FPT Engine Service Manual F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

FPT Industrial Engine Service Manual F5HFL463 F5HFL464 F5GFL463 F5GFL464 F5DFL463 F5DFL464

FPT Industrial S.P.A. Italy FPX

FPT Industrial Engine Parts Contact Phone: 269 673 1638 Email: engineparts2@gmail.com www.FPTIndustrialEngineParts.com

Printed in U.S.A. Copyright © 2012 CNH America LLC. All Rights Reserved.

Case is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A.

F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Engine - Service limits Timing Intake - Start before Top Dead Center (TDC) - End after Bottom Dead Center (BDC) Exhaust - Start before BDC - End after TDC

19 ° 37 ° 61 ° 21 °

Fuel system Injection Type Nozzle type Injection sequence

Bosch CP4.1 Bosch CRI2.2 1-3-4-2

Cylinder block and piston Cylinder bore Pistons - Outside diameter - Pin bore Clearance between cylinder bore and piston Piston protrusion Piston pin Clearance between piston pin and bore Piston ring lands - Top - Middle - Bottom Piston rings - Top - Middle - Bottom Clearance between Rings and Lands - Top - Middle - Bottom Piston ring end gap - Top - Middle - Bottom Camshaft bore inside diameter -1 - 2-3-4 -5 Camshaft Journals -1 - 2-3-4 -5 Clearance between cam bearings and journals Cam lift - Intake - Exhaust Tappets - Housing - Tappet (Upper and Lower) - Tappet (Middle) Clearance between tappets and housing

99.000 - 99.020 mm (3.8976 - 3.8984 in) 98.908 - 98.918 mm (3.8940 - 3.8944 in) 36.003 - 36.009 mm (1.4174 - 1.4177 in) 0.082 - 0.112 mm (0.0032 - 0.0044 in) -0.22 - 0.07 mm (-0.0087 - 0.0028 in) 35.990 - 35.996 mm (1.4169 - 1.4172 in) 0.004 - 0.019 mm (0.0002 - 0.0007 in) 2.21 mm (0.0870 in) 2.050 - 2.070 mm (0.0807 - 0.0815 in) 2.540 - 2.560 mm (0.1000 - 0.1008 in) 2.068 - 2.097 mm (0.0814 - 0.0826 in) 1.970 - 1.990 mm (0.0776 - 0.0783 in) 2.470 - 2.490 mm (0.0972 - 0.0980 in) 0.06 - 0.100 mm (0.0024 - 0.0039 in) 0.06 - 0.100 mm (0.0024 - 0.0039 in) 0.05 - 0.09 mm (0.0020 - 0.0035 in) 0.20 - 0.35 mm (0.0079 - 0.0138 in) 0.60 - 0.80 mm (0.0236 - 0.0315 in) 0.30 - 0.60 mm (0.0118 - 0.0236 in) 59.222 - 59.248 mm (2.3316 - 2.3326 in) 50.069 - 50.119 mm (1.9712 - 1.9732 in) 40.069 - 40.119 mm (1.5775 - 1.5795 in) 53.995 - 54.045 mm (2.1258 - 2.1278 in) 49.975 - 50.025 mm (1.9675 - 1.9695 in) 39.975 - 40.025 mm (1.5738 - 1.5758 in) 0.038 - 0.162 mm (0.0015 - 0.0064 in) 6.213 mm (0.2446 in) 5.5105 mm (0.2169 in) 15.000 - 15.018 mm (0.5906 - 0.5913 in) 15.924 - 15.954 mm (0.6269 - 0.6281 in) 15.960 - 15.975 mm (0.6283 - 0.6289 in) 0.03 - 0.068 mm (0.0012 - 0.0027 in)

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F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Connecting rod Small end bearing housing Big end bearing housing Small end bearing inside diameter Small end bearing inside diameter (installed) Big end bearing thickness - Red - Blue - Green Clearance between piston pin and small end bearing Maximum allowable twist for connecting rod

39.460 - 39.490 mm (1.5535 - 1.5547 in) 67.833 - 67.841 mm (2.6706 - 2.6709 in) 39.570 - 39.595 mm (1.5579 - 1.5589 in) 36.010 - 36.020 mm (1.4177 - 1.4181 in) 1.875 - 1.884 mm (0.0738 - 0.0742 in) 1.883 - 1.892 mm (0.0741 - 0.0745 in) 1.891 - 1.900 mm (0.0744 - 0.0748 in) 0.011 - 0.024 mm (0.0004 - 0.0009 in) 0.09 mm (0.0035 in) @ 125 mm (4.9213 in)

Crankshaft Main journal diameter (1-2-3-4) Main journal diameter (5) Rod journals Main bearing thickness Main bore diameter (1-2-3-4) Main bore diameter (5) Clearance between main bearings and journals (1-2-3-4) Clearance between main bearings and journals (5) Clearance between rod bearing and journals Main journal width for thrust bearing on crankshaft Main journal width for thrust bearing in cylinder block Thrust bearing thickness Clearance between the crankshaft and thrust bearing

76.182 - 76.208 mm (2.9993 - 3.0003 in) 83.182 - 83.208 mm (3.2749 - 3.2759 in) 64.015 - 64.038 mm (2.5203 - 2.5212 in) 2.165 - 2.174 mm (0.0852 - 0.0856 in) 80.588 - 80.514 mm (3.1728 - 3.1698 in) 87.588 - 87.614 mm (3.4483 - 3.4494 in) 0.064 - 0.095 mm (0.0025 - 0.0037 in) 0.059 - 0.100 mm (0.0023 - 0.0039 in) 0.033 - 0.041 mm (0.0013 - 0.0016 in) 31.85 - 32.150 mm (1.2539 - 1.2657 in) 32.50 - 32.55 mm (1.2795 - 1.2815 in) 2.51 - 2.56 mm (0.0988 - 0.1008 in) 0.095 - 0.270 mm (0.0037 - 0.0106 in)

Cylinder head and valves Valve guide seats in cylinder head Valve Guides - Inside diameter - Outside diameter Intake valves - Valve stem diameter - Valve face angle Exhaust valves - Valve stem diameter - Valve face angle Clearance between valve stem and guide Valve seat in the cylinder head - Intake - Exhaust Intake valve seat - Outside diameter - Seat angle Exhaust valve seat - Outside diameter - Seat angle Valve recess - Intake - Exhaust Valve spring height - Free spring - Under a load of 256 - 284 N (58 - 64 lb) - Under a load of 500 - 556 N (112 - 125 lb) Injector protrusion Rocker Assembly

12.960 - 12.995 mm (0.5102 - 0.5116 in) 8.023 - 8.038 mm (0.3159 - 0.3165 in) 12.950 - 12.985 mm (0.5098 - 0.5112 in) 7.985 - 8.000 mm (0.3144 - 0.3150 in) 60 ° 7.985 - 8.000 mm (0.3144 - 0.3150 in) 60 ° 0.040 - 0.053 mm (0.0016 - 0.0021 in) 39.987 - 40.013 mm (1.5743 - 1.5753 in) 43.787 - 43.813 mm (1.7239 - 1.7249 in) 40.063 - 40.088 mm (1.5773 - 1.5783 in) 60 ° 43.863 - 43.880 mm (1.7269 - 1.7276 in) 60 ° 0.3 - 0.7 mm (0.0118 - 0.0276 in) 0.3 - 0.7 mm (0.0118 - 0.0276 in) 44.6 mm (1.756 in) 34 mm (1.339 in) 23.8 mm (0.937 in) 1.7 - 2.35 mm (0.0669 - 0.0925 in)

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Engine - Engine and crankcase

- Rocker Shaft Outside diameter - Rockers Clearance between rockers and shaft

18.979 - 19.000 mm (0.7472 - 0.7480 in) 19.020 - 19.033 mm (0.7488 - 0.7493 in) 0.020 - 0.054 mm (0.0008 - 0.0021 in)

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Engine - Engine and crankcase

Engine - Service instruction - Finding Top Dead Center (TDC) For engines with access to the timing hole in the flywheel housing 1.

Fit the tool 380000150 through the case (1) and into the port on the flywheel, as shown.

2.

Using the tool 380000988 (1) rotate the flywheel until the notch (2) is visible in the inspection hole and cylinder one is at TDC.

NHVM12ENG0004AA

1

For engines without access to the timing hole in the flywheel housing NOTE: Prior to performing this procedure, ensure that the engine is near cylinder one TDC on the compression stroke by verifying that both push rods or rocker arm assemblies on number one cylinder are loose. If both push rods or rocker arms are tight, rotate the engine one full revolution on the crankshaft, in the direction of normal operation, and re check the push rods or rocker arm assemblies.

1.

Fabricate a wire pointer (1) as shown and attach it to a front cover bolt (2) that is located close to the vibration damper (3). Position the pointer approximately 1.6 mm (0.0625 in) from the damper.

2.

Rotate the engine in the direction of normal operation.

3.

Pry down on the cylinder number one intake valve and insert a 6.35 mm (0.25 in) spacer between the valve stem and rocker arm tip to hold the valve open.

4.

Slowly rotate the engine to TDC by hand until the piston contacts the valve and stops rotation. Make a reference mark (1) on the damper at the pointer.

5.

Rotate the engine counter clockwise as viewed from the front.

6.

Remove the spacer.

7.

Rotate the engine clockwise approximately 90 ° past TDC.

8.

Pry down on cylinder number one intake valve and again insert the spacer between the valve stem and rocker arm tip to hold the valve open.

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93110987

2

93110988

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Engine - Engine and crankcase

9.

Slowly rotate the engine back to TDC by hand until the piston contacts the valve and stops rotation.

Make another reference mark (1) on the damper at the pointer.

10.

Rotate the engine clockwise.

11.

Remove the spacer.

12.

Use a flexible tape measure and make a reference mark (1) at the center point between the two marks made on the damper. This mark represents true TDC.

13.

Align the center damper mark to the pointer. This is cylinder number one at TDC on the compression stroke.

93110989

4

93110990

5

Engine - Engine and crankcase

Crankcase Bore - Measure Prior operation: Connecting rod and piston - Remove (10.105) 1.

Measure the inside diameter if the cylinder bores.

2.

Measurements must be taken following the diagram shown. All measurements should be between 99.000 - 99.020 mm (3.8976 - 3.8984 in).

3.

Replace the block if the measurements exceed the above values.

73092826A

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1

Engine - Cylinder heads F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Valve cover - Remove 1.

2.

Disconnect the electrical connections and wire ties from the following components: •

Camshaft speed sensor (1)

•

Crankshaft speed sensor (2)

•

Oil pressure sensor (3)

•

Fuel temperature sensor (4)

•

Fuel heater (if equipped)

•

High pressure pump metering unit (5)

•

Fuel pressure sensor (6) 1

83119804

2

83119802

3

83119805A

4

Unbolt the main connector bracket (1).

3.

Cut the wire ties (1).

4.

Unbolt the wire stands (2) from the top of the valve cover.

5.

83119804

Drape the wiring harness (1) over the Exhaust Gas Recirculation (EGR) cooler.

Engine - Cylinder heads

6.

Remove the high pressure fuel lines (1) from the common rail and injectors.

7.

Remove the high pressure supply line (2) from the common rail.

8.

Unbolt the fuel return manifold (1).

9.

Disconnect the fuel return lines (2) and (3).

10.

83119806

5

23118184

6

83119807

7

23118185

8

Unbolt the common rail (1) from the valve cover (2).

NOTE: If your machine uses a remote mounted fuel filter base, skip steps 11 and 12.

11.

Disconnect the fuel return and supply lines (1) from filter base.

12.

Remove the fuel filter base (2).

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Engine - Cylinder heads

13.

Remove the clamp (1) holding the fuel injector return line.

83119808

14.

9

Remove the blowby line (1). (If applicable)

15.

Remove the fuel injectors (1). Refer to Fuel injectors - Remove (10.218) for the proper procedure.

16.

Remove the valve cover bolts (2).

17.

Remove the valve cover (3).

23118186

10

83119809

11

Engine - Cylinder heads

Valve cover - Install 1.

Place the valve cover (3) on the cylinder head.

2.

Torque the bolts (2) to 20 - 30 N·m (15 - 22 lb ft).

NOTE: Do not install the two bolts used for mounting the common rail at this time.

3.

Install the fuel injectors (1). Refer to Fuel injectors - Install (10.218) for the proper procedure.

83119809

1

23118185

2

83119808

3

83119807

4

NOTE: If your machine uses a remote mounted fuel filter base, skip steps 4 and 5.

4.

Install the fuel filter base (2).

5.

Connect the fuel supply and return lines (1) to the filter base.

6.

7.

Install the clamp (1) holding the fuel injector return line.

Install the common rail (1) on the valve cover (2) and torque the bolts to 20 - 30 N·m (15 - 22 lb ft).

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Engine - Cylinder heads

8.

Connect the fuel return lines (2) and (3).

9.

Install the fuel return manifold (1).

10.

11.

23118184

5

83119806

6

23118186

7

83119802

8

Install the high pressure fuel lines (1) and (2) and torque the fittings to 20 - 30 N·m (15 - 22 lb ft).

Connect the blowby recirculation line. (If applicable)

12.

Install the wire stands (2) on the valve cover.

13.

Bundle the wires as shown and tie them to the wire stands using wire ties (1).

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Engine - Cylinder heads F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464 14.

Install the main harness connector bracket (1).

83119804

15.

9

Connect the electrical connections and wire ties to the following components: •

Camshaft speed sensor (1)

•

Crankshaft speed sensor (2)

•

Oil pressure sensor (3)

•

Fuel temperature sensor (4)

•

Fuel heater (if equipped)

•

High pressure pump metering unit (5)

•

Fuel pressure sensor (6) 83119804

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10

Engine - Cylinder heads

Cylinder head - Remove Prior operation: Rocker arm - Remove (10.106) 1.

Remove the bolts (2).

2.

Attach lifting eyes to the cylinder head (1).

3.

Lift the cylinder head from the block using a suitable lifting device.

NOTE: Light tapping may be required to release the cylinder head from the locating dowels.

4.

Remove the cylinder head gasket.

23119867

Next operation: Cylinder head - Install (10.101)

1

Engine - Cylinder heads

Cylinder head - Disassemble Prior operation: Cylinder head - Remove (10.101) 1.

Number the valves before removal to ensure the correct orientation during assembly.

NOTE: The intake valves (1) and the exhaust valves (2) are different sizes.

2.

Compress the valve spring (4) using tool (1).

3.

Remove the keepers (2).

4.

Release the tool (1) and remove the cap (3) and spring (4).

5.

Repeat the operation for each valve.

6.

73092871

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73092872

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73092871

3

Turn the cylinder head upside down and remove the valves (5).

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Engine - Cylinder heads

7.

Remove the valve stem seals (1) from the valve guides.

73092873

Next operation: Cylinder head - Assemble (10.101)

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4

Engine - Cylinder heads

Cylinder head - Check Prior operation: Cylinder head - Disassemble (10.101) 1.

Check the bottom surface of the cylinder head for flatness using a straight edge.

2.

Use feeler gauges to check the gaps between the straight and cylinder head surface.

3.

Machine the surface of the cylinder head if values exceeding 0.20 mm (0.008 in) are found.

NOTICE: Machining should not exceed 0.13 mm (0.005 in). Replace the cylinder head if the surface cannot be machined to specifications.

4.

Check the valve seats for cracks and wear.

Next operation: Valve guide - Measure (10.101)

Engine - Cylinder heads

Cylinder head - Assemble Prior operation: Cylinder head - Disassemble (10.101) 1.

Lubricate the valve stems (1) with clean engine oil.

2.

Install the valves in the order of disassembly.

3.

Install the valve stem seals (2) and (3) on the valve guide using tool 380000134.

4.

Place the spring (4) and the plate (3) over the valve stem.

5.

Compress the spring (4) using tool (1).

6.

Install the keepers (2) in the groves of the valve stem and release the spring pressure.

73092881

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73092872

2

NOTE: Place a small amount of grease on the inside of the keepers to hold them in place until the spring pressure is released.

Next operation: Cylinder head - Install (10.101)

Engine - Cylinder heads

Cylinder head - Install Prior operation: Cylinder head - Remove (10.101) 1.

Measure the piston protrusion.

2.

Refer to the table below to select the cylinder head gasket with the correct thickness.

(A) Piston protrusion 0.07 - -0.07 mm (0.0028 - -0.0028 in) -0.08 - -0.22 mm (-0.0031 - -0.0087 in) 3.

73092790

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73092791

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(B) Gasket thickness 0.80 mm (0.031 in) 0.70 mm (0.028 in)

Install the gasket (1) on the cylinder block.

NOTE: Be sure the gasket is fully seated on the locating dowels (2).

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Head Bolts F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

4.

Install the cylinder head (1) on the block while aligning the locating dowels.

NOTE: Always use new head bolts for assembly.

5.

6.

Lubricate the head bolts (2).

23119867

3

23110998

4

Torque the head bolts to the specifications shown in the table below following the order shown in the figure.

Bolt size Phase 1 - M15x1.5x193 - M12x1.5x165 Phase 2 - M15x1.5x193 - M12x1.5x165 Phase 3 - M15x1.5x193 - M12x1.5x165

Torque value

Order number 1,2,3,4,5,6 7,8,9,10

120 - 140 N·m (89 - 103 lb ft) 57 - 73 N·m (42 - 54 lb ft)

1,2,3,4,5,6 7,8,9,10

85 - 95 ° 85 - 95 °

1,2,3,4,5,6 7,8,9,10

85 - 95 ° 55 - 65 °

Next operation: Rocker arm - Install (10.106)

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Engine - Cylinder heads

Valves - Cleaning Prior operation: Cylinder head - Disassemble (10.101) 1.

Remove carbon deposits from the valves using a wire wheel.

2.

Check that the valves show no signs of seizure or cracking. Replace if any defects are found.

93107215

Next operation: Valves - Measure (10.101)

1

Engine - Cylinder heads

Valves - Measure Prior operation: Valves - Cleaning (10.101) 1.

Measure the valve stem (1) using a micrometer (2).

The standard value is 7.985 - 8.000 mm (0.314 0.315 in).

73092877

Next operation: Cylinder head - Assemble (10.101)

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1

Engine - Cylinder heads

Valves Spring - Measure Prior operation: Cylinder head - Disassemble (10.101) 1.

Use the table below to measure the valve spring height at specific loads. If the values below are not met, replace the spring.

73092880

Height (H) 44.6 mm (1.756 in) (H1) 34 mm (1.339 in) (H2) 23.8 mm (0.937 in) Next operation: Cylinder head - Assemble (10.101)

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Load 0 N (0 lb) 256 - 284 N (58 - 64 lb) 502 - 554 N (113 - 125 lb)

1

Engine - Cylinder heads

Valve guide - Measure Prior operation: Cylinder head - Disassemble (10.101) 1.

Measure the inside diameter of the valve guides.

2.

Replace the valve guides if the measurement is not within 8.023 - 8.038 mm (0.3159 - 0.3165 in).

73092878A

Next operation: Valve seat - Replace (10.101)

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1

Engine - Cylinder heads

Valve seat - Replace Prior operation: Cylinder head - Disassemble (10.101) NOTICE: Use caution to avoid damaging the cylinder head during this procedure.

1.

Remove as much material from the valve seats as possible without damaging the cylinder head.

2.

Drive the valve seats from the cylinder head using a punch.

3.

Heat cylinder head to 80 - 100 °C (176 - 212 °F) while cooling the valve seats.

4.

Drive in the new valve seats using an appropriate punch.

5.

Cut the valve seats to the specifications in the table below.

NHPH12ENG0015AA

Valve seat specifications Intake valve seat (A) - Outside diameter - Seat angle (2) Exhaust valve seat (B) - Outside diameter - Seat angle (3) Valve recess - Intake (1) - Exhaust (4) Next operation: Cylinder head - Assemble (10.101)

40.063 - 40.088 mm (1.5773 - 1.5783 in) 60 ° 43.863 - 43.880 mm (1.7269 - 1.7276 in) 60 ° 0.3 - 0.7 mm (0.0118 - 0.0276 in) 0.3 - 0.7 mm (0.0118 - 0.0276 in)

1

Engine - Pan and covers

Engine oil pan - Remove 1.

Drain the engine oil.

2.

Remove the bolts (2).

3.

Remove the oil pan (1) and plate (3).

NOTE: The figures provided are for reference only. The shape and dimension of the oil pan and the pick up tube may vary depending on engine application.

4.

Remove the pick up tube support bolts (1).

5.

Remove the bolt (2) and remove the pick up tube (3).

73092776

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73092777

2

Engine - Pan and covers

Engine oil pan - Install 1.

Install a new o-ring on the pick up tube (3).

2.

Install the oil pick up tube (3).

3.

Torque the tube bolt (2) to 10 N·m (7 lb ft).

4.

Torque the support bolts (1) to 45 N·m (33 lb ft).

5.

73092777

1

73092800

2

73092776

3

Install the new gasket (1) on the oil pan (2).

6.

Install the oil pan (1) with the plate (3).

7.

Torque the bolt (2) as follows: •

M10x1.5 = 45 N·m (33 lb ft)

•

M8x1.25 = 25 N·m (18 lb ft)

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Engine - Pan and covers

Engine block cover Front - Remove 1.

Remove the blowby re-circulation system. Refer to Blowby re-circulation system - Remove (10.304) for the proper procedure.

2.

Remove the crankshaft pulley (1)

3.

83119821

1

83119833

2

Remove the bolts (1).

NOTE: Take note of the bolt size and location.

4.

Remove the front cover (2).

Engine - Pan and covers

Engine block cover Front - Install 1.

Clean the sealing surfaces of the cover (1).

2.

Install the front cover (1) and gasket.

3.

Loosely install two bolts to hold everything in place.

4.

Install the blowby recirculation drive hub (1) and torque the nut to 80 N·m (59 lb ft).

5.

Install the lower alignment tool 380100280 (2) on the crankshaft.

6.

23118187

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83119823

2

83119828

3

83119829

4

Install the upper alignment tool 380100281 (1) onto the drive hub to align the front cover.

Engine - Pan and covers

7.

Install the remainder of the bolts and torque to 20 30 N·m (15 - 22 lb ft).

8.

Remove the alignment tools.

83119833

5

Engine - Pan and covers

Timing gear housing - Remove Prior operation: Engine block cover Front - Remove (10.102) 1.

Remove the fuel injection pump (1). Refer to Injection pump - Remove (10.218) for the proper procedure.

2.

Remove the fan pulley (2).

3.

23118180

1

23118181

2

23118182

3

Remove the idler gear (1) and camshaft gear (2).

4.

Remove the bolts (1) from the timing gear housing and the three bolts (3) through the oil pan.

5.

Remove the timing gear housing (2).

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Engine - Pan and covers

Timing gear housing - Install 1.

Clean the sealing surfaces of the timing gear housing and apply LOCTITE® 598 ULTRA BLACK sealant (1) as shown.

2.

Install the timing gear housing (2) onto the engine block.

3.

Torque the timing gear housing bolts (1) to 20 - 30 N·m (15 - 22 lb ft) and the three oil pan bolts (3) to 45 N·m (33 lb ft).

4.

Install the camshaft gear (2) and torque to 20 - 30 N·m (15 - 22 lb ft). Refer to Camshaft gear - Install (10.106) for the proper timing procedure.

5.

Install the idler gear (1) and torque to 50 N·m (37 lb ft)

6.

Install the fuel injection pump (1). Refer to Injection pump - Install (10.218) for the proper procedure.

7.

Install the fan pulley (2).

NHVM12ENG0022AA

1

23118182

2

23118181

3

23118180

4

Engine - Crankshaft and flywheel

Engine flywheel - Remove 1.

Install tool 380000732 (1) in the flywheel housing to lock the flywheel rotation.

NOTE: On some applications, tool 380000988 may be required to mount tool 380000732 to the starter flange on the flywheel housing.

2.

73092772

1

93111650

2

Loosen the flywheel (1) mounting bolts.

NOTE: Do not remove the bolts at this point.

3.

Install two medium length bolts into the threaded holes (3) in order to attach a lifting device.

4.

Remove two mounting bolts and install guide pins (2) in their place.

5.

Attach a lifting device.

6.

Remove the remaining mounting bolts.

7.

Slide the flywheel along the guide pins.

8.

Remove the flywheel from the engine.

Next operation: Engine flywheel - Install (10.103)

Engine - Crankshaft and flywheel

Engine flywheel - Install Prior operation: Engine flywheel - Remove (10.103) 1.

Install two guide pins (2) into the flywheel mounting holes on the crankshaft.

2.

Install two bolts (3) suitable for lifting in the threaded holes in the flywheel (1).

3.

Lift the flywheel up to the guide pins using a lifting device.

4.

Align the locating dowel on the crankshaft with the hole on the flywheel.

5.

Install tool 380000732 (1) in the flywheel housing to lock the flywheel rotation.

NOTE: On some applications, tool 380000988 may be required to mount tool 380000732 to the starter flange on the flywheel housing.

6.

Torque the bolts to 25 - 35 N·m (18 - 26 lb ft).

7.

Then, turn the bolts an additional 90 °

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93111650

1

Engine - Crankshaft and flywheel

Flywheel housing - Remove 1.

Remove the bolts (1).

NOTE: There are two oil pan bolts securing the flywheel housing from the bottom side of the engine.

2.

Remove the flywheel housing (2).

NOTE: Light taps with a plastic hammer may be necessary to break the seal from the engine block and to work the housing off of the locating dowels.

23119868

1

Engine - Crankshaft and flywheel

Flywheel housing - Install 1.

Clean the sealing surfaces (1) of the flywheel housing and the engine block.

2.

Apply LOCTITE® 5970 sealant in a consistent 1.5 mm (0.059 in) bead around the sealing surface of the flywheel housing.

NOTICE: Be sure there are no lumps, air bubbles or gaps.

Do not use too much sealer as it could squeeze from the surface and obstruct lubrication passages.

3.

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2

Install the flywheel housing (2) within 10 min of sealant application.

NOTE: Be sure the housing is fully seated on the locating dowels.

4.

Torque the bolts (1) to: •

M8x1.25 - 30 - 40 N·m (22 - 30 lb ft)

•

M12x1.75 - 115 - 125 N·m (85 - 92 lb ft)

Engine - Crankshaft and flywheel

Crankshaft oil seal Rear seal - Install NOTE: Install the crankshaft seal dry to ensure a proper seal.

1.

Install the inner part of tool 380100076 onto the crankshaft.

2.

Slide the seal over the tool and start it onto the crankshaft.

3.

Install the outer part of tool 380100076 and begin to drive the seal onto the crankshaft using the nut.

4.

Drive the seal in until the tool contacts the flywheel housing.

5.

Remove the tool.

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Engine - Crankshaft and flywheel

Crankshaft oil seal Front seal - Install NOTE: Install the crankshaft seal dry to ensure a proper seal.

1.

Install the inner part of tool 380100279 onto the crankshaft.

2.

Slide the seal over the tool and start it onto the crankshaft.

3.

Install the outer part of tool 380100279 and begin to drive the seal onto the crankshaft using the nut.

4.

Drive the seal in until the it contacts the lip on the inside of the front cover.

NOTICE: Do not over tighten the nut when installing the seal. Damage to the seal could occur.

5.

Remove the tool.

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Engine - Crankshaft and flywheel

Crankshaft - Remove Prior operation: Connecting rod and piston - Remove (10.105) 1.

Remove the main bearing caps (1).

2.

Remove the crankshaft (2) using a suitable lifting device.

23119865

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Engine - Crankshaft and flywheel

Crankshaft - Install Prior operation: Piston cooling Spray nozzle - Install (10.304) 1.

Lubricate the main bearings with clean engine oil.

2.

Install the crankshaft (2).

3.

Install the main bearing caps (1).

4.

Torque the bolts to 50 N·m (37 lb ft), then, 80 N·m (59 lb ft), then, turn the bolts an additional 90 °.

23119865

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Engine - Crankshaft and flywheel

Crankshaft Journal - Measure - Clearance Prior operation: Crankshaft - Remove (10.103)

Main journals 1.

Clean the crankshaft journals and main bearings.

2.

Place a piece of plastic gauge (3) on the surface of the journal (2) as shown.

3.

Install the main bearing caps (1).

4.

Lubricate the bolts (1).

5.

Torque the bolts to 45 - 55 N·m (33 - 41 lb ft).

6.

Then, torque the bolts to 74 - 86 N·m (55 - 63 lb ft)

7.

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73092844A

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73092845A

3

Then, turn the bolts an additional 90 °.

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Engine - Crankshaft and flywheel

8.

Remove the main bearing caps.

9.

Compare the widest point of the plastic gauge to the scale on the package (1).

10.

The width of the wire should be between:

11.

•

0.064 - 0.095 mm (0.0025 - 0.0037 in) for journals 1, 2, 3, 4

•

0.059 - 0.100 mm (0.0023 - 0.0039 in) for journal 5

Replace the bearings if the values above cannot be obtained and perform the procedure again.

73092846A

4

73092867

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73092868

6

Connecting rod journals 1.

Clean the crankshaft journals and connecting rod bearings.

2.

Place a piece of plastic gauge (3) on the surface of the journal (2) as shown.

3.

Install the connecting rod caps (1).

4.

Lubricate the bolts (1).

5.

Torque the bolts to 45 - 55 N·m (33 - 41 lb ft).

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Engine - Crankshaft and flywheel

6.

Then, turn the bolts an additional 70 °.

7.

Remove the connecting rod caps.

8.

Compare the widest point of the plastic gauge to the scale on the package (1).

9.

The width of the wire should be between 0.033 0.041 mm (0.0013 - 0.0016 in)

10.

Replace the bearings if the value above cannot be obtained and perform the procedure again.

Next operation: Crankshaft - Install (10.103)

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73092870

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Engine - Crankshaft and flywheel

Crankshaft - End play Prior operation: Crankshaft - Install (10.103) 1.

Install a dial gauge (1) with a magnetic base (2) on the cylinder block.

2.

Set the gauge perpendicular to the crankshaft (3) as shown.

3.

Push the crankshaft in towards the engine block and zero the dial gauge.

4.

Pull the crankshaft out towards the dial gauge.

5.

The measurement should be 0.095 - 0.270 mm (0.0037 - 0.0106 in). Replace the thrust bearing if necessary.

73092847A

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Engine - Connecting rods and pistons

Connecting rod and piston - Exploded view

73092848A

(1) (2) (3) (4)

Snap ring Pin Piston Piston rings

(5) (6) (7) (8)

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1

Bolts Half bearings Connecting rod Bushing

Engine - Connecting rods and pistons

Connecting rod and piston - Remove Prior operation: Cylinder head - Remove (10.101) 1.

Remove the bolts (1).

2.

Remove the connecting rod caps (2).

3.

Push the connecting rod and piston assembly out of the top of the cylinder.

NOTE: Keep the bearings matched to the connecting rod in case of reuse after the overhaul.

73092817

Next operation: Connecting rod and piston - Install (10.105)

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Engine - Connecting rods and pistons

Connecting rod and piston - Disassemble Prior operation: Connecting rod and piston - Remove (10.105) 1.

Check the piston for signs of seizing, scoring or cracking. Replace if necessary.

2.

Remove the piston rings (2) using the tool 380000324 (1).

3.

4.

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Remove the snap rings (1).

Remove the piston pin (1).

NOTE: It may be necessary to lightly tap the pin to remove.

Next operation: Connecting rod and piston - Assemble (10.105)

Engine - Connecting rods and pistons

Connecting rod and piston - Assemble Prior operation: Connecting rod and piston - Disassemble (10.105) 1.

Install the piston pin (3) through the piston (2) and connecting rod (4).

NOTE: Use the markings on the piston (1) to correctly orient the piston on the connecting rod. The (→) marks the front of the engine as viewed from the top.

2.

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Install the snap rings (1).

3.

Install the piston rings (1) using the tool 380000221 (2).

4.

Arrange the rings so the end gaps are 120 ° apart.

Next operation: Connecting rod and piston - Install (10.105)

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Engine - Connecting rods and pistons

Connecting rod and piston - Install Prior operation: Connecting rod and piston - Remove (10.105) 1.

Install the bearings (1) on the connecting rod and cap.

2.

Lubricate the piston skirts, rings and the inside of the cylinder bores.

3.

Set the crankshaft for the cylinder to be installed to Bottom Dead Center (BDC).

4.

Align the notch in the piston skirt with the oil spray nozzle.

5.

Orient the openings in the piston rings 120 ° apart.

6.

Install the piston ring compressor 380000220.

7.

Push the connecting rod and piston assembly into the cylinder bore.

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NOTE: Lightly tapping the top of the piston with a wooden dowel may be necessary.

8.

Install the connecting rod cap.

NOTICE: The connecting rods are fracture split. Ensure the cap is seated correctly prior to torquing the bolts.

9.

Torque the bolts to 50 N·m (37 lb ft) then 70 °.

Next operation: Engine oil pan - Install (10.102)

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Engine - Connecting rods and pistons

Piston - Measure Prior operation: Connecting rod and piston - Disassemble (10.105) 1.

Measure the diameter of the piston (1) using a micrometer (2).

NOTE: The diameter of the piston must be measured at the point shown in the figure for accurate measurement.

2.

The diameter should be between 98.908 - 98.918 mm (3.8940 - 3.8944 in). Replace if necessary.

73092850

Next operation: Connecting rod and piston - Assemble (10.105)

1

Engine - Connecting rods and pistons

Piston Pin - Measure Prior operation: Connecting rod and piston - Disassemble (10.105) 1.

Measure the diameter of the piston pin (1) with a micrometer (2).

2.

The pin diameter should be between 36.003 - 36.009 mm (1.4174 - 1.4177 in). Replace if necessary.

3.

Lubricate the pin (1) and the pin housing with clean engine oil.

4.

Insert the pin into the piston. It must be inserted with slight finger pressure and it should not come out by gravity.

Next operation: Connecting rod and piston - Assemble (10.105)

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73092853

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73092854

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Engine - Connecting rods and pistons

Piston Ring - Measure Prior operation: Connecting rod and piston - Disassemble (10.105) 1.

Measure the thickness of the piston ring (2) with a micrometer (1).

2.

The thickness should be as follows. Replace if necessary.

3.

•

Top – 2.068 - 2.097 mm (0.0814 - 0.0826 in)

•

Middle – 1.970 - 1.990 mm (0.0776 - 0.0783 in)

•

Bottom – 2.470 - 2.490 mm (0.0972 - 0.0980 in)

73092855

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73092858

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73092856

3

Insert the rings (2), one at a time into the cylinder bore (3).

NOTE: Square the rings in the bore by inserting the piston upside down.

4.

Measure the ring end gap using feeler gauges (1).

5.

The end gap should be as follows. Replace if necessary.

6.

•

Top – 0.20 - 0.35 mm (0.0079 - 0.0138 in)

•

Middle – 0.60 - 0.80 mm (0.0236 - 0.0315 in)

•

Bottom – 0.30 - 0.60 mm (0.0118 - 0.0236 in)

Measure the clearance between the rings (3) and lands on the piston (2) with a feeler gauge (1).

NOTE: The top ring has a "V" shape. Refer to steps 8 - 11 to properly measure the top ring.

7.

The clearance should be as follows. Replace if necessary.

•

Middle – 0.06 - 0.100 mm (0.0024 - 0.0039 in)

•

Bottom – 0.05 - 0.09 mm (0.0020 - 0.0035 in)

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Engine - Connecting rods and pistons

8.

Install the top ring (2) on the piston (1).

9.

Install the piston into the cylinder bore (3) leaving the top ring exposed halfway.

10.

Measure the clearance (X) using feeler gauges.

11.

The clearance should be as follows. Replace if necessary.

•

Top – 0.06 - 0.100 mm (0.0024 - 0.0039 in)

73092857

Next operation: Connecting rod and piston - Assemble (10.105)

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4

Engine - Valve drive and gears

Rocker arm - Remove 1.

Remove the valve cover (1). Refer to Valve cover Remove (10.101) for the proper procedure.

2.

Remove the bolts (1).

3.

Remove the rocker assembly (2).

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83119807

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83119810

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Engine - Valve drive and gears

Rocker arm - Install 1.

Install the rocker assembly (2).

2.

Torque the bolts (1) to 7 N·m (5 lb ft) then to 10 N·m (7 lb ft).

NOTE: Valve clearance is hydraulically adjusted. Therefore, no manual adjustment is required.

3.

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Install the valve cover (1). Refer to Valve cover Install (10.101) for the proper procedure.

Engine - Valve drive and gears

Camshaft Push rod - Remove Prior operation: Rocker arm - Remove (10.106) 1.

Remove the push rods (1).

23119867

Next operation: Camshaft Push rod - Inspect (10.106)

1

Engine - Valve drive and gears

Camshaft Push rod - Inspect Prior operation: Camshaft Push rod - Remove (10.106) 1.

Check for wear or seizing on both ends of the push rods.

2.

Roll the push rods on a flat surface to check for deformities.

3.

Replace the push rods if any of the above conditions are found.

NOTE: The push rods are interchangeable between intake and exhaust rockers.

73092794

Next operation: Camshaft Push rod - Install (10.106)

1

Engine - Valve drive and gears

Camshaft Push rod - Install Prior operation: Camshaft Push rod - Inspect (10.106) 1.

Install the push rods (1).

NOTE: Be sure the ball end of the push rod is properly seated in the tappet.

23119867

Next operation: Rocker arm - Install (10.106)

1

Engine - Valve drive and gears

Camshaft - Remove Prior operation: Timing gear housing - Remove (10.102) NOTE: This procedure is best performed with the engine block rotated upside down to keep the tappets from interfering with removal of the camshaft.

1.

2.

Remove the bolts (1) and remove the camshaft retainer plate (2).

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73092823A

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Slide the camshaft (1) out of the engine bock.

NOTICE: Be sure not to damage the bushings during removal.

Next operation: Camshaft - Install (10.106)

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Engine - Valve drive and gears

Camshaft Tappets - Remove Prior operation: Camshaft - Remove (10.106) NOTE: Mark the location of the tappets to ensure the same position during installation.

1.

Remove the tappets (1).

73092824A

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1

Engine - Valve drive and gears

Camshaft - Measure Prior operation: Camshaft - Remove (10.106) 1.

Support the ends of the camshaft.

2.

Place a dial gauge on the center journal (1).

3.

Rotate the camshaft to check for radial movement.Replace the camshaft if the movement exceeds 0.015 mm (0.0006 in) or there are signs of wear or seizing on the surfaces.

4.

73092828

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73092829

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Check the diameter of the camshaft journals (1) on two perpendicular axis’, using a micrometer (2). Replace the camshaft if the values are not within the specifications shown in the chart below.

Camshaft journal 1 2, 3, 4 5

Specifications 53.995 - 54.045 mm (2.1258 - 2.1278 in) 49.975 - 50.025 mm (1.9675 - 1.9695 in) 39.975 - 40.025 mm (1.5738 - 1.5758 in)

Next operation: Camshaft - Install (10.106)

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Engine - Valve drive and gears

Camshaft Tappets - Install Prior operation: Camshaft Tappets - Remove (10.106) 1.

Lubricate the tappets (1) with clean engine oil.

2.

Install the tappets.

73092834

Next operation: Camshaft - Install (10.106)

1

Engine - Valve drive and gears

Camshaft - Install Prior operation: Camshaft - Remove (10.106) 1.

Lubricate the camshaft journals with clean engine oil.

2.

Install the camshaft (1).

NOTE: Be sure not to damage the bushings during installation.

3.

Install the retainer plate (1).

4.

Torque the bolts (2) to 20 - 30 N·m (15 - 22 lb ft).

Next operation: Camshaft - End play (10.106)

73092823A

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Engine - Valve drive and gears

Camshaft - End play Prior operation: Camshaft - Install (10.106) 1.

Check the end play of the camshaft. The measurement should be 0.10 - 0.36 mm (0.004 - 0.014 in).

73092836

1

Engine - Valve drive and gears

Camshaft bushings - Measure NOTE: There must not be any signs of wear or seizing on the journal surfaces.

1.

Measure the diameter of the camshaft bores (2) using a bore gauge (1).

2.

Measure the bores on two perpendicular axis'.

73092830

1 2, 3, 4 5

Camshaft bore inside diameter 59.222 - 59.248 mm (2.3316 - 2.3326 in) 50.069 - 50.119 mm (1.9712 - 1.9732 in) 40.069 - 40.119 mm (1.5775 - 1.5795 in)

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Engine - Valve drive and gears

Camshaft bushings - Replace 1.

Use the driver 380000667 (2) and hand grip 380000999 (3) to remove and replace the bushing (1).

NOTICE: Be sure to align the oil lubrication port in the block with the hole in the bushing.

73092832

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Engine - Valve drive and gears

Camshaft gear - Install 1.

Align the locating dowel on the camshaft with the corresponding hole on the gear while aligning the two timing dots (→) on the camshaft gear with the tapered tooth on the crankshaft gear.

2.

Torque the bolts (1) to 25 N·m (18 lb ft)

NHIL12ENG0023AA

1

Engine - Fuel filters

Fuel filters - Remove 1.

Disconnect the electrical connectors (4).

2.

Remove the fuel filter inlet line (3).

3.

Remove the fuel filter outlet line (1).

4.

Remove the fuel filter base (2) from the valve cover.

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Engine - Fuel filters

Fuel filters - Install 1.

Install the filter base (2) onto the valve cover.

2.

Connect the fuel filter inlet line (3).

3.

Connect the fuel filter outlet line (1).

4.

Connect the electrical connectors (4).

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Engine - Fuel injection system

Injection pump - Overview

83116822

(1) Metering unit (2) Cylinder head (3) High pressure port to rail

1

(4) Plunger (5) Bucket tappet (6) Roller

(7) Double cam (8) Drive shaft (9) Pump flange

The Bosch CP4.1 high pressure injection pump is a single radial-piston pump which is capable of producing pressures up to 200,000 kPa (29,008 psi).

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Engine - Fuel injection system

Fuel injection system - Bleed WARNING Pressurized system!

Only use the bleed screw to bleed air from the fuel system. DO NOT loosen the fuel or injector lines to bleed air. Injury or damage can occur. Fuel or injector lines are under very high pressure.

Failure to comply could result in death or serious injury.

W0285A

Machines with a primer button.

1.

Remove the fuel bleed screw from the top of the fuel filter housing.

2.

Press the primer button on the machine.

3.

Install the bleed screw when fuel is present at the top of the filter.

4.

Crank the engine.

NOTICE: Only crank the engine for 20 s at a time. Allow the starter to cool for 30 s before cranking again.

Machines without a primer button.

5.

Turn the key to the ON position.

6.

Allow the pump to run approximately 30 s.

7.

Turn the key to the OFF position.

8.

Loosen the bleed screw on top of the filter base to purge the air from the system.

9.

Tighten the bleed screw.

10.

Crank the engine.

NOTICE: Only crank the engine for 20 s at a time. Allow the starter to cool for 30 s before cranking again.

11.

Perform steps 5 through 10 if the engine cannot be started.

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Engine - Fuel injection system

Injection pump - Remove 1.

Remove the blowby recirculation drive hub. Refer to Blowby re-circulation system - Remove (10.304) for the proper procedure.

2.

Disconnect the fuel metering valve connector (1).

3.

Disconnect the fuel lines (2).

4.

Remove the nuts (3) from the pump mounting flange.

5.

Remove the pump.

NOTE: The high pressure pump drive gear is keyed and tapered, therefore may difficult to remove the pump.

83119800

1

Engine - Fuel injection system

Injection pump - Install 1.

Install the pump on the gear housing while aligning the pump shaft key (1) with the slot in the gear (2).

2.

Torque the nuts (3) to 25 N·m (18 lb ft).

3.

Connect the fuel lines (2).

4.

Connect the fuel metering valve connector (1).

5.

Install the blowby recirculation system. Refer to Blowby re-circulation system - Install (10.304) for the proper procedure.

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83119800

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F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

High pressure pump - Remove 1.

2.

3.

4.

Disconnect the electrical connections and wire ties from the following components: •

Camshaft speed sensor (1)

•

Crankshaft speed sensor (2)

•

Oil pressure sensor (3)

•

Fuel temperature sensor (4)

•

Fuel heater (if equipped)

•

High pressure pump metering unit (5)

•

Fuel pressure sensor (6) 83119804

1

83119804

2

83119802

3

83119805A

4

Unbolt the main connector bracket (1).

Cut the wire ties (1).

Drape the wiring harness (1) over the Exhaust Gas Recirculation (EGR) cooler.

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Engine - Fuel injection system

5.

Remove the high pressure fuel lines (1) from the common rail and the injectors.

6.

Disconnect the high pressure fuel supply line (2) from the injection pump and the common rail.

7.

83119806

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83119800

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83119807

7

Disconnect the fuel return lines (1) and (2) from the injection pump and from the return fuel manifold.

NOTE: It may be necessary to unbolt the fuel return manifold (3) from the engine block to remove the return fitting.

8.

Remove the common rail (1).

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Engine - Fuel injection system

High pressure pump - Install 1.

Install the common rail (1).

2.

Torque the bolts (2) to 20 - 30 N·m (15 - 22 lb ft).

3.

83119807

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83119800

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83119806

3

83119802

4

Connect the return fuel lines (1) and (2) to the injection pump and to the fuel return manifold (3).

4.

Install the high pressure supply line (2) to the injection pump and the common rail.

5.

Install the high pressure lines (1) to common rail and injectors.

NOTICE: Do not bend or force the high pressure fuel lines.

If installation is difficult, loosen and rotate the fuel injectors to properly install the lines.

6.

Bundle the wires as shown and tie them to the wire stands using wire ties (1).

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F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

7.

8.

Install the main harness connector bracket (1).

83119804

5

83119804

6

Connect the electrical connections and wire ties to the following components: •

Camshaft speed sensor (1)

•

Crankshaft speed sensor (2)

•

Oil pressure sensor (3)

•

Fuel temperature sensor (4)

•

Fuel heater (if equipped)

•

High pressure pump metering unit (5)

•

Fuel pressure sensor (6)

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Engine - Fuel injection system

Common rail Relief valve - Configure NOTE: If the pressure relief valve located on the high pressure common rail is replaced, the data must be reset in the engine controller.

NHPH12ENG0007AA

1.

Connect the Electronic Service Tool (EST) and configure for your machine.

2.

Press the “CONFIGURE” button (1).

3.

Select the “REPLACEMENT OF THE RAIL PRESSURE RELIEF VALVE (PRV) - RESET ECU DATA” function (2).

4.

Press the “RESET” button (3) and follow the on screen prompts.

1

F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Fuel injectors - Remove NOTE: Replacing the injectors with new requires the use of the Electronic Service Tool (EST) to configure the injector IMA codes.

1.

2.

3.

4.

Disconnect the electrical connections and wire ties from the following components: •

Camshaft speed sensor (1)

•

Crankshaft speed sensor (2)

•

Oil pressure sensor (3)

•

Fuel temperature sensor (4)

•

Fuel heater (if equipped)

•

High pressure pump metering unit (5)

•

Fuel pressure sensor (6) 83119804

1

83119804

2

83119802

3

83119805A

4

Unbolt the main connector bracket (1).

Cut the wire ties (1).

Drape the wiring harness (1) over the Exhaust Gas Recirculation (EGR) cooler.

F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

5.

Remove the intake manifold temperature/pressure sensor (1).

6.

Disconnect the electrical connections (2) from the injectors.

7.

Remove Exhaust Gas Recirculation (EGR) valve.

Refer to Exhaust Gas Recirculation (EGR) valve Remove (10.501) for the proper procedure.

8.

Remove the high pressure fuel lines (3) from the common rail and injectors.

9.

Remove the spring clips (1) from the top of the injectors.

10.

Remove the fuel return line (2).

11.

Remove the nut (1) and conical washer from the injector hold down.

12.

Use a heel bar (2) as shown to pull the injectors from the cylinder head.

83119806

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83119812

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83119814

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NOTE: Mark the location of each injector to ensure they are installed in the same cylinder.

FPT Industrial Engine Parts Contact Phone: 269 673 1638 Email: engineparts2@gmail.com Website: www.FPTIndustrialEngineParts.com

F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Fuel injectors - Install NOTE: When installing the original injectors, be sure they are installed in the same cylinder from which they were removed. When installing new injectors, the IMA code must be recorded and configured in the Electronic Service Tool (EST). Refer to Electrical system Electronic Service Tool (EST) - Configure (55.000) for the proper procedure.

1.

Install the crush washer onto the injector nozzle.

2.

Install the injectors with hold downs into the cylinder head.

3.

Loosely install the high pressure fuel lines.

4.

Torque the hold down nut (1) to 28 N·m (21 lb ft).

5.

Install the fuel return lines (2) and retain with spring clips (3).

6.

Tighten the high pressure fuel lines (3).

7.

Install the Exhaust Gas Recirculation (EGR) valve.

Refer to Exhaust Gas Recirculation (EGR) valve Install (10.501) for the proper procedure.

8.

Install the intake manifold temperature/pressure sensor (1).

9.

Install the connectors (2) for the injectors.

10.

83119812

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83119806

2

83119802

3

Bundle the wires as shown and tie them to the wire stands using wire ties (1).

F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

11.

12.

Install the main harness connector bracket (1).

83119804

4

83119804

5

Connect the electrical connections and wire ties to the following components: •

Camshaft speed sensor (1)

•

Crankshaft speed sensor (2)

•

Oil pressure sensor (3)

•

Fuel temperature sensor (4)

•

Fuel heater (if equipped)

•

High pressure pump metering unit (5)

•

Fuel pressure sensor (6)

FPT Industrial Engine Parts Contact Phone: 269 673 1638 Email: engineparts2@gmail.com Website: www.FPTIndustrialEngineParts.com

Engine - Fuel injection system

Fuel injectors - Configure - IMA codes

NHPH12ENG0006AA

1.

Connect EST and configure for your machine.

2.

Click the “Configure” button (1).

3.

Select “Engine Injector Code Configuration” (2) from the selection list.

4.

Click the “RETRIEVE DATA FROM CONTROLLER” button (3) to read the current data.

5.

Enter the IMA code for the new injector into the box for the appropriate injector number in the “MODIFIED VALUES” column (4).

6.

Press the “SAVE DATA TO CONTROLLER” button (5).

7.

Press “OK” to proceed to store the data in the engine controller.

8.

Disconnect EST.

1

Engine - Turbocharger and lines

Turbocharger - Overview - Boost pressure modulator valve

NHVM12ENG0021AA

1

The boost pressure modulator valve electrically regulates boost pressure that is sent to the turbocharger wastegate actuator.

It is mounted to the thermostat housing and it directs intake air between the inlet side of the turbocharger, the intake manifold and the wastegate via the boost pressure accumulator.

FPT Industrial Engine Parts Contact Phone: 269 673 1638 Email: engineparts2@gmail.com Website: www.FPTIndustrialEngineParts.com

Engine - Turbocharger and lines

Turbocharger - Overview - Boost pressure accumulator

NHVM12ENG0018AA

1

The boost pressure accumulator (1) dampens the pressure waves generated by the turbocharger wastegate and improves control and stability of the boost pressure. The accumulator is integrated with the oil cooler assembly.

FPT Industrial Engine Parts Contact Phone: 269 673 1638 Email: engineparts2@gmail.com Website: www.FPTIndustrialEngineParts.com

Engine - Turbocharger and lines

Turbocharger - Remove NOTICE: Do not attempt to adjust or modify the wastegate actuator in any way.

1.

Remove the hoses (1) and (2) from the waste gate actuator and compressor housing.

2.

Remove the oil supply line (1) from the top of the turbocharger and from the block.

3.

Remove the oil drain tube (2) from turbocharger.

4.

Unbolt the turbocharger from the exhaust manifold flange (3).

5.

Remove the turbocharger.

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Engine - Turbocharger and lines

Turbocharger - Install NOTICE: Do not attempt to adjust or modify the wastegate actuator in any way.

1.

Install the gasket and turbocharger onto the exhaust manifold mounting flange (3).

2.

Torque the nuts to 20 - 30 N·m (15 - 22 lb ft).

3.

Connect the oil drain tube (2) with gasket to the turbocharger.

4.

Install the oil supply line (1) to the block and the top of the turbocharger.

5.

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23119849

2

Connect the hoses (1) and (2) to the waste gate actuator and the compressor housing.

F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Intake manifold - Remove 1.

Remove the Exhaust Gas Recirculation (EGR) cooler. Refer to Exhaust Gas Recirculation (EGR) cooler - Remove (10.501) for the proper procedure.

2.

Disconnect the electrical connection from the Throttle Valve Actuator (TVA) (3) and the air pressure/temperature sensor (4).

3.

Remove the intake pipe (5) along with the TVA.

4.

Remove the bolts (1).

5.

Remove the intake manifold (2).

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F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Intake manifold - Install 1.

Install the intake manifold (2).

2.

Torque the bolts (1) to 20 - 30 N·m (15 - 22 lb ft).

3.

Install the Throttle Valve Actuator (TVA) (3) and intake tube (5).

4.

Torque the bolts (6) and nuts to 20 - 30 N·m (15 - 22 lb ft).

5.

Connect the electrical connections to the TVA and the air pressure/temperature sensor (4).

6.

Install the EGR cooler.

23119851

FPT Industrial Engine Parts Contact Phone: 269 673 1638 Email: engineparts2@gmail.com Website: www.FPTIndustrialEngineParts.com

1

F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Intake manifold - Remove - Spacer 1.

Remove the wiring harness (1).

2.

Remove the Exhaust Gas Recirculation (EGR) cooler (2). Refer to Exhaust Gas Recirculation (EGR) cooler - Remove (10.501) for the proper procedure.

3.

Remove the brackets for the exhaust gas temperature sensor (1) and the exhaust gas pressure sensor (2).

4.

Remove the intake manifold (3). Refer to Intake manifold - Remove (10.254) for the proper procedure.

5.

6.

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4

Remove the fuel injectors (1). Refer to Fuel injectors - Remove (10.218) for the proper procedure.

Remove the air intake manifold spacer (1).

F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Intake manifold - Install - Spacer 1.

Install the air intake manifold spacer (2).

2.

Torque the bolts (1) 15 N·m (11 lb ft) then to 27 N·m (20 lb ft).

3.

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23119863

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23119861

4

Install the fuel injectors (1). Refer to Fuel injectors - Install (10.218) for the proper procedure.

4.

Install the air intake manifold (3). Refer to Intake manifold - Install (10.254) for the proper procedure.

5.

Install the brackets for the exhaust gas temperature sensor (1) and the exhaust gas pressure sensor (2).

6.

Install the Exhaust Gas Recirculation (EGR) cooler (2). Refer to Exhaust Gas Recirculation (EGR) cooler - Install (10.501) for the proper procedure.

7.

Install the wiring harness (1).

FPT Industrial Engine Parts Contact Phone: 269 673 1638 Email: engineparts2@gmail.com Website: www.FPTIndustrialEngineParts.com

F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Exhaust manifold - Remove 1.

Remove the turbocharger. Refer to Turbocharger Remove (10.250) for the proper procedure.

2.

Remove the EGR flex pipe (1).

3.

Remove the exhaust gas temperature sensor (3).

4.

Remove the exhaust gas pressure sensor signal tube (2).

5.

Remove the exhaust manifold (4).

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F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Exhaust manifold - Install 1.

Clean the sealing surfaces.

2.

Install new gaskets.

3.

Install the exhaust manifold (4).

4.

Torque the nuts to 10 - 20 N·m (7 - 15 lb ft).

5.

Install the exhaust gas pressure sensor signal tube (2).

6.

Install the exhaust gas temperature sensor (3).

7.

Install the EGR flex pipe (1) and torque to 25 N·m (18 lb ft).

NOTICE: It is mandatory to replace both gaskets every time the EGR flex pipe is removed.

8.

Install the turbocharger. Refer to Turbocharger Install (10.250) for the proper procedure.

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1

Engine - Engine lubrication system

Engine oil filter - Overview

73092740

(1) Protective cover

1

(2) Cartridge

Engine - Engine lubrication system

Engine oil pump - Overview

73092739

(1) (2) (3) (4)

Main gear Secondary gear Housing Drive shaft

1

(5) (6) (7) (8)

Secondary shaft Cover Internal rotor External rotor

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Engine - Engine lubrication system

Blowby re-circulation system - Overview

23118179

(1) Cover

(2) Filter

1

(3) Drive hub

Engine - Engine lubrication system

Engine oil filter - Remove 1.

Unscrew the oil filter (1) from the oil filter base (2).

93111635

1

Engine - Engine lubrication system

Engine oil filter - Install 1.

Screw the oil filter (2) onto the oil filter support (1) until the seal touches the support..

2.

Turn the filter ¾ of a turn after seal contact.

93111635

1

Engine - Engine lubrication system

Engine oil pump - Remove Prior operation: Timing gear housing - Remove (10.102) 1.

Loosen the bolts (1) and remove the oil pump (2).

73092778

Next operation: Engine oil pump - Install (10.304)

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1

Engine - Engine lubrication system

Engine oil pump - Install Prior operation: Engine oil pump - Remove (10.304) 1.

Install the oil pump (2).

2.

Install the bolts (1) and make them snug.

NOTE: Do not fully tighten the bolts at this time.

3.

Check the backlash between the crankshaft gear and the oil pump gear using a dial gauge with magnetic base. The value must be between 0.068 - 0.168 mm (0.003 - 0.007 in).

4.

Torque the bolts (1) to 10 - 20 N·m (7 - 15 lb ft) then again at 20 - 30 N·m (15 - 22 lb ft).

73092784

Next operation: Timing gear housing - Install (10.102)

1

Engine - Engine lubrication system

Blowby re-circulation system - Remove 1.

Remove the cover (1).

2.

Remove the snap ring (1).

3.

Slide the filter (2) from the drive hub.

4.

Lock engine rotation.

5.

Remove the nut (1) inside the drive hub using a 19 mm allen wrench.

6.

Remove the drive hub (2)

FPT Industrial Engine Parts Contact Phone: 269 673 1638 Email: engineparts2@gmail.com Website: www.FPTIndustrialEngineParts.com

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83118147

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83118150

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Engine - Engine lubrication system

Blowby re-circulation system - Install 1.

Install the drive hub (2).

2.

Torque the nut (1) to 80 N·m (59 lb ft).

3.

Slide the filter (2) onto the drive hub.

4.

Install the snap ring (1).

5.

Install a new o-ring on the cover (1).

6.

Install the cover (1).

7.

Torque the nuts to 10 N·m (7 lb ft).

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83118147

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Engine - Engine lubrication system

Piston cooling Spray nozzle - Remove Prior operation: Engine oil pan - Remove (10.102) 1.

Remove the banjo bolt (1) and remove the oil nozzles (2).

NHVM12ENG0016AA

Next operation: Piston cooling Spray nozzle - Install (10.304)

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1

Engine - Engine lubrication system

Piston cooling Spray nozzle - Install Prior operation: Piston cooling Spray nozzle - Remove (10.304) 1.

Install the oil nozzles (2).

NOTICE: Be sure the locating tab on the nozzle is properly seated against the machined edge of the block to ensure proper nozzle alignment.

2.

Torque the banjo bolts (1) to 18 N·m (13 lb ft).

NHVM12ENG0016AA

Next operation: Engine oil pan - Install (10.102)

1

Engine - Engine cooling system

Water pump - Overview

23118605

(1) Pulley

1

(2) Pump housing

(3) Impeller

The water pump circulates coolant through the engine cooling system. It is a belt driven, centrifugal blade type pump.

FPT Industrial Engine Parts Contact Phone: 269 673 1638 Email: engineparts2@gmail.com Website: www.FPTIndustrialEngineParts.com

Engine - Engine cooling system

Coolant thermostat - Overview

NHVM12ENG0025AA

(1) Thermostat

(2) Check ball

1

(3) Housing

The thermostat acts as a temperature operated check valve. When the engine is cold, the valve remains closed and does not allow the flow of coolant to the radiator. This allows for a faster engine warm up time. When the engine reaches 80 °C (176 °F) the thermostat opens allowing the coolant to flow to the radiator to maintain the optimum engine temperature.

The integrated check ball helps bleed the cooling system of trapped air by allowing the air to pass into the radiator to be released from the system when the thermostat is closed.

FPT Industrial Engine Parts Contact Phone: 269 673 1638 Email: engineparts2@gmail.com Website: www.FPTIndustrialEngineParts.com

Engine - Engine cooling system

Water pump - Remove CAUTION Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in minor or moderate injury.

C0107B

1.

Drain the coolant.

2.

Remove the drive belt. Refer to Belt - Remove (10.414) for the proper procedure.

3.

Remove the bolts (1).

4.

Remove the water pump (2).

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1

F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Water pump - Install Prior operation: Water pump - Remove (10.400) 1.

Install a new seal (2) on the water pump (1).

2.

Install the water pump (1).

3.

Torque the bolts to 20 - 30 N·m (15 - 22 lb ft).

4.

Install the belt. Refer to Belt - Install (10.414) for the proper procedure.

5.

Fill with coolant.

73092789

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84496807- 22/04/2012

10.400 / 6

1

F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Coolant thermostat - Remove CAUTION Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in minor or moderate injury.

C0107B

1.

Drain coolant.

2.

Disconnect the upper radiator hose (5) and the Exhaust Gas Recirculation (EGR) cooler hose (3).

3.

Disconnect the coolant temperature sensor (4).

4.

Unbolt the bracket for the wastegate modulation solenoid (1) and let it hang.

5.

Remove the bolts (2) from the thermostat housing.

6.

Push in and turn the retainer plate (1).

7.

Remove the thermostat (2) from the housing.

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F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Coolant thermostat - Install 1.

Install the thermostat (1) into the housing.

2.

Orient the retainer plate (2) with the edges facing up.

3.

Push in on the retainer plate and turn until it is seated on the locks (3).

4.

Install the thermostat housing and gasket onto the cylinder head.

5.

Torque the bolts (2) to 20 - 30 N·m (15 - 22 lb ft).

6.

Install the wastegate modulation solenoid bracket (1).

7.

Connect the upper radiator hose (5) and the Exhaust Gas Recirculation (EGR) cooler hose (3).

8.

Connect the coolant temperature sensor (4).

9.

Fill with coolant.

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Engine - Oil cooler and lines

Engine oil cooler - Overview

73092745

1

The oil cooler circulates engine oil through cooling plates that sit in a coolant passage on the right hand side of the engine. This process transfers heat from the engine oil to the engine coolant.

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Engine - Oil cooler and lines

Engine oil cooler - Remove CAUTION Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in minor or moderate injury.

C0107B

1.

Drain coolant.

2.

Remove the lower radiator tube (1).

3.

NHVM12ENG0020AA

1

NHVM12ENG0019AA

2

NHVM12ENG0018AA

3

Remove the lower alternator support bracket (1).

4.

Remove the fittings (1) and (2).

5.

Remove the support bracket bolt (3).

6.

Remove the turbocharger oil drain tube (4).

7.

Remove the boost pressure accumulator (5).

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Engine - Oil cooler and lines

8.

Remove the oil cooler (1) assembly and gasket.

NOTE: The four bolts (→) fasten the oil cooler to the heat exchanger body and do not need to be removed to remove the oil cooler assembly. Refer to Engine oil cooler - Disassemble (10.408) for disassembly.

NHVM12ENG0017AA

4

Engine - Oil cooler and lines

Engine oil cooler - Disassemble 1.

Remove bolts (1), (2), (3) and (4).

2.

Remove the oil cooler (5) from the heat exchanger body (6).

NHVM12ENG0024AA

1

Engine - Oil cooler and lines

Engine oil cooler - Assemble 1.

Install the gaskets and oil cooler (5) to the heat exchanger body (6).

2.

Torque the bolts (1), (2), (3) and (4) to 25 N·m (18 lb ft)

NHVM12ENG0024AA

1

Engine - Oil cooler and lines

Engine oil cooler - Install Prior operation: Engine oil cooler - Assemble (10.408) 1.

Install the oil cooler (1) assembly.

2.

Torque the bolts as follows: •

M8x1.25x30 = 25 N·m (18 lb ft)

•

M8x1.25x50 = 25 N·m (18 lb ft)

3.

Install the boost pressure accumulator (5).

4.

Torque the bolts as follows: •

M6x1x14 = 10 N·m (7 lb ft)

•

M6x1x30 = 10 N·m (7 lb ft)

5.

Install the turbocharger oil drain tube (4) and torque to 10 N·m (7 lb ft).

6.

Install the support brackets (3) and torque the bolt to 25 N·m (18 lb ft)

7.

Install the fittings (1) and (2).

8.

NHVM12ENG0017AA

1

NHVM12ENG0018AA

2

NHVM12ENG0019AA

3

NHVM12ENG0020AA

4

Install the lower alternator support (1) and torque the bolts to 50 N·m (37 lb ft).

9.

Install the lower radiator tube (1).

10.

Torque the flange bolts and the support bracket bolt to 25 N·m (18 lb ft).

11.

Fill with coolant.

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Engine - Fan and drive

Belt - Remove 1.

Loosen the lower alternator bolt (1).

2.

Loosen the tensioner retaining bolt (2).

3.

Loosen the adjusting bolt jam nut (3).

4.

Turn the adjusting bolt (4) counter clockwise.

5.

Slide the belt (5) off of the water pump pulley (6).

83118121

1

Engine - Fan and drive

Belt - Install 1.

Route the drive belt (1) on the pulleys as shown.

2.

Turn the adjusting bolt (4) clockwise to apply tension to the belt (5) until the bracket reaches the end of its slot.

3.

Tighten the jam nut (3) on the adjusting bolt.

4.

Torque the tensioner retaining bolt (2) to 45 - 55 N·m (33 - 41 lb ft).

5.

Torque the lower alternator bolt (1) to 45 - 55 N·m (33 - 41 lb ft).

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Engine - Fan and drive

Belt tensioner - Remove 1.

Remove the belt (3). Refer to Belt - Remove (10.414) for the proper procedure.

2.

Remove the two retaining bolts (1).

3.

Remove the belt tensioner (2).

83118121

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1

Engine - Fan and drive

Belt tensioner - Install 1.

Install the belt tensioner (2).

2.

Install the belt (3). Refer to Belt - Install (10.414) for the proper procedure.

3.

Torque the bolts (1) to 45 - 55 N·m (33 - 41 lb ft).

83118121

1

Engine - Exhaust Gas Recirculation (EGR) exhaust treatment

Exhaust Gas Recirculation (EGR) valve - Remove 1.

Remove the hose (1).

2.

Remove the intake tube (2).

3.

Disconnect the electrical connector (1).

4.

Slide the TVA (2) and gaskets from the intake manifold.

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Engine - Exhaust Gas Recirculation (EGR) exhaust treatment

Exhaust Gas Recirculation (EGR) valve - Install 1.

Install the gasket.

2.

Install the TVA (2).

3.

Connect the electrical connection (1).

4.

Install the gasket.

5.

Install the intake tube (2).

6.

Torque the bolts and nuts to 10 N·m (7 lb ft) .

7.

Install the hose (1).

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Engine - Exhaust Gas Recirculation (EGR) exhaust treatment

Exhaust Gas Recirculation (EGR) valve - Remove CAUTION Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in minor or moderate injury.

C0107B

1.

Remove the plug (1) to drain the coolant from the engine.

2.

Disconnect the electrical connection (1).

3.

Remove the bolts (2).

4.

Remove the EGR valve (3).

NHVM12ENG0005AA

1

23119853

2

Engine - Exhaust Gas Recirculation (EGR) exhaust treatment

Exhaust Gas Recirculation (EGR) valve - Install 1.

Install the gasket.

2.

Install the EGR valve (3).

3.

Torque the bolts (2) to 5 - 15 N·m (4 - 11 lb ft).

4.

Connect the electrical connection (1).

5.

Fill with coolant.

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1

Engine - Exhaust Gas Recirculation (EGR) exhaust treatment

Exhaust Gas Recirculation (EGR) cooler - Remove CAUTION Burn hazard!

Do not handle any service fluid (engine coolant, engine oil, hydraulic oil, etc.) at temperatures that exceed 49 °C (120 °F). Allow fluids to cool before proceeding.

Failure to comply could result in minor or moderate injury.

C0107B

1.

Remove the plug (1) to drain the coolant from the engine.

2.

Remove the coolant line (4) from the bleed valve.

3.

Remove the EGR Flex pipe (6).

4.

Remove the coolant line (8) from the EGR valve housing.

5.

Remove the coolant line support bolt (7) .

6.

Disconnect the electrical connector (2) from the EGR valve.

7.

Remove the bolts (1) from the EGR valve housing.

8.

Remove the nuts (5) from the cooler.

9.

Remove the cooler (3).

FPT Industrial Engine Parts Contact Phone: 269 673 1638 Email: engineparts2@gmail.com Website: www.FPTIndustrialEngineParts.com

NHVM12ENG0005AA

1

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Engine - Exhaust Gas Recirculation (EGR) exhaust treatment

Exhaust Gas Recirculation (EGR) cooler - Install 1.

Clean the sealing surfaces.

2.

Install the gaskets.

3.

Install the cooler (3) onto the intake manifold.

4.

Torque the bolts (1) and nuts (5) to 20 - 30 N·m (15 - 22 lb ft).

5.

Connect the electrical connector (2) to the EGR valve.

6.

Install the coolant line (8) to the EGR valve housing.

7.

Install the support bracket bolt (7).

8.

Install the EGR flex pipe (6) and torque to 25 N·m (18 lb ft).

NOTICE: It is mandatory to replace both gaskets every time the EGR flex pipe is removed.

9.

Connect the coolant line (4) to the bleed valve.

10.

Fill with coolant.

FPT Industrial Engine Parts Contact Phone: 269 673 1638 Email: engineparts2@gmail.com Website: www.FPTIndustrialEngineParts.com

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Electrical systems - Engine cooling system F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Engine coolant temperature sensor - Overview

73092808

Voltage Working temperature range - Connector's side - Engine side

1

Specifications 6 - 28 V -40 - 130 °C (-40 - 266 °F) -40 - 140 °C (-40 - 284 °F)

The coolant temperature sensor measures the temperature of the coolant circulating through the engine. The data is then sent to the Engine Control Unit (ECU).

FPT Industrial Engine Parts Contact Phone: 269 673 1638 Email: engineparts2@gmail.com Website: www.FPTIndustrialEngineParts.com

Electrical systems - Engine oil system F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Engine oil pressure sensor - Overview

73092809

Contact closure with decreasing pressure Contact opening with increasing pressure

1

Specifications 0.2 bar (3 psi) 0.9 bar (13 psi)

The oil pressure sensor is located on the top of the oil filter base.

FPT Industrial Engine Parts Contact Phone: 269 673 1638 Email: engineparts2@gmail.com Website: www.FPTIndustrialEngineParts.com

Electrical systems - Engine intake and exhaust system F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Engine air pressure/temperature sensor - Overview

73092811

1

The air pressure temperature sensor, located on the intake manifold, is used to measure intake manifold pressure and temperature after the turbocharger.

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Electrical systems - Engine control system F5HFL463 F5HFL464 F5DFL463 F5DFL464 F5GFL463 F5GFL464

Engine timing sensors Crankshaft sensor - Overview It is an inductive type sensor placed on the front left side of the engine. It generates signals obtained by the magnetic flow lines closing up through the openings of a tone wheel splined on the engine crankshaft. The same signal is used to pilot the tachometer fitted on the vehicle instrument panel. It is connected to the Electronic Control Unit pins 25C (signal) and 24C (signal). The third pin is for shielding. The Sensor's resistance value is nearly 900 Ω.

73092812

1

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Electrical systems - Engine starting system

Engine starter - Overview

73092815

Manufacturer Electrical system Rated output

1

Specifications BOSCH 12 V 3 kW (4 Hp)

Electrical systems - Cold start aid

Glow plug system - Overview

93111647

1

A glow plug is typically comprised of a heating coil in a metal tube closed at one end and filled with electrically insulating ceramic powder. The closed end of the metal tube with the heating coil protrudes through a hole in the cylinder head into the combustion chamber. When the glow plug is electrically energized, its heated portion reaches a surface temperature of more than 1000 °C (1832 °F) within a few seconds. The air-fuel spray generated by the injection ignites close to the glow plug and initiates combustion.

Protrusion length Diameter of heating element Heat up time to 850 °C (1562 °F) Temperature T60 Switch on current at 11 V Operating current at 11 V after 20 s Runout heating element

Specifications 30.4 mm +/- 0.25 mm 4 mm +/- 0.1 mm Less than 5 s 950 - 1010 °C (1742 - 1850 °F) Less than 19 A 5 A +/- 1.0 A 0.4 mm

FPT Industrial Engine Parts Contact Phone: 269 673 1638 Email: engineparts2@gmail.com Website: www.FPTIndustrialEngineParts.com

Electrical systems - Cold start aid

Glow plug system - Remove 1.

2.

Remove the electrical connection (1) from the glow plug.

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2

Remove the glow plugs (1).

Electrical systems - Cold start aid

Glow plug system - Install 1.

Install the glow plugs (1).

2.

Torque to 8 - 10 N·m (71 - 89 lb in).

3.

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2

Install the electrical connections (1).

Electrical systems - Alternator

Alternator - Remove 1.

Remove the belt. Refer to Belt - Remove (10.414) for the proper procedure.

2.

Disconnect the electrical connections from the back side of the alternator (1).

3.

Remove the upper bolt (2).

4.

Remove the lower bolt (3).

5.

Remove the alternator from the bracket (4).

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Electrical systems - Alternator

Alternator - Install 1.

Install the alternator (1) on the support bracket (4) and install the bottom bolt (3).

2.

Roll the alternator towards the engine and install the top bolt (2) through the tensioner bracket.

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SPECIAL TOOL INDEX IU

Genuine 380000150 [Engine P.M.S. Positioning Tool] 380000988 [Flywheel Rotation Blocker] 380000134 [Valve Guide Seal Installer] 380100280 [Lower front engine cover aligment tool] 380100281 [Upper front engine cover alignment tool] 380000732 [Engine Turning Tool] 380000988 [Flywheel Rotation Blocker] 380000732 [Engine Turning Tool] 380000732 [Engine Turning Tool] 380000988 [Flywheel Rotation Blocker] 380000732 [Engine Turning Tool] 380100076 [Rear crankshaft seal installer] 380100076 [Rear crankshaft seal installer] 380100279 [Front Seal installer] 380100279 [Front Seal installer] 380000324 [Pliers For Assembling And Disassembling Piston Split Rings (110-150 mm)] 380000221 [Pliers For Piston Rings Removal And Installation (65 -110 mm)] 380000220 [Band For Piston Insertion Into Cylinder Sleeves (60 -125 mm)] 380000667 [Camshaft Bush Assembly And Disassembly Punch] 380000999 [Handle For Interchangeable Beaters]

Engine - Service instruction - Finding Top Dead Center Engine - Service instruction - Finding Top Dead Center Cylinder head - Assemble Engine block cover Front - Install Engine block cover Front - Install Engine flywheel - Remove Engine flywheel - Remove Engine flywheel - Remove Engine flywheel - Install Engine flywheel - Install Engine flywheel - Install Crankshaft oil seal Rear seal - Install Crankshaft oil seal Rear seal - Install Crankshaft oil seal Front seal - Install Crankshaft oil seal Front seal - Install Connecting rod and piston - Disassemble

Connecting rod and piston - Assemble

Connecting rod and piston - Install

Camshaft bushings - Replace

Camshaft bushings - Replace

Torque - Minimum tightening torques for normal assembly METRIC NON-FLANGED HARDWARE NOM. SIZE CLASS 8.8 BOLT and CLASS 8 NUT PLATED UNPLATED W/ZnCr M4 M5 M6 M8

2.2 N·m (19 lb in) 4.5 N·m (40 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in)

M10

37 N·m (27 lb ft)

M12

64 N·m (47 lb ft)

M16 M20 M24

158 N·m (116 lb ft) 319 N·m (235 lb ft) 551 N·m (410 lb ft)

2.9 N·m (26 lb in) 5.9 N·m (52 lb in) 10 N·m (89 lb in) 25 N·m (217 lb in) 49 N·m (36 lb ft) 85 N·m (63 lb ft) 210 N·m (155 lb ft) 425 N·m (313 lb ft) 735 N·m (500 lb ft)

CLASS 10.9 BOLT and CLASS 10 NUT PLATED UNPLATED W/ZnCr 3.2 N·m (28 lb 4.2 N·m (37 lb in) in) 6.4 N·m (57 lb 8.5 N·m (75 lb in) in) 11 N·m (96 lb 15 N·m (128 lb in) in) 26 N·m (234 lb 35 N·m (311 lb in) in) 70 N·m (51 lb 52 N·m (38 lb ft) ft) 121 N·m (90 lb 91 N·m (67 lb ft) ft) 225 N·m (166 lb 301 N·m (222 ft) lb ft) 440 N·m (325 lb 587 N·m (433 ft) lb ft) 762 N·m (560 lb 1016 N·m (750 ft) lb ft)

LOCKNUT CL.8 W/CL8.8 BOLT

2 N·m (18 lb in) 4 N·m (36 lb in) 6.8 N·m (60 lb in) 17 N·m (151 lb in) 33 N·m (25 lb ft) 58 N·m (43 lb ft) 143 N·m (106 lb ft) 290 N·m (214 lb ft) 501 N·m (370 lb ft)

LOCKNUT CL.10 W/CL10.9 BOLT 2.9 N·m (26 lb in) 5.8 N·m (51 lb in) 10 N·m (89 lb in) 24 N·m (212 lb in) 48 N·m (35 lb ft) 83 N·m (61 lb ft) 205 N·m (151 lb ft) 400 N·m (295 lb ft) 693 N·m (510 lb ft)

NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque specifications are shown in pound-feet.

INTRODUCTION

METRIC FLANGED HARDWARE NOM. SIZE

CLASS 8.8 BOLT and CLASS 8 NUT

UNPLATED M4 M5 M6 M8

2.4 N·m (21 lb in) 4.9 N·m (43 lb in) 8.3 N·m (73 lb in) 20 N·m (179 lb in)

M10

40 N·m (30 lb ft)

M12

70 N·m (52 lb ft)

M16 M20 M24

174 N·m (128 lb ft) 350 N·m (259 lb ft) 607 N·m (447 lb ft)

PLATED W/ZnCr 3.2 N·m (28 lb in) 6.5 N·m (58 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in) 54 N·m (40 lb ft) 93 N·m (69 lb ft) 231 N·m (171 lb ft) 467 N·m (345 lb ft) 809 N·m (597 lb ft)

CLASS 10.9 BOLT and CLASS 10 NUT

UNPLATED

IDENTIFICATION Metric Hex head and carriage bolts, classes 5.6 and up

1.

Manufacturer's Identification

2.

Property Class

1

Metric Hex nuts and locknuts, classes 05 and up

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LOCKNUT CL.10 W/CL10.9 BOLT

2.2 N·m (19 lb in) 4.4 N·m (39 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in)

3.1 N·m (27 lb in) 6.4 N·m (57 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in)

PLATED W/ZnCr

3.5 N·m (31 lb 4.6 N·m (41 lb in) in) 7.0 N·m (62 lb 9.4 N·m (83 lb in) in) 12 N·m (105 lb 16 N·m (141 lb in) in) 29 N·m (257 lb 39 N·m (343 lb in) in) 77 N·m (56 lb 57 N·m (42 lb ft) ft) 100 N·m (74 lb 134 N·m (98 lb ft) ft) 248 N·m (183 lb 331 N·m (244 ft) lb ft) 484 N·m (357 lb 645 N·m (476 ft) lb ft) 838 N·m (618 lb 1118 N·m (824 ft) lb ft)

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LOCKNUT CL.8 W/CL8.8 BOLT

37 N·m (27 lb ft) 53 N·m (39 lb ft) 63 N·m (47 lb ft) 91 N·m (67 lb ft) 158 N·m (116 lb ft) 318 N·m (235 lb ft) 552 N·m (407 lb ft)

226 N·m (167 lb ft) 440 N·m (325 lb ft)

1.

Manufacturer's Identification

2.

Property Class

3.

Clock Marking of Property Class and Manufacturer's Identification (Optional), i.e. marks 60 ° apart indicate Class 10 properties, and marks 120 ° apart indicate Class 8.

INCH NON-FLANGED HARDWARE NOMINAL SIZE

SAE GRADE 5 BOLT and NUT UNPLATED or PLATED SILVER

1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

8 N·m (71 lb in) 17 N·m (150 lb in) 30 N·m (22 lb ft) 48 N·m (36 lb ft) 74 N·m (54 lb ft) 107 N·m (79 lb ft) 147 N·m (108 lb ft) 261 N·m (193 lb ft) 420 N·m (310 lb ft) 630 N·m (465 lb ft)

SAE GRADE 8 BOLT and NUT

UNPLATED PLATED W/ZnCr or PLATED GOLD SILVER 11 N·m (97 lb in) 23 N·m (204 lb in) 40 N·m (30 lb ft) 65 N·m (48 lb ft) 98 N·m (73 lb ft) 142 N·m (105 lb ft) 196 N·m (145 lb ft) 348 N·m (257 lb ft) 561 N·m (413 lb ft) 841 N·m (620 lb ft)

12 N·m (106 lb in) 24 N·m (212 lb in) 43 N·m (31 lb ft) 68 N·m (50 lb ft) 104 N·m (77 lb ft) 150 N·m (111 lb ft) 208 N·m (153 lb ft) 369 N·m (272 lb ft) 594 N·m (438 lb ft) 890 N·m (656 lb ft)

LOCKNUT GrB W/ Gr5 BOLT

LOCKNUT GrC W/ Gr8 BOLT

PLATED W/ZnCr GOLD 16 N·m (142 lb in) 32 N·m (283 lb in) 57 N·m (42 lb ft) 91 N·m (67 lb ft) 139 N·m (103 lb ft) 201 N·m (148 lb ft) 277 N·m (204 lb ft) 491 N·m (362 lb ft) 791 N·m (584 lb ft) 1187 N·m (875 lb ft)

12.2 N·m (109 lb in) 17.5 N·m (155 lb 25 N·m (220 lb in) in)

8.5 N·m (75 lb in)

31 N·m (23 lb ft) 44 N·m (33 lb ft) 50 N·m (37 lb ft) 71 N·m (53 lb ft) 76 N·m (56 lb ft) 108 N·m (80 lb ft) 156 N·m (115 lb ft) 153 N·m (113 lb 215 N·m (159 lb ft) ft) 271 N·m (200 lb 383 N·m (282 lb ft) ft) 437 N·m (323 lb 617 N·m (455 lb ft) ft) 654 N·m (483 lb 924 N·m (681 lb ft) ft)

111 N·m (82 lb ft)

NOTE: For Imperial Units, 1/4 in and 5/16 in hardware torque specifications are shown in pound-inches. 3/8 in through 1 in hardware torque specifications are shown in pound-feet.

INCH FLANGED HARDWARE NOMSAE GRADE 5 BOLT and SAE GRADE 8 BOLT and INAL NUT NUT SIZE PLATED UNPLATED PLATED UNPLATED W/ZnCr or PLATED W/ZnCr or PLATED GOLD SILVER GOLD SILVER 1/4

9 N·m (80 lb in)

5/16

19 N·m (168 lb in)

3/8

33 N·m (25 lb ft)

7/16

53 N·m (39 lb ft)

1/2

81 N·m (60 lb ft)

9/16 5/8 3/4 7/8 1

117 N·m (86 lb ft) 162 N·m (119 lb ft) 287 N·m (212 lb ft) 462 N·m (341 lb ft) 693 N·m (512 lb ft)

12 N·m (106 lb in) 25 N·m (221 lb in) 44 N·m (33 lb ft) 71 N·m (52 lb ft) 108 N·m (80 lb ft) 156 N·m (115 lb ft) 216 N·m (159 lb ft) 383 N·m (282 lb ft) 617 N·m (455 lb ft) 925 N·m (682 lb ft)

13 N·m (115 lb in) 26 N·m (230 lb in) 47 N·m (35 lb ft) 75 N·m (55 lb ft) 115 N·m (85 lb ft) 165 N·m (122 lb ft) 228 N·m (168 lb ft) 405 N·m (299 lb ft) 653 N·m (482 lb ft) 979 N·m (722 lb ft)

17 N·m (150 lb in) 35 N·m (310 lb in) 63 N·m (46 lb ft) 100 N·m (74 lb ft) 153 N·m (113 lb ft) 221 N·m (163 lb ft) 304 N·m (225 lb ft) 541 N·m (399 lb ft) 871 N·m (642 lb ft) 1305 N·m (963 lb ft)

LOCKNUT GrF W/ Gr5 BOLT

8 N·m (71 lb in) 17 N·m (150 lb in)

LOCKNUT GrG W/ Gr8 BOLT

12 N·m (106 lb in) 24 N·m (212 lb in)

30 N·m (22 lb ft) 43 N·m (32 lb ft) 48 N·m (35 lb ft) 68 N·m (50 lb ft) 74 N·m (55 lb ft) 106 N·m (78 lb ft) 147 N·m (108 lb ft) 261 N·m (193 lb ft) 421 N·m (311 lb ft) 631 N·m (465 lb ft)

104 N·m (77 lb ft) 157 N·m (116 lb ft) 207 N·m (153 lb ft) 369 N·m (272 lb ft) 594 N·m (438 lb ft) 890 N·m (656 lb ft)

IDENTIFICATION Inch Bolts and free-spinning nuts

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Grade Marking Examples 1 2 3

Grade 2 - No Marks Grade 5 - Three Marks Grade 8 - Five Marks

SAE Grade Identification 4 Grade 2 Nut - No Marks 5 Grade 5 Nut - Marks 120 ° Apart 6 Grade 8 Nut - Marks 60 ° Apart

Inch Lock Nuts, All Metal (Three optional methods)

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Grade Identification Grade Grade A Grade B Grade C

Corner Marking Method (1) No Notches One Circumferential Notch Two Circumferential Notches

Flats Marking Method (2) No Mark Letter B Letter C

Clock Marking Method (3) No Marks Three Marks Six Marks

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