Case ISM Tier 4 Engine Service Manual 47632293 - PDF DOWNLOAD

ISM Tier 4 Engine See the following page for engine model numbers

SERVICE MANUAL

Printed in U.S.A.

Part number 47632293

Copyright © 2014 CNH Industrial America LLC. All Rights Reserved.

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

2nd edition English September 2014 Replaces part number 47434944

SERVICE MANUAL N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.220] Throttle linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 [10.501] Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16 [10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

Electrical systems ....................................................................... 55 [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

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[55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.989] Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11

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INTRODUCTION

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Contents INTRODUCTION Foreword - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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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Foreword - Ecology and the environment 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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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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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 unless instructed otherwise.

• 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.

• While 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 jeopardize 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 "Service Parts Catalogue", used for order processing

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INTRODUCTION

Protecting the electrical/electronic systems during charging or welding WARNING Battery acid causes burns. Batteries contain sulfuric acid.

Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately.

Failure to comply could result in death or serious injury.

W0111A

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 machine or on any attachments on the machine.

• 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 machine • Never allow welding cables to lay on, near or across any electrical wiring or electronic component while welding is in progress 4. Always disconnect the negative cable from the battery when charging the battery in the machine with a battery charger.

NOTICE: If welding must be performed on the unit, the battery ground cable must be disconnected from the machine 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.

Tools The tools that CNH suggests and illustrated 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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Torque - Minimum tightening torques for normal assembly METRIC NON-FLANGED HARDWARE NOM. SIZE

M4 M5 M6 M8

CLASS 8.8 BOLT and CLASS 8 NUT PLATED UNPLATED W/ZnCr

CLASS 10.9 BOLT and CLASS 10 NUT PLATED UNPLATED W/ZnCr

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)

3.2 N·m (28 lb in) 6.4 N·m (57 lb in) 11 N·m (96 lb in) 26 N·m (234 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)

52 N·m (38 lb ft) 91 N·m (67 lb ft) 225 N·m (166 lb ft) 440 N·m (325 lb ft) 762 N·m (560 lb ft)

4.2 N·m (37 lb in) 8.5 N·m (75 lb in) 15 N·m (128 lb in) 35 N·m (311 lb in) 70 N·m (51 lb ft) 121 N·m (90 lb ft) 301 N·m (222 lb ft) 587 N·m (433 lb ft) 1016 N·m (750 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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METRIC FLANGED HARDWARE NOM. SIZE

CLASS 8.8 BOLT and CLASS 8 NUT PLATED W/ZnCr

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)

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 3.5 N·m (31 lb in) 7.0 N·m (62 lb in) 12 N·m (105 lb in) 29 N·m (257 lb in) 57 N·m (42 lb ft) 100 N·m (74 lb ft) 248 N·m (183 lb ft) 484 N·m (357 lb ft) 838 N·m (618 lb ft)

4.6 N·m (41 lb in) 9.4 N·m (83 lb in) 16 N·m (141 lb in) 39 N·m (343 lb in) 77 N·m (56 lb ft) 134 N·m (98 lb ft) 331 N·m (244 lb ft) 645 N·m (476 lb ft) 1118 N·m (824 lb ft)

Metric Hex head and carriage bolts, classes 5.6 and up

1

1. Manufacturer's Identification 2. Property Class

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

IDENTIFICATION

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

SAE GRADE 8 BOLT and NUT

UNPLATED PLATED W/ZnCr or PLATED GOLD SILVER

LOCKNUT GrB W/ Gr5 BOLT

LOCKNUT GrC W/ Gr8 BOLT

PLATED W/ZnCr GOLD

12 N·m 16 N·m 8 N·m (71 lb 11 N·m (97 lb (106 lb in) (142 lb in) in) in) 17 N·m 23 N·m 24 N·m 32 N·m (150 lb in) (204 lb in) (212 lb in) (283 lb in) 40 N·m 43 N·m (31 lb 57 N·m (42 lb 30 N·m (22 lb (30 lb ft) ft) ft) ft) 65 N·m 48 N·m (36 lb 68 N·m (50 lb 91 N·m (67 lb (48 lb ft) ft) ft) ft) 98 N·m 104 N·m 139 N·m 74 N·m (54 lb (73 lb ft) (77 lb ft) (103 lb ft) ft) 107 N·m 142 N·m 150 N·m 201 N·m (79 lb ft) (105 lb ft) (111 lb ft) (148 lb ft) 147 N·m 196 N·m 208 N·m 277 N·m (108 lb ft) (145 lb ft) (153 lb ft) (204 lb ft) 261 N·m 348 N·m 369 N·m 491 N·m (193 lb ft) (257 lb ft) (272 lb ft) (362 lb ft) 420 N·m 561 N·m 594 N·m 791 N·m (310 lb ft) (413 lb ft) (438 lb ft) (584 lb ft) 630 N·m 841 N·m 890 N·m 1187 N·m (465 lb ft) (620 lb ft) (656 lb ft) (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) 108 N·m (80 lb ft) 156 N·m (115 lb 111 N·m (82 lb ft) 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) 76 N·m (56 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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INCH FLANGED HARDWARE NOMSAE GRADE 5 BOLT and SAE GRADE 8 BOLT and INAL NUT NUT SIZE UNPLATED PLATED UNPLATED PLATED or PLATED W/ZnCr or PLATED W/ZnCr SILVER GOLD SILVER GOLD 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

9 N·m (80 lb in) 19 N·m (168 lb in) 33 N·m (25 lb ft) 53 N·m (39 lb ft) 81 N·m (60 lb ft) 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)

LOCKNUT GrF W/ Gr5 BOLT

12 N·m (106 lb 13 N·m (115 lb 17 N·m (150 lb 8 N·m (71 lb in) in) in) in) 25 N·m (221 lb 26 N·m (230 lb 35 N·m (310 lb 17 N·m (150 lb in) in) in) in) 44 N·m (33 lb 47 N·m (35 lb 63 N·m (46 lb 30 N·m (22 lb ft) ft) ft) ft) 71 N·m (52 lb 75 N·m (55 lb 100 N·m (74 lb 48 N·m (35 lb ft) ft) ft) ft) 153 N·m 108 N·m (80 lb 115 N·m (85 lb 74 N·m (55 lb ft) (113 lb ft) ft) ft) 156 N·m 165 N·m 221 N·m 106 N·m (78 lb ft) (115 lb ft) (122 lb ft) (163 lb ft) 216 N·m 228 N·m 304 N·m 147 N·m (108 lb (159 lb ft) (168 lb ft) (225 lb ft) ft) 383 N·m 405 N·m 541 N·m 261 N·m (193 lb (282 lb ft) (299 lb ft) (399 lb ft) ft) 617 N·m 653 N·m 871 N·m 421 N·m (311 lb (455 lb ft) (482 lb ft) (642 lb ft) ft) 925 N·m 979 N·m 1305 N·m 631 N·m (465 lb (682 lb ft) (722 lb ft) (963 lb ft) ft)

LOCKNUT GrG W/ Gr8 BOLT

12 N·m (106 lb in) 24 N·m (212 lb in) 43 N·m (32 lb ft) 68 N·m (50 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

CONSUMABLES INDEX Consumable

Reference

Loctite® RTV 598™ Basic instructions - Shop and assembly Loctite® Instant Gasket 587™ Basic instructions - Shop and assembly Blue

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SERVICE MANUAL Engine N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.220] Throttle linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 [10.501] Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16 [10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

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CONSUMABLES INDEX Consumable Loctite® 5970™ Molykote® G-N Metal assembly paste Molykote® Loctite® 5970™ Loctite® 5970™

Reference

PAGE

Engine oil pan - Install Camshaft Tappets - Install

10.2 / 5 10.3 / 22

Cylinder head - Install Flywheel housing - Install Crankshaft oil seal Rear seal - Install

10.4 / 17 10.6 / 11 10.6 / 14

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Engine - 10 Engine and crankcase - 001

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Engine - 10 Engine and crankcase - 001

TECHNICAL DATA Engine Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Crankcase Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Engine Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SERVICE Engine Compression test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Compression test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Crankcase Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

DIAGNOSTIC Engine Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

(*) See content for specific models 47632293 16/09/2014

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Engine - Engine and crankcase

Engine - Torque N4LDI-TA-45SL N4LDI-TA-50SL

Parts name Bearing holder (upper / lower) Bearing holder (Cylinder block / crankshaft) Bearing holder (Cylinder block / crankshaft) Flywheel Connecting rod Crankshaft pulley Rocker arm assembly Head cover Drain ; oil sump Head bolt Injection pipe complete Glow plug Relief valve assembly Oil pressure switch High Pressure (HP) pump Return pipe Rail Oil pipe complete Cam gear Pump gear Rocker arm adjust screw Sensor ; Water temperature Sensor ; Induction temperature Sensor ; Exhaust temperature

Tightening torque 49 - 54 N·m (36 - 40 lb ft) 49 - 54 N·m (36 - 40 lb ft)

Hexagon bolt

25 - 29 N·m (18 - 21 lb ft)

Hexagon socket head bolt

73 - 78 N·m (54 - 58 lb ft) 49 - 54 N·m (36 - 40 lb ft) 274 - 333 N·m (202 - 246 lb ft) 27 - 39 N·m (20 - 29 lb ft) 12 - 16 N·m (9 - 12 lb ft) 29 - 39 N·m (21 - 29 lb ft) Snug torque 48 - 52 N·m (35 - 38 lb ft) after that 120 - 180 ° 20 - 25 N·m (14.8 - 18.4 lb ft) 15 - 20 N·m (11 - 15 lb ft) 59 - 69 N·m (44 - 51 lb ft) 14.7 - 19.6 N·m (10.8 - 14.5 lb ft) 25 - 35 N·m (18.4 - 25.8 lb ft) 12 - 14 N·m (9 - 10 lb ft) 12 - 14 N·m (9 - 10 lb ft) 10 - 13 N·m (7.4 - 9.6 lb ft) 68 - 72 N·m (50 - 53 lb ft) 58 - 62 N·m (43 - 46 lb ft) 12 - 16 N·m (9 - 12 lb ft) 20 - 24 N·m (15 - 18 lb ft) 14.5 - 24.5 N·m (10.7 - 18.1 lb ft) 25 - 35 N·m (18.4 - 25.8 lb ft)

Remarks

Angle method Injector / Rail

Apply an “Anti seize compound” to the threads of the sensor.

Engine - Torque N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Parts name Bearing holder (upper / lower) Bearing holder (Cylinder block / crankshaft) Bearing holder (Cylinder block / crankshaft) Flywheel Connecting rod Crankshaft pulley Rocker arm assembly Head cover Drain ; oil sump Return nut (Nozzle and holder) Head bolt

Tightening torque 49 - 54 N·m (36 - 40 lb ft) 49 - 54 N·m (36 - 40 lb ft)

Hexagon bolt

25 - 29 N·m (18 - 21 lb ft)

Hexagon socket head bolt

73 - 78 N·m (54 - 58 lb ft) 49 - 54 N·m (36 - 40 lb ft) 274 - 333 N·m (202 - 246 lb ft) 27 - 39 N·m (20 - 29 lb ft) 12 - 16 N·m (9 - 12 lb ft) 29 - 39 N·m (21 - 29 lb ft) 25 - 29 N·m (18 - 21 lb ft) Snug torque 48 - 52 N·m (35 - 38 lb ft) after that 120 - 180 ° 47632293 16/09/2014

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Remarks

Tighten return pipe Angle method

Engine - Engine and crankcase

Parts name Nozzle and holder Injection pipe complete Glow plug (engine and afterburner) Relief valve assembly Oil pressure switch Engine stop solenoid Sensor ; Water and induction temperature Sensor ; Speed Sensor ; Exhaust temperature

Tightening torque 59 - 69 N·m (44 - 51 lb ft) 23 - 36 N·m (17 - 27 lb ft) 15 - 20 N·m (11 - 15 lb ft) 59 - 69 N·m (44 - 51 lb ft) 14.7 - 19.6 N·m (10.8 - 14.5 lb ft) 14.7 - 24.5 N·m (10.8 - 18.1 lb ft) 14.7 - 19.6 N·m (10.8 - 14.5 lb ft) 5.6 - 8.4 N·m (4.1 - 6.2 lb ft) 25 - 35 N·m (18.4 - 25.8 lb ft)

Remarks

Apply an “Anti seize compound” to the threads of the sensor.

Engine - General specification N4LDI-TA-45SL N4LDI-TA-50SL

Engine model Number of cylinders Combustion system Bore x Stroke Displacement Compression ratio Engine speeds (RPM) High idle Rated Low idle Engine horsepower @ 2800 RPM Peak torque @ 1800 RPM Firing order Cylinder arrangement Valve arrangement Aspiration Emissions control Fuel injection system Lubrication method Oil capacity with filter inlcuded Oil filtration Water pump style Water pump flow @ rated RPM Coolant volume (engine only) Engine dry weight Air cleaner

N4LDI – TA – 50SL

N4LDI – TA – 45SL 4 Direct Injection (DI) 84 mm x 100 mm ( 3.31 in x 3.94 in) 2216 cm³ ( 135.2 in³ 18:1

2825 RPM +/- 25 (No load) 2800 RPM (Full load) 1200 RPM +/- 50 50 kW (68 Hp) 45 kW (61 Hp) 208 N·m (153 lb ft) 183 N·m (135 lb ft) 1-3-4-2 In-Line Vertical Overhead Turbocharged with waste gate External Exhaust Gas Recirculation (EGR) Common rail system HP-CRS Pressure feed by gerotor pump 7.1 L (7.5 US qt) Replaceable full flow spin on cartridge Centrifugal 55.5 L/min (14.7 US gpm) 4.2 l (4.4 US qt) 206 kg (454.2 lb) Dry type

Engine - General specification N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Engine model Number of cylinders Combustion system Bore x Stroke

N844L – F – 36SL

N844LT – F – 45SL 4 Swirl chamber 84 mm x 100 mm ( 3.31 in x 3.94 in)

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Engine - Engine and crankcase

Engine model Displacement Compression ratio Engine horsepower @ 2800 RPM Peak torque @ 1800 RPM Engine speeds (RPM) High idle Rated Low idle Firing Order Cylinder Arrangement Valve Arrangement Aspiration Emissions control Injection pump Injection nozzle Alternator output Starter output Lubrication method Oil capacity with filter included Oil filtration Water pump style Water pump flow @ rated RPM Coolant volume (engine only) Engine dry weight Air cleaner

N844L – F – 36SL N844LT – F – 45SL 2216 cm³ ( 135.2 in³) 22.5:1 36 kW (49 Hp) 44 kW (60 Hp) 143 N·m (105 lb ft) 188 N·m (139 lb ft) 2825 RPM +/- 25 (No load) 2800 RPM (Full load) 1200 RPM +/- 50 1-3-4-2 In-line vertical Overhead Indirect naturally aspirated Indirect turbocharged with waste gate N/A External Exhaust Gas Recirculation (EGR) Bosch, In-line mechanical injection Throttle type 12 V — 85 A 12 V — 2.0 kW Pressure feed with gerotor pump 7.1 L (7.5 US qt) Replaceable full flow spin on cartridge Centrifugal 55.5 L/min (14.7 US gpm) 2.8 l (3.0 US qt) 227 kg (500 lb) Dry type

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Engine - Engine and crankcase

Crankcase - Dimension Bore Standard

84 - 84.019 mm (3.3071 - 3.3078 in)

Standard Maximum

0.05 mm (0.002 in) 0.12 mm (0.005 in)

Head surface warp

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Engine - Engine and crankcase

Engine - Component identification N4LDI-TA-45SL N4LDI-TA-50SL

NHIL13ENG0043AA

(1) Diesel Oxidation Catalyst (DOC) Assembly (2) Throttle valve assembly (3) Exhaust Gas Recirculation (EGR) pipe (4) Exhaust Gas Recirculation (EGR) valve (5) Oil pressure switch

1

(6) Timing sensor

(11) Fuel filter

(7) Crankshaft pulley (8) Oil pressure relief valve

(12) High Pressure (HP) fuel pump (13) Common rail assembly

(9) Oil filter

(14) Blow-by recirculation filter

(10) Oil cooler

(15) Fuel injectors

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Engine - Engine and crankcase

Engine - Component identification N4LDI-TA-45SL N4LDI-TA-50SL

NHIL13ENG0044AA

(1) Differential pressure sensor (2) Engine PIN plate

1

(3) Exhaust Gas Recirculation (EGR) cooler (4) Turbocharger

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Engine - Engine and crankcase

Engine - Component identification N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

NHVM13ENG0187AA

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

Turbocharger Air pump Oil pressure switch Speed sensors

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

1

Crank pulley Injection pump Oil cooler Oil filter

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(9) Shut-off solenoid (10) Blow-by recirculation assembly (11) Glow plugs

Engine - Engine and crankcase

Engine - Component identification N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

NHVM13ENG0186AA

(1) Wastegate (2) Flywheel (3) Temperature sensor

1

(4) After burner assembly (5) Reed valve

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Engine - Engine and crankcase

Engine - Exploded view N4LDI-TA-45SL N4LDI-TA-50SL

NHIL13ENG0018AA

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

Fuel filter assembly Tappets Push rods Oil level dipstick tube Alternator Cylinder block

1

(7) Balancer assembly (8) Suction pipe and bracket (9) Oil pan gasket (10) Oil pan (11) Oil cooler (12) Oil filter

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Engine - Engine and crankcase

Engine - Exploded view N4LDI-TA-45SL N4LDI-TA-50SL

NHIL13ENG0017AA

(1) Rocker arm assembly (2) Valve cover gasket (3) Valve cover (4) Throttle valve (5) Intake manifold (6) Exhaust Gas Recirculation (EGR) cooler (7) Exhaust Gas Recirculation (EGR) valve

1

(8) Oil transfer pipe (9) Thermostat housing (10) Cylinder head gasket (11) Cylinder head assembly (12) Glow plug connector (13) Injection pipe / Return pipe (14) Fuel injectors

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Engine - Engine and crankcase

Engine - Exploded view N4LDI-TA-45SL N4LDI-TA-50SL

NHIL13ENG0016AA

(1) Diesel Oxidation Catalyst (DOC) assembly (2) Differential pressure sensor (3) Cylinder head (4) Cylinder head bolts (5) Exhaust manifold (6) Turbocharger (7) Cooling fan / Fan pulley

1

(8) Water pump (9) Cylinder block (10) Cylinder head gasket (11) Temperature sensor (12) Blow-by recirculation filter (13) Exhaust elbow

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Engine - Engine and crankcase

Engine - Exploded view N4LDI-TA-45SL N4LDI-TA-50SL

NHIL13ENG0019AA

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

Camshaft Camshaft gear Front plate and gasket Timing cover gasket Timing cover

1

(6) V-belt (7) Crankshaft pulley (8) Idler gear (9) Oil pump (10) High Pressure (HP) fuel pump

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Engine - Engine and crankcase

Engine - Exploded view

NHIL13ENG0023AA

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

Flywheel assembly Rear plate Thrust washer Bearing holders / bearings Piston / Rings / Piston pin

1

(6) Connecting rod (7) Key (8) Crankshaft (9) Gear; Balancer (10) Rear oil seal

The cylinder block assembly contains the pistons, connecting rods, crankshaft, timing gears, and engine oil pump.

The crankshaft is supported on five main bearings. The front bearing is positioned in a bore in front of the block. The other bearings are split liners located in holders bolted to the block. The camshaft is supported on four cam bearings located in the block.

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Engine - Engine and crankcase

Engine - Compression test N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Compression test is performed through the glow plug ports. The test adapter tool (1), is equipped with quick coupler ends for easy installation of the hose and gauge.

1. Remove the two pin connector from the fuel injection pump solenoid.

2. Remove the glow plug electrical wire and wire connector from top of the glow plugs. Refer to Cold start aid - Remove — Glow plug (55.202).

3. Remove all of the glow plugs.

SECT10C01PG17_1

1

SECT10C01PG17_2

2

NOTE: Be sure all the glow plugs are removed before starting the compression tests.

4. Install the adapter Tool No. FNH00120, hose and gauge assembly OEM1074 (2), in each port and crank the engine until pressure stabilizes. The gauge should read 2944.1 kPa (427 psi) plus or minus 344.7 kPa (50 psi).

NOTE: It may be necessary to remove some injector fuel lines to install the adapter tool.

NOTE: There should not be more than 344.7 kPa (50 psi) variation between the cylinders.

5. Install the glow plugs and electrical connections. Refer to Cold start aid - Install — Glow plug (55.202).

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Engine - Engine and crankcase

Engine - Compression test N4LDI-TA-45SL N4LDI-TA-50SL

Compression test is performed through the glow plug ports. The test adapter tool (1), is equipped with quick coupler ends for easy installation of the hose and gauge.

1. Remove the two pin connector (1) from the fuel metering unit located on the high pressure pump.

NHIL13ENG0030AA

1

SECT10C01PG17_1

2

SECT10C01PG17_2

3

2. Remove the glow plug electrical wire and wire connector from top of the glow plugs. Refer to Cold start aid - Remove — Glow plug (55.202).

3. Remove all of the glow plugs.

NOTE: Be sure all the glow plugs are removed before starting the compression tests.

4. Install the adapter Tool No. FNH00120, hose and gauge assembly OEM1074 (2), in each port and crank the engine until pressure stabilizes. The gauge should read 2944.1 kPa (427 psi) plus or minus 344.7 kPa (50 psi).

NOTE: It may be necessary to remove some injector fuel lines to install the adapter tool.

NOTE: There should not be more than 344.7 kPa (50 psi) variation between the cylinders.

5. Install the glow plugs and electrical connections. Refer to Cold start aid - Install — Glow plug (55.202).

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Engine - Engine and crankcase

Crankcase - Inspect 1. Inspect the cylinder block top face for cracks, damage, and warping. Replace the cylinder block if warp is greater than 0.12 mm (0.005 in).

2. Visually inspect the cylinder bore. There should be no scoring, rust, or corrosion.

3. Use a telescoping gauge to measure the cylinder bore at the top, center and bottom of the piston ring contact area (A) parallel to the crankshaft axis (2).

4. Repeat Step 3 perpendicular to the crankshaft axis (1).

5. If any of the measurements taken exceed 84.2 mm (3.315 in) replace the engine block.

NHIL13ENG0004AA

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1

Engine - Engine and crankcase

Engine - Troubleshooting N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Problem Engine does not start

Irregular engine speed

Engine stops during operation

Engine overheat

Possible Cause Correction Defective key switch or loose connection. Check for disconnected connectors, or broken wiring. Check the key switch contact points.

Insufficient charging or completely dis- Charge the battery. charged battery.

No fuel.

Check the fuel level. Fill to proper level if needed.

Air mixed in the fuel system.

See Injection pump - Bleed (10.218) to bleed the fuel system.

Improper fuel supply. Injection system mal- See Fuel injection system - Overview function.

(10.218) for an overview of the injection system.

Clogged fuel filter.

Replace the fuel filter.

Defective glow plug.

See Cold start aid - Test (55.202) to test the glow plug.

Improper viscosity of lubricating oil.

Check the oil. Change if needed.

Clogged air cleaner.

Clean the air cleaner.

Defective engine stop solenoid.

Check the switch. Check the wiring. Repair or replace as needed.

No engine compression.

See Engine - Compression test (10.001) to perform the engine compression test.

Electrical fault.

Check for fault codes using the diagnostic service tool.

Air mixed in the fuel system.

See Injection pump - Bleed (10.218) to bleed the fuel system.

There may be trouble with the injection Uneven fuel injection. pump. See Injection pump - Dynamic description (10.218) for injection pump information.

Clogged fuel filter.

Replace the fuel filter.

Trouble with the governor.

See Governor - Dynamic description (10.220) for governor information.

Electrical fault.

Check for fault codes using the diagnostic service tool.

No fuel.

Check the fuel level. Fill to proper level if needed.

Clogged fuel filter.

Replace the fuel filter.

Air mixed in the fuel system.

See Injection pump - Bleed (10.218) to bleed the fuel system.

Electrical fault.

Check for fault codes using the diagnostic service tool.

Insufficient cooling water.

Replenish the cooling water. Check and repair water leaking points.

Loosened or slipping fan belt.

Clean oil dust, etc. and retighten.

Replace the belt.

Failure of fan belt.

Clogged radiator.

Clean the radiator.

Clogged radiator fin.

Clean the radiator fins.

Cooling water passage clogged with dust, Clean out and wash parts. etc.

Improper function of thermostat.

Check and replace.

Insufficient lubricating oil.

Check and replace oil if needed.

Decrease the load.

Overloading the engine.

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Engine - Engine and crankcase

Problem Possible Cause Improper color of engine Too much engine oil. exhaust Too low viscosity of engine oil.

Electrical fault.

Defective burner assembly.

Improper engine exhaust Improper fuel. (black or dark gray) Clogged air cleaner.

Electrical fault.

Defective burner assembly.

Improper charging.

Loosened fan belt.

Electrical wiring fault.

Defective battery.

Defective alternator.

Starting motor does not operate.

Oil pressure lamp does not go out.

Starter electrical problems.

Insufficient engine oil.

Correction Check and adjust the quantity.

Check and change the oil if needed.

Check for fault codes using the diagnostic service tool.

See After-burner - Inspect (10.501) to inspect the burner assembly.

Check and change fuel if needed.

Clean the air cleaner.

Check for fault codes using the diagnostic service tool.

See After-burner - Inspect (10.501) to inspect the burner assembly.

Correct the belt tension.

Check the wiring from the battery to the alternator.

Check and charge the battery. Replace if needed.

See Alternator - Preliminary test — Alternator Output (55.301) for alternator testing.

See Engine starter - Troubleshooting (55.201).

Check and fill to specified gauge level.

Defective oil pressure switch.

Oil pressure lamp does not light up with the key switch turned ON. (While engine stops.)

See Engine oil pressure sensor and switch - Inspect – Pressure switch (10.304) to inspect the pressure switch.

Oil leakage from lubricating system.

Check and retighten leaking section.

Clogged oil filter.

Replace the oil filter.

Short circuit wiring between oil pressure Check the wiring from the oil pressure lamp and main contact. switch to the Engine Control Unit (ECU).

Burnt out lamp.

Replace the lamp.

Disconnected wire between battery and oil Check the wiring from the oil pressure pressure lamp. switch to the Engine Control Unit (ECU).

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Index Engine - 10 Engine and crankcase - 001 Crankcase - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Crankcase - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Engine - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine - Component identification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine - Compression test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine - Compression test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Engine - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Engine - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Engine - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

(*) See content for specific models 47632293 16/09/2014

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Engine - 10 Pan and covers - 102

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Engine - 10 Pan and covers - 102

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

Timing gear housing Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove - Front plate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install - Front plate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remove - Front plate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install - Front plate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

(*) See content for specific models 47632293 16/09/2014

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CONSUMABLES INDEX Consumable Loctite® 5970™

Reference Engine oil pan - Install

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PAGE 10.2 / 5

Engine - Pan and covers

Engine oil pan - Remove 1. Remove the oil pan retainer bolts (1).

2. Remove the oil pan and discard gasket.

NHIL12ENG0209AA

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Engine - Pan and covers

Engine oil pan - Install 1. Apply a thin coat of LOCTITE® 5970™ flange sealant or equivalent to the oil pan sealing area.

2. Install the pick up tube (1) and a new gasket.

NHIL12ENG0208AA

1

NHIL12ENG0209AA

2

NHIL13ENG0202AA

3

3. Install the oil pan and retaining bolts (1).

4. Torque the retaining bolts in the order shown to 8.3 11.3 N·m (6.1 - 8 lb ft).

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Engine - Pan and covers

Timing gear housing - Remove N4LDI-TA-45SL N4LDI-TA-50SL

Prior operation: Crankshaft pulley - Remove Pulley (10.103) NOTICE: Keep all parts clean from contaminants. Contaminates may cause rapid wear and shortened component life.

1. Remove the hydraulic pump or block off plates from the bottom left of the timing cover (3).

2. Remove the nuts (1) and bolts (2) from the timing cover.

3. Remove any wire fasteners and identify fastener locations for installation.

4. Remove the cover and gasket.

NOTICE: Take care not to damage the lip of the oil seal.

NOTICE: Never rotate the engine with the timing cover removed.

NHIL13ENG0057AA

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Engine - Pan and covers

Timing gear housing - Remove N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Prior operation: Crankshaft pulley - Remove Pulley (10.103) NOTICE: Keep all parts clean from contaminants. Contaminates may cause rapid wear and shortened component life.

1. Remove the hydraulic pump or block off plates from the bottom left of the timing cover (3).

2. Remove the nuts (1) and bolts (2) from the timing cover.

3. Remove any wire fasteners and identify fastener locations for installation.

4. Remove the cover and gasket.

NOTICE: Take care not to damage the lip of the oil seal.

NOTICE: Never rotate the engine with the timing cover removed.

NHIL13ENG0182AA

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Engine - Pan and covers

Timing gear housing - Inspect N4LDI-TA-45SL N4LDI-TA-50SL

NOTICE: Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. The timing cover contains the front oil seal (2) and the oil pump alignment pin (1). Inspect the front oil seal (2) for tears or signs of wear. Ensure the oil pump alignment pin (1) is intact in the housing.

NHIL13ENG0066AA

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Engine - Pan and covers

Timing gear housing - Inspect N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

NOTICE: Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. The timing cover contains the front oil seal (2) and the oil pump alignment pin (1). Inspect the front oil seal (2) for tears or signs of wear. Ensure the oil pump alignment pin (1) is intact in the housing.

NHIL13ENG0184AA

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Engine - Pan and covers

Timing gear housing - Install N4LDI-TA-45SL N4LDI-TA-50SL

NOTICE: Never rotate the engine with the timing cover removed.

NOTICE: Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure the timing cover and the nose of the crankshaft (2) are clean and free from damage. Clean the mating surface (1) of the plate.

NHIL12ENG0192AA

1

NHIL12ENG0192AA

2

NHIL13ENG0066AA

3

2. Align the pin hole (1) on the oil pump cover with the bolt hole directly above the crankshaft (3), to accept the pin on the timing cover.

3. Install a new gasket timing cover gasket.

4. Align the front timing cover to the studs (2) in the plate.

5. Ensure the pin (1) in the timing cover aligns with the pin hole (1), Figure 2 on the oil pump cover. Install the timing cover to the plate.

NOTICE: Take care not to damage the oil seal (2) during installation.

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6. Install the retaining bolts (2) and nuts (1) on the studs.

7. Evenly torque the retaining bolts (2) and nuts (1) to 50 N·m (37 lb ft).

NHIL13ENG0073AA

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4

Engine - Pan and covers

Timing gear housing - Install N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

NOTICE: Never rotate the engine with the timing cover removed.

NOTICE: Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

1. Ensure the timing cover (2) and the nose of the crankshaft (3) are clean and free from damage. Clean the mating surface (1) of the plate.

2. Install a new timing cover gasket.

NHIL13ENG0182AA

1

NHIL13ENG0182AA

2

NHIL13ENG0185AA

3

3. Align the front timing cover to the studs (1) in the block.

4. Guide the linkage for the injection pump into position so that the link is free to move inside the aperture on the cylinder block for the injection pump.

5. Ensure the pin (2) in the timing cover aligns with the pin hole (1) on the oil pump cover. Install the timing cover to the plate.

NOTICE: Take care not to damage the oil seal during installation.

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Engine - Pan and covers

6. Install the retaining bolts (2) and nuts (1) on the studs.

7. Evenly torque the retaining bolts (2) and nuts (1) to 50 N·m (37 lb ft).

NHIL13ENG0182AA

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4

Engine - Pan and covers

Timing gear housing - Remove - Front plate N4LDI-TA-45SL N4LDI-TA-50SL

Prior operation: Camshaft - Remove (10.106) 1. Remove the front plate retaining bolts (2).

2. Remove the front plate (1) and gasket (3).

NHIL13ENG0070AA

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Engine - Pan and covers

Timing gear housing - Install - Front plate N4LDI-TA-45SL N4LDI-TA-50SL

1. Clean the mating surface of the block and front plate.

2. Install a new gasket (3).

3. Install the front plate (1) and secure with retaining bolts (2).

4. Torque bolts (2) to 23 - 28 N·m (17 - 21 lb ft).

NHIL13ENG0070AA

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Engine - Pan and covers

Timing gear housing - Remove - Front plate N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Remove the retaining bolts.

2. Remove the front plate (2) and gasket (1).

NHVM13ENG0198AA

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Engine - Pan and covers

Timing gear housing - Install - Front plate N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Clean the mating surface of the block and front plate.

2. Install a new gasket (1).

3. Install the front plate (2) and secure with retaining bolts.

4. Torque retaining bolts to 23.0 - 28.0 N·m (17.0 - 21 lb ft).

NHVM13ENG0198AA

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1

Index Engine - 10 Pan and covers - 102 Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Timing gear housing - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Timing gear housing - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Timing gear housing - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Timing gear housing - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Timing gear housing - Install - Front plate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Timing gear housing - Install - Front plate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Timing gear housing - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Timing gear housing - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Timing gear housing - Remove - Front plate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Timing gear housing - Remove - Front plate (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

(*) See content for specific models 47632293 16/09/2014

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Engine - 10 Valve drive and gears - 106

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Engine - 10 Valve drive and gears - 106

TECHNICAL DATA Rocker arm Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Camshaft Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Valve drive and gears Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Camshaft Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Rocker arm Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Rocker shaft Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Rocker support Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Camshaft Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Tappets - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

(*) See content for specific models 47632293 16/09/2014

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Tappets - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Timing adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Camshaft gear Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

(*) See content for specific models 47632293 16/09/2014

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CONSUMABLES INDEX Consumable Molykote® G-N Metal assembly paste

Reference Camshaft Tappets - Install

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PAGE 10.3 / 22

Engine - Valve drive and gears

Rocker arm - Dimension Shaft Diameter Standard Minimum Shaft-to-Rocker Clearance Standard Maximum

14.95 - 14.97 mm (0.5886 - 0.58937 in) 14.87 mm (0.585 in) 0.032 - 0.068 mm (0.00126 - 0.00268 in) 0.2 mm (0.008 in)

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Camshaft - Dimension N4LDI-TA-45SL N4LDI-TA-50SL

Cam height-valve Standard Minimum Camshaft run out Standard Maximum Cam gear backlash Standard Allowable limit

34.438 - 34.538 mm (1.3558 - 1.3598 in) 34.1 mm (1.3425 in) Less than 0.03 mm (0.001 in) More than 0.1 mm (0.004 in) 0.08 - 43.06 mm (0.0031 - 1.6953 in) 0.25 mm (0.0098 in)

Camshaft - Dimension N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Cam height - (valve lobes) Standard Minimum Cam height - (injection pump lobes) Standard Minimum Camshaft run out Standard Maximum Cam gear backlash Standard Allowable limit

34.438 - 34.538 mm (1.3558 - 1.3598 in) 34.1 mm (1.3425 in) 42.94 - 43.06 mm (1.6906 - 1.6953 in) 42.8 mm (1.6850 in) Less than 0.03 mm (0.001 in) More than 0.1 mm (0.004 in) 0.08 - 43.06 mm (0.0031 - 1.6953 in) 0.25 mm (0.0098 in)

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Engine - Valve drive and gears

Valve drive and gears - Exploded view N4LDI-TA-45SL N4LDI-TA-50SL

NHIL13ENG0045AA

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

Rocker arm housing Springs Washers Rocker arm

1

(5) Oil pressure switch (6) Rocker shaft (7) Gasket

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Engine - Valve drive and gears

Valve drive and gears - Exploded view N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

NHIL13ENG0178AA

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

Rocker arm Spring Washers Oil pressure switch

1

(5) Rocker shaft (6) Rocker arm housing gasket (7) Rocker arm housing

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Engine - Valve drive and gears

Camshaft - Exploded view

NHIL13ENG0005AA

(1) Camshaft (2) Bearing (3) Washers

1

(4) Camshaft gear (5) Spacer (6) Key

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Engine - Valve drive and gears

Rocker arm - Remove N4LDI-TA-45SL N4LDI-TA-50SL

Prior operation: Rocker support - Remove (10.106) 1. Thread an 8mm bolt (4) into the front end of the rocker shaft (3).

2. Slowly withdraw the rocker shaft (3) while removing the rocker arms (1) and springs (2).

NHIL12ENG0189AA

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Engine - Valve drive and gears

Rocker arm - Remove N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Thread the banjo bolt from the oil supply line into the front end of the rocker shaft (4).

2. Slowly withdraw the rocker shaft (4) while removing the rocker arms (1), springs (2), and washers (3).

NHIL13ENG0178AA

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Engine - Valve drive and gears

Rocker arm - Inspect 1. Use a micrometer to measure the outside diameter of the rocker shaft.

NOTE: Rocker arms have no bushings and only one lube hole.

2. Calculate the clearance (2) between the rocker arm and rocker arm shaft. If the clearance exceeds 0.2 mm (0.008 in), replace the rocker arm.

3. Check the valve cap contact surface (1) for uneven wear and streaks.

NOTE: Minor damage can be fixed using a fine grinding stone or sand paper.

NHIL13ENG0050AA

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Engine - Valve drive and gears

Rocker arm - Install Prior operation: Rocker arm - Inspect (10.106) 1. Install the rocker shaft (5) into the rocker housing (1) while installing the rocker arms (4), washers (3) and springs (2).

NHIL13ENG0045AA

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Engine - Valve drive and gears

Rocker arm - Install N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Prior operation: Rocker arm - Inspect (10.106) 1. Install the rocker shaft (4) into the rocker housing (5) while installing the rocker arms (1), springs (2) and washers (3).

NHIL13ENG0178AA

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Engine - Valve drive and gears

Rocker arm - Clearance NOTICE: Adjust the valve clearance only while the engine is cold.

1. Rotate the crankshaft clockwise and bring each piston to Top Dead Center (TDC) on the compression stroke (both valves closed).

NOTE: This will ensure the tappet is in its lowest position before making the adjustment.

2. Loosen the nut (2) and adjust the clearance of both the intake and exhaust valves to 0.2 mm (0.008 in) (3) with the adjusting screw (1).

3. Hold the adjusting screw from turning and torque nut to 12 - 16 N·m (9 - 12 lb ft).

76075742

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Engine - Valve drive and gears

Rocker shaft - Inspect Prior operation: Rocker arm - Remove (10.106) 1. Use a micrometer to measure the wear points (arrows) on the rocker shaft.

2. The shaft diameter should be between 14.95 14.97 mm (0.588 - 0.589 in).

3. Replace the rocker shaft if the measured value at any point is less than 14.87 mm (0.585 in).

NHIL13ENG0048AA

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Engine - Valve drive and gears

Rocker support - Remove N4LDI-TA-45SL N4LDI-TA-50SL

Prior operation: Valve cover - Remove (10.101) 1. Remove the banjo fitting (3) on the pulley side of the engine.

2. Remove bolts (1).

3. Loosen nuts (2) one turn at a time, in an alternating order. This will prevent any distortion of the rocker shaft.

4. Remove nuts (2).

NHIL12ENG0175AA

1

NHIL12ENG0189AA

2

5. Remove the rocker arm shaft and support bracket (4) as an assembly.

6. Remove push rods from the cylinder head.

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Engine - Valve drive and gears

Rocker support - Remove N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Prior operation: Valve cover - Remove (10.101) 1. Remove the banjo fitting (3) on the pulley side of the engine.

2. Remove bolts (1).

3. Loosen nuts (2) one turn at a time, in an alternating order. This will prevent any distortion of the rocker shaft.

4. Remove nuts (2).

5. Remove the rocker arm shaft and support bracket (4) as an assembly.

6. Remove push rods from the cylinder head.

NHIL12ENG0189AA

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Engine - Valve drive and gears

Rocker support - Install N4LDI-TA-45SL N4LDI-TA-50SL

1. Install the push rods into the cylinder head.

2. Install a new gasket.

3. Install rocker arm shaft and support bracket (4) as an assembly on top of the cylinder head (5).

NOTICE: Ensure the push rods are properly seated on the ball of the rocker arm.

4. Evenly tighten the nuts and bolts (2) in an alternating order to prevent distortion.

5. Torque nuts and bolts (2) to 27 - 39 N·m (20 - 29 lb ft).

6. Install the banjo fitting (3) and torque to 10.0 - 12 N·m (7.4 - 9 lb ft).

NHIL12ENG0175AA

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Engine - Valve drive and gears

Rocker support - Install N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Install the push rods into the cylinder head.

2. Install a new gasket.

3. Install rocker arm shaft and support bracket (4) as an assembly on top of the cylinder head (5).

NOTICE: Ensure the push rods are properly seated on the ball of the rocker arm.

4. Evenly tighten the nuts and bolts (2) in an alternating order to prevent distortion.

5. Torque nuts and bolts (2) to 27 - 39 N·m (20 - 29 lb ft).

6. Install the banjo fitting (3) and torque to 10.0 - 12 N·m (7.4 - 9 lb ft).

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Engine - Valve drive and gears

Camshaft Tappets - Remove Prior operation: Cylinder head - Remove (10.101) 1. Remove the valve tappets (1) from the machined bores in the cylinder block.

NHIL12ENG0216AA

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Engine - Valve drive and gears

Camshaft Tappets - Install N4LDI-TA-45SL N4LDI-TA-50SL

1. Coat tappets with MOLYKOTE ® G-N METAL ASSEMBLY PASTE .

2. Insert valve tappets (1) into cylinder block bores.

NHIL12ENG0216AA

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Engine - Valve drive and gears

Camshaft Tappets - Install N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Coat tappets with clean engine oil.

2. Insert valve tappets (1) into cylinder block bores.

NHIL12ENG0216AA

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Engine - Valve drive and gears

Camshaft - Remove N4LDI-TA-45SL N4LDI-TA-50SL

Prior operation: Timing gear housing - Remove (10.102) 1. Refer to Timing gear housing - Remove (10.102).

NOTICE: The idler gear must be removed prior to rotating the camshaft. Refer to Engine oil pump - Remove (10.304) for the proper procedure.

2. Rotate the camshaft to access the retaining bolts (1) that secure the camshaft plate (2) and remove bolts.

3. Remove the plate (2).

4. Remove the camshaft (3) from the front of the block.

NHIL13ENG0032AA

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Engine - Valve drive and gears

Camshaft - Inspect N4LDI-TA-45SL N4LDI-TA-50SL

1. Place the camshaft in a set of V-blocks and check the runout using a dial indicator (1).

2. Replace or straighten the camshaft if the runout is greater than 0.1 mm (0.004 in).

3. Use a micrometer to measure the height of the camshaft lobes.

4. Replace the camshaft if any of the cam lobes are worn to less than the following dimensions: • Intake/Exhaust valve lobes: 34.1 mm (1.3425 in)

20093402

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Engine - Valve drive and gears

Camshaft - Install N4LDI-TA-45SL N4LDI-TA-50SL

1. Lubricate the cam lobes with engine oil.

2. Install the camshaft (3) into the engine block while aligning the timing marks of the High Pressure (HP) pump gear and camshaft gear (A).

NOTICE: The idler gear must be removed prior to rotating the camshaft. Refer to Engine oil pump - Remove (10.304) for the proper procedure.

3. Rotate the camshaft gear to access the bolt holes on the block.

4. Install the camshaft support plate (2) and secure with retaining bolts (1).

5. Torque bolts to 9 - 13 N·m (6.6 - 10 lb ft).

NHIL13ENG0032AA

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Engine - Valve drive and gears

Camshaft - Timing adjust N4LDI-TA-45SL N4LDI-TA-50SL

1. The idler gear is integral to the oil pump. See Engine oil pump - Install (10.304) for proper timing of the camshaft and crankshaft gears.

2. For timing of the high pressure fuel pump, see High pressure pump - Timing adjust (10.218).

NOTICE: It is very important to install the front cover prior to rotating the engine with the oil pump installed. Damage to the port shaft of the oil pump can occur.

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Engine - Valve drive and gears

Camshaft - Remove N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Prior operation: Timing gear housing - Remove (10.102) 1. Remove the bolts (3) securing the plate (1) to the block.

One must be accessed using the access hole (2) in the cam gear.

NOTICE: Never rotate the cam gear unless the idler gear is removed.

2. Remove the cam gear and camshaft out of the engine bore.

SECT10C01PG45_1

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Engine - Valve drive and gears

Camshaft - Inspect N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Place the camshaft in a set of V-blocks and check the runout using a dial indicator (1).

20093402

1

NHIL13ENG0167AA

2

2. Use a micrometer to measure the height of the camshaft lobes.

Height of intake/exhaust cam lobes (1): • Standard valvue — 34.453 - 34.508 mm (1.356 1.359 in) • Service limit — 34.100 mm (1.343 in) Height of injection pump cam lobes (2): • Standard value — 42.940 - 43.060 mm (1.691 1.695 in) • Service limit — 42.800 mm (1.685 in) 3. Replace or straighten the camshaft if the runout is less then the service limit.

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Engine - Valve drive and gears

Camshaft - Install N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Prior operation: Timing gear housing - Install — Front plate (10.102) 1. Install the tachometer shaft (3).

2. Carefully insert the camshaft (1) into its bore so as not to damage the bearings or bearing surfaces.

3. Align the retaining plate (4) to the block bolt holes and install the retaining bolts (2).

4. Torque the bolts to 8.8 - 12.9 N·m (6.5 - 9.5 lb ft)

NHIL13ENG0166AA

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Engine - Valve drive and gears

Camshaft gear - Remove N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Remove the slide (4) from the camshaft gear.

2. Use a gear pull to remove the gear assembly (5).

3. Remove the spacer (3), spacer gear (6), spacers (2), bearing (7) and key (1) from the camshaft (8).

20093401

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Engine - Valve drive and gears

Camshaft gear - Inspect N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Check the timing gears for wear and damage on the contact area. Replace if any defect is found.

2. Measure the backlash of gears with a feeler gauge or dial indicator. The measured value should be between 0.08 - 0.25 mm (0.0031 - 0.0098 in).

3. Replace the gears if the allowable limit is exceeded.

20093400

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Engine - Valve drive and gears

Camshaft gear - Install N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Install bearing (7), two spacers (2), spacer gear (6), and spacer (3).

NOTE: The spacer gear (6), serves as a spacer only. There is no other purpose for this gear.

2. Insert the key (1) into the key slot on shaft (8) and press the gear assembly (4) over the shaft onto the key.

3. Install the slider (5) back onto the gear assembly (4).

20093401A

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Engine - Valve drive and gears

Camshaft gear - Remove N4LDI-TA-45SL N4LDI-TA-50SL

1. Remove the nut (4) and spacer (3) from the camshaft.

2. Use a gear puller to remove the camshaft gear (2).

3. Collect the washers (1) and spacer (5).

NHIL13ENG0005AA

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Engine - Valve drive and gears

Camshaft gear - Inspect N4LDI-TA-45SL N4LDI-TA-50SL

1. Check the camshaft gear for wear and damage on the contact area (1). Replace if any defect is found.

NHIL13ENG0005AA

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Engine - Valve drive and gears

Camshaft gear - Install N4LDI-TA-45SL N4LDI-TA-50SL

1. Install bearing (6), two washers (1), spacer (5) and one washer (1).

2. Insert the key (7) into the slot on the shaft and press the cam gear (2) on the shaft aligning the key.

3. Install the spacer (3) and secure assembly with nut (4).

4. Torque the nut (4) to 68 - 72 N·m (50 - 53 lb ft).

NHIL13ENG0005AA

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1

Index Engine - 10 Valve drive and gears - 106 Camshaft - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Camshaft - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Camshaft - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Camshaft - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Camshaft - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Camshaft - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Camshaft - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Camshaft - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Camshaft - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Camshaft - Timing adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Camshaft Tappets - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Camshaft Tappets - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Camshaft Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Camshaft gear - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Camshaft gear - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Camshaft gear - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Camshaft gear - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Camshaft gear - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Camshaft gear - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Rocker arm - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Rocker arm - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rocker arm - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Rocker arm - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Rocker arm - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Rocker arm - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rocker shaft - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Rocker support - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Rocker support - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Rocker support - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Rocker support - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Valve drive and gears - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Valve drive and gears - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

(*) See content for specific models 47632293 16/09/2014

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Engine - 10 Cylinder heads - 101

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Engine - 10 Cylinder heads - 101

TECHNICAL DATA Cylinder heads Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Valves Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Spring - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Valve guide Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Valve seat Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FUNCTIONAL DATA Cylinder head Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Valve cover Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Cylinder head Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Valves Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

(*) See content for specific models 47632293 16/09/2014

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Spring - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Valve guide Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Valve seat Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

(*) See content for specific models 47632293 16/09/2014

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CONSUMABLES INDEX Consumable Molykote®

Reference Cylinder head - Install

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Engine - Cylinder heads

Cylinder heads - Dimension N4LDI-TA-45SL N4LDI-TA-50SL

Head warp Standard Maximum

0.05 mm (0.002 in) 0.12 mm (0.005 in)

Cylinder heads - Dimension N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Head warp Standard Maximum

0.05 mm (0.002 in) 0.12 mm (0.005 in)

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Engine - Cylinder heads

Valves - Dimension N4LDI-TA-45SL N4LDI-TA-50SL

Valve stem thickness Standard Maximum

6.955 - 6.97 mm (0.27382 - 0.27441 in) 6.89 mm (0.27126 in)

Standard Maximum

0.9 - 1.1 mm (0.03543 - 0.04331 in) 0.5 mm (0.01969 in)

Valve head thickness

Valves - Dimension N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Valve stem thickness Standard (Intake) Maximum (Intake) Standard (Exhaust) Maximum (Exhaust) Valve head thickness Standard Maximum

6.955 - 6.97 mm (0.27382 - 0.27441 in) 6.89 mm (0.27126 in) 6.94 - 6.95 mm (0.27323 - 0.27362 in) 6.84 mm (0.26929 in) 0.8 - 1.1 mm (0.03150 - 0.04331 in) 0.5 mm (0.01969 in)

Valves Spring - Dimension Out of square Standard Maximum

1.2 mm (0.04724 in) 2.0 mm (0.07874 in)

Free length Standard Maximum Spring force when compressed to 30.4 mm (1.20 in) Standard Maximum

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35 mm (1.37795 in) 33.5 mm (1.31890 in) 79.4 N (17.8 lb) 68.6 N (15.4 lb)

Engine - Cylinder heads

Valve guide - Dimension N4LDI-TA-45SL N4LDI-TA-50SL

Valve stem to valve guide clearance Standard Maximum

0.03 - 0.06 mm (0.00118 - 0.00236 in) 0.2 mm (0.00787 in)

Valve guide - Dimension N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Valve stem to valve guide clearance Standard (Intake) Maximum (Intake) Standard (Exhaust) Maximum (Exhaust)

0.03 - 0.06 mm (0.00118 - 0.00236 in) 0.2 mm (0.00787 in) 0.045 - 0.075 mm (0.00177 - 0.00295 in) 0.25 mm (0.00984 in)

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Engine - Cylinder heads

Valve seat - Dimension N4LDI-TA-45SL N4LDI-TA-50SL

Valve seat recess Standard Maximum

0.75 - 0.85 mm (0.02953 - 0.03346 in) 1.6 mm (0.06299 in)

Standard (Intake) Maximum (Intake) Standard (Exhaust) Maximum (Exhaust)

2.16 - 2.38 mm (0.08504 - 0.09370 in) 2.7 mm (0.10630 in) 1.50 - 1.86 mm (0.05906 - 0.07323 in) 2.5 mm (0.09843 in)

Valve seat width

Valve seat - Dimension N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Valve seat recess Standard Maximum

0.85 - 1.15 mm (0.03346 - 0.04528 in) 1.8 mm (0.07087 in)

Standard (Intake) Maximum (Intake) Standard (Exhaust) Maximum (Exhaust)

1.77 - 2.19 mm (0.06969 - 0.08622 in) 2.5 mm (0.098 in) 1.87 - 2.09 mm (0.07362 - 0.08228 in) 2.5 mm (0.098 in)

Valve seat width

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Engine - Cylinder heads

Cylinder head - Exploded view

NHIL13ENG0058AA

(1) Valve guide seals (2) Cap (3) Retainer

1

(4) Valve cotter (5) Spring (6) Valve

The cylinder head incorporates the valve assemblies, rocker arms, rocker shaft, push rods, and lifters. A swirl chamber located between the injector assembly and the main combustion chamber of the cylinders provides improved starting and greater fuel efficiency. Initial combustion starts in the precombustion chamber and as the expansion occurs a strong swirl pattern is created in the main combustion chamber for more complete combustion of the air-fuel mixture. The air intake manifold is separate from the cast aluminum valve cover. The exhaust manifold is bolted on the left-hand side of the cylinder head.. Cylinder heads have integral valve guides. Standard size valves only are used.

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Engine - Cylinder heads

Valve cover - Remove Prior operation: Throttle Valve Actuator (TVA) - Remove (55.014) 1. Remove the seal washer (2) and cap nuts (1).

2. Lift the valve cover (4) and gasket from the rocker shaft support (3).

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NHIL12ENG0174AA

1

NHIL12ENG0175AA

2

Engine - Cylinder heads

Valve cover - Install 1. Inspect and clean the gasket contact area (1) of the rocker shaft support housing.

NHIL12ENG0175AA

1

NHIL12ENG0174AA

2

2. Install the gasket and valve cover (4) onto the shaft support housing (3).

3. Install the seal washers (2) and cap nuts (1).

4. Evenly torque the cap nuts (1) to 8.3 - 11.3 N·m (6.1 8.3 lb ft).

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Engine - Cylinder heads

Cylinder head - Remove 1. Evenly loosen the cylinder head bolts following the pattern shown.

20002380

1

NHIL12ENG0188AA

2

2. Remove the head from the block.

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Engine - Cylinder heads

Cylinder head - Disassemble Prior operation: Cylinder head - Remove (10.101) 1. Clean the cylinder head and remove any carbon deposits from around the valve heads.

2. Remove the stem cap (1) from the valve stem.

3. Use a valve spring compressor to compress the spring.

4. Remove the valve spring keepers (2), spring cap (3) and spring (4) from each valve (5).

5. Remove the valves and place the valve components together in separately marked containers for reassembly in their original position.

6. Remove the valve guide seals (6).

NOTE: The valve guide seals for the intake and exhaust are different.

NHIL13ENG0058AC

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1

Engine - Cylinder heads

Cylinder head - Inspect 1. Clean all carbon deposits from the combustion chamber and valve ports using a wire brush and scraper.

2. Clean all dirt and residue from the gasket surface using care not to scratch or nick the machined surface.

3. Clean the cylinder head in solvent and air dry.

4. Inspect the head for cracks or damage in the following areas: • Valve ports • Valve seats • Water jackets 5. Inspect the gasket surfaces for scratches or nicks, which could cause leakage.

6. Examine the core hole plugs for rust or signs of leakage. If a plug shows signs of damaging rust or leakage, replace all plugs in the head.

7. Apply a straight edge to the bottom surface of the cylinder head at six locations from (A) to (F) and check for warp lengthwise, crosswise, and diagonally.

NHIL13ENG0075AA

1

20093371F

2

8. Use a feeler gauge at six points from (A) to (F) to measure distortion.

9. If distortion exceeds 0.12 mm (0.00472 in) at any point, replace the cylinder head.

NOTE: If any cracks or other damage is found during inspection, replace the cylinder head.

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Engine - Cylinder heads

Cylinder head - Assemble 1. Insert each valve (5) in the guide (6) from which it was removed and lightly lap the valve to be sure of an even seat around the valve face. Remove the valve and remove all traces of lapping compound.

2. Install new intake valve seals on the valve guides using a suitable driver.

NOTE: Be sure to check the seals, the valve guide seals for the intake and exhaust are different sizes.

3. Use a spring compressor to assemble the valves (5), springs (4), spring cap (3), keepers (2).

4. Install the valve stem cap (1).

NHIL13ENG0058AC

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1

Engine - Cylinder heads

Cylinder head - Install Prior operation: Cylinder head - Inspect (10.101) 1. Clean all dirt and residue from the gasket surface of the block and head using care not to scratch or nick the machined surface.

Head gasket selection During assembly, the engine compression ratio is established by the thickness of the head gasket used. For service replacement, head gaskets of different thickness are available. The correct head gasket must be selected based on piston protrusion. The correct head gasket usage is determined as follows: 1. Position each of the pistons at top dead center.

2. Use a dial indicator to determine the distance each piston projects above the face of the block.

NOTE: Measure each of the pistons while holding a slight down pressure on the piston.

NOTE: The variation in the amount of protrusion among all pistons must be within 0.1 mm (0.004 in).

3. Use the dimension taken from the cylinder which has the greatest projection and select a head gasket as indicated in the following chart.

Measured value 0.3 - 0.4 mm (0.01181 - 0.01575 in) 0.4 - 0.5 mm (0.01575 - 0.01969 in) 0.5 - 0.6 mm (0.01969 - 0.02362 in)

20002377

1

NHIL12ENG0211AA

2

Selection chart Thickness when tightened 1.1 mm (0.04331 in) 1.2 mm (0.04724 in) 1.3 mm (0.0512 in)

Install cylinder head 1. Install the head gasket (1) on the block (3).

2. Align the locating dowels (2) and install the cylinder head.

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Engine - Cylinder heads

3. Apply MOLYKOTE ® to the threads of each bolt and install.

4. Torque the head bolts in the sequence as shown to 48 - 52 N·m (35.4 - 38 lb ft).

5. Then turn the head bolts an additional 120 - 180 °.

20002380

3

NHIL12ENG0217AA

4

6. Install the push rods (1).

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Engine - Cylinder heads

Valves - Inspect N4LDI-TA-45SL N4LDI-TA-50SL

Prior operation: Cylinder head - Disassemble (10.101) 1. Clean all deposits from the valves using a soft wire brush. Inspect the condition of the valves and discard any that are badly burned, cracked, or bent.

2. Using a micrometer, measure the valve stem diameter at points (A), (B), and (C).

3. If the valve stem diameter is less than 6.89 mm (0.2713 in) it must be replaced.

Wear of valve stem Standard assembling value Service limit

20093375A

1

20093376

2

6.955 - 6.97 mm (0.2738 - 0.2744 in) 6.89 mm (0.2713 in)

4. If the valve head is less than 0.5 mm (0.0197 in) it must be replaced.

Valve head thickness Standard assembling value Service limit

0.9 - 1.1 mm (0.0354 - 0.0433 in) 0.5 mm (0.0197 in)

5. If inspection indicates that the valve may be reused, the valve should be ground: (1) 45 ° Angle Seat (2) Minimum Valve Margin Valve seat contact width Standard assembling value Intake 2.16 - 2.38 mm (0.0850 - 0.0937 in) Exhaust 1.50 - 1.86 mm (0.0591 - 0.0732 in)

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Repair value 2.7 mm (0.1063 in) 2.5 mm (0.0984 in)

Engine - Cylinder heads

6. After grinding the valve and seat: 1.

Check to ensure the seat contacts the center of the valve face.

2.

Use Prussian Blue to lightly coat the valve seat.

3.

Place the valve in position and rotate the valve slightly while holding a light pressure against the valve.

4.

If the blue is transferred to the center of the valve face, the contact is correct.

NOTE: If Prussian Blue is not available, mark the valve face or seat (1) with a soft lead pencil. Rotate the valve slightly in the seat. The penciled lines will be broken at the seat contact area.

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20093377

3

Engine - Cylinder heads

Valves - Inspect N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Prior operation: Cylinder head - Disassemble (10.101) 1. Clean all deposits from the valves using a soft wire brush. Inspect the condition of the valves and discard any that are badly burned, cracked, or bent.

2. Using a micrometer, measure the valve stem at points (A), (B), and (C).

3. Replace the valve if the measured values are less than: • Intake – 6.89 mm (0.27126 in) • Exhaust – 6.84 mm (0.26929 in)

20093375A

1

20093376

2

20093377

3

4. If the valve margin (2) is less than 0.5 mm (0.01969 in) it must be replaced.

5. Grind the valve face angle (1) to 45 ° if the valve is to be reused.

6. Check that the valve seat contacts the center of the valve face after grinding using valve lapping compound. Rotate the valve against the seat with a slight pressure.

7. If valve lapping compound is not available, mark the valve face or seat (1), with a soft lead pencil. Rotate the valve slightly in the seat. The penciled lines will be broken at the seat contact area.

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Engine - Cylinder heads

Valves Spring - Inspect 1. Place the valve springs on a flat surface.

2. Measure the free length of the spring and squareness.

If the spring exceeds 2.0 mm (0.079 in) out of square, replace springs.

3. Place the springs in a suitable spring load tester.

4. Compress the spring to 30.4 mm (1.197 in). If the spring exerts less than 7 kg (15.43 lb) of force, replace the springs.

SECT10C01P52_1

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1

Engine - Cylinder heads

Valve guide - Inspect N4LDI-TA-45SL N4LDI-TA-50SL

Thoroughly clean the valve guides before attempting to check internal wear.

1. Using a telescoping gauge and micrometer, measure the valve guide bore at the top and bottom wear points (1).

20093378A

1

20093379A

2

2. Determine the valve stem to valve guide clearance (1) by subtracting the valve stem outside diameter from the valve guide inside diameter. Replace valves if the clearance (1) is more than 0.2 mm (0.008 in).

3. Replace the cylinder head if excessive clearance is determined and the valves have met all specified measurement requirements.

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Engine - Cylinder heads

Valve guide - Inspect N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Thoroughly clean the valve guides before attempting to check internal wear.

1. Use a telescoping gauge and micrometer to measure the valve guide bore at the top and bottom wear points (1).

20093378A

1

20093379A

2

2. Determine the valve stem to valve guide clearance (1) by subtracting the valve stem outside diameter from the valve guide inside diameter. Replace valves if the clearance (1) exceeds: • 0.2 mm (0.008 in) for intake valves • 0.25 mm (0.010 in) for exhaust valves.

3. Replace the cylinder head if excessive clearance is determined and the valves have met all specified measurement requirements.

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Engine - Cylinder heads

Valve seat - Inspect N4LDI-TA-45SL N4LDI-TA-50SL

Examine the valve seats and surface the seat if damaged. Valve seat grinding requires that the seat be ground to the correct width and properly positioned. A valve that extends too deep into the combustion area will result in valve burning. If the valve is recessed too deep into the head it will cause a rapid build-up of carbon deposits.

20093372

1

Intake Exhaust (1) Correct valve seat width and location Standard assembling value 2.16 - 2.38 mm (0.0850 - 0.0937 in) 1.50 - 1.86 mm (0.0591 - 0.0732 in) Service limit 2.7 mm (0.1063 in) 2.5 mm (0.0984 in) (2) Valve recess Standard assembling value 0.75 - 0.85 mm (0.02953 - 0.03346 in) Service limit 1.6 mm (0.06299 in)

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Engine - Cylinder heads

1. Check the seat for surface defects. Use a 45 ° stone if necessary to reface. Grind away only enough material to provide a smooth even seat.

2. Check the seat width. If necessary, use a 15 ° stone to lower the seat contact point and use a 75 ° stone to raise the seat contact point.

NOTE: Refacing the seat should always be coordinated with refacing of the valve to ensure a compression tight fit.

20093373

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

2

Lower seat location — 15 ° stone Seat angle — 45 ° stone Raise seat location — 75 ° stone Intake Exhaust Contact width Standard assembling value 2.16 - 2.38 mm (0.08504 - 0.09370 in) 1.50 - 1.86 mm (0.05906 - 0.07323 in) Service limit 2.7 mm (0.10630 in) 2.5 mm (0.09843 in)

3. Coat the valve seat surface with compound and lap the contact surface turning the valve.

4. Check that the valve contact surface is within the standard value and the contact position is even.

5. When the cylinder head is replaced with a new one, adjust the seat contact width and seat recess to the specified values with a seat cutter before lapping.

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Engine - Cylinder heads

Valve seat - Inspect N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Examine the valve seats and surface the seat if damaged. Valve seat grinding requires that the seat be ground to the correct width and properly positioned. A valve that extends too deep into the combustion area will result in valve burning. If the valve is recessed too deep into the head it will cause a rapid build-up of carbon deposits.

20093372

1

(1) Correct valve seat width and location Standard assembling value Service limit (2) Valve recess Standard assembling value Service limit

Intake 1.77 - 2.19 mm (0.0697 - 0.0862 in) 2.5 mm (0.0984 in)

Exhaust 1.87 - 2.09 mm (0.0736 - 0.0823 in) 2.5 mm (0.0984 in)

0.85 - 1.15 mm (0.0335 - 0.0453 in) 1.8 mm (0.0709 in)

0.85 - 1.15 mm (0.0335 - 0.0453 in) 1.8 mm (0.0709 in)

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Engine - Cylinder heads

1. Check the seat for surface defects. Use a 45 ° stone to reface if needed.

NOTE: Grind away only enough material to provide a smooth even seat.

2. Check the seat width. If necessary, use a 15 ° stone to lower the seat contact point and use a 75 ° stone to raise the seat contact point.

NOTE: Refacing the seat should always be coordinated with refacing of the valve to ensure a compression tight fit.

20093373

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

Lower seat location - 15 ° stone Seat angle - 45 ° stone Raise seat location - 75 ° stone Contact width Standard assembling value Service limit

2

Intake Exhaust 2.16 - 2.38 mm (0.08504 - 0.09370 in) 1.50 - 1.86 mm (0.05906 - 0.07323 in) 2.7 mm (0.10630 in) 2.5 mm (0.09843 in)

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Engine - Cylinder heads

3. Coat the valve seat surface with compound and use a valve lapper (1) to lap the contact surface turning the valve.

4. Check that the valve contact surface is within the standard value and the contact position is even.

5. When the cylinder head is replaced with a new one, adjust the seat contact width and seat recess to the specified values with a seat cutter before lapping.

NHIL13ENG0055AA

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3

Index Engine - 10 Cylinder heads - 101 Cylinder head - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Cylinder head - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Cylinder head - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Cylinder head - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cylinder heads - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cylinder heads - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Valve guide - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Valve guide - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Valve guide - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Valve guide - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Valve seat - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Valve seat - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Valve seat - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Valve seat - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Valves - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Valves - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Valves - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Valves - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Valves Spring - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Valves Spring - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Engine - 10 Connecting rods and pistons - 105

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Engine - 10 Connecting rods and pistons - 105

TECHNICAL DATA Connecting rod and piston Connecting rod - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Piston Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Pin - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Ring - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Ring - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Connecting rod and piston Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Connecting rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Piston Ring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Ring - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Connecting rod bearing Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Piston pin bushings Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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Engine - Connecting rods and pistons

Connecting rod and piston Connecting rod - Dimension Rod twist Standard Maximum Rod bend Standard Maximum On crankshaft side play Standard Maximum Crankshaft bearing clearance Standard Maximum

0.08 mm (0.003 in) 0.2 mm (0.008 in) 0.05 mm (0.002 in) 0.15 mm (0.0059 in) 0.1 - 0.3 mm (0.004 - 0.012 in) 0.7 mm (0.028 in) 0.035 - 0.083 mm (0.0014 - 0.00327 in) 0.2 mm (0.008 in)

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Engine - Connecting rods and pistons

Piston - Dimension Diameter Standard Minimum Bore clearance Standard Maximum Piston pin bore Standard Maximum Piston pin clearance Standard Maximum

83.943 - 83.958 mm (3.30484 - 3.30543 in) 83.7 mm (3.2953 in) 0.0425 - 0.0615 mm (0.00167 - 0.00242 in) 0.25 mm (0.010 in) 27.996 - 28.000 mm (1.102 - 1.1023 in) 27.98 mm (1.102 in) 0.001 - 0.011 mm (0.00004 - 0.00043 in) 0.02 mm (0.0008 in)

Piston Pin - Dimension Diameter Standard Minimum Pin-to-bushing clearance Standard Maximum

27.994 - 28.0 mm (1.10213 - 1.10236 in) 27.97 mm (1.10118 in) 0.010 - 0.027 mm (0.00039 - 0.00106 in) 0.08 mm (0.0031 in)

Piston Ring - Dimension N4LDI-TA-45SL N4LDI-TA-50SL

End gap Combustion ring Maximum Intermediate ring Maximum Oil control ring Maximum

0.25 - 0.40 mm (0.00984 - 0.01575 in) 1.0 mm (0.039 in) 0.50 - 0.70 mm (0.01969 - 0.02756 in) 1.0 mm (0.039 in) 0.10 - 0.40 mm (0.00394 - 0.01575 in) 1.2 mm (0.047 in)

Ring-to-groove clearance Combustion ring Maximum Intermediate ring Maximum Oil control ring Maximum

— 0.25 mm (0.010 in) 0.04 - 0.08 mm (0.0015 - 0.0031 in) 0.25 mm (0.010 in) 0.02 - 0.06 mm (0.00079 - 0.00236 in) 0.25 mm (0.010 in)

Piston Ring - Dimension N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

End gap Combustion ring Maximum Intermediate ring

0.20 - 0.35 mm (0.00787 - 0.01378 in) 1.0 mm (0.039 in) 0.20 - 0.40 mm (0.0079 - 0.0157 in) 47632293 16/09/2014

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Engine - Connecting rods and pistons

Maximum Oil control ring Maximum Ring-to-groove clearance Combustion ring Maximum Intermediate ring Maximum Oil control ring Maximum

1.0 mm (0.039 in) 0.25 - 0.50 mm (0.00984 - 0.01969 in) 1.2 mm (0.047 in) 0.075 - 0.11 mm (0.00295 - 0.0043 in) 0.25 mm (0.010 in) 0.06 - 0.10 mm (0.00236 - 0.00394 in) 0.25 mm (0.010 in) 0.02 - 0.06 mm (0.00079 - 0.00236 in) 0.25 mm (0.010 in)

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Engine - Connecting rods and pistons

Connecting rod and piston - Remove 1. Remove the two nuts (1), retaining the connecting rod caps (2).

2. Remove the connecting rod caps and lower half of connecting rod bearing.

3. If necessary, remove any ridge from the top of the cylinder bores using a suitable ridge reamer.

76075710

1

SECT10C01PG46_3

2

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

5. Replace the connecting rod cap to the piston assembly it was removed from. Keep together in cylinder sequence.

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Engine - Connecting rods and pistons

Connecting rod and piston - Disassemble 1. Remove the piston pin retaining rings and drive the pin (2) out of the piston using a suitable driver (1).

20093381

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Engine - Connecting rods and pistons

Connecting rod and piston Connecting rod - Inspect

NHIL13ENG0060AA

(1) Gauge (2) Alignment fixture (3) Connecting rod

1

(A) Bent rod (B) Twisted rod

1. Check the connecting rods for damage and alignment.

Place each rod in an alignment fixture to check for bent or twisted condition.

2. Straighten or replace rods that are bent or twisted more than the following dimensions: • Maximum bend (A): 0.15 mm (0.0059 in) per 100 mm (3.94 in).

• Twist (B): 0.2 mm (0.0078 in) per 100 mm (3.94 in).

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Engine - Connecting rods and pistons

Connecting rod and piston - Assemble 1. Align the arrow marking (2) for the front side of the piston and the match marks (1) of the connecting rod and cap.

NOTE: Ensure the match marks (1) are aligned correctly.

2. Install the piston pin through the piston and connecting rod and secure with retaining clips.

NHIL13ENG0047AA

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1

Engine - Connecting rods and pistons

Connecting rod and piston - Install 1. Coat the bearing faces, pistons, and piston rings with clean engine oil. Slide the piston rings to permit a sufficient amount of oil to be applied in the grooves.

2. Set the piston ring gaps 120 ° apart from each other.

Do not position these gaps toward the piston pin or the right angle of the pin.

3. Using a piston ring compressor (1) insert the pistons in the cylinders with the arrow in the piston pointing toward the front of the engine.

NOTE: Install the pistons from the front to the rear in order.

20093408

1

NHIL13ENG0047AA

2

76075710A

3

4. Install the connecting rod caps (1) making sure the rod and cap matching marks (2), Figure 2 align. Tighten the connecting rod nuts (2) to 49 - 54 N·m (36 - 40 lb ft).

NOTE: After installation, ensure the crankshaft moves freely. Ensure the axial play of 0.1 - 0.3 mm (0.004 0.012 in) is provided between the connecting rod and crank pin.

NOTICE: Replace the connecting rod if axial play of the connecting rod on the crank pin is more then 0.7 mm (0.0276 in).

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Engine - Connecting rods and pistons

Piston Ring - Remove 1. Use piston ring pliers (1) to remove the piston rings.

20002376

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1

Engine - Connecting rods and pistons

Piston - Inspect 1. Wash the pistons and connecting rods in a suitable solvent and air dry.

2. Use a groove cleaner to remove the carbon deposits from the ring grooves.

NOTICE: Be careful to avoid cutting any metal from either side or the bottom of the grooves.

20093382

1

20093383

2

20093384

3

3. Inspect the piston ring lands for excessive wear. Use a new ring (1) and feeler gauge (2) to check the ring side clearance. Replace pistons having a ring side clearance exceeding the following dimensions: • Combustion ring = 0.25 mm (0.010 in) • Intermediate ring = 0.25 mm (0.010 in) • Oil control ring = 0.25 mm (0.010 in)

4. Use a micrometer to check the piston diameter at 90 ° from the piston pin bore. Replace the pistons if the measured value is less than 83.7 mm (3.3 in).

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Engine - Connecting rods and pistons

5. Use a telescoping gauge and a micrometer to measure the piston pin bore and the piston pin diameter. Replace piston and/or piston pins that exceed the following limits: • Bore diameter: 28.0 mm (1.102 in) • Pin diameter: 27.97 mm (1.101 in) • Clearance: 0.02 mm (0.0008 in) NOTE: In some instances the piston pin diameter may be equal to or slightly larger than the piston pin bore. This interference fit is normal.

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20093385

4

Engine - Connecting rods and pistons

Piston Ring - Inspect 1. Install a piston ring (1) cylinder bore.

2. Use the top of the piston to square the ring in the bore.

3. Measure the clearance of the ring end gap (2) with a feeler gauge.

4. Replace the piston rings if the end gap exceeds the following measurements: • Combustion ring = 1.0 mm (0.03937 in) • Intermediate ring = 1.0 mm (0.03937 in) • Oil control ring = 1.2 mm (0.04724 in) NHIL13ENG0046AA

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1

Engine - Connecting rods and pistons

Piston Ring - Install 1. Use piston ring pliers to install the piston rings. Position the ring gaps at approximately 120 ° from each other.

Install the third (oil control ring) first as follows: • Put the expander ring (1) into position in its groove.

• Install the outer oil ring (2) into position in its groove, while making sure the outer oil ring gap is 90 ° apart to the joint on the expander ring (1).

10044359

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1

Engine - Connecting rods and pistons

Connecting rod bearing - Inspect 1. Remove oil or foreign matter from the bearing and crankshaft.

2. Cut a piece of plastic gauge (1) to the same width as the bearing. Place it on the crankshaft and avoid the oil hole.

3. Install the rod cap and torque to 49.0 - 54 N·m (36.2 39.8 lb ft).

4. Remove the rod cap and measure the width of the flattened plastic gauge (3) using the scale (2) on the package.

5. The widest portion of the plastic gauge is the minimum clearance. Select the proper size bearing liners to obtain the correct clearance.

20093392

1

20093391

2

• Standard assemble value — 0.035 - 0.085 mm (0.001 - 0.003 in) • Service limit — 0.200 mm (0.008 in) 6. Install the connecting rod on the crankshaft and measure the play (1) in shaft direction. If the play is more than 0.7 mm (0.028 in) replace the connecting rod.

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Engine - Connecting rods and pistons

Piston pin bushings - Inspect 1. Use a telescoping gauge (1) and a micrometer (2) to measure the inside diameter of the connecting rod (3) piston pin bushing.

2. Measure the clearance between the bushing and piston pin.

3. Refer to Piston pin bushings - Replace (10.105), if the measured value exceeds 0.08 mm (0.00315 in).

20093388B

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Engine - Connecting rods and pistons

Piston pin bushings - Replace 1. Remove and install the connecting rod (3) piston pin bushings using a suitable driver (2) and press (1) a new bushing into the rod bore.

NHIL13ENG0062AA

1

NHIL13ENG0061AA

2

2. Ream and hone the bushing to the following finish size: • Pin to Bushing Clearance: • Standard = 0.010 - 0.027 mm (0.00039 0.00106 in) • Max. = 0.08 mm (0.00315 in) 3. Drill a hole in the new bushing using the lube port in the connecting rod as a guide.

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Index Engine - 10 Connecting rods and pistons - 105 Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Connecting rod and piston - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Connecting rod and piston Connecting rod - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Connecting rod and piston Connecting rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Connecting rod bearing - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Piston - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Piston - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Piston Pin - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Piston Ring - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Piston Ring - Dimension (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Piston Ring - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Piston Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Piston Ring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Piston pin bushings - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Piston pin bushings - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

(*) See content for specific models 47632293 16/09/2014

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Engine - 10 Crankshaft and flywheel - 103

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Engine - 10 Crankshaft and flywheel - 103

TECHNICAL DATA Crankshaft Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Crankshaft pulley Remove Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Engine flywheel Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Inspect - Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Replace - Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Flywheel housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Crankshaft oil seal Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Crankshaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Inspect - Thrust washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Main bearings Inspect - Block bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Replace - Block bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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CONSUMABLES INDEX Consumable Loctite® 5970™ Loctite® 5970™

Reference Flywheel housing - Install Crankshaft oil seal Rear seal - Install

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PAGE 10.6 / 11 10.6 / 14

Engine - Crankshaft and flywheel

Crankshaft - Dimension Journal diameter Standard Maximum

67.957 - 67.970 mm (2.6754 - 2.676 in) 67.4 mm (2.7 in)

Standard Maximum

51.964 - 51.975 mm (2.0458 - 2.0462 in) 51.90 mm (2.043 in)

Standard Maximum

0.03 mm (0.0012 in) 0.06 mm (0.0023 in)

Crankpin diameter

Runout

Endplay Standard Maximum Thrust washer thickness Standard Minimum Cylinder block bearing diameter Standard Journal-to-cylinder block bearing clearance Standard Maximum Center bearing to crankshaft clearance Standard Maximum Dynamic balancer Counterweight gear backlash Maximum

0.1 - 0.3 mm (0.0039 - 0.01181 in) 0.5 mm (0.0195 in) 2.95 - 3.0 mm (0.115 - 0.117 in) 2.8 mm (0.109 in) 68 mm x 72 mm ( 2.677 in x 2.835 in 0.044 - 0.116 mm (0.0017 - 0.0046 in) 0.2 mm (0.0079 in) 0.044 - 0.102 mm (0.001732 - 0.004016 in) 0.2 mm (0.0079 in) 0.2 - 0.4 mm (0.008 - 0.016 in) 0.4 mm (0.016 in)

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Engine - Crankshaft and flywheel

Crankshaft pulley - Remove Pulley 1. Remove the retaining nut (1) from crankshaft (4).

2. Place tension on the pulley (2) with a suitable puller and tap the end of the puller with a hammer to release the hold of the taper.

3. Remove the pulley (2).

4. Remove and retain the key (3).

76075736A

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Engine - Crankshaft and flywheel

Engine flywheel - Remove 1. Remove the flywheel retaining bolts (1).

2. Use a dead blow hammer to loosen the flywheel (2) from the shaft.

3. Remove flywheel (2).

NHIL13ENG0102AA

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Engine - Crankshaft and flywheel

Engine flywheel - Inspect - Ring gear Prior operation: Engine flywheel - Remove (10.103) 1. Inspect the ring gear (1) for cracked, broken, chipped, or worn gear teeth. If damaged is found, refer to Engine flywheel - Replace — Ring gear (10.103).

NHVM13ENG0193AA

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Engine - Crankshaft and flywheel

Engine flywheel - Replace - Ring gear 1. Remove the starter ring gear (1) using a hammer and chisel to crack the ring gear.

2. Heat the new ring gear to 120 - 150 °C (245 - 300 °F) from the inside only.

NOTICE: Use a temperature sensitive crayon to avoid overheating the gear.

3. Install the ring gear with the chamfered teeth side toward the engine.

4. Cool the ring gear quickly to obtain a good shrink fit on the flywheel.

20093403

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Engine - Crankshaft and flywheel

Engine flywheel - Install Prior operation: Engine flywheel - Inspect - Ring gear (10.103) 1. Fit the flywheel alignment hole to the crankshaft roll pin (1) and install flywheel (2), Figure 2.

NHIL12ENG0204AA

1

NHVM13ENG0193AA

2

2. Install the flywheel retaining bolts (1) and torque to 73 - 78 N·m (53 - 57 lb ft).

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Engine - Crankshaft and flywheel

Flywheel housing - Remove 1. Remove the retaining bolts (1) from the rear plate.

NHIL12ENG0204AA

1

NHIL13ENG0049AA

2

2. Remove rear plate (1).

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Engine - Crankshaft and flywheel

Flywheel housing - Install 1. Apply LOCTITE® 5970™ liquid gasket or equivalent to the threads of the M8 bolts and Install the rear plate (1).

NHIL13ENG0049AA

1

NHIL12ENG0204AA

2

2. Install the retaining bolts (1) to secure the rear plate.

3. Torque bolts to 23 - 28 N·m (17.0 - 21 lb ft).

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Engine - Crankshaft and flywheel

Flywheel housing - Test N4LDI-TA-45SL N4LDI-TA-50SL

1. Speed sensor is located on the flywheel housing where it senses engine speed as engine pulse.

2. Use a multimeter to test the resistance of the sensor. The resistance should be 109.5 - 143.5 Ω at 20 °C (68.0 °F). Replace sensor if outputs are out of range.

3. Use a dial indicator to check the sensor air gap.

There should be approximately 0.7 - 1.7 mm (0.0276 0.0669 in). If the gap is not in range, check the flywheel and flywheel housing for any damage or obstructions.

4. Ensure to set the O-ring to prevent oil leaking.

5. Torque the sensor to 5.6 - 8.4 N·m (4.1 - 6 lb ft).

NHIL13ENG0053AA

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Engine - Crankshaft and flywheel

Crankshaft oil seal Rear seal - Remove 1. Remove the rear plate, refer to Flywheel housing Remove (10.103).

2. Remove the rear oil seal (1).

NHIL13ENG0037AA

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Engine - Crankshaft and flywheel

Crankshaft oil seal Rear seal - Install 1. Apply LOCTITE® 5970™ to the rear oil seal.

2. Install the rear oil seal (1) over the rear of the crankshaft.

NOTICE: Do not allow the oil seal lip to tear or flip.

NHIL13ENG0037AA

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Engine - Crankshaft and flywheel

Crankshaft - Remove 1. Remove the crankshaft bearing hex head bolts (1) and the socket head hex bolts (2).

NHIL12ENG0208AA

1

NHIL12ENG0234AA

2

NHIL12ENG0206AA

3

2. Remove the oil pressure valve (1) from the right-hand side of the block.

3. Slide the crankshaft and main bearing assembly (1) through the rear of the block.

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Engine - Crankshaft and flywheel

Crankshaft - Inspect

20093394A

Taper Readings: (1) vs. (2)

1

Out-of-Round Readings: (A) vs. (B)

1. Inspect the crankshaft gear teeth for wear or damage and replace if necessary.

2. Mount the crankshaft in a set of V-blocks.

3. Use a dial indicator to measure the crankshaft journals for runout and taper.

4. The amount of taper in a journal is the difference in the measurements taken at points (1) and (2) on a journal.

5. The amount of out-of-round in a journal is the difference in the measurements taken at 90 ° points on the journal.

NOTE: The smallest reading taken at any one of the readings indicates the size of the journal.

6. Straighten or replace crankshafts that exceed runout specifications. Refer to Crankshaft - Dimension (10.103).

20093395

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2

Engine - Crankshaft and flywheel

Crankshaft - Inspect - Thrust washer 1. Check the thrust washer and replace if signs of wear, improper contact, seizure, or other damage, or if the thickness is less than 2.8 mm (0.110 in).

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Engine - Crankshaft and flywheel

Crankshaft - Install 1. Install the crankshaft (1) with bearing holders through the rear of the cylinder block.

2. Align the threaded holes (3) on the bearing holders with the bolt holes (2) in the cylinder block.

NHIL12ENG0205AA

1

NHIL12ENG0208AA

2

NHIL12ENG0234AA

3

3. Install the socket head hex bolts (2) at the rear of the block, and install the hex head bolt (1) at each center bearing. Torque the socket head bolts to 25 - 29 N·m (18.4 - 21.4 lb ft). Torque the hex head bolts to 49 54 N·m (36 - 40 lb ft).

4. Install the oil pressure relief valve (1) in the right-hand side of the block.

5. Torque the relief valve (1) to 49 - 50 N·m (36 - 37 lb ft).

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Engine - Crankshaft and flywheel

Crankshaft - End play 1. Use a dial indicator to measure the crankshaft end play.

If the end play is not within the allowable limit, remove the crankshaft and check the thrust washers. Refer to Crankshaft - Inspect — Thrust washer (10.103).

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20093405

1

NHIL13ENG0011AA

2

Engine - Crankshaft and flywheel

Main bearings - Inspect - Block bushing 1. Check the bushing for peeling, melting, seizure, or poor contact.

2. Using a telescoping gauge and micrometer, measure the oil clearance between the bushing and the crankshaft journal.

3. Measure the inside diameters at positions (1) and (2).

At each position, measure in both directions (3) and (4).

The oil clearance can be obtained by subtracting this value from the maximum crankshaft journal diameter.

4. If the oil clearance exceeds 0.2 mm (0.0078 in) replace the bushing.

20093396

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1

Engine - Crankshaft and flywheel

Main bearings - Replace - Block bushing

NHIL13ENG0078AA

Dimensions: (A) 12.5 mm (0.492 in) (B) 15 mm (0.591 in)

1

Identification: (1) Front side (2) Align (3) Lubrication hole

1. Remove the bushing from the front of the cylinder block housing using a bushing driving tool to prevent damage.

2. Inspect the bushing housing for marks, scratches, or damage.

NOTE: Fine scratches or marks can be removed with light sanding.

3. Lubricate the outer surface of the bushing with clean engine oil.

4. Align the oil hole (3) of the housing and bushing.

5. Use a bushing driving tool to press the bushing into the cylinder block from the engine front side until the bushing is flush with the block surface.

NOTICE: Do not press the bushing into the cylinder block from the opposite side.

NOTE: The leading edge of the bushing is chamfered to aid with installation.

6. Confirm the housing and bushing are in alignment (2).

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Engine - Crankshaft and flywheel

Main bearings - Disassemble

20044366

1

1. Remove the two retaining bolts (1) from the bearing holders (2).

2. Remove the bearing holders (2), upper main bearings (5), lower main bearings (4) and thrust washers (3).

NOTE: The upper main bearing (4) has the oil groove.

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Engine - Crankshaft and flywheel

Main bearings - Inspect Prior operation: Main bearings - Disassemble (10.103)

20044366

1

1. Cut two pieces of plastic gauge to the same width as the bearing. Place it on the upper main bearing (5) and the lower main bearing (4) and avoid the oil hole.

2. Install the bearing holder (2) and torque the bolts (1) to 49.0 - 54 N·m (36.2 - 39.8 lb ft).

NOTE: Do not permit the bearing holder to rotate, even the slightest amount.

3. Remove the bearing holders (2) and measure the width of the flattened plastic gauge using the gauge on the package.

4. Replace components or grind the crankshaft to the next undersized bearing as required to obtain the correct clearance if not within 0.2 mm (0.00787 in).

5. Check the thrust washer (3) for wear, poor contact, burning, or other defects.

6. Use a micrometer to measure the washer thickness.

If washer thickness is less than 2.8 mm (0.11 in), or found to be defective, the washers must be replaced.

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Engine - Crankshaft and flywheel

Main bearings - Assemble Prior operation: Main bearings - Inspect (10.103)

NHIL13ENG0014AA

(1) Upper bearing holder (2) Upper main bearing (with oil hole) (3) Stepped side

1

(4) Lower main bearing (5) Rear thrust washers (6) Front thrust washer

1. Install the bearing holder with the thrust washers to the flywheel side, facing the stepped side (3), Figure 1 forward.

NOTE: Be sure to install thrust washers (1) on the rear side of the lower (2) and upper (3) bearing holders. Position thrust washers with oil grooves facing outward from bearing holders.

76075741

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2

Engine - Crankshaft and flywheel

2. Install the remaining upper bearing holders (1) and the lower bearing holders (2) along with their bearings.

NOTE: The upper main bearings have the oil holes.

3. Torque the bearing holder retaining bolts to 49.0 54 N·m (36.2 - 39.8 lb ft).

76074367B

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3

Index Engine - 10 Crankshaft and flywheel - 103 Crankshaft - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Crankshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Crankshaft - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Crankshaft - Inspect - Thrust washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Crankshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Crankshaft oil seal Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Crankshaft oil seal Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Crankshaft pulley - Remove Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine flywheel - Inspect - Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine flywheel - Replace - Ring gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Flywheel housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Flywheel housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Flywheel housing - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Main bearings - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Main bearings - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Main bearings - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Main bearings - Inspect - Block bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Main bearings - Replace - Block bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

(*) See content for specific models 47632293 16/09/2014

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Engine - 10 Balancer and damper - 110

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Engine - 10 Balancer and damper - 110

SERVICE Balancer Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - Balancer and damper

Balancer - Remove 1. Remove the banjo bolts (4) and the oil transfer pipe (5).

2. Remove the balancer retaining bolts (3).

3. Remove the balancer assembly (6) from the engine block (2).

NOTE: Observe the quantity and thickness of the shims (1) (if used) for assembly.

20002374A

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1

Engine - Balancer and damper

Balancer - Install NOTE: The balancer assembly on the engines are different due to different connecting rods and length of piston strokes on each engine.

1. Position the cylinder block with the oil pan mounting surface facing down.

2. Position the No. (1) and the No. (4) pistons at Top Dead Center (TDC).

20002376A

1

10044365

2

20002374B

3

NOTE: When positioning balancer assembly for installation to engine, be sure balancer weights are oriented with weights down towards oil pan (flats on weights should be facing as shown).

3. With the balancer weights centered straight down (weights facing away from engine block), position the balancer assembly (6) and the original quantity of shims (1) (if used) on the cylinder block (2) using the dowel pins for alignment.

4. Install the M10 x 70 retaining bolts (3) and torque to 49 - 54 N·m (36 - 40 lb ft).

5. Install the oil transfer pipe (5) and secure with the banjo bolts (4).

NOTICE: Inspect the backlash between the balancer gear and the drive gear. Adjust the backlash to 0.2 - 0.4 mm (0.008 - 0.016 in) using shims.

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

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Engine - 10 Fuel filters - 206

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Engine - 10 Fuel filters - 206

SERVICE Fuel filters Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - Fuel filters

Fuel filters - Replace 1. Install the new filter and tighten by hand about 3/4 turn after the gasket contacts the mounting surface.

NOTICE: Do not use a tool when tightening.

NOTICE: Do not clean fuel filter cartridge, replace it.

2. Check for leaks.

NHIL13ENG0024AA

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Index Engine - 10 Fuel filters - 206 Fuel filters - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Throttle linkage - 220

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Engine - 10 Throttle linkage - 220

FUNCTIONAL DATA Governor Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47632293 16/09/2014

10.9 [10.220] / 2

Engine - Throttle linkage

Governor - Dynamic description N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

These engines have a mechanical governor in order to control engine speed. The governor is installed inside the timing cover.

The flyweight assembly is installed onto the camshaft gear, its movement is transmitted to the control rack of the injection pump through the slider control lever link. The spring which controls the movement of the flyweight is connected to the tension lever.

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Index Engine - 10 Throttle linkage - 220 Governor - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 47632293 16/09/2014

10.9 [10.220] / 4

Engine - 10 Fuel injection system - 218

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Engine - 10 Fuel injection system - 218

TECHNICAL DATA Fuel injection system General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Fuel injection system Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Injection pump Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Dynamic description - Fuel variation mechanism (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Dynamic description - Pumping elements (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Dynamic description - Delivery valves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

High pressure pump Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Common rail Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fuel injectors Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SERVICE Fuel injection system Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Inspect – Fuel pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Injection pump Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Bleed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

High pressure pump Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Remove - Pump gear (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

(*) See content for specific models 47632293 16/09/2014

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Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Install - Pump gear (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Timing adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Common rail Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Fuel injectors Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

(*) See content for specific models 47632293 16/09/2014

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Engine - Fuel injection system

Fuel injection system - General specification N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Injection pump Bosch In-Line 16 - 17.5 ° 2.532 - 3.022 mm (0.100 - 0.119 in)

Pump manufacturer Type Timing (Before Top Dead Center (BTDC)) Timing (piston height at Injection: Start BTDC) Injection nozzle • Nozzle type • Needle valve diameter • Pintle diameter Injection pressure Spray angle Service adjustments • Idle speed • Max. no-load speed

Throttle 0.4 mm (0.0157 in) 1 mm (0.039 in) 14700 kPa (2132.1 psi) 4° 1000 - 1100 RPM 2815 - 2855 RPM

Fuel injection system - Special tools N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Tool Description Injector Tester Injector Adapter Set

Tool No. FNH01721 FNH01728

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Engine - Fuel injection system

Fuel injection system - Overview N4LDI-TA-45SL N4LDI-TA-50SL

NHIL13ENG0025AA

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

Fuel filter Pressure sensor Common rail Pressure limiter

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

1

Injector assembly ECU Fuel tank HP pump

Common rail system: • The High Pressure (HP) pump (8) pressurizes the fuel and conveys it through the fuel injection pipe.

• The fuel accumulates in the common rail (3).

• The Engine Control Unit (ECU) (6) controls the fuel quantity, timing and spray frequency electronically according to engine speed and load.

• Pressurized fuel in the common rail (3) conveys through the high pressure pipe into the fuel injectors (5) and sprays into the combustion chamber.

NOTE: The ECU decides the start and end time in which the injector operates.

• The sensor (2) will determine and control the engine speed.

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Engine - Fuel injection system

Injection pump - Dynamic description N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

20097732

(1) Five-sided bolt (2) Delivery valve holder (3) Pump housing (4) Eye bolt (5) Plunger

1

(6) Control rack (7) Plunger spring (8) Tappet (9) Control sleeve (10) Plunger barrel

(11) Delivery valve (12) Delivery valve seat (13) Delivery valve spring (14) Sleeve flange

The injection pump is mounted in the cylinder block. It is driven by the engine's camshaft. Plunger (1) movement is constant, being raised by tappets (2) and returned by the plunger spring (3) as the engine rotates. The plunger barrel's (4) suction and discharge port opens onto the pump housing's fuel oil chamber, which is always filled with fuel.

When the plunger descends, fuel is sucked into the plunger barrel, and when the plunger reaches it's lowest point, the suction of fuel stops.

The plunger then ascends, and when the plunger barrel's suction and discharge port is closed by the plunger, the fuel oil pressure increases. The fuel oil then raises the delivery valve (5) and is delivered through the injection pipe to the nozzle. When the fuel pressure exceeds the force of the nozzle spring's set force, fuel is injected into the engine's combustion chamber in the form of a fine spray.

The plunger further ascends, and when the plunger helix meets the plunger barrel's suction and discharge port, fuel delivery ends (at the same time injection from the nozzle ends). The delivery valve is then closed by the set force of the delivery valve spring so that fuel is no longer delivered, even though the plunger continues to ascend.

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Engine - Fuel injection system

The effective stroke (2) is from the moment that the plunger barrel's (6) suction and discharge port is closed by the end of the plunger (beginning-of-injection) (4) until the suction and discharge port meets the plunger helix (1) (end-of-injection) (3). The effective stroke can be altered by rotating the plunger (5). Accordingly, the relationship between injection quantity and effective stroke is proportional.

20097776

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Engine - Fuel injection system

Injection pump - Dynamic description - Fuel variation mechanism N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

As well as pressurizing the fuel, the injection pump also functions to vary the fuel injection quantity.

A control sleeve is installed around the plunger barrel, and a flange on the bottom of the plunger is inserted into a groove in the control sleeve. Teeth on the control sleeve are engaged with teeth on the control rack so that movement of the control rack results in rotation of the plunger and, consequently, variation of the fuel injection quantity.

20097735

(A) Non delivery

1

(B) Partial delivery

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(C) Maximum delivery

Engine - Fuel injection system

Injection pump - Dynamic description - Pumping elements N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

The pumping elements are operated by cam lobes (1) that are incorporated on the engine valve train camshaft.

NHIL13ENG0167AA

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Engine - Fuel injection system

Injection pump - Dynamic description - Delivery valves N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Located above each pumping element is a delivery valve assembly. The delivery valve consists of a delivery valve holder (1), spring (2), piston and stem assembly (3) operating within a cylindrical guide (4) which terminates in a conical seat. The lower part of the stem has four vertical flutes which accurately locate within the guide while permitting fuel to pass. Above the flutes is a piston which is a lapped fit in the bore of the valve guide.

The delivery valve serves as a non-return valve and also as a means of rapidly reducing the fuel pressure in the injector line when injection ceases. Rapid pressure reduction is required to be sure injector needle valve "snaps" shut to prevent fuel "dribble", a condition which can cause carbon formation on the injector tip.

20093466

76075755

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

Spring Piston Valve guide Conical seat

2

(A) Valve closed (B) Valve open (C) Valve closing

The delivery valve operates as follows:

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1

Engine - Fuel injection system

Position (A): The pump plunger is at the bottom of the stroke and the inlet ports are uncovered, so the barrel and delivery guides are filled with fuel. As the fuel is at low pressure, the delivery valve is retained on the seat by spring pressure.

Position (B): The plunger has risen and closed both inlet ports, pressurized the fuel and the injection process begins. The pressurized fuel overcomes the spring tension, lifting the delivery valve off its seat until the piston is clear of the guide, permitting fuel to pass to the injector.

Position (C): The helical groove has uncovered the inlet port and released the fuel pressure. The delivery valve spring, aided by the high pressure still existing in the pipeline, forces the delivery valve to close rapidly.

During closing, the piston portion of the valve returning into the guide increases the volume of the injector line by the volume of this part of the valve.

This sudden increase in the volume of the injector line causes a rapid collapse of pressure and allows the injector needle valve to "snap" shut.

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Engine - Fuel injection system

High pressure pump - Dynamic description N4LDI-TA-45SL N4LDI-TA-50SL

The High Pressure (HP) pump is driven by the camshaft gear that is secured to the camshaft by a nut and keyway.

Fuel suction quantity is controlled by the solenoid valve. The solenoid valve opening period decides the spray quantity.

The excess fuel returns to the fuel tank. Pulsar for the rotary sensor detects cylinder position where it is placed onto the camshaft gear.

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Engine - Fuel injection system

Common rail - Dynamic description N4LDI-TA-45SL N4LDI-TA-50SL

The common rail accumulates the pressurized fuel, then distributes the fuel to the injectors through the pressure pipe.

A fuel pressure sensor is installed to detect the fuel pressure at the common rail. When the pressure in the common rail exceeds limitations, the fuel is returned through the pressure adjusting valve.

A fuel temperature sensor is installed to detect the fuel temperature at the fuel return pipe. To reduce pulsations, a flow damper orifice is installed on the high pressure pipe.

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Engine - Fuel injection system

Fuel injectors - Dynamic description N4LDI-TA-45SL N4LDI-TA-50SL

The fuel injectors spray the pressurized fuel from the common rail into the combustion chamber at the proper time with the correct quantity.

The injector nozzle is composed of a command piston, orifice for flow restriction, a control chamber and solenoid.

Spray timing and quantities are electronically controlled by the Engine Control Unit (ECU). Electric signals switch on and off the solenoid to determine electricity timing and trigger point.

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Engine - Fuel injection system

Fuel injectors - Dynamic description N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Throttle-type injectors are used in all engine applications.

The injectors have a 1.0 mm (0.04 in) single orifice and are set at 15700 kPa (2277.1 psi). The pressure adjustment is made by adding or deleting shims from the top of the injector pressure adjusting spring. The injectors have an injection angle of 4 °. The injector pipes are of the same length for each cylinder to help keep the injection intervals in time.

The engine injection function is to inject fuel into a pressurized cylinder in a fully atomized condition, which provides efficient combustion with minimum amount of smoke. Each injector assembly consists of a nozzle assembly containing a needle valve, a nozzle holder assembly, and injector needle valve regulating spring.

(1) (2) (3) (4) (5) (6) (7) (8) (9)

20097769

1

20097770

2

Nut Nipple joint Body Shim Spring Push rod Distance piece Nozzle nut Nozzle assembly

Fuel from the injection pump enters the injector inlet and passes down through a drilling in the nozzle holder and body to the needle valve seat. The fuel pressurized by the injection pump, lifts the needle valve off the seat against the action of the spring pressure. The fuel is then forced, in the atomized state, through the 1.0 mm (0.04 in) orifice in the nozzle tip. When pressure from the injection pump drops, the needle valve snaps back onto its seat under pressure from the spring.

To provide lubrication of the injector, a small amount of fuel is permitted to leak up between the needle valve and the nozzle body. The excess fuel rises to the top of the injector and returns to the fuel tank through the injection leak-offline.

(A) Nozzle closed (B) Nozzle initial opening (C) Nozzle fully opened

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Engine - Fuel injection system

Fuel injection system - Inspect N4LDI-TA-45SL N4LDI-TA-50SL

1. Check the high pressure piping, and common rail components.

• Use Service Tool D to run the active test “Fuel Leak Check Function”.

If the test fails, continue with the rest of the fuel system checks.

2. Visually inspect all fuel system components for damage or leaking components.

• Common rail piping • Injectors • Fuel hoses • Fuel filters 3. Check the amount of fuel in the tank and quality.

• Check the color. There should be no color, brownish, or milky substance.

• Check the odor. There should be no kerosene, heavy oil, or irritating odor.

NHIL13ENG0071AA

1

NHIL13ENG0024AA

2

• Check for separation of materials. There should be no water, or foreign objects in the tank.

• Check the viscosity. There should not be a waxy or sticky consistency.

If damage is found, repair or replace as needed.

If fuel is not being delivered, clean or replace fuel piping system. If the system is clean, check the fuel filter. Replace if needed, See Fuel filters - Replace (10.206)

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Engine - Fuel injection system

Fuel injection system - Inspect – Fuel pump N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Active test.

• Use the diagnostic service tool.

• Select the “Diagnostic Test” from the “Diagnostics” drop down menu.

• Select “Override Parameters”.

• Select “Engine Fuel Supply Lift Pump Relay Override”.

• Select ON from the “Change Parameter Value” menu.

2. If the fuel pump does not turn ON. Check the following: • Place the key switch ON. • Listen and check for the fuel pump pressurizing.

• Check the electrical connection to the fuel pump.

• Check the fuel pump relay.

• Fuel pump fuse.

If the electrical circuit is good, replace the fuel pump.

If the electrical circuit has failed, repair or replace as needed.

If the fuel pump does turn ON, but there is no fuel flow.

Check the following:

NHIL13ENG0170AA

• Low fuel level.

• Clogged fuel lines.

• Clogged fuel filter.

• Leaking fuel connection.

Fuel pump electrical wiring/connection specification: Value

Connector pin Pin 1 Pin 2

12.0 V Ground

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Engine - Fuel injection system

Injection pump - Remove N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

WARNING Pressurized system!

Never attempt to drain fluids or remove filters when the engine is running. Turn off the engine and relieve all pressure from pressurized systems before servicing the machine.

Failure to comply could result in death or serious injury.

W0905A

1. Remove the fuel injection lines (1) by loosening nuts (2) on the injection pump and the nuts on the injectors.

NOTICE: Cap and plug all openings to prevent contamination.

76075756

1

20097746

2

76075757

3

2. Disconnect the fuel tank return line by removing bolt (2).

3. Disconnect fuel inlet line (3) by loosening clamp screw (1).

4. Disconnect the wire (1) to the fuel shut-off solenoid (3) and remove the fuel shut-off solenoid.

5. Remove the mounting nuts and bolts (2).

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Engine - Fuel injection system

6. Raise the pump and remove the snap pin (1) and separate the governor link (2) from the pump control rack (3), Figure 5.

7. Remove the injection pump from the engine.

NOTE: If there are shims between the pump mounting flange and the engine block, carefully remove the shims and retain for installation.

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20097750

4

20097751

5

Engine - Fuel injection system

Injection pump - Install N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Attach the pump rack to the governor linkage.

2. Install injection pump assembly with shims into engine housing.

3. Install the pump mounting nuts and bolts and tighten to 13 - 17 N·m (9.6 - 12.5 lb ft).

4. Install fuel solenoid (5) into rear of injector housing.

5. Torque the fuel solenoid to 14.7 - 24.5 N·m (11 - 18 lb ft) and connect the electrical connection (1).

6. Connect the fuel inlet line (2) by tightening clamp screw (3).

7. Install the fuel return line by installing bolt (4). Torque to 25 - 30 N·m (18 - 22 lb ft).

20097748

1

20097748

2

8. Install injector lines (1) by tightening nuts (2) at the pump and nuts at the injectors. Torque to 23 - 36 N·m (17 - 27 lb ft).

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Engine - Fuel injection system

Injection pump - Bleed N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

20097762

1

Fuel flow chart (A) (B) (C) (D)

Fuel tank Fuel filter Lift pump Injection pump

(E) Injectors (3 or 4 Cylinders) (F) Cylinders (G) Return to injection pump (H) Return line to fuel tank

With a full tank of fuel, fuel from the tank will push air out of the fuel filter through the return to tank line. Fuel from the fuel filter will be delivered to the fuel transfer pump.

The Auto Bleed occurs whenever the engine is started and the throttle is set at full throttle.

1. Set the hand throttle at full throttle position.

2. Place ignition switch in the start position.

3. With the engine cranking, the fuel transfer pump, which is activated by the engine camshaft rotating, will deliver fuel to the injection pump.

4. Air that was in the injection pump will be returned to the fuel tank via the injector fuel return to tank line.

NOTE: The injector fuel return to tank line is connected to the fuel filter return to tank line.

5. Rotate the engine until it starts.

NOTE: Due to heat generation in the starter motor, do not engage the starter for more than 30 seconds continuously.

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Engine - Fuel injection system

High pressure pump - Remove N4LDI-TA-45SL N4LDI-TA-50SL

Prior operation: Timing gear housing - Remove (10.102) 1. Disconnect the electrical connection (1).

2. Remove the from tank supply line (4).

3. Remove the common rail return / return to tank banjo bolt (3) and lines.

4. Remove the common rail supply line (2).

NHIL12ENG0136AA

1

NHIL13ENG0072AA

2

NHIL13ENG0030AA

3

5. Remove the two retaining bolts (2).

6. Remove the High Pressure (HP) pump (1) and O-ring (3).

NOTICE: Never handle the HP pump by the pipe (1), leakage can occur.

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Engine - Fuel injection system

High pressure pump - Remove - Pump gear N4LDI-TA-45SL N4LDI-TA-50SL

Prior operation: High pressure pump - Remove (10.218) 1. Remove the nut (6) from the High Pressure (HP) pump (8) shaft.

2. Remove the pulser (5) and HP pump gear (4).

3. Remove the flange retaining bolts (1).

4. Remove the flange (2) and O-ring (3).

5. Remove O-ring (7).

NHIL13ENG0029AA

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Engine - Fuel injection system

High pressure pump - Inspect N4LDI-TA-45SL N4LDI-TA-50SL

1. Replace the High Pressure (HP) pump when indicated by the Engine Control Unit (ECU).

2. Inspect the HP pump for signs of leakage and O-ring (2) condition.

NOTICE: Never handle the HP pump by the pipe (1), leakage can occur 3. If the HP pump is out of specifications or damaged, install a new HP pump.

NHIL13ENG0029AA

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Engine - Fuel injection system

High pressure pump - Install - Pump gear N4LDI-TA-45SL N4LDI-TA-50SL

Prior operation: High pressure pump - Inspect (10.218) 1. Install the O-ring (7) onto the High Pressure (HP) pump (8) shaft.

2. Install the flange (2) onto the HP pump (8) and secure with the retaining bolts (1).

3. Install O-ring (3) into the flange (2).

4. Install the pump gear (4) onto the HP pump shaft.

5. Align the key position of the pump gear (4) and the pulser (5) and install the pulser.

6. Secure the gear and pulser with nut (6) and torque to 58 - 62 N·m (43 - 46 lb ft).

NHIL13ENG0029AA

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Engine - Fuel injection system

High pressure pump - Install N4LDI-TA-45SL N4LDI-TA-50SL

NOTICE: Never handle the High Pressure (HP) pump by the pipe (1), leakage can occur.

NHIL13ENG0030AA

1

NHIL13ENG0072AA

2

NHIL13ENG0032AA

3

NHIL12ENG0136AA

4

1. Install the O-ring (3) and HP pump (1).

2. Align the timing mark of the HP pump with the camshaft timing mark, as shown.

3. Install the HP pump retaining bolts (2), Figure 2 and torque to 58 - 62 N·m (43 - 46 lb ft).

4. Install the common rail supply line (2) and torque to 22.5 - 28.5 N·m (17 - 21 lb ft).

5. Install the common rail return / return to tank lines. Secure with washers and banjo bolt (3) and torque to 12.0 - 14.0 N·m (8.9 - 10.3 lb ft).

6. Install the from tank supply line (4) and torque to 20 25 N·m (15 - 18 lb ft).

7. Connect the electrical connection (1).

NOTE: If a new HP pump is installed, driving of the unit is necessary for proper calibration. Refer to the service tool for the calibration procedure of the HP pump.

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Engine - Fuel injection system

High pressure pump - Timing adjust N4LDI-TA-45SL N4LDI-TA-50SL

1. Make sure the cover indicator, and the pulley notch are aligned.

NHIL13ENG0105AA

1

NHIL13ENG0106AA

2

NHIL13ENG0107AA

3

2. Remove the inspection cover.

3. Check that the high pressure pump timing mark, and the camshaft gear timing mark are matched.

NOTE: If the timing marks are not aligned, remove the high pressure pump, align the timing marks and re-install the pump. See High pressure pump - Install (10.218) for the proper procedure.

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Engine - Fuel injection system

Common rail - Remove N4LDI-TA-45SL N4LDI-TA-50SL

1. Remove the hose clamp (2) from the return to pump hose (1) and remove hose.

NHIL12ENG0136AA

1

NHIL12ENG0229AA

2

NHIL12ENG0227AA

3

NHIL12ENG0169AA

4

2. Remove the injector supply pipes (2) and the common rail supply pipe (1) from the common rail.

3. Remove the retaining bolts (1).

4. Remove the common rail from the block.

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Engine - Fuel injection system

Common rail - Inspect N4LDI-TA-45SL N4LDI-TA-50SL

1. Replace the rail when indicated by the Engine Control Unit (ECU). Actively check the common rail assembly with the Service Tool D. 2. Check the common rail assembly for leaky conditions.

If the High Pressure (HP) pump is out of specifications, install a new one. Never dismantle the common rail assembly. Contact your authorized CNH dealer when service is necessary.

NOTICE: The common rail assembly is a delicate part, please handle with care. Avoid contamination of dust and foreign objects.

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Engine - Fuel injection system

Common rail - Install N4LDI-TA-45SL N4LDI-TA-50SL

1. Install the common rail onto the block and secure with the retaining bolts (1).

2. Torque retaining bolts (1) to 23 - 28 N·m (17 - 21 lb ft).

NHIL12ENG0227AA

1

NHIL12ENG0229AA

2

NHIL12ENG0136AA

3

3. Install the common rail supply pipe (1) and the injector supply pipes (2).

4. Torque supply pipes (2) to 20 - 25 N·m (15 - 18 lb ft).

5. Install the common rail return hose (1) and secure with hose clamp (2).

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Engine - Fuel injection system

Fuel injectors - Remove N4LDI-TA-45SL N4LDI-TA-50SL

1. Remove the injector supply pipes (1).

NHIL12ENG0228AA

1

NHIL13ENG0071AA

2

NHIL12ENG0170AA

3

NHIL12ENG0218AA

4

2. Remove the banjo bolts (1) from the return line (2).

NOTE: Each banjo fitting will have two washers.

3. Remove the fuel return line.

4. Remove the retaining bolt (1) from the injector clamp (2).

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Engine - Fuel injection system

5. Remove the injectors.

NHIL12ENG0171AA

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5

Engine - Fuel injection system

Fuel injectors - Inspect N4LDI-TA-45SL N4LDI-TA-50SL

1. Do not drop, shock or damage the injector. Dust and foreign objects may cause the injector to clog.

2. Check the injector assembly for fuel leakage. Use the Service Tool D for detailed inspection. If the injector assembly is out of specification, install a new one.

3. Solenoid resistance: 0.46 - 0.48 Ω at 20 °C (68.0 °F).

4. Do not dismantle the injector assembly, contact your authorized CNH when service is necessary.

5. Replace the O-ring every time an injector is removed to avoid leakage.

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Engine - Fuel injection system

Fuel injectors - Install N4LDI-TA-45SL N4LDI-TA-50SL

1. Install a new O-ring (1) on the injector.

2. Install the seal ring (3) onto the tip of the injector (2).

NHIL12ENG0171BA

1

NHIL12ENG0218AA

2

NHIL13ENG0071AA

3

3. Install the fuel injector in the head until the O-ring seats.

4. Install the injector clamp (2) and secure with retaining bolt (1).

5. Torque retaining bolts (1) to 22.6 - 28.4 N·m (16.7 21 lb ft).

6. Install the fuel return line (2) and secure with the banjo bolts (1) and washers.

7. Torque banjo bolts (1) to 15 - 20 N·m (11.1 - 15 lb ft).

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Engine - Fuel injection system

8. Install the injector supply pipes (1).

NHIL12ENG0228AA

4

NOTICE: If any injector was replaced with a new one, a revision level change in the Engine Control Unit (ECU) is necessary. Use Service Tool D, input the numerical value of the head of the new injector.

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Engine - Fuel injection system

Fuel injectors - Remove N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Clean all dirt, oil, and grease from the injectors (1) and surrounding areas.

2. Disconnect the fuel leak-off lines (2) and injector lines (3) from the injectors.

NHVM13ENG0194AA

1

20097771

2

3. Remove the injectors (1) and sealing washers (2) from the cylinder head.

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Engine - Fuel injection system

Fuel injectors - Disassemble N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Loosen and remove the nozzle nut (1) from the injector body (2) being careful not to drop or damage the nozzle.

2. Remove the nozzle assembly (3), spacer (4), spring (5) and shim (6).

3. Clean the nozzle body and the needle valve. Check the nozzle for any burn or score marks. Check the needle seat for evidence of fuel leakage or carbon deposits.

4. Correct fuel leakage at the seat using a polishing stick and polish the seat area.

5. Inspect the upper and lower contact surfaces of the nozzle holder for a clean contact surface area.

6. Check the contact area between the push rod and spring seat.

20097772

(1) Nozzle nut (2) Injector body (3) Nozzle assembly (4) Spacer (5) Spring (6) Shims (7) Rod (8) Nut (9) Leak-off line (10) Washer

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1

Engine - Fuel injection system

Fuel injectors - Assemble N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

NOTE: Clean all parts in clean fuel oil and assemble while still wet.

1. Install the shim(s) (9), spring (4), spacer (5), and nozzle assembly (7) in the injector body (3).

2. Install the nozzle nut (6) and tighten to 39 - 44 N·m (28.8 - 32.5 lb ft).

3. Check and adjust the injector pressure setting using an injector tester and an adapter fitting. Adjust the pressure setting to 15700 kPa (2277.1 psi).

20096956

(1) Nut (2) Leak-off line (3) Injector body (4) Spring (5) Spacer (6) Nozzle nut (7) Nozzle assembly (8) Rod (9) Shims (10) Washer

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Engine - Fuel injection system

Fuel injectors - Install N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Install the fuel injectors (1) and torque to 60 - 69 N·m (43.4 - 50 lb ft).

2. Install the fuel return line (2) on the injectors (1) and injection pump.

3. Install the injection piping (3) and torque to 15 - 24 N·m (11 - 18 lb ft).

NHVM13ENG0194AA

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1

Index Engine - 10 Fuel injection system - 218 Common rail - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Common rail - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Common rail - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Common rail - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Fuel injection system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel injection system - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Fuel injection system - Inspect – Fuel pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Fuel injection system - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel injection system - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel injectors - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Fuel injectors - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Fuel injectors - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Fuel injectors - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Fuel injectors - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Fuel injectors - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Fuel injectors - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Fuel injectors - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Fuel injectors - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 High pressure pump - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 High pressure pump - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 High pressure pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 High pressure pump - Install - Pump gear (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 High pressure pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 High pressure pump - Remove - Pump gear (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 High pressure pump - Timing adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Injection pump - Bleed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Injection pump - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Injection pump - Dynamic description - Delivery valves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Injection pump - Dynamic description - Fuel variation mechanism (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Injection pump - Dynamic description - Pumping elements (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Injection pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Injection pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

(*) See content for specific models 47632293 16/09/2014

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Engine - 10 Turbocharger and lines - 250

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Engine - 10 Turbocharger and lines - 250

FUNCTIONAL DATA Turbocharger Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Turbocharger Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Turbocharger - Dynamic description The turbocharger is a forced induction device used to allow more power to be produced for an engine of a given size.

The turbo charger is powered by exhaust gas to drive the turbine wheel and the other coaxial end.

There is a compressor wheel to force air into the engine and increase the power output. The turbo does not need any service or adjustments.

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Turbocharger - Remove N4LDI-TA-45SL N4LDI-TA-50SL N843LT-F-27 N843T-F-24 N844LT-F-45SL

1. Remove the retaining bolts (1) from the oil supply line, block side.

NHIL12ENG0230AA

1

NHIL12ENG0232AA

2

NHIL12ENG0181AA

3

2. Remove the oil supply line banjo fitting (1) from the turbocharge and remove supply line.

3. Remove the retaining bolts (1) oil return line (2) from turbocharger and engine block.

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4. Remove the three turbocharger flange nuts (1) from exhaust manifold.

5. Remove turbocharger.

NHIL12ENG0179AA

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Turbocharger - Inspect N4LDI-TA-45SL N4LDI-TA-50SL N843LT-F-27 N843T-F-24 N844LT-F-45SL

1. Check turbine (exhaust side) and compressor (intake side) housings for cracks.

2. Check oil line (return and supply) connections for damage to mating surfaces, stripped threads, or clogged ports.

3. Check turbine shaft for end play. Replace the turbocharger if the turbine shaft end play exceeds 0.09 mm (0.00354 in).

4. Check the inside of the turbine and compressor housings for any signs of oil leakage or damage resulting from a loose shaft.

5. Check turbine and compressor for any signs of missing pieces.

6. Check mating surfaces for damage that may not allow gaskets to seal.

7. If any damage is found on inspection, the turbocharger must be replaced with a new unit.

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Turbocharger - Install N4LDI-TA-45SL N4LDI-TA-50SL N843LT-F-27 N843T-F-24 N844LT-F-45SL

1. Install turbocharger (1) with a new gasket on exhaust manifold studs (2) and torque nuts to 23 - 28 N·m (17.0 - 21 lb ft).

NHIL12ENG0232AA

1

NHIL12ENG0181AA

2

NHIL12ENG0230AA

3

2. Install oil return line (1) with a new gasket, between turbocharger and engine block.

3. Install oil supply line (1) with a new gasket, to the engine block.

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4. Install the oil supply line banjo fitting (1) with washers and torque to 8 - 11 N·m (6 - 8 lb ft).

5. Check oil level before starting the engine to avoid damage to the turbocharger and engine.

NHIL12ENG0232AA

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4

Index Engine - 10 Turbocharger and lines - 250 Turbocharger - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Turbocharger - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Turbocharger - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Turbocharger - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(*) See content for specific models 47632293 16/09/2014

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Engine - 10 Intake and exhaust manifolds and muffler - 254

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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

SERVICE Intake manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Exhaust manifold Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Intake manifold - Remove Prior operation: Rocker support - Remove (10.106) 1. Remove the manifold retaining bolts (1).

2. Remove the intake manifold (2) and gasket (3).

3. Remove the spacer (4) and gasket (5) from the cylinder head.

NHIL13ENG0074AA

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1

Engine - Intake and exhaust manifolds and muffler

Intake manifold - Install 1. Install a new spacer gasket (5) and position the spacer (4) on the cylinder head.

2. Install a new intake manifold gasket (3) and position the intake manifold (2) over the spacer.

3. Install the manifold retaining bolts (1) and torque to 8.3 - 11.3 N·m (6.1 - 8 lb ft).

NHIL13ENG0074AA

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Engine - Intake and exhaust manifolds and muffler

Exhaust manifold - Remove 1. Remove the six bolts (2) and two nuts (1) from the exhaust manifold.

2. Remove manifold.

NHIL12ENG0219AA

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Engine - Intake and exhaust manifolds and muffler

Exhaust manifold - Install 1. Install the exhaust manifold, with new gasket, to the two studs (1) of the engine block.

NHIL12ENG0184AA

1

NHIL12ENG0219AA

2

2. Install the two nuts (1) on the studs, and the six retaining bolts (2).

3. Torque the nuts (1) and bolts (2) to 25 N·m (18.4 lb ft) evenly to prevent distortion.

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

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Engine - 10 Selective Catalytic Reduction (SCR) exhaust treatment - 500

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Engine - 10 Selective Catalytic Reduction (SCR) exhaust treatment - 500

FUNCTIONAL DATA Selective Catalytic Reduction (SCR) exhaust treatment Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Selective Catalytic Reduction (SCR) exhaust treatment - Dynamic description

NHIL14ENG0025FA

(1) (2) (3) (4) (5) (6) (7)

Engine Control Unit (ECU) Tractor or skid steer Differential pressure sensor Diesel Particulate Filter (DPF) Diesel Oxidation Catalyst (DOC) After burner Reed valve

1

(A) Boost (B) Water temperature (C) Rack position (D) Engine speed (E) Exhaust out (F) Air in (G) Flow from air pump

The Exhaust Gas Recirculation (EGR) valve recirculates a portion of exhaust gas into the induction port. This process effectively burns the recirculated gas and fuel mixture in the combustion chamber, which reduces the temperature and NOx. The reed valve (7) act like one way valve and prevent exhaust gas blow back to air pump.

Exhaust gas travels through the afterburner (6) into the Diesel Oxidation Catalyst (DOC) (5) and then into the Diesel Particulate Filter (DPF) (4).

The DPF’s function is to collect the soot which contains the exhaust gases, and remove the Particulate Matter (PM).

A differential pressure sensor (3) is installed on the DOC / DPF and will determine when soot collecting is beyond the allowable limit. Automatic regeneration will be processed and remove the soot from the filter.

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Index Engine - 10 Selective Catalytic Reduction (SCR) exhaust treatment - 500 Selective Catalytic Reduction (SCR) exhaust treatment - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Engine - 10 Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment - 501

FUNCTIONAL DATA Exhaust Gas Recirculation (EGR) valve Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Diesel Oxidation Catalyst (DOC) Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

After-burner Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Air pump Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Dynamic description - Reed valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Exhaust Gas Recirculation (EGR) valve Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Exhaust Gas Recirculation (EGR) cooler Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Diesel Oxidation Catalyst (DOC) Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Diesel Particulate Filters (DPF) Inspect – Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Air pump Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Remove - Reed valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Inspect - Reed valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Install - Reed valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

After-burner Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Exhaust Gas Recirculation (EGR) valve - Dynamic description The Exhaust Gas Recirculation (EGR) valve recirculates a portion of exhaust gas into the induction port. This process effectively burns the recirculated gas and fuel mixture in the combustion chamber, which reduces the temperature and NOx.

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Diesel Oxidation Catalyst (DOC) - Dynamic description N4LDI-TA-45SL N4LDI-TA-50SL

NHIL13ENG0012AA

1

The Diesel Oxidation Catalyst (DOC) oxidizes emissions gas and reduces the Hydrocarbons (HC) and the Carbon Monoxide (CO2) of emission gas contents. A pressure sensor is installed on the DOC to determine when soot collection reaches the border line.

The emissions control system is equipped with a Exhaust Gas Recirculation (EGR) device, which regulates the amount of spent exhaust gas that is mixed into the intake stream. Its purpose is to cool combustion chamber temperatures to the threshold that reduces the formation of Nitrogen Oxides (NOx ).

On the Direct Inject (DI) common rail system, smoke emit controlling is available at any situation, at start up, moderate speed or sudden load changes.

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After-burner - Dynamic description N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

The after-burner is an electronically controlled device used to raise exhaust temperatures and enhance the chemical reaction in the Diesel Oxidation Catalyst (DOC).

Stage one (preheat) 1. The glow plug (1) connected to the top of the burner heats up.

2. Injector number one (2) sprays fuel toward the glow plug.

3. The air pump feeds the fresh air (5) needed.

4. The three components ignite causing a fire, raising the temperature of the DOC Stage two 1. Injector number one (2) continues to inject fuel while injector number two (3) starts to spray fuel down stream of the exhaust pipe toward the DOC surface (4). This process will raise and enhance the exhaust temperature and activate the Diesel Particulate Filter (DPF).

2. The DPF will start the chemical reaction to burn off the soot, resolving the filter clogging.

NOTICE: Depending on the load factor, if the pressure difference is beyond the limit, the “Active regeneration” will start.

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NHIL13ENG0190AA

1

Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Air pump - Dynamic description N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

NHIL13ENG1419AA

1

The air pump (1) is driven by the engines V-belt. The air pump supplies compressed air to the afterburner promoting combustion to reduce NOx and particulate matter.

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Air pump - Dynamic description - Reed valve N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

NHIL13ENG1419AA

1

The reed valve (1) is installed in-line between the air pump and the afterburner. The reed valve is a type of check valve which restrict the flow of fluids to a single direction, opening and closing under changing pressure on each face.

This prevents exhaust gas blow back from the afterburner to enter in the air pump.

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Exhaust Gas Recirculation (EGR) valve - Remove N4LDI-TA-45SL N4LDI-TA-50SL

1. Disconnect the electrical connector (2).

2. Remove the coolant lines (1) from the valve body.

NHIL12ENG0151AA

1

NHIL13ENG0068AB

2

3. Remove the two bolts (5) from the Exhaust Gas Recirculation (EGR) cooler.

4. Remove the four bolts (1) from the EGR valve body (3).

5. Remove the EGR pipe (6) and gasket (2).

6. Remove EGR valve (3) and gasket (4).

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Exhaust Gas Recirculation (EGR) valve - Inspect N4LDI-TA-45SL N4LDI-TA-50SL

1. Replace the Exhaust Gas Recirculation (EGR) valve when indicated by the Engine Control Unit (ECU).

2. Actively check the EGR with the Service Tool D. If the EGR is out of specifications, replace with a new one.

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Exhaust Gas Recirculation (EGR) valve - Install N4LDI-TA-45SL N4LDI-TA-50SL

1. Install the Exhaust Gas Recirculation (EGR) valve (3), new gasket (4), EGR pipe (8), new gasket (2) to the intake manifold.

2. Use the four retaining bolts (1) to secure the valve and pipe to the intake manifold.

3. Install the EGR pipe (8) and new gasket (5) to the to the EGR cooler (6).

4. Torque bolts (1) and (7) to 23 - 28 N·m (17 - 21 lb ft).

NHIL13ENG0015AA

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NHIL12ENG0151AA

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5. Install the two coolant lines (1) to the EGR valve.

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

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Exhaust Gas Recirculation (EGR) valve - Remove N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Disconnect the electrical connector (1).

2. Remove the three bolts (3) connecting the pipe to the EGR valve body.

3. Remove the three retaining bolts (2) from the intake manifold and remove the EGR valve.

NHIL13ENG0214AA

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Exhaust Gas Recirculation (EGR) valve - Inspect N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Replace the Exhaust Gas Recirculation (EGR) valve when indicated by the Engine Control Unit (ECU).

2. Actively check the EGR with the Service Tool I. If the EGR is out of specifications, replace with a new one.

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Exhaust Gas Recirculation (EGR) valve - Install N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Install the three retaining bolts (2) to secure the Exhaust Gas Recirculation (EGR) valve to the intake manifold.

2. Install the EGR pipe and secure with three bolts (3).

3. Torque all bolts to 23 - 28 N·m (17 - 21 lb ft).

4. Connect the electrical connection (1).

NHIL13ENG0214AA

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Exhaust Gas Recirculation (EGR) cooler - Remove N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Loosen the hose clamp and remove the coolant hose (4) to drain fluid.

2. Loosen the hose clamp and remove hose (5).

3. Remove the two bolts (2) securing the pipe to the cooler.

4. Remove the bolt (3) securing the lower bracket.

5. Remove the two bolts (1) securing the EGR cooler to the exhaust manifold and remove the EGR cooler.

NHVM13ENG0215AA

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Exhaust Gas Recirculation (EGR) cooler - Install N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Install the two bolts (1) to secure the Exhaust Gas Recirculation (EGR) cooler to the exhaust manifold.

2. Install the bolt (3) to secure the lower bracket to the block.

3. Install the pipe to the cooler secure with the bolts (2).

4. Torque all bolts to 23 - 28 N·m (17 - 21 lb ft).

5. Install the hoses (4) and (5) and tighten hose clamps.

NHVM13ENG0215AA

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Diesel Oxidation Catalyst (DOC) - Remove N4LDI-TA-45SL N4LDI-TA-50SL

NOTE: The Diesel Oxidation Catalyst (DOC) mounting position depends on the application.

1. Remove the four retaining bolts (2) from the intake side of the DOC. 2. Remove the two DOC retaining strap bolts (1).

NHIL12ENG0127AA

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NHIL13ENG0012AA

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3. Disconnect the exhaust temperature sensors (3).

4. Disconnect the differential pressure sensor (2).

5. Remove the DOC assembly (1).

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Diesel Oxidation Catalyst (DOC) - Install N4LDI-TA-45SL N4LDI-TA-50SL

1. Install the Diesel Oxidation Catalyst (DOC) assembly in the retaining straps (1) and secure with bolts (3).

2. Install a new gasket and secure the DOC assembly with the four mounting bolts (2) on the intake side of the DOC. 3. Torque bolts (2) to 25.5 - 33.3 N·m (18.8 - 25 lb ft).

NHIL12ENG0127AA

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NHIL13ENG0012AA

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4. Connect the exhaust temperature sensors (2).

5. Connect the differential pressure sensor (1).

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Diesel Oxidation Catalyst (DOC) - Remove N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

NOTE: The Diesel Oxidation Catalyst (DOC) mounting position depends on the application.

1. Remove the retaining bolts (2) from the intake and exhaust sides of the DOC assembly.

NOTE: Intake retaining bolts shown.

2. Remove the two DOC retaining strap bolts (1).

NHVM13ENG0198AA

1

NHIL13ENG0168AA

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3. Disconnect the DOC inlet temperature sensor (3) wire connector.

NOTICE: Label connectors and pay attention to the connector wire routing, to avoid burning wires.

4. Disconnect the DPF inlet temperature sensor (4) wire connector.

5. Disconnect the DPF outlet temperature sensor (5) wire connector.

6. Disconnect the differential pressure sensor (2).

7. Remove the DOC assembly (1).

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Diesel Oxidation Catalyst (DOC) - Install N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Install the Diesel Oxidation Catalyst (DOC) assembly in the retaining straps (1) and secure with bolts (2).

2. Install new gaskets and secure the DOC assembly with the mounting bolts (2) on the intake and exhaust sides of the DOC. NOTE: Intake side retaining bolts shown.

3. Torque bolts (2) to 25.5 - 33.3 N·m (18.8 - 25 lb ft).

NHVM13ENG0198AA

1

NHIL13ENG0168AA

2

4. Connect the DOC inlet temperature sensor (2) wire connector.

5. Connect the Diesel Particulate Filter (DPF) inlet temperature sensor (3) wire connector.

6. Connect the Diesel Particulate Filter (DPF) outlet temperature sensor (4) wire connector.

7. Connect the differential pressure sensor (1).

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Diesel Particulate Filters (DPF) - Inspect – Differential pressure sensor N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Inspect the differential pressure sensor (1).

• Check the differential pressure sensor piping (2).

• Check the differential pressure sensor electrical connections.

If there is any damage, repair or replace as needed.

2. Replace the differential pressure sensor when indicated by the Engine Control Unit (ECU).

NHIL13ENG0168AA

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Air pump - Remove N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Loosen the V-belt (4) tension.

2. Disconnect the electrical connection.

3. Remove the intake hose (1) and exhaust hose (2).

4. Remove the air pump retaining bolts (3) and remove air pump.

NHVM13ENG0188AA

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Air pump - Inspect N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Active test.

• Use the diagnostic service tool.

• Select the “Diagnostic Test” from the “Diagnostics” drop down menu.

• Select “Override Parameters”.

• Select “ARD Air System Relay Override”.

• Select ON from the “Change Parameter Value” menu.

2. Check the air pump belt.

• If the belt is damaged or dirty, repair or replace as needed.

• See Air pump - Install (10.501) for belt tension.

3. Check the air pump piping.

• Make sure the induction pipe and discharge pipe are mounted in the correct position.

• The intake pipe (1) connects to the air intake port.

• The discharge pipe (2) connects to the reed valve.

• Repair or replace as needed.

NHVM13ENG0188AA

1

NHIL13ENG0164AA

2

4. Use a multi-meter to measure the resistance of the air pump: • 4.23 - 4.67 Ω at 20 °C (68 °F).

5. If the pump is out of specification, install a new air pump.

Air pump electrical wiring/connection specification: Value

Connector pin Pin 1 Pin 2

Ground 12.0 V

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Air pump - Install N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Use the air pump retaining bolts (3) to secure the air pump to the engine block.

2. Install the intake hose (1) and the exhaust hose (2).

NOTICE: Ensure the hose fittings for each port are secure to avoid damage to the air pump.

3. Connect the electrical connection.

4. Install the V-belt (4) and apply tension as follows: • New belt — 265 - 355 N (60 - 80 lb) • Used belt — 175 - 265 N (40 - 60 lb) NHVM13ENG0188AA

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Air pump - Remove - Reed valve N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Loosen the hose clamps (1) and (2), and remove the reed valve (3).

NHVM13ENG0188AA

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Air pump - Inspect - Reed valve N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Blow air in the valve from the regular direction indicated by the arrow on the valve, confirm air flow.

2. Blow air in the valve opposite the arrow on the valve. If any air leakage is confirmed, replace the valve.

NHIL13ENG0177AA

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

Air pump - Install - Reed valve N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Connect hoses (1) and (2) to the reed valve (3) and tighten the hose clamps.

NOTICE: The arrow on the reed valve case needs to point toward the afterburner. Incorrect installation will result in air pump damage.

NHVM13ENG0188AA

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

After-burner - Remove N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Disconnect the electrical connectors (1) from the injectors.

2. Disconnect the fuel supply lines (2) from the injectors.

3. Remove the air pump feed tube (5).

4. Remove the after-burner intake pipe (4).

5. Remove the after-burner exhaust pipe (3), connected to the Diesel Oxidation Catalyst (DOC).

6. Remove the after-burner retaining bolts and remove after-burner.

NHIL13ENG0163AA

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

After-burner - Inspect N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

NOTICE: Do not disassemble the after-burner body. Only the glow plug (1) is replaceable. The burner injectors are considered a subassembly (2).

1. The Engine Control Unit (ECU) will throw an error code if the after-burner is malfunctioning.

2. Inspect the after-burner body for signs of cracks or leakage.

NHIL13ENG0201AA

NOTE: Do not test resistance using the glow plug sheath.

3. Check the glow plug resistance.

• Use a multimeter to measure the resistance. There should be approximately 0.8 Ω.

• If the resistance is out of range, replace the glow plug.

4. Check the burner injector(s).

• Use a multimeter to check for continuity from pin 1 to pin 2. There should be continuity.

• If there is infinite resistance or 0 Ω, replace the injector.

5. If results do not change, replace the after-burner.

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Engine - Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment

After-burner - Install N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Secure the after-burner to the block with the retaining bolts.

2. Install the fuel supple line (2).

3. Install the after-burner intake pipe (4).

4. Install the after-burner exhaust pipe (3).

5. Install the air pump feed tube (5).

6. Install the injector electrical connection (1).

NHIL13ENG0163AA

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1

Index Engine - 10 Exhaust Gas Recirculation (EGR) - Diesel Particulate Filter (DPF) exhaust treatment - 501 After-burner - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 After-burner - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 After-burner - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 After-burner - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Air pump - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Air pump - Dynamic description - Reed valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Air pump - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Air pump - Inspect - Reed valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Air pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Air pump - Install - Reed valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Air pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Air pump - Remove - Reed valve (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Diesel Oxidation Catalyst (DOC) - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Diesel Oxidation Catalyst (DOC) - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Diesel Oxidation Catalyst (DOC) - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Diesel Oxidation Catalyst (DOC) - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Diesel Oxidation Catalyst (DOC) - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Diesel Particulate Filters (DPF) - Inspect – Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Exhaust Gas Recirculation (EGR) cooler - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Exhaust Gas Recirculation (EGR) cooler - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Exhaust Gas Recirculation (EGR) valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Exhaust Gas Recirculation (EGR) valve - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Exhaust Gas Recirculation (EGR) valve - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Exhaust Gas Recirculation (EGR) valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Exhaust Gas Recirculation (EGR) valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Exhaust Gas Recirculation (EGR) valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Exhaust Gas Recirculation (EGR) valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Engine - 10 Engine cooling system - 400

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Engine - 10 Engine cooling system - 400

TECHNICAL DATA Engine cooling system General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine cooling system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Water pump Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Coolant thermostat Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Water pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Coolant thermostat Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Engine - Engine cooling system

Engine cooling system - General specification N4LDI-TA-45SL N4LDI-TA-50SL

Engine model Type of system Water pump Drive belt deflection (Tension)

N４LTDI-TA-45SL N4LDI-TA-50SL Pressurized liquid with recirculating by-pass Centrifugal 10 - 15 mm (0.39 - 0.59 in) when 89 - 111 N (20 - 25 lb) force is applied midway between pulleys.

Thermostat Starts to open Fully open Radiator cap pressure rating Coolant

71 °C (160 °F) 82 °C (180 °F)

80 - 84 °C (176 - 183 °F) 95 °C (203 °F) 90 kPa (13 psi) Ethylene glycol and water in a 50/50% mixture.

Engine cooling system - General specification N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Engine model Type of system Water pump Drive belt deflection (Tension)

N844L-F-36SL

N844LT-F-45SL Pressurized liquid with recirculating by-pass Centrifugal 10 - 15 mm (0.39 - 0.59 in) when 89 - 111 N (20 - 25 lb) force is applied midway between pulleys.

Thermostat Starts to open Fully open Radiator cap pressure rating Coolant

69 - 73 °C (156 - 163 °F) 80 - 84 °C (176 - 183 °F) 82 °C (180 °F) 95 °C (203 °F) 48 kPa (7 psi) Ethylene glycol and water in a 50/50% mixture.

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Engine cooling system - Dynamic description The cooling system is the recirculating bypass type with a full length water jacket for each cylinder cast into the block.

The coolant is drawn from the bottom of the radiator by the water pump and passes around the cylinders and into the cylinder head.

The thermostat is located in the front of the cylinder head and thermostatically controls the flow of coolant from the engine to the radiator. When the thermostat is closed only a small amount of coolant is permitted to flow through the thermostat bypass to the radiator to effect a faster warm-up. When the thermostat is open, the coolant flows from the water outlet connection to the top tank of the radiator for maximum cooling.

Cooling occurs as the coolant passes down through the radiator cores which are exposed to the air flow created by the fan as air is drawn through the radiator.

SECT10C01PG88

1

(1) Radiator (2) Radiator cap (3) Thermostat

(4) Air flow (5) Water pump (6) Fan

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Water pump - Dynamic description The water pump (1) is an impeller attached to a shaft which is belt driven by the engine crankshaft. The impeller circulates water by centrifugal force. Coolant entering the pump housing from the radiator through the lower hose is thrown outward against the housing with sufficient force to cause a circulating action.

20093421

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Engine - Engine cooling system

Coolant thermostat - Dynamic description The thermostat (1) is located between the coolant outlet on the engine and the radiator. In this position the thermostat is able to sense the coolant temperature in the engine and regulate the flow of coolant to the radiator. When the engine is cold, only a small amount of coolant flows to the radiator through the thermostat bypass. As the engine warms up, the thermostat opens to allow sufficient coolant flow to the radiator to maintain a constant engine temperature.

NHIL13ENG0181AA

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Engine - Engine cooling system

Water pump - Remove 1. Remove the oil cooler hose (1), bypass hose (2) and lower radiator hose (4) from the water pump (3).

2. Remove the water pump retaining bolts (5) and remove the water pump (3) and gasket from the engine.

NHVM13ENG0196AA

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Engine - Engine cooling system

Water pump - Inspect 1. Coolant leakage can be seen from the weep hole (1) on top of the pump.

NHVM13ENG0196AA

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Engine - Engine cooling system

Water pump - Install 1. Install the water pump (3) and new gasket and tighten the retaining bolts (5).

2. Install the oil cooler hose (1), bypass hose (2) and lower radiator hose (4) on the water pump (3) and tighten the hose clamps.

NHVM13ENG0196AA

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Engine - Engine cooling system

Coolant thermostat - Remove 1. Remove the two retaining bolts (1) from the thermostat cover.

NHIL12ENG0184AA

1

NHIL12ENG0187AA

2

2. Remove the thermostat cover (1), gasket (2) and thermostat (3).

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Coolant thermostat - Test 1. Place the thermostat (1) in a container filled with a 50/50% mixture of antifreeze and water. Isolate the thermostat from the bottom of the container.

2. Place a high temperature thermometer (2) in the coolant mixture and heat the container.

3. Use a 0.08 mm (0.003 in) feeler gauge (3) to determine when the thermostat begins to open.

4. Note the coolant temperature at which the thermostat starts to open and when it is fully opened.

5. Replace the thermostat if it fails to open at the specified temperature. Thermostat opening temperature: • Start to open: 69 - 73 °C (156 - 163 °F) • Fully open: 82 °C (180 °F) • Valve lift: 8.0 mm (0.314 in)

20093423A

6. Thoroughly clean the gasket mating surfaces before installing thermostat.

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Engine - Engine cooling system

Coolant thermostat - Install 1. Thoroughly clean the mating surface (1) of the thermostat housing and thermostat cover.

2. Install the thermostat into the housing ensuring the air purge (3) is positioned between the castings (2) on the housing.

NHIL12ENG0225AA

1

NHIL12ENG0226AA

2

NHIL12ENG0186AA

3

NOTICE: If the air purge (3) is not in the correct position the thermostat will not function properly.

3. Install a new gasket and the thermostat cover (1).

4. Install the wire clamp (2) and thermostat cover M8 retaining bolts (3) and torque between 13 - 17 N·m (9.6 13 lb ft).

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Index Engine - 10 Engine cooling system - 400 Coolant thermostat - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Coolant thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Coolant thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Coolant thermostat - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine cooling system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine cooling system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine cooling system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Water pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Water pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Engine - 10 Engine lubrication system - 304

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Engine - 10 Engine lubrication system - 304

FUNCTIONAL DATA Engine lubrication system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Engine oil filter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Oil pressure valve Dynamic description - Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Engine oil pump Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Crankcase ventilation system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Engine lubrication system Check - Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Pressure test - Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Engine oil filter Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Engine oil pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Remove - Pick-up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Inspect - Pick-up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install - Pick-up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Crankcase ventilation system Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Engine lubrication system - Overview

NHIL13ENG0042AA

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

Turbocharger Oil pressure switch Oil pump Suction filter

1

(5) Oil filter (6) Oil cooler (7) Oil pressure relief valve

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NHIL13ENG0040AA

(1) Blow-by gas flow (2) Blow-by recirculation separator

2

(3) Only oil returns to block (4) Oil inlet pipe

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Engine oil filter - Overview

SECT10C01PG83_1

1

These engines utilize a cartridge type filter. Pressurized oil flows from the pump and enters the full flow filter through (1) and is discharge through (2). When the full flow filter is clogged, the safety valve (3) opens to bypass the oil, preventing engine lubrication failure or other troubles.

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Oil pressure valve - Dynamic description - Relief valve

NHIL12ENG0234AA

1

The pressure is relieved by allowing the pressurized fluid to flow from an auxiliary passage out of the main oil circuit.

When the set pressure of 402 kPa (58.3 psi) is exceeded, the relief valve is forced open and a portion of the fluid is diverted through the auxiliary route.

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Engine oil pump - Dynamic description A gerotor is a positive displacement pump. The name gerotor is derived from "Generated Rotor". A gerotor unit consists of an inner and outer rotor. The inner rotor has 4 teeth, and the outer rotor has 5 teeth. The inner rotor is located off-center and both rotors rotate. The geometry of the two rotors, partitions the volume between them into different dynamically-changing volumes. During the assembly's rotation cycle, each of these volumes changes continuously. An increase in volume creates a vacuum. This vacuum creates suction, and hence, this part of the cycle is where the oil intake is located. As a volume decreases compression occurs. During this compression period, oil can be pumped.

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Engine - Engine lubrication system

Crankcase ventilation system - Dynamic description A crankcase ventilation system is a way for gases to escape in a controlled manner from the crankcase of an internal combustion engine. This is necessary because internal combustion inevitably involves a small but continual amount of blow-by, which occurs when some of the gases from the combustion leak past the piston rings to end up inside the crankcase.

The blow-by recirculation system contains a Positive Crankcase Ventilation (PCV) valve where it separates the oil and gases to reduce valve deposits and Particulate Matter (PM).

The PCV valve is an emissions control device that routes unburned crankcase blow-by gases back into the intake manifold where they can be reburned.

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Engine - Engine lubrication system

Engine lubrication system - Check - Oil Consumption Log oil consumption as follows: 1. Change the engine oil and filter. Use the oil specified in the operator's manual.

2. Run the engine for 2 minutes.

3. Check the dipstick and add oil, if required, so the level is at the full mark.

4. Fill the fuel tank with fuel.

5. Record fuel consumption in liters (US gallons), oil added in liters (US gallons), and hour reading. Record fuel and oil use for 100 hours of operation, which is the recommended oil change interval. Check the dipstick before running the engine each day.

NOTE: The maximum allowable oil consumption is 0.8 %. The following table gives examples: Fuel Consumption 189.27 l (50 US gal) 378.54 l (100 US gal) 757.08 l (200 US gal)

Oil Consumption 1.5 l (1.6 US qt) 3.03 l (3.2 US qt) 6.06 l (6.4 US qt)

6. If the oil consumption is greater than 0.8 % of the fuel consumption, oil usage is excessive. A sample calculation for oil consumption follows: % consumption = (Quantity of Oil in Liters (US gallons) ⁄ Quantity of Fuel in Liters (US gallons)) x 100 Assume 0.25 l (0.07 US gal) oil is added for 50 l (13.2 US gal) fuel. % consumption = ( 0.25 l ⁄ 50 l) x 100 or ( 0.07 US gal ⁄ 13.2 US gal) x 100 % consumption = 0.5 %.

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Percentage 0.79 % 0.80 % 0.80 %

Engine - Engine lubrication system

Engine lubrication system - Pressure test - Engine oil 1. Disconnect the sending lead (2) and remove the oil pressure sending unit (1).

20093417

1

20093418

2

20002360A

3

2. Install the oil pressure test fitting NH00011 (1), and test gauge (2). Start the engine and observe gauge indicator. Gauge should indicate between 98.04 - 147.07 kPa (14.22 - 21.33 psi) at low idle and 244.76 - 343.36 kPa (35.5 - 49.8 psi) at high idle.

NOTE: Pressure test should be with engine at normal operating temperature.

3. If the gauge did not indicate the oil pressure within specified tolerances at low and high idle, troubleshoot the lube oil system.

NOTE: Main galley access port (3), located next to the relief valve (2), and external oil tube (1).

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Engine - Engine lubrication system

Engine oil filter - Replace 1. Remove the old oil filter.

2. Coat the new filter mounting surface with clean engine oil.

3. Install the new filter and tighten by hand.

4. Never reuse a filter if it was removed once.

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Engine - Engine lubrication system

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

2. Remove the collar (2), spring (3), and shims (4).

3. Remove the oil pump cover (5) and idle gear assembly (8) together.

4. Remove the rotor (6) and the thrust washer (7).

5. Remove the oil pump cover (5) from the idle gear (8).

76075745

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1

Engine - Engine lubrication system

Engine oil pump - Inspect Prior operation: Engine oil pump - Remove (10.304) 1. Check for excessive wear on the pump cover (1), inner rotor (3) and outer rotor (2), replace if parts are worn out or damaged.

2. Measure the inner to outer rotor clearance (A). Replace the components as required, if clearance is not within 0.25 mm (0.010 in).

76075745A

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1

Engine - Engine lubrication system

Engine oil pump - Install 1. Install the thrust washer (7) and pin (8).

76075745

1

NHIL12ENG0192AA

2

NHIL13ENG0036AA

3

2. Align the timing marks (A) on the idler gear , crankshaft gear and camshaft gear while you install the idler gear on the port shaft.

NOTICE: Once the oil pump is installed, do not rotate the engine until the front cover is installed.

3. Install the spring (10) and rotor (6).

4. Install the oil pump cover (5), shim (4), spring (3) and collar (2). Secure the assembly to the shaft with the snap ring (1).

5. Use a dial indicator (2) to measure the axial movement of the collar (1).

• Standard clearance: 0.01 - 0.15 mm (0.00039 0.0059 in) • Service limit: 0.2 mm (0.0079 in) 6. Install or remove shims (3) as needed to obtain the standard clearance value.

7. Replace the engine oil filter and fill the sump with oil.

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Engine - Engine lubrication system

Engine oil pump - Remove - Pick-up tube 1. Remove the two bolts (2) securing the strainer bracket.

2. Remove the pick-up tube (1) out of the bore.

NOTE: The pick-up tube is held in place by an O-ring seal.

NHIL12ENG0208AA

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1

Engine - Engine lubrication system

Engine oil pump - Inspect - Pick-up tube 1. Clean the filter mesh to remove any debris or foreign objects.

2. Inspect the O-ring on the pick-up tube for wear or damage. Replace the O-ring if it becomes stiff or damaged.

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Engine - Engine lubrication system

Engine oil pump - Install - Pick-up tube 1. Install the pick-up tube (1) into the bore (3) of the engine block.

2. Install the two securing bolts (2) for the strainer bracket and torque to 9.0 - 13.0 N·m (6.6 - 9.6 lb ft).

NHIL12ENG0208AA

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1

Engine - Engine lubrication system

Crankcase ventilation system - Remove 1. Loosen the hose clamps (1) and remove the hoses.

2. Remove the drain hose (2) from the block.

NHIL12ENG0159AA

1

NHIL12ENG0162AA

2

3. Remove the Blow-by recirculation filter assembly (1).

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Engine - Engine lubrication system

Crankcase ventilation system - Disassemble 1. Use a 27mm wrench to remove the bottom case (4) from the body (1).

2. Remove the filter (2) and the O-ring (3).

NHIL12ENG0163AB

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1

Engine - Engine lubrication system

Crankcase ventilation system - Inspect 1. Wipe and clean all liquid moisture and debris from the bottom case (4), filter (2) and body (1).

NOTICE: Do not use any chemical agents when cleaning.

Chemical agents could damage the internal rubber components.

2. Remove the O-ring (3) and inspect for damage or wear on the O-ring and the threads of the bottom case (4).

NOTICE: Do not remove the caps (1) at the top and side of the body.

NHIL12ENG0163AB

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1

Engine - Engine lubrication system

Crankcase ventilation system - Assemble 1. Install the O-ring (3) in place on the bottom case (4).

2. Install the filter (2) into the body (1) of the Blow–by recirculation filter assembly.

3. Thread the bottom case (4) into the body (1) and torque to 10 N·m (7.4 lb ft).

NHIL12ENG0163AB

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1

Engine - Engine lubrication system

Crankcase ventilation system - Install 1. Install the drain hose (2) to the block.

2. Install the upper hoses and secure with the hose clamps (1).

NHIL12ENG0159AA

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1

Index Engine - 10 Engine lubrication system - 304 Crankcase ventilation system - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Crankcase ventilation system - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Crankcase ventilation system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Crankcase ventilation system - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Crankcase ventilation system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Crankcase ventilation system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Engine lubrication system - Check - Oil Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine lubrication system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine lubrication system - Pressure test - Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine oil filter - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine oil filter - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine oil pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine oil pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Engine oil pump - Inspect - Pick-up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine oil pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine oil pump - Install - Pick-up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Engine oil pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine oil pump - Remove - Pick-up tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Oil pressure valve - Dynamic description - Relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - 10 Oil cooler and lines - 408

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Engine - 10 Oil cooler and lines - 408

FUNCTIONAL DATA Engine oil cooler Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine oil cooler Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - Oil cooler and lines

Engine oil cooler - Dynamic description Typical engine oil cooling units run with engine coolant. An oil cooler is functionally similar to thermal conversion, the engine oil and coolant are circulated at each circuit.

Circulated coolant passes the internal oil cooler and exchanges the excessive heat from the engine oil. The coolant displaces the heat and emits to the atmosphere through the radiator.

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Engine - Oil cooler and lines

Engine oil cooler - Remove 1. Remove the oil filter from the oil cooler (3).

2. Loosen the hose clamps and remove the inlet hose (1) and outlet hose (2).

3. Remove the nut (4) from the center of the oil cooler.

4. Remove oil cooler (3).

NHIL12ENG0201AA

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1

Engine - Oil cooler and lines

Engine oil cooler - Inspect 1. Confirm there is no leakage or clogging of the oil cooler.

Replace if an abnormal situation is confirmed.

NHIL12ENG0202AA

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1

Engine - Oil cooler and lines

Engine oil cooler - Install 1. Install the oil cooler (2) to the engine block and secure with nut (3).

2. Install the coolant hoses (1) and tighten the hose clamps.

3. Thread the oil filter onto the oil cooler (2).

NHIL12ENG0201AA

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1

Index Engine - 10 Oil cooler and lines - 408 Engine oil cooler - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine oil cooler - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine oil cooler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine oil cooler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

PRINTED IN U.S.A. © 2014 CNH Industrial 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.

47632293 16/09/2014 EN

SERVICE MANUAL Electrical systems N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Electrical systems - 55

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.989] Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.640] Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11

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CONSUMABLES INDEX Consumable Loctite® ODC-Free Cleaner and Degreaser Loctite® ODC-Free Cleaner and Degreaser LOCTITE® 8150™ LOCTITE® 8150™ LOCTITE® 8150™ LOCTITE® 8150™ LOCTITE® 8150™

Reference

PAGE

Throttle Valve Actuator

55.7 / 8

Exhaust Gas Recirculation

55.8 / 7

Exhaust Exhaust Exhaust Exhaust Exhaust

55.8 / 11 55.8 / 14 55.8 / 20 55.8 / 23 55.8 / 26

Gas Gas Gas Gas Gas

Recirculation Recirculation Recirculation Recirculation Recirculation

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Electrical systems - 55 Electrical system - 000

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Electrical systems - 55 Electrical system - 000

SERVICE Electrical system Computer support tools - Install - Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Computer support tools - Install - Communication adapter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Computer support tools - Configure - User authentication (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Computer support tools - Configure - USB port (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Computer support tools - Start up - Service Tool D (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Computer support tools - View - Start diagnosis (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Computer support tools - View - Project screen (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Computer support tools - View - DTC screen (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Computer support tools - View - Data monitoring screen (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Computer support tools - View - Trigger detection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Computer support tools - View - Active test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Computer support tools - View - Utility (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Computer support tools - View - Finish diagnosis (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Computer support tools - View - Open diagnosis history (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Computer support tools - Program - Engine Control Unit (ECU) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Computer support tools - View - Start training (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Computer support tools - Configure - System settings (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Computer support tools - View - Version information (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Computer support tools - View - Exit application (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Computer support tools - Remove - Service Tool D (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Computer support tools - Remove - Communication adapter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Computer support tools - Configure - License activation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Start up - Service Tool I (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Computer support tools - Configure - Communication adapter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Computer support tools - Program - Existing Engine Control Unit (ECU) (*) . . . . . . . . . . . . . . . . . . . . . . . 65 Computer support tools - Program - New Engine Control Unit (ECU) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Computer support tools - Configure - Fuel pump actuator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Computer support tools - View - Engine status (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Computer support tools - View - Diagnostic codes (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Computer support tools - View - Event codes (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

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Computer support tools - View - Product status report (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Computer support tools - View - Data logging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Computer support tools - View - Real time graphing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Computer support tools - View - Parameter override mode (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Computer support tools - Configure - Diesel Particulate Filter (DPF) soot load reset (*) . . . . . . . . . . . . . 79

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Electrical system Computer support tools - Install - Software NOTE: Do not connect communication interface to PC before installing communication interface driver. This may install driver improperly.

NOTE: When installing the diagnostic tool, be sure to login to the PC with administrator user account.

NOTE: Close all other applications including virus detection software.

1. Insert the Electronic Service Tool (EST) install disk.

2. From the EST Installation menu, click the “Install ISM Engine Diagnostic Software”.

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3. If this prompt appears, click the “Yes” button.

4. Select your language and click the “OK” button.

5. This splash screen will be displayed.

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6. Click on the “Next” button.

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7. Select the “I accept the terms in the license agreement” and then click the “Next” button.

8. Click on the “Install” button.

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9. This screen will display while the program is being installed.

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10. The following window is displayed when Service Tool I is installed successfully.

11. Click the “Finish” button NOTE: The first time Service Tool I is opened, you will need to configure the communication adapter. Refer to Electrical system Computer support tools - Configure - Communication adapter (55.000) for the proper procedure.

12. If this prompt appears, click the “Yes” button.

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13. Select the desired language.

14. Click the “Next” button.

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15. Click the “Next” button.

16. Select the drive location for the system to place the files.

NOTE: “C” is default.

17. Click the “Next” button.

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18. Click the “Install” button.

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19. Installation progress is shown.

20. Click the “Finish” button to complete the installation.

NOTE: To use the Service Tool D, you must first install the communication adapter drivers. Refer to Electrical system Computer support tools - Install - Communication adapter (55.000) for the proper procedure.

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Electrical system Computer support tools - Install - Communication adapter N4LDI-TA-45SL N4LDI-TA-50SL

NOTE: Do not connect the communication interface to your PC before installing communication interface driver. This may install the driver improperly.

NOTE: When installing the diagnostic tool, be sure to login to the PC with an administrator user account.

NOTE: Close all other applications including virus detection software.

Driver installation 1. Navigate to “C:\PCST\ISM_Engine\ISM_DI_Adapter_ Support” on your PC. 2. Double click “Setup_DST_iV140” to run the install.

3. Click the “Next” button.

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4. Click the “Next” button.

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5. Click the “Install” button.

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6. The install status screen will be displayed.

7. Click the “Finish” button.

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Software update 8. Navigate to “C:\PCST\ISM_Engine\ISM_DI_Adapter_ Support” on your PC. 9. Double click “DSTi_Interface_V230” to run the update.

10. Click the “Next” button.

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11. Follow the on-screen instructions.

NOTE: The ISM communication adapter is not equipped with a mode switch.

NOTE: If your PC is running Windows XP, refer to Electrical system Computer support tools - Configure - USB port (55.000) for additional instructions.

12. Click the “Next” button.

13. Click the “Next” button.

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14. Click the “Next” button.

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15. The install status screen will be displayed.

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16. Click the “Finish” button.

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Electrical system Computer support tools - Configure - User authentication N4LDI-TA-45SL N4LDI-TA-50SL

The Service Tool D software requires a license request using the Electronic Service Tool (EST) Order Form located on the Dealer Portal.

Order Form NOTE: User authentication is required to use the diagnostic tool after the software installation process.

NOTE: Do not change your computer configuration. User authentication may fail or user authentication is required again.

1. Log into the Dealer Portal under “Service” > “Service Tools” > “EST Order Form”.

Installation ID 1. On the Service Tool D click on “Start” > “All Programs” > ”Diagnostic Software“ > ”ServiceToolID” > “UserRegTool”.

2. When this screen appears you will see an alphanumeric code in the “Installation ID” window.

3. The “Installation ID” code must be submitted through the EST Order Form at the time of the license request, to obtain your “Confirmation ID”.

NOTE: Copy and Paste method is recommended for transferring the “Installation ID” code. If that is not available, transfer code electronically via USB memory stick.

4. Submit your EST Order Form and allow up to four days to receive your “Confirmation ID”, which will be returned via E-mail.

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Confirmation ID 1. When you receive your “Confirmation ID” vie E-mail, run the “UserRegTool” again on your “Service Tool D”.

2. Enter your “Confirmation ID” into the “Confirmation ID” window and click the

button to continue.

NOTE: Copy / Paste method is recommended for transferring the “Confirmation ID” code. If that is not available, transfer code electronically via USB memory stick.

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3. This window will be displayed if the authentication is complete. Click the ”OK’ button and exit this tool.

NOTE: The Service Tool D software activation is for one year. Each renewal request will be handled in exactly the same way as the initial license request, using the EST Order Form.

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Electrical system Computer support tools - Configure - USB port N4LDI-TA-45SL N4LDI-TA-50SL

NOTE: Configure the USB port on the PC when connecting to the vehicle for the first time after the diagnostic tool is installed.

1. The Operating System (OS) will detect connection automatically when connecting DST-i to the PC. 2. When using Windows XP, select “No, not at this time” and then click the “Next” button when the following screen is displayed.

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3. Click the “Next” button when the following screen is displayed.

4. The following screen is displayed if the software is installed properly. Click on the “Finish” button to complete the installation.

NOTE: This process may take several minutes depending on your PC specification. If the installation is not the first time and connected to the same USB port, this process may not run.

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Electrical system Computer support tools - Start up - Service Tool D N4LDI-TA-45SL N4LDI-TA-50SL

1. Open the Electronic Service Tool (EST).

2. To launch the Service Tool D diagnostic tool, select the “Additional Tools” button (1).

3. Click the “Start the ISM Indirect Inject (Service Tool D) Engine Controller Diagnostic Tool” button (2).

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4. If this prompt appears, click the check box and refer to Electrical system Computer support tools - Configure - User authentication (55.000) to complete the authentication process.

5. After the authentication process is completed, this window will be displayed at start up of the service tool.

6. Click “Menu” for the following options:

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Start Diagnosis Connect cable to vehicle and start trouble diagnosis.

Finish Diagnosis Finish diagnosis when diagnosis is in progress.

Open Diagnosis History Display working history.

Close Diagnosis History Close the history screen.

Start Training Operate in training mode when not connected to a vehicle.

Finish Training Stop training mode and return to normal mode.

ECU Reprogram

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Reprogram control software in the Engine Control Unit (ECU).

ECU Serial Number Write Write the ECU serial number in the engine ECU. System Setting Select the language to be displayed or set communication interface.

Version Info Display version information of the service tool.

Exit Application Exit the service tool program.

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Electrical system Computer support tools - View - Start diagnosis N4LDI-TA-45SL N4LDI-TA-50SL

New diagnosis 1. When connecting to a vehicle for the first time. Select “Start Diagnosis” > “New Diagnosis” from the menu.

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2. Click on the check box to continue. The Service Tool D acquires the necessary information by communications with the Engine Control Unit (ECU). The “Vehicle Selection” screen will appear when the information has been acquired properly.

Restart diagnosis 1. When reconnecting to a vehicle to continue a previous diagnosis history. Select “Start Diagnosis” > “Restart Diagnosis” from the menu.

NOTE: To restart diagnosis from the continuation of a previous diagnosis history, the vehicle that is restarted must be the same vehicle used for the previous diagnosis. If restarted with a different vehicle, the service tool may not display the proper information.

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2. Diagnosis history will be displayed. Select the diagnosis history whose continuous diagnosis is to be preformed. Click on the button to continue.

Vehicle conditions (DTC, Freeze Frame Data, etc.) will automatically be obtained and “Project” screen will appear when restarting the diagnosis.

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Vehicle selection 3. Communication with the ECU will start and the “Vehicle Selection” screen will appear.

4. With the “Vehicle Selection” screen displayed, select the “Option” information to narrow the vehicle selections. When complete, click on the check box.

5. The initial status of the vehicle will be displayed and the “Project” screen will automatically be displayed.

NOTE: Manual selection operation of the “Option” information on the “Vehicle Selection” screen may be required depending on the vehicle type.

NOTE: Do not use the system for a vehicle which has not responded. Be sure to select the correct vehicle information, otherwise correct diagnosis may not be possible.

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Electrical system Computer support tools - View - Project screen N4LDI-TA-45SL N4LDI-TA-50SL

1. The “Project” screen is displayed after the initial communication with the ECU. 2. Enter the project information or the vehicle information and click on the

button.

NOTE: Diagnosis can be preformed without entering the project information or vehicle information. This is informational only.

NOTE: Project information and vehicle information can be changed at any time.

3. Contents of project information and vehicle information which you have entered can only saved by clicking the button.

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Project info list 4. The “Project Info List” is displayed on the right side of the “Project” screen.

5. The date can be deleted from the “Project” view by right clicking on the data.

NOTE: Data titled ****-TOP and data marked with “*” cannot be deleted. This is the initial data when the diagnosis was started.

6. The memo can be added or changed from the “Project” view by right clicking on the data.

7. Saved data can be displayed in the “File” view. Icon meanings are in the table below.

NOTE: Data saved in Utility will vary depending on the vehicle being diagnosed.

Display DTC and Freeze Frame data.

Display data monitor measuring data.

Display data monitor setting data.

Display measuring data in the “Active Test” mode.

Display execution results of utility and saved data.

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Electrical system Computer support tools - View - DTC screen N4LDI-TA-45SL N4LDI-TA-50SL

Use this function to view Diagnostic Trouble Codes (DTC).

1. The DTC screen is displayed by clicking on the button.

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Operations in the DTC screen Read DTC screen Read DTC successively Display Freeze Frame data Save DTC Clear DTC Print DTC list Diagnosis manual Save data in CSV format Replay history in DTC

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Display freeze frame data 1. Freeze Frame data is displayed by clicking on the button.

2. Freeze Frame data can be printed by clicking on the button.

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Save DTC 1. DTC and Freeze Frame data is displayed by clicking on the

button.

NOTE: A confirmation screen is displayed before you save.

2. Click on the

to save the data.

3. Click on the

to cancel.

NOTE: Data saved in Project can be viewed by “Replay History of DTC”.

Clear DTC 1. When clearing the DTC data, stop the engine and turn the ignition switch to the ON position. A communication error may occur if the clear function is performed while the engine is running.

2. DTC saved in the ECU in the “past” can be cleared by clicking on the

button.

3. To clear the information, click on the

button.

4. To cancel, click on the NOTE: Just before the DTC is cleared, freeze frame data is saved into the project info. The data that is saved in Project can be viewed by “Replay History of DTC”.

NOTE: A memo can be saved with the DTC just before it is cleared.

NOTE: DTC can be deleted if it is in the “past” and the same DTC does not exist in the “present”.

NOTE: DTC in the “present” cannot be cleared.

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Diagnosis manual 1. Diagnosis manual related to the DTC is displayed by clicking on the

.

NOTE: Some vehicles have not been adapted to the function in Diagnosis manual. If vehicle is not adapted, this button will not be displayed.

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Replay history of DTC 1. DTC data and Freeze Frame data can be replayed from the “Replay” list.

2. Select the title from the list.

3. The content of selected title is displayed at the upper part of the screen.

4. Select <Current Data> to cancel replaying.

5. In the replay mode, “Read DTC”, “Clear DTC”, “Save DTC”, and Read DTC successively” functions cannot be used. To return to the original status, select <Current Data>.

6. “DTC-TOP” is the DTC data acquired by initial communication when diagnosis was started.

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Electrical system Computer support tools - View - Data monitoring screen N4LDI-TA-45SL N4LDI-TA-50SL

1. Data

monitor

screen

is

displayed

when

the

button is clicked.

2. Data monitor screen consists of: • List area • Graph area • Working area button to start the data moni-

3. Click on the toring setup.

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Data monitoring setup 1. The setting screen is displayed by clicking the button.

2. Click the been entered.

button after all of the settings have

Signal Setting Trigger Setting Save Settings

Tab options Select signals to be measured and settings for the graph.

Set the trigger conditions. Trigger settings can only be set after setting the signal settings.

Save setting information in project or external view. The content saved in project by “Save Setting” is registered in the list of “Select Signal Group” at the lower part of the data monitor screen.

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Signal setting 1. The list of parameters that can be measured is displayed in the left hand signal list.

2. Select target signal to be measured is displayed in the right hand signal list.

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Button description Select all available signals in the left hand signal list.

Selected signals move to the right hand list.

Maximum of 32 signals can be displayed. Total signals may be lower depending on the available parameters.

Select one signal in the left hand signal list and move it to the right hand list.

Select one signal in the right hand signal list and move it to the left hand list. Removes the signal from the monitoring list.

Moves all signal from the rights hand list into the left hand list. Removes all signals from the monitoring list.

Change the order of the signal list. Move the parameter up or down in the list.

Set the line color and the range of the Y-axis for each signal.

Set the display settings back to the default value.

Set the background color of the graph. Common for all signals.

Set the grid color of the graph. Common for all signals.

Set the cursor color of the graph. Common for all signals.

Set the trigger color of the graph. Common for all signals.

Set the flag color of the graph. Common for all signals.

Set the zero point color of the graph. Common for all signals.

Set the graph color settings back to the default colors.

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Trigger setting 1. Refer to Electrical system Computer support tools View - Trigger detection (55.000) for more details on trigger settings.

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Trigger settings and conditions

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Don’t use trigger Detect trigger all the time Detects change

Measures data without using a trigger.

Measure by using only detecting condition for trigger.

Measure by using starting condition and following detecting condition for trigger.

Use permitting condition Measure by using permitting condition and following detecting condition for trigger.

Detects change Detect change of signals as the trigger for establishing condition.

Setting for Starting / Permitting condition. These settings are required when “Use starting condition” or “Use permitting condition” is selected in “Setting for Trigger Using Condition”.

Select signal to set starting or permitting conditions for monitoring.

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Set reference value by using slide bar or up down buttons.

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Trigger settings and conditions Select condition for reference value to detect starting or permitting conditions.

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Setting for Trigger Detecting Condition. This setting is required when “Detect trigger all the time”, “Use permitting condition” or “Detects changes” is selected in “Setting for Trigger Using Conditions”.

Select signal to set starting or permitting conditions for monitoring.

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Set reference value by using slide bar or up down buttons.

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Select condition for reference value to detect starting or permitting conditions.

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Setting for Trigger point Setting for trigger point. Amount of data saved before the trigger set point in saved data.

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Save settings 1. Select a project where the setting is to be saved.

2. Enter a title.

NOTE: Enter notes (optional) 3. Click the save button and specify a destination folder.

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Display setting screen 1. Set the scale of the y-axis.

2. Set the color of the graph.

3. Set the style of the graph.

4. Set the starting point of the graph on the x-axis.

NOTE: The x-axis can only be set while the data is replaying.

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The maximum and the minimum values for each signal set in software are used for the “Default Settings”.

Set each value by spin button for “Manual setting”.

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Click on the button and select the color from the color setting dialog box.

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Draws a curve line to next data point.

Connects each data point by a straight line.

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Select line thickness.

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Replay measured data 1. Data can be replayed by selecting Data Monitor from the “Replay” list.

2. Select saved title from the list.

3. Selected data is replayed in the data monitor screen.

4. Select “<Current Data>” to cancel replaying.

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5. The following dialog is displayed by clicking or

and a memo can be added to the flag.

Available options while data is being replayed Add flag or delete flag in data. Clicking on the add flag will open a Flag Memo screen. Enter the data and click the save button.

Switch graph display modes.

Move cursor to the first or past data point.

Move cursor to the next flag.

Move the cursor to the right or to the left.

Move graph area to be displayed to the right or to the left.

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Available options while data is being replayed Enlarge or reduce the graph area to be displayed.

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Change the color of the graph or the scale of the Y-axis.

Save the measured data in CSV format.

Print data screen.

Set the time scale. Available only when the data is being replayed.

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Set the number of graphs to be displayed on the screen.

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Available options while data is being replayed Select data monitor setting registered in project in advance. External file can be selected by selecting “File”.

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Replay different data saved in project or cancel replaying.

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Monitoring data 1. Click on the

to start monitoring.

2. Click on the

to stop monitoring.

3. Increase the number of sampling signals for longer sampling time between measurements. To shorten the sampling time, reduce the number of monitored signals.

NOTE: Measured data is saved in 10 minute intervals. The progress of the measurement is displayed in the status bar in the bottom right hand corner. Old data is overwritten by new data when the 10 minute interval is reached.

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Save the data screen 1. The Save Data screen will open after the has been clicked.

2. Enter the title and memo information. Click on the save button to save the information with the data.

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Add flag during data monitoring.

Switch graph viewing modes.

Set the number of data graphs to be displayed in one screen.

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Change the color of the graph and change the scale the Y-axis.

Move the cursor to the first or last data point.

Move the cursor to the next flag.

Move the cursor to the right or to the left.

Move the graph area to be displayed.

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Enlarge or reduce the graph area to be displayed.

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Save the data in CSV format.

Print the data screen.

Scale the time base. Available only when viewing the data and not while in monitoring mode.

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Set the number of graphs to be displayed on the screen.

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Select data monitor setting registered in project in advance. External file can be selected by selecting “File”.

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Replay measured data saved in project.

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Electrical system Computer support tools - View - Trigger detection N4LDI-TA-45SL N4LDI-TA-50SL

Trigger detection is explained by giving an example for each trigger using condition.

Example 1 - Detect trigger all the time The trigger is caused when the engine speed is greater than the reference value of 4000 RPM.

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Example 2 - Use starting condition The trigger is caused when the coolant temperature is less than the reference valve of 80 °C and engine speed is greater than 2000 RPM.

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Example 3 - Use permitting condition The trigger is caused when the coolant temperature is greater than the reference value of 90 °C and engine speed is less than 1000 RPM.

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Electrical system Computer support tools - View - Active test N4LDI-TA-45SL N4LDI-TA-50SL

Active test can be used to test the circuits between the Engine Control Unit (ECU) and certain components such as injectors, Exhaust Gas Recirculation (EGR) valve or the glow plug relay.

1. The “Active Test” screen is displayed when the button is clicked.

2. Select the active test in the list and click the button.

NOTICE: Do not run active tests for longer than 30 s. Machine damage can occur.

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Execution screen 1. The “Active Test Execution” screen is displayed when a test item is selected in the “Active Test Item Selection” screen.

2. Set signal to be monitored to execute data monitor at the same time. Select the setting is finished.

when

3. Active test is available when is clicked.

Data monitor is started if synchronous monitor is selected.

4. Determine the driving specified value by using “Speed” button or the slide bar.

5. “Active Test” is executed when is clicked.

Driving instructions will be sent to the ECU. Check the operation of the vehicle and the operating sound of the actuator being driven.

6. During the “Active Test”, a flag can be added by clicking on the

button.

button is 7. “Active Test” is finished when the clicked. Title and memo information can be saved with the measured data when data monitor is executed at the same time.

8. Click the screen.

button to return to the “Item Select”

9. Work with graph screen of the findings of “Active Test” in the same way as the data monitor screen.

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Replay 1. Select “Active Test” from the “Replay” list in “Item Select” screen to replay data.

2. Select saved title from the list. After the item is selected the ”Execution” screen is displayed and the data is replayed.

3. Click on the

to cancel replaying.

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Electrical system Computer support tools - View - Utility N4LDI-TA-45SL N4LDI-TA-50SL

The utility menu provides various functions including injector compensation, fuel pump learning, and EGR maintenance time reset.

Item select screen 1. “Utility Item Select” screen is displayed when button is clicked.

2. Select utility item in the list then click

button.

3. When utility item to be preformed is selected, “Explanation”, “Executing Condition” and “Caution” will be displayed. Carefully read them and make sure you understand them before performing.

4. Once item to be preformed is decided, click on the Select button.

5. The utility screen will appear, operate according to the instructions shown on the screen.

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Injector compensation NOTE: When compensation data is to be registered to the ECU, verify that engine is OFF. Registration cannot be accomplished while the engine is running.

1. This function is used to set the compensation code for the new injector assembly or the injectors to the Engine Control Unit (ECU).

2. When this item is selected on the utility list screen, the “Injector Compensation” screen will appear.

3. The injector compensation value saved currently in the ECU is displayed as initial display.

4. Enter the cylinder data to be registered.

5. Click the button for corresponding cylinder to register, and execute registration.

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6. When the screen for rewriting appears, click the button.

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7. This screen will be displayed when the rewriting is correctly completed.

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Read compensation data for all cylinders from Engine Control Unit (ECU).

Register compensation data for all cylinders in ECU. Read compensation data from external file and change display. (No registering) Write displayed compensation data in external file.

Scan Compensation Data by using Quick Response (QR) code 1. Compensation data can be scanned directly from QR code printed on injector by connecting QR code scanner with PC Com port.

2. Select COM port and check QR Code Scanner.

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3. Click data area of corresponding cylinder to register.

Following example is clicking data area of cylinder number 1.

4. Scan data by using QR code scanner.

5. Register compensation data by clicking ton.

Procedure Character length Parity check Transmission rate

but-

Communication requirement for QR code scanner [Normal Mode] [8 bit] [No] [38400 bps]

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Communication requirement for QR code scanner [1 bit] Stop bit length Header STX Terminator CR LF [ Disabled ] Transmission of code ID mark [ Disabled ] Transmission of no. of digits [ Disabled ] BCC Enabled Reading MicroQR White code on black background Reading black-and-white inverted QR codes [Edit Mode] Edit/Non-edit mode for split QR Codes Reading PDF417 [ Disabled ] [ Disabled ] Reading MaxiCode Reading Data Matrix [ Disabled ] NOTE: Values in [Brackets] are default values and do not need to be changed.

Replay registered compensation data 1. The history is saved automatically when compensation data is registered. The history of registered compensation data can be replayed from the “Replay” list.

2. Select saved title from the list.

3. Selected history is replaced in the list at the upper part.

4. Select “<Current Data>” to cancel replaying.

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Fuel pump learning 1. The ECU constantly keeps learning to correct dispersion caused by differences in the types of fuel pumps used. After exchanging the ECU or the fuel pump, it is necessary to carry out the fuel pump learning utility.

2. When this item is selected on the utility item selection screen, the following screen is displayed.

3. Follow the instructions according to the steps of “Description” displayed on the screen.

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Data check/rewrite 1. The Data Check/Rewrite function allows the parameters in the ECU to be viewed (read) or updated (write).

2. When the Data Check/Rewrite function is selected on the utility screen, the following screen will be displayed.

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3. The value presently in the ECU will be displayed as the initial display.

4. Select the parameter to be rewritten.

5. Click on the into the ECU.

button to write the parameter

6. Click on the after checking the contents when cautions are displayed.

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7. As the check screen for rewriting will appear, click on button if rewriting is OK.

8. The following screen will be displayed when rewriting is complete.

9. When rewriting is complete, the signal of rewriting execution along with the completion message will change to blue color.

Replay rewritten data 1. The history is saved automatically in project when data is rewritten, so history of rewritten data can be replayed from “Replay” list.

2. Select saved title from the list.

3. Selected history is replayed in the list at the upper part.

4. Select “<Current Data>” to cancel replaying.

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Exhaust Gas Recirculation (EGR) maintenance time 1 reset 1. Use this function to reset EGR maintenance time 1.

2. When this item is selected on the utility item selection screen, the following screen will appear.

3. Follow the instructions according to steps of “Description” displayed on the screen.

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Electrical system Computer support tools - View - Finish diagnosis N4LDI-TA-45SL N4LDI-TA-50SL

1. Select “Finish Diagnosis” from “Menu” button during diagnosis to finish diagnosis in progress.

2. The confirmation screen is displayed when “Finish Diagnosis” is selected. Click on OK button to finish or the Cancel button to continue.

NOTE: Diagnosis with connecting vehicle is finished only, the application is not finished and it goes back to the Initial Screen.

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Electrical system Computer support tools - View - Open diagnosis history N4LDI-TA-45SL N4LDI-TA-50SL

1. Diagnostic history can be displayed by selecting “Open Diagnosis History” from “Menu” button. “Open Diagnosis History” function is not available during diagnosis.

Finish diagnosis to select this function.

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2. Diagnosis history select screen is displayed when the function is selected.

3. History of diagnosis performed in the past can be conformed by opening “Diagnosis History”. This is useful for analyzing.

4. When replaying diagnosis history, diagnosis can be restarted for the history by selecting “Start Diagnosis” > “Restart Diagnosis” from the menu.

Replay diagnosis history in the same screen as the one during trouble diagnosis.

Delete diagnosis history.

Import file exported by Service Tool D of other PC. Save diagnosis history in external file.

Print diagnosis history list.

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Electrical system Computer support tools - Program - Engine Control Unit (ECU) N4LDI-TA-45SL N4LDI-TA-50SL

1. Click the “Menu” button and select “ECU Reprogram” (1).

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2. Click the “Browse” button (1).

3. Browse window opens.

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4. Navigate to the folder (1) where the ECU software is located (C:\PCST\ISM_Engine_Software\...).

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5. The “Validate” button (1) should be active now. Click the “Validate” button.

6. The Reprogram section should be active now. Click the “Write” button (1).

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Screenshot after the “Second Boot Loader” is complete.

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Screenshot during the “Main Program” download.

7. Once the “Main Program” download is complete, follow the instructions in the pop-up window (1).

8. Click the “Close” button to exit the programming.

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Electrical system Computer support tools - View - Start training N4LDI-TA-45SL N4LDI-TA-50SL

Each function of the Service Tool D can be simulated without connecting to a vehicle.

1. Start training mode by selecting “Start Training” from the menu.

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2. When training mode is established, “DEMO” will be displayed in the status bar.

3. When operating in Training Mode, diagnosis function can be simulated without connecting to a vehicle.

4. To finish Training Mode, click on “Menu” then select “Finish Training”.

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Electrical system Computer support tools - Configure - System settings N4LDI-TA-45SL N4LDI-TA-50SL

In the System Setting, the following settings are provided. ”Language Select” for setting the language displayed on the Service Tool D. ”Communication Setting” for setting up the communication interface.

Language setting 1. Click “Language Select”.

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2. Check the radio button of the language to be selected and click on the button. The Service Tool D must be restarted in order to operate in the new selected language.

3. It is recommended to use the same language as the language specified in the Windows operating system.

If a language other than the language specified in the Windows operating system is used, button, window or character strings may not be displayed properly.

Communication setting 1. Communication interface can be set by selecting “System Setting” > “Communication Setting”.

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2. Select the communication interface by using the “Select Interface” pull down.

3. If you click on “Interface Setting” button, configuration application of communication interface to be used will start and “Communications Port”, “Baud Rate”, etc. can be set.

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Electrical system Computer support tools - View - Version information N4LDI-TA-45SL N4LDI-TA-50SL

1. Click the “Version Info” button.

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2. The version number of the tool is displayed.

3. Click “Details” to view the version number of each component.

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Electrical system Computer support tools - View - Exit application N4LDI-TA-45SL N4LDI-TA-50SL

1. Select “Exit Application” from “Menu” button during diagnosis to exit Service Tool D. 2. Click on the button to finish diagnosis and exit the application or click on the “Cancel” button to continue diagnosis.

NOTE: Application is exited instantly if diagnosis is not in progress.

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Electrical system Computer support tools - Remove - Service Tool D N4LDI-TA-45SL N4LDI-TA-50SL

1. Open the “Control Panel” by clicking on “Start” > “Control Panel” or “Start” > “Settings” > “Control Panel”.

2. In the “Control Panel” select “Programs and Features”.

3. From the list of installed applications, select “ ServiceToolID” then click on “Uninstall”.

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4. A message dialog box to confirm the removal of the diagnostic tool is displayed. Click on “Yes” to uninstall the program.

5. When the uninstall process is complete, the following screen will be displayed.

NOTE: In some cases you may need to reboot your PC after finishing the uninstall process. If a dialog box appears to requiring your PC to reboot, proceed with the reboot process.

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Electrical system Computer support tools - Remove Communication adapter N4LDI-TA-45SL N4LDI-TA-50SL

1. Open the “Control Panel” by clicking on “Start” > “Control Panel” or “Start” > “Settings” > “Control Panel”.

2. In the “Control Panel” select “Programs and Features”.

3. From the list of installed applications, select “ DST-i” then click on “Uninstall”.

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4. A message dialog box to confirm the removal of DST-i is displayed. Click on “Yes” to uninstall the program.

5. Click on “Yes” to continue.

NOTE: In some cases you may need to reboot your PC after finishing the uninstall process. If a dialog box appears to requiring your PC to reboot, proceed with the reboot process.

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Electrical system Computer support tools - Configure - License activation N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

License request 1. Log onto the Dealer Portal.

2. Under the “Service” menu, go to “Service Tools” and click “EST Marketplace”.

3. The “EST Marketplace” will then open. Under “EST Products”, select “3rd Party Tools and Passwords”.

4. Select “ISM Indirect Injection (IDI) Software License”.

5. Add this item to your cart and checkout.

6. After your request is processed, you will receive and e-mail containing your “Activation ID”.

NOTE: Processing may take up to 4 days.

Activating the service tool 1. Launch Service Tool I from the “Additional Tools” menu in EST. NOTE: The first time the program is opened, you will need to configure the communication adapter. Refer to Electrical system Computer support tools - Configure - Communication adapter (55.000) for the proper procedure.

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2. If this prompt appears, click “OK”.

NOTE: Check the box (1) if you do not want to see this window again.

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3. Click “Yes” (1) to begin activation.

NOTE: Your computer must have an internet connection to activate the service tool.

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4. Select “Online” (1) and click “Next” (2).

NOTE: The “Manual” license activation process is not supported.

5. Select “Activate” (1) and click “Next” (2).

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6. Enter your “Activation ID” (1) received in the above mentioned e-mail.

NOTE: Copy and Paste method is highly recommended to avoid typographical errors.

7. Click “Activate” (2).

NOTE: The button will become active when all required fields are populated.

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Electrical system - Start up - Service Tool I N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Open the Electronic Service Tool (EST).

2. To launch the Service Tool I diagnostic tool, select the “Additional Tools” button (1).

3. Click “Start the ISM Indirect Inject (Service Tool I) Engine Controller Diagnostic Tool” button (2).

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4. Verify the Engine Control Unit (ECU) information and icons are visible on the screen.

5. If you cannot connect to the ECU, verify that the communication adaptor is properly set. Refer to Electrical system Computer support tools - Configure Communication adapter (55.000) for the proper procedure.

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Electrical system Computer support tools - Configure Communication adapter N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

NOTE: A communication adapter must be selected before you can connect to the Engine Control Unit (ECU).

1. Click the “Utilities” menu and select “Preferences” (1).

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2. Select the “Communications” tab.

3. Select “RP1210 Compliant Device” (1) from the drop down menu.

4. Click “Advanced”.

5. Verify “DG DPA 4/4+/5 USB (150) - DG Dearborn Group” is selected.

6. Click “OK”.

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7. Click “OK”.

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Electrical system Computer support tools - Program - Existing Engine Control Unit (ECU) N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Use this procedure when programming an ECU that already has software installed.

1. Click the “WinFlash” icon (1).

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2. The service tool will begin to reconnect.

3. Click the “Folder” icon (1) and select the desired software to be installed in the ECU. 4. Confirm the software values: (A) Current software information.

(B) Desired software to be installed.

5. Click “Begin Flash” (2) to start programming the ECU.

6. Monitor the status bar (1) at the bottom of the screen.

7. When it reaches 100 %, programming is complete.

8. Key OFF, then key ON. the service tool will reconnect automatically.

9. Click the “Configuration Tool” icon (1).

10. Double click “Engine Serial Number” (2).

11. Enter the engine serial number.

NOTE: The engine serial number is located on the engine identification plate mounted above the fuel injection pump.

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Electrical system Computer support tools - Program - New Engine Control Unit (ECU) N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Use this procedure when programming a blank ECU. 1. Click “Flash” (1).

NOTE: This window will appear automatically when the service tool is connected to a blank ECU.

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2. Select the “Service” menu, “Copy Configuration”, then click “ECM Replacement” (1).

3. Click “No” (1) if this message appears: “No data is available. Load from the ECM now?”

4. Click “OK” (1) if this message appears: “No ECM Replacement data is available to display.”

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5. Click “Load from File” (1).

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6. Select the configuration data file (1).

7. Click “Open” (2).

8. Confirm all of the selections are checked (1).

9. Click “Program ECM” (2).

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Electrical system Computer support tools - Configure - Fuel pump actuator N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Use this procedure if the fuel pump actuator has been replaced.

1. Click the “Configuration Tool” icon (1).

2. Double click “Fuel Pump Actuator Calibration Code” (2).

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3. Enter the calibration code found on the solenoid.

NOTE: The correct code is the bottom alpha-numeric (1) as shown.

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Electrical system Computer support tools - View - Engine status N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Click the “Status Tool” icon (1) to view various engine parameters.

2. Click the “Groups” button (2) to view available preset groups of parameters.

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3. Click “New” to create a custom group.

4. Enter a name for the custom group.

NOTE: The name must be 26 characters or less.

5. Click “OK”.

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6. Scroll through the list of available parameters.

7. To add a parameter to your custom group, highlight the desired parameter and click the “Right arrow” icon (1) or double click the parameter.

8. To remove a parameter from your custom group, highlight the desired parameter and click the “Left arrow” icon (2) or double click the parameter.

9. Use the “Up arrow” and “Down arrow” icons (3) to move the parameter higher or lower within the list.

10. Click “OK” (4) to create the group.

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11. Select your group (1).

12. Click “OK” (2).

13. Observe your custom group of parameters on the status screen.

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Electrical system Computer support tools - View - Diagnostic codes N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

These codes are electrically based faults.

Active diagnostic trouble codes 1. Click the “Active Diagnostic Codes” icon (1).

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2. In this window, you can view the active codes in the Engine Control Unit (ECU) sorted by: • Code number (1).

• Description (2).

• Number of occurrences (3).

Logged diagnostic trouble codes 1. Click the “Logged Diagnostic Codes” icon (1).

2. This window displays diagnostic codes that are no longer active but have been stored in the ECU memory.

3. Click the “Clear” button (2) to clear the highlighted code.

4. Click the “Clear All” button (3) to clear the entire list of logged codes.

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Electrical system Computer support tools - View - Event codes N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

These codes are mechanically based faults.

Active event codes 1. Click the “Active Event Codes” icon (1).

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2. In this window, you can view the active codes in the Engine Control Unit (ECU) sorted by: • Code number (1).

• Description (2).

• Number of occurrences (3).

Logged event codes 1. Click the “Logged Event Codes” icon (1).

2. This window displays event codes that are no longer active but have been stored in the ECU memory.

3. Click the “Clear” button (2) to clear the highlighted code.

4. Click the “Clear All” button (3) to clear the entire list of logged codes.

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Electrical system Computer support tools - View - Product status report N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Click the “Product Status Report” icon (1).

2. Enter the “Report Name” in the field (2).

3. Check the desired items to appear on your report for the “Download List” (3) .

4. Click the “Create Report” button (4)

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5. The production report will appear as shown.

6. Click the “Save As” button (1) to save a copy of the report to your computer.

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Electrical system Computer support tools - View - Data logging N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Use this feature to record and save engine parameters over a set period of time.

1. Select the “Information” menu, then “Data Log”, “Recorder” (1).

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2. Configure the following items: • Log File - Where you want to save the file.

• Sample Rate - How many times you want to record the data per hour or minute.

• Duration - How long you would like it to record data.

• Pre-Trigger - Time that the data is captured prior to starting the recording. Must be between 0 - 30 s.

3. Select the desired engine parameters to be logged by clicking “Add” (1).

NOTE: Custom parameter groups can be selected or created from this window.

4. Click “OK” (2).

5. Click the “Start” button (1) to begin logging data.

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6. View the time remaining (1) in recording session.

NOTE: You can stop recording data at any time by clicking the “Stop Recorder” button (2).

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7. Click the “Graph” button (1).

8. Highlight the parameters (1) you would like to see in graph form and click the “Right arrow” icon (2).

9. Click the “OK” button (3) to create the graph.

10. View the logged data in the graph.

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Electrical system Computer support tools - View - Real time graphing N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Use this feature to view live engine parameters in graph form.

1. Select the “Information” menu, then click “Real Time Graphing” (1).

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2. Click “New”.

3. Highlight the desired engine parameters (1) to view on the graph and click the “Right arrow” icon (2) to add them to the set.

4. Click the “Save As” button (3) to save the graph set for future use.

NOTE: You will need to assign a name to the graph set with this selection.

5. Click the “OK” button (4) if you do not want to save the graph set.

NOTE: The selected parameters will be stored in the “<TEMPORARY SET>” graph set.

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6. Click the “OK” button (1).

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7. Monitor the graph.

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Electrical system Computer support tools - View - Parameter override mode N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Use this feature to override select parameters.

1. Select the “Diagnostics” menu, then click “Diagnostic Tests” (1).

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2. Highlight a parameter (1).

3. Click the “Change” button (2) .

4. Select the required items.

NOTE: Values vary based on the selected parameter.

5. Click the “OK” button (3).

NOTE: Override mode will stop automatically after 10 s.

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Electrical systems - Electrical system

Electrical system Computer support tools - Configure - Diesel Particulate Filter (DPF) soot load reset N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

Use this feature when the Diesel Particulate Filter (DPF) is cleaned or replaced.

1. Select the “Service” menu, then click “DPF Soot Load Reset” (1).

2. Click the “Reset” button (2).

NHPH13ENG0156AA

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1

Index Electrical systems - 55 Electrical system - 000 Electrical system - Start up - Service Tool I (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Electrical system Computer support tools - Configure - Communication adapter (*) . . . . . . . . . . . . . . . . . . . . . . . . 63 Electrical system Computer support tools - Configure - Diesel Particulate Filter (DPF) soot load reset (*) . . . . . . 79 Electrical system Computer support tools - Configure - Fuel pump actuator (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Electrical system Computer support tools - Configure - License activation (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Electrical system Computer support tools - Configure - System settings (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Electrical system Computer support tools - Configure - USB port (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Electrical system Computer support tools - Configure - User authentication (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Electrical system Computer support tools - Install - Communication adapter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electrical system Computer support tools - Install - Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electrical system Computer support tools - Program - Engine Control Unit (ECU) (*) . . . . . . . . . . . . . . . . . . . . . . . 49 Electrical system Computer support tools - Program - Existing Engine Control Unit (ECU) (*) . . . . . . . . . . . . . . . . 65 Electrical system Computer support tools - Program - New Engine Control Unit (ECU) (*) . . . . . . . . . . . . . . . . . . . 66 Electrical system Computer support tools - Remove - Communication adapter (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Electrical system Computer support tools - Remove - Service Tool D (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Electrical system Computer support tools - Start up - Service Tool D (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Electrical system Computer support tools - View - Active test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Electrical system Computer support tools - View - DTC screen (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Electrical system Computer support tools - View - Data logging (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Electrical system Computer support tools - View - Data monitoring screen (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Electrical system Computer support tools - View - Diagnostic codes (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Electrical system Computer support tools - View - Engine status (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Electrical system Computer support tools - View - Event codes (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Electrical system Computer support tools - View - Exit application (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Electrical system Computer support tools - View - Finish diagnosis (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Electrical system Computer support tools - View - Open diagnosis history (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Electrical system Computer support tools - View - Parameter override mode (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Electrical system Computer support tools - View - Product status report (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Electrical system Computer support tools - View - Project screen (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electrical system Computer support tools - View - Real time graphing (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Electrical system Computer support tools - View - Start diagnosis (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Electrical system Computer support tools - View - Start training (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Electrical system Computer support tools - View - Trigger detection (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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Electrical system Computer support tools - View - Utility (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Electrical system Computer support tools - View - Version information (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

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Electrical systems - 55 Engine control system - 015

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Electrical systems - 55 Engine control system - 015

SERVICE Engine timing sensors Test - Speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Inspect - Crankshaft and camshaft revolution sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Engine control system

Engine timing sensors - Test - Speed sensor N4LDI-TA-45SL N4LDI-TA-50SL N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34

Speed sensor is located on the timing cover where it senses engine speed as engine pulse.

1. Use the Service Tool D and see data monitoring.

2. Use a dial indicator to check the sensor air gap.

There should be approximately 0.5 - 1.2 mm (0.0197 0.0472 in). If the gap is not in range, check the timing cover for damage or obstructions.

3. Ensure to set the O-ring to prevent oil leaking.

4. Torque the sensor to 6 - 8 N·m (4 - 6 lb ft).

NHIL13ENG0051AA

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Electrical systems - Engine control system

Engine timing sensors - Inspect - Crankshaft and camshaft revolution sensors N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

NOTE: Crankshaft sensor is also referred to as revolution sensor (main).

NOTE: Camshaft sensor is also referred to as revolution sensor (backup).

1. Check the sensors are installed correctly.

• Make sure the o-rings are seated properly on the sensor.

2. Check the wiring harness to the sensors.

• Check the wiring harness to the crankshaft sensor.

• Check the wiring harness to the camshaft sensor.

• If the wiring harness is damaged, repair or replace as needed.

NHIL13ENG0179AA

Crankshaft sensor electrical wiring/connection specification: Value

Connector pin Pin 1 Pin 2 Pin 3

5.0 V Signal Ground

Camshaft sensor electrical wiring/connection specification: Value

Connector pin Pin 1 Pin 2 Pin 3

5.0 V Signal Ground

Tightening torque: 5.6 - 8.4 N·m (4.1 - 6.2 lb ft).

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Index Electrical systems - 55 Engine control system - 015 Engine timing sensors - Inspect - Crankshaft and camshaft revolution sensors (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine timing sensors - Test - Speed sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Engine starting system - 201

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Electrical systems - 55 Engine starting system - 201

TECHNICAL DATA Engine starter General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine starting system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Engine starter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Electrical test - No load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Starter solenoid - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

DIAGNOSTIC Engine starter Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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Electrical systems - Engine starting system

Engine starter - General specification Manufacturer Model Current Draw - Under Load - No Load No Load RPM No Load Voltage Clutch System Brush Length - New - Wear Limit Brush Spring Tension Commutator Diameter - New - Wear Limit Commutator Insulation Depth Armature Runout - Commutator - Armature Shaft - Ratings time - Weight

Denso Corporation 2288000-5120 500 A @ 7.5 V less than 110 A 4000 RPM 11.5 V Overrunning Pinion Clutch 15 mm (0.6 in) 12 mm (0.5 in) 26 - 35 N (5.8 - 7.9 lb) 35 mm (1.4 in) 34 mm (1.3 in) 0.2 - 0.85 mm (0.008 - 0.033 in) 0.02 - 0.05 mm (0.001 - 0.002 in) 0.02 mm (0.001 in) 30 Sec 4.6 kg

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Engine starting system - Dynamic description Description of operation The starting system consists of a starter motor equipped with an electromagnetic starter solenoid, a start relay, several safety switches, and heavy-duty wiring.

Starter components

SEC55CH4PG28

(1) (2) (3) (4) (5) (6) (7) (8)

Reduction uni cover Armature drive gear Motor/Field coil housing (Yoke) Permanent magnet Field coil Armature Brush spring Brush

1

(9) Plunger (10) Solenoid (11) Return spring (12) Pinion clutch (13) Pinion (14) Idler gear (15) Idler gear roller bearing

Starter motor assembly The starter motor features a high-speed motor that utilizes a gear reduction unit, an overrunning pinion clutch, (12), and permanent magnets, (4), in a field coil, (5), for magnetic field induction. The reduction unit consists of a small drive gear, (2), on the motor armature, (6), which drives an idler gear, (14), in the reduction unit. The idler gear is splined to the gear on the pinion clutch housing, (12). When the starter solenoid, (10), is energized, the solenoid plunger, (9), pushes the pinion gear, (13), out, engaging with the engine flywheel. The starter motor then is turning the flywheel, which rotates the engine. The use of the gear reduction unit allows use of the compact, high-speed motor and provides more torque and power to turn the engine flywheel. The sliding pinion mechanism is enclosed, resulting in a more durable mechanism.

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Starter solenoid The starter solenoid is an electromagnetic type solenoid that is located on the bottom of the starter motor assembly. The solenoid contains two coils, a pull-in coil, (1) and a hold-in coil (2) When the key switch is turned to the "START" position and the safety start relay is closed (safety switches closed), current from the battery will energize the solenoid's two coils. With the coils energized, the solenoid plunger, (3) pushes a spring (4) which will then push the pinion gear out to engage the flywheel. At the same time, a set of contacts (5), on the solenoid become closed, allowing current to flow to the starter motor.

Closing the contacts also supplies current to both ends of the solenoid pull in coil which makes the coil become non-energized. The hold-in coil continues to engage the pinion gear with the flywheel.

SEC55CH4PG29_1

2

Pinion clutch To prevent the engine from driving the starter motor once the engine is running, the pinion gear is equipped with an overrunning clutch. The clutch will disengage the pinion gear from the rest of the starter components once the engine has been started and the key switch is in the "START" position. The clutch consists of an outer gear/shell, (1), a cam with tapered notches, (2), rollers, (3), roller springs, (4), a splined pinion collar/tube that acts as a clutch hub, (5), and the pinion shaft, (6). As the starter motor engages and rotates, the rollers are locked against the pinion collar with the tension provided by the roller springs. While the rollers are locked, the clutch assembly is locked, allowing the pinion gear to rotate the flywheel. When the engine starts, the flywheel moves faster than the starter motor and this causes the rollers to become unlocked. With the rollers unlocked, the clutch assembly is unlocked, allowing the pinion gear and shaft to turn independently of the starter motor.

SEC55CH4P29_2

A-

Engaged, B -

3

Disengaged

(1) Clutch gear (2) Cam (3) Roller (4) Spline tube - inner (pinion collar) (5) Pinion shaft (6) Roller spring The clutch is not serviceable and is replaced as a complete assembly.

Once the engine is started and the key switch is released from the "START" position, the solenoid's pull in coil becomes energized, pulling the solenoid plunger in, which disengages the pinion from the flywheel.

SEC55CH4P29_3

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Electrical systems - Engine starting system

Engine starter - Remove 1. Disconnect the wiring harness connections (3) from the starter motor (1).

2. Remove the bolts (2) which secure the starter assembly (1) to the engine.

SEC55CH4P30_1

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Electrical systems - Engine starting system

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Engine starter - Disassemble

SEC55CH4PG30_2

(1) (2) (3) (4) (5) (6) (7) (8)

Felt washer Armature (with front bearing) Rear armature bearing Motor/Field coil housing Brush spring Brush holder Brush cover Through bolt

1

(9) Solenoid housing (10) Return spring (11) Steel ball (12) Pinion clutch (13) Reduction unit housing (14) Idler gear roller bearing (15) Roller (16) Idler gear

1. Remove the field coil wire (3) the solenoid terminal (4).

2. Remove the long through bolts (2) securing the motor assembly (1) to the gear reduction unit housing.

SEC55CH4P47_2

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Electrical systems - Engine starting system

3. Slide the motor assembly (2) from the gear reduction unit housing (1).

4. Remove the screws (3) which secure the brush cover (4), to the motor/field coil housing (5).

SEC55CH4PG31_2

3

SEC55CH4PG31_3

4

SEC55CH4PG32_1

5

SEC55CH4P32_2

6

NOTE: Before removing the brush holder scribe aligning marks on the brush holder and the motor/field coil housing.

5. Use a suitable pair of pliers to remove the insulated armature commutator brushes (2) from the brush holder (3).

6. Slide the brush holder (3) from the armature commutator (1).

7. Remove the armature (4) from the motor/field coil housing (3). The rear armature bearing (2) is a light press fit and it may be necessary to pull the armature from the housing, gripping on the front bearing (1).

8. Use an impact tool (2) to remove the two screws (1) securing the gear reduction cover (3) to the starter housing.

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Electrical systems - Engine starting system

NOTE: The pinion gear (1) and idler gear with roller bearings (2) will be free to fall out when the gear reduction unit cover (3) is removed from the starter assembly (4). Use care not to lose any of these pieces.

9. Carefully remove the reduction unit cover (3) from the starter assembly (4).

SEC55CH4PG32_3

7

SEC55CH4PG33_1

8

SEC55CH4PG33_2

9

10. Pull the pinion clutch assembly (1) from the reduction unit cover or the starter motor assembly.

11. Remove the steel ball (1) from the center of the pinion clutch.

NOTE: When removing the idler gear and bearing, be careful not to lose the bearing rollers contained in the bearing.

12. Remove the idler gear and bearing (1) and pinion gear from the reduction unit cover, if they were not removed when the reduction unit cover and the starter motor housing was separated.

SEC55CH4PG33_3

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Electrical systems - Engine starting system

13. Remove the return spring (1) from the electromagnetic solenoid.

SEC55CH4PG34_1

11

SEC55CH4PG34_2

12

SEC55CH4PG34_3

13

14. Remove the screws (1) securing the solenoid cover (2) to the starter housing. Pry the cover from the housing.

15. Remove the solenoid plunger and spring assembly (2) from the starter housing (1).

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Engine starter - Inspect

SEC55CH4PG35

(1) Normal wear pattern (2) Small wear pattern

1

(4) Milled condition excessive wear on 2 or 3 teeth.

(5) Milled tooth-metal buildup - Will not permit engagement

(3) Milled gears 1. Inspect the gear splines on the pinion clutch, the pinion, the armature, and the intermediate gear for damaged or missing splines. Replace any damaged parts.

2. Hold the pinion clutch housing and rotate the pinion.

The pinion should rotate smoothly, although not necessarily easily, in one direction only. If the pinion can spin in both directions, the clutch is defective and needs replaced.

3. Inspect the motor housing, brush cover, gear reduction unit, and starter housing for damage such as cracks, fatigue, wear, etc. Replace any damaged parts.

4. Inspect the brush terminals, battery terminals, and motor terminals for corrosion, loose connections or damage. Repair or replace any damaged parts.

5. Clean and inspect the solenoid plunger contact ring (1) and solenoid contacts (2). Dirty contacts or pitting may be cleaned with fine grit sandpaper or a fine abrasive pad.

6. Inspect that all bearings rotate freely when rotated manually by hand and are not damaged or have excessive play. Replace any damaged bearings.

20002308

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Electrical systems - Engine starting system

7. Inspect the armature windings (1) for burnt, broken or loose connections.

8. Inspect the commutator contacts (2) for burnt segments, indicating an open winding.

20002279

3

SEC55CH4PG36_3

4

20002267A

5

9. Use a suitable measuring device to measure the commutator diameter. The minimum commutator diameter is 34.0 mm (1.339 in). If the commutator is worn beyond these specifications, replace the armature.

10. Inspect the mica insulating valleys, (1) between the commutator contacts (2) for uneven wear. Use a suitable measuring device to check the distance (3) between the top of the contact to the bottom of the insulating valley. The distance should be 0.5 - 0.8 mm (0.020 - 0.031 in). If the distance is not within these specifications or there is uneven wear, the insulating valleys may be undercut with a suitable file.

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NOTICE: If not previously removed, the armature bearings will need to be removed for this test.

11. Place the armature (3) in a set of precision V-blocks (4) and use a dial indicator (2) to measure commutator (5) runout and shaft (1) runout. Commutator runout should not be more than 0.2 mm (0.008 in). Shaft runout should not be more than 0.5 mm (0.002 in)

20002266

6

SEC55CH4PG37_3

7

NOTICE: When measuring the brush length, remove the brush from the brush support and measure the middle portion of the brush.

12. Use a suitable measuring device to measure the length of the armature brushes. Compare the measurement of each brush with brush length specifications. If the brush is not within specifications or is damaged in any way, replace the brushes.

13. Test the brush spring tension by connecting a spring balance to the brush spring and pulling until the spring moves. Observe the reading indicated on the spring balance. If the reading is between 26 - 35 N (5.8 7.9 lb), the spring tension is within specifications. Otherwise, replace the brush springs

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SEC55CH4P38_1

8

Standard tension = (A) 26 - 35 N (5.8 - 8 lb) (1) Spring scale (2) Hook

(3) Brush (4) Brush spring

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Electrical systems - Engine starting system

Engine starter - Electrical test Armature 1. Use a growler (1) to inspect the armature coil (2) for short circuits. Replace if the armature is shorted.

SEC55CH4PG38_2

1

20002280

2

SEC55CH4PG39_1

3

2. Use an ohmmeter to test for continuity in the armature coil (2).

3. Touch one ohmmeter test probe to a commutator contact (1). Touch the ohmmeter test probe to an adjacent commutator contact.

4. Observe the ohmmeter. Repeat the test on each adjacent commutator contact. Little or no resistance indicates that there is continuity and the armature coil is good. High resistance indicates that the armature is defective and needs replaced.

5. If the armature is tested OK, touch one ohmmeter test probe to a commutator contact (1). Touch the other test probe to the armature shaft (2).

6. Observe the ohmmeter. A high resistance reading indicates the armature is good. Little or no resistance indicates that the armature is defective and needs to be replaced.

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Brush holder 1. Use an ohmmeter and touch one test probe to the insulated brush holder (1) and the other test probe to the brush holder plate (2).

2. Observe the ohmmeter. Repeat the test for the opposite insulated brush holder.

3. A reading high resistance indicates no continuity and the brush holder is good. Little or no resistance indicates that there is continuity and the brush holder is defective and needs replaced.

SEC55CH4PG39_2

4

SEC55CH4PG39_3

5

SEC55CH4PG40_1

6

Field coil 1. Use an ohmmeter to test the field coil.

2. Touch one ohmmeter test probe to one of the field coil brushes. Touch the other test probe to the remaining field coil brush.

3. Observe the ohmmeter. Little or no resistance indicates continuity and that the field coil is functioning properly.

High resistance indicates the field coil is defective and needs replaced.

NOTICE: Paint on the field coil/motor housing will give a false reading when testing to see if the field coil is grounded. Be sure to remove paint from the field coil/motor housing.

4. If the previous test indicated the field coil was not defective, touch one ohmmeter test probe to one of the field coil brushes (1). Touch the other test probe to the field coil housing (2).

5. Observe the ohmmeter. If the reading shows high resistance, indicating no continuity, the field coil is not grounded and is functioning properly. If there is little or no resistance indicating continuity, the field coil is defective and needs replaced.

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Electrical systems - Engine starting system

Engine starter - Assemble

20002285

(1) (2) (3) (4) (5) (6) (7) (8)

Felt washer Armature (with front bearing) Rear armature bearing Motor/Field coil housing Brush spring Brush holder Brush cover Through bolt

1

(9) Solenoid housing (10) Return spring (11) Steel ball (12) Pinion clutch (13) Reduction unit housing (14) Idler gear roller bearing (15) Roller (16) Idler gear

NOTE: Use white lithium grease to lubricate parts indicated.

1. Install the solenoid plunger (2) to the starter housing (1).

SEC55CH4PG34_3

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2

Electrical systems - Engine starting system

2. Install the solenoid cover and gasket to the starter housing. Install the screws (1) securing the solenoid cover (2) and gasket to the starter housing.

20002306

3

SEC55CH4PA34_1

4

SEC55CH4PA33_2

5

SEC55CH4PA32_3

6

3. Grease and install the return spring (1) to the solenoid.

4. Grease and install the steel ball (1) into the center of the pinion clutch.

5. Grease and install the pinion clutch (4) in the starter housing. Make sure the rear clutch bearing is completely seated in the housing.

6. Grease the idler gear bearing and gear and install the gear (2) and bearing onto the starter housing. Align the bearing and gear so that it meshes with the pinion clutch and is aligned with the hole in the housing for the pin which the bearing rides on.

7. Install the drive gear (1) in the proper recess in the reduction unit cover (3) as the cover is being installed onto starter motor housing.

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Electrical systems - Engine starting system

8. Secure the gear reduction cover (2) with the retaining screws (1).

20002277A

20002287

(1) Front armature bearing (2) Armature (3) Rear armature bearing (4) Motor/Field coil housing

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

8

Brush spring Brush holder Screws Through bolt

9. If removed, install the front and rear bearings (1) and (3) to the armature (2).

10. Install the armature (2) to the motor/field coil housing (4). Be sure that the rear bearing (3) is properly seated in the motor housing.

NOTE: When installing the field coil brushes be sure that the aligning marks made on the brush holder and motor/ field coil housing will line up when the brush holder is installed onto the armature commutator.

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(9) Brush cover (10) Brush

7

Electrical systems - Engine starting system

11. Install the field coil brushes (6) into the brush holder (7) holding the brush springs (5) away as the brush is being inserted into the insulated brush holder.

12. Install the brush holder (7) onto the armature commutator.

13. Secure the brush cover (8) to the brush holder (7) using the retaining screws (9).

NOTE: Be sure the aligning marks made on the starter housing and motor/field coil housing line up when installing the motor assembly to the starter assembly.

14. Install the motor assembly (2) into the starter housing assembly (1).

SEC55CH4P31_2

9

15. Secure the motor assembly (1) to the starter housing assembly using the long through bolts (2).

SEC55CH4PG47_2

10

SEC55CH4PG47_3

11

16. Install the field coil wire (2) the solenoid terminal (1).

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Electrical systems - Engine starting system

Engine starter - Electrical test - No load

SEC55CH4P48_1

(1) Ammeter (2) Switch

1

(3) Voltmeter (4) Battery

NOTE: Before installing the starter motor to the engine, it is recommended that a no load test be performed on the starter motor.

NOTE: Do not operate the starter for more than 30 seconds at a time.

1. Connect a battery and switch to the battery terminal of the starter and the 'S' terminal of the solenoid.

2. Connect an ammeter between the positive (+) battery terminal of the battery and the battery terminal of the starter solenoid.

3. Connect a voltmeter, after the ammeter, between the positive (+) lead from the battery and the negative (-) lead from the battery.

4. Close the switch and record the readings indicated on the ammeter and voltmeter.

5. Test starter components if any abnormal operation is noted.

6. Service limits 4000 RPM.

are

11.5 V,

110 A

maximum

at

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Electrical systems - Engine starting system

Engine starter - Install 1. Install the starter motor (1) to the engine and secure using the retaining bolts (2). Be sure all ground terminals are connected to the bottom starter bolt.

2. Connect the wiring harness connections to the starter (3).

SEC55CH4PA30_1

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1

Electrical systems - Engine starting system

Engine starter Starter solenoid - Electrical test

20002285

(1) (2) (3) (4) (5) (6) (7) (8)

Felt washer Armature (with front bearing) Rear armature bearing Motor/Field coil housing Brush spring Brush holder Brush cover Through bolt

1

(9) Solenoid housing (10) Return spring (11) Steel ball (12) Pinion clutch (13) Reduction unit housing (14) Idler gear roller bearing (15) Roller (16) Idler gear

NOTE: Use white lithium grease to lubricate parts indicated.

1. Install the solenoid plunger (2) to the starter housing (1).

SEC55CH4PG34_3

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2

Electrical systems - Engine starting system

2. Install the solenoid cover and gasket to the starter housing. Install the screws (1) securing the solenoid cover (2) and gasket to the starter housing.

20002306

3

SEC55CH4PA34_1

4

SEC55CH4PA33_2

5

SEC55CH4PA32_3

6

3. Grease and install the return spring (1) to the solenoid.

4. Grease and install the steel ball (1) into the center of the pinion clutch.

5. Grease and install the pinion clutch (4) in the starter housing. Make sure the rear clutch bearing is completely seated in the housing.

6. Grease the idler gear bearing and gear and install the gear (2) and bearing onto the starter housing. Align the bearing and gear so that it meshes with the pinion clutch and is aligned with the hole in the housing for the pin which the bearing rides on.

7. Install the drive gear (1) in the proper recess in the reduction unit cover (3) as the cover is being installed onto starter motor housing.

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Electrical systems - Engine starting system

8. Secure the gear reduction cover (2) with the retaining screws (1).

20002277A

20002287

(1) Front armature bearing (2) Armature (3) Rear armature bearing (4) Motor/Field coil housing

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

8

Brush spring Brush holder Screws Through bolt

9. If removed, install the front and rear bearings (1) and (3) to the armature (2).

10. Install the armature (2) to the motor/field coil housing (4). Be sure that the rear bearing (3) is properly seated in the motor housing.

NOTE: When installing the field coil brushes be sure that the aligning marks made on the brush holder and motor/ field coil housing will line up when the brush holder is installed onto the armature commutator.

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(9) Brush cover (10) Brush

7

Electrical systems - Engine starting system

11. Install the field coil brushes (10) into the brush holder (6) holding the brush springs (5) away as the brush is being inserted into the insulated brush holder.

12. Install the brush holder (6) onto the armature commutator.

13. Secure the brush cover (9) to the brush holder (6) using the retaining screws (7).

NOTE: Be sure the aligning marks made on the starter housing and motor/field coil housing line up when installing the motor assembly to the starter assembly.

14. Install the motor assembly (2) into the starter assembly (1).

SEC55CH4P31_2

9

15. Secure the motor assembly (1) to the starter assembly using the long through bolts (2).

SEC55CH4PG47_2

10

SEC55CH4PG47_3

11

16. Install the field coil wire (2) the solenoid terminal (1).

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Electrical systems - Engine starting system

Engine starter - Troubleshooting Problem Pinion shaft fails to advance

Pinion motor rotates but no rotation transmitted to engine

Motor rotates before pinion meshes with ring gear

Pinion meshes with ring gear but starting motor fails to turn

Motor fails to stop after engine starts and key switch is turned off

Possible Cause Wiring: Open circuit battery, and switch terminal connections.

Wiring: Open circuit, fuse.

Key switch: No contact.

Starter motor: Sleeve bearing burnt out.

Starter motor: Lever broken.

Solenoid: Plunger movement defective or coil open or shorted.

Starting motor: Clutch defective.

Correction Repair or replace.

Replace fuse.

Repair or replace.

Repair or replace.

Replace.

Repair or replace.

Replace.

Starting motor: Orbital gear or planetary Replace. gears damaged.

Replace.

Starter motor: Shift lever damaged.

Starter motor: :Shift lever damaged Starter motor: Slip ring defective.

Starter motor: Pinion teeth worn.

Starter motor: Pinion push out position defective.

Engine: Ring gear worn.

Solenoid defective Wiring: Line connecting solenoid to battery broken or defective ground.

Replace.

Replace.

Replace.

Adjust.

Wiring: Lead wire connecting solenoid to motor tightened improperly.

Starting motor: Ball bearing locked.

Starting motor: Brush worn.

Starting motor: Improper installation.

Starting motor: Brush spring defective.

Starting motor: Commutator dirty.

Starting motor: Armature of field coil defective.

Starting motor: Field coil-to-brush connection defective.

Solenoid: Contact not touching properly.

Solenoid: Contact contacting surface roughened.

Battery: In discharge state.

Key switch: defective.

Repair or replace.

Replace.

Replace.

Repair or replace.

Replace.

Replace.

Reinstall.

Replace.

Clean.

Repair or replace.

Replace.

Replace.

Replace.

Recharge or replace.

Replace.

Replace.

Defective solenoid.

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Index Electrical systems - 55 Engine starting system - 201 Engine starter - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Engine starter - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine starter - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine starter - Electrical test - No load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Engine starter - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine starter - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine starter - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Engine starter Starter solenoid - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Engine starting system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Alternator - 301

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Electrical systems - 55 Alternator - 301

TECHNICAL DATA Alternator General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Alternator Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Alternator Preliminary test - Alternator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Electrical test - Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Electrical test - Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Electrical test - Bench check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Electrical systems - Alternator

Alternator - General specification Manufacturer Model Polarity Rotational direction (viewed from pulley side) Drive belt tension Adjusting voltage Load characteristics - Terminal voltage - Current Brush length - Wear limit (min. length) - Original Brush contact rings - Wear limit (min. diameter) - Original diameter Bearing - Front - Rear Stator coil resistance Rotor coil resistance

Mitsubishi A007T03877 Negative ground Clockwise 10 - 15 mm (0.39 - 0.59 in) deflection @ 9 - 11 kg (20 - 25 lb) of force 14.5 - 15.0 V 13.5 V 30 A minimum at 2500 RPM 5 mm (0.20 in) 18.5 mm (0.728 in) 22.1 mm (0.871 in) 22.7 mm (0.894 in) ECSC8 6303DDG less than 1.0 Ω 2.8 Ω

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Electrical systems - Alternator

Alternator - Static description

T1530CHARGCIR2

1

Alternator Description of operation The 40 A output alternator is equipped with an integrated circuit (IC) regulator, meaning voltage is regulated internally and electronically within the alternator.

The principle components of the alternator are the stator (5) the rotor (2) the rectifier assembly (7) and the IC regulator (1).

The rectifier assembly (7) consist of two heat sinks, one positive (+) and one negative (-) and a diode trio.

The diode trio is used as a field supply diode and is connected to terminal 'L' on the alternator.

The IC regulator (1) is a solid state unit and can only be serviced as an assembly.

The internal components of the alternator are housed in a two-piece frame, which is divided into a drive end (front) frame (4) and a rear frame (6). The frame contains open slots to allow for cooling of the alternator.

The alternator is rotated in the frame by using a belt-driven pulley (3) which is powered off of the engine crankshaft pulley by a belt.

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Electrical systems - Alternator

T1530CHARGCIRA

2

Charging circuit The charging circuit and internal connections are shown. The charging system consists of an IC voltage regulator (6) (enclosed with dotted lines), a battery (5) and connecting wires. Because of the use of IC, the voltage regulator is very compact and is built into the alternator.

The IC voltage regulator (6) limits the field current to flow directly from the diode trio (2) to the field coil (7) without passing through the external circuit. Consequently, there are no voltage drops caused by the key switch or the external wiring as with conventional vibrating-contact regulators mounted separately from the alternator. To aid in initial voltage buildup when the engine is started the field current is supplied through the indicator lamp (3) from the battery (5).

Since the frequency pulse output of 1/10 the alternator speed develops on the 'P' terminal, this terminal is used for speed detection.

Principle of IC regulator The basic function of the IC voltage regulator is to make the terminal voltage constant by detecting the generated voltage and increasing/decreasing the field current.

As indicated, the regulator consists of two basic sections: a voltage control device and an output device to handle the field current. The voltage control device includes the voltage divider network, R1 and R2, a zener diode, DZ, for voltage reference, and a single amplifying transistor, Tr1. The output device is a darlington-type amplifier which is called power transistor, Tr2. The power transistor, Tr2, is placed in series with the alternator field coil and ground.

The signal amplifying transistor, Tr1, senses the generated voltage and turns the power transistor, Tr2, on and off many times per second most of the time the engine is in operation.

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Electrical systems - Alternator

The basic operating principles are explained as follows, see Figure 2: 1. When the key switch (4) is closed current from the battery (5) flows through the indicator lamp (3) and resistor R6, which are in parallel to the field coil (7). From here it continues to flow on through the field coil (7), to the ground completing the circuit back to the battery (5).

2. When the alternator begins to rotate, AC voltages are generated by the stator coil (1). The diodes in the rectifier assembly change the stator AC voltages to DC voltage which appears between ground and the 'B' terminal.

3. The stator also supplies DC field current through the diode trio (2), the field coil (7), the power transistor, Tr2, and then through the diodes in the rectifier assembly back to the stator.

4. When the generated voltage is low, no current flows in the zener diode, DZ, since the voltage at point 'A' is lower than the zener voltage.

5. As the speed and voltage increase, the voltage at point 'A' also increases until it reaches the limiting value set at the factory. As the zener diode, DZ, breaks down, current flows through R1, DZ, and the base-emitter circuit of Tr1 to ground. This renders Tr1 conductive, so that much of the current flows through the collector emitter circuit of Tr1. This reduces the base current of Tr2 thereby reducing the field current. This means that Tr1 turns on and Tr2 turns off.

6. When the generated voltage decreases, the zener diode, DZ, again turns off and Tr1 also turns off. This cycle repeats many times per second, and the alternator output voltage is, therefore, regulated within a narrow limit.

In other words, the action is similar to the conventional vibrating-contact regulator, in that current to the field coil (7) is varied to limit the output voltage, but in place of the voltage coil and spring system there is a voltage divider network, R1and R2, and a zener diode, DZ

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Electrical systems - Alternator

Alternator - Preliminary test - Alternator Output NOTICE: Start-up current can exceed ammeter capacity. Do not attempt to start the engine without first shorting the wires between the ammeter leads. Failure to comply could damage testing components.

NOTE: Use the following methods if an alternator/charging system analyzer is unavailable.

1. Connect a 50 A capacity test ammeter between the positive (+) battery cable and the key switch.

2. Connect a voltmeter to the battery terminal (1) of the alternator and to a ground source.

20098354

(A) (B) (C) (D) (E) 3. Observe the voltmeter. The meter should indicate battery voltage. If the voltmeter does not read battery voltage, the wiring between the alternator and the battery may be faulty and should be repaired or replaced.

4. Use a jumper wire to short the test ammeter leads and start the engine.

5. After the engine is started, remove the jumper wire between the test leads of the ammeter.

6. Increase the engine speed to approximately 2000 RPM and observe the ammeter reading.

7. If the ammeter indicates 5 A or less, observe the voltmeter reading. The voltmeter is indicating adjusting voltage, which is the amount of increased voltage the alternator supplies to the battery. The reading should indicate a higher voltage than what is indicated when voltage is taken at the battery. If the reading is not higher, the alternator is not generating enough voltage and a component may be malfunctioning.

8. If the ammeter indicated more than 5 A, continue to charge the battery until the ammeter reading falls below 5 A. If the reading does not fall below 5 A, test the battery or replace the battery with one that is fully charged.

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Alternator Voltmeter Key switch Ammeter Battery

1

Electrical systems - Alternator

SECT55C04PG10B

2

NOTE: Bench testing the alternator will achieve the best results for the following tests (see alternator bench testing).

9. If the previous test was satisfactory, open the key switch (OFF) and connect an ammeter between the battery terminal (B) of the alternator and the battery wire, as shown.

10. Connect the positive (+) lead of a voltmeter to the (B) terminal on the alternator. Connect the negative (-) lead to a suitable ground. Confirm that the voltmeter indicated battery voltage.

11. Apply the parking brake and start the engine. Turn on all 12 V powered accessories such as headlight and indicator lights. Immediately raise engine speed to 2000 RPM or more to record the maximum value indicated on the ammeter.

12. If the amperage value is more than 70 % of the nominal alternator output, as described in alternator specifications, the alternator is considered to be working satisfactorily.

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Electrical systems - Alternator

Alternator - Remove 1. Disconnect the negative (-) battery cable from the negative battery terminal.

2. Disconnect all wiring (2) from the rear of the alternator.

3. Loosen the alternator mounting bolts (1) and remove the V-belt (3) from the alternator drive pulley.

4. Remove the alternator mounting bolts (1) and remove the alternator from the engine.

SECT55C04PG9_2D

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1

Electrical systems - Alternator

Alternator - Disassemble NOTICE: Heat from a soldering gun can damage diodes. To avoid damage to diodes, use a pair of needle-nose pliers to remove excess heat from the area being soldered. Hold the pliers just below the solder joint to remove excess heat. Use a damp cloth to cool the components once they have been joined or separated. Failure to comply could damage diode.

SECT55C04P11_2

1.

2.

3.

4.

5.

6.

7.

8.

Alternator assembly Pulley nut Pulley assembly Bolt Front alternator frame assembly Bolt Front rotor bearing Rotor assembly

1

9. Rear rotor assembly 10. Stator 11. Rear alternator frame assembly 12. Terminal assembly 13. IC Regulator assembly 14. Rotor brush and spring 15. Rectifier

1. Mark the front alternator frame (5) the rear alternator frame (11) and the stator (10) with scribe marks to insure that the alternator is assembled as taken apart.

2. Remove the alternator frame retaining bolts (4).

3. Carefully separate the front frame (2) and the rear frame and stator (1). The rotor assembly (5) and the pulley (3) , will be removed with the front frame (2).

SECT55C04PG12_1

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2

Electrical systems - Alternator

4. To remove the pulley nut (1) use an impact wrench or place the rotor (3) into a soft jaw vice and use a wrench.

Remove the washer (6), the pulley (5), spacer (4) and the front frame (2) from the rotor (3).

SECT55C04PG12_2

3

SECT55C04PG12_3

4

SEC55CH4PG13_1

5

SECT55C04PG13_2

6

NOTICE: When removing the rear rotor bearing from the rotor, be sure to apply even pressure to the rear rotor bearing.

5. The rear rotor bearing (3) may be removed from the rotor (1) by using a bearing puller (2).

6. Remove the screws (1) which secure the regulator/rectifier assembly (2) to the rear alternator frame.

7. Remove the battery terminal nut (1) from the rear of the alternator frame.

8. Carefully remove the stator and the regulator/rectifier assembly from the rear alternator frame.

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Electrical systems - Alternator

NOTICE: Heat from a soldering gun can damage diodes.

To avoid damage to diodes, use a pair of needle-nose pliers to remove excess heat from the area being soldered. Hold the pliers just below the solder joint to remove excess heat.

Use a damp cloth to cool the components once they have been joined or separated. Failure to comply could damage diode.

9. Unsolder the stator leads (2) and remove the stator (1) from the rectifier/regulator assembly (3).

SEC55CH4PG13_3

7

SEC55CH4PG14_1

8

SECT55C04PG14_2

9

10. Unsolder the IC regulator assembly (1) from the rectifier assembly (2) at the solder joints (3).

11. Remove the screws (4) from the front alternator frame (1). Remove the retaining plate (3) and the front rotor bearing (2).

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Electrical systems - Alternator

Alternator - Electrical test - Stator 1. Use an ohmmeter and touch the ohmmeter test probes to different leads of the stator coil.

2. Observe the ohmmeter. The ohmmeter should read a resistance of less than 1 Ω for each of the phase wires, indicating continuity.

3. If there is no continuity, inspect the lead wire connection for breaks. The lead wire may be repaired with solder if damage is not excessive. If the lead wire is good, the stator coil is faulty and needs replaced.

SEC55CH4PG15_1

1

SEC55CH4PG15_2

2

4. Use an ohmmeter and touch one of the ohmmeter test probes to the stator coil and the other test probe to the stator core.

5. Observe the ohmmeter. Resistance should be high, indicating no continuity between the coil and the core.

If there is continuity, the stator is defective and needs replaced.

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Electrical systems - Alternator

Alternator - Electrical test - Rotor 1. Inspect the rotor brush contacts (1) for pitting, roughness and dirt. If necessary use # 600 grit fine sandpaper to clean dirt off of the contacts. If the contacts are pitted or damaged excessively, replace the rotor.

SEC55CH4PG16_1

1

SEC55CH4PG16_2

2

SEC55CH4PG16_3

3

2. Use a suitable measuring device to determine the outer diameter of each brush contact. The minimum outer diameter of the brush contacts is 22.1 mm (0.871 in).

3. Use an ohmmeter and touch one ohmmeter test probe to a brush contact. Touch the other test probe to the remaining brush contact.

4. Observe the ohmmeter. The ohmmeter resistance reading should be approximately 3 Ω. If the reading is not as specified, the rotor is defective and needs replaced.

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NOTICE: When testing the resistance between the brush contacts and rotor poles, be sure that the ohmmeter test probe touching the rotor pole is not insulated by paint.

5. Use an ohmmeter and touch one ohmmeter test probe to one of the rotor brush contacts (1) and the other test probe to one of the rotor poles (2).

6. Observe the ohmmeter. Resistance should be high, indicating no continuity between the rotor poles and brush contacts. If there is continuity, the rotor is defective and needs replaced.

SEC55CH4PG17_1

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Electrical systems - Alternator

Alternator - Inspect Alternator brushes

SEC55CH4PG18_2

1

(1) New brush, (2) Used brush, and (3) Wear limit.

1. Carefully clean the alternator brushes with a soft, dry cloth and electrical component cleaner, if available.

2. Inspect the brushes and brush springs for corrosion, damage, stretched springs, or a damaged brush holder.

If damaged, replace the brush assembly.

3. Use a suitable measuring device to measure brush wear. The minimum brush length is 5 mm (0.020 in).

If either brush is worn beyond specifications, replace the brush assemblies.

Alternator bearings 4. Inspect the alternator bearings for smooth operation by spinning the bearing. Replace bearings that are rough and do not rotate smoothly.

5. Inspect the bearings for grease leakage between the bearing seal (3) and races (1) and (2).

6. Inspect the inner race (2) and the outer race (1) for signs of spinning in the alternator frame or on the rotor shaft.

7. Replace bearings that are damaged in any way.

SEC55CH4P18_3

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2

Electrical systems - Alternator

Drive pulley 8. Inspect the drive pulley for a worn, bent, cracked, or otherwise damaged belt groove (1).

9. A polished surface in the bottom of the belt groove indicates a worn pulley.

SEC55CH4PG19_1

3

SEC55CH4PG19_2

4

Alternator frames 10. Inspect the bearing housing bores (2) for scoring, cracks or evidence that the bearing was spinning inside the bore.

11. Inspect the frames for cracked or broken mounting bosses (1) or any other distortion or damage.

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Electrical systems - Alternator

Alternator - Assemble NOTICE: When installing the rear rotor bearing, be sure that top sleeve used to press the bearing onto the rotor contacts the inner race of the bearing only.

1. Install the rear rotor bearing (3) and spacer onto the rotor by using a press (1) and sleeves, such as tubing or 15 mm (0.6 in) deep sockets (2). The bottom sleeve will support the rotor as the top sleeve presses the rear bearing spacer onto the rotor.

SEC55CH4PG19_3

1

SEC55CH4PG20_1

2

SEC55CH4PG20_2

3

2. Install the front rotor bearing (3) and front bearing retaining plate (2) into the front alternator frame (4) and secure using the four retaining screws (1).

3. Install the washer (2), pulley (6), spacer (5) and front frame (4) onto the rotor (3).

4. To install the pulley nut (1) use an impact wrench or place the rotor (3) into a soft jaw vice and use a wrench to tighten the pulley assembly to the rotor.

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Electrical systems - Alternator

5. Use the following guidelines when soldering alternator components.

• Clean all terminals to be soldered and remove excess solder.

• Preheat the soldering iron and use rosin-core solder to solder terminals and/or wires. To avoid damage to the rectifier diodes, use a pair of needle nose pliers to remove excess heat from the area being soldered.

Hold the pliers just below the solder joint on the rectifier to remove excess heat.

• Make good, solid, solder joints for best alternator performance.

• After soldering, quickly cool the solder joint with a damp cloth.

SEC55CH4PG21_1

4

SEC55CH4PG21_2

5

SEC55CH4PG21_3

6

6. Solder the IC regulator (1) and rectifier (2) together.

7. Solder the stator leads (1) to the terminals on the rectifier/regulator assembly (2).

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Electrical systems - Alternator

NOTICE: Secure the regulator/rectifier assembly to the rear alternator frame before pressing the stator into the rear frame.

8. Secure the regulator/rectifier assembly (2) the rear alternator frame using the retaining screws (1). Manually press the stator assembly into the rear alternator frame.

SEC55CH4P13_1

7

SECT55C04P13_2

8

SEC55CH4PG22_3

9

9. Install the battery terminal nut (1) to the rear of the alternator frame.

10. Push the brushes (1) and springs (2) to the brush holder and insert a piece of wire (3) through the rear of the alternator frame and into the brush holder to hold the brushes out of the way while the alternator halves are being assembled.

11. Assemble the front alternator frame (2) and rear alternator frame (1) together. Be sure to align the scribe marks made when the alternator was disassembled to insure proper reassembly. Use the bolts (3) to secure the front and rear frames together.

SECT55C04P12_1

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Electrical systems - Alternator

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Electrical systems - Alternator

Alternator - Electrical test - Bench check

SEC55CH4PG23_2

(1) Voltmeter (2) Ammeter (3) Switch

1

(4) Load resistor (5) Battery (6) Alternator

1. Connect the alternator to a testing circuit, as shown.

Set the load resistance to zero NOTICE: Alternator rotation direction is clockwise, as viewed looking at the pulley.

2. Slowly increase the alternator rotational speed and observe the voltage reading indicated on the voltmeter.

3. If the voltage is uncontrolled when increasing alternator speed and increases above 15.5 V, disassemble and check the alternator for malfunctioning components.

4. If the voltage reading is below 15.5 V, set alternator's rotational speed to 5000 RPM and set the load resistance to achieve maximum output from the alternator.

5. If the amperage value is more than 70 % of the nominal alternator output as described in alternator specifications, the alternator is considered to be working satisfactorily.

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Electrical systems - Alternator

Alternator - Install 1. Align the alternator with the alternator mounting holes located on the engine block and brackets. Use the adjusting/mounting bolts (1) to secure the alternator to the mounting brackets. Be sure to install the v-belt (3) into the drive pulley.

2. Connect all wire terminals (2) rear of the alternator.

SECT55C04P9_2

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1

Index Electrical systems - 55 Alternator - 301 Alternator - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Alternator - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Alternator - Electrical test - Bench check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Alternator - Electrical test - Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Alternator - Electrical test - Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Alternator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Alternator - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Alternator - Preliminary test - Alternator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Alternator - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Cold start aid - 202

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Electrical systems - 55 Cold start aid - 202

FUNCTIONAL DATA Cold start aid Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Glow plug system Cold start aid - Remove - Glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cold start aid - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cold start aid - Install - Glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(*) See content for specific models 47632293 16/09/2014

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Electrical systems - Cold start aid

Cold start aid - Overview

NHIL12ENG0173AA

1

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

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Electrical systems - Cold start aid

Cold start aid - Remove - Glow plug 1. Disconnect the negative battery cable from the battery.

2. Loosen the screw terminals on each glow plug (2).

3. Remove the power supply (3) from the terminal.

4. Remove the glow plug connector bar (1).

NHIL12ENG0222AA

1

NHIL12ENG0220AA

2

5. Remove glow plugs (1).

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Electrical systems - Cold start aid

Cold start aid - Test N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34

1. Clean the carbon from the sheath end of the glow plug.

NOTE: Do not test resistance using the glow plug sheath.

2. Use an ohmmeter and touch one test probe to the glow plug electrode.

3. Touch the other test probe to the glow plug body.

4. A resistance reading of 1 Ω is normal for the standard glow plug. If the resistance is too high, the glow plug is defective and needs replaced.

NHIL13ENG0027AA

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Electrical systems - Cold start aid

Cold start aid - Install - Glow plug 1. Install the glow plugs (1) and torque to 15 - 20 N·m (11 - 14.5 lb ft).

NHIL12ENG0221AA

1

NHIL12ENG0222AA

2

2. Attach the glow plug connector bar (1) to the screw terminals on the glow plugs.

3. Attach the power supply (3) to the screw terminal.

4. Tighten the screw terminals (2) on the glow plugs until the connector is tight on all glow plugs.

5. Connect the negative battery cable to the battery.

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Index Electrical systems - 55 Cold start aid - 202 Cold start aid - Install - Glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cold start aid - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cold start aid - Remove - Glow plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cold start aid - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

(*) See content for specific models 47632293 16/09/2014

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Electrical systems - 55 Fuel injection system - 010

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Electrical systems - 55 Fuel injection system - 010

SERVICE Fuel injection system Electrical test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Fuel shutoff solenoid Inspect – Linear solenoid and rack position sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Inspect – Linear solenoid and rack position sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(*) See content for specific models 47632293 16/09/2014

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Electrical systems - Fuel injection system

Fuel injection system - Electrical test N4LDI-TA-45SL N4LDI-TA-50SL

1. Check the Suction Control Valve (SCV).

• Use the Service Tool D to check the following parameters. See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000) for how to set up data monitoring.

• Target Rail Pressure • Actual Rail Pressure • Target SCV Current • Pump Learning Condition • Pump Difference Learning Correction Value 2. Start the engine, and allow it to warm up.

3. Change the accelerator, and monitor the graph.

• Target SCV Current • Actual SCV Current • (A) Accelerator ON. • (B) Accelerator OFF.

NHIL13ENG0088AA

Value

Engine Condition Engine idling at 1,000 RPM. Accelerator to 100 %.

1700 - 1900 mA 1100 - 2500 mA

The "Pump Difference Learning Correction Value" is +/450 mA or less.

When monitoring the graph the "Target Rail Pressure" and "Actual Rail Pressure" will drop 100 bar (1450.0 psi) or less within 20 s if: • The accelerator is depressed and the position abruptly goes from 0 - 100 %.

• The accelerator position abruptly returns to 0 % while driving. (Clutch is engaged to create a state of non injection.)

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Electrical systems - Fuel injection system

Fuel shutoff solenoid - Inspect – Linear solenoid and rack position sensor N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

The linear solenoid is a device controlled by the Engine Control Unit (ECU), a variety of plunger positions may determine the engine speed. The plunger position also assists with engine start up or shut down.

1. Remove the linear solenoid.

• Check the body of the solenoid for damage.

• Check for damage to the wiring harness and connector.

If there is visible damage, repair or replace as needed.

NHIL13ENG0195AA

2. Disconnect the linear solenoid connection (1).

3. Test the solenoid from pin 1 to pin 2.

Temperature (Degrees) 20 °C (68 °F)

Resistance (ohms) 3.7 - 4.1 Ω

If the resistance is incorrect, replace the solenoid. See Electrical system Computer support tools - Overview — Engine configuration parameters (55.000) to calibrate the new component.

4. Test the position sensor.

• Leave the position sensor (2) connected to the wiring harness.

• Place the key switch ON. • Press the plunger into the solenoid body.

• Monitor the voltage output on the diagnostic screen.

• The range should be between 1.0 - 4.0 V. If the range is incorrect, replace the sensor. See Electrical system Computer support tools - Overview — Engine configuration parameters (55.000) to calibrate the new component.

Fuel solenoid electrical wiring/connection specification: Value Ground 12.0 V

Connector pin Pin 1 Pin 2 Rack position sensor electrical wiring/connection specification:

Value 5.0 V reference Ground Signal output 1.0 - 4.0 V

Connector pin Pin 1 (B) Pin 2 (A) Pin 3 (C) 47632293 16/09/2014

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Electrical systems - Fuel injection system

Tightening torque: 14.7 - 24.5 N·m (10.8 - 18.1 lb ft).

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Electrical systems - Fuel injection system

Fuel shutoff solenoid - Inspect – Linear solenoid and rack position sensor N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

The linear solenoid is a device controlled by the Engine Control Unit (ECU), a variety of plunger positions may determine the engine speed. The plunger position also assists with engine start up or shut down.

1. Remove the linear solenoid.

• Check the body of the solenoid for damage.

• Check for damage to the wiring harness and connector.

If there is visible damage, repair or replace as needed.

NHIL13ENG0195AA

2. Disconnect the linear solenoid connection (1).

3. Test the solenoid from pin 1 to pin 2.

Temperature (Degrees) 20 °C (68 °F)

Resistance (ohms) 3.7 - 4.1 Ω

If the resistance is incorrect, replace the solenoid. See Electrical system Computer support tools - Configure - Fuel pump actuator (55.000) to calibrate the new component.

4. Test the position sensor.

• Leave the position sensor (2) connected to the wiring harness.

• Place the key switch ON. • Press the plunger into the solenoid body.

• Monitor the voltage output on the diagnostic screen.

• The range should be between 1.0 - 4.0 V. If the range is incorrect, replace the sensor. See Electrical system Computer support tools - Configure - Fuel pump actuator (55.000) to calibrate the new component.

Fuel solenoid electrical wiring/connection specification: Value Ground 12.0 V

Connector pin Pin 1 Pin 2 Rack position sensor electrical wiring/connection specification:

Value 5.0 V reference Ground Signal output 1.0 - 4.0 V

Connector pin Pin 1 (B) Pin 2 (A) Pin 3 (C)

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Electrical systems - Fuel injection system

Tightening torque: 14.7 - 24.5 N·m (10.8 - 18.1 lb ft).

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Index Electrical systems - 55 Fuel injection system - 010 Fuel injection system - Electrical test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel shutoff solenoid - Inspect – Linear solenoid and rack position sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel shutoff solenoid - Inspect – Linear solenoid and rack position sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(*) See content for specific models 47632293 16/09/2014

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Electrical systems - 55 Engine intake and exhaust system - 014

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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

FUNCTIONAL DATA Throttle Valve Actuator (TVA) Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Boost pressure sensor Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Throttle Valve Actuator (TVA) Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electrical test - Intake throttle system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Inlet air temperature sensor Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

(*) See content for specific models 47632293 16/09/2014

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CONSUMABLES INDEX Consumable Loctite® ODC-Free Cleaner and Degreaser

Reference Throttle Valve Actuator

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Electrical systems - Engine intake and exhaust system

Throttle Valve Actuator (TVA) - Dynamic description N4LDI-TA-45SL N4LDI-TA-50SL

The throttle valve assembly controls the throttle opening position according to engine condition, water temperature and barometric pressure, which supplies the set amount of air in the combustion chamber. It is used to reduce and control the emission gases and may rise the exhaust gas temperature at low idle speeds to activate the Diesel Oxidation Catalyst (DOC) function.

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Electrical systems - Engine intake and exhaust system

Boost pressure sensor - Inspect N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

The boost pressure sensor measures the induction of pressure in the intake system.

1. Check the wiring harness to the boost pressure sensor.

• If the wiring harness is damaged, repair or replace as needed.

NHIL13ENG0165AA

Boost pressure sensor electrical wiring/connection specification: Value

Connector pin Pin 1 Pin 2 Pin 3

5.0 V Ground Signal

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Electrical systems - Engine intake and exhaust system

Throttle Valve Actuator (TVA) - Remove N4LDI-TA-45SL N4LDI-TA-50SL

1. Disconnect the electrical connection from the Throttle Valve Assembly (TVA).

2. Remove the four retaining bolts (1).

3. Remove the TVA (2) and gasket (3) from the intake manifold.

NOTICE: The throttle valve is very delicate. Do not drop, shock, damage or get wet.

NOTICE: Do not dismantle the throttle valve and stop screw.

NHIL13ENG0052AA

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Electrical systems - Engine intake and exhaust system

Throttle Valve Actuator (TVA) - Inspect N4LDI-TA-45SL N4LDI-TA-50SL

Prior operation: Throttle Valve Actuator (TVA) - Remove (55.014) 1. Visually check the intake valve.

• Check for debris build up.

• Check the valve (flap) is not seized.

• See Throttle Valve Actuator (TVA) - Cleaning (55.014). If the valve is seized and can not be cleaned, replace the intake throttle valve.

NHIL12ENG0144AA

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Electrical systems - Engine intake and exhaust system

Throttle Valve Actuator (TVA) - Cleaning N4LDI-TA-45SL N4LDI-TA-50SL

NOTE: When cleaning the intake valve do not spray the valve directly with any kind of a chemical cleaner.

1. Spray LOCTITE® ODC-FREE CLEANER AND DEGREASER or equivalent onto a cloth.

2. Wipe the intake valve clean.

3. If the intake valve can not be cleaned, or the valve (flap) is seized, replace the intake throttle valve.

NHIL12ENG0144AA

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Electrical systems - Engine intake and exhaust system

Throttle Valve Actuator (TVA) - Install N4LDI-TA-45SL N4LDI-TA-50SL

NOTICE: The throttle valve is very delicate. Do not drop, shock, damage or sprinkle water.

1. Install a new gasket (3).

2. Install the Throttle Valve Actuator (TVA) (2) and secure with the four retaining bolts (1).

3. Torque retaining bolts (1) to 10 - 13 N·m (7.4 - 10 lb ft).

4. Connect the electrical connection.

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Electrical systems - Engine intake and exhaust system

Throttle Valve Actuator (TVA) - Electrical test - Intake throttle system N4LDI-TA-45SL N4LDI-TA-50SL

NOTE: ETC = Electronic Throttle Control 1. Verify the intake throttle system status • Place the key switch ON. • Use the Service Tool D to check the following parameters. See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000) for how to set up data monitoring.

• Target Idle Speed or Accelerator Angle • Engine Speed • Target Intake Throttle Position • Actual Intake Throttle Position • Intake Throttle Position Sensor Output Voltage 2. Start the engine, and allow it to warm up.

3. Change the accelerator, and monitor the graph.

• (1) Key switch On and engine OFF. “Intake Throttle Position” is at - 8 %.

• (2) Engine running. “Intake Throttle Position” is at 0 %.

• (3) Engine start up.

• (4) Accelerator OPEN. • (5) Accelerator CLOSE. • (6) Key switch OFF. • (7) Engine stopped.

NHIL13ENG0090AA

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4. Use the Service Tool D to observe the waveform for intake throttle valve motor terminals B57 and B44.

• The graph should look like this when monitoring connector X-002B pin 44 (ETC-) accelerator fully closed (idling).

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Electrical systems - Engine intake and exhaust system

The graph should look like this when monitoring connector X-002B pin 57 (ETC+) and connector X-002B pin 44 (ETC-) accelerator at 2800 RPM.

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The graph should look like this when monitoring connector X-002B pin 57 (ETC+) accelerator fully open.

5. Run the active test “Intake Throttle Check Function”.

See Electrical system Computer support tools Overview — Active Test (55.000).

• Use the Service Tool D to check the following parameters. See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000) for how to set up data monitoring.

• (A) Target Intake Throttle Position • (B) Actual Intake Throttle Position • (C) Intake Throttle Position Sensor Output Voltage

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Electrical systems - Engine intake and exhaust system

Inlet air temperature sensor - Inspect N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Measure the resistance of the inlet air temperature sensor from pin 1 to pin 2.

NHIL13ENG0180AA

Temperature

Voltage output

0 °C (32 °F) 20 °C (68.0 °F) 40 °C (104.0 °F) 60 °C (140.0 °F) 80 °C (176.0 °F)

5.74 Ω 2.54 Ω 1.15 Ω 0.58 Ω 0.31 Ω

Tightening torque: 14.7 - 19.6 N·m (10.8 - 14.5 lb ft)

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1

Index Electrical systems - 55 Engine intake and exhaust system - 014 Boost pressure sensor - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Inlet air temperature sensor - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Throttle Valve Actuator (TVA) - Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Throttle Valve Actuator (TVA) - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Throttle Valve Actuator (TVA) - Electrical test - Intake throttle system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Throttle Valve Actuator (TVA) - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Throttle Valve Actuator (TVA) - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Throttle Valve Actuator (TVA) - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(*) See content for specific models 47632293 16/09/2014

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Electrical systems - 55 Exhaust Gas Recirculation (EGR) electrical system - 989

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Electrical systems - 55 Exhaust Gas Recirculation (EGR) electrical system - 989

SERVICE Exhaust Gas Recirculation (EGR) electrical system Electrical test - EGR system (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Exhaust Gas Recirculation (EGR) temperature sensors Remove - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Inspect - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Remove - Diesel Oxidation Catalyst (DOC) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . 12 Inspect - Diesel Oxidation Catalyst (DOC) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install - Diesel Oxidation Catalyst (DOC) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Remove - Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . 15 Inspect – Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . 16 Install - Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Remove - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Inspect - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Install - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Remove - Diesel Particulate Filter (DPF) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Inspect - Diesel Particulate Filter (DPF) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install - Diesel Particulate Filter (DPF) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Remove - Diesel Particulate Filter (DPF) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Inspect - Diesel Particulate Filter (DPF) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Install - Diesel Particulate Filter (DPF) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Remove - Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . 27 Inspect – Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . 28 Install - Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 29

(*) See content for specific models 47632293 16/09/2014

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CONSUMABLES INDEX Consumable Loctite® ODC-Free Cleaner and Degreaser LOCTITE® 8150™ LOCTITE® 8150™ LOCTITE® 8150™ LOCTITE® 8150™ LOCTITE® 8150™

Reference

PAGE

Exhaust Gas Recirculation

55.8 / 7

Exhaust Exhaust Exhaust Exhaust Exhaust

55.8 / 11 55.8 / 14 55.8 / 20 55.8 / 23 55.8 / 26

Gas Gas Gas Gas Gas

Recirculation Recirculation Recirculation Recirculation Recirculation

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) electrical system - Electrical test - EGR system N4LDI-TA-45SL N4LDI-TA-50SL

1. Verify the Exhaust Gas Recirculation (EGR) system status • Place the key switch ON. • Use the Service Tool D to check the following parameters. See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000) for how to set up data monitoring.

• Target Idle Speed or Accelerator Angle • Engine Speed • Target EGR Position • Actual EGR Position • EGR Position Sensor Output Voltage 2. Start the engine, and allow it to warm up.

3. Change the accelerator, and monitor the graph.

• (A) Target Idle Speed • (B) Engine Speed • (C) see graph 2 below.

NHIL13ENG0098AA

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NHIL13ENG0095AA

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Detailed graph for: • Target EGR Position • Actual EGR Position • EGR Position Sensor Output Voltage

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

4. Use the Service Tool D to observe the waveform for EGR motor connector X-002B pin 58 and pin 45.

• The graph should look like this when monitoring connector X-002B pin 58 (EGR+) accelerator fully open.

NHIL13ENG0099AA

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NHIL13ENG0100AA

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NHIL13ENG0096AA

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NHIL13ENG0101AA

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The graph should look like this when monitoring connector X-002B pin 45 (EGR-) accelerator closed, at idle.

The graph should look like this when monitoring connector X-002B pin 45 (EGR-) accelerator at 2800 RPM.

5. Run the EGR active test “EGR Check Function”.

• Use the Service Tool D to check the following parameters. See Electrical system Computer support tools - Overview Data Monitoring Screen (55.000) for how to set up data monitoring.

• (A) Target EGR Position • (B) Actual EGR Position • (C) EGR Position Sensor Output Voltage

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) electrical system - Inspect N4LDI-TA-45SL N4LDI-TA-50SL

1. Remove the Exhaust Gas Recirculation EGR) valve pipe.

2. Remove the electrical connection.

NHIL12ENG0151AA

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NHIL13ENG0068AB

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NHIL12ENG0154AA

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3. Remove the valve.

4. Visually check the EGR valve.

• Check for debris build up.

• Check the valve (flap) is not seized.

• See Exhaust Gas Recirculation (EGR) electrical system - Cleaning (55.989). If the valve is seized and can not be cleaned, replace the EGR valve.

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) electrical system - Cleaning N4LDI-TA-45SL N4LDI-TA-50SL

NOTE: When cleaning the Exhaust Gas Recirculation (EGR) valve do not spray the valve directly with any kind of a chemical cleaner.

1. Spray LOCTITE® ODC-FREE CLEANER AND DEGREASER onto a cloth.

2. Wipe the EGR valve clean.

3. If the EGR valve can not be cleaned, or the valve (flap) is seized, replace the EGR valve.

4. Erase the fault codes.

5. Use Service Tool D to conduct the “EGR Maintenance Time ½ Initialization”. See Electrical system Computer support tools - Overview — Utility (55.000).

6. Use Service Tool D to conduct the “EGR Default Learning Value Initialization”. See Electrical system Computer support tools - Overview — Utility (55.000).

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) electrical system - Inspect N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

The Exhaust Gas Recirculation (EGR) valve recirculates a portion of exhaust gas to the induction port. This process effectively burns the recirculated gas and fuel mixture in the combustion chamber, which reduces the temperature and Nox as well.

1. Remove and then inspect the EGR valve.

2. Check and clean the following items every 1500 h.

• EGR valve (1) • EGR cooler (2) • Piping for EGR (3) • Intake manifold (4)

NHVM13ENG0197AA

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NHIL13ENG0169AA

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3. Active test.

• Use the diagnostic service tool.

• Select the “Diagnostic Test” from the “Diagnostics” drop down menu.

• Select “Override Parameters”.

• Select “EGR Actuator Control Command”.

• Select ON from the “Change Parameter Value” menu.

If there is a clicking sound and the test is OK, the valve is good. If the test fails, replace the EGR valve.

4. Measure the EGR valve electrical resistance.

• Test the solenoid from pin 1 to pin 2.

• The resistance should be approximately 7.9 - 8.7 Ω at 20.0 °C (68.0 °F).

• EGR valve (1) shown.

If the resistance is incorrect, replace the EGR valve.

EGR valve electrical wiring/connection specification: Value

Connector pin Pin 1 Pin 2

12.0 V Ground

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Remove Diesel Oxidation Catalyst (DOC) Inlet temperature sensor N4LDI-TA-45SL N4LDI-TA-50SL

1. Disconnect the wire harness connector (2).

2. Remove the temperature sensor (1) by turning counterclockwise.

NOTICE: Mark the position of the wire harness. If wires are not routed correctly, wire damage may occur.

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Inspect Diesel Oxidation Catalyst (DOC) Inlet temperature sensor N4LDI-TA-45SL N4LDI-TA-50SL

1. Use a multimeter to inspect the resistance of the inlet sensor (1). If the resistance is not within range, replace the sensor.

NHIL13ENG0012AA

Temperature (Degrees) 200 °C (392 °F) 650 °C (1202 °F)

Resistance (Ohms) 4.0 kΩ +/- 15 % 164.8 Ω +/- 5 %

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Install Diesel Oxidation Catalyst (DOC) Inlet temperature sensor N4LDI-TA-45SL N4LDI-TA-50SL

1. Apply a high temp anti seize compound such as LOCTITE® 8150™ or equivalent to the threads of the sensor.

2. Install the sensor (1) into the Diesel Oxidation Catalyst (DOC).

3. Torque the sensor to 25 - 35 N·m (18.4 - 26 lb ft).

4. Connect the wire connector (2) to the wire harness.

NOTICE: Ensure the wiring is routed properly in the engine bay to avoid damage.

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Remove Diesel Oxidation Catalyst (DOC) Outlet temperature sensor N4LDI-TA-45SL N4LDI-TA-50SL

1. Disconnect the wire harness connector (2).

2. Remove the temperature sensor (1) by turning counterclockwise.

NOTICE: Mark the position of the wire harness. If wires are not routed correctly, wire damage may occur.

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Inspect Diesel Oxidation Catalyst (DOC) Outlet temperature sensor N4LDI-TA-45SL N4LDI-TA-50SL

1. Use a multimeter to inspect the resistance of the sensor (1). If the resistance is not within range, replace the sensor.

NHIL13ENG0012AA

Temperature (Degrees) 200 °C (392 °F) 650 °C (1202 °F)

Resistance (Ohms) 4.0 kΩ +/- 15 % 164.8 Ω +/- 5 %

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Install Diesel Oxidation Catalyst (DOC) Outlet temperature sensor N4LDI-TA-45SL N4LDI-TA-50SL

1. Apply a high temp anti seize compound such as LOCTITE® 8150™ or equivalent to the threads of the sensor.

2. Install the sensor (1) into the Diesel Oxidation Catalyst (DOC).

3. Torque the sensor to 25 - 35 N·m (18.4 - 26 lb ft).

4. Connect the wire connector (2) to the wire harness.

NOTICE: Ensure the wiring is routed properly in the engine bay to avoid damage.

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Remove Diesel Oxidation Catalyst (DOC) Differential pressure sensor N4LDI-TA-45SL N4LDI-TA-50SL

1. Disconnect the wire harness connector.

2. Remove the hose clamps (2).

3. Carefully remove the hoses.

4. Remove retaining bolts from the sensor and remove sensor (1).

NOTICE: Take care when removing the hoses from the sensor connections, they are fragile.

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Inspect – Diesel Oxidation Catalyst (DOC) Differential pressure sensor N4LDI-TA-45SL N4LDI-TA-50SL

1. Inspect the differential pressure sensor (1).

• Check the differential pressure sensor piping (2).

• Check the differential pressure sensor electrical connections.

If there is any damage, repair or replace as needed.

2. Replace the differential pressure sensor when indicated by the Engine Control Unit (ECU).

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Install Diesel Oxidation Catalyst (DOC) Differential pressure sensor N4LDI-TA-45SL N4LDI-TA-50SL

1. Install the retaining bolts to secure the sensor (1).

2. Carefully install the hoses and secure with hose clamps (2).

NOTICE: Take care when installing the hoses to the sensor connections, they are fragile.

3. Connect the wire harness connector.

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Remove Diesel Oxidation Catalyst (DOC) Inlet temperature sensor N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Disconnect the wire harness connector (not shown).

2. Remove the temperature sensor (1) by turning counterclockwise.

NOTICE: Mark the position of the wire harness. If wires are not routed correctly, wire damage may occur.

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Inspect Diesel Oxidation Catalyst (DOC) Inlet temperature sensor N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Use a multimeter to inspect the resistance of the sensor (1). If the resistance is not within range, replace the sensor.

NHIL13ENG0168AA

Temperature (Degrees) 200 °C (392 °F) 650 °C (1202 °F)

Resistance (Ohms) 4.0 kΩ +/- 15 % 164.8 Ω +/- 5 %

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Install Diesel Oxidation Catalyst (DOC) Inlet temperature sensor N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Apply a high temp anti seize compound such as LOCTITE® 8150™ or equivalent to the threads of the sensor.

2. Install the sensor (1) into the Diesel Oxidation Catalyst (DOC).

3. Torque the sensor to 25 - 35 N·m (18.4 - 26 lb ft).

4. Connect the sensor wire connector to the wire harness.

NOTICE: Ensure the wiring is routed properly in the engine bay to avoid damage.

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Remove Diesel Particulate Filter (DPF) Inlet temperature sensor N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Disconnect the wire harness connector (not shown).

2. Remove the temperature sensor (1) by turning counterclockwise.

NOTICE: Mark the position of the wire harness. If wires are not routed correctly, wire damage may occur.

NHIL13ENG0168AA

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Inspect Diesel Particulate Filter (DPF) Inlet temperature sensor N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Use a multimeter to inspect the resistance of the sensor (1). If the resistance is not within range, replace the sensor.

NHIL13ENG0168AA

Temperature (Degrees) 200 °C (392 °F) 650 °C (1202 °F)

Resistance (Ohms) 4.0 kΩ +/- 15 % 164.8 Ω +/- 5 %

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Install Diesel Particulate Filter (DPF) Inlet temperature sensor N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Apply a high temp anti seize compound such as LOCTITE® 8150™ or equivalent to the threads of the sensor.

2. Install the sensor (1) into the Diesel Oxidation Catalyst (DOC).

3. Torque the sensor to 25 - 35 N·m (18.4 - 26 lb ft).

4. Connect the sensor wire connector to the wire harness.

NOTICE: Ensure the wiring is routed properly in the engine bay to avoid damage.

NHIL13ENG0168AA

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Remove Diesel Particulate Filter (DPF) Outlet temperature sensor N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Disconnect the wire harness connector (not shown).

2. Remove the temperature sensor (1) by turning counterclockwise.

NOTICE: Mark the position of the wire harness. If wires are not routed correctly, wire damage may occur.

NHIL13ENG0168AA

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Inspect Diesel Particulate Filter (DPF) Outlet temperature sensor N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Use a multimeter to inspect the resistance of the sensor (1). If the resistance is not within range, replace the sensor.

NHIL13ENG0168AA

Temperature (Degrees) 200 °C (392 °F) 650 °C (1202 °F)

Resistance (Ohms) 4.0 kΩ +/- 15 % 164.8 Ω +/- 5 %

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Install Diesel Particulate Filter (DPF) Outlet temperature sensor N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Apply a high temp anti seize compound such as LOCTITE® 8150™ or equivalent to the threads of the sensor.

2. Install the sensor (1) into the Diesel Oxidation Catalyst (DOC).

3. Torque the sensor to 25 - 35 N·m (18.4 - 26 lb ft).

4. Connect the sensor wire connector to the wire harness.

NOTICE: Ensure the wiring is routed properly in the engine bay to avoid damage.

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Exhaust Gas Recirculation (EGR) temperature sensors - Remove Diesel Oxidation Catalyst (DOC) Differential pressure sensor N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Disconnect the wire harness connector.

2. Remove the hose clamps.

3. Carefully remove the hoses (1).

4. Remove retaining bolts from the sensor and remove sensor (2).

NOTICE: Take care when removing the hoses from the sensor connections, they are fragile.

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Inspect – Diesel Oxidation Catalyst (DOC) Differential pressure sensor N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Inspect the differential pressure sensor (2).

• Check the differential pressure sensor piping (1).

• Check the differential pressure sensor electrical connections.

If there is any damage, repair or replace as needed.

2. Replace the differential pressure sensor when indicated by the Engine Control Unit (ECU).

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Install Diesel Oxidation Catalyst (DOC) Differential pressure sensor N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Install the retaining bolts to secure the sensor (1).

2. Carefully install the hoses (1) and secure with hose clamps.

NOTICE: Take care when installing the hoses to the sensor connections, they are fragile.

3. Connect the wire harness connector.

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Index Electrical systems - 55 Exhaust Gas Recirculation (EGR) electrical system - 989 Exhaust Gas Recirculation (EGR) electrical system - Cleaning (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Exhaust Gas Recirculation (EGR) electrical system - Electrical test - EGR system (*) . . . . . . . . . . . . . . . . . . . . . . . 4 Exhaust Gas Recirculation (EGR) electrical system - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Exhaust Gas Recirculation (EGR) electrical system - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Exhaust Gas Recirculation (EGR) temperature sensors - Inspect - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Exhaust Gas Recirculation (EGR) temperature sensors - Inspect - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Exhaust Gas Recirculation (EGR) temperature sensors - Inspect - Diesel Oxidation Catalyst (DOC) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Exhaust Gas Recirculation (EGR) temperature sensors - Inspect - Diesel Particulate Filter (DPF) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Exhaust Gas Recirculation (EGR) temperature sensors - Inspect - Diesel Particulate Filter (DPF) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Exhaust Gas Recirculation (EGR) temperature sensors - Inspect – Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Exhaust Gas Recirculation (EGR) temperature sensors - Inspect – Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Exhaust Gas Recirculation (EGR) temperature sensors - Install - Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Exhaust Gas Recirculation (EGR) temperature sensors - Install - Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Exhaust Gas Recirculation (EGR) temperature sensors - Install - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Exhaust Gas Recirculation (EGR) temperature sensors - Install - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Exhaust Gas Recirculation (EGR) temperature sensors - Install - Diesel Oxidation Catalyst (DOC) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Exhaust Gas Recirculation (EGR) temperature sensors - Install - Diesel Particulate Filter (DPF) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Exhaust Gas Recirculation (EGR) temperature sensors - Install - Diesel Particulate Filter (DPF) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Diesel Oxidation Catalyst (DOC) Differential pressure sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Diesel Oxidation Catalyst (DOC) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Diesel Oxidation Catalyst (DOC) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Diesel Particulate Filter (DPF) Inlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Exhaust Gas Recirculation (EGR) temperature sensors - Remove - Diesel Particulate Filter (DPF) Outlet temperature sensor (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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Electrical systems - 55 Engine cooling system - 012

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Electrical systems - 55 Engine cooling system - 012

SERVICE Engine coolant temperature sensor Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Engine cooling system

Engine coolant temperature sensor - Inspect N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Measure the resistance of the coolant temperature sensor from pin 1 to pin 2.

NHIL13ENG0180AA

Temperature

Voltage output

0 °C (32 °F) 20 °C (68.0 °F) 40 °C (104.0 °F) 60 °C (140.0 °F) 80 °C (176.0 °F)

5.74 Ω 2.54 Ω 1.15 Ω 0.58 Ω 0.31 Ω

Tightening torque: 14.7 - 19.6 N·m (10.8 - 14.5 lb ft)

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Index Electrical systems - 55 Engine cooling system - 012 Engine coolant temperature sensor - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Engine oil system - 013

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Electrical systems - 55 Engine oil system - 013

FUNCTIONAL DATA Engine oil pressure sensor and switch Dynamic description - Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine oil pressure sensor and switch Remove – Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install - Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Inspect – Pressure switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Electrical systems - Engine oil system

Engine oil pressure sensor and switch - Dynamic description - Pressure switch The oil pressure switch is located on top of the cylinder head. The engine oil pressure switch closes (circuit completed) when engine oil pressure is less than 27.6 kPa (4.0 psi). This illuminates the indicator light on the instrument panel.

The engine oil pressure switch is closed before the engine is started. If the switch does not work after the engine is started, the oil level inside the engine may be low or there may be a problem with the oil pump.

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Engine oil pressure sensor and switch - Remove – Pressure switch 1. Disconnect the wire.

2. Remove the oil pressure switch (1) from the cylinder head.

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Engine oil pressure sensor and switch - Install - Pressure switch 1. Install the oil pressure switch (1) into the cylinder head.

2. Torque the pressure switch to 14.7 - 19.6 N·m (10.8 14 lb ft).

3. Connect the wire.

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Engine oil pressure sensor and switch - Inspect – Pressure switch N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34

NOTE: See Oil pressure valve - Dynamic description — Pressure switch (10.304) for pressure switch description.

NOTE: See Engine lubrication system - Pressure test — Engine oil (10.304) for lubrication system pressure test.

1. Inspect the wiring harness to the oil pressure switch.

• If the wiring harness is damaged, repair or replace as needed.

2. Measure the resistance of the switch.

• Use a multimeter to check for continuity from the oil pressure switch pin 1 to pin 2.

• There should be continuity.

• If there is no continuity, the switch has failed. Replace the switch.

NHIL13ENG0175AA

Oil pressure switch electrical wiring/connection specification: Value

Connector pin Pin 1 Pin 2

12.0 V Ground

Tightening torque: 14.7 - 19.6 N·m (10.8 - 14.5 lb ft).

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Index Electrical systems - 55 Engine oil system - 013 Engine oil pressure sensor and switch - Dynamic description - Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine oil pressure sensor and switch - Inspect – Pressure switch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine oil pressure sensor and switch - Install - Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine oil pressure sensor and switch - Remove – Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Electronic modules - 640

N4LDI-TA-45SL , N4LDI-TA-50SL , N843LT-F-27 , N843T-F-24 , N844L-F-30 , N844L-F-34 , N844L-F-36SL , N844LT-F-45SL

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Contents Electrical systems - 55 Electronic modules - 640

SERVICE Electronic module Electrical test Engine Control Unit (ECU) verification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electrical test Engine Control Unit (ECU) verification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electrical test Engine Control Unit (ECU) verification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Electrical systems - Electronic modules

Electronic module - Electrical test Engine Control Unit (ECU) verification N4LDI-TA-45SL N4LDI-TA-50SL

1. Locate the Engine Control Unit (ECU).

• Disconnect the harness from the ECU. Place the key switch ON. 2. Use a multimeter to check the power supply and ground reference circuits.

• ECU harness connector X-002B pin 47 to connector X-002B pin 3.

• ECU harness connector X-002B pin 48 to connector X-002B pin 4.

• ECU harness connector X-002B pin 46 to connector X-002B pin 31.

• ECU harness connector X-002B pin 5 to connector X-002B pin 1.

• ECU harness connector X-002B pin 6 to connector X-002B pin 2.

• ECU harness connector X-002B pin 46 to connector X-002B pin 18.

The multimeter should read between 8 - 18 V. A. If any of the readings are incorrect, continue with 3.

B. If the readings are correct continue with 5.

3. Check the power supply circuits of the Engine Control Unit (ECU) at the engine harness connector.

Place the key switch ON. Use a multi-meter to measure the voltage from the harness side of: • ECU harness connector X-002B pin 47 to chassis ground.

• ECU harness connector X-002B pin 48 to chassis ground.

• ECU harness connector X-002B pin 46 to chassis ground.

• ECU harness connector X-002B pin 5 to chassis ground.

• ECU harness connector X-002B pin 6 to chassis ground.

The multimeter should read between 8 - 18 V. A. If any of the readings are incorrect. Repair or replace the circuit to the ECU connector.

B. If the readings are correct continue with 4.

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4. Check the ground circuits of the Engine Control Unit (ECU) at the engine harness connector.

Place the key switch OFF. Use a multi-meter to check for continuity from the harness side of: • ECU harness connector X-002B pin 3 to chassis ground.

• ECU harness connector X-002B pin 4 to chassis ground.

• ECU harness connector X-002B pin 31 to chassis ground.

• ECU harness connector X-002B pin 1 to chassis ground.

• ECU harness connector X-002B pin 2 to chassis ground.

• ECU harness connector X-002B pin 18 to chassis ground.

There should be continuity.

A. If any of the readings are incorrect. Repair or replace the circuit to the ECU connector.

B. If the readings are correct continue with 5.

5. Use the Service Tool D to check the software level.

• If the incorrect software level is installed. Install the correct software level. Test the system for proper operation.

• If the correct software level is installed, replace the ECU. Install the current software level. Test the system to verify repairs.

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Electronic module - Inspect N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

The Engine Control Unit (ECU) monitors and control various components within the engine bay.

1. Always make sure the electrical connections are secure and tight. Loose connections can cause problems.

2. The ECU contains an internal atmospheric pressure sensor and is very delicate. Please handle with care.

3. Do not block the vent (1).

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Electrical systems - Electronic modules

Electronic module - Electrical test Engine Control Unit (ECU) verification N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Locate the Engine Control Unit (ECU).

• Disconnect the harness from the ECU. Place the key switch ON. 2. Use a multi-meter to measure the voltage from the harness side of: • ECU harness connector X-002 pin 1 to connector X-002 pin 20.

• ECU harness connector X-002 pin 4 to connector X-002 pin 39.

• ECU harness connector X-002 pin 21 to connector X-002 pin 39.

• ECU harness connector X-002 pin 18 to connector X-002 pin 80.

• ECU harness connector X-002 pin 19 to connector X-002 pin 79.

• ECU harness connector X-002 pin 38 to connector X-002 pin 60.

• ECU harness connector X-002 pin 58 to connector X-002 pin 59.

• ECU harness connector X-002 pin 78 to connector X-002 pin 59.

• ECU harness connector X-002 pin 13 to connector X-002 pin 59.

• ECU harness connector X-002 pin 33 to connector X-002 pin 59.

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The multimeter should read between 8 - 18 V. A. If any of the readings are incorrect, continue with 3.

B. If the readings are correct continue with 5.

3. Check the power supply circuits of the Engine Control Unit (ECU) at the engine harness connector.

Use a multi-meter to measure the voltage from the harness side of: • ECU harness connector X-002 pin 1 to chassis ground.

• ECU harness connector X-002 pin 4 to chassis ground.

• ECU harness connector X-002 pin 21 to chassis ground.

• ECU harness connector X-002 pin 18 to chassis ground.

• ECU harness connector X-002 pin 19 to chassis ground.

• ECU harness connector X-002 pin 38 to chassis ground.

• ECU harness connector X-002 pin 58 to chassis ground.

• ECU harness connector X-002 pin 78 to chassis ground.

• ECU harness connector X-002 pin 13 to chassis ground.

• ECU harness connector X-002 pin 33 to chassis ground.

The multimeter should read between 8 - 18 V. A. If any of the readings are incorrect. Repair or replace the circuit to the ECU connector.

B. If the readings are correct continue with 4.

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4. Check the ground circuits of the Engine Control Unit (ECU) at the engine harness connector.

Use a multi-meter to check for continuity from the harness side of: • ECU harness connector X-002 pin 20 to chassis ground.

• ECU harness connector X-002 pin 39 to chassis ground.

• ECU harness connector X-002 pin 40 to chassis ground (EH units only).

• ECU harness connector X-002 pin 45 to chassis ground (Mechanical units only).

• ECU harness connector X-002 pin 80 to chassis ground.

• ECU harness connector X-002 pin 79 to chassis ground.

• ECU harness connector X-002 pin 60 to chassis ground.

• ECU harness connector X-002 pin 59 to chassis ground.

There should be continuity.

A. If any of the readings are incorrect. Repair or replace the circuit to the ECU connector.

B. If the readings are correct continue with 5.

5. Use the Service Tool I to check the software level.

• If the incorrect software level is installed. Install the correct software level. Test the system for proper operation.

• If the correct software level is installed, replace the ECU. Install the current software level. Test the system to verify repairs.

NOTE: For mechanical unit schematic, see Wiring harnesses - Electrical schematic sheet 10 Engine ISM IDI Mechanical Units (55.100).

NOTE: For EH unit schematic, see Wiring harnesses - Electrical schematic sheet 06 Engine ISM - EH Units (55.100).

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Electrical systems - Electronic modules

Electronic module - Electrical test Engine Control Unit (ECU) verification N843LT-F-27 N843T-F-24 N844L-F-30 N844L-F-34 N844L-F-36SL N844LT-F-45SL

1. Locate the Engine Control Unit (ECU).

• Disconnect the harness from the ECU. Place the key switch ON. 2. Use a multi-meter to measure the voltage from the harness side of: • ECU harness connector X-9100 pin 1 to connector X-9100 pin 20.

• ECU harness connector X-9100 pin 4 to connector X-9100 pin 39.

• ECU harness connector X-9100 pin 21 to connector X-9100 pin 39.

• ECU harness connector X-9100 pin 18 to connector X-9100 pin 80.

• ECU harness connector X-9100 pin 19 to connector X-9100 pin 79.

• ECU harness connector X-9100 pin 38 to connector X-9100 pin 60.

• ECU harness connector X-9100 pin 58 to connector X-9100 pin 59.

• ECU harness connector X-9100 pin 78 to connector X-9100 pin 59.

• ECU harness connector X-9100 pin 13 to connector X-9100 pin 59.

• ECU harness connector X-9100 pin 33 to connector X-9100 pin 59.

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Electrical systems - Electronic modules

The multimeter should read between 8 - 18 V. A. If any of the readings are incorrect, continue with 3.

B. If the readings are correct continue with 5.

3. Check the power supply circuits of the Engine Control Unit (ECU) at the engine harness connector.

Use a multi-meter to measure the voltage from the harness side of: • ECU harness connector X-9100 pin 1 to chassis ground.

• ECU harness connector X-9100 pin 4 to chassis ground.

• ECU harness connector X-9100 pin 21 to chassis ground.

• ECU harness connector X-9100 pin 18 to chassis ground.

• ECU harness connector X-9100 pin 19 to chassis ground.

• ECU harness connector X-9100 pin 38 to chassis ground.

• ECU harness connector X-9100 pin 58 to chassis ground.

• ECU harness connector X-9100 pin 78 to chassis ground.

• ECU harness connector X-9100 pin 13 to chassis ground.

• ECU harness connector X-9100 pin 33 to chassis ground.

The multimeter should read between 8 - 18 V. A. If any of the readings are incorrect. Repair or replace the circuit to the ECU connector.

B. If the readings are correct continue with 4.

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Electrical systems - Electronic modules

4. Check the ground circuits of the Engine Control Unit (ECU) at the engine harness connector.

Use a multi-meter to check for continuity from the harness side of: • ECU harness connector X-9100 pin 20 to chassis ground.

• ECU harness connector X-9100 pin 39 to chassis ground.

• ECU harness connector X-9100 pin 40 to chassis ground (where populated).

• ECU harness connector X-9100 pin 45 to chassis ground (where populated).

• ECU harness connector X-9100 pin 80 to chassis ground.

• ECU harness connector X-9100 pin 79 to chassis ground.

• ECU harness connector X-9100 pin 60 to chassis ground.

• ECU harness connector X-9100 pin 59 to chassis ground.

There should be continuity.

A. If any of the readings are incorrect. Repair or replace the circuit to the ECU connector.

B. If the readings are correct continue with 5.

5. Use the Service Tool I to check the software level.

• If the incorrect software level is installed. Install the correct software level. Test the system for proper operation.

• If the correct software level is installed, replace the ECU. Install the current software level. Test the system to verify repairs.

NOTE: For schematic, see Wiring harnesses - Electrical schematic sheet 04 – Engine Control Unit (ECU) – machine connector (55.100).

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Index Electrical systems - 55 Electronic modules - 640 Electronic module - Electrical test Engine Control Unit (ECU) verification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electronic module - Electrical test Engine Control Unit (ECU) verification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electronic module - Electrical test Engine Control Unit (ECU) verification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electronic module - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

(*) See content for specific models 47632293 16/09/2014

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

PRINTED IN U.S.A. © 2014 CNH Industrial 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.

47632293 16/09/2014 EN

SPECIAL TOOL INDEX Genuine FNH00120 [Oil Pump Port Block Installer Adapter] FNH00120 [Oil Pump Port Block Installer Adapter]

OEM OEM1074 [Compression Gauge] OEM1074 [Compression Gauge]

Reference

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Engine - Compression test

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Engine - Compression test

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Reference

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Engine - Compression test

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Engine - Compression test

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47632293 16/09/2014

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

PRINTED IN U.S.A. © 2014 CNH Industrial 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.

47632293 16/09/2014 EN