Captura 2022-01-19 A Las 4.09.46 P. M.

RENR5082-09
November 2012
Specifications
C280 Marine Engines
PKA1-Up (Engine)
NKB1-Up (Engine)
SCB1-Up (Engine)
TSJ1-Up (Engine)
LDL1-Up (Engine)
NDT1-Up (Engine)
RDW1-Up (Engine)
TDX1-Up (Engine)
SAFETY.CAT.COM
i05086812
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, including human factors
that can affect safety. 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
verify that you are authorized to perform this work, and 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.
A non-exhaustive list of 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. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. 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 you are authorized to perform this work, and that the
product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair
procedures that you intend to use.
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. Cat dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci-
fications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR5082-09 3
Table of Contents
Table of Contents Cylinder Block ...................................................... 68

Cylinder Block ...................................................... 71
Cylinder Block ...................................................... 76
Cylinder Liner ....................................................... 78
Specifications Section Piston and Rings (Three Ring Piston) .................. 78
Piston and Rings (Three Ring Piston) .................. 79
Engine Design ....................................................... 4
Connecting Rod ................................................... 80
Engine Design ....................................................... 4
Connecting Rod ................................................... 83
Engine Design ....................................................... 5
Connecting Rod and Main Bearing Journals ........ 84
Engine Design ....................................................... 5
Crankshaft ........................................................... 86
Fuel Injection Lines ................................................ 6
Crankshaft Seals ................................................. 89
Fuel Filter Housing .................................................. 8
Crankshaft Seals ................................................. 91
Fuel Transfer Pump ............................................... 9
Housing (Front) ..................................................... 93
Fuel Transfer Pump ............................................. 10
Gear Group (Front) ............................................... 95
Fuel Injector Mechanism ........................................ 11
Housing (Rear) ..................................................... 97
Fuel Injector .......................................................... 12
Housing (Rear) ..................................................... 99
Fuel Injector .......................................................... 12
Gear Group (Rear) .............................................. 100
Fuel Pressure Control Valve ................................. 13
Gear Group (Rear) .............................................. 103
Aftercooler ........................................................... 13
Manual Barring Group ........................................ 104
Aftercooler ........................................................... 14
Flywheel ............................................................. 105
Aftercooler ........................................................... 14
Engine Speed/Timing Wheel .............................. 106
Camshaft ............................................................. 15
Flexible Coupling ................................................ 107
Camshaft ............................................................. 17
Vibration Damper (Dual) ..................................... 108
Camshaft ............................................................. 18
Vibration Damper (Single) .................................. 109
Camshaft Bearings .............................................. 20
Vibration Damper (Single) ................................... 110
Camshaft Bearings .............................................. 21
Engine Lifting Bracket .......................................... 111
Camshaft Bearing Position .................................. 22
Engine Lifting Bracket .......................................... 112
Engine Support ................................................... 112
Engine Support ................................................... 113
Stub Shaft (Front) ................................................ 113
Valve Mechanism ................................................. 28
Stub Shaft (Front) ................................................ 114
Cylinder Head, Valves, Valve Springs and Valve Seat
Stub Shaft (Front) ................................................ 115
Inserts ................................................................. 30
Air Starting Motor ................................................ 116
Cylinder Head, Valves, Valve Springs and Valve Seat
Pressure Regulating Valve ................................. 116
Inserts ................................................................. 32
Pressure Regulating Valve ................................. 117
Compression Release Valve ................................. 34
Boost Pressure Sensor ........................................ 118
Manual Valve Group (Cylinder Pressure) ............. 35
Atmospheric Pressure Sensor ............................. 118
Turbocharger ........................................................ 36
Probe Adapter ...................................................... 119
Turbocharger ........................................................ 37
Probe Adapter ...................................................... 119
Exhaust Manifold ................................................. 38
Engine Speed Sensor ......................................... 120
Air Cleaner Adapter .............................................. 39
Prelube Pump Motors ......................................... 120
Air Inlet Elbow ....................................................... 39
Pressure Contactor ............................................. 121
Air Inlet Elbow ....................................................... 40
Pressure Transducer .......................................... 121
Air Inlet Shutoff ..................................................... 41
Pressure Transducer .......................................... 122
Air Shutoff ............................................................. 41
Pressure Switch .................................................. 122
Air Shutoff ............................................................. 42
Thermocouple ..................................................... 123
Prelube Pump ....................................................... 43
Prelube Pump ....................................................... 44
Engine Oil Pump .................................................. 45 Index Section
Engine Oil Pump .................................................. 47
Engine Centrifugal Oil Filter .................................. 51 Index ................................................................... 124
Engine Oil Filter ................................................... 51
Engine Oil Filter ................................................... 51
Priority Valve ........................................................ 54
Engine Oil Cooler ................................................. 55
Engine Oil Cooler ................................................. 55
Engine Oil Temperature Regulator ....................... 56
Crankcase Breather ............................................. 56
Water Temperature Regulator .............................. 57
Water Temperature Regulator .............................. 57
Water Pump ......................................................... 58
Auxiliary Water Pump (Sea Water) ....................... 63
Auxiliary Water Pump (Sea Water) ....................... 66
4 RENR5082-09
Specifications Section
Specifications Section When the crankshaft is viewed from the flywheel end,
the crankshaft rotates in the following direction.
i02508912 Standard rotation .......................... Counterclockwise

Engine Design Reverse rotation ....................................... Clockwise
SMCS Code: 1000 Note: The front end of the engine is opposite the
flywheel end of the engine. The left side and the right
S/N: TSJ1-Up
side of the engine are determined from the flywheel
S/N: RDW1-Up end. The number 1 cylinder is the front right cylinder.
i02508914
Engine Design
SMCS Code: 1000
S/N: NKB1-Up
S/N: TDX1-Up
g01192815
Illustration 1
Engine design
(A) Exhaust valve
(B) Inlet valve
(C) Flywheel
Number and arrangement of cylinders ............. V-12
Valves per cylinder

g01192830
Inlet valves ........................................................ 2 Illustration 2
Engine design
Exhaust valves ................................................. 2
(A) Exhaust valve
(B) Inlet valve
Displacement .......................... 221.7 L (13527 cu in) (C) Flywheel
Bore ............................................ 280 mm (11.0 inch) Number and arrangement of cylinders .............. V-16
Stroke ......................................... 300 mm (11.8 inch) Valves per cylinder
Compression ratio .............................................. 13:1 Inlet valves ........................................................ 2
Combustion ....................................... Direct Injection Exhaust valves ................................................. 2
Firing order Displacement .......................... 295.6 L (18036 cu in)
Standard rotation Bore ............................................ 280 mm (11.0 inch)

CCW ........................ 1-12-9-4-5-8-11-2-3-10-7-6
Reverse rotation Stroke ......................................... 300 mm (11.8 inch)
CW ........................... 1-6-7-10-3-2-11-8-5-4-9-12
Compression ratio .............................................. 13:1
Valve lash
Combustion ....................................... Direct Injection
Inlet ................................... 0.60 mm (0.024 inch)
Firing order
Exhaust ............................. 1.00 mm (0.040 inch)
Standard rotation
CCW .... 1-2-5-6-3-4-9-10-15-16-11-12-13-14-7-8
RENR5082-09 5
Reverse rotation Compression ratio .............................................. 13:1

CW ....... 1-8-7-14-13-12-11-16-15-10-9-4-3-6-5-2
Valve lash
Firing order
Inlet ................................... 0.60 mm (0.024 inch)
Standard rotation CCW .................... 1-5-3-6-2-4
Exhaust ............................. 1.00 mm (0.040 inch) Reverse rotation CW ........................ 1-4-2-6-3-5
When the crankshaft is viewed from the flywheel end, Valve lash
Inlet ..................................... 0.60 mm (.024 inch)
Standard rotation .......................... Counterclockwise
Exhaust ............................. 1.00 mm (0.040 inch)
Reverse rotation ....................................... Clockwise
When the crankshaft is viewed from the flywheel end,
Note: The front end of the engine is opposite the the crankshaft rotates in the following direction.
side of the engine are determined from the flywheel Standard rotation .......................... Counterclockwise
end. The number 1 cylinder is the front right cylinder.
i02509989 Note: The front end of the engine is opposite the

Engine Design side of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder.
SMCS Code: 1000
S/N: SCB1-Up i02508916
S/N: LDL1-Up Engine Design

SMCS Code: 1000
S/N: PKA1-Up
S/N: NDT1-Up
g00572932
Illustration 3
Engine design
(A) Inlet valve
(B) Exhaust valve
Number and arrangement of cylinders ........ In-line 6 g00572928

Illustration 4
Valves per cylinder Engine design

(A) Inlet valve
Inlet valves ........................................................ 2 (B) Exhaust valve
Exhaust valves ................................................. 2 Number and arrangement of cylinders ........ In-line 8

Displacement ............................. 110.8 L (6764 cu in) Valves per cylinder
Bore ............................................ 280 mm (11.0 inch) Inlet valves ........................................................ 2
Stroke ......................................... 300 mm (11.8 inch) Exhaust valves ................................................. 2

6 RENR5082-09
Displacement ............................ 147.8 L (9019 cu in)
Bore ............................................ 280 mm (11.0 inch)
Stroke ......................................... 300 mm (11.8 inch)
Compression ratio .............................................. 13:1
Firing order
Standard rotation CCW .............. 1-6-2-5-8-3-7-4
Reverse rotationCW ................... 1-4-7-3-8-5-2-6
g01979854
Valve lash Illustration 5
Inlet ................................... 0.60 mm (0.024 inch) (1) Connector .................. 105 ± 10 N·m (77 ± 7 lb ft)
Exhaust ............................. 1.00 mm (0.040 inch)
When the crankshaft is viewed from the flywheel end,

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

side of the engine are determined from the flywheel
end. The number 1 cylinder is the front cylinder.
i03683502
Fuel Injection Lines

SMCS Code: 1252
Part No.: 235-3362, 7E-1704
S/N: PKA1-Up
Part No.: 246-3392
S/N: NKB1-Up
Part No.: 235-3362, 7E-1704
S/N: SCB1-Up
g01979855
Illustration 6
Part No.: 235-3362, 7E-1704
S/N: TSJ1-Up (2) Connector .................. 105 ± 10 N·m (77 ± 7 lb ft)
Part No.: 235-3362, 7E-1704
S/N: LDL1-Up
Part No.: 235-3362, 7E-1704
S/N: NDT1-Up
Part No.: 235-3362, 7E-1704
S/N: RDW1-Up
Part No.: 235-3362, 7E-1704
S/N: TDX1-Up
Note: Lubricate the bores for the O-ring seals and

lubricate the O-ring seals lightly with clean diesel fuel.
RENR5082-09 7
g01979858
Illustration 9
View B of the fuel pressure regulator
(4) Connector .................. 105 ± 10 N·m (77 ± 7 lb ft)
After O-ring seal (5) and retainer (6) are installed,

Illustration 7
g01979856 lubricate setscrew (7) and lubricate the bore for
the setscrew in the valve's body with 1P-0808
Right side view of Vee engine
Multipurpose Grease.
(3) Connector .................. 105 ± 10 N·m (77 ± 7 lb ft) (7) Desired fuel pressure after adjustment of the
setscrew ................... 820 ± 20 kPa (119 ± 3 psi)
(8) Spring
Length under test force ...... 56 mm (2.2047 inch)
Test force .................................... 218.262 ± 17 N
(49.0675 ± 3.8218 lb)
Free length after test ......... 77 mm (3.0315 inch)
Outside diameter ........ 24.500 mm (0.9646 inch)
g01979857
Illustration 8
View A-A

8 RENR5082-09
i00637255
Fuel Filter Housing

SMCS Code: 1262
Part No.: 7W-1543
g00286930
Illustration 10
Front View
(1) Install the check valves so that the arrows point

in the direction of fuel flow.
(2) 2W-6862 Spring

Length under test force ....... 33.5 mm (1.32 inch)
Test force .......................... 222 ± 18 N (50 ± 4 lb)
Free length after test ...... 87.88 mm (3.460 inch)
g00286932
Illustration 11
End View
(3) 7C-0807 Spring

Length under test force ... 24.46 mm (0.963 inch)
Test force .......................... 140 ± 11 N (32 ± 3 lb)
Free length after test ...... 33.21 mm (1.307 inch)
RENR5082-09 9
i04981115
Fuel Transfer Pump

SMCS Code: 1256
Part No.: 240-8297
S/N: NKB1-Up
Part No.: 240-8297
S/N: TSJ1-Up
Part No.: 240-8297
S/N: RDW1-Up
Part No.: 240-8297
S/N: TDX1-Up
g03162097
Illustration 12
Table 1
Specification for 240-8297 Fuel Transfer Pump Gp
Item Qty Part Specification Description
1 1 238-0939 Spring Free length of spring is 57.1 mm (2.25 inch).
Minimum bypass cracking pressure is 965 kPa (140 psi).
2 1 4W-7990 Valve
Maximum bypass full open pressure is 1205 kPa (175 psi).
Diameter is 15.869 ± 0.006 mm (0.6248 ± 0.0002 inch).
3 1 4W-9325 Shaft As Bore in the bearing for shaft is 15.951 mm (0.6280 inch).
Width of gears is 41.815 ± 0.009 mm (1.6463 ± 0.0004 inch).
4 1 4W-9296 Shaft As Bore in the bearing for shaft is 15.951 mm (0.6280 inch).
Width of gears is 41.815 ± 0.009 mm (1.6463 ± 0.0004 inch).
10 RENR5082-09
i02388202
Fuel Transfer Pump

SMCS Code: 1256
Part No.: 235-3359
S/N: PKA1-Up
Part No.: 235-3359
S/N: SCB1-Up
Part No.: 235-3359
S/N: LDL1-Up
Part No.: 235-3359
S/N: NDT1-Up
g01192292
Illustration 13
(1) 238-0939 Spring

Free length of spring ........... 57.1 mm (2.25 inch)
Outside diameter ................ 31.7 mm (1.25 inch)
(2) Relief valve

Cracking pressure .................. 895 kPa (130 psi)
Fully open pressure .............. 1170 kPa (170 psi)
(3) Diameter of shafts ............... 15.869 ± 0.006 mm

(0.6248 ± 0.0002 inch)
Bore in bearings for shafts ...................... 15.951 mm

(0.6280 inch)
(4) Width of gears ..................... 29.224 ± 0.006 mm

(1.1505 ± 0.0002 inch)
RENR5082-09 11
i04987769
Fuel Injector Mechanism

SMCS Code: 1102; 1290
Part No.: 1W-0789
g03167202
Illustration 14
Table 2
Specification for 1W-0789 Valve Mechanism Gp

Tighten jam nuts after valve lash or Unit injector timing adjustment is
1 3 6V-5019 Jam Nut completed.
Torque to 200 ± 25 N·m (150 ± 18 lb ft).
Diameter of the new rocker arm shaft is 69.900 ± 0.015 mm
(2.7520 ± 0.0006 inch).
2 1 1W-8410 Arm Shaft Assembly
Diameter of bore in the bearings for rocker arm shaft is 70.000 ± 0.015 mm
(2.7559 ± 0.0006 inch).
- - Guide springs must not be reused. If the guide springs are removed,
3
always install new guide springs.
Diameter of a new lifter is 55.900 ± 0.010 mm (2.2008 ± 0.0004 inch).
4 1W-2470 Valve Lifter Group
Bore in the guide for the lifter is 56.000 ± 0.020 mm (2.2047 ± 0.0008 inch).
12 RENR5082-09
i04981251
Fuel Injector
SMCS Code: 1290
Part No.: 288-2403
g03162156
Illustration 15
Table 3
Specification for 288-2403 Fuel Injector Gp
Before assembly, lubricate the bore lightly with glycerin or approved equivalent.
Use clamp to draw the injector into the bore. Do not tap or hit the injector.
1 1 7S-3224 Bolt Torque to 215 ± 40 N·m (160 ± 30lb ft).
i02388589 Fuel injector installation

Fuel Injector 1. For lubrication of the O-ring seals, put
multipurpose grease in the bore of the cylinder
SMCS Code: 1290 head.
Part No.: 235-3336
2. Put the injector in the bore. Use the clamp bolt
(1) and the fuel injector clamp to push the injector
into the correct position.
Note: Do not tap or hit the injector.
3. Tighten the clamp bolt (1) that holds the fuel

injector clamp to the specified torque.
4. Be certain that the fuel injector body below the

solenoid is not in contact with the valve springs.
g01192446
Illustration 16
(1) Clamp bolt

Torque .................... 215 ± 40 N·m (159 ± 30 lb ft)
(2) Timing dimension

Timing dimension ........... 118.2 mm (4.6535 inch)
RENR5082-09 13
i02684388 i02657165
Fuel Pressure Control Valve Aftercooler

SMCS Code: 1715 SMCS Code: 1063
Part No.: 235-3362 Part No.: 185-5775
S/N: TSJ1-Up
Part No.: 185-5775
S/N: RDW1-Up
g01192903
Illustration 17
(1) Set the adjusting bolt in order to provide the

following fuel pressure. .................. 820 ± 20 kPa
(119 ± 3 psi)
g01334928
Illustration 18
(1) The aftercooler core must withstand the following

water pressure. ......................... 500 kPa (72 psi)
(2) Put a light coat of glycerin on all O-ring seals at

assembly.
(3) Bolt
Tighten 84 bolts.
Torque .......................... 50 ± 10 N·m (37 ± 7 lb ft)
14 RENR5082-09
i02657186 i02303991
Aftercooler Aftercooler
Part No.: 179-9333 Part No.: 175-1364
S/N: NKB1-Up S/N: PKA1-Up
Part No.: 179-9333 Part No.: 175-1364
S/N: TDX1-Up S/N: SCB1-Up
Part No.: 175-1364
S/N: LDL1-Up
Part No.: 175-1364
S/N: NDT1-Up
g01334935
Illustration 19

water pressure. ......................... 500 kPa (72 psi)
(2) Put a light coat of glycerin on all O-ring seals at Illustration 20

g01153635
assembly.
(3) Bolt water pressure. ......................... 500 kPa (72 psi)
Tighten 112 bolts.
(2) Put a light coat of glycerin on all O-ring seals at
Torque .......................... 50 ± 10 N·m (37 ± 7 lb ft) assembly.
(3) Torque for the retaining screws ......... 30 ± 7 N·m

(22 ± 5 lb ft)
RENR5082-09 15
i02306362
Camshaft
SMCS Code: 1210
Part No.: 179-3448, 179-3458, 7E-8158
S/N: NKB1-Up
Part No.: 179-3455
S/N: TSJ1-Up
Part No.: 179-3444, 179-3455, 7E-8151
S/N: RDW1-Up
Part No.: 179-3448, 179-3458, 7E-8158
g01192933
S/N: TDX1-Up Illustration 22
Location of dowels on the camshaft bearing journal
g00575160
Illustration 21
g01192943
Illustration 23
(1) Thickness of new thrust plate .. 15.00 ± 0.25 mm Location of dowels on the camshaft bearing journal
(0.600 ± 0.010 inch)
Thickness of surface on camshaft for new NOTICE

plate .............. 12.00 ± 0.05 mm (0.472 ± 0.002 inch) Correct cam segment relationship (timing) must be ob-
served at assembly. If the cam segments are out of
(2) Diameter of camshaft journal .. 173.80 ± 0.03 mm time, serious engine damage will occur.
(6.843 ± 0.001 inch)
Note: The position of the single dowel in relation to
Bore in camshaft bearing after the variable dowel determines the letter designation
installation ................................ 174.151 ± 0.020 mm of the cam journals. The single dowel is located on
(6.8563 ± 0.0008 inch) the same end as the locating groove. The variable
dowel is located on the end opposite the locating
(3) Thickness of the plate ............... 11.80 ± 0.05 mm groove.
(0.465 ± 0.002 inch)
(4) Locating groove
(5) Location of the single dowel in the face of the

camshaft bearing journal
Distance from the top of the dowel to the camshaft
bearing journal .. 7.0 ± 0.5 mm (0.28 ± 0.02 inch)
16 RENR5082-09
(6) Location of the variable dowel in the face of the (12) Rear of engine
camshaft bearing journal
(13) Front of engine
bearing journal .. 7.0 ± 0.5 mm (0.28 ± 0.02 inch)
g01192949
Illustration 24
Letter designation of C280-12 camshaft journals
(7) The C280-12 camshaft must be assembled in

an assembly fixture or the camshaft must be g00595829
assembled in the cylinder block. Illustration 26
The rolling torque for the C280-12 camshaft must be (14) Specified camshaft lobe lift
a maximum of the following value. .. 22 N·m (16 lb ft)
To find the specified camshaft lobe lift, use the
procedure that follows:
1. Measure the total height of the camshaft (15).
2. Measure base circle (16).
3. Subtract base circle (16) from the total height of

camshaft (15). The difference is the specified
camshaft lobe lift (14).
4. Specified camshaft lobe lift (14) for the camshaft

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

g01192963
Illustration 25
Inlet lobe ...................... 19.500 mm (0.7677 inch)
(8) The C280-16 camshaft must be assembled in Lobe for the fuel injection pump ......... 21.473 mm
an assembly fixture or the camshaft must be (0.8454 inch)
assembled in the cylinder block.
The rolling torque for the C280-16 must be a

maximum of the following value. ..... 28 N·m (21 lb ft)
(9) Camshaft bearing journals
Install the camshaft bearing journals with the grooved

end toward the front of the engine (13).
(10) Camshaft segments
Install the camshaft segments with the grooved

flange toward the front of the engine for SAE standard
rotation engines. Install the camshaft segments with
the grooved flange toward the rear of the engine for
SAE opposite rotation engines.
(11) Torque of the bolts for the camshaft

segment ................. 270 ± 40 N·m (200 ± 30 lb ft)
RENR5082-09 17
i02305891
Camshaft
SMCS Code: 1210
Part No.: 179-3440, 179-3451, 7E-8137
S/N: LDL1-Up
Part No.: 179-3442, 179-3453, 7E-8144
S/N: NDT1-Up
g00469453
Illustration 29
NOTICE
Correct cam segment relationship (timing) must be ob-
time, serious engine damage will occur.
Note: The position of the single dowel in relation to

the variable dowel determines the letter designation
of the cam journals. The single dowel is located on
the same end as the locating groove. The variable
groove.
g01192998
(5) Locating groove
Illustration 27
(6) Location of the single dowel in the face of the
(1) Timing bolt location camshaft bearing journal
(2) Diameter of camshaft journal .. 173.80 ± 0.03 mm Distance from the top of the dowel to the camshaft
(6.843 ± 0.001 inch) bearing journal .. 7.0 ± 0.5 mm (0.28 ± 0.02 inch)
Bore in camshaft bearing after (7) Location of the variable dowel in the face of the
installation .................................. 174.151 ± 0.02 mm camshaft bearing journal
(6.8563 ± 0.0008 inch)
(3) Thickness of new plate ............ 11.80 ± 0.05 mm bearing journal .. 7.0 ± 0.5 mm (0.28 ± 0.02 inch)
(0.465 ± 0.002 inch)
g01193020
Illustration 30
g01193003
Illustration 28
18 RENR5082-09


is the following value:
g01193058
Illustration 31
Letter designation of C280-8 camshaft journals Exhaust lobe ................ 19.500 mm (0.7677 inch)
(8) Camshaft bearing journal Inlet lobe ...................... 19.500 mm (0.7677 inch)
Install the camshaft bearing journals with the grooved Lobe for the fuel injection pump ......... 21.473 mm
end toward the front of the engine. (0.8454 inch)
(9) Camshaft segments i02657287
Install the camshaft segments with the grooved Camshaft

flange toward the rear of the engine for SAE standard
rotation engines. Install the camshaft segments with SMCS Code: 1210
the grooved flange toward the front of the engine for
SAE opposite rotation engines. Part No.: 7E-7200
S/N: PKA1-Up
(10) Torque of the bolts for the camshaft
Part No.: 7E-7199
segment ................. 270 ± 40 N·m (200 ± 30 lb ft)
S/N: SCB1-Up
(11) The camshaft must be assembled in an Part No.: 7E-7199
assembly fixture or the camshaft must be S/N: LDL1-Up
Part No.: 7E-7200
Apply a force at the rear end of the camshaft S/N: NDT1-Up
(11). The rolling torque for the C280-6 must be a
maximum of the following value. ............. 22 N·m
(16 lb ft)
Apply a force at the rear end of the camshaft
(11). The rolling torque for the C280-8 must be a
maximum of the following value. ............. 28 N·m
(21 lb ft)
g00289772 g00515083
Illustration 32 Illustration 33
(12) Specified camshaft lobe lift (1) Diameter of camshaft journal .. 173.80 ± 0.03 mm
(6.843 ± 0.001 inch)
procedure that follows: Bore in camshaft bearing after
installation ... 174.00 ± 0.05 mm (6.850 ± 0.002 inch)
RENR5082-09 19
(2) Thickness of new plate ............ 11.80 ± 0.05 mm Distance from the top of the dowel to the camshaft
(0.465 ± 0.002 inch) bearing journal .. 7.0 ± 0.5 mm (0.28 ± 0.02 inch)
(3) Timing bolt location
g00289771
Illustration 36
Letter designation of 3606 camshaft journals
g00289768
Illustration 34
g00469407
Illustration 37
Letter designation of 3608 camshaft journals
g00469453
Illustration 35
Location of dowels on the camshaft bearing journal (8) Camshaft bearing journal
NOTICE Install the camshaft bearing journals with the grooved

Correct cam segment relationship (timing) must be ob- end toward the front of the engine.
time, serious engine damage will occur. (9) Camshaft segments
Install the camshaft segments with the grooved

Note: The position of the single dowel in relation to flange toward the rear of the engine for standard
the variable dowel determines the letter designation rotation engines. Install the camshaft segments with
of the cam journals. The single dowel is located on the grooved flange toward the front of the engine for
the same end as the locating groove. The variable reverse rotation engines.
groove. (10) Tighten the bolts for the camshaft segment to
the following torque. ...................... 270 ± 40 N·m
(5) Locating groove (200 ± 30 lb ft)
(6) Location of the single dowel in the face of the (11) The camshaft must be assembled in an
camshaft bearing journal assembly fixture or the camshaft must be
bearing journal .. 7.0 ± 0.5 mm (0.28 ± 0.02 inch) Apply a force at the rear end of the camshaft
(11). The rolling torque for the 3606 must be a
(7) Location of the variable dowel in the face of the maximum of the following value. ............. 22 N·m
camshaft bearing journal (16 lb ft)
20 RENR5082-09
Apply a force at the rear end of the camshaft i01130581

(11). The rolling torque for the 3608 must be a
maximum of the following value. ............. 28 N·m Camshaft Bearings
(21 lb ft)
SMCS Code: 1211
S/N: NKB1-Up
S/N: TSJ1-Up
S/N: RDW1-Up
S/N: TDX1-Up
g00289772
Illustration 38
(12) Specified camshaft lobe lift

procedure that follows:

g00480148
Illustration 39
is the following value: Note: The left camshaft bearings and the right
camshaft bearings in the rear of the cylinder block
Exhaust lobe ................ 19.500 mm (0.7677 inch) must be installed so that the engine timing pin
will pass freely through the cylinder block and the
Inlet lobe ...................... 19.500 mm (0.7677 inch) bearing.
Lobe for fuel injection pump ............... 21.473 mm (1) Angle from the horizontal centerline to the
(0.8454 inch) center of the timing pin hole in the rear camshaft
bearings ...................................... 25 ± 5 degrees
(2) Install the camshaft bearings with the bearing

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

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

journals ....... 173.80 ± 0.03 mm (6.843 ± 0.001 inch)
RENR5082-09 21
i00641074
Camshaft Bearings
SMCS Code: 1211
S/N: PKA1-Up
S/N: SCB1-Up
S/N: LDL1-Up
S/N: NDT1-Up
g00287581
Illustration 40
Note: Install the camshaft bearings with the bearing

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

installation .............................. 174.00 ± 0.06 mm
(6.850 ± .002 inch)
Diameter of camshaft journals ..... 173.80 ± 0.03 mm

(6.843 ± .001 inch)
Note: The camshaft bearing in the rear of the cylinder

block must be installed so that the engine timing pin
will pass freely through the cylinder block and the
bearing.
(2) Distance from the top surface of the

cylinder block to the center line of the oil
hole .......... 206.00 ± 0.50 mm (8.110 ± .020 inch)
22 RENR5082-09
i02306622
Camshaft Bearing Position

SMCS Code: 1211
S/N: TSJ1-Up
S/N: RDW1-Up
g00480206
Illustration 41
Right side view
The right camshaft bearings from the front surface of (E) ................... 919.0 ± 1.5 mm (36.18 ± 0.06 inch)
the cylinder block are the following dimensions:
(F) ................... 459.0 ± 1.5 mm (18.07 ± 0.06 inch)
(A) ............... 2759.0 ± 1.0 mm (108.62 ± 0.04 inch)
(G) .......................... 8 ± 1.5 mm (0.315 ± 0.06 inch)
(B) ................. 2299.0 ± 1.5 mm (90.51 ± 0.06 inch)
(C) ................. 1839.0 ± 1.5 mm (72.40 ± 0.06 inch)
(D) ................. 1379.0 ± 1.5 mm (54.29 ± 0.06 inch)

RENR5082-09 23
g00480207
Illustration 42
Left side view
The left camshaft bearings from the front surface of

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

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

24 RENR5082-09
i02306627

SMCS Code: 1211
S/N: NKB1-Up
S/N: TDX1-Up
g00480325
Illustration 43
Right side view
The right camshaft bearings from the front surface of (H) ................... 459.0 ± 1.5 mm (18.07 ± 0.06 inch)
(I) ............................ 8 ± 1.5 mm (0.315 ± 0.06 inch)
(A) ............... 3679.0 ± 1.0 mm (144.84 ± 0.04 inch)
(B) ............... 3219.0 ± 1.5 mm (126.73 ± 0.06 inch)
(C) ............... 2759.0 ± 1.0 mm (108.62 ± 0.04 inch)
(D) ................. 2299.0 ± 1.5 mm (90.51 ± 0.06 inch)
(E) ................. 1839.0 ± 1.5 mm (72.40 ± 0.06 inch)
(F) ................. 1379.0 ± 1.5 mm (54.29 ± 0.06 inch)
(G) ................... 919.0 ± 1.5 mm (36.18 ± 0.06 inch)

RENR5082-09 25
g00480328
Illustration 44
Left side view
The left camshaft bearings from the front surface of

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

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

26 RENR5082-09
i00641062

SMCS Code: 1211
S/N: SCB1-Up
S/N: LDL1-Up
g00287545
Illustration 45
The camshaft bearings from the rear surface of the (F) ..................... 440.0 ± 1.5 mm (17.32 ± .06 inch)
cylinder block are the following dimensions:
(G) ......................... 30.0 ± 1.0 mm (1.18 ± .04 inch)
(A) ................... 2490.0 ± 1.5 mm (98.03 ± .06 inch)
(B) ................... 2080.0 ± 1.5 mm (81.89 ± .06 inch)
(C) ................... 1670.0 ± 1.5 mm (65.75 ± .06 inch)
(D) ................... 1260.0 ± 1.5 mm (49.61 ± .06 inch)
(E) ..................... 850.0 ± 1.5 mm (33.47 ± .06 inch)

RENR5082-09 27
i01426579

SMCS Code: 1211
S/N: PKA1-Up
S/N: NDT1-Up
g00467571
Illustration 46
The camshaft bearings from the rear surface of the (J) ........................ 30.0 ± 1.0 mm (1.18 ± 0.04 inch)
cylinder block are the following dimensions:
(A) ............... 3310.0 ± 1.5 mm (130.32 ± 0.06 inch)
(B) ................ 2900.0 ± 1.5 mm (114.17 ± 0.06 inch)
(C) ................. 2490.0 ± 1.5 mm (98.03 ± 0.06 inch)
(D) ................. 2080.0 ± 1.5 mm (81.89 ± 0.06 inch)
(E) ................. 1670.0 ± 1.5 mm (65.75 ± 0.06 inch)
(F) ................. 1260.0 ± 1.5 mm (49.61 ± 0.06 inch)
(G) ................... 850.0 ± 1.5 mm (33.47 ± 0.06 inch)
(H) ................... 440.0 ± 1.5 mm (17.32 ± 0.06 inch)

28 RENR5082-09
i04984450
Valve Mechanism
SMCS Code: 1102
Part No.: 1W-0789
g03164477
Illustration 47
RENR5082-09 29
Table 4
Specification for 1W-0789 Valve Mechanism Gp
Tighten jam nuts after valve lash or Unit injector timing adjustment is
1 3 6V-5019 Jam Nut completed.
Torque to 200 ± 25 N·m (150 ± 18 lb ft).
Before assembly, lubricate the arm shaft assembly and the rocker arms
(3).
Assemble bearing in rocker arm so that the oil holes are aligned
2 1 1W-8410 Arm Shaft Assembly Diameter of new rocker arm shaft is 69.900 ± 0.015 mm
(2.7520 ± 0.0006 inch).
Diameter of bore in new bearings for new rocker arm shaft is
70.000 ± 0.015 mm (2.7559 ± 0.0006 inch).
Valve lash adjustment:
4 - - Inlet valve clearance is 0.60 ± 0.08 mm (0.024 ± 0.003 inch).
Exhaust valve clearance is 1.00 ± 0.08 mm (0.039 ± 0.003 inch).
5 2 8L-3441 Nut Torque to 100 ± 15 N·m (75 ± 11 lb ft).
Diameter of bridge dowel is 19.055 ± 0.003 mm (0.7502 ± 0.0001 inch).
Diameter of bore in bridge is 19.162 ± 0.030 mm (0.7544 ± 0.0012 inch).
6 2 4W-5441 Bridge Guide Dowel
Diameter of bore in cylinder head plug for dowel is 19.017 ± 0.020 mm
(0.7487 ± 0.0008 inch).
7 2 6V-5625 Bolt Torque to 430 ± 60 N·m (320 ± 44 lb ft).
- - Guide springs must not be reused. If the guide springs are removed,
8
always install new guide springs.
9 2 6V-6869 Bolt Torque to 430 ± 60 N·m (320 ± 44 lb ft).
Diameter of a new lifter is 41.910 ± 0.010 mm (1.6500 ± 0.0004 inch).
10 1 1W-2470 Valve Lifter Group
Bore in the guide for the lifter is 42.000 ± 0.020 mm (1.6535 ± 0.0008 inch).
30 RENR5082-09
i02686581
Cylinder Head, Valves, Valve

Springs and Valve Seat Inserts
SMCS Code: 1101; 1103; 1104; 1105; 1108
Part No.: 296-6835
g01193067
Illustration 48
(1) Assembled height of rocker arm support (6) 1W-1748 Spring (outer spring)
dowels .............. 8.0 ± 1.0 mm (0.32 ± 0.04 inch)
(2) Inside diameter of assembled valve Test force ...................... 758 ± 76 N (170 ± 17 lb)
guides .................................. 16.031 ± 0.028 mm Free length after test ......... 114.0 mm (4.49 inch)
(0.6311 ± 0.0011 inch) Outside diameter ................ 68.0 mm (2.68 inch)
(3) Assembled height of valve (7) Procedure to tighten the cylinder head nuts
guides ............. 20.0 ± 2.0 mm (0.79 ± 0.08 inch)
1. Lubricate the washer face and the stud threads
(4) Assembled height of bridge with 5P-3931 Anti-Seize Compound.
dowels .......... 105.0 ± 2.0 mm (4.13 ± 0.08 inch)
2. Assemble the cylinder head, the seals, the gasket
(5) 1W-1749 Spring (inner spring) and the washers. Tighten the nuts by hand.
Length under test force ....... 79.3 mm (3.12 inch) 3. Simultaneously tension each pair of the studs with
Test force .......................... 361 ± 36 N (80 ± 8 lb) either of the following tensioners:
Free length after test ........ 107.0 mm (4.21 inch)
RENR5082-09 31
207-5034 Stud Tensioner Tool Bore in head for valve seat

Gp ................ 40000 ± 1520 kPa (5800 ± 220 psi) inserts ... 97.000 ± 0.025 mm (3.8189 ± 0.0010 inch)
191-5320 Stud Tensioner Tool (14) Angle of face of valve seat inserts
Gp ............ 125000 ± 4920 kPa (18130 ± 715 psi)
Inlet ................................... 20.75 ± 0.15 degrees
Tighten the nuts by hand. Slowly release the Exhaust ............................. 30.75 ± 0.15 degrees
pressure.
Full face contact is required between both the valve
4. Repeat Step 3. and the insert for the full 360 degrees. The minimum
width of the seat is the following dimension. .. 3.0 mm
(8) Torque for pressure relief plug ....... 275 ± 25 N·m (0.12 inch)
(200 ± 18 lb ft)
(15) Maximum recess from the closed valve face to
(9) Thickness of combustion the surface of the cylinder head ............. 2.0 mm
gasket ....... 4.20 ± 0.05 mm (0.160 ± 0.004 inch) (0.08 inch)
Surfaces must be parallel within the following Maximum projection of the closed valve above the
dimension. .............................. 0.03 mm (0.001 inch) surface of the cylinder head .... 0.50 mm (0.020 inch)
(10) Angle of valve face (16) Outside diameter of the head of the inlet
valve ....... 90.00 ± 0.20 mm (3.543 ± 0.008 inch)
Angle of the inlet valve
face ................................... 20.25 ± 0.10 degrees Outside diameter of head of the exhaust
Angle of the exhaust valve valve ............. 90.00 ± 0.20 mm (3.543 ± 0.008 inch)
face ................................... 30.25 ± 0.10 degrees
(17) The minimum valve lip thickness that can be
used again is the following dimension. .. 5.40 mm
(0.213 inch)
g00290111
Illustration 49
Inlet And Exhaust Valves
(11) Depth of bore for new valve seat

insert ....... 24.00 ± 0.15 mm (0.945 ± 0.006 inch)
(12) Valve stem

Coat the inlet valve stems and the exhaust valve
stems with 8T-2998 Lubricant prior to installation
in the cylinder head.
Minimum diameter of valve stem ...... 15.629 mm
(0.6153 inch)
Install the valve guide into the cylinder head.

The bore in the new valve guide is the following
dimension. ................................. 16.031 ± 0.028 mm
(0.6311 ± 0.0011 inch)
(13) Diameter of valve seat

inserts .................................. 97.195 ± 0.015 mm
(3.8266 ± 0.0006 inch)
32 RENR5082-09
i02684405
Cylinder Head, Valves, Valve

Springs and Valve Seat Inserts
SMCS Code: 1101; 1103; 1104; 1105; 1108
Part No.: 256-7231
g01193067
Illustration 50
(1) Assembled height of rocker arm support (6) 1W-1748 Spring (outer spring)
dowels .............. 8.0 ± 1.0 mm (0.32 ± 0.04 inch)
(2) Inside diameter of assembled valve Test force ...................... 758 ± 76 N (170 ± 17 lb)
guides .................................. 16.031 ± 0.028 mm Free length after test ......... 114.0 mm (4.49 inch)
(0.6311 ± 0.0011 inch) Outside diameter ................ 68.0 mm (2.68 inch)
(3) Assembled height of valve (7) Procedure to tighten the cylinder head nuts
guides ............. 20.0 ± 2.0 mm (0.79 ± 0.08 inch)
1. Lubricate the washer face and the stud threads
(4) Assembled height of bridge with 5P-3931 Anti-Seize Compound.
dowels .......... 105.0 ± 2.0 mm (4.13 ± 0.08 inch)
2. Assemble the cylinder head, the seals, the gasket
(5) 1W-1749 Spring (inner spring) and the washers. Tighten the nuts by hand.
Length under test force ....... 79.3 mm (3.12 inch) 3. Simultaneously tension each pair of the studs with
Test force .......................... 361 ± 36 N (80 ± 8 lb) either of the following tensioners:
Free length after test ........ 107.0 mm (4.21 inch)
RENR5082-09 33
207-5034 Stud Tensioner Tool Bore in head for valve seat

Gp ................ 40000 ± 1520 kPa (5800 ± 220 psi) inserts ... 97.000 ± 0.025 mm (3.8189 ± 0.0010 inch)
191-5320 Stud Tensioner Tool (14) Angle of face of valve seat

Gp ............ 125000 ± 4920 kPa (18130 ± 715 psi) inserts ............................... 30.75 ± 0.15 degrees
Tighten the nuts by hand. Slowly release the Full face contact is required between both the valve
pressure. and the insert for the full 360 degrees. The minimum
width of the seat is the following dimension. .. 3.0 mm
4. Repeat Step 3. (0.12 inch)
(8) Torque for pressure relief plug ....... 275 ± 25 N·m (15) Maximum recess from the closed valve face to
(200 ± 18 lb ft) the surface of the cylinder head ............. 2.0 mm
(0.08 inch)
(9) Thickness of combustion
gasket ....... 4.20 ± 0.05 mm (0.160 ± 0.004 inch) Maximum projection of the closed valve above the
surface of the cylinder head .... 0.50 mm (0.020 inch)
Surfaces must be parallel within the following
dimension. .............................. 0.03 mm (0.001 inch) (16) Outside diameter of the head of the inlet
valve ....... 90.00 ± 0.20 mm (3.543 ± 0.008 inch)
(10) Angle of valve face
Outside diameter of head of the exhaust
Angle of the inlet valve valve ............. 90.00 ± 0.20 mm (3.543 ± 0.008 inch)
face ................................... 30.25 ± 0.10 degrees
Angle of the exhaust valve (17) The minimum valve lip thickness that can be
face ................................... 30.25 ± 0.10 degrees used again is the following dimension. .. 5.40 mm
(0.213 inch)
g00290111
Illustration 51
Inlet And Exhaust Valves
(11) Depth of bore for new valve seat

insert ....... 24.00 ± 0.15 mm (0.945 ± 0.006 inch)
(12) Valve stem

Coat the inlet valve stems and the exhaust valve
stems with 8T-2998 Lubricant prior to installation
in the cylinder head.
Minimum diameter of valve stem ...... 15.629 mm
(0.6153 inch)
Install the valve guide into the cylinder head.

The bore in the new valve guide is the following
dimension. ................................. 16.031 ± 0.028 mm
(0.6311 ± 0.0011 inch)
(13) Diameter of valve seat

inserts .................................. 97.195 ± 0.015 mm
(3.8266 ± 0.0006 inch)
34 RENR5082-09
i04981414
Compression Release Valve

SMCS Code: 1118
Part No.: 7W-9957
g03162271
Illustration 52
Table 5
Specifications for 7W-9957 Compression Release Valve Gp
Length under test force is 90.0 mm (3.54 inch).
1 1 197-4708 Spring Test force is 3300 ± 100 N (742 ± 22 lb).
Free length after test is 103.5 mm (4.07 inch).
Use the following procedure to install the compression release valve:
2 1 - Tighten the valve body to 275 ± 25 N·m (203 ± 18 lb ft).

Run the engine for at least four minutes at rated conditions.
Again, tighten the valve body to 275 ± 25 N·m (203 ± 18 lb ft).
Use the following procedure in order to set the compression release valve:
Turn the adapter (5) until the seat (1) opens at 20940 ± 300 kPa
(3037.13760 ± 43.51200 psi).
3 1 - Once the setting is made, rotate the adapter (5) until the flat that requires the
least rotational movement is perpendicular with a hole in the body.
Tighten the set screw (3).
The minimum travel of the seat (1) after the setting of the set screw (3) is
0.85 mm (0.033 inch)
RENR5082-09 35
i04981411
Manual Valve Group (Cylinder

Pressure)
SMCS Code: 1223
Part No.: 197-5805
g03162268
Illustration 53
Table 6
Specifications for 197-5805 Manual Valve Gp

- Before assembly, apply Loctite C5A copper antiseize to the threads.

1 1
Tighten the cap to 17 ± 3 N·m (150 ± 27 lb in).
- Apply Loctite C5A copper antiseize to the threads of the stem. Orient the
2 1
valve so that the valve stem points to the up position.
3 1 - Tighten the nut to 50 ± 3 N·m (37 ± 2 lb ft).
4 1 - Lubricate the threads with Loctite C5A copper antiseize.
(1) Cap
Put 5P-3931 Anti-Seize Compound on the
threads of the cap
Torque for the cap .......... 17 ± 3 N·m (13 ± 2 lb ft)
(2) Put 5P-3931 Anti-Seize Compound on the

threads of the stem. Orient the valve so that the
valve stem points to the up position.
(3) Nut torque ...................... 50 ± 3 N·m (37 ± 2 lb ft)
Put 5P-3931 Anti-Seize Compound on the threads

of the valve at assembly.
Note: If a coupling or an adapter is used in assembly,

put 5P-3931 Anti-Seize Compound on the threads
before installation.
36 RENR5082-09
i01039213
Turbocharger
SMCS Code: 1052
Part No.: 157-5514, 189-4427
S/N: SCB1-Up
Part No.: 157-5514, 189-4427
S/N: TSJ1-Up
Part No.: 157-5514, 189-4427
S/N: LDL1-Up
Part No.: 157-5514, 189-4427
S/N: RDW1-Up
g00536086
Illustration 54
(1) Torque for impeller retaining bolt ..... 48 ± 12 N·m (5) Tighten the bolts to the following
(35 ± 9 lb ft) torque. ........................... 30 ± 7 N·m (22 ± 5 lb ft)
(2) Tighten the bolts to the following (6) Tighten the bolts to the following
torque. ......................... 50 ± 10 N·m (37 ± 7 lb ft) torque. ......................... 50 ± 10 N·m (37 ± 7 lb ft)
torque. ......................... 50 ± 10 N·m (37 ± 7 lb ft) torque. ........................... 15 ± 3 N·m (11 ± 2 lb ft)
torque. ........................... 30 ± 7 N·m (22 ± 5 lb ft) torque. ......................... 50 ± 10 N·m (37 ± 7 lb ft)
RENR5082-09 37
(9) Tighten the bolts to the following

torque. ......................... 50 ± 10 N·m (37 ± 7 lb ft)
i02308873
Turbocharger
SMCS Code: 1052
Part No.: 284-8276
S/N: PKA1-Up
Part No.: 284-8276
S/N: NKB1-Up
Part No.: 258-2287, 258-2288, 258-2291,
284-8276
S/N: NDT1-Up
Part No.: 258-2287, 258-2288, 258-2291,
284-8276
S/N: TDX1-Up
g01156365
Illustration 55
(1) Bolt torque ................... 67 ± 10 N·m (50 ± 7 lb ft) (4) Torque for the jam nut ........................ 10 ± 2 N·m
(7.5 ± 1.5 lb ft)
(2) Nut torque .................... 50 ± 10 N·m (37 ± 7 lb ft)
(3) Bolt torque ...................... 6 ± 1 N·m (4.5 ± 1 lb ft)
38 RENR5082-09
i01010957
Exhaust Manifold
SMCS Code: 1059
Part No.: 126-3577
S/N: PKA1-Up
Part No.: 125-2453
S/N: NKB1-Up
Part No.: 126-3572
S/N: SCB1-Up
Part No.: 112-3432
S/N: TSJ1-Up
Part No.: 126-3572
S/N: LDL1-Up
g00518568
Illustration 57
Part No.: 126-3577
S/N: NDT1-Up
Part No.: 112-3432 threads of the bolts and tighten the bolts to the
S/N: RDW1-Up following torque. .......... 55 ± 10 N·m (40 ± 7 lb ft)
Part No.: 125-2453 (2) Put 5P-3931 Anti-Seize Compound on the

S/N: TDX1-Up threads of the plug and tighten the plug to the
following torque. ...... 130 ± 15 N·m (96 ± 11 lb ft)

threads of the adapter and tighten the adapter to
the following torque. ...................... 200 ± 25 N·m
(150 ± 18 lb ft)

threads of the caps at assembly.
(5) Put 5P-3931 Anti-Seize Compound on

the washer face and tighten the bolts for
mounting the exhaust manifold to the following
torque. ..................... 120 ± 20 N·m (90 ± 15 lb ft)

threads of the bolts and tighten the bolts to the
following torque. .... 135 ± 20 N·m (100 ± 15 lb ft)
g00518570
Illustration 56
RENR5082-09 39
i01956929 i01044727
Air Cleaner Adapter Air Inlet Elbow

Part No.: 154-1252, 4W-3618, 7W-4916 Part No.: 2W-3333
S/N: PKA1-Up
Part No.: 154-1252, 4W-3618, 7W-4916
S/N: NKB1-Up
Part No.: 4W-3618, 7W-4916
S/N: SCB1-Up
Part No.: 4W-3618, 7W-4916
S/N: TSJ1-Up
Part No.: 4W-3618, 7W-4916
S/N: LDL1-Up
Part No.: 154-1252, 4W-3618, 7W-4916
S/N: NDT1-Up
g00545811
Illustration 59
Part No.: 4W-3618, 7W-4916
S/N: RDW1-Up (1) Tighten the bolts to the following
Part No.: 154-1252, 4W-3618, 7W-4916 torque. ......................... 75 ± 10 N·m (55 ± 7 lb ft)
S/N: TDX1-Up
g00289587
Illustration 58
(1) Assemble the two tandem clamps around the

hose.
Maximum torque on clamp bolts .. 10 N·m (7 lb ft)
40 RENR5082-09
i04974992
Air Inlet Elbow

SMCS Code: 1071
Part No.: 190-3600
S/N: PKA1-Up
Part No.: 190-3600
S/N: NKB1-Up
Part No.: 190-3600
S/N: NDT1-Up
Part No.: 190-3600
S/N: TDX1-Up
g03158184
Illustration 60
Table 7
Specification for 190-3600 Air Inlet Elbow Gp

Assemble the two tandem clamps around the hose.
1 8 116-8535 Clamp
Maximum torque on clamp bolts is 10 N·m (89 lb in).
RENR5082-09 41
i01130659 (4) After the bevel washer is properly installed,

tighten the capscrews to the following
Air Inlet Shutoff torque. ........................... 25 ± 6 N·m (18 ± 4 lb ft)
SMCS Code: 1078
i03318640
Part No.: 150-7891
S/N: PKA1-Up Air Shutoff
Part No.: 150-7891 SMCS Code: 1078
S/N: SCB1-Up
Part No.: 317-9554
Part No.: 150-7891 S/N: NKB1-Up
S/N: LDL1-Up
Part No.: 317-9554
Part No.: 150-7891 S/N: TSJ1-Up
S/N: NDT1-Up
Part No.: 317-9554
S/N: RDW1-Up
Part No.: 317-9554
S/N: TDX1-Up
g00535450
Illustration 61
(1) Cylinder assembly

Maximum pressure to the cylinder
assembly .............................. 1720 kPa (250 psi)
The cylinder assembly must not trip below the
following pressure, and the cylinder assembly
must not trip at the following pressure. .. 515 kPa
(74 psi)
The supply pressure should be above
the following value for consistent g01697635
Illustration 63
operation. .............................. 1100 kPa (160 psi)
(1) Manual reset shaft
(2) Manual pull knob
Minimum actuation pressure ........... 515 kPa (75 psi)
Maximum allowable supply pressure ......... 1720 kPa

(250 psi)
Minimum supply pressure ........... 1100 kPa (160 psi)
The air shutoff must be operated after every 150

hours of service or the air shutoff must be operated
weekly.
g00535487
Illustration 62
(2) Body
(3) Cover
42 RENR5082-09
i04974749
Air Shutoff
SMCS Code: 1078
Part No.: 352-2419
S/N: NKB1-Up
Part No.: 352-2419
S/N: TSJ1-Up
Part No.: 352-2419
S/N: RDW1-Up
Part No.: 352-2419
S/N: TDX1-Up
g03157967
Illustration 64
RENR5082-09 43
Table 8
Specification for 352-2419 Air Shutoff Gp
1 2 8L-2779 O-Ring Seal Before assembly, lubricate the bore lightly with 5P-3975 Rubber Lubricant.
2 1 5P-5599 O-Ring Seal Before assembly, lubricate the bore lightly with 5P-3975 Rubber Lubricant.
3 1 180-3916 Spring Free length is 248.4 mm (9.78 inch).
4 1 061-7540 O-Ring Seal Before assembly, lubricate the bore lightly with 5P-3975 Rubber Lubricant.
5 1 150-7917 Spring Free length is 50.8 mm (2.00 inch).
6 1 5P-5600 O-Ring Seal Before assembly, lubricate the bore lightly with 5P-3975 Rubber Lubricant.
7 1 6V-6228 O-Ring Seal Before assembly, lubricate the bore lightly with 5P-3975 Rubber Lubricant.
Minimum supply pressure is 1100 kPa (160 psi).
- - -
Maximum supply pressure is 1720 kPa (249 psi).
i04969511
Prelube Pump
SMCS Code: 1319
Part No.: 1W-0899
g03152736
Illustration 65
44 RENR5082-09
Table 9
Specification for 1W-0899 Prelubrication Oil Pump Gp and 1W-4776 Prelubrication Oil Pump Gp
- - Depth of the idler pocket is between 31.72 to 31.76 mm

A
(1.249 to 1.250 inch).
B - - Bore of bearing after installation is 19.13 mm (0.753 inch).
C 1 3N-1285 Rotor Outside diameter is 85.53 ± 0.02 mm (3.367 ± 0.001 inch).
D 1 3N-1284 Idler As Thickness is 31.790 ± 0.010 mm (1.2516 ± 0.0004 inch).
The clearance between the back of the rotor and the
- - - machined surface in the bottom housing is 0.013 ± 0.076 mm
(0.0005 ± 0.0030 inch).
i01100050 (3) Outside diameter of the

rotor .................................. 85.509 to 85.547 mm
Prelube Pump (3.3665 to 3.3680 inch)
SMCS Code: 1319 (4) Idler pocket
Part No.: 173-3853, 221-0129 Depth of the idler pocket (air driven
pump) ............................... 31.725 to 31.750 mm
(1.2490 to 1.2500 inch)
Depth of the idler pocket (electrically driven
pump) ......................... 21.340 mm (0.8402 inch)
g00288335
Illustration 66
(1) Inside diameter of idler gear bearing .. 19.126 mm

(0.7530 inch)
(2) Idler gear

Thickness of idler gear in the air driven
pump ................................. 31.775 to 31.801 mm
(1.2510 to 1.2520 inch)
Thickness of electrically driven idler
gear .... 22.25 to 22.28 mm (0.876 to 0.877 inch)
Pump end clearance

Measure the clearance between the back of the
rotor and the machined surface in the bottom
housing. ................................ 0.013 to 0.076 mm
(0.0005 to 0.0030 inch)
RENR5082-09 45
i02099558 The maximum permissible temperature for installation

of the gear .......................................... 316°C (601°F)
Engine Oil Pump
(4) Length of gears
SMCS Code: 1304
4W-4458 Drive Shaft
Part No.: 2W-5577 Assembly ............................. 95.000 ± 0.020 mm
S/N: PKA1-Up (3.7402 ± 0.0008 inch)
4W-4459 Drive Shaft
Part No.: 2W-5584
Assembly ........................... 120.000 ± 0.020 mm
S/N: SCB1-Up
(4.7244 ± 0.0008 inch)
Part No.: 1W-0797 4W-4460 Drive Shaft
S/N: TSJ1-Up Assembly ........................... 140.000 ± 0.020 mm
(5.5118 ± 0.0008 inch)
Part No.: 2W-5584 4W-4482 Idler Shaft
S/N: LDL1-Up Assembly ........................... 120.000 ± 0.020 mm
(4.7244 ± 0.0008 inch)
Part No.: 2W-5577 4W-4483 Idler Shaft
S/N: NDT1-Up Assembly ............................. 95.000 ± 0.020 mm
Part No.: 1W-0797 (3.7402 ± 0.0008 inch)
S/N: RDW1-Up 4W-4484 Idler Shaft
Assembly ........................... 140.000 ± 0.020 mm
(5.5118 ± 0.0008 inch)
(5) Diameter of idler shaft ......... 59.930 ± 0.010 mm

(2.3594 ± 0.0004 inch)
g00288421
Illustration 68
(6) Distance from the top of the dowels to the surface

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

shaft ...................................... 60.115 ± 0.020 mm
(2.3667 ± 0.0008 inch)
g00288420
Illustration 67
(8) Install the bearings in the cover to the following
depth. ........ 7.50 ± 0.25 mm (0.295 ± 0.010 inch)
(1) Diameter of new drive shaft .. 59.930 ± 0.010 mm
(2.3594 ± 0.0004 inch)
(9) Bore in bearing for drive
shaft ...................................... 60.115 ± 0.020 mm
(2) Distance from the end of the drive shaft to the
(2.3667 ± 0.0008 inch)
gear face ....... 169.5 ± 0.5 mm (6.67 ± 0.02 inch)
(10) Align the oil holes in the bearings with the oil
The maximum permissible temperature for installation
holes in the cover.
of the gear .......................................... 316°C (601°F)
(3) Distance from the end of the idler shaft to the

gear face ......... 52.5 ± 0.5 mm (2.07 ± 0.02 inch)
46 RENR5082-09
(16) Install the dowel in this position for a

counterclockwise rotation of the engine.
(17) Install the dowel in this position for a clockwise

rotation of the engine.
g00288422
Illustration 69
(11) Bearings
To minimize the press fit, cool the bearings and
the bearing driver.
Temperature ............................ 75 °C ( 103 °F)
(11) Depth of bearings in the
housing .............................. 12.30 ± 0.25 mm
(0.484 ± 0.010 inch)
(12) Bore in bearings in

housing ................................ 60.126 ± 0.040 mm
(2.3672 ± 0.0016 inch)
(13) Align the oil hole in the bearing with the oil hole
in the housing.
(14) End clearance between the gears and the

housing ... 0.14 to 0.26 mm (0.006 to 0.010 inch)
g00288423
Illustration 70
(15) Oil pump cover assembly

Height of dowel ....... 8 ± 1 mm (0.32 ± 0.04 inch)
RENR5082-09 47
i04971912
Engine Oil Pump

SMCS Code: 1304
Part No.: 4W-0675
S/N: NKB1-Up
Part No.: 4W-0675
S/N: TDX1-Up
g03155436
Illustration 71
(4) Drive shaft assembly (5) Idler shaft assembly
Table 10
Specification for 4W-0675 Engine Oil Pump Gp

1 1 6V-7702 O-Ring Seal Before assembly, lightly lubricate the bore that is being sealed.
Assemble the dowel in the position (2) for counter clockwise engine
rotation.
6 1 6V-3538 Dowel
Assemble the dowel in the position (3) for clockwise engine rotation.
Extension of dowel is 8.00 ± 1.00 mm (0.315 ± 0.039 inch).
Prior to operation, the pump bearings must have an external supply
- - - of oil. Before the pump is operated, lubricate the pump with oil.
Rotate the pump by hand and make sure that the pump rotates
freely.
- - - Nominal flow with the pump at 1524 rpm is 1800 L/min

(476 US gpm).
48 RENR5082-09
g03155439
Illustration 72
Table 11
- - Depth of the bearings in the cover is 7.50 ± 0.25 mm

E
(0.295 ± 0.009 inch).
Distance from the top of the dowels to the surface of the cover is
F 2 7N-5683 Dowel
12.00 ± 1.00 mm (0.472 ± 0.039 inch).
Bore of bushing after installation is 60.115 ± 0.020 mm
G 1 4W-3997 Bushing
(2.3667 ± 0.0008 inch).
Bore of bushing after installation is 60.115 ± 0.020 mm
H 1 4W-3996 Bushing
(2.3667 ± 0.0008 inch).
Before assembly, cool the bearings and the bearing driver to 75° C
- - - ( 103° F) to minimize the press fit.
Align the oil holes in the bearing with the oil holes in the cover.
g03155440
Illustration 73
RENR5082-09 49
Table 12
Outer diameter of bushing is 66.126 ± 0.020 mm
(2.6034 ± 0.0008 inch).
Thickness is 3.000 ± 0.013 mm (0.1181 ± 0.0005 inch).
J 2 7E-7066 Bushing
Before assembly, cool the bearings and the bearing driver to
75° C ( 103° F) to minimize the press fit.
Align the oil holes in the bearing with the oil holes in the body.
- - Depth of the bearings in the body is 12.30 ± 0.25 mm

K
(0.484 ± 0.010 inch).
L - - Depth of body assembly is 155 mm (6 inch).
g03155437
Illustration 74
(4) Drive shaft assembly
Table 13
- - Distance from the end of the drive shaft to the gear face is
M
169.50 ± 0.50 mm (6.673 ± 0.020 inch).
N 1 7W-2825 Pump Drive Shaft Diameter is 59.930 ± 0.010 mm (2.3594 ± 0.0004 inch).
Length is 155.000 ± 0.020 mm (6.1024 ± 0.0008 inch).
P 1 4W-6856 Gear Maximum permissible temperature of the gear for shrinking is
316° C (601° F).
50 RENR5082-09
g03155438
Illustration 75
(5) Idler shaft assembly
Table 14
- - Distance from the end of the idler shaft to the gear face is
R
51.00 ± 0.50 mm (2.008 ± 0.020 inch).
S 1 2W-8274 Idler Shaft Diameter is 59.930 ± 0.010 mm (2.3594 ± 0.0004 inch).
Length is 155.000 ± 0.020 mm (6.1024 ± 0.0008 inch).
T 1 4w-6859 Gear Maximum permissible temperature of the gear for shrinking is
316° C (601° F).
RENR5082-09 51
i04981116
Engine Centrifugal Oil Filter

SMCS Code: 1328
Part No.: 1W-0806
g03162116
Illustration 76
Table 15
Specification for 1W-0806 Centrifugal Oil Filter Gp

Torque to 55 ± 10 N·m
1 4 2D-8154 Taperlock Stud
(41 ± 7 lb ft)
i01089975 (2) Put clean engine oil on the O-ring seals at

assembly.
Engine Oil Filter
SMCS Code: 1318 i04976850
Part No.: 7C-9591 Engine Oil Filter

SMCS Code: 1318
Part No.: 1W-0798
g00284480
Illustration 77
(1) Hex head on shaft flange ................... 25 ± 1 mm

(0.98 ± 0.04 inch)
52 RENR5082-09
g03159636
Illustration 78
RENR5082-09 53
Table 16
Specification for 1W-0798 Engine Oil Filter Gp
1 1 7X-4789 Quad Ring Seal Before assembly, lightly lubricate the bore with clean engine oil.
2 2 2W-6862 Spring Test force is 222 ± 18 N (50 ± 4 lb).
3 1 6V-0973 O-Ring Seal Before assembly, lightly lubricate the bore with clean engine oil.
4 2 6V-3683 O-Ring Seal Before assembly, lightly lubricate the bore with clean engine oil.
5 1 6V-6963 Quad Ring Seal Before assembly, lightly lubricate the bore with clean engine oil.
6 4 259-4600 O-Ring Seal Before assembly, lightly lubricate the bore with clean engine oil.
7 1 5P-7818 O-Ring Seal Before assembly, lightly lubricate the bore with clean engine oil.
8 1 4P-9174 Detent As Before assembly, apply green Loctite 609 to threads.
9 1 3N-1308 Spring Free length after test is 37.80 ± 0.38 mm (1.488 ± 0.015 inch).
D 1 6V-3980 Dowel Extension of dowel is 25.00 ± 1.00 mm (0.984 ± 0.039 inch).
54 RENR5082-09
i04974990
Priority Valve
SMCS Code: 1327
Part No.: 1W-0804
g03158178
Illustration 79
Table 17
Specification for 1W-0804 Priority Valve Gp
Length under test force is 164 mm (6.5 inch).
1W-2240 Control Valve
1 1 Test force is 435 ± 22 N (98 ± 5 lb).
Spring
2 1 2G-5664 Spring Test force is 3425 ± 169 N (770 ± 38 lb).
RENR5082-09 55
i01039621 i00606491
Engine Oil Cooler Engine Oil Cooler

Part No.: 4P-2302 Part No.: 1W-0809
S/N: PKA1-Up S/N: PKA1-Up
Part No.: 1W-0887 Part No.: 1W-0809
S/N: NKB1-Up S/N: SCB1-Up
S/N: SCB1-Up S/N: TSJ1-Up
Part No.: 1W-0887 Part No.: 1W-0809
S/N: TSJ1-Up S/N: LDL1-Up
S/N: LDL1-Up S/N: NDT1-Up
S/N: NDT1-Up S/N: RDW1-Up
Part No.: 1W-0887
S/N: RDW1-Up
Part No.: 1W-0887
S/N: TDX1-Up
g00284482
Illustration 81
(1) Dimension between the centerline of the

first bolt hole and the face of the oil cooler
bonnets ............. 436 ± 1 mm (17.17 ± 0.04 inch)
g00536388
Illustration 80
(1) During assembly, put a light coat of glycerin on

the O-ring seals. Also, put a light coat of glycerin
in the bores of the elbow.
(2) The dimension between the centerline of the first

bolt hole and the face of the oil cooler bonnets is
the following value. .......................... 344 ± 1 mm
(13.54 ± 0.04 inch)
56 RENR5082-09
i01571825 i02310247
Engine Oil Temperature Crankcase Breather

Regulator SMCS Code: 1317
SMCS Code: 1330 Part No.: 254-6938
S/N: PKA1-Up
Part No.: 120-9453
Part No.: 254-6939
S/N: NKB1-Up
Part No.: 254-6938
S/N: SCB1-Up
Part No.: 254-6939
S/N: TSJ1-Up
Part No.: 254-6938
S/N: LDL1-Up
Part No.: 254-6938
S/N: NDT1-Up
Part No.: 254-6939
g00274459
Illustration 82 S/N: RDW1-Up
When the oil temperature regulator is completely Part No.: 254-6939

open, the temperature is the following value. .. 85 °C S/N: TDX1-Up
(185°F)
Minimum opening distance at 85 °C

(185 °F) ..................................... 10.4 mm (0.41 inch)
g01157144
Illustration 83
(1) Clamps
Torque ....................... 4 ± 0.5 N·m (35.5 ± 5 lb in)
(2) Clamps
Torque ........................ 7 ± 1.5 N·m (62 ± 13 lb in)
(3) O-ring seals
Apply clean engine oil in the bores.

RENR5082-09 57
i01957045
Water Temperature Regulator

SMCS Code: 1355
Part No.: 6I-4953
g00286978
Illustration 84
Fully open temperature ........................ 37 °C (99 °F)
Minimum opening distance at 37 °C

(99 °F) ....................................... 10.4 mm (0.41 inch)
i04981271
Water Temperature Regulator

SMCS Code: 1355
Part No.: 198-3427
g00286978
Illustration 85
Table 18
Specifications for 198-3427 Water Temperature Regulator

Fully open temperature is 95 °C (203 °F)
198-3427 Water Temperature
1 1 Minimum opening distance at 95 °C (203 °F) is 10.4 mm
Regulator
(0.41 inch)
58 RENR5082-09
i04966709
Water Pump
SMCS Code: 1361
Part No.: 7E-8180
S/N: PKA1-Up
Part No.: 7E-8181
S/N: NKB1-Up
Part No.: 7E-8180
S/N: SCB1-Up
Part No.: 7E-8181
S/N: TSJ1-Up
Part No.: 7E-8180
S/N: LDL1-Up
Part No.: 7E-8180
S/N: NDT1-Up
Part No.: 7E-8181
S/N: RDW1-Up
Part No.: 7E-8181
S/N: TDX1-Up
g03150596
Illustration 86
RENR5082-09 59
Table 19
Specification for 304-4948 Water Pump Gp , 7E-3172 Water Pump Gp , 7E-8180 Water
Pump Gp , and 7E-8181 Water Pump Gp
Before assembly, lightly lubricate the bore with 5P-3975 Rubber
Lubricant.
Use the 8T-3034 Water Pump Seal Driver and hand pressure in
order to install the water seal (2) and the ring together in the pump
housing bore. Ensure that the polished face of the ring is toward
the groove of the seal assembly.
Before assembly, remove the spring from the seal.
Put clean water on the seal assembly as the only lubrication for
assembly. Do not get any grease or oil on the seal faces.
1 1 292-5982 Face Seal Gp
Do not stretch the rubber of the seal assembly at installation. If the
seal is stretched, the service life is shortened.
Use the 8T-3034 Water Pump Seal Driver and hand pressure
to install the seal assembly on the pump shaft until the seal face
makes light contact with the smooth face of the ring.
The seal assembly must rotate with the water pump shaft. Do not
use any lubricant (except clean water) that will reduce the friction
between the seal and the shaft.
Install the carbon seal assembly spring.
3 1 134-5958 O-Ring Seal
Lubricant.
4 1 6V-7701 O-Ring Seal
Lubricant.
- - Diameter of the shaft at the seat area of the carbon seal assembly
A
is 44.45 ± 0.02 mm (1.750 ± 0.001 inch).
- - Diameter of the impeller shaft at the location of the lip type seal is
B
49.20 ± 0.20 mm (1.937 ± 0.008 inch).
C - - Diameter of impeller shaft is 64.85 ± 0.02 mm (2.553 ± 0.001 inch).
- - Diameter of the impeller shaft at the support end is

D
88.878 ± 0.013 mm (3.4991 ± 0.0005 inch).
Width of groove in the impeller shaft is 12.00 ± 0.05 mm
E 1 1W-2828 Thrust Washer
(0.472 ± 0.002 inch).
End play for impeller shaft is 0.05 to 0.25 mm (0.002 to 0.009 inch).
60 RENR5082-09
g03150667
Illustration 87
Table 20
- - Dimension between surface of pump housing to 188-0449

F
Bushing (6) is 92.50 ± 1.00 mm (3.642 ± 0.039 inch).
- - Bore of 188-0449 Bushing (6) after installation is 65.00 ± 0.02 mm

J
(2.559 ± 0.001 inch).
- - Bore of 188-0450 Bushing (5) after installation is 89.08 ± 0.02 mm

K
(3.507 ± 0.001 inch).
RENR5082-09 61
g03150676
Illustration 88
Section G-G
Table 21
- - Install the 188-0450 Bushing (5) with the bearing joint at a 15

L
degree angle from the vertical centerline of the pump housing.
62 RENR5082-09
g03150679
Illustration 89
Section H-H
Table 22
- - Install the 188-0449 Bushing (6) with the bearing joint at a 5

M
degree angle from the horizontal centerline of the pump housing.
RENR5082-09 63
i01022547
Auxiliary Water Pump

(Sea Water)
SMCS Code: 1371
Part No.: 7E-8182
g00525257
Illustration 90
(1) Diameter of the shaft at the seat area of the a. Remove the spring from the seat.
carbon seal assembly ......... 44.450 ± 0.020 mm
(1.7500 ± 0.0008 inch) b. Put clean water on the seal assembly as the
only lubrication for assembly. DO NOT get any
(2) Seal assembly grease or oil on the seal faces.
1. Ring and water seal c. DO NOT stretch the rubber of the seal
assembly at installation. If the seal is stretched,
a. Lubricate the housing bore with a light amount the service life is shortened.
of glycerin.
d. Use the 8T-3034 Water Pump Seal Driver and
b. Use the 8T-3034 Water Pump Seal Driver hand pressure to install the seal assembly on
and hand pressure in order to install the seal the pump shaft until the seal face makes light
(3) and the ring together in the pump housing contact with the smooth face of the ring.
bore. Ensure that the polished face of the ring
is toward the groove of the seal assembly. Note: The seal assembly must rotate with the water
pump shaft. DO NOT use any lubricant (except clean
2. Seal assembly. water) that will reduce the friction between the seal
and the shaft.
64 RENR5082-09
e. Install the carbon seal assembly spring.
(3) Seal. Put a light coat of glycerin on the seal and

in the housing bore at assembly.
(4) Diameter of the impeller shaft at the location of

the lip type seal .................... 49.200 ± 0.020 mm
(1.9370 ± 0.0008 inch)
(5) Diameter of impeller shaft .... 64.850 ± 0.020 mm

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

end. ...................................... 88.878 ± 0.013 mm
(3.4991 ± 0.0005 inch)

threads of the bolt at assembly.
(8) Tighten the plug to the following

torque. ......................... 100 ± 5 N·m (75 ± 4 lb ft)
(9) Put a light coat of glycerin on the O-ring seal

at assembly. Put a light coat of glycerin in the
housing bore at assembly.
(10) Put a light coat of clean engine oil on the seal at

assembly.
(11) Thickness of thrust washer ..... 11.85 ± 0.05 mm

(0.467 ± 0.002 inch)
Width of groove in the impeller shaft for the thrust

washer .......... 12.00 ± 0.05 mm (0.472 ± 0.002 inch)
g00525370
Illustration 91
End play for impeller shaft .............. 0.05 to 0.25 mm
(0.002 to 0.010 inch) (12) Bore in impeller shaft bearing .. 65.00 ± 0.06 mm
(2.559 ± 0.002 inch)
(13) Dimension of impeller shaft bearing from surface

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

(3.507 ± 0.002 inch)
The shaft support bearing should be flush with the

surface of the pump housing during installation.
RENR5082-09 65
(18) Install the shaft support bearing (14) with the

bearing joint at a 15 degree angle from the
vertical centerline of the pump housing.
g00525411
Illustration 92
Positioning Impeller Shaft Bearing
View A-A
(15) The oil hole in the impeller shaft bearing (12)

from the horizontal centerline of the pump
housing is the following angle. .... 50 ± 1 degrees
(16) Install the impeller shaft bearing (12) with

the bearing joint at a 5 degree angle from the
horizontal centerline of the pump housing.
g00525452
Illustration 93
Positioning Shaft Support Bearing
View B-B
(17) The oil hole in the shaft support bearing (14)

from the vertical centerline of the pump housing
is the following angle. ................. 60 ± 1 degrees
66 RENR5082-09
i01023156
Auxiliary Water Pump

(Sea Water)
SMCS Code: 1371
Part No.: 130-6765
S/N: NKB1-Up
Part No.: 130-6765, 130-6771
S/N: TDX1-Up
g00525819
Illustration 94
Typical Example
(1) Diameter of the shaft at the seat area of the b. Use the 8T-3034 Water Pump Seal Driver
carbon seal assembly ......... 44.450 ± 0.020 mm and hand pressure in order to install the seal
(1.7500 ± 0.0008 inch) (3) and the ring together in the pump housing
bore. Ensure that the polished face of the ring
(2) Seal assembly is toward the groove of the seal assembly.
1. Ring and water seal 2. Seal assembly.
a. Lubricate the housing bore with a light amount a. Remove the spring from the seat.
of glycerin.
b. Put clean water on the seal assembly as the
only lubrication for assembly. DO NOT get any
grease or oil on the seal faces.
RENR5082-09 67
c. DO NOT stretch the rubber of the seal

assembly at installation. If the seal is stretched,
the service life is shortened.
d. Use the 8T-3034 Water Pump Seal Driver and

hand pressure to install the seal assembly on
the pump shaft until the seal face makes light
contact with the smooth face of the ring.
Note: The seal assembly must rotate with the water

pump shaft. DO NOT use any lubricant (except clean
water) that will reduce the friction between the seal
and the shaft.
e. Install the carbon seal assembly spring.
(3) Seal. Put a light coat of glycerin on the seal and

in the housing bore at assembly.
(4) Diameter of the impeller shaft at the location of

the lip type seal .................... 49.200 ± 0.020 mm
(1.9370 ± 0.0008 inch)
(5) Diameter of impeller shaft .... 64.850 ± 0.020 mm

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

end. ...................................... 88.878 ± 0.013 mm
(3.4991 ± 0.0005 inch)

threads of the bolt at assembly.
(8) Put a light coat of glycerin on the O-ring seal

at assembly. Put a light coat of glycerin in the Illustration 95
g00525960
housing bore at assembly.
(11) Bore in impeller shaft bearing .. 65.00 ± 0.06 mm
(9) Put a light coat of clean engine oil on the seal at (2.559 ± 0.002 inch)
assembly.
(12) Dimension of impeller shaft bearing from surface
(10) Thickness of thrust washer ..... 11.85 ± 0.05 mm of pump housing .......................... 92.5 ± 1.0 mm
(0.467 ± 0.002 inch) (3.64 ± 0.04 inch)
Width of groove in the impeller shaft for the thrust (13) Bore in shaft support bearing .. 89.08 ± 0.06 mm
washer .......... 12.00 ± 0.05 mm (0.472 ± 0.002 inch) (3.507 ± 0.002 inch)
End play for impeller shaft .............. 0.05 to 0.25 mm The shaft support bearing should be flush with the
(0.002 to 0.010 inch) surface of the pump housing during installation.
68 RENR5082-09
(17) Install the shaft support bearing (13) with the

bearing joint at a 15 degree angle from the
vertical centerline of the pump housing.
i02693050
Cylinder Block
SMCS Code: 1201
Part No.: 149-0481
S/N: TSJ1-Up
Part No.: 149-0481
S/N: RDW1-Up
g00525966
Illustration 96
Positioning Impeller Shaft Bearing
View A-A
(14) The oil hole in the impeller shaft bearing (11)

from the horizontal centerline of the pump
housing is the following angle. .... 50 ± 1 degrees
(15) Install the impeller shaft bearing (11) with

the bearing joint at a 5 degree angle from the
horizontal centerline of the pump housing.
g00480024
Illustration 98
(1) Cylinder head studs
Install the cylinder head studs with the following

procedure:
1. Coat the lower half of each stud with 1.5 mm

(0.06 inch) thick coating of 4C-4774 Water and
Temperature Resistant Grease.
Illustration 97
g00525970 2. Thoroughly clean the top of the cylinder block.
Positioning Shaft Support Bearing
3. Install the cylinder head studs.
View B-B
Tighten the cylinder head studs to the following
(16) The oil hole in the shaft support bearing (13) torque. ....................... 100 ± 20 N·m (75 ± 15 lb ft)
from the vertical centerline of the pump housing
is the following angle. ................. 60 ± 1 degrees
RENR5082-09 69
4. Apply a bead of sealant at the top of the block 3. Tighten all side bolts by hand. Ensure that the
around each stud. This will ensure that the washer face and the side bolt threads have a
counterbore is filled with grease. clean coating of 4C-5593 Anti-Seize Compound.
Ensure that all surfaces that contact the bearing
5. Coat the upper half of each stud with 1.5 mm are free of 4C-5593 Anti-Seize Compound.
(.06 inch) thick coating of 4C-4774 Water and
Temperature Resistant Grease. 4. Start at the front face of the block.
(2) Apply 8T-9014 Silicone Sealant to the covers Tighten the side bolts on the side of the cap with
when the covers are installed to the block. the tab slot to the following torque. .. 215 ± 40 N·m
(160 ± 30 lb ft)
(3) The dowels protrude from the rear face
of the cylinder block at the following 5. Simultaneously tension each pair of the studs with
distance. ......... 20.0 ± 1.0 mm (0.79 ± 0.04 inch) either of the following tensioners:
(4) The dowels protrude from the front face 207-5034 Stud Tensioner Tool
of the cylinder block at the following Gp ................ 65000 ± 2400 kPa (9425 ± 350 psi)
distance. ......... 20.0 ± 1.0 mm (0.79 ± 0.04 inch)
191-5320 Stud Tensioner Tool
Gp ............. 111500 ± 3950 kPa (16200 ± 575 psi)
Tighten the nuts by hand. Slowly release the

pressure.
6. Repeat Step 5.
(8) Bore in the block for main

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

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

(10.5118 ± 0.0008 inch)
(9) Tighten the side bolts according to the following

procedure.
g00480025 1. Start at the front face of the block.

Illustration 99
Front view of cylinder block Tighten the side bolts on the side of the
cap opposite the tab slot to the following
(5) The dowels protrude above the cylinder block torque. ..................... 215 ± 40 N·m (160 ± 30 lb ft)
face at the following distance. ..... 60.0 ± 1.0 mm
(2.36 ± 0.04 inch) 2. Start at the front face of the block.
(6) The dowels protrude above the cylinder block Tighten the side bolts on the side of the cap with the
face at the following distance. ....... 8.0 ± 1.0 mm tab slot to the following torque. ... 1825 ± 175 N·m
(0.32 ± 0.04 inch) (1340 ± 130 lb ft)
(7) Procedure for tightening the main bearings 3. Start at the front face of the block.
1. Torque the studs in the cylinder block. Tighten the side bolts on the side of the
Torque for the studs .. 100 ± 20 N·m (75 ± 15 lb ft) torque. ............. 1825 ± 175 N·m (1340 ± 130 lb ft)
2. Assemble the main bearing cap and the washer.
Hand tighten the nut.
70 RENR5082-09
(14) Main bearing cap
g00480026
Illustration 100
Rear view of cylinder block
(10) The center line of the camshaft bearing

bore to the top surface of the cylinder
block .............. 206.0 ± 5.0 mm (8.11 ± 0.20 inch)
(11) The dowels protrude above the cylinder block

face at the following distance. ....... 8.0 ± 1.0 mm
(0.32 ± 0.04 inch)
(12) Width of main bearing cap ... 499.95 ± 0.03 mm

(19.683 ± 0.001 inch)
Width of cylinder block for main bearing

cap ............ 500.00 ± 0.05 mm (19.685 ± 0.002 inch)
Clearance between the sides of the main bearing cap

and the cylinder block ..................... 0.03 to 0.13 mm
(0.001 to 0.005 inch)
g00480066
Illustration 101
Main bearing cap
(13) The dowel protrudes from the main bearing cap

at the following distance. ............. 10.0 ± 0.5 mm
(0.39 ± 0.02 inch)
RENR5082-09 71
i04981329
Cylinder Block
SMCS Code: 1201
Part No.: 149-0483
S/N: NKB1-Up
Part No.: 149-0483
S/N: TDX1-Up
g03162196
Illustration 102
Right side view
72 RENR5082-09
g03162197
Illustration 103
Left side view
Table 23
Specification for 149-0483 Cylinder Block Gp

1 25 6V-4589 O-Ring Seal Before assembly, lubricate the bore lightly with clean engine oil.
2 32 6V-3539 Dowel Protrusion (C) of the dowel is 60.0 ± 1.0 mm (2.36 ± 0.04 inch).
3 35 6V-3538 Dowel Protrusion (D) of the dowel is 8.0 ± 1.0 mm (0.31 ± 0.04 inch).
4 4 7N-2328 Dowel Protrusion (G) of the dowel is 20.0 ± 1.0 mm (0.79 ± 0.04 inch).
5 20 8L-2786 O-Ring Seal Before assembly, lubricate the bore lightly with clean engine oil.
6 1 3P-0651 O-Ring Seal Before assembly, lubricate the bore lightly with clean engine oil.
7 2 3P-0656 O-Ring Seal Before assembly, lubricate the bore lightly with clean engine oil.
8 16 175-5060 Sleeve Install the sleeve with the marked “TOP” toward up.
RENR5082-09 73
g03162198
Illustration 104
Table 24

L - - Bore in cylinder block for main bearing is 265.00 ± 0.02 mm (10.433 ± 0.001 inch).
- - The distance from the centerline of the crankshaft bearing bore to the top of the
M
cylinder block is 946.0 mm (37.24 inch).
- - The distance from the centerline of the crankshaft bearing bore to the bottom of the
N
cylinder block is 405.0 mm (15.94 inch).
The Bearing cap assembly must be installed with the part number toward the front
of the block. The number of the main bearing cap must also match the cast number
on the left side of each main bearing saddle.
124-1836 Bearing Width in the cylinder block for the bearing cap assembly is 500.00 ± 0.05 mm
9 9 (19.685 ± 0.002 inch).
Cap As
Width (P) of bearing cap assembly is 499.95 ± 0.03 mm (19.683 ± 0.001 inch).
Protrusion of 6V-3538 Dowel from the bearing cap assembly is 10.0 ± 0.5 mm
(0.39 ± 0.02 inch).
74 RENR5082-09
g03162281
Illustration 105
RENR5082-09 75
Table 25
10 16 218-0660 Bolt Torque to 1800 ± 200 N·m (1328 ± 148 lb ft).
Use the following procedure to install the taperlock stud in the cylinder block:
1. Coat the half of each taperlock stud with 1.5 mm (0.06 inch) thick coating of
187-0450 Taperlock 4C-4774 Water and Temperature Resistant Grease.
11 64
Stud 2. Install taperlock stud in the cylinder block.
3. Tighten the taperlock stud to 100 ± 20 N·m (74 ± 15 lb ft).
4. Coat the upper half of each taperlock stud with 1.5 mm (0.06 inch) thick coating
of 4C-4774 Water and Temperature Resistant Grease.
12 18 3S-7079 Bolt
Use the following procedure in order to tighten the main bearing assembly:
1. Again, tighten taperlock stud (15) in the cylinder block to 100 ± 20 N·m
(74 ± 15 lb ft).
2. Assemble bearing cap assembly (9), washer (13), and hand tighten the nut (14).
3. Assemble all side bolt (12) on the tab slot side of the cap and hand tighten bolt
13 18 1W-0122 Washer (12). Before assembly, lubricate washer face “13” and the threads of the bolts
with clean engine oil.
4. Starting at front face of the block, tighten the side bolt (12) on the tab slot side of
the cap to 215 ± 40 N·m (159 ± 30 lb ft).
5. Starting at front face of the block, simultaneously tension each pair of taperlock
stud (15) with either tensioner 207-5034 Stud Tensioner Tool Gp or tensioner
191-5320 Stud Tensioner Tool Gp. Apply 1415000 ± 50000 N (318106 ± 11240 lb)
force for each stud. Hand tighten nut (14) and slowly release the pressure.
14 18 1W-0123 Nut 6. Repeat Step 5.
7. Repeat sequentially Step 6 and Step 7 for cap 2 through cap 9.
8. Assemble all side bolt (12) on the side opposite to the tab slot side of the
cap and hand tighten bolt (12). Before assembly, lubricate washer face “13” and
threads of the bolts with clean engine oil.
9. Starting at front face of the block, tighten the side bolt (12) on the side opposite
to the tab slot side of the cap to 215 ± 40 N·m (159 ± 30 lb ft).
10. Starting at front face of the block, tighten the side bolt (12) on tab slot side of
the cap to 1825 ± 175 N·m (1346 ± 129 lb ft).
11. Starting at front face of the block, tighten the side bolt (12) on the side opposite
15 8 1W-0121 Taperlock Stud
to the tab slot side of the cap to 1825 ± 175 N·m (1346 ± 129 lb ft).
16 8 8S-4757 Bolt Torque to 1125 ± 100 N·m (830 ± 74 lb ft).

17 16 7B-8363 Bolt Torque to 1125 ± 100 N·m (830 ± 74 lb ft).
76 RENR5082-09
i02693063 4. Apply a bead of sealant at the top of the block

around each stud. This will ensure that the
Cylinder Block counterbore is filled with grease.
SMCS Code: 1201 5. Coat the upper half of each stud with 1.5 mm
(0.06 inch) thick coating of 4C-4774 Water and
Part No.: 121-6023
Temperature Resistant Grease.
S/N: PKA1-Up
Part No.: 145-9313 (2) The dowels protrude from the front face
S/N: SCB1-Up of the cylinder block at the following
distance. ........... 8.0 ± 1.0 mm (0.32 ± 0.04 inch)
Part No.: 145-9313
S/N: LDL1-Up (3) The dowels protrude from the rear face
of the cylinder block at the following
Part No.: 121-6023 distance. ......... 20.0 ± 1.0 mm (0.79 ± 0.04 inch)
S/N: NDT1-Up
(4) The dowels protrude from the front face of the
cylinder block at the following distance.
7N-2328 Dowel .......................... 20.0 ± 1.0 mm
(0.79 ± 0.04 inch)
g01193083
Illustration 106
Right Side View
(1) Cylinder head studs

g01193086
Install the cylinder head studs with the following Illustration 107
procedure: Front view of cylinder block
1. Coat the lower half of each stud with 1.5 mm (5) The dowels protrude above the cylinder block
(0.06 inch) thick coating of 4C-4774 Water and face at the following distance. ....... 8.0 ± 1.0 mm
Temperature Resistant Grease. (0.32 ± 0.04 inch)
2. Thoroughly clean the top of the cylinder block. (6) The dowels protrude above the cylinder block
face at the following distance. ..... 60.0 ± 1.0 mm
3. Install the cylinder head studs. (2.36 ± 0.04 inch)
Tighten the cylinder head studs to the following Apply 4C-4774 Water and Temperature Resistant
torque. ....................... 100 ± 20 N·m (75 ± 15 lb ft) Grease to the dowel before the head is assembled.
RENR5082-09 77
(7) Bore in the block for main Tighten the side bolts on the side of the cap with the
bearings ............................. 265.000 ± 0.020 mm tab slot to the following torque. ... 1825 ± 175 N·m
(10.4330 ± 0.0008 inch) (1340 ± 130 lb ft)
1.00 mm (0.040 inch) oversize .. 266.000 ± 0.020 mm 10. Start at the front face of the block.
(10.4724 ± 0.0008 inch)
Tighten the side bolts on the side of the
2.00 mm (0.080 inch) oversize .. 267.000 ± 0.020 mm cap opposite the tab slot to the following
(10.5118 ± 0.0008 inch) torque. ............. 1825 ± 175 N·m (1340 ± 130 lb ft)
(8) The centerline of the crankshaft bearing bore to (11) Width of main bearing cap ... 499.95 ± 0.03 mm
the top surface of the cylinder block .. 946.00 mm (19.683 ± 0.001 inch)
(37.244 inch)
Width of cylinder block for main bearing
Procedure for tightening the main bearings cap ............ 500.00 ± 0.05 mm (19.685 ± 0.002 inch)
1. Torque studs (9) in the cylinder block again. Clearance between the sides of the main bearing cap
and the cylinder block ..................... 0.03 to 0.13 mm
Torque for the studs .. 100 ± 20 N·m (75 ± 15 lb ft) (0.001 to 0.005 inch)
2. Assemble the main bearing cap and the washer.

Hand tighten the nut.
3. Assemble the side bolts on the side of the cap

with the tab slot. Tighten the side bolts by hand.
Lubricate the washer face and the threads with
engine oil before assembly.
4. Start at the front face of the block.
Tighten the side bolts on the side of the cap with

the tab slot to the following torque. .. 215 ± 40 N·m
(160 ± 30 lb ft)
g01193094
5. Simultaneously tension each pair of the studs with Illustration 108
either of the following tensioners: Main bearing cap
207-5034 Stud Tensioner Tool (12) The dowel protrudes from the main bearing cap
Gp ................ 65000 ± 2400 kPa (9425 ± 350 psi) at the following distance. ............. 10.0 ± 0.5 mm
(0.39 ± 0.02 inch)
191-5320 Stud Tensioner Tool
Gp ............. 111500 ± 3950 kPa (16200 ± 575 psi) (13) Main bearing cap
Tighten the nuts by hand. Slowly release the

pressure.
6. Repeat Step 5.
7. Tighten the side bolts on the side of the cap

opposite the tab slot hand tight. Lubricate the
washer face and the threads with engine oil before
assembly.
Tighten the side bolts on the side of the

torque. ..................... 215 ± 40 N·m (160 ± 30 lb ft)

78 RENR5082-09
i01231253 i03325140
Cylinder Liner Piston and Rings

SMCS Code: 1216
(Three Ring Piston)
Part No.: 179-3167 SMCS Code: 1214
Part No.: 314-2700
g00536351
Illustration 109
g01038789
Illustration 110
(1) Groove for the combustion gasket
Depth of groove ......................... 3.50 ± 0.03 mm (1) The top ring must be installed with the yellow
(0.138 ± 0.001 inch) colored strip to the right of the ring end gap.
The dimension must not vary more than the Install the top ring with the “UP-1” facing upward.
following value. ............. 0.020 mm (0.0008 inch) The ring end gap must be 120 ± 20 degrees from
the adjacent ring end gap.
(2) Large bore in new liner ...... 290.025 ± 0.025 mm
(11.4183 ± 0.0010 inch) (2) The second ring must be installed with the green
colored strip to the right of the ring end gap.
(3) Flange Install the intermediate ring with the “UP-2” facing
upward. The ring end gap must be 120 ± 20
Thickness of flange .................. 33.00 ± 0.03 mm degrees from the adjacent ring end gap.
(1.299 ± 0.001 inch)
The dimension must not vary more than the (3) Install the oil control ring and the oil ring spring
following value. ............. 0.013 mm (0.0005 inch) with the gaps at an angle of 180 degrees across
from each other. The white colored portion of
(4) Small bore in new liner ...... 280.025 ± 0.025 mm the oil ring spring must be visible through the oil
(11.0246 ± 0.0010 inch) control ring gap. The ring end gap must be 120 ±
20 degrees from the adjacent ring end gap.
Note: The values in Table 26 are specifications for a

new piston.
RENR5082-09 79
Table 26
Piston and Piston Rings
Item (1) Top Ring (2) Second Ring (3) Oil Control Ring
Width Of Groove In 6.185 ± 0.015 mm 6.155 ± 0.015 mm 8.050 ± 0.010 mm
New Piston (0.2435 ± 0.0006 inch) (0.24232 ± 0.00059 inch) (0.3169 ± 0.0004 inch)
5.9825 ± 0.0075 mm 5.9825 ± 0.0075 mm 7.976 ± 0.011 mm
Width Of Piston Ring
(0.2355 ± 0.0003 inch) (0.2355 ± 0.0003 inch) (0.3140 ± 0.0004 inch)
Clearance Between Groove 0.2025 ± 0.0225 mm .1725 ± 0.0225 mm .074 ± 0.021 mm
and Piston Ring (0.0080 ± 0.0009 inch) (0.0068 ± 0.0009 inch) (0.0029 ± 0.0008 inch)
Piston Ring End Gap(1) 1.15 ± 0.15 mm 1.95 ± 0.15 mm 1.1 ± 0.20 mm
(0.0453 ± 0.0059 inch) (0.0768 ± 0.0059 inch) (0.043 ± 0.008 inch)
(1) The given value is for rings that are installed in a bore of 280 mm (11.024 inch).
Bore in the piston for the pin .... 120.025 ± 0.010 mm (2) The second ring must be installed with the green
(4.7254 ± 0.0004 inch) colored strip to the right of the ring end gap.
Install the intermediate ring with the “UP-2” facing
Diameter of piston pin ............... 119.994 ± 0.006 mm upward. The ring end gap must be 120 ± 20
(4.7242 ± 0.0002 inch) degrees from the adjacent ring end gap.
Cold clearance between piston pin and bore in (3) Install the oil control ring and the oil ring spring
piston ...... 0.031 ± 0.016 mm (0.0012 ± 0.0006 inch) with the gaps at an angle of 180 degrees across
from each other. The white colored portion of
the oil ring spring must be visible through the oil
i02378093
control ring gap. The ring end gap must be 120 ±
Piston and Rings 20 degrees from the adjacent ring end gap.
(Three Ring Piston) Note: The values in Table 27 are specifications for a
new piston.
SMCS Code: 1214
Part No.: 197-6700
g01038789
Illustration 111
(1) The top ring must be installed with the yellow

colored strip to the right of the ring end gap.
Install the top ring with the “UP-1” facing upward.
The ring end gap must be 120 ± 20 degrees from
the adjacent ring end gap.
80 RENR5082-09
Table 27
Piston and Piston Rings
Item (1) Top Ring (2) Second Ring (3) Oil Control Ring
Width Of Groove In 6.185 ± 0.015 mm 6.185 ± 0.015 mm 8.050 ± 0.010 mm
New Piston (0.2435 ± 0.0006 inch) (0.2435 ± 0.0006 inch) (0.3169 ± 0.0004 inch)
5.9825 ± 0.0075 mm 5.9825 ± 0.0075 mm 7.925 ± 0.011 mm
Width Of Piston Ring
(0.2355 ± 0.0003 inch) (0.2355 ± 0.0003 inch) (0.3120 ± 0.0004 inch)
Clearance Between 0.2025 ± 0.0225 mm 0.2025 ± 0.0225 mm 0.125 ± 0.021 mm
Groove and Piston Ring (0.0080 ± 0.0009 inch) (0.0080 ± 0.0009 inch) (0.0049 ± 0.0008 inch)
Piston Ring End Gap(1) 1.15 ± 0.15 mm 1.95 ± 0.15 mm 1.10 ± 0.20 mm
(0.0453 ± 0.0059 inch) (0.0768 ± 0.0059 inch) (0.043 ± 0.008 inch)
(1) The given value is for rings that are installed in a bore of 280 mm (11.024 inch).
Bore in the piston for the pin .... 120.028 ± 0.008 mm

(4.7255 ± 0.0003 inch)
Diameter of piston pin ............... 119.994 ± 0.006 mm

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

piston ...... 0.034 ± 0.014 mm (0.0013 ± 0.0006 inch)
i04984611
Connecting Rod
SMCS Code: 1218
Part No.: 263-1853
S/N: NKB1-Up
Part No.: 263-1853
S/N: TSJ1-Up
Part No.: 263-1853
S/N: RDW1-Up
Part No.: 263-1853
S/N: TDX1-Up
g03164556
Illustration 112
RENR5082-09 81
Table 28
Specification for 263-1853 Connecting Rod Gp
- - Bore in the connecting rod for piston pin bushing is 130.000 ± 0.015 mm
A
(5.1181 ± 0.0006 inch).
Bore in the bushing for new piston pin is 120.114 ± 0.008 mm
B 1 4P-6125 Bushing
(4.7289 ± 0.0003 inch).
Bore in the bearings for crankshaft before installation is 218.1 ± 0.3 mm
C 1 227-2902 Bearing
(8.59 ± 0.01 inch)
- - Bore in the connecting rod for the bearing for crankshaft is 225.000 ± 0.015 mm
D
(8.8583 ± 0.0006 inch).
E - - Distance between the center of the bearings is 600.00 mm (23.622 inch).
g03164597
Illustration 113
Table 29
- - Angle above centerline on either side of the bushing joint for bushing for the piston
F
pin is 15 degrees.
For Installation of bushing for the piston pin in the connection rod, heat the
- - connecting rod to a minimum length (G) of 250.00 mm (9.843 inch) at temperature
G
190 ± 15 °C (374 ± 27 °F) or prior to installation, cool bushing (B) at temperature
of 90 °C ( 130 °F).
g03164598
Illustration 114
82 RENR5082-09
Table 30
Use the following procedure in order to tighten the connecting rod bolt:
Do not use the connecting rod bolt assembly, if the dimension is more than
329.00 mm (12.953 inch).
1 4 369-7181 Bolt As 1. Before assembly, assure that the retainer and bolt head are free from Molylube.
2. Before applying thread lubricant, install the bolt into the retainer plate and rod.
3. After installation of bolt, lubricate the threads of the bolt, nut, and contact face of
the nut with Bell - Ray Molylube 67700.
4. Turn all four nuts by hand until the nuts contact the face of the cap. No resistance
should be felt that would indicate thread damage or debris in the joint. Threading the
nut by hand provides an opportunity to identify problems with the threads. If the nuts
and/or bolts cannot be threaded by hand, the nuts and/or bolts must be replaced. Do
not use an impact wrench to install the nuts up to the face of the cap.
5. Tighten all four nuts (2) to 105 ± 20 N·m (77 ± 15 lb ft).
6. Tighten nut 1, 4, 2, and 3 in the sequence as shown in Illustration 114 to
375 ± 15 N·m (277 ± 11 lb ft).
7. Again, tighten nut 2, 3, 1, and 4 in the sequence as shown in Illustration 114 to
375 ± 15 N·m (277 ± 11 lb ft)
8. Again, tighten nut 1, 4, 2, and 3 in the sequence as shown in Illustration 114 to
2 4 205-0640 Nut an angle of 180 ± 5 degrees.
If, torque or turn tolerance are not met in any of the above step. Then, loosen all
bolts (1) until zero reading is taken and apply torque again. In order to resue bolt (1),
the zero reading should be less than 20000 N (4496 lb).
RENR5082-09 83
i03342462 2. Raise the temperature of the piston pin end of

the connecting rod before installing the bearing.
Connecting Rod This must be for a minimum length of 250 mm
(10 inch). Raise the temperature evenly. Raise
SMCS Code: 1218 the temperature thoroughly. This is the alternative
method.
Part No.: 318-2344
S/N: PKA1-Up
Note: Do not use a torch to heat the connecting rod.
Part No.: 319-7945
S/N: NKB1-Up Heat the connecting rod to the following
temperature. ............... 190° ± 15°C (374° ± 27°F)
Part No.: 263-1852, 318-2344
S/N: SCB1-Up (2) Bore in piston pin bearing for new piston
pin .. 120.114 ± 0.008 mm (4.7289 ± 0.0003 inch)
Part No.: 319-7945
S/N: TSJ1-Up Diameter of new piston pin ....... 119.994 ± 0.006 mm
Part No.: 318-2344 (4.7242 ± 0.0002 inch)
S/N: LDL1-Up
Tight fit between connecting rod and piston pin
Part No.: 318-2344 bearing .. 0.120 to 0.180 mm (0.0047 to 0.0071 inch)
S/N: NDT1-Up
Note: Assemble the piston pin retainer so the word
Part No.: 319-7945 “OUT” is visible.
S/N: RDW1-Up
Part No.: 319-7945
S/N: TDX1-Up
g00287847
Illustration 116
Positioning piston pin bearing
g00287846 Note: The bearing junction and the locating hole are
Illustration 115
180 degrees across from each other. The bearing
junction and the locating hole must be assembled
(1) Bore in connecting rod for piston pin
within area (A). Area (A) is 90 ± 15 degrees from the
bearing ............................... 130.000 ± 0.015 mm
centerline through the connecting rod bores.
(5.1181 ± 0.0006 inch)
(3) Bore in bearing for
The piston pin bearing may be installed in the
crankshaft ..................... 216.145 to 216.306 mm
connecting rod by using either of the following
(8.5096 to 8.5160 inch)
methods:
(4) Bore in connecting rod for
1. Lower the temperature of the piston pin bearing
bearing ....... 225.000 + 0.025 mm to 0.065 mm
before installing the piston pin bearing in the
(8.8582 + 0.0009 inch to 0.0025 inch)
connecting rod. This is the preferred method of
installation.
Total allowed runout ............ 0.066 mm (0.0026 inch)
Minimum temperature to cool piston pin
Clearance between bearing and
bearing ........................................ 90°C ( 130°F)
crankshaft ................................... 0.171 to 0.282 mm
(0.0067 to 0.0111 inch)
(5) Distance between center of

bearings ...................... 600.00 mm (23.622 inch)
84 RENR5082-09
Reuse Information for the Note: This torque procedure was developed with
334-0519 Molylube Anti-Seize Lubricant. The use of
Connecting Rod Bolts any other lubricant may result in an incorrect torque
value and in subsequent failure of the connecting
Inspect connecting rod bolts at each service of the
rod bolt.
connecting rod bearings. There should be no fretting
on the shank of the connecting rod bolt. This includes
2. Turn all four nuts by hand until the nuts contact
the knurled area of the connecting rod bolts. Ensure
the face of the cap. No resistance should be felt
that the connecting rod bolts meet the guidelines for
that would indicate thread damage or debris in
reusable parts. Refer to Guidelines For Reusable
the joint. Threading the nuts by hand provides an
Parts, SEBF8063, “Visual Inspection Of Connecting
opportunity to identify problems with the threads.
Rods”. Do not reuse the nuts.
If the nuts and/or bolts cannot be threaded by
hand, the nuts and/or bolts must be replaced. Do
not use a impact wrench to install the nuts up to
the face of the cap.
3. Tighten nuts (1), (4), (2), and (3).
Torque ....................... 105 ± 15 N·m (75 ± 10 lb ft)
4. Tighten nuts (1), (4), (2), and (3).
Torque ..................... 375 ± 15 N·m (277 ± 11 lb ft)
5. Without loosening the nuts, tighten the nuts for

the second time in the following order: nut (2), nut
Illustration 117
g00775406 (3), nut (1), and nut (4).
This illustration identifies dimension (X) for the connecting rod bolt.
Torque ..................... 375 ± 15 N·m (277 ± 11 lb ft)
Do not reuse a connecting rod bolt if dimension (X) is
more than 329.00 mm (12.953 inch). 6. Tighten the nuts again in the following order: nut
(1), nut (4), nut (2), and nut (3).
Tightening Procedure for Turn the nuts in a clockwise

Connecting Rod Bolts direction. .................................... 180 ± 5 degrees
Note: Connecting rod bolt (1) and connecting rod i02110239

bolt (2) are on the same side of the connecting rod as
the raised bosses and the tab slots for the connecting Connecting Rod and Main
rod bearing.
Bearing Journals
SMCS Code: 1230
Refer to Guidelines For Reusable Parts, SEBF8009,

“Main And Connecting Rod Bearings” for more
information.
Connecting Rod Bearing Journals
Table 31
Diameter Of Crankshaft Journal (Bearing Surface)
For Connecting Rod Bearings
Original Size Journal 216.000 ± 0.025 mm
g00756010
(8.5039 ± 0.0010 inch)
Illustration 118
Undersize Journal 215.500 ± 0.025 mm
This illustration identifies the connecting rod bolts and nuts.
0.50 mm (0.020 inch) (8.4843 ± 0.0010 inch)
1. Use 334-0519 Molylube Anti-Seize Lubricant to Undersize Journal 215.000 ± 0.025 mm
lubricate the threads of the bolts, of the nuts, and 1.00 mm (0.040 inch) (8.4646 ± 0.0010 inch)
the seating face of the nut after the bolt for the
connecting rod is installed in the connecting rod.
RENR5082-09 85
Clearance between bearing and new

journal .... 0.173 to 0.285 mm (0.0068 to 0.0112 inch)
Main Bearing Journals
Table 32
Diameter Of Crankshaft Journal (Bearing
Surface) For Main Bearings
Original Size Journal 250.000 ± 0.025 mm
(9.8425 ± 0.0010 inch)
0.50 mm (.020 inch) (9.8228 ± 0.0010 inch)
1.00 mm (0.040 inch) (9.8031 ± 0.0010 inch)
Clearance between bearing and new

journal ... 0.265 to 0.385 mm (0.0104 to 0.0152 inch)
86 RENR5082-09
i05169650
Crankshaft
SMCS Code: 1202
Part No.: 193-5846
S/N: PKA1-Up
Part No.: 189-2500
S/N: NKB1-Up
Part No.: 179-3572
S/N: SCB1-Up
Part No.: 191-5424
S/N: TSJ1-Up
Part No.: 179-3572
S/N: LDL1-Up
Part No.: 193-5846
S/N: NDT1-Up
Part No.: 191-5424
S/N: RDW1-Up
Part No.: 189-2500
S/N: TDX1-Up
g03132838
Illustration 119
RENR5082-09 87
Table 33
Specification for 179-3572 Crankshaft Gp , 189-2500 Crankshaft Gp , 191-5424 Crankshaft Gp
, 193-5846 Crankshaft Gp , and 361-8852 Crankshaft Gp
- - Diameter of new connecting rod journals is 216.000 ± 0.025 mm

B
(8.5039 ± 0.001 inch).
- - Diameter of new main bearing journals is 250.000 ± 0.025 mm

C
(9.8425 ± 0.0001 inch).
F - - Crankshaft end play is 0.600 to 0.175 mm (0.0236 to 0.0069 inch).
1 2 345-4127 Thrust Plate Install the thrust plates on the rear main bearing for rear driven
equipment. Install the thrust plates on the front main bearing for
front driven equipment.
2 8 7W-1632 Plug Torque to 300 ± 40 N·m (221 ± 30 lb ft).
g03132990
Illustration 120
Section E-E
Table 34

Tighten the counterweight bolts according to the following procedure.
1. Install the counterweight with the heavy side toward the rod.
2. Apply 4C-5591 Anti-Seize Compound to the threads and seating
surfaces of bolts (4) and (5).
3. Seat the counterweight by tightening bolt (5) first to 1500 ± 100 N·m
(1106 ± 74 lb ft).
- 4. Tighten bolts (4) to 1500 ± 100 N·m (1106 ± 74 lb ft).
48 186-0144 Bolt
5. Loosen bolts (4) and bolt (5).
6. Reseat the counterweight by tightening bolt (5) first to 320 ± 30 N·m
(236 ± 22 lb ft).
7. Tighten bolts (4) to 320 ± 30 N·m (236 ± 22 lb ft).
8. Again, tighten the bolt (5) to 320 ± 30 N·m (236 ± 22 lb ft).
9. Again, turn the bolt (5) to additional angle of 120 ± 5 degrees.
10. Again, turn the bolts (4) to additional angle of 120 ± 5 degrees.
88 RENR5082-09
g03132989
Illustration 121
(3) Timing bracket assembly
Table 35
Extension of dowel from the crankshaft timing pin bracket is 5.0 ± 1.0 mm
G 1 6V-3537 Dowel
(0.20 ± 0.04 inch).
RENR5082-09 89
i04964529
Crankshaft Seals
SMCS Code: 1160; 1161
Part No.: 7E-9610
S/N: NKB1-Up
Part No.: 7E-9610
S/N: TSJ1-Up
Part No.: 7E-9610
S/N: RDW1-Up
Part No.: 7E-9610
S/N: TDX1-Up
g03167997
Illustration 122
(2) Front face of cylinder block (5) Sleeve
90 RENR5082-09
Table 36
Specification for 7E-9610 Crankshaft Seal Gp
Standard rotation engine will have crankshaft seals on the rear of the
engine.
3 1 190-2463 Seal As
Reverse rotation engine will have crankshaft seals on the front of the
engine.
Standard rotation engine will have crankshaft seals on the front of the
4 1 190-2462 Seal As engine.
Reverse rotation engine will have crankshaft seals on the rear of the engine.
Before assembly, apply Chemtool Alpha 2000 Calcium Complex Grease to
6 1 106-2033 Crankshaft Adapter
the bore to avoid moisture penetration causing corrosion.
Before assembly, apply green Loctite 620 to inner diameter of the sleeve.
Position the sleeves on the adapters. Make sure that the arrow on the
outside diameter of the sleeve is pointing in the direction of the rotation of
7 2 160-8173 Wear Sleeve
the crankshaft.
Assemble the sleeve onto the adapter. Make sure that the adapter bottoms
out against the shoulder.
RENR5082-09 91
i04964713
Crankshaft Seals
SMCS Code: 1160; 1161
Part No.: 7W-9683
S/N: PKA1-Up
Part No.: 7W-9683
S/N: SCB1-Up
Part No.: 7W-9683
S/N: LDL1-Up
Part No.: 7W-9683
S/N: NDT1-Up
g03148701
Illustration 123
(2) Front face of cylinder block (6) Sleeve
92 RENR5082-09
Table 37
Specification for 7W-9683 Crankshaft Seal Gp
Standard rotation engine will have crankshaft seals on the rear
of the engine.
3 1 190-2463 Seal As
Reverse rotation engine will have crankshaft seals on the front
of the engine.
Standard rotation engine will have crankshaft seals on the front
of the engine.
4 1 190-2462 Seal As
Reverse rotation engine will have crankshaft seals on the rear of
the engine.
102-4112 Crankshaft Before assembly, apply Chemtool Alpha 2000 Calcium Complex
5 1
Adapter Grease to the bore to avoid moisture penetration causing corrosion.
106-2033 Crankshaft Before assembly, apply Chemtool Alpha 2000 Calcium Complex
7 1
Adapter Grease to the bore to avoid moisture penetration causing corrosion.
Before assembly, apply green Loctite 620 to inner diameter of the
sleeve.
Position the sleeves on the adapters. Make sure that the arrow on
8 2 160-8173 Wear Sleeve the outside diameter of the sleeve is pointing in the direction of
the rotation of the crankshaft.
Assemble the sleeve onto the adapter. Make sure that the adapter
bottoms out against the shoulder.
RENR5082-09 93
i04961691
Housing (Front)
SMCS Code: 1162
Part No.: 1W-0023
g03146338
Illustration 124
94 RENR5082-09
Table 38
Specification for 1W-0023 Front Housing Gp
1 1 9S-8005 O-Ring Plug Before assembly, lightly lubricate the bore with engine oil.
2 3 6V-5049 O-Ring Seal Before assembly, lightly lubricate the bore with engine oil.
Use the following procedure to tighten the engine speed sensor:
1. Before assembly, apply white Loctite 594 to threads.

2. Install the engine speed sensor into the 5/8 threaded hole and
turn until the magnetic core contact with a tooth of the flywheel
3 1 7C-1897 Speed Sensor Gp
ring gear.
3. Back out 180 degrees and tighten the locknut.
4. Tighten the locknut to 45 ± 7 N·m (33 ± 5 lb ft).
5. The clearance between the engine speed sensor and the
flywheel ring gear is 0.56 ± 0.84 mm (0.022 ± 0.033 inch).
Extension (F) after installation is 10.00 ± 1.00 mm
4 4 1W-0104 Hollow Dowel
(0.394 ± 0.039 inch).
Extension (H) after installation is 4.00 ± 1.00 mm
5 4 1W-0104 Hollow Dowel
(0.157 ± 0.039 inch).
Extension (G) after installation is 6.00 ± 0.50 mm
6 4 7N-2043 Dowel
(0.236 ± 0.020 inch).
7 1 8L-2786 O-Ring Seal Before assembly, lightly lubricate the bore with engine oil.
8 1 6V-3833 O-Ring Seal Before assembly, lightly lubricate the bore with engine oil.
9 1 3P-0655 O-Ring Seal Before assembly, lightly lubricate the bore with engine oil.
RENR5082-09 95
i04961051
Gear Group (Front)

SMCS Code: 1206
Part No.: 1W-0790
g03145818
Illustration 125
(9) Crankshaft gear
96 RENR5082-09
Table 39
Specification for 1W-0790 Front Gear Gp
Bore of 190-6465 Bearing after installation is 69.950 ± 0.010 mm
1 1 180-3864 Gear As (2.7539 ± 0.0004 inch).
Installation depth is 2.50 ± 0.50 mm (0.098 ± 0.020 inch).
Bore of 190-6465 Bearing after installation is 69.950 ± 0.010 mm
2 1 180-3865 Gear As (2.7539 ± 0.0004 inch).
Installation depth is 2.50 mm (0.098 inch).
Position of the oil hole for engines with standard rotation is 2
3 1 1N-3842 Idler Shaft
O'clock.
Position of the oil hole for engines with reverse rotation is 8 O'clock.
Position of the oil hole for engines with standard rotation is 5
4 1 1N-3842 Idler Shaft O'clock.
Position of the oil hole for engines with reverse rotation is 11
O'clock.
5 2 5S-9134 O-Ring Seal Before assembly, lightly lubricate the bore that is being sealed.
8 2 1N-3834 Thrust Washer Thickness is 9.45 ± 0.05 mm (0.372 ± 0.002 inch).
RENR5082-09 97
i04958269
Housing (Rear)
SMCS Code: 1157
Part No.: 288-8541
S/N: NKB1-Up
Part No.: 288-8541
S/N: TSJ1-Up
Part No.: 288-8541
S/N: RDW1-Up
Part No.: 288-8541
S/N: TDX1-Up
g03143640
Illustration 126
98 RENR5082-09
Table 40
Specification for 288-8541 Rear Housing and 7E-9630 Flywheel Housing Gp
Tighten the bolts on the rear housing in the following sequence
with the turbocharger supports in position:
- - -
Tighten bolts (2) and bolts (3) to the specified torque first.
Tighten bolts (7) and bolts (8) to the specified torque second.
Tighten bolts (1) and bolts (4) to the specified torque third.
Length of 1/2 inch diameter bolt is 50.8 mm (2.00 inch).
1 20 1A-1460 Bolt
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
2 8 4J-7945 Bolt
The bolts are contained in the mounting group for the turbocharger.
3 2 5D-1972 Bolt
The bolts are contained in the mounting group for the gas lines.
4 1 0S-1585 Bolt
Torque to 135 ± 20 N·m (100 ± 15 lb ft).
6 2 5P-7813 O-Ring Seal Before assembly, lightly lubricate the bore that is being sealed.
7 10 6V-9608 Bolt
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
8 4 2H-3756 Bolt
Torque to 270 ± 40 N·m (199 ± 30 lb ft).
RENR5082-09 99
i02097583
Housing (Rear)
SMCS Code: 1157
Part No.: 135-6529
S/N: PKA1-Up
Part No.: 135-6529
S/N: SCB1-Up
Part No.: 135-6529
S/N: LDL1-Up
Part No.: 135-6529
S/N: NDT1-Up
g00900687
Illustration 127
(1) 1/2 inch Bolt Torque .................... 270 ± 40 N·m (200 ± 30 lb ft)
Torque .................... 135 ± 20 N·m (100 ± 15 lb ft) (3) Plug
(2) 5/8 inch Bolt Torque ...................... 125 ± 15 N·m (90 ± 11 lb ft)
100 RENR5082-09
Tighten the bolts for the rear housing in the following i02016107
sequence:
Gear Group (Rear)
1. Bolts (B)
SMCS Code: 1206
2. Bolts (C)
Part No.: 289-9979
S/N: NKB1-Up
3. Bolts (D)
Part No.: 289-9979
4. Bolts (E) S/N: TSJ1-Up
5. Bolts (A) Part No.: 289-9979
S/N: RDW1-Up
Table 41
Part No.: 289-9979
Installation Chart For The S/N: TDX1-Up
Bolt Length
Rear Housing Bolts
Diameter Part mm
Bolt inch
inch Number
1A-1460
A 1/2 50.8 2.00
Bolt
2H-3756
B 5/8 228.6 9.00
Bolt
0S-1569
C 5/8 101.6 4.00
Bolt
1D-4599
D 5/8 177.8 7.00
Bolt
6V-9608
E 5/8 254.0 10.00
Bolt
g00483155
Illustration 128
(1) Camshaft drive gears
g01042492
Illustration 129
(2) Idler gears

Backlash between the camshaft drive gears and
the idler gears ....................... 0.160 to 0.795 mm
(0.0063 to 0.0313 inch)
RENR5082-09 101
Bore for bearing .......................... 150 ± 0.02 mm Use the following procedure in order to tighten the
(5.905 ± 0.0008 inch) mounting bolts for the idler shaft.
(A) Base diameter. ..................... 160 ± 0.02 mm
(6.299 ± 0.0008 inch)
(B) Depth of installed bearing in gear's
bore ........... 3.0 ± 0.5 mm (0.118 ± 0.02 inch)
(C) Circular runout of the bearing bore
established by the axis of the gear's base
diameter. ................... 0.13 mm (0.0051 inch)
(D) Inner diameter of bearing bore after
machining ..................... 150.002 ± .020 mm
(5.9056 ± 0.0008 inch)
(E) Maximum roughness of machined bearing
bore .................................... 0.8 micrometers
(3) Small cluster idler gear

Backlash between the idler gears and the small Illustration 131
g00483157
cluster idler gear ................... 0.067 to 0.778 mm
(0.0026 to 0.0306 inch) 1. Use the following sequence in order to tighten and
turn the bolts.
(4) Idler gear
Two idler shafts with 8 bolt
(5) Torque for the bolts that connect the idler gear to patterns ........................................ 1-5-3-7-2-6-4-8
the small cluster idler gear ............. 135 ± 20 N·m
(100 ± 15 lb ft) One idler shaft with 10 bolt
pattern ................................. 1-6-3-8-5-10-7-2-9-4
(6) Crankshaft gear
2. Tighten the bolts.
Backlash between the idler gear and the
crankshaft ............................. 0.216 to 0.949 mm
Torque ..................... 160 ± 16 N·m (120 ± 12 lb ft)
(0.0085 to 0.0374 inch)
3. Tighten each of the bolts for an additional 45 ±
5 degrees.
(8) Locking plate and bolts
(9) Bolt that holds the camshaft drive gear in position
Use the following procedure in order to install the

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

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

compression stroke for the number one cylinder.
Install the crankshaft timing pin.
NOTICE
If the crankshaft timing pin location is missed, do not
turn the flywheel in the opposite direction to install the
crankshaft timing pin. If the crankshaft timing pin loca-
tion is missed, repeat Step 1.
g00483156
Illustration 130
2. Install the camshaft timing pin.
(7) Mounting bolts for the idler shafts
102 RENR5082-09
3. Put the camshaft drive gear (1) in position on the (13) Install the bearing in small cluster idler gear (3)
camshaft. Install the plate and the bolt hand tight. to the following depth. .................... 3.0 ± 0.5 mm
(0.12 ± 0.02 inch)
Note: Make sure that the gear taper and the camshaft
taper are clean and dry. Make sure that the gear (14) Bearing for the small cluster idler gear
taper and the camshaft taper are free of dirt, rust
and lubricants. Outside diameter of bearing for small cluster idler
gear (3) ............................... 114.171 ± 0.026 mm
4. To prevent the crankshaft from turning, engage the (4.4949 ± 0.0010 inch)
manual barring group. Tighten the locking guide. Bore in gear for bearing ...... 114.000 ± 0.020 mm
(4.4882 ± 0.0008 inch)
Torque ..................... 270 ± 25 N·m (200 ± 18 lb ft)
5. Apply 4C-5591 Anti-Seize Compound to the

threads and to the seating face of the bolt. Use a
torque multiplier to tighten the camshaft bolt.
Torque ............. 2000 ± 275 N·m (1480 ± 200 lb ft)
6. Strike the plate with a hammer in order to seat the

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

torque.
8. Loosen the locking guide on the manual barring g00483240

group. Verify the relation of the crankshaft to the Illustration 133
camshaft by installing the timing pins. If both
timing pins cannot be installed, loosen the bolt and (15) Install the bearing in idler gear (2) to the
the camshaft drive gear. Repeat the procedure for following depth. .. 3.0 ± 0.5 mm (0.12 ± 0.02 inch)
installing the camshaft drive gear.
(16) Bearing for the idler gear
(10) Outside diameter of idler gear Inside diameter of bearing for idler gear
shaft ................................... 149.850 ± 0.020 mm (2) .. 150.002 ± 0.020 mm (5.9056 ± 0.0008 inch)
(5.8996 ± 0.0008 inch) Bore in gear for bearing ..... 160.000 ± 0.020 mm
(6.2992 ± 0.0008 inch)
(11) Thickness of idler gear thrust
washers .... 9.60 ± 0.05 mm (0.378 ± 0.002 inch)
(12) Idler gear shaft

Outside diameter of the shaft for the small cluster
idler gear ............................ 105.860 ± 0.020 mm
(4.1677 ± 0.0008 inch)
g00483159
Illustration 132
RENR5082-09 103
i01223335 1. Rotate the engine to the Top Center Position of the

compression stroke for the number one cylinder.
Gear Group (Rear) Install the crankshaft timing pin.
SMCS Code: 1206
NOTICE
Part No.: 9Y-9345 If the crankshaft timing pin location is missed, do not
S/N: PKA1-Up turn the flywheel in the opposite direction to install the
crankshaft timing pin. If the crankshaft timing pin loca-
Part No.: 9Y-9345 tion is missed, repeat Step 1.
S/N: SCB1-Up
Part No.: 9Y-9345 2. Install the camshaft timing pin.
S/N: LDL1-Up
3. Put the camshaft drive gear (1) in position on
Part No.: 9Y-9345 the camshaft (2). Apply 4C-5592 Anti-Seize
S/N: NDT1-Up Compound to the threads of bolt (3). Install the
plate and the bolt (3) hand tight.
Note: Make sure that the gear taper and the camshaft
taper are clean and dry. Make sure that the gear
taper and the camshaft taper are free of dirt, rust
and lubricants.
4. To prevent the crankshaft from turning, engage

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

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

bolt.
Tighten the bolt to the following

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

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

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

group. Verify the relation of the crankshaft to the
g00289173
camshaft by installing the timing pins. If both
Illustration 134 timing pins cannot be installed, loosen the bolt and
the camshaft drive gear. Repeat the procedure for
(1) Camshaft drive gear installing the camshaft drive gear.
(2) Camshaft (4) Tighten the mounting bolts for the idler gear to the
following torque. .... 270 ± 40 N·m (200 ± 30 lb ft)
(3) Bolt and plate that holds the camshaft drive gear
in position When the timing pin is engaged in the crankshaft, the
mounting bolts must be visible through the holes in
Procedure for installing the camshaft drive gear the idler gear.
Note: Use the manual barring group to rotate the (5) Small cluster idler gear
engine. The engine should be prelubed before
rotating the crankshaft in order to perform service Backlash between the camshaft drive gear (1)
work. Rotating the crankshaft before prelube may and the idler gear (5) ............ 0.269 to 0.434 mm
cause damage to the crankshaft bearings if the (0.0106 to 0.0171 inch)
mating surface is dry.
(6) Idler shaft assembly
104 RENR5082-09
Outside diameter of shaft .. 105.840 ± 0.020 mm

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

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

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

Bore in crankshaft gear ......... 235.10 ± 0.03 mm
(9.256 ± 0.001 inch)
(10) Crankshaft
Diameter of crankshaft .......... 235.00 ± 0.03 mm
(9.252 ± 0.001 inch)
i04984591
Manual Barring Group

SMCS Code: 1235
Part No.: 9Y-4252
g03164538
Illustration 135
RENR5082-09 105
Table 42
Specification for 9Y-4252
Add 1P-0808 Multipurpose Grease to the gear contacting end of the bracket
1 1 3B-8489 Grease Fitting
until visible.
2 1 7W-0194 Guide Torque to 270 ± 25 N·m (199 ± 18 lb ft).
3 2 5P-3456 O-Ring Seal Lubricate the seal and bore with clean engine oil.
i04945507
Flywheel
SMCS Code: 1156
Part No.: 6I-4961, 9Y-6182
g03130498
Illustration 136
Typical example
Table 43
Specification for 6I-4961 Flywheel Gp, 7E-8348 Flywheel Gp, 9Y-6182 Flywheel Gp, and 4P-9511 Flywheel Gp
Item Qty Part Number Specification Description
- - When the flywheel is installed, put the dash mark on the flywheel
1
near the pilot bore in alignment with the dash mark on the crankshaft.
Use the following procedure to tighten the bolts:
Before assembly, lubricate the threads and bearing surface with
2 20 6V-5605 Bolt Loctite C5A Copper Anti-Seize.
Torque to 800 ± 80 N·m (590 ± 59 lb ft).
Tighten the bolts to an additional 90 degrees + 2 - 5 degrees.
106 RENR5082-09
i02509458
Engine Speed/Timing Wheel

SMCS Code: 1206
Part No.: 154-2709
g01256172
Illustration 137
(1) Engine speed/timing wheel
(2) Bolts
(3) Extra tooth
(4) Speed/timing sensors
(2) Bolts
Torque ........................................ 120 N·m (88.5 lb ft)

RENR5082-09 107
i05193233
Flexible Coupling
SMCS Code: 3279
Part No.: 147-0085
S/N: NKB1-Up
Part No.: 147-0085
S/N: TDX1-Up
g03328006
Illustration 138
Typical example
Table 44
Specifications for the 147-0085 Flexible Coupling

Item Qty Part No. Specification Description
1 16 6V-8807 Bolt
Tighten to 532 ± 27 N·m (392± 20 lb ft)
2 32 113-7430 Bolt
3 24 152-0193 Bolt Tighten to 1015 ± 55 N·m (750 ± 40 lb ft)
4 24 152-0194 Bolt Tighten to 1375 ± 75 N·m (1015 ± 55 lb ft)
108 RENR5082-09
i01957346
Vibration Damper
(Dual)
SMCS Code: 1205
Part No.: 7W-0127
S/N: TSJ1-Up
Part No.: 7W-0127
S/N: NDT1-Up
Part No.: 7W-0127
S/N: RDW1-Up
g00467780
Illustration 139
(1) Dash mark (4) Bolts
(2) Center of inner damper Torque ............ 1350 ± 150 N·m (1000 ± 110 lb ft)
Align the center mark on the damper with the mark (5) Outer vibration damper
on the crankshaft.
(6) Inner vibration damper
(3) Center of outer damper
(7) Damper to crankshaft adapter
When the damper is installed the mark should be
rotated 36 degrees clockwise as the damper is (8) Crankshaft gear
viewed from the front of the engine.
RENR5082-09 109
(9) Crankshaft
Position the sleeve on the adapter so that the arrow

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

for the correct orientation.
(11) Bolts
Torque ............ 1350 ± 150 N·m (1000 ± 110 lb ft)
i00651428
Vibration Damper
(Single)
SMCS Code: 1205
Part No.: 1W-0864
S/N: NKB1-Up
Part No.: 1W-0864
S/N: LDL1-Up
Part No.: 1W-0864
S/N: TDX1-Up
g00289513
Illustration 140
(1) Vibration damper
Install the vibration damper with the dash mark and

the number 1 piston at the top center position.

torque. ........... 1350 ± 150 N·m (1000 ± 110 lb ft)
110 RENR5082-09
i04947822
Vibration Damper
(Single)
SMCS Code: 1205
Part No.: 1W-0791
S/N: SCB1-Up
Part No.: 1W-0791
S/N: LDL1-Up
g03135217
Illustration 141
Table 45
Specification for 1W-0791 Damper Gp

Before assembly, apply blue Loctite 242 or Loctite 243 to threads.
1 48 1A-2029 Bolt
Torque to 55 ± 7 N·m (41 ± 5 lb ft).
2 - - Align the dash marks for proper orientation.
Before assembly, apply 4C-5591 Anti-Seize Compound to threads
3 12 9S-8893 Bolt and bearing surfaces.
Torque to 1150 ± 150 N·m (848 ± 111 lb ft).
Apply green Loctite 620 to inner diameter of sleeve.
4 1 160-8173 Wear Sleeve Position the sleeve on the adapter so the arrow on the sleeve is
pointing in the direction of the crankshaft rotation.
Before assembly, apply 4C-5591 Anti-Seize Compound to threads
5 8 6V-6920 Bolt
and bearing surfaces.
RENR5082-09 111
i04981212
Engine Lifting Bracket

SMCS Code: 1122
Part No.: 7C-7950
S/N: NKB1-Up
Part No.: 7C-7950
S/N: TSJ1-Up
Part No.: 7C-7950
S/N: RDW1-Up
Part No.: 7C-7950
S/N: TDX1-Up
g03162098
Illustration 142
Table 46
Specification for 7C-7950 Engine Lifting Gp
- - - Position the bracket on the engine so that the clevis pin hole is in
a horizontal plane.
Before assembly, apply Loctite C5A Copper anti seize to washer
1 16 9X-6003 Nut face and threads.
Torque to 2150 ± 250 N·m (1586 ± 184 lb ft).
112 RENR5082-09
i00609985 i01034661
Engine Lifting Bracket Engine Support

Part No.: 1W-0826 Part No.: 9Y-2028
Part No.: 1W-0826 Part No.: 6I-2786
S/N: SCB1-Up S/N: NKB1-Up
Part No.: 1W-0826 Part No.: 9Y-2028
S/N: LDL1-Up S/N: SCB1-Up
Part No.: 1W-0826 Part No.: 6I-2786
S/N: NDT1-Up S/N: TSJ1-Up
Part No.: 9Y-2028
S/N: LDL1-Up
Part No.: 9Y-2028
S/N: NDT1-Up
Part No.: 6I-2786
S/N: RDW1-Up
Part No.: 6I-2786
S/N: TDX1-Up
g00284632
Illustration 143
(1) Tighten the nuts to the following

torque. ........... 2150 ± 250 N·m (1580 ± 185 lb ft)
Apply 5P-3931 Anti-Seize Compound to nuts prior

to assembly.
g00533499
Illustration 144
(1) Tighten the bolt to the following

torque. ............. 1150 ± 150 N·m (850 ± 110 lb ft)
RENR5082-09 113
i01851704 i01037613
Engine Support Stub Shaft (Front)

Part No.: 9Y-2033 Part No.: 142-2425
Part No.: 9Y-2033 Part No.: 142-2425
S/N: SCB1-Up S/N: NKB1-Up
Part No.: 9Y-2033 Part No.: 142-2425
S/N: LDL1-Up S/N: TSJ1-Up
Part No.: 9Y-2033 Part No.: 142-2425
S/N: NDT1-Up S/N: NDT1-Up
Part No.: 142-2425
S/N: RDW1-Up
Part No.: 142-2425
S/N: TDX1-Up
g00943376
Illustration 145
Typical example
(1) Bolt
Tighten all of the bolts to the following
torque: ............. 1150 ± 150 N·m (840 ± 110 lb ft)
g00535002
Illustration 146
(1) Tighten bolts to the following

torque. ........... 1600 ± 200 N·m (1180 ± 150 lb ft)
(2) Position the shaft with the dash mark at the top
while the No. 1 cylinder is at TC.
(3) Sleeve
114 RENR5082-09
Apply 4C-9507 Retaining Compound to the bore of

the sleeve. Position the sleeve on the flange so that
the arrow that is on the outer diameter of the sleeve
is pointing in the direction of the crankshaft rotation.
Press the sleeve onto the flange until the sleeve
i01037815
Stub Shaft (Front)

SMCS Code: 1237
Part No.: 125-3660
S/N: SCB1-Up
Part No.: 125-3660
S/N: LDL1-Up
g00535080
Illustration 147
(1) Tighten the bolts to the following Apply 4C-9507 Retaining Compound to the bore of
torque. ........... 1600 ± 200 N·m (1180 ± 150 lb ft) the sleeve. Position the sleeve on the flange so that
(2) Tighten the bolts to the following is pointing in the direction of the crankshaft rotation.
torque. ............. 1150 ± 150 N·m (840 ± 110 lb ft) Press the sleeve onto the flange until the sleeve
(3) The lower bolt hole is offset. Align the dash marks
(4) Sleeve
RENR5082-09 115
i01038317
Stub Shaft (Front)

SMCS Code: 1237
Part No.: 2W-2774
S/N: SCB1-Up
Part No.: 2W-2774
S/N: LDL1-Up
g00535437
Illustration 148

torque. ........... 1600 ± 200 N·m (1180 ± 150 lb ft)

torque. ............. 1150 ± 150 N·m (840 ± 110 lb ft)
(3) The lower bolt hole is offset. Align the dash marks
(4) Sleeve
Apply 4C-9507 Retaining Compound to the bore of

the sleeve. Position the sleeve on the flange so that
is pointing in the direction of the crankshaft rotation.
Press the sleeve onto the flange until the sleeve
116 RENR5082-09
i02787858 Tighten the rotor clamp nut until the following

clearance between the rear end plate and the
Air Starting Motor rotor is reached: ........................ 0.03 to 0.08 mm
(0.001 to 0.003 inch)
SMCS Code: 1451
Check the clearance again after the bolt for the rotor
Part No.: 7W-8586, 7W-8588
clamp nut is tightened.
S/N: PKA1-Up
Part No.: 7W-0014, 7W-0015 (6) Rotor retainer bolt
S/N: NKB1-Up
Torque ..................................... 120 N·m (90 lb ft)
Part No.: 7W-8586, 7W-8588
S/N: SCB1-Up
i00659899
Part No.: 7W-0014, 7W-0015

S/N: TSJ1-Up
Pressure Regulating Valve
Part No.: 7W-8586, 7W-8588 SMCS Code: 1451
S/N: LDL1-Up
Part No.: 2W-2751
Part No.: 7W-8586, 7W-8588
S/N: NDT1-Up
Part No.: 7W-0014, 7W-0015
S/N: RDW1-Up
Part No.: 7W-0014, 7W-0015
S/N: TDX1-Up
g00290531
Illustration 150
g01392582
Illustration 149
(1) Adjusting screw
Typical example
(2) Inlet pressure

(1) Cover
Maximum inlet pressure ....... 3100 kPa (450 psi)
Tighten the bolts evenly in small increases until
the following torque is reached: ............... 80 N·m
(3) Outlet pressure
(60 lb ft)
Minimum outlet pressure ...... 1517 kPa (220 psi)
(2) Bolt Maximum outlet pressure ..... 1655 kPa (240 psi)
Torque ....................................... 36 N·m (27 lb ft)
(3) Bolt
Torque ....................................... 78 N·m (60 lb ft)
(4) Bolt (pinion)

Torque ...................................... 110 N·m (80 lb ft)
(5) Rotor clamp nut

RENR5082-09 117
i04981254
Pressure Regulating Valve

SMCS Code: 1451
Part No.: 4W-2100
g03162176
Illustration 151
(1) Adjusting screw
Table 47
Specification for 4W-2100 Pressure Reducing Valve

2 - - Maximum inlet pressure is 2758 kPa (400 psi).
3 - - Outlet pressure is 827 to 965 kPa (120 to 140 psi).
118 RENR5082-09
i02480800 i02479833
Boost Pressure Sensor Atmospheric Pressure Sensor

Part No.: 236-7535 Part No.: 236-7534
g01238949 g01238488
Illustration 152 Illustration 153
(1) Sensor assembly (1) Sensor assembly
(2) Plug with socket A, socket B, and socket C (2) Plug with socket A, socket B, and socket C
(3) Port fitting (3) Port fitting

Torque ................... 22.5 ± 2.5 N·m (16.5 ± 2 lb ft) Torque ................... 22.5 ± 2.5 N·m (16.5 ± 2 lb ft)
Operating temperature ........................ 40 to 125 °C Operating temperature ........................ 40 to 125 °C

( 40 to 257 °F) ( 40 to 257 °F)
Maximum input pressure (absolute Maximum input pressure (absolute

pressure) ......................................... 472 kPa (68 psi) pressure) ......................................... 116 kPa (17 psi)
Input supply voltage ............................. 5 ± 0.25 VDC Input supply voltage ............................. 5 ± 0.25 VDC
Maximum supply current ................................. 20 mA Maximum supply current ................................. 20 mA
Install the sensor so that the pressure port is lower Install the sensor so that the pressure port is lower
than the wire end. Mount the sensor as close to than the wire end. Mount the sensor as close to
vertical as possible. vertical as possible.
RENR5082-09 119
i01044813
Probe Adapter
SMCS Code: 0770
Part No.: 134-1087
g00540564
Illustration 154
(1) Probe Adapter
Apply 4C-5597 Anti-Seize Compound to the threads

of the probe adapter.
Tighten the probe adapter to the following

torque. ............................................. 70 N·m (50 lb ft)
i01044768
Probe Adapter
SMCS Code: 0770
Part No.: 150-7137
g00540514
Illustration 155
(1) Probe Adapter
Apply 4C-5597 Anti-Seize Compound to the threads

of the probe adapter.
Tighten the probe adapter to the following

torque. ......................................... 200 N·m (150 lb ft)
120 RENR5082-09
i04415089
Engine Speed Sensor

SMCS Code: 1907
Part No.: 191-8305
g02612277
Illustration 156
Table 48
Specifications for 191-8304 Speed Sensor Gp and 191-8305 Speed Sensor Gp

Note: Before assembly, lubricate the O-ring seal lightly with the lubricant that is being sealed.
1 - - Torque to 28 ± 7 N·m (250 ± 62 lb in)
Output type of the sensor is analog signal.
Minimum clearance the sensor and the gear tooth is 0.5 mm (0.02 inch)
i02314596
Prelube Pump Motors

SMCS Code: 1469
Part No.: 173-3854, 1W-0899, 221-0132
Electric Prelube Pump Motors

Table 49
Electric Prelube Pump Motors
Motor Voltage Rating Phase Frequency Current Draw Power Rating Speed
1.5 kW
173-3854 380 VAC 3 60 Hz 3.4 Amperes 1750 RPM
(2.00 hp)
200, 400 or 6.8, 3.4 or 6, 1.5 kW
221-0132 3 50 or 60 Hz 1450/1750
240, 480 VAC 3 Amperes (2.00 hp)
RENR5082-09 121
Air Prelube Pump Motors i01091150
Table 50 Pressure Transducer

Air Prelube Pump Motors
SMCS Code: 1904
Power
Motor Pressure Speed Part No.: 144-4003
Rating
690 kPa 1.5 kW
1W-0899 1200 rpm
(100 psi) (2.00 hp)
i01085192
Pressure Contactor
SMCS Code: 7400
Part No.: 144-0103
g00567974
Illustration 158
Input pressure ............... 0 to 4000 kPa (0 to 580 psi)
Input voltage ........................................ 10 to 32 VDC
Output signal ............................................ 4 to 20 mA
g00567974
Illustration 157
Operating range ...... 500 to 3000 kPa (73 to 435 psi)

122 RENR5082-09
i01091233
Pressure Transducer
SMCS Code: 1904
Part No.: 141-9880
g00567974
Illustration 159
Input pressure ............................. 1000 kPa (145 psi)
Input voltage ........................................ 10 to 32 VDC
Output signal ............................................ 4 to 20 mA
i04981689
Pressure Switch
SMCS Code: 7400
Part No.: 150-1240
g03162656
Illustration 160
RENR5082-09 123
Table 51
Specification for 150-1240 Pressure Switch
Final installation torque for the pressure switch is 22 ± 3 N·m
1 - - (195 ± 27 lb in).
Contact position is normally open below deactuation pressure.
- - - Actuation pressure at 40 to 121°C (-40 to 250 °F) is 9.0 ± 3.0 kPa

(1.3 ± 0.4 psi).
- - - Minimum deactuation pressure at 40 to 121°C (-40 to 250 °F) is 7 kPa

(1 psi).
i04981330
Thermocouple
SMCS Code: 7498
Part No.: 114-1653
g03162280
Illustration 161
Table 52
Specification for 114-1653 Temperature Sensor Gp

Before assembly, apply Loctite nickel anti seize to threads.
1 - -
Tighten the bolt to 12 ± 3 N·m (106 ± 27 lb in).
124 RENR5082-09
Index Section
Index
A Fuel Injector Mechanism ........................................ 11
Fuel Pressure Control Valve.................................. 13
Aftercooler ....................................................... 13–14 Fuel Transfer Pump........................................... 9–10
Air Cleaner Adapter ............................................... 39
Air Inlet Elbow.................................................. 39–40
Air Inlet Shutoff ...................................................... 41 G
Air Shutoff........................................................ 41–42
Air Starting Motor.................................................. 116 Gear Group (Front)................................................ 95
Atmospheric Pressure Sensor.............................. 118 Gear Group (Rear) ...................................... 100, 103
Auxiliary Water Pump (Sea Water).................. 63, 66
H
B
Housing (Front)...................................................... 93
Boost Pressure Sensor......................................... 118 Housing (Rear) ................................................ 97, 99
C I
Camshaft ................................................... 15, 17–18 Important Safety Information ................................... 2

Camshaft Bearing Position .................. 22, 24, 26–27
Camshaft Bearings .......................................... 20–21
Compression Release Valve ................................. 34 M
Connecting Rod............................................... 80, 83
Reuse Information for the Connecting Rod Manual Barring Group ......................................... 104
Bolts ................................................................. 84 Manual Valve Group (Cylinder Pressure) .............. 35
Tightening Procedure for Connecting Rod
Bolts ................................................................. 84
Connecting Rod and Main Bearing Journals ......... 84 P
Crankcase Breather............................................... 56
Crankshaft ............................................................ 86 Piston and Rings (Three Ring Piston) ............. 78–79
Crankshaft Seals ............................................. 89, 91 Prelube Pump.................................................. 43–44
Cylinder Block............................................ 68, 71, 76 Prelube Pump Motors.......................................... 120
Cylinder Head, Valves, Valve Springs and Valve Seat Air Prelube Pump Motors................................. 121
Inserts ............................................................ 30, 32 Electric Prelube Pump Motors ......................... 120
Cylinder Liner ........................................................ 78 Pressure Contactor.............................................. 121
Pressure Regulating Valve ........................... 116–117
Pressure Switch................................................... 122
E Pressure Transducer ................................... 121–122
Priority Valve.......................................................... 54
Engine Centrifugal Oil Filter................................... 51 Probe Adapter ...................................................... 119
Engine Design ..................................................... 4–5
Engine Lifting Bracket................................... 111–112
Engine Oil Cooler .................................................. 55 S
Engine Oil Filter ..................................................... 51
Engine Oil Pump.............................................. 45, 47 Specifications Section ............................................. 4
Engine Oil Temperature Regulator ........................ 56 Stub Shaft (Front) ......................................... 113–115
Engine Speed Sensor.......................................... 120
Engine Speed/Timing Wheel ............................... 106
Engine Support............................................. 112–113 T
Exhaust Manifold ................................................... 38
Table of Contents..................................................... 3
Thermocouple...................................................... 123
F Turbocharger ................................................... 36–37
Flexible Coupling ................................................. 107

Flywheel .............................................................. 105 V
Fuel Filter Housing .................................................. 8
Fuel Injection Lines.................................................. 6 Valve Mechanism .................................................. 28
Fuel Injector........................................................... 12 Vibration Damper (Dual)...................................... 108
RENR5082-09 125
Index Section
Vibration Damper (Single) ............................ 109–110
Water Pump........................................................... 58
Water Temperature Regulator ............................... 57
126 RENR5082-09
Index Section
RENR5082-09 127
Index Section
©2012 Caterpillar Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge
All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.

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RENR5082-09

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Cylinder Block ...................................................... 68

i02508912 Standard rotation .......................... Counterclockwise

Number and arrangement of cylinders ............. V-12

Valves per cylinder

Stroke ......................................... 300 mm (11.8 inch) Valves per cylinder

Compression ratio .............................................. 13:1 Inlet valves ........................................................ 2

Combustion ....................................... Direct Injection Exhaust valves ................................................. 2

Firing order Displacement .......................... 295.6 L (18036 cu in)

Standard rotation Bore ............................................ 280 mm (11.0 inch)

Reverse rotation Compression ratio .............................................. 13:1

i02509989 Note: The front end of the engine is opposite the

S/N: LDL1-Up Engine Design

Number and arrangement of cylinders ........ In-line 6 g00572928

Valves per cylinder Engine design

Exhaust valves ................................................. 2 Number and arrangement of cylinders ........ In-line 8

Stroke ......................................... 300 mm (11.8 inch) Exhaust valves ................................................. 2

Displacement ............................ 147.8 L (9019 cu in)

Bore ............................................ 280 mm (11.0 inch)

Stroke ......................................... 300 mm (11.8 inch)

Compression ratio .............................................. 13:1

Combustion ....................................... Direct Injection

When the crankshaft is viewed from the ﬂywheel end,

Standard rotation .......................... Counterclockwise

Reverse rotation ....................................... Clockwise

Note: The front end of the engine is opposite the

Fuel Injection Lines

Note: Lubricate the bores for the O-ring seals and

(4) Connector .................. 105 ± 10 N·m (77 ± 7 lb ft)

After O-ring seal (5) and retainer (6) are installed,

(2) Connector .................. 105 ± 10 N·m (77 ± 7 lb ft)

(4) Connector .................. 105 ± 10 N·m (77 ± 7 lb ft)

Fuel Filter Housing

(1) Install the check valves so that the arrows point

(2) 2W-6862 Spring

(3) 7C-0807 Spring

Fuel Transfer Pump

Fuel Transfer Pump

(1) 238-0939 Spring

(2) Relief valve

(3) Diameter of shafts ............... 15.869 ± 0.006 mm

Bore in bearings for shafts ...................... 15.951 mm

(4) Width of gears ..................... 29.224 ± 0.006 mm

Fuel Injector Mechanism

Speciﬁcation for 1W-0789 Valve Mechanism Gp

i02388589 Fuel injector installation

Note: Do not tap or hit the injector.

3. Tighten the clamp bolt (1) that holds the fuel

4. Be certain that the fuel injector body below the

(1) Clamp bolt

(2) Timing dimension

Fuel Pressure Control Valve Aftercooler

(1) Set the adjusting bolt in order to provide the

(1) The aftercooler core must withstand the following

(2) Put a light coat of glycerin on all O-ring seals at

(1) The aftercooler core must withstand the following

(2) Put a light coat of glycerin on all O-ring seals at Illustration 20

(3) Torque for the retaining screws ......... 30 ± 7 N·m

Thickness of surface on camshaft for new NOTICE