GV51790U

GV51790U GV51790U
400S404A-22 2015/01/08
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 ADPG0139
Cylinder Block 17 Timing Case 43

ACPG0004 ADPG0139
Cylinder Block 19 Timing Case 45

ACPG0004 ADPG0139
Crankshaft, Pistons & Connecting Rods 21 Timing Case 47

ACPG0004 ADPG0139
Crankshaft, Pistons & Connecting Rods 23 Timing Case 49

ACPG0004 ADPG0139
Rear End Oil Seal 25 Miscellaneous 51

ACPG0004 ADPG0139
Cylinder Head 27 Camshaft & Gears 53

ACPG0004 ADPG0139
Cylinder Head 29 Fuel Injection Pump 55

ACPG0004 AFPG0015
Cylinder Head 31 High Pressure Fuel Pipes 57

ACPG0004 AFPG0015
Rocker Shaft Assembly 33 Atomisers 59

ACPG0004 AFPG0015
Pipes 35 Fuel Leak-Off Pipe 61

ACPG0004 AFPG0015
Page 5
Engine Breakdown
Flywheel Housing 63 Front End Drive Input 89

CDPG0004 KBPG0001
Flywheel & Starter Ring 65 Water Pump 91

DDPG0005 LBPG0003
Starter Motor 67 Thermostat & Housing 93

EDPG0001 LBPG0003
Starter Motor Breakdown 69 Thermostat & Housing 95

EDPG0001 LBPG0003
Starter Motor 71 Water Outlet & Inlet 97

EDPG0001 LDPG0001
Pulleys 73 Alternator 99
FBPG0001 NDPG0002
Sump 75 Drive Belt & Tensioner 101

GBPG0001 NEPG0001
Dipstick & Filler Tube 77 Blanking Plates 103

GBPG0001 QCPG0026
Dipstick & Filler Tube 79 Cylinder Head Cover 105

GBPG0001 TBPG0001
Sump 81 Feed Pipes 107

GCPG0000 TBPG0001
Filler 83 Air Filter Assembly 109

HBPG0020 TDPG0001
Oil Filter 85 Air Filter Assembly 111

JBPG0000 TDPG0001
Oil Filter 87 Air Filter Assembly 113

JCPG0000 TDPG0001
Page 6
Engine Breakdown
Exhaust Manifold 115 Radiator & Cowling 141

UBPG0001 ZMPG5502
Exhaust Connection 117 Fan 143

UDPG0001 ZMPG5502
Lift Pump 119 Fan 145

VBPG0003 ZMPG5502
Fuel Filter 121 Guards 147

VBPG0003 ZMPG5502
Pipework & Connections 123 Guards 149

VBPG0003 ZMPG5502
Cold Start System 125 Radiator & Cowling 151

WDPG0000 ZMPG5512
Engine Lifting Eyes 127 Radiator & Cowling 153

XBPG0000 ZMPG5512
Throttle & Stop Controls 129

ZAPG0001
Instrumentation 131
ZJPG0002
Instrumentation 133
ZLPG0001
Radiator & Cowling 135

ZMPG5502

ZMPG5502

ZMPG5502
Page 7
Engine Breakdown
Section Page
Fan 155
ZMPG5512
Fan 157
ZMPG5512
Guards 159
ZMPG5512
Guards 161
ZMPG5512
Engine Mounts 163

ZMPG5512
Electrical 165
ZPPG0001
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

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.
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
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.
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.
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
1 1 LEVEL 2 - REPAIR
Page 13
Level 3 - Overhaul Plate A
AAAAAAGN

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.
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.
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.
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.
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
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
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 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
Footnotes
(A) SERVICE BY COMPLETE ENGINE

(B) REFER TO U5MK8267
Page 17
Cylinder Block Plate B
ACPG0004
2
1
Page 18
Cylinder Block Plate B
ACPG0004
1 U65996590 R a. 1 GASKET
2 011310612 2 SCREW
History
a.
1 165996590 1 GASKET - TIMING CASE
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
1 115256990 1 CRANKSHAFT ASSEMBLY

2 F 115256990 1 CRANKSHAFT ASSEMBLY
3 U15276270 1 CRANKSHAFT GEAR
4 030509020 1 KEY
5 199266210 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
33 U5ME0030A 1 BIG END BRG KIT - U/S
Page 21
Crankshaft, Pistons & Connecting Rods Plate B
ACPG0004
3 2
12
8
10
11
Page 22
Crankshaft, Pistons & Connecting Rods Plate B
ACPG0004
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
Service Options
1 115017705 4 PISTON AND RING KIT - O/S (A) +0.25
3 115107975 1 PISTON RING KIT - OVERSIZE +0.25MM
Footnotes
(A) CONTAINS GUDGEON PIN AND CIRCLIPS
Page 23
Rear End Oil Seal Plate A
ACPG0004
Page 24
Rear End Oil Seal Plate A
ACPG0004
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
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 120166380 R a. 4 INTAKE VALVE (A)
10 U10136470 1 VALVE SEAT INSERT INLET
11 120406070 4 SEAL - VALVE STEM (A)
12 198216700 4 VALVE SPRING
13 120186080 4 CAP
14 120226070 4 VALVE COLLET
15 120176380 4 EXHAUST VALVE (B)
16 U10136460 1 VALVE SEAT INSERT EXHAUST
17 120406050 4 SEAL - VALVE STEM (B)
18 198216700 4 VALVE SPRING
19 120186080 4 CAP
20 120226070 4 VALVE COLLET
21 120216041 4 VALVE SPRING CAP
22 120216041 4 VALVE SPRING CAP
History
a.
1 111011030 1 CYLINDER HEAD ASSEMBLY
9 120166390 4 INTAKE VALVE
Footnotes
(A) INLET
(B) EXHAUST
Page 27
Cylinder Head Plate B
B 929887S ACPG0004
Page 28
B 929887S ACPG0004
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
Page 29
A 929888S ACPG0004
Page 30
A 929888S ACPG0004
1 P 1 GASKET - CYLINDER HEAD

2 111136480 14 SCREW
3 111136490 4 SCREW
4 012110655 2 STUD
5 012110860 2 STUD
Service Options
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
1 120037240 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
Page 33
Pipes Plate A
ACPG0004
Page 34
Pipes Plate A
ACPG0004
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
1 140036220 1 RELIEF VALVE

2 052109078 1 SEAL - O RING
Page 37
Oil Pump Plate A
U5MK8267.
4
5
11
7 6
10
Page 38
Oil Pump Plate A
U5MK8267.
1 U5MK8267 1 OIL PUMP IDLER GEAR

2 F U5MK8267 1 SHAFT
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
11 1 LEAFLET
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
ADPG0139
Page 40
Timing Case Plate A
ADPG0139
1 1 TIMING CASE (A)

2 U65996630 R a. 1 GASKET - TIMING CASE
3 011310640 7 SCREW
4 011310660 4 SCREW
5 023100006 2 NUT
History
a.
2 165996630 1 GASKET - TIMING CASE
Footnotes
(A) SEE FOLLOWING PARTS LIST FOR SERVICE COMPONENTS
Page 41
Timing Case Plate B
ADPG0139
1 2
Page 42
Timing Case Plate B
ADPG0139
1 U65116730 1 TIMING CASE

2 030300414 1 PIN
3 198636160 1 SEAL - FRONT END OIL
Page 43
Timing Case Plate C
ADPG0139
10
7
6 9
1
2
11 12
3
13
Page 44
Timing Case Plate C
ADPG0139
1 125616121 1 BRACKET
2 U65996640 R a. 1 GASKET - TIMING CASE
3 125156263 1 ARM
4 198211110 1 SPRING
5 052100070 1 SEAL - O RING
6 198217750 1 SPRING
7 023100008 1 NUT
8 012810635 1 SCREW
9 2648A120 1 NUT
10 26420462 1 ANTI-TAMPER CAP
11 012810635 1 SCREW
12 2318A207 1 NUT
13 2314F004 4 SCREW
History
a.
2 165996640 1 GASKET
Page 45
Timing Case Plate D
ADPG0139
12
1
10
11
4
Page 46
Timing Case Plate D
ADPG0139
1 125046613 1 CONTROL LEVER

2 125116221 1 SHAFT
3 052100080 1 SEAL - O RING
4 131046560 1 BOLT
5 020800010 1 NUT
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 47
Timing Case Plate E
ADPG0139
1
3
5
8
9
10
11
12
13
Page 48
Timing Case Plate E
ADPG0139
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
8 131466251 1 BOLT
9 025100006 1 WASHER
10 020109239 1 NUT
11 198346160 1 RING
13 064210012 1 CAP
Page 49
Miscellaneous Plate A
ADPG0139
Page 50
Miscellaneous Plate A
ADPG0139
1 198217970 1 TOOL (A)
Footnotes
(A) REFER TO WORKSHOP MANUAL
Page 51
Camshaft & Gears Plate A
ADPG0139
Page 52
Camshaft & Gears Plate A
ADPG0139
1 120027070 1 CAMSHAFT
2 F 120027070 1 CAMSHAFT
3 034100508 1 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
Fuel Injection Pump Plate A
AFPG0015
5 6
1
3
Page 54
Fuel Injection Pump Plate A
AFPG0015
1 131010080 1 FUEL INJECTION PUMP

2 P 1 INJECTOR SHIM (A)
3 010800820 1 SCREW
4 2311D559 2 SCREW
5 027100008 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)
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 55
High Pressure Fuel Pipes Plate A
AFPG0015
7
1
Page 56
High Pressure Fuel Pipes Plate A
AFPG0015
1 131507520 Q 1 1 FUEL INJECTION PIPE

5 199106021 3 CLAMP
6 199106021 3 CLAMP
7 010110625 3 SCREW
8 023100006 3 NUT
Page 57
Atomisers Plate A
AFPG0015
Page 58
Atomisers Plate A
AFPG0015
1 131406440 4 INJECTOR
2 131426230 1 SEAL - INJECTOR
3 U31426200 R a. 4 SEAL - INJECTOR
History
a.
3 131426200 4 SEAL - INJECTOR
Page 59
Fuel Leak-Off Pipe Plate A
AFPG0015
Page 60
Fuel Leak-Off Pipe Plate A
AFPG0015
1 U31607160 R a. 1 PIPE - FUEL INJ LEAK OFF

2 198487450 1 BOLT
3 025100008 1 WASHER
4 025100008 1 WASHER
History
a.
1 U31607080 1 PIPE - FUEL INJ LEAK OFF
Page 61
Flywheel Housing Plate A
CDPG0004
10
8
2
9 3
6
4
Page 62
Flywheel Housing Plate A
CDPG0004
1 U10447441 1 FLYWHEEL HOUSING

2 110367570 1 BACKPLATE
3 2314H102 R b. 10 SCREW
4 2314J004 4 SCREW
5 2318A604 4 NUT
6 011511020 2 SCREW
7 2314J006 R a. 6 SCREW
8 2314J604 2 SETSCREW
9 2314J004 2 SCREW
10 2487646 2 PLUG
History
a.
7 011511045 6 SCREW
b.
3 011510816 10 SCREW
Page 63
Flywheel & Starter Ring Plate A
DDPG0005
3
4
Page 64
Flywheel & Starter Ring Plate A
DDPG0005
1 U15357940 1 FLYWHEEL ASSEMBLY

2 F U15357940 1 FLYWHEEL
3 U15376160 1 STARTER RING
4 010109341 6 BOLT
Page 65
Starter Motor Plate A
EDPG0001
Page 66
EDPG0001
1 185086600 F U5MK8261 1 STARTER MOTOR (A)
Footnotes
(A) BOSCH
Page 67
Starter Motor Breakdown Plate B
EDPG0001
1 3
2 4
5
9 7
Page 68
Starter Motor Breakdown Plate B
EDPG0001
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 69
EDPG0001
Page 70
EDPG0001
1 U5MK8261 P 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 71
Pulleys Plate A
FBPG0001
Page 72
Pulleys Plate A
FBPG0001
1 145336620 1 WATER PUMP PULLEY
Page 73
Sump Plate A
GBPG0001
5
4
6
7
Page 74
Sump Plate A
GBPG0001
1 110708390 1 SUMP
2 U10996920 R a. 1 GASKET - SUMP
3 2314F002 R b. 30 SCREW
4 U40406790 A U978798P 1 OIL SUCTION STRAINER
R c.
5 140987090 A U978798P 1 PIPE - OIL SUCTION
6 052109076 1 SEAL - O RING
7 011310612 2 SCREW
History
a.
2 110996920 1 GASKET - SUMP
b.
3 010109235 30 SCREW
c.
4 140406730 A U978798P 1 OIL SUCTION STRAINER
Page 75
Dipstick & Filler Tube Plate A
GBPG0001
Page 76
Dipstick & Filler Tube Plate A
GBPG0001
1 198416690 1 DIPSTICK
2 110756490 1 DIPSTICK TUBE
3 011310612 R a. 1 SCREW
4 052100100 2 SEAL - O RING
History
a.
3 010109235 1 SCREW
Page 77
Dipstick & Filler Tube Plate B
GBPG0001
Page 78
Dipstick & Filler Tube Plate B
GBPG0001
1 U98436290 1 BLANKING PLATE

2 052100100 1 SEAL - O RING
3 052100100 1 SEAL - O RING
4 011310612 1 SCREW
Page 79
Sump Plate A
GCPG0000
Page 80
Sump Plate A
GCPG0000
1 T10109238 R a. 2 SUMP DRAIN PLUG

2 025100016 2 WASHER
History
a.
1 010109238 2 SCREW
Page 81
Filler Plate A
HBPG0020
Page 82
Filler Plate A
HBPG0020
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 83
Oil Filter Plate A
JBPG0000
Page 84
Oil Filter Plate A
JBPG0000
1 140517050 1 OIL FILTER
Page 85
Oil Filter Plate A
JCPG0000
Page 86
Oil Filter Plate A
JCPG0000
1 140546020 1 CONNECTION
Page 87
Front End Drive Input Plate A
KBPG0001
Page 88
Front End Drive Input Plate A
KBPG0001
1 U15397401 1 CRANKSHAFT PULLEY

2 034100508 1 KEY
3 020109086 1 NUT
Page 89
Water Pump Plate A
LBPG0003
6
3
Page 90
Water Pump Plate A
LBPG0003
1 U45010062 1 WATER PUMP

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
Page 91
Thermostat & Housing Plate A
B 982535T LBPG0003
6
3
Page 92
B 982535T LBPG0003
1 145046110 1 THERMOSTAT HOUSING

2 145206230 1 THERMOSTAT
3 U45996930 R a. 1 GASKET - THERMOSTAT HSG
4 011310655 2 BOLT
5 023100006 2 NUT
6 064500030 1 PLUG
7 0650588 1 PLUG
History
a.
3 145996930 1 GASKET - THERMOSTAT HSG
Page 93
A 982536T LBPG0003
6
3
Page 94
A 982536T LBPG0003
1 U45046111 1 THERMOSTAT HOUSING

2 145206230 1 THERMOSTAT
4 011310655 2 BOLT
5 023100006 2 NUT
6 064500030 1 PLUG
7 0650588 1 PLUG
History
a.
Page 95
Water Outlet & Inlet Plate A
LDPG0001
Page 96
Water Outlet & Inlet Plate A
LDPG0001
1 145226320 1 CONNECTION
3 011510825 2 SCREW
History
a.
Page 97
Alternator Plate A
NDPG0002
7
6
9
8 3
2
11
10
Page 98
Alternator Plate A
NDPG0002
1 T414270 R b. 1 ALTERNATOR
2 U85977340 1 ALTERNATOR BRACKET
3 2314H022 1 SCREW
4 011510820 3 SCREW
5 U85727130 1 LEVER
6 2314H004 R a. 1 SCREW
7 026100008 1 WASHER
8 2314H004 R a. 1 SCREW
9 026109017 1 WASHER
10 020900008 1 NUT
11 027100008 1 WASHER
History
a.
6 011510825 1 SCREW
8 011510825 1 SCREW
b.
1 U85046501 G 1 ALTERNATOR
Page 99
Drive Belt & Tensioner Plate A
NEPG0001
Page 100
Drive Belt & Tensioner Plate A
NEPG0001
1 T80109107 R a. 1 BELT
History
a.
1 080109107 1 BELT
Page 101
Blanking Plates Plate A
QCPG0026
1
2
Page 102
Blanking Plates Plate A
QCPG0026
1 U65166670 1 PLATE
2 U65206940 1 COVER
3 2314J014 2 SCREW
4 2318A604 2 NUT
Page 103
Cylinder Head Cover Plate A
TBPG0001
12
4
11
13
14
16
15
1
10
Page 104
Cylinder Head Cover Plate A
TBPG0001
1 U11211220 R a. 1 CYLINDER HEAD COVER

2 111996401 1 GASKET - CYL. HEAD COVER
3 110566080 1 BREATHER VALVE
4 011100408 4 METRIC BOLT
5 135566570 1 PIPE - AIR
6 U35996951 R b. 1 GASKET
7 011310620 2 SCREW
8 110666280 1 PLATE
9 110666060 1 GAUZE
10 015600406 6 SCREW
11 011310640 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 U11217422 1 CYLINDER HEAD COVER
b.
6 135996950 1 GASKET
Page 105
Feed Pipes Plate A
TBPG0001
Page 106
Feed Pipes Plate A
TBPG0001
1 064210015 1 CAP
Page 107
Air Filter Assembly Plate A
TDPG0001
10
4
2
Page 108
Air Filter Assembly Plate A
TDPG0001
1 135016350 1 AIR FILTER ASSEMBLY (A)

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 (B)
Footnotes
(A) MAY REQUIRE REORIENTATION WHEN FITTING

(B) IF FITTED
Page 109
Air Filter Assembly Plate B
TDPG0001
Page 110
Air Filter Assembly Plate B
TDPG0001
1 135016350 1 AIR FILTER ASSEMBLY (A)

2 F 135016350 1 BODY
3 135326206 1 MAIN AIR FILTER
4 26510402 1 INDICATOR
5 26510194 1 VALVE
6 26510418 1 BRACKET
Footnotes
(A) MAY REQUIRE REORIENTATION WHEN FITTING
Page 111
Air Filter Assembly Plate C
TDPG0001
Page 112
Air Filter Assembly Plate C
TDPG0001
1 2638C245 1 LABEL (A,B)
Footnotes
(A) ETHER WARNING LABEL

(B) REFER TO SERVICE BULLETIN NO.81 (1100 SERIES)
Page 113
Exhaust Manifold Plate A
UBPG0001
Page 114
Exhaust Manifold Plate A
UBPG0001
1 135617120 1 EXHAUST MANIFOLD

2 135996780 1 GASKET - EXHAUST MANIFOLD
3 011510860 6 SCREW
4 023100008 2 NUT
Page 115
Exhaust Connection Plate A
UDPG0001
Page 116
Exhaust Connection Plate A
UDPG0001
1 W14120360 1 FLANGE
2 314990013 1 GASKET - EXHAUST
3 011510825 4 SCREW
4 W14120360 1 FLANGE
5 314990013 1 GASKET - EXHAUST
6 011510825 4 SCREW
Page 117
Lift Pump Plate A
VBPG0003
Page 118
Lift Pump Plate A
VBPG0003
1 130506350 1 LIFT PUMP

2 2415A070 1 SEAL - O RING
3 2314F003 2 SCREW
Page 119
Fuel Filter Plate A
VBPG0003
7 3
11
1
9
12
5
4
10
Page 120
Fuel Filter Plate A
VBPG0003
1 2656613 1 FUEL FILTER ASSEMBLY (A)

2 TPN508 1 SUPPORT BRACKET
3 2314J004 R a. 2 SCREW
4 020900010 2 NUT
5 027100010 2 WASHER
6 2314H003 1 SCREW
7 26561117 1 FUEL FILTER KIT
8 F 26561117 1 ELEMENT
9 0490786 1 SEAL
10 0490786 1 SEAL
11 26560014 1 SEAL - O RING
12 011510820 1 SCREW
History
a.
3 010111030 2 BOLT
026200010 2 WASHER
b.
026100008 2 WASHER
011510825 1 SCREW
Footnotes
(A) CONTAINS FILTER BOWL - 26560601
Page 121
Pipework & Connections Plate A
VBPG0003
11
12
13
14
2
4 1
7
6
8
3
10
Page 122
Pipework & Connections Plate A
VBPG0003
1 131246290 1 PIPE - LOW PRESSURE FUEL

2 33811114 1 OLIVE
3 T68209189 R a. 1 HOSE
4 2481882 R a. 1 CLIP
5 2481882 R a. 1 CLIP
6 131246290 1 PIPE - LOW PRESSURE FUEL
7 33811114 1 OLIVE
8 T68209628 R b. 1 HOSE - FUEL
9 2481882 R b. 1 CLIP
10 2481882 R b. 1 CLIP
11 32184226 1 PLUG
12 2411D010 R c. 1 WASHER
13 0650204 2 PLUG
14 0920154 2 WASHER
History
a.
3 068209126 1 HOSE
4 067100015 1 HOSE CLIP
5 067100015 1 HOSE CLIP
b.
8 068209227 1 HOSE - FUEL
9 067100015 1 HOSE CLIP
10 067100015 1 HOSE CLIP
c.
12 0920146 1 WASHER
Page 123
Cold Start System Plate A
WDPG0000
Page 124
Cold Start System Plate A
WDPG0000
1 185366190 4 GLOWPLUG
2 F 185366190 1 GLOWPLUG
3 F 185366190 1 NUT
4 185376150 1 BAR
5 023100004 1 NUT
Page 125
Engine Lifting Eyes Plate A
XBPG0000
Page 126
Engine Lifting Eyes Plate A
XBPG0000
1 U95816760 1 LIFTING EYE

2 011510820 1 SCREW
3 026100008 1 WASHER
4 U95816760 1 LIFTING EYE
Page 127
Throttle & Stop Controls Plate A
ZAPG0001
Page 128
Throttle & Stop Controls Plate A
ZAPG0001

2 U85206520 1 SOLENOID
3 025100016 1 WASHER
History
a.
U85206452 1 SOLENOID
Page 129
Instrumentation Plate A
ZJPG0002
Page 130
ZJPG0002
1 185246290 1 OIL PRESSURE SWITCH

2 198486871 1 BANJO BOLT
3 140996260 1 WASHER
4 140996260 1 WASHER
5 064400010 1 PLUG
Page 131
ZLPG0001
Page 132
ZLPG0001
1 W85720580 1 WATER TEMPERATURE SWITCH
Page 133
Radiator & Cowling Plate A
B 957500W ZMPG5502
3
4
Page 134
B 957500W ZMPG5502
1 U45506580 1 RADIATOR
2 F U45506580 1 RADIATOR
3 24850072 1 RADIATOR CAP
4 24850083 1 SHROUD
Page 135
Radiator & Cowling Plate B
B 957500W ZMPG5502
2
3
6
Page 136
B 957500W ZMPG5502
1 U45977221 1 BRACKET
2 2314H003 2 SCREW
3 2314H002 2 SCREW
4 U45977201 1 BRACKET
5 U98116931 1 MOUNTING
6 023100008 1 NUT
7 023100008 1 NUT
Page 137
Radiator & Cowling Plate C
B 957500W ZMPG5502
Page 138
Radiator & Cowling Plate C
B 957500W ZMPG5502
1 U45537130 1 HOSE
2 0180067 1 CLIP
3 0180067 1 CLIP
4 U45537140 1 HOSE
5 0180067 1 CLIP
6 0180067 1 CLIP
Page 139
Radiator & Cowling Plate D
B 957500W ZMPG5502
1 4
3
5
Page 140
Radiator & Cowling Plate D
B 957500W ZMPG5502
1 U45976820 1 BRACKET
2 2314F006 2 SCREW
3 2314J003 2 SCREW
4 U45977370 1 ENGINE MOUNT
5 2314H003 2 SCREW
6 010211425 4 BOLT
8 010211425 3 BOLT
9 2314H003 2 SCREW
Page 141
Fan Plate A
B 957500W B 990523X ZMPG5502
Page 142
Fan Plate A
B 957500W B 990523X ZMPG5502
1 145306880 1 FAN
2 010109600 4 SCREW
Page 143
Fan Plate A
B 957500W A 990524X ZMPG5502
Page 144
Fan Plate A
B 957500W A 990524X ZMPG5502
1 U45307130 1 FAN
2 145386910 1 EXTENSION
3 2314F006 4 SCREW
Page 145
Guards Plate A
B 957500W B 31/12/2009 ZMPG5502
Page 146
Guards Plate A
B 957500W B 31/12/2009 ZMPG5502
1 U75316371 1 FAN GUARD

2 U75316330 1 FAN GUARD
3 011510812 6 SCREW
4 U75316312 1 GUARD
5 2314H002 2 SCREW
6 20186 2 HOSE CLIP
Page 147
Guards Plate A
B 957500W A 01/01/2010 ZMPG5502
8
5
Page 148
Guards Plate A
B 957500W A 01/01/2010 ZMPG5502
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 20186 2 HOSE CLIP
Page 149
A 957501W ZMPG5512
3
4
Page 150
A 957501W ZMPG5512
1 U45506580 1 RADIATOR
2 F U45506580 1 RADIATOR
3 24850072 1 RADIATOR CAP
4 24850083 1 SHROUD
5 20186 1 HOSE CLIP
Page 151
A 957501W ZMPG5512
Page 152
A 957501W ZMPG5512
1 U45537130 1 HOSE
2 0180067 1 CLIP
3 0180067 1 CLIP
4 U45537140 1 HOSE
5 0180067 1 CLIP
6 0180067 1 CLIP
Page 153
Fan Plate A
A 957501W B 990523X ZMPG5512
Page 154
Fan Plate A
A 957501W B 990523X ZMPG5512
1 U45307130 1 FAN
2 010109600 4 SCREW
Page 155
Fan Plate A
A 957501W A 990524X ZMPG5512
Page 156
Fan Plate A
A 957501W A 990524X ZMPG5512
1 U45307130 1 FAN
2 145386910 1 EXTENSION
3 2314F006 4 SCREW
Page 157
Guards Plate A
A 957501W ZMPG5512
3 4
Page 158
Guards Plate A
A 957501W ZMPG5512
1 T413163 1 FAN GUARD

2 F T413163 1 FAN GUARD
3 T413025 1 FAN GUARD
4 2314F004 5 SCREW
5 011510812 4 SCREW
Page 159
Guards Plate B
A 957501W ZMPG5512
3 2
6
Page 160
Guards Plate B
A 957501W ZMPG5512
1 U45977222 1 BRACKET
2 2314F004 2 SCREW
3 2314H002 2 SCREW
4 U98116931 1 MOUNTING
5 U45977201 1 BRACKET
6 023100008 1 NUT
7 023100008 1 NUT
8 2314H003 2 SCREW
Page 161
Engine Mounts Plate A
A 957501W ZMPG5512
3 5
4
Page 162
Engine Mounts Plate A
A 957501W ZMPG5512
1 U45976820 1 BRACKET
2 2314F006 2 SCREW
3 2314J003 2 SCREW
5 2314H003 1 SCREW
6 010211425 1 BOLT
8 2314H003 1 SCREW
9 010211425 1 BOLT
Page 163
Electrical Plate A
ZPPG0001
Page 164
Electrical Plate A
ZPPG0001
1 20195 1 CONNECTION KIT

2 F 20195 3 CONNECTION
Page 165
Fuel Pre-Lift Pump Plate A
ZVPG0003
Page 166
Fuel Pre-Lift Pump Plate A
ZVPG0003
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
1 130506300 1 PRIMER
Page 169
Parts Index
Page 170
Parts Index
Description Part No. Page Description Part No. Page
ADJUSTING SCREW 199486220 33 131046560 47
AIR FILTER 135016350 109, 111 131466251 49

ASSEMBLY
198486780 35
ALTERNATOR T414270 99
198487450 61
U85046501 99
BRACKET 125616121 45
ALTERNATOR U85977340 99
BRACKET 26510418 111
ANTI-TAMPER CAP 131276440 49 U30976791 109
131466272 49 U45976820 141, 163
26420462 45 U45977201 137, 161
ARM 125156263 45 U45977221 137
ARMATURE 28730305 69 U45977222 161
BACKPLATE 110367570 63 BREATHER VALVE 110566080 105
BALL BEARING 040106203 17 BUSH 198517222 17
040109057 53 198517226 17
BANJO BOLT 198486871 131 198517229 17
BAR 185376150 125 28730302 69
BELT 080109107 101 28730303 69
T80109107 101 28730306 69
BIG END BEARING U5ME0030 21 CAMSHAFT 120027070 53

KIT
CAMSHAFT GEAR 120016290 53
BIG END BRG KIT - U5ME0030A 21
CAP 064210012 49
U/S
064210015 107
BLANKING PLATE U98436290 79
064210018 27
BOLT 010109341 65
064210030 27, 27
010111030 121
120186080 27, 27
010211425 141, 141,
163, 163 CIRCLIP 036500028 23, 23
010700860 21 036800010 39
011310655 93, 95
Page 171
Parts Index
CLAMP 199106021 57, 57 CYLINDER HEAD U11211220 105

COVER
CLIP 0180067 139, 139,
139, 139, U11217422 105
153, 153,
153, 153 DIPSTICK 198416690 77
0180072 109 DIPSTICK TUBE 110756490 77
21825194 109 DOWEL 030500612 17, 21,

21, 21, 21
2481882 123, 123,
123, 123 030500616 17
COLLAR 199236540 39 030501025 17
CON ROD 115026330 23 DRAIN PLUG 26560183 167

ASSEMBLY
DRIVE 28730301 69
CON ROD BOLT 115176140 23
ENGINE MOUNT U45977370 141, 163
CON ROD NUT 020109120 23
U45977380 141, 163
CONNECTION 140546020 87
EXHAUST 135617120 115
145226320 97 MANIFOLD
CONNECTION KIT 20195 165 EXHAUST VALVE 120176380 27
CONTROL LEVER 125046613 47 EXTENSION 145386910 145, 157
125306151 47 FAN 145306880 143
125416440 129 U45307130 145, 155,

157
COVER 140116220 39
FAN GUARD T413025 159
U65206940 103
T413163 159
W14501020 109
U75316330 147, 149
CRANKSHAFT 115256990 21
ASSEMBLY U75316371 147
CRANKSHAFT U15276270 21 U75316390 149

GEAR
U75316400 149
CRANKSHAFT U15397401 89
FLANGE W14120360 117, 117
PULLEY
FLYWHEEL U15357940 65
CYLINDER HEAD 111011030 27, 27
ASSEMBLY
ASSEMBLY
Page 172
Parts Index
FLYWHEEL U10447441 63 GASKET - 135996780 115

HOUSING EXHAUST
MANIFOLD
FUEL FILTER 130306360 167
GASKET - SUMP 110996920 75
FUEL FILTER 2656613 121
ASSEMBLY U10996920 75
FUEL FILTER BOWL 26560182 167 GASKET - 145996051 97

THERMOSTAT HSG
FUEL FILTER KIT 26561117 121
145996930 93, 95
FUEL INJECTION 131507520 57
PIPE U45996051 97
131507530 57 U45996930 93, 95
131507540 57 GASKET - TIMING 165996590 19

CASE
131507550 57
165996630 41
FUEL INJECTION 131010080 55
PUMP U65996630 41
GASKET 135996950 105 U65996640 45
145996921 91 GAUZE 110666060 105
165996640 45 GLOWPLUG 185366190 125
U35996951 105 GUARD U75316312 147
U65996590 19 GUDGEON PIN 115326220 23
GASKET - CYL. 111996401 105 HOLDER 110156360 21

HEAD COVER
110156370 21
GASKET - 111147711 29
CYLINDER HEAD 110156380 21
111147721 29 110156390 21
111147751 31 28730307 69
111147761 31 HOSE 068209126 123
111147771 31 145537300 91
111147780 31 T68209189 123
GASKET - 314990013 117, 117 U35597790 109

EXHAUST
U45537130 139, 153
Page 173
Parts Index
U45537140 139, 153 020109177 49
HOSE - FUEL 068209227 123 020109239 49
T68209628 123 020800010 47
HOSE CLIP 067100015 123, 123, 020900008 99

123, 123
020900010 121
20186 147, 149,
151 023100004 125
2481877 91, 91 023100006 41, 57,

91, 93,
INDICATOR 26510402 111 95, 105
INJECTOR 131406440 59 023100008 45, 55,

109, 115,
INTAKE VALVE 120166380 27 137, 137,
161, 161
120166390 27
023100010 33
KEY 030509020 21
024500006 47
034100508 53, 89
024600010 105
KIT 28730308 69
2318A207 45
LABEL 2638C245 113
2318A401 149
LEVER U85727130 99
2318A604 63, 71,
LIFT PUMP 130506350 119
103
LIFTING EYE U95816760 127, 127
2648A120 45
MAIN AIR FILTER 135326206 111
OIL FILLER CAP 198436390 83
MAIN BEARING KIT U5MB0025 21
U98436350 83
U5MB0025A 21
OIL FILTER 140517050 85
METRIC BOLT 011100408 105
OIL PIPE 140607020 35
MOUNTING U98116931 137, 161
OIL PRESSURE 185246290 131
NEEDLE BEARING 042309017 17 SWITCH
042309018 17 OIL PUMP IDLER U5MK8267 39

GEAR
NUT 020109076 33
OIL SUCTION 140406730 75
020109086 89 STRAINER
Page 174
Parts Index
U40406790 75 198466010 17
OLIVE 33811114 123, 123 198466020 17
PIN 030300414 43 198466920 17
030309005 17 198466940 17
031100004 47 2487646 63
PIPE - AIR 135566570 105 32184226 123
PIPE - FUEL INJ U31607080 61 U98466960 47

LEAK OFF
PRE-FUEL FILTER 130306380 167
U31607160 61 ASSY
PIPE - LOW 131246290 123, 123 PRIMER 130506300 169

PRESSURE FUEL
PUSHROD 120456310 33
PIPE - OIL SUCTION 140987090 75
RADIATOR U45506580 135, 151
PISTON AND RING 115017491 23
KIT RADIATOR CAP 24850072 135, 151
PISTON AND RING 115017705 23 RELIEF VALVE 140036220 37

KIT - O/S
RING 198346160 49, 49
PISTON RING KIT 115107970 23
ROCKER ARM 120356131 33
PISTON RING KIT - 115107975 23 ASSEMBLY
OVERSIZE
120356141 33
PLATE 110666280 105
ROCKER BOX 120037240 33
199566750 53
ROCKER SHAFT 120316201 33
U65166670 103
ROCKER SHAFT 198217170 33
PLUG 064100045 17 SPRING
064209055 17, 17, 17 SCREW 010109235 75, 77
064210010 27 010109238 81
064210025 17, 27, 27 010109406 21, 21,

21, 21
064400010 131
010109600 143, 155
064500030 93, 95
010110625 57
0650204 123
010800820 55
0650588 93, 95
Page 175
Parts Index
011310612 19, 53, 2314H002 137, 147,

75, 77, 79 161
011310620 105 2314H003 109, 121,

137, 141,
011310635 33, 91 141, 161,
163, 163
011310640 41, 105
2314H004 99, 99
011310660 41, 105
2314H005 109, 149
011510812 147, 149,
159 2314H022 99
011510816 63 2314H102 63
011510820 99, 121, 2314J003 141, 163
127
2314J004 63, 63,
011510825 97, 99, 71, 121
99, 117,
117, 121 2314J006 63
011510860 115 2314J007 71
011511020 63 2314J014 103
011511045 63 SEAL 0490786 121, 121
011511070 21, 21, 21 SEAL - FRONT END 198636160 43

OIL
012810635 45, 45
SEAL - INJECTOR 131426200 59
015600406 105
131426230 59
111136480 29, 31
U31426200 59
111136490 29, 31
SEAL - O RING 052100070 45
131046650 49
052100080 47
2311D559 55
052100100 77, 79, 79
2314F002 75
052100280 83
2314F003 119
052100400 83
2314F004 45, 159,
161 052109076 33, 75
2314F006 141, 145, 052109078 37

157, 163
2415A070 119
Page 176
Parts Index
26560014 121 SPACER 199216340 109
26560184 167 U99216320 53
SEAL - REAR END 050209083 25 SPRING 198211110 45

OIL
198216720 39
SEAL - ROCKER 120996130 33
BOX 198217750 45
SEAL - VALVE 120406050 27 198217880 47

STEM
198217910 49
120406070 27
STARTER MOTOR 185086600 67, 69
SETSCREW 2314J604 63
U5MK8261 71
SHAFT 125116211 47
STARTER MOTOR - U5MK8261R 71
125116221 47 EXCHANGE
SHIM 131437491 55 STARTER RING U15376160 65
131437501 55 STUD 010109441 17
131437511 55 012109044 33
131437521 55 012110635 17
131437531 55 012110655 29, 31
131437731 55 012110660 17
131437761 55 012110860 29, 31
199286150 39 T12119005 105
199286160 39 SUMP 110708390 75
199286170 39 SUMP DRAIN PLUG T10109238 81
199286180 39 SUPPORT BRACKET TPN508 121
SHROUD 24850083 135, 151 TAPPET 120116160 33
SLIDER 125256250 53 TERMINAL KIT U85656070 71
SMALL END BUSH 198517265 23 THERMOSTAT 145206230 93, 95
SOLENOID 28730304 69 THERMOSTAT 145046110 93

HOUSING
U85206452 129
U45046111 95
U85206520 129
Page 177
Parts Index
THRUST WASHER 199266200 21, 21 0920154 123
199266210 21 140996260 35, 35,

131, 131
199266270 39
140996270 105
TIMING CASE U65116730 43
199280300 33
TOOL 198217970 51
2411D010 123
VALVE 26510194 111
WATER PUMP U45010062 91
VALVE COLLET 120226070 27, 27
WATER PUMP 145336620 73
VALVE SEAT U10136460 27 PULLEY
INSERT
WATER W85720580 133
U10136470 27 TEMPERATURE
SWITCH
VALVE SPRING 198216700 27, 27
VALVE SPRING CAP 120216041 27, 27
WASHER 025100006 47, 49
025100008 61, 61
025100010 49
025100016 81, 129
026100008 99, 121,

127
026109017 99
026200010 121
027100008 55, 99
027100010 121
0920146 123
Page 178

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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

How to use your Parts Book

Parts Lists & Illustrations

For fitting instructions please refer to your engine Service Manual.

Section Page Section Page

Level 1 - Service 11 Relief Valve 37

Level 2 - Repair 13 Oil Pump 39

Level 3 - Overhaul 15 Timing Case 41

Cylinder Block 17 Timing Case 43

Cylinder Block 19 Timing Case 45

Crankshaft, Pistons & Connecting Rods 21 Timing Case 47

Crankshaft, Pistons & Connecting Rods 23 Timing Case 49

Rear End Oil Seal 25 Miscellaneous 51

Cylinder Head 27 Camshaft & Gears 53

Cylinder Head 29 Fuel Injection Pump 55

Cylinder Head 31 High Pressure Fuel Pipes 57

Rocker Shaft Assembly 33 Atomisers 59

Pipes 35 Fuel Leak-Off Pipe 61

Section Page Section Page

Flywheel Housing 63 Front End Drive Input 89

Flywheel & Starter Ring 65 Water Pump 91

Starter Motor 67 Thermostat & Housing 93

Starter Motor Breakdown 69 Thermostat & Housing 95

Starter Motor 71 Water Outlet & Inlet 97

Sump 75 Drive Belt & Tensioner 101

Dipstick & Filler Tube 77 Blanking Plates 103

Dipstick & Filler Tube 79 Cylinder Head Cover 105

Sump 81 Feed Pipes 107

Filler 83 Air Filter Assembly 109

Oil Filter 85 Air Filter Assembly 111

Oil Filter 87 Air Filter Assembly 113

Section Page Section Page

Exhaust Manifold 115 Radiator & Cowling 141

Exhaust Connection 117 Fan 143

Lift Pump 119 Fan 145

Fuel Filter 121 Guards 147

Pipework & Connections 123 Guards 149

Cold Start System 125 Radiator & Cowling 151

Engine Lifting Eyes 127 Radiator & Cowling 153

Throttle & Stop Controls 129

Radiator & Cowling 135

Radiator & Cowling 137

Radiator & Cowling 139

Engine Mounts 163

Fuel Pre-Lift Pump 167

Fuel Pre-Lift Pump 169

A From Engine Number

B Upto Engine Number

C Repairs and Replaces

D See Appropriate Section - Reference Number

H New for Old Part

O Reference for Detailed Breakdown

P Other Service Options Available

R See History Section