Case F2CFA614BE019 F2CFA614CE019 Tier 2 Engine Service Manual 47441651 - PDF DOWNLOAD

F2CFA614B*E019 F2CFA614C*E019 Tier 2 Engine

SERVICE MANUAL

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.

Part number 47441651 1st edition English October 2012

Contents INTRODUCTION Engine....................................................................................... 10 Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001 Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.101 Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.102 Crankshaft and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.103 Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.105 Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.106 Balancer and damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.110 Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.114 Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.206 Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.210 Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.218 Turbocharger and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.250 Intake and exhaust manifolds and muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.254 Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.304 Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400 Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.408 Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.414

Electrical systems ....................................................................... 55 Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.010 Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.012 Engine oil system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.013 Engine intake and exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.014 Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.015 Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.201 Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.301

47441651 09/10/2012

INTRODUCTION

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Contents INTRODUCTION Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Basic instructions - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Basic instructions - Shop and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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INTRODUCTION

Foreword Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment of some of the substances required by advanced technology, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature.

NOTE: The following are recommendations that may be of assistance: •

Become acquainted with and ensure that you understand the relative legislation applicable to your country.

•

Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning agents, etc., with regard to their effect on man and nature and how to safely store, use, and dispose of these substances.

•

Agricultural consultants will, in many cases, be able to help you as well.

Helpful hints •

Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems that may cause considerable spillage.

•

In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances that may be harmful to your health.

•

Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.

•

Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc. Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper way to comply with local legislation and available resources.

•

Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should not be allowed to get into the soil, but should be collected and disposed of properly.

•

Do not open the air-conditioning system yourself. It contains gases that should not be released into the atmosphere. Your CNH dealer or air conditioning specialist has a special extractor for this purpose and will have to recharge the system properly.

•

Repair any leaks or defects in the engine cooling or hydraulic system immediately.

•

Do not increase the pressure in a pressurized circuit as this may lead to a component failure.

•

Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, allowing the loss of oils, coolant, etc.

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INTRODUCTION

Safety rules Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

Throughout this manual and on machine decals, you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you.

Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. The color associated with DANGER is RED. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

The color associated with WARNING is ORANGE. CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. The color associated with CAUTION is YELLOW.

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation which, if not avoided, could result in machine or property damage. The color associated with Notice is BLUE. Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety.

Information NOTE: Note indicates additional information which clarifies steps, procedures, or other information in this manual.

Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage.

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INTRODUCTION

Basic instructions - Important notice regarding equipment servicing All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel, strictly complying with the instructions given, and using, whenever possible, the special tools.

Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall be responsible for any subsequent damages.

The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manufacturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer.

In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer.

The information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for continuous improvement. Some information could not be updated due to modifications of a technical or commercial type, or changes to the laws and regulations of different countries.

In case of questions, refer to your CNH Sales and Service Networks.

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INTRODUCTION

Basic instructions - Shop and Assembly SHIMMING For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value indicated on each shim.

ROTATING SHAFT SEALS For correct rotating shaft seal installation, proceed as follows: •

before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes.

•

thoroughly clean the shaft and check that the working surface on the shaft is not damaged.

•

position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that they will deviate the fluid towards the inner side of the seal.

•

coat the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing lip and the dust lip on double lip seals with grease.

•

insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a hammer or mallet.

•

whilst inserting the seal, check that it is perpendicular to the seat; once settled, make sure that it makes contact with the thrust element, if required.

•

to prevent damaging the seal lip on the shaft, position a protective guard during installation operations.

O-RING SEALS Lubricate the O-RING seals before inserting them in the seats, this will prevent them from overturning and twisting, which would jeopardise sealing efficiency.

SEALING COMPOUNDS Apply one of the following sealing compounds on the mating surfaces when specified: SILMATE® RTV1473, or LOCTITE® RTV 598 or LOCTITE® INSTANT GASKET 587 BLUE. Before applying the sealing compound, prepare the surfaces as directed on product container or as follows: •

remove any incrustations using a metal brush.

•

thoroughly de-grease the surfaces using a locally approved cleaning agent such as safety solvent or brake parts cleaner.

SPARE PARTS Only use "CNH Original Parts" or " CNH Parts".

Only genuine spare parts guarantee the same quality, duration and safety as original parts, as they are the same parts that are assembled during standard production. Only "CNH Original Parts" or " CNH Parts" can offer this guarantee.

When ordering spare parts, always provide the following information: •

machine model (commercial name) and serial number

•

part number of the ordered part, which can be found in the "Microfiches" or the "Service Parts Catalogue", used for order processing

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INTRODUCTION

PROTECTING THE ELECTRONIC/ ELECTRICAL SYSTEMS DURING CHARGING OR WELDING To avoid damage to the electronic/electrical systems, always observe the following: 1.

Never make or break any of the charging circuit connections, including the battery connections, when the engine is running.

2.

Never short any of the charging components to ground.

3.

Always disconnect the ground cable from the battery before arc welding on the combine or on any header attached to the combine.

4.

•

position the welder ground clamp as close to the welding area as possible

•

if welding in close proximity to a computer module, then the module should be removed from the combine

•

never allow welding cables to lay on, near or across any electrical wiring or electronic component while welding is in progress

Always disconnect the negative cable from the battery when charging the battery in the combine with a battery charger.

NOTICE: If welding must be performed on the unit, either the combine or the header (if it is attached), the battery ground cable must be disconnected from the combine battery. The electronic monitoring system and charging system will be damaged if this is not done.

Remove the battery ground cable. Reconnect the cable when welding is completed.

WARNING Battery acid causes severe burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing.

Antidote - EXTERNAL: flush with water. INTERNAL: drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or vegetables oil. Call physician immediately. EYES: flush with water for 15 minutes and get prompt medical attention.

84-110

TOOLS The tools that CNH suggests and illustrate in this manual have been: •

specifically researched and designed for use with CNH machines

•

essential for reliable repair operations

•

accurately built and rigorously tested so as to offer efficient and long-lasting operation

By using these tools, repair personnel will benefit from: •

operating in optimal technical conditions

•

obtaining the best results

•

saving time and effort

•

working in safe conditions

NOTE: The terms "front", "rear", "right-hand" and "left-hand" (when referred to different parts) are determined from the rear, facing in the direction of travel of the machine during operation.

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INTRODUCTION

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.

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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

20083681

2

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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)

20083680

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)

INTRODUCTION

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.

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INTRODUCTION

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

20083682

3

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

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INTRODUCTION

Inch Lock Nuts, All Metal (Three optional methods)

20090268

4

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

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

SERVICE MANUAL Engine

F2CFA614B*E019 F2CFA614C*E019

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Contents Engine - 10

Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.001 F2CFA614B*E019 , F2CFA614C*E019

Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.101 F2CFA614B*E019 , F2CFA614C*E019

Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.102 F2CFA614B*E019 , F2CFA614C*E019

Crankshaft and flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.103 F2CFA614B*E019 , F2CFA614C*E019

Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.105 F2CFA614B*E019 , F2CFA614C*E019

Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.106 F2CFA614B*E019 , F2CFA614C*E019

Balancer and damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.110 F2CFA614B*E019 , F2CFA614C*E019

Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.114 F2CFA614B*E019 , F2CFA614C*E019

Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.206 F2CFA614B*E019 , F2CFA614C*E019

Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.210 F2CFA614B*E019 , F2CFA614C*E019

Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.218 F2CFA614B*E019 , F2CFA614C*E019

Turbocharger and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.250 F2CFA614B*E019 , F2CFA614C*E019

Intake and exhaust manifolds and muffler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.254 F2CFA614B*E019 , F2CFA614C*E019

Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.304 F2CFA614B*E019 , F2CFA614C*E019

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10

Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.400 F2CFA614B*E019 , F2CFA614C*E019

Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.408 F2CFA614B*E019 , F2CFA614C*E019

Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.414 F2CFA614B*E019 , F2CFA614C*E019

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10

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10

Engine - 10 Engine and crankcase - 001

F2CFA614B*E019 F2CFA614C*E019

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Contents Engine - 10 Engine and crankcase - 001

TECHNICAL DATA Engine Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Engine Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Crankcase Liner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Liner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Liner - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Liner - Measure Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Engine - Engine and crankcase

Engine - Service limits Engine specifications Compression ratio Bore Stroke Displacement Turbocharging Lubrication Oil pressure (Warm engine) - Idling - Peak RPM Cooling Water pump control Thermostat (Start of opening) Intake valve timing - Opens before TDC - Closes after BDC Exhaust valve timing - Opens before BDC - Closes after TDC Valve lash setting (when engine is cold) - Intake - Exhaust Firing Order Injection pressure Injector calibration

15.9:1 117 mm (4.6 in) 135 mm (5.3 in) 8710 cm³ Inter-cooled, Direct injection Forced by gear pump, relief valve single action oil filter 4 bar (58 psi) 5 bar (73 psi) Liquid cooled Belt driven 83.5 - 86.5 °C (182.3 - 187.7 °F) 17 ° 31 ° 48 ° 9° 0.35 - 0.45 mm (0.014 - 0.018 in) 0.55 - 0.65 mm (0.022 - 0.026 in) 1-4-2-6-3-5 1800 bar (26100 psi) 290 - 302 bar (4205 - 4379 psi)

Cylinder block and piston Cylinder liner bore - Upper - Lower Cylinder liner external diameter - Upper - Lower Clearance between the OD of liners and ID of bores - Upper - Lower Cylinder liner - ID A* - ID B* * Selection class - Protrusion Pistons - Measuring dimension - External diameter (supplied as spares) - External diameter (production only) - Pin bore OD of piston - ID of cylinder liner Piston protrusion Piston pin diameter Piston pin OD - pin bore Piston ring grooves - Top

130.500 - 130.525 mm (5.138 - 5.139 in) 129.510 - 129.535 mm (5.099 - 5.100 in) 130.461 - 130.486 mm (5.136 - 5.137 in) 129.475 - 129.500 mm (5.097 - 5.098 in)

0.014 - 0.064 mm (0.001 - 0.003 in) 0.010 - 0.060 mm (0.0004 - 0.0024 in) 117.000 - 117.012 mm (4.606 - 4.607 in) 117.010 - 117.022 mm (4.607 - 4.607 in) 0.035 - 0.065 mm (0.001 - 0.003 in) 15 mm (0.591 in) 116.894 - 116.906 mm (4.602 - 4.603 in) 116.904 - 116.916 mm (4.603 - 4.603 in) 52.016 - 52.022 mm (2.048 - 2.048 in) 0.094 - 0.118 mm (0.004 - 0.005 in) 0.873 - 1.117 mm (0.034 - 0.044 in) 51.994 - 52.000 mm (2.047 - 2.047 in) 0.016 - 0.028 mm (0.0006 - 0.0011 in) 3.120 - 3.140 mm (0.123 - 0.124 in) 47441651 09/10/2012

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Engine - Engine and crankcase

- Middle - Bottom Piston rings - Combustion ring - Intermediate ring - Oil control ring Clearance between piston rings and grooves - Combustion ring - Intermediate ring - Oil control ring Piston ring end gap in cylinder liners - Combustion ring - Intermediate ring - Oil control ring

2.550 - 2.570 mm (0.100 - 0.101 in) 4.02 - 4.04 mm (0.158 - 0.159 in) 3.000 mm (0.118 in) 2.470 - 2.500 mm (0.097 - 0.098 in) 3.970 - 3.990 mm (0.156 - 0.157 in) 0.050 - 0.100 mm (0.002 - 0.004 in) 0.030 - 0.070 mm (0.001 - 0.003 in) 0.3 - 0.4 mm (0.012 - 0.016 in) 0.60 - 0.75 mm (0.024 - 0.030 in) 0.35 - 0.65 mm (0.014 - 0.026 in)

Connecting rod Small end bush housing - Nominal Big end bearing housing - Nominal - Class 1 - Class 2 - Class 3 Small end bushing diameter - Outside - Inside Big end bearing shell thickness - Red - Green - Yellow Clearance between small end bush and housing Clearance between piston pin and bushing Connecting rod weight - Class A - Class B - Class C Maximum connecting rod axis misalignment tolerance

55.700 - 55.730 mm (2.193 - 2.194 in) 85.987 85.987 85.997 86.006

-

86.013 85.996 86.005 86.013

mm mm mm mm

(3.385 (3.385 (3.386 (3.386

-

3.386 3.386 3.386 3.386

in) in) in) in)

55.780 - 55.820 mm (2.196 - 2.198 in) 52.015 - 52.030 mm (2.048 - 2.048 in) 1.994 - 2.002 mm (0.079 - 0.079 in) 2.002 - 2.010 mm (0.079 - 0.079 in) 2.010 - 2.018 mm (0.079 - 0.079 in) 0.05 - 0.12 mm (0.002 - 0.005 in) 0.015 - 0.036 mm (0.001 - 0.001 in) 3308 - 3338 g (116.7 - 117.7 oz) 3339 - 3368 g (117.8 - 118.8 oz) 3369 - 3398 g (118.8 - 119.9 oz) 0.08 mm (0.003 in)

Crankshaft Main journals - Rated value - Class 1 - Class 2 - Class 3 Crankpins - Rated value - Class 1 - Class 2 - Class 3 Main bearing shells - Red - Green - Yellow Big end bearing shells - Red

92.970 92.970 92.980 92.990

-

93.000 92.979 92.989 93.000

mm mm mm mm

(3.6602 (3.6602 (3.6606 (3.6610

-

81.915 81.915 81.925 81.935

-

81.945 81.924 81.934 81.945

mm mm mm mm

(3.225 (3.225 (3.225 (3.226

3.226 3.225 3.226 3.226

-

3.6614 3.6606 3.6610 3.6614

in) in) in) in)

2.968 - 2.978 mm (0.117 - 0.117 in) 2.978 - 2.988 mm (0.117 - 0.118 in) 2.988 - 2.998 mm (0.118 - 0.118 in) 1.994 - 2.002 mm (0.079 - 0.079 in)

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in) in) in) in)

Engine - Engine and crankcase

- Green - Yellow Main bearing housings - Rated value - Class 1 - Class 2 - Class 3 Clearance between bearing shells and main journals Clearance between bearing shells and big ends Main journal, thrust bearing Main bearing housing, thrust bearing Thrust bearing thickness Crankshaft end play Main journals and Crankpins - Alignment - Ovalization - Taper

2.002 - 2.010 mm (0.079 - 0.079 in) 2.010 - 2.018 mm (0.079 - 0.079 in) 99.000 - 99.030 mm (3.8976 - 3.8988 in) 99.000 - 99.009 mm (3.8976 - 3.8980 in) 99.010 - 99.019 mm (3.8980 - 3.8984 in) 99.020 - 99.030 mm (3.8984 - 3.8988 in) 0.050 - 0.090 mm (0.0020 - 0.0035 in) 0.040 - 0.080 mm (0.0016 - 0.0031 in) 32.94 - 32.99 mm (1.297 - 1.299 in) 38.94 - 38.99 mm (1.533 - 1.535 in) 3.38 - 3.43 mm (0.133 - 0.135 in) 0.09 - 0.34 mm (0.004 - 0.013 in) 0.04 mm (0.002 in) -

Cylinder head and valve train Valve guide housing in cylinder head Valve guide - Inside diameter - Outside diameter Valve guides - housings in the cylinder head Intake valves - Valve stem diameter - Valve face angle Exhaust valves - Valve stem diameter - Valve face angle Clearance between valve guide and valve stem Valve seat in cylinder head - Intake - Exhaust Outside diameter of valve seat - Intake - Exhaust Valve seat angle - Intake - Exhaust Recessing of the valves - Intake - Exhaust Clearance between valve seat and cylinder head - Intake - Exhaust Valve spring height at No load 437 - 483 N (98 - 109 lb) load 707 - 773 N (159 - 174 lb) load Injector protrusion Camshaft bushing housing in the cylinder head Camshaft bearing journals O.D. of the camshaft bushings

12.980 - 12.997 mm (0.511 - 0.512 in) 8.023 - 8.038 mm (0.316 - 0.316 in) 13.012 - 13.025 mm (0.512 - 0.513 in) 0.015 - 0.045 mm (0.0006 - 0.0018 in) 7.970 - 7.985 mm (0.314 - 0.314 in) 60 ° 7.970 - 7.985 mm (0.314 - 0.314 in) 45 ° 0.040 - 0.070 mm (0.0016 - 0.0028 in) 41.985 - 42.020 mm (1.653 - 1.654 in) 40.985 - 41.020 mm (1.614 - 1.615 in) 42.060 - 42.075 mm (1.656 - 1.656 in) 42.060 - 42.075 mm (1.656 - 1.656 in) 60 ° 45 ° 0.5 - 0.8 mm (0.020 - 0.031 in) 1.6 - 1.9 mm (0.063 - 0.075 in)

0.040 - 0.090 mm (0.0016 - 0.0035 in) 0.040 - 0.090 mm (0.0016 - 0.0035 in) 70.77 mm (2.786 in) 51.00 mm (2.008 in) 39.00 mm (1.535 in) 1.2 - 1.5 mm (0.047 - 0.059 in) 69.000 - 69.030 mm (2.717 - 2.718 in) 64.924 - 64.940 mm (2.556 - 2.557 in) 69.090 - 69.155 mm (2.720 - 2.723 in) 47441651 09/10/2012

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Engine - Engine and crankcase

I.D. of the camshaft bushings Clearance between bushings and housings in the cylinder head Clearance between bushings and bearing journals Cam lift - Intake lobe - Exhaust lobe Diameter of the rocker shaft Bushing housing in the rocker arms - Intake - Exhaust Clearance between bushings and housings - Intake - Exhaust - Injector Clearance between bushings of rocker arms and shaft - Intake - Exhaust

64.990 - 65.045 mm (2.559 - 2.561 in) 0.060 - 0.115 mm (0.002 - 0.005 in) 0.050 - 0.122 mm (0.002 - 0.005 in)

7.4034 mm (0.2915 in) 8.2108 mm (0.3233 in) 31.964 - 31.980 mm (1.258 - 1.259 in) 32.025 - 32.041 mm (1.261 - 1.261 in) 32.025 - 32.041 mm (1.261 - 1.261 in) 0.074 - 0.130 mm (0.0029 - 0.0051 in) 0.081 - 0.140 mm (0.0032 - 0.0055 in) 0.050 - 0.091 mm (0.0020 - 0.0036 in)

0.045 - 0.077 mm (0.002 - 0.003 in) 0.045 - 0.077 mm (0.002 - 0.003 in)

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Engine - Engine and crankcase

Engine - Detailed view

LHSIDEVIEW4

1

Left Hand Side View

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Engine - Engine and crankcase

RHSIDEVIEW4

2

Right Hand Side View

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Engine - Engine and crankcase

FRONTVIEW4

3

Front View

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Engine - Engine and crankcase

REARVIEW4

4

Rear View

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Engine - Engine and crankcase

TOPVIEW4

5

Top View

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Engine - Engine and crankcase

Engine - Service instruction - Finding Top Dead Center (TDC) 1.

Install the tool 380003118 to the flywheel housing in place of the starter.

2.

Turn the engine flywheel in the direction of normal rotation.

3.

Look for the hole with one reference mark that appears after the hole with two reference marks on the engine flywheel through the inspection hole on the bottom of the flywheel housing.

4.

This closely indicates cylinder number one being on Top Dead Center (TDC) of the compression stroke.

5.

To obtain the exact position of cylinder one TDC, remove the engine speed sensor.

6.

Insert the tool 380000150 (1) through the speed sensor hole.

7.

The tool (1) should go into the hole (3) in the engine flywheel (4). If not, turn the flywheel (4) in the direction of normal rotation until the tool (1) drops in to the hole (3).

8.

Remove the tool (1).

TOPDEADCENTER2

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1

Engine - Engine and crankcase

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

Use tool 380000366 (2) in conjunction with tool 380000152 (4) as shown in the figure.

2.

Check to make sure the plate (4) rests on the cylinder liner correctly.

3.

Screw down the nut of the screw (1) and extract the cylinder liner (3) from the crankcase.

LINERPULLER

Next operation: Crankcase Liner - Measure (10.001)

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1

Engine - Engine and crankcase

Crankcase Liner - Install Prior operation: Crankcase Liner - Measure (10.001) 1.

Whenever the liners are removed, the water seals (3), (4) and (5) must be replaced before installing liners into the cylinder block.

2.

Install the adjusting ring (1) on the cylinder liner (2).

3.

Lubricate the seals and install the liner into the cylinder block using the appropriate tool.

NOTE: The adjustment ring (1) is supplied as a spare part with the following thicknesses: - 0.08 mm (0.0031 in) - 0.10 mm (0.0039 in) - 0.12 mm (0.0047 in).

4.

CYLINDERLINER

1

LINERLOCK

2

After completing the installation of all the cylinder liners, lock the cylinder liners (1) to the block (2) with the pins 380000363 (3).

Next operation: Crankcase Liner - Measure (10.001)

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Engine - Engine and crankcase

Crankcase Liner - Measure Prior operation: Crankcase Liner - Remove (10.001) 1.

The internal diameter of the cylinder liner is checked for ovalization, taper, and wear, using a bore dial (1) centesimal gauge (2) previously set to ring gauge (3), which has a diameter of 117 mm (4.606 in).

NOTE: If a 117 mm (4.606 in) is not available, it is acceptable to use a micrometer.

2.

LINERMEASURE

1

LINERMEASURE2

2

LINERMEASURE4

3

The measurements have to be made on each single cylinder liner at three different heights and in two different positions perpendicular to each other as shown in the figure.

3.

Upon finding a maximum wear value greater than 0.150 mm (0.006 in) or maximum ovalization value greater than 0.100 mm (0.004 in) as compared to the values in the following table, you need to replace the cylinder liner. No grinding, facing, or reconditioning is permitted.

4.

Selection Class •

A = 117.000 - 117.012 mm (4.606 - 4.607 in).

•

B = 117.010 - 117.022 mm (4.607 - 4.607 in).

NOTE: The cylinder liners are supplied as spare parts with selection class "A".

"X" - Indicates the location of the marking that designates the selection class.

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Engine - Engine and crankcase

5.

The diagram shown in the figure gives the outside diameter of the cylinder liner and the inside diameter of its seat. The cylinder liners can, if necessary, be extracted and installed several times in different seats.

•

A = 130.500 - 130.525 mm (5.1378 - 5.1388 in).

•

B = 129.510 - 129.535 mm (5.0988 - 5.0998 in).

•

C = 130.461 - 130.486 mm (5.1363 - 5.1372 in).

•

D = 129.475 - 129.500 mm (5.0974 - 5.0984 in).

LINERSINBLOCK

LINERMEASURE3

5

Crankcase Assembly With Cylinder Liners Next operation: Crankcase Liner - Install (10.001)

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4

Engine - Engine and crankcase

Crankcase Liner - Measure Protrusion Prior operation: Crankcase Liner - Install (10.001) 1.

Place the compression plate 380000115 (1) on top of the cylinder liner.

2.

Install the tool 380000140 (2) using the spacers 380000142 (3) and existing head bolts (7).

3.

Tighten the screw (4) to a torque of 170 N·m (125 lb ft).

4.

Using the dial gauge 380001004 (5) and the dial gauge base 380000364, (6) check that the protrusion of the cylinder liner over block deck is 0.035 0.065 mm (0.001 - 0.003 in).

5.

If the protrusion is not within spec, remove the liner.

Refer to Crankcase Liner - Remove (10.001) for specific instructions.

6.

Replace the adjusting ring. Refer to Crankcase Liner - Install (10.001) callout (1). Choose the appropriate thickness to achieve the desired specification.

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

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PROTRUSION

1

Index Engine - 10 Engine and crankcase - 001 Crankcase Liner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Crankcase Liner - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Crankcase Liner - Measure Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Crankcase Liner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Engine - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine - Service instruction - Finding Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Cylinder heads - 101

F2CFA614B*E019 F2CFA614C*E019

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Contents Engine - 10 Cylinder heads - 101

SERVICE Valve cover Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Cylinder head Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Valves Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Valve guide Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Valve seat Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Engine - Cylinder heads

Valve cover - Remove 1.

Remove the bolts (2) and remove the valve cover (1).

VALVECOVER4

Next operation: Valve cover - Install (10.101)

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1

Engine - Cylinder heads

Valve cover - Remove 1.

2.

3.

4.

Remove the support bracket (1).

83116810

1

83116811

2

83116812

3

83116815

4

Remove the top valve cover (2).

Remove the turbocharger (3).

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

Remove the lower valve cover (4).

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Engine - Cylinder heads

Valve cover - Install Prior operation: Valve cover - Remove (10.101) 1.

Install the valve cover (1) and tighten the screws (2) to the required torque using the sequence illustrated below.

VALVECOVER4

VALVECOVER

2

Valve cover torque sequence

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1

Engine - Cylinder heads

Valve cover - Install 1.

Install the lower valve cover (1).

2.

Torque the bolts (2) to standard torque value.

3.

Install the top valve cover (3).

4.

Torque the bolts (4) to standard torque value.

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83116815

1

83116811

2

Engine - Cylinder heads

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

Install the tool 380000131 (9) with bracket (4).

2.

Install the plate 380000112 (2) then screw on the lever (1) for the tool 380000131 and compress the valve springs (6) until the keepers (3) are removed.

3.

Loosen the lever (1) and remove the plate (2).

4.

Remove the upper plate (5), the spring (6), and the lower plate (7). Repeat this operation for all cylinders.

5.

Turn the cylinder head upside down and remove the valves (8).

VALVESPRING

Next operation: Cylinder head - Assemble (10.101)

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1

Engine - Cylinder heads

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

Check the sealing surface (1) of the cylinder head for flatness using a straight edge (2) and a set of feeler gauges (3).

2.

If deformations are found, the head surface must be machined. The maximum amount of material to be removed is 0.2 mm (0.008 in).

NOTICE: Valve sink and injector protrusion must be checked and must meet the proper specifications after machining the cylinder head surface.

CYLINDERHEAD

Next operation: Cylinder head - Install (10.101)

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1

Engine - Cylinder heads

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

Installing the valves and valve seals 1.

Lubricate the valve stem and insert the valves in the respective valve guides.

2.

Install the lower caps (1).

3.

Use the tool 380000114 and install the valve seals (2) on the valve guides (3) of the exhaust valves.

VALVESEAL

1

VALVESPRING4

2

Installing the valve springs 4.

Set the springs (6) and the upper plates (5) over the valve stems.

5.

Install tool 380000131 (7) and secure it with bracket (4).

6.

Set tool 380000112 (2) over the springs (6) and secure it with the lever (1) from tool 380000131.

7.

Tighten the lever (1) to compress the valve springs (6) and install the keepers (3).

8.

Remove the tools (2) and (7).

Next operation: Cylinder head - Install (10.101)

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Engine - Cylinder heads

Cylinder head - Remove Prior operation: Fuel injectors - Remove (10.218) 1.

Remove the cylinder head retaining screws.

2.

Using a suitable hoist (1), lift the cylinder head (2) from the cylinder block (3).

CYLINDERHEAD

Next operation: Cylinder head - Install (10.101)

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1

Engine - Cylinder heads

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

Set the pistons 1 and 6 to top dead center.

2.

Install the head gasket (2) onto the block deck.

3.

Using a suitable hoist (1), carefully lower the cylinder head (3) into position on the block.

4.

5.

CYLINDERHEAD

1

CYLINDERHEAD2

2

CYLINDERHEAD3

3

Lubricate the bolts with clean engine oil and tighten the bolts to the required torque following the steps below. Refer to the diagram 4 below for the proper torque order.

•

Stage 1 = 50 N·m (37 lb ft)

•

Stage 2 = 100 N·m (74 lb ft)

Using the angle measurement tool 380000304 (1), turn the bolts to the angle described below. Refer to the diagram 4 below for the proper torque order.

•

Stage 3 = 90 °

•

Stage 4 = 75 °

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Engine - Cylinder heads

CYLINDERHEAD4

4

Cylinder head torque order diagram Next operation: Fuel injectors - Install (10.218)

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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.

BAPH04APH151ASA

Next operation: Valves - Measure (10.101)

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1

Engine - Cylinder heads

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

Using a micrometer, check that the valve stem measurements are as specified.

2.

If necessary, grind the valve seats, removing the least amount of material as possible.

VALVE

Next operation: Cylinder head - Assemble (10.101)

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1

Engine - Cylinder heads

Valves Spring - Check Prior operation: Cylinder head - Disassemble (10.101)

VALVESPRING2

1.

Before assembly, the flexibility of the valve springs must be checked.

2.

Compare the load and elastic deformation data with those of the new springs given below.

•

(H) = 70.77 mm (2.786 in) at no load.

•

(H1) = 51 mm (2.008 in) at a load of 437 - 483 N (98 - 109 lb).

•

(H2) = 39 mm (1.535 in) at a load of 707 - 773 N (159 - 174 lb).

1

VALVESPRING

Next operation: Cylinder head - Assemble (10.101)

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2

Engine - Cylinder heads

Valve guide - Replace Prior operation: Cylinder head - Disassemble (10.101)

VALVEGUIDE

1.

Remove the valve guides by means of tool 380000365.

2.

Install the guides using tools 380000365 and 380000136.

3.

Tool 380000136 determines the exact assembly position of the of the valve guides in the cylinder head. If the tool is not available, the guides need to be driven into the cylinder head so they protrude by 16.3 - 16.7 mm (0.642 - 0.657 in).

1

Next operation: Cylinder head - Assemble (10.101)

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Engine - Cylinder heads

Valve seat - Replace Prior operation: Cylinder head - Disassemble (10.101) 1.

To replace the valve seats, follow the procedure below.

NOTE: Valve must be ground whenever the valves or valve guides are replaced or ground.

2.

Check the valve seats (2). If slight scratches or burns are found, ream them with a suitable tool (1) according to the specifications.

3.

If it is necessary to replace them, use the reaming tool, taking care not to affect the cylinder head, remove as much material as possible from the valve seat. This will make it easier to remove the valve seat with a punch.

4.

To install the valve seats, heat the cylinder head to 80 - 100 °C (176 - 212 °F).

5.

While the cylinder head is being heated, chill the valve seats using liquid nitrogen.

6.

Using the appropriate drift, install the valve seats (2) in the cylinder head.

7.

Using tool (1), grind the valve seats to the specified angles.

8.

After grinding the valve seats, using tool 380000364 and dial gauge 380001004, check the valve sink is as specified:

VALVESEAT

•

Intake = 0.5 - 0.8 mm (0.020 - 0.031 in).

•

Exhaust = 1.6 - 1.9 mm (0.063 - 0.075 in).

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1

Engine - Cylinder heads

VALVESEAT

2

Next operation: Cylinder head - Assemble (10.101)

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Index Engine - 10 Cylinder heads - 101 Cylinder head - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Cylinder head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cylinder head - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Valve guide - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Valve seat - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Valves - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Valves - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Valves Spring - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Engine - 10 Pan and covers - 102

F2CFA614B*E019 F2CFA614C*E019

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Contents Engine - 10 Pan and covers - 102

SERVICE Engine oil pan Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Engine block cover Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Rear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Engine - Pan and covers

Engine oil pan - Remove 1.

Remove the screws (1).

2.

Remove the mounting plate (2), oil pan (3) and seal.

3.

OILPAN2

1

OILPAN4

2

Remove the screws (1) and disconnect the oil pick up tube (2).

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Engine - Pan and covers

Engine oil pan - Install NOTICE: Make sure all components are clean prior to assembly.

1.

2.

3.

4.

Lay out the bracket (1) and rubber gasket (2) on a flat surface as shown.

23119873

1

23119843

2

23119844

3

23119835

4

Spray soapy water around the edges (1) of the oil pan.

Install the gasket (1) onto the oil pan (2).

Install the bracket (1) on the oil pan (2) and dry the water.

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Engine - Pan and covers

5.

6.

Remove the plug (1) from the flywheel housing.

23119838

5

23119839

6

23119839

7

23009845

8

Apply a bead of LOCTITE® 5970 to the engine block approximately 1.5 mm (0.059 in) thick at the joints of the front cover (1) and flywheel housing (2).

NOTE: Installation of the oil pan is recommended within 5 min of sealant application.

7.

8.

Install M10x1.5 guide pins that are approximately 120 mm long into locations (5), (10), (17) and (22) to ensure proper alignment of the oil pan during assembly.

Apply LOCTITE® 5970 to all four corners of the oil pan gasket.

NOTE: 60 - 80 ° coverage is recommended.

NOTE: Installation of the oil pan is recommended within 5 min of sealant application.

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Engine - Pan and covers

9.

Evenly lift the oil pan assembly (1) onto the engine block.

23119840

10.

9

Install oil pan bolts into locations (1), (2), (3) and (4) and hand tighten.

NOTICE: Ensure no movement of the oil pan assembly occurs.

11.

Install the remaining oil pan bolts.

12.

Torque the bolts to 40 - 46 N·m (30 - 34 lb ft) following the torque order shown.

13.

Repeat step 12.

14.

23119841

10

23119846

11

23119840

12

Check the gap between the oil pan bracket (2) and engine block (1) using a feeler gauge. The measurement should be no more than 0.1 mm (0.004 in).

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Engine - Pan and covers

15.

Install the plug (1) in the flywheel housing.

23119842

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13

Engine - Pan and covers

Engine block cover Front - Remove Prior operation: Crankshaft damper - Remove (10.110) 1.

Remove the screws (1) and detach the cover from the engine block (2).

FRONTCOVER2

Next operation: Engine block cover Front - Install (10.102)

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1

Engine - Pan and covers

Engine block cover Front - Install Prior operation: Engine block cover Front - Remove (10.102) 1.

2.

Apply the appropriate sealant (1) to the sealing surface of the front cover (2).

FRONTCOVER

1

FRONTCOVER2

2

Install the front cover (1) onto the engine block and tighten the screws (2) to the required torque.

Next operation: Crankshaft damper - Install (10.110)

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Engine - Pan and covers

Engine block cover Rear - Remove Prior operation: Engine flywheel - Remove (10.103) 1.

Remove the screws (1) and remove the rear cover (2).

REARCOVER

Next operation: Engine block cover Rear - Install (10.102)

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1

Engine - Pan and covers

Engine block cover Rear - Install Prior operation: Engine block cover Rear - Remove (10.102) 1.

Clean the sealing surface of the rear cover (2) and apply LOCTITE® 598 ULTRA BLACK (1) or equivalent silicone sealant onto cover with a bead diameter of 1.3 - 2 mm (0.051 - 0.079 in) as shown in the figure.

NOTICE: The rear cover must be installed with 10 minutes of sealant application.

2.

Install the rear cover using a torque wrench.

3.

Tighten the bolts to standard torque using the torque charts provided. Torque - Minimum tightening torques for normal assembly ().

Next operation: Engine flywheel - Install (10.103)

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REARCOVER2

1

REARCOVER3

2

Index Engine - 10 Pan and covers - 102 Engine block cover Front - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine block cover Front - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine block cover Rear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine block cover Rear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Crankshaft and flywheel - 103

F2CFA614B*E019 F2CFA614C*E019

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10.103 / 1

Contents Engine - 10 Crankshaft and flywheel - 103

FUNCTIONAL DATA Engine flywheel Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine flywheel Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Crankshaft oil seal Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Crankshaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Service instruction - Bearing selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Crankshaft gears Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Main bearings Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Engine - Crankshaft and flywheel

Engine flywheel - Detailed view

FLYWHEEL2

1

Engine Flywheel This illustration shows the reference marks on the flywheel indicating the position of the cylinders.

•

(A) - Hole with one reference mark corresponding to the TDC of pistons 3 and 4.

•

(B) - Hole with one reference mark corresponding to the TDC of pistons 1 and 6.

•

(C) - Hole with one reference mark corresponding to the TDC of pistons 2 and 5.

•

(D) - Hole with two reference marks that indicates 54 ° before TDC of pistons 1 and 6.

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Engine - Crankshaft and flywheel

Engine flywheel - Remove 1.

To keep the engine flywheel (3) from turning, install tool 380000144 (1).

2.

Remove the bolts (2) and carefully remove the flywheel (3) from its housing (4).

FLYWHEEL

Next operation: Engine flywheel - Install (10.103)

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1

Engine - Crankshaft and flywheel

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

Align the dowel pin with the relevant hole on the flywheel (1).

2.

Install the flywheel (1) on the crankshaft.

3.

Lubricate the threads on the bolts (2) with engine oil make them snug.

4.

Install the tool 380000144 (3) to keep the flywheel from rotating.

5.

Tighten the bolts (2) to a torque of 100 N·m (74 lb ft).

6.

FLYWHEEL4

1

FLYWHEEL5

2

Using tool 380000304 (1) turn the bolts 60 °.

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Engine - Crankshaft and flywheel

Crankshaft oil seal Rear seal - Remove Prior operation: Engine flywheel - Remove (10.103) 1.

Install the seal removal tool 380000121 (2) and remove the seal (1).

REARSEAL

Next operation: Crankshaft oil seal Rear seal - Install (10.103)

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1

Engine - Crankshaft and flywheel

Crankshaft oil seal Rear seal - Install Prior operation: Crankshaft oil seal Rear seal - Remove (10.103) 1.

Install the seal (1) onto the tool 380000127 (2).

2.

Mount the tool (2) onto the crankshaft.

3.

Tighten the nut (3) to drive the seal (1) into the rear cover.

REARSEAL2

Next operation: Engine flywheel - Install (10.103)

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1

Engine - Crankshaft and flywheel

Crankshaft oil seal Front seal - Remove Prior operation: Crankshaft damper - Remove (10.110) 1.

Remove the front main seal (1) from the front cover (3) using tool 380000118 (2).

FRONTSEAL4A

Next operation: Crankshaft oil seal Front seal - Install (10.103)

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1

Engine - Crankshaft and flywheel

Crankshaft oil seal Front seal - Install Prior operation: Crankshaft oil seal Front seal - Remove (10.103) 1.

Install the seal (1) onto the tool 380000124 (2).

2.

Install the tool (2) onto the front cover (3).

3.

Install the seal (1) by tightening the center nut (4) of the tool.

FRONTSEAL5

Next operation: Crankshaft damper - Install (10.110)

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1

Engine - Crankshaft and flywheel

Crankshaft - Remove 1.

Remove the crankshaft (2) using tool 380000362 (1).

CRANKSHAFT

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1

Engine - Crankshaft and flywheel

Crankshaft - Service instruction - Bearing selection 1.

2.

Determine the class of each connecting rod by identifying the color code marked on the connecting rod as shown.

•

(1) - Weight grade

•

(2) - Diameter class

Use the tables below to identify the weight grade and diameter class of each connecting rod.

NHVM12ENG0013AA

1

Weight grade Color Yellow Green Blue

Grade A B C

Weight 3450 - 3470 g (121.70 - 122.40 oz) 3471 - 3490 g (122.44 - 123.11 oz) 3491 - 3510 g (123.14 - 123.81 oz)

Class 1 2 3

Diameter 85.987 - 85.996 mm (3.3853 - 3.3857 in) 85.997 - 86.005 mm (3.3857 - 3.3860 in) 86.006 - 86.013 mm (3.3861 - 3.3863 in)

Diameter class Color Yellow Green Blue 3.

Determine the diameter class of the crank pin journals. The class numbers are stamped on the last throw of the crankshaft at the time of manufacture.

NOTE: If the crankshaft has been ground or you cannot find the stamping, each journal must be measured and classed individually.

4.

Use the tables below to determine the correct bearing halves to be used for each connecting rod and crank pin combination.

NOTE: The upper (U) and lower (L) bearing halves can be different thicknesses.

NHVM12ENG0011AA

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2

Engine - Crankshaft and flywheel

Bearing selection for a standard crankshaft

Standard

Crank pin diameter

Class

81.915 - 81.925 mm (3.2250 - 3.2254 in)

1

81.925 - 81.935 mm (3.2254 - 3.2258 in)

81.935 - 81.945 mm (3.2258 - 3.2262 in)

1

2

3

(U)

Green

Green

Yellow*

(L)

Green

Yellow*

Yellow*

(U)

Red

Green

Green

(L)

Green

Green

Yellow*

(U)

Red

Red

Green

(L)

Red

Green

Green

1

2

3

(U)

Green/Black

Green/Black

Yellow/Black*

(L)

Green/Black

Yellow/Black*

Yellow/Black*

(U)

Red/Black

Green/Black

Green/Black

(L)

Green/Black

Green/Black

Yellow/Black*

(U)

Red/Black

Red/Black

Green/Black

(L)

Red/Black

Green/Black

Green/Black

2

3

Red = 1.994 - 2.002 mm (0.0785 - 0.0788 in) Green = 2.002 - 2.010 mm (0.0788 - 0.0791 in) Yellow* = 2.010 - 2.018 mm (0.0791 - 0.0794 in) * Production only. Substitute with Green bearings if needed.

Bearing selection for an undersize crankshaft

-0.127 mm (-0.005 in)

Crank pin diameter

Class

81.789 - 81.799 mm (3.2200 - 3.2204 in)

1

81.799 - 81.809 mm (3.2204 - 3.2208 in)

2

81.809 - 81.819 mm (3.2208 - 3.2212 in)

3

Red/Black = 2.057 - 2.065 mm (0.0810 - 0.0813 in) Green/Black = 2.065 - 2.073 mm (0.0813 - 0.0816 in) Yellow/Black* = 2.073 - 2.081 mm (0.0816 - 0.0819 in) * Production only. Substitute with Green/Black bearings if needed.

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Engine - Crankshaft and flywheel

Determine the block bearing bore class. The class numbers are stamped on the inside of the block at the number seven main journal.

5.

NHVM12ENG0010AA

3

NHVM12ENG0012AA

4

Determine the diameter class of the main journals.

The class numbers are stamped on the last throw of the crankshaft at the time of manufacture.

NOTE: If the crankshaft has been ground or you cannot find the stamping, each journal must be measured and classed individually.

6.

Use the tables below to determine the correct bearing halves to be used for each block bore and main journal combination.

NOTE: The upper (U) and lower (L) bearing halves can be different thicknesses.

Bearing selection for a standard crankshaft

Standard

Main journal diameter

Class

92.970 - 92.980 mm (3.6602 - 3.6606 in)

1

92.980 - 92.990 mm (3.6606 - 3.6610 in)

2

92.990 - 93.000 mm (3.6610 - 3.6614 in)

1

2

3

(U)

Green

Green

Yellow*

(L)

Green

Yellow*

Yellow*

(U)

Red

Green

Green

(L)

Green

Green

Yellow*

(U)

Red

Red

Green

(L)

Red

Green

Green

3

Red = 2.968 - 2.978 mm (0.1169 - 0.1172 in) Green = 2.978 - 2.988 mm (0.1172 - 0.1176 in) Yellow* = 2.988 - 2.998 mm (0.1176 - 0.1180 in) * Production only. Substitute with Green bearings if needed.

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Engine - Crankshaft and flywheel

Bearing selection for an undersize crankshaft

-0.127 mm (-0.005 in)

Main journal diameter

Class

92.843 - 92.853 mm (3.6552 - 3.6556 in)

1

92.853 - 92.863 mm (3.6556 - 3.6560 in)

2

92.863 - 92.872 mm (3.6560 - 3.6564 in)

3

1

2

3

(U)

Green/Black

Green/Black

Yellow/Black*

(L)

Green/Black

Yellow/Black*

Yellow/Black*

(U)

Red/Black

Green/Black

Green/Black

(L)

Green/Black

Green/Black

Yellow/Black*

(U)

Red/Black

Red/Black

Green/Black

(L)

Red/Black

Green/Black

Green/Black

Red/Black = 3.031 - 3.041 mm (0.1193 - 0.1197 in) Green/Black = 3.041 - 3.051 mm (0.1197 - 0.1201 in) Yellow/Black* = 3.051 - 3.061 mm (0.1201 - 0.1205 in) * Production only. Substitute with Green/Black bearings if needed.

7.

Verify the oil clearance is within the specifications below using plastic gauge. Refer to Crankshaft Journal - Clearance (10.103) for the proper procedure.

•

Main journals: 0.050 - 0.090 mm (0.0020 0.0035 in)

•

Crank pin journals: 0.040 - 0.080 mm (0.0016 - 0.0031 in)

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Engine - Crankshaft and flywheel

Crankshaft - End play 1.

The end play is checked by setting a dial gauge 380001004 (2) with a magnetic base on the crankshaft (1) as shown in the figure. If you find the end play to be greater than the specification, the bearing shells with the thrust bearing must be replaced. Repeat the check.

CRANKENDPLAY

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1

Engine - Crankshaft and flywheel

Crankshaft Journal - Clearance Prior operation: Crankshaft - Remove (10.103) 1.

2.

3.

Install the appropriate main bearing halves (1) into their seats in the cylinder block.

MAINBEARING

1

CRANKSHAFT

2

MAINCAPS

3

Using the hoist and tool 380000362 (1), install the crankshaft (2) in the cylinder block.

Place the main bearing halves (1) on the main journals (2).

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Engine - Crankshaft and flywheel

4.

Place a section of calibrated wire (2), lengthwise on the crankshaft journal (3).

5.

Install the main journals (1).

6.

MAINCAPS2

4

CALIBRATEDWIRE2

5

MAINCAPS3

6

The clearance between the main bearings and their journals is measured by comparing the width of the calibrated wire (2) at its widest point to the graduated scale on the packaging (1) containing the calibrated wire. The numbers on the scale give the clearance of the coupling in millimeters. If you find the clearance is not within the specification, replace the bearings and repeat the clearance check.

7.

Position the main bearing caps (4) and fit the strengthening plate (2) following the procedure described.

8.

Tighten the inner bolts (3) and then the outer bolts (1) by hand starting from main journal 7 and continuing until main journal 1.

9.

Tighten the bolts using torque wrench always starting from main journal 7 and continuing until main journal 1.

10.

Tighten the bolts in the following stages: •

140 N·m (103 lb ft)

•

60 °

•

60 °

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Engine - Crankshaft and flywheel

Crankshaft gears - Replace 1.

Check the teeth on the gear (1). If they are damaged or worn, the gear must be replaced using an appropriate extractor.

2.

When it is time to install the gear (1) onto the crankshaft (2), the gear must be heated for a maximum of 2 hours in a furnace at a temperature no higher than 180 °C (356 °F).

3.

Install the gear (1) on the crankshaft (2) while it is still hot. Allow it to cool down after installation.

4.

If replacing the alignment pin (3), check the protrusion after installation. It should be 2.5 - 3.5 mm (0.098 - 0.138 in) from the face of the crankshaft (2).

CRANKGEAR

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1

Engine - Crankshaft and flywheel

Main bearings - Remove Prior operation: Crankshaft - Remove (10.103) 1.

Remove the crankshaft half bearings (1) from the cylinder block.

MAINBEARING

Next operation: Crankshaft Journal - Clearance (10.103)

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1

Index Engine - 10 Crankshaft and flywheel - 103 Crankshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Crankshaft - Service instruction - Bearing selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Crankshaft Journal - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Crankshaft gears - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Crankshaft oil seal Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Crankshaft oil seal Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Crankshaft oil seal Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Crankshaft oil seal Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine flywheel - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Main bearings - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Engine - 10 Connecting rods and pistons - 105

F2CFA614B*E019 F2CFA614C*E019

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Contents Engine - 10 Connecting rods and pistons - 105

FUNCTIONAL DATA Connecting rod and piston Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Connecting rod and piston Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Engine - Connecting rods and pistons

Connecting rod and piston - Exploded view

CONRODPISTON

(1) (2) (3) (4) (5)

Connecting rod Half bearings Connecting rod cap Cap bolts Snap ring

1

(6) Oil control ring (7) Bevel cut intermediate ring (8) Trapazoidal combustion ring (9) Piston pin (10) Piston

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Engine - Connecting rods and pistons

Connecting rod and piston - Remove Prior operation: Engine oil pan - Remove (10.102) 1.

Rotate the block (1) to the vertical position.

2.

Remove the screws (2) from the connecting rod cap (3)and remove the cap (3) from the connecting rod.

3.

Remove the piston (1) and the connecting rod assembly from the top side of the engine block.

4.

Repeat these steps for the remaining cylinders.

ENGINEROTATE

1

PISTONASSM

2

NOTE: Keep the connecting rod half bearings in the corresponding housings and or take note of their assembly position because they must be installed in the original position if they are reused.

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.

Make sure that the piston does not show any signs of seizing, scoring or cracking. Replace if necessary.

2.

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

3.

PISTONRING

1

PISTONPIN

2

Remove the snap rings (2) that hold the piston pin in place using round tipped pliers (1).

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Engine - Connecting rods and pistons

4.

Remove the piston pin (1). It may be necessary to use hammer and wooden dowel to remove the pin.

PISTONPIN2

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

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3

Engine - Connecting rods and pistons

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

2.

Install the piston pin (1).

PISTONPIN2

1

PISTONPIN

2

Install the snap rings (2) using the round tipped pliers (1) to hold to the assembly together.

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Engine - Connecting rods and pistons

3.

Install the piston rings (1) on the piston (2) by using the pliers 380000324 (3).

4.

The rings need to be mounted with the word "TOP" (4) facing upwards. Direct the ring openings so they are staggered 120 ° apart.

PISTONRING5

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

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3

Engine - Connecting rods and pistons

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

Checking connecting rod alignment 1.

Check the parallelism of the rod axis (1) by using a suitable device (5) and following the instructions below: •

Fit the connecting (1) on the spindle of the tool (5) and lock it with the screw (4).

•

Set the spindle (3) on the "V" supports, resting the connecting rod (1) on the stop bar (2).

2.

Check the torsion of the connecting rod (5) by comparing two points (A) and (B) of the pin (3) on the horizontal plane of the axis of the connecting rod.

3.

Position the mount (1) of the dial gauge (2) so that the gauge is pre-loaded by approximately 0.5 mm (0.020 in) on the pin (3) at point (A) and zero the dial gauge (2). Shift the spindle (4) with the connecting rod (5) and compare any deviation on the opposite side (B) of the pin (3). The difference between (A) and (B) must be no greater than 0.08 mm (0.003 in).

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CONNECTINGROD3

1

CONNECTINGROD4

2

Engine - Connecting rods and pistons

4.

Check the bending of the connecting rod (5) by comparing the two points (C) and (D) of the pin on the vertical plane of the axis of the connecting rod.

5.

Position the vertical mount (1) of the dial gauge (2) so that this rests on the pin (3) at point (C).

6.

Swing the connecting rod backwards and forwards seeking the highest position of the pin a zero the dial gauge (2) at this point.

7.

Shift the spindle (4) with the connecting rod (5) and repeat the check on the highest point on the opposite side (D) of the pin (3). The difference between point (C) and point (D) must be no greater than 0.08 mm (0.0031 in).

CONNECTINGROD5

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

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3

Engine - Connecting rods and pistons

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

2.

Install the previously selected bearing halves (1) onto the connecting rod and connecting rod cap.

CONRODPISTON2

1

PISTONASSM2

2

Install the piston assemblies (2) into the cylinder liners using the ring compression band 380000220 (1).

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Engine - Connecting rods and pistons

PISTONASSM3

3

(1) Connecting rod and piston assembly - (2) Markings on the piston crown specifying the assembly position and the selection class - (3) Indicates the marking area for the connecting rod and cap.

3.

The connecting rod cap screws may be reused providing the thread diameter (d) measured in zone (L) is at least 13.4 mm (0.528 in). Otherwise, replace the screw.

4.

Lubricate the screws with engine oil before assembling.

5.

Install the connecting rod caps (1) with the bearing halves.

6.

Tighten the connecting rod cap screws (2) to 50 N·m (37 lb ft) torque.

7.

Using the tool 380001001 (3), tighten the screws an additional 90 °.

Next operation: Engine oil pan - Install (10.102) 47441651 09/10/2012

10.105 / 12

CAPBOLT

4

CONRODPISTON3

5

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 (2) with a micrometer (1).

2.

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

3.

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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PISTONPIN3

1

PISTONPIN4

2

Engine - Connecting rods and pistons

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

2.

3.

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

PISTONRING2

1

PISTONRING3

2

BAPH04APH129ASA

3

Check the clearance between the rings (2) and their landings on the piston (1) with a feeler gauge (3).

The ring (2) of the first landing has a "V" shape. The clearance (X) between the ring and landing is measured by setting the piston (1) with the ring in the cylinder liner (3) so that the ring is exposed half way out of the cylinder liner.

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Engine - Connecting rods and pistons

4.

Using a feeler gauge (2), check the opening between the ends of the rings (1).

5.

The ring must be inserted in the cylinder liner for an accurate measurement. If the gap is less than or greater than as required, replace the rings.

PISTONRING4

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

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4

Engine - Connecting rods and pistons

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

Using a micrometer (2), measure the diameter of the piston (1) to determine the assembly clearance.

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

PISTON

PISTON

2

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

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1

Index Engine - 10 Connecting rods and pistons - 105 Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Connecting rod and piston - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Connecting rod and piston - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Connecting rod and piston Connecting rod - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Engine - 10 Valve drive and gears - 106

F2CFA614B*E019 F2CFA614C*E019

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10.106 / 1

Contents Engine - 10 Valve drive and gears - 106

SERVICE Rocker arm Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Crosshead - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Camshaft Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Timing plate - Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Camshaft bushings Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Camshaft gear Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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Engine - Valve drive and gears

Rocker arm - Remove Prior operation: Valve cover - Remove (10.101) 1.

Remove the screws (1) securing the rocker shaft to the cylinder head.

2.

Install tool 380000149 (1) to the rocker shaft (2) and lift the entire assembly from the cylinder head.

3.

Remove the valve bridges (3) from the valves.

Next operation: Rocker arm - Install (10.106)

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ROCKERASSEMBLY2

1

ROCKERASSEMBLY

2

Engine - Valve drive and gears

Rocker arm Crosshead - Install 1.

Install the valve crossheads (1) onto the valve stems.

CROSSHEAD

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1

Engine - Valve drive and gears

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

Make sure the adjusting screws (4) on the rocker arms (2) are fully backed off. Failure to do so may cause binding during the installation process.

2.

Apply tool 380000149 (1) to the rocker shaft.

3.

Torque the bolts (3) to 94 - 115 N·m (69 - 85 lb ft).

ROCKERASSEMBLY

Next operation: Rocker arm - Clearance (10.106)

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1

Engine - Valve drive and gears

Rocker arm - Clearance Prior operation: Rocker arm - Install (10.106) 1.

Using the chart below, and the reference marks (1) and (2) on the flywheel (3), adjust the appropriate valves.

2.

Turn the flywheel (3) until the double reference mark (2) is seen through the inspection hole (4) in the flywheel housing (5).

3.

Continue to turn the flywheel using tool (6) until the single reference mark (1) can be seen through the inspection hole (4).

4.

Determine which cylinder has both rocker arms loose. When both rocker arms are loose on a single cylinder, this indicates that the piston is on the compression stroke.

•

If cylinder number one is on the compression stroke, follow the first table.

•

If cylinder number six is on the compression stroke, follow the second table.

5.

Adjust the valve clearance by loosening the lock nut (1) on the adjusting screw.

6.

Insert the correct feeler gauge (3) between the rocker arm and the valve crosshead (2).

•

Intake - 0.35 - 0.45 mm (0.014 - 0.018 in).

•

Exhaust - 0.35 - 0.45 mm (0.014 - 0.018 in).

7.

Turn the adjusting screw to set the clearance. Make sure that the feeler gauge can be removed, but a slight friction can be felt.

8.

Hold the adjusting screw in place and torque the lock nut (1) to 34 - 44 N·m (25 - 32 lb ft).

TOPDEADCENTER

1

ROCKERASSEMBLY3

2

Table for adjusting valves starting with cylinder #1 at T.D.C on the compression stroke Valves to be adjusted Starting position and amount of rotation 1 1 TDC on the compression stroke.

4 120 ° 2 120 ° 6 120 ° 3 120 ° 5 120 °

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Engine - Valve drive and gears

Table for adjusting valves starting with cylinder #6 at T.D.C on the compression stroke Valves to be adjusted Starting position and amount of rotation 6 6 TDC on the compression stroke.

3 120 ° 5 120 ° 1 120 ° 4 120 ° 2 120 ° NOTE: 120 ° after T.D.C. equals the amount of rotation required to view the next reference mark on the flywheel through the inspection hole on the bottom side of the flywheel housing.

Next operation: Valve cover - Install (10.101)

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Engine - Valve drive and gears

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

Place the camshaft (4) on the tailstock (1) and check the cam lift (3) using a dial gauge (2).

2.

When the camshaft (4) is on the tailstock (1), check the alignment of the supporting pin (3) using a dial gauge (2).

3.

If the misalignment exceeds 0.035 mm (0.0014 in), replace the shaft.

4.

To check the clearance of the camshaft and bushing, measure the inside diameter of the bushing and the outside diameter of the camshaft pin (1).

5.

Subtract the pin diameter from the bush diameter to obtain the clearance. If the clearance exceeds 0.150 mm (0.0059 in), replace the bushes and, if necessary, the camshaft.

Next operation: Camshaft - Install (10.106)

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CAMSHAFT

1

CAMSHAFT2

2

CAMSHAFT3

3

Engine - Valve drive and gears

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

Slide the camshaft (1) out of the cylinder head (2) being careful not to damage the bearings.

93110980

Next operation: Camshaft - Install (10.106)

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1

Engine - Valve drive and gears

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

Install the camshaft (3) into the cylinder head taking care not to damage the bearings.

2.

Turn the camshaft to align the reference marks.

3.

Clean the plate (1) of all impurities and oil residues.

4.

Apply silicone sealant (6) to the plate (1) in a 1.3 2.0 mm (0.051 - 0.079 in) diameter bead as shown in the figure.

NOTICE: Do not get sealant on the inner groove (5).

5.

Install the plate (1) within 10 minutes of applying the sealant and the gasket (2) and tighten the bolts (4) to the required torque.

CAMSHAFT

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1

Engine - Valve drive and gears

Camshaft - Timing check 1.

Set the engine to cylinder number one Top Dead Center (TDC). Refer to Engine - Service instruction (10.001) for the proper procedure.

2.

Set the rod of a dial gauge (1) and magnetic base (2) on the roller (3) of the cylinder number three exhaust rocker as shown.

3.

Remove the clearance from the exhaust rocker by tightening the adjusting screw until shoe touches the valve bridge.

4.

Pre-load the gauge to a minimum of 10 mm (0.394 in) .

5.

Using the tool 380003118, turn the crankshaft clockwise (as viewed from the flywheel) until the dial gauge reads the minimum value.

6.

Zero the dial gauge.

7.

Turn the engine flywheel counterclockwise until the dial gauge gives a reading of: •

4.70 mm (0.185 in) without an engine brake.

•

5.29 mm (0.208 in) with an engine brake.

83110999

1

TOPDEADCENTER4

2

NOTE: This value indicates the amount of lift that lobe has on the camshaft.

8.

9.

The camshaft is in time when the following conditions apply: •

The dial indicator reads the values described in step 7.

•

The hole marked with two reference marks (5) can be seen through the inspection window.

•

The tool 380000150 (1) can be inserted into the hole (3) in the engine flywheel (4) through the seat (2) of the engine speed sensor.

Refer to Camshaft - Timing adjust (10.106) for the proper adjustment procedure, if all the conditions in step 8 cannot be obtained.

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Engine - Valve drive and gears

Camshaft - Timing adjust 1.

Turn the engine in the direction of normal rotation and set the engine to 1 and 6 T.D.C. Refer to Engine Service instruction (10.001) for the proper procedure.

Setting camshaft position using tool 380002818 2.

Install the tool 380002818 (1) at the front of the camshaft.

3.

Locate the reference hole (2) on the cylinder head.

4.

Rotate the tool (1) in order to insert the pin (3) into the reference hole in the cylinder head.

5.

Fasten the tool (1) using two M8 x 1.25 bolts (2).

CAMSHAFT2

1

CAMSHAFT3

2

NHVM12ENG0027AA

3

Setting camshaft position without special tool 6.

Remove the blow by recirculation cover (1) form the front side of the cylinder head.

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Engine - Valve drive and gears

7.

Position the camshaft so the three holes are oriented as shown in the figure.

8.

Install the camshaft drive gear (1) so that the mounting holes in the shaft are aligned with the slots (2) in the drive gear.

9.

Install the gear (1) with the spokes (4) oriented as shown in the figure.

10.

Tighten the bolts (3).

NHVM12ENG0028AA

4

NHVM12ENG0026AA

5

NOTE: Do not torque the bolts at this time.

11.

Refer to Camshaft - Timing check (10.106) to ensure the engine is properly timed.

12.

Torque the bolts (3) to 25 N·m (18 lb ft) then turn the bolts an additional 45 °.

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Engine - Valve drive and gears

Camshaft Timing plate - Alignment 1.

Set the engine to 54 ° Before Top Dead Center (BTDC) or until the double notch on the flywheel can be seen through the inspection window in the flywheel housing.

2.

Loosen the screws (1) holding the timing plate (2) in position.

3.

Set the timing plate with the tooth (3) aligned with the sensor housing (4).

4.

Insert the tool 380000151 into the timing sensor housing (4) to ensure proper alignment.

5.

Tighten the bolts (1) to the prescribed torque and remove the tool from the timing sensor housing.

GEARDRIVE

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1

Engine - Valve drive and gears

Camshaft bushings - Replace Prior operation: Camshaft - Remove (10.106)

CAMBUSHING

1

* Measurement to be taken after installation.

1.

The surface of the bushing must show no sign of seizing or scoring. Replace them if they do.

2.

Measure the inside diameter of the bushings with a bore gauge. If you find a higher tolerance than specified, replace them.

3.

To remove and install the bushings, use the appropriate drift 380000146.

CAMBUSHING4

(A) Drift with seat for removal and installation of bushings (B) Grub screw for positioning bushings (C) Reference mark to insert bushing 7 correctly (D) Reference marks (red) to insert bushings 1 - 6 (E) Guide bushing

2

(F) Guide line (G) Guide bushing to secure the seventh bushing mount (H) Plate securing the yellow bushing to the cylinder head (I) Grip (L) Extension coupling

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Engine - Valve drive and gears

Removal 4.

Remove the bushings in the following sequence: (7), (6), (5), (4), (3), (2), (1).

5.

The bushings are driven out towards the front side of the cylinder head.

6.

Bushings (5), (6) and (7) do not require the drift extension or the guide bushing.

7.

For bushings (1), (2), (3) and (4) it is necessary to use the extension and the guide bushings.

8.

Make sure the drift positioned accurately during remove so as not to damage the cylinder head.

CAMBUSHING3

3

CAMBUSHING5

4

CAMBUSHING6

5

Installation 9.

Using the drift with the extension, insert bushings (1), (2), (3), (4) and (5) and proceed as follows.

10.

Position the bushing to be installed on the drift (A) making the grub screw (B) coincide with the seat on the bushing.

11.

Position the guide bushing (E) and secure the guide bushing (G) on the seat of the seventh bushing with the plate (H).

12.

While driving in the bushing, make the reference mark (F) match the mark (M) so the lubrication hole in the bushing will align with the oil passage in its seat.

13.

The bushing is fully seated when the first red reference mark (D) is flush with the guide bushing (G).

14.

To insert bushing (6), unscrew the grip (I) and the extension (N).

15.

Position the extension (N) and the guide bushing (E) as shown in the figure, and repeat the steps outlined for bushings (1), (2), (3), (4) and (5).

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Engine - Valve drive and gears

16.

To insert bushing (7), unscrew the grip (I) and the extension (N).

17.

Install the guide (G) from the inside as shown in the figure.

18.

Position the bushing on the drift (A).

19.

Line up the lubrication hole in the bushing with the oil passage in its seat.

20.

Drive the bushing into position. It is fully inserted when the reference mark (C) is flush with the bushing seat.

CAMBUSHING7

Next operation: Camshaft - Install (10.106)

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6

Engine - Valve drive and gears

Camshaft gear - Remove Prior operation: Engine block cover Rear - Remove (10.102) 1.

Using the proper tools, remove the screws (2) and remove the camshaft gear (1) together with the phonic wheel.

GEARDRIVE

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1

Index Engine - 10 Valve drive and gears - 106 Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Camshaft - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Camshaft - Timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Camshaft Timing plate - Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Camshaft bushings - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Camshaft gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Rocker arm - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rocker arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rocker arm Crosshead - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Balancer and damper - 110

F2CFA614B*E019 F2CFA614C*E019

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10.110 / 1

Contents Engine - 10 Balancer and damper - 110

SERVICE Crankshaft damper Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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10.110 / 2

Engine - Balancer and damper

Crankshaft damper - Remove Prior operation: Belt - Remove (10.414) 1.

Remove the screws and separate the pulleys (1) and (2) with the vibration damper (3).

BELT7

Next operation: Crankshaft damper - Install (10.110)

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1

Engine - Balancer and damper

Crankshaft damper - Install Prior operation: Crankshaft damper - Remove (10.110) 1.

Install the pulley (2).

BELT7

2.

Install the vibration damper (1).

3.

Install the pulley (3).

4.

Lubricate the threads of the bolts with clean engine oil.

5.

Torque the bolts to 70 N·m (52 lb ft) then turn an additional 70 °.

Next operation: Belt - Install (10.414)

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1

Index Engine - 10 Balancer and damper - 110 Crankshaft damper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Crankshaft damper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Pump drives - 114

F2CFA614B*E019 F2CFA614C*E019

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Contents Engine - 10 Pump drives - 114

FUNCTIONAL DATA Crankcase gears Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Crankcase gears Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Injection pump drive Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Engine - Pump drives

Crankcase gears - Overview

TIMINGGEAR

(1) - Camshaft (2) - Bushing

(3) - Pin (4) - Articulated rod

1

(5) - Camshaft gear (6) - Idler gear

(7) - Twin idler gear (8) - Crankshaft gear

The bushings (2) can be replaced when they are worn. They must be pressed out and pressed in from the block side of the gear.

Maximum amount of play between the bushings and the pins: •

Idler gear = 0.045 - 0.075 mm (0.0018 - 0.0030 in)

•

Twin idler gear = 0.045 - 0.085 mm (0.0018 - 0.0033 in)

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Engine - Pump drives

Crankcase gears - Remove Prior operation: Camshaft gear - Remove (10.106) 1.

Remove the screws (1) and remove the thrust plate (2).

2.

Using the proper tools, remove the screws (3) from the intermediate gear (3).

3.

Remove the gear (4) from the engine.

4.

Remove the screws (1) from the idler gear (2).

5.

Remove the retaining screw (3) and remove the link rod (4).

Next operation: Crankcase gears - Install (10.114)

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GEARDRIVE2

1

GEARDRIVE3

2

Engine - Pump drives

Crankcase gears - Install Prior operation: Crankcase gears - Remove (10.114) 1.

Install the link rod (1) and install the screw (2) loosely.

2.

Install the intermediate gear (3).

3.

Tighten the screws (4) using the sequence below.

•

Stage 1 = 30 N·m (22 lb ft)

•

Stage 2 = 90 °

4.

Install the tool 380002823 (1).

5.

Check and adjust the position of the link rod (3) for the intermediate gear.

6.

Tighten the screw (2) to the required torque.

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GEARDRIVE3

1

GEARDRIVE4

2

Engine - Pump drives

7.

Install the upper intermediate gear (2) and tighten the screws (1) to the required torque.

GEARDRIVE2

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3

Engine - Pump drives

Injection pump drive - Remove Prior operation: Engine block cover Rear - Remove (10.102) 1.

Remove the nut (1) securing the gear (2) to the shaft and remove the gear.

2.

If removal is difficult, loosen the pump screws and lightly tap on the shaft with a hammer. Remove the gear.

GEARDRIVE

Next operation: Injection pump drive - Install (10.114)

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1

Engine - Pump drives

Injection pump drive - Install Prior operation: Injection pump drive - Remove (10.114) 1.

Install the high pressure pump gear (1).

2.

Use the flat washer in conjunction with the nut replacing the one supplied with the pump.

3.

Torque the nut (2) to 105 N·m (77 lb ft).

GEARDRIVE

Next operation: Engine block cover Rear - Install (10.102)

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1

Index Engine - 10 Pump drives - 114 Crankcase gears - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Crankcase gears - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Crankcase gears - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Injection pump drive - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Injection pump drive - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Engine - 10 Fuel filters - 206

F2CFA614B*E019 F2CFA614C*E019

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Contents Engine - 10 Fuel filters - 206

SERVICE Fuel filters Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - Fuel filters

Fuel filters - Remove 1.

Unscrew the fuel filter (1) from its base (2).

LEFTSIDEVIEW

Next operation: Fuel filters - Install (10.206)

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1

Engine - Fuel filters

Fuel filters - Install Prior operation: Fuel filters - Remove (10.206) 1.

Spin the filter (1) onto the base.

2.

Once the seal contacts the sealing surface on the base, turn the filter an additional 3/4 of a turn.

LEFTSIDEVIEW

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1

Index Engine - 10 Fuel filters - 206 Fuel filters - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel filters - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Lift pump and lines - 210

F2CFA614B*E019 F2CFA614C*E019

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Contents Engine - 10 Lift pump and lines - 210

FUNCTIONAL DATA Fuel lift pump Gear pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - Lift pump and lines

Fuel lift pump Gear pump - Overview Installed on the rear side of the high pressure pump and used to supply it. It is controlled by the high pressure pump shaft.

Normal operating conditions

TRANSFERPUMP

(A) Fuel inlet from tank

1

(B) Fuel outlet to filter

(1) and (2) By-pass valves in closed position

Overpressure conditions at outlet

TRANSFERPUMP2

2

The by-pass valve (1) cuts in when overpressure is generated at outlet (B). The existing pressure, overcoming the valve spring (1), makes inlet and outlet fuel use the passage (2).

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Engine - Lift pump and lines

Drain conditions

TRANSFERPUMP3

3

The by-pass valve (2) cuts in when, with the engine off, the fuel system shall be filled through the priming pump. In this situation the by-pass valve (1) stays closed whereas by-pass valve (2) opens due inlet pressure, and fuel is drained out through (B).

NOTE: The mechanical supply pump cannot be replaced individual, therefore it cannot be removed from the high pressure pump.

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Index Engine - 10 Lift pump and lines - 210 Fuel lift pump Gear pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Fuel injection system - 218

F2CFA614B*E019 F2CFA614C*E019

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Contents Engine - 10 Fuel injection system - 218

FUNCTIONAL DATA Fuel injection system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

High pressure pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Pressure regulating valve Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Common rail Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Fuel injectors Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SERVICE High pressure pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Common rail Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fuel injectors Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Measure - Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Engine - Fuel injection system

Fuel injection system - Overview

FUELSYSTEM

1

The common rail fuel system is equipped with a special pump that maintains fuel at a constant high pressure regardless of phase and cylinder under injection. The high pressure fuel is accumulated in a common duct shared by all electric injectors. Therefore, fuel at injection pressure, calculated by the EDC, is always available at the electric injection inlet. When the solenoid valve of an injector is energized by the ECU, high pressure fuel is taken directly from the rail and injected into the related cylinder.

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Engine - Fuel injection system

Fuel supply diagram

FUELSUPPLY

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

High-pressure pump Fuel filter Tank Fuel pre-filter

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

2

EDC 7 UC31 Electric injectors Common rail Pressure sensor

NOTICE: After installing the high-pressure fuel lines, frequently check the engine oil during the following 20 hours of work. If the level increases, there is a fuel leak that must be addressed immediately.

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Engine - Fuel injection system

High pressure pump - Overview CP3 High-Pressure Pump

HPPUMP

1

(1) Fuel outlet fitting to rail

(4) Control gear

(2) High-pressure pump

(5) Fuel inlet fitting from the filter

(3) Pressure regulator

(6) Fuel outlet fitting to filter support

(7) Fuel fitting from control unit heat exchanger (8) Fuel outlet fitting from supply pump to filter (9) Mechanical supply pump

High pressure pump with 3 radial pistons controlled by the timing gear, without needing any setting. On the rear side of the high pressure pump is fitted the mechanical supply pump controlled by the high pressure pump shaft. The drive gear and the pressure regulator are the only serviceable parts on the high pressure pump.

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Engine - Fuel injection system

HPFUELPUMP2

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

Cylinder Three-lobe element Cap intake valve Ball delivery valve

2

(5) Pistons (6) Pump shaft (7) Low-pressure fuel inlet (8) Pumping elements supply fuel ducts

Every pumping unit is composed of: •

A piston (5) is actuated by a three-lobe element (2) floating on the pump shaft (6). The element (2), being floating on a misaligned part of the shaft (6), when the shaft rotates, does not rotate therewith but is only translated in a circular movement along a wider radius, with the resulting alternate actuation of the three pumping elements.

•

Cap intake valve (3).

•

Ball delivery valve (4).

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Engine - Fuel injection system

HPFUELPUMP3

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

Fuel outlet fitting to the rail Delivery valve to the rail Pumping element Pump shaft

3

(5) Pumping element supply duct (6) Pressure regulator supply duct (7) Pressure regulator

Pumping element (3) is oriented to pump shaft (4) cam. During intake, the pumping element is supplied through supply duct (5). The fuel amount to be sent to the pumping element is set by the pressure regulator (7). The pressure regulator meters fuel flow to pumping element according to the Pulse Width Modulated (PWM) signal received from the EDC. During the pumping element compression stage, fuel reaches the pressure required to open the delivery valve to the common rail (2) and to feed it through the outlet (1).

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Engine - Fuel injection system

HPFUELPUMP4

(1) Pumping element inlet (2) Pump lubrication ducts (3) Pumping element inlet

4

(4) Main pumping element supply duct (5) Pressure regulator (6) Pumping element inlet

(7) Regulator exhaust duct (8) Pressure relief valve (9) Fuel drain from regulator inlet

The pump shaft is lubricated by fuel through the delivery and return ducts (2). The pressure regulator (5) establishes the fuel amount to send to the pumping elements. Excess fuel is drained out to through duct (9). The 5 bar (73 psi) pressure relief valve acts as a fuel exhaust manifold and keeps a 5 bar (73 psi) constant pressure at the regulator inlet.

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Engine - Fuel injection system

HPFUELPUMP5

(1) Fuel outlet duct

5

(2) Fuel outlet duct

(3) High pressure outlet fitting for common rail

The figure above shows high pressure fuel flow through the pumping element outlet ducts.

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Engine - Fuel injection system

Operation The cylinder is filled through the cap intake valve only if the supply pressure is suitable to open the delivery valves set on the pumping elements. About 2 bar (29 psi).

The amount of fuel supplying the high-pressure pump is metered by the pressure regulator, placed on the low-pressure system. The pressure regulator is controlled by the EDC7 control unit through a PWM signal.

When fuel is sent to a pumping element, the related piston is moving downwards (suction stroke). When the piston stroke is reversed, the intake valve closes and the remaining fuel in the pumping element chamber is compressed above the supply pressure valve existing in the rail.

The generated pressure makes the exhaust valve open and the compressed fuel reached the high-pressure circuit.

The pumping element compresses the fuel till top dead center (delivery stroke) is reached. Afterwards, the pressure decreases till the exhaust valve is closed. The pumping element piston goes back towards the bottom dead center and the remaining fuel is decompressed.

When the pumping element chamber pressure becomes less than supply pressure, the intake valve is again opened and the cycle is repeated.

The delivery valves must always be free in their movements, and free of impurities and oxidation. The rail delivery pressure is modulated by the electronic control unit, through the pressure regulator solenoid valve.

The pump is lubricated and cooled by the fuel.

The radialjet pump disconnection - re-connection time on the engine is highly reduced in comparison with traditional injection pumps, because it does not require setting.

If the pipe between the fuel filter and the high-pressure pump is to be removed and installed, be sure that hands and components are absolutely clean.

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Engine - Fuel injection system

Pressure regulating valve - Overview Located at the high-pressure pump inlet, on low pressure system, it modulates the amount of fuel for high-pressure pump supply based on commands received from ECU. It mainly consists of parts below: •

Trapezoidal-section lock pin

•

Valve control pin

•

Pre-load valve

•

Coils

When no control signal is present, the pressure regulator is normally open, therefore the high-pressure pump is in maximum delivery condition.

The ECU modulates a PWM control signal to extend or reduce section of fuel supply line to high-pressure pump.

The component cannot be replaced as an individual part, therefore it cannot be removed.

The quantity high-pressure supply fuel is metered by a proportional valve positioned on the low-pressure system and it is managed by the EDC 7 control unit.

The delivery pressure to the rail is modulated between 250 - 1400 bar (3625 - 20300 psi) by the ECU operating on pressure regulator solenoid valve.

It is a Normally open solenoid valve.

It's resistance is 3.2 Ω.

It is connected to ECU pins C5 and C7.

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Engine - Fuel injection system

Common rail - Overview

20101558

(1) Rail (2) Fuel return

1

(3) Pipelines to injectors (4) Fuel supply

(5) Pressure sensor (6) Overpressure valve

The common rail has an internal volume sized to quickly pressurize the fuel at start up, while having a sufficient volume to support full load fuelling rates. The volume in the common rail is sufficient to allow the injectors to supply fuel to the cylinders under full load, while still maintaining a stabile rail pressure, from fuel supplied by the high pressure pump.

A fuel pressure sensor (5) is screwed into the one end of the common rail. It provides feedback to the engine electronic control unit where the sensor values are monitored. Rail pressure is changed as needed based on sensor feedback and other engine operating parameters.

An overpressure valve (6) is installed in the other end. It protects the common rail and associated components by exhausting excess pressure in the rail to the return line and back to the fuel tank. It opens at about 1850 - 1950 bar (26825 - 28275 psi).

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Engine - Fuel injection system

Fuel injectors - Overview

ELECTROINJ

(1) Fuel return port

1

(2) Fuel supply

Description •

Normally open solenoid valve.

•

Connected to the EDC 7 UC31 on connector A.

•

The resistance of each injector coil is 0.56 - 0.57 Ω.

•

The electro-injector can be considered as consisting of 2 parts

•

•

Actuator/atomizer - including pressure rod, needle and nozzle

•

Control solenoid valve - including coil and pilot valve

The solenoid valve controls the atomizer needle lift.

Injection start •

When the coil is energized, the lock pin moves upward.

•

The control volume fuel flow to the return duct causing a control volume pressure drop.

•

At the same time, fuel pressure in the pressure chamber causes needle uplift and therefore fuel injection in the cylinder.

End of injection •

When the coil is de-energized, the lock pin returns to the lock position for a force balance suck to return to needle close position and stop injection.

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Engine - Fuel injection system

High pressure pump - Remove Prior operation: Injection pump drive - Remove (10.114) 1.

Disconnect the fuel lines (1) from the high pressure fuel pump (2).

2.

Remove the screws and detach the high pressure pump (2) from the gear case.

HPFUELPUMP6

Next operation: High pressure pump - Install (10.218)

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1

Engine - Fuel injection system

High pressure pump - Install Prior operation: High pressure pump - Remove (10.218) 1.

2.

3.

Apply LOCTITE® 5970 (1) to high pressure pump flange (2) as shown in the figure. The bead must be within 1.3 - 2.0 mm (0.051 - 0.079 in) in diameter.

PUMPFLANGE

1

PUMPFLANGE2

2

HPPUMP2

3

Install the gauge 380002817 (1) to check and adjust the position of the high pressure pump connection flange (2). Tighten the flange screws to the required torque.

Install the high pressure pump (1) onto the flange (2) and tighten the screws to the required torque.

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Engine - Fuel injection system

4.

Install the fuel supply line (1) from the high pressure pump to the rail fitting on the cylinder head.

5.

Torque the nuts to 35 N·m (26 lb ft).

NOTICE: Do not reuse high pressure fuel lines after removal. They should be replaced with new.

FUELLINE

Next operation: Injection pump drive - Install (10.114)

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4

Engine - Fuel injection system

Common rail - Remove 1.

Remove the retaining screws (1) and remove the rail (2).

INJECTOR

Next operation: Common rail - Install (10.218)

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1

Engine - Fuel injection system

Common rail - Install Prior operation: Common rail - Remove (10.218) 1.

Install the high pressure common rail (2) and tighten the screws (1) by hand.

NOTICE: The fuel injectors and new fuel pipes should be installed prior to torquing the rail screws. Refer to Fuel injectors - Install (10.218) for the proper procedure.

2.

Tighten the screws to the required torque.

INJECTOR

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1

Engine - Fuel injection system

Fuel injectors - Remove NOTICE: The injector must be replaced as a unit. Do not disassemble the injector as it may void your warranty.

1.

Remove the retaining bracket (1) and remove the injector (2) from the cylinder head.

INJECTOR

Next operation: Fuel injectors - Install (10.218)

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1

Engine - Fuel injection system

Fuel injectors - Install Prior operation: Fuel injectors - Remove (10.218) NOTICE: The injector must be replaced as a unit. Do not disassemble the injector as it may void your warranty.

1.

Lubricate the new injector seals with clean engine oil prior to installation.

2.

Install the injector (1) and bracket (2) with new seals.

3.

Make sure the distance (X) between the spring and the injector is equal on both sides.

4.

Lubricate the bolts with clean engine oil and torque to 26 N·m (19 lb ft).

5.

Install new high pressure fuel pipes (1). Make the fittings finger tight.

6.

Torque the mounting bolts of the rail to 26 N·m (19 lb ft).

7.

Then tighten the fittings to the specifications indicated in the table below.

Fitting type (A) - Rail.

(B) - Injector.

(C) - Cylinder head.

Description M18 x 1.5 M14 x 1.5 M16 x 1.5

INJECTOR

1

INJECTOR2

2

Torque 38 - 42 N·m (28 - 31 lb ft) 33 - 37 N·m (24 - 27 lb ft) 38 - 42 N·m (28 - 31 lb ft)

NOTICE: After installing the high-pressure fuel lines, during the following 20 hours of operation, frequently check the engine oil level. It must not increase.

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Engine - Fuel injection system

Fuel injectors - Measure - Protrusion 1.

Check the injector protrusion (2) with the dial gauge (1). It should be between 1.2 - 1.5 mm (0.047 - 0.059 in).

INJECTOR3

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1

Engine - Fuel injection system

Fuel injectors - Leakage test 1.

Disconnect the fuel return line at the “T” connector (1) on the cylinder head.

2.

Install an auxiliary line from the return port on the cylinder head to a bucket.

3.

Start the engine and set to 1400 RPM.

4.

Collect the return fuel for 1 min at 1400 RPM.

5.

The collected fuel should be less than 130 ml (4.4 US fl oz).

23116821

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1

Index Engine - 10 Fuel injection system - 218 Common rail - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Common rail - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Common rail - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Fuel injection system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel injectors - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Fuel injectors - Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fuel injectors - Measure - Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Fuel injectors - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Fuel injectors - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 High pressure pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 High pressure pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 High pressure pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Pressure regulating valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Engine - 10 Turbocharger and lines - 250

F2CFA614B*E019 F2CFA614C*E019

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Contents Engine - 10 Turbocharger and lines - 250

SERVICE Turbocharger Remove - Oil line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Engine - Turbocharger and lines

Turbocharger - Remove - Oil line 1.

2.

Remove the oil drain line (1) from the turbocharger (2).

OILCOOLER5

1

RIGHTSIDEVIEW

2

Remove the oil supply line (1) from the turbocharger (2).

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Engine - Turbocharger and lines

Turbocharger - Remove Prior operation: Turbocharger - Remove (10.250) 1.

Remove the mounting bolts (1) from the turbocharger (2) and remove it from the engine.

RIGHTSIDEVIEW

Next operation: Turbocharger - Install (10.250)

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1

Engine - Turbocharger and lines

Turbocharger - Install Prior operation: Turbocharger - Remove (10.250) 1.

Install the turbocharger (1) onto the exhaust manifold using a new seal.

2.

Tighten the screws (2) to the required torque.

RIGHTSIDEVIEW

Next operation: Turbocharger - Install (10.250)

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1

Index Engine - 10 Turbocharger and lines - 250 Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Turbocharger - Remove - Oil line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Intake and exhaust manifolds and muffler - 254

F2CFA614B*E019 F2CFA614C*E019

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Contents Engine - 10 Intake and exhaust manifolds and muffler - 254

FUNCTIONAL DATA Intake and exhaust manifolds and muffler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Intake manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Exhaust manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Engine - Intake and exhaust manifolds and muffler

Intake and exhaust manifolds and muffler - Overview The cylinder head is of a cross flow design, which means the intake is on one side of the cylinder head and the exhaust is on the other. This provides for a more efficient intake system. With the hot exhaust gases exiting on the opposite side, the intake gases remain cooler and more dense. The turbo-charging system consists of an air filter, and an HX55 turbocharger with waste-gate.

AIRINTAKE2

1

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Engine - Intake and exhaust manifolds and muffler

Intake manifold - Remove 1.

Remove the screws (2) and detach the intake manifold (1) from the cylinder head.

INTAKEMANIFOLD

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1

Engine - Intake and exhaust manifolds and muffler

Intake manifold - Install 1.

Install the intake manifold (1).

2.

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

INTAKEMANIFOLD

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1

Engine - Intake and exhaust manifolds and muffler

Exhaust manifold - Remove Prior operation: Turbocharger - Remove (10.250) 1.

Remove the screws (1) and detach the exhaust manifold (2) from the engine.

RIGHTSIDEVIEW

Next operation: Exhaust manifold - Install (10.254)

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1

Engine - Intake and exhaust manifolds and muffler

Exhaust manifold - Install Prior operation: Exhaust manifold - Remove (10.254) 1.

Install the exhaust manifold (1) and tighten the screws (2) to the required torque.

RIGHTSIDEVIEW

Next operation: Turbocharger - Install (10.250)

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1

Index Engine - 10 Intake and exhaust manifolds and muffler - 254 Exhaust manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Exhaust manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Intake and exhaust manifolds and muffler - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Intake manifold - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Intake manifold - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Engine lubrication system - 304

F2CFA614B*E019 F2CFA614C*E019

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Contents Engine - 10 Engine lubrication system - 304

TECHNICAL DATA Oil pressure valve Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Engine oil pump Dimension Overpressure Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Engine lubrication system Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Engine oil filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Bypass valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Oil pressure valve Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Engine oil pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Blowby re-circulation system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SERVICE Engine oil filter Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Engine oil pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Remove - Recovery oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install - Recovery oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Blowby re-circulation system Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Piston cooling

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Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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Engine - Engine lubrication system

Oil pressure valve - Dimension Check the spring height at the indicated load ranges.

•

(Hf) = 63 mm (2.480 in) @ No load.

•

(H1) = 51 mm (2.008 in) @ 161 - 177 N (36.2 - 39.8 lb).

•

(H2) = 36.4 mm (1.433 in) @ 293 - 323 N (65.869 72.613 lb).

OVERPSI

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1

Engine - Engine lubrication system

Engine oil pump - Dimension Overpressure Valve Check the spring height at the indicated load ranges.

•

(Hf) = 43.65 mm (1.719 in) @ No load.

•

(H1) = 33.5 mm (1.319 in) @ 184 - 196 N (41.4 44.1 lb).

•

(H2) = 22.95 mm (0.904 in) @ 315 - 333 N (70.8 74.9 lb).

OVERPSI

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1

Engine - Engine lubrication system

Engine lubrication system - Plumbing schema

LUBEDIAGRAM4

1

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Engine - Engine lubrication system

Engine oil filter - Overview

OILFILTER

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

Closure cap Cartridge Spring Support O-ring

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

1

Tank O-ring Washer Washer Support

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(9) Plug M14x1.5 (10) Plug M38x1.5 (11) By pass valve

Engine - Engine lubrication system

Engine oil filter Bypass valve - Overview

FILTERBYPASS

1

The valve quickly opens at 3.1 - 3.7 bar (45.0 - 53.7 psi).

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Engine - Engine lubrication system

Oil pressure valve - Overview The oil pressure control valve is located on the left-hand side of the crankcase. Start of opening pressure is 5 bar (72.5 psi).

PSICONTROLF3C

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1

Engine - Engine lubrication system

Engine oil pump - Overview The oil pump (1) is a non-serviceable part. If any damage is present, replace the entire oil pump assembly. If there is damage to the crankshaft gear (2), refer to Crankshaft gears - Replace (10.103) for gear replacement.

OILPUMP

OILPUMP2

2

(1) Overpressure valve - Start of opening pressure 9.4 - 10.8 bar (136.3 - 156.6 psi).

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1

Engine - Engine lubrication system

Blowby re-circulation system - Overview

BLOWBY

1

Part of the gas produced by combustion during engine operation, leaks through the gaps in the piston rings into the crankcase and mixes with oil fumes in the sump.

This mixture, conveyed upward, is partially separated from the oil by a device located in the upper part of the timing cover and introduced into the air intake circuit.

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Engine - Engine lubrication system

Engine oil filter - Replace 1.

Remove the plug (2).

2.

Unscrew the filter casing (1) by a couple of turns and wait for a few minutes. By doing this, the remaining oil has a chance to drain out.

3.

Completely remove the casing.

4.

Pull the cartridge out of the casing.

5.

Insert a new cartridge in the casing aligning the centering tabs (2) on the upper plate (1) with the seats.

6.

The cartridge should be pushed into the casing until it snaps into the locking detent.

7.

At the same time, the tabs on the upper plate should slide into the housings.

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OILFILTER2

1

OILFILTER3

2

Engine - Engine lubrication system

8.

Install the oil filter by tightening the cartridge casing (1) onto the support (4).

9.

During this process, both the seal (3) for the oil outlet duct/cartridge element and the casing/support seal (2) will gradually come in contact with its sealing surface.

10.

Tighten the filter casing to a torque of 65 Nm (48 lb ft).

11.

OILFILTER4

3

OILFILTER5

4

Install and tighten the protective cap (1) on the filter casing.

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Engine - Engine lubrication system

Engine oil filter - Remove 1.

Remove the oil filter (1).

RIGHTSIDEVIEW

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1

Engine - Engine lubrication system

Engine oil filter - Install 1.

Spin the oil filter (1) onto the base until the seal contacts the sealing surface.

2.

Turn the filter an additional 3/4 of a turn.

RIGHTSIDEVIEW

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1

Engine - Engine lubrication system

Engine oil pump - Remove Prior operation: Engine block cover Rear - Remove (10.102) 1.

Remove the screws (1) and detach the oil pump (2) from the engine block.

GEARDRIVE3

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 (1) and tighten the screws (2) to the required torque.

GEARDRIVE3

Next operation: Engine block cover Rear - Install (10.102)

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1

Engine - Engine lubrication system

Engine oil pump - Remove - Recovery oil pump 1.

2.

Remove the bolts securing the drain tube (1).

NHIL12ENG0031AA

1

NHIL12ENG0030AA

2

Remove the bolts (1) and remove the recovery oil pump (2) from the engine block.

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Engine - Engine lubrication system

Engine oil pump - Install - Recovery oil pump 1.

Install the recovery oil pump (2) onto the engine block.

NOTICE: Be sure the intermediate gear shaft is properly seated in the main bearing cab prior to torquing the bolts.

2.

3.

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

NHIL12ENG0030AA

1

NHIL12ENG0031AA

2

Install the drain tube (1).

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Engine - Engine lubrication system

Blowby re-circulation system - Remove 1.

Remove the screws (1) and the blow-by box (2).

2.

Remove the screws (2) to remove the cover (1).

3.

Remove the centrifugal filter (3).

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BLOWBY

1

BLOWBY2

2

Engine - Engine lubrication system

Blowby re-circulation system - Install 1.

Install the centrifugal filter (1) onto the timing plate.

2.

Tighten the screws (2) to the required torque.

3.

BLOWBY3

1

BLOWBY4

2

Install the cover (1) and tighten the retaining screws (2) to the required torque.

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Engine - Engine lubrication system

4.

Inspect the check valve (1) in the blow by body (2) for any abnormalities.

5.

Install the blow by body (1) with the related seal.

6.

Torque screws (2) to the required torque.

7.

Install the cover (3) and tighten the screws (4) to the required torque.

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BLOWBY5

3

BLOWBY

4

Engine - Engine lubrication system

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

Loosen the screw (1) and remove the oil spray nozzle (2).

SPAYNOZZLE

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 spray nozzle (2). Make sure the positioning dowel is properly positioned in the hole in the block (3).

2.

Lubricate the retaining bolt (1) with clean engine oil.

3.

Tighten the bolt to 33 - 37 N·m (24 - 27 lb ft).

SPAYNOZZLE2

Next operation: Engine oil pan - Install (10.102)

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1

Index Engine - 10 Engine lubrication system - 304 Blowby re-circulation system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Blowby re-circulation system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Blowby re-circulation system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Engine lubrication system - Plumbing schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Engine oil filter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine oil filter - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine oil filter Bypass valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine oil pump - Dimension Overpressure Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine oil pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Engine oil pump - Install - Recovery oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Engine oil pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine oil pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine oil pump - Remove - Recovery oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Oil pressure valve - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Oil pressure valve - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Piston cooling Spray nozzle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Piston cooling Spray nozzle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Engine - 10 Engine cooling system - 400

F2CFA614B*E019 F2CFA614C*E019

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Contents Engine - 10 Engine cooling system - 400

FUNCTIONAL DATA Engine cooling system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Water pump Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Coolant thermostat Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Water pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Coolant thermostat Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Engine - Engine cooling system

Engine cooling system - Overview The engine cooling system is a closed circuit, forced circulation system. It consists mainly of the following components.

•

Expansion tank (not supplied)

•

A heat exchanger to cool down lubrication oil

•

A water pump with centrifugal system incorporated in the cylinder block

•

Fan (not supplied)

•

A 2-way thermostat controlling the coolant circulation.

The water pump is driven by the crankshaft by a poli-V belt and sends coolant to the cylinder, especially to the cylinder head, (bugger quantity). When the coolant temperature reaches and overcomes the operating temperature, the thermostat is opened and form here the coolant flows into the radiator and is cooled down by the fan. The pressure inside the system, due to the temperature change, is adequately controlled through the expansion vessel.

COOLINGSYSTEM2

1

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Engine - Engine cooling system

Water pump - Overview

63101565

1

The water pump consists of: •

Rotor (1)

•

Shaft with bearing (2)

•

Mounting flange (3)

•

Drive pulley with dust shield (4)

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Engine - Engine cooling system

Coolant thermostat - Overview Closed Thermostat The thermostat should start to open at a temperature of 83 - 87 °C (181 - 189 °F). The minimum amount travel is 9.5 mm (0.4 in) at 95 °C (203 °F).

THERMOSTAT4

(1) Coolant from the engine (2) Passage to the heater

1

(3) Radiator by-pass passage (4) Passage to the radiator

Open Thermostat

THERMOSTAT5

(1) Coolant from the engine (2) Passage to the heater (3) Radiator by-pass passage

2

(4) Passage to the radiator (5) Passage to the expansion tank

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Engine - Engine cooling system

Water pump - Remove Prior operation: Belt - Remove (10.414) 1.

Remove the water pump (1).

FRONTVIEW6

Next operation: Water pump - Install (10.400)

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1

Engine - Engine cooling system

Water pump - Install 1.

Install a new seal on the water pump.

2.

Install the water pump (1) onto the engine block.

3.

Torque the bolts to 20 - 24 N·m (15 - 18 lb ft).

FRONTVIEW6

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1

Engine - Engine cooling system

Coolant thermostat - Remove 1.

Remove the thermostat (1) assembly from the front of the engine.

FRONTVIEW6

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1

Engine - Engine cooling system

Coolant thermostat - Install 1.

Install the thermostat assembly (1) onto the front of the engine.

FRONTVIEW6

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1

Index Engine - 10 Engine cooling system - 400 Coolant thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Coolant thermostat - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Coolant thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine cooling system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Water pump - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - 10 Oil cooler and lines - 408

F2CFA614B*E019 F2CFA614C*E019

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Contents Engine - 10 Oil cooler and lines - 408

FUNCTIONAL DATA Engine oil cooler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine oil cooler Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Engine - Oil cooler and lines

Engine oil cooler - Overview

OILCOOLER

(1) Oil cooler gasket (2) Internal heat exchanger element

1

(3) Cover (4) Oil filter

(5) Oil filter seal

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Engine - Oil cooler and lines

Engine oil cooler - Remove 1.

Remove the screws (2) and remove the oil cooler (1) from the engine block.

OILCOOLER5

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1

Engine - Oil cooler and lines

Engine oil cooler - Install 1.

Install the oil cooler (1) and tighten the bolts (2) to 56 - 70 N·m (41 - 52 lb ft).

OILCOOLER5

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1

Index Engine - 10 Oil cooler and lines - 408 Engine oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine oil cooler - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Fan and drive - 414

F2CFA614B*E019 F2CFA614C*E019

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Contents Engine - 10 Fan and drive - 414

SERVICE Belt Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Belt tensioner Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Idler pulley Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Engine - Fan and drive

Belt - Remove 1.

Remove tension from the belt (1) by rotating the belt tensioner (2) away from the belt.

63101564

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1

Engine - Fan and drive

Belt - Install 1.

Install the belt (1) on all the pulleys except the belt tensioner (2) in the configuration shown.

2.

Rotate the tensioner away from the belt and slide the belt into position on the tensioner pulley.

3.

Slowly release the tensioner.

4.

Check to make sure the belt is correctly positioned on all the pulleys.

63101564

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1

Engine - Fan and drive

Belt tensioner - Remove Prior operation: Belt - Remove (10.414) 1.

Remove the belt tensioner (1).

FRONTVIEW6

Next operation: Belt tensioner - Install (10.414)

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1

Engine - Fan and drive

Belt tensioner - Install Prior operation: Belt tensioner - Remove (10.414) 1.

Install the belt tensioner (1).

FRONTVIEW6

Next operation: Belt - Install (10.414)

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1

Engine - Fan and drive

Idler pulley - Remove Prior operation: Belt - Remove (10.414) 1.

Remove the idler pulley (1).

FRONTVIEW6

Next operation: Idler pulley - Install (10.414)

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1

Engine - Fan and drive

Idler pulley - Install 1.

Install the idler pulley (1) onto the engine block.

2.

Torque the bolts to 100 - 110 N·m (74 - 81 lb ft).

FRONTVIEW6

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1

Index Engine - 10 Fan and drive - 414 Belt - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Belt - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Belt tensioner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Belt tensioner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Idler pulley - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Idler pulley - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2012 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CNH policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CNH Dealer.

47441651 09/10/2012 EN

SERVICE MANUAL Electrical systems

F2CFA614B*E019 F2CFA614C*E019

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55

Contents Electrical systems - 55

Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.010 F2CFA614B*E019 , F2CFA614C*E019

Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.012 F2CFA614B*E019 , F2CFA614C*E019

Engine oil system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.013 F2CFA614B*E019 , F2CFA614C*E019

Engine intake and exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.014 F2CFA614B*E019 , F2CFA614C*E019

Engine control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.015 F2CFA614B*E019 , F2CFA614C*E019

Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.201 F2CFA614B*E019 , F2CFA614C*E019

Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.301 F2CFA614B*E019 , F2CFA614C*E019

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Electrical systems - 55 Fuel injection system - 010

F2CFA614B*E019 F2CFA614C*E019

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Contents Electrical systems - 55 Fuel injection system - 010

FUNCTIONAL DATA Fuel temperature sensor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Fuel pressure sensor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Fuel injection system

Fuel temperature sensor - Overview

TEMPSENSOR

1

Fuel temperature sensor EDC connector Connector C Connector C

Pin number 18 35

Specifications •

Manufacturer - BOSCH

•

Maximum Torque - 35 Nm (26 lb ft)

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Wire color Orange/Black White/Red

Electrical systems - Fuel injection system

Fuel pressure sensor - Overview

FUELPRESSURE

1

Fuel pressure sensor Reference 1 2 3

Description ECU pin Ground Supply pressure

Pin number 12C 13C 14C

Installed on one rail end, it measures the actual fuel pressure in order to determine injection pressure.

The injection pressure value is used for pressure check and to determine the injection electric command duration.

It is supplied with 5 V. It is connected to the ECU on pins 12C, 13C, 14C.

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Index Electrical systems - 55 Fuel injection system - 010 Fuel pressure sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Engine cooling system - 012

F2CFA614B*E019 F2CFA614C*E019

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Contents Electrical systems - 55 Engine cooling system - 012

FUNCTIONAL DATA Engine coolant temperature sensor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Engine cooling system

Engine coolant temperature sensor - Overview

COOLANTTEMP

1

Coolant temperature sensor Pin number

Connector Connector C Connector C

15 26

Wire color Pink Yellow

The N.T.C. type sensor located on the coolant outlet pipe on the cylinder head measures the coolant temperature for the various operating conditions. It identifies fuel enrichment for a cold engine and fuel reduction for a hot engine.

Sensor resistance is higher with colder temperatures. The resistance range is shown below: •

-10 °C (14 °F) = 8100 - 10770 Ω.

•

20 °C (68 °F) = 2280 - 2720 Ω.

•

80 °C (176 °F) = 290 - 364 Ω.

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Index Electrical systems - 55 Engine cooling system - 012 Engine coolant temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Engine oil system - 013

F2CFA614B*E019 F2CFA614C*E019

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Contents Electrical systems - 55 Engine oil system - 013

FUNCTIONAL DATA Engine oil pressure/temperature sensor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Engine oil system

Engine oil pressure/temperature sensor - Overview

TEMPPSISENSOR

1

Oil temperature/pressure sensor Reference 1 2 3 4

Description Ground Temperature signal Power supply Pressure signal

EDC connector Sensor Connector C Sensor Connector C Sensor Connector C Sensor Connector C

Pin number 24 27 32 28

This component incorporates a temperature sensor and a pressure sensor. It is installed onto the engine oil filter base in a horizontal position. It measures the engine oil temperature and pressure. The signal is sent to the EDC control unit which, in turn, controls the gauge and the low pressure warning lights in the instrument cluster. The temperature signal is only used by the EDC control unit.

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Index Electrical systems - 55 Engine oil system - 013 Engine oil pressure/temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Engine intake and exhaust system - 014

F2CFA614B*E019 F2CFA614C*E019

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Contents Electrical systems - 55 Engine intake and exhaust system - 014

FUNCTIONAL DATA Intake air pressure and temperature sensor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Engine intake and exhaust system

Intake air pressure and temperature sensor - Overview

TEMPPSISENSOR

1

Air temperature/pressure sensor Reference 1 2 3 4

Description Ground Temperature signal Power supply Pressure signal

EDC connector Connector C Connector C Connector C Connector C

Pin number 25 36 33 34

This component incorporates a temperature sensor and a pressure sensor. It is installed onto the intake manifold and measures the maximum supplied air flow rate used to accurately calculate the amount of fuel to be injected at every cycle. The sensor uses a 5 V supply and the out put voltage is proportional to the pressure or temperature measured by the sensor.

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Index Electrical systems - 55 Engine intake and exhaust system - 014 Intake air pressure and temperature sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Engine control system - 015

F2CFA614B*E019 F2CFA614C*E019

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Contents Electrical systems - 55 Engine control system - 015

FUNCTIONAL DATA Engine control system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Engine control unit Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Engine wire harness Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Engine speed/RPM sensor Flywheel - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Camshaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SERVICE Engine control unit Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Engine wire harness Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Engine speed/RPM sensor Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Electrical systems - Engine control system

Engine control system - Overview

ELECCOMPLOC

(1) (2) (3) (4) (5) (6)

Fuel temperature sensor Camshaft speed sensor Starter motor EDC 7 control unit A/C Compressor Oil pressure/temperature sensor

1

(8) Alternator (9) Intake air heater (10) Bulkhead connector for electro-injectors (11) Coolant temperature sensor (12) Flywheel speed sensor (13) Fuel adjustment valve on the high pressure fuel pump.

(7) Air pressure/temperature sensor

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Electrical systems - Engine control system

Engine control unit - Overview

CONTROLMODULE

1

EDC 7 UC31control unit (A) Electro injector connector

(B) Chassis connector

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(C) Sensor connector

Electrical systems - Engine control system

CONNECTORA

2

Electro injector connector A ECU pin out for connector A ECU pin (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)

Wire color Purple Gray Blue Red Pink Yellow Orange Green White Black White Brown

Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid Free Free Free Free Solenoid Solenoid Solenoid Solenoid Solenoid Solenoid

valve valve valve valve valve valve

for for for for for for

electronic electronic electronic electronic electronic electronic

cylinder cylinder cylinder cylinder cylinder cylinder

5 6 4 1 3 2

Function injection injection injection injection injection injection

valve valve valve valve valve valve

for for for for for for

electronic electronic electronic electronic electronic electronic

cylinder cylinder cylinder cylinder cylinder cylinder

2 3 1 4 6 5

injection injection injection injection injection injection

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Electrical systems - Engine control system

CONNECTORC

3

Sensor connector C ECU pin out for connector C ECU pin (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36)

Wire color White Red Pink Orange/Black Black White Brown White Yellow Orange/Black Blue Orange Red Green White/Red Orange

Function Free Free Free Free Free Free Free Free Camshaft speed sensor Camshaft speed sensor Free Pressure sensor on rail Pressure sensor on rail (ground) Pressure sensor on rail Coolant temperature sensor Free Free Fuel temperature sensor Flywheel speed sensor Free Free Free Flywheel speed sensor Engine oil temperature/pressure sensor - (ground) Air temperature/pressure sensor - (ground) Coolant temperature sensor Engine oil temperature/pressure sensor - (temperature signal) Engine oil temperature/pressure sensor - (pressure signal) Free Free Free Engine oil temperature/pressure sensor - (power supply) Air temperature/pressure sensor (power supply) Air temperature/pressure sensor (pressure signal) Fuel temperature sensor Air temperature/pressure sensor (temperature signal)

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Electrical systems - Engine control system

CONNECTORB

4

Chassis connector B ECU pin out for connector B ECU pin (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30) (31) (32) (33) (34) (35) (36) (37) (38) (39)

Wire number 7151 7153 0151 0151 7151 7151 0151 0151 0094 5163 Green White -

Function Free +30 positive +30 positive Free Ground Ground Free +30 positive +30 positive Ground Ground Preheat enable relay - (ground) Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free EDC system diagnosis inducing - (power supply) Free Free Free Free CAN - L line (ECB) CAN - H line (ECB) Free Free Free Free 47441651 09/10/2012

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Electrical systems - Engine control system

ECU pin (40) (41) (42) (43) (44) (45) (46) (47) (48) (49) (50) (51) (52) (53) (54) (55) (56) (57) (58) (59) (60) (61) (62) (63) (64) (65) (66) (67) (68) (69) (70) (71) (72) (73) (74) (75) (76) (77) (78) (79) (80) (81) (82) (83) (84) (85) (86) (87) (88) (89)

Wire number 9164 2298

Function + 15 positive Free Water in fuel sensor - (signal) Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Free Preheating enable relay - (positve) Free Free Free Free Free Free Free Free Free Free Free Free Free EDC control unit diagnosis K line

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Electrical systems - Engine control system

EDC system functions The EDC 7 UC31 electronic control unit manages the following main functions: •

Fuel injection

•

Accessory functions such as: •

Cruise control

•

Speed limiter

•

PTO

•

etc,

•

Self diagnosis

•

Recovery

•

Enables interfacing with other electronic systems available on the vehicle for diagnostic purposes

Fuel dosing Fuel dosing is calculated based on •

Accelerator position

•

Engine RPM

•

Quantity of air intake

Fuel delivery corrections based on: •

Coolant temperature •

When the engine is cold, it encounters greater operating resistance, mechanical friction is high and the engine oil is still very viscous. Fuel injected also tends to condense on cold metal surfaces. Fuel dosing is therefore greater than with a hot engine.

Fuel delivery corrections to prevent: •

Noise

•

Fumes

•

Overloads •

•

Behaviors that could lead to the above mentioned items are well known, so the control unit is programmed with specific instructions to prevent them.

Overheating •

In the event of engine overheating, the control unit will "De-rate" the engine. This decreases the fuel delivery proportional to the temperature reached by the coolant.

Pressure can be adjusted in case of •

•

External device actuation •

Speed reducer

•

Cruise control

•

etc.

Serious defects involving load reduction or engine stop

After determining the mass of air introduced by measuring its volume and temperature, the control unit calculates the corresponding mass of fuel to be injected into the cylinder involved. Fuel temperature is also taken into account.

Injection lead Injection lead, or the start of fuel delivery expressed in degrees, can differ from one injection to the next, even from one cylinder to another. It is calculated according to engine load, for example, accelerator position, engine RPM and air intake.

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Electrical systems - Engine control system

Lead is corrected as required: •

During acceleration

•

According to coolant temperature

Lead is used to obtain: •

Reduced emissions

•

Noise abatement

•

No overload

•

Better vehicle acceleration

High injection lead is set at start, based on coolant temperature. Delivery start feedback is given by the electro valve impedance variation.

Engine start Cylinder 1 flywheel and camshaft sensors synchronization takes place at first engine turns. The accelerator pedal signal is ignored at start. Start delivery is exclusively based on coolant temperature. The control unit enables the accelerator pedal, when it detects flywheel acceleration and an increase in RPM.

Cold start Pre-heating is activated when one of the three temperature sensors (coolant, air or fuel), records a temperature below 10 °C (50 °F). The pre-heat warning light goes on when the ignition key is turned to the "ON" position and stays on for a variable period of time according to temperature, while the grid heater raises the temperature of the air, then the light starts blinking to indicate that the engine can be started. The warning light switches off after the engine is running, while the heater continues being fed for a variable period of time to complete the heating process. The operation is cancelled to avoid draining the batteries if the engine is not started within 20-25 seconds with the warning light blinking. The pre-heat curve is also variable based on battery voltage.

Hot start When the ignition key is turned to the "ON" position, the warning light goes on for about 2 seconds for a short test and then switches off when all reference temperatures are above 10 °C (50 °F). The engine can be started at this point.

Run up When the ignition key is turned to the "ON" position, the control unit transfer data stored at a previous engine stop to the main memory (After Run), and diagnoses that data.

After run At each engine stop, the control unit is still fed by the main relay for a few seconds. This enables the microprocessor to transfer data from the main volatile memory to a nonvolatile, cancelable and re-writable (EEPROM) memory to make the data available for the next start (Run Up).

This data essentially consists of: •

Miscellaneous settings

•

Engine idling

•

Component settings

•

Breakdown memory

The process lasts typically from 2 to 7 seconds depending on the amount of data to be stored. the control unit then sends a command to the main relay and makes it disconnect from the battery.

NOTICE: This procedure must never be interrupted. You must wait at least 10 seconds after engine shutdown to disconnect the battery. System operation will not be affected until the fifth improper procedure, after which an error is stored in the breakdown memory and the engine is de-rated to a lower performance at the next start. The EDC warning light will be illuminated. Repeated procedure interruptions could damage the control unit.

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Electrical systems - Engine control system

Cut-off Refers to the supply cut-off function during deceleration.

Cylinder balancing individual cylinder balancing contributes to increasing comfort and operability. This function enables individual personalized fuel delivery control and delivery start for each cylinder, to compensate for injector hydraulic tolerances.

The flow differences between the various injectors cannot be evaluated directly by the control unit. This information is provided by the entry of the codes for each injector, by means of the electronic service tool.

Synchronization search The control unit can recognize the to inject fuel into even in the absence of a signal from the camshaft sensor. If this occurs with the engine running, the combustion sequence is already acquired, so the control unit continues with the sequence it has already synchronized on. If it occurs with engine stopped, the control unit actuates one electro valve.

Injection will occur within two shaft revolutions at the most so the control unit is only required to synchronize on the firing sequence and start the engine.

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Electrical systems - Engine control system

Engine wire harness - Detailed view

WIRINGHARNESS3

1

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Electrical systems - Engine control system

Function

Sensor code 78247 85157 85153 85156 42030 47032 78013 47042 48035 48042 ST

Fuel injector Fuel pressure sensor on the rail Engine coolant temperature sensor Air pressure/temperature sensor Engine oil pressure sensor Engine oil temperature sensor Camshaft sensor Fuel temperature sensor Crankshaft sensor Camshaft sensor Cable routing inside the cylinder head

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Electrical systems - Engine control system

Engine speed/RPM sensor Flywheel - Overview

SPEEDSENSOR

1

Flywheel speed sensor ECU connector Connector C Connector C

Pin number Pin 19 Pin 23

Wire color Black White

Specification •

Manufacturer - BOSCH

•

Maximum torque - 6 - 10 Nm (53 - 89 lb in)

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Electrical systems - Engine control system

Engine speed/RPM sensor Camshaft - Overview

SPEEDSENSOR

1

Camshaft speed sensor ECU connector Connector C Connector C

Pin number 9 10

Cable color White Red

This induction type sensor is located on the rear timing cover. The camshaft generates signals from the magnetic flow lines that close through the 6 plus 1 phase teeth of a phonic wheel mounted on the cam gear. The control unit uses this signal as an injection step signal. The sensor air gap is not adjustable.

Specifications: •

Manufacturer - BOSCH

•

Maximum torque - 6 - 10 Nm (53 - 89 lb in)

•

Resistance - 880 - 920 Ω

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Electrical systems - Engine control system

Engine control unit - Remove 1.

Disconnect the fuel line (1) from the cooling plate on the back of the ECU (2).

2.

Remove the screws and detach the ECU and cooling plate from the engine block, together as one unit.

ELECCONTROL

Next operation: Engine control unit - Install (55.015)

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1

Electrical systems - Engine control system

Engine control unit - Install Prior operation: Engine control unit - Remove (55.015) 1.

Install the ECU (2) and cooling plate onto the engine block as one unit.

2.

Install the fuel line (1) onto the cooling plate.

ELECCONTROL

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1

Electrical systems - Engine control system

Engine wire harness - Install 1.

Install the internal wiring harness (1) for the injectors and the rail.

2.

Secure it using bands in the locations marked by the arrows.

3.

WIRINGHARNESS

1

WIRINGHARNESS2

2

Pass the harness through the hole (1) in the cylinder head

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Electrical systems - Engine control system

Engine speed/RPM sensor Camshaft - Remove 1.

Remove the screw and remove the camshaft speed sensor (1).

GEARDRIVE

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1

Index Electrical systems - 55 Engine control system - 015 Engine control system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine control unit - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Engine control unit - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine control unit - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine speed/RPM sensor Camshaft - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Engine speed/RPM sensor Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Engine speed/RPM sensor Flywheel - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine wire harness - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine wire harness - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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Electrical systems - 55 Engine starting system - 201

F2CFA614B*E019 F2CFA614C*E019

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Contents Electrical systems - 55 Engine starting system - 201

FUNCTIONAL DATA Engine starter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine starter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - Engine starting system

Engine starter - Overview Specifications •

Manufacturer - DENSO

•

Type - 2280005641

•

Electrical system - 24 V

•

Nominal output - 4.5 kW

STARTER

1

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Electrical systems - Engine starting system

Engine starter - Remove 1.

Disconnect the cables from the starter and solenoid.

2.

Remove the starter (1) and solenoid as one unit from the rear housing.

RIGHTSIDE

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1

Electrical systems - Engine starting system

Engine starter - Install 1.

Install the starter (1) and solenoid as one unit onto the flywheel housing.

2.

Install the cables on the starter and the solenoid.

RIGHTSIDE

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1

Index Electrical systems - 55 Engine starting system - 201 Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine starter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Alternator - 301

F2CFA614B*E019 F2CFA614C*E019

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Contents Electrical systems - 55 Alternator - 301

FUNCTIONAL DATA Alternator Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Alternator Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Electrical systems - Alternator

Alternator - Overview Specicifications •

Manufacturer - LEECE NEVILLE

•

Rating - 12 V; 185 A

ALTERNATOR2

Pin (R) (L) (B-) (B+)

1

Description AC connector Driver warning light connector Negative Positive

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Electrical systems - Alternator

Alternator - Overview Specicifications •

Manufacturer - ISKRA

•

Rating - 12 V; 120 A

ALTERNATOR

1

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Electrical systems - Alternator

Alternator - Remove Prior operation: Belt - Remove (10.414) 1.

Remove the alternator (1).

FRONTVIEW6

Next operation: Alternator - Install (55.301)

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1

Electrical systems - Alternator

Alternator - Install Prior operation: Alternator - Remove (55.301) 1.

Install the alternator (1).

FRONTVIEW6

Next operation: Belt - Install (10.414)

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1

Index Electrical systems - 55 Alternator - 301 Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Alternator - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Alternator - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2012 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CNH policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CNH Dealer.

47441651 09/10/2012 EN

SPECIAL TOOL INDEX Genuine 380003118 [FPT 9.0 (Cursor) Engine Turning Tool & Adapter, and Clamp] 380000150 [Engine TDC Positioning Tool] 380000366 [Tool To Extract Cylinder Liners] 380000152 [Tool to extract the cylinder liners (115 mm)] 380000363 [ Cylinder Liners Retainers] 380000115 [Adapter - Cylinder liner compression plate ] 380000140 [Compression Tool For Checking The Protrusion Of Cylinder Liners] 380000142 [Spacers] 380001004 [Dial Gauge (0 - 5 mm)] 380000364 [Comparator Holder Base For Different Surveys] 380000131 [Tool To Take Down-Fit Engine Valves] 380000112 [Adapter Plate] 380000131 [Tool To Take Down-Fit Engine Valves] 380000114 [Valve Guide Installer for 12.9 L Cursor Engines] 380000131 [Tool To Take Down-Fit Engine Valves] 380000112 [Adapter Plate] 380000131 [Tool To Take Down-Fit Engine Valves] 380000304 [Angle Torque Thightening Screw Tool] 380000365 [Cylinder Head Valve Guide Remover And Installer] 380000365 [Cylinder Head Valve Guide Remover And Installer] 380000136 [Tool To Fit Back Valve Guide] 380000136 [Tool To Fit Back Valve Guide] 380000364 [Comparator Holder Base For Different Surveys] 380001004 [Dial Gauge (0 - 5 mm)] 380000144 [Engine Flywheel Stop] 380000144 [Engine Flywheel Stop]

Reference

PAGE

Engine - Service instruction - Finding Top Dead Center

10.001 / 12

Engine - Service instruction - Finding Top Dead Center

10.001 / 12

Crankcase Liner - Remove

10.001 / 13

Crankcase Liner - Remove

10.001 / 13

Crankcase Liner - Install

10.001 / 14

Crankcase Liner - Measure Protrusion

10.001 / 17

Crankcase Liner - Measure Protrusion

10.001 / 17

Crankcase Liner - Measure Protrusion Crankcase Liner - Measure Protrusion

10.001 / 17 10.001 / 17

Crankcase Liner - Measure Protrusion

10.001 / 17

Cylinder head - Disassemble

10.101 / 7

Cylinder head - Disassemble Cylinder head - Disassemble

10.101 / 7 10.101 / 7

Cylinder head - Assemble

10.101 / 9

Cylinder head - Assemble

10.101 / 9

Cylinder head - Assemble Cylinder head - Assemble

10.101 / 9 10.101 / 9

Cylinder head - Install

10.101 / 11

Valve guide - Replace

10.101 / 16

Valve guide - Replace

10.101 / 16

Valve guide - Replace

10.101 / 16

Valve guide - Replace

10.101 / 16

Valve seat - Replace

10.101 / 17

Valve seat - Replace

10.101 / 17

Engine flywheel - Remove

10.103 / 4

Engine flywheel - Install

10.103 / 5

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9

Genuine 380000304 [Angle Torque Thightening Screw Tool] 380000121 [Crankshaft Rear Seal Extractor] 380000127 [Crankshaft Rear Seal Installer] 380000118 [Extractor For Crankshaft Front Gasket] 380000124 [Tool To Install The Crankshaft Front Gasket] 380000362 [Crankshaft Lifting Hook] 380001004 [Dial Gauge (0 - 5 mm)] 380000362 [Crankshaft Lifting Hook] 380000324 [Pliers For Assembling And Disassembling Piston Split Rings (110-150 mm)] 380000324 [Pliers For Assembling And Disassembling Piston Split Rings (110-150 mm)] 380000220 [Band For Piston Insertion Into Cylinder Sleeves (60 -125 mm)] 380001001 [Set Of 2 Gauges For Angular Tightening With 1/2” And 3/4” Square Mount] 380000149 [Percussion Extractor (rocker shaft remover/installer)] 380000149 [Percussion Extractor (rocker shaft remover/installer)] 380003118 [FPT 9.0 (Cursor) Engine Turning Tool & Adapter, and Clamp] 380000150 [Engine TDC Positioning Tool] 380002818 [Camshaft Alignment Tool] 380002818 [Camshaft Alignment Tool] 380000151 [Tool For Timing Of Phonic Wheel On Timing Gear] 380000146 [Camshaft Bushing Remover And Installer] 380002823 [Gauge For Centre Distance Check Between Camshaft And Idle Gear] 380002817 [Camshaft - High Pressure Pump Alignment Gauge]

Reference

PAGE

Engine flywheel - Install

10.103 / 5

Crankshaft oil seal Rear seal - Remove

10.103 / 6

Crankshaft oil seal Rear seal - Install

10.103 / 7

Crankshaft oil seal Front seal - Remove

10.103 / 8

Crankshaft oil seal Front seal - Install

10.103 / 9

Crankshaft - Remove

10.103 / 10

Crankshaft - End play

10.103 / 15

Crankshaft Journal - Clearance

10.103 / 16

Connecting rod and piston - Disassemble

10.105 / 5

Connecting rod and piston - Assemble

10.105 / 8

Connecting rod and piston - Install

10.105 / 11

Connecting rod and piston - Install

10.105 / 12

Rocker arm - Remove

10.106 / 3

Rocker arm - Install

10.106 / 5

Camshaft - Timing check

10.106 / 11

Camshaft - Timing check

10.106 / 11

Camshaft - Timing adjust

10.106 / 12

Camshaft - Timing adjust

10.106 / 12

Camshaft Timing plate - Alignment

10.106 / 14

Camshaft bushings - Replace

10.106 / 15

Crankcase gears - Install

High pressure pump - Install

09/10/2012

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10.114 / 5

10.218 / 15

09/10/2012

11

New Holland Site 100 Brubaker Avenue New Holland, Pennsylvania United States 17557 SERVICE - Technical Publications & Tools

PRINTED IN U.S.A. © 2012 CNH America LLC. All rights reserved. No part of the text or illustrations of this publication may be reproduced.

CNH policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved.

All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your CNH Dealer.

47441651 09/10/2012 EN