RENR2200 04 Specification

RENR2200-04
Specification
3500B Locomotive Engines
S/N 5PS1-UP
S/N C8R1-UP
S/N 3ZW1-UP
S/N 6HZ1-UP
S/N BCK1-UP
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3500B Locomotive Engines RENR2200-04
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Specifications
Media Number -RENR2200-04 Publication Date -01/12/2008 Date Updated -03/12/2008
i01430864
Engine Design
SMCS - 1000
S/N - 5PS1-UP
S/N - 7AF1-UP
S/N - C8R1-UP
Illustration 1 g00293348
Cylinder and valve location
(A) Inlet valves
(B) Exhaust valves
Number and arrangement of cylinders ... 60 degree V-8
Valves per cylinder ... 4
Displacement ... 34.5 L (2105 cu in)
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Bore ... 170 mm (6.7 inch)
Stroke ... 190 mm (7.5 inch)
Compression ratio ... 14:1
Combustion ... Direct injection
When the crankshaft is viewed from the flywheel end, the crankshaft rotates in the following
direction: ... Counterclockwise
Firing order (injection sequence)
Standard rotation CCW ... 1, 2, 7, 3, 4, 5, 6, 8
Valve lash
Inlet ... 0.50 mm (0.020 inch)
Exhaust ... 1.00 mm (0.040 inch)
Note: The front end of the engine is opposite the flywheel end of the engine. The left side and the
right side of the engine are determined from the flywheel end. The number 1 cylinder is the front
cylinder on the right side. The number 2 cylinder is the front cylinder on the left side.
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Specifications
i01430869
Engine Design
SMCS - 1000
S/N - 3ZW1-UP
S/N - 8DF1-UP
(A) Inlet valves
(B) Exhaust valves
Bore ... 170 mm (6.7 inch)
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Standard rotation CCW ... 1, 12, 9, 4, 5, 8, 11, 2, 3, 10, 7, 6
Valve lash
Inlet ... 0.50 mm (0.020 inch)
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Specifications
i01430901
Engine Design
SMCS - 1000
S/N - 6HZ1-UP
S/N - 9WF1-UP
(A) Inlet valve
(B) Exhaust valve
Bore ... 170 mm (6.7 inch)
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Standard rotation CCW ... 1, 2, 5, 6, 3, 4, 9, 10, 15, 16, 11, 12, 13, 14, 7, 8
Valve lash
Inlet ... 0.50 mm (0.020 inch)
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Specifications
i03657840
Fuel Filter (Primary)

SMCS - 1260
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
(1) Torque for the nut ... 25 5 Nm (221 44 lb in)
(2) Lubricate the bore and the shaft of the O-ring seal lightly with the clean engine oil.
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(3) 7S-9323 Spring
Length under test force ... 27.94 mm (1.100 inch)

Test force ... 27.7 to 32.3 N (6.2 to 7.3 lb)
Free length after test ... 42.67 mm (1.680 inch)
Outside diameter ... 17.32 mm (0.682 inch)
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Specifications
i02723705
Fuel Pressure Regulator

SMCS - 1277
S/N - -
Typical example
(1) Fuel manifold adapter
(3) Valve plunger
(2) 9N-4053 Spring

Test force ... 40.8 2.1 N (9.2 0.5 lb)
Free length after test force ... 57.2 mm (2.25 inch)
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Specifications
i03229222
Fuel Transfer Pump

SMCS - 1256
S/N - -
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(3) Check valve
When the fuel transfer pump group is viewed from the drive end, the drive gear rotates in the
clockwise direction.
Minimum output ... 21 L/min (5.5 US gpm)
Minimum output is attained under the following conditions:
Pump pressure ... 415 kPa (60 psi)
Pump speed ... 2400 rpm
Minimum cracking pressure of bypass valve ... 620 kPa (90 psi)
Maximum pressure of fully open bypass valve ... 965 kPa (140 psi)
(1) Dimensions for terminal bushing
Inside diameter of the terminal bushing for gear shaft ... 12.783 mm (0.5033 inch)
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Installation depth of terminal bushing ... 1.5 0.5 mm (0.06 0.02 inch)
(2) Dimensions for drive shaft assembly
Diameter of the shaft ... 12.700 to 12.675 mm (0.5000 to 0.4990 inch)

Diameter of the gear ... 29.801 0.006 mm (1.1733 0.0002 inch)
Length of the gear ... 25.347 0.008 mm (0.9979 0.0003 inch)
(4) Dimensions for idler gear assembly
Diameter of the gear ... 29.801 0.006 mm (1.1733 0.0002 inch)

Length of the gear ... 25.347 0.008 mm (0.9979 0.0003 inch)
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Specifications
i02895028
Fuel Injector Mechanism

SMCS - 1102; 1290
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
S/N - C8R1-UP
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(3) Timing pin
(A) Bore in the sleeve bearing for the rocker arm shaft assembly after installation ... 45.077
0.015 mm (1.7747 0.0006 inch)
(1) Torque for the nut ... 120 15 Nm (90 11 lb ft)
(B) Diameter of the rocker arm shaft ... 45.000 0.013 mm (1.7716 0.0005 inch)
(2) 100-3878 Injector Spring

Test force ... 300 25 N (67.4 5.6 lb)
(C) Dimensions for the unit injector lifter assembly
Diameter of the unit injector lifter assembly ... 34.950 0.010 mm (1.3760 0.0004 inch)
Bore in the head for the unit injector lifter assembly ... 35.000 0.025 mm (1.3779 0.0010
inch)
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(4) Lubricate the bore of the O-ring seal lightly with clean engine oil.
Note: Start the retainer nuts of the cap assembly by hand so that the terminal studs are not cross
threaded.
(5) Torque for the cap assembly ... 2.50 0.25 Nm (22 2 lb in)
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Specifications
i02895694
Fuel Injector
SMCS - 1290
S/N - -
Note: Prior to installation of the fuel injector group, lubricate the bore in the cylinder head with
1P-0808 Multipurpose Grease . Use the clamp to press the injector into the bore. Do not tap on the
top surface of the injector.
(1) Torque for the bolt ... 65 7 Nm (48 5 lb ft)
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(A) Timing dimension ... 64.34 0.20 mm (2.533 0.008 inch)
Note: Before assembly, lubricate the bore and the threads of valve assembly (2) with 1P-0808
Multipurpose Grease .
(2) Valve assembly
Torque for valve assembly ... 165 10 Nm (120 7 lb ft)

Torque for terminal nuts ... 2.4 0.2 Nm (21 2 lb in)
(3) Torque for unit injector nozzle ... 310 20 Nm (230 15 lb ft)
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Specifications
i02874925
Camshaft
SMCS - 1210
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
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(1) Left hand camshaft assembly
(2) Right hand camshaft assembly
(A) Thickness of the groove in a new camshaft assembly ... 8.75 0.05 mm (0.344 0.002 inch)
(C) Extension of the dowel from the camshaft assembly ... 12.0 0.5 mm (0.47 0.02 inch)
(D) Thickness of a new thrust washer ... 8.50 0.05 mm (0.335 0.002 inch)
(E) Journal surface
Diameter of bearing journals for a new camshaft ... 91.88 0.02 mm (3.617 0.001 inch)
Bore in camshaft bearing after installation ... 92.00 0.06 mm (3.622 0.002 inch)
Note: End play for a new camshaft assembly is 0.15 to 0.35 mm (0.006 to 0.014 inch).
(3) Torque for 16 bolts ... 55 7 Nm (41 5 lb ft)
(F) Extension of the dowel from the end of the rear right hand camshaft and the front left hand
camshaft ... 22.0 0.5 mm (0.87 0.02 inch)
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Use the following procedure in order to determine the camshaft lobe lift:
1. Measure camshaft lobe height (H) .
2. Measure base circle (J) .
3. Subtract the base circle (J) from the camshaft lobe height (H). The difference is the actual
camshaft lobe lift.
(G) Specified camshaft lobe lift
Inlet lobe ... 12.7500 mm (0.50197 inch)

Injector lobe ... 13.7313 mm (0.54060 inch)
Exhaust lobe ... 13.2499 mm (0.52165 inch)
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Specifications
i02990771
Camshaft
SMCS - 1210
S/N - 5PS1-UP
S/N - 7AF1-UP
S/N - C8R1-UP
(1) Left hand camshaft assembly
(2) Right hand camshaft assembly
(A) Thickness of the groove for thrust washer in a new camshaft assembly ... 8.75 0.05 mm
(0.344 0.002 inch)
(B) Extension of the dowel from the camshaft assembly ... 12.0 0.5 mm (0.47 0.02 inch)
(C) Thickness of a new thrust washer ... 8.50 0.05 mm (0.335 0.002 inch)
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(D) Dimensions for the journal surface
Diameter of bearing journal ... 91.88 0.02 mm (3.617 0.001 inch)

Bore in camshaft bearing after installation ... 92.00 0.06 mm (3.622 0.002 inch)
Note: End play for a new camshaft assembly is 0.15 to 0.35 mm (0.006 to 0.014 inch).
(E) Specified camshaft lobe lift
Inlet lobe ... 12.7500 mm (0.50197 inch)

Injector lobe ... 13.7313 mm (0.54060 inch)
Exhaust lobe ... 13.2500 mm (0.52165 inch)
Use the following procedure in order to determine the actual camshaft lobe lift:
1. Measure camshaft lobe height (F) .
2. Measure base circle (G) .
3. Subtract the base circle (G) from the camshaft lobe height (F) . The difference is the actual
camshaft lobe lift.
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Specifications
i02703316
Valve Mechanism
SMCS - 1102
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
S/N - C8R1-UP
Type 1
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(1) Torque for the locknut ... 70 15 Nm (50 11 lb ft)
(3) Dowel
Diameter of the new dowel ... 11.008 0.003 mm (0.4334 0.0001 inch)
Bore in the bridge for the dowel ... 11.07 0.03 mm (0.436 0.001 inch)
Bore in the head for the dowel ... 10.968 0.020 mm (0.4318 0.0008 inch)
(4) Guide springs
Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8172, "Visual Inspection of
the 7N-4782 Lifter Guide Spring 3500 Fmaily of Engines".
(A) Rocker arm shaft
After the 123-4271 Sleeve Bearing is installed in the rocker arm the bearing must be
machined to size. ... 45.056 0.015 mm (1.7739 0.0006 inch)
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Maximum roughness average (Ra) ... 0.8 micrometer (32 microinch)

Diameter of the rocker arm shaft ... 45.000 0.013 mm (1.7716 0.0005 inch)
(B) Valve lash
Inlet ... 0.50 mm (0.020 inch)

(C) Height to the top of the dowel ... 66.5 0.5 mm (2.62 0.02 inch)
(D) Valve lifter
Diameter of the new valve lifter ... 29.900 0.010 mm (1.1772 0.0004 inch)
Bore in the head for the valve lifter ... 30.000 0.025 mm (1.1811 0.0010 inch)
Type 2
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(6) Guide springs
Refer to Guidelines for Reusable Parts and Salvage Operations, SEBF8172, "Visual Inspection of
the 7N-4782 Lifter Guide Spring 3500 Fmaily of Engines".
(E) Rocker arm shaft
Diameter of the rocker arm shaft ... 45.000 0.013 mm (1.7716 0.0005 inch)
(F) Valve lash
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Inlet ... 0.50 mm (0.020 inch)

(G) Valve lifter
Diameter of the new valve lifter ... 29.900 0.010 mm (1.1772 0.0004 inch)
Bore in the head for the valve lifter ... 30.000 0.025 mm (1.1811 0.0010 inch)
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Specifications
i03129420
Cylinder Head
SMCS - 1100
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
Typical example
(1) Locating pad
(2) Pipe plug
NOTICE
The pipe plug at location (2) MUST be installed on this engine.
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Use the following procedure to tighten the cylinder head bolts:
Note: Before assembly, coat the threads of the cylinder head bolts with clean engine oil.
1. Tighten the bolt 1 through bolt 8 in the numerical sequence that is shown in Illustration 2 to
30 5 Nm (22 4 lb ft).
400 35 Nm (300 26 lb ft).
575 20 Nm (420 15 lb ft).
Note: Tighten the bolts (3) only after the cylinder head bolts have been given final torque.
(3) Torque for two bolts ... 55 10 Nm (41 7 lb ft)
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Typical example
Note: Apply 6V-6640 Sealant to the bores of the cup plugs before assembly.
(A) Depth of the cup plugs in the top of the cylinder head ... 9.0 0.5 mm (0.35 0.02 inch)
(B) Height of new cylinder head ... 142.00 0.15 mm (5.591 0.006 inch)
(C) Depth of the cup plugs in the cylinder head below the bottom of the chamfer ... 1.0 0.5 mm
(0.04 0.02 inch)
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Specifications
i03076672
Cylinder Head
SMCS - 1100
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
Typical example
(1) Locating pad
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NOTICE
The pipe plug at location (2) is installed in the cylinder head for
engines with dry exhaust manifolds. If the pipe plug is not installed into
the water passage, the coolant will leak and engine damage will result.
For engines with dry exhaust manifolds, make sure that the pipe plug
is installed.
Typical example
Top view
(3) Before assembly, lubricate the thread of the pipe plug.
Use the following procedure to tighten the bolts of the cylinder head that is shown in Illustration
2:
Note: Before assembly, coat the threads of the bolt with clean engine oil.
1. Tighten the bolt 1 through bolt 8 in the numerical sequence to 30 5 Nm (22 4 lb ft).
2. Tighten the bolt 1 through bolt 8 in the numerical sequence to 200 15 Nm (150 11 lb
ft).
3. Again tighten the bolt 1 through bolt 8 in the numerical sequence to 200 15 Nm (150
11 lb ft).
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4. Turn the bolt 1 through bolt 8 in the numerical sequence to an additional rotation of 180 5
degrees.
Typical example
(A) Height of the new cylinder head ... 142.00 0.15 mm (5.591 0.006 inch)
Note: Before assembly, apply 6V-6640 Sealant to the bore of the ten cup plugs.
(B) Installation depth of two cup plugs from the top surface of the cylinder head ... 9.0 0.5 mm
(0.35 0.02 inch)
(D) Installation depth of eight cup plugs from the top surface of the cylinder head ... 1.0 0.5 mm
(0.04 0.02 inch)
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Specifications
i03167032
Cylinder Head
SMCS - 1100
S/N - -
Typical example
(1) Locating pad
(2) Pipe plug
NOTICE
The pipe plug at location (2) MUST be installed on this engine.
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Typical example
Use the following procedure to tighten the cylinder head bolts:
Note: Lubricate the threads of the bolts for the cylinder head with clean engine oil before
assembly.
30 5 Nm (22 4 lb ft).
200 15 Nm (150 11 lb ft).
3. Again tighten the bolt 1 through bolt 8 in the numerical sequence that is shown in
Illustration 2 to 200 15 Nm (150 11 lb ft).
4. Turn the bolt 1 through bolt 8 in the numerical sequence that is shown in Illustration 2 to an
additional rotation of 180 5 degrees.
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Typical example
Note: Apply 6V-6640 Sealant to the bores of the cup plugs before assembly.
(A) Depth of the cup plugs in the top of the cylinder head ... 9.0 0.5 mm (0.35 0.02 inch)
(B) Height of new cylinder head ... 142.00 0.15 mm (5.591 0.006 inch)
(C) Depth of the cup plugs in the cylinder head below the bottom of the chamfer ... 1.0 0.5 mm
(0.04 0.02 inch)
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Specifications
i03129740
Cylinder Head Valves

SMCS - 1105
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
(1) 101-1180 Spring
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Quantity ... 4
Test force ... 450 23 N (101.2 5.1 lb)
(2) 101-1177 Spring
Quantity ... 4
Test force ... 133 7 N (30.0 1.6 lb)
Note: Coat the inlet valve stems and the exhaust valve stems with clean engine oil prior to
installation into the cylinder head.
(A) Dimensions for the valves
Diameter of the new valves ... 9.441 0.008 mm (0.3717 0.0003 inch)
Bore in intake and exhaust valve guides after installation of valve guides into cylinder head
assembly ... 9.487 0.025 mm (0.3735 0.0010 inch)
(B) Height from the top of the cylinder head to the top of the valve guides ... 26.0 2.0 mm (1.02
0.08 inch)
(C) Valve face angle ... 29.50 0.25 degrees
(D) Outside diameter of the valve heads ... 56.00 0.15 mm (2.205 0.006 inch)
(E) Depth of counterbore for valve seat inserts ... 16.00 0.15 mm (0.630 0.006 inch)
(F) Angle of the face of the valve seat insert ... 30.25 0.25 degrees
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Note: For installation, reduce the temperature of the valve seat inserts to 20 C (4 F). Apply
4C-9506 Retaining Compound to the outside diameter of the valve seat inserts and install the
valve seat inserts. Do not hammer the valve seat inserts.
(G) Dimensions for the valve seat inserts
Diameter of counterbore for inlet valve seat inserts ... 60.508 0.025 mm (2.3822 0.0010
inch)
Diameter of counterbore for exhaust valve seat inserts ... 60.000 0.025 mm (2.3622
0.0010 inch)
Outside diameter of inlet valve seat inserts ... 60.119 0.015 mm (2.3669 0.0006 inch)
Outside diameter of Exhaust valve seat inserts ... 60.627 0.015 mm (2.3869 0.0006 inch)
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Specifications
i02894904
Cylinder Head Valves

SMCS - 1105
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
S/N - C8R1-UP
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Typical example
Note: Before assembly, coat the inlet valve stems and the exhaust valve stems with clean engine oil.
(A) Height from the top of the cylinder head to the top of the valve guides ... 26.0 1.0 mm (1.02
0.04 inch)
(1) 281-6157 Spring
Quantity ... 4
Test force ... 562.0 28.0 N (126.3 6.3 lb)
(2) 194-4902 Spring
Quantity ... 4
Test force ... 146.0 7.3 N (32.8 1.6 lb)
(3) Install the two valve stem seals to the inlet valves.
(4) Install the two washers to the exhaust valves.
(B) Dimension for the valves
Diameter of the inlet valve stems ... 9.441 0.010 mm (0.3717 0.0004 inch)
Diameter of the exhaust valve stems ... 12.464 0.025 mm (0.4907 0.0010 inch)
(C) Bore in cylinder head for valve seat inserts
Inlet ... 60.508 0.025 mm (2.3822 0.0010 inch)

Exhaust ... 60.000 0.025 mm (2.3622 0.0010 inch)
(5) Valve guide
Bore of the inlet valve guide after installation ... 9.487 0.025 mm (0.3735 0.0010 inch)
Bore of the exhaust valve guide after installation ... 12.619 0.025 mm (0.4968 0.0010 inch)
(D) Valve face angles
Inlet ... 19.40 0.25 degrees

Exhaust ... 44.40 0.25 degrees
(E) Diameter of the valve heads ... 56.00 0.15 mm (2.205 0.006 inch)
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Typical example
(F) Diameter of the valve seat inserts
Inlet ... 60.627 0.015 mm (2.3869 0.0006 inch)

Exhaust ... 60.119 0.015 mm (2.3669 0.0006 inch)
(G) Angle of the face of valve seat inserts
Inlet ... 20.00 0.25 degrees

Exhaust ... 45.00 0.25 degrees
(H) Depth of bore in cylinder head for valve seat inserts ... 16.00 0.15 mm (0.630 0.006 inch)
(J) Outside diameter of the face of the valve seat inserts ... 53.6 mm (2.11 inch)
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Specifications
i03139721
Turbocharger
SMCS - 1052
S/N - 5PS1-UP
S/N - 7AF1-UP
S/N - C8R1-UP
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Note: Before assembly, lubricate the threads and the bearing surface of the bolts (1) and the bolts
(2) with 4C-5599 Anti-Seize Compound .
(1) Torque for eight bolts ... 54 5 Nm (40 4 lb ft)
Use the following procedure in order to tighten the clamp assemblies (2) :
1. Tighten the clamp assemblies to 14 3 Nm (125 27 lb in).
2. Gently tap around the clamp assemblies.
3. Again, tighten the clamp assemblies to 14 3 Nm (125 27 lb in).
Use the following procedure in order to tighten the bolts for the half flange (3) :
1. Tighten bolts (4) in any sequence to 54 5 Nm (40 4 lb ft).
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Specifications
i03139981
Turbocharger
SMCS - 1052
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 8DF1-UP
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Note: Before assembly, lubricate the threads and the bearing surface of the bolts (1) and the bolts
(2) with 4C-5599 Anti-Seize Compound .
(1) Use the following procedure in order to tighten the flange nuts:
1. Align the joint in order to get all four flange nuts started on the bolts.
2. Snug bolts for the joint
3. Tighten the bolts in a crisscross pattern to 54 5 Nm (40 4 lb ft).
4. Again, tighten the bolts in a crisscross pattern to 54 5 Nm (40 4 lb ft).
Typical example
Tighten the bolts for the compressor housing to 40 2 Nm (30 1 lb ft).
Tighten the bolts for the turbine housing to 40 2 Nm (30 1 lb ft).
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Specifications
i03414341
Turbocharger
SMCS - 1052
S/N - 3ZW1-UP
Note: Before assembly, lubricate the threads and the bearing surface of the bolts with 4C-5599
Anti-Seize Compound .
(1) Torque for the bolts to the exhaust manifold ... 54 5 Nm (40 4 lb ft)
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(5) Cartridge's bolt torque ... 40 2 Nm (30 1 lb ft)
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Specifications
i03140083
Turbocharger
SMCS - 1052
S/N - 6HZ1-UP
S/N - 9WF1-UP
Rear view
(1) Torque for four V-band clamp assemblies ... 60 5 Nm (44 4 lb ft)
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Specifications
i03119342
Turbocharger Support
SMCS - 1052
S/N - 6HZ1-UP
51
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Specifications
i03114083
Exhaust Manifold
SMCS - 1059
S/N - 5PS1-UP
S/N - 7AF1-UP
S/N - C8R1-UP
Top view of engine
Note: Apply 4C-5599 Anti-Seize Compound to the threads of the bolts and to the face of the
washers. Tighten diagonally opposite bolts simultaneously.
(1) Torque for the bolts ... 55 5 Nm (41 4 lb ft)
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washers.
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Specifications
i03114039
Exhaust Manifold
SMCS - 1059
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
Typical example
Top view of engine
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Rear view of engine
washers. Tighten diagonally opposite bolts simultaneously.
55
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Specifications
i03114005
Air Cleaner Adapter

SMCS - 1051
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
(1) Torque for 32 bolts ... 12 4 Nm (105 35 lb in)
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Specifications
i03134947
Air Inlet and Exhaust Lines

SMCS - 1058; 1061
S/N - 5PS1-UP
S/N - 6HZ1-UP
Front view of engine
(1) Lubricate the bore for the O-ring seals with glycerin or an approved equivalent.
Note: Lubricate the threads of the plugs (2) and the threads of the bolts (3) with 4C-5599 Anti-Seize
Compound before assembly.
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(2) Torque for four plugs ... 20 5 Nm (15 4 lb ft)
Right side view of engine
Bolt tightening sequence
(4) Use the following procedure in order to tighten the bolts of the aftercooler assembly:
1. Assemble the seals to the aftercooler core.
2. Temporarily secure the bottom seal to the aftercooler with tape. Do not use an adhesive, a
silicone lubricant, or any other lubricant for retention of the seal.
3. Assemble the aftercooler with seals to the inlet manifold.
4. Inspect the bottom seal in order to ensure that the seal is seating correctly in the recess.
5. Install the aftercooler cover.
6. Inspect the upper seal in order to ensure that the seal is seating correctly in the recess.
7. Install the cover bolts. Hand tighten the cover bolts.
8. Tighten the bolts in the numerical sequence to 24 Nm (18 lb ft).
9. Again, tighten the bolts in the numerical sequence to 47 Nm (35 lb ft).
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10. Remove the tape.
59
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Specifications
i03127722

SMCS - 1058; 1061
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 8DF1-UP
60
____________________________________________________________________________________________________________________________
Note: Lubricate the threads of the plugs with 4C-5599 Anti-Seize Compound before assembly.
(3) Torque for two plugs ... 20 5 Nm (15 4 lb ft)
61
____________________________________________________________________________________________________________________________
Specifications
i03690160

SMCS - 1058; 1061
S/N - 5PS1-UP
S/N - 7AF1-UP
S/N - C8R1-UP
62
____________________________________________________________________________________________________________________________
(1) Before assembly, lubricate the bore of the O-ring seals lightly with 5P-3975 Rubber Lubricant .
8. Tighten the bolts in the numerical sequence to 24 6 Nm (212 53 lb in). Refer to Illustration
2.
9. Again, tighten the bolts in the numerical sequence to 24 6 Nm (212 53 lb in). Refer to
Illustration 2.
Note: Before assembly, lubricate the threads of the plugs with 4C-5599 Anti-Seize Compound .
(3) Torque for the plugs ... 20 5 Nm (177 44 lb in)
63
____________________________________________________________________________________________________________________________
Specifications
i03137489

SMCS - 1058; 1061
S/N - 6HZ1-UP
S/N - 9WF1-UP
64
____________________________________________________________________________________________________________________________
View A-A
65
____________________________________________________________________________________________________________________________
View B-B
Note: Lubricate the threads of the plugs with 4C-5599 Anti-Seize Compound before assembly.
(4) Torque for two plugs ... 20 5 Nm (15 4 lb ft)
66
____________________________________________________________________________________________________________________________
Specifications
i03557502
Engine Oil Pump

SMCS - 1304
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
Note: The rotation of the drive gear is clockwise when you view the engine oil pump from the
drive end.
Note: Before you install the pump, lubricate the moving parts with clean engine oil. Rotate the
pump by hand in order to ensure that the pump rotates freely.
(1) 107-7175 Spring

Test force ... 555.6 20.0 N (124.9 4.5 lb)
67
____________________________________________________________________________________________________________________________
(B) Dimension for the gears
Length of new gear ... 110.000 0.015 mm (4.3307 0.0006 inch)

Depth of the bore in the oil pump body for new gear ... 110.15 0.02 mm (4.337 0.001
inch)
(C) Dimensions for the idler shaft
Diameter of new shaft ... 31.742 0.008 mm (1.2497 0.0003 inch)

Bore in the sleeve bearing for the new shaft ... 31.811 0.013 mm (1.2524 0.0005 inch)
(D) Extension of the hollow dowel from the oil pump cover ... 6.0 0.5 mm (0.24 0.02 inch)
(E) Distance from the end of the pump shaft assembly to the gear face ... 34.0 0.5 mm (1.34
0.02 inch)
(F) Dimensions for the pump drive shaft
Diameter of new pump drive shaft ... 31.742 0.008 mm (1.2497 0.0003 inch)
Bore in the sleeve bearing for the pump drive shaft after assembly ... 31.811 0.013 mm
(1.2524 0.0005 inch)
68
____________________________________________________________________________________________________________________________
(G) Distance from the gear face to the pump drive shaft assembly ... 47.0 0.5 mm (1.85 0.02
inch)
(H) Installation depth of the sleeve bearing in the pump cover ... 1.5 0.5 mm (0.06 0.02 inch)
(J) Installation depth of the sleeve bearing in the oil pump body assembly ... 1.5 0.5 mm (0.06
0.02 inch)
69
____________________________________________________________________________________________________________________________
(K) Position of the bearing joints from the centerline through the bearing bores ... 45 15 degrees
(2) Pump cover
(L) Extension of the hollow dowel from the oil pump cover ... 6.0 1.0 mm (0.24 0.04 inch)
Bench test specifications
Unrestricted flow rate per minute at 1000 rpm ... 410 L (108 US gal)
Pump pressure at 300 rpm with fully blocked outlet ... 570 to 630 kPa (83 to 91 psi)
70
____________________________________________________________________________________________________________________________
Specifications
i03602902
Engine Oil Pump

SMCS - 1304
S/N - 5PS1-UP
S/N - 7AF1-UP
S/N - C8R1-UP
drive end.
(1) 2S-2760 Spring

Test force ... 499 24 N (112 5 lb)
Approximate free length after test ... 152.91 mm (6.020 inch)
71
____________________________________________________________________________________________________________________________
(2) Before assembly, lubricate the O-ring seal lightly with 5P-3975 Rubber Lubricant .
(B) Dimensions for the gears

Depth of the bore in the oil pump body for the new gear ... 54.15 0.02 mm (2.132 0.001
inch)
(C) Dimensions for the pump shaft
Diameter of the new shaft ... 31.742 0.008 mm (1.2497 0.0003 inch)
Bore in the sleeve bearing for the new shaft after assembly ... 31.811 0.013 mm (1.2524
0.0005 inch)
(D) Extension of the hollow dowel from the pump cover ... 6.0 0.5 mm (0.24 0.02 inch)
(E) Distance from the end of the idler shaft to the gear face ... 34.0 0.5 mm (1.34 0.02 inch)

0.0005 inch)
(G) Distance from the end of the shaft to the gear face ... 47.0 0.5 mm (1.85 0.02 inch)
72
____________________________________________________________________________________________________________________________
0.02 inch)
(K) Position of bearing joints from the centerline through the bearing bores ... 45 15 degrees
73
____________________________________________________________________________________________________________________________
(3) Pump cover
Unrestricted flow rate at 700 rpm ... 135.0 L (35.7 US gal)

Pump pressure at 300 rpm with fully blocked outlet ... 570 to 630 kPa (83 to 91 psi)
74
____________________________________________________________________________________________________________________________
Specifications
i03560066
Engine Oil Pump

SMCS - 1304
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 8DF1-UP
drive end.
(1) 2S-2760 Spring

Test force ... 499 24 N (112.2 5.4 lb)
Approximate free length after test ... 152.91 mm (6.020 inch)
Outside diameter ... 27 mm (1.1 inch)
75
____________________________________________________________________________________________________________________________
(2) Before assembly, lubricate the O-ring seal lightly with 5P-3975 Rubber Lubricant .
(B) Dimensions for the gears

Depth of the bore in the oil pump body for the new gear ... 84.15 0.02 mm (3.313 0.001
inch)
(C) Dimensions for the pump shaft

0.0005 inch)
(D) Extension of hollow dowel from the oil pump cover ... 6.0 1.0 mm (0.24 0.04 inch)
(E) Distance from the end of the idler shaft to the gear face ... 34.0 0.5 mm (1.34 0.02 inch)

0.0005 inch)
(G) Distance from the end of the shaft to the gear face ... 47.0 0.5 mm (1.85 0.02 inch)
76
____________________________________________________________________________________________________________________________
0.02 inch)
(K) Position of bearing joints from the centerline through the bearing bores ... 45 15 degrees
77
____________________________________________________________________________________________________________________________
(3) Pump cover
Unrestricted flow rate at 700 rpm ... 220 L/min (58.1 US gpm)
Pump pressure at 300 rpm with fully blocked outlet ... 570 to 630 kPa (83 to 91 psi )
78
____________________________________________________________________________________________________________________________
Specifications
i03562881
Engine Oil Cooler Bypass and Cooling Jet Sequence Valves

SMCS - 1314; 1331
S/N - -
79
____________________________________________________________________________________________________________________________
Front view
(1) Lubricate the bore of the O-ring seals lightly with the clean engine oil.
(2) Torque for the plug ... 100 15 Nm (74 11 lb ft)
Use the following tightening sequence for the clamp bolts:
1. Snugly tighten the clamp assembly (6) to the tube assembly (7) .
2. Tighten the two bolts (5) of the clamp assembly to the outlet adapter (3) to 47 9 Nm (35 7
lb ft).
3. Tighten the two bolts (4) of the clamp assembly to the tube assembly (7) to 47 9 Nm (35 7
lb ft).
Note: The oil cooler bypass valve must open with a pressure difference of 180 20 kPa (26 3 psi).
80
____________________________________________________________________________________________________________________________
(8) 2W-1635 Spring for oil cooler bypass valve

Test force ... 518 26 N (116 6 lb)
Note: The cooling jet sequence valves must start to open at a pressure difference of 130 30 kPa (19
4 psi).
Note: The cooling jet sequence valves must be fully open at a pressure difference of 200 30 kPa
(29 4 psi).
(9) 6B-9202 Spring for the cooling jet sequence valve

Test force ... 85 to 100 N (19.0 to 22.4 lb)
81
____________________________________________________________________________________________________________________________
Specifications
i03670352
Engine Oil Filter

SMCS - 1318
S/N - -
82
____________________________________________________________________________________________________________________________
Front view
(1) Lubricate the bore of the O-ring seals lightly with clean engine oil.
(2) 2W-1635 Spring

Test force ... 518 26 N (116 6 lb)
Note: The bypass valve (3) must move freely in the bore.
(3) Bypass valve
Start to open pressure ... 287 7 kPa (41.6 1.0 psi)

Fully open pressure ... 480 7 kPa (69.6 1.0 psi)
83
____________________________________________________________________________________________________________________________
84
____________________________________________________________________________________________________________________________
Specifications
i03742181
Engine Oil Filter

SMCS - 1318
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
Front view
(1) Lubricate the bore of the O-ring seals lightly with clean engine oil.
85
____________________________________________________________________________________________________________________________
(3) 2W-1635 Spring

Test force ... 518 26 N (117 6 lb)
Free length after test force ... 143.4 mm (5.65 inch)
Note: Bypass valve (4) must move freely in the bore.
(4) Bypass valve
Start to open pressure: ... 287 7 kPa (42 1 psi)

Fully open pressure: ... 480 7 kPa (70 1 psi)
86
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Specifications
i03137363
Crankcase Breather
SMCS - 1317
S/N - 5PS1-UP
S/N - 7AF1-UP
S/N - C8R1-UP
(3) Breather assembly
(4) Cover assembly
(1) Lubricate the bore of two O-ring seals lightly with clean engine oil.
(2) Torque for three hose clamps ... 3.0 0.5 Nm (27 4 lb in)
87
____________________________________________________________________________________________________________________________
Specifications
i02712900
Crankcase Breather
SMCS - 1317
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
Typical example
(1) Breather assembly
(2) Cover assembly
(3) Torque for the hose clamps ... 3.0 0.5 Nm (27 4 lb in)
88
____________________________________________________________________________________________________________________________
Specifications
i03139762
Engine Oil Pan

SMCS - 1302
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
S/N - C8R1-UP
89
____________________________________________________________________________________________________________________________
Typical example
(1) Before assembly, apply 1P-0808 Multipurpose Grease in order to lubricate the bores of the O-ring
seals.
(2) As required, apply 8T-9014 Silicone Sealant or 138-8436 Liquid Gasket to the joints of the
gasket.
(4) Torque for two oil drain plugs ... 145 15 Nm (105 11 lb ft)
In order to prevent stress on the tube assembly (6) , use the following tightening procedure during
assembly:
1. Tighten two bolts (5) to 47 9 Nm (35 7 lb ft).
2. Tighten two bolts (3) to 47 9 Nm (35 7 lb ft).
90
____________________________________________________________________________________________________________________________
Specifications
i01957454
Water Temperature Regulator

SMCS - 1355
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
S/N - C8R1-UP
Fully open temperature ... 92 C (197 F)
91
____________________________________________________________________________________________________________________________
Minimum opening distance at 92 C (197 F) ... 10.4 mm (0.41 inch)
92
____________________________________________________________________________________________________________________________
Specifications
i03700561
Water Pump
SMCS - 1361
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
S/N - C8R1-UP
93
____________________________________________________________________________________________________________________________
(2) Ring assembly
(3) Water pump seal group
(1) Do not lubricate the sealing lip of the lip type seal.
(4) Lubricate the bore of the O-ring seals with glycerin or an approved equivalent.
(5) Lubricate the shaft with a thin film of clean engine oil before pressing the impeller onto the shaft.
The end of the shaft must be flush with the face of the impeller within 0.15 mm (0.006 inch).
(B) Bore of the impeller for new shaft ... 25.342 0.013 mm (0.9977 0.0005 inch)
(C) Width of the groove for thrust washer ... 8.75 0.05 mm (0.344 0.002 inch)
(D) Thickness of new thrust washer ... 8.5 mm (0.33 inch)
(E) Clearance between the impeller and the cover ... 0.5000 0.4925 mm (0.01968 0.01939 inch)
(6) Torque for the taperlock studs ... 35 5 Nm (26 4 lb ft)
(7) Torque for the full nuts ... 27 4 Nm (239 35 lb in)
Minimum leakage per minute for the lip type seal at 138 kPa (20 psi) of air pressure is less than 24 cc
(1.5 cu in).
Minimum leakage per minute for the water pump seal assembly at 138 kPa (20 psi) of air pressure is
less than 20 cc (1.2 cu in).
94
____________________________________________________________________________________________________________________________
Specifications
i03780690
Auxiliary Water Pump

SMCS - 1371
S/N - -
Typical example
(A) Width of groove in the shaft for thrust washer ... 6.25 0.05 mm (0.246 0.002 inch)
(B) Thickness of the new thrust washer ... 6.000 0.025 mm (0.2362 0.0010 inch)
(C) Dimensions of the shaft
95
____________________________________________________________________________________________________________________________
Bore in the sleeve bearing for auxiliary drive shaft ... 75.000 0.055 mm (2.9528 0.0022
inch)
Diameter of new auxiliary drive shaft (not shown) ... 74.900 0.015 mm (2.9488 0.0006
inch)
(D) Dimensions for the impeller
Bore diameter of the impeller ... 19.000 0.013 mm (0.7480 0.0005 inch)
Diameter in the shaft for impeller ... 19.050 to 19.063 mm (0.7500 to 0.7505 inch)
(E) Installation depth of the sleeve bearing in the water pump housing ... 1.5 0.5 mm (0.06 0.02
inch)
Note: Do not lubricate the sealing lip of the lip type seal (1) .
Minimum leakage per minute for the lip type seal at 138 kPa (20 psi) of air pressure is less than 24 cc
(1.5 cu in).
(3) Use the following procedure in order to assemble the water pump seal assembly.
1. Lubricate the outside diameter of ceramic ring and rubber seal (2) with clean water or with
207-1600 Rubber Lubricant .
2. Orient the polished face of the ceramic ring toward water pump seal assembly.
3. Use the installation tool and hand pressure to seat the ceramic ring and the rubber seal into the
water pump housing.
4. Remove spring (4) from the water pump seal assembly.
5. Lubricate the inside diameter of the water pump seal assembly with clean water or with 207-
1600 Rubber Lubricant .
6. Use the seal installation tool and hand pressure to install the water pump seal assembly onto the
shaft until the face of the water pump seal assembly makes light contact with the face of the
ceramic ring and rubber seal.
7. Install spring (4) onto the water pump seal assembly.
Assembled length of the spring ... 17.45 0.79 mm (0.687 0.031 inch)
Load on spring at assembled length ... 40.03 4.45 N (9.0 1.0 lb)
Minimum leakage per minute for the water pump seal assembly at 138 kPa (20 psi) of air pressure is
less than 20 cc (1.2 cu in).
(6) Lubricate the shaft with a thin film of clean engine oil before pressing the impeller (5) onto the
shaft. The end of the shaft must be flush with the face of the impeller within 0.15 mm (0.006 inch).
(7) Lubricate the bore of the O-ring seal lightly with sealant that is being sealed.
(8) Lubricate the bore of the O-ring seal with clean engine oil, glycerin or clean water.
96
____________________________________________________________________________________________________________________________
Specifications
i03152764
Cylinder Block
SMCS - 1201
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
S/N - C8R1-UP
97
____________________________________________________________________________________________________________________________
Front view
Right side view
98
____________________________________________________________________________________________________________________________
Note: During assembly, the bottom of spacer plates, top of cylinder block and both sides of plate
gasket must be free of fuel, oil, water, gasket adhesives, assembly compounds and any other
contaminants.
(A) Thickness of the spacer plate ... 12.313 mm (0.4848 inch)
(B) Thickness of the plate gasket between the cylinder block and spacer plate ... 0.194 to 0.218
mm (0.0076 to 0.0086 inch)
(C) Extension of the dowel from the top face of the cylinder block ... 21.0 0.5 mm (0.83 0.02
inch)
(2) Lubricate the bore of the O-ring seals lightly with the lubricant that is being sealed.
(D) Height of the cylinder liner
For the correct method of determining the height of the cylinder liner, refer to Testing And
Adjusting, "Cylinder Liner Projection".
(E) Bore in the block for the camshaft bearings ... 98.000 0.020 mm (3.8583 0.0008 inch)
(F) The oil holes in the camshaft bearings must be positioned from horizontal at the following
angle: ... 20 5 degrees
Note: All centerlines through the oil holes in the camshaft bearings (F) and the camshaft bearing
joints (3) must be in the position that is shown for each side of the cylinder block.
(G) New dimension from centerline of crankshaft bearing bore to the top of the block ... 586 mm
(23.1 inch)
(H) New dimension from centerline of crankshaft bearing bore to bottom of block (pan rails) ...
230 mm (9.1 inch)
(J) Bore in the block for the main bearings
Standard, original new size ... 169.742 0.020 mm (6.6827 0.0008 inch)
0.63 mm (0.025 inch) larger than original size ... 170.372 0.020 mm (6.7075 0.0008
inch)
(K) Dimension for crankshaft main bearing cap
Width of crankshaft main bearing cap ... 340.030 0.015 mm (13.3870 0.0006 inch)
Width of cylinder block for crankshaft main bearing cap ... 339.985 0.015 mm (13.3852
0.0006 inch)
Tight press fit between the sides of the crankshaft main bearing cap and the cylinder
block ... 0.075 mm (0.0030 inch)
Loose press fit between the sides of the crankshaft main bearing cap and the cylinder
block ... 0.015 mm (0.0006 inch)
(4) Main bearing cap
Use the following procedure to tighten the crankshaft main bearing cap bolts:
99
____________________________________________________________________________________________________________________________
1. Install main bearing caps with the part number and "FRONT" toward the front of the block.
Each cap has a number. Each cap must be installed in the same position as the correct
number on the side of the cylinder block pan rail.
2. Before assembly, apply clean engine oil on the threads of the bolts.
3. Tighten bolt (5) through bolt (8) in the numerical sequence that is shown in Illustration 1 to
a torque of 190 14 Nm (140 10 lb ft).
4. Tighten bolt (5) through bolt (8) again in the numerical sequence to a rotation of 180 5
degrees.
(L) Extension of the dowel from the rear face of the cylinder block ... 6.0 0.5 mm (0.24 0.02
inch)
(M) Extension of the dowel from the front face of the cylinder block ... 6.0 0.5 mm (0.24 0.02
inch)
(N) Extension of the dowel from the rear face of the cylinder block ... 19.0 0.5 mm (0.75 0.02
inch)
(P) Extension of the dowel from the front face of the cylinder block ... 40.0 0.5 mm (1.57 0.02
inch)
100
____________________________________________________________________________________________________________________________
Specifications
i02871050
Cylinder Liner
SMCS - 1216
S/N - -
(A) Bore in new cylinder liner ... 170.025 0.025 mm (6.6939 0.0010 inch)
(B) Thickness of flange (1) on cylinder liner ... 12.65 0.02 mm (0.498 0.001 inch)
Use the liner again with any used piston or any new piston if all the measurements are in the
following range. Use a FLEX-HONE first. ... 170.000 to 170.152 mm (6.6929 to 6.6989 inch)
Use the liner again with the original piston if the measurements of the upper bore are in the
following range. Use a FLEX-HONE first. ... 170.000 to 170.229 mm (6.6929 to 6.7019 inch)
Use the following procedure to install the cylinder liner:
1. Apply liquid soap on the cylinder block liner bore surfaces and the rubber seals that are on
the lower end of the cylinder liner.
101
____________________________________________________________________________________________________________________________
2. Dip the filler band (2) completely in clean engine oil for a moment.
3. Immediately install the filler band in the groove that is under the flange.
4. Immediately install the cylinder liner into the cylinder block before the expansion of the
filler band.
Note: Refer to Reuse And Salvage Guidelines, SEBF8049, "Visual Inspection of the Piston" for
more information. Also, refer to Guideline For Reusable Parts And Salvage Operations,
SEBF8068, "Cylinder Liners" for more information.
102
____________________________________________________________________________________________________________________________
Specifications
i03661131
Piston and Rings - One-Piece Piston

SMCS - 1214
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
103
____________________________________________________________________________________________________________________________
Use the 246-1176 Piston Ring Groove Gauge Gp for measuring the top ring groove.
Use the 1U-6431 Piston Ring Groove Gauge Gp for measuring the intermediate ring groove. Refer
to the instruction card that is with the gauge group.
Top Piston Ring (1)

Install the top piston ring with the "UP-1" side toward the top of the piston.
When the new top piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch),
the clearance between the ends of the piston ring is the following value. ... 0.625 0.125 mm
(0.0246 0.0049 inch)
Thickness of new top piston ring ... 3.88 mm (0.153 inch)
Intermediate Piston Ring (2)

Install the intermediate piston ring with the "UP-2" side toward the top of the piston.
When the new intermediate piston ring is installed in a cylinder liner with a bore size of 170 mm
(6.7 inch), the clearance between the ends of the piston ring is the following value. ... 1.00 0.15
mm (0.039 0.006 inch)
Thickness of new intermediate piston ring ... 3.785 mm (0.1490 inch)
104
____________________________________________________________________________________________________________________________
Oil Control Piston Ring (3)

Orient the ends of the oil ring spring to 180 degrees from the gap. The white colored portion of the
piston ring must be visible at the ring end gap.
Width of groove in new piston for the oil control piston ring ... 4.04 mm to 4.07 mm (0.159 to
0.160 inch)
Thickness of new oil control piston ring ... 3.980 0.010 mm (0.1567 0.0004 inch)
When the new oil control piston ring is installed in a cylinder liner with a bore size of 170 mm
(6.7 inch), the clearance between the ends of the piston ring is the following value. ... 0.5 to 0.8
mm (0.02 to 0.03 inch)
Note: After the piston rings have been installed, rotate the piston rings so that the end gaps are
120 degrees from each other.
Note: Prior to assembly of the piston pin, the piston pin, the piston pin bore, the connecting rod
eye, and the connecting rod pin bearing must be completely lubricated with clean engine oil.
Piston Pin Bore (4)
Note: Measure the pin bore in two places. Take one measurement within the minor diameter.
Move laterally and take another measurement within the minor diameter. Take the measurements
close to the center of the pin bore. Do not take the measurements on the outside edges.
105
____________________________________________________________________________________________________________________________
(B) Angle of bushing locator on far side ... 45 degrees
(C) Bore diameter of piston pin ... 70.060 to 70.075 mm (2.7583 to 2.7562 inch)
Piston Pin (5)

Outside diameter ... 69.962 0.005 mm (2.7544 0.0002 inch)
Inside diameter ... 30.5 0.5 mm (1.20 0.02 inch)
Length ... 101.85 0.15 mm (4.010 0.006 inch)
Note: The 197-0560 Piston Pin is not interchangeable with other pistons and connecting rods.
Pin Retainer (6)

Assemble the retainer with the opening above line A-A.
Refer to Table 1 for the part numbers of the tools that are used in servicing the piston.
Table 1
Service Tools
Pt. No. Description
6V-4020 Piston Ring Expander Gp
6V-4023 Handle As
6V-4024 Guide Ring
1P-1861 Retaining Ring Pliers
1U-7616 Piston Ring Compressor Gp
246-1176 Piston Ring Groove Gauge Gp (1)
1U-6431 Piston Ring Groove Gauge Gp (2)
(1) Only for the top ring groove

(2) Only for the intermediate ring groove
106
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Specifications
i02872093
Piston and Rings - One-Piece Piston

SMCS - 1214
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
S/N - C8R1-UP
107
____________________________________________________________________________________________________________________________
Note: Refer to Guideline for Reusable Parts for information on the pistons, the piston pins, and the
retaining rings.
This piston has a square top piston ring. Use the 246-1176 Piston Ring Groove Gauge Gp for
measuring the top piston ring groove.
This piston has a keystone type of intermediate piston ring. Use the 1U-6431 Piston Ring Groove
Gauge Gp for measuring the intermediate piston ring groove. For correct use of the piston ring
groove gauge group, refer to the instruction card that is with the piston ring groove gauge group.
Note: Prior to the installation of the piston rings, the ring grooves must be completely lubricated
with clean engine oil. After assembly, the mating surfaces of the rings to the cylinder liner must be
completely lubricated with clean engine oil.
Top Piston Ring (1)

Install the top piston ring with the "UP-1" side toward the top of the piston.
When the new top piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch),
the clearance between the ends of the piston ring is the following value. ... 0.625 0.125 mm
(0.0246 0.0049 inch)
108
____________________________________________________________________________________________________________________________

Install the intermediate piston ring with the "UP-2" side toward the top of the piston.
When the new intermediate piston ring is installed in a cylinder liner with a bore size of 170 mm
(6.7 inch), the clearance between the ends of the piston ring is the following value. ... 1.00 0.15
mm (0.039 0.006 inch)

The ends of the oil control piston ring should be a distance of 180 degrees from the ring end gap
when the oil control piston ring is assembled. The white colored portion of the piston ring must be
visible at the ring end gap.
Width of groove in new piston for the oil control piston ring ... 4.04 mm to 4.07 mm (0.159 to
0.160 inch)
Thickness of new oil control piston ring ... 3.97 to 3.99 mm (0.156 to 0.157 inch)
When the new oil control piston ring is installed in a cylinder liner with a bore size of 170 mm
(6.7 inch), the clearance between the ends of the piston ring is the following value. ... 0.5 mm to
0.8 mm (0.02 to 0.03 inch)
Note: After the piston rings have been installed, rotate the piston rings so that the end gaps are
120 degrees from each other.
109
____________________________________________________________________________________________________________________________
Note: Prior to assembly of the piston pin, the piston pin, the piston pin bore, the connecting rod
eye, and the connecting rod pin bearing must be completely lubricated with clean engine oil.
Piston Pin Bore (4)
(B) Angle of bushing locator on far side ... 45 degrees
(C) Bore diameter of piston pin ... 70.0705 0.0075 mm (2.75867 0.00030 inch)
Piston Pin (5)

Dimensions for piston pin
Outside diameter of piston pin ... 69.930 0.005 mm (2.7531 0.0002 inch)
Inside diameter of piston pin ... 30.5 0.5 mm (1.20 0.02 inch)
Length of piston pin ... 102.0 + 0.0 - 0.3 mm (4.02 + 0.00 - 0.01)
Note: The 263-8955 Piston Pin is not interchangeable with the former 197-0560 Piston Pin .
Pin Retainer (6)

Assemble the pin retainer with the opening above section A-A.
Refer to Table 2 for the part numbers of the tools that are used in servicing the piston.
Table 1
Service Tools
Pt. No. Description
271-0498 Expander Ring
1P-1861 Retaining Ring Pliers
1U-7616 Piston Ring Compressor Gp
246-1176 Piston Ring Groove Gauge Gp (1)
1U-6431 Piston Ring Groove Gauge Gp (2)
(1) Only for the top ring groove

(2) Only for the intermediate ring groove
110
____________________________________________________________________________________________________________________________
Specifications
i03132941
Piston and Rings - Two-Piece Piston

SMCS - 1214
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
111
____________________________________________________________________________________________________________________________
This piston has a Keystone top and Keystone intermediate rings. The 1U-6431 Piston Ring
Groove Gauge is necessary for measuring the ring grooves in Keystone pistons. For correct use of
the gauge group, see the instruction card that is with the gauge group.
Top Piston Ring (1)

Install the top ring with the "Up-1" side toward the top of the piston.
When the piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the
clearance between the ends of the piston ring is the following value. ... 0.625 0.125 mm (0.0246
0.0049 inch)
The increase in the clearance between the ends of the piston ring for each 0.03 mm (0.001 inch)
increase in the cylinder liner bore size is the following value. ... 0.08 mm (0.003 inch)

Install the intermediate ring with the "Up-2" side toward the top of the piston.
When the piston is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the clearance
between the ends of the piston ring is the following value. ... 1.00 0.15 mm (0.039 0.006 inch)
112
____________________________________________________________________________________________________________________________

Width of groove in piston for the new piston ring ... 5.050 0.010 mm (0.1988 0.0004 inch)
Thickness of new piston ring ... 4.954 0.019 mm (0.1950 0.0007 inch)
Clearance between groove and new piston ring ... 0.067 to 0.125 mm (0.0026 to 0.0049 inch)
When the piston ring is installed in a cylinder liner with a bore size of 170 mm (6.7 inch), the
clearance between the ends of the piston ring is the following value. ... 0.70 0.19 mm (0.028
0.007 inch)
Install the oil control ring so that the gap in the spring is 180 degrees away from the gap in the
ring. The white portion of the spring must be visible at the ring gap.
After all of the piston rings have been installed, rotate the rings so that the end gaps are separated
by 120 degrees. The ring gap for the oil ring must be aligned in the plane of the pin bore.
Piston Pin Bore (4)

Measure the piston pin bore in the bushings in two places for each bushing in a vertical direction.
Bore diameter in the crown assembly for piston pin ... 70.035 0.005 mm (2.7573 0.0002 inch)
Bore diameter in the piston skirts for piston pin ... 69.983 0.005 mm (2.7552 0.0002 inch)
Piston Pin (5)

Measure the piston pin diameter on each end in a vertical and horizontal direction.
Inside diameter of the piston pin ... 35.0 0.5 mm (1.38 0.02 inch)
Outside diameter of the piston pin ... 69.962 0.005 mm (2.7544 0.0002 inch)
Length of the piston pin ... 133.00 0.13 mm (5.236 0.005 inch)
Pin Retainer (6)

Assemble the retainer with the opening toward the top of the piston.
113
____________________________________________________________________________________________________________________________
Specifications
i03660673
Connecting Rod
SMCS - 1218
S/N - -
114
____________________________________________________________________________________________________________________________
(A) Angle above the centerline on either side of the bearing joint for the sleeve bearing for the
piston pin. ... 10 degrees
Note: The connecting rod must be heated prior to installation of the sleeve bearing for the piston
pin. Do not use a torch to heat the connecting rod.
(B) The connecting rod may be heated from 175 to 260 C (347 to 500 F) for the installation of
the sleeve bearing for the piston pin. Minimum length for heating the connecting rod ... 105 mm
(4.1 inch)
Note: Thoroughly lubricate the piston pin with clean engine oil prior to assembly of the piston and
the connecting rod.
(C) Dimensions for the piston pin
115
____________________________________________________________________________________________________________________________
Bore in the sleeve bearing for the piston pin after installation of the sleeve bearing ... 70.000
0.008 mm (2.7559 0.0003 inch)
Bore in the connecting rod for the sleeve bearing for the piston pin ... 75.760 0.015 mm
(2.9827 0.0006 inch)
(D) Distance between the center of the bearings ... 380 mm (15.0 inch)
(E) Protrusion of the dowel from the connecting rod cap ... 4.0 0.5 mm (0.16 0.02 inch)
(F) Bore in the connecting rod for the bearing for the crankshaft connecting rod journal after
applying final torque to the connecting rod bolts ... 143.028 0.015 mm (5.6310 0.0006 inch)
(G) Bore in the connecting rod bearing for crankshaft ... 135.133 to 135.194 mm (5.3202 to
5.3226 inch)
(1) Etch the cylinder number on the connecting rod and the cap in this location. Mark the
connecting rod and the cap with numbers. Mark the numbers on the same side of the connecting
rod as the bearing retainer notch.
Note: Install the connecting rod in the engine with the part number to the rear of the engine.
View H-H
(3) Location pin for correct installation of connecting rod caps
(2) The chamfer side must be adjacent to the crank pin thrust surface when the connecting rod and
piston group is assembled in the engine.
Side clearance between two connecting rods on the same new crankshaft pin ... 0.850 0.332 mm
(0.0335 0.0131 inch)
Use the following procedure for tightening the connecting rod bolts:
Note: Bolt 1 and bolt 2 must be on the same end of the connecting rod cap that has bearing tabs
and location pin (3) .
116
____________________________________________________________________________________________________________________________
1. Before assembly, apply 6V-4876 Lubricant on the bolt threads, the bolt shank and the bolt
seat.
2. Tighten the bolt 1 and bolt 2 to 90 5 Nm (66 4 lb ft).
3. Tighten the bolt 3 and bolt 4 to 90 5 Nm (66 4 lb ft).
4. Again, tighten the bolt 3 and bolt 4 to 90 5 Nm (66 4 lb ft).
5. Tighten all bolts for an additional 90 5 degrees.
117
____________________________________________________________________________________________________________________________
Specifications
i01359201
Connecting Rod and Main Bearing Journals

SMCS - 1230
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
S/N - C8R1-UP
Refer to Guidelines For Reusable Parts, SEBF8009, "Main Bearings And Connecting Rod
Bearings" for more information.
Connecting Rod Bearing Journals
Table 1
Diameter Of Crankshaft Journal (Bearing Surface) For Connecting Rod Bearings
Original Size Journal

135.000 0.025 mm (5.3150 0.0010 inch)
Undersize Journal
134.370 0.025 mm (5.2902 0.0010 inch)
0.63 mm (0.025 inch)
Undersize Journal
133.730 0.025 mm (5.2650 0.0010 inch)
1.27 mm (0.050 inch)
Clearance between bearing and new journal ... 0.107 to 0.218 mm (0.0042 to 0.0086 inch)
Main Bearing Journals
118
____________________________________________________________________________________________________________________________
Table 2
Diameter Of Crankshaft Journal (Bearing Surface) For Main Bearings
Original Size Journal

160.000 0.025 mm (6.2992 0.0010 inch)
Undersize Journal
159.370 0.025 mm (6.2744 0.0010 inch)
0.63 mm (0.025 inch)
Undersize Journal
158.730 0.025 mm (6.2492 0.0010 inch)
1.27 mm (0.050 inch)
Clearance between bearing and new journal ... 0.122 to 0.241 mm (0.0048 to 0.0095 inch)
119
____________________________________________________________________________________________________________________________
Specifications
i03340020
Crankshaft
SMCS - 1202
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 9WF1-UP
(1) Thrust plates
Refer to Specifications, "Connecting Rod And Main Bearing Journals" for more information.
(B) Crankshaft end play ... 0.17 to 0.63 mm (0.007 to 0.025 inch)
120
____________________________________________________________________________________________________________________________
(2) Torque for the plugs ... 50 7 Nm (37 5 lb ft)
Note: Do not reuse counterweight bolts.
(3) Use the following procedure to tighten the bolts of the counterweight:
1. Before assembly, lubricate the threads of the bolts, the bolt shank, the washers and the contact
surface under the bolt head with 6V-4876 Lubricant .
2. Tighten all the bolts evenly to 70 5 Nm (50 4 lb ft).
3. Rotate each bolt for an additional 120 5 degrees.
121
____________________________________________________________________________________________________________________________
Specifications
i03530820
Crankshaft
SMCS - 1202
S/N - 5PS1-UP
S/N - 7AF1-UP
S/N - C8R1-UP
(1) Thrust plates
122
____________________________________________________________________________________________________________________________
2. Tighten the bolts to 200 5 Nm (150 4 lb ft).
3. Loosen the bolts.
4. Again, tighten the bolts evenly to 70 5 Nm (50 4 lb ft).
123
____________________________________________________________________________________________________________________________
Specifications
i03126565
Crankshaft
SMCS - 1202
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 8DF1-UP
(1) Thrust plates are used only on the center main bearing journal of the crankshaft.
124
____________________________________________________________________________________________________________________________
(2) Torque for six plugs ... 50 7 Nm (37 5 lb ft)
2. Tighten 36 bolts evenly to 70 5 Nm (50 4 lb ft).
125
____________________________________________________________________________________________________________________________
Specifications
i04035774
Crankshaft
SMCS - 1202
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
126
____________________________________________________________________________________________________________________________
Note: Do not reuse the counterweight bolts.
Use the following procedure to tighten the bolts (2) :
1. Before assembly, lubricate the threads of the bolts, the bolt shank, the washers, and the contact
surface under the bolt head with molylube.
2. Tighten the bolts evenly to 70 5 Nm (50 4 lb ft).
Note: After the crankshaft is assembled into the cylinder block, the crankshaft end play should be
between 0.17 to 0.63 mm (0.007 to 0.025 inch)
127
____________________________________________________________________________________________________________________________
Specifications
i03350941
Crankshaft Wear Sleeves and Seals

SMCS - 1160
S/N - -
(1) Flywheel housing group
(2) Front housing group
Note: The crankshaft seal group cannot be used once the seal has been separated from the wear
sleeve.
128
____________________________________________________________________________________________________________________________
Note: Make sure that the correct crankshaft seal group is installed on each end of the crankshaft.
(3) 113-8433 Crankshaft Seal Gp
Install the crankshaft seal group in the flywheel housing group on a standard rotation
engine.
Install thecrankshaft seal group in the front housing group on a reverse rotation engine.
(4) 113-8432 Crankshaft Seal Gp
Install the crankshaft seal group in the front housing group on a standard rotation engine.
Install the crankshaft seal group in the flywheel housing group on a reverse rotation engine.
(A) The crankshaft seal group is installed from both ends of the crankshaft at the following
distance. ... 8.0 0.5 mm (0.31 0.02 inch)
(B) The wear sleeve is installed from both ends of the crankshaft at the following distance. ... 0.5
0.5 mm (0.02 0.02 inch)
129
____________________________________________________________________________________________________________________________
Specifications
i02875170
Housing (Front)
SMCS - 1162
S/N - -
Refer to Table 2 for the correct position of the fasteners.
Note: Use a standard torque for the fasteners that are listed in Table 2.
Table 1
Front Housing Bolt
Length
Installation Chart
Diameter
Location Part mm inch
inch
1/4 1 8T-6765 Pipe Plug 14.2 0.3 0.56 0.01
1/2 2 9H-8260 Bolt 158.75 6.250
1/2 4 0S-1587 Bolt 44.45 1.750
130
____________________________________________________________________________________________________________________________
5/8 5 1D-4593 Bolt 139.7 5.50
(3) Torque for six plugs ... 25 5 Nm (18 4 lb ft)
Note: Trim gasket (6) with face (7) after assembly.
131
____________________________________________________________________________________________________________________________
Specifications
i03125700
Gear Group (Front)

SMCS - 1206
S/N - -
132
____________________________________________________________________________________________________________________________
(5) Idler gear assembly
(6) Water pump drive gear
(7) Crankshaft gear
Note: Install the socket setscrew to the bottom of the threaded hole.
(1) Torque for the socket setscrew ... 6 1 Nm (55 9 lb in)
(2) Pump drive shaft assembly
Bore in sleeve bearing after assembly ... 75.000 0.055 mm (2.9528 0.0022 inch)
Diameter of new pump drive shaft assembly ... 74.900 0.015 mm (2.9488 0.0006 inch)
(3) Lubricate the bore of four O-ring seals lightly with lubricant that is being sealed.
(4) Thrust washer
Thickness of new thrust washer ... 8.50 0.05 mm (0.335 0.002 inch)
133
____________________________________________________________________________________________________________________________
Width of groove in new pump drive shaft assembly ... 8.750 0.025 mm (0.3445 0.0010
inch)
End play for the pump drive shaft assembly ... 0.250 0.075 mm (0.0098 0.0030 inch)
(8) Shaft
Bore in sleeve bearing after machining ... 90.000 0.010 mm (3.5433 0.0004 inch)
Note: After the sleeve bearing is installed in the gear the sleeve bearing must be machined to size.
134
____________________________________________________________________________________________________________________________
Specifications
i03062920
Gear Group (Rear)

SMCS - 1206
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
S/N - C8R1-UP
135
____________________________________________________________________________________________________________________________
Rear gear train
(1) Ring
(13) Plate
Note: Before assembly, it is critical that the taper of the camshaft and the tapered bore of the
camshaft drive gear are clean, dry, and free of residue.
Refer to Disassembly and Assembly for the installation procedure for the left camshaft drive gear
(2) .
(6) Gear shaft
After the sleeve bearing is installed in the gear the sleeve bearing must be machined to size.
Diameter of the gear shaft ... 74.990 0.010 mm (2.9524 0.0004 inch)
Bore in the sleeve bearing for the gear shaft after machining ... 75.060 0.010 mm (2.9551
0.0004 inch)
Refer to Disassembly and Assembly for the installation procedure for the right camshaft drive gear
(7) .
(8) Idler shaft
136
____________________________________________________________________________________________________________________________
After the sleeve bearing is installed in the gear the sleeve bearing must be machined to size.
Diameter of the idler shaft ... 81.000 0.010 mm (3.1890 0.0004 inch)
Bore in the sleeve bearing for the idler shaft after machining ... 81.060 0.010 mm (3.1913
0.0004 inch)
Vertical line
(9) Use the following procedure to tighten the bolt for the camshaft drive gears:
1. Tighten the bolt for the camshaft drive gear to 360 40 Nm (260 30 lb ft).
2. Mark a vertical line on the head of the bolt for the camshaft drive gear. Refer to Illustration
2.
3. Place a driver against the retaining plate of the camshaft drive gear. Strike the driver solidly
with a hammer 3 to 4 times.
4. Tighten the bolt for the camshaft drive gear again to 360 40 Nm (260 30 lb ft).
137
____________________________________________________________________________________________________________________________
5. Repeat Steps 3 and 4 until the mark on the bolt turns a minimum of 90 degrees. Refer to
Illustration 3.
Rear view of engine
(14) The mark on the balancer gear assembly (4) must be in alignment with the mark on the
crankshaft gear (12) .
138
____________________________________________________________________________________________________________________________
Specifications
i03091223
Balancer Group (Front)

SMCS - 1220
S/N - 5PS1-UP
S/N - 7AF1-UP
S/N - C8R1-UP
139
____________________________________________________________________________________________________________________________
(3) Balancer gear
(4) Crankshaft gear
(1) Torque for four bolts ... 140 10 Nm (105 7 lb ft)
(B) Dimensions for the gear shaft
Diameter of the new gear shaft ... 74.900 0.015 mm (2.9488 0.0006 inch)
Bore in the sleeve bearing after assembly ... 75.000 0.053 mm (2.9528 0.0021 inch)
(C) Thickness of the thrust plate ... 6.35 0.25 mm (0.250 0.010 inch)
(2) The mark on the balancer gear must be in alignment with the mark on the crankshaft gear.
140
____________________________________________________________________________________________________________________________
Specifications
i02867501
Accessory Drive (Lower Left Hand)

SMCS - 1207
S/N - 5PS1-UP
(2) Adapter assembly
(5) Drive gear for jacket water pump and oil pump
(1) Thrust washer
141
____________________________________________________________________________________________________________________________
Quantity ... 2
Thickness of one new thrust washer ... 8.50 0.05 mm (0.335 0.002 inch)
Width of groove in new auxiliary drive shaft ... 8.750 0.025 mm (0.3445 0.0010 inch)
End play for auxiliary drive shaft ... 0.175 to 0.325 mm (0.0069 to 0.0128 inch)
(3) Lubricate the bore of the four O-ring seals lightly with the lubricant that is being sealed.
(4) Diameter of new auxiliary drive shaft ... 74.900 0.015 mm (2.9488 0.0006 inch)
(6) Bore in the sleeve bearing after assembly ... 75.000 0.055 mm (2.9527 0.0022 inch)
Note: After the bearing is installed in the idler gear assembly (7) the bearing must be machined to
size.
(8) Bearing
Bore in the bearing after assembly ... 105.970 0.010 mm (4.1720 0.0004 inch)
(9) Diameter of new idler shaft ... 105.880 0.020 mm (4.1685 0.0008 inch)
142
____________________________________________________________________________________________________________________________
Specifications
i03604440
Accessory Drive (Lower Left Hand)

SMCS - 1207
S/N - -
Front view
(2) Lightly lubricate the bore of the O-ring seals with the lubricant that is being sealed.
143
____________________________________________________________________________________________________________________________
Section B-B
(3) Diameter of the new shaft ... 89.88 0.02 mm (3.539 0.001 inch)
(4) Dimensions of the idler gear assembly
Bore in the sleeve bearing of the idler gear assembly after installation ... 90.000 0.010 mm
(3.5433 0.0004 inch)
Maximum roughness average (Ra) ... 0.8 micrometer (31.5 microinch)
Note: After the bearing is installed in the gear the bearing must be machined to size.
(5) Dimensions of the auxiliary drive shaft
Diameter of the new auxiliary drive shaft ... 74.900 0.015 mm (2.9488 0.0006 inch)
Width of groove in the new auxiliary drive shaft for the thrust washer ... 8.750 0.025 mm
(0.3445 0.0010 inch)
End play for the auxiliary drive shaft ... 0.175 to 0.325 mm (0.0069 to 0.0128 inch)
(6) Thickness of the new thrust washer ... 8.50 0.05 mm (0.335 0.002 inch)
144
____________________________________________________________________________________________________________________________
Adapter assembly
(C) Installation depth of the sleeve bearing in the adapter assembly ... 1.5 0.5 mm (0.06 0.02
inch)
(D) Bore in the sleeve bearing of the adapter assembly after installation ... 75.000 0.055 mm
(2.9527 0.0022 inch)
145
____________________________________________________________________________________________________________________________
Specifications
i03605121
Accessory Drive (Upper Right Hand)

SMCS - 1207
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
146
____________________________________________________________________________________________________________________________
(1) Lightly lubricate the bore of the O-ring seals with the lubricant that is being sealed or with the
approved equivalent.
Diameter of new auxiliary drive shaft ... 74.900 0.015 mm (2.9488 0.0006 inch)
Width of groove in the new auxiliary drive shaft ... 8.750 0.025 mm (0.3445 0.0010 inch)
Note: During assembly, align the hole in the sleeve bearing with the adapter.
(4) Bore in the sleeve bearing of the adapter assembly after installation ... 75.000 0.055 mm (2.9527
0.0022 inch)
(5) Bore in the sleeve bearing of the adapter assembly after installation ... 75.000 0.055 mm (2.9527
0.0022 inch)
147
____________________________________________________________________________________________________________________________
Specifications
i03604642

SMCS - 1207
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
Front view of engine
148
____________________________________________________________________________________________________________________________
(1) Lightly lubricate the bore of the O-ring seals with the lubricant that is being sealed.
Section A-A
Note: During assembly, align the hole in the sleeve bearing with the adapter.
(2) Bore in the sleeve bearing of the adapter assembly after installation ... 75.000 0.055 mm
(2.9527 0.0022 inch)
Diameter of the new auxiliary drive shaft ... 74.900 0.015 mm (2.9488 0.0006 inch)
Width of groove in the new auxiliary drive shaft for the thrust washer ... 8.750 0.025 mm
(0.3445 0.0010 inch)
End play for the auxiliary drive shaft ... 0.175 to 0.325 mm (0.0069 to 0.0128 inch)
149
____________________________________________________________________________________________________________________________
Adapter assembly
(D) Bore in the sleeve bearing of the adapter assembly after installation ... 75.000 0.055 mm
(2.9527 0.0022 inch)
150
____________________________________________________________________________________________________________________________
Specifications
i02895664

SMCS - 1207
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
151
____________________________________________________________________________________________________________________________
(1) Lubricate the bore of the O-ring seal lightly with the lubricant that is being sealed.
152
____________________________________________________________________________________________________________________________
Section A-A
(B) Dimensions for the sleeve bearing
Bore in sleeve bearing before assembly ... 44.475 0.025 mm (1.7510 0.0010 inch)
Diameter of accessory drive gear ... 44.400 0.015 mm (1.7480 0.0006 inch)
(C) Dimensions for the sleeve bearing
Bore in sleeve bearing after assembly ... 75.000 0.055 mm (2.9527 0.0022 inch)
Diameter of accessory drive gear ... 74.900 0.015 mm (2.9488 0.0006 inch)
153
____________________________________________________________________________________________________________________________
Specifications
i02911556
Auxiliary Drive (Lower Left Hand)

SMCS - 1207
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
154
____________________________________________________________________________________________________________________________
(5) Crankshaft gear
(1) Pump drive shaft

Width of groove in new shaft for thrust washer ... 8.750 0.025 mm (0.3445 0.0010 inch)
End play for shaft ... 0.175 to 0.325 mm (0.0069 to 0.0128 inch)
Bore in the sleeve bearing after assembly ... 75.000 0.055 mm (2.9528 0.0022 inch)
(2) Thickness of new thrust washer ... 8.50 0.05 mm (0.335 0.002 inch)
After the bearing is installed in the gear the bearing must be machined to size.
Bore in the bearing after assembly ... 90.000 0.010 mm (3.5433 0.0004 inch)
(6) Diameter of new shaft ... 89.880 0.020 mm (3.5386 0.0008 inch)
(7) Lubricate the bore of three O-ring seals with the lubricant that is being sealed.
155
____________________________________________________________________________________________________________________________
Specifications
i02869986
Flywheel
SMCS - 1156
S/N - -
156
____________________________________________________________________________________________________________________________
Typical example
(1) Flywheel gear
(2) Crankshaft
Note: When the flywheel assembly is installed, align the dash mark on the flywheel assembly with
the dash mark on the crankshaft.
Note: Before assembly, lubricate the threads of the bolts (3) with clean engine oil, molybdenum
disulfide or graphite base lubricant.
(3) Torque for the 12 bolts ... 1150 60 Nm (840 44 lb ft)
157
____________________________________________________________________________________________________________________________
Specifications
i03104647
Flywheel Housing Cover

SMCS - 1157
S/N - -
158
____________________________________________________________________________________________________________________________
Typical example
(1) Apply 5P-3975 Rubber Lubricant to the entire mating surface of the flywheel housing cover
assembly.
(B) Distance between the cup plug and the starter pad ... 9.75 0.25 mm (0.384 0.010 inch)
159
____________________________________________________________________________________________________________________________
Specifications
i02958521
Engine Trunnion
SMCS - 1153
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
160
____________________________________________________________________________________________________________________________
161
____________________________________________________________________________________________________________________________
Specifications
i02888159
Vibration Damper
SMCS - 1205
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
162
____________________________________________________________________________________________________________________________
Typical example
(3) Torque for the six bolts ... 1125 100 Nm (820 75 lb ft)
Note: The alignment mark on the damper group (2) must be aligned with the alignment mark on
the adapter (1) .
Note: Apply 4C-4030 Thread Lock Compound to the threads of the bolts (4) .
(4) Torque for the 48 bolts ... 55 7 Nm (41 5 lb ft)
163
____________________________________________________________________________________________________________________________
Specifications
i03295581
Vibration Damper
SMCS - 1205
S/N - -
Note: The alignment mark on the crankshaft (1) must be aligned with the alignment mark on the
damper adapter (2) .
Note: Before assembly, lubricate the threads of the bolts with molybdenum disulfide base
lubricant.
(3) Torque for six bolts ... 1150 60 Nm (840 44 lb ft)
164
____________________________________________________________________________________________________________________________
Specifications
i04015783
Vibration Damper
SMCS - 1205
S/N - -
Typical example
Note: The alignment mark on the damper group (2) must be aligned with the alignment mark on
the adapter (1) .
165
____________________________________________________________________________________________________________________________
lubricant.
Note: Lubricate the threads of the bolts with blue Loctite 242.
166
____________________________________________________________________________________________________________________________
Specifications
i03295685
Vibration Damper
SMCS - 1205
S/N - -
Note: The alignment mark on the crankshaft (2) must be aligned with the alignment mark on the
lubricant.
167
____________________________________________________________________________________________________________________________
Specifications
i03105503
Vibration Damper Guard

SMCS - 1205
S/N - -
168
____________________________________________________________________________________________________________________________
Typical example
169
____________________________________________________________________________________________________________________________
Specifications
i02832479
Stub Shaft (Front)

SMCS - 1237
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
Typical example
(2) Torque for the six bolts ... 1150 150 Nm (840 110 lb ft)
170
____________________________________________________________________________________________________________________________
Note: The alignment mark on the stub shaft (3) must be aligned with the alignment mark on the
171
____________________________________________________________________________________________________________________________
Specifications
i03534444
Auxiliary Drive Pulley

SMCS - 1205
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
172
____________________________________________________________________________________________________________________________
(1) Lubricate the sealing lip of the lip type seal with the lubricant that is being sealed. Install the
lip type seal as the lip type seal is shown.
(2) Lightly lubricate the bore of the O-ring seal with the lubricant that is being sealed.
173
____________________________________________________________________________________________________________________________
Specifications
i03126588
Auxiliary Drive Coupling

SMCS - 1207
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
(2) Lubricate the sealing lip of the lip type seal with the lubricant that is being sealed.
174
____________________________________________________________________________________________________________________________
Specifications
i02899402
Belt Tension Chart

SMCS - 1357
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
Note: Do not use the belt tension chart for belts with tensioners that are spring loaded.
Table 1
Belt Tension Chart
Suggested
Suggested
Gauge
Gauge Reading Gauge
Belt Belt (Frequency)
Size (Force)
Width Tension Tension
of
of Belt Belt (Frequency) (Frequency)
Belt Basic
Belt Tension Tension "Initial" (1) "Used" (2) (3)
Gauge Gauge
(Force) (Force)
Number Number
"Initial" "Used"
(1) (2) (3)
8-
27.82
RIB 489
mm 800 22 BT-33- 98 10 HZ Clavis Type
POLY 44 N 76 8 HZ
(1.095 N (180 109 14
- RIB (110
inch) 5 lb)
10 lb)
Measure the tension of the belt that is farthest from the engine.
(1) Belt tension "lnitial" is for a new belt.
(2) Belt tension "Used" is for a belt that has operated for 30 minutes or more of operation at the rated speed.
( 3 ) If a belt falls below the "Used" belt tension, the belt should be tightened again to the high side of the "Used" belt
tension.
175
____________________________________________________________________________________________________________________________
Specifications
i03134661
Electric Starting Motor

SMCS - 1453
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
176
____________________________________________________________________________________________________________________________
When the electric starting motor is viewed from the pinion end, the motor rotates in the following
direction. ... Clockwise
No load conditions at 25 C (77 F)
Speed ... 6500 1000 rpm

Current draw ... 87.5 12.5 Amp
Voltage ... 30 VDC
(B) The clearance between the pinion and the housing ... 9.1 mm (0.36 inch)
(1) Final installation torque for the nut for ground terminal ... 30.5 3.5 Nm (270 30 lb in)
(2) Final installation torque for the nut for hold-in coil terminal ... 2.25 0.25 Nm (20 2 lb in)
(3) Final installation torque for the nut for pull-in coil terminal ... 2.25 0.25 Nm (20 2 lb in)
(4) Final installation torque for the nut for motor terminal ... 30.5 3.5 Nm (270 30 lb in)
Note: A maximum of three cable terminals or wire terminals may be used with the nut. A
maximum of two of the terminals may be equal to or greater than 0 AWG.
(5) Final installation torque for the nut for switch terminal ... 30.5 3.5 Nm (270 30 lb in)
(6) Final installation torque for the nut for motor frame terminal ... 30.5 3.5 Nm (270 30 lb in)
Solenoid
177
____________________________________________________________________________________________________________________________
Current consumption (draw) at 30 V and at 25 C (77 F)
Pull-in windings ... 38 Amp

Hold-in windings ... 6 Amp
178
____________________________________________________________________________________________________________________________
Specifications
i02942994

SMCS - 1453
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
179
____________________________________________________________________________________________________________________________
When the electric starting motor is viewed from the pinion end, the motor rotates in the following
Speed ... 6950 1650 rpm

Current draw ... 115 25 Amp
Voltage ... 23 VDC
(B) Clearance between the pinion and the housing is the following value. ... 9.1 mm (0.36 inch)
(1) Final installation torque for the ground terminal nut ... 30.5 3.5 Nm (270 30 lb in)
(2) Final installation torque for the switch terminal nut ... 2.25 0.25 Nm (20 2 lb in)
Note: The switch terminal must be insulated with heat shrink tubing. Do not use molded
terminals.
(3) Final installation torque for the switch terminal nut ... 2.25 0.25 Nm (20 2 lb in)
(4) Final installation torque for the motor terminal nut ... 30.5 3.5 Nm (270 30 lb in)
Note: A maximum of three cable terminals or wire terminals may be used with the battery
terminal nut. A maximum of two of the terminals may be equal to or greater than 0 AWG.
(5) Final installation torque for the battery terminal nut ... 30.5 3.5 Nm (270 30 lb in)
(6) Final installation torque for the motor frame terminal nut ... 30.5 3.5 Nm (270 30 lb in)
Solenoid assembly
Current consumption at 20V and 25 C (77 F)
Pull-in windings ... 49.3 3.3 Amp

Hold-in windings ... 6.8 Amp
180
____________________________________________________________________________________________________________________________
Specifications
i03134620

SMCS - 1453
S/N - 5PS1-UP
When the electric starting motor is viewed from the drive end, the motor rotates in the following
181
____________________________________________________________________________________________________________________________
Speed ... 5500 rpm minimum

Current draw ... 140 Amp maximum
Voltage ... 24 VDC
(2) Final installation torque for the nut for battery terminal ... 30.5 3.5 Nm (270 30 lb in)
terminals.
(5) Final installation torque for the nut for motor frame terminal ... 30.5 3.5 Nm (270 30 lb in)
Solenoid
Pull-in windings ... 51 Amp

Hold-in windings ... 7 Amp
182
____________________________________________________________________________________________________________________________
Specifications
i03134502

SMCS - 1453
S/N - 5PS1-UP
183
____________________________________________________________________________________________________________________________
View A-A
When the electric starting motor is viewed from the drive end, the motor rotates in the following
Speed ... 7643 1683 rpm

Current draw ... 67.5 7.5 Amp
Voltage ... 23 VDC
(B) The clearance between the pinion and the housing ... 9.1 mm (0.36 inch)
(3) Final installation torque for the nut for battery terminal ... 30.5 3.5 Nm (270 30 lb in)
terminals.
(6) Final installation torque for the bolt for motor frame terminal ... 8 3 Nm (70 27 lb in)
Solenoid
Pull-in windings ... 56.5 4.5 Amp

Hold-in windings ... 14.6 Amp max
184
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Specifications
i02987324
Fuel Pressure Sensor

SMCS - 7414
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
Typical example
(1) Final installation torque for the pressure sensor group ... 10 2 Nm (90 18 lb in)
185
____________________________________________________________________________________________________________________________
Operating temperature ... -40 to 125 C (-40 to 257 F)
Operating voltage ... 5.00 0.25 VDC
186
____________________________________________________________________________________________________________________________
Specifications
i02845092
Engine Oil Pressure Sensor

SMCS - 1924
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
S/N - C8R1-UP
187
____________________________________________________________________________________________________________________________
188
____________________________________________________________________________________________________________________________
Specifications
i02987331
Turbocharger Inlet Pressure Sensor

SMCS - 1052
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
189
____________________________________________________________________________________________________________________________
190
____________________________________________________________________________________________________________________________
Specifications
i02995988
Engine Speed/Timing Sensor

SMCS - 1905; 1907
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
Note: Before installation, coat the sensor assembly's threads with 4c-5599 Anti-Seize Compound .
(1) Final installation torque for the sensor assembly ... 40 5 Nm (30 4 lb ft)
191
____________________________________________________________________________________________________________________________
Operating temperature ... 40 to 121 C (40 to 250 F)
Operating voltage ... 12 to 14 V
(2) Sliphead
Before installation, make sure that the sliphead is fully extended.
192
____________________________________________________________________________________________________________________________
Specifications
i03535661
Engine Speed/Timing Sensor

SMCS - 1905; 1907
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
S/N - C8R1-UP
(1) Final installation torque for the speed sensor group ... 40 5 Nm (30 4 lb ft)
193
____________________________________________________________________________________________________________________________
Operating voltage ... 12 to 14 VDC
Output frequency ... 9 Hz to 10 kHz
Duty cycle ... 50 %
194
____________________________________________________________________________________________________________________________
Specifications
i03011867
Crankcase Pressure Sensor

SMCS - 1916
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
S/N - C8R1-UP
195
____________________________________________________________________________________________________________________________
196
____________________________________________________________________________________________________________________________
Specifications
i02911305
Atmospheric Pressure Sensor

SMCS - 1923
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
S/N - C8R1-UP
197
____________________________________________________________________________________________________________________________
198
____________________________________________________________________________________________________________________________
Specifications
i03534581
Engine Speed Sensor

SMCS - 1907
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 7AF1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
199
____________________________________________________________________________________________________________________________
Clearance between the speed sensor group and the flywheel ring gear ... 0.50 to 0.75 mm (0.020 to
0.030 inch)
Use the following procedure to install the speed sensor group (1) :
1. Install the speed sensor group into the 5/8 threaded hole and turn until the magnetic core
makes contact with a tooth of the flywheel ring gear.
2. Back out 180 degrees.
3. Tighten the nut to 25 5 mm (221 44 inch).
200
____________________________________________________________________________________________________________________________
Specifications
i03001872
Engine Speed Sensor

SMCS - 1907
S/N - 3ZW1-UP
S/N - 5PS1-UP
S/N - 6HZ1-UP
S/N - 8DF1-UP
S/N - 9WF1-UP
S/N - C8R1-UP
(1) Final installation torque for locknut ... 25 5 Nm (18 4 lb ft)
201
____________________________________________________________________________________________________________________________
Resistance at 25 C (77 F) ... 142
Minimum air gap ... 0.50 mm (0.035 inch)
Screw the speed sensor into the hole by hand until the end of the sensor barely contacts the gear
tooth. Then, back out the sensor by a 1/2 turn (180 degrees in the counterclockwise direction).
202
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RENR2200 04 Specification

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RENR2200-04

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(A) Inlet valves

(B) Exhaust valves

Number and arrangement of cylinders ... 60 degree V-8

Valves per cylinder ... 4

Displacement ... 34.5 L (2105 cu in)

Bore ... 170 mm (6.7 inch)

Stroke ... 190 mm (7.5 inch)

Compression ratio ... 14:1

Combustion ... Direct injection

Firing order (injection sequence)

Standard rotation CCW ... 1, 2, 7, 3, 4, 5, 6, 8

Inlet ... 0.50 mm (0.020 inch)

Exhaust ... 1.00 mm (0.040 inch)

(A) Inlet valves

(B) Exhaust valves

Number and arrangement of cylinders ... 60 degree V-12

Valves per cylinder ... 4

Displacement ... 51.8 L (3158 cu in)

Bore ... 170 mm (6.7 inch)

Stroke ... 190 mm (7.5 inch)

Compression ratio ... 14:1

Combustion ... Direct injection

Firing order (injection sequence)

Standard rotation CCW ... 1, 12, 9, 4, 5, 8, 11, 2, 3, 10, 7, 6

Inlet ... 0.50 mm (0.020 inch)

Exhaust ... 1.00 mm (0.040 inch)

(A) Inlet valve

(B) Exhaust valve

Number and arrangement of cylinders ... 60 degree V-16

Valves per cylinder ... 4

Displacement ... 69.1 L (4210 cu in)

Bore ... 170 mm (6.7 inch)

Stroke ... 190 mm (7.5 inch)

Compression ratio ... 14:1

Combustion ... Direct injection

Firing order (injection sequence)

Inlet ... 0.50 mm (0.020 inch)

Exhaust ... 1.00 mm (0.040 inch)

Fuel Filter (Primary)

(1) Torque for the nut ... 25 5 Nm (221 44 lb in)

(3) 7S-9323 Spring

Length under test force ... 27.94 mm (1.100 inch)

Fuel Pressure Regulator

(1) Fuel manifold adapter

(3) Valve plunger

(2) 9N-4053 Spring

Length under test force ... 28.5 mm (1.12 inch)

Fuel Transfer Pump

Minimum output ... 21 L/min (5.5 US gpm)

Minimum output is attained under the following conditions:

Pump pressure ... 415 kPa (60 psi)

Pump speed ... 2400 rpm

(1) Dimensions for terminal bushing

(2) Dimensions for drive shaft assembly

Diameter of the shaft ... 12.700 to 12.675 mm (0.5000 to 0.4990 inch)

(4) Dimensions for idler gear assembly

Diameter of the gear ... 29.801 0.006 mm (1.1733 0.0002 inch)