GN65732U GN65732U

404D-22 2012/04/02

The information given within this parts book was correct at the time of printing and is subject to change without
notice. Always refer to your local Perkins outlet for the latest information. Only fully trained personnel should car-
ry out servicing of engines. Before working on any engine always refer to the correct user service and maintenance
manual.

Always refer to your local Perkins outlet before purchasing any parts

Subject to any existing rights of third parties, the information given in this document is the property of Perkins En-
gines Limited and should not be copied, in whole or part, without the prior written consent of the Company.
Contents
1. Introduction Pg. 4

2. How To Use Your Parts Book Pg. 4

3. Engine Breakdown Pg. 5

4. Symbol Descriptions Pg. 9

5. Parts Lists & Illustrations Pg. 11

6. Parts Index Pg. 170

 Introduction

The build list of your engine, found on the front page of this parts book, provides a unique
reference to the components fitted to your engine; therefore this parts book is only applicable to
this particular engine

Always quote your build list and engine serial number when contacting your Perkins outlet.

How to use your Parts Book

This parts book has been designed to provide you with all the information you need to identify
parts to service your engine. There are several features within the book to make it easy to find
the parts you require.

Front Page
This lists your build list number and the date of publication of this book

Symbol Descriptions
Provides a quick reference guide to the symbols used within the book.

Engine Breakdown
Use this to identify all the major sections of your engine and the relevant pages within the book.

Parts Lists & Illustrations

This section shows each major section of your engine broken down into individual part numbers
along with an associated illustration for identifying the parts you require.

The illustrations used in this parts book are representational only and should only be used for
identification purposes.

For fitting instructions please refer to your engine Service Manual.

Parts Index
Using either the part number or description of the part you require this section will help you
locate the page within the Parts Lists & Illustrations section where the part appears.
 Engine Breakdown

Section Page Section Page

Level 1 - Service 11 Relief Valve 37

AAAAAAGN ACPG0004

Level 2 - Repair 13 Oil Pump 39

AAAAAAGN U5MK8267.

Level 3 - Overhaul 15 Timing Case 41

AAAAAAGN ADPG0015

Cylinder Block 17 Timing Case 43

ACPG0004 ADPG0015

Cylinder Block 19 Timing Case 45

ACPG0004 ADPG0015

Crankshaft, Pistons & Connecting Rods 21 Timing Case 47

ACPG0004 ADPG0015

Crankshaft, Pistons & Connecting Rods 23 Timing Case 49

ACPG0004 ADPG0015

Rear End Oil Seal 25 Miscellaneous 51

ACPG0004 ADPG0015

Cylinder Head 27 Camshaft & Gears 53

ACPG0004 ADPG0015

Cylinder Head 29 Timing Case 55

ACPG0004 ADPG0139

Cylinder Head 31 Timing Case 57

ACPG0004 ADPG0139

Rocker Shaft Assembly 33 Timing Case 59

ACPG0004 ADPG0139

Pipes 35 Timing Case 61

ACPG0004 ADPG0139

Page 5
 Engine Breakdown

Section Page Section Page

Timing Case 63 Sump 89

ADPG0139 GBPG0001

Miscellaneous 65 Dipstick & Filler Tube 91

ADPG0139 GBPG0001

Camshaft & Gears 67 Dipstick & Filler Tube 93

ADPG0139 GBPG0001

Fuel Injection Pump 69 Sump 95

AFPG0015 GCPG0000

High Pressure Fuel Pipes 71 Filler 97

AFPG0015 HBPG0020

Atomisers 73 Oil Filter 99

AFPG0015 JBPG0000

Fuel Leak-Off Pipe 75 Oil Filter 101

AFPG0015 JCPG0000

Flywheel Housing 77 Front End Drive Input 103

CDPG0004 KBPG0001

Flywheel & Starter Ring 79 Water Pump 105

DDPG0005 LBPG0003

Starter Motor 81 Thermostat & Housing 107

EDPG0001 LBPG0003

Starter Motor Breakdown 83 Thermostat & Housing 109

EDPG0001 LBPG0003

Starter Motor 85 Water Outlet & Inlet 111

EDPG0001 LDPG0001

Pulleys 87 Alternator 113

FBPG0001 NDPG0002

Page 6
 Engine Breakdown

Section Page Section Page

Drive Belt & Tensioner 115 Throttle & Stop Controls 141
NEPG0001 ZAPG0001

Blanking Plates 117 Heater/Starter Switch 143

QCPG0026 ZEPG0001

Cylinder Head Cover 119 Heater/Starter Switch 145

TBPG0001 ZEPG0001

Feed Pipes 121 Instrumentation 147

TBPG0001 ZJPG0002

Air Filter Assembly 123 Instrumentation 149

TDPG0001 ZLPG0001

Air Filter Assembly 125 Radiator & Cowling 151

TDPG0001 ZMPG0002

Exhaust Manifold 127 Radiator & Cowling 153

UBPG0001 ZMPG0002

Exhaust Connection 129

UDPG0001

Lift Pump 131

VBPG0003

Fuel Filter 133

VBPG0003

Pipework & Connections 135

VBPG0003

Cold Start System 137

WDPG0000

Engine Lifting Eyes 139

XBPG0000

Page 7
 Engine Breakdown

Section Page

Radiator & Cowling 155

ZMPG0002

Fan 157
ZMPG0002

Guards 159
ZMPG0002

Guards 161
ZMPG0002

Engine Mounts 163

ZMPG0002

Electrical 165
ZPPG0002

Fuel Pre-Lift Pump 167

ZVPG0003

Fuel Pre-Lift Pump 169

ZVPG0003

Page 8
Symbols and Notes

Symbol Description

A From Engine Number

B Upto Engine Number

C Repairs and Replaces

D See Appropriate Section - Reference Number

E Alternative

F Order

G Remanufactured Part

H New for Old Part

I Number of Teeth

J Thickness

K Bottom

L Top

M Left Hand

N Right Hand

O Reference for Detailed Breakdown

P Other Service Options Available

Q Cylinder Number

R See History Section

Page 9
 Level 1 - Service Plate A

AAAAAAGN

Recommended stocking and service lists

Perkins provides Recommended stocking and service lists, for Distributor use when
recommending parts stocks for Dealers, preferred customers (eg fleets) etc. These lists
are based on agreed workshop capability and are at three distinct levels:
Level 1 - Service
The Level 1 workshop has the ability to perform basic non-intrusive maintenance on
Perkins engines.
Listes recommandées pour le stock et la maintenance
Perkins fournit des listes recommandées pour le stock et la maintenance afin d'aider le
Distributeur dans ses conseils aux Agents, aux clients habituels, etc.. Ces listes sont
basées sur le niveau technique des Ateliers avec trois niveaux distincts :
Niveau 1- Maintenance
L'atelier de niveau 1 est capable d'executer l'entretien de base des moteurs Perkins (sans
demontage).
Empfohlene Lagerbestands- und Servicelisten
Perkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche die
Vertragshändler verwenden können, um Händlern und Kunden (z.B. Fuhrparks) einen
bestimmten Ersatzteilbestand zu empfehlen. Diese Listen basieren auf den vereinbarten
Werkstattfähigkeiten, welche in die folgenden drei Stufen unterteilt werden:
Stufe 1 - Service
Werkstätten der Stufe 1 können grundlegende und einfache Wartungsarbeiten an
Perkins-Motoren ohne Spezialwerkzeug durchführen.
Listas de servicio y de stock recomendadas
Perkins proporciona Listas de servicio y de stock recomendadas, para que las use el
Distribuidor al recomendar stocks de repuestos a los Distribuidores, a los clientes
preferidos (por ejemplo, flotas), etc. Estas listas se basan en capacidad del taller
acordada y se dividen en tres niveles diferentes:
Nivel 1 - Servicio
El taller del Nivel 1 puede llevar a cabo un mantenimiento no intrusivo en los motores
Perkins.
Elenco parti consigliate ad uso stock ed assistenza
Perkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza;
ciò per soddisfare le richieste dei dealers, clienti preferenziali ecc. Questi elenchi tengono
in considerazione la capacità operativa concordata con l’officina e sono distinti in tre livelli
Livello 1 - Assistenza
Il livello 1 prevede che l’officina sia in grado di operare in maniera basilare sui motori
Perkins.

Page 10
 Level 1 - Service Plate A

AAAAAAGN

Item Part No. References Qty. Description Notes

1 1 LEVEL 1 - SERVICE

Page 11
 Level 2 - Repair Plate A

AAAAAAGN

Recommended stocking and service lists

Perkins provides Recommended stocking and service lists, for Distributor use when
recommending parts stocks for Dealers, preferred customers (eg fleets) etc. These lists are
based on agreed workshop capability and are at three distinct levels:
Level 2 - Repair
The Level 2 workshop has the ability to perform maintenance service,and inspection service on
Perkins engines.
Listes recommandées pour le stock et la maintenance
Perkins fournit des listes recommandées pour le stock et la maintenance afin d'aider le
Distributeur dans ses conseils aux Agents, aux clients habituels, etc.. Ces listes sont basées sur
le niveau technique des Ateliers avec trois niveaux distincts :
Niveau 2 - Maintenance & reparation
L'atelier de niveau 2 est capable d’executer toutes les opérations d'entretien, la reparation des
composants externes (demarreur, alternateur,etc) et le diagnostic pour les problèmes touchant à
l'electronique
Empfohlene Lagerbestands- und Servicelisten
Perkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche die Vertragshändler
verwenden können, um Händlern und Kunden (z.B. Fuhrparks) einen bestimmten
Ersatzteilbestand zu empfehlen. Diese Listen basieren auf den vereinbarten
Werkstattfähigkeiten, welche in die folgenden drei Stufen unterteilt werden:
Stufe 2 - Reparatur
Werkstätten der Stufe 2 können Instandsetzungs- und Inspektionsarbeiten an Perkins-Motoren
durchführen.
Listas de servicio y de stock recomendadas
Perkins proporciona Listas de servicio y de stock recomendadas, para que las use el
Distribuidor al recomendar stocks de repuestos a los Distribuidores, a los clientes preferidos
(por ejemplo, flotas), etc. Estas listas se basan en capacidad del taller acordada y se dividen en
tres niveles diferentes:
Nivel 2 - Reparación
El taller de Nivel 2 puede llevar a cabo el servicio de mantenimiento y el servicio de inspección
en los motores Perkins.
Elenco parti consigliate ad uso stock ed assistenza
Perkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza; ciò per
soddisfare le richieste dei dealers, clienti preferenziali ecc. Questi elenchi tengono in
considerazione la capacità operativa concordata con l’officina e sono distinti in tre livelli :
Livello 2 - Riparazione
Nel livello 2 l’officina è in grado di svolgere la manutenzione e di fare controlli di
assistenza sui motori Perkins.

Page 12
 Level 2 - Repair Plate A

AAAAAAGN

Item Part No. References Qty. Description Notes

1 1 LEVEL 2 - REPAIR

Page 13
 Level 3 - Overhaul Plate A

AAAAAAGN

Recommended stocking and service lists

Perkins provides Recommended stocking and service lists, for Distributor use when recommending parts
stocks for Dealers, preferred customers (eg fleets) etc. These lists are based on agreed workshop capability
and are at three distinct levels:
Level 3 - Overhaul.
The Level 3 workshop has the ability to perform complete service work on Perkins engines. Can repair and
fully overhaul engine, including engine test. Can perform all levels of electronics diagnosis and application
related faults.
Listes recommandées pour le stock et la maintenance
Perkins fournit des listes recommandées pour le stock et la maintenance afin d'aider le Distributeur dans ses
conseils aux Agents, aux clients habituels, etc.. Ces listes sont basées sur le niveau technique des Ateliers
avec trois niveaux distincts :
Niveau 3 - Maintenance, reparation & refection
L' atelier de niveau 3 est capable de couvrir toutes les opérations d'entretien des moteurs Perkins. Il peut
aussi réparer et entièrement refaire des moteurs ainsi que les tester. Il est capable d'effectuer un diagnostic
pour les problèmes touchant à l'electronique et aux applications.
Empfohlene Lagerbestands- und Servicelisten
Perkins stellt empfohlene Lagerbestands- und Servicelisten bereit, welche die Vertragshändler verwenden
können, um Händlern und Kunden (z.B. Fuhrparks) einen bestimmten Ersatzteilbestand zu empfehlen. Diese
Listen basieren auf den vereinbarten Werkstattfähigkeiten, welche in die folgenden drei Stufen unterteilt
werden:
Stufe 3 - Überholung
Werkstätten der Stufe 3 können umfassende Servicearbeiten an Perkins-Motoren durchführen. Sie können
Motoren reparieren und komplett überholen und außerdem Motorprüfungen durchführen. Sie können
umfassende elektronische Diagnoseprüfungen durchführen und anwendungsspezifische Störungen
untersuchen.
Listas de servicio y de stock recomendadas
Perkins proporciona Listas de servicio y de stock recomendadas, para que las use el Distribuidor al
recomendar stocks de repuestos a los Distribuidores, a los clientes preferidos (por ejemplo, flotas), etc. Estas
listas se basan en capacidad del taller acordada y se dividen en tres niveles diferentes:
Nivel 3 - Reparación general
El taller de Nivel 3 puede llevar a cabo un trabajo de servicio completo en los motores Perkins. Puede
reparar y reacondicionar completamente un motor, incluyendo probar el motor. Puede llevar a cabo todos los
niveles de diagnóstico electrónico y las fallas relacionadas con la aplicación.
Elenco parti consigliate ad uso stock ed assistenza
Perkins fornisce ai distributori un elenco di parti consigliate ad uso stock ed assistenza; ciò per soddisfare le
richieste dei dealers, clienti preferenziali ecc. Questi elenchi tengono in considerazione la capacità operativa
concordata con l’officina e sono distinti in tre livelli :
Livello 3 - Revisione
Nel livello 3 l’officina è in grado di svolgere lavori di assistenza completi sui motori Perkins. E’ in grado di
riparare e svolgere una revisione completa del motore, incluso le prove. Può anche effettuare diagnosi sull’
elettronica a tutti i livelli e sui relativi difetti nelle applicazioni.

Page 14
 Level 3 - Overhaul Plate A

AAAAAAGN

Item Part No. References Qty. Description Notes

1 1 LEVEL 3 - OVERHAUL

Page 15
 Cylinder Block Plate A

ACPG0004

14
22 13

18 19
8

20

7
3

2
11
12

17 16

6 4 21

15

10

Page 16
 Cylinder Block Plate A

ACPG0004

Item Part No. References Qty. Description Notes

1 1 CYLINDER BLOCK ASSEMBLY (A)

2 198466940 4 PLUG
3 198466010 3 PLUG
4 198466020 3 PLUG
5 064210025 2 PLUG
6 064209055 1 PLUG
7 064209055 3 PLUG
8 064209055 1 PLUG
9 198466920 2 PLUG
10 198517222 P 1 BUSH
11 042309017 1 NEEDLE BEARING
12 042309018 1 NEEDLE BEARING
13 040106203 1 BALL BEARING
14 064100045 1 PLUG
15 R a. 1 SHAFT (B)
16 012110635 1 STUD
17 012110660 1 STUD
18 010109441 3 STUD
19 030500612 2 DOWEL
20 030500616 2 DOWEL
21 030501025 2 DOWEL
22 030309005 2 PIN
Service Options
10 198517226 J (-)0.25MM 1 BUSH
10 198517229 J (-)0.50MM 1 BUSH

History
a.
15 165296220 1 SHAFT

Footnotes

(A) SERVICE BY COMPLETE ENGINE

(B) REFER TO U5MK8267

Page 17
 Cylinder Block Plate B

ACPG0004

Page 18
 Cylinder Block Plate B

ACPG0004

Item Part No. References Qty. Description Notes

1 165996590 1 GASKET - TIMING CASE

2 011310612 2 SCREW

History
a.
4 U65166580 1 PLATE

Page 19
 Crankshaft, Pistons & Connecting Rods Plate A

ACPG0004

33

1 5

4
7
6
3 30

26

27

24

20
29
21

18
28
14
23
15

12
31
22
8
17
9

25
16
11

19

10
32

13

Page 20
 Crankshaft, Pistons & Connecting Rods Plate A

ACPG0004

Item Part No. References Qty. Description Notes

1 115256990 R a. 1 CRANKSHAFT ASSEMBLY

2 F 115256990 1 CRANKSHAFT ASSEMBLY
3 U15276270 1 CRANKSHAFT GEAR
4 030509020 1 KEY
5 199266210 1 THRUST WASHER
6 199266200 1 THRUST WASHER
7 199266200 1 THRUST WASHER
8 110156360 Q 1 1 HOLDER
9 F 110156360 1 CAP
10 F 110156360 1 CAP
11 030500612 2 DOWEL
12 010109406 2 SCREW
13 011511070 1 SCREW
14 110156370 Q 2 1 HOLDER
15 F 110156370 1 CAP
16 F 110156370 1 CAP
17 030500612 2 DOWEL
18 010109406 2 SCREW
19 011511070 1 SCREW
20 110156380 Q 3 1 HOLDER
21 F 110156380 1 CAP
22 F 110156380 1 CAP
23 030500612 2 DOWEL
24 010109406 2 SCREW
25 011511070 1 SCREW
26 110156390 Q 4 1 HOLDER
27 F 110156390 1 CAP
28 F 110156390 1 CAP
29 030500612 2 DOWEL
30 010109406 2 SCREW
31 010700860 2 BOLT
32 U5MB0025 P 1 MAIN BEARING KIT
33 U5ME0030 1 BIG END BEARING KIT
Service Options
32 U5MB0025A J (-) 0.25MM 1 MAIN BEARING KIT

History
a.
1 115256990 1 CRANKSHAFT ASSEMBLY

Page 21
 Crankshaft, Pistons & Connecting Rods Plate B

ACPG0004

3 2

12

8
10

11

Page 22
 Crankshaft, Pistons & Connecting Rods Plate B

ACPG0004

Item Part No. References Qty. Description Notes

1 115017491 4 PISTON AND RING KIT

2 F 115017491 1 PISTON
3 115107970 1 PISTON RING KIT
4 115026330 4 CON ROD ASSEMBLY
5 F 115026330 1 ROD
6 F 115026330 1 CAP
7 198517265 1 SMALL END BUSH
8 115176140 2 CON ROD BOLT
9 020109120 2 CON ROD NUT
10 115326220 4 GUDGEON PIN
11 036500028 4 CIRCLIP
12 036500028 4 CIRCLIP

Page 23
 Rear End Oil Seal Plate A

ACPG0004

Page 24
 Rear End Oil Seal Plate A

ACPG0004

Item Part No. References Qty. Description Notes

1 050209083 1 SEAL - REAR END OIL (A,B)

Footnotes

(A) SEE SERVICE BULLETIN NO.195

(B) ALSO ORDER WEAR SLEEVE - 29990037

Page 25
 Cylinder Head Plate A

ACPG0004

22
21
1
20
2 4
14
19

13
18
7
12
17

11

8
16

10

15

Page 26
 Cylinder Head Plate A

ACPG0004

Item Part No. References Qty. Description Notes

1 111011030 R a. 1 CYLINDER HEAD ASSEMBLY

2 F 111011030 1 CYLINDER HEAD
3 064210010 3 PLUG
4 064210018 7 CAP
5 064210025 3 PLUG
6 064210025 3 PLUG
7 064210030 1 CAP
8 064210030 1 CAP
9 120166390 4 INTAKE VALVE
10 U10136470 1 VALVE SEAT INSERT
11 120406070 4 SEAL - VALVE STEM
12 198216700 4 VALVE SPRING
13 120186080 4 CAP
14 120226070 4 VALVE COLLET
15 120176380 4 EXHAUST VALVE
16 U10136460 1 VALVE SEAT INSERT
17 120406050 4 SEAL - VALVE STEM (A)
18 198216700 4 VALVE SPRING
19 120186080 4 CAP
20 120226070 R b. 4 VALVE COLLET
R b.
21 120216041 4 VALVE SPRING CAP
22 120216041 4 VALVE SPRING CAP

History
a.
1 111011030 1 CYLINDER HEAD ASSEMBLY
b. General History Section
20 TPN645 4 VALVE SEAT INSERT
20 TPN646 4 VALVE SEAT INSERT

Footnotes

(A) EXHAUST

Page 27
 Cylinder Head Plate B

B 929887S ACPG0004

Page 28
 Cylinder Head Plate B

B 929887S ACPG0004

Item Part No. References Qty. Description Notes

1 P 1 GASKET - CYLINDER HEAD

2 111136480 14 SCREW
3 111136490 4 SCREW
4 012110655 2 STUD
5 012110860 2 STUD
Service Options
1 111147711 J 1.2MM 1 GASKET - CYLINDER HEAD 1.2MM
1 111147721 J 1.3MM 1 GASKET - CYLINDER HEAD 1.3MM

Page 29
 Cylinder Head Plate B

A 929888S ACPG0004

Page 30
 Cylinder Head Plate B

A 929888S ACPG0004

Item Part No. References Qty. Description Notes

1 P 1 GASKET - CYLINDER HEAD

2 111136480 14 SCREW
3 111136490 4 SCREW
4 012110655 2 STUD
5 012110860 2 STUD
Service Options
1 111147771 J 1.3MM X GASKET - CYLINDER HEAD 1.3MM
1 111147761 J 1.2MM X GASKET - CYLINDER HEAD 1.2MM
1 111147751 J 1.1MM X GASKET - CYLINDER HEAD 1.1MM

Page 31
 Rocker Shaft Assembly Plate A

ACPG0004

7
8
10
3
9

5 6

16

15

14

12
2

11

13

Page 32
 Rocker Shaft Assembly Plate A

ACPG0004

Item Part No. References Qty. Description Notes

1 120037240 R a. 1 ROCKER BOX

2 F 120037240 1 ROCKER BOX
3 120316201 1 ROCKER SHAFT
4 052109076 1 SEAL - O RING
5 120356131 4 ROCKER ARM ASSEMBLY INLET
6 120356141 4 ROCKER ARM ASSEMBLY EXHAUST
7 198217170 3 ROCKER SHAFT SPRING
8 199486220 8 ADJUSTING SCREW
9 020109076 8 NUT
10 199280300 6 WASHER
11 120996130 1 SEAL - ROCKER BOX
12 120456310 8 PUSHROD
13 120116160 8 TAPPET
14 012109044 4 STUD
15 023100010 4 NUT
16 011310635 2 SCREW

History
a.
1 120036821 1 ROCKER BOX

Page 33
 Pipes Plate A

ACPG0004

Page 34
 Pipes Plate A

ACPG0004

Item Part No. References Qty. Description Notes

1 140607020 1 OIL PIPE

2 198486780 1 BOLT
3 140996260 1 WASHER
4 140996260 1 WASHER

Page 35
 Relief Valve Plate A

ACPG0004

Page 36
 Relief Valve Plate A

ACPG0004

Item Part No. References Qty. Description Notes

1 140036220 1 RELIEF VALVE

2 052109078 1 SEAL - O RING

Page 37
 Oil Pump Plate A

U5MK8267.

4
5

7 6

10

Page 38
 Oil Pump Plate A

U5MK8267.

Item Part No. References Qty. Description Notes

1 U5MK8267 1 OIL PUMP IDLER GEAR

2 F U5MK8267 1 SHAFT
3 199266270 1 THRUST WASHER
4 F U5MK8267 1 IDLER GEAR
5 F U5MK8267 1 ROTOR
6 140116220 1 COVER
7 P 1 SHIM
8 198216720 1 SPRING
9 199236540 1 COLLAR
10 036800010 1 CIRCLIP
Service Options
7 199286150 J (+)0.10MM 1 SHIM
7 199286160 J (+)0.15MM 1 SHIM
7 199286170 J (+)0.20MM 1 SHIM
7 199286180 J (+)0.50MM 1 SHIM

Page 39
 Timing Case Plate A

ADPG0015

Page 40
 Timing Case Plate A

ADPG0015

Item Part No. References Qty. Description Notes

1 1 TIMING CASE (A)

2 165996630 1 GASKET - TIMING CASE
3 011310640 7 SCREW
4 011310660 4 SCREW
5 023100006 1 NUT

Footnotes

(A) SEE FOLLOWING PARTS LIST FOR SERVICE COMPONENTS

Page 41
 Timing Case Plate B

ADPG0015

Page 42
 Timing Case Plate B

ADPG0015

Item Part No. References Qty. Description Notes

1 U65116570 1 TIMING CASE

2 030300414 1 PIN
3 198636160 1 SEAL - FRONT END OIL

History
a.
052300850 1 SEAL - O RING
110416290 1 BEARING HOLDER ASSEMBLY

Page 43
 Timing Case Plate C

ADPG0015

10

7
6 9

1
2

11 12
3

13

Page 44
 Timing Case Plate C

ADPG0015

Item Part No. References Qty. Description Notes

1 125616121 R d. 1 BRACKET
2 165996640 1 GASKET
3 125156263 1 ARM
4 198211110 1 SPRING
5 052100070 1 SEAL - O RING
6 198217750 1 SPRING
7 023100008 1 NUT
8 012810635 R a. 1 SCREW
R b.
9 2648A120 1 NUT
10 26420462 1 ANTI-TAMPER CAP
11 012810635 R a. 1 SCREW
12 2318A207 1 NUT
13 2314F004 R c. 4 SCREW
R e.

History
a.
8 012800640 1 SCREW
11 012800640 1 SCREW
b.
8 2315C039 1 SCREW
c.
13 010109600 4 SCREW
d.
1 125616140 1 BRACKET
e.
13 011310614 4 SCREW
125616120 1 BRACKET

Page 45
 Timing Case Plate D

ADPG0015

11

1
10

12
4

Page 46
 Timing Case Plate D

ADPG0015

Item Part No. References Qty. Description Notes

1 125046613 R b. 1 CONTROL LEVER

2 125116221 1 SHAFT
3 052100080 R a. 1 SEAL - O RING
4 131046560 1 BOLT
5 020800010 1 NUT
6 125306151 R c. 1 CONTROL LEVER
7 125116211 1 SHAFT
8 024500006 1 NUT
9 025100006 1 WASHER
10 198217880 1 SPRING
11 031100004 1 PIN
12 U98466960 1 PLUG

History
a.
3 025100008 1 WASHER
b.
1 125046612 1 CONTROL LEVER
c.
6 125306150 1 CONTROL LEVER

Page 47
 Timing Case Plate E

ADPG0015

1
3

5
8

10
11
12

13

Page 48
 Timing Case Plate E

ADPG0015

Item Part No. References Qty. Description Notes

1 131046650 1 SCREW
2 F 131046650 1 BOLT
3 020109177 1 NUT
4 025100010 1 WASHER
5 198217910 1 SPRING
6 198346160 1 RING
7 131276440 1 ANTI-TAMPER CAP
8 131466251 1 BOLT
9 025100006 1 WASHER
10 020109239 1 NUT
11 198346160 1 RING
12 131466272 R a. 1 ANTI-TAMPER CAP
13 064210012 1 CAP

History
a.
12 131466270 1 ANTI-TAMPER CAP

Page 49
 Miscellaneous Plate D

ADPG0015

Page 50
 Miscellaneous Plate D

ADPG0015

Item Part No. References Qty. Description Notes

1 198217970 1 TOOL (A)

Footnotes

(A) REFER TO WORKSHOP MANUAL

Page 51
 Camshaft & Gears Plate A

ADPG0015

Page 52
 Camshaft & Gears Plate A

ADPG0015

Item Part No. References Qty. Description Notes

1 120027070 1 CAMSHAFT
2 F 120027070 1 CAMSHAFT
3 034100508 1 WOODRUFF KEY
4 120016290 1 CAMSHAFT GEAR
5 040109057 1 BALL BEARING
6 U99216320 1 SPACER
7 125256250 1 SLIDER
8 199566750 1 PLATE
9 011310612 2 SCREW

Page 53
 Timing Case Plate A

A 14/04/2009 ADPG0139

Page 54
 Timing Case Plate A

A 14/04/2009 ADPG0139

Item Part No. References Qty. Description Notes

1 1 TIMING CASE (A)

2 165996630 1 GASKET - TIMING CASE
3 011310640 7 SCREW
4 011310660 4 SCREW
5 023100006 2 NUT

Footnotes

(A) SEE FOLLOWING PARTS LIST FOR SERVICE COMPONENTS

Page 55
 Timing Case Plate B

A 14/04/2009 ADPG0139

1 2

Page 56
 Timing Case Plate B

A 14/04/2009 ADPG0139

Item Part No. References Qty. Description Notes

1 U65116730 1 TIMING CASE

2 030300414 1 PIN
3 198636160 1 SEAL - FRONT END OIL

Page 57
 Timing Case Plate C

A 14/04/2009 ADPG0139

10

7
6 9

1
2

11 12
3

13

Page 58
 Timing Case Plate C

A 14/04/2009 ADPG0139

Item Part No. References Qty. Description Notes

1 125616121 1 BRACKET
2 165996640 1 GASKET
3 125156263 1 ARM
4 198211110 1 SPRING
5 052100070 1 SEAL - O RING
6 198217750 1 SPRING
7 023100008 1 NUT
8 012810635 R a. 1 SCREW
9 2648A120 1 NUT
10 26420462 1 ANTI-TAMPER CAP
11 012810635 R a. 1 SCREW
12 2318A207 1 NUT
13 2314F004 4 SCREW

History
a.
8 012800640 1 SCREW
11 012800640 1 SCREW

Page 59
 Timing Case Plate D

A 14/04/2009 ADPG0139

12

1
10

11
4

Page 60
 Timing Case Plate D

A 14/04/2009 ADPG0139

Item Part No. References Qty. Description Notes

1 125046613 1 CONTROL LEVER

2 125116221 1 SHAFT
3 052100080 1 SEAL - O RING
4 131046560 1 BOLT
5 020800010 1 NUT
6 125306151 1 CONTROL LEVER
7 125116211 1 SHAFT
8 025100006 1 WASHER
9 024500006 1 NUT
10 198217880 1 SPRING
11 U98466960 1 PLUG
12 031100004 1 PIN

Page 61
 Timing Case Plate E

A 14/04/2009 ADPG0139

1
3

5
8

9
10
11
12

13

Page 62
 Timing Case Plate E

A 14/04/2009 ADPG0139

Item Part No. References Qty. Description Notes

1 131046650 1 SCREW
2 F 131046650 1 BOLT
3 020109177 1 NUT
4 025100010 1 WASHER
5 198217910 1 SPRING
6 198346160 1 RING
7 131276440 1 ANTI-TAMPER CAP
8 131466251 1 BOLT
9 025100006 1 WASHER
10 020109239 1 NUT
11 198346160 1 RING
12 131466272 1 ANTI-TAMPER CAP
13 064210012 1 CAP

Page 63
 Miscellaneous Plate A

A 14/04/2009 ADPG0139

Page 64
 Miscellaneous Plate A

A 14/04/2009 ADPG0139

Item Part No. References Qty. Description Notes

1 198217970 1 TOOL (A)

Footnotes

(A) REFER TO WORKSHOP MANUAL

Page 65
 Camshaft & Gears Plate A

A 14/04/2009 ADPG0139

Page 66
 Camshaft & Gears Plate A

A 14/04/2009 ADPG0139

Item Part No. References Qty. Description Notes

1 120027070 1 CAMSHAFT
2 F 120027070 1 CAMSHAFT
3 034100508 1 WOODRUFF KEY
4 120016290 1 CAMSHAFT GEAR
5 040109057 1 BALL BEARING
6 U99216320 1 SPACER
7 125256250 1 SLIDER
8 199566750 1 PLATE
9 011310612 2 SCREW

Page 67
 Fuel Injection Pump Plate A

B 13/04/2009 AFPG0015

5 6

1
3

Page 68
 Fuel Injection Pump Plate A

B 13/04/2009 AFPG0015

Item Part No. References Qty. Description Notes

1 131010080 1 FUEL INJECTION PUMP

2 P 1 INJECTOR SHIM (A)
R a.
3 010800820 R b. 1 SCREW
4 2311D559 R b. 2 SCREW
5 027100008 R b. 2 WASHER
6 023100008 3 NUT
Service Options
2 131437491 X SHIM (B)
2 131437731 X SHIM (C)
2 131437761 X SHIM (D)
2 131437501 X SHIM (E)
2 131437511 X SHIM (F)
2 131437521 X SHIM (G)
2 131437531 X SHIM (H)

History
a.
2 P 1 SHIM
b.
3 010800820 2 SCREW
4 010700820 1 SCREW
5 027100008 1 WASHER

Footnotes

EMISSIONS CRITICAL COMPONENT - TO ENSURE CORRECT ENGINE TIMING RETAIN ORIGINAL SHIM DETAILS
(A)
FOR EXACT REPLACEMENTS.
(B) THICKNESS - 0.2MM - WITH BEAD
(C) THICKNESS - 0.25MM - WITH BEAD
(D) THICKNESS - 0.35MM - WITH BEAD
(E) THICKNESS - 0.3MM - WITH BEAD
(F) THICKNESS - 0.4MM - WITH BEAD
(G) THICKNESS - 0.5MM - WITH BEAD
(H) THICKNESS - 0.5MM - WITHOUT BEAD

Page 69
 High Pressure Fuel Pipes Plate A

B 13/04/2009 AFPG0015

7
1

Page 70
 High Pressure Fuel Pipes Plate A

B 13/04/2009 AFPG0015

Item Part No. References Qty. Description Notes

1 131507520 Q 1 1 FUEL INJECTION PIPE

2 131507530 Q 2 1 FUEL INJECTION PIPE
3 131507540 Q 3 1 FUEL INJECTION PIPE
4 131507550 Q 4 1 FUEL INJECTION PIPE
5 199106021 3 CLAMP
6 199106021 3 CLAMP
7 010110625 3 SCREW
8 023100006 3 NUT

Page 71
 Atomisers Plate A

B 13/04/2009 AFPG0015

Page 72
 Atomisers Plate A

B 13/04/2009 AFPG0015

Item Part No. References Qty. Description Notes

1 131406440 4 INJECTOR
2 131426230 1 SEAL - INJECTOR
3 131426200 4 SEAL - INJECTOR

Page 73
 Fuel Leak-Off Pipe Plate A

B 13/04/2009 AFPG0015

Page 74
 Fuel Leak-Off Pipe Plate A

B 13/04/2009 AFPG0015

Item Part No. References Qty. Description Notes

1 U31607080 1 PIPE - FUEL INJ LEAK OFF

2 198487450 1 BOLT
3 025100008 1 WASHER
4 025100008 1 WASHER

Page 75
 Flywheel Housing Plate A

CDPG0004

11

2
9

10 4

6
5

Page 76
 Flywheel Housing Plate A

CDPG0004

Item Part No. References Qty. Description Notes

1 110447440 1 FLYWHEEL HOUSING

2 110367570 1 BACKPLATE
3 011510816 10 SCREW
4 010111030 4 BOLT
5 020500010 4 NUT
6 027100010 4 WASHER
7 011511020 2 SCREW
8 011511045 1 SCREW
9 011511235 2 BOLT
10 2314J004 R a. 2 SCREW
R a.
R a.
11 2487646 2 PLUG

History
a.
10 010111030 2 BOLT
10 026200010 2 WASHER
10 027100010 2 WASHER

Page 77
 Flywheel & Starter Ring Plate A

DDPG0005

3
4

Page 78
 Flywheel & Starter Ring Plate A

DDPG0005

Item Part No. References Qty. Description Notes

1 U15357940 1 FLYWHEEL ASSEMBLY

2 F U15357940 1 FLYWHEEL
3 U15376160 1 STARTER RING
4 010109341 6 BOLT

Page 79
 Starter Motor Plate A

EDPG0001

Page 80
 Starter Motor Plate A

EDPG0001

Item Part No. References Qty. Description Notes

1 185086600 F U5MK8261 1 STARTER MOTOR (A)

Footnotes

(A) BOSCH

Page 81
 Starter Motor Breakdown Plate B

EDPG0001

1 3

2 4
5

9 7

Page 82
 Starter Motor Breakdown Plate B

EDPG0001

Item Part No. References Qty. Description Notes

1 185086600 F U5MK8261 1 STARTER MOTOR (A)

2 28730303 1 BUSH
3 28730304 1 SOLENOID
4 28730302 1 BUSH
5 28730301 1 DRIVE
6 28730305 1 ARMATURE
7 28730307 1 HOLDER
8 28730306 1 BUSH
9 28730308 1 KIT

Footnotes

(A) BOSCH

Page 83
 Starter Motor Plate A

EDPG0001

Page 84
 Starter Motor Plate A

EDPG0001

Item Part No. References Qty. Description Notes

1 U5MK8261 1 STARTER MOTOR (A)

2 F U5MK8261 1 STARTER MOTOR
3 U85656070 1 TERMINAL KIT
4 2314J004 2 SCREW
5 2314J007 2 SCREW
6 2318A604 2 NUT
7 1 LEAFLET
Service Options
1 U5MK8261R G 1 STARTER MOTOR - EXCHANGE

Footnotes

(A) REMY

Page 85
 Pulleys Plate A

FBPG0001

Page 86
 Pulleys Plate A

FBPG0001

Item Part No. References Qty. Description Notes

1 145336620 1 WATER PUMP PULLEY

Page 87
 Sump Plate A

GBPG0001

6
7

Page 88
 Sump Plate A

GBPG0001

Item Part No. References Qty. Description Notes

1 110708390 1 SUMP
2 110996920 1 GASKET - SUMP
3 010109235 30 SCREW
4 140406730 A U978798P 1 OIL SUCTION STRAINER (A)
R a.
R c.
5 140987090 A U978798P 1 PIPE - OIL SUCTION (B)
R a.
R b.
R c.
6 052109076 1 SEAL - O RING
7 011310612 2 SCREW

History
a.
4 140406680 A U978798P 1 STRAINER
5 140987070 A U978798P 1 PIPE - OIL SUCTION
b.
5 140987020 A U978798P 1 PIPE - OIL SUCTION
c. B U978797P
4 140406360 1 STRAINER
5 140986630 1 OIL PIPE

Footnotes

(A) USED ONLY WITH 140987090

(B) USED ONLY WITH 140406730

Page 89
 Dipstick & Filler Tube Plate A

GBPG0001

Page 90
 Dipstick & Filler Tube Plate A

GBPG0001

Item Part No. References Qty. Description Notes

1 198416690 1 DIPSTICK
2 110756490 1 DIPSTICK TUBE
3 010109235 1 SCREW
4 052100100 2 SEAL - O RING

Page 91
 Dipstick & Filler Tube Plate B

GBPG0001

Page 92
 Dipstick & Filler Tube Plate B

GBPG0001

Item Part No. References Qty. Description Notes

1 U98436290 R a. 1 BLANKING PLATE

2 052100100 1 SEAL - O RING
3 052100100 1 SEAL - O RING
4 011310612 1 SCREW

History
a.
1 198436290 1 PLUG

Page 93
 Sump Plate A

GCPG0000

Page 94
 Sump Plate A

GCPG0000

Item Part No. References Qty. Description Notes

1 010109238 2 SCREW
2 025100016 2 WASHER

Page 95
 Filler Plate A

HBPG0020

Page 96
 Filler Plate A

HBPG0020

Item Part No. References Qty. Description Notes

1 U98436350 1 OIL FILLER CAP

2 052100400 1 SEAL - O RING
3 198436390 1 OIL FILLER CAP
4 052100280 1 SEAL - O RING

Page 97
 Oil Filter Plate A

JBPG0000

Page 98
 Oil Filter Plate A

JBPG0000

Item Part No. References Qty. Description Notes

1 140517050 1 OIL FILTER

Page 99
 Oil Filter Plate A

JCPG0000

Page 100
 Oil Filter Plate A

JCPG0000

Item Part No. References Qty. Description Notes

1 140546020 1 CONNECTION

Page 101
 Front End Drive Input Plate A

KBPG0001

Page 102
 Front End Drive Input Plate A

KBPG0001

Item Part No. References Qty. Description Notes

1 U15397401 R a. 1 CRANKSHAFT PULLEY

2 034100508 1 WOODRUFF KEY
3 020109086 1 NUT

History
a.
1 115391020 1 CRANKSHAFT PULLEY

Page 103
 Water Pump Plate A

LBPG0003

6
3

Page 104
 Water Pump Plate A

LBPG0003

Item Part No. References Qty. Description Notes

1 U45010062 R a. 1 WATER PUMP

R b.
2 145996921 1 GASKET
3 145537300 1 HOSE
4 2481877 1 HOSE CLIP
5 2481877 1 HOSE CLIP
6 011310635 4 SCREW
7 023100006 1 NUT

History
a.
1 145010061 1 WATER PUMP
b.
1 145010060 1 WATER PUMP

Page 105
 Thermostat & Housing Plate A

B 982535T LBPG0003

6
3

Page 106
 Thermostat & Housing Plate A

B 982535T LBPG0003

Item Part No. References Qty. Description Notes

1 145046110 1 THERMOSTAT HOUSING

2 145206230 1 THERMOSTAT
3 145996930 1 GASKET - THERMOSTAT HSG
4 011310655 2 BOLT
5 023100006 2 NUT
6 064500030 1 PLUG
7 0650588 R a. 1 PLUG
R b.

History
a.
7 064500060 2 PLUG
b.
7 064500060 1 PLUG

Page 107
 Thermostat & Housing Plate A

A 982536T LBPG0003

6
3

Page 108
 Thermostat & Housing Plate A

A 982536T LBPG0003

Item Part No. References Qty. Description Notes

1 U45046111 1 THERMOSTAT HOUSING

2 145206230 1 THERMOSTAT
3 145996930 1 GASKET - THERMOSTAT HSG
4 011310655 2 BOLT
5 023100006 2 NUT
6 064500030 1 PLUG
7 0650588 1 PLUG

Page 109
 Water Outlet & Inlet Plate A

LDPG0001

Page 110
 Water Outlet & Inlet Plate A

LDPG0001

Item Part No. References Qty. Description Notes

1 145226320 1 CONNECTION
2 145996051 1 GASKET - THERMOSTAT HSG
3 011510825 2 SCREW

Page 111
 Alternator Plate A

NDPG0002

7
6

9
8 3

2
11

10

Page 112
 Alternator Plate A

NDPG0002

Item Part No. References Qty. Description Notes

1 U85046501 G 1 ALTERNATOR
R b.
R e.
2 U85977340 R d. 1 ALTERNATOR BRACKET
3 2314H022 1 SCREW
4 011510820 3 SCREW
5 U85727130 R a. 1 LEVER
6 011510825 1 SCREW
7 026100008 1 WASHER
8 011510825 1 SCREW
9 026109017 1 WASHER
10 020900008 R c. 1 NUT
11 027100008 1 WASHER
Service Options
1 U85046501R 1 EXCHANGE ALTERNATOR

History
a.
5 185727130 1 LEVER
b.
1 185046500 1 ALTERNATOR
c.
10 023100008 1 NUT
d.
2 TPN744 1 ALTERNATOR BRACKET
e.
1 TPN766 1 ALTERNATOR

Page 113
 Drive Belt & Tensioner Plate A

NEPG0001

Page 114
 Drive Belt & Tensioner Plate A

NEPG0001

Item Part No. References Qty. Description Notes

1 080109107 1 BELT

Page 115
 Blanking Plates Plate A

QCPG0026

1
2

Page 116
 Blanking Plates Plate A

QCPG0026

Item Part No. References Qty. Description Notes

1 U65166670 1 PLATE
2 U65206940 R a. 1 COVER
3 2314J014 2 SCREW
4 2318A604 2 NUT

History
a.
2 TPN958 1 COVER

Page 117
 Cylinder Head Cover Plate A

TBPG0001

12
4

11
13

14
16

15 1

10

Page 118
 Cylinder Head Cover Plate A

TBPG0001

Item Part No. References Qty. Description Notes

1 U11217422 R a. 1 CYLINDER HEAD COVER

R c.
2 111996401 1 GASKET - CYL. HEAD COVER
3 110566080 1 BREATHER VALVE
4 011100408 4 METRIC BOLT
5 135566570 1 PIPE - AIR
6 135996950 1 GASKET
7 011310620 2 SCREW
8 110666280 R d. 1 PLATE
9 110666060 1 GAUZE
10 015600406 6 SCREW
11 011310640 R b. 1 SCREW
12 011310660 3 SCREW
13 024600010 4 NUT
14 140996270 4 WASHER
15 T12119005 1 STUD
16 023100006 1 NUT

History
a.
1 U11211011 1 CYLINDER HEAD COVER
b.
11 011310640 2 SCREW
c.
1 111217421 1 CYLINDER HEAD COVER
d.
8 110666210 1 RETAINING PLATE

Page 119
 Feed Pipes Plate A

TBPG0001

Page 120
 Feed Pipes Plate A

TBPG0001

Item Part No. References Qty. Description Notes

1 064210015 R a. 1 CAP
R a.
R a.

History
a.
1 010109600 2 SCREW
1 165206810 1 COVER
1 3688A035 1 GASKET

Page 121
 Air Filter Assembly Plate A

TDPG0001

10

4
2

Page 122
 Air Filter Assembly Plate A

TDPG0001

Item Part No. References Qty. Description Notes

1 135016350 1 AIR FILTER ASSEMBLY

2 U30976791 1 BRACKET
3 2314H005 2 SCREW
4 199216340 1 SPACER
5 2314H003 2 SCREW
6 023100008 2 NUT
7 U35597790 1 HOSE
8 0180072 1 CLIP
9 21825194 1 CLIP
10 W14501020 1 COVER

Page 123
 Air Filter Assembly Plate B

TDPG0001

Page 124
 Air Filter Assembly Plate B

TDPG0001

Item Part No. References Qty. Description Notes

1 135016350 R a. 1 AIR FILTER ASSEMBLY

2 F 135016350 1 BODY
3 135326206 1 MAIN AIR FILTER
4 26510402 1 INDICATOR
5 26510194 1 VALVE
6 26510418 1 BRACKET

History
a.
1 135016350 1 AIR FILTER ASSEMBLY
26510418 1 BRACKET

Page 125
 Exhaust Manifold Plate A

UBPG0001

Page 126
 Exhaust Manifold Plate A

UBPG0001

Item Part No. References Qty. Description Notes

1 135617120 1 EXHAUST MANIFOLD

2 135996780 1 GASKET - EXHAUST MANIFOLD
3 011510860 6 SCREW
4 023100008 2 NUT

Page 127
 Exhaust Connection Plate A

UDPG0001

Page 128
 Exhaust Connection Plate A

UDPG0001

Item Part No. References Qty. Description Notes

1 W14120360 R a. 1 FLANGE
2 314990013 1 GASKET - EXHAUST
3 011510825 4 SCREW
4 W14120360 R a. 1 FLANGE
5 314990013 1 GASKET - EXHAUST
6 011510825 4 SCREW

History
a.
1 314120070 1 FLANGE
4 314120070 1 FLANGE

Page 129
 Lift Pump Plate A

VBPG0003

Page 130
 Lift Pump Plate A

VBPG0003

Item Part No. References Qty. Description Notes

1 130506350 1 LIFT PUMP

2 2415A070 1 SEAL - O RING
3 2314F003 2 SCREW

Page 131
 Fuel Filter Plate A

VBPG0003

3
8
4
12

14
1
10

6
5

13
7

11

Page 132
 Fuel Filter Plate A

VBPG0003

Item Part No. References Qty. Description Notes

1 2656613 1 FUEL FILTER ASSEMBLY

2 TPN508 1 SUPPORT BRACKET
3 010111030 2 BOLT
4 026200010 2 WASHER
5 020900010 2 NUT
6 027100010 2 WASHER
7 026100008 2 WASHER
8 26561117 1 FUEL FILTER KIT
9 F 26561117 1 ELEMENT
10 0490786 1 SEAL
11 0490786 1 SEAL
12 26560014 1 SEAL - O RING
13 011510820 1 SCREW
14 011510825 1 SCREW

Page 133
 Pipework & Connections Plate A

VBPG0003

11

12
13
14
2

3 7
6

10

9 8

Page 134
 Pipework & Connections Plate A

VBPG0003

Item Part No. References Qty. Description Notes

1 131246290 R a. 1 PIPE - LOW PRESSURE FUEL

2 33811114 1 OLIVE
3 068209126 1 HOSE
4 067100015 1 HOSE CLIP
5 067100015 1 HOSE CLIP
6 131246290 1 PIPE - LOW PRESSURE FUEL
7 33811114 1 OLIVE
8 068209227 1 HOSE - FUEL
9 067100015 1 HOSE CLIP
10 067100015 1 HOSE CLIP
11 32184226 1 PLUG
12 0920146 1 WASHER
13 0650204 2 PLUG
14 0920154 2 WASHER

History
a.
1 131246270 1 PIPE - FUEL

Page 135
 Cold Start System Plate A

WDPG0000

Page 136
 Cold Start System Plate A

WDPG0000

Item Part No. References Qty. Description Notes

1 185366190 4 GLOWPLUG
2 F 185366190 1 GLOWPLUG
3 F 185366190 1 NUT
4 185376150 1 BAR
5 023100004 R a. 1 NUT

History
a.
5 020100004 1 NUT
027100004 1 WASHER

Page 137
 Engine Lifting Eyes Plate A

XBPG0000

Page 138
 Engine Lifting Eyes Plate A

XBPG0000

Item Part No. References Qty. Description Notes

1 U95816760 R a. 1 LIFTING EYE

2 011510820 1 SCREW
3 026100008 1 WASHER
4 U95816760 R a. 1 LIFTING EYE

History
a.
1 195816100 1 LIFTING EYE
4 195816100 1 LIFTING EYE

Page 139
 Throttle & Stop Controls Plate A

ZAPG0001

Page 140
 Throttle & Stop Controls Plate A

ZAPG0001

Item Part No. References Qty. Description Notes

1 125416440 1 CONTROL LEVER

2 U85206452 R a. 1 SOLENOID
R b.
3 025100016 1 WASHER

History
a.
2 U85206451 1 SOLENOID
b.
2 185206450 1 SOLENOID

Page 141
 Heater/Starter Switch Plate A

B 16/11/2009 ZEPG0001

ON
F
F
O

Page 142
 Heater/Starter Switch Plate A

B 16/11/2009 ZEPG0001

Item Part No. References Qty. Description Notes

1 385201161 1 SWITCH
2 F 385201161 1 IGNITION SWITCH
3 385210061 1 KEY
4 385800010 1 CAP
5 390190030 1 PLATE

Page 143
 Heater/Starter Switch Plate A

A 17/11/2009 ZEPG0001

ON
F
F
O

Page 144
 Heater/Starter Switch Plate A

A 17/11/2009 ZEPG0001

Item Part No. References Qty. Description Notes

1 385202910 1 SWITCH
2 F 385202910 1 IGNITION SWITCH
3 385800010 1 CAP
4 385210390 1 IGNITION KEY
5 390190030 1 PLATE

Page 145
 Instrumentation Plate A

ZJPG0002

Page 146
 Instrumentation Plate A

ZJPG0002

Item Part No. References Qty. Description Notes

1 185246290 1 OIL PRESSURE SWITCH

2 198486871 1 BANJO BOLT
3 140996260 1 WASHER
4 140996260 1 WASHER
5 064400010 1 PLUG

Page 147
 Instrumentation Plate A

ZLPG0001

Page 148
 Instrumentation Plate A

ZLPG0001

Item Part No. References Qty. Description Notes

1 W85720580 R a. 1 WATER TEMPERATURE SWITCH

History
a.
1 385720510 1 WATER TEMPERATURE SWITCH

Page 149
 Radiator & Cowling Plate A

ZMPG0002

3
4

Page 150
 Radiator & Cowling Plate A

ZMPG0002

Item Part No. References Qty. Description Notes

1 U45506580 R a. 1 RADIATOR
2 F U45506580 1 RADIATOR
3 24850072 1 RADIATOR CAP
4 24850083 1 SHROUD

History
a.
1 TPN440 1 RADIATOR

Page 151
 Radiator & Cowling Plate B

ZMPG0002

Page 152
 Radiator & Cowling Plate B

ZMPG0002

Item Part No. References Qty. Description Notes

1 U45537130 1 HOSE
2 0180067 R a. 1 CLIP
3 0180067 R a. 1 CLIP
4 U45537140 1 HOSE
5 0180067 R a. 1 CLIP
6 0180067 R a. 1 CLIP

History
a.
2 TPN465 1 HOSE CLIP
3 TPN465 1 HOSE CLIP
5 TPN465 1 HOSE CLIP
6 TPN465 1 HOSE CLIP

Page 153
 Radiator & Cowling Plate C

ZMPG0002

2
3
6

Page 154
 Radiator & Cowling Plate C

ZMPG0002

Item Part No. References Qty. Description Notes

1 U45977221 R c. 1 BRACKET
2 2314H003 2 SCREW
3 2314H002 2 SCREW
4 U45977201 R b. 1 BRACKET
5 U98116931 R a. 1 MOUNTING
6 023100008 1 NUT
7 023100008 1 NUT

History
a.
5 2638D017 1 MOUNTING
b.
4 U45977200 1 BRACKET
c.
1 U45977220 1 BRACKET

Page 155
 Fan Plate A

ZMPG0002

Page 156
 Fan Plate A

ZMPG0002

Item Part No. References Qty. Description Notes

1 145306880 1 FAN
2 010109600 1 SCREW

Page 157
 Guards Plate A

B 31/12/2009 ZMPG0002

Page 158
 Guards Plate A

B 31/12/2009 ZMPG0002

Item Part No. References Qty. Description Notes

1 U75316371 R a. 1 FAN GUARD

2 U75316330 1 FAN GUARD
3 011510812 6 SCREW
4 U75316312 R a. 1 GUARD
5 2314H002 2 SCREW
6 U45546860 1 GUARD
7 011510812 4 SCREW
8 20186 2 HOSE CLIP

History
a.
1 U75316300 1 FAN GUARD
4 U75316310 1 GUARD

Page 159
 Guards Plate A

A 01/01/2010 ZMPG0002

10
5

Page 160
 Guards Plate A

A 01/01/2010 ZMPG0002

Item Part No. References Qty. Description Notes

1 U75316400 1 FAN GUARD

2 F U75316400 1 FAN GUARD
3 2314H005 2 SCREW
4 2318A401 2 NUT
5 U75316330 1 FAN GUARD
6 011510812 6 SCREW
7 U75316390 1 FAN GUARD
8 U45546860 1 GUARD
9 011510812 4 SCREW
10 20186 2 HOSE CLIP

Page 161
 Engine Mounts Plate A

ZMPG0002

1 4

3
5

Page 162
 Engine Mounts Plate A

ZMPG0002

Item Part No. References Qty. Description Notes

1 U45976820 1 BRACKET
2 2314F006 2 SCREW
3 2314J003 R b. 2 SCREW
4 U45977370 R a. 1 ENGINE MOUNT
5 2314H003 2 SCREW
6 010211425 4 BOLT
7 U45977380 R a. 1 ENGINE MOUNT
8 010211425 R c. 3 BOLT
9 2314H003 2 SCREW

History
a.
4 U10267291 1 BRACKET
7 U10267271 1 BRACKET
b.
3 011511025 2 SCREW
c.
8 010211425 1 BOLT

Page 163
 Electrical Plate A

ZPPG0002

Page 164
 Electrical Plate A

ZPPG0002

Item Part No. References Qty. Description Notes

1 20195 1 CONNECTION KIT

2 F 20195 3 CONNECTION

History
a.
385620200 2 CONNECTION (A)

Footnotes

(A) STARTER MOTOR

Page 165
 Fuel Pre-Lift Pump Plate A

ZVPG0003

Page 166
 Fuel Pre-Lift Pump Plate A

ZVPG0003

Item Part No. References Qty. Description Notes

1 130306380 1 PRE-FUEL FILTER ASSY

2 F 130306380 1 FUEL FILTER HEAD
3 26560182 1 FUEL FILTER BOWL
5 26560183 3 DRAIN PLUG
4 130306360 1 FUEL FILTER
6 26560184 1 SEAL - O RING

Page 167
 Fuel Pre-Lift Pump Plate B

ZVPG0003

Page 168
 Fuel Pre-Lift Pump Plate B

ZVPG0003

Item Part No. References Qty. Description Notes

1 130506300 1 PRIMER

Page 169
 Parts Index

Page 170
 Parts Index

Description Part No. Page Description Part No. Page

ADJUSTING SCREW 199486220 33 010211425 163, 163,

163
AIR FILTER 135016350 123, 125,
ASSEMBLY 125 010700860 21

ALTERNATOR 185046500 113 011310655 107, 109

TPN766 113 011511235 77

U85046501 113 131046560 47, 61

ALTERNATOR TPN744 113 131466251 49, 63

BRACKET
198486780 35
U85977340 113
198487450 75
ANTI-TAMPER CAP 131276440 49, 63
BRACKET 125616120 45
131466270 49
125616121 45, 59
131466272 49, 63
125616140 45
26420462 45, 59
26510418 125, 125
ARM 125156263 45, 59
U10267271 163
ARMATURE 28730305 83
U10267291 163
BACKPLATE 110367570 77
U30976791 123
BALL BEARING 040106203 17
U45976820 163
040109057 53, 67
U45977200 155
BANJO BOLT 198486871 147
U45977201 155
BAR 185376150 137
U45977220 155
BEARING HOLDER 110416290 43
ASSEMBLY U45977221 155

BELT 080109107 115 BREATHER VALVE 110566080 119

BIG END BEARING U5ME0030 21 BUSH 198517222 17

KIT
198517226 17
BLANKING PLATE U98436290 93
198517229 17
BOLT 010109341 79
28730302 83
010111030 77, 77,
28730303 83
133
28730306 83

Page 171
 Parts Index

Description Part No. Page Description Part No. Page

CAMSHAFT 120027070 53, 67 125416440 141

CAMSHAFT GEAR 120016290 53, 67 COVER 140116220 39

CAP 064210012 49, 63 165206810 121

064210015 121 TPN958 117

064210018 27 U65206940 117

064210030 27, 27 W14501020 123

120186080 27, 27 CRANKSHAFT 115256990 21, 21

ASSEMBLY
385800010 143, 145
CRANKSHAFT U15276270 21
CIRCLIP 036500028 23, 23 GEAR
036800010 39 CRANKSHAFT 115391020 103
PULLEY
CLAMP 199106021 71, 71
U15397401 103
CLIP 0180067 153, 153,
153, 153 CYLINDER HEAD 111011030 27, 27
ASSEMBLY
0180072 123
CYLINDER HEAD 111217421 119
21825194 123
COVER
COLLAR 199236540 39
U11211011 119
CON ROD 115026330 23
U11217422 119
ASSEMBLY
DIPSTICK 198416690 91
CON ROD BOLT 115176140 23
DIPSTICK TUBE 110756490 91
CON ROD NUT 020109120 23
DOWEL 030500612 17, 21,
CONNECTION 140546020 101
21, 21, 21
145226320 111
030500616 17
385620200 165
030501025 17
CONNECTION KIT 20195 165
DRAIN PLUG 26560183 167
CONTROL LEVER 125046612 47
DRIVE 28730301 83
125046613 47, 61
ENGINE MOUNT U45977370 163
125306150 47
U45977380 163
125306151 47, 61
EXCHANGE U85046501R 113
ALTERNATOR

Page 172
 Parts Index

Description Part No. Page Description Part No. Page

EXHAUST 135617120 127 3688A035 121

MANIFOLD
GASKET - CYL. 111996401 119
EXHAUST VALVE 120176380 27 HEAD COVER

FAN 145306880 157 GASKET - 111147711 29

CYLINDER HEAD
FAN GUARD U75316300 159
111147721 29
U75316330 159, 161
111147751 31
U75316371 159
111147761 31
U75316390 161
111147771 31
U75316400 161
GASKET - 314990013 129, 129
FLANGE 314120070 129, 129 EXHAUST
W14120360 129, 129 GASKET - 135996780 127
EXHAUST
FLYWHEEL U15357940 79
MANIFOLD
ASSEMBLY
GASKET - SUMP 110996920 89
FLYWHEEL 110447440 77
HOUSING GASKET - 145996051 111
THERMOSTAT HSG
FUEL FILTER 130306360 167
145996930 107, 109
FUEL FILTER 2656613 133
ASSEMBLY GASKET - TIMING 165996590 19
CASE
FUEL FILTER BOWL 26560182 167
165996630 41, 55
FUEL FILTER KIT 26561117 133
GAUZE 110666060 119
FUEL INJECTION 131507520 71
PIPE GLOWPLUG 185366190 137
131507530 71 GUARD U45546860 159, 161
131507540 71 U75316310 159
131507550 71 U75316312 159
FUEL INJECTION 131010080 69 GUDGEON PIN 115326220 23
PUMP
HOLDER 110156360 21
GASKET 135996950 119
110156370 21
145996921 105
110156380 21
165996640 45, 59

Page 173
 Parts Index

Description Part No. Page Description Part No. Page

110156390 21 U5MB0025A 21

28730307 83 METRIC BOLT 011100408 119

HOSE 068209126 135 MOUNTING 2638D017 155

145537300 105 U98116931 155

U35597790 123 NEEDLE BEARING 042309017 17

U45537130 153 042309018 17

U45537140 153 NUT 020100004 137

HOSE - FUEL 068209227 135 020109076 33

HOSE CLIP 067100015 135, 135, 020109086 103

135, 135
020109177 49, 63
20186 159, 161
020109239 49, 63
2481877 105, 105
020500010 77
TPN465 153, 153,
153, 153 020800010 47, 61

IGNITION KEY 385210390 145 020900008 113

INDICATOR 26510402 125 020900010 133

INJECTOR 131406440 73 023100004 137

INTAKE VALVE 120166390 27 023100006 41, 55,

71, 105,
KEY 030509020 21 107, 109,
119
385210061 143
023100008 45, 59,
KIT 28730308 83 69, 113,
123, 127,
LEVER 185727130 113
155, 155
U85727130 113
023100010 33
LIFT PUMP 130506350 131
024500006 47, 61
LIFTING EYE 195816100 139, 139
024600010 119
U95816760 139, 139
2318A207 45, 59
MAIN AIR FILTER 135326206 125
2318A401 161
MAIN BEARING KIT U5MB0025 21
2318A604 85, 117

Page 174
 Parts Index

Description Part No. Page Description Part No. Page

2648A120 45, 59 390190030 143, 145

OIL FILLER CAP 198436390 97 U65166580 19

U98436350 97 U65166670 117

OIL FILTER 140517050 99 PLUG 064100045 17

OIL PIPE 140607020 35 064209055 17, 17, 17

140986630 89 064210010 27

OIL PRESSURE 185246290 147 064210025 17, 27, 27

SWITCH
064400010 147
OIL PUMP IDLER U5MK8267 39
GEAR 064500030 107, 109

OIL SUCTION 140406730 89 064500060 107, 107

STRAINER
0650204 135
OLIVE 33811114 135, 135
0650588 107, 109
PIN 030300414 43, 57
198436290 93
030309005 17
198466010 17
031100004 47, 61
198466020 17
PIPE - AIR 135566570 119
198466920 17
PIPE - FUEL 131246270 135
198466940 17
PIPE - FUEL INJ U31607080 75
2487646 77
LEAK OFF
32184226 135
PIPE - LOW 131246290 135, 135
PRESSURE FUEL U98466960 47, 61
PIPE - OIL SUCTION 140987020 89 PRE-FUEL FILTER 130306380 167
ASSY
140987070 89
PRIMER 130506300 169
140987090 89
PUSHROD 120456310 33
PISTON AND RING 115017491 23
KIT RADIATOR TPN440 151
PISTON RING KIT 115107970 23 U45506580 151
PLATE 110666280 119 RADIATOR CAP 24850072 151
199566750 53, 67 RELIEF VALVE 140036220 37

Page 175
 Parts Index

Description Part No. Page Description Part No. Page

RETAINING PLATE 110666210 119 011510816 77

RING 198346160 49, 49, 011510820 113, 133,

63, 63 139

ROCKER ARM 120356131 33 011510825 111, 113,

ASSEMBLY 113, 129,
129, 133
120356141 33
011510860 127
ROCKER BOX 120036821 33
011511020 77
120037240 33
011511025 163
ROCKER SHAFT 120316201 33
011511045 77
ROCKER SHAFT 198217170 33
SPRING 011511070 21, 21, 21

SCREW 010109235 89, 91 012800640 45, 45,

59, 59
010109238 95
012810635 45, 45,
010109406 21, 21, 59, 59
21, 21
015600406 119
010109600 45, 121,
157 111136480 29, 31

010110625 71 111136490 29, 31

010700820 69 131046650 49, 63

010800820 69, 69 2311D559 69

011310612 19, 53, 2314F003 131

67, 89, 93
2314F004 45, 59
011310614 45
2314F006 163
011310620 119
2314H002 155, 159
011310635 33, 105
2314H003 123, 155,
011310640 41, 55, 163, 163
119, 119
2314H005 123, 161
011310660 41, 55,
119 2314H022 113

011510812 159, 159, 2314J003 163

161, 161
2314J004 77, 85

Page 176
 Parts Index

Description Part No. Page Description Part No. Page

2314J007 85 SHIM 131437491 69

2314J014 117 131437501 69

2315C039 45 131437511 69

SEAL 0490786 133, 133 131437521 69

SEAL - FRONT END 198636160 43, 57 131437531 69

OIL
131437731 69
SEAL - INJECTOR 131426200 73
131437761 69
131426230 73
199286150 39
SEAL - O RING 052100070 45, 59
199286160 39
052100080 47, 61
199286170 39
052100100 91, 93, 93
199286180 39
052100280 97
SHROUD 24850083 151
052100400 97
SLIDER 125256250 53, 67
052109076 33, 89
SMALL END BUSH 198517265 23
052109078 37
SOLENOID 185206450 141
052300850 43
28730304 83
2415A070 131
U85206451 141
26560014 133
U85206452 141
26560184 167
SPACER 199216340 123
SEAL - REAR END 050209083 25
OIL U99216320 53, 67

SEAL - ROCKER 120996130 33 SPRING 198211110 45, 59

BOX
198216720 39
SEAL - VALVE 120406050 27
198217750 45, 59
STEM
198217880 47, 61
120406070 27
198217910 49, 63
SHAFT 125116211 47, 61
STARTER MOTOR 185086600 81, 83
125116221 47, 61
U5MK8261 85
165296220 17

Page 177
 Parts Index

Description Part No. Page Description Part No. Page

STARTER MOTOR - U5MK8261R 85 VALVE 26510194 125

EXCHANGE
VALVE COLLET 120226070 27, 27
STARTER RING U15376160 79
VALVE SEAT TPN645 27
STRAINER 140406360 89 INSERT

140406680 89 TPN646 27

STUD 010109441 17 U10136460 27

012109044 33 U10136470 27

012110635 17 VALVE SPRING 198216700 27, 27

012110655 29, 31 VALVE SPRING CAP 120216041 27, 27

012110660 17 WASHER 025100006 47, 49,

61, 63
012110860 29, 31
025100008 47, 75, 75
T12119005 119
025100010 49, 63
SUMP 110708390 89
025100016 95, 141
SUPPORT BRACKET TPN508 133
026100008 113, 133,
SWITCH 385201161 143 139
385202910 145 026109017 113
TAPPET 120116160 33 026200010 77, 133
TERMINAL KIT U85656070 85 027100004 137
THERMOSTAT 145206230 107, 109 027100008 69, 69,
113
THERMOSTAT 145046110 107
HOUSING 027100010 77, 77,
133
U45046111 109
0920146 135
THRUST WASHER 199266200 21, 21
0920154 135
199266210 21
140996260 35, 35,
199266270 39
147, 147
TIMING CASE U65116570 43
140996270 119
U65116730 57

TOOL 198217970 51, 65

Page 178
 Parts Index

Description Part No. Page

199280300 33

WATER PUMP 145010060 105

145010061 105

U45010062 105

WATER PUMP 145336620 87

PULLEY

WATER 385720510 149

TEMPERATURE
SWITCH

W85720580 149

WOODRUFF KEY 034100508 53, 67,

103

Page 179