Service Parts

Engine

Engine Model:

PSI 8.8 L
Generator Models:
125/150ERESC
125/150REZGC
125REZGT
125/150RZGC

TP-6846 8/16b
 Table of Contents
Description Page
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Numbering System Significance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
How to Find Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Model Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1--1: Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1--2: Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1--3: Fan Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1--4: Lifting Eye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1--5: Flywheel Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1--6: Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1--7: Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1--8: Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1--9: Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1--10: Starter Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1--11: Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1--12: Front Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1--13--1: Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1--13--2: EPR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1--13--3: PVC Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1--15: Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1--18: Turbo/Exhaust Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1--20--1: Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1--20--2: Turbocharger Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1--21: Intake Crossover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1--22: Charge Air Cooler Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1--23: Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
1--24: Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2--1: Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2--2: Valve Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2--3: Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2--4: Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2--5: Coolant Crossover Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2--6: Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2--7: Sensors and Spark Plugs, Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2--8: Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2--9: Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2--10: Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2--11: Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2--12: Piston & Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2--13: Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2--14: Crankshaft Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2--15: Front Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
2--16: Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2--17: Oil Pump Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
 Introduction
This manual lists service replacement parts for PSI 8.8L Illustrations
engines. Illustrations (or exploded-view drawings) best
Information in this publication represents data available representing the widest range of variations accompany
at the time of print. Kohler Co. reserves the right to most groups in this manual. Illustrations do not depict all
change this publication and the products represented details and may not show all parts. Do not substitute
without notice and without any obligation or liability illustrations for assembly or disassembly.
whatsoever. How to Find Part Numbers
This manual includes the following main sections: Use the following steps to locate a service replacement
Table of Contents. Lists the sections of the manual. part.
Introduction (and other information sections). 1. Locate the nameplate to identify the
Contains introductory material about part numbers, specification number.
illustrations, and hardware. 2. Turn to the Specification Number Index. The
first column lists the generator set spec numbers.
Index. Lists the generator set specification number and
engine part numbers. 3. Find the engine number at the intersection of the
spec row and the engine number column. Note the
Group Parts Lists. List the part numbers of parts in the engine number.
groups. 4. Page forward to locate the group and engine
identified above or find the appropriate page in the
Numbering System Significance Table of Contents.
This manual uses the following numbering systems:
5. Find the part on the illustration and note the item
Specifcation Number/Engine Number. The product number of the part or find the part description in
identification number located on the generator set the parts list.
nameplate. Engne numbers break down into groups.
Group Number. A unique number representing a parts
group needed to assemble a generator set function. For
example, Group 1--2 is the Starter group.
Part Number. The part number identifies an individual
assembly, subassembly, component, or accessory kit.

TP-6846 8/16 3
 Specification Number Index
Engine
Specification Number Number
125REZGC/125ERESC
GM81460--GA1 GM77528--1
GM81460--GA3 GM77528--1
GM81460--GA5 GM77528--1
GM81460--GA6 GM77528--1
GM81460--GA7 GM77528--1
GM81460--GA9 GM77528--1
GM99493--GA1 GM99486--1
GM99493--GA3 GM99486--1
GM99493--GA5 GM99486--1
GM99493--GA6 GM99486--1
GM99493--GA7 GM99486--1
GM99493--GA8 GM99486--1
GM99493--GA9 GM99486--1
125REZGT
GM87010--GA1 GM77414--1
GM99497--GA1 GM99487--1
125RZGC
GM81460--GA2 GM77528--2
GM81460--GA4 GM77528--2
GM81460--GA8 GM77528--2
GM99493--GA2 GM99486--2
GM99493--GA4 GM99486--2
150REZGC/150ERESC
GM80580--GA1 GM77529--1
GM80580--GA3 GM77529--1
GM80580--GA5 GM77529--1
GM80580--GA7 GM77529--1
GM80580--GA8 GM77529--1
GM80580--GA9 GM77529--1
GM99599--GA1 GM99488--1
GM99599--GA3 GM99488--1
GM99599--GA5 GM99488--1
GM99599--GA7 GM99488--1
GM99599--GA8 GM99488--1
GM99599--GA9 GM99488--1
150RZGC
GM80580--GA2 GM77529--2
GM80580--GA4 GM77529--2
GM80580--GA6 GM77529--2
GM99599--GA2 GM99488--2
GM99599--GA4 GM99488--2
GM99599--GA6 GM99488--2

4 TP-6846 8/16
 1--1: Dipstick

4
1

Items not shown: 5

38010914

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM52279 Dipstick w/tube 1 1 1 1 1
2 # Bolt, M8-1.25 x 40 Hx Hd Gr 8.8 1 1 1 1 1
3 GM61733 Washer 1 1 1 1 1
4 GM75194 Washer, Flat 5/16 USS 1 1 1 1 1
5 GM75195 Washer, Flat 5/16 SAE 1 1 1 1 1

TP-6846 8/16 5
 1--1: Dipstick

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM52279 Dipstick w/tube 1 1 1 1 1
2 GM75194 Washer, Flat 5/16 USS 1 1 1 1 1
3 GM61733 Washer 1 1 1 1 1
4 GM75195 Washer, Flat 5/16 SAE 1 1 1 1 1

6 TP-6846 8/16
 1--2: Starter

2
5
4
6 9
10

3
7
1 8

38080316

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM17378 Bolt, starter 2 2 2 2 2
2 GM94039 Starter 1 1 1 1 1
3 GM75165 Bolt, Starter Extended Thru 1 1 1 1 1
4 # Nut 1 1 1 1 1
5 # Washer 1 1 1 1 1
6 GM72312 Nut, M8-1.25 flange serrated 1 1 1 1 1
7 GM25975 Washer, flat 2 2 2 2 2
8 GM25977 Nut, 10-24 2 2 2 2 2
9 # Bolt 1 1 1 1 1
10 GM87689 Starter Bracket 1 1 1 1 1

TP-6846 8/16 7
 1--2: Starter

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM17378 Bolt, starter 2 2 2 2 2
2 GM75165 Bolt, Starter Extended Thru 1 1 1 1 1
3 GM94039 Starter, 8.8L 1 1 1 1 1
4 GM101418 Bracket, Starter 1 1 1 1 1
5 GM101426 Nut 1 1 1 1 1
6 GM72376 Extender, threaded rod M6-1.0 1 1 1 1 1
7 GM72312 Nut, M8-1.25 flange serrated 1 1 1 1 1
8 GM25975 Washer, flat 2 2 2 2 2
9 GM60723 #10 Lockwasher 2 2 2 2 2
9 GM47683 Washer, lock #10 2 2 2 2 2
10 GM25977 Nut, 10-24 2 2 2 2 2
11 GM101433 Screw 1 1 1 1 1

8 TP-6846 8/16
 1--3: Fan Spacer

38080606

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM16147 Spacer, fan 1 1 1 1 1
2 # Bolt, M8-1.25 x 80 Skt Hd Gr8.8 4 4 4 4 4

TP-6846 8/16 9
 1--3: Fan Spacer

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM16147 Spacer, fan 1 1 1 1 1
2 GM81604 Fan Spacer Bolt 4 4 4 4 4

10 TP-6846 8/16
 1--4: Lifting Eye

38080907

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87589 Lifting Eye 1 1 1 1 1
2 # Bolt 2 2 2 2 2

TP-6846 8/16 11
 1--5: Flywheel Adapter

38000105

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM75117 Adapter, FF Flywheel 1 1 1 1 1
2 GM73567 Screw, Cap 3/8-16 x 2 Sk tHd 6 6 6 6 6
Gr8

12 TP-6846 8/16
 1--5: Flywheel Adapter

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM75117 Adapter, Ff Flywheel 1 1 1 1 1
2 GM73567 Bolt 6 6 6 6 6

TP-6846 8/16 13
 1--6: Flywheel Housing

Items not shown: 6

38080204

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM19723 Plate, Cover 1 1 1 1 1
2 GM75116 Housing, SAE3 Universal 1 1 1 1 1
3 GM75114 Plate, Cover Borg-Warner F/W 1 1 1 1 1
4 GM75198 Bolt, M10-1.50 x 30 Sk Hd Gr8.8 6 6 6 6 6
5 # Bolt, 1/4-20x1/2 Flange Hd Ser 8 8 8 8 8
6 # Bolt, 5/8-18 x 1 Hx Hd Zinc 1 1 1 1 1

14 TP-6846 8/16
 1--6: Flywheel Housing

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM75114 Plate, Cover F/W 1 1 1 1 1
2 GM19723 Plate, cover 1 1 1 1 1
3 GM75116 Housing, SAE3 1 1 1 1 1
4 GM75198 Bolt, M10-1.50 X 30 Skhd Gr8.8 6 6 6 6 6
5 GM101434 Bolt 8 8 8 8 8

TP-6846 8/16 15
 1--7: Exhaust Manifold

2
1 1

3
4

38080834

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM75182 Manifold 2 2 2 2 2
2 GM19721 Gasket, exhaust manifold 2 2 2 2 2
3 # Washer, Flat 5/16 Thick Hard 16 16 16 16 16
4 GM23738 Bolt, M8-1.25 x 30 16 16 16 16 16

16 TP-6846 8/16
 1--7: Exhaust Manifold

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM101419 Shield, Cylinder 2 2 2 2 2
2 GM101420 Shield, Cylinder 6 6 6 6 6
3 GM19721 Gasket, exhaust manifold 2 2 2 2 2
4 GM101424 Manifold, Exhaust 2 2 2 2 2
5 GM101441 Washer 16 16 16 16 16
6 GM101431 Bolt 2 2 2 2 2
7 GM101440 Bolt 16 16 16 16 16

TP-6846 8/16 17
 1--8: Exhaust Pipe

38080833

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM75184 Tube, RH Exhaust 1 1 1 1 1
2 GM75185 Tube, LH Exhaust 1 1 1 1 1
3 GM75191 Clamp, V-Band 3.87” dia 4 4 4 4 4

18 TP-6846 8/16
 1--8: Exhaust Pipe

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM75184 Tube, RH Exhaust 1 1 1 1 1
2 GM75185 Tube, LH Exhaust 1 1 1 1 1
3 GM75191 Clamp, V-Band 3.87” Dia 4 4 4 4 4

TP-6846 8/16 19
 1--9: Thermostat

88086002

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87600 Thermostat Outlet 1 1 1
2 GM87617 Bolt 3 3 3
3 GM87618 Thermostat 1 1 1

20 TP-6846 8/16
 1--9: Thermostat, continued

88086003

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87594 Coolant Elbow 1 1
2 GM87617 Bolt 3 3
3 GM87618 Thermostat 1 1

TP-6846 8/16 21
 1--9: Thermostat, continued

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM101407 Thermostat outlet 1 1
2 GM87618 Thermostat 1 1 1 1 1
3 GM87617 Bolt 2 2 2 2 2
4 GM101408 P-Clamp 1 1 1 1 1
5 # Nut 2 2 2 2 2
6 GM101409 Bracket 1 1 1 1 1

22 TP-6846 8/16
 1--10: Starter Stud

38080314

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 # Washer 1 1 1 1 1
2 GM53103 Starter Adapter 1 1 1 1 1

TP-6846 8/16 23
 1--10: Starter Stud

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM101406 Washer, Star 1 1 1 1 1
2 GM53103 Starter Adapter 1 1 1 1 1

24 TP-6846 8/16
 1--11: Wiring

17 2

3
20 22 18

1 16

7
4

13
19
6

14
11 12 Harness
8
10

15

21

38081225

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM75103 Nut, Flange 1/4-20 Serrated 8 8 8 8
2 GM72292 Sensor, O2 1 1 1 1
3 GM87945 ECM, 125 kW 1 1 1 1
3 GM87946 ECM, 150 kW 1 1 1 1
4 GM87604 Plate 1 1 1 1
5 GM29604 Isolator, relay box 2 2 2 2
6 GM87607 Relay Bracket 1 1 1 1
7 GM72302 Sensor, T map 3-bar 1 1 1 1
8 GM72304 Sensor, knock 2 2 2 2
9 GM75168 Bracket, Gcp Mount 1 1 1 1
10 GM75169 Stud, Knock Sensor Mounting 2 2 2 2
11 GM75171 Guard, Knock Sensor 2 2 2 2
12 GM87609 Harness 1 1 1 1
13 GM72312 Nut, M8-1.25 flange serrated 4 4 4 4
14 # Nut 2 2 2 2
15 # Washer 1 1 1 1
16 GM87612 Washer 1 1 1 1
17 # Bolt 4 4 4 4
18 GM87613 Bolt 1 1 1 1
19 # Bolt 2 2 2 2
20 # Bolt 4 4 4 4
21 # Bolt 1 1 1 1
22 GM72327 Bolt, M6-1.0 x 20 flange head 4 4 4 4

TP-6846 8/16 25
 1--11: Wiring

13

10

3 6

11 5

1
8 Harness 7
2

12

38081226

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM75103 Nut, Flange 1/4-20 Serrated 4
2 GM75125 Bushing, 3/8MPT X 1/4FPT 1
3 GM72292 Sensor, O2 1
4 GM87604 Plate 1
5 GM29604 Isolator, relay box 2
6 GM29605 Bracket, relay box 1
7 GM72303 Sender, oil pressure 1
8 GM87610 Harness 1
9 # Washer 1
10 # Bolt 2
11 # Bolt 2
12 # Bolt 1
13 GM72327 Bolt, M6-1.0 x 20 flange head 4

26 TP-6846 8/16
 1--11: Wiring

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM72292 Sensor, O2 1 1 1 1 1
2 GM87604 Plate 1 1 1 1 1
3 GM101442 ECU, Programmed 1
3 GM101445 ECU, Programmed 1
3 GM101444 ECU, Programmed 1
3 GM101446 ECU, Programmed 1
3 GM101443 ECU, Programmed 1
4 GM29604 Isolator, relay box 2 2 2 2 2
5 GM29605 Bracket, relay box 1 1 1 1 1
6 GM72304 Sensor, knock 2 2 2 2 2
7 GM75168 Bracket, Gcp Mount 1 1 1 1 1
8 GM75169 Stud, Knock Sensor Mounting 2 2 2 2 2
9 GM75171 Guard, Knock Sensor 2 2 2 2 2
10 GM101421 Harness, Engine 1 1 1 1
10 GM101497 Harness, Engine 1
11 GM101427 Nut 4 4 4 4 4
12 GM101430 Washer, Star 1 1 1 1 1
13 GM87612 Washer 1 1 1 1 1
14 GM101432 Bolt 4 4 4 4 4
15 GM101435 Bolt 2 2 2 2 2
16 GM101436 Nut, Flange 1/4 8 8 8 8 8
17 GM101437 Bolt 4 4 4 4 4
18 GM101438 Bolt 1 1 1 1 1
19 GM72327 Bolt, M6-1.0 x 20 flange head 4 4 4 4 4

TP-6846 8/16 27
 1--12: Front Mount

38080901

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM19724 Mount, front engine 1 1 1 1 1
2 GM72382 Bolt 4 4 4 4 4

28 TP-6846 8/16
 1--13--1: Fuel System

25 24 10 21 19

22
6
7
15
23
3

9 13 20 12
11
14
18
17
16

26
4
5
8
2

38080467

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87593 Map Sensor 1
2 GM16158 Hose, PCV, 3/8”
3 GM38939 Fitting, 3/8 MPT Plug, Hex 1
4 GM73579 Elbow 1
5 GM38928 Fitting, intake manifold vac 1
6 GM29586 Valve, throttle, 60 mm 1
7 GM29592 Gasket (manifold adapter) 1
8 GM69488 Clamp, hose 3/8 (spring type) 2
9 GM75132 Washer, M6 Conical 4
10 GM69499 Adapter, mixer 1
11 GM69503 Seal 1
12 GM69504 O-ring 1
13 GM69510 O-ring 2
14 GM75150 Spacer 1
15 GM87605 Throttle Body Adaptor 1
16 GM87606 Elbow Gasket 1
17 GM39601 Sensor, coolant temperature 1
18 GM29609 Sensor, inlet air 1
19 GM69518 Bolt, M8 x 1.25 x 25 hex head, 4
gr. 8.8
20 GM87612 Washer 1
21 GM69521 Washer, M8 4
22 GM87613 Bolt 1
23 GM72327 Bolt, M6-1.0 x 20 flange head 4
24 GM72328 Nut 3
25 GM87615 Bolt 4
26 - EPR (See group 1--13--2) 1

TP-6846 8/16 29
 1--13--1: Fuel System

16

3
13
4
6

15 12 7

11
10

14

38080469

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM16158 Hose, PCV, 3/8”
2 GM38939 Fitting, 3/8 MPT Plug, Hex 1 1 1 1
3 GM73579 Elbow 1 1 1 1
4 GM28915 Clamp, hose, 5 in. 2 2 2 2
5 GM38928 Fitting, intake manifold vac 1 1 1 1
6 GM66214 Hose, hump, intake 4 x 4 1 1 1 1
7 GM69488 Clamp, hose 3/8 (spring type) 2 2 2 2
8 GM69502 Elbow, mixer to turbo 1 1 1 1
9 GM87602 Support Bracket 1 1 1 1
10 GM28960 Washer, flat SAE 2 2 2 2
11 GM24188 Washer, lock 1/4 in. 2 2 2 2
12 GM28961 Bolt, 1/4-20 x 3/4 in.hex grd. 5 2 2 2 2
13 GM69521 Washer, M8 4 4 4 4
14 GM87614 Bolt 2 2 2 2
15 GM69522 Bolt, M8 x 1.25 x 25 hex head 4 4 4 4
16 GM72329 E480 EPR kit 1 1 1 1

30 TP-6846 8/16
 1--13--1: Fuel System

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
2 GM38939 Fitting, 3/8 MPT Plug, Hex 1 1 1 1
3 GM73579 Elbow 1 1 1 1
4 GM28915 Clamp, hose, 5 in. 2 2 2 2
5 GM38928 Fitting, intake manifold vac 1 1 1 1
6 GM66214 Hose, hump, intake 4 x 4 1 1 1 1
7 GM69488 Clamp, hose 3/8 (spring type) 1 1 1 1
8 GM69502 Elbow, mixer to turbo 1 1 1 1
9 GM101411 Bracket, Mixer 1 1 1 1
10 GM72302 Sensor, T map 3-bar 1 1 1 1
11 GM28960 Washer, flat SAE 2 2 2 2
12 GM24188 Washer, lock 1/4 in. 2 2 2 2
13 GM28961 Bolt, 1/4-20 x 3/4 in.hex grd. 5 2 2 2 2
14 GM69521 Washer, M8 4 4 4 4
15 GM101432 Bolt 1 1 1 1
16 GM87614 Bolt 2 2 2 2
17 GM69522 Bolt, M8 x 1.25 x 25 hex head 4 4 4 4
18 GM72329 E480 EPR kit 1 1 1 1

TP-6846 8/16 31
 1--13--1: Fuel System

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM87593 Map Sensor 1
3 GM38939 Fitting, 3/8 MPT Plug, Hex 1
4 GM73579 Elbow 1
5 GM38928 Fitting, intake manifold vac 1
6 GM29586 Valve, throttle, 60 mm 1
7 GM29592 Gasket (manifold adapter) 1
8 GM69488 Clamp, hose 3/8 (spring type) 2
9 GM75132 Washer, M6 Conical 4
10 GM69499 Adapter, mixer 1
11 GM69503 Seal 1
12 GM69504 O-ring 1
13 GM69510 O-ring 2
14 GM75150 Spacer 1
15 GM101447 Throttle, Inlet Casting 1
16 GM87606 Elbow Gasket 1
17 GM60247 Temp Send Unit E-Controls 1
18 GM29609 Sensor, inlet air 1
19 GM101422 Seal, Map Sensor 1
20 GM69518 Bolt, M8 x 1.25 x 25 hex head 4
21 GM87612 Washer 1
22 GM69521 Washer, M8 4
23 GM87613 Bolt 1
24 GM72327 Bolt, M6-1.0 x 20 flange head 4
26 GM101439 Bolt, Socket Head 4
27 GM72329 E480 EPR kit 1

32 TP-6846 8/16
 1--13--2: EPR

4
1
6

38080464

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM69496 EPR 1
2 GM69497 Mixer 1
3 GM69509 Adapter, EPR, 1 1/4 NPT 1
4 GM75151 Screw, Tabulated M4 X 12 2
5 GM69524 Bolt, M4 x .70 x 16 sht hd 4
6 GM72323 Stud, M5-.80 x 25 4
7 GM72324 Nut, M5-.80 flange 4

TP-6846 8/16 33
 1--13--2: EPR

4
3
1

6 5

38080463

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM69493 EPR 1 1 1 1
2 GM69497 Mixer 1 1 1 1
3 GM69509 Adapter, EPR, 1 1/4 NPT 1 1 1 1
4 GM69524 Bolt, M4 x .70 x 16 sht hd 4 4 4 4
5 GM72323 Stud, M5-.80 x 25 4 4 4 4
6 GM72324 Nut, M5-.80 flange 4 4 4 4

34 TP-6846 8/16
 1--13--2: EPR

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM69493 EPR assembly 1 1 1 1 1
2 GM69497 Mixer 1 1 1 1 1
3 GM69509 Adapter, EPR, 1 1/4 NPT 1 1 1 1 1
4 GM69524 Bolt, M4 x .70 x 16 sht hd 4 4 4 4 4
5 GM72323 Stud, M5-.80 x 25 4 4 4 4 4
6 GM72324 Nut, M5-.80 flange 4 4 4 4 4

TP-6846 8/16 35
 1--13--3: PVC Hose Assembly

Image not available

38080485

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
GM16158 Hose, PCV, 3/8” x 12” 1
GM16158 Hose, PCV, 3/8” x 35” 1 1 1 1 1
GM16158 Hose, PCV, 3/8” x 4.5” 1
GM16159 Valve, PCV 1
GM36134 Sleeve, thermo 12” 1
GM69488 Clamp, hose 3/8 (spring type) 5
GM69488 Clamp, hose 3/8 (spring type) 1 1 1 1 1
GM75131 Clamp, Hose 7/8”Od 2
GM69492 Tube, 0.625 ID x 3 in. 2
GM101412 Adapter 1
GM101413 Insulation, 11.5” 1
GM101414 Insulation, 5 “ 1
# Tie, zip 8

36 TP-6846 8/16
 1--15: Alternator
16
4
10
23

19 17 6

15
22
24 12
5 18
9
20
21
11

14

8
25
13
1

2 3
38080315

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM16121 Pulley, idler 1 1 1 1 1
2 GM87590 Fan Belt 1 1 1 1 1
3 GM87599 Water Pump Pulley 1 1 1 1 1
4 GM16180 Alternator, 70 amp 1 1 1 1 1
5 GM19741 Pulley, idler 1 1 1 1 1
6 GM19742 Spacer, .437 ID x 2.343 in. 1 1 1 1 1
7 GM19743 Spacer, .437 ID x 2.906 in. 1 1 1 1 1
8 GM19744 Spacer, .437 ID x 3.718 in. 1 1 1 1 1
9 GM19746 Pulley, tensioner 1 1 1 1 1
10 GM19747 Spacer, alternator mounting .375 1 1 1 1 1
ID x 2.19 in.
11 GM19748 Brace, alternator 1 1 1 1 1
12 GM23423 Plate, idler 1 1 1 1 1
13 GM23422 Washer, idler 1 1 1 1 1
14 GM23421 Spacer, idler short 1 1 1 1 1
15 GM23420 Spacer, idler long 1 1 1 1 1
16 GM28959 Nut, M6-1.0 2 2 2 2 2
17 GM23738 Bolt, head head, M8-1.25 x 30 1 1 1 1 1
18 GM72312 Nut, M8-1.25 flange serrated 1 1 1 1 1
19 GM61733 Washer 1 1 1 1 1
20 GM72313 Washer, lock M10 5 5 5 5 5
21 GM73559 Bolt 2 2 2 2 2
22 GM23739 Nut, M10 x 1.5 2 2 2 2 2
23 # Bolt 1 1 1 1 1
24 GM23740 Bolt, M10-1.5 x 120, gr. 5 3 3 3 3 3
25 GM87682 Alternator Bracket 1 1 1 1 1

TP-6846 8/16 37
 1--15: Alternator

15

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM16121 Pulley, idler 1 1 1 1 1
2 GM87599 Water Pump Pulley 1 1 1 1 1
3 GM19741 Pulley, idler 1 1 1 1 1
4 GM19742 Spacer, .437 ID x 2.343 in. 1 1 1 1 1
5 GM19743 Spacer, .437 ID x 2.906 in. 1 1 1 1 1
6 GM19744 Spacer, .437 ID x 3.718 in. 1 1 1 1 1
7 GM19746 Pulley, tensioner 1 1 1 1 1
8 GM19747 Spacer, alter. mtg .375 ID x 2.19 1 1 1 1 1
in.
9 GM19748 Brace, alternator 1 1 1 1 1
10 GM23423 Plate, idler 1 1 1 1 1
11 GM23422 Washer, idler 1 1 1 1 1
12 GM23421 Spacer, idler short 1 1 1 1 1
13 GM23420 Spacer, idler long 1 1 1 1 1
14 GM101417 Alternator 1 1 1 1 1
15 GM87590 Fan Belt 1 1 1 1 1
16 GM87682 Alternator Bracket 1 1 1 1 1
17 GM28959 Nut, M6-1.0 2 2 2 2 2
18 GM23738 Bolt, head head, M8-1.25 x 30 1 1 1 1 1
19 GM72312 Nut, M8-1.25 flange serrated 1 1 1 1 1
20 GM61733 Washer 1 1 1 1 1
21 GM72313 Washer, lock M10 5 5 5 5 5
22 GM73559 Bolt 2 2 2 2 2
23 GM23739 Nut, M10 x 1.5 2 2 2 2 2
24 GM101429 Bolt 1 1 1 1 1
25 GM23740 Bolt, M10-1.5 x 120, gr. 5 3 3 3 3 3

38 TP-6846 8/16
 1--18: Turbo/Exhaust Adapter
3

2
4
5

7 6
Items not shown: 8

38080838

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM75188 Bracket, Lifting Eye 1 1 1 1 1
2 GM75189 Bracket, Exhaust Support 1 1 1 1 1
3 GM75183 Adapter, Turbo Exh Casting 1 1 1 1 1
4 # Washer, Flat 7/16” (Hardened) 2 2 2 2 2
5 # Bolt, 7/16-14 x 6 Hex Head 2 2 2 2 2
6 # Bolt, M10-1.50 x 25 Hx Hd Gr8.8 3 3 3 3 3
7 GM72313 Washer, lock M10 3 3 3 3 3
8 # Nut, 7/16-14 Flange head 2 2 2 2 2

TP-6846 8/16 39
 1--20--1: Turbocharger

15

8
10
7

13

14
12
11
3
1
4

38080468

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM28893 Clamp, hose, 1 1/4 in. 2 2 2 2
2 GM28897 Turbocharger 1 1 1 1
3 GM28899 Plate assembly, oil drain 1 1 1 1
4 GM28901 Hose, oil drain, 7/8 in. ID, 3 in.
5 GM28903 Fitting, oil supply turbo 1 1 1 1
6 GM28906 Sensor, map 1 1 1 1
7 GM28914 Hose 1 1 1 1
8 GM29601 Clamp, 2 3/4-3 5/8 in. 1 1 1 1
9 GM29603 Clamp, 1 9/16-2 1/2 in. 1 1 1 1
10 GM28930 Clamp, V–band, 2 3/4 in. 1 1 1 1
11 GM72311 Bolt, M8-1.25 x 20 hxhd gr 8.8 2 2 2 2
12 GM61733 Washer 2 2 2 2
13 GM23739 Nut, M10 x 1.5 4 4 4 4
14 GM72315 Stud, M10-1.50 x 40, grade 8.8 4 4 4 4
15 GM87688 Turbo Supply Hose 1 1 1 1

40 TP-6846 8/16
 1--20--1: Turbocharger

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM39220 Clamp, hose S-12 1 1/4 in. 2 2 2 2
1 GM28893 Clamp, hose, 1 1/4 in. 2 2 2 2
2 GM28897 Turbocharger 1 1 1 1
3 GM28901 Hose, oil drain, 7/8 in. ID, 3 in. 1 1 1 1
4 GM28903 Fitting, oil supply turbo 1 1 1 1
5 GM28906 Sensor, map 1 1 1 1
6 GM28930 Clamp, V–band, 2 3/4 in. 1 1 1 1
7 GM101422 Seal, Map Sensor 1 1 1 1
8 GM101423 Tube, Turbo 1 1 1 1
9 GM72311 Bolt, M8-1.25 x 20 hxhd gr 8.8 2 2 2 2
10 GM61733 Washer 2 2 2 2
11 GM23739 Nut, M10 x 1.5 4 4 4 4
12 GM72315 Stud, M10-1.50 x 40, grade 8.8 4 4 4 4
13 GM72357 Hose, Teflon 28 in. 1 1 1 1

TP-6846 8/16 41
 1--20--2: Turbocharger Inlet

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM24342 Fitting 1 1 1 1
2 GM101416 Fitting 1 1 1 1
3 GM101448 Elbow Mixer To Turbo 1 1 1 1

42 TP-6846 8/16
 1--21: Intake Crossover

1 4

38080831

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM75143 Tube, Turbo to Throttle Body 1
2 # Bolt 1/4-20x5/8 Flange Hd Ser 1
3 GM72302 Sensor, T map 3-bar 1
4 GM29601 Clamp, 2 3/4-3 5/8 in. 2
5 GM29600 Elbow, Rubber 90 deg. Tube to 1
Throttle

TP-6846 8/16 43
 1--22: Charge Air Cooler Tubing

7
3

12

1 11
13

6
9

10

14
38080647

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM16144 Clamp, hose 1” 4 4
2 GM39417 Hose, heater 3/8 in. ID, rubber
19 in.
3 GM39417 Hose, heater 3/8 in. ID, rubber
19 in.
4 GM72286 Hose, heater 1 in. ID 1 1
5 GM72287 Hose, sil 2.5 ID x 3 lined (black) 3 3
6 GM87595 Turbo Tube 1 1
7 GM87596 Intake Tube 1 1
8 GM87597 Radiator Inlet Hose 1 1
9 GM87598 Radiator Outlet Hose 1 1
10 GM72289 Ftg, 3/8 in. hse brb x 1/4 in. mpt, 4 4
brs
11 GM28895 Clamp, hose, 13/16-1 1/2 in. 2 2
12 GM28914 Hose 1 1
13 GM29601 Clamp, 2 3/4-3 5/8 in. 7 7
14 GM29603 Clamp, 1 9/16-2 1/2 in. 5 5

44 TP-6846 8/16
 1--23: Breather
3
1 2

2 4
9

8
7

6
7 38080708

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM28949 Ftg, 5/8 bd hse x 3/8 MPT x 90 1 1 1 1
2 GM28893 Clamp, hose, 1 1/4 in. 2 2 2 2
3 GM24351 Hose, elbow 1 1 1 1
4 GM29847 Fitting, 1/2 x 5/8 in., 90 deg. elb 1 1 1 1
5 GM73575 Separator filter assembly 1 1 1 1
6 GM70877 Filter, GM 8.1L Turbo Poly. CCV 1 1 1 1
7 GM28895 Clamp, hose, 13/16-1 1/2 in. 2 2 2 2
8 GM75186 Hose, 1” Molded Breather 1 1 1 1
9 GM16213 Bushing, reducing 3/4”-1/2” 1 1 1 1

TP-6846 8/16 45
 1--23: Breather

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM16144 Clamp, hose 1” 2 2 2 2
2 GM28895 Clamp, hose, 13/16-1 1/2 in. 2 2 2 2
3 GM69492 Tube, 0.625 ID x 14” 1 1 1 1
4 GM101414 Insulation 17” 1 1 1 1
5 GM101415 Fitting 1 1 1 1
6 # Tie, zip 4 4 4 4
7 GM88418 Bracket, Breather 8.1L 1 1 1 1
8 GM88419 Hose, Breather 8.1L 1 1 1 1
9 GM88420 Filter, Air / Oil Separator 1 1 1 1
10 GM101425 Insulation, 7 in. 1 1 1 1
11 GM16225 Washer, flat 3/8” (hardened) 2 2 2 2
12 GM88421 Bolt, M10-1.5x25 Flange Hd 2 2 2 2
13 GM78170 CCV Insulation Wrap 2 2 2 2

46 TP-6846 8/16
 1--24: Throttle Body

10

3 7

11 5

6
12

1
8

38080466

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM75125 Bushing, 3/8MPT X 1/4FPT 1 1 1 1
2 GM29586 Valve, throttle, 60 mm 1 1 1 1
3 GM29592 Gasket (manifold adapter) 1 1 1 1
4 GM87605 Throttle Body Adaptor 1 1 1 1
5 GM87606 Elbow Gasket 1 1 1 1
6 GM39601 Sensor, temperature 1 1 1 1
7 GM29609 Sensor, inlet air 1 1 1 1
8 GM72303 Sender, oil pressure 1 1 1 1
9 GM28963 Washer, lock M6 4 4 4 4
10 GM72316 Bolt, M6-1.0 x 50 skt hd 4 4 4 4
11 GM72327 Bolt, M6-1.0 x 20 flange head 4 4 4 4
12 GM72328 Nut 3 3 3 3

TP-6846 8/16 47
 1--24: Throttle Body

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM75125 Bushing, 3/8MPT X 1/4FPT 1 1 1 1 1
2 GM29586 Valve, throttle, 60 mm 1 1 1 1 1
3 GM29592 Gasket (manifold adapter) 1 1 1 1 1
4 GM87605 Throttle Body Adaptor 1 1 1 1 1
5 GM87606 Elbow Gasket 1 1 1 1 1
6 GM60247 Temp Send Unit E-Controls 1 1 1 1 1
7 GM29609 Sensor, inlet air 1 1 1
8 GM72303 Sender, oil pressure 1 1 1 1 1
9 GM28963 Washer, lock M6 4 4 4 4 4
10 GM72316 Bolt, M6-1.0 x 50 skt hd 4 4 4 4 4
11 GM72327 Bolt, M6-1.0 x 20 flange head 4 4 4 4 4

48 TP-6846 8/16
 2--1: Cylinder Head

1
5

8
4

13

14

7
6

3 12

10

11

88083502

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87591 Bolt Head Kit 2 2 2 2 2
2 GM87611 Plug 2 2 2 2 2
3 GM87641 Seal 16 16 16 16 16
4 GM87642 Spring 16 16 16 16 16
5 GM87643 Retainer 16 16 16 16 16
6 GM87645 Core Plug 2 2 2 2 2
7 GM87646 Dowell 4 4 4 4 4
8 GM87678 Key 16 16 16 16 16
9 GM87679 Exhaust Valve 8 8 8 8 8
10 GM87680 Intake Valve 8 8 8 8 8
11 GM87683 Cylinder Head Gasket (LT) 1 1 1 1 1
12 GM87684 Cylinder Head Gasket (RT) 1 1 1 1 1
13 GM87694 Valve Spring Shim 16 16 16 16 16
14 GM87703 Cylinder Head 2 2 2 2 2

TP-6846 8/16 49
 2--1: Cylinder Head

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM87611 Plug 2 2 2 2 2
2 GM87641 Seal 16 16 16 16 16
3 GM87645 Core Plug 2 2 2 2 2
4 GM87646 Dowell 4 4 4 4 4
5 GM87679 Exhaust Valve 8 8 8 8 8
6 GM87680 Intake Valve 8 8 8 8 8
7 GM87683 Cylinder Head Gasket (LT) 1 1 1 1 1
8 GM87684 Cylinder Head Gasket (RT) 1 1 1 1 1
9 GM18923 Bolt, cylinder head 8 8 8 8 8
10 GM18922 Bolt, cylinder head 4 4 4 4 4
11 GM18921 Bolt, cylinder head 24 24 24 24 24
12 GM101457 Spring, Valve 16 16 16 16 16
13 GM101458 Retainer, Valve Spring 16 16 16 16 16
14 GM101459 Key 32 32 32 32 32
15 GM101476 Head, Cylinder 2 2 2 2 2
16 GM101477 Shim, Valve Spring 16 16 16 16 16

50 TP-6846 8/16
 2--2: Valve Actuation

7 6
88084000

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87647 Lifter Guide 8 8 8 8 8
2 GM87648 Lifter Tray 1 1 1 1 1
3 GM87649 Bolt 4 4 4 4 4
4 GM87650 Rocker Bolt 16 16 16 16 16
5 GM87668 Rocker Valve 16 16 16 16 16
6 GM87686 Lifter Valve 16 16 16 16 16
7 GM87696 Intake Push Rod 8 8 8 8 8
8 GM87697 Exhaust Push Rod 8 8 8 8 8

TP-6846 8/16 51
 2--2: Valve Actuation

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM87647 Lifter Guide 8 8 8 8 8
2 GM87648 Lifter Tray 1 1 1 1 1
3 GM87649 Bolt 4 4 4 4 4
4 GM87686 Lifter Valve 16 16 16 16 16
5 GM101465 Valve 16 16 16 16 16
6 GM101471 Push Rod (Exhaust) 8 8 8 8 8
7 GM101470 Push Rod (Intake) 8 8 8 8 8

52 TP-6846 8/16
 2--3: Engine Cover

6
8

11 10

9 1

88085001

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87652 Valley Cover 1 1 1 1 1
2 GM87653 Bolt 14 14 14 14 14
GM87654 Spark Plug Wire 8 8 8 8 8
4 GM87655 Bolt 16 16 16 16 16
5 GM87657 Valve Cover Gasket 2 2 2 2 2
6 GM87658 Bolt 14 14 14 14 14
7 GM87659 Ignition Coil 8 8 8 8 8
8 GM87660 Oil Fill Cap 1 1 1 1 1
9 GM87666 Intake Manifold Gasket 2 2 2 2 2
10 GM87676 Valve Cover 1 1 1 1 1
11 GM87677 Valve Cover 1 1 1 1 1

TP-6846 8/16 53
 2--3: Engine Cover

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM87653 Bolt 14 14 14 14 14
2 GM87654 Spark Plug Wire 8 8 8 8 8
3 GM87655 Bolt 16 16 16 16 16
4 GM87658 Bolt 14 14 14 14 14
5 GM87659 Ignition Coil 8 8 8 8 8
6 GM101460 Cover, Valve W / Oil Fill 1 1 1 1 1
7 GM87666 Intake Manifold Gasket 2 2 2 2 2
8 GM87676 Valve Cover 1 1 1 1 1
9 GM101449 Cap, Oil 1 1 1 1 1
10 GM101456 Cover, Valley 1 1 1 1
10 GM101466 Cover, Valley 1 1 1 1 1
11 GM101452 Gasket, V/Cover 2 2 2 2 2
12 GM101453 Grommet, V/Cover 14 14 14 14 14

54 TP-6846 8/16
 2--4: Water Pump

88085500

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87661 Water Pump 1 1 1 1 1
2 GM87662 Fastener 3 3 3 3 3
3 GM87693 Bolt 1 1 1 1 1
GM18963 Water Pump Gasket 2 2 2 2 2

TP-6846 8/16 55
 2--4: Water Pump

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM87661 Water Pump 1 1 1 1 1
2 GM87662 Fastener 3 3 3 3 3
3 GM87693 Bolt 1 1 1 1 1
GM18963 Water Pump Gasket 2 2 2 2 2

56 TP-6846 8/16
 2--5: Coolant Crossover Pipe

3 1 2

88086001

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87601 Clamp 1 1 1 1 1
2 GM87603 Clamp 1 1 1 1 1
3 GM87656 Bypass Hose 1 1 1 1 1
4 GM87663 Bolt 4 4 4 4 4
5 GM87695 Coolant Pipe 1 1 1 1 1
6 GM87698 Gasket 2 2 2 2 2

TP-6846 8/16 57
 2--5: Coolant Crossover Pipe

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM101461 Pipe, Crossover 1 1 1 1 1
2 GM87663 Bolt 4 4 4 4 4
3 GM101410 Clamp 1 1 1 1 1
4 GM87601 Clamp 1 1 1 1 1
5 GM87653 Bolt 1 1 1 1 1
6 GM101464 Plug 1 1 1 1 1
7 GM87611 Plug 1 1 1 1 1
8 GM18964 Gasket, engine coolant 2 2 2 2 2
crossover
9 GM99156 Hose 1 1 1 1 1

58 TP-6846 8/16
 2--6: Intake Manifold

88086500

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87611 Plug 2 2 2 2 2
2 GM87664 Intake Manifold 1 1 1 1 1
3 GM87665 Bolt 10 10 10 10 10

TP-6846 8/16 59
 2--6: Intake Manifold

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM101463 Manifold, Intake 1 1 1 1 1
2 GM87611 Plug 2 2 2 2 2
3 GM101450 Bolt 10 10 10 10 10
4 GM101451 Washer 10 10 10 10 10

60 TP-6846 8/16
 2--7: Sensors and Spark Plugs, Oil Filter
2

88087000

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87592 Oil Filter 1 1 1 1 1
2 GM87608 Spark Plug 8 8 8 8 8
3 GM87616 Bolt 1 1 1 1 1
4 GM87674 Crank Sensor 1 1 1 1 1

TP-6846 8/16 61
 2--7: Sensors and Spark Plugs, Oil Filter

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM87592 Filter 1 1 1 1 1
2 GM87608 Spark Plug 8 8 8 8 8
3 GM87613 Bolt 1 1 1 1 1
4 GM101454 Sensor, Crk/Shf 1 1 1 1 1

62 TP-6846 8/16
 2--8: Flywheel

88087500

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM75071 Flywheel 1 1 1 1 1
2 GM87673 Bolt 6 6 6 6 6

TP-6846 8/16 63
 2--8: Flywheel

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM75071 Flywheel, Eng 1 1 1 1 1
2 GM87673 Bolt 6 6 6 6 6

64 TP-6846 8/16
 2--9: Cylinder Block

5 10 11

3
4
12

1 9 6 2

88080001

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87611 Plug 2 2 2 2 2
2 GM72314 Plug, pipe 3/8 in. int. Manifold 3 3 3 3 3
3 GM87620 Core Plug 8 8 8 8 8
4 GM87621 Cam Bore Plug 1 1 1 1 1
5 GM87622 Oil Plug 14 14 14 14 14
6 GM87623 Bypass Valve 2 2 2 2 2
7 GM87667 Bearing Set 1 1 1 1 1
8 GM87670 Dowell 2 2 2 2 2
9 GM87671 Adapter 1 1 1 1 1
10 GM87699 Oil Jet 7 7 7 7 7
11 GM87700 Oil Jet 1 1 1 1 1
12 GM87702 Crankcase 1 1 1 1 1

TP-6846 8/16 65
 2--10: Crankshaft

88080500

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87624 Crankshaft Seal 1 1 1 1 1
2 GM87644 Crank Bearing Set 1 1 1 1 1
3 GM87619 Crankshaft 1 1 1 1 1

66 TP-6846 8/16
 2--10: Crankshaft

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM101462 Crankshaft 1 1 1 1 1
2 GM87624 Crankshaft Seal 1 1 1 1 1
3 GM101455 Ring, Crankshaft 1 1 1 1 1
4 GM101475 Bearing, Main 1 1 1 1 1

TP-6846 8/16 67
 2--11: Camshaft

4
3

88081000

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87625 Camshaft 1 1 1 1 1
2 GM87626 Retainer 1 1 1 1 1
3 GM87627 Bolt 2 2 2 2 2
4 GM87675 Pin 1 1 1 1 1

68 TP-6846 8/16
 2--11: Camshaft

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM87625 Camshaft 1 1 1 1 1
2 GM87626 Retainer 1 1 1 1 1
3 GM87627 Bolt 2 2 2 2 2

TP-6846 8/16 69
 2--12: Piston & Rods

5 3 4
2 1

88081502

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87587 Rod Assembly 8 8 8 8 8
2 GM87681 Rod Bearing 8 8 8 8 8
3 GM87690 Piston 8 8 8 8 8
4 GM87691 Piston Ring Set 1 1 1 1 1
5 GM87692 Pin 8 8 8 8 8

70 TP-6846 8/16
 2--12: Piston & Rods

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM101473 Rod, Connecting 8 8 8 8 8
2 GM87690 Piston 8 8 8 8 8
3 GM87691 Piston Ring Set 8 8 8 8 8
4 GM87692 Pin 8 8 8 8 8
5 GM101472 Bearing, C/Rod 8 8 8 8 8

TP-6846 8/16 71
 2--13: Oil Pump
2

88082000

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87628 Bolt 1 1 1 1 1
2 GM87675 Pin 2 2 2 2 2
3 GM87687 Oil Pump Tube 1 1 1 1 1

72 TP-6846 8/16
 2--13: Oil Pump

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM87628 Bolt 1 1 1 1 1
2 GM87675 Pin 2 2 2 2 2
3 GM101469 Pump, Oil 1 1 1 1 1

TP-6846 8/16 73
 2--14: Crankshaft Balancer

3 4

88082501

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87634 Washer 1 1 1 1 1
2 GM87635 Bolt 1 1 1 1 1
3 GM87636 Key 1 1 1 1 1
4 GM87587 Rod Assembly 1 1 1 1 1

74 TP-6846 8/16
 2--14: Crankshaft Balancer

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM87634 Washer 1 1 1 1 1
2 GM87635 Bolt 1 1 1 1 1
3 GM87588 Balancer 1 1 1 1 1

TP-6846 8/16 75
 2--15: Front Drive

5
7
1

88082502

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87616 Bolt 1 1 1 1 1
2 GM87629 Bolt 3 3 3 3 3
3 GM87630 Front Cover 1 1 1 1 1
4 GM87631 Gasket 1 1 1 1 1
5 GM87632 Seal 1 1 1 1 1
6 GM87633 Cover Bolt 6 6 6 6 6
7 GM87672 Camshaft Sensor 1 1 1 1 1
8 GM87675 Pin 2 2 2 2 2
9 GM87701 Timing Set 1 1 1 1 1

76 TP-6846 8/16
 2--15: Front Drive

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM87613 Bolt 1 1 1 1 1
2 GM87629 Bolt 3 3 3 3 3
3 GM87631 Gasket 1 1 1 1 1
4 GM87632 Seal 1 1 1 1 1
5 GM87655 Bolt 6 6 6 6 6
6 GM87672 Camshaft Sensor 1 1 1 1 1
7 GM87675 Pin 2 2 2 2 2
8 GM101474 Timing Set, Cam Sprocket 1 1 1 1 1
9 GM87630 Front Cover 1 1 1 1 1

TP-6846 8/16 77
 2--16: Oil Pan

5 1

88083002

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87637 Oil Pan 1 1 1 1 1
2 GM87638 Oil Pan Gasket 1 1 1 1 1
3 GM87639 Drain Plug 1 1 1 1 1
4 GM87640 Bolt 12 12 12 12 12
5 GM87685 Washer 1 1 1 1 1

78 TP-6846 8/16
 2--16: Oil Pan

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM87638 Oil Pan Gasket 1 1 1 1 1
2 GM87639 Drain Plug 1 1 1 1 1
3 GM87629 Bolt 12 12 12 12 12
4 GM18989 Pan, oil (includes 1 1 1 1 1
pan,plug,gasket)
5 GM87685 Washer 1 1 1 1 1

TP-6846 8/16 79
 2--17: Oil Pump Drive

88084500

Engine Number/Qty.
Item Part No. Description GM77414--1 GM77528--1 GM77528--2 GM77529--1 GM77529--2
1 GM87629 Bolt 1 1 1 1 1
2 GM87651 Oil Pump Drive 1 1 1 1 1
3 GM87669 Oil Pump Shaft 1 1 1 1 1

80 TP-6846 8/16
 2--17: Oil Pump Drive

Engine Number/Qty.
Item Part No. Description GM99488--2 GM99488--1 GM99487--1 GM99486--1 GM99486--2
1 GM87629 Bolt 1 1 1 1 1
2 GM87651 Oil Pump Drive 1 1 1 1 1
3 GM101467 Shaft, Oil Pump 1 1 1 1 1
4 GM101468 Retainer, Oil Pump Shaft 1 1 1 1 1

TP-6846 8/16 81
 Notes

82 TP-6846 8/16
 Notes

TP-6846 8/16 83
 KOHLER CO. Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KOHLERPower.com
Kohler Power Systems
Asia Pacific Headquarters
TP-6846 8/16b 7 Jurong Pier Road
Singapore 619159
E 2013, 2014, 2016 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455