service repair manual

1. SEBP2658-25
October 2007
Parts
Manual See “General Information”
for New Parts Manual
Features.
3406C Marine Engine
4TB3482-Up (Engine)
This Parts Manual is also Available in .PDF Format on Compact Disc
(CD-ROM) - Caterpillar Form No. SERP2658

2. TABLE OF CONTENTS
Name Page Name Page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . A18
REPAIR ALTERNATIVES . . . . . . . . . . . . . . . . . . . . A28
SUPPLEMENTAL COOLANT ADDITIVES . . . . . . A33
MAINTENANCE PARTS . . . . . . . . . . . . . . . . . . . . . . A38
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A60
ENGINE ARRANGEMENT . . . . . . . . . . . . . . . . . . . . 1
ENGINE AR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
BASIC ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ADAPTER GP-OIL PAN DRAIN . . . . . . . . . . . . 34
AIR COMPRESSOR GP . . . . . . . . . . . . . . . . . . . . 35
BARRING GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
CAMSHAFT GP . . . . . . . . . . . . . . . . . . . . . . . . . . 43
CLUTCH GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
COVER GP-CYLINDER BLOCK . . . . . . . . . . . . 46
COVER GP-FLYWHEEL HOUSING . . . . . . . . 50
COVER GP-FRONT HOUSING . . . . . . . . . . . . 51
COVER GP-VALVE MECHANISM . . . . . . . . . . 55
CRANKSHAFT GP . . . . . . . . . . . . . . . . . . . . . . . . 56
CYLINDER BLOCK AS . . . . . . . . . . . . . . . . . . . . 57
CYLINDER BLOCK GP . . . . . . . . . . . . . . . . . . . . 58
CYLINDER HEAD AS . . . . . . . . . . . . . . . . . . . . . . 86
CYLINDER HEAD GP . . . . . . . . . . . . . . . . . . . . . . 90
DAMPER & PULLEY GP . . . . . . . . . . . . . . . . . . 98
DAMPER GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
DRIVE GP-ACCESSORY . . . . . . . . . . . . . . . . . . 104
DRIVE GP-AUXILIARY . . . . . . . . . . . . . . . . . . . . 108
DRIVE GP-FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
DRIVE GP-PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 113
FASTENER GP-FRONT HOUSING . . . . . . . . 114
FLYWHEEL GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
GEAR GP-FRONT . . . . . . . . . . . . . . . . . . . . . . . . 116
GUARD GP-DAMPER . . . . . . . . . . . . . . . . . . . . . . 117
HOUSING GP-FLYWHEEL . . . . . . . . . . . . . . . . 119
HOUSING GP-FRONT . . . . . . . . . . . . . . . . . . . . 122
KIT-CRANKSHAFT BEARING . . . . . . . . . . . . . . 124
LIFTING GP-ENGINE . . . . . . . . . . . . . . . . . . . . . . 125
LINER-CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . 126
LINES GP-AIR COMPRESSOR . . . . . . . . . . . . 127
MOUNTING GP-ALTERNATOR . . . . . . . . . . . . 129
MOUNTING GP-HYD PUMP DRIVE . . . . . . . . 135
PAN GP-OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
PARTS GP-MISCELLANEOUS . . . . . . . . . . . . . . 138
PISTON & ROD GP . . . . . . . . . . . . . . . . . . . . . . . . 140
POWER TAKE-OFF GP . . . . . . . . . . . . . . . . . . . . 143
PULLEY GP-AUXILIARY DRIVE . . . . . . . . . . . . 144
PULLEY GP-CRANKSHAFT . . . . . . . . . . . . . . . . 145
ROCKER ARM GP . . . . . . . . . . . . . . . . . . . . . . . . 146
SUPPORT GP-ENGINE . . . . . . . . . . . . . . . . . . . . 148
VALVE MECHANISM GP . . . . . . . . . . . . . . . . . . 152
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . 154
BASE GP-OIL FILTER . . . . . . . . . . . . . . . . . . . . 154
BREATHER GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
FASTENER GP-OIL PUMP MOUNTING . . . . . . 157
FILTER AS-ENGINE OIL . . . . . . . . . . . . . . . . . . 158
FILTER GP-ENGINE OIL . . . . . . . . . . . . . . . . . . 159
GAUGE GP-OIL FILTER PRESS DIFF . . . . . . 165
GAUGE GP-OIL LEVEL (DIPSTICK) . . . . . . . . 166
LINES GP-ENGINE OIL . . . . . . . . . . . . . . . . . . . . 171
LINES GP-SUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 176
LINES GP-TURBOCHARGER OIL . . . . . . . . . . 178
PUMP GP-ENGINE OIL . . . . . . . . . . . . . . . . . . . . 181
PUMP GP-SUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 184
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 188
CONNECTION GP-EXPANSION TANK . . . . . . 188
COOLANT CONDITIONER GP . . . . . . . . . . . . 189
COOLER GP-ENGINE OIL . . . . . . . . . . . . . . . . 191
COOLER GP-TRANSMISSION OIL . . . . . . . . 192
COVER GP-COOLING SYSTEM . . . . . . . . . . . . 193
COVER GP-MARINE TMSN COOLER . . . . . . 194
FAN GP-BLOWER . . . . . . . . . . . . . . . . . . . . . . . . 195
FILLER & CAP GP . . . . . . . . . . . . . . . . . . . . . . . . 196
FOOT VALVE & STRAINER AS . . . . . . . . . . . . 198
HEAT EXCHANGER GP-SEA WATER . . . . . . 199
HOUSING & REGULATOR GP . . . . . . . . . . . . . . 206
LINES GP-AFTERCOOLER WATER . . . . . . . . 208
LINES GP-HYDRAULIC OIL COOLER . . . . . . 210
LINES GP-WATER . . . . . . . . . . . . . . . . . . . . . . . . 212
PUMP AS-BILGE . . . . . . . . . . . . . . . . . . . . . . . . . . 229
PUMP GP-AUXILIARY SEA WATER . . . . . . . . 231
PUMP GP-AUXILIARY WATER . . . . . . . . . . . . 246
PUMP GP-BILGE . . . . . . . . . . . . . . . . . . . . . . . . . . 249
PUMP GP-WATER . . . . . . . . . . . . . . . . . . . . . . . . 251
RADIATOR GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
SWITCH GP-COOLANT LEVEL . . . . . . . . . . . . 263
TANK GP-EXPANSION . . . . . . . . . . . . . . . . . . . . 265
AIR INLET AND EXHAUST SYSTEM . . . . . . . . . . 268
ADAPTER GP-AIR CLEANER . . . . . . . . . . . . . . 268
AFTERCOOLER GP-WATER . . . . . . . . . . . . . . 269
AIR CLEANER GP . . . . . . . . . . . . . . . . . . . . . . . . 270
CAP AS-RAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
CARTRIDGE GP-TURBOCHARGER . . . . . . . . 278
COVER GP-TURBOCHARGER DRAIN . . . . . . 285
ELBOW GP-EXHAUST . . . . . . . . . . . . . . . . . . . . 286
ELBOW-EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . 292
FITTING GP-EXHAUST . . . . . . . . . . . . . . . . . . . . 294
FLANGE GP-EXHAUST . . . . . . . . . . . . . . . . . . . . 296
LINES GP-AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
MANIFOLD GP-EXHAUST . . . . . . . . . . . . . . . . 303
MANIFOLD GP-INLET . . . . . . . . . . . . . . . . . . . . 304
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
MUFFLER GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
PIPE GP-EXHAUST . . . . . . . . . . . . . . . . . . . . . . 308
SEBP2658-25 TABLE OF CONTENTS A1

3. TABLE OF CONTENTS
Name Page Name Page
PRECLEANER AS . . . . . . . . . . . . . . . . . . . . . . . . 310
PRECLEANER GP . . . . . . . . . . . . . . . . . . . . . . . . 311
SHUTOFF GP-AIR . . . . . . . . . . . . . . . . . . . . . . . . 312
TURBOCHARGER GP . . . . . . . . . . . . . . . . . . . . 316
TURBOCHARGER GP-WATER
COOLED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
VALVE GP-AIR CONTROL . . . . . . . . . . . . . . . . 332
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
ACTUATOR GP-AIR . . . . . . . . . . . . . . . . . . . . . . 333
CABLE AS-GOVERNOR CONTROL . . . . . . . . 334
CONTROL AR-GOVERNOR . . . . . . . . . . . . . . . . 337
CONTROL GP-FUEL RATIO . . . . . . . . . . . . . . . . 338
CONTROL GP-GOVERNOR . . . . . . . . . . . . . . . . 342
COVER GP-FUEL TRANSFER . . . . . . . . . . . . 349
DRAIN GP-FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . 350
DRIVE GP-GOVERNOR & FUEL PUMP . . . . . . 352
DRIVE GP-TACHOMETER . . . . . . . . . . . . . . . . 359
FASTENER GP-FUEL INJ PUMP . . . . . . . . . . 361
FILTER & LINES GP-FUEL . . . . . . . . . . . . . . . . 363
FILTER GP-FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . 366
GOVERNOR GP . . . . . . . . . . . . . . . . . . . . . . . . . . 372
INJECTOR GP-FUEL . . . . . . . . . . . . . . . . . . . . . . 384
LINES GP-FLEXIBLE FUEL . . . . . . . . . . . . . . . . 385
LINES GP-FUEL FILTER . . . . . . . . . . . . . . . . . . 386
LINES GP-FUEL INJECTION . . . . . . . . . . . . . . 390
LINES GP-FUEL RATIO CONTROL . . . . . . . . 410
NOZZLE AS-FUEL VALVE . . . . . . . . . . . . . . . . . . 411
PUMP & MTG GP-FUEL TRANSFER . . . . . . . . 412
PUMP GP-FUEL INJECTION . . . . . . . . . . . . . . 413
PUMP GP-FUEL PRIMING . . . . . . . . . . . . . . . . 437
PUMP GP-FUEL TRANSFER . . . . . . . . . . . . . . 439
PUMP GP-GOV & FUEL INJ . . . . . . . . . . . . . . . . 440
PUMP GP-UNIT INJECTION . . . . . . . . . . . . . . . . 450
SEPARATOR GP-WATER . . . . . . . . . . . . . . . . . . 451
TORQUE CONTROL GP . . . . . . . . . . . . . . . . . . 452
VALVE GP-FUEL RELIEF . . . . . . . . . . . . . . . . . . 454
ELECTRICAL AND STARTING SYSTEM . . . . . . 455
ADAPTER-SENSOR . . . . . . . . . . . . . . . . . . . . . . 455
ALTERNATOR GP-CHARGING . . . . . . . . . . . . 456
BATTERY GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484
BOX GP-JUNCTION . . . . . . . . . . . . . . . . . . . . . . 491
CAMERA GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 501
CONTACTOR AS-WATER TEMP . . . . . . . . . . . . 503
CONTACTOR GP . . . . . . . . . . . . . . . . . . . . . . . . . . 504
CONTACTOR GP-ALARM . . . . . . . . . . . . . . . . . . 508
CONTACTOR GP-TEMPERATURE . . . . . . . . 510
CONTROL GP-MANUAL VOLTAGE . . . . . . . . 511
CONTROL GP-VOLTAGE . . . . . . . . . . . . . . . . . . 512
CONVERSION GP-WIRING . . . . . . . . . . . . . . . . 514
DIODE GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 515
FASTENER GP-WIRING HARNESS . . . . . . . . 516
HARNESS AS-THERMOCOUPLE . . . . . . . . . . 519
HARNESS AS-WIRING . . . . . . . . . . . . . . . . . . . . 520
LUBRICATOR GP-AIR MOTOR . . . . . . . . . . . . 523
MODULE GP-INTERFACE . . . . . . . . . . . . . . . . 524
MOUNTING GP-CONTACTOR . . . . . . . . . . . . . . 526
SENSOR GP-SPEED . . . . . . . . . . . . . . . . . . . . . . 529
SHUTOFF GP-ELECTRICAL . . . . . . . . . . . . . . 534
SILENCER GP-AIR STARTING . . . . . . . . . . . . 538
SOLENOID GP-SHUTOFF . . . . . . . . . . . . . . . . 540
STARTING AID GP-ETHER . . . . . . . . . . . . . . . . 543
STARTING MOTOR GP-AIR . . . . . . . . . . . . . . . . 545
STARTING MOTOR GP-ELECTRIC . . . . . . . . 561
SUPPORT GP-BATTERY . . . . . . . . . . . . . . . . . . 608
SWITCH AS-TEMPERATURE . . . . . . . . . . . . . . 609
SWITCH GP-ENGINE . . . . . . . . . . . . . . . . . . . . . . 610
SWITCH GP-HEAT START . . . . . . . . . . . . . . . . 612
SWITCH GP-REMOTE STARTING . . . . . . . . . . 613
SWITCH GP-START . . . . . . . . . . . . . . . . . . . . . . 614
SWITCH GP-STARTING AID . . . . . . . . . . . . . . 617
SWITCH GP-TEMPERATURE . . . . . . . . . . . . . . 619
THERMOCOUPLE . . . . . . . . . . . . . . . . . . . . . . . . 621
VALVE GP-AIR STARTING . . . . . . . . . . . . . . . . 622
VALVE GP-PRESSURE REDUCING . . . . . . . . 624
WIRING GP-ALTERNATOR . . . . . . . . . . . . . . . . 625
WIRING GP-ENGINE . . . . . . . . . . . . . . . . . . . . . . 626
WIRING GP-PANEL . . . . . . . . . . . . . . . . . . . . . . . . 626
WIRING GP-SHUTOFF . . . . . . . . . . . . . . . . . . . . 628
OPERATOR STATION . . . . . . . . . . . . . . . . . . . . . . . . 629
AMMETER GP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 629
BOX GP-INSTRUMENT PANEL . . . . . . . . . . . . 631
GAUGE GP-AIR INLET
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . 632
GAUGE GP-COOLANT
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . 633
GAUGE GP-ENGINE OIL PRESSURE . . . . . . 635
GAUGE GP-ENGINE PERCENT LOAD . . . . . . 639
GAUGE GP-FUEL CONSUMPTION
RATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640
GAUGE GP-FUEL LEVEL . . . . . . . . . . . . . . . . . . 643
GAUGE GP-FUEL PRESSURE . . . . . . . . . . . . 645
GAUGE GP-FUEL TEMPERATURE . . . . . . . . 647
GAUGE GP-GEAR OIL PRESSURE . . . . . . . . 648
GAUGE GP-MANIFOLD AIR TEMP . . . . . . . . 650
GAUGE GP-MANIFOLD PRESSURE . . . . . . . . 652
GAUGE GP-MARINE GEAR OIL . . . . . . . . . . . . 653
GAUGE GP-OIL TEMPERATURE . . . . . . . . . . 654
LINES GP-INSTRUMENT PANEL . . . . . . . . . . 657
METER GP-SERVICE . . . . . . . . . . . . . . . . . . . . . . 660
MOUNTING GP-INSTRUMENT PANEL . . . . . . 665
MOUNTING GP-TACHOMETER . . . . . . . . . . . . 669
PANEL GP-INSTRUMENT . . . . . . . . . . . . . . . . . . 670
PYROMETER GP . . . . . . . . . . . . . . . . . . . . . . . . . . 683
SPEEDOMETER GP . . . . . . . . . . . . . . . . . . . . . . 684
TACHOMETER GP-ELECTRIC . . . . . . . . . . . . 685
VOLTMETER GP . . . . . . . . . . . . . . . . . . . . . . . . . . 689
A2 TABLE OF CONTENTS SEBP2658-25

4. TABLE OF CONTENTS
Name Page Name Page
MARINE TRANSMISSION . . . . . . . . . . . . . . . . . . . . 693
FASTENER GP-MARINE TMSN . . . . . . . . . . . . 693
KIT-HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 696
KIT-LOCK & SEALING . . . . . . . . . . . . . . . . . . . . 697
MOUNTING GP-MARINE TMSN . . . . . . . . . . . . 701
PUMP AS-MARINE TMSN OIL . . . . . . . . . . . . . . 712
TRANSMISSION GP-MARINE . . . . . . . . . . . . . . 714
VALVE AS-CONTROL . . . . . . . . . . . . . . . . . . . . . . 830
SERVICE EQUIPMENT AND SUPPLIES . . . . . . 836
CHART-AUTOMATIC START/STOP . . . . . . . . 836
CHART-INSTRUMENT PANEL . . . . . . . . . . . . . . 839
CHART-MECHANICAL CONTROLS . . . . . . . . 842
CHART-PLATE & FILM . . . . . . . . . . . . . . . . . . . . 849
INSERT-LINER SEAT . . . . . . . . . . . . . . . . . . . . . . 849
KIT-ENGINE PARTS . . . . . . . . . . . . . . . . . . . . . . 849
KIT-MARINE TRANSMISSION . . . . . . . . . . . . . . 855
KIT-RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 857
PART NUMBER INDEX . . . . . . . . . . . . . . . . . . . . . . B1
SEBP2658-25 TABLE OF CONTENTS A3

5. BASIC ENGINE
4N-2272 COVER GP-VALVE MECHANISM
SMCS-1107 i02399318
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME
1 2 3 4 5 6 (PRODUCT LEVEL)
SEE
PAGE
C 1 1 7E-0330 1 COVER (ROCKER ARM)
2 1 7C-6514 2 ADAPTER
1 8C-5196 2 SEAL-O-RING
C 3 1 7E-0329 2 BASE
4 1 9L-8925 26 BOLT (5/16-18X1.25-IN)
BD 5 1 5P-5678 SEAL
C 6 1 7E-0333 1 COVER
7 1 6N-2985 1 CAP AS-FILLER (ENGINE OIL)
B-USE AS REQUIRED
C-CHANGE FROM PREVIOUS TYPE
D-ORDER BY THE METER
GRAPHIC #1 <END> g00953101
SEBP2658-25 1 of 1 BASIC ENGINE 55

6. BASIC ENGINE
4N-0741 CRANKSHAFT GP
SMCS-1202 i02854173
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME
1 2 3 4 5 6 (PRODUCT LEVEL)
SEE
PAGE
1 1 211-0592 7 BEARING-MAIN (STANDARD)
AB 1 4W-5698 BEARING-MAIN (0.63-MM US)
AB 1 4W-5699 BEARING-MAIN (1.27-MM US)
AB 1 4W-5700 BEARING-MAIN (0.63-MM OS)
AB 1 4W-5701 BEARING-MAIN (0.63-MM US - 0.63-MM OS)
R 2 1 6I-1453 1 CRANKSHAFT AS
2A 1 1W-9302 1 GEAR-CRANKSHAFT (80-TEETH)
2B 1 7S-5005 1 DOWEL
2C 1 4N-0684 1 DOWEL
3 1 253-1752 2 PLATE-THRUST
4 1 142-5868 1 SEAL GP-CRANKSHAFT (REAR)
5 1 142-5867 1 SEAL GP-CRANKSHAFT (FRONT)
A-NOT PART OF THIS GROUP
B-USE AS REQUIRED
R-REMFG PART MAY BE AVAILABLE
GRAPHIC #1 <END> g01421579
56 BASIC ENGINE 1 of 1 SEBP2658-25

7. BASIC ENGINE
202-1257 CYLINDER BLOCK AS
S/N: 4TB7397-UP
PART OF 152-7642 CYLINDER BLOCK GP
SMCS-1201 i01570723
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME
1 2 3 4 5 6 (PRODUCT LEVEL)
SEE
PAGE
1 1 167-8081 7 CAP-CRANKSHAFT BEARING
2 1 167-8083 14 BOLT (7/8-14X7.5-IN)
3 1 9H-1031 14 WASHER-HARD (24X41.5X6-MM THK)
GRAPHIC #1 <END> g00816962
SEBP2658-25 1 of 1 BASIC ENGINE 57

8. BASIC ENGINE
4P-3720 CYLINDER BLOCK GP
S/N: 4TB3482-4209
FIELD REPLACEMENT FOR 7E-4697–PAGE 60: FOR 8N-9267–PAGE 66
FIELD INSTALLATION
SMCS-1201 i01883678
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME
1 2 3 4 5 6 (PRODUCT LEVEL)
SEE
PAGE
1 1 4K-1388 1 SEAL-O-RING
2 1 9F-2247 3 PLUG-PIPE
3 1 7M-7410 1 PLUG-PIPE
4 1 9S-8009 3 PLUG
5 1 7H-3171 3 PLUG-PIPE
6 1 4P-2098 1 CYLINDER BLOCK AS
1 4N-5857 1 CAP-CRANKSHAFT BEARING
1 3P-1323 14 BOLT-BEARING CAP (7/8-14X7.75-IN)
1 9H-1031 14 WASHER-HARD (24X41.5X6-MM THK)
7 1 5M-6214 1 PLUG-PIPE
8 1 3J-5389 1 PLUG
9 1 030-7571 4 BOLT (3/8-16X1-IN)
10 1 4W-8585 1 COVER
11 1 7W-6081 1 GASKET
12 1 2M-6471 2 PLUG-CUP
13 1 4N-6658 1 BEARING-SLEEVE (1.3-IN WIDE)
14 1 4N-0685 6 BEARING-SLEEVE (1-IN WIDE)
15 1 3J-5390 6 PLUG
16 1 2M-9780 2 SEAL-O-RING
17 1 8S-9094 1 PLUG-ORIFICE
18 1 9S-4190 2 PLUG-O-RING
58 BASIC ENGINE 1 of 2 SEBP2658-25

9. BASIC ENGINE
4P-3720 CYLINDER BLOCK GP (contd. ) i01883678
GRAPHIC #1 <END> g00953159
SEBP2658-25 2 of 2 BASIC ENGINE 59

10. BASIC ENGINE
7E-4697 CYLINDER BLOCK GP*R
S/N: 4TB4382-6186
FIELD REPLACEMENT ORDER 108-3916–PAGE 77, 152-7642–PAGE 79, 6-7E-3632
JET AS-PISTON COOLING, 6-111-8606 BOLT
SMCS-1201 i02575828
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME
1 2 3 4 5 6 (PRODUCT LEVEL)
SEE
PAGE
1 1 7E-3632 6 JET AS-PISTON COOLING
C 2 1 8T-6757 3 PLUG-PIPE
3 1 7W-6534 1 PLUG-PIPE
4 1 108-3913 1 CYLINDER BLOCK AS
4A 1 9L-5854 6 BAND-FILLER (130.2-MM ID)
4B 1 110-2220 6 SEAL-LINER (141-MM ID)
4C 1 142-7072 6 SEAL-LINER (140.2-MM ID)
4D 1 142-6217 6 SEAL-O-RING
4E 1 3P-1323 14 BOLT-BEARING CAP (7/8-14X7.75-IN)
4F 1 9H-1031 14 WASHER-HARD (24X41.5X6-MM THK)
4G 1 2W-6000 6 LINER-CYLINDER
4H 1 4N-5857 7 CAP-CRANKSHAFT BEARING
C 5 1 8T-6763 3 PLUG-PIPE
6 1 1S-9540 2 DOWEL
7 1 3S-5496 2 SEAL-O-RING
C 8 1 7W-6492 1 PLUG-PIPE
9 1 119-5155 1 SEAL-O-RING
10 1 030-7571 4 BOLT (3/8-16X1-IN)
11 1 4W-8585 1 COVER
12 1 7W-6081 1 GASKET
13 1 4N-0683 4 DOWEL
14 1 4N-1650 2 DOWEL
C 15 1 6I-2981 1 PLATE-BLOCK
C 16 1 6I-4024 1 GASKET-PLATE
17 1 8S-9094 1 PLUG-ORIFICE
B 18 1 9S-4190 2 PLUG-O-RING
B 19 1 114-4427 2 SEAL-O-RING
C 20 1 7X-7732 6 PLUG-PIPE
21 1 7E-6479 6 BOLT-SPECIAL (OIL JET)
22 1 4N-0685 6 BEARING-SLEEVE (1-IN WIDE)
23 1 4N-6658 1 BEARING-SLEEVE (1.3-IN WIDE)
C 24 1 8T-6764 1 PLUG-PIPE
25 1 9S-8009 1 PLUG
26 1 100-7399 2 PLUG
27 1 3E-6747 2 SEAL-O-RING
28 1 9S-4182 1 PLUG-O-RING
29 1 9X-7378 1 SEAL-O-RING
FA 1 101-0523 6 INSERT-LINER SEAT (5.21-MM THK) (0.05MM US)
A-NOT PART OF THIS GROUP
B-USE AS REQUIRED
C-CHANGE FROM PREVIOUS TYPE
F-NOT SHOWN
60 BASIC ENGINE 1 of 2 SEBP2658-25

11. BASIC ENGINE
7E-4697 CYLINDER BLOCK GP (contd. ) i02575828
GRAPHIC #1 <END> g00952384
SEBP2658-25 2 of 2 BASIC ENGINE 61

12. BASIC ENGINE
7E-4697 CYLINDER BLOCK GP*R
S/N: 4TB6187-7396
FIELD REPLACEMENT ORDER 108-3916–PAGE 77, 152-7642–PAGE 79, 6-7E-3632
JET AS-PISTON COOLING, 6-111-8606 BOLT
SMCS-1201 i02575837
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME
1 2 3 4 5 6 (PRODUCT LEVEL)
SEE
PAGE
C 1 1 151-5928 6 JET AS-PISTON COOLING
2 1 8T-6757 3 PLUG-PIPE
3 1 7W-6534 1 PLUG-PIPE
4 1 9S-8009 1 PLUG
5 1 8T-6763 3 PLUG-PIPE
6 1 1S-9540 2 DOWEL
7 1 3S-5496 2 SEAL-O-RING
8 1 7W-6492 1 PLUG-PIPE
9 1 030-7571 4 BOLT (3/8-16X1-IN)
10 1 4W-8585 1 COVER
11 1 7W-6081 1 GASKET
12 1 9X-7378 1 SEAL-O-RING
13 1 4N-0683 4 DOWEL
14 1 4N-1650 2 DOWEL
15 1 6I-2981 1 PLATE-BLOCK
16 1 6I-4024 1 GASKET-PLATE
17 1 8S-9094 1 PLUG-ORIFICE
B 18 1 9S-4190 2 PLUG-O-RING
B 19 1 114-4427 2 SEAL-O-RING
20 1 7X-7732 6 PLUG-PIPE
C 21 1 151-5925 6 BOLT (7/16-14-2A-THD)
24 1 8T-6764 1 PLUG-PIPE
CY 25 1 152-7646 1 CYLINDER BLOCK GP 84
26 1 119-5155 1 SEAL-O-RING
27 1 100-7399 2 PLUG
28 1 3E-6747 2 SEAL-O-RING
29 1 9S-4182 1 PLUG-O-RING
FA 1 101-0523 6 INSERT-LINER SEAT (5.21-MM THK) (0.05MM US)
A-NOT PART OF THIS GROUP
B-USE AS REQUIRED
C-CHANGE FROM PREVIOUS TYPE
F-NOT SHOWN
Y-SEPARATE ILLUSTRATION
62 BASIC ENGINE 1 of 2 SEBP2658-25

13. BASIC ENGINE
7E-4697 CYLINDER BLOCK GP (contd. ) i02575837
GRAPHIC #1 <END> g00953174
SEBP2658-25 2 of 2 BASIC ENGINE 63

14. BASIC ENGINE
7E-4697 CYLINDER BLOCK GP*R
FIELD REPLACEMENT ORDER 108-3916–PAGE 77, 152-7642–PAGE 79, 6-7E-3632
JET AS-PISTON COOLING, 6-111-8606 BOLT
SMCS-1201 i02575839
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME
1 2 3 4 5 6 (PRODUCT LEVEL)
SEE
PAGE
1 1 151-5928 6 JET AS-PISTON COOLING
2 1 8T-6757 3 PLUG-PIPE
3 1 7W-6534 1 PLUG-PIPE
4 1 9S-8009 1 PLUG
5 1 8T-6763 3 PLUG-PIPE
6 1 1S-9540 2 DOWEL
7 1 3S-5496 2 SEAL-O-RING
8 1 7W-6492 1 PLUG-PIPE
9 1 030-7571 4 BOLT (3/8-16X1-IN)
10 1 4W-8585 1 COVER
11 1 7W-6081 1 GASKET
12 1 9X-7378 1 SEAL-O-RING
13 1 4N-0683 4 DOWEL
14 1 4N-1650 2 DOWEL
15 1 6I-2981 1 PLATE-BLOCK
16 1 6I-4024 1 GASKET-PLATE
17 1 8S-9094 1 PLUG-ORIFICE
B 18 1 9S-4190 2 PLUG-O-RING
B 19 1 114-4427 2 SEAL-O-RING
20 1 7X-7732 6 PLUG-PIPE
21 1 151-5925 6 BOLT (7/16-14-2A-THD)
24 1 8T-6764 1 PLUG-PIPE
CY 25 1 202-1258 1 CYLINDER BLOCK GP 85
26 1 119-5155 1 SEAL-O-RING
27 1 100-7399 2 PLUG
28 1 250-0466 2 SEAL-O-RING
29 1 9S-4182 1 PLUG-O-RING
FA 1 101-0523 6 INSERT-LINER SEAT (5.21-MM THK)
A-NOT PART OF THIS GROUP
B-USE AS REQUIRED
C-CHANGE FROM PREVIOUS TYPE
F-NOT SHOWN
Y-SEPARATE ILLUSTRATION
64 BASIC ENGINE 1 of 2 SEBP2658-25

15. BASIC ENGINE
7E-4697 CYLINDER BLOCK GP (contd. ) i02575839
GRAPHIC #1 <END> g00799422
SEBP2658-25 2 of 2 BASIC ENGINE 65

16. BASIC ENGINE
8N-9267 CYLINDER BLOCK GP*R
S/N: 4TB3482-4209
FIELD REPLACEMENT ORDER 108-3916–PAGE 77, 152-7642–PAGE 79, 6-111-8606 BOLT,
6-7W-4990 JET AS-PISTON COOLING
SMCS-1201 i01883690
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME
1 2 3 4 5 6 (PRODUCT LEVEL)
SEE
PAGE
1 1 7W-4990 6 JET AS-PISTON COOLING
2 1 8T-6757 3 PLUG-PIPE
B 3 1 7M-7410 1 PLUG-PIPE
4 1 2W-6000 6 LINER-CYLINDER
5 1 8T-6763 3 PLUG-PIPE
6 1 1S-9540 2 DOWEL
7 1 3S-5496 2 SEAL-O-RING
8 1 7W-6492 1 PLUG-PIPE
9 1 030-7571 4 BOLT (3/8-16X1-IN)
10 1 4W-8585 1 COVER
11 1 7W-6081 1 GASKET
12 1 2M-6471 1 PLUG-CUP
13 1 4N-0683 4 DOWEL
14 1 4N-1650 2 DOWEL
15 1 6I-2981 1 PLATE-BLOCK
16 1 6I-4024 1 GASKET-PLATE
17 1 8S-9094 1 PLUG-ORIFICE
18 1 9S-4190 1 PLUG-O-RING
19 1 2M-9780 1 SEAL-O-RING
20 1 8T-6767 6 PLUG-PIPE
21 1 7E-6479 6 BOLT-SPECIAL (OIL JET)
22 1 4N-0685 6 BEARING-SLEEVE (1-IN WIDE)
23 1 4N-6658 1 BEARING-SLEEVE (1.3-IN WIDE)
24 1 8T-6764 1 PLUG-PIPE
25 1 9S-8009 1 PLUG
26 1 4K-1388 1 SEAL-O-RING
27 1 3E-6777 18 SEAL-O-RING
28 1 3P-1323 14 BOLT-BEARING CAP (7/8-14X7.75-IN)
29 1 9H-1031 14 WASHER-HARD (24X41.5X6-MM THK)
30 1 4N-5857 7 CAP-CRANKSHAFT BEARING
31 1 9L-5854 6 BAND-FILLER (130.2-MM ID)
AH 32 1 4W-4588 SLEEVE-LIFTER BORE
AJ 1 4W-6061 SLEEVE-CYLINDER LINER
B 33 1 9S-4190 1 PLUG-O-RING
B 34 1 2M-9780 1 SEAL-O-RING
35 1 100-7399 1 PLUG
36 1 3E-6747 1 SEAL-O-RING
AFH 1 5N-0093 INSERT-LINER SEAT (2.71-MM THK)
AFH 1 2W-3815 INSERT-LINER SEAT (1.605-MM THK)
AFH 1 9Y-3368 INSERT-LINER SEAT (0.822-MM THK)
A-NOT PART OF THIS GROUP
B-USE AS REQUIRED
F-NOT SHOWN
H-FOR SALVAGE OF DAMAGED LIFTER BORES IN CYL BLOCK. QUANTITY TO BE DETERMINED BY USER.
J-FOR SALVAGE OF THE BOTTOM LINER O-RING BORE. QUANTITY TO BE DETERMINED BY USER.
66 BASIC ENGINE 1 of 2 SEBP2658-25

17. BASIC ENGINE
8N-9267 CYLINDER BLOCK GP (contd. ) i01883690
GRAPHIC #1 <END> g00953195
SEBP2658-25 2 of 2 BASIC ENGINE 67

18. Thank you very much for
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19. BASIC ENGINE
8N-9267 CYLINDER BLOCK GP*R
S/N: 4TB4210-6186
FIELD REPLACEMENT ORDER 108-3916–PAGE 77, 152-7642–PAGE 79, 6-111-8606 BOLT,
6-7W-4990 JET AS-PISTON COOLING
SMCS-1201 i01870333
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME
1 2 3 4 5 6 (PRODUCT LEVEL)
SEE
PAGE
1 1 7W-4990 6 JET AS-PISTON COOLING
2 1 8T-6757 3 PLUG-PIPE
3 1 108-3913 1 CYLINDER BLOCK AS
3A 1 197-9322 6 LINER-CYLINDER
3B 1 110-2220 6 SEAL-LINER (141-MM ID)
3C 1 142-7072 6 SEAL-LINER (140.2-MM ID)
3D 1 142-6217 6 SEAL-O-RING (140.20MM ID)
3E 1 3P-1323 14 BOLT-BEARING CAP (7/8-14X7.75-IN)
3F 1 9H-1031 14 WASHER-HARD (24X41.5X6-MM THK)
3G 1 4N-5857 7 CAP-CRANKSHAFT BEARING
3H 1 9L-5854 6 BAND-FILLER (130.2-MM ID)
4 1 8T-6763 3 PLUG-PIPE
5 1 1S-9540 2 DOWEL
6 1 3S-5496 2 SEAL-O-RING
7 1 7W-6492 1 PLUG-PIPE
8 1 119-5155 1 SEAL-O-RING
9 1 030-7571 4 BOLT (3/8-16X1-IN)
10 1 4W-8585 1 COVER
11 1 7W-6081 1 GASKET
12 1 4N-0683 4 DOWEL
13 1 4N-1650 2 DOWEL
14 1 6I-2981 1 PLATE-BLOCK
15 1 6I-4024 1 GASKET-PLATE
16 1 8S-9094 1 PLUG-ORIFICE
17 1 9S-4190 1 PLUG-O-RING
18 1 114-4427 1 SEAL-O-RING
19 1 7X-7732 6 PLUG-PIPE
20 1 111-8606 6 BOLT-SPECIAL (OIL JET)
21 1 4N-0685 6 BEARING-SLEEVE (1-IN WIDE)
22 1 4N-6658 1 BEARING-SLEEVE (1.3-IN WIDE)
23 1 8T-6764 1 PLUG-PIPE
24 1 9S-8009 1 PLUG
25 1 100-7399 2 PLUG
26 1 3E-6747 2 SEAL-O-RING
27 1 9S-4182 1 PLUG-O-RING
28 1 9X-7378 1 SEAL-O-RING
B 29 1 7W-6534 1 PLUG-PIPE
AHB 30 1 4W-4588 SLEEVE-LIFTER BORE
ABFJ 1 4W-6061 SLEEVE-CYLINDER LINER
AFHB 1 5N-0093 INSERT-LINER SEAT (2.71-MM THK)
AFHB 1 2W-3815 INSERT-LINER SEAT (1.605-MM THK)
AFHB 1 9Y-3368 INSERT-LINER SEAT (0.822-MM THK)
A-NOT PART OF THIS GROUP
B-USE AS REQUIRED
F-NOT SHOWN
H-FOR SALVAGE OF DAMAGED LIFTER BORES IN CYL BLOCK.
J-FOR SALVAGE OF THE BOTTOM LINER O-RING BORE.
68 BASIC ENGINE 1 of 2 SEBP2658-25

20. BASIC ENGINE
8N-9267 CYLINDER BLOCK GP (contd. ) i01870333
GRAPHIC #1 <END> g00952448
SEBP2658-25 2 of 2 BASIC ENGINE 69

21. BASIC ENGINE
8N-9267 CYLINDER BLOCK GP*R
S/N: 4TB6187-7384
FIELD REPLACEMENT ORDER 108-3916–PAGE 77, 152-7642–PAGE 79, 6-111-8606 BOLT,
6-7W-4990 JET AS-PISTON COOLING
SMCS-1201 i01871860
NOTE
REF
NO
GRAPHIC
REF PART NUMBER QTY
PART NAME
1 2 3 4 5 6 (PRODUCT LEVEL)
SEE
PAGE
C 1 1 151-5929 6 JET AS-PISTON COOLING
2 1 8T-6757 3 PLUG-PIPE
B 3 1 7W-6534 1 PLUG-PIPE
4 1 2W-6000 6 LINER-CYLINDER
5 1 8T-6763 3 PLUG-PIPE
6 1 1S-9540 2 DOWEL
7 1 3S-5496 2 SEAL-O-RING
8 1 7W-6492 1 PLUG-PIPE
9 1 030-7571 4 BOLT (3/8-16X1-IN)
10 1 4W-8585 1 COVER
11 1 7W-6081 1 GASKET
12 1 9X-7378 1 SEAL-O-RING
13 1 4N-0683 4 DOWEL
14 1 4N-1650 2 DOWEL
15 1 6I-2981 1 PLATE-BLOCK
16 1 6I-4024 1 GASKET-PLATE
17 1 8S-9094 1 PLUG-ORIFICE
18 1 9S-4190 1 PLUG-O-RING
19 1 114-4427 1 SEAL-O-RING
20 1 7X-7732 6 PLUG-PIPE
C 21 1 151-5925 6 BOLT (7/16-14-2A-THD)
24 1 8T-6764 1 PLUG-PIPE
25 1 9S-8009 1 PLUG
26 1 119-5155 1 SEAL-O-RING
27 1 110-2220 18 SEAL-LINER (141-MM ID)
28 1 3P-1323 14 BOLT-BEARING CAP (7/8-14X7.75-IN)
29 1 9H-1031 14 WASHER-HARD (24X41.5X6-MM THK)
30 1 4N-5857 7 CAP-CRANKSHAFT BEARING
31 1 9L-5854 6 BAND-FILLER (130.2-MM ID)
ABH 32 1 4W-4588 SLEEVE-LIFTER BORE
B 33 1 9S-4190 1 PLUG-O-RING
B 34 1 114-4427 1 SEAL-O-RING
35 1 100-7399 2 PLUG
36 1 3E-6747 2 SEAL-O-RING
37 1 9S-4182 1 PLUG-O-RING
ABFJ 1 4W-6061 SLEEVE-CYLINDER LINER
ABFH 1 5N-0093 INSERT-LINER SEAT (2.71-MM THK)
ABFH 1 2W-3815 INSERT-LINER SEAT (1.605-MM THK)
ABFH 1 9Y-3368 INSERT-LINER SEAT (0.822-MM THK)
A-NOT PART OF THIS GROUP
B-USE AS REQUIRED
C-CHANGE FROM PREVIOUS TYPE
F-NOT SHOWN
H-FOR SALVAGE OF DAMAGED LIFTER BORES IN CYL BLOCK.
J-FOR SALVAGE OF THE BOTTOM LINER O-RING BORE.
70 BASIC ENGINE 1 of 2 SEBP2658-25