Service Parts. General Motors 4.3 L Powertrain EPA Certified Engines. Engine. Engine Model: Generator Models: 38RCL 40/45REZG 40/45ERES.

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1 Service Parts Engine Engine Model: General Motors 4.3 L Powertrain EPA Certified Engines Generator Models: 38RCL 40/45REZG 40/45ERES TP /b

2 Table of Contents Description Page Introduction... 3 Number System Significance... 3 Illustrations... 3 How to Find Part Numbers... 3 Hardware References... 3 Model Index : Dipstick : Starter : Fan Spacer : Lifting Eye, Idler, Belt : Flywheel Adapter : Flywheel/Housing : Exhaust Manifold : Exhaust Pipe : Thermostat : High Voltage Switch (HVS) : Electrical : Ignition System : Fuel System : Pulley Assembly : Alternator : Engine Block/Lower End... --: Engine Head/Upper End... 4

3 This manual lists service replacement parts for General Motors 4.3L engines. Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever. This manual includes the following main sections: Table of Contents. Lists the sections of the manual. Introduction (and other information sections). Contains introductory material about part numbers, illustrations, and hardware. Index. Lists the engine models and groups. Group Parts Lists. List the part numbers of parts in the groups. Numbering System Significance This manual uses the following numbering systems: Model. The product identification number located on the nameplate. Engines break down into groups. Group Number. A unique number representing a parts group needed to assemble a generator set function. For example, Group -- is the Starter group. Part Number. The part number identifies an individual assembly, subassembly, component, or accessory kit. Introduction Illustrations Illustrations (or exploded-view drawings) best representing the widest range of variations accompany most groups in this manual. Illustrations do not depict all details and may not show all parts. Do not substitute illustrations for assembly or disassembly. How to Find Part Numbers Use the following steps to locate a service replacement part.. Locate the nameplate to identify the model number.. Turn to the Model Index. The first column identifies the groups of parts that make up the engine. The headings identify the models. 3. Find the group variation number at the intersection of the group row and the model column. Note the variation number. 4. Page forward to locate the group and variation identified above or find the appropriate page in the Table of Contents. 5. Find the part on the illustration and note the item number of the part or find the part description in the parts list. TP / 3

4 Model Index Variation Model Group Description 38RCL 40REZG 45REZG -: Dipstick : Starter : Fan Spacer : Lifting Eye, Idler, Belt : Flywheel Adapter : Flywheel/Housing : Exhaust Manifold : Exhaust Pipe : Thermostat : High Voltage Switch (HVS) Coil & Distributor : Electrical : Ignition System : Fuel System : Pulley Assembly : Alternator : Engine Block/Lower End 4.3 L 4.3 L 4.3 L -: Engine Head/Upper End 4.3 L 4.3 L 4.3 L 4 TP /

5 Variation: : Dipstick GM75 Clamp, Dipstick GM759 Tube, Dipstick 3 GM67 Dipstick, oil 4.3L 4 # Bolt /4-0x5/8 Flange Hd Ser # Common hardware; procure locally. TP / 5

6 Variation: : Starter GM678 Starter GM7378 Bolt, starter 6 TP /

7 Variation: : Fan Spacer GM5969 Spacer, fan GM5970 Bolt, Fan 4 TP / 7

8 Variation: : Lifting Eye, Idler, Belt Items not shown: # Bolt, 3/8-6 x / HxHd Gr 5 3 GM6956 Washer, 3/8 4 3 GM490 Washer,flat3/8SAE 4 4 GM67 Bracket, exhaust/lifting eye 5 GM673 Spacer,.75 OD x.38 ID x GM63 Belt, fan standard 7 GM63 Bracket, pulley 8 GM5974 Nut, 3/8-6 # Common hardware; procure locally. 8 TP /

9 Variation: : Lifting Eye, Idler, Belt GM8507 Belt, Alt TP / 9

10 Variation: : Flywheel Adapter GM755 Adapter # Bolt, 3/8-6 x Skt Hd Gr8 4 # Common hardware; procure locally. 0 TP /

11 Variation: : Flywheel/Housing 3 4 Items not shown: GM756 Housing, SAE3 Universal GM754 Plate, Cover F/W 3 GM7598 Bolt, M0-.50 x 30 SkHd Gr # Bolt, /4-0x/ Flange Hd Ser 4 5 # Bolt,5/8-8xHxHdZinc # Common hardware; procure locally. TP /

12 Variation: : Exhaust Manifold See Group GM698 Manifold, exhaust GM6 Shield, heat exhaust ( wire) 3 GM67 Shield, heat exhaust ( wire) 4 GM64 Bolt, 3/8-6 x hex hd grade 5 5 GM65 Washer, flat 3/8 (hardened) 6 GM7578 Kit, Exhaust Hardware (includes 3 nut, stud, spring) 7 GM7580 Gasket, Exh Manifold (dual) 8 GM7579 Gasket, Exh Manifold (single) TP /

13 Variation: : Exhaust Pipe GM645 Clamp, muffler 3 GM608 Pipe, Y 3 GM65 Seal, exhaust 4 GM490 Washer,flat3/8SAE 5 # Nut, Lock 3/8-6 w/o Nyl Insrt # Common hardware; procure locally. TP / 3

14 Variation: : Thermostat # Bolt, 3/8-6 x 3 /4 HxHd Gr.5 GM6956 Washer, 3/8 3 GM60 Cover, thermostat 4 GM6536 Gasket, water outlet 5 GM6537 Thermostat, engine cooling 6 GM648 Spacer, thermostat cover # Common hardware; procure locally. 4 TP /

15 Variation: : High Voltage Switch (HVS) Items not shown: 6, GM7554 Distributor, HVS Ignition GM756 Yoke, HVS Dist Alignment 3 GM7564 Coil, Ignition HVS 4 GM7563 Bracket, Ignition coil 5 GM65 Washer, flat 3/8 (hardened) 6 GM73 Bolt, M8-.5 x 0 flange head 7 # Bolt, 3/8-6x Flange Hd Ser # Common hardware; procure locally. TP / 5

16 Variation: : Electrical Items not shown: 9, 0,,, 3, GM79 Sensor, O GM9608 Sensor, coolant 3 GM7303 Sender, oil pressure 4 GM65 Washer, flat 3/8 (hardened) 5 GM7544 Bracket, Lifting Eye 6 GM9604 Isolator, relay box 7 GM7538 Harness Stationary, IEPR 8 GM750 Oil Pressure Fitting 9 GM434 Fitting 0 GM7503 Nut, Flange /4-0 Serrated # Washer, Star 3/8 # Bolt, 3/8-6x3/4 Flange Hd Ser 3 # Bolt, /4-0x3/8 Flange Hd Ser 4 # Bolt, 3/8-6x Flange Hd Ser # Common hardware; procure locally. 6 TP /

17 Variation: : Ignition System Items not shown: GM65 Retainer, spark plug wire (3) GM655 Retainer, spark plug wire 3 GM7 Spark plug 6 4 GM7553 Retainer, Wire Spark Plug 6 5 GM7556 Wires, Spark Plug HVS 6 GM7557 Retainer, Spark Plug Wire(3) 7 GM7560 Loom, Split /4 46 in. 8 # Bolt, /4-0x/ Flange Hd Ser 4 # Common hardware; procure locally. TP / 7

18 Variation: : Fuel System Items not shown: 5, 6, 0, 5, 6, 7, 8, 9, 30, 3, GM657 Elbw, PCV sys 5/8 in. 45 deg. GM4579 Hose, fuel 3/8 in. 3 GM4579 Hose, fuel 3/8 in. 4 GM9586 Valve, throttle, 60 mm 5 GM898 Fitting, /8 NPT x 3/8 in. 6 GM69487 Ftg, /8NPT x 3/8 90 deg. elbow nylon 7 GM69488 Clamp, hose 3/8 (spring type) 4 8 GM69489 Clamp, hose 5/8 (spring type) 9 GM69490 Adapter, barb 5/8 to 3/8 nylon 0 GM6038 Gasket, man. adapter venturi GM6949 Tube, 0.65 ID x 3 in. GM69495 EPR assembly GM7584 EPR assembly (dual fuel) 3 GM69498 Throttle adapter 4 GM69506 Adapter, 4.3L intake to 44mm TB 5 GM69507 Mixer, 4.3L Emissions 6 GM7568 Adapter, EPR, 3/4 NPT 7 GM695 Sensor, bar TMAP 8 GM7380 Gasket, manifold 9 GM695 Elbow, PCV 0 GM6953 Bolt, M6 x.0 x 5 skt hd, gr GM6957 Bolt, 5/6-8 x 3/4 skt hd, gr. 5 4 GM6959 Washer, flat, /4 3 GM47684 Bolt, /4-0 x in. skt. hd. gr GM6950 Bolt, M6 x.0 x 6 hx hd, gr GM6954 Bolt,M4x.70x6shthd 4 6 GM6955 Stud,M6x.0x GM6956 Nut, M6 hex, flanged 4 8 GM7548 Ftg, /8NPT x 3/8Hs 45 deg. 9 GM69504 O-ring 30 GM7550 Spacer 3 GM755 Screw, Tabulated M4 X 3 GM66 Plug, /8 8 TP /

19 Variation: : Pulley Assembly 6 7 See Group GM67 Pulley, fan GM63 Pulley, crankshaft/fan 3 GM630 Washer, crankshaft pulley 4 # Bolt, 7/6-0 x /4 HxHd Gr8 5 # Bolt, 3/8-4 x SktHd Grade GM73 Bolt, M8-.5 x 0 hxhd gr GM6733 Washer 4 # Common hardware; procure locally. TP / 9

20 Variation: : Alternator Items not shown: 3, 4, 5, 6, GM680 Alternator, 70 amp GM66 Pulley, tensioner 3 GM6 Pulley, idler 4 GM490 Washer,flat3/8SAE 4 5 GM6 Bracket, alternator 6 GM68 Spacer, mount, 0 mm 7 GM683 Block, mount 8 GM68 Spacer, mount, 8 mm 9 # Bolt, M8-.5 x 0 HxHd Gr8.8 0 # Bolt, M8-.5 x 50 HxHd Gr 8.8 # Bolt, 3/8-6 x 4 / HxHd Gr 5 3 GM73 Nut, M8-.5 flange serrated 3 GM6733 Washer 4 # Bolt, M0-.50 x 90 HxHd Gr8.8 5 GM733 Washer, lock M0 6 GM6956 Washer, 3/8 3 7 # Bolt, M0-.50 x 85 HxHd Gr8.8 8 GM8959 Nut, M6-.0 # Common hardware; procure locally. 0 TP /

21 Notes TP /

22 Variaton: 4.3 L -: Engine Block/Lower End _ TP /

23 Variaton: 4.3 L -: Engine Block/Lower End GM644 Ring kit, piston std. 6 GM6444 Ring kit, piston (0.50 mm OS) 6 GM644 Piston kit, eng (std) 6 GM756 Piston kit, eng (0.7mm OS) 6 GM6445 Piston kit, eng (0.5mm OS) 6 3 GM757 Rod, conn 6 4 GM75046 Bolt, conn rod (mj9x x43) 6 5 GM75089 Bearing kit, conn rod (std) 6 8 Block, eng (incls:bearing, cm/shf/cap, crlshf (only)/bolt, crishf/plug, eng blk core) 9 GM74998 Plug, eng blk oil gal (rr) LH 0 GM6397 Plug, camshaft rear bearing hole GM6599 Pin, crnkshft rear oil seal locator GM6547 Pin, cylinder head locator 4 3 GM38899 Pin 4 GM6585 Plug, eng blk core hole (brass) 5 GM750 Valve, oll fltr bypass 6 GM7509 Pin, cm/shf spkt 8 GM75065 Camshaft 9 GM7535 Chain kit, tmg (w/spkts) 0 - Sprocket, cm/shft (see chain kit) - - Spricket, cr/shft GM6593 Bolt, camshaft sprocket 3 3 GM6356 Bolt, camshaft retainer 4 GM6368 Retainer, camshaft 5 GM643 Bearing, camshaft (# posn) 6 GM643 Bearing, camshaft(# posn, Axxxxxxx on housing flange) 6 GM6433 Bearing, camshaft(# posn, housing flange is blank) 7 GM643 Bearing, camshaft(#3 posn, housing flange is blank) 7 GM6433 Bearing, camshaft(#3 posn, Axxxxxxx on housing flange) 8 GM643 Bearing, camshaft (#4 posn) 3 GM75087 Gasket, w/pmp (part of 35) 3 GM646 Bolt, water pump 3/8-6 x GM680 Stud, water pump RH 35 GM7536 Pump kit, water 36 GM6589 Shaft, oil pump drive 37 GM6476 Pin, locator /4 x 5/8 38 GM6583 Retainer, oil pump drive shaft 39 GM648 Pump, oil (.74 dia. tube) 40 GM6347 Bolt, oil pump 7/6-4 x 3/8 4 GM6478 Screen, oil pump 4 GM6580 Plug, oil pressure relief valve bore 43 GM757 Valve, oil press rlf (part of 39, 47) 44 GM75093 Spring, oil press rlf vlv 45 GM64 Bolt, oil pump cover 46 GM6549 Pin, oil press rlf vlv spr st (part of 39, 47) 47 GM6376 Cover, oil pump 48 GM6503 Fitting, oil filter 49 GM835 Filter, oil 50 GM75008 Gear, flywhl ring (part of 08) 5 GM75005 Weight, flywhl (barrel-shaped AR pin,.65 long) 5 GM74996 Weight, flywhl (pin groove) AR (barrel-shaped pin (groove-f) 5 GM75047 Bolt, flywhl (7/6-0 x 3/3) 6 53 GM7503 Pin, flywhl loc 54 - Seal, cr/shf rr oil (part of 7) - 55 GM6495 Crankshaft, (incl 53) 56 GM75003 Pin, eng frt cvr loc 57 GM75079 Gasket, eng frt cvr 58 GM750 Balancer, crishf 60 GM75037 Bolt, eng frt 6 6 GM75078 Cover, eng frt 6 GM6498 Key, crankshaft balancer 63 GM754 Bearing kit, crishf (#,, 3) (std) 3 64 GM6447 Bearing kit, crankshaft (.00 mm OS) 65 GM6588 Bolt,crishfbrgcap Not sold separately 67 GM3898 Gasket, crkshft rear oil seal hsg 68 GM6389 Stud, crkshft rear oil seal retain 68 GM6389 Stud, cr/shf rr oil seal ret (/4-0x34) 69 GM6505 Bolt, crankshaft rear oil seal housing 70 GM6506 Bolt, crankshaft rear oil seal housing 7 GM7508 Housing, crishf rr oil seal (incl 54, 68) 7 - Not sold separately 73 GM7506 Bolt, oil pan bfl (m6xx6,.7 AR od 74 GM75080 Gasket, oil pan 76 GM757 Pan, oil (incl 77, 78) 77 GM75088 Seal, oil pan drn plug (o ring) 78 - not used 79 GM660 Bolt, oil pan not used 8 GM65 Plug, 476 x.3 83 GM38955 Seal, cr/shf frt oil 84 GM7500 Nut, crishf rr oil seal ret 86 GM75009 Washer, o/pmp cvr (part of #39) 3 88 GM6359 Bolt, balancer shaft gear 89 GM7505 Gear kit, balr shf (lncls drive &driven gr) 90 GM6357 Retainer, balancer shaft 9 GM639 Balancer, internal 9 GM6397 Plug, camshaft rear bearing hole 93 GM75090 Bearing kit, balr shf (incls rr brg, instr sh & spacer) 94 GM653 Bolt, balancer shaft retainer 95 - See item not used 05 GM6483 Gasket, water pump cover 07 GM75035 Bolt, w/pmp cvr (/4-0x 0.6, 0.5 thd) 07 GM660 Bolt, water pump cover 6 08 GM75063 Flywheel, eng (incls ring gear) 09 Plug, eng blk cool drn hole (/4-8 nptf thd) 3 GM6388 Grommet, engine front cover 6 4 GM7506 Bearing, clu pilot 0 GM6355 Bearing, balancer shaft front - See item Bolt, gr/shf posn sen 7 GM7508 Sensor, cr/shf posn 3 GM7564 Shoe, tmg chain tensr 3 GM653 Bolt, balancer shaft retainer 33 GM7563 Bracket, tmg belt tensr TP / 3

24 Variaton: 4.3 L -: Engine Head/Upper End 6370_ 4 TP /

25 Variaton: 4.3 L -: Engine Head/Upper End GM6470 Cover, valve rocker arm RH GM7565 Cover, vlv rkr arm LH GM75066 Cap, oil fil 3 - See Group See Group See Group See Group -0 9 GM638 Grommet, valve rocker arm cover GM650 Plug, 3/8-8 x.4 AR GM75045 Plug AR 3 GM6454 Bolt, intake manifold 8 4 GM75085 Manifold, int 5 GM6448 Gasket kit, int manif (incls intake manifold gaskets) 7 GM638 Bolt, valve rocker arm cover 6 GM6383 Gasket, valve rocker arm cover 3 GM6373 Bolt, cy. hd, lg (7/6-4x3 5/64) 0 4 GM6374 Bolt, cy. hd, md (7/6-4x3 /6) 4 5 GM6375 Bolt, cy. hd, short (7/6 x 3/4) See Group GM6456 Valve, exhaust (std) 6 9 GM640 Valve, intake standard 6 30 GM654 Lifter, valve 3 GM6400 Rod, valve push 33 GM6465 Gasket, cylinder head 34 GM6486 Head, cylinder 36 GM6385 Seal, intake valve stem oil 6 37 GM6386 Spring, valve (w/o damper) 39 GM6385 Seal, intake valve stem oil 6 39 GM6496 Seal, exh vlv stem oil 6 4 GM659 Key, valve stem 4 4 GM640 Cap, valve spring 46 - not used 47 - not used 63 - not used 64 - See Group See Group - 78 GM6396 Grommet, PCV valve - not used 95 GM6459 Guide, valve lifter push rod 96 GM653 Bolt, balancer shaft retainer 96 GM657 Bolt, valve lifter guide 97 GM75058 Nipple, htr inl hose 98 GM7508 Clamp, w/pmp inl hose 99 GM7509 Hose, w/pmp inl (incl clamps) 05 GM6485 Support, valve rocker arm 06 GM75084 Arm, vlv rkr (incl 07) 07 - Bolt, vlv rkr arm piv (part of 06) - GM753 Gasket kit, cyl hd ( head gaskets, intake manif gaskets, valve stem seals TP / 5

26 Notes 6 TP /

27 Notes TP / 7

28 TP /b 00, 0 by Kohler Co. All rights reserved. KOHLER CO. Kohler, Wisconsin Phone , Fax For the nearest sales and service outlet in the US and Canada, phone KohlerPower.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 6959 Phone (65) , Fax (65)

Service Parts. Engine. Engine Model: General Motors 5.0/5.7 L Powertrain EPA Certified Engines. Generator Models:

Service Parts. Engine. Engine Model: General Motors 5.0/5.7 L Powertrain EPA Certified Engines. Generator Models: Service Parts Engine Engine Model: General Motors 5.0/5.7 L Powertrain EPA Certified Engines Generator Models: 8/60RCL 50/60REZG(B) 50/60ERES(B) 80REZGB/D 80RZGD 80ERESB/D 00REZGB/D 00RZGD 00ERESB/D TP-67