Generac Power Systems 0H0923PMNL User manual

0h0923PMNL
6.8l i t e r
GAS ENGINE
PARTS
MANUAL
Ford
Engine Part Number Note:
Engine Assembly Build Date From 1/1/2009 to
present is Generac P/N: 0H0923

6.8L Gas Engine Table of Contents
QUICK REFERENCE GUIDE................................................................................................................................... 1
6.8L GAS ENGINE ................................................................................................................................................... 2
CYLINDER BLOCK .................................................................................................................................................. 4
CYLINDER HEAD..................................................................................................................................................... 6
TIMING COVER........................................................................................................................................................ 8
PISTON, ROD AND CRANK .................................................................................................................................. 10
TIMING GEARS...................................................................................................................................................... 12
CAMSHAFT ............................................................................................................................................................ 14
BALANCE SHAFT .................................................................................................................................................. 15
ROCKER COVER ................................................................................................................................................... 16
OIL PUMP............................................................................................................................................................... 17
OIL PAN .................................................................................................................................................................. 18
CRANKCASE VENTILATION ................................................................................................................................. 19
OIL FILTER ............................................................................................................................................................. 20
WATER PUMP ........................................................................................................................................................ 22
THERMOSTAT ........................................................................................................................................................ 23
DAMPER/PULLEY .................................................................................................................................................. 24
INTAKE MANIFOLD................................................................................................................................................ 25
IGNITION SYSTEM ................................................................................................................................................ 26
Legend
“A/R” AS REQUIRED
“STD” STANDARD SIZE
“O.S.” OVERSIZE
“U.S.” UNDERSIZE
“NA” NOT AVAILABLE
NOTE
The information in this manual is known to be accurate as of the date of release shown on the
cover. However, engineering changes can occur without notice. To obtain the proper parts,
please be sure to use the serial number of the unit being serviced when ordering from this
manual.
All other parts not shown in this manual can be found in the Owner's Manual for the
unit being serviced. Owner's Manuals can be found at:
www.generac.com

1
6.8L Gas Engine Quick Reference Guide
QUICK REFERENCE ENGINE PARTS
ENGINE IDENTIFICATION
Description Part Number Special Notes
Scheduled Maintenance Kit 0G15870ESV Oil Filter, Spark Plugs, Air Filter
Oil Filter 0D5419 Oil capacity – see owner's manual
Air Cleaner Element 0F5419
V-Belt See owner's manual
Thermostat 0F2844 Coolant capacity – see owner's manual
Thermostat O-ring 0F2843
Starter Motor 0D5418
Spark Plug 0D34540186 Spark plug gap – see owner's manual
ENGINE
SIZE: 6.8 Liter FUEL: LP/NG MAKE: Ford ENGINE P/N: 0H0923
Left Side Valve Cover ENGINE SERIAL NUMBER
ENGINE ASSEMBLY
BUILD DATE
SECONDARY ENGINE
PART NUMBER
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.

2
6.8L Gas Engine
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.

ITEM PART NO. DESCRIPTION QTY
6006 0H09230158 LONG BLOCK A/R
6009 0H09230114 SHORT BLOCK A/R
3
6.8L Gas Engine
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.

4
6.8L Gas Engine Cylinder Block
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.

ITEM PART NO. DESCRIPTION QTY
6A008 0D34540108 DOWEL, HEAD TO BLOCK 4
6010 0H09230149 BARE BLOCK 1
6026 0F7316B111 PLUG, 1.75SS, CUP, 4 LEFT, 4 RIGHT,2REAR 10
6026 0H09230164 PLUG, 13.84MM, CUP, FRONT 2
6026 0D34540103 PLUG, 3/8-18X.425 SOCKET HEAD 2
6026 0E96180118 PLUG, 38.3MM, CUP, SS, 1 FRONT, 1 REAR 2
6345 0F19600111 BOLT, MAIN CAP, M10X1.5X94.5, HEX HEAD*** 11
6345 0F19600113 STUD BOLT, M8X1.25XM10X1.5X126*** 1
6345 0F1960A176 BOLT, MAIN CAP, M9X1.25X53 HEX HEAD*** 12
6A346 0D34540145 DOWEL, MAIN CAP 12
8555 0H09230166 TUBE, WATER, FOR HEATER 1
18663 0H09230137 TUBE, WATER 1
6397 0F97650111 PIN, DOWEL, TO TIMING CVR.,8.0X45.5 (HM2) 2
NOT SHOWN 0H09230201 NUT, M12 4
NOT SHOWN 0H09230202 BOLT, MOUNT TO BLOCK,M10X1.5X28.5 4
NOT SHOWN 0H09230191 BOLT, MOUNT TO BLOCK,M10X1.5X70 4
HM1 0H09230193 PIN, DOWEL, TO TIMING CHAIN GUIDES 2
HB1 0H09230198 SCREW, KNOCK SENSOR, M8X30MM 1
*** DO NOT RE USE MAIN BEARING CAP BOLTS
5
6.8L Gas Engine Cylinder Block
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.

6
6.8L Gas Engine Cylinder Head
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.

7
6.8L Gas Engine Cylinder Head
ITEM PART NO. DESCRIPTION QTY
6049 0H09230159 HEAD, CYLINDER, RH, BARE 1
6049 0H09230160 HEAD, CYLINDER, LH, BARE 1
6049 0H09230117 HEAD, CYLNDR, RH, W/VALVES & CAMSHAFT 1
6049 0H09230118 HEAD,CYLNDR, LH, W/VALVES & CAMSHAFT 1
6051 0D34540170 GASKET, CYLINDER HEAD, RH 1
6051 0D34540171 GASKET, CYLINDER HEAD, LH 1
6057 0F1960A196 INSERT, INTAKE VALVE SEAT 10
6057 0F1960A197 INSERT, EXHAUST VALVE SEAT 10
6065 0F19600105 HEAD BOLT, LONG,M11X1.5X213.5,HH,FLANGE 24
6L293 0F19600124 BOLT, CAM CAPS, M6X1.0X42.5 26
HB1 0D34540176 BOLT, BALANCE SHAFT CAPS, M6X1.0X84.5 6
6A008 0D34540108 PIN, DOWEL, HEAD TO BLOCK 4
6026 0D34540166 PLUG, CYLNDR HEAD PRESS. RELIEF, 11.4MM CUP 4
6026 0E96180118 PLUG, 38.3MM CUP, STAINLESS STEEL 2
6026 0F97650114 PLUG, OIL GALLERY, 3/8-16 PIPE or is it 3/8-18 pipe? 4
NOT SHOWN 0D34540187 PLUG, PIPE, 1/8-27 SOCKET HEX 2
6505 0D34540178 VALVE, EXHAUST 10
6507 0D34540179 VALVE, INTAKE 10
6510 0D34540180 BUSHING, VALVE GUIDE, INTAKE&EXHAUST 20
6571 0F19600130 SEAL, VALVE STEM 20
6513 0D34540181 SPRING, VALVE 20
6514 0D34540182 RETAINER, VALVE SPRING 20
6518 0D34540183 LOCK, VALVE SPRING 40
6C501 0D34540177 ADJUSTER, VALVE LASH 20
6564 0D34540184 ARM, ROCKER 20
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.

8
6.8L Gas Engine Timing Cover
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.

9
6.8L Gas EngineTiming Cover
ITEM PART NO. DESCRIPTION QTY
6019 0D34540205 COVER & GASKETS, FRONT 1
6020 0D34540206 GASKET, FRONT COVER, LH 1
6020 0D34540207 GASKET, FRONT COVER, CENTER 1
6020 0D34540208 GASKET, FRONT COVER, RH 1
6B288 0D34540230 SENSOR, CAM 1
6C315 0F73160110 SENSOR, CRANK 1
6700 0D34540217 TIMING COVER CRANKSHAFT SEAL 1
HB1 0F19600134 SCREW/WASHER, FRONT CVR, M10X1.5X103.1 3
HB2 0F73160125 BOLT, FRONT COVER, M8X1.25X53 A/R
NOT SHOWN 0F19600135 STUD, FRONT CVR, M10X1.5X1.5X103.1 2
HS1 0F73160111 BOLT, CAM AND CRANK SENSORS TO TIMING CVR, M6X1.0X27.5 2
HT1 0F19600236 STUD, WASHER, FRNT CVR, M10X1.5/M8X1.25X106.7 5
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.

10
6.8L Gas Engine Piston, Rod and Crank
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.

11
6.8L Gas Engine Piston, Rod and Crank
ITEM PART NO. DESCRIPTION QTY
6108 0F19600136 PISTON, STANDARD 10
6108 0H09230204 PISTON, .010"/.25MM 0/S A/R
6108 0H09230205 PISTON, .020/.50MM O/S A/R
6135 0F19600137 PIN, PISTON 10
6140 0D34540113 RETAINER, PISTON PIN 20
6148 0F19600138 RINGSET, STANDARD(SET IS FOR 2 PISTONS) 5
6148 0F1960A143 RINGSET, .010/.25MM O/S A/R
6148 0F1960A144 RINGSET, .020"/.50MM O/S A/R
6200 0F1960A153 ROD ASSY., CONNECTING 10
6214 0D34540120 BOLT, CONNECTING ROD 20
6207 0F19600139 BUSHING, PIN 10
6211 0F73160117 BEARING, ROD, STANDARD 20
6211 0F1960A141 BEARING, ROD, .020"/.50MM UNDERSIZE A/R
6303 0D34540122 CRANKSHAFT 1
6D309 0F19600142 BEARING KIT, MAIN, STANDARD GRADE 1 A/R
6D309 0F1960A120 BEARING KIT, MAIN, STANDARD GRADE 2 A/R
6D309 0F1960A121 BEARING KIT, MAIN, STANDARD GRADE 3 A/R
6D309 0H09230121 BEARING KIT,MAIN .010"0R .25MM U/S, GRADE 1 A/R
6D309 0H09230122 BEARING KIT,MAIN .010"0R .25MM U/S, GRADE 2 A/R
6D309 0H09230123 BEARING KIT, MAIN .010" OR .25MM U/S GRADE 3 A/R
6D309 0H09230224 BEARING KIT, MAIN, .020" OR .50MM, UNDERSIZE A/R
6D309 0H09230209 BEARING KIT, MAIN, .030" OR .75MM UNDERSIZE A/R
6701 0D34540126 SEAL, CRANKSHAFT REAR OIL 1
6K301 0F73160148 RETAINER, REAR OIL SEAL 1
NOT SHOWN 0F97650111 PIN,DOWEL,REAR CRANKSHAFT SEAL RETAINER 2
NOT SHOWN 0F73160111 BOLT, REAR CRANKSHAFT SEAL RETAINER, M8X1.0X27.5 6
6306 0D34540216 GEAR, CRANKSHAFT TIMING 1
6B316 0F73160147 KEY, WOODRUFF, CRANKSHAFT, 3/16"X1.40" 1
6310 0F19600146 SLINGER, REAR CRANKSHAFT, OIL 1
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.

12
6.8L Gas Engine Timing Gears
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.

13
6.8L Gas Engine Timing Gears
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.
ITEM PART NO. DESCRIPTION QTY
6K255 0D34540209 `ARM, TIMING CHAIN, TENSIONER, RH 1
6M256 0F19600147 GUIDE, TIMING CHAIN, RH 1
6L266 0D34540211 TENSIONER, TIMING CHAIN, LH 1
6L266 0D34540212 TENSIONER, TIMING CHAIN, RH 1
6256 0D34540190 GEAR, CAM RH 1
6256 0D34540191 GEAR, CAM LH 1
6268 0F19600150 CHAIN, TIMING 2
6M274 0D34540214 ARM, TIMING CHAIN TENSIONER, LH 1
6K297 0F19600152 GUIDE, TIMING CHAIN, LH 1
6278 0D34540193 WASHER, CAMSHAFT, 13.5X48.5X5.3 1
6279 0D34540204 BOLT, CAM SPROCKET, M10X1.5X47.5, HEX HEAD 2
6306 0D34540216 SPROCKET, CRANK 1
NOT SHOWN 0H09230172 RING, IGNITION PULSE, CRANK PULSE SENSOR 1
HB4 0E96180124 BOLT, TIMING CHAIN GUIDES, 1LH,2RH, M6X1.0X22.5 3
HB3 0D34540220 BOLT, TIMING CHAIN GUIDES, LH, M6X1.0X67.5 1
HB2 0H09230203 BOLT, TENSIONER, M8X1.25X53 4
HB1 0D34540221 BOLT M8 X 1.25 X 53MM A/R
6P250 CONTACT PARTS 2

14
6.8L Gas Engine Camshaft
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.
ITEM PART NO. DESCRIPTION QTY
6250 0D34540188 CAMSHAFT, RH 1
6250 0D34540189 CAMSHAFT, LH 1
6265 0D34540192 SPACER, CAM GEAR, RH 1

15
6.8L Gas Engine Balance Shaft
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.
ITEM PART NO. DESCRIPTION QTY
6A303 0D34540194 GEAR, BALANCE SHAFT, ON CAMSHAFT 1
6A304 0D34540195 GEAR, BALANCE SHAFT, ON BALANCE SHAFT 1
6A311 0D34540196 BALANCE SHAFT & GEAR 1

16
6.8L Gas Engine Rocker Cover
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.
ITEM PART NO. DESCRIPTION QTY
6582 0D34540199 COVER, ROCKER & GASKET, RIGHT 1
6582 0H09230132 CVR, RKR & GSKT, LEFT, (AFTER 05/04) 1
6C519 0H09230213 "A" STUD&GROMMET, RKR CVR TO HEAD A/R
6C519 0H09230212 "B" BOLT & GROMMET, RKR CVR TO HEAD A/R
6A892 0H09230218 GROMMET, PCV VALVE 1
6763 0H09230154 TUBE, EXTENSION, OIL/2007 1
6766 0D34540203 CAP, OIL FILLER 1

17
6.8L Gas Engine Oil Pump
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.
ITEM PART NO. DESCRIPTION QTY
6600 0F73160179 PUMP ASSY., OIL 1
HB1 0F73160180 BOLT, OIL PUMP, M6X1.0X42.5, HEX 3
6622 0F19600165 SCREEN & COVER 1
HS1 0F73160111 BOLT, PICK UP TUBE TO BLOCK, M8X1.0X27.5, HEX HEAD 2
6626 0D34540148 SEAL, SCREEN AND COVER 1
HM1 0D34540160 SPACER, SCREEN & COVER, M8X1.25X19 1
HB2 0D34540162 BOLT, SCREEN & COVER TO SPACER, M8X1.25X19 HEX 1

18
6.8L Gas Engine Oil Pan
Note: The right and left banks of engine are determined by viewing the engine from the flywheel side.
ITEM PART NO. DESCRIPTION QTY
6675 0D34540150 PAN, OIL 1
6710 0D34540151 GASKET, OIL PAN 1
HB1 0F19600170 BOLT, OIL PAN, M8X30, HEX FLANGE HEAD 18