Contents

Cylinder Block and Pan………………………………………… 2

Pistons and Crankshaft…………………………………………. 4
Valve Cover and Cylinder Head……………………………….. 6
Rocker and Valve Assembly…………………………………… 8
Camshaft, Timing Chain & Gears……………………………… 10
Timing Cover and Damper…………………………………….. 12
Fuel Injection Pump, Lines and Fittings……………………….. 14
Fuel Nozzles, Lines and Filters………………………………… 16
Fuel Pump and Intake Manifold……………………………….. 18
Lube Oil System……………………………………………….. 20
Flywheel and Damper Plates…………………………………… 22
Glow Plugs…………………………………………………….. 24
Starter and Alternator………………………………………….. 26
Engine Wiring Diagram…………………………………………28
Instrument Panel……………………………………………….. 30
Instrument Panel Wiring Diagram………………………………31
Soft Start Relay Wiring Diagram………………………………… 32
Sea Water Pumps………………………………………………. 34
Pulleys and Belts……………………………………………….. 36
Engine Water Pump…………………………………………….. 38
Heat Exchanger and Thermostat…………………………………40
Aftercooler……………………………………………………… 42
Exhaust System………………………………………………… 44
Exhaust System Cont…………………………………………… 46
Exhaust Elbow…………………………………………………. 48
Oil Cooler and Throttle Linkage………………………………. 50
Mounts, Engine and Transmission…………………………….. 52
Dress Parts…….…………………………………………………53
Tachometer Adjustment……………………………………….. 54
Engine Specifications………………………………………….. 56
Torque Specifications………………………………………….. 58
Alternator Wiring Diagram………………………………………59
Page 1 FIGURE A
1A 6500101 Long Block Complete, 6.5. Comes w/ cylinder heads, valve 1
covers, oil pump, steel oil pan, pistons for turbocharger

6252001 6.5L Oil Filter Bypass Valve (Not Shown) 1

6252002 6.5L Lube Cooler Bypass Valve (Not Shown) 1
6252003 Plug, Req'd for Above (Not Shown) 1

2340377 Overhaul Gasket Kit, 6.5, (Not Shown) 1

6500503 Cylinder Head Gasket, 6.5 (Not Shown) 2

2A 6250102 Connector 1

3A 6250103 Oil Pump Drive Assembly 1

4A 6250104 Oil Pump Drive Gasket 1

5A 6250105 Oil Pump Drive Clamp 1

6A 6250106 Bolt, 10mm x 1.5 x 25mm 1

7A 6250107 Front End Cover Pin (Not Shown) 2

6250108 Pin Dowel, 5/8x1 3/16" Flywheel Housing Locator 2

7.1A 6250127 Block Heater (all 97 MY & later) (Not Shown) 1

6250117 Block Heater Cord (all 97 MY & later) (Not Shown) 1
6250120 Plug, Freeze - Engine Block (Not Shown) 5

8A 2335515 Oil Pan 1

6500405 Seal, Square for Groove in Oil Pan 5ft
6250405 Oil Pan Gasket (Not Shown) 1
2338464 Brass Freeze Plug, 9/16" (Not Shown) 1

9A 6500119 Oil Pan Seal, 6.5 1

6200119 Oil Pan Seal, 6.2 1

10A 2338412 SS Hex Head Capscrew, 6mm x 1 x 25mm 22

2338415 Flatwasher, SS, 6mm (Not Shown) 22

11A 2338413 SS Hex Head Capscrew, 8mm x 1.25 x 80mm 2

2338444 Flatwasher, SS, 8mm (Not Shown) 2

12A 3921989 6.2 Oil Pan Plug Washer, Nylon, 3/8" 2

13A 6500113 6.5 Oil Pan Drain Plug, 3/8" NPT 2

P0103-6-6 6.5 Fitting for Oil Drain Kit opt
2340011 Plug, Brass 1/2" NPT Turbo Oil Drain for Oil Pan (6.2/6.5) 1
3921988 6.2 Oil Pan Drain Plug 2

14A 2332300 Oil Pan Tray 1

15A 2338414 SS Hex Head Capscrew, 1/4 x 20 x 1/2" GR5 6

Note Concerning Block: Standard manufacturing procedure is to line bore block and main bearing caps
as a unit. Bearing caps are NOT interchangeable.
 Page 2
Cylinder Block and Pan

6A

3A 5A

4A

1A

2A

15A
9A
14A

8A

11A

10A 12A

13A

Figure A
Page 3 FIGURE B

1B 6250201 Connecting Rod Ass'y with Bolts & Nuts 1

2B 6250202 Nut, Connecting Rod 16

6250212 Bolt, Connecting Rod 16

3B 6250203 Rod Bearing Shells (Std) 16

6250213 Rod Bearing Shells (.026 O.S.) Set of 2 8

4B 6500204 Piston and Pin Ass'y (Turbo 18:1) 8

6500214 Piston and Pin Ass'y (.020 O.S. Turbo 18:1) 8
6500214A Piston, Pin and Rings Ass'y (.020 O.S. Turbo 18:1) 8
6500215 Piston and Pin Ass'y (.030 O.S. Turbo 18:1) 8
6500215A Piston, Pin and Rings Ass'y (.030 O.S. Turbo 18:1) 8
6500224 Piston and Pin Ass'y (NA 21.3:1) 8
6500234 Piston and Pin Ass'y (O.S. NA 21.3:1) 8

5B 6250205 Piston Pin Retainer 16

6B 6500206 Ring Set (Std 6.5) 8

6500216 Ring Set (.020 O.S., 6.5) 8
6500217 Ring Set (.030 O.S., 6.5) 8

Figure C

1C 6500301 Sprocket, Crankshaft 1

2C 6250302 Key 3/16" x 3/4" 1

3C Bearings per Chart

4C 6500303 Forged Steel Crankshaft, 6.5 1

6500304 Crankshaft, 6.5 1
6200304 Crankshaft, 6.2 1

5C 6500305 Rear Crank Seals, 6.5 1

6200305 Rear Crank Seals, 6.2 1
6250305 Front Crank seal (Not Shown) 1

6C 6250306 Bolt, Crank Main Bearing Cap (Outboard, old style) 10

6250316 Bolt, Crank Main Bearing Cap (Inboard) 10
6250326 Bolt, Crank Main Bearing Cap, 10mm (Outboard) 10
 Page 4
Pistons and Crankshaft

5B
3B 6B
4B

2B 1B

Figure B

3C

2C 5C
1C

4C

* Not serviced separately

6C

Figure C
Page 5 Figure D

1D 6250401 Valve Cover (Std) 1

6500411 Valve Cover (CDR Valve) (Not Shown) 1
6500421 CDR Valve (Not Shown) 1
6500431 Grommet (Not Shown) 1
2340319 Dual Vent Kit (Not Shown) 1
2335000 Valve Cover Gasket (Not Shown) 1

2D 6250402 Washer-Headed Bolt 7

3D 6250403 Stud, Valve Cover 9

Figure E

1E 6500501 Cylinder Head Ass'y (6.5 Marine Turbo) 2

6500511 Cylinder Head Ass'y (6.5 NA) 2
6500521 *Prechamber (6.5 Turbo)(Not Shown) 8
6500531 *Prechamber (6.5 NA)(Not Shown) 8
6250501 *Plug, cylinder Head (Not Shown) 8
* These are part of the Cylinder Head Ass'y

2E 6250502 Plug, Cylinder Head Water jacket (Not Shown) 2

3E 6500503 Head Gasket (6.5) 2

6200503 Head Gasket (6.2) 2
6500504 Head Gasket Kit (6.5) 2

4E 6250504 Cylinder Head Bolts, 12mm x 1.75 x 97mm w/ seal 34

5E 6500505 Bolt, 10mm x 1.5 x 20mm 2

6E 6500506 Stud, Waterhole Cover 2

7E 6250507 Cover, Cylinder Head Water Hole (w/o Boss) 2

8E 6250508 Gasket, Water Hole Cover 4

Lifting Brackets (Not Shown)

2331207 Strap, Front Lifting 1

Stud, 10mm x 1.5 x 20mm + Nut + 20mm 1
Stud, 10mm x 1.5 x 20mm + Nut + 30.5mm 1

2331206 Strap, Rear Lifting 1

6250511 Bolt, 10mm x 1.5 x 20mm 2
Valve Cover and Cylinder Head Page 6

2D
1D

3D

Figure D

6E

5E
7E

1E 8E
4E

3E

Figure E
Page 7 Figure F

1-5F 6250600 Shaft Assembly 4

1F 6250601 Shaft (Only) 4

2F 6250602 Retainer, Rocker Shaft Bolt 8

3F 6250603 Bolt, Rocker Shaft 8

4F 6250604 Rocker Arm 16

5F 6250605 Retainer, Rocker Arm (Plastic) 16

6F 6250606 Push Rod 16

7F 6250607 Clamp Assembly w/ Bolt 4

8F 6250608 Guide, Hydraulic Valve Lifter 8

9F 6250609 Hydraulic Valve Lifter 16

10F 6250610 Valve Keepers (Intake & Exhaust) 32

11F 6250611 Cap, Inlet Valve Spring 8

6250621 Rotator Assembly, Exhaust Valve 8

12F 6250612 Shield, Valve Stem Oil (Intake & Exhaust) 16

(Not Shown)

13F 6250613 Seal, Valve Stem Oil (Intake, O-ring Style) 8

6250623 Seal, Valve Stem Oil (Exhaust, Cap Style) 8

14F 6250614 Valve Spring (Intake & Exhaust) 16

15F 6250615 Shim, Valve Spring (Intake & Exhaust) 16

16F 6250616 Valve, Exhaust (Std.) 8

6250626 Valve, Exhaust (0.089mm O.S.) AR
6250636 Valve, Intake (Std.) 8
6250646 Valve, Intake (0.089mm O.S.) AR
 Rocker and Valve Assembly Page 8

5F
4F

3F

2F 10F

12F

1F 14F
11F
13F

7F 15F 16F

17F

6F

8F

9F

Figure F
Page 9 Figure G

1G 6250701 Bolt, Camshaft End 1

2G 6250702 Washer, Camshaft 1

3G 6250703 Sprocket, Camshaft 1

4G 6250704 Bolt, 8mm x 1.25 x 16mm 2

5G 6250705 Thrust Bearing, Camshaft 1

6G 6250706 Ring, Camshaft Sprocket Spacer 1

7G 6250302 Key, Woodruff, 3/16" x 3/4" 2

8G 6250708 Bearing, Camshaft #1 1

6250718 Bearing, Camshaft #2 1
6250728 Bearing, Camshaft #3 1
6250738 Bearing, Camshaft #4 1
6250748 Bearing, Camshaft #5 1

9G 6250709 Camshaft 1

10G 6250710 Gear, Fuel Pump Drive 1

11G 6500301 Sprocket, Crankshaft (6.5) 1

6200301 Sprocket, Crankshaft (6.2) 1

12G 6250712 Chain Timing 1

 Page 10
Camshaft, Timing Chain & Gears

4G 8G

2G 10G 7G 9G

1G 6G
3G 5G

10G

3G

2G

1G

11G
12G

Figure G
Page 11 Figure H

1H 6250801 Cover, Timing Gear 1

6250811 Cover, Timing Gear (MY 1997 & later) 1

2H 6250802 Bolt, 10mm x 1.5 x 30mm 3

3H 6250813 Bolt, 10mm x 1.5 x 55mm 4

4H 6250804 Baffle, Crankcase Vent (6.2 only) 1

5H 6250805 Nut for Crankcase Baffle (6.2 only) 1

6H 6500806 Damper, Crankshaft Torsional (6.5) 1

6200806 Damper, Crankshaft Torsional (6.2) 1

7H 6250807 Bolt, Crankshaft Damper 1

8H 6250808 Washer, Crankshaft Damper 1

6250302 Key, Woodruff 3/16" x 3/4" (Not Shown) 1

6250819 Timing Indicator (Not Shown) 1

6250829 Bolt, Indicator (Not Shown) 2

6250810 Plug, Front Cover, Crank Possion Sen. (Not Shown) 1

 Timing Cover and Damper Page 12

1H
2H
5H

4H 3H

6H

8H

7H

Figure H
Page 13 Figure I

1I 6250901 Gear, Driven Fuel Injection Pump 1

2I 6250902 Bolt, 8mm x 1.25 x 20mm 3

3I 6250903 Gasket, Fuel Pump Drive 1

4I 2348340 Fuel Injection Pump (NA) - 160hp 1

2340265 Fuel Injection Pump--Turbo Engines, DB2 1
2340263 Fuel Injection Pump - Turbo Engine, DB2 340hp 1
2340282 Fuel Shut Off Soleniod - Injection Pump 1
2340283 Cold Advance Solenoid - Injection Pump 1
6250904 Stud, Upper 10mm x 1.5 x 45.5mm 1
6250914 Stud, Lower 10mm x 1.5 x 52mm 2
6250924 Nut, 10mm 3

5I 6250915 Fuel Pipe for Cylinder #1 1

6250925 Fuel Pipe for Cylinder #2 1
6250935 Fuel Pipe for Cylinder #3 1
6250945 Fuel Pipe for Cylinder #4 1
6250955 Fuel Pipe for Cylinder #5 1
6250965 Fuel Pipe for Cylinder #6 1
6250975 Fuel Pipe for Cylinder #7 1
6250985 Fuel Pipe for Cylinder #8 1

6I 6500906 Clip, Fuel Line 8

7I 6250907 Clip, Offset Bolt Hole (On Fuel Line Bracket) 4

6250917 Clamp, Centered Screw Hole (Near Back of Pump) 4
(Not Shown)
6250927 Insert, Short Rubber 4
6250937 Screw, Washer Headed, Self-Drilling 4

8I 6250908 Bracket, Fuel Line (Right Side) (Not Shown) 1

6250918 Bracket, Fuel Line (Left Side) 1
6250928 Nuts for Brackets 4

9I 6250909 Pipe Adaptor, Injection Pump Inlet 1

10I 2338462 Clamp, SS Worm-Gear, #4 1

11I 6250911 Hose, Fuel & Oil-Resistant, .25" ID x 5" 1

2327001 Coupling, 3/8" to 1/4" (Not Shown) 1
 Page 14
Fuel Injection Pump, Lines and Fittings

1I 4I
5I

6I
2I

3I 7I

8I

10I 11I

9I

Figure I
Page 15 Figure J

1J 6251001 Cap, Injection Nozzle 2

2J 6251002 Clamp, Fuel Drain Back Hose 18

3J 6501003 Nozzle, Injector - Turbo Engines, 6.5 8

6501003R Nozzle, Injector Rebuilt - Turbo Engines, 6.5 8
6201003 Nozzle, Injector - Turbo Engines, 6.2 8
6501013 Nozzle, Injector - NA Engines 8

4J 6251004 Gasket, Injector Nozzle Seat 8

5J 6251005 Hose, Fuel Drain Back - Short with Clamps 7

6251025 Hose, Fuel Drain Back - Long with Clamps 1

6J 6251006 Pipe, Fuel Drain Back 1

7J 6251007 Clip, Fuel Drain Back, Right Head 1

8J 6251008 Clip, Fuel Drain Back, Left Head 1

9J 6251009 Clip, Fuel Drain Back, Top Center 1

10J 6251010 Bolt, Washer-Headed, 10mm x 1.5 x 20mm 2

11J 6251011 Hose, Fuel drain Back, From Governor 1

12J 6251012 Clamp, Fuel Return Line 2

13J R900 Racor 900 With Electric Priming Pump 1

6250386 Racor 900 (Opt., Not shown) 1
R2040TMOR Element, Racor 900, 10 Micron (Not Shown) AR
6250370 Electric Fuel Pump for 500, 900 (Opt., Not shown) AR

6501014 Fuel Line, Lift Pump to Injection Pump (Not Shown) 1

Used on engines without secondary fuel filter ass'y

Items below are for optional secondary fuel filter ass'y.

14J 2327000 Secondary Fuel Filter Element 1

15J 6251015 Head, Secondary Fuel Filter Adaptor 1

16J 2338611 3/8" Fuel Line Ass'y, Filter Pump to Filter Head 1

17J 2338463 Bushing, Fuel Line Adaptor 1

18J 2338612 1/4" Fuel Line Ass'y, Filter Head to Inj. Pump 1

19J 2338420 SS Hex Head Capscrew, 3/8-16 x 3/4" 2

20J 2338459 SS Lockwasher, 10mm 2

21J 2338419 SS Hex Head Capscrew, 10mm x 1.5 x 20mm 2

22J 2338455 SS Lockwasher, 10mm 2

2338459 SS Flatwasher, 10mm 2

23J 2331208 Fuel Filter Bracket 1

 Page 16
Fuel Nozzles, Lines and Filters

11J
12J

8J
3J
2J 4J

1J
9J

5J 6J 10J
7J

18J

20J 19J

17J

15J 13J
23J 14J
16J
22J

21J

Figure J
Page 17 Figure K

1K 6251101 Fuel Pump Assembly 1

6251111 Push Rod, Fuel Pump (Not Shown) 1

2K 6251112 Washer-headed Bolt w/ Lock Washer 1

3K 6251103 Gasket, Fuel Pump 1

4K 6251104 Plate, Fuel Pump Spacer 1

5K 6251105 Bolt, Fuel Pump Spacer 2

6K 6251106 Gasket, Fuel Pump Spacer 1

Figure L

1L 6501201 Manifold, Air Inlet, 6.5 1

6251201 Manifold, Air Inlet, 6.2 1
6251211 Freeze Plug, Brass 1", 6.2 (Not Shown) 1

2L 6251202 Bolt, 10mm x 1.5 x 30mm 3

2338428 Bolt, 10mm x 1.5 x 60mm (6.2L Only) 1
2338459 Washer, 10mm (6.2L Only) 1

3L 6251203 Stud, Short 8

6251213 Stud, Long (6.2L requires 4 and 1 bolt, See 2L) 5

4L 6251204 Gasket, Intake Manifold 2

5L 2335520 Air Intake Adaptor, 6.5 1

6501706 Air Intake Adaptor Gasket, 6.5 1
2335506 Air Intake Adaptor, 6.2 (No Gasket Required) 1

6L 2340211 SS Hex Capscrew, 8mm x 1.25 x30mm, 6.5 6

2338409 SS Hex Capscrew, 8mm x 1.25 x25mm, 6.2 2
2338444 SS Flatwasher, 8mm, 6.2 (Not Shown) 2

7L 2337301 Hose, Aftercooler to Intake Adaptor, Formed 1

8L 2338437 Clamp, SS, #52, Worm-Gear 2

9L 2337003 Air Cleaner Ass'y, NA (Not shown) 1

 Page 18
Fuel Pump and Intake Manifold

3K 4K 6K
2K 1K

5K

Figure K

8L
7L
6L

5L

1L 2L

3L
4L

Figure L
Page 19 Figure M

1M 6251301 Cap, Oil filler Tube 1

2M 6251312 Tube Ass'y, Oil Fill w/ Vent 1

3M 2338406 SS Hex Head Capscrew 3/8-16 x 1/2" 2

2338443 SS Lockwasher, 3/8" (Not Shown) 2

4M 6251304 Grommet, Filler Tube 1

5M 6251305 Shaft, Oil Pump Drive 1

6251315 Retainer, Oil Pump Drive Shaft (Not Shown) 1

6M 6251326 Oil Pump Ass'y & Screen, 6.5 1

6251306 Oil Pump Ass'y & Screen, 6.2 1
6251316 Bolt, Hex Head, 11mm x 1.5 x 66mm (Not Shown) 1

7M 6251307 Dipstick, Oil Level 1

(X =535mm, Y=474mm, Z=17mm)

8M 2330107 Tube Ass'y for Dipstick 1

9M 4990012 O-ring, Dipstick Tube to Block 3/8 x 1/2 x 1/16" 1

10M 2338414 SS Hex Head Capscrew 1/4-20 x 1/2" 1

11M 2338458 SS Lockwasher, 1/4" 1

2338450 SS Flat Washer, 1/4" (Not shown) 1

12M 2328600 Remote Oil Filter Adaptor (Mounts on Block) 1

6438385 O-Ring, Oil Filter Adaptor 1
6438386 Seal, Oil Filter Adaptor (Repalces 6438385 after 1
s/n 2143)
P48F-8-8 Fittings for Adaptor 2

13M 2328601 Remote-Mount Oil Filter Head 1

14M 6438384 Oil Filter 1

15M 2340179 Oil Filter Line (90 degree fitting) 1

2340180 Oil Filter Line (straight fitting) 1

6250382 Oil Pressure Sender, Single Station (std)(Not Shown) 1

6250383 Oil Pressure Sender, Dual Station (opt)(Not Shown) 1
2340132 Oli Pressure Alarm Switch-10 psi (Not Shown) 1
 Page 20
Lube Oil System

5M
1M

2M
6M

3M

4M

13M 12M
11M

10M

14M
7M 15M
8M

9M

Figure M
Page 21 Figure N

1N 2338888 Flywheel Ass'y, w/ Ring Gear *(Std. Rear Starter) 1

2326425* Ring Gear (avail as separate replacement part) 1
* Available Only Thru Peninsular

6251401 Flywheel Ass'y, w/ Ring Gear (Front Starter) 1 (opt)

6251411 Ring Gear (Front Starter) 1 (opt)

2N 6251402 Flywheel Bolts 6

3N 2325800 Damper Plate Bolts, 3/8-16 x 7/8" Gr5 6

4N 2340061 4-Stage Damper Plate (Std.) 1

2340060 Centaflex Drive Plate (Not Shown) 1 (opt)
838653 Bolts for Centaplex Plate 6 (opt)
2340064 Starter Shim Plate (Not Shown) 1 (opt)
(Not Used w/ 4-Stage Damper Plate)

5N 2335514 Flywheel Housing 1

6N 2339100 SS Hex Head Capscrew, 10mm x 70mm (97& later) 5

2340043 SS Hex Head Capscrew, 3/8-16 x 2.75" (96 & pre) 5
2338459 SS Lockwasher, 10mm (Not Shown) 5

7N 2336400 Flywheel Housing Shield 1

8N 2338414 SS Hex Head Capscrew, 1/4-20 x 1/2" 4

2338458 SS Lockwasher, 1/4" (Not Shown) 4

9N 2322401 Lower Starter Hole Cover (Std.) 1

10N 2338473 SS Socket Head Screw, 10mm x 1.5 x 30mm 1

11N 2338455 SS Lockwasher, 10mm 1

12N 2322400 Upper Starter Hole Cover 1(opt)

13N 2338406 SS Hex Head Capscrew, 3/8-16 x 1/2" 3 (opt)

2338443 SS Lockwasher, 3/8" (Not Shown) 3 (opt)

* The following are needed to install Hurth Transmission:

2338442 SS Hex Head Capscrew, 7/16-14 x 1.25" 4
2340145 Stud, 7/16-3/4 x 7/16-1/2 Gr5, 1.5" O.A. 2
2340017 SS Lockwasher, 7/16" 4
2340084 SS, Nylok Nuts, 7/16-20" 2
2327410 Dipstick, ZF for tube w/ 60 Degree Bend 1
2327411 Tube, Dipstick w/ 60 Degree Bend to Clear Starter 1

* The following are needed to install Borg-Warner Transmission:

2340025 SS Hex Head Capscrew, 7/16-14 x 3.5" 6
2340017 SS Lockwasher, 7/16" 6
 Flywheel and Damper Plates Page 22

3N
1N

2N

4N

12N
13N

6N

5N

9N
7N 11N
10N
8N

Figure N
Page 23 Figure O

1O 6251502 Glow Plug 8

2337953 Glow Plug Timer Kit, Current Engines (Not Shown) 1

2337952 * Glow Plug Timer (Not Shown) 1
2340160A * Solenoid, Glow Plugs (Not Shown) 1
2340326 * Switch, Glow Plugs (Not Shown) 1
* All components of the glow Plug Timmer Kit

2O 2337950 Glow Plug Controller (Service Part Only) 1

2337949 Wire Connector For Glow Plug Controller 1

3O 2337951 Grommet, Glow Plug Contoller 2

 Glow Plugs Page 24

1O

3O

Mating connector 2337949

2O

Figure O
Page 25 Figure P

1P 2340150 Starter, Rear Mount Gear Reduction-Std. 1

2340160A Solenoid (for Old Style Prestolite starter) 1

2P 2338404 SS Hex Head Capscrew 3/8-16 x 1 1/4" 2

2338443 SS Lockwasher, 3/8 (Not Shown) 2

3P 2338467 Brass Hex Nut, 5mm x .8 1

4P 2338685 Brass Hex Nut, 10mm x .8 1

5P 6251605 Starter, Front Mount (Optional) 1

6P 6251606 Bolts, Mounting, Front Mount Starter 2

Note: Standard Rear Mount Starter and Optional Front Mount Starter use different ring gears.
See page 21, 1N.

7P 2328603 Alternator, 51 Amp. 1

2340155 Alternator, 90 Amp. 1

8P 2340106 Adaptor, Mounting (Not shown) 1

See page 33 for alternator pulley, mounting brackets, bolts, etc.

 Starter and Alternator Page 26

2P
Upper rear starter
1P

3P 4P

4P
3P

Lower rear starter

5P Alternator 7P
6P

Figure P
Page 27 Figure Q

2336320 Breaker, 20 amp. 1

2337907 Soft Start Relay 1

5173135 Mounting Bracket, Soft Start Relay & Breaker 1

2340044 SS Hex Head Capscrew 1/4-20 x 3/4" 3

2338471 SS Hex Nut , 1/4"-20 3

2338450 SS Flat Washer, 1/4" 3

2338458 SS Lockwasher, 1/4" 3

2337952 Glow Plug Timer (See pg. 23) (Current Engines) 1

2337950 Glow Plug Controller (See pg. 23) (Older Engines) 1

6251502 Glow Plug (See pg. 23) 8

6251701 140o F Cold Advance Temp. Switch 1

6250381 Oil Pressure Sender for 80 lb gauge 1

(Single Station/Panel Installation-Standard)

6250382 Oil Pressure Sender for 100 lb gauge 1

(Single Station/Panel Installation-Standard)

6250383 Oil Pressure Sender 1

(Dual Station/Panel Installation-Opt.)

6250384 Water Temp. Sender 1

(Single Station/Panel Installation-Standard)

6250385 Water Temp. Sender 1

(Dual Station/Panel Installation-Opt.)

2337910 Engine Speed Sensor for Digital Techometer 1 (opt)

2337926 Wiring Harness, Basic Engine with Digital Tach 1 (opt)

2337916 Wiring Harness, Basic Engine with GP Timer 1
2337906 Wiring Harness, Basic Engine with GP Controller 1

2337901 Harness, 18' Extension 1

2337905 Harness, 12' Extension 1 (opt)

2337903 Harness, 18" Pigtail - Female End (new style plug) 1 (opt)

2337903 Harness, 18" Pigtail - Male End (new style plug) 1 (opt)

2340023 Y-Harness, 24" Dual Panel 1

2340200 Instrument Panel (See pg. 29) 1

2340132 Oil Pressure Alarm Switch-10 psi (Not Shown) 1

2340133 Water Temp. Alarm Switch-210o (Not Shown) 1

 ENGINE WIRING DIAGRAM Page 28

Battery

LT. PURPLE GREEN

BLUE
Wires
supplied
by

black
customer
BROWN YELLOW- TAN

(if used)
RED

Neutral
switch

yellow / red
NOT ORANGE GREY
USED

red / white
starter

red COLOR CODE VIEW FROM

red yellow / red
WIRING SIDE OF PLUG

soft red / white

start
circut
breaker

relay

red
red

red
orange
tan

yellow
red
glow plugs

orange lt.blue
purple

oil pressure
sender brown
grey

orange
glow plug
solenoid
oil pressure
green alarm
purple

tan
green

Figure Q
water temp.
purple

sender
red

water temp
alarm
green

H.P.C.A.
solanoid
purple to
with brown gray (tach)
grey

white injection (lamp) red

pump (battery)
temp. body
switch red

purple
to
yellow (excite)

injection
purple pump
body
grey a.c. tap (tach) black (ground)
fuel shut-off not used
switch (6 ga. wire)
yellow

51 Amp 90 Amp
yellow
Page 29 Figure R

Dual engine applications require two panels.

1R 2340200 Instrument Panel Assembly 1

Consists of the following components:

2R 2340220 Blank Panel 1

3R 2340203 Gauge, Water Temperature, 100-240 o F. 1

4R 2340202 Gauge, Oil Pressure, 0-100 psi 1

2340212 Gauge, Oil Pressure, 0-80 psi 1

5R 2340201 Tachometer, 0-4000 rpm 1

2340214 Digital Tachometer with Hour Meter (Not Shown) 1 (opt)

6R 2340204 Voltmeter, 12V DC 1

7R 2340205 Ignition Switch w/ Key 1

8R 2340207 Indicator Light, Amber 1

9R 2340208 Indicator Light, Red 1

10R 2340206 Toggle Switch, Lights 1

11R 2340209 15 Amp Circuit Breaker 1

12R 2340326 Switch, Glow Plug Timer (3-way) 1

2340210 Nine-Position Plug (Not Shown) 1

2340215 Alarm Buzzer (Not Shown) 1

Optional Gauges (Not Shown):

2340217 Speedometer, (0-60 mph) 1 (opt)

2340218 Fuel Gauge 1 (opt)

2340219 Oil Temperature Gauge 1 (opt)

 Page 30
Instrument Panel

1R - Complete Panel
(as shown)

6R

2R

5R

11R
4R

10R

9R

12R
8R

3R 7R

Figure R
 Page 31
LT. BLUE
alarm
PURPLE RED

DK BLUE
la
la m la indicator
la
m p m lamp m
p p p

indicator
volts oil lamp temp

glow plug tachometer

timer ignition
glow plug
timer switch
switch

circuit breaker panel light switch

PURPLE
PURPLE
ORANGE
ORANGE
BLACK
YELLOW/RED
GREEN TAN
PURPLE
RED

LT. BLUE
GREY

INSTRUMENT PANEL
WIRING PLUG
P/N 2340200
 SOFT START RELAY WIRING Page 32

CHANGE FROM PRESTOLITE STARTER

WITH REMOTE SOLENOID TO STARTER
WITH SOLENOID MOUNTED ON TOP. STARTER
SOLENOID

RELAY DO NOT
#10 RED ADD-ON WIRE
(JUMPER WIRE) USE ‘R’
CABLE
(BATTERY) TO
BATTERY

(AUXILIARY) TO STARTER
(#10 ADD-ON WIRE)
GR S R

#10 RED WIR

#10 RED WIR
OU
ND

CIRCUT
W
IRE

BREAKER

E
E
YELLO
W WIR
E W/ R
ED STR
IPE
#10 RED WIRE W/WHITE STRIPE

#10 ADD-ON WIRE

ENGINE
HARNESS
Page 33 Sea Water Pump

2340128 Jabsco Pump (2001 & later) 1

2340103 Jabsco Service Kit (Includes Items with *) 1
2340123 Jabsco Impeller Kit (Impeller and Gasket only) 1

Jabsco Figure 1
1 2327101 Screw, End Cover 6
2 2327102 End Cover 1
3 2327103 * Gasket 1
4 2327104 * Impeller 1
5 2327105 Cam 1
6 2327106 Screw, Cam 1
7 2327107 Wearplate 1
8 2327108 * Seal Assembly (Complete) 1
9 2327109 Seal Spacer 1
10 2327110 Shaft 1
11 2327111 Bearing, Inner Seal 1
12 2327112 Ball Bearing 1
13 2327113 Retainer Ring, Bearing/Shaft 1
14 2327114 Retainer Ring, Bearing/Housing 1
15 2327115 Outer Bearing Seal 1
16 2327116 Body 1
17 2327117 Key 1

2340129A Complete Johnson Pump Assembly (Pre 2001) 1

2340129 Johnson Pump Only (Pre 2001) 1
2340101 Johnson Service Kit (Includes Items with *) 1

Johnson Figure 2
1 2340118 Body 1
2 2340119 End Cover 1
3 2320123 * Impeller 1
4 2340120 Cam 1
5 2340121 Shaft 1
6 2340122 * Gasket 1
7 * Rubber Insert (Not Serviced Separately) 1
8 2327312 * End Cover Screw 6
9 2340124 * Lip Seal 2
10 2340125 O-ring 1
11 2327309 Ball Bearing 2
12 2340126 Retaining Clip 1
13 2340127 Cam Screw 1
14 2320128 Washer 1

The following parts are required for mounting pumps.

2330730 Sea Water Pump Bracket (Needed for both the Jabsco and 1
Johnson pumps, Not used for the turnaround Johnson Pump)
2340146 Sea Water Pump Bracket (Johnson, used w/ 2330730) AR
2340259 Sea Water Pump Bracket, Turnaround (Johnson) AR
2340078 SS Hex Head Capscrew, 5/16-18 x 3/4" 3
2340049 SS Lockwasher, 5/16" 3
2338425 SS Hex Head Capscrew, 3/8-16 x 7/8" 2
2338443 SS Lockwasher, 3/8" 2
2338422 SS Flat Washer, 3/8" 2
2340147 Drive Key, 3/16 x 1" 1
2338435 SS Roll Pin 1
Page 34
Page 35 Pulleys and Belts

1 2338426 SS Hex Head Capscrew, 3/8-16 x 7/8" 2

2 2338455 SS Lockwasher, 10mm 2
3 2340162 Hex Head Caspcrew, Gr 8, 1/2-13 x 3.25" 1
* 2340161 SS Lockwasher, 1/2" 1

4 2330208 Alternator & Water Pump Bracket 1

2340187 Alt. & Water Pump Bracket (Turnaround-Jabsco) AR
2340189 Alt. & Water Pump Bracket (Turnaround-Johnson) AR
6 2335516 Sea Water Pump Pulley 1
7 2338435 SS Roll Pin, 1/8 x 1.5" 1
8 2338445 SS Allenhead Cup Point Setscrew, 1/4-20 x 3/8" 1
9 2336100 Belt, Seawater Pump 1
2336102 Belt, Seawater Pump, Turnaround 1
10 2338428 SS Hex Head Capscrew, 10mm x 1.5 x 60mm 4
* 2338455 SS Lockwasher, 10mm (Not shown) 4
11 2335512 Crankshaft Pulley 1
12 2336101 Belt Set, Matched Pair, Engine Water Pump & Alternator 1
13 2335513 Engine Water Pump Pulley 1
14 2334002 Alternator Pulley 1
15 2338427 SS Hex Head Capscrew, 8mm x 1.25 x 20mm 4

16 2328603 Alternator, 51 Amp 1

2340155 Alternator, 90 Amp 1
17 2338439 Brass Hose Barb, 1"NPT x 1.25" Hose x Straight 1
17A ******* Sea Water Pump (see pp31-34 for part #s)
19 2338443 SS Lockwasher, 3/8" 2
20 2330730 Sea Water Pump Bracket (Needed for both the Jabsco and 1
Johnson pumps, Not used for the turnaround Johnson Pump)
2340146 Sea Water Pump Bracket (Johnson, used w/ 2330730) AR
2340259 Sea Water Pump Bracket, Turnaround (Johnson) AR
21 2330201 Alternator Mounting Bracket 1
22 2330209 SS Hex Head Capscrew, 3/8-16 x2" 3
* 2338443 SS Lockwasher, 3/8" (Not shown) 3
* 2338459 SS Flat Washer (Not Shown) 3

27 2338460 SS Hex Head Capscrew, 10mm x 1.5 x 130mm 1

28 2338425 SS Hex Head Capscrew, 5/16-18 x 7/8" 1
2340049 SS Lockwasher, 5/16" (Not Shown) 1
29 2338479 SS Flat Washer, 5/16" 1
30 2331200 Alternator Adjusting Strap 1

31 2338402 SS Hex Head Capscrew, 10mm x 1.5 x 120mm 1

77 2340106 Spacer, Alternator/Water Pump Bracket 3/4" (As required) 1
98 2338446 SS Worm-Gear Hose Clamp, #20 2
142 2338426 SS Hex Head Capscrew, 3/8-16 x 7/8" 2
151 513109 Hose, Wire-Reinforced, 1.25" I.D. x 9" 1
161 6253316 Engine Water Pump 1
166 2340135 Brass Hose Barb, 1" NPT x 1.5" Hose x Straight 1
 Pulleys and Belts Page 36

28 29
30
161
16
21
31 14
22* 27
77

1 3*
15
20
19
13
18
2
4 142
77
17A 6
17 7
166 8
9
10*
12 11
98
151

NOTE: Bolts marked with an asterisk (*) require lockwashers and/or flatwashers that are NOT SHOWN.
See parts list on opposing page.
Page 37 Engine Water Pump

4 2330208 Alternator & Waterpump Bracket 1

2340187 Alt. & Water Pump Bracket (Turnaround-Jabsco) AR
2340189 Alt. & Water Pump Bracket (Turnaround-Johnson) AR
18 2338613A Grommet, Injection Pump Access 1
23 2338407 SS Hex Head Capscrew, 8mm x 1.25 x 50mm 6
24 2340170 Heat Exchanger Mounting Bracket, Raised HE (std) 1
2340172 Heat Exchanger Mounting Bracket, Lowered HE 1
27 2338460 SS Hex Head Capscrew, 10mm x 1.5 x 140mm 1

30 2331200 Alternator Adjusting Strap 1

31 2338402 SS Hex Head Capscrew, 10mm x 1.5 x 120mm 3
32 2335504 Water Pump Spacer 1
33 6253503 Water Pump Gasket 1
34 2338408 SS Hex Head Capscrew, 8mm x 1.25 x 70mm 2

35 2337300 Coolant Hose, 2.125" I.D.x 5.5", Raised HE (std) 1

2337302 Coolant Hose, 2.125" I.D.x 3", Lowered HE 1
36 2338447 SS Worm-Gear Hose Clamp, #36 4
37 2335519 Water Pump Inlet Pipe 1
38 P218P-4 Brass Pipe Plug, 1/4" NPT 1
39 2337303 Coolant Hose, 2.125" I.D.x 4" 1

40 2338433 SS Worm-Gear Hose Clamp, #16 4

41 512311 Hose, Wire-Reinforced, 1" x 11" 1
512317 Older Engine Set up had 1" x 17" Hose
42 512312 Hose, Wire-Reinforced, 1" x 12" 1
512313 Older Engine Set up had 1" x 13" Hose
43 P125HBL-6-8 Hose Barb, Brass (used with manifold vent) 1
2340011 Brass Plug (without manifold vent) 1
57 2338403 SS Hex Head Capscrew, 10mm x 1.5 x 110mm 1
77 2340106 Spacer, Alternator/Water Pump Bracket 3/4" (As required) 1
87 2338416 SS Worm-Gear Hose Clamp, #10 2
88 513018 Hose, Wire-Reinforced, 5/8" ID x 18" 1

95 2338409 SS Hex Head Capscrew, 8mm x 1.25 x 25mm 7

96 2330202 Fuel Pump Preload 1
97 2338406 SS Hex Head Capscrew, 3/8-16 x 1/2" 2
* 2338443 SS Lockwasher, 3/8" (Not Shown) 2

135 P125HBL-6-8 Brass Hose Barb, (98 and later) 1

2340011 Brass Pipe Plug, 1/2", (pre 98) 1
161 6253316 Engine Fresh Water Pump 1
162 445751 Steel Pipe Plug, 1/2" 1
164 P68HB-10-8 Brass Hose Barb, 1/2"NPT x 5/8" x Straight 1
177 6251301 Oil Fill Cap 1
178 6251312 Oil Filler Tube, Vented 1
179 6251304 Grommet, Oil Fill Tube 1
 Engine Water Pump Page 38

177
178 87
97 179
24
88

95 87
96
18 30
o 32
33 27
164 162
31
95

35 31
34 4
36 77
161
43 31
34

40
40
39 41
42 36

37
38

NOTE: Bolts marked with an asterisk (*) require lockwashers and/or flatwashers that are NOT SHOWN.
See parts list on opposing page.
Page 39 Heat Exchanger & Thermostat

23 2338407 SS Hex Head Capscrew, 8mm x 1.25 x 50mm 6

24 2340170 Raised Heat Exchanger Mounting Bracket (std) 1
2340172 Lowered 2-1/2" Heat Exchanger Mounting Bracket (opt) 1
2340312 Expansion Tank (req. w/ Lowered Heat Exchanger) 1
2340313 Cap, Expansion Tank 1
25 2340173 Heat Exchanger Rubber Mount 2
105 2340174 Heat Exchanger Mount Strap 2
106 2340175 H. E. Mounting Bolts, 3/8-16 x 4" SS 4
* 2338443 SS Lockwasher, 3/8" 4
* 2338405 SS Nut, 3/8"-16 4

84 6250508 Gasket, Water Hole Cover 2

85 2335505 Thermostat Manifold 1
86 P269HB-10-8 Brass Hose Barb, 1/2" NPT x 5/8" Hose x 90oT 1
87 2338416 SS Worm-Gear Hose Clamp, # 10 2
88 513018 Hose, Wire-Reinforced, 5/8" ID x 18" 1
89 6253708 Thermostat Gasket 1
90 2338401 SS Hex Head Capscrew, 10mm x 1.25 x 25mm 2
* 2338455 SS Lockwasher, 10mm 2

91 2338482 SS Worm-Gear Hose Clamp, # 28 2

92 2340256 "S" Hose, Thermostat Outlet, 1-7/8" ID x 6.5" 1
(S Hose used with Raised Heat Exchanger)
2340254 Coolant Hose, Thermostat Outlet, 1-7/8" ID x 6.5" 1
93 2337304 Hose, Heat-Exchanger Overflow, 5/16" ID x 24" 1
98 2338446 SS Worm-Gear Hose Clamp, # 20 4
112 2338601 Heat Exchanger Fill Cap 1
114 2340157 Zinc Plug, 1/2" NPT 1
115 2340153 Heat Exchanger Ass'y, 5" Standard 1
2340154 Heat Exchanger Ass'y, 5" Cupronickel (Opt) 1
117 2340255 "S" Hose, Heat Exchanger Outlet 1
(S Hose used with Raised Heat Exchanger)
5131105 Hose, Wire Reinforced, 1.25" ID X 10-1/2" 1
513112 Hose, Wire Reinforced, 1.25" ID X 12" (older engines) 1
135 2340011 Pipe Plug, Brass, 1/2" NPT 2
2338441A Plug, Countersunk, 1" Pipe (for behind thermostat) 1
161 6253316 Engine Water Pump 1
188 2337211 Vent Hose Ass'y (HE to Turbo Ex Housing, Raised HE) 1
2337201 Vent Hose Ass'y (HE to Thermostat Manifold, Lowered HE) 1
189 6253718 Thermostat Housing Outlet 1
190 P149F-4-2 Elbow, Brass, 1/8" NPT x #4 Flare 1
191 6253719 Thermostat, 160o TF Standard Marine 1
6253729 Thermostat, 190o TF Standard Marine 1
196 1635490 Hex Flange Head Capscrew, 10mm x 1.5 x 30mm 4
198 2340133 Water Temperature Alarm Switch, 210o 1

2340195 Heat Exchanger End Cap Rubber Gasket (Not Shown) 2

2340408A Remote Thermostat Kit w/ Bypass (for Add-On) * items included 1

2340408 * Remote Thermostat w/ Bypass (Replacement) (Not Shown) 1
5130040 * Hose, Wire Reinforced, 5/8" (Not Shown) 18"
5130010 * Hose, Wire Reinforced, 1-1/4" (Not Shown) 15"
2338446 * SS Worm-Gear Hose Clamp, #20 (Not Shown) 2
2338417 * SS Worm-Gear Hose Clamp, #12 (Not Shown) 2
B4503-10-08-FG* Hose Barb, 1/2" NPT x 5/8" Hose x 45o (Not Shown) 1

2340290 Kit for Cabin Heat (Not Shown) ** items included 1

2340291 ** Valve, Ball, Cabin Heat (Not Shown) 2
2340292 ** Nipple, 3" x 1/2", Cabin Heat (Not Shown) 1
2340293 ** Nipple, 1/2" x Close, Cabin Heat (Not Shown) 1
2340294 ** Tee, 1/2" Street, Cabin Heat (Not Shown) 1
2340295 ** Elbow, 1/2" 90o Street, Cabin Heat (Not Shown) 1
2340296 ** Elbow, 1/2" 45o Street, Cabin Heat (Not Shown) 1
P68HB-10-8 ** Brass Hose Barb (Not Shown) 2
 Heat Exchanger and Thermostat Page 40

198 90 189
135 85 89 191 91 24
92 93
196 112
115

84 86
87

114 25 105 106

117
98

88
87

161 4
77

NOTE: Bolts marked with an asterisk (*) require lockwashers and/or flatwashers that are NOT SHOWN.
See parts list on opposing page.
Page 41 Aftercooler

2 2338459 SS Flat Washer, 10mm 6

76 2338430 SS Nut, 10mm x 1.5 2
90 2338401 SS Hex Head Capscrew, 10mm x 1.5 x 25mm 2
* 2338455 SS Lockwasher, 10mm 2
98 2338446 SS Worm-Gear Hose Clamp, #20 4
103 2338421 SS Worm-Gear Hose Clamp, #40 2
199 5131105 Hose, Wire-Reinforced, 1.25" ID x 10-1/2" 1
513112 Hose, Wire-Reinforced, 1.25" ID x 12" (older engines) 1

127 513103 Hose, 3-Ply Connector, 1.25" ID 1

129 2331153 Rear Bracket, Aftercooler 1
143 2338420 SS Hex Head Capscrew, 3/8"-16 x 3/4" 4
* 2338443 SS Lock Washer, 3/8" 4
152 2338459 SS Flat Washer, 10mm 4

158 2340115 Tube, Eng. Oil Cooler to Aftercooler, 1.25" Diam. 1

159 2338705 Formed Hose, Aftercooler Inlet 1
171 2338437 SS Worm-Gear Hose Clamp, #52 2
172 2337301 Formed Hose, Aftercooler to Intake 1
174 2331600 Front Bracket, Aftercooler 1
175 2334854 Spacer, Aftercooler Bracket 1

187 2340171 Aftercooler Assembly 1

2340171T Aftercooler Assembly, Twin Turbo 1
2340301 U-Pipe (for 220hp Engines w/o Aftercooler) 1
2340302 Hump Hose to connect 2340301, U-Pipe 1

2340169 Aftercooler Gasket Set (2340171) 1

 Aftercooler Page 42

171 172
159
103

187

98
199 158
98
76
152

174 2 127
143*

129 152
175

90
2
143*

NOTE: Bolts marked with an asterisk (*) require lockwashers and/or flatwashers that are NOT SHOWN.
See parts list on opposing page.
Page 43 Exhaust System

2 2338459 SS Flat Washer, 10mm 34

18 2338405 SS Hex Nut, 3/8"-16 2
19 2338443 SS Lockwasher, 3/8" 32
21 2330201 Alternator Mounting Bracket 1
22 2330209 SS Hex Head Capscrew, 3/8-16 x 2" 3
26 2338404 SS Hex Head Capscrew, 3/8-16 x 1.25" 18
31 2338402 SS Hex Head Capscrew, 10mm x 1.25 x120mm 8
53 2335501 End Cap, Exhaust Manifold 2
54 2336902 Gasket, End Cap 4
2340030 Hose, Vent Ass'y - Left End Cap to "J" Pipe (Not Shown) 1
5140050 * Hose, 7520-6 7"
P125HBL-6-8 * Hose Barb, Brass 1
P129HB-6-4 * Hose Barb, Brass 90o 1
2338481 * Clamp, SS Worm Gear #5 2
* Items Included in Hose, Vent Ass'y #2340030
55 2338440 Hose Barb, 1" NPT x 1" Hose x 90o T 2
56 2335500 Manifold, Exhaust 2
57 2338403 SS Hex Head Capscrew, 10mm x 1.5 x110mm 8
* 2338455 SS Lockwasher, 10mm 8
58 2338441 Plug, 1" NPT Brass Pipe 3
59 2335529 Riser, Exhaust Manifold 2
60 2340104 SS Stud, 3/8"-16 x 1.75" 2
109 2336701 Plug, Brass Expansion Cup, 1.25" 2
120 2336903 Gasket, Exhaust Riser to Crossover 2
121 2335530 Crossover, Exhaust Manifold 1
123 P68HB-12-8 Hose Barb, Brass 1/2" NPT x 3/4" Hose, Straight (oil pan) 1
2340011 Pipe Plug, Brass, 1/2" NPT (w/using rear eng block drain) 1
124 2340003 Elbow, Brass, 1/2" NPT x #10 Flare x 90o (oil cooler) 2
134 2337203 Oil Line Ass'y, 1/4" x 12" w/ # 5 Swivels 1
136 P2225P-4 Tee, Brass Pipe, 1/4" NPT 1
137 6250382 Sender, Oil Pressure, Single Station (Std) 1
6250383 Sender, Oil Pressure, Dual Station (Opt) 1
P209P-4-2 Bushing, Brass Reducer, 1/4" x 1/8" NPT (Not shown) 1
138 P2202P-4-4 Elbow, Brass Street, 1/4" NPT x 90o T 1
139 2336909 Silicone Turbo Drain Hose, 3/4" X 5" ( w/ rear oil drain) 1
2336908 Oil Drain Plate (mounts to engine block)(Not Shown) 1
11504595 Bolt, Oil Drain Plate 2
2336911 Gasket, Oil Drain Plate 1
512230 Hose, Wire -Reinforced, 3/4" x 32" 1
145 2338417 SS Worm-Gear Hose Clamp, # 12 2
156 P149F-5-4 Elbow, Brass, 1/4" NPT x #5 Flare x 90o T 1
157 2336907 Gasket, Exhaust Outlet 1
194 2338424 SS Hex Head Capscrew, 3/8"-16 x 1.75" 7
 Exhaust System Page 44

See Page 46 38 197 144 134

160

167 166
98
159
17 141
19 116
169 163
142 140 168 165
123
155
98

127
130 127
98
137
134
156 136
157
138 145
139
22 21
58
124
123 121
19
60
194 2
53 54
55
120
2
19

57* 109 58 54 59 18 26
31 56

NOTE: Bolts marked with an asterisk (*) require lockwashers and/or flatwashers that are NOT SHOWN.
See parts list on opposing page.
Page 45 Exhaust System Continued

17 2338438 Hose Barb, 1" NPT x 1.25" Hose x 90o T 1

19 2338443 SS Lockwasher, 3/8" 32
38 2340132 Oil Pressure Alarm Switch, 10 psi 1
98 2338446 SS Worm-Gear Hose Clamp, # 20 4
2340408 Remote Thermostat w/ Bypass (Replacement) 1
2340408A Remote Thermostat w/ Bypass Kit (for Add-On) 1
116 513120 Hose, Wire-Reinforced, 1.25" ID x 18" 1
123 P68HB-12-8 Hose Barb, Brass, 1/2" NPT x 3/4" Hose, Straight 2
127 513103 Hose, 3-Ply Connector, 1.25" ID x 3" 1
513123 Hose, Wire-Reinforced, 1.25" ID x 23" 1
130 2340114 Tube, 1.25" Diam., Brass, Heat Exch. To Turbo 1
134 2337203 Oil Line Ass'y, 1/4" x 12" w/ # 5 Swivels 1
140 6E043 Plate, Oil Outlet 1
141 2336906 Gasket, Oil Drain 1
142 2338426 SS Hex Head Capscrew, 3/8-16 x 7/8" 2
144 P48F-5-4 Connector, Brass Straight, 1/4" NPT x #5 Flare 1
155 8927270 Stud, Turbo, 3/8"-16 x 3/8-24 x 1.5" 4
159 2337301 Hose, Formed, After Cooler Inlet 1
160 6250340 Turbocharger Assembly, Complete 1
6250371 Turbo Cartridge 1
6250398 Turbo Exhaust Housing 1
2335535 Turbo Compressor Housing 1
163 6250399 Clamp, V-Band, Turbo Exhaust 1
165 See Page 47 Exhaust Elbows
166 2338438 Hose Barb, 1" NPT x 1.25" Hose x 90o T (Stn) 1
2338439 Hose Barb, 1" NPT x 1.25" Hose x Straight (Opt) 1
2338441 Plug, 1" NPT Brass Pipe (Not Shown) 1
P218P-4 Brass Pipe Plug, 1/4" NPT (Not Shown) 1
167 2337001 Air Cleaner Ass'y w/ Vent<98 (Includes Foam Element) 1
2337002 Air Cleaner Ass'y >97 (Includes Foam Element) 1
2317002 Air Cleaner Foam Element 1
168 2338459 Turbo Washer 4
169 2340087 Turbo Locknut, 3/8"-24 4
197 P2225P-4 Tee, Brass Pipe, 1/4" NPT 1
 Exhaust System Page 46

38 197 144 134

160

167 166
98
159
17 141
19 116
169 163
142 140 168 165
123
155
98

127
130 127
98
137
134
156 136
157
138 145
139
22 21
58
124
123 121
19
194 2
53 54
55
120
2
19

57* 109 58 54 59 18 26
31 56

NOTE: Bolts marked with an asterisk (*) require lockwashers and/or flatwashers that are NOT SHOWN.
See parts list on opposing page.
Page 47 Exhaust Elbows

1 2335533 Exhaust Discharge Elbow, 4" (220 hp Engines) 1

2 2335033 Cast Aluminum, 90o T - 5" Cuff (310 hp Engines)(Std) 1

3 2335034 Exhaust Discharge Elbow, 6" (340 hp Engines) (Opt) 1

4 2335033S Cast Aluminum, 90o T - 5" Cuff (shortend for Transom)(Opt) 1

2335532 Cast Aluminum, 90o T - 4" Cuff (shortend for Transom)(Opt) 1

5 2335035 Cast Aluminum, 45o T - 5" Cuff (310 hp Engines)(Opt) 1

6 2335518 4" Exhaust Elbow (NA Engines/Non-Turbo) 1

 EXHAUST ELBOWS Page 48

1 2

3 4

5 6
Page 49 Oil Cooler & Throttle Linkage

70 6251211 Brass Freeze Plug, 1" (6.2 Only) 1

71 2340267 Transmission Cooler Bracket for 2-1/2 inch Cooler 2
2340275 Transmission Cooler Bracket for 3 inch Cooler 2
75 2331731 Throttle Bracket, Right Side, Formed 1
76 2338430 SS Hex Nut, 10mm x 1.5 3
78 2336775 Nylon Flanged Bushing 2
79 2330204 Throttle Linkage Ass'y 1

80 2331201 Throttle Bracket, Left Side 1

81 2331100 Connector Link 1
82 2338450 SS Flat Washer, 1/4" 3
83 49011 Cotter Pin, 3/32" x 1/2" 1

98 2338446 SS Worm-Gear Hose Clamp, #20 7

116 513118 Hose, Wire-Reinforced, 1.25" ID x 18" 1
117 513112 Hose, Wire-Reinforced, 1.25" ID x 12" 1
127 2340134 Hose, 3-Ply Connector, 1.25" ID x 3" 1
131 2337018 Transmission Oil Cooler, 2.5" 1
P149F-8-8 Fitting for Transmission Oil Cooler 2

150 2337016 Oil Cooler, Engine, 3" 1

2340003 Fittings for Oil Cooler 4
2340181 8.5" Oil Cooler Hose 1
2340182 9.5" Oil Cooler Hose 1
151 513109 Hose, Wire-Reinforced, 1.25" ID x 9" 1
513118 Hose, Wire-Reinforced, 1.25" ID x 18", Turnaround Pump
152 2338459 SS Flat Washer, 10mm 3

153 2340018 Mounting Bracket, Engine Oil Cooler, Top 1

2340019 Mounting Bracket, Engine Oil Cooler, Bottom 1
( Hardware for Mounting Brackets )
* 2340040 SS Hex Nut, 5/16-18 4
* 2340049 SS Lockwasher, 5/16" 8
2340078 SS Hex Head Capscrew, 5/16-18 x 3/4" 8

158 2340115 Tube, Engine Oil Cooler to Aftercooler, 1.25" 1

195 2338331 Linkage clip 1
 Oil Cooler and Throttle Linkage Page 50

74
73
72
76
76 78 80
75 79 195
98 152
152
116 82
78
132 82 83
71 81

77 131

98
117 98

Stb. side of engine

158

151
98 153

150

98

127

Port Side of Engine

NOTE: Bolts marked with an asterisk (*) require lockwashers and/or flatwashers that are NOT SHOWN.
See parts list on opposing page.
Page 51 Mounts, Engine & Transmission

Front Mounts
1 2328604 Mount, Front Right Mount w/ Shaft (Std) 1
2 2328606 Mount, Front Left Mount w/ Shaft (Std) 1
(Above Mounts Include:)
2340113 Shaft, Knurled 1
2338423 SS Capscrew, 3/8-16 x 2.75" - Gr 8 4
2338443 SS Lockwasher, 3/8" 4
2338405 SS Hex Nut, 3/8-16 4

3 2340026 SS Capscrew 10mm x 30mm 6

* 2338455 Lockwasher, 10mm 6
2338404 SS Capscrew, 3/8-16 x 1.25" (older engines) 6
* 2338443 SS Lockwasher, 3/8" (older engines) 6

4 2328607 Dual-Flex Vibration Mounts (Std) 4

Rear Mounts
5 2328605 Mounts, Rear, for use w/ Borg Warner (Std) 2
(Above Items Each Include:)
2340113 Shaft, Knurled 1
2338423 Capscrew, 3/8-16 x 2.75" - Gr 8 1
2338459 SS Flat Washer, 10mm 1
2338418 Lockwasher, 3/8" Gr 8 1
2338411 Hex Nut, 3/8-16 Gr 8 1
6 2338442 SS Capscrew, 7/16-14 x 1.25" 4
* 2340017 SS Lockwasher, 7/16" 4

Optional Rear Mounts

7 2338449 Mount, Right Rear (w/ Twin Disc Gears) 1
8 2338448 Mount, Left Rear (w/ Twin Disc Gears) 1
9 2338442 SS Capscrew, 7/16-14 x 1.25" (Twin Disc) 4
* 2340017 SS Lockwasher, 7/16" (Twin Disc) 4

7 2340144 Mount, Right Rear (w/ Hurth Gears) 1

8 2340143 Mount, Left Rear (w/ Hurth Gears) 1
9 2340054 SS Hex Head Capscrew, 12mm x 30mm 4
* 2340028 SS Lockwasher, 12mm 4

7 2340035 Mount, Right Rear, 4o Angle for Borg-Warner 1

8 2340034 Mount, Left Rear, 4o Angle for Borg-Warner 1
9 2338472 SS Hex Head capscrew, 7/16-14 x 1" 4
* 2340017 SS Lockwasher, 7/16" 4

2340142 Mount, Rear Aluminum, for use with remote- 1

mounted Marine Gear (Not Shown)

7 2328609 Borg-Warner 5000 Right Mount (Not shown) 1

8 2328610 Borg-Warner 5000 Left Mount (Not shown) 1
 Mounts, Engine and Transmission Page 52

1
2

3*

Standard
front mounts

6*

Standard
rear mounts

8 7

9*
Optional
NOTE: The Optional Rear Mounts
rear mounts
shown here are for illustration
only. Actual mounts may differ
in apearance.

NOTE: Bolts marked with an asterisk (*) require lockwashers and/or flatwashers that are NOT SHOWN.
See parts list on opposing page.
Page 53 DRESS PARTS

The following are buffed standard parts which may be used, optionally,
to enhance the appearance of the PENINSULAR 400. The quantity
of each part needed to dress up an engine is shown in parentheses.

Standard Dress Up
Part # Description Part #: Quantity:

2335505 Thermostat Manifold, Buffed 2335005 (1)

6253718 Thermostat Outlet, Buffed 2335006 (1)

2335512 Pulley, Crankshaft, Buffed 2335012 (1)

2335513 Pulley, Engine Water Pump, Buffed 2335013 (1)

2334002 Pulley, Alternator, Buffed 2335015 (1)

2335516 Pulley, Sea Water Pump, Buffed 2335016 (1)

2335519 Engine Water Pump Pipe, Buffed 2335019 (1)

2335520 Air Intake Adaptor, Buffed 6.5 2335020 (1)

2335506 Air Intake Adaptor, Buffed 6.2 2335011 (1)

 Page 54

FARIA TACHOMETER ADJUSTMENT

1. Low end adjustment. - set at factory.

2. High end adjustment. - use 5/64 allen wrench to adjust.

3. Adjustment dial. - should be set at "5" prior to calibrating.

Page 55 Engine Specifications
General Data

Type 90-degree V8 diesel

Displacement 6.5L 400 cu. in.
Bore 103mm 4.055 in.
Stroke 97mm 3.818 in.
Compression Ratio 21.3:1 (160HP)
19.0:1 (205 HP)
18.0:1 (225 and higher)
Firing Order 1-8-7-2-6-5-4-3
Oil Pressure (at idle, hot) 69kPa 10psi
Oil Pressure (at 2000 RPM) 276 to 310kPa 40-45psi

Cylinder Bore
Diameter 102.974 to 103.000 mm 4.0541 to 4.0552 in
Out-of-Round Limit Taper 0.02mm 0.0008 in.
Limit (Thrust Side) 0.02mm 0.0008 in.

Piston
Clearance (Bores 1 to 6) 0.094 to 0.120 mm 0.0037 to 0.0047 in
Clearance (Bores 7 and 8) 0.107 to 0.133mm 0.0042 to 0.0052 in

Piston Ring
Top Compression Ring:
Ring End Gap 0.26 to 0.51 mm 0.010 to 0.020 in.
2nd Compression Ring:
Ring Side Clearance 0.039 to 0.079 mm 0.0015 to 0.0031 in
Ring End Gap 0.75 to 1.00 mm 0.030 to 0.039 in.
Oil Control Ring:
Ring Side Clearance 0.040 to 0.090 mm 0.0016 to 0.0035 in
Ring End Gap 0.25 to 0.51 mm 0.0098 to 0.0236 in

Piston Pin
Diameter 30.9961 to 31.0039 mm 1.2203 to 1.2206 in
Clearance 0.0101 to 0.0309 mm 0.0003 to 0.0012 in

Crankshaft
Main Journal
Diameter (#1 to #4) 74.914 to 74.941 mm 2.9494 to 2.9504 in
Diameter (#5) 74.912 to 74.936 mm 2.9492 to 2.9502 in
Taper Limit 0.005mm 0.0002 in.
Out-of-Round Limit 0.005mm 0.0002 in
Main Bearing Clearance:
#1 to #4 0.045 to 0.083 mm 0.0018 to 0.0033 in
#5 0.055 to 0.093 mm 0.0022 to 0.0037 in
Crankshaft End-Play 0.10 to 0.25 mm 0.0039 to 0.0098 in
Crankshaft (continued) Page 56
Crankpin:
Diameter 60.913 to 60.939 mm 2.3981 to 2.3992 in.
Taper Limit 0.005 mm 0.0002 in.
Out-of-Round Limit 0.005 mm 0.0002 in.
Rod Bearing Clearance Rod 0.045 to 0.100 mm 0.0018 to 0.0039 in.
Side Clearance 0.17 to 0.63 mm 0.0067 to 0.0248 in.

Camshaft
Lobe lift:
Intake 7.133 mm 0.281 in.
Exhaust 7.133 mm 0.281 in.
Journal Diameter:
#1 to #4 54.970 to 55.025 mm 2.1643 to 2.1663 in.
#5 54.970 to 51.025 mm 2.1643 to 2.0089 in.
Clearance:
#1 to #4 0.025 to 0.118 mm 0.0010 to 0.0046 in.
#5 Camshaft 0.020 to 0.113 mm 0.0008 to 0.0044 in.
End-Play 0.051 to 0.305 mm 0.0020 to 0.0120 in.

Valve System
Lifter Type Rocker Hydraulic Roller
Arm Ratio Valve 1.5 to 1 Not Adjustable
Lash Face Angle 45 degrees
Seat Angle Seat 46 degrees
Runout Limit Seat 0.05mm 0.002 in.
Width:
Intake 0.89 to 1.53 mm 0.035 to 0.060 in.
Exhaust 1.57 to 2.36 mm 0.062 to 0.093 in.
Valve Face:
Recession into Deck 0.863 to 1.218 mm 0.034 to 0.048 in.
Stem Clearance:
Intake 0.026 to 0.069 mm 0.0010 to 0.0027 in.
Exhaust 0.026 to 0.069 mm 0.0010 to 0.0027 in.
Valve Spring:
Pressure (Closed) 356 Nat 46.0 mm 392 pounds at 1.81 in.
Pressure (Open) 1025 Nat 35.3 mm 1130 pounds at 1.39 in.
Installed Height 46 mm 1.81 in.
Timing Chain Free-Play:
New 12.7mm 0.500 in.
Used 20.3mm 0.800 in.
Hydraulic Lifter Diameter 23.39 to 23.41 mm 0.923 to 0.9217 in.
Lifter Bore Diameter 23.45 to 23.47 mm 0.923 to 0.924 in.
Lifter to Bore Clearance Limit 0.11 mm 0.0043 in.

Cylinder Head
Head/Case Deck Warpage Limits:
Overall Length 0.15mm 0.006 in.
Transverse Width 0.08mm 0.003 in.
Pre-Combustion Chamber Fit Limits:
Protrusion From Deck 0.051 mm 0.002 in.
Procession Into Deck 0 mm 0.0 in.
Page 57
Torque Specifications
Fastener Torque

N-m Lb-Ft

Camshaft sprocket bolt (pump drive gear) 75-90 55-66

Camshaft thrust plate Connecting rod nuts 18-27 13-20

Connecting rod nuts 60-70 44-52

Crankshaft pulley bolts 34-48 25-35

Cylinder head bolts

First torque (to seat gasket) 27 20
Second torque 68 50
Final torque Additional 90o-95o Additional 90o-95o

Cylinder head temperature switch 19-27 13-20

Cylinder head coolant passage plate bolts/studs 34-50 25-37

Exhaust manifold bolts/studs 36-49 27-36

Front cover to block bolts 34-50 25.-37

Fuel filter mounting bolts 34-50 25-37

Fuel injection pump bracket bolts 18-27 13-20

Fuel injection drive gear bolts 18-27 13-20

Fuel injection pump mounting bolts 34-50 25-37

Fuel return line bracket nuts 18-27 13-20

Fuel injection line fitting nuts (at pump) 24-36 18-27

Fuel injection line fitting nuts (at nozzles) 27-39 19-29

Fuel supply line fittings at lift pump 24-26 17-19

Flywheel mounting bolts 80-95 60-70

Fast idle/cold advance temperature switch 10-12 7-9

Glow plugs 11-16 8-12

 Page 58
Torque Specifications (continued)
Fastener Torque

N-m Lb-Ft

Intake manifold bolts/studs 34-50 25-37

Lifting bracket bolts/studs 45-60 33-44

Main bearing cap bolts (inner) 141-160 104-118

Main bearing cap bolts (outer)

12mm 126-145 93-107
10mm 34-50 25-37

Nozzles 60-80 44-60

Oil fill tube bolts 18-27 13-20

Oil filter fitting 34-50 25-37

Oil pan bolts (except two at rear) 6-14 4-10

Oil pan rear bolts 18-27 13-20

Oil pump drive clamp bolt 34-50 25-37

Oil pump mounting bolt 80-100 60-74

Rocker arm cover bolts/studs 18-35 13-25

Rocker arm shaft bolts 50-60 37-44

Thermostat cover bolt/studs 34.-50 25-37

Torsional damper bolt 270 200

Valve lifter guide clamp bolt 18-35 13-25

Water crossover mounting bolts/studs 34-50 25-37

Water pump to plate bolts 27-34 20-25

Water pump to front cover bolts/studs 18-27 13-20

Water pump/front cover to cylinder case bolt/studs 34-50 25-37

Turbocharger drain tube plate 16-20 12-15

Turbocharger mounting nuts 45-52 33-38

 ALTERNATOR WIRING Page 59

NOT USED
GREY WIRE
( A.C. - 1/2 Voltage
Output Connect
To Tach.)

MAKE UP GROUND
RED WIRE (power) BLACK WIRE #4 GAUGE
(12 Volt Connection)
(Ground Must Be Connected)

90 AMP Alternator Wiring

YELLOW WIRE
(Ignition To Key Switch)
GREY WIRE
( A.C. - 1/2 Voltage
BROWN WIRE Output Connect
To Tach.)

RED WIRE (power) NOT USED

(12 Volt Connection)

51 AMP Alternator Wiring