Isuzu 2.2L Diesel Engine Parts Manual PN 0D9255

  5   5   2   9   D   0

2.2

LITER

D I E S E L

ISUZU 

ENGINE  PARTS MANUAL

P.O BOX 310 EAGLE, WI 53119 

PRINTED IN U.S.A. Revision 0: 09/ 11/03 

2.2L DIESEL TABLE OF CONTENTS SERVICE SERVICE RECOMMENDA RECOMMENDATIONS ........... ...................... ...................... ....................... ....................... ...................... ....................... ....................... ...................... ....................... ............... ... 2-5 QUICK REFERENCE PARTS .......... ..................... ....................... ....................... ....................... ....................... ...................... ....................... ....................... ....................... ....................... ............. .. 2 CYLINDER HEAD, HEAD, COVER & OTHER PARTS.............................. ARTS......................................... ...................... ....................... ....................... ...................... ........................ ................ ... 6 CYLINDER BLOCK & OTHER PARTS PARTS ........... ....................... ....................... ...................... ....................... ....................... ...................... ....................... ........................ ..................... ......... 8 TIMING GEAR CASE & OTHER PARTS ......................... ............. ......................... .......................... .......................... ......................... ......................... ......................... .....................10 .........10 FLYWHEEL FLYWHEEL HOUSING ........... ...................... ...................... ....................... ....................... ...................... ....................... ....................... ...................... ........................ ........................ .................... ......... 14 OIL PAN .......... ..................... ....................... ....................... ...................... ....................... ....................... ....................... ....................... ...................... ....................... ........................ ....................... ...................... ........... 15 OIL PUMP & FIXING PARTS .......... ...................... ....................... ...................... ....................... ....................... ...................... ....................... ....................... ....................... ....................... ............. .. 16 MAIN MOVING MOVING PARTS ........... ...................... ...................... ....................... ....................... ....................... ....................... ...................... ....................... ....................... ....................... ..................... ......... 18 ROCKER ARM AND VALVE VALVE .......... ...................... ....................... ...................... ....................... ....................... ...................... ....................... ....................... ....................... ....................... ............. .. 20 OIL FILTER FILTER & FUEL FILTER FILTER .......... ...................... ....................... ...................... ....................... ....................... ...................... ....................... ....................... ....................... ....................... ............. .. 22 OIL PIPE ............ ....................... ...................... ....................... ....................... ....................... ....................... ...................... ....................... ....................... ....................... ....................... ....................... ................... ....... 23 COOLING SYSTEM ........... ...................... ....................... ....................... ...................... ....................... ....................... ...................... ....................... ........................ ....................... ....................... ............... ... 24 EXHAUST MANIFOLD ........... ...................... ...................... ....................... ....................... ....................... ....................... ...................... ....................... ........................ ....................... ...................... ........... 25 FUEL INJECTION PIPE & NOZZLE ........... ....................... ....................... ...................... ....................... ....................... ....................... ....................... ....................... ....................... ........... 26 ENGINE HANGER ........... ...................... ....................... ....................... ...................... ....................... ....................... ....................... ....................... ....................... ....................... ....................... ................. ..... 27 INJECTION PUMP, PUMP, CAMSHAFT & OTHER PARTS .......................... ............. ......................... ......................... .......................... .......................... ........................ ............. .. 28 ELECTRICAL PARTS ........... ...................... ...................... ....................... ....................... ....................... ....................... ...................... ....................... ........................ ....................... ...................... ........... 30 ENGINE COMMON PARTS .......... ...................... ....................... ...................... ....................... ....................... ....................... ....................... ...................... ....................... ........................ ............... ... 32

LEGEND “AR” (STD) “ O . S .” “ U . S .” “NA”

AS REQUIRED S TA TA N D A R D S I Z E OV E R S I Z E UNDERSIZE N O T AVA I L A B L E

NOTICE! THE INFORMATION IN THIS MANUAL IS KNOWN TO BE ACCURATE AS OF THE DATE OF RELEASE RELEASE SHOWN SHOWN ON THE COVER. COVER. HOWEVER HOWEVER,, ENGINEERIN ENGINEERING G CHANGES CHANGES CAN OCCUR WITHOUT NOTICE. NOTICE. TO OBTAIN OBTAIN THE PROPER PARTS, PARTS, PLEASE BE SURE TO USE THE MODEL NUMBER OF THE UNIT BEING SERVICED WHEN ORDERING FROM THIS MANUAL. 1

2.2L DIESEL SERVICE RECOMMENDATIONS SPECIFICATIONS: CRANKCASE OIL CAPACITY: COOLING SYSTEM CAPACITY:

2.1 U.S. GALLONS (8.0 LITERS) 2.5 U.S. GALLONS (9.3 LITERS)

RECOMMENDED FLUIDS COOLANT: USE A 50/50 MIXTURE OF LOW SILICATE ETHYLENE GLYCOL BASE ANTI-FREEZE AND SOFT WATER. (IF DESIRED, A HIGH QUALITY RUST INHIBITOR MAY BE ADDED TO THE RECOMMENDED COOLANT MIXTURE.) WHEN ADDING COOLANT, ALWAYS ADD THE RECOMMENDED 50/50 MIXTURE.

ENGINE OIL: USE A HIGH QUALITY DETERGENT OIL HAVING API CLASSIFICATION “FOR SERVICE CC OR CD.” THE SAE VISCOSITY RATING OF THE OIL SHOULD BE CAREFULLY SELECTED, BASED ON THE PREVAILING AMBIENT TEMPERATURE RANGE ANTICIPATED BEFORE THE NEXT OIL CHANGE. RECOMMENDED SAE VISCOSITY GRADES ARE AS FOLLOWS:

TEMPERATURE

RECOMMENDED OIL GRADE

ABOVE 90°F

SAE 40

32°F TO 90°F

SAE 30

12°F TO 32°F

SAE 20

QUICK REFERENCE PARTS PAGE

PART NUMBER

DESCRIPTION

7 22 33 24 22 22 26 24 24

0A86220358 0A86220296 062780 0A86220306 0A86220370 0A86220297 0A86220310 0A86220304 0A86220303

PLUG, GLOW CARTRIDGE, OIL FILTER AIR CLEANER BELT, COOLING FAN FILTER ASSEMBLY, FUEL CARTRIDGE, FUEL FILTER NOZZLE ASSY, INJECTION THERMOSTAT PUMP ASSY, WATER

2

QTY 4 1 1 1 1 1 4 1 1

2.2L DIESEL SERVICE RECOMMENDATIONS 8 KW - 35 KW SMALL STANDBY GENERATOR SETS Following is a recommended maintenance schedule for Generac small standby and residential generator sets from 8 kW to 35 kW in size, and applies to both diesel engine and gas engine driven units. The established intervals in the schedule are the maximum recommended when the unit is used in an average service application. They will need to be decreased (performed more frequently) if the unit is used in a severe application. Use the unit hour meter or calendar time, whichever occurs first, from the previous maintenance interval to determine the next required maintenance interval. Service Maintenance Interval Information: The various service maintenance intervals are designated by interval numbers as follows: 1

 An early inspection of the generator set to insure it is ready to operate when required and to identify any  potential problem areas.  Performed monthly or following each 10 hours of operation of the unit and requires approximately . 5 man-hours  per unit to complete. This inspection may be performed by the end user providing the following safety steps are taken to prevent the engine from starting automatically without warning:

To prevent injury, perform the following steps in the order indicated before starting any maintenance: • • • •

Disable the generator set from starting and/or connecting to the load by setting the control panel Auto-Off-Manual switch to the “OFF” position. Remove the control panel fuse. Turn off the battery charger. Remove the negative battery cable.

The battery charger must be turned off BEFORE removing the battery cable to prevent an over current con-  dition from burning out sensitive control panel components and circuits. Following all maintenance, reverse these steps to insure the unit is returned to standby setup for normal operation when required. 2

 A break-in service inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas.  Performed ONLY ONCE following the first three months or the first 30 hours of operation after purchase of the unit and requires approximately 2.5 man-hours per unit to complete. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an authorized Generac Service Dealer.

3

 An operational inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas.  Performed semi-annually or following each 50 hours of operation of the unit and requires approximately 1.5 man-hours per unit to complete. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an authorized Generac Service Dealer.

4

 A mid-level inspection of the generator set to insure it is ready to operate and carry the load when required, and to identify any potential problem areas.  Performed annually or following each 100 hours of operation of the unit and requires approximately 4.0 man-hours  per unit to complete. This inspection contains some maintenance tasks which require special tools, equipment, and/or knowledge to accomplish and should be performed only by an authorized Generac Service Dealer.

3

2.2L DIESEL Maintenance Tasks

Level 1 Recommended to be done monthly/ 10 hrs.

Level 2 Task Comp. (DateInitials)

Required to be done 3 months/ Break-in 30 hrs.

1. Disable the unit from operating per the first page warning. 2. Check the engine oil level. Adjust as necessar y. 3. Check the engine coolant level. Adjust as necessary. 4. Check the engine coolant thermal protection level. Correct as necessar y. 5. Check the natural gas delivery system on gas engine driven units. Tighten connections as necessary. 6. Check the diesel fuel supply level for diesel engine driven units. Fill as necessar y. 7. Drain water and sediment from the diesel fuel tank on diesel engine driven units. 8. Drain water from the fuel line water separator on diesel engine driven units if the unit is equipped with one. 9. Check the air inlets and outlets for debris. Clean as necessary. 10. Check the battery electrolyte level if accessible. Adjust as necessary. 11. Check the battery posts, cables, and charger for loose connections, corrosion, and proper operation. Correct as necessary. 12. Check the unit wiring for loose connections, corrosion, and damage. Correct as necessar y. 13. Check the engine accessory drive belts for wear, weather cracking, and damage. Replace as necessary.

4

Level 3 Task Comp. (DateInitials)

Required to be done Semiannually/ 50 hrs.

Level 4 Task Comp. (DateInitials)

Required to be done Annually/ 100 hrs.

Task Comp. (DateInitials)

2.2L DIESEL Maintenance Tasks

Level 1 Recommended to be done monthly/ 10 hrs.

Level 2 Task Comp. (DateInitials)

Required to be done 3 months/ Break-in 30 hrs.

14. Visually inspect the unit looking for leaks, wear or damage, loose connections or components, and corrosion. Correct as necessary. 15. Test the engine and transfer switch safety devices. Correct and/or adjust as necessary. 16. Initiate an automatic start and transfer of the unit to site load and exercise it for at least 1 hour looking for leaks, loose connections or components, and abnormal operating conditions. Correct as necessary. 17. Start and exercise the unit at full rated load (use a load bank if the site load is not enough) for at least 2 hours looking for leaks, loose connections or components, and abnormal operating conditions. Correct as necessar y. 18. Change the engine oil. 19. Replace the engine oil filter(s). 20. Replace the engine air filter(s). 21. Replace the engine fuel filter(s) on diesel engine driven units and re-prime the fuel system. 22. Check the engine spark plugs on gas engine driven units. Clean and re-gap or replace as necessar y. 23. Perform a 5 minute no-load operational run of the unit looking for any post service problems. 24. Return the unit to standby setup for operation when required.

5

Level 3 Task Comp. (DateInitials)

Required to be done Semiannually/ 50 hrs.

Level 4 Task Comp. (DateInitials)

Required to be done Annually/ 100 hrs.

Task Comp. (DateInitials)

2.2L DIESEL CYLINDER HEAD, COVER & OTHER PARTS

6

2.2L DIESEL CYLINDER HEAD, COVER & OTHER PARTS ITEM

PART NUMBER

DESCRIPTION

1 5 6 7 8 10 12 15 16 19 20 21 22 23 24 25 27 28 29 35 36 37 38

0A86220101 0A86220102 0A86220380 0A86220381 0A86220367 0A86220103 0A86220104 0A86220105 0A86220106 0A86220107 0A86220108 0A86220109 0A86220110 0A86220112 0A86220113 0A86220114 0A86220115 0A86220116 0A86220117 0A86220118 0A86220119 0A86220120 0A8622A132 0A86220122 0A86220358 0A86220382

HEAD ASSY, CYL CUP, SEALING D=22 CUP, SEALING D=44.5 PLUG, DRILLED PAS D=8 VALVE GUIDE SEAT, VALVE INSERT, INLET SEAT, VALVE INSERT, EXH PLUG, HOT STUD, RKR BRKT STUD, WATER PUMP STUD, MANIFOLD SEAL, VALVE PLUG GASKET, CYL HEAD BOLT, CYL HEAD BOLT, CYL HEAD COVER ASSY, CYL HEAD VALVE ASSY, VENTILATOR SCREW, VALVE CAP ASSY, OIL FILLER PACKING, OIL FILLER CAP GSKT, CYL HEAD COVER BOLT, COVER 20mm BOLT, COVER PLUG, GLOW CONNECTOR, GLOW PLUG

39 40

7

QTY 1 6 1 5 8 4 4 4 6 1 2 8 2 1 5 10 1 1 4 1 1 1 5 5 4 1

2.2L DIESEL CYLINDER BLOCK & OTHER PARTS

8

2.2L DIESEL CYLINDER BLOCK & OTHER PARTS ITEM

PART NUMBER

DESCRIPTION

1 2 3 4 5 8 9 11 12 13 13-1 14 17 18

0A86220123 0A86220383 0A86220124 0A8622A124 0A8622B124 0A86220125 0A86220126 0A86220127 0A86220128 0A86220129 0A86220225 0A86220130 0A86220131 0A86220132 0A8622A132 0A86220133 0A86220134 0A86220384 0A86220135 0A86220136 0A86220137 0A86220138 0A86220139 0A86220140 0A86220141 0A86220137 0A86220144 0A86220145 0A86220146 0A86220147 0A86220148 0A86220149 0A86220150 0A86220151 NA 0A86220121 0A86220153

BLOCK ASSY, CYL BOLT CUP, SEALING D=35 CUP, SEALING D=22 CUP, SEALING D=12 BEARING, NEEDLE CAM PLUG, THRUST CAM PLUG, WATER DRAIN PLUG, OIL GALLERY PT 1/8 PLUG, OIL GALLERY PT 1/8 PLUG COVER, INJ PUMP HSG NUT BOLT, 14MM BOLT, 20MM STUD, INJ PMP, HSG CVR STUD, OIL PAN STUD, OIL FILTER M20 PIN, CONTROL LINK PIN, STRAIGHT HSG DOWEL PIN, STRAIGHT RETAINER PLUG, CYL BLK M14 PACKING, PLUG DOWEL, CYL HEAD DOWEL PIN, STRAIGHT, INJ PUMP STUD, INJ PUMP, L1=20 STUD, WATER PMP L1=40 STUD, TIMG CASE L1=60 STUD, TIMG CASE L1=50 LEVEL GAUGE, OIL L=121 RETAINER, CRK, REAR SEAL, OIL CRK, REAR PACKING, RETAINER (USE BOND) BOLT CLIP, F/PUMP LEAD WIRE

19 20 21 22 23 24 25 26 27 28 29 30 31 34 36 37 38 39 40 41 42 48

9

QTY 1 10 5 1 5 1 1 1 3 1 1 1 2 5 1 1 2 1 2 2 2 2 1 1 2 2 8 8 1 1 1 1 1 1 NA 6 1

2.2L DIESEL TIMING GEAR CASE & OTHER PARTS

10

2.2L DIESEL TIMING GEAR CASE & OTHER PARTS ITEM

PART NUMBER

DESCRIPTION

1 2 5 6 7 8 9 11 14 16 17 18 19 20 22 23 24 26 27 29-1 29-2 30 31 32 33 34 35 36 37 38 39 40 41 43 44 46 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 62-1

0A86220154 0A86220155 0A86220156 0A86220157 0A86220158 0A86220159 0A86220160 0A86220161 0A86220162 0A86220163 0A86220164 0A86220165 0A86220166 0A86220167 0A86220169 0A86220170 0A86220171 0A86220172 0A86220173 0A86220174 0A86220175 0A86220176 0A86220177 0A86220178 0A86220179 0A86220180 0A86220181 0A86220182 0A86220183 0A86220184 0A86220185 0A86220186 0A86220187 0A86220188 0A86220189 0A86220190 0A86220191 0A86220192 0A86220193 0A86220194 0A86220195 0A86220196 0A86220197 0A86220198 0A86220199 0A86220201 0A86220202 0A86220203 0A86220204 0A86220205 0A86220206 0A86220185

FLYWEIGHT ASSY SLEEVE ASSY SHAFT, LEVER D=8 L=50 LEVER ASSY, GUIDE SHIFTER, GOVERNOR SHFT, SHIFTER D=6 L=25 RING, SNAP LEVER, TENSION, GOV'NR SPRING, MAIN LEVER ASSY, FLOATING SHAFT, FLOATING LEVER PLUG, SHAFT PT 1/8 PIECE, GUIDE PIN, G/LEVER PIN, SPRIT, G/LEVER PLATE, LINK, LEVER-PUMP SPRING, START SPRING, SET LINK ASSY, CONTROL PIN, SNAP, LINK PLATE LEVER ASSY, MAIN SPRING ADJUSTER, GOVERNOR SPRING, RETURN BUSH, LEVER, MAIN SPRG BUSH, LEVER, MAIN SPRG CUP, SEALING, BUSH D=10 LEVER, GOV'NR CONTROL O-RING, CONTROL SHFT WASHER, THRUST NUT, LEVER TO SHFT PIN, CONTROL SPRG WASHER SCREW, CONTROL L=38 NUT, SCREW SCREW SET, FULL LOAD NUT, SCREW EYE, START SPRING SCREW, SET, IDLE SPRG WASHER, IDLE SPRG, LWR WASHER, IDLE SPRG, UPR RING, SNAP, IDLE SPRG PACKING, SET SCREW NUT, CAP, SET SCREW NUT, SET SCREW CAP, IDLE SET SPRING, IDLE SHAFT ASSY, FUEL CUT SPRG, RET, FUEL CUT LEVER, FUEL CUT O-RING, SHAFT WASHER, THRUST NUT, SHAFT-LEVER WASHER

11

QTY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1

2.2L DIESEL TIMING GEAR CASE & OTHER PARTS (CONT’D)

12

2.2L DIESEL TIMING GEAR CASE & OTHER PARTS (CONT’D) ITEM

PART NUMBER

DESCRIPTION

63 64 65 66 70 71 72 73 74 75 77 78 79 81 82 93 94 102

0A86220208 0A86220209 0A86220121 0A86220211 0A86220212 0A86220213 0A86220214 0A86220215 0A86220216 0A86220217 0A86220218 0A86220219 0A86220220 0A86220221 0A86220119 0A86220223 0A86220224 0A86220225

COVER, GOV'NR LEVER PACKING, COVER BOLT CASE, GEAR, TIMING SEAL, OIL CRK, FRT COVER, ANGLEICH CUP, SEALING, D=16 O-RING, CVR ANGLEIGH BOLT, COVER FIX BOLT, W/DETENT HOLE l-16 BOLT, TIMING CASE-BLK BOLT, TIMING CASE-BLK NUT, TIMING CASE CAP ASSY, OIL FILLER PACKING, CAP SEAL, LEAD WIRE, LEAD SEAL PLUG

13

QTY 1 1 4 1 1 1 1 1 1 1 2 6 2 2 1 2 2 1

2.2L DIESEL FLYWHEEL HOUSING

ITEM

PART NUMBER

DESCRIPTION

1 2 3 4

0A86220226 0A86220227 0A86220228 0A86220229

HSG, FLYWHL, L=158 BOLT, HSG, BLOCK STUD, BLOCK, HSG NUT

14

QTY 1 4 2 2

2.2L DIESEL OIL PAN

ITEM

PART NUMBER

DESCRIPTION

1 5 6 7 8 9

0A86220230 0A86220231 0A86220232 NA 0A86220132 0A86220131

PAN ASSY, OIL PLUG, OIL DRAIN O-RING, DRAIN PLUG USE SEALANT BOLT, 14MM NUT

15

QTY 1 1 1 20 2

2.2L DIESEL OIL PUMP & FIXING PARTS

16

2.2L DIESEL OIL PUMP & FIXING PARTS ITEM

PART NUMBER

DESCRIPTION

1 7 8 9 10 12 13 14 15 17 20 21 22

0A86220235 0A86220236 0A86220237 0A86220238 0A86220239 0A86220240 0A86220241 0A86220242 0A86220243 0A86220244 0A86220245 0A86220246 0A86220247

PUMP ASSY, OIL PUMP SUB ASSY, OIL VALVE, RELIEF PLUG, VALVE SPRING, VALVE PIN, OIL PUMP O-RING, OIL PUMP BOLT, OIL PUMP SUB BOLT, OIL PUMP SUB BOLT, O/PUMP-CYL BLK STRAINER ASSY, OIL BOLT, STRAINER O-RING, STRAINER ID=13.8

17

QTY 1 1 1 1 1 2 1 1 1 4 1 1 1

2.2L DIESEL MAIN MOVING PARTS

18

2.2L DIESEL MAIN MOVING PARTS ITEM

PART NUMBER

DESCRIPTION

1 2 7 7 10 10 12 13 14 15 16 18 19 20 25 25-2 26 30 30-1 31 31-1 33 34 35 36 37

0A86220248 0A86220249 0A86220250 0A86220251 0A86220252 0A86220253 0A86220254 0A86220255 0A86220256 0A86220257 0A86220258 0A86220259 0A86220260 0A86220261 0A86220262 0A86220263 0A86220264 0A86220265 0A86220266 0A86220267 0A86220268 0A86220269 0A86220270 0A86220271 0A86220272 0A86220273

BEARING KIT, CRANK METAL, THRUST PISTON, STD PISTON, O.S. 0.25 RING SET, PISTON STD RING SET, PISTON O.S. 0.25 ROD ASSY, CONN ROD BOLT, CONN ROD NUT, CONN ROD BUSH, CONN ROD METAL SET, CONN ROD PIN, PISTON RING, SNAP CRKSHAFT ASSY (TOCCO) FLYWHEEL ASSY FLYWHEEL, REAR GEAR, RING WASHER, FLYWHEEL BOLT, FLYWHEEL BOLT, FLYWHEEL BOLT, FLYWHEEL F TO R KEY, WOODRUFF GEAR, CRKSHFT, Z=37 PULLEY, CRKSHFT BOLT, PULLEY WASHER, PULLEY

19

QTY 1 2 4 AR 4 AR 4 8 8 4 4 4 8 1 1 1 1 6 4 6 4 1 1 1 1 1

2.2L DIESEL ROCKER ARM AND VALVE

20

2.2L DIESEL ROCKER ARM AND VALVE ITEM

PART NUMBER

DESCRIPTION

1 2 3 4 5 6 7 8 9 10 11 12 13 14 23 25 26 27 29 30 32

0A86220274 0A86220275 0A86220276 0A86220277 0A86220278 0A86220279 0A86220280 0A86220281 0A86220282 0A86220283 0A86220284 0A86220285 0A86220131 0A86220287 0A86220289 0A86220290 0A86220291 0A86220292 0A86220293 0A86220294 0A86220295

BRACKET, ROCKER SHAFT, ROCKER CUP, SEALING D=12 CUP, SEALING D =8 PIN, ROCKER SHAFT ARM, ROCKER, INLET ARM, ROCKER, EXHAUST SCREW, ADJ NUT, ADJ SCREW SPRING, ROCKER PLUG, RKR SHAFT PACKING, PLUG NUT BOLT, RKR BRKT VALVE, INLET VALVE, EXHAUST SPRING, VALVE SEAT, VALVE SPRING COLLAR, SPLIT TAPPET ROD, PUSH

21

QTY 1 1 1 1 1 4 4 8 8 4 1 1 6 5 4 4 8 8 16 8 8

2.2L DIESEL OIL FILTER & FUEL FILTER

TEM

PART NUMBER

DESCRIPTION

1 2 3 4 19 20 21 22 23 24 25 26 27 28 29

0A86220296 0A86220370 0A86220297 0A86220371 0A86220372 0A86220298 0A86220373 0A86220299 0A86220300 0A86220372 0A86220298 0A86220374 0A86220375 0A86220376 0A86220377

CARTRIDGE, OIL FILTER FILTER ASSEMBLY, FUEL CARTRIDGE, FUEL FILTER BODY BOLT, EYE JOINT, OUT PACKING, EYE JOINT JOINT, EYE, FILTER OUT PLUG, FUEL FILTER PACKING, PLUG, FUEL FILTER BOLT, EYE JOINT, IN PACKING, EYE JOINT JOINT, EYE, FILTER IN BRACKET, FUEL FILTER BOLT, BRACKET FIX BOLT, FUEL FILTER

22

QTY 1 1 1 1 1 2 1 1 1 1 2 1 1 2 2

2.2L DIESEL OIL PIPE

ITEM

PART NUMBER

DESCRIPTION

1

0A86220302

PIPE,OIL PUMP, CYL BLK

23

QTY 1

2.2L DIESEL COOLING SYSTEM

ITEM

PART NUMBER

DESCRIPTION

1 3 4 5 7

0A86220303 0A86220110 NA 0A86220385 0A86220386 0A86220387 0A86220220 0A86220304 0A86220305 0A86220371 0A86220165 0A86220324 0A86220386 0A86220388 0A86220389 0A86220306

PUMP ASSY, WATER PLUG PACKING, WATER PUMP (USE SEALANT) BOLT, WATER PUMP L=45 BOLT, WATER PUMP L=40 BOLT, WATER PUMP L=60 NUT THERMOSTAT PACKING, OUTLET PIPE PIPE, WATER OUTLET PLUG, SWITCH, PT 1/8 BOLT, OUTLET PIPE BOLT, OUTLET PIPE PULLEY, FAN D=103 BOLT, PULLEY W/PUMP BELT, COOLING FAN

8 9 10 11 12 13 15 19 20

24

QTY 1 1 NA 1 2 2 2 1 1 1 1 1 1 1 2 1

2.2L DIESEL EXHAUST MANIFOLD

ITEM

PART NUMBER

DESCRIPTION

1 2 3 4 29

0A86220307 0A86220308 0A86220220 0A86220390 0A86220309

MANIFOLD, EXH GSKT, EXH MANIFOLD NUT BOLT GSKT, EXH PIPE

25

QTY 1 1 2 6 1

2.2L DIESEL FUEL INJECTION PIPE & NOZZLE

ITEM

PART NUMBER

DESCRIPTION

1 3 4 5 6 10 16 19 20 21 22 23

0A86220310 0A86220311 0A86220312 0A86220313 0A86220391 0A86220314 0A86220392 0A86220315 0A86220316 0A86220317 0A86220393 0A86220318

NOZZLE ASSY, INJ HEAT SHEILD, NOZZLE GSKT, NOZZLE HOLDER GSKT, HEAT SHIELD WASHER, CORRUGATED PIPE ASSY, INJ CLIP, FUEL HOSE PIPE ASSY, FUEL, SUCTION PIPE ASSY, FUEL LEAK OFF HOSE, FUEL, FEED L/OFF BOLT, EYE GASKET

26

QTY 4 4 4 4 4 4 2 1 1 1 4 8

2.2L DIESEL ENGINE HANGER

ITEM

PART NUMBER

DESCRIPTION

1 2 3 10 11 12 13

0A86220319 0A86220320 0A86220246 0A86220322 0A86220323 0A86220324 0A86220325

HANGER, FRONT HANGER, REAR BOLT PLATE, ADJ, GEN BOLT, GEN BOLT, ADJ PLATE, GEN NUT, GEN

27

QTY 1 1 2 1 1 1 1

2.2L DIESEL INJECTION PUMP, CAMSHAFT & OTHER PARTS

28

2.2L DIESEL INJECTION PUMP, CAMSHAFT & OTHER PARTS ITEM

PART NUMBER

DESCRIPTION

1 3 3 3 3 3 3 3 3 3 5 6 10 12 13 14 15 18 19 20 25 26 27 28 32-1 40 41 42 43 44

0A86220326 0A86220327 0A86220328 0A86220329 0A86220330 0A86220331 0A86220332 0A86220333 0A86220334 0A86220335 0A86220220 0A86220324 0A86220338 0A86220339 0A86220340 0A86220341 0A86220342 0A86220343 0A86220344 0A86220345 0A86220346 0A86220347 0A86220348 0A86220349 0A86220350 0A86220394 0A86220395 0A86220351 0A86220352 0A86220395

PUMP ASSY, INJ PFR SHIM, INJ PUMP, T=0.2 SHIM, INJ PUMP, T=0.3 SHIM, INJ PUMP, T=0.4 SHIM, INJ PUMP, T=0.5 SHIM, INJ PUMP, T=0.6 SHIM, INJ PUMP, T=0.7 SHIM, INJ PUMP, T=0.8 SHIM, INJ PUMP, T=1.0 SHIM, INJ PUMP, T=1.2 NUT BOLT SHAFT, CAM, INJ PMP &VALVE RING, WEAR, CAMSHFT PIN, CAMSHAFT BEARING, BALL, FRT BEARING, BALL, REAR GEAR, INJ PUMP & VALVE NUT, CAM GEAR RING, SNAP, CAMSHFT, FRT SHAFT ASSY, IDLE GEAR GEAR, W/BUSH,IDLE Z=44 COLLAR,THRUST,IDLE GEAR BOLT, SHAFT PUMP ASSY, FUEL, ELEC BRACKET, FUEL PUMP BOLT, FUEL PUMP HOSE, F/PUMP-F/PIPE HOSE, PUMP-F/FILTER CLIP, FUEL HOSE

29

QTY 4 AR AR AR AR AR AR AR AR AR 8 8 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 1 1 4

2.2L DIESEL ELECTRICAL PARTS

30

2.2L DIESEL ELECTRICAL PARTS ITEM

PART NUMBER

DESCRIPTION

1 3 4 5 7 13

0A86220353 0A86220397 0A86220185 0A86220398 0A86220354 0A86220358

STARTER ASSY BOLT, STARTER WASHER NUT, STARTER CABLE ALTERNATOR ASSY PLUG, GLOW

31

QTY 1 2 1 1 1 4

2.2L DIESEL ENGINE COMMON PARTS

32

2.2L DIESEL ENGINE COMMON PARTS ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

PART NUMBER

DESCRIPTION

0A8241 052647 046526 0A8366 022131 051756 0A8515 0A8984 035685 062780 062781 0A6928 022145 022129 045771 0A8804 040976 0A8645 095262 042574 074908 022769 090330 0A8584 053666 0A8916 0C3723 0A9100 0C3724 053667 057522 039288 051698 0A6751 0A9765 020619 022237 0A9860 0A9861 028739 051767

ADAPTOR, SAE4 TO SAE3 SCREW SHC M10-1.5 X 25 G12.9 WASHER LOCK M10 MOUNTING FOOT,ENG2.2 WASHER FLAT 3/8-M10 ZINC SCREW HHC M10-1.5 X 20 G8.8 BRKT A/C SUPT 2.2ISU HOSE, FRMD AIR INLET CLAMP HOSE #28 1.32 - 2.25 AIR CLNR DNLDSN FWG MOUNTING BAND 5.25"D SCREW HHC M8-1.25 X 20 SS G8.8 WASHER FLAT 5/16 ZINC WASHER LOCK M8-5/16 NUT HEX M8-1.25 G8 YEL CHR EXH TUBE (ENG-FLEX) SCREW SHC M8-1.25 X 20 G12.9 ADAPTOR COOLING FAN FAN, COOLING 18" ADAPTOR 1/8NPTF TO 1/8-28 SCREW HH TAPTITE M5-0.8 X 10 BP WASHER SHAKEPROOF INT #10 LUG DIS 16-14AWG M-FSTN BR/T (SEE NOTE) SWITCH OIL PRESSURE HOBBS SENDER OIL PRESSURE SPACER THERMSTAT 2.2 SPACER THERMSTAT 2.2 GASKET,THERMOSTAT GASKET THERMSTAT 2.2 SENDER WATER TEMP SENSOR COOLANT LEVEL SCREW HHC M8-1.25 X 55 G8.8 SCREW HHC M8-1.25 X 75 G8.8 SW-TMP 245DEG 3/8NPT HARNESS ENGINE GR25 (NOT SHOWN) SCREW HHC 3/8-24 X 1/2 G5 WASHER LOCK 3/8 STARTER LEAD, 2.2L ALTERNATOR LEAD, 2.2L TIE WRAP 3.9" X .10" NAT'L UL (NOT SHOWN) SCREW HHC M6-1.0 X 45 G8.8

QTY 1 12 24 2 12 12 1 1 2 1 2 8 14 18 8 1 4 1 1 2 2 2 5 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1* 1* 3 1

* LEADS COME WITH ENGINE, CRIMP AS SHOWN NOTE:

THE CONNECTIONS ON THE FUEL CUT-OFF SOLENOID AND FUEL PUMP SHOULD BE CUT OFF AND REPLACED WITH ITEM 23. (ITEM 23 IS NOT SHOWN)

33