service repair manual

1. Fig. 001 CYLINDER BLOCK
DL200-3

2. Fig. 001 CYLINDER BLOCK
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 150102-00004A CYLINDER BLOCK ASS'Y 1
1A - CYLINDER BLOCK 1 D
1B - THRUST BEARING CAP ASS'Y 1 D
1BA - BEARING CAP;THRUST 1 D
1BB 65.91710-0001 RING;STOPPER 2
1C - BEARING CAP ASS'Y 6 D
1CA - BEARING CAP 1 D
1CB 65.91710-0001 RING;STOPPER 2
1D 65.90020-0066A BOLT;BRG CAP 14
1E 65.04410-0021A BUSH;CAMSHAFT 6 B
1F 65.04410-0022 BUSH;CAMSHAFT 1 B
1G 65.90302-0009 PLUG;CORE 2
1H 65.90302-0042 PLUG;CORE 8
1I 65.90302-0034 PLUG;CORE 5
1J 65.91606-0041 PLUG;CORE 2
1K 06.31641-0618 BALL;STEEL 1
20 65.90320-0022 PLUG SCREW PT1/8 1
21 65.91001-0013A PIN;CORE 6
30 410127-00088 RELIEF VALVE ASS'Y 1
30A 06.56021-0102 O-RING 1
30B - RELIEF VALVE 1 D
33 06.22022-1063 PIN 2
34 65.91605-0002 COVER;CORE HOLE 1
35 65.90310-0134 SCREW;PLUG 2
36 06.56190-0732 SEAL;RING 2
40 65.01201-0075A CYLINDER LINER-GRADE 6 D
41 65.01201-0076 LINER;CYLINDER-1A 6
42 65.01201-0077 LINER;CYLINDER-1B 6
43 65.01201-0078 LINER;CYLINDER-2A 6
44 65.01201-0079 LINER;CYLINDER-2B 6
1DL200-3

3. Fig. 002 TIMING GEAR CASE
DL200-3

4. Fig. 002 TIMING GEAR CASE
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
2 130405-00027A CASE;TIMING GEAR 1
3 65.91710-0016 RING;STOPPER 2
4 65.01903-0034 GASKET 1
5 65.90020-0063B BOLT;HEX M10X25 3
6 65.90020-0080 BOLT;COLLARED HEX. 1
7 65.98130-0241 ADAPTER 1
8 410127-00040 RELIEF VALVE ASS'Y 1
8A 65.96501-0074 O-RING 1
10 65.91601-0011 COVER 1
11 65.38901-0018A GASKET;PTO 1
12 06.01943-3318 BOLT ASS'Y M12X1.5X35 2
1DL200-3

5. Fig. 003 FLYWHEEL HOUSING
DL200-3

6. Fig. 003 FLYWHEEL HOUSING
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 150114-00098A FLYWHEEL HOUSING ASS'Y 1
1A 150114-00142 HOUSING,FLYWHEEL 1
1B 65.01414-0004A COVER 1
1C 06.01923-3111 BOLT, M8X16 2
1D 65.96401-0014 CAP;RUBBER 1
5 65.01510-0040 SEAL;OIL 1
6 400613-00006 GASKET;F.W.H 1
7 65.90020-0100 BOLT, 103mm 9
8 65.90020-0101 BOLT, 57mm 4
9 65.90020-0105 BOLT, 67mm 4
10 65.91710-0009 RING;STOPPER 2
1DL200-3

7. Fig. 004 OIL SEAL
DL200-3

8. Fig. 004 OIL SEAL
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.01501-5003A COVER;SEALING 1
2 65.01510-0157 SEAL;OIL 1
3 65.01905-0009 GASKET 1
4 06.01923-3116 BOLT ASS'Y M8X28 8
1DL200-3

9. Fig. 005 OIL SPRAY NOZZLE
DL200-3

10. Fig. 005 OIL SPRAY NOZZLE
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.01601-5020 OIL SPRAY NOZZLE ASS'Y 6
2 65.05401-5031 RELIEF VALVE ASS'Y 6
1DL200-3

11. Fig. 006 BREATHER SYSTEM
DL200-3

12. Fig. 006 BREATHER SYSTEM
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 110436-00094 BRACKET,BREATHER PIPE 1
2 06.01923-3114 BOLT ASS'Y M8X22 4
3 110972-00036 HOUSING;BREATHER 1
4 06.01923-3114 BOLT ASS'Y M8X22 4
5 420101-00503 HOSE,AIR 1
6 65.97402-0042 CLIP;HOSE 1
7 65.97402-0043 CLIP;HOSE 1
8 65.96301-0551 HOSE;RUBBER 1
9 65.97402-0025 CLAMP;HOSE 2
10 420215-00024 PIPE,OIL DRAIN 1
11 06.01923-3212 BOLT ASS'Y 2
12 65.96301-0422A HOSE;RUBBER 1
13 65.97402-0025 CLAMP;HOSE 2
14 410104-00025 CHECK VALVE ASS'Y 1
15 65.96301-0535 HOSE;RUBBER 1
16 65.97402-0015 CLIP;HOSE 2
17 420215-00010 PIPE;OIL DRAIN 1
18 65.98150-0071 SCREW;HOLLOW 1
19 65.96507-0043 RING;SEAL A14X20 2
20 65.90201-0122 BOLT;STUD 1
21 65.97401-5019 CLIP;PIPE 1
22 06.16731-2107 WASHER 1
23 06.11063-8214 NUT 1
24 65.96301-0441 HOSE;RUBBER 1
25 06.67020-0105 CLAMP;HOSE 1
26 110972-00005 HOUSING;BREATHER 1
27 401002-00082 O-RING 1
28 06.01923-3113 BOLT ASS'Y M8X20 3
29 430201-00103 ADAPTER;OIL DRAIN BREATHER 1
30 06.56190-0719 RING;SEAL 1 120822~
1DL200-3

13. Fig. 007 CRANKSHAFT
DL200-3

14. Fig. 007 CRANKSHAFT
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.02101-0069A CRANK SHAFT 1
2 06.22022-1018 PIN;DOWEL 1
3 65.02115-0016 GEAR;CRANKSHAFT 1
4 65.01110-6140A METAL;MAIN 7
5 65.01150-6008 WASHER;THRUST 2
1DL200-3

15. Fig. 008 VIBRATION DAMPER
DL200-3

16. Fig. 008 VIBRATION DAMPER
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.02201-0002 DAMPER;VIBRATION 1
2 65.90020-0062B BOLT;HEX M10X20 6
1DL200-3

17. Fig. 009 FLYWHEEL
DL200-3

18. Fig. 009 FLYWHEEL
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 150111-00049 FLYWHEEL SUB ASSY 1
1A - FLYWHEEL ASS'Y 1 D
1AA 65.02301-0294 FLYWHEEL 1
1AB 65.02310-0006 GEAR;RING 1
1B 65.02130-0004 BUSH;DRIVING 1
6 65.90020-0140A BOLT;COLLARED HEX. 8
1DL200-3

19. Fig. 010 CONNECTING ROD
DL200-3

20. Fig. 010 CONNECTING ROD
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.02401-6035 CONNECTING ROD ASS'Y 6
1A 65.02411-0009 BOLT;CONNECTING ROD 2
6 65.02410-0040 METAL;CON-ROD(STD) 6
7 65.02410-0041 METAL;CON-ROD(0.25) 6 US
8 65.02410-0042 METAL;CON-ROD(0.50) 6 US
11 65.02410-0050 METAL;CON-ROD(STD) 6
12 65.02410-0051 METAL;CON-ROD(0.25) 6 US
13 65.02410-0052 METAL;CON-ROD(0.50) 6 US
1DL200-3

21. Fig. 011 PISTON
DL200-3

22. Fig. 011 PISTON
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 130602-00239 PISTON 6
2 401004-00097 PISTON RING KIT 1
2A - RING;TOP 6 K
2B - RING;SECOND 6 K
2C - RING;PISTON 6 K
5 65.02502-0017A PIN;PISTON 6
8 06.29020-0125 RING;LOCK 12
1DL200-3

23. Fig. 012 CRANK SHAFT PULLEY
DL200-3

24. Fig. 012 CRANK SHAFT PULLEY
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 130711-00001A PULLEY;CRANKSHAFT 1
2 65.90701-0099 WASHER 1
3 06.02106-0723 BOLT;SOCKET 8
1DL200-3

25. Fig. 013 CYLINDER HEAD
DL200-3

26. Fig. 013 CYLINDER HEAD
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 150113-00009 CYLINDER HEAD ASS'Y 1
1A - HEAD;CYLINDER 1 D
1B 65.03203-1062 SEAT;VALVE IN. 12 B
1C 65.03203-1063 SEAT;VALVE EX. 12 B
1D 65.03201-1016B GUIDE;VALVE 24 B
1E 65.90302-0048 CORE;PLUG 10
1F 65.90302-0029 PLUG;CORE 21
1G 65.03205-0006B BUSH;INJ. NOZZLE 6
1H 65.96501-0088 O-RING 12
10 65.91030-0005 PIN 2
11 65.90021-0009 BOLT;HEAD 26
12 65.90201-0134 BOLT;STUD 24
13 65.03901-0071 GASKET;CYLINDER HEAD 1
1DL200-3

27. Fig. 014 CYLINDER HEAD COVER
DL200-3

28. Fig. 014 CYLINDER HEAD COVER
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 150106-00064 CYL. HEAD COVER ASS'Y 1
2 65.90020-0109 BOLT;COLLARED HEX. 14
3 65.03905-0037A GASKET;HEAD COVER 1
4 65.03905-5002 PACKING;HEAD COVER 14
5 65.03402-0009 COVER;INTERMEDIATE 1
6 400603-00050 GASKET;INTERMEDIATE 1
7 65.90020-0138 BOLT;COLLARED HEX. 16
8 65.01810-5011 CAP;OIL FILLER 1
1DL200-3

29. Fig. 015 VALVE
DL200-3

30. Fig. 015 VALVE
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.04101-0065B VALVE;INTAKE 12
2 65.04101-0066B VALVE;EXHAUST 12
3 65.04102-0024 SPRING;VALVE 24
6 65.04103-0018 PLATE;VALVE SPRING 24
7 65.04104-0009 COTTER;VALVE 48
8 65.90701-0098 WASHER 24
9 65.04902-0016 SEAL;VALVE STEM 24
10 65.04130-0009A CALIPER;INTAKE 6
11 65.04130-0011 CALIPER;EXHAUST 6
1DL200-3

31. Fig. 016 ROCKER ARM
DL200-3

32. Fig. 016 ROCKER ARM
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
- 65.04200-6038D R/A ARM SHAFT ASS'Y 2
2 65.04201-5042C ROCKER ARM;INTAKE 3
3 65.04201-5043C ROCKER ARM;EXHAUST 3
4 65.04203-5020A SHAFT;ROCKER ARM 1
5 65.04202-0033 BRACKET;ROCKER ARM 1
6 65.04202-0034 BRACKET;ROCKER ARM 1
7 65.04202-0035 BRACKET;ROCKER ARM 2
8 65.97601-0124 SPRING;COMPESSION 3
9 65.90701-0136B WASHER 6
10 06.29010-0120 RING;SNAP 2
11 65.90030-0018 BOLT;SOCKET 1
12 06.16110-0106 WASHER 1
13 65.04205-0014 SCREW;ADJUST 6
14 65.90501-0003 NUT 6
15 65.04209-5002 CAP;INTAKE 3
16 65.04209-0006 CAP;EXHAUST 3
17 65.90020-0120 BOLT;COLLARED HEX. 8
1DL200-3

33. Fig. 017 VALVE TAPPET & PUSH ROD
DL200-3

34. Fig. 017 VALVE TAPPET & PUSH ROD
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.04301-5003C TAPPET;VALVE 12
2 65.04302-5015 ROD;PUSH 12
1DL200-3

35. Fig. 018 CAM SHAFT
DL200-3

36. Fig. 018 CAM SHAFT
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.04401-0046 CAM SHAFT 1
2 06.22022-1016 PIN;DOWEL 1
3 65.90720-0032 WASHER;THRUST 1
4 06.01913-2911 BOLT ASS'Y M6X16 2
1DL200-3

37. Fig. 019 CAM SHAFT DRIVE
DL200-3

38. Fig. 019 CAM SHAFT DRIVE
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.04501-0017 GEAR;CAM SHAFT 1
2 65.90020-0117 BOLT;COLLARED HEX. 4
3 65.04505-5018 GEAR;IDLE 1
4 65.04506-0016 PIN;IDLE GEAR 1
5 65.90720-0034B WASHER;THRUST 1
6 65.90020-0118 BOLT;COLLARED HEX. 3
7 65.11301-5002 GEAR;DRIVE 2
8 65.04506-0015 PIN;IDLE GEAR 2
9 65.90720-0033A WASHER;THRUST 1
10 65.90020-0118 BOLT;COLLARED HEX. 1
11 65.90020-0119 BOLT;COLLARED HEX. 1
1DL200-3

39. Fig. 020 OIL PUMP
DL200-3

40. Fig. 020 OIL PUMP
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.05100-6063A OIL PUMP ASS'Y 1
1A - HOUSING;OIL PUMP 1 D
1B 65.05104-0023 GEAR;OIL PUMP 1
1C 65.05104-0022 GEAR;OIL PUMP 1
1D 65.05201-0016 GEAR;DRIVE;OIL PUMP 1
1E 06.22022-0907 PIN;DOWEL 6M6X10 1
1F 65.05103-0034 COVER;OIL PUMP 1
1G 06.01913-3114 BOLT ASS'Y M8X22 4
9 06.22022-0909 PIN;DOWEL 6M6X14 2
10 65.90020-0085 BOLT;COLLARED HEX. 2
1DL200-3

41. Fig. 021 OIL COOLER & FILTER
DL200-3

42. Fig. 021 OIL COOLER & FILTER
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.05601-7082 OIL COOLER ASS'Y 1
1A 65.05604-0030A HOUSING;OIL COOLER 1
1B 65.05606-5032A ELEMENT;OIL COOLER 1
1C 65.05902-0022 GASKET;OIL COOLER 2
1D 06.01923-3119 BOLT ASS'Y M8X40 4
1E 65.54109-0005A SCREW;PLUG M22X1.5 1
1F 65.05610-0007A GUIDER;WATER FLOW 1
1G 06.02097-8306 BOLT;SOCKET 2
1H 06.16731-2105 WASHER 2
2 65.05501-7099 OIL FILTER ASS'Y 1
2A 65.05503-0050 HEAD;OIL FILTER 1
2B 06.31641-0433 BALL;STEEL 1
2C 65.97601-0075 SPRING 1
2D 65.90310-0115 PLUG 1
2E 06.56190-0726 SEAL;RING 1
2F 65.05510-5032A FILTER;OIL 1
3 06.01923-3123 BOLT ASS'Y M8X60 1
4 65.90201-0139 BOLT 1
5 06.15010-2311 WASHER 1
6 06.16731-2107 WASHER 1
7 65.05901-0031 GASKET;OIL FILTER 1
23 65.05902-0023 GASKET;OIL COOLER 1
24 06.01923-3117 BOLT ASS'Y M8X30 10
25 06.01923-3119 BOLT ASS'Y M8X40 10
26 06.01913-3128 BOLT M8X85 8
27 65.90201-0135 BOLT;STUD 3
28 06.15010-2311 WASHER 14
29 06.16731-2107 WASHER 5
30 65.90001-0098 BOLT 2
31 06.01913-3129 BOLT ASS'Y M8X90 1
1DL200-3

43. Fig. 022 OIL PAN
DL200-3

44. Fig. 022 OIL PAN
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 65.05801-5249 PAN;OIL 1
4 65.05904-0035 GASKET;OIL PAN 1 ~130603 I 400604-00026 1
4 400604-00026 GASKET,OIL PAN 1 130604~
5 06.01923-3120 BOLT ASS'Y M8X45 22
7 65.05806-5005A TUBE;OIL LEVEL GAUGE 1
9 65.05805-5238 OIL LEVEL GAUGE 1
10 65.05701-6122 OIL PIPE ASS'Y 1
10A 65.05707-5011 COVER;STRAINER 1
10B 65.05740-0222 BRACKET;OIL SUCT.PIPE 1
10C 65.97401-0137 CLIP;PIPE 1
10D 06.01283-7115 BOLT M8X25 1
10E 06.15010-2311 WASHER 1
10F 65.90510-0012 NUT 1
17 65.05901-0032 GASKET 1
18 06.01913-3115 BOLT ASS'Y M8X25 1
19 06.01913-3119 BOLT ASS'Y M8X40 2
20 460102-00034 DRAIN ASSY 1
20A 65.96340-5013A HOSE;DRAIN 1
20B 410202-00014 COCK ASSY;DRAIN 1
23 65.98130-0203 ADAPTER 1
24 06.56190-0732 SEAL;RING 1
25 65.01813-5019 PIPE;OIL FILLER 1
26 65.05903-0029A GASKET 1
27 06.01913-3114 BOLT ASS'Y M8X22 4
28 65.01810-5011 CAP;OIL FILLER 1
1DL200-3

45. Fig. 023 COOLING WATER PIPE
DL200-3

46. Fig. 023 COOLING WATER PIPE
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 600102-00001 CONNECTION 1
2 420211-00039A PIPE;COOLING WATER 1
3 65.98130-0143 ADAPTER 1
4 06.56180-0716 RING;SEAL 3
5 420101-00256 HOSE;RUBBER 1
6 06.08092-2402 SCREW;PLUG M10X1.25 2
7 120122-00003 BOLT;SPACER 3 ~130418 I 120122-00003A 3
7 120122-00003A BOLT,SPACER 3 130419~
8 420108-00280 HOSE;RUBBER 1
9 06.56190-0728 RING;SEAL 1
10 65.98130-0068 NIPPLE 1
11 65.06301-0219A PIPE;COOLING WATER 1
12 65.96501-0089A O-RING 2
13 06.67020-0101 CLAMP;HOSE 2
14 06.67020-0105 CLAMP;HOSE 2
15 06.01923-3214 BOLT;HEX. M10X22 2
1DL200-3

47. Fig. 024 THERMOSTAT
DL200-3

48. Fig. 024 THERMOSTAT
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 300738-00009A THERMOSTAT ASS'Y 1
1A 110980-00021A HOUSING;THERMOSTAT 1
1B 300738-00010 THERMOSTAT 1
1C 401002-00055 O-RING 1
2 65.06904-0021 GASKET;THERMOSTAT 1
3 06.01013-9225 BOLT;HEX 6
40 06.16110-0107 WASHER;SPRING 6
41 06.15010-2312 WASHER;PLAIN 6
42 400602-00241 GASKET 1
43 600102-00003 CONNECTION 1
44 06.01923-3123 BOLT ASS'Y M8X60 3
45 06.01923-3131 BOLT;HEX. 1
46 430220-00008 OUTLET,WATER 1
47 400602-00316 GASKET;WATER PUMP 1
48 06.01923-3117 BOLT ASS'Y M8X30 2
49 65.90350-0005 SCREW;PLUG PT 3/8 1
1DL200-3

49. Fig. 025 WATER PUMP
DL200-3

50. Fig. 025 WATER PUMP
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 400921-00015B WATER PUMP ASS'Y 1
1A 400923-00005A HOUSING;WATER PUMP 1 D
1B 65.93410-0087 BEARING 1
1C 65.06520-6008 SEAL;MECHANICAL 1
1D 06.29020-0132 SNAP RING 55X2 1
1E 130707-00011A PULLEY;BELT 1
1F 400902-00005 IMPELLER 1
10 06.22022-0907 PIN;DOWEL 6M6X10 2
11 06.01923-3126 BOLT;HEX. M8X75 9
12 110508-00182B COVER,PUMP 1
13 06.01923-3119 BOLT ASS'Y M8X40 1
14 400602-00096 GASKET;WATER PUMP 1
15 06.01923-3124 BOLT ASS'Y M8X65 5
16 400602-00113A GASKET;WATER PUMP 1
17 420211-00172 PIPE,COOLING WATER 1
18 400631-00003 GASKET;C/W PIPE 1
19 06.01923-3117 BOLT ASS'Y M8X30 2
20 130205-00059 BELT 5PK-1013L 1
21 110951-00327 SPACER 3
22 110417-00002 BRACKET;IDLE PULLEY 2
23 130710-00008 PULLEY;IDLE 1
24 65.91701-0154 SPACER 1
25 06.16731-2109 WASHER;SPRING A12 1
26 06.11063-8216 NUT;HEX 1
27 65.19103-6010A EYE BOLT ASS'Y 1
32 06.01923-3223 BOLT ASSY 2
33 06.01923-3225 BOLT ASS'Y M10X70 1
34 06.16731-2108 WASHER;SPRING 1
35 06.11063-8215 NUT;HEX. M10 1
36 06.01923-3218 BOLT ASS'Y M10X35 1
1DL200-3

51. Fig. 026 COOLING FAN
DL200-3

52. Fig. 026 COOLING FAN
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
3 06.01913-3213 BOLT ASS`Y M10X20 6
7 130709-00020A PULLEY;FAN 1
8 210101-00101 FAN DRIVE ASS'Y 1
9 06.01913-3219 BOLT ASS'Y M10X40 4
10 65.96801-0224 BELT 8PK-1735L 1
1DL200-3

53. Fig. 027 EXHAUST MANIFOLD
DL200-3

54. Fig. 027 EXHAUST MANIFOLD
Key No Part No Description Qty S.C Serial No ICA Replacable Qty
1 240102-00096 EXHAUST MANIFOLD ASS'Y 1
1A 240102-00097 MANIFOLD;EXHAUST 1
1B 240102-00098 MANIFOLD;EXHAUST 1
1C 240102-00099 MANIFOLD;EXHAUST 1
1D 65.96507-0059A RING;SEAL 8
5 65.08901-0045 GASKET;EXHAUST MANIFOLD 6
6 65.90535-0003 NUT 24
7 65.91701-0086 SPACER 24
10 65.90201-0076 BOLT;STUD 2
1DL200-3

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