Perkins 1104C-44

Tier II Diesel Engine

Parts Book

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RE38247 RE382471104C-44 2004/10/01

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.

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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. 136

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

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

This parts book has been designed to provide you with all the information you need to identifyparts to service your engine. There are several features within the book to make it easy to findthe 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 numbersalong 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 foridentification 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 youlocate the page within the Parts Lists & Illustrations section where the part appears.

Introduction

How to use your Parts Book

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Engine Breakdown

Page 5

Section Page

Short EngineACE40003

11

Cylinder Block & LinersACHR0035

13

Crankshaft, Main & Big End BearingsACHR0035

15

Pistons & RingsACHR0035

17

Connecting RodsACHR0035

19

Rear End Oil SealACHR0035

21

Cylinder Head AssemblyACHR0035

23

Rocker Shaft AssemblyACHR0035

25

Timing Gear & CamshaftACHR0035

27

Fuel Injection PumpAFHR4281

29

High Pressure Fuel PipesAFHR4281

31

AtomisersAFHR4281

33

Pick-Up SensorAFHR4281

35

Pick-Up SensorAFHR4281

37

Throttle & Stop ControlsAFHR4281

39

Clutch & Gearbox MountsBDHR0532

41

Flywheel HousingCDHR1062

43

Flywheel & Starter RingDDHR1007

45

Starter MotorEDHR0608

47

SumpGBHR2765

49

Dipstick & Filler TubeGBHR2765

51

Oil StrainerGBHR2765

53

Cylinder Head CoverHBHR2739

55

Cylinder Head CoverHBHR2739

57

BreatherHBHR2739

59

Blanking PlatesHBHR2739

61

Section Page

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Engine Breakdown

Page 6

Oil CoolerJBHR2441

63

Oil FilterJBHR2441

65

Blanking PlatesJBHR2441

67

Remote Lubricating Oil CoolerJDHR0023

69

Front End Drive InputKBHR0519

71

Water PumpLBHR2253

73

Water PumpLBHR2253

75

PipesLBHR2253

77

Water Outlet HousingLDHR0704

79

Water Outlet HousingLDHR0704

81

Alternator Bracket & FixingsNDHR2708

83

Timing CaseQCHR0024

85

Timing CaseQCHR0024

87

Section Page

Timing CoverQCHR0024

89

Air CompressorQDHR1384

91

PipeworkQDHR1384

93

Lubricating Oil Pump & Delivery HousingRBHR0031

95

Induction ManifoldTBHR0884

97

Pipework & ConnectionsTBHR0884

99

Exhaust ManifoldUBHR0519

101

Exhaust OutletUDHR0403

103

Lift PumpVBHR2250

105

Filter to Injection Pump PipeVBHR2250

107

Injection Pump to Filter PipeVBHR2250

109

Heater PlugsWDHR0345

111

Section Page

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Engine Breakdown

Page 7

Engine Lifting EyesXBHR0458

113

Engine MountsZCHR0987

115

Engine MountsZCHR0987

117

Lubricating Oil Pressure Switch/GaugeZJHR0546

119

Lubricating Oil Pressure Switch/GaugeZJHR0546

121

Temperature Gauge & SenderZLHR0360

123

Fuel Pre-Lift PumpZVHR1023

125

Water TrapZVHR1023

127

Water TrapZVHR1023

129

Miscellaneous & AuxiliariesZZHR1012

131

Top Service KitSACR0350

133

Bottom Service KitSGBR0371

135

Section Page

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Engine Breakdown

Page 8

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Page 9

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

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Short Engine Plate A

ACE40003

Page 10

1

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Short Engine Plate A

ACE40003

Page 11

Item Part No. References Qty. Description Notes

1 RE40003 1 SHORT ENGINE2 ZZ50311 1 CYLINDER BLOCK KIT3 ZZ90224 H 1 CRANKSHAFT KIT4 P 4 CONROD KIT5 4115P011 4 PISTON AND RING KIT6 2418F704 1 REAR OIL SEAL HOUSING7 3211C002 10 METRIC BOLT

Service Options

3 ZZ90224P 1 CRANKSHAFT KIT4 4115C311 4 CONROD KIT GRADE F4 4115C312 4 CONROD KIT GRADE G4 4115C313 4 CONROD KIT GRADE H4 4115C314 4 CONROD KIT GRADE J4 4115C315 4 CONROD KIT GRADE K4 4115C316 4 CONROD KIT GRADE L

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Cylinder Block & Liners Plate A

ACHR0035

Page 12

21

22

1312

8

20

1611

10

19

2

3

4

5

6

17

18

9

14

1

237

15

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Cylinder Block & Liners Plate A

ACHR0035

Page 13

Item Part No. References Qty. Description Notes

1 ZZ50311 1 CYLINDER BLOCK KIT2 F ZZ50311 1 CYLINDER BLOCK3 F ZZ50311 1 BEARING CAP4 F ZZ50311 2 BEARING CAP5 F ZZ50311 1 BEARING CAP6 F ZZ50311 1 BEARING CAP7 10 THIMBLE8 32166329 10 SCREW9 3112D071 1 CAMSHAFT BUSH10 3241A012 1 PLUG11 3241A011 2 PLUG12 0650588 1 PLUG13 0650710 1 PLUG14 3212P008 1 PLUG15 3244A009 2 DOWEL16 32141316 2 PLUG17 2485A108 1 BLANKING PLUG18 3212V006 1 PLUG19 2113A001 4 PISTON COOLING JET20 2314F001 4 SCREW21 3623A009 1 BLANKING PLATE22 3688A039 1 JOINT23 2314H033 4 SCREW

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Crankshaft, Main & Big End Bearings Plate A

ACHR0035

Page 14

7

5

6

8

2

4

1

3

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Crankshaft, Main & Big End Bearings Plate A

ACHR0035

Page 15

Item Part No. References Qty. Description Notes

1 ZZ90224 H 1 CRANKSHAFT KIT2 F ZZ90224 1 CRANKSHAFT3 U5MB0019 1 MAIN BEARING KIT4 U5ME0013 P 1 BIG END BEARING KIT5 31137551 P 2 THRUST WASHER6 31137561 P 2 THRUST WASHER7 0500012 1 WOODRUFF KEY8 3117C221 1 CRANKSHAFT GEAR

Service Options

1 ZZ90224P 1 CRANKSHAFT KIT3 U5MB0019A J (-)0.25MM 1 MAIN BEARING KIT3 U5MB0019B J (-) 0.50MM 1 MAIN BEARING KIT3 U5MB0019C J (-)0.75MM 1 MAIN BEARING KIT4 U5ME0013A J (+) 0.010" 1 BIG END BEARING KIT4 U5ME0013B J (+)0.020" 1 BIG END BEARING KIT4 U5ME0013C J (+) 0.030" 1 BIG END BEARING KIT5 31137312 J (+)0.007" 2 THRUST WASHER6 31137322 J (+)0.007" 2 THRUST WASHER

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Pistons & Rings Plate A

ACHR0035

Page 16

4

3

1

2

5

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Pistons & Rings Plate A

ACHR0035

Page 17

Item Part No. References Qty. Description Notes

1 4115P011 4 PISTON AND RING KIT2 F 4115P011 1 PISTON3 F 4115P011 1 PISTON PIN4 2721332 2 CIRCLIP5 UPRK0003 1 PISTON RING KIT

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Connecting Rods Plate A

ACHR0035

Page 18

2

4

1

3

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Connecting Rods Plate A

ACHR0035

Page 19

Item Part No. References Qty. Description Notes

1 P 4 CONROD KIT2 F SERVICE OPTION 1 CONROD3 3112A005 1 SMALL END BUSH4 3212V003 2 CON ROD BOLT

Service Options

1 4115C311 4 CONROD KIT GRADE F1 4115C312 4 CONROD KIT GRADE G1 4115C313 4 CONROD KIT GRADE H1 4115C314 4 CONROD KIT GRADE J1 4115C315 4 CONROD KIT GRADE K1 4115C316 4 CONROD KIT GRADE L

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Rear End Oil Seal Plate A

ACHR0035

Page 20

1

2

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Rear End Oil Seal Plate A

ACHR0035

Page 21

Item Part No. References Qty. Description Notes

1 2418F704 1 REAR OIL SEAL HOUSING2 3211C002 10 METRIC BOLT

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Cylinder Head Assembly Plate A

ACHR0035

Page 22

3

9

22

8

5

4

19

1421

76

13

18

23

20

15

10

16

11

12

1724

25

1

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Cylinder Head Assembly Plate A

ACHR0035

Page 23

Item Part No. References Qty. Description Notes

1 ZZ80270 1 CYLINDER HEAD KIT2 F ZZ80270 1 CYLINDER HEAD ASSEMBLY3 1 CYLINDER HEAD4 3313E021 4 VALVE GUIDE5 3313E021 4 VALVE GUIDE6 3314A151 4 INLET VALVE INSERT7 3314A161 4 EXHAUST VALVE INSERT8 32416117 2 PLUG9 0650588 4 PLUG10 3142H071 4 INLET VALVE11 2418M519 4 VALVE STEM SEAL (A)12 3174A016 4 VALVE SPRING13 3342A011 4 VALVE CAP14 3142W004 8 COTTER15 3142A151 4 EXHAUST VALVE16 2418M514 4 VALVE STEM SEAL (B)17 3174A016 4 VALVE SPRING18 3342A011 4 VALVE CAP19 3142W004 8 COTTER20 3278A006 1 PLUG21 2415H003 1 O RING22 2431154 1 PLUG23 3681E051 1 CYLINDER HEAD GASKET24 3218A011 7 SCREW25 3218A012 3 SCREW

Footnotes

(A) GREEN

(B) BROWN

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Rocker Shaft Assembly Plate A

ACHR0035

Page 24

8

14

16

15

9

2

5

11

1

12

6

18

3

19

4

10 13

7

17

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Rocker Shaft Assembly Plate A

ACHR0035

Page 25

Item Part No. References Qty. Description Notes

1 4115R612 1 ROCKER ASSEMBLY2 4115R703 1 ROCKER SHAFT ASSEMBLY3 F 4115R703 1 ROCKER ARM SHAFT4 2485A104 2 PLUG5 4115R314 4 ROCKER ARM ASSEMBLY6 F 4115R314 1 ROCKER ARM7 F 4115R314 1 PAD8 0576052 1 NUT9 32114145 1 SCREW10 3174A015 3 ROCKER SHAFT SPRING11 4115R315 4 ROCKER ARM ASSEMBLY12 F 4115R315 1 ROCKER ARM13 F 4115R315 1 PAD14 0576052 1 NUT15 32114145 1 SCREW16 2722A022 2 CIRCLIP17 2134A502 2 WASHER18 2316A901 1 SCREW19 2316A902 3 SCREW

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Timing Gear & Camshaft Plate A

ACHR0035

Page 26

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2

1

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Timing Gear & Camshaft Plate A

ACHR0035

Page 27

Item Part No. References Qty. Description Notes

1 3141D212 1 CAMSHAFT2 3142U031 8 TAPPET3 31434307 8 PUSHROD

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Fuel Injection Pump Plate A

AFHR4281

Page 28

9

7

4

1110

12

5

8

6

3

2

1

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Fuel Injection Pump Plate A

AFHR4281

Page 29

Item Part No. References Qty. Description Notes

1 2644N203/24 1 FUEL INJECTION PUMP2 F 2644N203/24 1 FUEL INJECTION PUMP3 1 SOLENOID (A)4 3117L251 1 FUEL INJECTION PUMP GEAR5 2411D008 3 WASHER6 2314H004 3 SCREW7 2415787 1 O RING8 2487D002 1 CAP9 3641A007 1 BRACKET10 2314H003 1 SCREW11 2318A603 1 NUT12 2314J002 1 SCREW

Footnotes

(A) TO BE ADVISED

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High Pressure Fuel Pipes Plate A

AFHR4281

Page 30

56

4

3

1

2

7

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High Pressure Fuel Pipes Plate A

AFHR4281

Page 31

Item Part No. References Qty. Description Notes

1 3525A091 1 FUEL INJECTION PIPE - NO 1 2 3525A092 1 FUEL INJECTION PIPE - NO 2 3 3525A093 1 FUEL INJECTION PIPE - NO 3 4 3525A094 1 FUEL INJECTION PIPE - NO 4 5 2481Y011 2 CLIP6 2481Y012 1 CLIP7 2646E019 1 CLIP8 2481D221 1 CLIP (A)

Footnotes

(A) NOT ILLUSTRATED

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Atomisers Plate A

AFHR4281

Page 32

4

1

2

3

5

6

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Atomisers Plate A

AFHR4281

Page 33

Item Part No. References Qty. Description Notes

1 2645K013 4 ATOMISER2 F 2645K013 1 ATOMISER HOLDER3 F 2645K013 1 NOZZLE4 L311FF02 1 INJECTOR WASHER5 3751A241 4 INJECTOR CLAMP6 2314W009 4 SCREW

Service Options

1 2645K013R G 4 EXCHANGE ATOMISER

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Pick-Up Sensor Plate A

AFHR4281

Page 34

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Pick-Up Sensor Plate A

AFHR4281

Page 35

Item Part No. References Qty. Description Notes

1 2848A127 1 SENDER2 3161C018 1 CABLE

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Pick-Up Sensor Plate C

AFHR4281

Page 36

1

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Pick-Up Sensor Plate C

AFHR4281

Page 37

Item Part No. References Qty. Description Notes

1 2485A109 1 CORE PLUG

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Throttle & Stop Controls Plate A

AFHR4281

Page 38

1

2

3

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Throttle & Stop Controls Plate A

AFHR4281

Page 39

Item Part No. References Qty. Description Notes

1 3651A016 1 SUPPORT BRACKET2 2314H002 1 SCREW3 2481D556 1 CLIP

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Clutch & Gearbox Mounts Plate A

BDHR0532

Page 40

1

3

45

2

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Clutch & Gearbox Mounts Plate A

BDHR0532

Page 41

Item Part No. References Qty. Description Notes

1 37148242 1 ADAPTOR2 0350025 2 DOWEL3 2314J604 12 SETSCREW4 0748352 2 SCREW5 0920052 2 WASHER

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Flywheel Housing Plate A

CDHR1062

Page 42

1

4

6

2

5

3

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Flywheel Housing Plate A

CDHR1062

Page 43

Item Part No. References Qty. Description Notes

1 37138092 1 FLYWHEEL HOUSING2 0350025 2 DOWEL3 2487A452 1 BLANKING PLUG4 2314J004 6 SCREW5 36843154 1 SEAL6 32815118 1 PLUG

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Flywheel & Starter Ring Plate A

DDHR1007

Page 44

45

6

2

31

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Flywheel & Starter Ring Plate A

DDHR1007

Page 45

Item Part No. References Qty. Description Notes

1 41117314 1 FLYWHEEL ASSEMBLY2 F 41117314 1 FLYWHEEL3 31162121 1 STARTER RING GEAR4 0096836 6 SCREW5 33117127 6 WASHER6 33127117 1 ADAPTOR

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Starter Motor Plate A

EDHR0608

Page 46

2

3

1

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Starter Motor Plate A

EDHR0608

Page 47

Item Part No. References Qty. Description Notes

1 37513041 1 SPACER2 2313M082 3 STUD3 2318A604 3 NUT

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Sump Plate A

GBHR2765

Page 48

2

1

5

4

6

8

3

7

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Sump Plate A

GBHR2765

Page 49

Item Part No. References Qty. Description Notes

1 3717Y061 1 SUMP2 3681K037 1 SUMP JOINT3 3627P041 1 BRIDGE PIECE4 2311D039 2 SCREW5 32186405 2 PLUG6 2415715 2 O RING7 2314H031 2 SCREW8 2314H002 18 SCREW

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Dipstick & Filler Tube Plate A

GBHR2765

Page 50

9

3

6

7

5

4

1

8

2

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Dipstick & Filler Tube Plate A

GBHR2765

Page 51

Item Part No. References Qty. Description Notes

1 4126A081 1 DIPSTICK TUBE2 F 4126A081 1 DIPSTICK TUBE3 0180170 1 CLIP4 3353D005 1 NUT5 33812116 1 OLIVE6 2314F909 1 SCREW7 2314F002 1 SCREW8 3178C168 1 DIPSTICK9 3733A009 1 BRACKET

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Oil Strainer Plate A

GBHR2765

Page 52

3

2

1

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Oil Strainer Plate A

GBHR2765

Page 53

Item Part No. References Qty. Description Notes

1 3575A059 1 SUCTION PIPE2 36832137 1 JOINT3 2314H004 2 SCREW

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Cylinder Head Cover Plate A

HBHR2739

Page 54

2

8

9

711

5

6

12

13

3

1

10

4

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Cylinder Head Cover Plate A

HBHR2739

Page 55

Item Part No. References Qty. Description Notes

1 4142X292 1 CYLINDER HEAD COVER ASSY2 F 4142X292 1 CYLINDER HEAD COVER3 3681A055 1 ROCKER COVER JOINT4 2161A011 10 SCREW5 3174A017 1 SPRING6 3788A002 1 CAP7 3789A001 1 DIAPHRAGM8 3615A009 1 COVER PLATE9 2151A001 4 SCREW10 3788A003 1 CAP11 4142X099 1 OIL FILLER CAP12 F 4142X099 1 OIL FILLER CAP13 2415A131 1 O RING

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Cylinder Head Cover Plate B

HBHR2739

Page 56

1

2

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Cylinder Head Cover Plate B

HBHR2739

Page 57

Item Part No. References Qty. Description Notes

1 3788N003 1 COVER2 2314F003 3 SCREW

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Breather Plate A

HBHR2739

Page 58

3

5 2

1

4

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Breather Plate A

HBHR2739

Page 59

Item Part No. References Qty. Description Notes

1 4134K014 1 BREATHER PIPE2 F 4134K014 1 BREATHER PIPE3 3688A038 1 JOINT4 2161A011 2 SCREW5 2415A068 1 O RING

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Blanking Plates Plate A

HBHR2739

Page 60

1

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Blanking Plates Plate A

HBHR2739

Page 61

Item Part No. References Qty. Description Notes

1 2485A124 1 CUP PLUG

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Oil Cooler Plate A

JBHR2441

Page 62

4

7

8

6

5

3

1

2

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Oil Cooler Plate A

JBHR2441

Page 63

Item Part No. References Qty. Description Notes

1 4134W003 1 OIL COOLER2 2486A215 1 OIL COOLER3 3685A025 2 JOINT4 F 4134W003 1 COOLER5 3685A024 1 JOINT6 2314K161 3 SCREW7 2314H004 10 SCREW8 2314H006 4 SCREW

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Oil Filter Plate A

JBHR2441

Page 64

6

5

4

2 3

7

9

8

1

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Oil Filter Plate A

JBHR2441

Page 65

Item Part No. References Qty. Description Notes

1 4134E057 1 OIL FILTER HEAD2 F 4134E057 1 OIL FILTER HEAD3 33554128 1 CONNECTION4 3688A041 1 JOINT5 3773A081 1 ADAPTOR6 3688A039 1 JOINT7 2314H038 4 SCREW8 3278A007 1 PLUG9 2415H009 1 O RING

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Blanking Plates Plate A

JBHR2441

Page 66

2

1

3

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Blanking Plates Plate A

JBHR2441

Page 67

Item Part No. References Qty. Description Notes

1 3623A009 1 BLANKING PLATE2 3688A039 1 JOINT3 2314H033 4 SCREW

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Remote Lubricating Oil Cooler Plate A

JDHR0023

Page 68

1

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Remote Lubricating Oil Cooler Plate A

JDHR0023

Page 69

Item Part No. References Qty. Description Notes

1 2654407 1 OIL FILTER

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Front End Drive Input Plate A

KBHR0519

Page 70

21

3

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Front End Drive Input Plate A

KBHR0519

Page 71

Item Part No. References Qty. Description Notes

1 3114V041 1 CRANKSHAFT PULLEY2 3241N001 1 BLOCK3 32186137 3 BOLT

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Water Pump Plate A

LBHR2253

Page 72

15

2

1

17

18

16

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Water Pump Plate A

LBHR2253

Page 73

Item Part No. References Qty. Description Notes

1 U5MW0194 1 WATER PUMP KIT2 F U5MW0194 1 WATER PUMP3 F U5MW0194 1 BODY4 F U5MW0194 1 COVER5 F U7LW0172 1 GASKET6 F U7LW0172 1 IMPELLER7 F U7LW0172 1 DRIVE SHAFT8 F U7LW0172 1 SEAL9 F U7LW0172 1 CIRCLIP10 F U7LW0172 1 CIRCLIP11 F U7LW0172 1 ROLLER BEARING12 F U7LW0172 1 OIL SEAL13 F U7LW0172 1 BEARING14 24880232 1 WATER PUMP GEAR15 3682A011 1 WATER PUMP JOINT (A)16 2314K164 2 SCREW17 2314H005 2 SCREW18 2314H012 5 SCREW

Footnotes

(A) ALSO INCLUDED IN REPAIR KIT U7LW0172

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Water Pump Plate B

LBHR2253

Page 74

11

5

7

8

9

10

3

4

2

6

1

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Water Pump Plate B

LBHR2253

Page 75

Item Part No. References Qty. Description Notes

1 U7LW0172 1 WATER PUMP REPAIR KIT2 F U7LW0172 1 IMPELLER3 F U7LW0172 1 ROLLER BEARING4 F U7LW0172 1 BEARING5 F U7LW0172 1 OIL SEAL6 F U7LW0172 1 SEAL7 F U7LW0172 1 CIRCLIP8 F U7LW0172 1 CIRCLIP9 24880234 1 COVER JOINT10 F U7LW0172 1 DRIVE SHAFT11 3682A011 1 WATER PUMP JOINT

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Pipes Plate A

LBHR2253

Page 76

1

2

4

3

5

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Pipes Plate A

LBHR2253

Page 77

Item Part No. References Qty. Description Notes

1 4133L048 1 CONNECTION2 F 4133L048 1 CONNECTION3 2418F002 1 O RING4 2418F001 1 O RING5 2314H003 2 SCREW

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Water Outlet Housing Plate A

B 31/01/2004 LDHR0704

Page 78

3

1

4

2

6

5

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Water Outlet Housing Plate A

B 31/01/2004 LDHR0704

Page 79

Item Part No. References Qty. Description Notes

1 4133L503 1 CONNECTION2 F 4133L503 1 CONNECTION3 2485C041P 1 THERMOSTAT4 2415H008 1 O RING5 2314H012 1 SCREW6 2314H004 1 SCREW

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Water Outlet Housing Plate A

A 01/02/2004 LDHR0704

Page 80

2

7

1

4

5

3

8

6

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Water Outlet Housing Plate A

A 01/02/2004 LDHR0704

Page 81

Item Part No. References Qty. Description Notes

1 4133L509 1 CONNECTION2 F 4133L509 1 CONNECTION3 F 4133L509 1 THERMOSTAT4 2415H219 1 O RING5 29990015 1 PLUG6 29990016 1 O RING7 2314H012 1 SCREW8 2314H004 1 SCREW

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Alternator Bracket & Fixings Plate A

NDHR2708

Page 82

11

7

1

2

9

3

4

8

6

5

10

12

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Alternator Bracket & Fixings Plate A

NDHR2708

Page 83

Item Part No. References Qty. Description Notes

1 4141A013 1 BRACKET2 F 4141A013 1 BRACKET3 3318H105 1 SLEEVE4 3318H106 1 SLEEVE5 2314J013 2 SCREW6 2318A604 2 NUT7 3823A054 1 BRACKET8 2314J002 1 SCREW9 2314J002 2 SCREW10 3615X014 1 LEVER11 2314H003 1 SCREW12 2318A603 1 NUT

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Timing Case Plate A

QCHR0024

Page 84

2

3

4

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Timing Case Plate A

QCHR0024

Page 85

Item Part No. References Qty. Description Notes

1 3716C471 1 TIMING CASE2 2418F436 1 FRONT OIL SEAL3 3617V015 1 TIMING CASE JOINT4 3617V016 1 TIMING CASE JOINT5 2314H003 8 SCREW6 2314H034 4 SCREW

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Timing Case Plate B

QCHR0024

Page 86

1

2

3

4

5

6

78

910

11

12

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Timing Case Plate B

QCHR0024

Page 87

Item Part No. References Qty. Description Notes

1 3117N042 1 IDLER GEAR2 F 3117N042 1 IDLER GEAR3 0050345 2 BUSH4 33426161 1 HUB5 3241H009 1 PLATE6 2314J010 3 SCREW7 3117N001 1 CAMSHAFT GEAR8 0500012 1 WOODRUFF KEY9 3321A003 1 WASHER10 2116053 1 DOWEL11 3112X011 1 THRUST WASHER12 2314J606 1 SCREW

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Timing Cover Plate A

QCHR0024

Page 88

2

3

14

5

6

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Timing Cover Plate A

QCHR0024

Page 89

Item Part No. References Qty. Description Notes

1 4142A504 1 TIMINGGEAR COVER2 F 4142A504 1 TIMING COVER3 3681P047 1 COVER JOINT4 2314H002 9 SCREW5 2314H012 5 SCREW6 2314J002 1 SCREW

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Air Compressor Plate A

QDHR1384

Page 90

1

34

5

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Air Compressor Plate A

QDHR1384

Page 91

Item Part No. References Qty. Description Notes

1 2488A296 1 EXHAUSTER2 3687H005 1 JOINT3 2311D569 1 SCREW4 2314H034 4 SCREW5 2314J004 1 SCREW

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Pipework Plate A

QDHR1384

Page 92

2

3

1

4

5

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Pipework Plate A

QDHR1384

Page 93

Item Part No. References Qty. Description Notes

1 3437H005 1 OIL PIPE2 0576111 2 NUT3 0566002 2 OLIVE4 3355M005 1 ADAPTOR5 2415D053 1 PLAIN WASHER

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Lubricating Oil Pump & Delivery Housing Plate A

RBHR0031

Page 94

1

2

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Lubricating Oil Pump & Delivery Housing Plate A

RBHR0031

Page 95

Item Part No. References Qty. Description Notes

1 4132F071 1 OIL PUMP2 2314J008 5 SCREW

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Induction Manifold Plate A

TBHR0884

Page 96

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2

1

4

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Induction Manifold Plate A

TBHR0884

Page 97

Item Part No. References Qty. Description Notes

1 4148K007 1 CONNECTION2 F 4148K007 1 CONNECTION3 3682A013 1 INLET MANIFOLD JOINT4 2314H034 4 SCREW

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Pipework & Connections Plate A

TBHR0884

Page 98

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2

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Pipework & Connections Plate A

TBHR0884

Page 99

Item Part No. References Qty. Description Notes

1 3611M006 3 PLATE2 2314H033 12 SCREW3 3684N503 3 JOINT

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Exhaust Manifold Plate A

UBHR0519

Page 100

3

1

2

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Exhaust Manifold Plate A

UBHR0519

Page 101

Item Part No. References Qty. Description Notes

1 3778E232 1 EXHAUST MANIFOLD2 3218J013 8 SCREW3 3681V512 1 EXHAUST MANIFOLD JOINT

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Exhaust Outlet Plate A

UDHR0403

Page 102

7

2

1

3

4

8

6

5

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Exhaust Outlet Plate A

UDHR0403

Page 103

Item Part No. References Qty. Description Notes

1 3767A011 1 ELBOW2 3688C018 3 JOINT3 2313C078 3 STUD4 2318A634 3 NUT5 3688C018 1 JOINT6 3623E006 1 FLANGE7 2314J005 3 SCREW8 2318A634 3 NUT

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Lift Pump Plate A

VBHR2250

Page 104

5

1

2

4

3

Repair Kit

ReparatursaetzRepair Jeu

Repare CorredoLa Juego

10

8

7

9

6

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Lift Pump Plate A

VBHR2250

Page 105

Item Part No. References Qty. Description Notes

1 4132A008 1 LIFT PUMP2 F 4132A008 1 LIFT PUMP3 F U5MK0696 3 SPACER4 F U5MK0696 3 MOUNTING5 26560201 1 FUEL FILTER ELEMENT KIT6 26560177 1 O RING7 2314F909 2 SCREW (A)8 2131A507 2 WASHER (A)9 3763A046 1 CONNECTION10 U5MK0696 1 MOUNTING KIT

Footnotes

(A) ALSO INCLUDED IN REPAIR KIT U5MK0696

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Filter to Injection Pump Pipe Plate A

VBHR2250

Page 106

2

1

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Filter to Injection Pump Pipe Plate A

VBHR2250

Page 107

Item Part No. References Qty. Description Notes

1 2646F003 1 FUEL FEED PIPE2 1 FUEL FILTER

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Injection Pump to Filter Pipe Plate A

VBHR2250

Page 108

5

3

4

6

1

2

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Injection Pump to Filter Pipe Plate A

VBHR2250

Page 109

Item Part No. References Qty. Description Notes

1 2646F004 1 FUEL FEED PIPE2 3763A045 1 CONNECTION3 2481D456 1 CLIP4 3733A008 1 BRACKET5 3313A006 1 SPACER6 2314H008 1 SCREW

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Heater Plugs Plate A

WDHR0345

Page 110

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2

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Heater Plugs Plate A

WDHR0345

Page 111

Item Part No. References Qty. Description Notes

1 2666A016 4 GLOW PLUG2 3161C015 1 BAR

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Engine Lifting Eyes Plate A

XBHR0458

Page 112

12

43

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Engine Lifting Eyes Plate A

XBHR0458

Page 113

Item Part No. References Qty. Description Notes

1 3617A015 1 LIFTING BRACKET2 2314J002 2 SCREW3 3624A016 1 LIFTING BRACKET4 2314J002 2 SCREW

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Engine Mounts Plate A

ZCHR0987

Page 114

2

1

3

4

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Engine Mounts Plate A

ZCHR0987

Page 115

Item Part No. References Qty. Description Notes

1 3837L101 1 BRACKET2 2314J637 4 SCREW3 3837L111 1 BRACKET4 2314J633 4 SCREW

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Engine Mounts Plate B

ZCHR0987

Page 116

1

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Engine Mounts Plate B

ZCHR0987

Page 117

Item Part No. References Qty. Description Notes

1 2487207 8 PLUG

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Lubricating Oil Pressure Switch/Gauge Plate A

ZJHR0546

Page 118

2

1

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Lubricating Oil Pressure Switch/Gauge Plate A

ZJHR0546

Page 119

Item Part No. References Qty. Description Notes

1 3278A004 1 PLUG2 2415H002 1 O RING

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Lubricating Oil Pressure Switch/Gauge Plate B

ZJHR0546

Page 120

1

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Lubricating Oil Pressure Switch/Gauge Plate B

ZJHR0546

Page 121

Item Part No. References Qty. Description Notes

1 0650594 1 PLUG

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Temperature Gauge & Sender Plate A

ZLHR0360

Page 122

2

1

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Temperature Gauge & Sender Plate A

ZLHR0360

Page 123

Item Part No. References Qty. Description Notes

1 3278A006 1 PLUG2 2415H003 1 O RING

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Fuel Pre-Lift Pump Plate A

ZVHR1023

Page 124

3

7

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1

5

2

4

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Fuel Pre-Lift Pump Plate A

ZVHR1023

Page 125

Item Part No. References Qty. Description Notes

1 0650204 1 PLUG2 2411D013 1 PLAIN WASHER3 0650204 1 PLUG4 2411D013 1 PLAIN WASHER5 33532129 1 NUT6 0566004 1 OLIVE7 33532129 1 NUT8 0566004 1 OLIVE

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Water Trap Plate A

ZVHR1023

Page 126

1

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Water Trap Plate A

ZVHR1023

Page 127

Item Part No. References Qty. Description Notes

1 2656F823 1 FUEL FILTER

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Water Trap Plate B

ZVHR1023

Page 128

2

4

8

10

9

1

7

3

6

5

4

3

2

1

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Water Trap Plate B

ZVHR1023

Page 129

Item Part No. References Qty. Description Notes

1 26550005 1 FUEL FILTER ELEMENT KIT2 F 26550005 1 ELEMENT3 F 26550005 2 O RING4 F 26550005 1 O RING5 F 26550005 1 O RING6 F 26550005 1 O RING7 F 2656F823 1 CONTAINER8 26560614 1 PLUG9 F 26560614 1 PLUG10 26431192 1 WASHER

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Miscellaneous & Auxiliaries Plate A

ZZHR1012

Page 130

3

2

1

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Miscellaneous & Auxiliaries Plate A

ZZHR1012

Page 131

Item Part No. References Qty. Description Notes

1 2431154 1 PLUG2 2431154 1 PLUG3 2431154 1 PLUG

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Top Service Kit Plate A

SACR0350

Page 132

Top Service Kit

Kit d'Entretien Haut du Moteur

Wartungssatz für Motoroberteil

Kit per la manutenzione della parte superiore del motore

Juego de Servicio Superior

1

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Top Service Kit Plate A

SACR0350

Page 133

Item Part No. References Qty. Description Notes

1 U5LT0350 1 TOP JOINT AND GASKET KIT

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Bottom Service Kit Plate A

SGBR0371

Page 134

Bottom Joints & Gasket Kit

Kit d'Entretien Bas du Moteur

Wartungssatz für Motorunterteil

Kit per la manutenzione della parte inferiore del motore

Juego de Servicio de la Parte Inferior

1

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Bottom Service Kit Plate A

SGBR0371

Page 135

Item Part No. References Qty. Description Notes

1 U5LB0371 1 BOTTOM JOINT AND GASKET 2 2415715 1 O RING3 36832137 1 JOINT4 3617V015 1 TIMING CASE JOINT5 3617V016 1 TIMING CASE JOINT6 3681P047 1 COVER JOINT7 26420318 1 O RING8 3688A041 1 JOINT9 3688A039 1 JOINT10 3682A011 1 WATER PUMP JOINT11 3688A035 1 JOINT12 3685A024 1 JOINT13 3685A025 1 JOINT14 3681K037 1 SUMP JOINT

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Parts Index

Page 136

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Page 137

Parts Index

Description Part No. Page

ADAPTOR 33127117 45

3355M005 93

37148242 41

3773A081 65

ATOMISER 2645K013 33

BAR 3161C015 111

BIG END BEARING KIT

U5ME0013 15

U5ME0013A 15

U5ME0013B 15

U5ME0013C 15

BLANKING PLATE 3623A009 13, 67

BLANKING PLUG 2485A108 13

2487A452 43

BLOCK 3241N001 71

BOLT 32186137 71

BOTTOM JOINT AND GASKET KIT

U5LB0371 135

BRACKET 3641A007 29

3733A008 109

3733A009 51

3823A054 83

3837L101 115

3837L111 115

4141A013 83

BREATHER PIPE 4134K014 59

BRIDGE PIECE 3627P041 49

BUSH 0050345 87

CABLE 3161C018 35

CAMSHAFT 3141D212 27

CAMSHAFT BUSH 3112D071 13

CAMSHAFT GEAR 3117N001 87

CAP 2487D002 29

3788A002 55

3788A003 55

CIRCLIP 2721332 17

2722A022 25

CLIP 0180170 51

2481D221 31

2481D456 109

2481D556 39

2481Y011 31

2481Y012 31

2646E019 31

CON ROD BOLT 3212V003 19

CONNECTION 33554128 65

3763A045 109

3763A046 105

4133L048 77

4133L503 79

4133L509 81

4148K007 97

CONROD KIT 4115C311 11, 19

4115C312 11, 19

4115C313 11, 19

Description Part No. Page

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Parts Index

Page 138

4115C314 11, 19

4115C315 11, 19

4115C316 11, 19

CORE PLUG 2485A109 37

COTTER 3142W004 23, 23

COVER 3788N003 57

COVER JOINT 24880234 75

3681P047 89, 135

COVER PLATE 3615A009 55

CRANKSHAFT GEAR

3117C221 15

CRANKSHAFT KIT ZZ90224 11, 15

ZZ90224P 11, 15

CRANKSHAFT PULLEY

3114V041 71

CUP PLUG 2485A124 61

CYLINDER BLOCK KIT

ZZ50311 11, 13

CYLINDER HEAD COVER ASSY

4142X292 55

CYLINDER HEAD GASKET

3681E051 23

CYLINDER HEAD KIT

ZZ80270 23

DIAPHRAGM 3789A001 55

DIPSTICK 3178C168 51

DIPSTICK TUBE 4126A081 51

DOWEL 0350025 41, 43

2116053 87

3244A009 13

Description Part No. Page

ELBOW 3767A011 103

EXCHANGE ATOMISER

2645K013R 33

EXHAUST MANIFOLD

3778E232 101

EXHAUST MANIFOLD JOINT

3681V512 101

EXHAUST VALVE 3142A151 23

EXHAUST VALVE INSERT

3314A161 23

EXHAUSTER 2488A296 91

FLANGE 3623E006 103

FLYWHEEL ASSEMBLY

41117314 45

FLYWHEEL HOUSING

37138092 43

FRONT OIL SEAL 2418F436 85

FUEL FEED PIPE 2646F003 107

2646F004 109

FUEL FILTER 2656F823 127

FUEL FILTER ELEMENT KIT

26550005 129

26560201 105

FUEL INJECTION PIPE - NO 1 CYL

3525A091 31

FUEL INJECTION PIPE - NO 2 CYL

3525A092 31

FUEL INJECTION PIPE - NO 3 CYL

3525A093 31

FUEL INJECTION PIPE - NO 4 CYL

3525A094 31

FUEL INJECTION PUMP

2644N203/24 29

Description Part No. Page

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Page 139

Parts Index

FUEL INJECTION PUMP GEAR

3117L251 29

GLOW PLUG 2666A016 111

HUB 33426161 87

IDLER GEAR 3117N042 87

INJECTOR CLAMP 3751A241 33

INJECTOR WASHER L311FF02 33

INLET MANIFOLD JOINT

3682A013 97

INLET VALVE 3142H071 23

INLET VALVE INSERT

3314A151 23

JOINT 36832137 53, 135

3684N503 99

3685A024 63, 135

3685A025 63, 135

3687H005 91

3688A035 135

3688A038 59

3688A039 13, 65, 67, 135

3688A041 65, 135

3688C018 103, 103

LEVER 3615X014 83

LIFT PUMP 4132A008 105

LIFTING BRACKET 3617A015 113

3624A016 113

MAIN BEARING KIT U5MB0019 15

U5MB0019A 15

Description Part No. Page

U5MB0019B 15

U5MB0019C 15

METRIC BOLT 3211C002 11, 21

MOUNTING KIT U5MK0696 105

NUT 0576052 25, 25

0576111 93

2318A603 29, 83

2318A604 47, 83

2318A634 103, 103

33532129 125, 125

3353D005 51

O RING 2415715 49, 135

2415787 29

2415A068 59

2415A131 55

2415H002 119

2415H003 23, 123

2415H008 79

2415H009 65

2415H219 81

2418F001 77

2418F002 77

26420318 135

26560177 105

29990016 81

OIL COOLER 2486A215 63

4134W003 63

Description Part No. Page

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Parts Index

Page 140

OIL FILLER CAP 4142X099 55

OIL FILTER 2654407 69

OIL FILTER HEAD 4134E057 65

OIL PIPE 3437H005 93

OIL PUMP 4132F071 95

OLIVE 0566002 93

0566004 125, 125

33812116 51

PISTON AND RING KIT

4115P011 11, 17

PISTON COOLING JET

2113A001 13

PISTON RING KIT UPRK0003 17

PLAIN WASHER 2411D013 125, 125

2415D053 93

PLATE 3241H009 87

3611M006 99

PLUG 0650204 125, 125

0650588 13, 23

0650594 121

0650710 13

2431154 23, 131, 131, 131

2485A104 25

2487207 117

26560614 129

29990015 81

3212P008 13

3212V006 13

Description Part No. Page

32141316 13

32186405 49

32416117 23

3241A011 13

3241A012 13

3278A004 119

3278A006 23, 123

3278A007 65

32815118 43

PUSHROD 31434307 27

REAR OIL SEAL HOUSING

2418F704 11, 21

ROCKER ARM ASSEMBLY

4115R314 25

4115R315 25

ROCKER ASSEMBLY

4115R612 25

ROCKER COVER JOINT

3681A055 55

ROCKER SHAFT ASSEMBLY

4115R703 25

ROCKER SHAFT SPRING

3174A015 25

SCREW 0096836 45

0748352 41

2151A001 55

2161A011 55, 59

2311D039 49

2311D569 91

2314F001 13

Description Part No. Page

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Page 141

Parts Index

2314F002 51

2314F003 57

2314F909 51, 105

2314H002 39, 49, 89

2314H003 29, 77, 83, 85

2314H004 29, 53, 63, 79, 81

2314H005 73

2314H006 63

2314H008 109

2314H012 73, 79, 81, 89

2314H031 49

2314H033 13, 67, 99

2314H034 85, 91, 97

2314H038 65

2314J002 29, 83, 83, 89, 113, 113

2314J004 43, 91

2314J005 103

2314J008 95

2314J010 87

2314J013 83

2314J606 87

2314J633 115

2314J637 115

2314K161 63

2314K164 73

Description Part No. Page

2314W009 33

2316A901 25

2316A902 25

32114145 25, 25

32166329 13

3218A011 23

3218A012 23

3218J013 101

SEAL 36843154 43

SENDER 2848A127 35

SETSCREW 2314J604 41

SHORT ENGINE RE40003 11

SLEEVE 3318H105 83

3318H106 83

SMALL END BUSH 3112A005 19

SPACER 3313A006 109

37513041 47

SPRING 3174A017 55

STARTER RING GEAR

31162121 45

STUD 2313C078 103

2313M082 47

SUCTION PIPE 3575A059 53

SUMP 3717Y061 49

SUMP JOINT 3681K037 49, 135

SUPPORT BRACKET 3651A016 39

TAPPET 3142U031 27

THERMOSTAT 2485C041P 79

Description Part No. Page

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Parts Index

Page 142

THRUST WASHER 3112X011 87

31137312 15

31137322 15

31137551 15

31137561 15

TIMING CASE 3716C471 85

TIMING CASE JOINT

3617V015 85, 135

3617V016 85, 135

TIMINGGEAR COVER

4142A504 89

TOP JOINT AND GASKET KIT

U5LT0350 133

VALVE CAP 3342A011 23, 23

VALVE GUIDE 3313E021 23, 23

VALVE SPRING 3174A016 23, 23

VALVE STEM SEAL 2418M514 23

2418M519 23

WASHER 0920052 41

2131A507 105

2134A502 25

2411D008 29

Description Part No. Page

26431192 129

33117127 45

3321A003 87

WATER PUMP GEAR 24880232 73

WATER PUMP JOINT

3682A011 73, 75, 135

WATER PUMP KIT U5MW0194 73

WATER PUMP REPAIR KIT

U7LW0172 75

WOODRUFF KEY 0500012 15, 87

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