SENR9500-10

November 2012

Specifications
C-9 Engines for Caterpillar Built
Machines
HAA 1-Up (Machine)
D3C 1-Up (Machine)
GAG 1-Up (Machine)
BRZ 1-Up (Machine)
4ZF 1-Up (Engine)

SAFETY.CAT.COM
 i05086812

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first satisfying
yourself that you have considered all safety rules and precautions applicable to the operation of the
product in the location of use, including site-specific rules and precautions applicable to the
worksite. If a tool, procedure, work method or operating technique that is not specifically
recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others.
You should also ensure that you are authorized to perform this work, and that the product will not be
damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that
you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci-
fications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury
or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SENR9500 3
Table of Contents

Table of Contents Injection Actuation Pressure Sensor ....... ....... 42

Engine Oil Pressure Sensor .............. ............. 43
Specifications Section Engine Oil Temperature Sensor ........... .......... 43
Atmospheric Pressure Sensor............ ............ 44
Engine Design ......................... ......................... 4 Inlet Air Temperature Sensor............. ............. 44
Fuel Filter Base......................... ........................ 4 Turbocharger Outlet Pressure Sensor...... ...... 44
Fuel Priming Pump and Water Separator..... .... 4 Speed/Timing Sensor ................... .................. 44
Unit Injector Hydraulic Pump .............. .............. 5 Speed/Timing Sensor ................... .................. 45
Unit Injector............................ ........................... 6 Electronic Control Module ............... ............... 45
Lifter Group............................ ........................... 8 Air Compressor........................ ....................... 45
Rocker Shaft........................... .......................... 8
Valve Mechanism ....................... ...................... 8 Index Section
Valve Mechanism Cover................. ................ 10
Index................................ ............................... 47
Cylinder Head Valves ................... .................. 10
Cylinder Head......................... ........................ 13
Compression Brake .................... .................... 15
Turbocharger ......................... ......................... 16
Air Inlet Elbow......................... ........................ 20
Exhaust Manifold...................... ...................... 21
Camshaft ............................ ............................ 21
Engine Oil Pump....................... ...................... 22
Engine Oil Pan........................ ........................ 23
Water Temperature Regulator Housing ..... ..... 23
Water Temperature Regulator ............ ............ 24
Water Pump (Pulley for Serpentine Belt ) ... ... 24
Water Pump (V-Belt Pulley) .............. ............. 24
Cylinder Block Cover Group .............. ............. 25
Cylinder Block......................... ........................ 25
Cylinder Liner......................... ......................... 27
Cylinder Liner Projection ................ ................ 28
Crankshaft ........................... ........................... 28
Crankshaft Seals ...................... ...................... 28
Connecting Rod Bearing Journal.......... .......... 29
Main Bearing Journal................... ................... 29
Connecting Rod....................... ....................... 30
Piston and Rings ...................... ...................... 31
Front Housing and Covers............... ............... 32
Gear Group (Front)..................... .................... 34
Rear Power Take-Off (RPTO)............. ............ 35
Flywheel .......................................................... 35
Flywheel Housing ...................... ..................... 36
Belt Tension Chart ..................... ..................... 37
Fan Drive ............................ ............................ 38
Alternator and Regulator................. ................ 38
Alternator and Regulator................. ................ 39
Electric Starting Motor .................. .................. 39
Electric Starting Motor .................. .................. 40
Coolant Temperature Sensor............. ............. 41
Fuel Pressure Sensor................... .................. 41
Injection Actuation Oil Temperature Sensor .. . 42
4 SENR9500
Specifications Section

Specifications Section i01377880

i02841820
Fuel Filter Base
SMCS Code: 1261; 1262
Engine Design S/N: D3C1–Up
SMCS Code: 1201
S/N: BRZ1–Up
S/N: D3C1–Up
S/N: ALA; 4ZF1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up

Illustration 1 g01101255
Cylinder and valve location
(A) Exhaust valves
(B) Inlet valves
Illustration 2 g00727450

Bore ............................................112.0 mm (4.41 inch)

(1) Put 7M-7456 Bearing Mount Compound on the
Stroke ........................................ 149.0 mm (5.87 inch) tapered end of the stud to the following distance.
.......................................6 ± 1.5 mm (0.24 ± 0.06 inch)
Displacement..................................... 8.8 L (537 cu in)
(2) Distance from the sealing surface of the filter base
Cylinder arrangement .....................In-line six cylinder to the end of the stud ................................23 ± 1.3 mm
(0.91 ± 0.05 inch)
Valves per cylinder .................................................... 4
(3) Sealing surface of the stud........................11.5 mm
Type of combustion ..............................Direct injection (0.452 inch)
Valve lash with engine stopped (cold) Note: Do not damage this surface.
Inlet.............. 0.38 ± 0.08 mm (0.015 ± 0.003 inch) (4) Torque for stud...............70 ± 15 N·m (52 ± 11 lb ft)
Exhaust ....... 0.64 ± 0.08 mm (0.025 ± 0.003 inch)
Note: The front of the engine is opposite of the i01430533
flywheel end of the engine. The left side and the right
side of the engine are viewed from the flywheel end of Fuel Priming Pump and Water
the engine. The no. 1 cylinder is the front cylinder. Separator
Crankshaft rotation direction (view from the flywheel SMCS Code: 1258; 1263
end) .................................................Counterclockwise
S/N: D3C1–Up
Firing order (injection sequence) ...........1, 5, 3, 6, 2, 4
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up
SENR9500 5
Specifications Section

(9) Tighten the plugs to the following torque:

..............................................95 ± 10 N·m (70 ± 7 lb ft)

(10) Tighten the bolts to the following torque:

.......................................2.25 ± 0.25 N·m (20 ± 2 lb in)

(11) Tighten the stud to the following torque:

..................................................10 ± 4 N·m (7 ± 3 lb ft)

Dimension (A) .......... 21 ± 0.5 mm (0.875 ± 0.02 inch)

(12) Electrical connection

Voltage ................................................24.0 ± 2.0 VDC

Water Separator and Fuel Filter

Illustration 3 g00728171

(1) Fuel filter base and electric priming pump

(2) Toggle switch
(3) Fuel line
(4) Filter element
(5) Bowl
Illustration 5 g00728241
(6) Electrical connection for the electric priming pump
Use the following procedure in order to assemble the
(7) Drain water separator and fuel filter:
Note: In order to open the self-ventilated drain, turn 1. Remove the cap from the bottom of the fuel filter.
the plug counterclockwise.
2. Remove the O-ring (13) from the cap. Discard the
(8) Plug
cap.
Fuel Priming Pump 3. Lubricate the O-ring with clean oil. Install the O-ring
into the groove of bowl (5).

4. Thread the bowl onto the bottom of fuel filter (4)

and tighten the bowl by hand.

i01834399

Unit Injector Hydraulic Pump

SMCS Code: 1714

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up
Illustration 4 g00749423

(8) Tighten the plug to the following torque:

.................................................. 11 ± 2 N·m (8 ± 1 lb ft)
6 SENR9500
Specifications Section

order to ensure that the gasket compresses

completely. Use the same torque sequence that was
used previously. Final tightening torque for the bolts
................................................28 ± 2 N·m (20 ± 1 lb ft)

(6) Tighten the fitting for the fuel outlet port to the
following torque....................... 15 ± 2 N·m (11 ± 1 lb ft)

Low speed pump performance.

Engine RPM ................................................... 800

Minimum fuel flow ...... 0.45 L/min (0.119 US gpm)
Fuel pressure ..............................425 kPa (62 psi)

High speed pump performance.

Engine RPM ................................................. 2750

Minimum fuel flow ...... 2.27 L/min (0.600 US gpm)
Fuel pressure ..............................425 kPa (62 psi)

i02820444
Illustration 6 g00939387
Typical example Unit Injector
(1) Tighten the fitting for the oil inlet port to the SMCS Code: 1290
following torque...................... 40 + 4 N·m (30 + 3 lb ft) S/N: D3C1–Up
Fuel Transfer Pump S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up

Illustration 7 g00937083
Rear view of the fuel transfer pump (view A-A)

(2) Tighten the fitting for the oil outlet port to the
following torque...................... 48 + 5 N·m (35 + 4 lb ft)

(3) Tighten the three mounting bolts for the fuel

transfer pump to a snug fit. Final tightening torque for
the bolts .............................8.0 ± 0.4 N·m (70 ± 4 lb in)

(4) Tighten the fitting for the fuel inlet port to the
following torque....................... 15 ± 2 N·m (11 ± 1 lb ft)

(5) Tighten the four tie bolts for the pump housing to a
snug fit. Use a crisscross pattern as a torque
sequence. Begin with the bolt in the lower left corner
of the pump housing and tighten the four tie bolts to
28 ± 2 N·m (20 ± 1 lb ft). Torque the bolts again in
SENR9500 7
Specifications Section

Note: Lubricate the bore in the cylinder head lightly

with the lubricant that is being sealed.

Note: Install the fuel injector group (1) so the

electrical connector is facing toward the exhaust side
of the cylinder head.
Use the following procedure to install the fuel injector
group:

1. Seat the fuel injector group in the bore.

2. Tighten the bolt (2) which is closest to the exhaust

side (5) of the cylinder head until the bolt is seated.

3. Tighten the bolt (3) which is closest to the inlet side

(6) of the cylinder head to 12 ± 1 N·m
(105 ± 9 lb in).

Illustration 8 g01407502
(4) O-ring seal

Illustration 10 g01407507
View B-B
(7) Backup ring
(8) O-ring seal
(9) O-ring seal
(10) Backup ring

Illustration 9 g01407503
View A-A
8 SENR9500
Specifications Section

(A) Diameter of a new valve lifter body

.................29.464 ± 0.013 mm (1.1600 ± 0.0005 inch)
(2) Lubricate the roller pin with clean engine oil.

i01156458

Rocker Shaft
SMCS Code: 1102

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up

Illustration 11 g01407504
Top view of fuel injector group

Note: The top of the fuel injector group has four bolts
(11) that are used for securing the top cover on the
fuel injector group. There are two holes (12) in the top
of the fuel injector group that are used for assembly
purposes only. Do not install bolts in the two bolt
holes (12).
Illustration 13 g00614447

i02820477
(1) Diameter of new rocker arm shaft
Lifter Group .................28.000 ± 0.013 mm (1.1024 ± 0.0005 inch)
SMCS Code: 1209 (2) The plugs are measured from the end of the shaft
to the top edge of the plug. Depth of installation
S/N: D3C1–Up ........................... 1.25 ± 0.25 mm (0.049 ± 0.010 inch)
S/N: BRZ1–Up
i02843166
S/N: ALA; 4ZF1–Up
Valve Mechanism
SMCS Code: 1102

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up

Illustration 12 g01407530
(1) Valve lifter insert
(3) Valve lifter roller
SENR9500 9
Specifications Section

Illustration 15 g01417771

(B) Diameter of the new rocker arm shaft

.................28.000 ± 0.013 mm (1.1024 ± 0.0005 inch)

(C) Depth of installation of the two cup plugs from the

end of the rocker arm shaft to the top edge of the cup
plugs .................. 1.25 ± 0.25 mm (0.049 ± 0.010 inch)

Illustration 14 g01417772
(1) Valve bridge
(3) Valve pushrod

Valve lash

Inlet valve .... 0.38 ± 0.08 mm (0.015 ± 0.003 inch)

Exhaust valve............................... 0.64 ± 0.08 mm
(0.025 ± 0.003 inch)
Note: Tighten the nut (2) after you set the valve lash.

(2) Torque for the nut ..............30 ± 7 N·m (22 ± 5 lb ft)

(4) Lubricate the bore in the cylinder block for the
valve lifter assemblies with a 50/50 mixture of clean
engine oil and 8T-2998 Lubricant before installation.

(A) Bore diameter of the valve rocker arm

.................28.050 ± 0.013 mm (1.1043 ± 0.0005 inch)
10 SENR9500
Specifications Section

Illustration 16 g01454259

Note: Tighten the bolts in a numerical sequence that

is shown in Illustration 16 to standard torque.

(5) 163-2459 Spring

Quantity ..............................................................6
Length under test force ......... 14.5 mm (0.57 inch)
Test force.....................65.0 ± 3.5 N (14.6 ± 0.8 lb)
Approximate free length after test......... 30.75 mm
(1.211 inch)
Outside diameter............... 34.80 mm (1.370 inch)

i01498741

Valve Mechanism Cover

SMCS Code: 1107

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up Illustration 17 g00728341
Typical example

Tighten the bolts in a numerical sequence to the

following torque.......................28 ± 7 N·m (21 ± 5 lb ft)

i02835272

Cylinder Head Valves

SMCS Code: 1105

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up
SENR9500 11
Specifications Section

Illustration 19 g01416603
View of area C

(F) Angle of face of inlet valve seat insert ....... 65.00 ±

0.25 degrees

Illustration 18 g01416580
Section view of the cylinder head valves
(1) Inlet valve
(2) Exhaust valve

Note: Coat the inlet valve stems and the exhaust

valve stems with 8T-2998 Lubricant prior to
installation into the cylinder head.

(A) Height to the valve guide above the top surface of

the cylinder head ..... 12.0 ± 0.5 mm (0.47 ± 0.02 inch)

(3) 190-6117 Spring

Length under test force ..... 37.70 mm (1.484 inch) Illustration 20 g01416597

Test force.......................350 ± 17 N (78.7 ± 3.8 lb) View of area D

Approximate free length after test......... 57.80 mm
(2.276 inch) (G) Angle of face of exhaust valve seat insert (first
Outside diameter............... 31.79 mm (1.252 inch) cut) ...................................................... 20 ± 1 degrees

(4) 190-6115 Spring (H) Angle of face of exhaust valve seat insert (second
cut) ............................................ 45.00 ± 0.25 degrees
Length under test force ......... 36.5 mm (1.44 inch)
Test force.........................187 ± 8 N (42.0 ± 1.8 lb)
Approximate free length after test......... 57.80 mm
(2.276 inch)
Outside diameter............... 23.18 mm (0.913 inch)

(B) New valve stem diameter ......... 9.441 ± 0.010 mm

(0.3717 ± 0.0004 inch)

(E) Diameter of valve heads ............. 36.00 ± 0.13 mm

(1.417 ± 0.005 inch)

Illustration 21 g01416605

(J) Depth of the bore in the cylinder head for the valve
seat insert
12 SENR9500
Specifications Section

Inlet.............. 9.50 ± 0.05 mm (0.374 ± 0.002 inch)

Exhaust ..... 12.00 ± 0.05 mm (0.472 ± 0.002 inch)

Note: Shrink the valve seat inserts by reducing the

temperature. Shrinking the valve seat inserts allows
placement into the counterbore.

(K) Angle of valve face

Inlet valve ........................... 65.75 ± 0.25 degrees

Exhaust valve .....................45.75 ± 0.25 degrees

(L) Bore in cylinder head for valve seat insert

Inlet valve ............................... 37.000 ± 0.015 mm

(1.4567 ± 0.0006 inch)
Exhaust valve......................... 37.500 ± 0.015 mm
(1.4764 ± 0.0006 inch)

(M) Outside diameter of the valve seat insert

Inlet valve ............................... 37.060 ± 0.013 mm

(1.4591 ± 0.0005 inch)
Exhaust valve......................... 37.560 ± 0.013 mm
(1.4787 ± 0.0005 inch)
SENR9500 13
Specifications Section

i02615804

Cylinder Head
SMCS Code: 1100

Part No.: 210-5987

S/N: HAA1–Up
S/N: D3C1–Up
Part No.: 210-5987
S/N: GAG1–Up
S/N: BRZ1–Up
Part No.: 210-5987
S/N: AEM; 4ZF1–Up
Part No.: 210-5987
S/N: BLT; 4ZF1–Up
Part No.: 210-5987
S/N: ALA; 4ZF1–Up
14 SENR9500
Specifications Section

Illustration 22 g01313396
SENR9500 15
Specifications Section

Note: Lubricate bolts with clean engine oil prior to

assembly.
Use the following procedure in order to tighten the
cylinder head bolts:

1. Tighten bolt (1) through bolt (26) in a numerical

sequence.

Tighten the bolts to the following torque.

........................................160 ± 15 N·m (118 ± 11 lb ft)

2. Tighten bolt (1) through bolt (26) again in a

numerical sequence.
Illustration 24 g00613567
Tighten the bolts again to the following torque. View A-A
.......................................160 ± 15 N·m ( 118 ± 11 lb ft)
Note: Apply 4C-9507 Retaining Compound to the
3. Place a mark on bolt (1) through bolt (26). Rotate bores for the cup plugs prior to assembly.
bolt (1) through bolt (26) in a numerical sequence.
(27) The cup plugs (X) are measured from the head
Rotate the bolts in the clockwise direction. ............. 90 face to the top edge of the plug. Depth of installation
degrees (1/4 turn) ...................................1.5 ± 0.5 mm ( 0.06 ± 0.02 inch)
4. Loosen bolt (1) through bolt (26) in a numerical Height of new cylinder head ........... 130.00 ± 0.15 mm
sequence. ( 5.118 ± 0.006 inch)
Loosen bolts to the following torque. ......0 N·m (0 lb ft) Note: The flatness of the cylinder head should be
within 0.15 mm ( 0.006 inch). The flatness should
5. Repeat steps 1 through 3. also be a maximum of 0.05 mm ( 0.002 inch) for any
150.00 mm ( 5.906 inch) span.
6. Tighten bolt (27) through bolt (31) in a numerical
sequence.
i01385654
Tighten the bolts to the following torque.....28 ± 7 N·m
( 21 ± 5 lb ft) Compression Brake
SMCS Code: 1119; 1129
(32) Plug (not shown)
S/N: D3C1–Up
Tighten the plugs for the high pressure oil gallery
on each end of the cylinder head to the following S/N: BRZ1–Up
torque. .....................350 ± 30 N·m ( 258 ± 22 lb ft)
S/N: ALA; 4ZF1–Up

Illustration 23 g01094412
16 SENR9500
Specifications Section

Illustration 26 g01440729
Typical example
(1) Clamp

Illustration 25 g00732397

(1) Tighten two bolts (1) to the following torque.

................................................28 ± 7 N·m (21 ± 5 lb ft)

(2) Injector lash adjustment screw. Loosen locknut

(3). Turn adjustment screw (2) clockwise to the point
of contact with the bridge pin. Turn adjustment screw
(2) counterclockwise for 360 degrees, plus an
additional 60 degrees counterclockwise 1/8 turn. Hold
adjustment screw (2) in place and tighten locknut (3)
to the following torque.........................55 N·m (41 lb ft)
Illustration 27 g01440730
Note: The individual components of the Compression
Typical example of a turbocharger with a wastegate
Brake are not serviced separately.
(1) Clamp
(2) Wastegate
i02894588
(1) Clamps
Turbocharger To tighten clamps (1) on the turbocharger, use the
SMCS Code: 1052 following procedure:

S/N: D3C1–Up 1. Tighten the clamp.

S/N: BRZ1–Up Tighten the clamp to the following torque.
S/N: ALA; 4ZF1–Up ..........................................14 ± 1 N·m (10.3 ± 0.7 lb ft)

2. Gently tap the clamp with a soft faced hammer.

3. Again tighten the clamp.

Tighten the clamp to the following torque.

..........................................14 ± 1 N·m (10.3 ± 0.7 lb ft)

(2) Wastegate

Opening pressure of the wastegate......... 138 kPa

(20 psi)
SENR9500 17
Specifications Section

Illustration 28 g01440731 Illustration 30 g01440733

Typical example Typical example
(1) Clamp (3) Clamp

Illustration 29 g01440732 Illustration 31 g01440735

Typical example of a turbocharger with a wastegate Typical example of a turbocharger with a wastegate
(1) Clamp (3) Clamp
(2) Wastegate (4) Wastegate

(1) Clamps (3) Clamp

To tighten clamps (1) on the turbocharger, use the To tighten the clamp (3) on the turbocharger, use the
following procedure: procedure that follows.

1. Tighten the clamp. 1. Tighten the clamp.

Tighten the clamp to the following torque. Tighten the clamp to the following torque.........18 N·m
..........................................14 ± 1 N·m (10.3 ± 0.7 lb ft) (13.3 lb ft)

2. Gently tap the clamp with a soft faced hammer. 2. Loosen the clamp.

3. Again tighten the clamp. Loosen the clamp to the following torque...........6 N·m
(53.1 lb in)
Tighten the clamp to the following torque.
..........................................14 ± 1 N·m (10.3 ± 0.7 lb ft) 3. Tighten the clamp.

(2) Wastegate Tighten the clamp to the following torque.

.........................................13.5 ± 1 N·m (9.9 ± 0.7 lb ft)
Opening pressure of the wastegate......... 193 kPa
(28 psi) (4) Wastegate

Opening pressure of the wastegate......... 156 kPa

(23 psi)
18 SENR9500
Specifications Section

Tighten the clamp nut to the following torque.

.........................................................18 N·m (13.3 lb ft)

2. Loosen the clamp.

Loosen the clamp nut to the following torque.....6 N·m

(53.1 lb in)

3. Tighten the clamp.

Tighten the clamp nut to the following torque.

.........................................13.5 ± 1 N·m (9.9 ± 0.7 lb ft)
(7) Bolt

Illustration 32 g01440737
Tighten the bolts (7) for the compressor clamp
assembly in opposite pairs. Tighten the bolts for the
Typical example compressor clamp assembly to the following torque
(5) Clamp 17.5 ± 1 N·m (12.90 ± 0.70 lb ft).

(5) Clamps Apply 5P-3931 Anti-Seize Compound to the nuts

that are used to mount the turbocharger. Tighten the
To tighten clamps (5) on the turbocharger, use the nuts to the following torque 70 ± 15 N·m
following procedure: (51.6 ± 11.0 lb ft).

1. Tighten the clamp.

Tighten the clamp to the following torque.

..........................................18 ± 3 N·m (13.3 ± 2.2 lb ft)

2. Gently tap the clamp with a soft faced hammer.

3. Again tighten the clamp.

Tighten the clamp to the following torque.

..........................................18 ± 3 N·m (13.3 ± 2.2 lb ft)

Illustration 34 g01440739
Typical example
(8) Clamp
(9) Bolt

(8) Clamp
To tighten the clamp (8) on the turbocharger, use the
following procedure:

1. Tighten the clamp.

Tighten the clamp to the following torque.........18 N·m

Illustration 33 g01440738
(13.3 lb ft)
Typical example
(6) Clamp 2. Loosen the clamp.
(7) Bolt
Loosen the clamp to the following torque...........6 N·m
(6) Clamp (53.1 lb in)
To tighten the clamp (6) on the turbocharger, use the 3. Tighten the clamp.
following procedure:
Tighten the clamp to the following torque.
1. Tighten the clamp.
.........................................13.5 ± 1 N·m (9.9 ± 0.7 lb ft)

(9) Bolt
SENR9500 19
Specifications Section

Tighten the bolt to the following torque.

..................................13.5 ± 1 N·m (9.9 ± 0.7 lb ft)

Illustration 36 g01440754
Typical example of a turbocharger with a wastegate
Illustration 35 g01440751 (13) Clamp
Typical example of a turbocharger with a wastegate (14) Wastegate
(15) Clamp
(10) Clamp
(11) Wastegate
(12) Clamp
(13) Clamp

(10) Clamp To tighten the clamp (13) on the turbocharger, use the
following procedure:
To tighten the clamp (10) on the turbocharger, use the
following procedure: 1. Tighten the clamp.

1. Tighten the clamp. Tighten the clamp to the following torque.........18 N·m
(13.3 lb ft)
Tighten the clamp to the following torque.........18 N·m
(13.3 lb ft) 2. Loosen the clamp.

2. Loosen the clamp. Loosen the clamp to the following torque...........6 N·m
(53.1 lb in)
Loosen the clamp to the following torque...........6 N·m
(53.1 lb in) 3. Tighten the clamp.

3. Tighten the clamp. Tighten the clamp to the following torque.

.........................................13.5 ± 1 N·m (9.9 ± 0.7 lb ft)
Tighten the clamp to the following torque.
.........................................13.5 ± 1 N·m (9.9 ± 0.7 lb ft) (14) Wastegate

(11) Wastegate Opening pressure of the wastegate......... 165 kPa

(24 psi)
Opening pressure of the wastegate......... 156 kPa
(23 psi) (15) Clamp

(12) Clamp Tighten the clamp to the following torque.

..................................13.5 ± 1 N·m (9.9 ± 0.7 lb ft)
Tighten the clamp (12) to the following torque.
..................................13.5 ± 1 N·m (9.9 ± 0.7 lb ft)
20 SENR9500
Specifications Section

Illustration 37 g01440757 Illustration 38 g01440766

Typical example Typical example
(16) Clamp (18) Bolt
(17) Bolt (19) Bolt

(16) Clamp (18) Bolt

To tighten the clamp (16) on the turbocharger, use the 1. Tighten the bolt.
following procedure:
Tighten the turbine clamp plate bolts (18) to the
1. Tighten the clamp. following torque...........15.8 ± 0.6 N·m (11.6 ± 0.4 lb ft)
Tighten the clamp to the following torque.........18 N·m (19) Bolt
(13.3 lb ft)
1. Tighten the bolt.
2. Loosen the clamp.
Tighten the compressor clamp plate bolts (19) in
Loosen the clamp to the following torque...........6 N·m opposite pairs. Tighten the compressor clamp plate
(53.1 lb in) bolts to the following torque.....................17.5 ± 1 N·m
(12.9 ± 0.7 lb ft)
3. Tighten the clamp.
Apply 5P-3931 Anti-Seize Compound to the nuts
Tighten the clamp to the following torque. that are used to mount the turbocharger. Tighten the
............................................13 ± 1 N·m (9.6 ± 0.7 lb ft) nuts to the following torque 70 ± 15 N·m
(51.6 ± 11.0 lb ft).
(17) Bolt
To tighten the Bolt (17) on the turbocharger, use the i01391076
following procedure:
Air Inlet Elbow
1. Tighten the bolt.
SMCS Code: 1071
Tighten the bolt to the following torque.............18 N·m
S/N: D3C1–Up
(13.3 lb ft)
S/N: BRZ1–Up
2. Loosen the bolt.
S/N: ALA; 4ZF1–Up
Loosen the bolt to the following torque...............6 N·m
(53.1 lb in)

3. Tighten the bolt.

Tighten the bolt to the following torque.......13 ± 1 N·m

(9.6 ± 0.7 lb ft)
SENR9500 21
Specifications Section

188-9037 S/N: ALA; 4ZF1–Up

Illustration 39 g00621798

(1) Air Inlet Elbow

Apply 1U-8846 Liquid Gasket to the face of the
elbow and spread the sealant uniformly. The elbow
must be assembled and tightened within ten minutes.
Illustration 41 g01417808
(2) Tighten the bolts to the following torque.
Typical example
................................................28 ± 7 N·m (21 ± 5 lb ft)
(1) Cylinder head
173-6107
(2) Torque for 12 taperlock studs ................35 ± 5 N·m
(26 ± 4 lb ft)

(3) Torque for four taperlock studs..............35 ± 5 N·m

(26 ± 4 lb ft)
(4) Install the gasket with the tab upward, as shown.
(5) Apply 4C-5599 Anti-Seize Compound to the
threads of the locknuts and the bearing surface of the
locknuts and the washers before assembly.

i02845826

Camshaft
Illustration 40 g00733157
SMCS Code: 1210

(1) Air Inlet Elbow S/N: D3C1–Up

Apply 1U-8846 Liquid Gasket to the face of the S/N: BRZ1–Up

elbow and spread the sealant uniformly. The elbow S/N: ALA; 4ZF1–Up
must be assembled and tightened within ten minutes.

(2) Tighten the bolts to the following torque.

................................................28 ± 7 N·m (21 ± 5 lb ft)

i02843259

Exhaust Manifold
SMCS Code: 1059

S/N: D3C1–Up
S/N: BRZ1–Up
22 SENR9500
Specifications Section

In order to determine the actual camshaft lobe lift, use

the following procedure:

1. Measure the camshaft lobe height (D).

2. Measure the base circle (E).

3. Subtract the base circle (E) from the camshaft lobe

height (D). The difference is the actual camshaft
lobe lift.

Maximum permissible difference between actual lobe

lift and the specified lobe lift of a new camshaft
................................................± 0.10 mm (0.004 inch)

i01154462

Engine Oil Pump

SMCS Code: 1304

S/N: D3C1–Up
Illustration 42 g01419279
(1) Cam gear S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up
(2) Camshaft

End play of a new camshaft......... 0.13 ± 0.08 mm

(0.005 ± 0.003 inch)
Maximum permissible end play of a worn
camshaft.............................. 0.46 mm (0.018 inch)

(A) Diameter of the bearing journals for a new

camshaft .......................................65.126 ± 0.013 mm
(2.5640 ± 0.0005 inch)

(B) Plate

Thickness of the new plate ..... 4.7 mm (0.19 inch)

Thickness of the groove in the new camshaft
....................4.83 ± 0.05 mm (0.190 ± 0.002 inch)

Illustration 44 g00613083

Illustration 43 g01419280

Illustration 45 g00613105
(C) Specified camshaft lobe lift
Section view of bypass valve
Exhaust lobe ................... 6.858 mm (0.2700 inch)
Inlet lobe.......................... 8.655 mm (0.3407 inch) (1) Distance between the front face of the gear and
the housing ...... 43.00 ± 0.25 mm (1.693 ± 0.010 inch)
SENR9500 23
Specifications Section

(2) Length of the gears ................. 33.000 ± 0.025 mm • Connecting joint of the front housing and the front
(1.2992 ± 0.0010 inch) of the cylinder block

Depth of the bores for the gears ....... 33.13 ± 0.02 mm • Connecting joint of the flywheel housing and the
(1.304 ± 0.001 inch) rear of the cylinder block

(3) Diameter of the gear shafts ..... 15.600 ± 0.005 mm Use the following procedure to tighten the bolts for
the oil pan.
(0.6142 ± 0.0002 inch)
Tighten the four bolts (X) to the following torque.
Bores in the pump bodies for the gear shafts
................................................31 ± 3 N·m (23 ± 2 lb ft)
.................15.641 ± 0.008 mm (0.6158 ± 0.0003 inch)
Start with bolt (Z) and tighten all remaining bolts in a
(4) 105-1805 Spring for relief valve counterclockwise sequence.
Outside diameter................... 13.0 mm (0.51 inch) Tighten the bolts to the following torque.....31 ± 3 N·m
Free length ........................ 64.98 mm (2.558 inch) (23 ± 2 lb ft)
Assembled length ................. 54.5 mm (2.15 inch)
Load at assembled length................51.99 ± 1.9 N Start again with bolt (Z) and tighten all the bolts in a
(12 ± 0.4 lb) counterclockwise sequence.

(5) Relief valve plunger Tighten the bolts to the following torque.....31 ± 3 N·m
(23 ± 2 lb ft)
Diameter of the plunger.......... 17.000 ± 0.013 mm
(0.6693 ± 0.0005 inch) Tighten the oil drain plug to the following torque.
Bore in the pump body for the plunger ................................................40 ± 5 N·m (30 ± 4 lb ft)
.......... 17.100 ± 0.025 mm (0.6732 ± 0.0010 inch)
i02822670

i01952078
Water Temperature Regulator
Engine Oil Pan Housing
SMCS Code: 1302 SMCS Code: 1393

S/N: D3C1–Up S/N: D3C1–Up

S/N: BRZ1–Up S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up S/N: ALA; 4ZF1–Up

Illustration 46 g01015517

Apply 230-6262 Sealant to four areas on the

sealing surface of the oil pan. The areas are marked
location (Y). The areas are at the corners of the oil
pan in the following locations:

Illustration 47 g01410924

(1) Lubricate the sealing lip of the lip type seal lightly
with glycerin or an approved equivalent.
24 SENR9500
Specifications Section

i01151061

Water Temperature Regulator

SMCS Code: 1355

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up

Illustration 48 g00589065

Fully open temperature of the water temperature

Illustration 49 g00730883
regulator................................................ 92 °C (198 °F)

Begin to open temperature of the water temperature (1) Clearance between the impeller and the housing
regulator........................81 ° to 84 °C (178 ° to 183 °F) ............................... 0.75 ± 0.25 mm (.030 ± .010 inch)
(2) Seal
(1) Minimum stroke of the water temperature
regulator at fully open temperature................ 10.4 mm (3) Height of seal............................... 10.70 ± 0.15 mm
(0.41 inch) (0.42 ± 0.01 inch)

i01386280 (4) Distance from the front of the water pump pulley to
the face of the housing ....................... 136.9 ± 0.3 mm
Water Pump (5.40 ± 0.01 inch)
(Pulley for Serpentine Belt ) (5) The bearing must not extend beyond the edge of
the housing.
SMCS Code: 1361

S/N: D3C1–Up i01386232

S/N: BRZ1–Up Water Pump

S/N: ALA; 4ZF1–Up (V-Belt Pulley)
SMCS Code: 1361

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up
SENR9500 25
Specifications Section

Illustration 51 g01101767

Use the following procedure to tighten the bolts for

the cylinder block cover group:

1. Tighten bolt (1) through bolt (11) in the numerical

sequence that is shown.
Illustration 50 g00730817
2. Again tighten the bolt (1) through bolt (11) in the
(1) Clearance between the impeller and the housing numerical sequence that is shown.
............................... 0.75 ± 0.25 mm (.030 ± .010 inch)
(12) Torque for the bolt............15 ± 3 N·m (11 ± 2 lb ft)
(2) Seal
i02845073
(3) Height of seal............................... 10.70 ± 0.15 mm
(0.42 ± 0.01 inch)
Cylinder Block
(4) Distance from the first V-groove of the water pump SMCS Code: 1201
pulley to the face of the housing ......... 151.8 ± 0.3 mm
(5.98 ± 0.01 inch) S/N: D3C1–Up
(5) The bearing must not extend beyond the edge of S/N: BRZ1–Up
the housing.
S/N: ALA; 4ZF1–Up
i02843502

Cylinder Block Cover Group

SMCS Code: 1201

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up
26 SENR9500
Specifications Section

Illustration 52 g01418207 Illustration 54 g01418605

Right side view View C-C

(G) Distance from the centerline of the crankshaft

bore to the top surface of the cylinder block
.....................356.50 ± 0.15 mm (14.035 ± 0.006 inch)

(J) Camshaft bores

Bore diameters in the cylinder block for the

camshaft bearings except for the front camshaft
bearing. ..................................70.000 ± 0.038 mm
(2.7559 ± 0.0015 inch)
Bore diameter in the cylinder block for the front
camshaft bearing. .................. 70.000 ± 0.025 mm
(2.7559 ± 0.0010 inch)

Illustration 53 g01418249
(K) Distance from the centerline of the crankshaft to
the bottom surface of the cylinder block .....110.00 mm
View B-B
(4.331 inch)
(A) Distance from the top of the cylinder block to the (L) Bore in the cylinder block for the seven main
top of the dowel........ 14.0 ± 0.5 mm (0.55 ± 0.02 inch) bearings .......................................112.000 ± 0.013 mm
(D) Distance from the rear face of the cylinder block (4.4094 ± 0.0005 inch)
to the end of dowels.............................. 12.0 ± 0.5 mm (M) Width of the main bearing cap
(0.47 ± 0.02 inch) ...............175.000 ± 0.020 mm (6.8898 ± 0.0008 inch)
(E) Distance from the front face of the cylinder block Use the following procedure in order to tighten the
to the end of dowels.................................8.0 ± 0.5 mm main bearing cap bolts (1) :
(0.31 ± 0.02 inch)
1. Orient the main bearing cap correctly. The part
(F) Installation depth of the cup plug from the block number on the main bearing cap must face to the
face to the top edge of the plug .......... 1.25 ± 0.25 mm right and to the front face of the block.
(0.049 ± 0.010 inch)
Note: The main bearing caps are marked with
identification numbers “1” through “7” . Install the
main bearing caps into the correct positions.
SENR9500 27
Specifications Section

2. Lubricate the main bearing cap bolts. Use SAE

30W oil or molybdenum grease to lubricate the
threads and the washer face.
3. Torque the main bearing cap bolts to 95 ± 5 N·m
(70 ± 4 lb ft).

4. Put an alignment mark on each cap and bolt.

5. Rotate the bolts in the clockwise direction to an

angle of 90 ± 5 degrees.

Illustration 56 g01418614
View R-R

(2) The oil hole in the bearing must be in alignment

with the oil hole in the block.
The flatness of the top contact surface of the cylinder
block must be within 0.05 mm (0.002 inch) for any
150 mm (5.9 inch) section of the surface.

i02844254

Illustration 55 g01418610
Cylinder Liner
View H-H
SMCS Code: 1216

NOTICE S/N: D3C1–Up

Camshaft bearings must be installed into their correct
position. Failure to do so will result in engine damage. S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up
The camshaft bearings are installed into the cylinder
block at the following positions:

Position (N) .............................. 816.50 ± 0.80 mm

(32.146 ± 0.031 inch)
Position (P) .............................. 536.50 ± 0.80 mm
(21.122 ± 0.031 inch)
Position (S) .............................. 294.50 ± 0.80 mm
(11.594 ± 0.031 inch)
Position (T) .................................. 0.50 ± 0.25 mm
(0.020 ± 0.010 inch)

(U) Installation depth of the cup plug from the block

face to the top edge of the plug .......... 1.25 ± 0.25 mm
(0.049 ± 0.010 inch)
28 SENR9500
Specifications Section

Table 1
Specifications

0.060 to −0.060 mm
Liner projection
(0.0024 to −0.0024 inch)

Maximum variation in each liner 0.051 mm (0.0020 inch)

Maximum average variation be-

0.080 mm (0.0031 inch)
tween adjacent liners

Maximum variation between all

0.102 mm (0.0040 inch)
six liners

i02765209

Crankshaft
SMCS Code: 1202

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up

Illustration 57 g01418223

Note: Apply 5P-3975 Rubber Lubricant to the

cylinder liner seal prior to assembly.

Outside diameters of the cylinder liner

Position (A) .............................. 128.95 ± 0.03 mm

(5.077 ± 0.001 inch)
Position (B) .............................. 123.80 ± 0.30 mm
(4.874 ± 0.012 inch) Illustration 58 g01384054
Position (C) .............................. 123.95 ± 0.13 mm
(1) Main bearing journals
(4.880 ± 0.005 inch) (2) Connecting rod bearing journals
Position (D) .............................. 126.00 ± 0.27 mm
(4.961 ± 0.011 inch) (A) Average diameter of gear after assembly
Position (E) .............................. 126.24 ± 0.03 mm ........................112.48 ± 0.10 mm (4.428 ± 0.004 inch)
(4.970 ± 0.001 inch)
Position (F) .............................. 120.34 ± 0.08 mm Maximum diameter of gear after assembly
(4.738 ± 0.003 inch) ............................................... 112.63 mm (4.434 inch)

Bore diameter for the cylinder liner Crankshaft end play after assembly into cylinder
............... 112.025 ± 0.025 mm (4.4104 ± 0.0010 inch) block ................0.21 to 0.60 mm (0.008 to 0.024 inch)

i02084820 i02844263

Cylinder Liner Projection Crankshaft Seals

SMCS Code: 1216 SMCS Code: 1160; 1161

S/N: D3C1–Up S/N: D3C1–Up

S/N: BRZ1–Up S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up S/N: ALA; 4ZF1–Up
SENR9500 29
Specifications Section

When the front crankshaft seal (3) is installed, the

front face of the seal must be 2.5 mm (0.10 inch)
from the face of the front housing (2).

Illustration 59 g01418240
(4) O-ring seal
(5) Bolt
Illustration 61 g01419999
Detail B
(7) Rear crankshaft seal group with dust lip

Note: The rear crankshaft seal group (6) is a double

lipped seal that is used for wet flywheel housing
applications.

i02741422

Connecting Rod Bearing

Journal
SMCS Code: 1202; 1219; 1225

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up
Table 2
Connecting Rod Bearing Journal
Illustration 60 g01123043
Detail A Original size journal 80.000 ± 0.020 mm
(3.1496 ± 0.0008 inch)
Note: Refer to Disassembly and Assembly for the
complete procedure that is used for information that Reuse And Salvage Guidelines, SEBF8041
relates to the removal and the installation of the front
and the rear crankshaft seals. Note: No undersized bearings exist for the
connecting rod bearing journals.
Note: The crankshaft seal excluder (1) can be
installed with the front seal for use in applications that i04041250
operate in harsh environments. If the extruder is used
on your application, lubricate the inside diameter of
the crankshaft seal excluder with liquid soap prior to
Main Bearing Journal
assembly to the crankshaft pulley. SMCS Code: 1202; 1203

S/N: D3C1–Up
30 SENR9500
Specifications Section

S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up
Table 3
Diameter of Crankshaft Journal (Bearing Surface) for Main
Bearings

104.000 ± 0.020 mm
Original size journal
(4.0945 ± 0.0008 inch)

Undersized journal 0.25 mm 103.75 ± 0.02 mm

(0.00984 inch) (4.08464 ± 0.00079 inch)

Undersized journal 103.49 ± 0.02 mm

0.51 mm (0.02008 inch) (4.07440 ± 0.00079 inch)

Reuse And Salvage Guidelines, SEBF8041

Table 4
Main Bearing Bore

Main bearing bore (original size) 112.000 ± 0.013 mm

(4.4094 ± 0.0005 inch)

Reuse And Salvage Guidelines, SEBF8735

Note: No oversized bearings exist for the main bore

of the cylinder block.

i02840023 Illustration 62 g01418268

Connecting Rod Note: Handle the fractured connecting rod with care.
SMCS Code: 1218 Use a soft jawed vise in order to hold the connecting
rod when you are loosening the connecting rod cap
S/N: D3C1–Up bolts. Use a soft faced hammer in order to tap the
connecting rod cap, if necessary.
S/N: BRZ1–Up
(A) Bore in the bearing for the piston pin
S/N: ALA; 4ZF1–Up .................46.035 ± 0.008 mm (1.8124 ± 0.0003 inch)

(B) Bore in the connecting rod for the piston pin

bearing..... 50.640 ± 0.013 mm (1.9937 ± 0.0005 inch)
(C) The bearing joint must be within ± 5 degrees of
either location.

Note: The connecting rod must be heated for the

installation of the piston pin bearing. Do not use a
torch.

(D) The connecting rod may be heated from

175 to 260 °C (347 to 500 °F) for the installation of
the piston pin bearing. Maximum distance for heating
the connecting rod ....................... 83.0 mm (3.27 inch)
Note: Thoroughly lubricate the piston pin with clean
engine oil prior to assembly of the piston and
connecting rod.

(E) Distance between the center of the bearings

...............................................217.00 mm (8.543 inch)

(G) Bore in the connecting rod for the crankshaft

bearing..... 85.000 ± 0.013 mm (3.3465 ± 0.0005 inch)
SENR9500 31
Specifications Section

Two-Piece Articulated Piston

Illustration 63 g01416591
View F-F
Illustration 64 g00293184

(1) Etch the cylinder number on the connecting rod

and the cap in this location. Mark the connecting rod
and the cap with a number 1 through 6. Mark the
numbers on the same side of the connecting rod as
the bearing retainer notch (3).

Note: Install the rod and piston group in the engine

with the part number of the forging for the rod
assembly to the rear of the engine. The rear of the
engine is the flywheel end of the engine. Lubricate
the rod and piston group with clean engine oil before
you insert the rod and piston group into the block.
(2) Use the following procedure to tighten the
connecting rod bolts:

1. Torque the bolts to 50 ± 5 N·m (37 ± 4 lb ft).

2. Rotate each bolt in a clockwise direction for 90 ± 5

degrees (1/4 of a turn).

i01801986

Piston and Rings Illustration 65 g00729728

SMCS Code: 1214; 1215 (1) Crown assembly

S/N: D3C1–Up (2) Connecting rod

S/N: BRZ1–Up Note: Install the rod and piston group in the engine
with the part number of the forging for the rod
S/N: ALA; 4ZF1–Up assembly to the rear of the engine. The rear of the
engine is the flywheel end of the engine. Lubricate
the rod and piston group with clean engine oil before
you insert the rod and piston group into the block.

Top Ring and Intermediate Ring

(3) The top ring has the mark “UP-1” .
Install the piston ring with the side marked “UP-1”
toward the top of the piston. The colored stripe faces
to the right of the ring end gap.

Piston ring end gap............................. 0.40 ± 0.10 mm

( 0.016 ± 0.004 inch)
32 SENR9500
Specifications Section

Minimum depth of the groove in new piston for the top Thoroughly lubricate the piston pin with clean engine
ring ............................................ 5.16 mm ( 0.203 inch) oil prior to assembly.

Thickness of new top piston ring ........ 2.88 ± 0.05 mm i02818173

( 0.113 ± 0.002 inch)
(4) The intermediate ring has the mark “UP-2” .
Front Housing and Covers
SMCS Code: 1162; 1166
Install the piston ring with the side marked “UP-2”
toward the top of the piston. The colored stripe faces S/N: D3C1–Up
to the right of the piston ring end gap.
S/N: BRZ1–Up
Piston ring end gap..................................0.6 ± 0.1 mm
( 0.02 ± 0.01 inch) S/N: ALA; 4ZF1–Up

Width of groove in new piston for intermediate piston

ring .................... 3.06 ± 0.01 mm ( 0.121 ± 0.001 inch)

Minimum depth of the groove in new piston for the

intermediate ring .......................5.16 mm ( 0.203 inch)

Thickness of new intermediate piston ring

.......................... 3.00 ± 0.01 mm ( 0.120 ± 0.001 inch)

Oil Control Ring

(5) The oil control piston ring has a spring that is
installed with the ring. The gap in the spring should be
a distance of 180 degrees from the ring end gap
when the oil control piston ring is assembled. The
colored portion can be to the right or to the left of the
ring end gap.

Piston ring end gap............................. 0.45 ± 0.15 mm

( 0.018 ± 0.006 inch)

Width of groove in new piston for oil control piston Illustration 66 g01405402
ring .................... 4.03 ± 0.01 mm ( 0.159 ± 0.001 inch) (1) Cylinder block
(2) Front housing
Minimum depth of groove in new piston for oil control
piston ring ................................. 4.69 mm ( 0.187 inch) Apply 1U-8846 Gasket Sealant to the front housing
sealing surfaces before assembling the front housing
Thickness of new oil control piston ring to the cylinder block. The front housing must be
.......................... 4.00 ± 0.01 mm ( 0.157 ± 0.001 inch) assembled and the front housing must be tightened to
the cylinder block within ten minutes.
After the piston rings have been installed, rotate the
piston rings so that the end gaps are 120 degrees (3) Length of the bolts that are marked for location
from each other. “A” .............................................. 20.0 mm (0.79 inch)
(6) Piston skirt (4) Length of the bolts that are marked for location
“B” .............................................. 50.0 mm (1.97 inch)
Lubricate the entire piston in zone (A) prior to
assembly into the cylinder block. Use clean engine
oil.

Piston Pin
(7) Piston pin

Piston pin diameter .................... 46.00 ± 0.01 mm

( 1.811 ± 0.001 inch)
Length of piston pin.................... 91.50 ± 0.15 mm
( 3.602 ± 0.006 inch)
SENR9500 33
Specifications Section

Illustration 67 g01405420
(5) Front housing cover

(6) Length of the bolts that are marked for location

“C” .............................................. 30.0 mm (1.18 inch)

(7) Length of the bolt that is marked for location “D”

..................................................... 60.0 mm (2.36 inch)
(8) Apply 154-9731 Thread Lock Compound to the
serrations of the studs before installing the studs into
the front housing cover (5).
34 SENR9500
Specifications Section

i01150365

Gear Group (Front)

SMCS Code: 1206

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up

Illustration 68 g00610268
Typical example
SENR9500 35
Specifications Section

(1) Camshaft idler gear

Distance (B) between the front of the bearing face

and the front of the gear face.............. 0.40 ± 0.25 mm
(0.016 ± 0.010 inch)

Diameter of new shaft (A) ............ 80.000 ± 0.013 mm

(3.1496 ± 0.0005 inch)
(2) Camshaft gear

(3) Tighten the bolts for the camshaft idler gear to the
following torque...................70 ± 15 N·m (50 ± 11 lb ft)
(4) Align the timing marks on the camshaft idler gear
(1) with the holes on the camshaft gear (2) and the
crankshaft gear (5).
(5) Crankshaft gear
(6) Oil pump drive gear

(7) Bolt

Tighten the oil pump idler gear bolt to the

following torque............70 ± 15 N·m (50 ± 11 lb ft)
(8) Oil pump idler gear

Distance (C) between the rear of the bearing face and

Illustration 69 g00627786
the rear of the gear face...................... 0.75 ± 0.25 mm
(0.030 ± 0.010 inch) (1) Hydraulic pump drive
Diameter of new shaft (D) ............ 28.644 ± 0.013 mm (2) Idler gear
(1.1277 ± 0.0005 inch)

i01175026

Rear Power Take-Off (RPTO)

SMCS Code: 1165-RE

S/N: D3C1–Up Illustration 70 g00627841

S/N: BRZ1–Up View A-A

S/N: ALA; 4ZF1–Up (3) The reliefs in the bearing must line up with the
reliefs in the gear within 2 degrees.

Note: The bearing must not project beyond the front

face or the rear face of the gear.

i01589748

Flywheel
SMCS Code: 1156

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up
36 SENR9500
Specifications Section

Illustration 71 g00824292 Illustration 72 g00612544

Typical Example Typical view

116-5386 (1) Bearing joint position

(1) Ring Gear The bearing joint position is the following

dimension off the vertical axis. ..... 15 degrees ± 1
The maximum temperature for installation of the ring degree
gear is the following value. ................. 320 °C (608 °F)
(2) Apply 1U-8846 Sealant to all sealing surfaces of
(2) Bolt the flywheel housing. The flywheel housing must be
assembled and tightened to the cylinder block within
Tighten the bolts to the following torque. ten minutes.
........................................300 ± 40 N·m (221 ± 30 lb ft)

123-0815
(1) Ring Gear

The maximum temperature for installation of the ring

gear is the following value. ................. 315 °C (600 °F)
(2) Bolt

Tighten the bolts to the following torque.

........................................300 ± 40 N·m (221 ± 30 lb ft)

i01382853
Illustration 73 g00612690
Flywheel Housing View A-A
SMCS Code: 1157 Typical on both sides

S/N: D3C1–Up (3) Bearing depth

S/N: BRZ1–Up The bearing depth is the following distance from
S/N: ALA; 4ZF1–Up the inside face of the flywheel housing.
............................ 4.0 ± 0.5 mm (0.16 ± 0.02 inch)
(4) Rear face of block
SENR9500 37
Specifications Section

i05084397

Belt Tension Chart

SMCS Code: 1357

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up
Table 5
Specification for the 7N-9693 Tension Chart

Item Qty Part Specification Description

The new belt tension chart has been standardized. The belt tension chart eliminates confusion about the
correct belt tension to use. Studies were completed with different belt suppliers and the information that
was gathered from the studies was developed into a new belt tension for each belt size .
The chart does not apply to belts that use a spring loaded tensioner .
For more accurate results, a Clavis frequency gauge should be used in order to measure the natural fre-
quency of the belt. By the use of a formula, the natural frequency is converted into the belt tension force. If
the Clavis frequency gauge cannot be used, then use the appropriate Kent-Moore belt tension gauge to
- - -
measure the belt tension force.
When matched sets of belts are used, check the tension of all the belts in order to verify that the lowest belt
is in the acceptable tolerance range. Variations in tension between the belts can vary by as much as 65
pounds.
In order to determine the tension of a “banded” belt, refer to the chart above. Multiply the tension value of
the belt by the number of belts that are banded together.Two 1/2 inch belts would require a used belt ten-
sion equal to twice the value of the used belt tension for one 1/2 inch belt (2 X 80 = 160 lb).

Table 6
Belt Tension Chart
SAE or RMA Belt SIze Width of Belt (Top Belt Tension “Initial”” (1) Belt Belt Tension “Used”” (3) (4)
Reference) Tension
Used(2)

IN MM IN MM LB N LB N LB N
3/8 (0.380) 10A 0.42 10.72 145±10 645±44 115±10 510±44 70±10 311±44

7/16 (0.440) 11A 0.46 11.68 155±10 689±44 125±10 560±10 75±10 333±44

1/2 (0.500) 13A 0.55 13.89 165±10 734±44 130±10 580±10 80±10 356±44

5V/5VX 5V 0.63 15.88 180±10 801±44 145±10 645±10 85±10 378±44

11/16 (0.600) 15A 0.69 17.48 180±10 801±44 145±10 645±10 85±10 378±44

3/4 (0.660) 17A 0.75 19.05 205±10 912±44 165±10 730±44 95±10 422±44

7/8 (0.790) 20A 0.88 22.23 205±10 912±44 165±10 730±44 95±10 422±44

15/16 N/A 0.98 23.83 205±10 912±44 165±10 730±44 95±10 422±44
4K 4PK 0.54 13.72 145±10 645±44 115±10 510±44 60±10 267±44
6K 6PK 0.82 20.94 215±10 956±44 170±10 755±10 90±10 400±44
8K 8PK 1.1 27.82 285±10 1179±44 230±10 1025±10 115±10 511±44
10K 10PK 1.38 35.05 355±10 1579±44 285±10 1270±10 145±10 645±44
12K 12PK 1.66 42.16 425±10 1891±44 340±10 1510±10 175±10 778±44
14K 14PK 1.94 49.28 495±10 2202±44 395±10 1755±10 205±10 912±44
15K 15PK 2.08 52.83 530±10 2358±44 425±10 1890±44 215±10 956±44
(1) Belt Tension “Initial ” is for a new belt.
(2) Belt tension with less than 10 hours of operation
(3) Belt tension “Used” is for a belt that has operated for more than 30 minutes of operation at the rated speed..
(4) If a belt falls below the “Used” belt tension, the belt should be tightened again to 80% of the “Initial” belt tension.
38 SENR9500
Specifications Section

i01389093 S/N: BLT; 4ZF1–Up

Fan Drive
SMCS Code: 1359

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up

Illustration 76 g00739513

Illustration 74 g00629689
Typical example

Illustration 77 g00739518

117-1379 Alternator
Illustration 75 g00629722 Voltage ................................................................. 12 V
Detail A
Amperage .....................................................130 Amp
Note: Lightly lubricate the seal lips with 2S-3230
Bearing Lubricant. Install the seal with the seal lip in Note: Load the battery with a carbon pile 4C-4911
the correct position. Battery Load Tester in order to get the maximum
alternator output.
(1) Fill the seal cavity with 2S-3230 Bearing
Lubricant. Polarity ..............................................Negative ground
3
(2) Put 23 cc (1.4 in ) of 2S-3230 Bearing Lubricant Rotation .......................................................Clockwise
in the cavity between the bearings.
(3) Fill the cap of the housing with 2S-3230 Bearing The minimum full load current at 5000 rpm is the
Lubricant. following value. ............................................. 119 Amp

The minimum full load current at 1500 rpm is the

i01592573
following value. ...............................................41 Amp
Alternator and Regulator Output voltage ............................................14 ± 1.0 V
SMCS Code: 1405; 1410
(1) Tighten the output terminal to the following torque.
S/N: D3C1–Up ...........................................7.1 ± 0.8 N·m (63 ± 7 lb in)
S/N: BRZ1–Up (2) Tighten the shaft nut to the following torque.
S/N: ALA; 4ZF1–Up .....................................127.4 ± 9.8 N·m (94 ± 7.2 lb ft)
SENR9500 39
Specifications Section

(3) Tighten the bolt to the following torque. The minimum full load current at 5000 rpm is the
...........................................6.2 ± 0.6 N·m (55 ± 5 lb in) following value. ...............................................68 Amp

Voltage setting .....................................No adjustment The minimum full load current at 1500 rpm is the
following value. ...............................................29 Amp
i01430635
Output voltage ............................................28 ± 1.0 V
Alternator and Regulator (1) Tighten the output terminal to the following torque.
SMCS Code: 1405; 1410 ...........................................7.1 ± 0.8 N·m (63 ± 7 lb in)

S/N: D3C1–Up (2) Tighten the shaft nut to the following torque.
.....................................127.4 ± 9.8 N·m (94 ± 7.2 lb ft)
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up (3) Tighten the bolt to the following torque.
...........................................6.2 ± 0.6 N·m (55 ± 5 lb in)

Voltage setting .....................................No adjustment

i01401505

Electric Starting Motor

SMCS Code: 1453

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up

Illustration 78 g00739513

Illustration 79 g00739518

177-6972 Alternator

Voltage .................................................................24 V

Amperage .......................................................70 Amp

Note: Load the battery with a carbon pile 4C-4911
Battery Load Tester in order to get the maximum
alternator output.

Polarity ..............................................Negative ground

Rotation ............................................... Either direction

40 SENR9500
Specifications Section

106-8554, 104-7044, 6v-5795 (4) Nut

The terminal that is on the switch terminal must

be insulated with heat shrink tubing.
Tighten the nut on the switch terminal to the
following torque.......2.25 ± 0.25 N·m (20 ± 2 lb in)

(5) Nut

Tighten the nut on the motor terminal to the

following torque..........30.5 ± 3.5 N·m (22 ± 3 lb ft)

(6) Nut

Tighten the nut on the motor frame terminal to the

following torque...............8 ± 3 N·m (71 ± 27 lb in)
Illustration 80 g00286672 Solenoid

Current draw at 20 V and 25 °C (77 °F)

Pull-in windings ............................ 56.5 ± 4.5 amp

Hold-in windings .................................... 14.6 amp

i01598650

Electric Starting Motor

SMCS Code: 1453

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up
Illustration 81 g00286673
Typical Example S/N: BLT; 4ZF1–Up

When the electric starting motor is viewed from the

pinion end, the motor rotates in the following
direction. .....................................................Clockwise

No load conditions at 25 °C (77 °F)

Speed ........................................7643 ± 1683 rpm

Current draw ................................. 67.5 ± 7.5 amp
Voltage ..........................................................23 V

(1) Nut
Three wires are the maximum that may fit
between the nuts.
Tighten the nut on the battery terminal to the Illustration 82 g00282688
following torque..........30.5 ± 3.5 N·m (22 ± 3 lb ft) Typical example
(2) Nut

Tighten the nut on the ground terminal to the

following torque..........30.5 ± 3.5 N·m (22 ± 3 lb ft)

(3) Nut

Tighten the nut on the ground terminal to the

following torque.......2.25 ± 0.25 N·m (20 ± 2 lb in)
SENR9500 41
Specifications Section

Illustration 83 g00489813 Illustration 84 g01429733

Typical solenoid connections Typical example
(2) Plug
When the electric starting motor is viewed from the
drive end, the motor rotates in the following direction. (1) Final installation torque .....20 ± 3 N·m (15 ± 2 lb ft)
..................................................................... Clockwise
Operating voltage ............................4.75 to 8.50 Volts
No load conditions at 25°C (77°F)
Output type ......................................................Analog
Speed ........................................7018 ± 1517 rpm
Current ..................................... 125.5 ± 27.5 amp i01198674
Voltage .......................................................... 11 V

(1) Tighten the nut on the battery terminal to the

Fuel Pressure Sensor
following torque.................30.5 ± 3.5 N·m (22 ± 3 lb ft) SMCS Code: 1718

(2) Tighten the ground terminal to the following S/N: D3C1–Up

torque................................30.5 ± 3.5 N·m (22 ± 3 lb ft) S/N: BRZ1–Up
(3) Tighten the nut to the following torque. S/N: ALA; 4ZF1–Up
.......................................2.25 ± 0.25 N·m (20 ± 2 lb in)

(4) Tighten the nut on the switch terminal to the

following torque..............2.25 ± 0.25 N·m (20 ± 2 lb in)

(5) Tighten the nut on the motor terminal to the

following torque...................... 8 ± 3 N·m (71 ± 27 lb in)

(6) Tighten the nut on the motor frame terminal to the

following torque...................... 8 ± 3 N·m (71 ± 27 lb in)
Solenoid

Current draw at 12 V and 25°C (77°F)

Pull-in windings ...................................89 ± 5 amp

Hold-in windings .................23 ± 2 amp maximum Illustration 85 g00641090

i02870347
(1) Tighten the sensor to the following torque.
..................................................10 ± 2 N·m (7 ± 1 lb ft)
Coolant Temperature Sensor
SMCS Code: 1906

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up
42 SENR9500
Specifications Section

i01199627 (2) Final installation torque for the pressure sensor

group.......................................20 ± 2 N·m (15 ± 1 lb ft)
Injection Actuation Oil
Operating voltage .............................5.00 ± 0.25 VDC
Temperature Sensor
SMCS Code: 192T Operating temperature .......................... −40 to 120 °C
(−40 to 248 °F)
S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up

Illustration 86 g00641959

(1) Plug

(2) Tighten the sensor to the following torque.

................................................20 ± 3 N·m (15 ± 2 lb ft)

i02848617

Injection Actuation Pressure

Sensor
SMCS Code: 1925

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up

Illustration 87 g01405950
(1) Connector plug assembly
SENR9500 43
Specifications Section

i04402163

Engine Oil Pressure Sensor

SMCS Code: 1924

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up

Illustration 88 g02587196

Table 7
Specification for the 161-1705 Engine Oil Pressure Sensor

Item Qty Part Specification Description

Torque the pressure sensor to 10 ± 2 N·m (90 ± 18 lb in).

Prior to installing the pressure sensor onto the engine, apply 5P-3413 Pipe
1 - -
Sealant to the first three threads of the sensor.
Operating voltage is 5.00 ± 0.25 VDC.

i02145717

Engine Oil Temperature Sensor

SMCS Code: 1929

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up

Illustration 89 g00641959

(1) Plug

(2) Tighten the sensor to the following torque.

................................................48 ± 5 N·m (35 ± 4 lb ft)
44 SENR9500
Specifications Section

i02779332 i01198657

Atmospheric Pressure Sensor Turbocharger Outlet Pressure

SMCS Code: 1923 Sensor
S/N: D3C1–Up SMCS Code: 1917

S/N: BRZ1–Up S/N: D3C1–Up

S/N: ALA; 4ZF1–Up S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up

Illustration 90 g01122320

Illustration 92 g00641090
(1) Torque for the sensor .....10 ± 2 N·m (90 ± 18 lb in)
(1) Tighten the sensor to the following torque.
i01198588 ..................................................10 ± 2 N·m (7 ± 1 lb ft)

Inlet Air Temperature Sensor i02307203

SMCS Code: 1921
Speed/Timing Sensor
S/N: D3C1–Up
SMCS Code: 1907; 1912
S/N: BRZ1–Up
S/N: D3C1–Up
S/N: ALA; 4ZF1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up

Illustration 91 g00641048

(1) Tighten the sensor to the following torque.

Illustration 93 g01155565
................................................20 ± 5 N·m (15 ± 4 lb ft)
(1) Bolt
(2) Plug (2) Sensor
(3) Flange
SENR9500 45
Specifications Section

Note: The sensors must be replaced as a pair. S/N: BRZ1–Up

1. Seat both sensors to the sensor's flanges before S/N: ALA; 4ZF1–Up
tightening the bolt to the bracket.

2. Torque the bolt (1) to 28 ± 7 N·m (21 ± 5 lb ft).

i04372667

Speed/Timing Sensor
SMCS Code: 1907; 1912

S/N: D3C1–Up
S/N: BRZ1–Up
S/N: ALA; 4ZF1–Up

Illustration 95 g00732425
Engine control module

(1) Bolt

Tighten the bolt (1) on the wiring harness to the

following torque..........6 ± 1 N·m (4.43 ± 0.74 lb ft)

i02729145

Air Compressor
SMCS Code: 1803

Illustration 94 g01405981 S/N: D3C1–Up

(2) Low output speed sensor group S/N: BRZ1–Up
(4) High output speed sensor group
S/N: ALA; 4ZF1–Up
Table 8
S/N: BLT; 4ZF1–Up
Specifications for 245-4630 Speed Sensor Gp

Item Qty Parts Specification Description

Locate each sensor to the sen-

sor support before tightening
the bolt.
Final installation torque for the
bolt (1) of the mounting bracket
(3) for the speed sensor group
is 28 ± 7 N·m (248 ± 62 lb in).
1 - -
The speed sensor group must
be replaced as a pair. Each
sensor has a different part
number.
Output type of the speed sen-
sor group is analog.

i01430652

Electronic Control Module

SMCS Code: 1901

S/N: D3C1–Up
46 SENR9500
Specifications Section

Illustration 96 g01368656
Typical example
(1) Drive gear
(2) Nut

(3) Torque for four bolts.........60 ± 12 N·m (44 ± 9 lb ft)

Table 9
Required Tool

Part
Tool Number Part Description Qty

A 132-5451 Holding Fixture 1

1. Clean inner diameter of gear and outer diameter of

shaft with solvent. Lubricate the washer and shaft
threads with engine oil. Install Tool (A) on drive
gear (1) for the compressor. Tighten the nut (2) to
the following value.

Torque value ...................170 ± 15 N·m (125 ± 11 lb ft)

2. Tap gear (1) once with a hammer by using the

impact socket or a similar driver.

3. Tighten the nut (2) again to the following value.

Torque value ...................170 ± 15 N·m (125 ± 11 lb ft)

4. Tap gear (1) again with a hammer by using the

impact socket or a similar driver.

5. Tighten the nut (2) again to the following value.

Torque value ...................170 ± 15 N·m (125 ± 11 lb ft)

SENR9500 47
Index Section

Index
A Fuel Filter Base.................................................. 4
Fuel Pressure Sensor...................................... 41
Air Compressor................................................ 45
Fuel Priming Pump and Water Separator.......... 4
Air Inlet Elbow.................................................. 20
Fuel Priming Pump ........................................ 5
173-6107...................................................... 21
Water Separator and Fuel Filter..................... 5
188-9037...................................................... 21
Alternator and Regulator............................ 38–39
Atmospheric Pressure Sensor......................... 44 G
Gear Group (Front).......................................... 34
B
Belt Tension Chart ........................................... 37 I
Important Safety Information ............................. 2
C Injection Actuation Oil Temperature Sensor .... 42
Injection Actuation Pressure Sensor ............... 42
Camshaft ......................................................... 21
Inlet Air Temperature Sensor........................... 44
Compression Brake ......................................... 15
Connecting Rod............................................... 30
Connecting Rod Bearing Journal..................... 29 L
Coolant Temperature Sensor........................... 41
Crankshaft ....................................................... 28 Lifter Group........................................................ 8
Crankshaft Seals ............................................. 28
Cylinder Block.................................................. 25 M
Cylinder Block Cover Group ............................ 25
Cylinder Head.................................................. 13 Main Bearing Journal....................................... 29
Cylinder Head Valves ...................................... 10
Cylinder Liner................................................... 27 P
Cylinder Liner Projection ................................. 28
Piston and Rings ............................................. 31
Two-Piece Articulated Piston ....................... 31
E
Electric Starting Motor ............................... 39–40 R
106-8554, 104-7044, 6v-5795...................... 40
Electronic Control Module ............................... 45 Rear Power Take-Off (RPTO).......................... 35
Engine Design ................................................... 4 Rocker Shaft...................................................... 8
Engine Oil Pan................................................. 23
Engine Oil Pressure Sensor ............................ 43
S
Engine Oil Pump.............................................. 22
Engine Oil Temperature Sensor ...................... 43 Specifications Section ....................................... 4
Exhaust Manifold............................................. 21 Speed/Timing Sensor ................................ 44–45

F T
Fan Drive ......................................................... 38 Table of Contents............................................... 3
Flywheel .......................................................... 35 Turbocharger ................................................... 16
116-5386 ...................................................... 36 Turbocharger Outlet Pressure Sensor............. 44
123-0815...................................................... 36
Flywheel Housing ............................................ 36
Front Housing and Covers............................... 32
48 SENR9500
Index Section

U
Unit Injector........................................................ 6
Unit Injector Hydraulic Pump ............................. 5
Fuel Transfer Pump ....................................... 6

V
Valve Mechanism .............................................. 8
Valve Mechanism Cover.................................. 10

W
Water Pump (Pulley for Serpentine Belt ) ........ 24
Water Pump (V-Belt Pulley) ............................. 24
Water Temperature Regulator ......................... 24
Water Temperature Regulator Housing ........... 23
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