Kenr5396 04 01 All

KENR5396-04
April 2010
Specifications
C175-16 and C175-20 Engines for 793F
and 797F Off-Highway Trucks
LAJ1-Up (Machine)
SSP1-Up (Machine)
B7B1-Up (Engine)
LLM1-Up (Engine)
SAFETY.CAT.COM
i03684547
Important Safety Information

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

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by NOTICE labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this

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

ture failures, product damage, personal injury or
death.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
KENR5396-04 3
Table of Contents
Table of Contents Electric Starting Motor .........................................

Inlet Manifold Temperature Sensor .......................
69
70
Fuel Pressure Sensor .......................................... 70
Fuel Pressure Sensor .......................................... 70
Specifications Section Engine Speed Sensor ........................................... 71
Engine Speed Sensor ........................................... 71
Engine Design ....................................................... 4
Fuel Temperature Sensor ..................................... 72
Engine Design ....................................................... 4
Engine Oil Pressure Sensor ................................. 72
Fuel Filter (Secondary) ........................................... 5
Turbocharger Exhaust Temperature Sensor ......... 72
Fuel Filter Base ...................................................... 5
Crankcase Pressure Sensor ................................. 72
Fuel Transfer Pump ............................................... 6
Atmospheric Pressure Sensor .............................. 73
Fuel Transfer Pump ............................................... 6
Fuel Injector ............................................................ 7
Fuel Lines ............................................................... 8 Index Section
Fuel Lines ............................................................. 13
Fuel Lines ............................................................. 14 Index ..................................................................... 74
Camshaft ............................................................. 19
Camshaft ............................................................. 20
Lifter Group ........................................................... 21
Lifter Group ........................................................... 21
Valve Mechanism ................................................. 22
Cylinder Head ...................................................... 23
Cylinder Head Valves ........................................... 25
Cylinder Head Valves ........................................... 27
Turbocharger ........................................................ 28
Turbocharger ........................................................ 29
Turbocharger Support ........................................... 29
Exhaust Manifold ................................................. 30
Exhaust Fitting ...................................................... 32
Pressure Control Valve (Oil Regulator Valve and Oil
Bypass Valve) ..................................................... 32
Engine Oil Pump .................................................. 33
Engine Oil Pump .................................................. 34
Engine Oil Scavenge Pump ................................. 35
Engine Oil Scavenge Pump ................................. 36
Engine Oil Pan ..................................................... 38
Water Pump ......................................................... 39
Water Pump ......................................................... 40
Auxiliary Water Pump .......................................... 41
Cylinder Block ...................................................... 42
Cylinder Block ...................................................... 45
Cylinder Block ...................................................... 47
Cylinder Block ...................................................... 50
Cylinder Liner ....................................................... 52
Piston and Rings .................................................. 53
Connecting Rod ................................................... 54
Connecting Rod and Main Bearing Journals ........ 55
Crankshaft ........................................................... 56
Crankshaft Wear Sleeves and Seals ................... 59
Gear Group (Front) ............................................... 60
Gear Group (Front) ............................................... 62
Gear Group (Rear) ................................................ 63
Accessory Drive ................................................... 63
Flywheel ............................................................... 65
Flywheel Housing ................................................ 65
Vibration Damper ................................................. 66
Vibration Damper ................................................. 67
Belt Tensioner ....................................................... 67
Belt Tensioner ....................................................... 67
Alternator and Regulator ...................................... 68
Electric Starting Motor ......................................... 68
4 KENR5396-04
Specifications Section
Specifications Section i02605915
Engine Design
i03099560
SMCS Code: 1000
Engine Design S/N: LAJ1-Up; LLM1-Up
SMCS Code: 1000
S/N: SSP1-Up; B7B1-Up
g01304641
Illustration 2
Cylinder and valve location
g01262912
(A) Inlet valves
Illustration 1 (B) Exhaust valves
Cylinder and valve location
(A) Inlet valves Number and arrangement of
(B) Exhaust valves cylinders ............................................ 60 degree V-20
Number and arrangement of Valves per cylinder .................................................. 4

cylinders ............................................ 60 degree V-16
Displacement ............................ 106.2 L (6481 cu in)
Valves per cylinder .................................................. 4
Bore ............................................. 175 mm (6.7 inch)
Displacement ................................. 85 L (5187 cu in)
Stroke .......................................... 220 mm (7.5 inch)
Bore ........................................... 175 mm (6.89 inch)
Compression ratio .............................................. 14:1
Stroke ........................................ 220 mm (8.66 inch)
Combustion ........................................ Direct injection
Compression ratio .............................................. 14:1
When the crankshaft is viewed from the flywheel
Combustion ........................................ Direct injection end the crankshaft rotates in the following
direction. ....................................... Counterclockwise
When the crankshaft is viewed from the flywheel
end the crankshaft rotates in the following Firing order (injection sequence)
direction. ....................................... Counterclockwise
Standard rotation CCW ... 1, 2, 11, 12, 3, 4, 15, 16, 7,
Firing order (injection sequence) 8, 19, 20, 9, 10, 17, 18, 5, 6, 13, 14.
Standard rotation Note: The front end of the engine is opposite the
CCW .. 1, 2, 5, 6, 13, 14, 9, 10, 15, 16, 11, 12, 3, 4, 7, 8 flywheel end of the engine. The left and the right side
of the engine are determined from the flywheel end.
Note: The front end of the engine is opposite the The number 1 cylinder is the front cylinder on the
flywheel end of the engine. The left and the right side right side. The number 2 cylinder is the front cylinder
of the engine are determined from the flywheel end. on the left side.
The number 1 cylinder is the front cylinder on the
right side. The number 2 cylinder is the front cylinder
on the left side.
KENR5396-04 5
i02904054 i03083460
Fuel Filter (Secondary) Fuel Filter Base

SMCS Code: 1261 SMCS Code: 1262
Part No.: 316-1741 Part No.: 236-5484
Part No.: 317-1613
S/N: LAJ1-Up; LLM1-Up
g01563177
Illustration 4
Typical example
(A) Length for applying 154-9731 Thread Lock

Compound on the tapered end of the taperlock
stud ................. 10.0 1.5 mm (0.39 0.06 inch)
(1) Torque for the taperlock stud ............. 68 7 Nm

(50 5 lb ft)
g01446148
Illustration 3
(1) Filter base
(2) Filter housing
After initial gasket contact, tighten the filter

housing. ................................................ 360 degrees
6 KENR5396-04
i03235419 i03235344
Fuel Transfer Pump Fuel Transfer Pump

Part No.: 307-7303 Part No.: 313-9061
S/N: SSP1-Up; B7B1-Up S/N: LAJ1-Up; LLM1-Up
g01263179 g01263179
Illustration 5 Illustration 6
(1) Inlet port (1) Inlet port
(2) Outlet port (2) Outlet port
(3) Priming port (3) Priming port
Minimum requirements Minimum requirements

Volume per minute at 650 kPa (94 psi) and 2412 Volume per minute at 650 kPa (94 psi) and 2412
rpm .......................................... 14 L (3.7 US gal) rpm .......................................... 15 L (4.0 US gal)
rpm .......................................... 12 L (3.2 US gal) rpm ....................................... 13.2 L (3.5 US gal)
rpm ......................................... 0.6 L (0.2 US gal) rpm ......................................... 0.6 L (0.2 US gal)
Minimum cracking pressure for the bypass Minimum cracking pressure for the bypass
valve ....................................... 793 kPa (115 psi) valve ....................................... 793 kPa (115 psi)
Maximum full open pressure for the bypass Maximum full open pressure for the bypass
valve ....................................... 862 kPa (125 psi) valve ....................................... 862 kPa (125 psi)
KENR5396-04 7
i03670348 7. Assemble the fuel lines into the head and rail (5)
without contacting the ends of the fuel lines with
Fuel Injector parts on the engine.
SMCS Code: 1290 8. Hand tighten the bolts into the head and the bolts
for the rail.
Part No.: 319-8470, 328-7100
9. Tighten the bolt of the injector to a torque of
Part No.: 319-8470 10 Nm (7 lb ft).
10. Evenly tighten the bolts into the head and the
rail to a torque of 20 Nm (15 lb ft). When you
tighten the bolts, the rotation of each bolt should
not exceed 90 degrees at one time.
11. Tighten the bolt (1 ) to a torque of 100 20 Nm

(75 lb ft).
12. Again, evenly tighten the bolts into the head and
the rail to a torque of 40 5 Nm (30 lb ft). When
you tighten the bolts, the rotation of each bolt
should not exceed 45 degrees at one time.
g01560135
Illustration 7
Special instructions for injectors and for high

pressure line components
1. Loosen bolts (3) from the fuel line to the fuel rail.
2. Apply clean engine oil to the collar of the tube joint

prior to disassembly.
3. Remove the fuel line (2).
4. Install the injector (4).
5. Tighten the bolt (1) from 30 to 50 Nm

(22 to 38 lb ft).
6. Remove the bolt for the fuel injector.
Note: Lubricate the bore of the O-ring seals with

1P-0808 Multipurpose Grease.
Note: Lubricate both ends of the fuel lines with clean

engine oil prior to assembly.
8 KENR5396-04
i03670567
Fuel Lines
SMCS Code: 1274
Part No.: 289-5093, 304-9602, 315-5619,
327-0844, 328-2001
g01971674
Illustration 8
KENR5396-04 9
g01424059 g01424147
View of Detail A View of Detail E
(24) Torque for the adapter ................. 150 10 Nm

(111 7 lb ft)
g01424133
Illustration 12
View of Detail F
Illustration 10
g01424095 (25) Torque for the fuel fitting .............. 250 10 Nm
View of Detail B
(184 7 lb ft)
(20) Torque for the fuel fittings ............ 250 10 Nm Note: Ensure that all parts are extremely clean. All
(184 7 lb ft) of the parts must not be contaminated with any dirt
or debris.
Reference: Reuse and Salvage Guidelines,

SEBF9109, Cleaning and Handling Procedures for
the Common Rail Fuel System Components
Procedure for the installation of the

rails and the quill tubes
1. Tighten the bolts that hold rail (1) and rail (7) to
the cylinder block in the following order: 15, 16,
14, 17, 12, 19, 13, and 18.
10 KENR5396-04
Torque ........................................ Standard torque Torque for the bolts .................. 20 Nm (177 lb in)
Complete step 2 in the following order: 15, 16, 14, 9. Evenly tighten the bolts into the rail.
17, 13, 18, 12, and 19.
Turn each bolt no more than 90 degrees at one
2. Remove the bolts that attach quill tubes (5) to the time.
rails. If the bolts are already installed, remove the
bolts that attach the quill tubes to the cylinder Torque for the bolts .................. 20 Nm (177 lb in)
head.
10. Evenly tighten the bolts into the cylinder head.

time.
Torque for the bolts .................... 40 Nm (30 lb ft)
11. Evenly tighten the bolts into the rail.

time.

lines
g01421625
Illustration 13
View of Detail D
3. Apply clean engine oil to joint (22) at the collar to

quill tubes. Refer to Illustration 13. Slide the collar
away from the cylinder head and the rail prior to
disassembly.
4. Apply clean engine oil to O-rings (23). Refer to

Illustration 13.
g01424406
Illustration 14
5. Lubricate both ends of quill tubes (21) with clean View of Detail G
engine oil prior to assembly. Refer to Illustration
13. Assemble the quill tubes into the cylinder head
and the rail.
6. Evenly hand tighten the bolts into the cylinder

head.
7. Evenly hand tighten the bolts into the rail.

time.
KENR5396-04 11
10. Evenly tighten the bolts of block (6) to the pump

adapter.
Torque ........................................ Standard torque
11. Install adjustable bracket (11) and tighten

adjustable bracket (11) by using the adjustable
bracket's mounting hardware.
12. Lubricate the O-ring (27) that seals the collar

of the line (9) with clean engine oil. Refer to
Illustration 15. Lubricate the end (26) of line (9)
with clean engine oil prior to assembly. Refer to
Illustration 14.
13. Evenly hand tighten line (9) to the pump with the
washers and the bolts.
14. Evenly hand tighten line (9) to block (6) with the
Illustration 15
g01424407 washers and the bolts.
View of Detail H
15. Evenly tighten line (9) to the pump.
1. Lubricate the O-ring (27) that seals the collar
of the line (10) with clean engine oil. Refer to Turn each bolt no more than 90 degrees at one
Illustration 15. Lubricate the end (26) of line (10) time.
with clean engine oil prior to assembly. Refer to
Illustration 14. Torque for the bolts .................. 20 Nm (177 lb in)
2. Off the engine, insert line (10) into block (6). 16. Evenly tighten line (9) to block (6).
3. Evenly tighten line (10) to block (6) with the Turn each bolt no more than 90 degrees at one
washers and the bolts. time.
Torque for the bolts .................... 10 Nm (88 lb in) Torque for the bolts .................. 20 Nm (177 lb in)
4. On the engine, insert line (10) into rail (1). Refer to 17. Evenly tighten line (9) to the pump.
Illustration 9.
5. Evenly hand tighten line (10) to rail (1) with the time.
6. Evenly hand tighten the bolts of block (6) to the
pump adapter. 18. Evenly tighten line (9) to block (6).
7. Evenly tighten line (10) to rail (1). Turn each bolt no more than 45 degrees at one
time.
time. Torque for the bolts .................... 40 Nm (30 lb ft)
Torque for the bolts .................. 20 Nm (177 lb in) 19. Install adjustable bracket (8) and tighten
8. Evenly tighten the bolts of block (6) to the pump bracket's mounting hardware.
adapter.
20. Lubricate the O-rings (27) that seal the collars
Torque for the bolts .................. 20 Nm (177 lb in) of the line (4) with clean engine oil. Refer to
Illustration 15. Lubricate the ends (26) of line (4)
9. Evenly tighten line (10) to rail (1). with clean engine oil prior to assembly. Refer to
Illustration 14.
time.
12 KENR5396-04

time.
31. Evenly tighten clamps (3) and hardware to line

(4). Refer to Illustration 16.


g01424845
Illustration 16
View of Detail C
21. Insert line (4) into rail (1) and into rail (7). Refer to
Illustration 16 and illustration 10.
22. Evenly hand tighten line (4) to rail (1) with the
24. Install the low pressure return fuel line (28) and
the mounting hardware for the low pressure return
fuel line that connects to rail (1) and to rail (7).
Tighten the low pressure return fuel line (28) to the

following torque. .............. 55 5 Nm (40 4 lb ft)
25. Evenly hand tighten clamps (3) and hardware to

line (4). Refer to Illustration 16.

27. Evenly tighten line (4) to rail (1).
Torque for the bolts .................. 20 Nm (177 lb in)

time.

g01971693
Turn each bolt no more than 90 degrees at one Illustration 17
time.
(29) Torque for the cap .. 250 10 Nm (184 7 lb ft)
(30) 258-9943 Spring
Length under test force ....... 36.6 mm (1.44 inch)
Test force .................. 75.0 5.5 N (16.9 1.2 lb)
Free length after test .. 50.438 mm (1.9857 inch)
time.
Outside diameter ..................... 12.30 0.15 mm
(0.484 0.006 inch)

KENR5396-04 13
i03672360
Fuel Lines
SMCS Code: 1274
Part No.: 284-8351
g01973033
Illustration 18
(1) Lubricate the bore of the O-ring seals for the

connector with 5P-3975 Rubber Lubricant.
(2) Torque for the tube assembly ............ 40 4 Nm

(30 3 lb ft)
(3) Tighten the bolts evenly for the fuel line

assemblies. ........ 42.5 2.5 Nm (31.3 1.8 lb ft)
14 KENR5396-04
i03672320
Fuel Lines
SMCS Code: 1274
Part No.: 290-4478, 304-9602, 315-5619,
327-0844, 328-2002
g01973014
Illustration 19
KENR5396-04 15
g01424941 g01424951
View of Detail A View of Detail E
(26) Torque for the adapter ................. 150 10 Nm

(111 7 lb ft)
g01424952
Illustration 23
View of Detail F
Illustration 21
g01424942 (27) Torque for the fuel fitting .............. 250 10 Nm
View of Detail B
(184 7 lb ft)
(22) Torque for the fuel fittings ............ 250 10 Nm Note: Ensure that all parts are extremely clean. All
(184 7 lb ft) of the parts must not be contaminated with any dirt
or debris.
Reference: Reuse and Salvage Guidelines,

SEBF9109, Cleaning and Handling Procedures for
the Common Rail Fuel System Components

rails and the quill tubes
1. Tighten the bolts that hold rail (1) and rail (7) to
the cylinder block in the following order: 16, 17,
15, 18, 14, 19, 12, 21, 13, and 20.
16 KENR5396-04
Torque ........................................ Standard torque Torque for the bolts .................. 20 Nm (177 lb in)
Complete step 2 in the following order: 16, 17, 15, 9. Evenly tighten the bolts into the rail.
18, 14, 19, 13, 20, 12, and 21.
2. Remove the bolts that attach quill tubes (5) to the time.
rails. If the bolts are already installed, remove the
bolts that attach the quill tubes to the cylinder Torque for the bolts .................. 20 Nm (177 lb in)
head.

time.
11. Evenly tighten the bolts into the rail.

time.

lines
g01424946
Illustration 24
View of Detail D
3. Apply clean engine oil to joint (24) at the collar to

quill tubes. Refer to Illustration 24. Slide the collar
away from the cylinder head and the rail prior to
disassembly.
4. Apply clean engine oil to O-rings (25). Refer to

Illustration 24.
g01424955
Illustration 25
5. Lubricate both ends of quill tubes (23) with clean View of Detail G
24. Assemble the quill tubes into the cylinder head
and the rail.
6. Evenly hand tighten the bolts into the cylinder

head.
7. Evenly hand tighten the bolts into the rail.

time.
KENR5396-04 17
10. Evenly tighten the bolts of block (6) to the pump

adapter.
11. Install adjustable bracket (11) and tighten

bracket's mounting hardware.
12. Lubricate the O-ring (29) that seals the collar of

line (9) with clean engine oil. Refer to Illustration
26. Lubricate the end (28) of line (9) with clean
25.
13. Evenly hand tighten line (9) to the pump with the
14. Evenly hand tighten line (9) to block (6) with the
Illustration 26
g01424956 washers and the bolts.
View of Detail H
15. Evenly tighten line (9) to the pump.
1. Lubricate the O-ring (29) that seals the collar of
line (10) with clean engine oil. Refer to Illustration Turn each bolt no more than 90 degrees at one
26. Lubricate the end (28) of line (10) with clean time.
25. Torque for the bolts .................. 20 Nm (177 lb in)
2. Off the engine, insert line (10) into block (6). 16. Evenly tighten line (9) to block (6).
3. Evenly tighten line (10) to block (6) with the Turn each bolt no more than 90 degrees at one
washers and the bolts. time.
Torque for the bolts .................... 10 Nm (88 lb in) Torque for the bolts .................. 20 Nm (177 lb in)
4. On the engine, insert line (10) into rail (1). Refer to 17. Evenly tighten line (9) to the pump.
Illustration 20.
5. Evenly hand tighten line (10) to rail (1) with the time.
6. Evenly hand tighten the bolts of block (6) to the
pump adapter. 18. Evenly tighten line (9) to block (6).
7. Evenly tighten line (10) to rail (1). Turn each bolt no more than 45 degrees at one
time.
time. Torque for the bolts .................... 40 Nm (30 lb ft)
Torque for the bolts .................. 20 Nm (177 lb in) 19. Install adjustable bracket (8) and tighten
8. Evenly tighten the bolts of block (6) to the pump bracket's mounting hardware.
adapter.
20. Lubricate the O-rings (29) that seal the collars
Torque for the bolts .................. 20 Nm (177 lb in) of the line (4) with clean engine oil. Refer to
Illustration 26. Lubricate the ends (28) of line (4)
9. Evenly tighten line (10) to rail (1). with clean engine oil prior to assembly. Refer to
Illustration 25.
time.
18 KENR5396-04

time.



g01424945
Illustration 27
View of Detail C
21. Insert line (4) into rail (1) and into rail (7). Refer to
Illustration 27 and Illustration 21.
24. Install the low pressure return fuel line (30) and
the mounting hardware for the low pressure return
fuel line that connects to rail (1) and to rail (7).
Refer to Illustration 27 and Illustration 21.
Tighten the low pressure return fuel line (30) to the

following torque. .............. 55 5 Nm (40 4 lb ft)



time.
28. Evenly tighten line (4) to rail (7). g01973013

Illustration 28
time. (31) Torque for the cap .. 250 10 Nm (184 7 lb ft)
Torque for the bolts .................. 20 Nm (177 lb in) (32) 258-9943 Spring
Test force .................. 75.0 5.5 N (16.9 1.2 lb)
Free length after test .. 50.438 mm (1.9857 inch)
Outside diameter ..................... 12.30 0.15 mm
time.
(0.484 0.006 inch)

KENR5396-04 19
i03241532
Camshaft
SMCS Code: 1210
Part No.: 274-7725
g01460209
Illustration 30
(2) Torque for eight taperlock studs ........ 35 5 Nm

(26 4 lb ft)
(B) Extension of the dowel from the end of the front

camshaft .......... 11.5 0.5 mm (0.45 0.02 inch)
g01460189
Illustration 29
Note: Before assembly, apply 8T-2998 Lubricant

to the sides of the thrust washer. Apply a thin coat
of 8T-2998 Lubricant to the area of the camshaft
bearing that is in contact with the groove of the thrust
washer.
(1) Dimensions for thrust washer

Thickness of the new thrust
washer ...... 8.50 0.05 mm (0.335 0.002 inch)
Thickness of the groove in new
camshaft ... 8.75 0.05 mm (0.344 0.002 inch)
End play for new camshaft ....... 0.15 to 0.35 mm
(0.006 to 0.014 inch)
Note: Before assembly of the camshaft to the cylinder

block, apply a thin coat of 8T-2998 Lubricant to
the outer diameter of each camshaft journal and
camshaft bearing.
g01420238
Illustration 31
(A) Dimensions for journal surface
Use the following procedure in order to determine the
Diameter of the bearing actual camshaft lobe lift:
journal ..... 91.88 0.02 mm (3.617 0.001 inch)
Bore in the bearing for camshaft after 1. Measure camshaft lobe height (D).
assembly ............................. 92.152 0.015 mm
(3.6280 0.0006 inch) 2. Measure base circle (E).
3. Subtract the base circle (E) from the lobe height

(D). The difference is the actual camshaft lobe lift
(C).
(C) Specified camshaft lobe lift

Inlet lobe ..................... 12.448 mm (0.4901 inch)
Exhaust lobe ............... 17.184 mm (0.6765 inch)
20 KENR5396-04
i03242547
Camshaft
SMCS Code: 1210
Part No.: 274-7729
g01460209
Illustration 33

(26 4 lb ft)
(B) Extension of the dowel from the end of the front

camshaft .......... 11.5 0.5 mm (0.45 0.02 inch)
g01460189
Illustration 32
Note: Before assembly, apply 8T-2998 Lubricant

to the sides of the thrust washer. Apply a thin coat
of 8T-2998 Lubricant to the area of the camshaft
bearing that is in contact with the groove of the thrust
washer.
(1) Dimensions for thrust washer

Thickness of the new thrust
washer ...... 8.50 0.05 mm (0.335 0.002 inch)
Thickness of the groove in new
camshaft ... 8.75 0.05 mm (0.344 0.002 inch)
End play for new camshaft ....... 0.15 to 0.35 mm
(0.006 to 0.014 inch)
Note: Before assembly of the camshaft to the cylinder

block, apply a thin coat of 8T-2998 Lubricant to
the outer diameter of each camshaft journal and
camshaft bearing.
g01420238
Illustration 34
(A) Dimensions for journal surface
Use the following procedure in order to determine the
Diameter of the bearing actual camshaft lobe lift:
journal ..... 91.88 0.02 mm (3.617 0.001 inch)
Bore in the bearing for camshaft after 1. Measure camshaft lobe height (D).
assembly ............................. 92.152 0.015 mm
(3.6280 0.0006 inch) 2. Measure base circle (E).
3. Subtract the base circle (E) from the lobe height

(D). The difference is the actual camshaft lobe lift
(C).
(C) Specified camshaft lobe lift

Inlet lobe ..................... 12.448 mm (0.4901 inch)
Exhaust lobe ............... 17.184 mm (0.6765 inch)
KENR5396-04 21
i03242561
Lifter Group
SMCS Code: 1209
Part No.: 283-9354
g01561595
Illustration 37
(A) Height to the top of the hollow

dowel ................ 8.0 0.5 mm (0.31 0.02 inch)
(B) Height to the top of the hollow

dowel ................ 7.5 1.0 mm (0.30 0.04 inch)
i03907195
Lifter Group
g01446322
SMCS Code: 1209
Illustration 35
Part No.: 357-4826
Note: Before assembly, apply clean engine oil or
8T-2998 Lubricant to the lifter inserts and lifter shaft
assembly.
(1) Torque for eight bolts ... 55 10 Nm (41 7 lb ft)
g01561546
Illustration 36
g01446322
Illustration 38
(2) Torque for two bolts ..... 55 10 Nm (41 7 lb ft)
8T-2998 Lubricant to the lifter inserts and lifter shaft
assembly.
(1) Torque for eight bolts ... 55 10 Nm (41 7 lb ft)

22 KENR5396-04
Note: Prior to setting the valve lash for each valve,

firmly tap the rocker arm at the top of the adjustment
screw with a soft mallet. This will ensure that the lifter
roller seats against the base circle of the camshaft
lobe.
Allow the engine to cool before you perform a valve

lash adjustment.
g01561546
Illustration 39
(2) Torque for two bolts .. 105 20 Nm (77 15 lb ft)
g01952469
Illustration 41
Note: Use the 1U-8869 Dial Indicator in order to set

Illustration 40
g01561595 the valve lash for this assembly. If a dial indicator is
not available, a feeler gauge may be used for the
(A) Height to the top of the hollow adjustments.
dowel ................ 8.0 0.5 mm (0.31 0.02 inch)
(A) Dimensions for valve lash
(B) Height to the top of the hollow
dowel .................. 11 0.5 mm (0.43 0.02 inch) Inlet valves .... 1.0 0.08 mm (0.04 0.003 inch)
Exhaust valves ............................ 1.5 0.08 mm
(0.06 0.003 inch)
i03761691
(1) Torque for three bolts ..................... 200 30 Nm
Valve Mechanism (150 22 lb ft)
SMCS Code: 1102 (2) Torque for two nuts ... 120 15 Nm (90 11 lb ft)
Part No.: 297-8806
(3) Orientation of the bridge assemblies ....... Ensure
that the cutout feature is positioned inward toward
NOTICE the rocker arm shaft assembly during installation.
During installation of the pushrods, care must be ex-
ercised to ensure that the end of the pushrod seats (4) Rocker arm shaft
correctly into the lifter cup. Use a flashlight in order to
inspect the installation of the pushrod end in the lifter Bore in the bearing for the rocker arm shaft after
cup prior to starting the engine. Damage to the valve installation .......................... 50.086 0.0150 mm
train components will occur if the components are not (1.9719 0.0006 inch)
assembled correctly. Diameter of the machined surface of the rocker
arm shaft .............................. 50.000 0.013 mm
(1.9685 0.0005 inch)
8T-2998 Lubricant to the ball end and sockets of
the pushrod. Also, lubricate the rocker arm shaft with
clean engine oil before assembly.
KENR5396-04 23
i03246522 (1) Apply clean engine oil to the bore of two O-ring
seals.
Cylinder Head
Note: Apply 4C-5599 Anti-Seize Compound to the
SMCS Code: 1100 threads of the injector sleeve prior to assembly.
Part No.: 323-9919, 339-0356
(2) Installation torque for the injector
sleeve ........................ 120 10 Nm (90 7 lb ft)
g01561694
Illustration 43
(C) Height of the cylinder head ... 208 mm (8.2 inch)
Note: Before assembly, apply 4C-9506 Retaining

g01647494
Illustration 42 Compound to the bores of the cup plugs.
Use the following procedure in order to tighten the (E) Installation depth of the cup plugs from the
bolts: cylinder head surface ................ 1.00 0.25 mm
(0.039 0.010 inch)
Note: Before assembly, apply clean engine oil to the
threads of the bolts.
1. Hand tighten the bolt 1 through bolt 6 to a

maximum torque of 15 Nm (11 lb ft).
2. Tighten the bolt 1 through bolt 6 in a numerical

sequence to 100 10 Nm (75 7 lb ft).
3. Again, tighten the bolt 1 through bolt 6 in

a numerical sequence to 250 15 Nm
(185 11 lb ft).
4. Again, turn the bolt 1 through bolt 6 in a numerical

sequence to 180 5 degrees.
24 KENR5396-04
g01647495
Illustration 44
g01647496
Illustration 45
(G) Installation depth of the cup plugs from the

cylinder head surface ................ 0.75 0.25 mm
(0.030 0.010 inch)
KENR5396-04 25
i03683187
Cylinder Head Valves

SMCS Code: 1105
Part No.: 323-9918
g01647815
Illustration 46
(1) 318-4785 Spring Bore in the new valve guide for the exhaust valve
after installation ................... 12.626 0.020 mm
Length under test force ............ 88 mm (3.5 inch) (0.4971 0.0008 inch)
Test force .................. 810 40 N (182.1 9.0 lb)
Free length after test .... 109.24 mm (4.301 inch) Note: Before assembly to the valve guide, apply
Outside diameter ............ 49.01 mm (1.930 inch) clean engine oil to the valve stem.
(2) 318-4786 Spring (B) Dimensions for the valves
Length under test force ... 82.63 mm (3.253 inch) Diameter of the intake valve
Test force .................. 540 27 N (121.4 6.1 lb) stem ..................................... 12.573 0.010 mm
Free length after test .... 102.77 mm (4.046 inch) (0.4950 0.0004 inch)
Outside diameter ........ 34.398 mm (1.3542 inch) Diameter of the exhaust valve
stem ..................................... 12.573 0.010 mm
Note: Before assembly to the cylinder head, apply (0.4950 0.0004 inch)
clean engine oil to the outer diameter of the valve
guide. (C) Diameter of the valve head
(A) Dimensions for the valve guides Inlet ......... 58.50 0.15 mm (2.303 0.006 inch)
Exhaust ... 56.50 0.15 mm (2.224 0.006 inch)
Height to the top of the valve
guide ................ 42.0 0.5 mm (1.65 0.02 inch) (D) Valve face angle
Bore in the new valve guide for the intake valve
after installation ................... 12.626 0.020 mm Inlet ................................... 70.75 0.25 degrees
(0.4971 0.0008 inch) Exhaust ............................. 45.60 0.25 degrees
26 KENR5396-04
g01647817
Illustration 47
(E) Angle for the face of the valve seat inserts

Inlet ................................... 20.00 0.25 degrees
Exhaust ............................. 45.00 0.25 degrees
(F) Dimensions for the valve seat inserts

Outer diameter of the inlet valve seat
insert .................................... 67.150 0.013 mm
(2.6437 0.0005 inch)
Bore in the cylinder head for the inlet valve seat
insert .................................... 66.995 0.020 mm
(2.6376 0.0008 inch)
Outer diameter of the exhaust valve seat
insert .................................... 66.900 0.013 mm
(2.6339 0.0005 inch)
Bore in the cylinder head for the exhaust valve
seat insert ............................ 66.745 0.020 mm
(2.6277 0.0008 inch)
Outer diameter of the face of the valve seat
inserts ..... 50.00 0.25 mm (1.968 0.010 inch)
(G) Depth of the bore in the cylinder head for the

valve seat inserts
Inlet ......... 14.03 0.15 mm (0.552 0.006 inch)
Exhaust ... 14.63 0.15 mm (0.576 0.006 inch)
KENR5396-04 27
i03681422
Cylinder Head Valves

SMCS Code: 1105
Part No.: 339-0355
g01647815
Illustration 48
(1) 318-4785 Spring Bore in the new valve guide for the exhaust valve
Length under test force ............ 88 mm (3.5 inch) (0.4971 0.0008 inch)
Test force .................. 810 40 N (182.1 9.0 lb)
Free length after test .... 109.24 mm (4.301 inch) Note: Before assembly to the valve guide, apply
Outside diameter ............ 49.01 mm (1.930 inch) clean engine oil to the valve stem.
(2) 318-4786 Spring (B) Dimensions for the valves
Length under test force ... 82.63 mm (3.253 inch) Diameter of the intake valve
Test force .................. 540 27 N (121.4 6.1 lb) stem ..................................... 12.573 0.010 mm
Free length after test .... 102.77 mm (4.046 inch) (0.4950 0.0004 inch)
Outside diameter ........ 34.398 mm (1.3542 inch) Diameter of the exhaust valve
stem ..................................... 12.573 0.010 mm
Note: Before assembly to the cylinder head, apply (0.4950 0.0004 inch)
clean engine oil to the outer diameter of the valve
guide. (C) Diameter of the valve head
(A) Dimensions for the valve guides Inlet ......... 58.50 0.15 mm (2.303 0.006 inch)
Exhaust ... 56.50 0.15 mm (2.224 0.006 inch)
Height to the top of the valve
guide ................ 42.0 0.5 mm (1.65 0.02 inch) (D) Valve face angle
Bore in the new valve guide for the intake valve
after installation ................... 12.626 0.020 mm Inlet ................................... 70.75 0.25 degrees
(0.4971 0.0008 inch) Exhaust ............................. 45.60 0.25 degrees
28 KENR5396-04
i03677240
Turbocharger
SMCS Code: 1052
Part No.: 327-7738
g01647817
Illustration 49
(E) Angle for the face of the valve seat inserts

Inlet ................................... 20.00 0.25 degrees
Exhaust ............................. 45.00 0.25 degrees
(F) Dimensions for the valve seat inserts

Outer diameter of the inlet valve seat
insert .................................... 62.100 0.013 mm
(2.4449 0.0005 inch)
Bore in the cylinder head for the inlet valve seat
insert .................................... 62.000 0.015 mm
(2.4409 0.0006 inch) g01975335
Outer diameter of the exhaust valve seat Illustration 50
insert .................................... 61.120 0.013 mm
(2.4063 0.0005 inch) Use the following procedure to tighten the turbine
Bore in the cylinder head for the exhaust valve clamp assembly (1):
seat insert ............................ 61.000 0.015 mm
(2.4016 0.0006 inch) Note: Before assembly, lubricate the threads of the
Outer diameter of the face of the valve seat turbine clamp assembly with 4C-5599 Anti-Seize
inserts ..... 50.00 0.25 mm (1.968 0.010 inch) Compound.
(G) Depth of the bore in the cylinder head for the 1. Tighten the turbine clamp assembly to 18 to 20 Nm
valve seat inserts (159 to 177 lb in).
Inlet ......... 14.03 0.15 mm (0.552 0.006 inch) 2. Gently hit around the turbine clamp assembley
Exhaust ... 14.63 0.15 mm (0.576 0.006 inch) with a soft hammer.
3. Again, tighten the turbine clamp assembley to

18 to 20 Nm (159 to 177 lb in).
(2) Torque for the bolts ........ 40 3 Nm (30 2 lb ft)
(3) Torque for the plug assembly ......... 14 to 17 Nm

(124 to 150 lb in)
KENR5396-04 29
i02950938 i03295647
Turbocharger Turbocharger Support

Part No.: 306-9495, 306-9496 Part No.: 243-6449, 319-9463
S/N: LAJ1-Up; LLM1-Up S/N: SSP1-Up; B7B1-Up
Part No.: 243-6449
g01427272
Illustration 52
Typical example
g01269136
Illustration 51
Note: Lubricate all the threads with 5P-3931

Anti-Seize Compound before assembly.
Use the following procedure to tighten the turbine

clamp assembly (1):
1. Tighten the turbine clamp assembly to 20 Nm

(15 lb ft).
2. Loosen the turbine clamp assembly by two to

three turns.
g01679413
Illustration 53
3. Gently hit around the turbine clamp assembley Section A-A
with a soft hammer.
(D) Height to the top of the dowel after
4. Again tighten the turbine clamp assembley to installation ....... 12.0 1.0 mm (0.47 0.04 inch)
18 to 20 Nm (13 to 15 lb ft).
(2) Torque for the bolts ........ 40 3 Nm (29 2 lb ft)

30 KENR5396-04
i03248614
Exhaust Manifold
SMCS Code: 1059
Part No.: 324-2352
g01679414
Illustration 54
Section B-B
(E) Height to the top of the dowel after

installation ......... 8.0 0.5 mm (0.31 0.02 inch)
g01455986
Illustration 56
Note: Before assembly, apply 4C-5599 Anti-Seize

Compound to the threads, the bearing surfaces, and
the inside diameter of the clamps (1).
(1) Torque for eight clamps ................. 7.5 1.0 Nm

(65 9 lb in)
(2) Clearance between the convolutions of the

assembled bellows between the manifold and the
turbocharger ......................... 1.3 mm (0.05 inch)
g01679416
Illustration 55
(3) After assembly, bend the tab of the gasket to the
Section C-C
surface that is adjacent.
Note: Apply 4C-9506 Retaining Compound to the Note: Before assembly, apply 4C-5599 Anti-Seize
bore of the cup plugs. Compound to the spacers (4), the washer face and
threads of the bolts (5).
(F) Installation depth of the cup
plugs ......... 1.25 0.25 mm (0.049 0.010 inch) (5) Torque for eight bolts ..... 65 5 Nm (48 4 lb ft)
KENR5396-04 31
i02952881 i03248602
Exhaust Manifold Exhaust Manifold

Part No.: 289-6083, 289-6087 Part No.: 296-8500
g01455986
Illustration 58
Note: Before assembly, apply 4C-5599 Anti-Seize

Compound to the threads and the clamping surface
of the clamps (1).
g01468167 (1) Torque for eight clamps ..................... 12 2 Nm

Illustration 57 (105 18 lb in)
(1) Use the following procedure to tighten four clamp (2) Clearance between the convolutions of the
assemblies: assembled bellows between the manifold and the
turbocharger ......................... 1.3 mm (0.05 inch)
1. Tighten the clamp assemblies to 12 2 Nm
(105 18 lb in). (3) After assembly, bend the tab of the gasket to the
surface that is adjacent.
2. Gently tap around the clamp assemblies with a
soft hammer. Note: Before assembly, apply 4C-5599 Anti-Seize
Compound to the spacers (4) and the threads of the
3. Again, tighten the clamp assemblies to 12 2 Nm bolts (5).
(105 18 lb in).
(5) Torque for eight bolts ..... 65 5 Nm (48 4 lb ft)
(2) Before assembly, lubricate the bearing surfaces
of the hard washers with 4C-5599 Anti-Seize
Compound.
Note: Before assembly, lubricate the threads and the

bearing surfaces of the bolt with 4C-5599 Anti-Seize
Compound.
(3) Torque for four bolts ....... 65 5 Nm (48 4 lb ft)

32 KENR5396-04
i03248580 i03822189
Exhaust Fitting Pressure Control Valve

SMCS Code: 1061-X6
(Oil Regulator Valve and Oil
Part No.: 324-5552, 325-4728
Bypass Valve)
S/N: SSP1-Up; B7B1-Up SMCS Code: 1315; 1319-VL
Part No.: 324-5552 Part No.: 328-1699
g01269533
Illustration 59
Use the following procedure to tighten the clamp

assemblies (1):
Note: Before assembly, apply 4C-5599 Anti-Seize g01563294

Compound to threads, the bearing surfaces, and the Illustration 60
inside diameter of the clamp assemblies.
(1) 177-7130 Shim
1. Tighten the clamp assemblies to 12 2 Nm
Thickness of one shim ...... 1.00 mm (0.039 inch)
(105 18 lb in).
Used with the 288-4597 Spring
2. Gently hit around the clamp assemblies with a
soft hammer. Approximate pressure change with one
shim .............................................. 21 kPa (3 psi)
3. Again, tighten the clamp assemblies to 12 2 Nm Used with the 285-6589 Spring
(105 18 lb in).
Approximate pressure change with one
shim .............................................. 14 kPa (2 psi)
(2) 288-4597 Spring for the regulator valve of the oil

Test force .................. 1871 126 N (421 28 lb)
Free length after test ........ 105.4 mm (4.15 inch)
Outside diameter ................ 48.2 mm (1.90 inch)
(3) 285-6589 Spring for the oil bypass valve

Test force .................... 1669 83 N (375 19 lb)
Free length after test ........ 148.3 mm (5.84 inch)
Outside diameter ................ 48.2 mm (1.90 inch)
(4) Lubricate the O-ring seal with the lubricant that is

being sealed.
KENR5396-04 33
i03252440
Engine Oil Pump

SMCS Code: 1304
Part No.: 307-9784
g01463127
Illustration 63
(A) Distance from the end of the shaft to the gear

face ................. 47.9 0.5 mm (1.89 0.02 inch)
(B) Dimensions for the gear

Length of the new gear .. 150.42 mm (5.922 inch)
g01463167
Illustration 61 Depth of the bore for the new
gear ................................... 150.555 0.020 mm
(5.9273 0.0008 inch)
(C) Dimensions for the shaft

Diameter of the shaft .. 50.795 mm (1.9998 inch)
Bore in the sleeve bearing for the shaft after
assembly ............................. 50.918 0.040 mm
(2.0046 0.0016 inch)
Note: Do not machine the sleeve bearings after

installation.
(D) Extension of two dowels from the oil pump

cover ................. 8.0 0.5 mm (0.31 0.02 inch)
g01462967
Illustration 62
(E) Installation depth of two sleeve bearings in the oil
pump cover ....... 1.5 0.5 mm (0.06 0.02 inch)
(F) Installation depth of two sleeve bearings in the oil

pump body ................................. 1.50 0.25 mm
(0.059 0.010 inch)
(G) Distance from the end of the shaft to the gear

face ................. 41.5 0.5 mm (1.63 0.02 inch)
(H) Position the bearing joints from the centerline

through the bearing bores of the pump
cover. ................................................ 30 degrees
(J) Position the bearing joints from the centerline

through the bearing bores of the oil pump
body. ......................................... 30 15 degrees
34 KENR5396-04
Bench test specifications

Unrestricted nominal flow rate per minute at 2394
rpm ..................................... 1542 L (405 US gal)
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.
i03252461
Engine Oil Pump

SMCS Code: 1304
Part No.: 297-8808
g01463127
Illustration 66
(A) Distance from the end of the shaft to the gear

face ................. 71.4 0.5 mm (2.81 0.02 inch)

Length of the new gear .......... 108 mm (4.3 inch)
Depth of the bore for the new
gear ...... 108.20 0.02 mm (4.260 0.001 inch)
(C) Diameter of the shaft ...... 59.93 mm (2.359 inch)
(D) Extension of two dowels from the oil pump

cover ................. 8.0 0.5 mm (0.31 0.02 inch)
Note: Before assembly, cool the sleeve bearings and

the bearing driver to 75 C (103 F) for minimizing
Illustration 64
g01463167 the press fit.
(E) Installation depth of two sleeve bearings in the oil

pump cover ....... 1.5 0.5 mm (0.06 0.02 inch)
(F) Installation depth of two sleeve bearings in the oil

pump body ................................. 1.50 0.25 mm
(0.059 0.010 inch)
(G) Distance from the end of the shaft to the gear

face ................. 43.0 0.5 mm (1.69 0.02 inch)
(H) Position the bearing joints from the centerline

cover. ........................................ 30 15 degrees
g01462967 (J) Position the bearing joints from the centerline
Illustration 65
body. ......................................... 30 15 degrees

Unrestricted nominal flow rate per minute at 2394
rpm ..................................... 1824 L (480 US gal)
KENR5396-04 35
Note: Before you install the pump, lubricate the (C) Distance from the end of the idler shaft to the
moving parts with clean engine oil. Rotate the pump gear face ......... 41.6 0.5 mm (1.64 0.02 inch)
by hand in order to ensure that the pump rotates
freely. (D) Installation depth of the sleeve bearings in the
scavenge oil body .......................... 1.5 0.5 mm
(0.06 0.02 inch)
i03250580
Engine Oil Scavenge Pump Note: Do not machine the sleeve bearings after
installation.
SMCS Code: 1312
(1) Drive shaft
Part No.: 262-1275
S/N: SSP1-Up; B7B1-Up Diameter of the new drive shaft ........ 50.795 mm
(1.9998 inch)
Bore in the sleeve bearing for the new drive shaft
(2.0046 0.0012 inch)
(2) Idler shaft

Diameter of the new idler shaft ......... 50.795 mm
(1.9998 inch)
Bore in the sleeve bearing for the new idler
shaft ..................................... 50.918 0.030 mm
(2.0046 0.0012 inch)
(3) Use the following procedure in order to tighten

the bolt:
g01651716
Illustration 67
1. Tap on the drive gear in order to seat the taper
of the drive gear.
2. Tighten the bolt to 265 40 Nm (195 30 lb ft).
3. Repeat this procedure until the torque does not

change.
g01651673
Illustration 68
Section A-A
NOTICE
Before operation, the pump must be lubricated with
clean engine oil and the pump must turn freely by hand
or damage to parts can be the result.
Note: Lubricate the bores for the O-ring seal lightly

with the lubricant that is being sealed.

g01651715
Illustration 69
Depth of the bore in the scavenge oil body for the (E) Position the bearing joints from the centerline
new gear ................................ 129.68 0.02 mm through the bearing bores of the pump
(5.105 0.001 inch)
body. ......................................... 30 15 degrees
36 KENR5396-04
(4) Installation depth of the sleeve bearing in the i03250620

pump body ........ 1.5 0.5 mm (0.06 0.02 inch)
Engine Oil Scavenge Pump
SMCS Code: 1312
Part No.: 262-1287
g01651716
Illustration 71
g01676704
Illustration 70
(F) Extension of two dowels from the

cover ................. 8.0 0.5 mm (0.31 0.02 inch)
(G) Installation depth of the sleeve bearing in the

cover ................. 1.5 0.5 mm (0.06 0.02 inch)
(H) Position the bearing joints from the

centerline through the bearing bores of
the cover. .................................. 30 15 degrees

Unrestricted flow rate per minute at 1668
g01651673
rpm ..................................... 1404 L (370 US gal) Illustration 72
Section A-A
NOTICE
Before operation, the pump must be lubricated with
clean engine oil and the pump must turn freely by hand
or damage to parts can be the result.
Note: Lubricate the bores for the O-ring seal lightly

with the lubricant that is being sealed.

Depth of the bore in the scavenge oil body for the
new gear ................................ 147.46 0.02 mm
(5.805 0.001 inch)
(C) Distance from the end of the idler shaft to the

gear face ......... 41.6 0.5 mm (1.64 0.02 inch)
(D) Installation depth of the sleeve bearings in the

scavenge oil body .......................... 1.5 0.5 mm
(0.06 0.02 inch)
KENR5396-04 37
Note: Do not machine the sleeve bearings after

installation.
(1) Drive shaft

Diameter of the new drive shaft ........ 50.795 mm
(1.9998 inch)
Bore in the sleeve bearing for the new drive shaft
(2.0046 0.0012 inch)
(2) Idler shaft

Diameter of the new idler shaft ......... 50.795 mm
(1.9998 inch)
Bore in the sleeve bearing for the new idler
shaft ..................................... 50.918 0.030 mm
(2.0046 0.0012 inch)
(3) Use the following procedure in order to tighten

the bolt:
g01676704
1. Tap on the drive gear in order to seat the taper Illustration 74
of the drive gear.
(F) Extension of two dowels from the
2. Tighten the bolt to 265 40 Nm (195 30 lb ft). cover ................. 8.0 0.5 mm (0.31 0.02 inch)
3. Repeat this procedure until the torque does not (G) Installation depth of the sleeve bearings in the
change. cover ................. 1.5 0.5 mm (0.06 0.02 inch)
(H) Position the bearing joints from the

centerline through the bearing bores of
the cover. .................................. 30 15 degrees

Unrestricted flow rate per minute at 1891
rpm ..................................... 1824 L (480 US gal)
g01651715
Illustration 73
(E) Position the bearing joints from the centerline

through the bearing bores of the pump
body. ......................................... 30 15 degrees
(4) Installation depth of the sleeve bearings in the

pump body ........ 1.5 0.5 mm (0.06 0.02 inch)
38 KENR5396-04
i03254524
Engine Oil Pan

SMCS Code: 1302
Part No.: 300-5521
Part No.: 302-5395
g01655315
Illustration 77
View B-B
Note: The sealing surfaces of the oil pan should be

free of oil, debris, gasket material that is protruding,
or any other sealant. The oil pan must be assembled
and tightened to the cylinder block within ten minutes
of applying sealant.
(1) Lubricate the bore for the O-ring seals for the
suction screen lightly with the lubricant that is
being sealed or an approved equivalent.

(26 4 lb ft)
g01655313
(3) Torque for eight nuts ...... 47 3 Nm (35 2 lb ft)
Illustration 75
Typical view (4) Lubricate the bore for the O-ring seal for the
elbow assembly lightly with the lubricant that is
(5) Lubricate the bore for the O-ring seal for the oil
pump adapter lightly with the lubricant that is
(6) Lubricate the bore for the O-ring seal for the
male coupler lightly with glycerin or an approved
equivalent.
(7) Lubricate the bore for the O-ring seal for the plugs
lightly with glycerin or an approved equivalent.
(9) Apply 4C-9614 Silicone Sealant to a bead of

g01655395
Illustration 76 5 mm (0.2 inch) at six places on the sealing
View A-A surface of the oil pan for the gasket joints.
(8) Flywheel housing
(10) Front accessory drive housing Note: Lubricate the threads of the oil drain plug lightly
with lubricant that is being sealed or an approved
equivalent.
(11) Torque for the oil drain plug ............. 55 6 Nm

(41 4 lb ft)
KENR5396-04 39
i03681260 Note: Lubricate the shaft with clean engine oil before
pressing the impeller on the pump shaft.
Water Pump
(B) The end of the pump shaft must be flush
SMCS Code: 1361 with the face of the impeller within 0.15 mm
( 0.006 inch).
Part No.: 313-7600
(3) Pump shaft
Diameter of the pump shaft for the

impeller ................................... 25.400 to 25.410 mm
(1.0000 to 1.0004 inch)
Bore diameter of the impeller ..... 25.350 0.012 mm

(0.9980 0.0005 inch)
(6) Torque for the bearing locknut ....... 300 30 Nm

(221 22 lb ft)
Torque for the setscrews .................. 4.00 1.25 Nm

(35 11 lb in)
Note: Install the dry water pump seal (7) into the
pump housing. Install the seal within two minutes
after the seal has been removed from the tube. Use
the correct installation tool and use a slow, even
motion to press the water pump seal into the housing.
(7) Maximum leakage per minute for the water pump

g01464807
Illustration 78 seal at 138 kPa (20 psi) of air pressure is less
than 24.0 cc (1.5 cu in).
(1) Before assembly, lubricate the bore of the seal
lightly with 5P-3975 Rubber Lubricant. (8) Lubricate the O-ring seal with P-80 or 5P-3975
Rubber Lubricant.
(2) Torque for four taperlock studs .......... 35 5 Nm
(26 4 lb ft) (9) Maximum leakage per minute for the seal group
at 138 kPa (20 psi) of air pressure is less than
20.0 cc (1.2 cu in).
g01977636
Illustration 79
(4) Retainer
(5) Bearing assembly
(A) The distance between the impeller and the pump

housing ................................ 14.24 mm (0.561 inch)
40 KENR5396-04
i03681302
Water Pump
SMCS Code: 1361
Part No.: 279-0771
g01977639
Illustration 81
(3) Plate retainer
(4) Bearing housing
(A) The distance between the impeller and the pump

housing ...................................... 9.6 mm (0.38 inch)
Note: Lubricate the shaft with clean engine oil before

pressing the impeller on the pump shaft.
(B) The end of the pump shaft must be flush

with the face of the impeller within 0.15 mm
( 0.006 inch).
Illustration 80
g01636692 (2) Pump shaft
(1) Before assembly, lubricate the bore of the O-ring Diameter of the pump shaft for the
seal lightly with 5P-3975 Rubber Lubricant. impeller ................................... 31.750 to 31.763 mm
(1.2500 to 1.2505 inch)
Bore diameter of the impeller ..... 31.705 0.013 mm

(1.2482 0.0005 inch)
(5) Torque for the locknut .................... 100 20 Nm

(74 15 lb ft)
Torque for the setscrews .................. 4.00 1.25 Nm

(35 11 lb in)
Note: Install the dry water pump seal (6) into the
pump housing. Install the seal within two minutes
after the seal has been removed from the tube. Use
the correct installation tool and use a slow, even
motion to press the water pump seal into the housing.
(6) Maximum leakage per minute for the water pump

seal at 138 kPa (20 psi) of air pressure is less
than 20.0 cc (1.2 cu in).
(7) Lubricate the O-ring seal with P-80 or 5P-3975

Rubber Lubricant.
KENR5396-04 41
(8) Maximum leakage per minute for the water seal

assembly at 138 kPa (20 psi) of air pressure is
less than 20.0 cc (1.2 cu in).
i03681305
Auxiliary Water Pump

SMCS Code: 1371
Part No.: 250-6720
g01977644
Illustration 82
42 KENR5396-04
(8) Maximum leakage per minute for the lip type seal
at 138 kPa (20 psi) of air pressure is less than
24.0 cc (1.5 cu in).
Use the following procedure to install the seal group.
1. Lubricate the outside diameter of the ceramic

ring and rubber seal (10) with clean water or with
207-1600 Rubber Lubricant.
2. Seat the ceramic ring (11) and the rubber seal into
the housing.
3. Remove the spring (13) from the seal assembly

g01567194
(12).
Illustration 83
View of area C 4. Press the seal assembly on the shaft until the
(9) Ring assembly faces of the seal makes the contact lightly.
(1) Torque for four taperlock studs .......... 35 5 Nm 5. Install the spring.
(26 4 lb ft)
Maximum leakage per minute for the seal (10) at
(2) Lubricate the bore of the seal with glycerin or 138 kPa (20 psi) of air pressure is less than 20.0 cc
approved equivalent. (1.2 cu in).
Note: Before pressing the impeller on the shaft,

i02963763
lubricate the shaft with clean engine oil.
(B) Dimensions for shaft

Cylinder Block
Bore diameter of the SMCS Code: 1201
impeller ................................ 25.342 0.013 mm Part No.: 283-9344
(0.9977 0.0005 inch) S/N: SSP1-Up; B7B1-Up
Diameter of the shaft for the
impeller ............................. 25.400 to 25.413 mm
(1.0000 to 1.0005 inch)
Width in the groove of the shaft for the thrust
washer ...... 8.75 0.05 mm (0.344 0.002 inch)
(3) Torque for the taperlock studs ........... 35 5 Nm

(26 4 lb ft)
(4) Torque for the nuts .... 27 4 Nm (240 35 lb in)
(5) Thickness of the thrust washer ............... 8.5 mm

(0.33 inch)
(D) The end of the pump shaft must be flush

with the face of the impeller within 0.15 mm
( 0.006 inch).
(E) Distance between the vanes of the

impeller and the outside of the housing
(6) .................................... 31.5800 0.4425 mm
(1.24330 0.01742 inch)
(7) Lubricate the bore of the seal with glycerin or

approved equivalent.
Note: Do not lubricate the lip type seal (8).
g01446441
Illustration 84
Pictorial view
KENR5396-04 43
(1) 248-7585 Orifice
Orifice (1) must be fully seated in the bore and flush

with the face of the cylinder block. After you insert
the orifice into the bores, apply 4C-9507 Retaining
Compound to the outside diameter of the orifice.
Install the outside diameter of the orifice's chamfer
toward the cylinder block. Orifice (1) is only for the
number three cylinder through the number eight
cylinder .
(2) 248-7584 Orifice

with the face of the cylinder block. After you insert g01566793
the orifice into the bores, apply 4C-9507 Retaining Illustration 86
Compound to the outside diameter of the orifice. Right side view
toward the cylinder block. Orifice (2) is only for the (5) Lubricate the O-ring seal with clean engine oil
number one cylinder and for the number two cylinder . prior to assembly.
(3) Lubricate the O-ring seal with clean engine oil (B) Extension of dowel from the face of the cylinder
prior to assembly. block ............... 19.0 1.0 mm (0.75 0.04 inch)
g01490693 g01490673
Front view of engine Rear view of engine
(A) Extension of dowel from the face of the cylinder (6) Apply 6V-6640 Sealant to the outside diameter
block ............... 16.0 1.0 mm (0.63 0.04 inch) of the cup plugs before assembly.
(4) Centerline through the oil holes in the camshaft (C) New dimension from centerline of crankshaft
bearings bearing bore to the top of the block ....... 650 mm
(25.6 inch)
Install the camshaft bearings so the oil holes are
horizontal. Ensure that the groove in the bearing for
the camshaft is centered with the oil hole.
44 KENR5396-04
Use the following procedure to tighten the main

bearing cap bolts:
1. Tighten studs (11) to 100 20 Nm (75 15 lb ft).
2. Again tighten studs (11) to 100 20 Nm

(75 15 lb ft).
3. Assemble main bearing caps (7) with the part

number toward the front of the cylinder block.
4. Lubricate the threads of the studs (11) and

both faces of washer plate (12) with engine oil.
Assemble main bearing cap and hand tighten the
nuts.
5. Lubricate the threads of bolts (9) and both sides of

washers (8) with engine oil. Assemble and hand
tighten the bolts and the washers in the side of
the cylinder block.
Illustration 88
g01438675 6. Start at the front of the engine (number one main
Front view of engine
bearing cap). Tighten all the side bolts on the right
hand side (same side as the bearing tab slots) of
(7) Main bearing cap
(8) Washer
the cylinder block to 100 20 Nm (75 15 lb ft).
(9) Bolt
(10) Nut 7. Use the 278-1150 Stud Tensioner Tool Group.
(11) Stud
(12) Washer plate Start at the front of the engine (number one
main bearing cap). Tension both studs (11)
(D) Installation depth of the cup plugs. .. 3.4 1.8 mm simultaneously to 530000 N (119150 lb).
(0.13 0.07 inch)
8. Hand tighten both nuts (10) with the use of the
gear drives on the tensioner.
9. Release the hydraulic pressure on the tensioner.
10. Repeat Step 7 through Step 9 for main bearing

caps 2 through 9.
11. Repeat Step 7 through Step 9 again for all the

main bearing caps.
12. Start at the front of the engine (number one main

bearing). Tighten all the side bolts on the left hand
side (opposite side as the bearing tab slots) of the
cylinder block to 100 20 Nm (75 15 lb ft).
13. Start at the front of the engine (number one main

hand side (same side as the bearing tab slots) of
Illustration 89
g01490634 14. Start at the front of the engine (number one main
Right side view
bearing). Tighten all the side bolts on the left hand
side (opposite side as the bearing tab slots) of the
(E) Bore in the block for the main bearings cylinder block to 530 70 Nm (390 50 lb ft).
Standard, original new

size .................................... 210.000 0.020 mm
(8.2677 0.0008 inch)
KENR5396-04 45
i03626078
Cylinder Block
SMCS Code: 1201
Part No.: 342-7302
g01944984
Illustration 91
(A) Extension of dowels from the face of the cylinder

block ................. 7.0 0.5 mm (0.28 0.02 inch)
(B) Extension of dowels from the face of the cylinder

g01446441 block ............... 16.0 1.0 mm (0.63 0.04 inch)
Illustration 90
(4) Centerline through the oil holes in the camshaft

(1) 248-7585 Orifice
bearings
with the head face of the cylinder block. After you
insert the orifice into the bores, apply 4C-9506
Retaining Compound to the outside diameter of the
orifice. Install the outside diameter of the orifice's
chamfer toward the cylinder block. Orifice (1) is only
for the number three cylinder through the number
eight cylinder .
(2) 248-7584 Orifice

with the face of the cylinder block. After you insert
the orifice into the bores, apply 4C-9506 Retaining
Compound to the outside diameter of the orifice.
toward the cylinder block. Orifice (2) is only for the
number one cylinder and for the number two cylinder .
g01945433
Illustration 92
(3) Lubricate the O-ring seal with clean engine oil Right side view
prior to assembly.
(5) Lubricate the O-ring seal with clean engine oil
prior to assembly.
46 KENR5396-04
(C) Extension of dowels from the face of the cylinder (E) Installation depth of the cup plugs. .. 3.4 1.8 mm
block ............... 19.0 1.0 mm (0.75 0.04 inch) (0.13 0.07 inch)
g01945434 g01945436
Rear view of engine Right side view
(6) Apply 4C-9506 Retaining Compound to the (F) Bore in the block for the main bearings
outside diameter of the cup plugs before
assembly. Standard, original new
size .................................... 210.000 0.020 mm
(D) New dimension from centerline of crankshaft (8.2677 0.0008 inch)
bearing bore to the top of the cylinder
block .................................... 650 mm (25.6 inch) Note: The main bearing caps (7) must be installed
with the identifying marks toward the front of the
engine. The number of the main bearing cap (7) must
also match the cast number on the left side of each
main bearing saddle.

bearing cap assembly bolts:
1. Tighten the studs (11) to 100 20 Nm

(74 15 lb ft).
2. Again tighten the studs (11) to 100 20 Nm

(74 15 lb ft).
3. Assemble main bearing cap assembly (7) with the

part number toward the front of the cylinder block.
4. Lubricate the threads of the studs (11) and both

faces of the plate (12) with engine oil. Assemble
main bearing cap assembly and hand tighten the
nuts.
g01945435
Illustration 94 5. Lubricate the threads of the bolts (9) and both
Front view of engine sides of the hard washers (8) with engine oil.
(7) Bearing cap assembly Assemble and hand tighten the bolts and the hard
(8) Hard washer washers in the side of the cylinder block.
(9) Bolt
(10) Nut
(11) Stud
(12) Plate
KENR5396-04 47
6. Start at the front of the engine (number one main i03210503

hand side (same side as the bearing tab slots) of Cylinder Block
SMCS Code: 1201
7. Use the 278-1150 Stud Tensioner Tool Group.
Part No.: 284-8359
Start at the front of the engine (number
one main bearing cap). Tension both studs
(11) simultaneously to 530000 5000 N
(119149 1124 lb).
Tension the studs of the bearing cap assembly

with hydraulic cylinder group stud by using
135000 1000 kPa (19580 145 psi) pressure.

71500 500 kPa (10370 73 psi) pressure.
8. Hand tighten both the nuts (10) with the use of the
10. Repeat Step 7 through Step 9 for the cap of the

main bearings 2 through 9.
11. Repeat Step 7 through Step 9 again for all cap of

the main bearings.
12. Start at the front of the engine (number one cap

of the main bearing). Tighten all the side bolts on
the left hand side (opposite side as the bearing
tab slots) of the cylinder block to 100 20 Nm
(74 15 lb ft). g01637142
Illustration 96

(1) 279-0776 Orifice
the right hand side (same side as the bearing
The Orifice (1) must be fully seated in the bore and
flush with the head face of the cylinder block. After
(391 52 lb ft).
you insert the orifice into the bores, apply 4C-9507
orifice. Install the orifice with the outside diameter of
the chamfer toward the cylinder block. Orifice (1) is
only for the number five cylinder through the number
ten cylinder.
(391 52 lb ft).
(2) 279-0774 Orifice

only for the number one cylinder through the number
four cylinder.
(3) Before assembly, lubricate the O-ring seal with

clean engine oil.
48 KENR5396-04
g01637143 g01490673
Front view of engine Rear view of engine
(A) Extension of dowel from the face of the cylinder (6) Before assembly, apply 4C-9507 Retaining
block ............... 16.0 1.0 mm (0.63 0.04 inch) Compound to the outside diameter of the cup
plugs.
(4) Install the camshaft bearings in the centerline
through the oil holes. (C) New dimension from the centerline of the
crankshaft bearing bore to the top of the
Install the camshaft bearings so the oil holes are block .................................... 650 mm (25.6 inch)
g01566793
Illustration 98
Right side view of engine
(5) Before assembly, lubricate the O-ring seal with

clean engine oil. g01677973
Illustration 100
(B) Extension of dowel from the face of the cylinder Front view of engine
block ............... 19.0 1.0 mm (0.75 0.04 inch) (7) Bearing cap assembly
(8) Hard washer
(9) Bolt
(10) Nut
(11) Stud
(12) Plate
(D) Installation depth of the cup plugs. .. 3.4 1.8 mm

(0.13 0.07 inch)
KENR5396-04 49

135000 1000 kPa (19580 145 psi) pressure.

71500 500 kPa (10370 72 psi) pressure.

11. Repeat Step 7 through Step 10 again for all cap

of the main bearings 1 through 11.

Illustration 101
g01490634 the left hand side (opposite side as the bearing
Right side view of engine
(75 15 lb ft).
(E) Bore in the block for the main bearings
Standard, original new size ... 210.00 0.02 mm of the main bearing). Tighten all the side bolts on
(8.268 0.001 inch) the right hand side (same side as the bearing
Use the following procedure to tighten the main (390 50 lb ft).
bearing cap bolts:
1. Tighten the studs (11) to 100 20 Nm of the main bearing). Tighten all the side bolts on
(75 15 lb ft). the left hand side (opposite side as the bearing
2. Again tighten the studs (11) to 100 20 Nm (390 50 lb ft).
(75 15 lb ft).
3. Assemble the main bearing cap assembly (7) with

the part number toward the front of the cylinder
block.

the main bearing cap assembly and hand tighten
the nuts.
5. Lubricate the threads of the bolts (9) and both

sides of the hard washers (8) with engine oil.
Assemble and hand tighten the bolts and the hard
washers in the side of the cylinder block.

(75 15 lb ft).
7. Use the 278-1150 Stud Tensioner Tool Gp.
Start at the front of the engine (number one cap

of the main bearing). Tension both studs (11)
simultaneously to 530000 N (119150 lb).
50 KENR5396-04
i03626644
Cylinder Block
SMCS Code: 1201
Part No.: 342-7305
g01944984
Illustration 103
(A) Extension of dowels from the face of the cylinder

block ................. 7.0 0.5 mm (0.28 0.02 inch)
(B) Extension of dowels from the face of the cylinder

g01637142 block ............... 16.0 1.0 mm (0.63 0.04 inch)
Illustration 102
(4) Centerline through the oil holes in the camshaft

(1) 279-0776 Orifice
bearings
only for the number five cylinder through the number
ten cylinder.
(2) 279-0774 Orifice

only for the number one cylinder through the number
four cylinder. Illustration 104
g01945433
Right side view

(3) Lubricate the O-ring seal with clean engine oil
prior to assembly. (5) Lubricate the O-ring seal with clean engine oil
prior to assembly.
KENR5396-04 51
(C) Extension of dowels from the face of the cylinder (E) Installation depth of the cup plugs. .. 3.4 1.8 mm
block ............... 19.0 1.0 mm (0.75 0.04 inch) (0.13 0.07 inch)
g01945434 g01945436
Rear view of engine Right side view
(6) Apply 4C-9506 Retaining Compound to the (F) Bore in the block for the main bearings
outside diameter of the cup plugs before
assembly. Standard, original new
size .................................... 210.000 0.020 mm
(D) New dimension from centerline of crankshaft (8.2677 0.0008 inch)
bearing bore to the top of the cylinder
block .................................... 650 mm (25.6 inch) Note: The main bearing caps (7) must be installed
with the identifying marks toward the front of the
engine. The number of the main bearing cap (7) must
also match the cast number on the left side of each
main bearing saddle.

bearing cap assembly bolts:
1. Tighten the studs (11) to 100 20 Nm

(74 15 lb ft).
2. Again tighten the studs (11) to 100 20 Nm

(74 15 lb ft).
3. Assemble the main bearing cap assembly (7) with

the part number toward the front of the cylinder
block.

the main bearing cap assembly and hand tighten
g01945435
the nuts.
Illustration 106
Front view of engine 5. Lubricate the threads of the bolts (9) and both
(7) Bearing cap assembly sides of the hard washers (8) with engine oil.
(8) Hard washer Assemble and hand tighten the bolts and the hard
(9) Bolt washers in the side of the cylinder block.
(10) Nut
(11) Stud
(12) Plate
52 KENR5396-04
6. Start at the front of the engine (number one cap i02953078

the right hand side (same side as the bearing Cylinder Liner
(74 15 lb ft). SMCS Code: 1216
Part No.: 317-6283
7. Use the 278-1150 Stud Tensioner Tool Gp.
Start at the front of the engine (number one

cap of the main bearing). Tension both studs
(11) simultaneously to 530000 5000 N
(119149 1124 lb).

135000 1000 kPa (19580 145 psi) pressure.

71500 500 kPa (10370 73 psi) pressure.

11. Repeat Step 7 through Step 10 again for all cap

of the main bearings 1 through 11.

the left hand side (opposite side as the bearing Illustration 108
g01468507
(74 15 lb ft).

(391 52 lb ft).

(391 52 lb ft).
g01468487
Illustration 109
(A) Thickness of flange on liner ... 114.70 0.10 mm

(4.516 0.004 inch)
KENR5396-04 53
(B) Diameter for the sleeve ......... 184.50 0.20 mm Top Piston Ring (1)
(7.264 0.008 inch)
Install the top piston ring with the UP-1 side toward
(C) Bore in new liner ............... 175.025 0.025 mm the top of the piston.
(6.8907 0.0010 inch)
Width of groove in new piston for the top piston
(D) Outside diameter of the ring .................. 3.60 0.10 mm (0.142 0.004 inch)
sleeve ................................ 185.450 0.025 mm
(7.3012 0.0010 inch) Thickness of new top piston ring .. 3.465 to 3.510 mm
(0.1364 to 0.1382 inch)
(E) Inside diameter of the
sleeve ................................ 174.045 0.050 mm When the new top piston ring is installed in a cylinder
(6.8522 0.0020 inch) liner with a bore size of 175 mm (6.9 inch), the
clearance between the ends of the piston ring is the
(F) Thickness of the sleeve .......... 25.50 0.25 mm following value. ............................ 0.625 0.125 mm
(1.004 0.010 inch) (0.0246 0.0049 inch)
Use the following procedure to install the cylinder

liner:
Intermediate Piston Ring (2)
Install the intermediate piston ring with the UP-2
1. Install the O-ring seals (1) before the liner is
side toward the top of the piston.
installed in the cylinder block.
Width of groove in new piston for the intermediate
2. Put liquid soap on the cylinder block liner bore
piston ring ..................................... 3.110 0.010 mm
surface. Also, put liquid soap on the O-ring seals
(0.1224 0.0004 inch)
(1).
Thickness of new intermediate piston
3. Install the liner in the cylinder block immediately,
ring ................. 2.97 to 2.99 mm (0.117 to 0.118 inch)
before the O-ring seals (1) expand.
When the new intermediate piston ring is installed in
i03431420 a cylinder liner with a bore size of 175 mm (6.9 inch),
the clearance between the ends of the piston ring is
Piston and Rings the following value. ...................... 1.000 0.125 mm
(0.0394 0.0049 inch)
SMCS Code: 1214
Part No.: 307-4407 Oil Control Piston Ring (3)
The ends of the oil control piston ring should be a
Part No.: 293-5430, 307-4407 distance of 180 degrees from the ring end gap when
S/N: LAJ1-Up; LLM1-Up the oil control piston ring is assembled.
Width of groove in new piston for the oil control piston

ring .......... 4.060 0.010 mm (0.1598 0.0004 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 175 mm (6.9 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.
Piston Pin (4)

Note: Before assembly of the piston pin to the piston,
coat the piston pin with clean engine oil.
g01782934
Illustration 110
54 KENR5396-04
Outside diameter ....................... 75.000 0.005 mm i02959141

(2.9528 0.0002 inch)
Connecting Rod
Inside diameter ..... 31.0 0.3 mm (1.22 0.01 inch)
SMCS Code: 1218
Length ......... 102.00 0.25 mm (4.016 0.010 inch)
Part No.: 322-8380, 322-8381
Bore in piston for the piston pin .. 75.121 0.008 mm
(2.9575 0.0003 inch)
g01439838
Illustration 112
Use the following procedure to tighten the bolts of

the connecting rod:
Note: Before assembly, apply 6V-4876 Lubricant to

the threads of bolt (2), on the rings at the middle of
the bolt, and on the contact surface under the bolt
head.
g01567093
Illustration 111
1. Install the spacers (1) and the bolts (2). Hand
tighten the bolts.
Pin Retainer (5)
Note: Bolt 1 is identified as the middle bolt on the tab
Note: Install the pin retainer with the gap toward the side of the bearing on the rod. Tighten this bolt first in
area (6). Refer to Illustration 111. order to seat the bearing into the bore.
Thickness of pin retainer ................. 2.36 0.08 mm 2. Tighten bolt 1 and bolt 2 to 105 5 Nm
(0.093 0.003 inch) (75 4 lb ft).
Width of groove in new piston for the pin retainer 3. Tighten bolt 3 and bolt 4 to 105 5 Nm
....................... 2.65 to 2.85 mm (0.104 to 0.112 inch) (75 4 lb ft).
Refer to Table 1 for the part numbers of the tools that 4. Tighten bolt 5 and bolt 6 to 105 5 Nm
are used in servicing the piston. (75 4 lb ft).
Table 1
5. Repeat Step 2 through Step 4.
Service Tools
Pt. No. Description 6. Again, turn bolt 3 and bolt 4 to 90 5 degrees.
271-0504 Piston Ring Expander 7. Again, turn bolt 5 and bolt 6 to 90 5 degrees.
255-8897 Piston Ring Compressor
8. Again, turn bolt 1 and bolt 2 to 90 5 degrees.
1P-1861 Retaining Ring Pliers
Note: It is important to tighten bolt 1 and bolt 2 last
in order to ensure even distribution of the load on
the bolts.
KENR5396-04 55
The side clearance between two connecting rods

on the same new crankshaft pin is the following
value. ............ 1.0 0.38 mm (0.0394 0.0150 inch)
The 322-8380 Connecting Rod Gp is assembled in

the even number cylinder bank of the engine with
the chamfer side that is facing the fillet radius of the
crankshaft. When the marking on the side of the rod
indicates Even Front the arrow should be pointing
to the front of the engine.
The 322-8381 Connecting Rod Gp is assembled

into the odd number cylinder bank of the engine with
the chamfer side that is facing the fillet radius of the
crankshaft. When the marking on the side of the rod
indicates Odd Front the arrow should be pointed
to the front of the engine.
Careful handling of the connecting rod is required

at all times. The fracture face of the connecting rod
and the fracture face of the connecting rod cap must
not make contact with any surface. The connecting
rod and the connecting rod cap must be laid flat on
the sides. When possible, the rod assembly should
be kept together in order to protect the fracture face
when the connecting rod is out of the engine.
The connecting rod and the connecting rod cap must

g01476634
Illustration 113 be marked only with a mechanical etcher with the
(C) Measure across the diameter at 90 degrees from the horizontal number of the cylinder. The cylinder number must be
(D) Measure across the diameter at 25 degrees above the etched on the same surface as the part number and
horizontal
the serial number for the connecting rod.
(E) Measure across the diameter at 25 degrees below the
horizontal
i02897981
(A) Bore in bearing for new piston
pin ... 75.040 0.008 mm (2.9543 0.0003 inch) Connecting Rod and Main
Diameter of new piston pin ........ 75.000 0.005 mm Bearing Journals
(2.9527 0.0002 inch)
SMCS Code: 1230
(B) Distance between center of bearings .... 420 mm Part No.: 286-5801, 322-3030, 322-3031
(16.5354 inch)
Refer to Guidelines For Reusable Parts, SEBF8009,
The specification for the bore in the bearing (F) is the Main Bearings And Connecting Rod Bearings for
average of the readings that are taken at positions more information.
(C), (D), and (E).
Connecting Rod Bearing Journals
(F) Bore in bearing for
crankshaft ............................ 150.228 .034 mm Table 2
(5.9145 0.0013 inch)
Diameter Of Crankshaft Journal (Bearing Surface)
For Connecting Rod Bearings
The specification for the bore in the connecting rod
(G) is the average of the readings that are taken at Original Size Journal 150 mm (5.9055 inch)
positions (C), (D), and (E).
Undersize Journal Not available
Not available
(G) After the bolts are tightened, the bore in the
connecting rod for the bearing is the following Undersize Journal Not available
dimension. ......................... 157.000 0.013 mm Not available
(6.1811 0.0005 inch)
Clearance between bearing and new
Clearance between bearing and new journal .................................. 0.169 mm to 0.286 mm
crankshaft ............................ 0.169 mm to 0.286 mm (0.0067 inch to 0.0113 inch)
(0.0067 inch to 0.0113 inch)
56 KENR5396-04
Main Bearing Journals
Table 3
Diameter Of Crankshaft Journal (Bearing
Surface) For Main Bearings
Original Size Journal 200 mm (7.8740 inch)
Not available
Not available
Clearance between bearing and new

journal .................................. 0.176 mm to 0.308 mm
(0.0069 inch to 0.0121 inch)
i03292560
Crankshaft
SMCS Code: 1202
Part No.: 318-3128
Part No.: 289-2488
g01676750
Illustration 114
Note: Before assembling the crankshaft into the (2) Main bearing journal
cylinder block, lubricate the main bearing journals
with clean engine oil. Refer to Specifications, Main Bearing Journals for
more information on the main bearing journals and
Note: The thrust plates should be used only on the main bearing.
rear main bearing.
End play for a new crankshaft ........ 0.17 to 0.63 mm

(0.007 to 0.025 inch)
(A) Extension of the dowels ................ 9.0 0.5 mm

(0.35 0.02 inch)
(1) Connecting rod journal
Refer to Specifications, Connecting Rod Bearing

Journals for more information on the connecting rod
bearing journals and connecting rod bearings.
KENR5396-04 57
g01473592
Illustration 115
(3) Torque for the plugs ....... 50 7 Nm (37 5 lb ft)
Use the following procedure to tighten the bolt

assemblies (4):
Note: Do not reuse the counterweight bolts. Tighten

the counterweight bolts evenly.
1. Lubricate the threads of the bolts, shank, the

contact surface under the bolt head and the
washer with 6V-4876 Lubricant.
2. Tighten the bolts to 220 20 Nm (160 15 lb ft).
3. Again, rotate each bolt to 90 5 degrees.
(D) Maximum extension of the spring pin ....... 8 mm

(0.3 inch)
58 KENR5396-04
g01473613
Illustration 116
(G) Extension of the dowels .............. 10.0 0.5 mm

(0.39 0.02 inch)
KENR5396-04 59
i02957453
Crankshaft Wear Sleeves and

Seals
SMCS Code: 1160
Part No.: 248-4115
g01566574
Illustration 118
(5) Crankshaft
(A) The crankshaft seal group is installed from

both ends of the crankshaft at the following
distance. ........... 0.5 0.5 mm (0.02 0.02 inch)
Use the following procedure to remove the crankshaft

g01281910
Illustration 117 seal group:
(3) Flywheel housing
(4) Front housing 1. Remove the seal from each end of the engine.
Note: Make sure that the correct seal is installed on Note: Seals and wear sleeves cannot be used again,
each end of the crankshaft. after the seals and the wear sleeves are separated.
(1) 245-3574 Crankshaft seal group 2. Remove the wear sleeves with the 5P-7409
Sleeve Distorter and the 6V-3143 Distorter
DO NOT separate the wear sleeves from the Adapter.
crankshaft seals. Once the wear sleeves and
crankshaft seals are separated, the crankshaft seals Use the following procedure to install the crankshaft
cannot be used again. seal group:
Install the 245-3574 Crankshaft seal group in the 1. DO NOT separate the wear sleeves from the
front housing on a standard rotation engine. crankshaft seals. Once the wear sleeves and
crankshaft seals are separated, the crankshaft
Install the 245-3574 Crankshaft seal group in the seals cannot be used again.
flywheel housing on a reverse rotation engine.
Note: For a complete procedure with Illustrations,
(2) 245-3575 Crankshaft seal group refer to the Disassembly and Assembly Manual.
Install the 245-3575 Crankshaft seal group in the 2. Install the sleeve and the seal assembly with the
flywheel housing on a standard rotation engine. correct tools.
Install the 245-3575 Crankshaft seal group in the 3. Clean the outer surface of the crankshaft and the
front housing on a reverse rotation engine. inner surface of the wear sleeve with 169-5464
Quick Cure Primer (Aerosol Spray).
4. Carefully, put a thin coat of 4C-9507 Retaining

Compound on the inner surface of the wear sleeve
and on the crankshaft surface.
60 KENR5396-04
5. Install the crankshaft seals and the wear sleeves

as a unit. Install the unit on the end of the
crankshaft with the correct tools. Refer to Table 4.
Table 4
Tools for the Installation of the Crankshaft Seal
Part Number quantity
250-4586 Seal Locator 1
250-4587 Seal Installer 1
258-0933 Bolt 2
9S-8858 Nut 2
i03677300
Gear Group (Front)

SMCS Code: 1206
Part No.: 300-3114
g01786693
Illustration 119
(6) Crankshaft gear (9) Auxiliary drive gear
Note: Before assembly, lubricate both sides of the (1) Torque for four bolts ....................... 190 30 Nm
washers lightly with clean engine oil. (140 22 lb ft)
KENR5396-04 61
(2) Before assembly, lubricate both sides of the

washers lightly with clean engine oil.
(3) Lubricate the bore for the O-ring seals lightly with
the lubricant that is being sealed.
(4) Idler gear assembly

Bore in the sleeve bearing after
installation ............................ 89.964 0.010 mm
(3.5419 0.0004 inch)
Installation depth of the sleeve
bearing .............. 2.3 0.5 mm (0.09 0.02 inch)
(5) Bore in the sleeve bearing of the front adapter

assembly after installation ... 75.000 0.055 mm
(2.9527 0.0022 inch)
(7) Pump adapter

installation ............................ 75.000 0.055 mm
(2.9527 0.0022 inch)
bearing .............. 1.5 0.5 mm (0.06 0.02 inch)
(8) Diameter of the new idler shaft .. 89.88 0.02 mm

(3.539 0.001 inch)
(10) Bore in the sleeve bearing of the pump adapter

after installation .......... 94.056 mm (3.7030 inch)
Note: Before assembly, lubricate both sides of the

washers lightly with clean engine oil.
(11) Torque for four bolts ..................... 190 30 Nm

(140 22 lb ft)
(12) Diameter of the new pump drive

shaft ..................................... 74.900 0.015 mm
(2.9488 0.0006 inch)
62 KENR5396-04
i03677320
Gear Group (Front)

SMCS Code: 1206
Part No.: 300-3115
g01473755
Illustration 120
(4) Crankshaft gear (8) Auxiliary drive gear
(1) Torque for four bolts ....................... 190 30 Nm (6) Pump adapter
(140 22 lb ft)
(2) Lubricate the bore for the O-ring seals lightly with installation ............................ 75.000 0.055 mm
the lubricant that is being sealed. (2.9527 0.0022 inch)
(3) Idler gear assembly bearing ............... 1.5 0.5 mm (0.06 0.02 inch)
Bore in sleeve bearing after (7) Diameter of the new idler shaft .. 89.88 0.02 mm
installation ............................ 89.964 0.010 mm (3.539 0.001 inch)
(3.5419 0.0004 inch)
Installation depth of the sleeve (9) Bore in the sleeve bearing for pump adapter after
bearing .............. 2.3 0.5 mm (0.09 0.02 inch) installation ................... 94.056 mm (3.7030 inch)
(5) Bore in the sleeve bearing for front adapter (10) Torque for four bolts ..................... 190 30 Nm
assembly after installation ... 75.000 0.055 mm (140 22 lb ft)
(2.9527 0.0022 inch)
KENR5396-04 63
(11) Diameter of new pump drive i03678100

shaft ..................................... 74.900 0.015 mm
(2.9488 0.0006 inch) Accessory Drive
SMCS Code: 1207
i03045329
Part No.: 329-8191
Gear Group (Rear) S/N: SSP1-Up; B7B1-Up
SMCS Code: 1206 Part No.: 329-8193

Part No.: 327-0824
Part No.: 327-0824, 327-0825
g01283065
Illustration 121
(2) Camshaft drive gear
(5) Crankshaft gear
(1) Cluster gear shaft

Diameter .............................. 74.970 0.010 mm
(2.9516 0.0004 inch)
Maximum roughness average g01642094
(Ra) ...................... 0.4 micrometer (16 microinch) Illustration 122
Typical example for C175-16 engine
(3) Idler gear assembly
installation ............................ 75.060 0.010 mm
(2.9551 0.0004 inch)
Maximum roughness average
(Ra) ...................... 0.8 micrometer (32 microinch)
bearing .............. 2.0 0.5 mm (0.08 0.02 inch)
(4) The mark on the idler gear assembly must be in

alignment with the mark on the crankshaft gear.
64 KENR5396-04
Note: Head of the dowel must be always below the

surface of the thrust washer (2).
(2) Use the following procedure in order to install the

thrust washer:
1. Install thrust washer on the cage assembly (1)

with the small hole on the upper dowel.
Diameter of small hole ............ 4.587 0.008 mm

(0.1806 0.0003 inch)
2. Lightly tap the thrust washer until the thrust

washer is flush on cage assembly.
(3) Diameter of new idler shaft for the cluster gear

assembly ............................ 119.814 0.012 mm
(4.7171 0.0005 inch)
(4) Lubricate the bore for the O-ring seals lightly with
the lubricant that is being sealed.
g01442221
Illustration 123
(5) Shaft assembly
End play of the PTO after assembly

...................... 0.15 to 0.77 mm (0.006 to 0.030 inch)
Diameter of new shaft for the auxiliary drive

gear ....... 63.430 0.010 mm (2.4972 0.0004 inch)
Note: Install the socket setscrew to the bottom of the

threaded hole.
Torque for the socket setscrew .................. 6 1 Nm

(53 9 lb in)
(6) Torque for the bolts ........................ 570 80 Nm

(420 59 lb ft)
(7) Torque for the bolts ........................ 300 40 Nm

(221 30 lb ft)
(8) Bore in the sleeve bearing in the adapter

assembly after installation .. 63.5 mm (2.50 inch)
(9) Torque for the taperlock studs ......... 65 10 Nm

(48 7 lb ft)
Note: Ensure that the mating surfaces of the bolt and

the plate are free from the grease.
(10) Torque for the bolt ...................... 900 100 Nm

(664 74 lb ft)
g01642096
Illustration 124
(1) Bore in the sleeve bearing in the cage assembly

after installation .................. 63.5 mm (2.50 inch)
KENR5396-04 65
(2) Torque for 16 bolts ....................... 1100 60 Nm

(820 44 lb ft)
(3) Lubricate the bore of the plug assemblies with

glycerin or approved equivalent.
i03236056
Flywheel Housing
SMCS Code: 1157
Part No.: 252-6061
Part No.: 274-1556
g01977594
Illustration 125
(11) Lubricate both sides of the seal washer with

clean engine oil.
i03243077
Flywheel
SMCS Code: 1156
Part No.: 329-2491, 342-7913
Part No.: 329-2490, 342-7909
g01313258
Illustration 127
(1) Mating surface for the flywheel housing
For information on inspecting the flywheel housing,

refer to Systems Operation/Testing and Adjusting.
Note: Before installation of the flywheel housing,

inspect the front face of the flywheel housing and
the rear face of the cylinder block. The components
must be free of the following substances: oil, fuel,
water, gasket adhesive, assembly compounds, and
any other foreign material.
To seal the joint between the flywheel housing and

g01651493
the cylinder block, apply a 6 mm (0.2 inch) wide strip
Illustration 126 of 1U-8846 Gasket Sealant to the mating surface
(1) Flywheel gear of the flywheel housing.
Note: Refer to Testing And Adjusting, Flywheel -

Inspect for the correct method of flywheel inspection.
Note: Before assembly, lubricate the threads of the

bolt and seating area of the bolt with clean engine oil.
66 KENR5396-04
i03258040
Vibration Damper
SMCS Code: 1205
Part No.: 317-1640
g01644154
Illustration 128
(2) Use four numbers of M20 X 2.5 - 60 mm bolts.
(3) Use 18 numbers of M20 X 2.5 - 190 mm bolts.
g01277026
Illustration 129
(2) Damper group
Note: Apply 4C-4030 Thread Lock Compound to

the threads of the bolts.
(1) Torque for 48 bolts ......... 55 7 Nm (41 5 lb ft)

KENR5396-04 67
i03242559 i03015906
Vibration Damper Belt Tensioner

Part No.: 288-6598 Part No.: 217-8938
g01396207
Illustration 131
(A) Minimum limited travel ..................... 71 degrees
(1) Spring force at assembly is 14.1 1.7 Nm

(10 1 lb ft) at 25 degrees from the free arm stop.
i02864881
Belt Tensioner
SMCS Code: 1358
Part No.: 190-0642
g01645366
Illustration 130
(2) Damper group
Note: Apply 4C-4030 Thread Lock Compound to

the threads of the bolts.
(1) Final installation torque for 24 bolts ... 76 5 Nm

(55 4 lb ft)
g01427156
Illustration 132
(A) Limited travel .................. 71 degrees (minimum)
(1) Spring force at assembly 25.4 2.6 Nm

(19 2 lb ft) at 30 degrees from the free arm
position
68 KENR5396-04
i03250500 Note: Use a 7/16 ring terminal for (B+) terminal.

Alternator and Regulator (1) (B+) terminal. Final installation torque for the
nut ....................... 18.2 2.4 Nm (160 21 lb in)
SMCS Code: 1405
(2) R terminal is the optional alternating current from
Part No.: 272-1889
the stator which is not used for diagnostics.
(3) (B-) terminal. Final installation torque for the

bolt ............................ 4.4 1.0 Nm (40 9 lb in)
(4) Final installation torque for the

locknut ....................... 127 10 Nm (95 7 lb ft)
i02787428
Electric Starting Motor

SMCS Code: 1453
Part No.: 276-8900
g01676701
Illustration 133
g01401956
Illustration 135
g01676702
Illustration 134
Voltage ............................................................... 24 V
Amperage ................................................... 150 Amp
Note: Load the battery with a carbon pile 4C-4911

Battery Load Tester in order to get the maximum
alternator output. g01401955
Illustration 136
View A-A
Polarity ............................................ Negative ground
When the electric starting motor is viewed from
Rotation ............................................ Either direction the pinion end, the motor rotates in the following
direction. ................................................... Clockwise
Minimum full load current at 5000 rpm ....... 150 Amp
No load conditions at 25 C (77 F)
Minimum full load current at 2000 rpm ......... 56 Amp
Speed ...................................... 6950 1650 rpm
Output voltage ............................................. 28 1 V Current draw ................................. 115 25 Amp
KENR5396-04 69
Voltage .................................................... 23 VDC
(B) Clearance between the pinion and the

housing ................................. 9.1 mm (0.36 inch)
(1) Final installation torque for the ground terminal

nut ....................... 30.5 3.5 Nm (270 30 lb in)

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 g01401955

nut ......................... 2.25 0.25 Nm (20 2 lb in) Illustration 138
View A-A
(4) Final installation torque for the motor terminal
nut ....................... 30.5 3.5 Nm (270 30 lb in) When the electric starting motor is viewed from
the pinion end, the motor rotates in the following
Note: A maximum of three cable terminals or wire direction. ................................................... Clockwise
terminals may be used with the battery terminal nut
(5). A maximum of two of the cable terminals may be No load conditions at 25 C (77 F)
equal to or greater than 0 AWG.
Speed ...................................... 6950 1650 rpm
(5) Final installation torque for the battery terminal Current draw ................................. 115 25 Amp
nut ....................... 30.5 3.5 Nm (270 30 lb in) Voltage .................................................... 23 VDC
(6) Final installation torque for the motor frame (B) Clearance between the pinion and the
terminal nut ......... 30.5 3.5 Nm (270 30 lb in) housing ................................. 9.1 mm (0.36 inch)
Solenoid assembly (1) Final installation torque for the ground terminal
nut ..................... 26 1.5 Nm (230 13.00 lb in)
Current consumption at 20V and 25 C (77 F)
Pull-in windings ........................... 49.3 3.3 Amp nut ......................... 2.25 0.25 Nm (20 2 lb in)
Hold-in windings ............................ 6.8 Amp max
Note: The switch terminal must be insulated with
heat shrink tubing. Do not use molded terminals.
i02896017
(3) Final installation torque for the switch terminal
Electric Starting Motor nut ......................... 2.25 0.25 Nm (20 2 lb in)
SMCS Code: 1453
(4) Final installation torque for the motor terminal
Part No.: 276-8901 nut ..................... 26 1.5 Nm (230 13.00 lb in)
Note: A maximum of three cable terminals or wire

terminals may be used with the battery terminal nut
(5). A maximum of two of the cable terminals may be
equal to or greater than 0 AWG.
(5) Final installation torque for the battery terminal

nut ..................... 26 1.5 Nm (230 13.00 lb in)
(6) Final installation torque for the motor frame

terminal nut ....... 26 1.5 Nm (230 13.00 lb in)
Solenoid assembly
Current consumption at 20V and 25 C (77 F)

g01401956
Illustration 137
Pull-in windings ........................... 49.3 3.3 Amp
Hold-in windings ............................ 6.8 Amp max
70 KENR5396-04
i03040142 Operating temperature ........................ 40 to 125 C

(40 to 257 F)
Inlet Manifold Temperature
Sensor i02974120
SMCS Code: 1921 Fuel Pressure Sensor

Part No.: 238-0112 SMCS Code: 7414
Part No.: 274-6721
g01178443
Illustration 139
(1) Final installation torque for temperature sensor Illustration 141

g01502573
group ............................. 20 3 Nm (15 2 lb ft)

(1) Final installation torque for the pressure sensor
Output type ................................................... Passive group .......................... 10 2 Nm (90 18 lb in)
Operating temperature ........................ 40 to 150 C Operating voltage ............................... 5.0 0.5 VDC
(40 to 302 F)
Operating temperature ........................ 40 to 125 C
(40 to 257 F)
i03013584
Fuel Pressure Sensor

SMCS Code: 7414
Part No.: 287-1866
g01165144
Illustration 140

group ............................. 45 6 Nm (33 4 lb ft)
Operating voltage ........................... 5.00 0.25 VDC

KENR5396-04 71
i03076684 i03076699
Engine Speed Sensor Engine Speed Sensor

Part No.: 191-8304, 191-8305 Part No.: 244-5544
g01560233
Illustration 143
Note: Before assembly, lubricate the O-ring seal

lightly with the lubricant that is being sealed.
(1) Final installation torque for the sensor

g01075831 group ............................. 28 7 Nm (21 5 lb ft)
Illustration 142
(1) Final installation torque for the sensor (40 to 302 F)
group ............................. 28 7 Nm (21 5 lb ft)
Output type .......................................... Analog signal
(40 to 302 F) Minimum clearance between the sensor and gear
tooth ............................................ 0.5 mm (0.02 inch)
Minimum clearance between the sensor and gear
tooth ............................................ 0.5 mm (0.02 inch) Note: The wiring harness must be tied down less
than 102 mm (4.0 inch) from the sensor. Twisting of
Output type .......................................... Analog signal the wires minimizes the effect of the electrical noise.
Note: The wiring harness must be tied down less
than 102 mm (4.0 inch) from the sensor. Twisting of
the wires minimizes the effect of the electrical noise.
72 KENR5396-04
i02973702 i03132901
Fuel Temperature Sensor Turbocharger Exhaust

SMCS Code: 1922
Temperature Sensor
Part No.: 238-0112 SMCS Code: 1052; 1919
Part No.: 247-7635
g01502163
Illustration 144
g01560217
Illustration 146
(1) Final installation torque for the temperature
sensor group .................. 20 3 Nm (15 2 lb ft)
Note: Apply 4C-5599 Anti-Seize Compound to the
threads of the temperature sensor group.
Output type ................................................... Passive
Operating temperature ........................ 40 to 150 C (1) Final installation torque for the temperature
sensor group .................. 45 5 Nm (33 4 lb ft)
(40 to 302 F)
i02974181 (40 to 1562 F)
Engine Oil Pressure Sensor Operating voltage .............................. 7.5 to 8.5 VDC
SMCS Code: 1924 Output type ...................................................... PWM

Part No.: 274-6721 Output frequency ................................. 500 100 Hz
i03015973
Crankcase Pressure Sensor

SMCS Code: 1916
Part No.: 306-6834
g01502573
Illustration 145

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

(40 to 257 F)
Operating voltage ............................... 5.0 0.5 VDC g01154822

Illustration 147
KENR5396-04 73
(1) Final installation torque for the sensor

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

(40 to 257 F)
Operating voltage ............................... 5.0 0.5 VDC
Note: Install the pressure sensor group so that the

pressure port is lower than the connector end. Mount
the pressure sensor group as close to vertical as
possible.
i02879859
Atmospheric Pressure Sensor

SMCS Code: 1923
Part No.: 306-6834
g01154731
Illustration 148

group .......................... 10 2 Nm (90 18 lb in)
Operating voltage ............................... 5.0 0.5 VDC

(40 to 257 F)
74 KENR5396-04
Index Section
Index
A I
Accessory Drive..................................................... 63 Important Safety Information ................................... 2

Alternator and Regulator ....................................... 68 Inlet Manifold Temperature Sensor........................ 70
Atmospheric Pressure Sensor............................... 73
Auxiliary Water Pump ............................................ 41
L
B Lifter Group............................................................ 21
Belt Tensioner........................................................ 67
P
C Piston and Rings ................................................... 53

Intermediate Piston Ring (2) .............................. 53
Camshaft ......................................................... 1920 Oil Control Piston Ring (3) ................................. 53
Connecting Rod..................................................... 54 Pin Retainer (5).................................................. 54
Connecting Rod and Main Bearing Journals ......... 55 Piston Pin (4) ..................................................... 53
Crankcase Pressure Sensor.................................. 72 Top Piston Ring (1) ............................................ 53
Crankshaft ............................................................ 56 Pressure Control Valve (Oil Regulator Valve and Oil
Crankshaft Wear Sleeves and Seals..................... 59 Bypass Valve) ...................................................... 32
Cylinder Block...................................... 42, 45, 47, 50
Cylinder Head........................................................ 23
Cylinder Head Valves ...................................... 25, 27 S
Cylinder Liner ........................................................ 52
Specifications Section ............................................. 4
E
T
Electric Starting Motor ..................................... 6869
Engine Design ......................................................... 4 Table of Contents..................................................... 3
Engine Oil Pan....................................................... 38 Turbocharger ................................................... 2829
Engine Oil Pressure Sensor .................................. 72 Turbocharger Exhaust Temperature Sensor ......... 72
Engine Oil Pump.............................................. 3334 Turbocharger Support ........................................... 29
Engine Oil Scavenge Pump............................. 3536
Engine Speed Sensor............................................ 71
Exhaust Fitting....................................................... 32 V
Exhaust Manifold ............................................. 3031
Valve Mechanism .................................................. 22
Vibration Damper............................................. 6667
F
Flywheel ................................................................ 65 W
Flywheel Housing .................................................. 65
Fuel Filter (Secondary) ............................................ 5 Water Pump..................................................... 3940
Fuel Filter Base ....................................................... 5
Fuel Injector............................................................. 7
Fuel Lines .................................................... 8, 1314
Procedure for the installation of the lines..... 10, 16
Procedure for the installation of the rails and the
quill tubes ..................................................... 9, 15
Fuel Pressure Sensor............................................ 70
Fuel Temperature Sensor ...................................... 72
Fuel Transfer Pump ................................................. 6
Gear Group (Front).......................................... 60, 62

Gear Group (Rear) ................................................ 63
KENR5396-04 75
Index Section
2010 Caterpillar Cat, Caterpillar, their respective logos, Caterpillar Yellow and the Power edge Printed in U.S.A.
All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.

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KENR5396-04

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Electric Starting Motor .........................................

Specifications Section i02605915

Number and arrangement of Valves per cylinder .................................................. 4

Fuel Filter (Secondary) Fuel Filter Base

(A) Length for applying 154-9731 Thread Lock

(1) Torque for the taperlock stud ............. 68 7 Nm

(1) Filter base

(2) Filter housing

After initial gasket contact, tighten the filter

Fuel Transfer Pump Fuel Transfer Pump

Minimum requirements Minimum requirements

11. Tighten the bolt (1 ) to a torque of 100 20 Nm

Special instructions for injectors and for high

2. Apply clean engine oil to the collar of the tube joint

3. Remove the fuel line (2).

4. Install the injector (4).

5. Tighten the bolt (1) from 30 to 50 Nm

6. Remove the bolt for the fuel injector.

Note: Lubricate the bore of the O-ring seals with

Note: Lubricate both ends of the fuel lines with clean

(24) Torque for the adapter ................. 150 10 Nm

Reference: Reuse and Salvage Guidelines,

Procedure for the installation of the

Turn each bolt no more than 45 degrees at one

Torque for the bolts .................... 40 Nm (30 lb ft)

11. Evenly tighten the bolts into the rail.

Turn each bolt no more than 45 degrees at one

Torque for the bolts .................... 40 Nm (30 lb ft)

Procedure for the installation of the

3. Apply clean engine oil to joint (22) at the collar to

4. Apply clean engine oil to O-rings (23). Refer to

6. Evenly hand tighten the bolts into the cylinder

7. Evenly hand tighten the bolts into the rail.

8. Evenly tighten the bolts into the cylinder head.

Turn each bolt no more than 90 degrees at one

Torque for the bolts .................... 40 Nm (30 lb ft)

10. Evenly tighten the bolts of block (6) to the pump

Torque ........................................ Standard torque

11. Install adjustable bracket (11) and tighten

12. Lubricate the O-ring (27) that seals the collar

Turn each bolt no more than 45 degrees at one

Torque for the bolts .................... 40 Nm (30 lb ft)

31. Evenly tighten clamps (3) and hardware to line

Torque ........................................ Standard torque

32. Evenly tighten clamps (2) and hardware to line

Torque ........................................ Standard torque

Tighten the low pressure return fuel line (28) to the

25. Evenly hand tighten clamps (3) and hardware to

26. Evenly hand tighten clamps (2) and hardware to

27. Evenly tighten line (4) to rail (1).

Torque for the bolts .................. 20 Nm (177 lb in)

Turn each bolt no more than 90 degrees at one

28. Evenly tighten line (4) to rail (7).

30. Evenly tighten line (4) to rail (7).

(1) Lubricate the bore of the O-ring seals for the

(2) Torque for the tube assembly ............ 40 4 Nm

(3) Tighten the bolts evenly for the fuel line

(26) Torque for the adapter ................. 150 10 Nm