454

S/N: H4C1-Up
Part No.: 219-4454

S/N: H4C1-Up
Part No.: 219-4453

S/N: EED1-Up
Part No.: 219-4453

S/N: EED1-Up
Part No.: 219-4453

S/N: RJG1-Up
Part No.: 219-4453

S/N: RJG1-Up
Part No.: 219-4454

S/N: Z9K1-Up
Part No.: 219-4454

S/N: Z9K1-Up
Part No.: 219-4454

S/N: JRP1-Up
Part No.: 219-4454

S/N: JRP1-Up
Part No.: 219-4453

S/N: DLS1-Up
Part No.: 219-4453

S/N: DLS1-Up
Part No.: 219-4453

S/N: BTW1-Up
Part No.: 219-4453

S/N: BTW1-Up
Part No.: 219-4453

S/N: JNW1-Up
Part No.: 219-4453

S/N: JNW1-Up
Part No.: 219-4453

S/N: BWX1-Up
Part No.: 219-4453

S/N: BWX1-Up
Table 1
Diameter of Crankshaft Journal (Bearing

Surface) For Connecting Rod
Original Size Journal
SMCS Code: 1202; 1203
97.028 0.020 mm
(3.8200 0.0008 inch)
Refer to Guideline For Reusable Parts And Salvage

Operations, SEBF8009, Main and Connecting Rod
Bearings and Guideline For Reusable Parts and
Salvage Operations, SEBF8041, Specifications for
Crankshaft in Caterpillar Engines.
Table 2
Main Bearing Journals
Clearance between new bearing and new

journal ... 0.070 to 0.178 mm (0.0028 to 0.0070 inch)
Original Size Journal
120.650 0.020 mm
(4.7500 0.0008 inch)
Undersize Journal
0.63 mm (0.025 inch)
120.015 0.020 mm
(4.7250 0.0008 inch)
Undersize Journal
1.27 mm (0.050 inch)
119.380 0.020 mm
(4.7000 0.0008 inch)
SENR9936-06
53
Main bearing cap with two bolts

journal ................................... 0.076 to 0.186 mm
(0.0030 to 0.0073 inch)
Main bearing cap with four bolts
journal ................................... 0.071 to 0.178 mm
(0.0028 to 0.0070 inch)
Table 3
Main Bearing Bore

Original Size of the Bore
In the Block
129.891 0.013 mm
(5.1138 0.0005 inch)
Oversize Bore 0.63 mm

(0.025 inch)
130.526 0.013 mm
(5.1388 0.0005 inch)
i02801090
Connecting Rod
SMCS Code: 1218
Part No.: 319-6714
S/N: 5301-Up
Part No.: 319-6714
S/N: 2211-Up
Part No.: 319-6714
S/N: LWA1-Up
Part No.: 319-6714
S/N: GEB1-Up
Part No.: 319-6714
S/N: TPB1-Up
Part No.: 319-6714
S/N: H4C1-Up
Part No.: 213-4836
S/N: EED1-Up
Part No.: 213-4836
S/N: RJG1-Up
Part No.: 319-6714
S/N: Z9K1-Up
Part No.: 239-6144
S/N: JRP1-Up
Part No.: 213-4836
S/N: DLS1-Up
Part No.: 213-4836
S/N: BTW1-Up
Part No.: 213-4836
S/N: JNW1-Up
Part No.: 213-4836
S/N: BWX1-Up
Illustration 88
g01318414
Tightening sequence, and index mark for torque-turn process

(1),(2),(3),(4) Bolts for rod cap
54
SENR9936-06
Note: The connecting rods should be installed in the

engine so that the part number of the forging for the
rod assembly is facing the connecting rod that is on
the same crankshaft pin. The opposite side of the
connecting rods will face the thrust surface of the
crankshaft journal.
Use the following procedure for tightening the bolts
for the rod cap:
1. Prior to assembly, lubricate the threads of the
bolts and the seating face of the bolt heads with
clean engine oil.
2. Finger tighten all of the bolts.
3. Tighten bolts (1) and (3) to 70 4 Nm (50 3 lb ft).
4. Tighten bolts (2) and (4) to 70 4 Nm (50 3 lb ft).
Note: Use a paint stick to place an index mark on
each of the bolts. Use the index mark as a reference
in order to torque the bolts for an additional angle.
5. Tighten bolts (2) and (4) by an additional angle
(A) of 60 5 degrees.
6. Tighten bolts (1) and (3) again to 70 4 Nm
(50 3 lb ft).
Illustration 89
g01399607
(6) Bearing for piston pin
7. Tighten bolts (1) and (3) by an additional angle

(A) of 60 5 degrees.
(5) Connecting rod

(B) Inside diameter of connecting rod of bearing
for the piston pin ............ 64.592 0.013 mm
(2.5430 0.0005 inch)
(C) Distance between the center of the bore for
the bearing for piston pin and the center of the
bore for the crankshaft journal .... 274.91 mm
(10.823 inch)
(D) Inside diameter of connecting rod
for the crankshaft journal after the
bearing for connecting rod has been
installed and the bolts have been
torqued. ....................... 103.500 0.013 mm
(4.0748 0.0005 inch)
SENR9936-06
Illustration 90
55
g01399634
Note: The bearing joint must be located within area

(E) along the horizontal centerline of the piston pin
bore.
Illustration 91
(7) Oil jet tube assembly
(8) Torque for the special bolt of oil jet tube

assembly ....................... 25 6 Nm (18 4 lb ft)
(F) Maximum angle from the horizontal

centerline ......................................... 5 degrees
Note: The bore of bearing for piston pin must be
machined after installation into the connecting rod.
(G) Outside diameter of bearing for piston
pin before installation into the connecting
rod .. 64.717 0.013 mm (2.5479 0.0005 inch)
(H) Dimensions for piston pin
Bore diameter of bearing for the piston pin after
machining ............................ 60.035 0.008 mm
(2.3636 0.0003 inch)
Diameter of piston pin .......... 59.975 0.005 mm
(2.3612 0.0002 inch)
Note: Apply heat to the connecting rod prior to
installation of bearing for piston pin. Do not use a
torch to heat the connecting rod.
g01401199
i02856149
Piston and Rings

SMCS Code: 1214; 1215
Part No.: 213-4836
S/N: EED1-Up
Part No.: 213-4836
S/N: RJG1-Up
Part No.: 213-4836
S/N: DLS1-Up
Part No.: 213-4836
S/N: BTW1-Up
Part No.: 213-4836
S/N: JNW1-Up
Part No.: 213-4836
S/N: BWX1-Up
(J) Maximum length for heating the connecting

rod during the installation of bearing for piston
pin ............................................ 95 mm (3.7 inch)
Temperature for heating for connecting
rod .............................. 175 to 260 C (347 to 500 F)
Illustration 92
g01391600
Note: Refer to Guideline for Reusable Parts for

information on the pistons, the piston pins, and the
retaining rings.
56
The 1U-6431 Piston Ring Groove Gauge Gp is

used for measuring the ring grooves in keystone
style pistons. Refer to the Special Instruction that is
supplied with the piston ring groove gauge group.
The 5P-3519 Piston Ring Groove Gauge Gp is
available for checking the ring grooves with straight
sides. Refer to the Guideline for Reusable Parts for
instructions on the piston ring groove gauge group.
Note: Lubricate the entire piston in zone (A) with
clean engine oil prior to assembly into the cylinder
block.
Top Piston Ring (1)

Install the piston ring with the side marked UP-1
toward the top of the piston. The red stripe faces to
the right of the piston ring end gap.
When a new piston ring is installed in a cylinder liner
with a bore of 137.16 mm (5.400 inch), the clearance
between the ends of the piston ring is the following
value: .............. 0.40 0.10 mm (0.016 0.004 inch)
Increase in the clearance between the ends of the
piston ring for each 0.03 mm (0.001 inch) increase in
the cylinder liner bore ............. 0.08 mm (0.003 inch)
Intermediate Piston Ring (2)

toward the top of the piston. The blue stripe faces to
the right of the piston ring end gap.
value: ...... 0.770 0.125 mm (0.0303 0.0049 inch)
Oil Control Piston Ring (3)

The ends of the oil control piston ring should be a
distance of 180 degrees from the ring end gap when
the oil control piston ring is assembled. The white
colored portion of the piston ring must be visible at
the ring end gap.
Width of groove in new piston for oil control piston
ring .......... 4.030 0.010 mm (0.1587 0.0004 inch)
Thickness of new oil control piston
ring .......... 3.980 0.010 mm (0.1567 0.0004 inch)
SENR9936-06
Clearance between groove and oil control piston

ring .......................................... 0.05 mm (0.002 inch)
value: .............. 0.55 0.15 mm (0.022 0.006 inch)
Note: After the piston rings have been installed,
rotate the piston rings so that the end gaps are 120
degrees from each other.
Piston Pin Bore (4)

Note: Thoroughly lubricate the piston pin with clean
engine oil before the piston is inserted into the piston
and the rod assembly.
Diameter of the bore in the finished bearing that
is installed into the piston skirt for the piston
pin .. 60.0925 0.0075 mm (2.36584 0.00030 inch)
Diameter of the new piston pin .. 59.975 0.005 mm
(2.3612 0.0002 inch)
SENR9936-06
57
i02856206
Piston and Rings
Top Piston Ring (1)

toward the top of the piston. The purple colored stripe
faces to the right of the piston ring end gap.
SMCS Code: 1214; 1215

Part No.: 319-6714
S/N: 5301-Up
When a new piston ring is installed in a cylinder

liner with a bore of 145 mm (5.7 inch), the clearance
value: .............. 0.40 0.10 mm (0.016 0.004 inch)
Part No.: 319-6714

S/N: 2211-Up
Part No.: 319-6714
S/N: LWA1-Up
Increase in clearance between the ends of the piston

rings for each 0.030 mm (0.0012 inch) increase in the
cylinder liner bore ................... 0.08 mm (0.003 inch)
Part No.: 319-6714

S/N: GEB1-Up
Intermediate Piston Ring (2)
Part No.: 319-6714

S/N: TPB1-Up

toward the top of the piston. The white colored stripes
face to the right of the piston ring end gap.
Part No.: 319-6714

S/N: H4C1-Up

value: ...... 0.600 0.125 mm (0.0236 0.0049 inch)
Part No.: 319-6714

S/N: Z9K1-Up
Part No.: 239-6144
S/N: JRP1-Up

ring for each 0.030 mm (0.0012 inch) increase in the
Oil Control Piston Ring (3)

The spring ends of the new piston ring should be a
distance of 180 degrees from the ring end gap when
the piston ring is assembled. The green colored
stripe must be visible at the ring end gap.
Width of groove in new piston for piston
ring ............ 3.020 0.010 mm (0.1189 0.0004 inch)
Illustration 93
g01391600
Note: Refer to Guideline for Reusable Parts for

information on the pistons, the piston pins, and the
retaining rings.
The 1U-6431 Piston Ring Groove Gauge Gp is
used for measuring the ring grooves in keystone
style pistons. Refer to the Special Instruction that is
supplied with the piston ring groove gauge group.
The 5P-3519 Piston Ring Groove Gauge Gp is
available for checking the ring grooves with straight
sides. Refer to the Guideline for Reusable Parts for
instructions on the piston ring groove gauge group.
Note: Lubricate the entire piston in zone (A) with
clean engine oil prior to assembly into the cylinder
block.
Thickness of new piston ring ....... 2.980 0.010 mm

(0.1173 0.0004 inch)
Clearance between groove and piston ring .. 0.05 mm
(0.002 inch)
value. .............. 0.55 0.15 mm (0.022 0.006 inch)
ring for each 0.030 mm (0.0012 inch) increase in the
Note: After all piston rings have been installed, rotate
the piston rings so that the end gaps are 120 degrees
from each other.
58
SENR9936-06
Piston Pin Bore (4)

Note: Thoroughly lubricate the piston pin with clean
engine oil before the piston is inserted into the piston
and the rod assembly.
Diameter of the bore in the bearing that is
installed into the piston skirt for the piston
pin .. 60.0925 0.0075 mm (2.36584 0.00030 inch)
Diameter of the new piston pin .. 59.975 0.005 mm
(2.3612 0.0002 inch)
i02801103
Housing (Front)
SMCS Code: 1151
Part No.: 238-9862
Illustration 95
g01399843
Note: The rear face of the front housing assembly (3)

and the front face of the cylinder block must be free of
oil, fuel, water, dirt and any other contaminants during
assembly. The gasket for the front housing assembly
must also be free of contaminants during assembly.
Note: The gasket (2) for the front housing assembly
must be trimmed after assembly with the face (4) so
that the gasket is flush.
Illustration 94
g01399842
(1) Studs are supplied with a previously applied

thread lock compound. Install the shortest
threaded end of stud into the front housing
assembly.
SENR9936-06
59
Part No.: 233-2462

S/N: LWA1-Up
Part No.: 219-6921
S/N: GEB1-Up
Part No.: 219-6921
S/N: TPB1-Up
Part No.: 233-2462
S/N: H4C1-Up
Part No.: 233-2462
S/N: EED1-Up
Part No.: 233-2462
S/N: RJG1-Up
Part No.: 233-2462
S/N: Z9K1-Up
Part No.: 233-2462
S/N: JRP1-Up
Part No.: 233-2462
S/N: DLS1-Up
Part No.: 233-2462
S/N: BTW1-Up
Part No.: 233-2462
S/N: JNW1-Up
Part No.: 233-2462
S/N: BWX1-Up
Illustration 96
g01399846
View A-A
(6) Cylinder block
(5) Apply a continuous bead of 4C-9612 Silicone

Sealant immediately prior to assembling the front
housing assembly. After assembly of the front
housing assembly, remove excess sealant from
the flange with a straight edge.
(7) Apply 4C-9612 Silicone Sealant to the T-shaped
joints immediately prior to the installation of the
gasket for the pan. The application of the sealant
should cover the entire width of the T-shaped
joints, as shown.
i02801118
Housing (Rear)
SMCS Code: 1157
Part No.: 233-2462
S/N: 5301-Up
Part No.: 233-2462
S/N: 2211-Up
Illustration 97
g01399863
60
SENR9936-06
Note: The rear face of the cylinder block and the

front face of the rear housing (1) must be free of
oil, fuel, water, dirt, assembly compounds and any
other contaminants during assembly. The gasket for
the rear housing must also be free of contaminants
during assembly.
(B) Dowel extension from the rear housing at two
places ............. 19.0 0.5 mm (0.75 0.02 inch)
Illustration 99
g01399869
Rear view

the rear housing:
1. Start with bolt (5) and continue to tighten all of the
remaining bolts in the numerical sequence that is
shown to a torque of 55 10 Nm (41 7 lb ft).
Bolt (5) and bolt (6) are 3/8-16 X 1 3/4 inches.

Bolts (7) through bolts (14) are 3/8-16 X 2 1/4
inches.
Illustration 98
g01399864
View A-A
(3) Cylinder block
(2) Apply a continuous bead of 230-6262 Sealant

immediately prior to assembling the rear housing.
After assembly of the rear housing, remove any
excess sealant from the flange with a straight
edge.
(4) Apply 230-6262 Sealant to the T-shaped joints
immediately prior to the installation of the gasket
for the pan. The application of the sealant should
cover the entire width of the T-shaped joints, as
shown.
i02801133
Gear Group (Front)

SMCS Code: 1206
Part No.: 235-0993
S/N: 5301-Up
Part No.: 235-0993
S/N: 2211-Up
Part No.: 235-0993
S/N: LWA1-Up
Part No.: 235-7134
S/N: GEB1-Up
SENR9936-06
61
Part No.: 235-7134

S/N: TPB1-Up
Part No.: 235-0993
S/N: H4C1-Up
Part No.: 235-0993
S/N: EED1-Up
Part No.: 235-7134
S/N: RJG1-Up
Part No.: 235-0993
S/N: Z9K1-Up
Part No.: 235-0993
S/N: JRP1-Up
Illustration 101
g01399901
Tightening sequence
Part No.: 235-0993

S/N: DLS1-Up
Part No.: 235-0993
S/N: BTW1-Up
Note: Tighten the bolts for the camshaft gear in the

sequence 1, 4, 2, 5, 3, 6, 1, 4. Refer to Illustration
101.
Part No.: 235-0993

S/N: JNW1-Up
(2) Torque for the 12 bolts of the camshaft

gear ....................... 240 40 Nm (175 30 lb ft)
Part No.: 235-0993

S/N: BWX1-Up
(4) Lubricate the shaft, the bearing bore, and the

thrust faces of the idler gear assembly with clean
engine oil.
(7) Torque for the bolt ........ 55 10 Nm (41 7 lb ft)
Illustration 102
g01399922
Section A-A
Illustration 100
(1)
(3)
(5)
(6)
Damper group
Gear assembly
Crankshaft gear
Gear
g01399881
(8) Lubricate the drive idler shaft with clean engine

oil.
Note: Install the thrust plate with the oil groove side
toward the idler gear assembly.
(9) Lubricate the thrust faces of the thrust plate with
clean engine oil.
(10) Torque for the five locking bolts ..... 55 10 Nm
(41 7 lb ft)
62
SENR9936-06
i02866666
Gear Group (Rear)

SMCS Code: 1204; 1206
S/N: LWA1-Up
S/N: H4C1-Up
Part No.: 231-6378
S/N: EED1-Up
Part No.: 216-0812
S/N: RJG1-Up
S/N: Z9K1-Up
Part No.: 231-6378
S/N: DLS1-Up
Part No.: 295-7963
S/N: JNW1-Up
Illustration 104
g01428030
Typical example
Tightening sequence

engine oil.
thrust faces of the camshaft gear assembly with
clean engine oil.
(3) With the no. 1 piston in the top dead center (TDC)
position, align the timing marks. The mark on the
camshaft gear assembly must be in alignment
with the drilled timing marks in the rear housing.
Tighten the bolts for the camshaft gear assembly (2)
in the sequence 7, 10, 8, 11, 9, 12, 7, 10. Refer to
Illustration 104. ............ 240 40 Nm (175 30 lb ft)
idler gear assembly (4) must be in alignment with
the mark on the crankshaft gear assembly.
Illustration 103
Typical example
Rear view of engine
g01428033

thrust faces of the crankshaft gear assembly with
clean engine oil.
SENR9936-06
63
(17) Torque for two bearing locknuts ... 406 68 Nm

(300 50 lb ft)
(18) Bend the tab on the two lockwashers that aligns
with the slot in the bearing locknuts.
i02867504
Gear Group (Rear)

SMCS Code: 1204; 1206
Part No.: 253-2634
S/N: JRP1-Up
Illustration 105
g01428031
Typical example
Section A-A
(13) Install the plate with the side marked OUT

away from the gear face.
engine oil.
(15) Install the thrust plate with the side marked
OUT away from the gear face.
Illustration 107
Rear view of engine
Illustration 106
g01428029
Typical example
Section B-B
(16) Lubricate the bore and the O-ring seals lightly

with the lubricant that is being sealed.
g01428404
64
Illustration 108
SENR9936-06
g01428402
Tightening sequence

engine oil.
clean engine oil.
Illustration 108. ............ 240 40 Nm (175 30 lb ft)
engine oil.
engine oil.
the mark on the crankshaft gear assembly (7).
clean engine oil.
Illustration 109
g01428403
Section A-A

engine oil.
SENR9936-06
65
i02866758
Gear Group (Rear)

SMCS Code: 1204; 1206
Part No.: 263-2941
S/N: BTW1-Up
Part No.: 263-2941
S/N: BWX1-Up
Illustration 110
g01428401
Section B-B

(300 50 lb ft)
Illustration 111
Rear view of engine
g01428074
66
Illustration 112
SENR9936-06
g01428072
Tightening sequence

engine oil.
clean engine oil.
Illustration 112. ............. 240 40 Nm (175 30 lb ft)
engine oil.
engine oil.
the mark on the crankshaft gear assembly.
clean engine oil.
Illustration 113
g01428073
Section A-A

engine oil.
SENR9936-06
67
i02899682
Gear Group (Rear)

SMCS Code: 1204; 1206
Part No.: 245-9776
S/N: 5301-Up
Part No.: 245-9776
S/N: 2211-Up
Part No.: 245-9776
S/N: LWA1-Up
Part No.: 245-9776
S/N: GEB1-Up
Part No.: 245-9776
S/N: TPB1-Up
Part No.: 245-9776
S/N: H4C1-Up
Illustration 114
g01428071
Section B-B
Part No.: 245-9776

S/N: Z9K1-Up

(300 50 lb ft)
Illustration 115
g01443779
Note: Lubricate the shaft, the bearing bore, and the

engine oil.
(1) Torque for the bolts of the idler gear
assembly ..................... 55 10 Nm (41 7 lb ft)
68
SENR9936-06

clean engine oil.

thrust faces of the cranshaft gear assembly with
clean engine oil.
(3) With the number one piston in the top dead

center position, align the timing marks. The mark
on the camshaft gear must be in alignment with
the mark in the rear housing.
Illustration 117
g01400787
Section A-A
Illustration 116
g01400123
(12) Lubricate the O-ring seals lightly with clean

engine oil.
Tightening sequence
Note: Tighten the bolts for the camshaft gear in the

sequence 1, 4, 2, 5, 3, 6, 1, 4. Refer to Illustration 116.
(4) Torque for the 12 bolts of the camshaft gear
assembly ............... 240 40 Nm (175 30 lb ft)
(5) Install the plate with the side marked OUT away
from the gear face.
engine oil.
(6) Torque for the bolts of the idler gear
assembly ..................... 55 10 Nm (41 7 lb ft)
engine oil.
i02857719
Flywheel
SMCS Code: 1156
Part No.: 245-9777
S/N: 5301-Up
Part No.: 245-9777
S/N: 2211-Up
Part No.: 245-9777
S/N: LWA1-Up
Part No.: 245-9777
S/N: H4C1-Up
Part No.: 231-6377
S/N: EED1-Up
Part No.: 245-9777
S/N: Z9K1-Up
(7) Torque for the locking bolt of idler gear

assembly ..................... 55 10 Nm (41 7 lb ft)
Part No.: 245-9777

S/N: JRP1-Up
(8) Torque for the bolts for the stub shaft of idler gear
assembly ............... 135 20 Nm (100 15 lb ft)
Part No.: 231-6377

S/N: DLS1-Up
(9) Install the thrust plate with the side marked OUT
Part No.: 224-3167

S/N: BTW1-Up
(10) With the number one piston in the top dead

center position, align the timing marks. The mark
on the idler gear must be in alignment with the
mark on the crankshaft gear.
Part No.: 231-6377

S/N: JNW1-Up
Part No.: 224-3167
S/N: BWX1-Up
SENR9936-06
69
i02900830
Flywheel
SMCS Code: 1156
Part No.: 273-2713, 273-2715, 273-2716,
273-7293
S/N: JRP1-Up
Illustration 119
g01450105
Typical example
Illustration 118
g01427833
(1) Flywheel assembly

Maximum runout of the face ................. 0.43 mm
(0.017 inch)
Maximum eccentricity of the pilot bore in the drive
hub .................................... 0.23 mm (0.009 inch)
Eccentricity of the coupling pilot bore ........... N/A
Note: Lubricate the threads of the bolts with clean
engine oil, molybdenum disulfide or a graphite base
lubricant before assembly.
(1) Torque for the eight bolts ............... 120 20 Nm

(90 15 lb ft)
70
SENR9936-06
i02857727
i02857899
Flywheel
Flywheel Housing
SMCS Code: 1156
SMCS Code: 1157
Part No.: 248-3309

S/N: GEB1-Up
Part No.: 226-0297, 302-4288

S/N: EED1-Up
Part No.: 248-3309

S/N: TPB1-Up
Part No.: 226-0297

S/N: RJG1-Up
Part No.: 216-0811

S/N: RJG1-Up
Part No.: 226-0297, 302-4288

S/N: DLS1-Up
Illustration 120
g01249502
(1) Gear
(2) Flywheel assembly

Maximum runout of the face ................. 0.43 mm
(0.017 inch)
Maximum eccentricity of the pilot bore in the drive
hub .................................... 0.23 mm (0.009 inch)
Eccentricity of the coupling pilot bore ........... N/A
Note: Lubricate the threads with clean engine oil,
molybdenum disulfide or a graphite base lubricant
before assembly.
Illustration 121
Rear view of engine
g01423950
SENR9936-06
71
Illustration 123
g01427297
Section A-A
Note: The seal and the sleeve of the crankshaft seal

group must not be used if the seal and the sleeve
have been separated.
(37) The seal driver must not contact the seal within
the following diameter. ........... 177.80 0.25 mm
(7.000 0.010 inch)
Illustration 122
g01423951
Note: The front face of the flywheel housing group

and the rear face of the rear housing must be free of
oil, fuel, water, assembly compounds and any other
contaminants during assembly. The gasket for the
flywheel housing group must be free of contaminants
during assembly.
the flywheel housing group:
1. For bolt (1) and bolt (2), use 3/8-16 X 6 1/4
inch bolts. Torque the bolt (1) and bolt (2) in the
numerical sequence that is shown in Illustration
121 to 55 10 Nm (41 7 lb ft).
2. For bolt (3) through bolt (10), use 1/2-13 X 6
1/2 inch bolts. Torque the bolt (3) through bolt
(10) in the numerical sequence that is shown in
Illustration 121 to 135 20 Nm (100 15 lb ft).
3. For bolt (11) through bolt (16), use 3/8-16 X 4 inch
bolts. For bolt (17) through bolt (30), use 3/8-16 X
5 1/4 inch bolts. For bolt (31) through bolt (36), use
3/8-16 X 3 inch bolts. Torque the bolt (11) through
bolt (36) in the numerical sequence that is shown
in Illustration 121 to 47 9 Nm (35 7 lb ft).
Note: Check assembled installation depth of the

crankshaft seal group with the crankshaft in any axial
position.
(C) Assembled installation depth ........ 6.4 0.6 mm
(0.25 0.02 inch)
72
SENR9936-06
i02884495
Flywheel Housing
SMCS Code: 1157
Part No.: 245-9775
S/N: 5301-Up
Part No.: 245-9775
S/N: 2211-Up
Part No.: 245-9775
S/N: LWA1-Up
Part No.: 245-9775
S/N: H4C1-Up
Part No.: 245-9775
S/N: Z9K1-Up
Part No.: 259-3123
S/N: JRP1-Up
Part No.: 217-5685
S/N: BTW1-Up
Part No.: 217-5685
S/N: BWX1-Up
Illustration 125
g01424823
Typical example
Right side view of the engine

during assembly.
Illustration 124
Typical example
Rear view of engine
g01424781
1. For bolt (1) and bolt (2), use 3/8-16 X 6 1/4 inch
bolts. Torque the bolt (1) and bolt (2 ) in the
124 to 55 10 Nm (41 7 lb ft).
SENR9936-06
73

bolts. For bolt (17) through bolt (34), use 3/8-16 X
4 3/4 inch bolts. For bolt (35) and bolt (36), use
3/8-16 X 3 inch bolts. Torque the bolt (11) through
bolt (36) in the numerical sequence that is shown
in Illustration 124 to 47 9 Nm (35 7 lb ft).
i02883213
Flywheel Housing
SMCS Code: 1157
Part No.: 273-1642
S/N: BTW1-Up
Part No.: 273-1642
S/N: BWX1-Up
3. Again torque the bolt (1) and bolt (2) in the

124 to 55 10 Nm (41 7 lb ft).
Illustration 126
g01436141
Section A-A

(7.000 0.010 inch)
position.
(0.25 0.02 inch)
Illustration 127
Rear view of engine
g01435183
74
SENR9936-06

bolts. For bolt (17) and bolt (18), use 3/8-16 X
5 1/2 inch bolts. For bolt (19) and bolt (20), use
3/8-16 X 4 3/4 inch bolts. For bolt (21) and bolt
(22), use 3/8-16 X 5 1/2 inch bolts. For bolt (23)
through bolt (28), use 3/8-16 X 4 3/4 inch bolts.
For bolt (29) through bolt (34), use 3/8-16 X 5 1/2
inch bolts. For bolt (35) and bolt (36), use 3/8-16
X 3 inch bolts. Torque the bolt (11) through bolt
3. Again torque the bolt (1) and bolt (2) in the
127 to 55 10 Nm (41 7 lb ft).
Illustration 129
g01435182
Section A-A
Illustration 128
g01435181
Right side view of the engine

during assembly.
1. For bolt (1) and bolt (2), use 3/8-16 X 6 1/4 inch
bolts. Torque the bolt (1) and bolt (2 ) in the
127 to 55 10 Nm (41 7 lb ft).

(7.000 0.010 inch)
position.
(0.25 0.02 inch)
SENR9936-06
75
i02883207
Flywheel Housing
SMCS Code: 1157
Part No.: 294-9164
S/N: JNW1-Up
Illustration 131
g01435175
Illustration 130
Rear view of engine
g01435177

during assembly.
1. For bolt (1) and bolt (2), use 3/8-16 X 6 1/4
inch bolts. Torque the bolt (1) and bolt (2) in the
130 to 55 10 Nm (41 7 lb ft).
bolts. For bolt (17), use bolt size of 3/8-16 X 5 1/2
inches. For bolt (18) through bolt (24), use 3/8-16
X 5 1/4 inch bolts. For bolt (33) and bolt (34), use
3/8-16 X 3 1/2 inch bolts. For bolt (35) and bolt
(36), use 3/8-16 X 3 inch bolts. Torque the bolt
(11) through bolt (36) in the numerical sequence
that is shown in Illustration 130 to 47 9 Nm
(35 7 lb ft).
76
Illustration 132
SENR9936-06
g01435176
Section A-A

(7.000 0.010 inch)
position.
(C) Assembled installation depth ....... 5.8 to 6.4 mm
(0.23 to 0.25 inch)
SENR9936-06
77
i02858265
Flywheel Housing
SMCS Code: 1157
Part No.: 216-0822
S/N: GEB1-Up
Part No.: 216-0822
S/N: TPB1-Up
Illustration 133
g01424195
Rear view of engine

during assembly.
2. For bolt (9), use bolt size of 3/8-16 X 6 1/4 inches.
Torque the bolt (9) in the numerical sequence
(41 7 lb ft).

inch bolts. For bolt (16) through bolt (26), use
3/8-16 X 3 inch bolts. For bolt (27) through bolt
(42), use 3/8-16 X 5 1/4 inch bolts. Torque the bolt
(10) through bolt (42) in the numerical sequence
(35 7 lb ft).
78
SENR9936-06
i02845077
Coolant Temperature Sensor

SMCS Code: 1906
Part No.: 256-6453
S/N: 5301-Up
Part No.: 256-6453
S/N: 2211-Up
S/N: LWA1-Up
Illustration 134
g01427322
Part No.: 197-8392, 264-4297

S/N: GEB1-Up
Section A-A
Part No.: 197-8392, 264-4297

S/N: TPB1-Up

Part No.: 256-6453

S/N: H4C1-Up
(7.000 0.010 inch)
position.
(B) Assembled installation depth ........ 6.4 0.6 mm
(0.25 0.02 mm)
Part No.: 197-8392, 256-6453, 264-4297

S/N: EED1-Up
Part No.: 197-8392, 264-4297
S/N: RJG1-Up
Part No.: 256-6453
S/N: Z9K1-Up
Part No.: 197-8392, 256-6453, 264-4297
S/N: JRP1-Up
Part No.: 197-8392, 256-6453, 264-4297
S/N: DLS1-Up
Part No.: 197-8392, 256-6453, 264-4297
S/N: BTW1-Up
Part No.: 256-6453, 264-4297
S/N: JNW1-Up
Part No.: 197-8392, 256-6453, 264-4297
S/N: BWX1-Up
Illustration 135
g01089060
(1) Final installation torque for the temperature

sensor group .................. 20 3 Nm (15 2 lb ft)
SENR9936-06
79
Output type ................................................... Passive

Operating temperature ........................ 40 to 150 C
(40 to 302 F)
i02847523
Coolant Temperature Sensor
i01432272
Coolant Flow Switch

SMCS Code: 7422
Part No.: 171-8708
S/N: LWA1-Up
SMCS Code: 1906
Part No.: 171-8708

S/N: GEB1-Up
Part No.: 130-9811

S/N: EED1-Up
Part No.: 171-8708

S/N: TPB1-Up
Part No.: 130-9811

S/N: RJG1-Up
Part No.: 171-8708

S/N: H4C1-Up
Part No.: 130-9811

S/N: JRP1-Up
Part No.: 171-8708

S/N: RJG1-Up
Part No.: 130-9811

S/N: DLS1-Up
Part No.: 171-8708

S/N: Z9K1-Up
Part No.: 130-9811

S/N: BTW1-Up
Part No.: 171-8708

S/N: JRP1-Up
Part No.: 130-9811

S/N: JNW1-Up
Part No.: 171-8708

S/N: BTW1-Up
Part No.: 130-9811

S/N: BWX1-Up
Part No.: 134-6054

S/N: JNW1-Up
Part No.: 171-8708
S/N: BWX1-Up
Illustration 136
g01391967

(40 to 302 F)
Illustration 137
g00117939
Typical example
(1) Connector
(2) Rivet head for test procedure
Test with the paddle in a vertical position and the
force (F) on rivet head (2):
80
SENR9936-06
With an increase in flow (force), the switch opens at

the following value: .......................... 0.362 0.029 N
(0.0814 0.0065 lb)
With a decrease in flow (force), the switch closes at
the following minimum value: ..... 0.303 N (0.0681 lb)
Note: When the switch is installed in the engine
cooling system, there is not enough force from the
flow of coolant at engine cranking speed in order to
activate the switch. When the engine is running at
low idle, the flow of coolant has enough force in order
to activate the switch.
i02839267
Fuel Temperature Sensor

SMCS Code: 1922
Part No.: 130-9811
S/N: GEB1-Up
Part No.: 130-9811
S/N: TPB1-Up
Part No.: 130-9811
S/N: EED1-Up
Part No.: 130-9811
S/N: RJG1-Up
Part No.: 130-9811
S/N: JRP1-Up
Part No.: 130-9811
S/N: DLS1-Up
Part No.: 130-9811
S/N: BTW1-Up
Part No.: 130-9811
S/N: JNW1-Up
Part No.: 130-9811
S/N: BWX1-Up
Illustration 138
g01089060

sensor ............................ 20 5 Nm (15 4 lb ft)
(40 to 302 F)
SENR9936-06
81
i02845081
Fuel Temperature Sensor

(40 to 302 F)
SMCS Code: 1922

Part No.: 256-6453
S/N: 5301-Up
i02787430
Fuel Filter Pressure Differential

Switch
Part No.: 256-6453

S/N: 2211-Up
Part No.: 256-6453, 264-4297
S/N: LWA1-Up
SMCS Code: 1256; 1261

Part No.: 275-1253
S/N: 5301-Up
Part No.: 197-8392, 264-4297

S/N: GEB1-Up
Part No.: 275-1253

S/N: 2211-Up
Part No.: 197-8392, 264-4297

S/N: TPB1-Up
Part No.: 258-0883

S/N: LWA1-Up
Part No.: 256-6453, 264-4297

S/N: H4C1-Up
Part No.: 197-8392, 256-6453, 264-4297
S/N: EED1-Up
Part No.: 197-8392, 264-4297
S/N: RJG1-Up
Part No.: 258-0883

S/N: GEB1-Up
Part No.: 258-0883
S/N: TPB1-Up
Part No.: 275-1253
S/N: H4C1-Up
Part No.: 256-6453, 264-4297

S/N: Z9K1-Up
Part No.: 197-8392, 256-6453, 264-4297
S/N: JRP1-Up
Part No.: 197-8392, 256-6453, 264-4297
S/N: DLS1-Up
Part No.: 197-8392, 256-6453, 264-4297
S/N: BTW1-Up
Part No.: 256-6453, 264-4297
S/N: JNW1-Up
Part No.: 197-8392, 256-6453, 264-4297
S/N: BWX1-Up
Part No.: 258-0883, 275-1253

S/N: EED1-Up
Part No.: 258-0883
S/N: RJG1-Up
Part No.: 258-0883
S/N: Z9K1-Up
Part No.: 258-0883, 275-1253
S/N: JRP1-Up
Part No.: 258-0883, 275-1253
S/N: DLS1-Up
Part No.: 258-0883, 275-1253
S/N: BTW1-Up
Part No.: 258-0883, 275-1253
S/N: JNW1-Up
Part No.: 258-0883, 275-1253
S/N: BWX1-Up
Illustration 139
g01089060

82
SENR9936-06
i02853439
Mass Air Flow Sensor

SMCS Code: 1439-AI
Part No.: 194-6725
S/N: 5301-Up
Part No.: 194-6725
S/N: 2211-Up
Part No.: 194-6722, 194-6724, 194-6725
S/N: GEB1-Up
Illustration 140
g01392341
Part No.: 194-6722, 194-6724, 194-6725

S/N: TPB1-Up
(1) O-ring seals

(2) Sleeve
Part No.: 194-6722, 194-6724, 194-6725

S/N: EED1-Up
(3) Final installation torque for the pressure switch

group .................. 6.78 1.41 Nm (60 12 lb in)
Part No.: 194-6722, 194-6724, 194-6725

S/N: RJG1-Up
Actuation pressure at 21 3 C
(70 37 F) ........... 110.3 13.8 kPa (16.0 2.0 psi)
Part No.: 194-6722, 194-6724, 194-6725

S/N: JRP1-Up
(104 37 F) ..... 89.6 to 124.1 kPa (13.0 to 18.0 psi)
Part No.: 194-6722, 194-6724, 194-6725

S/N: DLS1-Up
(194 37 F) ......... 103.4 20.7 kPa (15.0 3.0 psi)
Part No.: 194-6722, 194-6724, 194-6725

S/N: BTW1-Up
Minimum deactuation pressure at 40 to 121 C

(40 to 250 F) ............................... 69 kPa (10.0 psi)
Contact position .......................................... Normally
closed below deactuation pressure
Part No.: 194-6724, 194-6725

S/N: JNW1-Up
Part No.: 194-6722, 194-6724, 194-6725
S/N: BWX1-Up
Illustration 141
g01421159
(1) Final installation torque for the pressure sensor

group .......................... 10 2 Nm (90 18 lb in)
Operating voltage ........................... 5.00 0.25 VDC
(40 to 257 F)
SENR9936-06
83
i02853437
i02665532
Mass Air Flow Sensor
Engine Oil Pressure Sensor
SMCS Code: 1439-AI
SMCS Code: 1924
Part No.: 274-6717, 274-6719, 276-6793

S/N: 5301-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: 5301-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: 2211-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: 2211-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: LWA1-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: LWA1-Up
S/N: H4C1-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: H4C1-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: EED1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: Z9K1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: JRP1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: DLS1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: JNW1-Up
Illustration 142
Part No.: 274-6717, 274-6719, 276-6793

S/N: EED1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: Z9K1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: JRP1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: DLS1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: JNW1-Up
g01275664
Illustration 143

group .......................... 10 2 Nm (90 18 lb in)
g01155331
Operating voltage ............................... 5.0 0.5 VDC
Note: Prior to installing the pressure sensor group

onto the engine, apply 5P-3413 Pipe Sealant to the
first three threads of the pressure sensor group.

(40 to 257 F)

group .......................... 10 2 Nm (90 18 lb in)
(40 to 257 F)
Maximum operating pressure (absolute
pressure) ..................................... 1135 kPa (165 psi)
84
SENR9936-06
i02845092
i02666631
Engine Oil Pressure Sensor
Atmospheric Pressure Sensor
SMCS Code: 1924
SMCS Code: 1923
Part No.: 194-6725

S/N: 5301-Up
Part No.: 194-6724

S/N: GEB1-Up
Part No.: 194-6725

S/N: 2211-Up
Part No.: 194-6724

S/N: TPB1-Up
Part No.: 194-6722, 194-6724, 194-6725

S/N: GEB1-Up
Part No.: 194-6724

S/N: EED1-Up
Part No.: 194-6722, 194-6724, 194-6725

S/N: TPB1-Up
Part No.: 194-6724

S/N: RJG1-Up
Part No.: 194-6722, 194-6724, 194-6725

S/N: EED1-Up
Part No.: 194-6724

S/N: JRP1-Up
Part No.: 194-6722, 194-6724, 194-6725

S/N: RJG1-Up
Part No.: 194-6724

S/N: DLS1-Up
Part No.: 194-6722, 194-6724, 194-6725

S/N: JRP1-Up
Part No.: 194-6724

S/N: BTW1-Up
Part No.: 194-6722, 194-6724, 194-6725

S/N: DLS1-Up
Part No.: 194-6724

S/N: JNW1-Up
Part No.: 194-6722, 194-6724, 194-6725

S/N: BTW1-Up
Part No.: 194-6724

S/N: BWX1-Up
Part No.: 194-6724, 194-6725

S/N: JNW1-Up
Part No.: 194-6722, 194-6724, 194-6725
S/N: BWX1-Up
Illustration 145
g01190345

group .......................... 10 2 Nm (90 18 lb in)
Illustration 144
g01068621

group .......................... 10 2 Nm (90 18 lb in)

(40 to 257 F)

(40 to 257 F)
Maximum operating pressure (absolute

pressure) ......................................... 472 kPa (68 psi)
SENR9936-06
85
i02879859
i02845102
SMCS Code: 1923
SMCS Code: 1923
Part No.: 274-6717, 274-6719, 276-6793

S/N: 5301-Up
Part No.: 194-6725

S/N: 5301-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: 2211-Up
Part No.: 194-6725

S/N: 2211-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: LWA1-Up
Part No.: 194-6722, 194-6725

S/N: GEB1-Up
Part No.: 248-2162, 274-6717, 274-6719,

276-6793
S/N: H4C1-Up
Part No.: 194-6722, 194-6725

S/N: TPB1-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: EED1-Up
Part No.: 248-2162, 274-6717, 274-6719,
276-6793
S/N: Z9K1-Up
Part No.: 274-6717, 274-6719, 276-6793
S/N: JRP1-Up
Part No.: 194-6722, 194-6725

S/N: EED1-Up
Part No.: 194-6722, 194-6725
S/N: RJG1-Up
Part No.: 194-6722, 194-6725
S/N: JRP1-Up
Part No.: 194-6722, 194-6725
S/N: DLS1-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: DLS1-Up
Part No.: 194-6722, 194-6725

S/N: BTW1-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: JNW1-Up
Part No.: 194-6725

S/N: JNW1-Up
Part No.: 194-6722, 194-6725
S/N: BWX1-Up
Illustration 146
g01154731

group .......................... 10 2 Nm (90 18 lb in)
(40 to 257 F)
Illustration 147
g01392045

group .......................... 10 2 Nm (90 18 lb in)
(40 to 257 F)
86
SENR9936-06
i02854065
i02854115
Inlet Manifold Temperature

Sensor
Turbocharger Inlet Pressure

Sensor
SMCS Code: 1921
SMCS Code: 1052; 1917
Part No.: 130-9811

S/N: GEB1-Up
Part No.: 194-6725

S/N: 5301-Up
Part No.: 130-9811

S/N: TPB1-Up
Part No.: 194-6725

S/N: 2211-Up
Part No.: 130-9811

S/N: EED1-Up
Part No.: 194-6722, 194-6724, 194-6725

S/N: GEB1-Up
Part No.: 130-9811

S/N: RJG1-Up
Part No.: 194-6722, 194-6724, 194-6725

S/N: TPB1-Up
Part No.: 130-9811

S/N: JRP1-Up
Part No.: 194-6722, 194-6724, 194-6725

S/N: EED1-Up
Part No.: 130-9811

S/N: DLS1-Up
Part No.: 194-6722, 194-6724, 194-6725

S/N: RJG1-Up
Part No.: 130-9811

S/N: BTW1-Up
Part No.: 194-6722, 194-6724, 194-6725

S/N: JRP1-Up
Part No.: 130-9811

S/N: JNW1-Up
Part No.: 194-6722, 194-6724, 194-6725

S/N: DLS1-Up
Part No.: 130-9811

S/N: BWX1-Up
Part No.: 194-6722, 194-6724, 194-6725

S/N: BTW1-Up
Part No.: 194-6724, 194-6725
S/N: JNW1-Up
Part No.: 194-6722, 194-6724, 194-6725
S/N: BWX1-Up
Illustration 148
g01391967

(40 to 302 F)
Illustration 149
g01190345

group .......................... 10 2 Nm (90 18 lb in)
(40 to 257 F)
SENR9936-06
87
i02854172
Turbocharger Inlet Pressure

Sensor
SMCS Code: 1052; 1917
Part No.: 279-9828, 279-9829

S/N: 5301-Up
Part No.: 279-9828, 279-9829
S/N: 2211-Up
Part No.: 279-9828, 279-9829
S/N: LWA1-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: 5301-Up
Part No.: 230-7149, 235-8210, 239-2397

S/N: GEB1-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: 2211-Up
Part No.: 230-7149, 235-8210, 239-2397

S/N: TPB1-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: LWA1-Up
Part No.: 279-9828, 279-9829

S/N: H4C1-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: H4C1-Up
Part No.: 279-9828, 279-9829, 283-3443

S/N: EED1-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: EED1-Up
Part No.: 230-7149, 235-8210, 239-2397

S/N: RJG1-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: Z9K1-Up
Part No.: 279-9828, 279-9829

S/N: Z9K1-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: JRP1-Up
Part No.: 279-9828, 279-9829

S/N: JRP1-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: DLS1-Up
Part No.: 279-9828, 279-9829, 283-3443

S/N: DLS1-Up
Part No.: 274-6717, 274-6719, 276-6793

S/N: JNW1-Up
Part No.: 230-7149, 239-2397, 280-4101

S/N: BTW1-Up
Part No.: 230-7149, 239-2397, 279-9828
S/N: JNW1-Up
Part No.: 230-7149, 239-2397, 280-4101
S/N: BWX1-Up
Illustration 150
g01154731

group .......................... 10 2 Nm (90 18 lb in)
(40 to 257 F)
i02857202
Speed/Timing Sensor
SMCS Code: 1907; 1912
88
SENR9936-06
Camshaft Position Sensor
Crankshaft Position Sensor
Illustration 152
g01423342
(2) Speed sensor

(3) Bracket
Ensure that the bracket is installed in the orientation

that is shown.
Illustration 151
g01423337
(2) Bracket
(3) Speed sensor
Ensure that the bracket is installed in the orientation

that is shown.
Lubricate the seal for the speed sensor with clean
engine oil before installation.
(1) Torque for the bolt .......... 28 7 Nm (21 5 lb ft)
Ensure that the speed sensor is seated before the
bolt is tightened.
Lubricate the seal for the speed sensor with clean

engine oil before installation.
(1) Torque for bolt ................ 28 7 Nm (21 5 lb ft)
Ensure that the speed sensor is seated before the
bolt is tightened.
SENR9936-06
89
Index Section
Index
A
Atmospheric Pressure Sensor......................... 8485
Important Safety Information ................................... 2

Inlet Manifold Temperature Sensor........................ 86
C
Camshaft ............................................................... 31
Compression Brake ............................................... 13
Connecting Rod..................................................... 53
Connecting Rod Bearing Journal........................... 52
Coolant Flow Switch .............................................. 79
Coolant Temperature Sensor........................... 7879
Crankshaft ............................................................ 47
Crankshaft Seals ................................................... 49
Cylinder Block........................................................ 43
Cylinder Head......................................................... 11
Cylinder Head Valves ............................................ 10
Cylinder Liner .................................................. 4546
M
Main Bearing Journal............................................. 52
Mass Air Flow Sensor...................................... 8283
P
Piston and Rings .............................................
Intermediate Piston Ring (2) ........................
Oil Control Piston Ring (3) ...........................
Piston Pin Bore (4).......................................
Top Piston Ring (1) ......................................
55, 57
5657
5657
56, 58
5657
Electronic Unit Injector Mechanism ......................... 6

Electronic Unit Injector Rocker Arm......................... 7
Electronic Unit Injector Wiring ................................. 7
Engine Design ......................................................... 4
Engine Oil Bypass Valve ................................. 3839
Engine Oil Filter Base...................................... 3233
Engine Oil Pan................................................. 4042
Engine Oil Pressure Sensor ............................ 8384
Engine Oil Pump.............................................. 34, 36
Oil Pump Body (4).............................................. 37
Oil Pump Spacer Assembly (3).......................... 37
Pump Body (2) ................................................... 37
Exhaust Manifold ................................. 24, 26, 2830
Specifications Section ............................................. 4

Speed/Timing Sensor ............................................ 87
Camshaft Position Sensor ................................. 88
Crankshaft Position Sensor ............................... 88
F
Flywheel .......................................................... 6870
Flywheel Housing .......................... 70, 7273, 75, 77
Fuel Filter Base ................................................... 56
Fuel Filter Pressure Differential Switch ................. 81
Fuel Temperature Sensor ................................ 8081
Fuel Transfer Pump ................................................. 5
G
Gear Group (Front)................................................ 61
Gear Group (Rear) .............................. 6263, 65, 67
H
Housing (Front)...................................................... 58
Housing (Rear) ...................................................... 59
T
Table of Contents..................................................... 3
Turbocharger ....................................... 16, 18, 2022
Turbocharger Inlet Pressure Sensor ............... 8687
V
Valve Mechanism ................................................ 89
Vibration Damper............................................. 4951
W
Water Pump........................................................... 43
Water Temperature Regulator ............................... 42
90
Index Section
SENR9936-06
SENR9936-06
91
Index Section
2008 Caterpillar
All Rights Reserved
Printed in U.S.A.

001a HM02316 - 00 Engine Specifications

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SENR9936-06

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Note: The front of the engine is opposite of the

Crankshaft rotation ................. Counterclockwise

Note: Number one cylinder is the front cylinder

Firing order ............ 1, 10, 9, 6, 5, 12, 11, 4, 3, 8, 7, 2

(A) Inlet valves

Bore ........................................ 137.2 mm (5.40 inch)

Stroke ..................................... 152.4 mm (6.00 inch)

(A) Inlet valves

Bore ............................................. 145 mm (5.7 inch)

Displacement ................................. 32 L (1953 cu in)

When the fuel transfer pump is using diesel fuel, the

Fuel Transfer Pump

Fuel Filter Base

SMCS Code: 1256

SMCS Code: 1261; 1262

Part No.: 286-2531

Part No.: 237-9307

Pressure regulating valve

Note: Maximum inlet pressure to the pump shall not

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

Part No.: 260-9631

(2) Torque for the stud ..... 70 15 Nm (50 11 lb ft)

Part No.: 255-8001, 260-9631

Fuel Filter Base

Part No.: 260-9631

Part No.: 255-8001, 260-9631

SMCS Code: 1261; 1262

Part No.: 255-8001, 260-9631

Part No.: 266-9459

Part No.: 255-8001, 260-9631

Part No.: 266-9459

Part No.: 255-8001, 260-9631

Part No.: 266-9459

Part No.: 260-9631

(A) Length for applying 154-9731 Thread Lock

Electronic Unit Injector

SMCS Code: 1290

Part No.: 255-8001, 260-9631

Note: Refer to Testing and Adjusting, Electronic Unit

Part No.: 255-8001, 260-9631

Note: Before installation of the unit injector, lubricate

(1) Torque for cap nut .. 2.50 0.25 Nm (22 2 lb in)

Part No.: 223-6408, 249-8717

Use the following procedure to tighten the bolt (3)

Part No.: 223-6408

1. Tighten the bolt for the clamp to 55 10 Nm

Part No.: 223-6408, 249-8717

Part No.: 223-6408, 249-8717

3. Tighten the bolt for the clamp again to 55 10 Nm

Electronic Unit Injector Rocker

Part No.: 223-6408

Part No.: 278-1363

Part No.: 223-6408

Note: The sleeve bearing and pin must not extend

Electronic Unit Injector Wiring

Note: Install the flat part of the connector seal against

Note: Refer to Testing and Adjusting, Engine Valve

Left side of engine

(1) Rocker arm