sb-iii sr mp iv w-di 2.2 engine (40423-2-pm rev 10)

8/14/2019 Sb-III Sr Mp IV W-di 2.2 Engine (40423-2-Pm Rev 10)

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Printed (July 24, 2006)

Copyright 1992 - Thermo King Corp. - Minneapolis, MN U.S.A.Electronically printed in U.S.A.

SB-III SR MP IVw/di 2.2 Engine

TK 40423-10.0

Printed ( Monday, July24,2006)Copyright1992 - Thermo King Corp.- Minneapolis,M N,U.S.A.


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General InformationTables of Contents

This Parts Manual contains a numerical table of con-tents listing each assembly name, its associated Gridnumber and page number. The numerical table of con-tents is arranged numerically by Grid number. Thereare references in a parts list referring to other Grid num-bers, the numerical table of contents is arranged to facil-

itate finding the referenced illustrations. At the rear ofthis parts manual are two indexes, a numerical andalphabetical. The indexes contain all of the part num-bers and descriptions which appear in this manual.

Assemblies and Subassemblies

When parts are indented in the description list, they arepreceded with a bullet ( ). This indicates that thepart(s) is available separately or included in an assem-bly.

GRID NO. 67D6SWITCH PANEL ASSEMBLY

For example: the switch panel nameplate (99-6280) isavailable separately, available as part of the switchpanel (99-1960) and with the panel assembly (45-1239).

REF PART# DESCRIPTION QTY

45-1239 PANEL - assy, switch 1

1 99-1960 PANEL 1

99-6280 NAMEPLATE - panel 1

2 33-743 GASKET 1

A AC . . . . . . . . . alternatingcurrent

A/R . . . . . . . . as requiredaccum . . . . . . accumulatoradj . . . . . . . . . adjustingal . . . . . . . . . . aluminumalt. . . . . . . . . . alternatorA or amp . . . . ampereassy. . . . . . . . assembly

B bd . . . . . . . . . boardbrg . . . . . . . . . bearingbrkr . . . . . . . . breaker

brkt . . . . . . . . bracketC C . . . . . . . . . . Celsius

cw . . . . . . . . . clockwiseccw . . . . . . . . counter- clockwisecam . . . . . . . . camshaftcompr . . . . . . compressorcond. . . . . . . . condenserconn. . . . . . . . connecting,

connectorcyl . . . . . . . . . cylinder

D def . . . . . . . . . defrostdeg . . . . . . . . degreedehyd. . . . . . . dehydratordia . . . . . . . . . diameterDC . . . . . . . . . direct currentdisch . . . . . . . dischargediff . . . . . . . . . differential

E EMI . . . . . . . . Extended . . . . . . . . . . . Maintenance

IntervalEEC. . . . . . . . European

Economic Community

eng . . . . . . . . engine

E (continued)evap. . . . . . . . evaporatorexch . . . . . . . . exchangerexp . . . . . . . . . expansionext . . . . . . . . . external

F F . . . . . . . . . . . Farenheitfill . . . . . . . . . . fillisterfi . . . . . . . . . . . fuel injectionfl . . . . . . . . . . . flarefpt . . . . . . . . . . female pipe

threadft . . . . . . . . . . . feet

ftg . . . . . . . . . . fittingH hex . . . . . . . . . hexagon

hh . . . . . . . . . . hexagon headhd . . . . . . . . . . headhp . . . . . . . . . . horsepowerhsg . . . . . . . . . housing

I id . . . . . . . . . . inside diameterin . . . . . . . . . . inch (2.54

centimeters)incl . . . . . . . . . includesinj . . . . . . . . . . injectionint . . . . . . . . . . internalint th . . . . . . . . internal tooth

L liq . . . . . . . . . . liquidlg . . . . . . . . . . long

M mm . . . . . . . . . milimetermpt . . . . . . . . . male pipe threadmod . . . . . . . . modulating

N neg . . . . . . . . . negativeNo. . . . . . . . . . numberNS . . . . . . . . . not suppliedNSS . . . . . . . . not sold

separately

O os . . . . . . . . . . oversizedod . . . . . . . . . . outside diameter

P pcb . . . . . . . . . printed circuit board

pkg . . . . . . . . . packageph . . . . . . . . . . phasepos . . . . . . . . . positivepsi . . . . . . . . . . pounds per

square inch

R rad . . . . . . . . . radiatorrcvr . . . . . . . . . receiverref . . . . . . . . . . referencereg . . . . . . . . . regulatorreq . . . . . . . . . requiredrpm . . . . . . . . . revolutions per

minute

S sec . . . . . . . . . secondsld. . . . . . . . . . soldersoc hd. . . . . . . socket headsol. . . . . . . . . . solenoidspl. . . . . . . . . . specialsq . . . . . . . . . . squaress . . . . . . . . . . stainless steelstd. . . . . . . . . . standardstl . . . . . . . . . . steelsuct. . . . . . . . . suctionsw . . . . . . . . . . switch

T term . . . . . . . . terminaltemp . . . . . . . . temperaturethk. . . . . . . . . . thick

U us . . . . . . . . . . undersize

V vib. . . . . . . . . . vibrasorber

W W . . . . . . . . . . wattw/ . . . . . . . . . . withw/o . . . . . . . . . without

ABBREVIATIONS The following abbreviations appear in parts manuals


3/265

SB-III SR MP IV w/di 2.2 EngineContents

Name Grid PageSB-III SR MP IV REFERENCE SHEET . . . . . . . . . . . . . . . . . . . . . . . . .2U89. . . . . . . . . . . . . . . . . . . . . .5CHECK VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9G12. . . . . . . . . . . . . . . . . . . .131BATTERY BOX ASSEMBLY (DOMESTIC) . . . . . . . . . . . . . . . . . . . . . .38B2 . . . . . . . . . . . . . . . . . . . .189IDLER ASSEMBLY (BEFORE 1/96) . . . . . . . . . . . . . . . . . . . . . . . . . . .65F2 . . . . . . . . . . . . . . . . . . . . .93MUFFLER GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65F5 . . . . . . . . . . . . . . . . . . . . .73RECEIVER TANK GROUP (BEFORE 5/99) . . . . . . . . . . . . . . . . . . . . .66B4 . . . . . . . . . . . . . . . . . . . .133FUEL TANKS (30 & 50 GALLON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67C2. . . . . . . . . . . . . . . . . . . .233CYLINDER BLOCK GROUP (di 2.2) . . . . . . . . . . . . . . . . . . . . . . . . . . .68D1. . . . . . . . . . . . . . . . . . . . . .7CYLINDER HEAD GROUP (di 2.2 & se 2.2, Engines ManufacturedBEFORE 1/99) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68D3. . . . . . . . . . . . . . . . . . . . .13GEAR CASE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68D5. . . . . . . . . . . . . . . . . . . . .35

STARTER MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68D7. . . . . . . . . . . . . . . . . . . . .27OIL PAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68D8 . . . . . . . . . . . . . . . . . . . . .31FUEL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68D9. . . . . . . . . . . . . . . . . . . . .37OIL PUMP GROUP (di 2.2 & se 2.2) . . . . . . . . . . . . . . . . . . . . . . . . . . .68D10. . . . . . . . . . . . . . . . . . . .39CRANKSHAFT GROUP (di 2.2 & se 2.2) . . . . . . . . . . . . . . . . . . . . . . .68D11. . . . . . . . . . . . . . . . . . . .15CAMSHAFT GROUP (di 2.2 & se 2.2) . . . . . . . . . . . . . . . . . . . . . . . . .68D12. . . . . . . . . . . . . . . . . . . .23MANIFOLD GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68D13. . . . . . . . . . . . . . . . . . . .25OIL FILTER GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68D14. . . . . . . . . . . . . . . . . . . .33WATER PUMP GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68E1 . . . . . . . . . . . . . . . . . . . . .41STARTER & GLOW PLUG GROUP (di 2.2 & se 2.2) . . . . . . . . . . . . . .68E2 . . . . . . . . . . . . . . . . . . . . .49FUEL INJECTION GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68E3 . . . . . . . . . . . . . . . . . . . . .43INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68E4 . . . . . . . . . . . . . . . . . . . . .45ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70A3 . . . . . . . . . . . . . . . . . . . . .69

CONDENSER RADIATOR MOUNTING . . . . . . . . . . . . . . . . . . . . . . . .70A9 . . . . . . . . . . . . . . . . . . . .139THROTTLE SOLENOID GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70B6 . . . . . . . . . . . . . . . . . . . . .63PRESSURE DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70E1 . . . . . . . . . . . . . . . . . . . .169COMPRESSOR X430 (R22) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72A12 . . . . . . . . . . . . . . . . . . .107CONDENSER SHUTTER ASSEMBLY (OPTION 048030) . . . . . . . . . .72E13 . . . . . . . . . . . . . . . . . . .225STARTER - 12V GEAR REDUCTION (C201, di 2.2 & se 2.2) . . . . . . .74G12. . . . . . . . . . . . . . . . . . . .51INTEGRAL FUEL TANK (25 GALLON) . . . . . . . . . . . . . . . . . . . . . . . . .75A7 . . . . . . . . . . . . . . . . . . . .241ALTERNATOR ASSEMBLY (37 AMP) . . . . . . . . . . . . . . . . . . . . . . . . .78A9 . . . . . . . . . . . . . . . . . . . .173GASKET SET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80A6 . . . . . . . . . . . . . . . . . . . . .29ALTERNATOR GROUP (PRESTOLITE, BEFORE 3/91) . . . . . . . . . . .84D14. . . . . . . . . . . . . . . . . . .171FRESH AIR EXCHANGE GROUP (OPTION 048233) . . . . . . . . . . . . .84E3 . . . . . . . . . . . . . . . . . . . .229FANSHAFT ASSEMBLY & ROLLER BEARING . . . . . . . . . . . . . . . . . .84E5 . . . . . . . . . . . . . . . . . . . . .913-WAY VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86A3 . . . . . . . . . . . . . . . . . . . .129AIR CLEANER GROUP (SB-II 30 di 2.2) . . . . . . . . . . . . . . . . . . . . . . .86A7 . . . . . . . . . . . . . . . . . . . . .77ENGINE & COMPRESSOR GROUP (SOFT MOUNT) . . . . . . . . . . . . .89C2. . . . . . . . . . . . . . . . . . . . .79BATTERY GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89F14 . . . . . . . . . . . . . . . . . . .187REFRIGERANT HOSE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90E4 . . . . . . . . . . . . . . . . . . . .141THROTTLING VALVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .96A5 . . . . . . . . . . . . . . . . . . . .127ALTERNATOR GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96A7 . . . . . . . . . . . . . . . . . . . .177FANS & BELTS GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96A8 . . . . . . . . . . . . . . . . . . . . .85COMPRESSOR GROUP - X430 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96A9 . . . . . . . . . . . . . . . . . . . .101DEHYDRATOR GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97D5. . . . . . . . . . . . . . . . . . . .137NAMEPLATES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97G2. . . . . . . . . . . . . . . . . . . .231EVAPORATOR COMPONENTS (BEFORE 12/93). . . . . . . . . . . . . . . .100E2 . . . . . . . . . . . . . . . . . . .213ALTERNATOR (37 AMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101A3 . . . . . . . . . . . . . . . . . . .179ALTERNATOR (65 AMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101A4 . . . . . . . . . . . . . . . . . . .183


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5/265

SB-III SR MP IV w/di 2.2 EngineContents

Name Grid Page


6/2655

2U89 SB-III SR MP IV REFERENCE SHEET Revised9/3/98SB-IIISR MP IVREFERENCE

SHEET2U899/3/98


7/2656

2U89SB-III SR MP IV REFERENCE SHEETRevised9/3/98B/M DESCRIPTION Date

048323 SB-III SR MP IV 10/91

048407 Oil Bath Air Cleaner 4/95

048413 65 Amp Alternator 4/95

048233 Fresh Air Exchange 4/95

048386 Modulation 10/91

048489 External Battery Box 4/95

048414 Compressor Oil Filter 4/95

048332 Compound Gauge 4/95

048387 Datalogger/Communications 4/95

048416 Fuel Heater 4/95

048482 ABS Doors 4/95

092852 Frost Plug Heater 4/95

048152 Painted Grille 4/95

048411 Modulation 4/95

713586 Indicator Lights 4/95

048434 R403B 4/95

048469 R404A 4/95

048030 Condenser Shutters 4/95

048408 Silicone Hose 4/95

092315 Simpson Leads 4/95

048355 Threaded Battery Cables 4/95

714181 Door Switch Kit 4/95

048024 Top Screen 4/95

711058 Integral Fuel Tank 4/95

710270 Fuel Tank Kit - 30/50 Gallon 22 Inch Diameter 4/95

710278 Fuel Tank Kit - 75/120 Gallon 22 Inch Diameter 4/95


8/2657

68D1 CYLINDER BLOCK GROUP (di 2.2) Revised6/2/04CYLINDER BLOCKGROUP (di 2.2)

68D16/2/04


9/2658

68D1CYLINDER BLOCK GROUP (di 2.2)Revised6/2/04


8101-257 ENGINE (remanufactured) 11 101-264 SHORT BLOCK - assembly 1

2 11-2755 PLUG - frost (32 mm) 2

3 11-5788 ADAPTER - water 1

4 11-5785 BEARING SET - camshaft (std) 1

11-6842 BEARING SET - camshaft (0.50 mm us) 1



5 11-2757 PLUG - frost (45 mm) 3

11-5954 PLUG - frost (46.5 mm, some engines may require a largerfrost plug)

3

6 11-3369 PLUG - frost (18 mm) 3

7 55-5459 BOLT - bearing cap 10

8 11-3368 PLUG - frost (16 mm) 2

9 11-3385 PLUG - frost (36 mm) 3

10 55-2405 PIN - dowel (cylinder head) 2

11 11-5790 PIN - rear plate (std) 1

55-5578 PIN - rear plate (1st os, 7/16 dia) 1

55-6376 PIN - rear plate (2nd os, 1/2 dia) 1

55-6377 PIN - rear plate (3rd os, 1/2 dia) 1

12 10-310 PLATE - cylinder block (rear)

1

13 55-5464 BOLT - rear plate 4

14 55-5465 BOLT - rear plate 2

15 * 33-2880 SEAL - oil (crankshaft rear) 1

17 55-4145 BOLT - cover 4

18 55-5463 BOLT - reamer 1

55-5481 LOCKWASHER 1

55-2430 NUT - reamer bolt 1

19 11-5795 BREATHER - air 1

20 11-5796 CAP - breather 121 * 33-1634 GASKET - breather 1

22 * 33-1635 ELEMENT 1

23 55-5467 BOLT - breather 1

24 55-2433 NUT - breather 2

25 55-790 LOCKWASHER 2

26 55-5466 STUD - breather 2

27 * 33-1636 GASKET - breather 1

28 55-5460 PLUG - oil gallery 4


10/2659

68D1 CYLINDER BLOCK GROUP (di 2.2) Revised6/2/04


11/26510

68D1CYLINDER BLOCK GROUP (di 2.2)Revised6/2/04


29 * 33-653 GASKET - plug 1

30 55-5461 PLUG - oil gallery 1

31 55-3529 PIN - oil pan 2

32 11-5789 DUCT - water 1

33 11-5793 PIN - gear case 2

34 55-5453 STUD - gear case 3

55-790 LOCKWASHER 3

55-2433 NUT 3

35 55-5462 PLUG - water drain 1

36 11-5794 PLATE - cylinder block (front) 1

37 55-9332 BOLT - plate 5

38 * 33-3202

GASKET - front plate 139 10-363 KIT - cover & o-ring 1

40 33-2757 O-RING - camshaft cover 1

41 11-9627 COVER - camshaft (rear) 1

33-3390 GASKET 1

42 40-335 HEATER - frost plug 143 11-7081 SLEEVE - cylinder 4

* 30-262 GASKET SET (see 80A6) 1


12/26511

107D10 SHORT BLOCK ASSEMBLY (se 2.2) Revised4/2/96SHORT BLOCKASSEMBLY (se 2.2)

107D104/2/96


13/26512

107D10SHORT BLOCK ASSEMBLY (se 2.2)Revised4/2/96


101-264 SHORT BLOCK - assembly (before 2/96) 1


14/26513

68D3 CYLINDER HEAD GROUP (di 2.2 & se 2.2, EnginesManufactured BEFORE 1/99) Revised6/2/05CYLINDER HEADGROUP (di 2.2 & se

2.2, EnginesManu-factured BEFORE1/99)68D36/2/05


15/265


16/26515

68D11 CRANKSHAFT GROUP (di 2.2 & se 2.2) Revised7/17/06CRANKSHAFTGROUP (di 2.2 & se

2.2)68D117/17/06


17/26516

68D11CRANKSHAFT GROUP (di 2.2 & se 2.2)Revised7/17/06


1 11-5900 PISTON (std, incl rings, pin & snap ring) 411-9577 PISTON (std, EPA se 2.2 engines, S/N E0001 & after) 4

11-5901 PISTON (0.25 mm os, incl rings, pin & snap ring) 4

11-5902 PISTON (0.50 mm os, incl rings, pin & snap ring) 411-9579 PISTON (0.50 mm os, EPA se 2.2 engines, S/N E00001 &

after)4

11-5903 PISTON (0.75 mm os, incl rings, pin & snap ring) 411-5904 PISTON (1.00 mm os, incl rings, pin & snap ring) 4

2 11-8082 RING SET (std) 4

13-500 RING SET (std, EPA se 2.2 engines, S/N E00001 & after) 411-8083 RING SET (0.25 mm os) 4

11-8084 RING SET (0.50 mm os) 4

11-9580 RING SET (0.50 mm os, EPA se 2.2 engines, S/N E00001 &after)

4

11-8448 RING SET (0.75 mm os) 4

11-8085 RING SET (1.00 mm os) 4

3 11-7997 PIN - piston 4

4 11-8002 RING - snap 8

5 11-5824 ROD - connecting (before S/N 936751, see note) 411-6873 ROD - connecting (S/N 936751 & after see note) 4

6 11-5825 BUSHING - connecting rod 4

11-7523 BUSHING - rod (unfinished) 4

7 55-5250 BOLT - connecting rod 8

8 55-5251 NUT 8

9 11-5826 BEARING SET - connecting rod (std) 411-5827 BEARING SET - connecting rod (0.25 mm us) 4

11-5828 BEARING SET - connecting rod (0.50 mm us) 411-5829 BEARING SET - connecting rod (0.75 mm us) 4

11-5830 BEARING SET - connecting rod (1.00 mm us) 410 10-266 KIT - bolt (crankshaft pulley boss) 111 77-1591 BOSS - pulley 1

12 10-305 GEAR SET - camshaft (di & se engines, before 2/96, see100C8 ) 1

11-8852 GEAR SET - crankshaft (se engines, 2/96 & after, see 134C1) 113 11-9558 CRANKSHAFT (see note) 114 55-1933 KEY - crankshaft (square) 115 11-5806 BEARING SET - crankshaft (std) 1

11-5807 BEARING SET - crankshaft (0.25 mm us) 1

11-5808 BEARING SET - crankshaft (0.50 mm us) 111-5809 BEARING SET - crankshaft (0.75 mm us) 1

11-5810 BEARING SET - crankshaft (1.00 mm us) 1


18/26517

68D11 CRANKSHAFT GROUP (di 2.2 & se 2.2) Revised7/17/06


19/26518

68D11CRANKSHAFT GROUP (di 2.2 & se 2.2)Revised7/17/06

NOTE: Item 13, CRANKSHAFT P/N 11-5836, has been replaced with Item 24, CRANKSHAFT P/N 11-9558.The two crankshafts are interchangeable except for the key. Use Item 14, KEY P/N 55-1933, with Item13, CRANKSHAFT P/N 11-5836. Use Item 25, KEY P/N 55-9932 with Item 24, CRANKSHAFT P/N11-9558.

NOTE: Item 5, CONNECTING ROD P/N's 11-5824 & 11-6873 are not inter-changeable. Engine SN 936751and after use a heavier CONNECTING ROD P/N 11-6873. Do not intermix with CONNECTING RODP/N 11-5824. The connecting rods may be replaced as a set of four only. CONNECTING ROD P/N 11-5824 weighs 880 grams. P/N 11-6873 weighs 1090 grams. Also see Service Bulletin 369.

NOTE: EPA se 2.2 engines with S/N E00001 & after, see grid 173B0.

NOTE: Use Kit 70-208 for 8 pin clutch.


16 11-5811 BEARING SET - thrust 1

17 11-5833 RING - wear 118 11-5837 FLYWHEEL (6 pin, 30s) 1

11-5775 FLYWHEEL (50s) 112-779 FLYWHEEL (gen set) 1

19 11-5838 GEAR - ring 1

70-206 KIT - bushing (6 pin clutch, incl pins, bushings & adhesive) 1

77-2760 BUSHING - coupling (50s) 8

51-869 PIN - dowel 8

21 55-4513 SCREW - flywheel 8

22 55-5489 WASHER - flywheel 123 77-2390 PULLEY - damper (crankshaft, se 2.2 after 2/96) 1

24 11-9558 CRANKSHAFT (see note, incl key) 125 55-9932 KEY - crankshaft (woodruff, for crankshaft 11-9558 only) 1

26 11-9591 SPEEDI SLEEVE - front seal 1


20/26519

173B0 CRANKSHAFT GROUP (EPA se 2.2, S/N E00001 &AFTER) Revised7/17/06CRANKSHAFTGROUP (EPA se

2.2, S/N E00001 &AFTER)173B07/17/06


21/26520

173B0CRANKSHAFT GROUP (EPA se 2.2, S/N E00001 &

AFTER)Revised7/17/06


1 11-9577 PISTON (std, incl rings, pin & snap ring) 411-9579 PISTON (0.50 mm os, incl rings, pin & snap ring) 4

2 13-500 RING SET (std) 4

11-9580 RING SET (0.50 mm os) 4

3 11-7997 PIN - piston 4

4 11-8002 RING - snap 8

5 11-6873 ROD - connecting 46 11-5825 BUSHING - connecting rod 4

11-7523 BUSHING - connecting rod (unfinished) 4


8 55-5251 NUT 8

9 11-5826 BEARING SET - connecting rod (std) 4

11-5827 BEARING SET - connecting rod (0.25 mm us) 411-5828 BEARING SET - connecting rod (0.50 mm us) 411-5829 BEARING SET - connecting rod (0.75 mm us) 411-5830 BEARING SET - connecting rod (1.00 mm us) 4

10 10-266 KIT - bolt (crankshaft pulley boss) 111 77-2390 PULLEY - damper (crankshaft) 1

12 11-8852 GEAR SET - crankshaft 113 11-9558 CRANKSHAFT (see note) 114 55-1933 KEY - crankshaft (square) 115 11-5806 BEARING SET - crankshaft (std) 1



16 11-5811 BEARING SET - thrust 1

17 11-5833 RING - wear 118 12-776 FLYWHEEL (8 pin, 30s) 1

11-5775 FLYWHEEL (50s) 112-779 FLYWHEEL (gen set) 1

19 11-5838

GEAR - ring 170-208 KIT - bushing (8 pin clutch, incl pins, bushings & adhesive) 1

20 77-2760 BUSHING - coupling (50s) 8

51-817 PIN - dowel 8

21 55-4513 SCREW - flywheel 822 55-5489 WASHER - flywheel 123 11-9558 CRANKSHAFT (see note) 1

24 55-9932 KEY - woodruff 125 11-9591 SPEEDI SLEEVE - front seal 1


22/26521

173B0 CRANKSHAFT GROUP (EPA se 2.2, S/N E00001 &AFTER) Revised7/17/06NOTE: This Grid is for EPA engines, S/N E00001 & after. For non-EPA se 2.2 engines built before 1/99, see

grid 68D11.

NOTE: Item 13, CRANKSHAFT P/N 11-5836, has been replaced with Item 23, CRANKSHAFT P/N 11-9558.The two crankshafts are interchangeable except for the key. Use Item 14, KEY P/N 55-1933, withItem 13, CRANKSHAFT P/N 11-5836. Use Item 24, KEY P/N 55-9932 with Item 23, CRANKSHAFTP/N 11-9558.



23/26522

173B0CRANKSHAFT GROUP (EPA se 2.2, S/N E00001 &

AFTER)Revised7/17/06


24/26523

68D12 CAMSHAFT GROUP (di 2.2 & se 2.2) Revised9/15/03CAMSHAFTGROUP (di 2.2 & se

2.2)68D129/15/03


25/26524

68D12CAMSHAFT GROUP (di 2.2 & se 2.2)Revised9/15/03


1 11-5840 CAMSHAFT 12 55-2030 KEY - camshaft 1

3 11-5842 PLATE - thrust 1

4 55-2443 SCREW - plate 25 10-305 GEAR SET - camshaft (di 2.2 see 68D5; se 2.2, before 2/96,

see 100C8)1

11-8846 GEAR SET - camshaft (se 2.2, 2/96 & after, see 134C1) 16 11-4048 WASHER - camshaft gear 17 55-3454 SCREW - gear 1

8 11-5850 VALVE - intake 49 11-5851 VALVE - exhaust 4

10 11-5847 SPRING - valve 811 55-2450 SEAT - spring (bottom) 8

12 11-4050 RETAINER - spring (top) 813 11-2929 LOCK - valve (package of 10) 16

14 55-1952 PLUG - end 215 55-2447 RING - snap 216 11-5852 ARM - rocker 817 11-5854 BRACKET - rocker shaft 418 55-2113 WASHER 419 55-5495 SCREW - rocker arm 1

20 11-5855 SPRING - rocker arms 321 11-5853 SHAFT - rocker arm 122 55-5493 SCREW - rocker arm & valve cover 323 55-2446 NUT - valve adjust 824 55-5492 SCREW - valve adjust 825 11-5849 ROD - push 8

26 11-5848 TAPPET 827 11-4414 SEAL - valve stem (set of 8) 1



26/26525

68D13 MANIFOLD GROUP Revised4/1/99MANIFOLDGROUP

68D134/1/99


27/26526

68D13MANIFOLD GROUPRevised4/1/99

NOTE: The exhaust spacer is used only on early di 2.2 engine.


1 11-5863 MANIFOLD - intake 12 * 33-1649 GASKET - intake 1

3 55-2433 NUT - manifold 6

4 55-5500 WASHER - manifold 45 55-5453 STUD - intake manifold 46 55-5454 STUD - exhaust manifold 27 55-6951 BOLT - intake manifold 48 * 33-1650 GASKET - exhaust manifold 19 11-5864 MANIFOLD - exhaust 1

10 55-5488 BOLT - exhaust manifold 611 11-5919 SPACER - exhaust (see note) 112 55-790 LOCKWASHER 2



28/26527

68D7 STARTER MOUNTING Revised12/9/01STARTER MOUNT-ING

68D712/9/01


29/26528

68D7STARTER MOUNTINGRevised12/9/01


1 11-5878 HANGER - engine (front) 12 55-2443 SCREW - hanger 1

3 11-5877 HANGER - engine (rear) 1

4 55-5513 SCREW - hanger 15 55-5512 SCREW - hanger 16 45-1993 STARTER 17 55-5516 NUT - starter 28 55-2423 FLATWASHER 29 55-2424 LOCKWASHER 2

10 55-5515 BOLT - starter 2


30/26529

80A6 GASKET SET Revised5/9/00GASKET SET80A6

5/9/00


31/26530

80A6GASKET SETRevised5/9/00

NOTE: The exhaust spacer is used only on early di 2.2 engine.


30-262 GASKET SET 11 33-1656 O-RING - nozzle 4

2 33-1657 GASKET - nozzle 4

3 33-1651 O-RING - injection pump 1

4 33-1645 O-RING - oil filter 1

5 33-1646 O-RING - water pump 1

6 33-3202 GASKET - front plate 1

7 33-1627 GASKET - cylinder head 1

8 33-3169 GASKET - housing 1

9 33-1630 GASKET - valve cover 1

10 11-4414 SEAL - valve stem (set of 8) 1

11 33-1649

GASKET - intake manifold 112 33-1629 GASKET - cover (before 2/96) 1

13 33-1631 GASKET - valve cover 1

14 33-1628 GASKET - cover (rear) 1

15 33-1650 GASKET - exhaust manifold 1

16 33-2880 SEAL - oil (crankshaft rear) 1

17 33-1642 SEAL - oil (rear oil base) 1

18 33-1634 GASKET - oil breather cap (before 2/96) 1

19 33-1636 GASKET - oil breather (before 2/96) 1

20 33-1655 GASKET - oil fill tube & cover 221 33-653 GASKET - plug 1

22 33-1643 SEAL - oil (front oil base) 1

23 33-713 O-RING - gear case 1

24 33-1638 O-RING - gear case 1

25 33-2881 SEAL - oil (crankshaft front) 1

26 33-1641 O-RING - fuel pump 1

27 33-2170 O-RING - gear cover 1

28 33-796 O-RING - oil pipe 2

29 11-5919 SPACER - exhaust (see note) 1


32/26531

68D8 OIL PAN Revised9/24/99OIL PAN68D8

9/24/99


33/26532

68D8OIL PANRevised9/24/99


1 12-542 BASE - oil 155-6389 SCREW - oil base A/R

2 55-5482 PLUG - oil drain 2


4 55-5484 PLUG - oil pan 1

5 * 33-1655 GASKET - cover 2

6 11-4641 COVER - oil pan 2

7 55-3531 BOLT - cover 4

8 * 33-1642 SEAL - rear 19 * 33-1643 SEAL - front 1

10 55-5485 BOLT - oil pan (25 mm) 1811 55-5486 BOLT - oil pan (40 mm) 4

12 11-7486 DIPSTICK 133-2965 GASKET - dipstick 133-631 GASKET 1

13 11-4989 TUBE - oil fill 1

33-144 O-RING - tube 1* 30-262 GASKET SET 1


34/26533

68D14 OIL FILTER GROUP Revised10/5/98OIL FILTERGROUP

68D1410/5/98


35/26534

68D14OIL FILTER GROUPRevised10/5/98


1 11-5856 BODY - oil filter mounting 12 11-2801 BALL - valve 1

3 11-2800 SPRING 1

4 33-646 O-RING 1

5 55-5496 PLUG 1

6 55-3527 PLUG 1

7 11-4078 VALVE - relief 1

8 33-656 O-RING - valve 1

9 55-5498 BOLT - filter body (45 mm lg) 110 55-5497 BOLT - filter body (80 mm lg) 1

11 11-9099 FILTER - oil 111-9100 FILTER - oil (EMI) 1

12 * 33-1645 O-RING - body to block 1* 30-262 GASKET SET (see 80A6) 1


36/26535

68D5 GEAR CASE COVER Revised4/29/03GEAR CASECOVER

68D54/29/03


37/26536

68D5GEAR CASE COVERRevised4/29/03


1 11-5797 CASE - gear 12 * 33-2170 O-RING - case 1

3 * 33-713 O-RING - case 1

4 * 33-1638 O-RING - gear case 15 55-2433 NUT - case 1

55-790 LOCKWASHER 155-5453 STUD 1

6 * 33-288 SEAL - crankshaft 17 11-7500 PUMP - fuel 1

8 55-5469 STUD - fuel 39 55-5475 NUT - pump 3

55-1567 LOCKWASHER 310 55-6945 SCREW - case to cylinder block (60 mm lg) 611 Not Used

12 51-642 SCREW - case to cylinder block (30 mm lg) 313 55-6944 SCREW - case to cylinder block (45 mm lg) 214 55-5474 SCREW - cover 415 11-5798 COVER - timing 216 33-1640 GASKET - cover 2

17 * 33-1641 O-RING 118 55-5491 SCREW - idler shaft 1

19 11-4048 WASHER 120 10-305 GEAR SET - idler 121 11-5875 BEARING - idler 1

22 11-5899 CAM - pump 1

23 11-5845 SHAFT 124 11-5841 SHAFT - idler 125 33-796 GASKET - joint 226 11-5844 COLLAR - thrust 127 55-5559 SCREW - collar 2

28 11-5857 PIPE - oil 129 55-2462 BOLT - pipe 1

30 55-5500 LOCKWASHER 131 55-5499 SCREW - eye 1



38/26537

68D9 FUEL PUMP ASSEMBLY Revised7/20/01FUEL PUMPASSEMBLY

68D97/20/01


39/26538

68D9FUEL PUMP ASSEMBLYRevised7/20/01


11-7500 PUMP - fuel (incl 20) 11 11-5895 PUMP - priming 1

2 33-1653 O-RING 2

3 11-2808 SPRING 2

4 11-2930 VALVE 2

5 55-5525 BOLT - eye 1

6 55-2208 GASKET - eye bolt 4

7 11-2760 ADAPTER 1

8 11-2923 PISTON 1

9 11-6540 SPRING (14 light coils, 7psi, 48kPa) 1

10 33-1652 GASKET 1

11 55-1953

PLUG 112 55-5524 BOLT - eye 1

13 11-2854 FILTER - screen 1

14 11-5890 GUIDE 1

15 11-5889 PIN 1

16 11-2770 ROLLER 1

17 11-5894 RING - snap 1

18 33-2017 WASHER 1

19 11-6987 PLUG 1

20 11-7499 FITTING - banjo 121 11-5887 TAPPET 1


40/26539

68D10 OIL PUMP GROUP (di 2.2 & se 2.2) Revised1/4/00OIL PUMP GROUP(di2.2 & se 2.2)

68D101/4/00


41/26540

68D10OIL PUMP GROUP (di 2.2 & se 2.2)Revised1/4/00


1 11-6017 PUMP - oil 12 55-2464 PIN - pinion gear 1

3 11-3458 GEAR - pinion 1

4 11-5805 PIPE - oil pump 15 55-5488 BOLT - oil pump 2


42/26541

68E1 WATER PUMP GROUP Revised2/14/03WATER PUMPGROUP

68E12/14/03


43/26542

68E1WATER PUMP GROUPRevised2/14/03


1 11-5860 HOUSING - thermostat 12 11-5862 PIPE - bypass 1

3 55-5504 PLUG - housing 1

4 * 33-3169 GASKET - housing 15 55-5455 SCREW - housing 26 55-2433 NUT - housing 27 55-790 LOCKWASHER 58 55-2391 STUD - housing 29 55-3401 CLAMP - hose 1

10 11-5861 HOSE - bypass (neoprene) 111-5932 HOSE - bypass (silicone) 1

11 55-3401 CLAMP - hose 112 11-9356 PUMP - water 1

811-9356 PUMP - water (remanufactured) 1

13 **NSS IMPELLER 1

14 **NSS SEAL 1

15 **NSS THROWER 1

16 **NSS BEARING 1

17 11-5859 CENTER - pulley (w/ 5/16/-18 threads) 1

18 55-2454 SCREW - set 1


20 55-5502 PLUG 1

21 * 33-1646 O-RING 122 55-5503 SCREW - pump (50 mm lg) 2

23 55-6944 SCREW - pump (30 mm lg) 124 55-2433 NUT - pump 225 44-4066 SWITCH - water temperature (low speed start) 1

26 44-6880 HARNESS - low speed start 1* 30-262 GASKET SET (see 80A6) 1


44/26543

68E3 FUEL INJECTION GROUP Revised6/14/00FUEL INJECTIONGROUP

68E36/14/00


45/26544

68E3FUEL INJECTION GROUPRevised6/14/00

NOTE: Items 14,15 & 17 have been replaced with item 22.


1 11-5871 PIPE - injection (No. 1) 12 11-5872 PIPE - injection (No. 2) 1

3 11-5873 PIPE - injection (No. 3) 1

4 11-5874 PIPE - injection (No. 4) 15 101-256 PUMP - injection 16 11-3452 CLIP - pipe 27 55-5509 CLAMP - hose 98 11-5867 HOSE - fuel return 19 55-2408 SCREW - clamp 1

10 55-5500 LOCKWASHER 111 55-5510 CLAMP - hose 112 11-5866 HOSE - fuel (nozzle to nozzle) 313 11-5876 CAP - nozzle 114 55-2430 NUT - holder 4

15 55-5508 WASHER 416 11-5868 BRACKET - holder 417 55-5452 STUD - holder 418 13-650 NOZZLE - injection (incl 19) 4

813-650 INJECTOR - nozzle (remanufactured) 4

19 11-5869 NOZZLE 420 * 33-1656 O-RING - nozzle 4

21 * 33-1657 GASKET - nozzle 4* 30-262 GASKET SET (see 80A6) 1

22 55-6381 SCREW - nozzle 4


46/26545

68E4 INJECTION PUMP Revised3/3/06INJECTION PUMP68E4

3/3/06


47/26546

68E4INJECTION PUMPRevised3/3/06


1 101-256 PUMP - injection 12 11-5879 BRACKET - injection pump 1

3 55-5568 SCREW - gear 6

4 * 10-305 GEAR SET - idler 1

5 11-5881 CENTER - injection pump gear 1


7 55-5557 NUT - injection pump 1

8 * 33-1651 O-RING - injection pump 1

9 55-5519 SCREW - bracket (85 mm lg) 155-6945 SCREW - bracket (60 mm lg) 1

10 55-6944 SCREW - bracket (30 mm lg) 411 11-5882 BRACKET - injection pump 1

12 55-5520 SCREW - bracket 213 11-5883 BRACKET - injection pump 1

14 55-5522 FLATWASHER 215 55-6951 SCREW - adjust 216 55-9331 SCREW - bracket 217 44-6728 HARNESS - fuel injection solenoid 118 44-6727 VALVE - solenoid (fuel, 12V) 1

44-7672 VALVE - solenoid (fuel, 24V) 1

33-1667 O-RING - solenoid 119 55-5585 WASHER 120 55-5586 NUT 121 33-1668 GASKET - connector 522 11-5915 CONNECTOR - fuel return/outlet 123 11-5917 VALVE - bleed 1

24 11-5914 SPRING - throttle return 125 11-5913 LEVER - throttle 126 55-5584 LOCKWASHER 127 55-5583 NUT 1

28 55-5587 BOLT - eye 129 11-5916 CONNECTOR - fuel inlet 1

30 55-5588 SPACER - connector 131 11-6648 LEVER - throttle 132 55-6213 WASHER 133 11-6650 BUSHING - upper 134 11-6651 BUSHING - lower 135 11-6649 SPRING - throttle return 1

36 11-7663 CONNECTOR - fuel return/outlet 137 11-7664 CONNECTOR - fuel inlet 138 33-3320 SET - gasket (complete set of internal o-rings & gaskets) 1


48/26547

68E4 INJECTION PUMP Revised3/3/06


49/26548

68E4INJECTION PUMPRevised3/3/06

NOTE: GEAR SET 10-305 includes: Crankshaft Gear (11-5835); Camshaft Gear (11-5839; Gear A (11-5843);Gear B (11-5846; Injection Pump Gear (11-5880).


39 33-3213 GASKET - injection pump 1



50/26549

68E2 STARTER & GLOW PLUG GROUP (di 2.2 & se 2.2) Revised10/17/02STARTER & GLOWPLUG GROUP (di

2.2 & se 2.2)68E210/17/02


51/265


52/26551

74G12 STARTER - 12V GEAR REDUCTION (C201, di 2.2 & se2.2) Revised1/15/04STARTER -12VGEAR REDUC-

TION (C201,di 2.2& se 2.2)74G121/15/04


53/26552

74G12STARTER - 12V GEAR REDUCTION (C201, di 2.2 & se

2.2)Revised1/15/04

NOTE: Starter ID number: S-13-89C

NOTE: *Starter 45-1229 has been replaced with 45-1285. Parts for starter 45-1285 will work in 45-1229

NOTE: **Starter 845-1263 (se & di 2.2) has the same parts as 45-1285 except for items 8, 9 & 19 (Gear Case,Solenoid and Rear Cover).


* 45-1229 STARTER (C201) 1* 45-1285 STARTER (C201) 1

* 845-1285 STARTER (remanufactured, C201) 1

**845-1263 STARTER (remanufactured, se & di 2.2) 11 77-1581 RETAINER - bearing 1

2 44-6681 SHAFT 1

3 77-1580 BEARING - ball 1


5 44-6676 PINION - clutch assembly (incl 2, 3, 4, 6) 1

6 44-6677 STOPPER - assembly 1

7 55-5556 BOLT - solenoid 2

8 44-6422 GEAR CASE (45-1229 & 45-1285) 1

44-7401 GEAR CASE (45-1263) 1

9 44-6424 SOLENOID (45-1229 & 45-1285) 1

44-6679 SOLENOID (45-1263) 1

10 44-6678 SHIFT LEVER - assembly 1


12 44-7016 ARMATURE (incl 11 & 13) 1


14 44-6671 COIL - field 1

15 44-7311 BRUSH (set of 4)

1

16 44-7019 HOLDER - brush 1

17 44-6674 SPRING - brush 4

18 55-5363 SCREW - retainer 3

19 44-6413 COVER - rear (45-1229 & 45-1285) 1

44-7402 COVER - rear (45-1263) 1

20 55-5364 SCREW - brush holder 4

21 55-5555 BOLT - thru 2

22 44-6680 KIT - dust cover 1


54/26553

128G1 STARTER ASSEMBLY (C201, di 2.2 & se 2.2) Revised1/2/02STARTER ASSEM-BLY (C201, di 2.2 &

se 2.2)128G11/2/02


55/26554

128G1STARTER ASSEMBLY (C201, di 2.2 & se 2.2)Revised1/2/02

NOTE: STARTER (P/N 45-1671), has been replaced with STARTER (P/N 45-1993).


45-1993 STARTER (see note) 11 * 77-2331 RETAINER - bearing 1

2 55-5363 SCREW - retainer 3

3 44-6676 PINION - clutch assembly 1

4 44-6681 SHAFT 1

5 77-1580 BEARING 1

6 77-1579 BEARING 1

7 44-6677 STOPPER - assembly 1

8 * 41-1360 CASE - gear 1

9 44-6679 SOLENOID 1

10 44-6680 KIT - dust cover 1

11 55-5556

SCREW - solenoid 212 44-6678 LEVER - shift 1

13 * 41-1353 ARMATURE 1

14 77-1578 BEARING 1

15 77-1577 BEARING 1

16 * 41-1354 COIL - field 1

17 41-1359 KIT - brush (incl positive & negative brushes, set of 4) 1

18 * 41-1356 BRUSH & HOLDER - assembly 1

19 * 41-1357 SPRING - brush 4

20 Not Used21 44-7402 COVER - rear 1

22 55-5363 SCREW - brush holder 4

23 * 55-8422 SCREW - thru 2


56/26555

102A11 FUEL FILTER & HOSES Revised1/6/98FUEL FILTER &HOSES

102A111/6/98


57/26556

102A11FUEL FILTER & HOSESRevised1/6/98


1 11-7263 BASE - fuel filter 155-5078 NUT - filter base 2

55-402 LOCKWASHER 2

2 11-7264 ELEMENT - water separator 13 11-6285 ELEMENT - fuel filter 14 11-6499 CLAMP - element 45 11-7481 PLUG - water sensor 16 55-7137 SCREW - plug 27 11-5981 SLEEVE 1

8 11-7434 FITTING 19 11-4367 HOSE (1/4 od x 35 ft lg) A/R

10 11-4372 HOSE (3/8 od x 35 ft lg) A/R11 11-4841 NUT (1/4) 1112 10-243 KIT - sleeve & eyelet (1/4) 11

13 55-5961 NUT - fitting 414 55-5962 WASHER - hose (1/4) 115 33-1885 GROMMET - hose (1/4) 116 33-1886 GROMMET - hose (3/8) 317 11-6496 FITTING (5/16 x 1/4) 1

18 Not Used19 Not Used

20 55-5587 BOLT - eye 121 33-1668 GASKET - connector 522 11-7664 CONNECTOR - fuel inlet 123 55-5588 SPACER 124 11-5917 VALVE - bleed 1

25 11-5915 CONNECTOR - fuel return 126 101-256 PUMP - injection 127 11-4941 NUT (3/8) 428 10-242 KIT - sleeve & eyelet (3/8) 429 11-7435 FITTING - elbow 130 11-4381 ADAPTER 1

31 55-1922 WASHER 332 11-7500 PUMP - fuel 133 11-6321 BLOCK - fuel 1

55-433 PLUG - pipe 2

34 11-4381 ADAPTER - fuel block 135 11-4380 ELBOW (3/8) 136 11-5926 NUT - hose 137 10-253 KIT - fuel heater (optional) 1

38 55-2537 HANGER - fuel heater 155-101 SCREW - hanger 2


58/26557

102A11 FUEL FILTER & HOSES Revised1/6/98


59/265


60/265


61/26560

143E8FUEL FILTER & HOSES (se 2.2)Revised1/31/06

NOTE: This spin-on fuel filter is used on SB-III built after 1/98 (S/N 0485AP5074)


1 11-9015 HEAD - fuel filter 155-5078 NUT 2

55-402 FLATWASHER 2

2 11-9017 SPUD - fuel filter 13 11-9016 SHAFT - water bleed 14 11-9342 FILTER - fuel 1

11-9342 FILTER - fuel (EMI 3000) 1203-393 SEALER - thread A/R

5 11-5320 ELBOW - hose (1/4) 3

11-6837 FITTING - hose (straight) 16 10-243 KIT - sleeve & eyelet (3/8) 37 11-4841 NUT - hose (1/4) 38 11-4367 HOSE (1/4 od x 35 ft lg) A/R9 11-7435 FITTING - hose (3/8) 1

10 10-242 KIT - sleeve & eyelet (3/8) 311 11-4941 NUT - hose (3/8) 312 11-4372 HOSE (3/8 od x 35 ft lg) A/R13 101-281 PUMP - injection (see 100C12, before 1/99) 1

8101-281 PUMP - injection (remanufactured) 1

101-320 PUMP - injection (see 152C14, 1/99 & after) 114 11-7433 PUMP - fuel (see 100C9) 1

15 91-8732 BRACKET - fuel filter (SB-III) 191-8845 BRACKET - fuel filter (Super-II) 155-3281 SCREW - bracket 255-402 FLATWASHER 655-5078 NUT 4

16 91-387 BRACKET - fuel line (Super-II) 155-6545 SCREW - bracket 2

17 11-6862 FITTING (3/8) 118 11-6861 FITTING (1/4) 119 55-549 CLAMP - tube 120 91-758 CLAMP - tube 1

55-140 SCREW - clamp 155-411 FLATWASHER 1

21 92-2747 BRACKET - fuel line (SB) 155-538 SCREW - bracket 155-411 FLATWASHER 1

55-366 LOCKWASHER 122 10-342 KIT - check valve 1

11-9245 VALVE - check 1


62/26561

117C14 DIESEL FUEL HEATER (SB-III) Revised2/13/98DIESEL FUELHEATER (SB-III)

117C142/13/98


63/26562

117C14DIESEL FUEL HEATER (SB-III)Revised2/13/98


1 10-297 KIT - fuel heater 111-5285 HEATER - fuel 1

99-9591 FITTING 1

2 10-242 KIT - fuel line (3/8) 2

3 11-4941 NUT - hose (3/8) 2

4 11-4959 ELBOW 2

5 55-101 SCREW 2

6 55-4118 NUT 2

7 55-1521 CLAMP - hose 2

55-2330 BANDWRAP 8

8 55-2537 HANGER - fuel heater 1

55-538

SCREW 155-411 FLATWASHER 2

55-366 LOCKWASHER 1

55-291 NUT 1

9 11-4372 HOSE (3/8 od x 35 ft lg, nylon) A/R10 12-538 HOSE (3/8 x 25 ft) A/R11 55-7398 ADAPTER - hose 1

203-385 SEALER - thread A/R12 11-7691 TUBE - radiator 1


64/26563

70B6 THROTTLE SOLENOID GROUP Revised10/6/98THROTTLE SOLE-NOID GROUP

70B610/6/98


65/26564

70B6THROTTLE SOLENOID GROUPRevised10/6/98

NOTE: Replace items 10 &11 with item 14.


1 99-6400 BOLTSTRIP - top 199-8473 BOLTSTRIP (bottom) 1

2 99-8554 BRACKET - solenoid 1

55-5488 BOLT - manifold 13 99-8553 BRACKET - solenoid 1

55-4998 SCREW - bracket 255-790 LOCKWASHER 2

4 55-411 FLATWASHER 455-366 LOCKWASHER 4

55-2699 LOCKWASHER (internal/external tooth) 15 55-291 NUT 46 44-9181 SOLENOID 1

44-8198 PLUNGER 17 91-3095 BOOT (rubber) 1


55-1533 NUT 2

9 99-8555 ROD - solenoid 1

10 55-431 FLATWASHER 2

11 55-605 PIN - cotter 212 44-2756 DIODE - assembly 113 44-6881 STRAP - ground 114 11-4874 CLIP - solenoid rod 2

15 55-2762 BOLT - eye 1


66/26565

102A13 BYPASS OIL FILTER (di 2.2) Revised3/26/04BYPASS OIL FIL-TER (di2.2)

102A133/26/04


67/26566

102A13BYPASS OIL FILTER (di 2.2)Revised3/26/04


1 11-4372 HOSE (3/8 od x 35 ft lg) A/R2 11-4941 NUT - hose (3/8) 2

3 11-5437 COUPLING - oil pan 1

4 55-229 TEE 15 11-6338 SUPPORT - filter 1

55-529 SCREW - support 255-402 FLATWASHER 255-5078 NUT 291-5592 BRACKET - support 1

6 11-9099 FILTER - oil (standard) 111-9100 FILTER - oil (EMI) 1

7 11-9101 FILTER - bypass 18 10-242 KIT - sleeve & eyelet (3/8) 59 55-4515 CONNECTOR - hose 4

10 11-7486 DIPSTICK 133-2965 GASKET 1

11 11-4989 TUBE - oil fill 133-144 O-RING 155-5955 SCREW - tube 2

55-4608 LOCKWASHER 212 44-4774 SWITCH - oil pressure 113 55-1633 CAP - hose 1

14 91-1437 BRACKET - hose 115 11-5911 HOSE - oil drain (17.5 in) 1

91-1437 BRACKET - hose support 116 55-5592 ELBOW - oil drain 117 12-542 BASE - oil 1

55-6369 SCREW - oil base A/R

18 55-6016 CLAMP - hose 155-291 NUT 1

55-366 LOCKWASHER 119 91-1435 HOSE (1/4 od) 1

20 11-6837 FITTING 421 10-243 KIT - sleeve & eyelet 422 11-4841 NUT - hose (1/4) 4

23 41-377 SWITCH - oil level 1

33-3877 GASKET - switch 1

44-9589 RECEPTACLE 1

44-9591 PIN - terminal 2

44-9590 WEDGE 1

24 55-4496 ELBOW - oil pressure sensor 1


68/26567

102A13 BYPASS OIL FILTER (di 2.2) Revised3/26/04


69/265


70/265


71/26570

70A3ENGINE COOLING SYSTEMRevised4/19/02


1 10-345 KIT - tank, expansion 155-2796 CLAMP - fuel line 2

11-4677 HOSE 1

81-293 FITTING - barb 1

55-2539 BUSHING 1

12-777 TANK - expansion 1

55-145 SCREW 4

55-411 FLATWASHER 455-366 LOCKWASHER 4

2 11-5406 CAP - radiator 13 11-7292 TUBE - radiator bleed (air) 14 12-547 COIL - radiator 1

55-4974 NUT - captive 65 55-3401 CLAMP - hose (1-1/2 in) 2

55-3402 CLAMP - hose (2 in) 26 55-1521 CLAMP - hose (5/8 in) 87 11-5908 HOSE - expansion tank to radiator (silicone) 1

11-5907 HOSE - expansion tank to radiator (silicone) 1

8 11-5909 HOSE - engine to radiator (EPDM) 111-5910 HOSE - engine to radiator (silicone) 1

9 11-9529 HOSE - engine to radiator (EPDM) 111-9530 HOSE - engine to radiator (silicone) 1

10 33-487 GASKET - thermostat housing 111 11-7702 THERMOSTAT 1

12 11-3346 ADAPTER - water outlet 155-5424 SCREW (M8) 255-790 LOCKWASHER 2

13 55-5094 DRAIN COCK - coolant 114 55-475 ELBOW 115 55-1592 CONNECTOR - hose 2

16 98-796 HOSE (EPDM, 25 ft) A/R12-383 HOSE (25 ft, silicone) A/R

17 67-914 TANK - accumulator 118 11-5861 HOSE - bypass (EPDM) 1

11-5932 HOSE - bypass (silicone) 119 99-1655 HOSE - overflow 1

20 44-6534 SENSOR - coolant level 155-4560 NUT 155-2996 LOCKWASHER 155-2001 FLATWASHER 1

21 55-6411 NIPPLE 1

22 11-5739 HOSE - accumulator tank (EPDM) 1


72/26571

70A3 ENGINE COOLING SYSTEM Revised4/19/02


73/26572

70A3ENGINE COOLING SYSTEMRevised4/19/02


11-5738 HOSE - accumulator tank (silicone) 123 55-4983 PLUG 2

24 99-8260 BRACKET - hose support 1


74/26573

65F5 MUFFLER GROUP Revised4/10/95MUFFLER GROUP65F5

4/10/95


75/265


76/26575

133A4 IDLER ASSEMBLY (1/96 & AFTER) Revised7/30/04IDLER ASSEMBLY(1/96 & AFTER)

133A47/30/04


77/26576

133A4IDLER ASSEMBLY (1/96 & AFTER)Revised7/30/04


78-1013 HOUSING - idler shaft 11 92-4303 HOUSING - bearing idler 1

2 55-6418 VENT - air 1

55-6416 CAP 1

3 55-3350 SCREW - oil plug 2

33-1009 O-RING 1

4 33-2134 SEAL - oil 2

203-278 GREASE (gallon) A/R

5 77-1070 BEARING - roller 2

6 77-2613 SHAFT - idler pulley 1

7 99-3264 TUBE - fan shaft housing 1

8 33-872

O-RING 19 91-7482 CAP - housing bearing 1

10 55-533 SCREW - cap 4

55-371 FLATWASHER 4

11 99-7978 SHIM (0.005 thk) A/R

99-7979 SHIM (0.007 thk) A/R

99-7980 SHIM (0.020 thk) A/R

204-475 GREASE (1 lb) A/R

12 55-457 KEY 2

13 11-6863 SLEEVE - repair (set of 10) 1


78/26577

86A7 AIR CLEANER GROUP (SB-II 30 di 2.2) Revised3/3/04AIR CLEANERGROUP (SB-II30 di

2.2)86A73/3/04


79/26578

86A7AIR CLEANER GROUP (SB-II 30 di 2.2)Revised3/3/04


1 11-5934 HOSE - dry air cleaner 111-7763 HOSE - oil bath air cleaner 1

2 55-4979 CLAMP - hose (2-1/2 in) 1

55-1636 CLAMP - hose (3 in) 13 11-9262 INDICATOR - air restrictor (before 2/93) 14 11-6222 ELBOW - air intake 1

55-5579 SCREW - elbow 255-5411 LOCKWASHER 255-4625 FLATWASHER 2

5 33-1664 GASKET - elbow 16 11-7659 HOSE - breather 1

55-2332 BANDWRAP 27 55-4747 CONNECTOR - breather hose (straight) 18 11-7400 FILTER - air cleaner (dry) 1

9 11-5562 CLAMP - air cleaner (dry) 211-3326 CLAMP - oil bath air cleaner 155-4967 NUT 455-371 FLATWASHER 855-141 SCREW - band 4

10 99-8686 BRACKET - dry air cleaner 191-736 BRACKET - dry air cleaner (EEC) 1

99-7992 BRACKET - oil bath air cleaner 155-4967 NUT - bracket 455-371 FLATWASHER 4

11 91-938 PLATE - air indicator 155-5695 SCREW - plate 1

55-5411 LOCKWASHER 112 11-6220 HOSE - indicator 113 55-6132 ADAPTER - hose 1

55-3364 PLUG - pipe (oil bath) 114 Not Used15 11-3975 CLEANER - air (oil bath) 1

16 11-3631

CLAMP 117 11-2536 CUP 1

11-2670 CUP - inner 1

33-828 GASKET - cup 1

18 55-1592 CONNECTOR - hose (elbow) 119 11-4579 ELBOW - oil bath air cleaner 120 11-7757 INDICATOR - air restrictor (2/93 & after) 121 11-7828 FITTING - air restriction indicator (2/93 & after) 1


80/26579

89C2 ENGINE & COMPRESSOR GROUP (SOFT MOUNT) Revised2/13/01ENGINE & COM-PRESSOR GROUP

(SOFT MOUNT)89C22/13/01


81/26580

89C2ENGINE & COMPRESSOR GROUP (SOFT MOUNT)Revised2/13/01


1 55-5578 PIN - dowel 22 55-1525 STUD (1-3/4 lg) 4

55-1487 STUD (2-1/4 lg) 2

3 55-375 LOCKWASHER 64 55-402 FLATWASHER 65 22-723 FLANGE - compressor (30s, see 89G1) 1

22-734 FLANGE - compressor (50s, see 89G1) 16 98-5090 BRACKET - engine 17 55-4266 SCREW - bracket to engine (socket head) 4

8 55-1418 WASHER - special 49 55-285 NUT 10

10 55-5576 PIN - dowel 211 99-798 BOLT - oil base 212 91-7709 MOUNT - vibration (set of 2) 2

13 55-5749 WASHER - special 414 55-4963 NUT 415 91-1407 BOLT - engine bracket 216 55-2519 WASHER - bolt 217 91-2619 MOUNT - vibration (oil base) 4

18 12-439 HOUSING - flywheel (30s) 112-448 HOUSING - flywheel (50s) 1

19 55-5417 SCREW - mount 120 55-451 LOCKWASHER 1

55-4767 FLATWASHER 121 92-407 SPACER - snubber 122 92-1152 PLATE - snubber 1

23 55-5594 SCREW - plate 224 55-5006 LOCKWASHER 225 91-1480 BOLTSTRIP 226 91-1409 ANGLE - snubber 127 91-1410 BRACKET - snubber 1

55-289 NUT - bracket 4

55-375 LOCKWASHER 428 99-1433 MOUNT - vibration 229 91-1411 SPACER 1


82/26581

149B4 6 PIN COUPLING w/SMALL SHAFT COMPRESSOR (di2.2 & se 2.2 ENGINE) Revised7/17/066 PIN COUPLINGw/SMALL SHAFT

COMPRESSOR (di2.2 & se 2.2ENGINE)149B47/17/06


83/26582

149B46 PIN COUPLING w/SMALL SHAFT COMPRESSOR (di

2.2 & se 2.2 ENGINE)Revised7/17/06



1 102-650 COMPRESSOR - X430 (dry, no oil, see 147A9) 18102-650 COMPRESSOR - X430 (remanufactured, dry) 1

2 22-655 CRANKSHAFT 1

3 22-1100 SEAL - bellows 14 22-755 COVER - drive 15 33-2120 SEAL 16 77-2504 COUPLING - compressor drive (6 pin) 17 55-9024 KEY (1-1/8 lg) 18 77-2498 SPACER 1

9 55-4316 SCREW - coupling (3/8-16) 110 11-5837 FLYWHEEL (6 pin, 30s) 111 55-6376 PIN - dowel 6

55-6377 PIN - dowel (0.501 oversize) 612 77-2856 BUSHING 6

13 11-5775 FLYWHEEL (50s) 114 107-299 CLUTCH (see 125E4) 1

70-206 KIT - bushing (6 pin clutch, incl pins, bushings & adhesive) 115 77-2760 BUSHING - coupling (50s) 6

16 51-869 PIN - dowel 6


84/26583

149B7 6 PIN COUPLING w/LARGE SHAFT COMPRESSOR (di2.2 & se 2.2 ENGINE) Revised7/17/066 PIN COUPLINGw/LARGE SHAFT

COMPRESSOR (di2.2 & se 2.2ENGINE)149B77/17/06


85/26584

149B76 PIN COUPLING w/LARGE SHAFT COMPRESSOR (di

2.2 & se 2.2 ENGINE)Revised7/17/06

NOTE: 102-821 & 8102-821 will not fit in Sentry, SMX and older SL units.



1 102-647 COMPRESSOR - X430 (dry, no oil, see 144F14) 1102-821 COMPRESSOR - X430 (Multi-Temp 7 qt, less/ filter & oil, see

185B2)1

8102-821 COMPRESSOR - X430 (Multi-Temp 7 qt, w/ filter & oil, see185B2)

1

2 22-1027 CRANKSHAFT 13 22-1101 SEAL - bellows 1

4 22-1028 COVER - drive end 15 33-3004 SEAL 16 77-2509 COUPLING (6 pin) 1

7 55-9032 KEY (5/8 lg) 18 77-2505 SPACER 19 55-9031 SCREW - coupling (M12 x 1.75 x 70 mm) 1

55-9092 SCREW - clutch (M12 x 1.75 x 80 mm) 110 11-5837 FLYWHEEL (6 pin, 30s) 111 55-6376 PIN - dowel 6

55-6377 PIN - dowel (0.501 oversize) 612 77-2856 BUSHING 613 11-5775 FLYWHEEL (50s) 114 107-275 CLUTCH 1

70-194 KIT - clutch repair 1

70-206 KIT - bushing (6 pin clutch, incl pins, bushings & adhesive) 1

15 77-2760 BUSHING - coupling (50s) 6

16 51-869 PIN - dowel 6


86/26585

96A8 FANS & BELTS GROUP Revised6/3/03FANS & BELTSGROUP

96A86/3/03


87/265


88/26587

96A8 FANS & BELTS GROUP Revised6/3/03


89/26588

96A8FANS & BELTS GROUPRevised6/3/03


55-2252 SCREW 255-2038 FLATWASHER 2

55-365 LOCKWASHER 2

15 99-8228 CHANNEL - idler (left) 155-529 SCREW - channel 455-402 FLATWASHER 455-375 LOCKWASHER 4

16 99-7989 NUTPLATE - idler 217 91-5572 ARM - idler adjusting 1

18 78-603 BELT - fan 119 78-629 BELT - engine to idler (30s) 120 77-2397 PULLEY - fan drive 121 55-5606 SCREW 4

55-5411 LOCKWASHER 4

22 77-1665 SPACER - pulley 123 77-1369 PULLEY 124 77-1665 SPACER - pulley 125 77-1345 PULLEY - water pump 1

77-1346 SPACER - pulley 1

55-144 SCREW 355-371 FLATWASHER 3

55-421 LOCKWASHER (internal thread) 326 78-751 BELT - alternator (before 4/91) 1

78-929 BELT - alternator (after 3/91) 127 41-2195 ALTERNATOR (37 amp, model EA, see 96A7, 30s, before 4/

91)1

41-2194 ALTERNATOR (23 amp, model 8MR) 1

41-5458 ALTERNATOR (37 amp, after 3/91) 177-762 PULLEY - alternator (37 amp, before 4/91) 177-2022 PULLEY - alternator (after 3/91) 1

28 55-1933 KEY 1

29 77-1591 BOSS - pulley 130 10-266 KIT - bolt (crankshaft) 1

11-5465 WASHER 131 55-457 KEY - woodruff 232 55-529 SCREW - arm 4

55-375 LOCKWASHER 455-402 FLATWASHER 455-5078 NUT 1

33 99-8135 COVER - housing bearing 155-1587 SCREW 455-1800 LOCKWASHER 4


90/26589

96A8 FANS & BELTS GROUP Revised6/3/03


91/26590

96A8FANS & BELTS GROUPRevised6/3/03


55-4742 WASHER 434 99-4353 RING 1

35 91-1199 GUIDE - belt 1

55-312 NUT - guard 455-790 LOCKWASHER 255-371 FLATWASHER 4


92/26591

84E5 FANSHAFT ASSEMBLY & ROLLER BEARING Revised7/30/04FANSHAFTASSEMBLY &

ROLLER BEARING84E57/30/04


93/26592

84E5FANSHAFT ASSEMBLY & ROLLER BEARINGRevised7/30/04


78-706 FANSHAFT - assembly 11 55-3350 SCREW - oil plug 2

2 33-1009 O-RING 2

3 55-6418 VENT - air 1

55-6416 CAP 1

4 * 33-2134 SEAL - oil 2


5 77-2614 SHAFT - fan 1

6 55-533 SCREW - cap 4

55-371 FLATWASHER 4

7 91-1203 CAP 1

8 * 33-982

O-RING 19 * 77-1070 BEARING - roller 2


10 92-4304 HOUSING 1

11 99-2901 SHIM (0.005 thk) A/R

99-2902 SHIM (0.007 thk) A/R

99-4231 SHIM (0.020 thk) A/R

* 70-135 KIT - fanshaft repair 112 11-6863 SLEEVE - repair (set of 10) 1


94/26593

65F2 IDLER ASSEMBLY (BEFORE 1/96) Revised5/16/06IDLER ASSEMBLY(BEFORE 1/96)

65F25/16/06


95/26594

65F2IDLER ASSEMBLY (BEFORE 1/96)Revised5/16/06

NOTE: 78-593 has been replaced with 78-1013, see 133A4.


78-593 IDLER - assembly (this idler has been replaced with 78-1013,see 133A4)

1

1 99-7939 HOUSING - bearing idler 1

2 55-6418 VENT - air 1

55-6416 CAP 1

3 55-3350 SCREW - oil plug 2

33-1009 O-RING 1

4 33-2134 SEAL - oil 2


5 77-1070 BEARING - roller 2

6 77-2613 SHAFT - idler pulley 1

7 99-3264 TUBE - fan shaft housing 1

8 33-872 O-RING 1

9 99-7940 CAP - housing bearing 1

10 55-533 SCREW - cap 4

55-371 FLATWASHER 4

11 99-7978 SHIM (0.005 thk) A/R

99-7979 SHIM (0.007 thk) A/R

99-7980 SHIM (0.020 thk) A/R


12 55-457 KEY 2

13 11-6863 SLEEVE - repair (set of 10) 1


96/26595

102A12 REFRIGERATION COMPONENTS Revised4/20/04REFRIGERATIONCOMPONENTS

102A124/20/04


97/26596

102A12REFRIGERATION COMPONENTSRevised4/20/04


1 67-912 COIL - condenser (see 70A9) 12 66-5325 TUBE - 3-way to condenser 1

3 91-372 CLAMP - tube (see 90E4) 2

4 66-7392 VALVE - relief (high pressure) 133-1015 O-RING 1

5 66-5828 TUBE - valve to tank 199-3060 FITTING - saddle 1

6 66-5721 VALVE - check 17 66-4223 TUBE - valve 1

8 66-5498 TUBE - coil to valve 19 91-373 CLAMP - tube (see 90E4) 1

10 55-546 CLAMP - tube 255-1230 SCREW - clamp 255-1511 LOCKWASHER 2

11 66-5331 TUBE - tee to gauge (optional) 112 66-5330 CONNECTOR - gauge 113 66-4907 GAUGE - compound (see 120C2, optional) 114 67-1179 TANK - receiver 115 66-5834 TUBE - receiver to drier 1

16 66-5501 VALVE - check 117 55-3065 CLAMP - tube 1

18 66-5833 TUBE - drier to exchanger 119 61-600 DEHYDRATOR (o-ring seal, after 11/92) 120 99-1617 CLAMP - dehydrator 221 91-445 CLAMP - tube (see 90E4) 122 66-5389 TUBE - tee to defrost 1

23 55-6434 TEE 124 66-5352 TUBE - 3-way valve to tee 125 66-5328 TUBE - check valve to tee 126 66-6067 VALVE - 3-way (see 86A3) 1

55-214 SCREW - valve 255-366 LOCKWASHER 2

27 66-5320 TUBE - 3-way to solenoid (w/ nut) 166-6023 TUBE - 3-way to solenoid (solder type) 1

28 66-5908 VALVE - pilot solenoid (w/ solder fittings) 141-1525 COIL 1

44-2756 DIODE 155-8786 NUT - valve 191-1434 SPACER - solenoid 155-3230 SCREW - solenoid 2

55-414 LOCKWASHER 229 66-5353 TUBE - solenoid 1


98/26597

102A12 REFRIGERATION COMPONENTS Revised4/20/04


99/26598



66-5354 NUT - flare 130 66-4346 TEE 1

31 66-6190 TUBE - hose to solenoid (w/ compound gauge) 1

66-6191 TUBE - hose to solenoid (w/o compund gauge) 155-5356 ADAPTER - flare 1

66-5355 TUBE - hose to tee (use with compound pressure gaugeoption)

1

32 66-5388 TUBE - vibrasorber to 3-way 133 66-5387 TUBE 134 55-6844 TEE - tube 135 55-2536 CLAMP - tube 2

36 66-7472 HOSE - throttling 137 66-5318 VALVE - suction 1

38 33-230 O-RING - valve 139 66-5936 VALVE - throttling (see 96A5) 140 N/A COMPRESSOR (see 72A12) 141 66-6024 VIBRASORBER - suction 1

42 33-2805 GASKET 343 22-735 MANIFOLD - discharge 144 66-129 VALVE - discharge 145 91-9135 BRACKET - discharge tube 146 55-5920 U-BOLT 1

55-5292 NUT 2

55-431 FLATWASHER 247 66-4987 TUBE - discharge 148 66-5784 VIBRASORBER - discharge 149 67-1070 TANK - accumulator 1

67-1195 TANK - accumulator (w/o coolant coil) 150 66-5327 TUBE - accumulator balance 1

51 91-1748 CLAMP - tube 152 55-6436 ELBOW (1/4) 1

53 55-6437 ELBOW (1-3/8) 154 66-5321 TUBE - exchanger to accumulator (use with accumulator tank

67-1070)1

66-7326 TUBE - exchanger to accumulator (use with accumulator tank67-1195)

1

55 66-9618 TUBE - defrost 1

56 99-8001 CLAMP - defrost tube 155-4954 NUT 155-2958 FLATWASHER 1

57 11-4256 HOSE 158 55-2240 CLAMP - tube 159 66-5313 TUBE - defrost to distributor 1


100/26599

102A12 REFRIGERATION COMPONENTS Revised4/20/04


101/265100


CAUTION: Both discharge manifold gaskets MUST be the same part number (thickness).


60 66-5816 TUBE - coil to exchanger 161 55-6020 CLAMP - tube (see 90E4) 1

55-3344 SCREW - clamp 2

55-1800 LOCKWASHER 262 67-991 HEAT EXCHANGER 163 66-5856 TUBE - equalizer 164 55-2536 CLAMP 165 66-5857 VALVE - expansion (R502) 1

66-3650 ELEMENT - power 1

66-9378 SCREEN - filter 1

66 67-916 COIL - evaporator 167 66-7789 VALVE - regulator 1

44-5175

COIL - valve 168 55-6020 CLAMP - tube 1

69 66-5391 TUBE - valve inlet 170 66-5374 VALVE - solenoid (hot gas bypass, see 138A7) 1

91-6449 BRACKET - solenoid 171 66-5392 TUBE - valve outlet 172 55-6434 TEE 173 66-5390 TUBE - tee to tee 1

74 91-2689 BRACKET - heat exchanger 199-2221 STRIP (neoprene) A/R

75 91-3454 BRACKET - gauge 176 91-1749 SPACER - clamp 177 66-7000 TUBE - valve to exchanger 1


102/265101

96A9 COMPRESSOR GROUP - X430 Revised3/23/06COMPRESSORGROUP - X430

96A93/23/06


103/265102

96A9COMPRESSOR GROUP - X430Revised3/23/06


1 102-647 COMPRESSOR - X430 (w/ large shaft, see 144F14) 1102-821 COMPRESSOR - X430 (Multi-Temp 7 qt, less/ filter & oil, see

185B2)1


1

203-513 OIL - compressor A/R2 22-723 FLANGE - compressor (30s) 1

22-734 FLANGE - compressor (50s) 13 55-2306 SCREW - flange 6

55-896 FLATWASHER 6

4 55-308 ELBOW - test port 15 55-1983 CAP - flare 2

33-768 GASKET - flare 2

6 55-2381 SCREW - valve & cover 57 55-896 FLATWASHER 28 66-5318 VALVE - suction 1

9 66-2296 CAP - valve (plastic) 1

66-3015 CAP - valve (brass) 1

10 33-3007 GASKET - plastic cap 1

33-350 GASKET - brass cap 1

11 55-6804 WASHER - sealing 612 33-230 O-RING - valve 114 66-5936 VALVE - throttling (24 psi, see 96A5) 115 33-1221 O-RING - valve 1

16 55-6776 SCREW - discharge valve 217 66-129 VALVE - discharge (incl 9 & 10) 118 33-2805 GASKET - valve 319 55-9024 KEY - compressor 120 33-2120 SEAL - oil 121 204-972 TOOL - keyway alignment 1

22 22-755 COVER - drive end 123 22-735 MANIFOLD - discharge 1

24 55-6822 SCREW - manifold 425 55-3364 PLUG - pipe 226 91-4134 PLATE - cover 127 33-3101 GASKET - cover 1

28 11-1886 VALVE (Schrader) 129 55-1418 WASHER 2

30 91-9135 BRACKET - discharge 131 55-5920 U-BOLT 1

55-2752 NUT 255-431 FLATWASHER 2


104/265103

124C11 COMPRESSOR GROUP - X430 Revised3/23/06COMPRESSORGROUP - X430

124C113/23/06


105/265104

124C11COMPRESSOR GROUP - X430Revised3/23/06


1 102-647 COMPRESSOR - X430 (w/ large shaft, dry, see 144F14) 1102-650 COMPRESSOR - X430 (w/ small shaft, dry, see 147A9) 1

8102-650 COMPRESSOR - X430 (remanufactured, dry) 1

102-821 COMPRESSOR - X430 (Multi-Temp 7 qt, less/ filter & oil, see185B2)

1


1

2 22-723 FLANGE - compressor (30s) 122-734 FLANGE - compressor (50s, Super-II & SB-III) 122-720 FLANGE - compressor (Sentry 50) 1

3 55-2306 SCREW - flange 655-896 FLATWASHER 6

4 55-308 ELBOW - test port 1

5 55-1983 CAP - flare 233-768 GASKET - flare 2

6 55-2381 SCREW - valve & cover 5

7 55-896 FLATWASHER 28 66-5318 VALVE - suction 19 66-2296 CAP - valve (plastic) 1

66-3015 CAP - valve (brass) 1

10 33-3007 GASKET - plastic cap 1

33-350 GASKET - brass cap 1

11 55-6804 WASHER - sealing 612 33-230 O-RING - valve 1

14 66-5936 VALVE - throttling (24 psi, see 87G8) 166-5933 VALVE - throttling (23-25 psi, see 100C13) 166-5932 VALVE - throttling (17-19 psi, see 87G9) 1

15 33-1221 O-RING - valve 116 55-6822 SCREW - discharge valve 217 66-129 VALVE - discharge (incl 9 & 10) 1

18 33-2805 GASKET - valve 319 55-9032 KEY - compressor 1

20 33-3004 SEAL - oil (large shaft, 1-3/16 dia) 133-2120 SEAL - oil (small shaft, 1.0 dia) 1

21 204-972 TOOL - keyway alignment 122 22-1028 COVER - drive end (large shaft, 1-3/16 dia) 1

22-755 COVER - drive end (small shaft, 1.0 dia) 123 22-759 MANIFOLD - discharge 1

24 55-6822 SCREW - manifold 425 55-3364 PLUG - pipe 226 91-4134 PLATE - cover 127 33-3101 GASKET - cover 1


106/265105

124C11 COMPRESSOR GROUP - X430 Revised3/23/06


107/265106

124C11COMPRESSOR GROUP - X430Revised3/23/06


NOTE: 102-821 & 8102-821 will not fit in Sentry, SMX and older SL units.


28 11-2886 VALVE (Schrader) 129 91-9135 BRACKET - discharge tube 1

30 55-5920 U-BOLT 1

55-2752 NUT 255-431 FLATWASHER 2

31 55-1418 WASHER - bracket 2


108/265107

72A12 COMPRESSOR X430 (R22) Revised9/17/03COMPRESSORX430 (R22)

72A129/17/03


109/265108

72A12COMPRESSOR X430 (R22)Revised9/17/03


102-490 COMPRESSOR - X430 (R12, R22 or R502, see note) 1102-491 COMPRESSOR - X430 (w/ unloader head, R12 or R502, see

note)1

1 23-129 BODY - compressor (w/ unloader hole) 123-123 BODY - compressor (w/o unloader hole) 1

2 51-115 NUT (12 point) 2


4 22-639 ROD - connecting (incl 2, 3 & 6) 4

5 22-1246 BEARING SET - connecting rod (standard) 4

22-1004 BEARING SET (0.005 us) 4

22-1005 BEARING SET (0.010 us) 4

22-1006 BEARING SET (0.020 us) 4

22-1007 BEARING SET (0.030 us) 4

6 11-475 BUSHING - connecting rod 4

7 NSS PIN - piston 4

8 22-850 PISTON (incl 7, 9, 10, 30, 31) 4

9 55-2122 RING - snap 8

10 51-115 NUT 4

55-895 WASHER - compressor 4

11 77-167 BEARING (drive end) 1

12 22-123 PLUG - oil metering 1


55-4720 PLUG 3

55-1409 RIVET (steel) 4

14 77-169 BEARING (pump end) 1

15 55-4213 PIN - dowel 1

16 22-306 SCREEN - suction 1

33-1221 O-RING 1

17 * 55-6750 PLUG - oil fill 1

33-1223

O-RING 118 22-656 SLEEVE (X430) 4

19 * 33-408 O-RING 4

20 22-990 PLATE - valve 4

21 * 33-822 O-RING 3

22 22-350 SIGHT GLASS 3

23 * 33-2552 GASKET - compressor cylinder head 2

24 22-789 HEAD - cylinder 2

25 55-6805 SCREW (2 in lg) 12


110/265109

72A12 COMPRESSOR X430 (R22) Revised9/17/03


111/265110



55-6806 SCREW (2-5/8 in lg) 8

26 55-6804 WASHER - sealing 20

33-2019 O-RING 20

27 * 33-2805 GASKET - manifold 2

28 22-625 HEAD - unloader 1

29 55-3364 PLUG 1

30 NSS REED - piston 4

31 NSS HEAD - piston 4


33-2095 O-RING 1

33 22-653 VALVE - check 2

34 33-1549

GASKET - oil pump 135 22-663 HOUSING - oil pump 1

822-663 HOUSING - pump (remanufactured) 1

55-4210 PIN - dowel 1

36 * 33-239 O-RING 2

37 * 33-1175 O-RING 1

38 55-6752 PLUG - oil pump cover 1

33-2095 O-RING 1

39 22-555 COVER - pump 1

55-4211 PIN - dowel 140 55-681 SCREW - cover 2

41 55-183 SCREW 8

* 55-896 WASHER - compressor 10

42 * 33-672 O-RING 1

43 22-784 REGULATOR - oil pressure 1

44 33-2513 GASKET - drive plate 1

45 22-611 SCREEN - oil pickup 1

46 99-4848 CLAMP 1

55-366 LOCKWASHER 2

55-291 NUT 2

47 99-4849 BRACKET 1

48 55-165 SCREW 2

55-366 LOCKWASHER 2

49 11-5513 VALVE (90 deg) 1

50 22-1160 PUMP - oil 1

51 * 33-1223 O-RING 1


112/265111

72A12 COMPRESSOR X430 (R22) Revised9/17/03


113/265112


NOTE: The heads on this compressor do not have ports. If needed, use cylinder head 22-300 which has a 1/ 8 pipe port. Compressor 102-490 has been replaced with compressor 102-650, see Grid 147A9. Com-pressor 102-491 has been replaced with 102-649, see Grid 147A10.



52 22-1149 SHAFT - oil pump 1

53 55-9760 KEY 1

54 Not Used55 * 33-2515 GASKET - oil sump 1

56 22-552 SUMP - oil 1

57 55-1417 SCREW - oil sump 16

* 55-896 FLATWASHER 16

58 22-787 VALVE - check (oil return) 1


60 * 33-2205 O-RING 1

61 55-6823 SCREW - cylinder head (4-1/8 lg) 3

67-404 OIL - compressor 1* 30-243 KIT - gasket (X426/X430 compressor) 1

203-346 KIT - acid test 1


114/265113

147A9 COMPRESSOR - X430 (DRY, 1.0 DIA CRANKSHAFT) Revised9/17/03COMPRESSOR -X430 (DRY, 1.0 DIA

CRANKSHAFT)147A99/17/03


115/265114

147A9COMPRESSOR - X430 (DRY, 1.0 DIA CRANKSHAFT)Revised9/17/03


102-650 COMPRESSOR - X430 (dry) 18102-650 COMPRESSOR - X430 (remanufactured, dry) 1

1 23-129 BODY - compressor 1


55-1409 RIVET - counterweight A/R


4 55-4720 PLUG 3

5 55-4213 PIN - dowel 1



8 22-639 ROD - connecting 4


10 51-115 NUT (12 point) 2

11 11-475 BUSHING - piston pin 4


22-1004 BEARING SET (0.005 us) 4

22-1005 BEARING SET (0.010 us) 4

22-1006 BEARING SET (0.020 us) 4

22-1007 BEARING SET (0.030 us) 4

13 22-850 PISTON 4

14 NSS PIN - piston 415 55-2122 RING - retaining 8

16 51-115 NUT 1

55-895 FLATWASHER 1



19 * 33-1549 GASKET - pump end 1

20 22-663 HOUSING - oil pump 1


55-4210 PIN - dowel 1

21 * 33-1223 O-RING 2


23 55-9760 KEY - shaft 1

24 22-1160 PUMP - oil (incl items 21-23) 1

25 * 33-239 O-RING 2

26 * 33-1175 O-RING 1


33-2095 O-RING 4


116/265115

147A9 COMPRESSOR - X430 (DRY, 1.0 DIA CRANKSHAFT) Revised9/17/03


117/265116



28 22-555 COVER - pump 1

29 55-4211 PIN - dowel 1

30 22-784 REGULATOR 1

31 * 33-672 O-RING 1

32 55-681 SCREW - cover to housing 2


33 55-183 SCREW - pump 8

34 11-9001 VALVE - tee 1

203-393 SEALER - thread A/R

55-1983 CAP - valve 1


36 * 33-2205

O-RING 137 99-4848 CLAMP - screen 1

38 55-291 NUT 1


40 99-4849 BRACKET - screen 1

41 55-165 SCREW - bracket 2

55-366 LOCKWASHER 2

42 55-6751 PLUG - magnetic 2

33-2095 O-RING 4

43 * 33-2515 GASKET - oil sump 1644 22-747 SUMP - oil 1




* 33-822 O-RING 3

47 * 33-2552 GASKET - cylinder head 2


49 55-6805 SCREW (2 in lg) 12

50 55-6806 SCREW (2-5/8 in lg) 8


52 33-2019 O-RING 20

53 22-656 SLEEVE - cylinder 4

54 * 33-408 O-RING 4


56 55-6750 PLUG - oil fill 1



118/265


119/265118


NOTE: The heads on this compressor do not have ports. If needed, use cylinder head P/N 22-788, which hasa 1/8 pipe port.

NOTE: This compressor does not contain compressor oil. Add one gallon of oil before running compressor.R404A & R134a use 203-513 oil. R12, R22, R502, R403B, R402A & R401B use 67-404 oil.

NOTE: Both discharge manifold gaskets MUST be the same part number (thickness).


58 33-1221 O-RING 1




62 22-1100 SEAL - crankshaft (for 1.0 dia crankshaft) 1

63 33-2513 GASKET - drive end 1

64 22-671 PLATE - crankshaft cover 1

65 55-9106 SCREW - housing 9

55-896 FLATWASHER 9

66 99-6545 PLATE - suction inlet 1

67 55-329 SCREW - plate 4

68 11-2886

VALVE (Schrader) 169 91-5630 PLATE - cover 1

70 91-9858 PLATE - cover (w/ lifting hole) 1



67-404 OIL - compressor (use w/ R12, R22, R502, R403B, R402A, &R401B, 1 gallon)

A/R

203-513 OIL - compressor (use w/ R404A & R134a, 1 liter) A/R* 30-243 KIT - gasket 1


120/265119

147A10 COMPRESSOR - X430 (w/UNLOADER HEAD, DRY, 1.0DIA CRANKSHAFT) Revised9/17/03COMPRESSOR -X430 (w/

UNLOADER HEAD,DRY, 1.0 DIACRANKSHAFT)147A109/17/03


121/265120

147A10COMPRESSOR - X430 (w/UNLOADER HEAD, DRY, 1.0

DIA CRANKSHAFT)Revised9/17/03


102-649 COMPRESSOR - X430 (dry, w/ unloader head) 11 23-129 BODY - compressor 1


55-1409 RIVET - counterweight A/R


4 55-4720 PLUG 3

5 55-4213 PIN - dowel 1



8 22-639 ROD - connecting 4


10 51-115

NUT (12 point) 211 11-475 BUSHING - piston pin 4


22-1004 BEARING SET (0.005 us) 4

22-1005 BEARING SET (0.010 us) 4

22-1006 BEARING SET (0.020 us) 4

22-1007 BEARING SET (0.030 us) 4

13 22-850 PISTON 4

14 NSS PIN - piston 4

15 55-2122 RING - retaining 816 51-115 NUT 1

55-895 FLATWASHER 1



19 * 33-1549 GASKET - pump end 1

20 22-663 HOUSING - oil pump 1


55-4210 PIN - dowel 1

21 * 33-1223 O-RING 2


23 55-9760 KEY - shaft 1

24 22-1160 PUMP - oil (incl items 21-23) 1

25 * 33-239 O-RING 2

26 * 33-1175 O-RING 1


33-2095 O-RING 4


122/265121

147A10 COMPRESSOR - X430 (w/UNLOADER HEAD, DRY, 1.0DIA CRANKSHAFT) Revised9/17/03


123/265122




28 22-555 COVER - pump 1

29 55-4211 PIN - dowel 1

30 22-784 REGULATOR 1

31 * 33-672 O-RING 1

32 55-681 SCREW - cover to housing 2


33 55-183 SCREW - pump 8

34 11-9001 VALVE - tee 1

203-393 SEALER - thread A/R

55-1983 CAP - valve 1


36 * 33-2205

O-RING 137 99-4848 CLAMP - screen 1

38 55-291 NUT 1


40 99-4849 BRACKET - screen 1

41 55-165 SCREW - bracket 2

55-366 LOCKWASHER 2

42 55-6751 PLUG - magnetic 2

33-2095 O-RING 4

43 * 33-2515 GASKET - oil sump 1644 22-747 SUMP - oil 1




* 33-822 O-RING 3

47 * 33-2552 GASKET - cylinder head 2


49 55-6805 SCREW (2 in lg) 12

50 55-6806 SCREW (2-5/8 in lg) 8


52 33-2019 O-RING 20

53 22-656 SLEEVE - cylinder 4

54 * 33-408 O-RING 4


56 55-6750 PLUG - oil fill 1



124/265123

147A10 COMPRESSOR - X430 (w/UNLOADER HEAD, DRY, 1.0DIA CRANKSHAFT) Revised9/17/03


125/265124



NOTE: The heads on this compressor do not have ports. If needed, use cylinder head P/N 22-788, which has1/8 pipe port.


NOTE: This compressor does not contain compressor oil. Add one gallon of oil before running compressor.R404A & R134a use 203-513 oil. R12, R22, R502, R403B, R402A & R401B use 67-404 oil.


58 33-1221 O-RING 1




62 22-1100 SEAL - crankshaft (for 1.0 dia crankshaft) 1

63 33-2513 GASKET - drive end 1

64 22-671 PLATE - crankshaft cover 1

65 55-9106 SCREW - housing 9

55-896 FLATWASHER 9

66 99-6545 PLATE - suction inlet 1


68 11-2886

VALVE (Schrader) 169 91-5630 PLATE - cover 1

70 91-9858 PLATE - cover (w/ lifting hole) 1



73 22-625 HEAD - unloader (see 51B2) 1

74 55-6823 SCREW - cylinder head (4-1/8 in lg) 3

203-513 OIL - compressor (use w/ R134a, R404A) A/R* 30-243 KIT - gasket 1

sb-iii sr mp iv w-di 2.2 engine (40423-2-pm rev 10)

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