Case New Holland VM Motori R 753 IE4 Tier 4B (final) & Stage IV Engine Manual 47730965 - DOWNLOAD

SERVICE MANUAL VM Motori R 753 IE4 Tier 4B (final) and Stage IV Engine

Printed in U.S.A. © 2015 CNH Industrial America LLC. All Rights Reserved.

Case, Case IH, New Holland, and Styer are trademarks registered in the United States and many other countries, owned by or licensed to CNH Industrial N.V., its subsidiaries or affiliates.

Part number 47730965 1st edition English August 2015

SERVICE MANUAL R 753 IE4

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Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 [10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 [10.501] Exhaust Gas Recirculation (EGR) exhaust treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16

Electrical systems ....................................................................... 55 [55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.989] Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

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INTRODUCTION

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Contents INTRODUCTION Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety rules - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Torque – Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Torque – Standard torque data for hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Basic instructions - Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Product overview – Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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INTRODUCTION

Foreword - 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 manufacturer reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication but are subject to change without notice.

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

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INTRODUCTION

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

Throughout this manual 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 that, if not avoided, will result in death or serious injury.

WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation that, if not avoided, could result in machine or property damage.

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 that 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

Safety rules - Ecology and the environment Soil, air, and water quality is important for all industries and life in general. When legislation does not yet rule the treatment of some of the substances that advanced technology requires, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature.

Familiarize yourself with the relative legislation applicable to your country, and make sure that you understand this legislation. Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, anti-freeze, cleaning agents, etc., with regard to the effect of these substances on man and nature and how to safely store, use, and dispose of these substances.

Helpful hints • Avoid the use of cans or other inappropriate pressurized fuel delivery systems to fill tanks. Such delivery systems may cause considerable spillage.

• In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of these products 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 you drain fluids such as used engine coolant mixtures, engine oil, hydraulic fluid, brake fluid, etc. Do not mix drained brake fluids or fuels with lubricants. Store all drained fluids safely until you can dispose of the fluids in a proper way that complies with all local legislation and available resources.

• Do not allow coolant mixtures to get into the soil. Collect and dispose of coolant mixtures properly.

• The air-conditioning system contains gases that should not be released into the atmosphere. Consult an air-conditioning specialist or use a special extractor to recharge the system properly.

• Repair any leaks or defects in the engine cooling system 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. Penetrating weld splatter may burn a hole or weaken hoses, allowing the loss of oils, coolant, etc.

Battery recycling Batteries and electric accumulators contain several substances that can have a harmful effect on the environment if the batteries are not properly recycled after use. Improper disposal of batteries can contaminate the soil, groundwater, and waterways. CNH strongly recommends that you return all used batteries to a CNH dealer, who will dispose of the used batteries or recycle the used batteries properly. In some countries, this is a legal requirement.

Mandatory battery recycling NOTE: The following requirements are mandatory in Brazil.

Batteries are made of lead plates and a sulfuric acid solution. Because batteries contain heavy metals such as lead, CONAMA Resolution 401/2008 requires you to return all used batteries to the battery dealer when you replace any batteries. Do not dispose of batteries in your household garbage.

Points of sale are obliged to: • Accept the return of your used batteries • Store the returned batteries in a suitable location • Send the returned batteries to the battery manufacturer for recycling

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INTRODUCTION

Torque – Minimum tightening torques for normal assembly NOTE: In the metric tables, nominal sizes M4 through M8 hardware torque specifications are shown as a Newton meters (pound-inches) numerical value.

Nominal sizes M10 through M24 hardware torque specifications are shown as a Newton meters (pound-feet) numerical value.

Metric non-flanged hardware Plain (PLN) an unplated hardware finish with residual manufacturing oils Zinc-dichromate (ZND) – a yellow colored chemical plating formula yellow applied to the hardware

Nominal size

M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24

Class (CL) 8.8 bolt and Class (CL) 8 nut PLN and ZND N·m (lb in)

Class (CL) 10.9 bolt and Class (CL) 10 nut PLN and ZND N·m (lb in)

Locknut CL 8 w/CL 8.8 bolt ZND N·m (lb in)

Locknut CL 10 w/CL 10.9 bolt ZND N·m (lb in)

2.9 (26) 5.9 (52) 10.1 (89) 24.5 (217)

4.2 (37) 8.5 (75) 14.5 (128) 35.1 (311)

2 (18) 4 (36) 6.8 (60) 17 (151)

2.9 (26) 5.8 (51) 10 (89) 24 (212)

N·m (lb ft)

N·m (lb ft)

N·m (lb ft)

N·m (lb ft)

48.7 (36) 85 (63) 135 (100) 210 (155) 299 (221) 425 (313) 735 (542)

69.5 (90) 121 (67) 193 (142) 301 (222) 414 (305) 587 (433) 1016 (749)

33 58 92 143 203 290 501

(25) (43) (68) (106) (150) (214) (370)

48 (35) 83 (61) 132 (97) 205 (151) 281 (207) 400 (295) 693 (510)

Metric flanged hardware Plain (PLN) – an unplated hardware finish with residual manufacturing oils Zinc-dichromate (ZND) – a yellow colored chemical plating formula yellow applied to the hardware

Nominal size

M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24

Class (CL) 8.8 bolt and Class (CL) 8 nut PLN and ZND N·m (lb ft)

Class (CL) 10.9 bolt and Class (CL) 10 nut PLN and ZND N·m (lb ft)

Locknut CL 8 w/CL 8.8 bolt ZND N·m (lb ft)

Locknut CL 10 w/CL 10.9 bolt ZND N·m (lb ft)

3.2 (28) 6.5 (58) 11.1 (98) 27 (239)

4.6 (41) 9.4 (83) 15.9 (141) 39 (345)

2.2 (19) 4.4 (39) 7.5 (66) 18 (163)

3.1 (27) 6.4 (57) 11 (96) 27 (240)

N·m (lb ft)

N·m (lb ft)

N·m (lb ft)

N·m (lb ft)

53.6 (40) 93 (69) 148 (109) 231 (171) 329 (243) 467 (345) 809 (597)

76.5 (56) 134 (98) 213 (157) 331 (244) 455 (336) 645 (476) 1118 (824)

37 (27) 63 (47) 101 (75) 158 116) 223 (165) 318 (235) 552 (407)

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53 91 145 226 309 440

(39) (67) (107) (167) (228) (325)

INTRODUCTION

Identification markings Metric hex head, flange hex head and carriage bolts, Classes (CL) 5.6 and upward

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Metric bolt identification markings 1. Manufacturer's identification 2. Property class

Metric hex nuts and locknuts, Classes (CL) 05 and upward

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Metric hex nut identification markings • (1) – Manufacturer's identification • (3) – Property class • (2) – Clockwise type markings indicate property class and may include manufacturer identification (if applied), Example: property marks 240 ° apart (shown) at the eight o’clock position indicate a Class 8 property, and marks 300 ° apart at the ten o’clock position indicate a Class 10 property.

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INTRODUCTION

NOTE: In the Imperial units tables, the nominal sizes, 1/4 (0.25) in (inch) and 5/16 (0.3125) in (inch) hardware torque specifications are shown as a Newton meters (pound-inches) numerical value.

Nominal sizes 3/8 (0.375) in (inch) through 1 (1.0) in (inch) hardware torque specifications are shown as a Newton meters (pound-feet) numerical value.

Inch non-flanged hardware Plain (PLN) – an unplated hardware finish with residual manufacturing oils Zinc-dichromate (ZND) – a yellow colored chemical plating formula yellow applied to the hardware

Nominal size

1/4 (0.25) in 5/16 (0.3125) in 3/8 (0.375) in 7/16 (0.4375) in 1/2 (0.50) in 9/16 (0.5625) in 5/8 (0.625) in 3/4 (0.75) in 7/8 (0.875) in 1 (1.0) in

SAE Grade (GR) 5 bolt and nut PLN and ZND N·m (lb in)

SAE Grade (GR) 8 bolt and nut PLN and ZND N·m (lb in)

Flange locknut GR F w/ GR 5 bolt ZND N·m (lb in)

Flange locknut GR G w/ GR 8 bolt ZND N·m (lb in)

11 (97) 23 (204)

16 (142) 32 (283)

8.5 (75) 17.5 (155)

12.2 (109) 25 (220)

N·m (lb ft)

N·m (lb ft)

N·m (lb ft)

N·m (lb ft)

40 (30) 65 (48) 98 (73) 142 (105) 196 (145) 348 (257) 561 (413) 841 620)

57 (42) 91 (67) 139 (103) 201 (148) 277 (204) 491 (362) 791 (584) 1187 (875)

31 (23) 50 (37) 76 (56) 111 (82) 153 (113) 271 (200) 437 (323) 654 (483)

44 (33) 71 (53) 108 (80) 156 (115) 215 (159) 383 (282) 617 (455) 924 (681)

Inch flanged hardware Plain (PLN) – an unplated hardware finish with residual manufacturing oils Zinc-dichromate (ZND) – a yellow colored chemical plating formula yellow applied to the hardware

Nominal size

1/4 (0.25) in 5/16 (0.3125) in 3/8 (0.375) in 7/16 (0.4375) in 1/2 (0.50) in 9/16 (0.5625) in 5/8 (0.625) in 3/4 (0.75) in 7/8 (0.875) in 1 (1.0) in

SAE Grade (GR) 5 bolt and nut PLN and ZND N·m (lb ft)

SAE Grade (GR) 8 bolt and nut PLN and ZND N·m (lb ft)

Flange locknut GR F w/ GR 5 bolt ZND N·m (lb ft)

Flange locknut GR G w/ GR 8 bolt ZND N·m (lb ft)

12 (106) 25 (221)

17 (150) 35 (310)

8 (71) 17 (150)

12 (106) 24 (212)

N·m (lb ft)

N·m (lb ft)

N·m (lb ft)

N·m (lb ft)

44 (33) 71 (52) 108 (90) 156 (115) 216 (159) 383 (282) 617 (455) 925 (682)

63 (46) 100 (74) 153 (113) 221 (163) 304 (225) 541 (399) 871 (642) 1305 (963)

30 (22) 48 (35) 74 (55) 106 (78) 147 (108) 261 (193) 421 (311) 631 (465)

43 (32) 68 (50) 104 (77) 157 (116) 207 (153) 369 (272) 594 (438) 890 (656)

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INTRODUCTION

Identification marking Grades of inch bolts and free-spinning nuts SAE (J995) bolt head and nut grade identification

Grade

Grade identification marking

Marking description

Grade 2 No line marks

Grade 5 Three line marks

Grade 8 Six line marks

Grade 2 No circumferential line marks

Grade 5 Two circumferential line marks located 120° apart

Grade 2 Two circumferential line marks located 60° apart

Grade 2 No circumferential line marks

Grade 5 Two circumferential line marks located 120° apart

Grade 8 Two circumferential line marks located 60° apart

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INTRODUCTION

Grades of inch prevailing torque locknuts, all metal (three common marking methods) On prevailing torque locknuts, the grade of nut is identified by one of three different sets of markings that denote the strength level and manufacturer.

Common prevailing torque locknut grade identification markings

Grade

Grade identification marking

Marking description

Grade A No marks

Grade B (hex nut) and Grade F (flange nut) Three raised or indented dot marks (Marks do not have to be in corners.)

Grade C (hex nut) and Grade F (flange nut) Six raised or indented dot marks (Marks do not have to be in corners.)

Grade A No letter mark on side flat

Grade B Letter B on side flat

Grade C Letter C on side flat

Grade A No notches

Grade B One circumferential notch on all six corners

Grade C Two circumferential notches on all six corners

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INTRODUCTION

Torque – Standard torque data for hydraulics Installation of adjustable fittings in straight thread O-ring bosses NOTICE: O-ring boss fittings can be used multiple times. Always inspect the O-ring for damage and lubricate the O-ring with clean hydraulic oil or petroleum jelly at installation. Damaged O-rings will cause leakage and affect performance.

Nonadjustable O-ring boss fittings 1. Inspect the components and make sure the port, O-ring, sealing surfaces, and threads are clean, and free of damage.

2. Install the O-ring if needed. Take special care not to cut the O-ring on the threads.

NOTE: Apply electrical tape over the threads to prevent O-ring damage if installing the O-ring, and then remove the tape.

3. Lubricate the threads and O-ring with clean hydraulic oil or petroleum jelly.

4. Install the O-ring (2) in the groove (4) adjacent to the metal backup washer (1) which is assembled at the extreme end of the groove.

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5. Install the fitting into the SAE straight thread boss and hand tighten until the metal backup washer (1) contacts the face of the boss (3).

NOTICE: Do not over tighten and distort the metal backup washer.

6. Using the proper size wrenches, holding the head end of the fitting with a wrench, and then torque the locknut (5) and washer (1) against the face of the boss (3) to the proper specified torque value.

Adjustable (swivel) O-ring boss fittings 1. Inspect the components and make sure the port, O-ring, sealing surfaces, and threads are clean, and free of damage.

2. Install the O-ring if needed. Take special care not to cut the O-ring on the threads.

NOTE: Apply electrical tape over the threads to prevent O-ring damage if installing the O-ring, and then remove the tape.

3. Lubricate the threads and O-ring with clean hydraulic oil or petroleum jelly.

4. Install the O-ring (2) in the groove (4) adjacent to the metal backup washer which is assembled at the extreme end of the groove.

5. Completely back-off the locknut (5) and washer (1) .

6. Install the fitting into the SAE straight thread boss and hand tighten until the metal backup washer (1) contacts the face of the boss (3).

NOTICE: Do not over tighten and distort the metal backup washer.

7. Position the fitting as needed by turning the head of the fitting counterclockwise up to a maximum of one turn.

8. Using the proper size wrenches, hold the head end of the fitting with a wrench, and then torque the locknut (5) and washer (1) against the face of the boss (3) to the proper specified torque value.

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INTRODUCTION

Standard torque data for hydraulic tubes and fittings NOTICE: These torques are not recommended for tubes of 12.7 mm (1/2 in) Outer Diameter (OD) and larger with wall thickness of 0.889 mm (0.035 in) or less. The torque is specified for 0.889 mm (0.035 in) wall tubes on each application individually.

NOTE: Acronyms in the following table, Joint Industry Council (JIC), Outer Diameter (OD).

Size

Tubing OD mm (in)

Thread size

Torque N·m (lb ft)

O-ring boss plugs, adjustable fitting locknuts, swivel JIC – 37 ° seats Torque N·m (lb ft)

4 5 6 8 10 12 14 16 20 24 32

6.4 (1/4) 7.9 (5/16) 9.5 (3/8) 12.7 (1/2) 15.9 (5/8) 19.1 (3/4) 22.2 (7/8) 25.4 (1) 31.8 (1-1/4) 38.1 (1-1/2) 50.8 (2)

7/16–20 1/2–20 9/16–18 3/4–16 7/8–14 1-1/16–12 1-3/16–12 1-5/16–12 1-5/8–12 1-7/8–12 2-1/2–12

12 – 16 (9 – 12) 16 – 20 (12 – 15) 29 – 33 (21 – 24) 47 – 54 (35 – 40) 72 – 79 (53 – 58) 104 – 111 (77 – 82) 122 – 136 (90 – 100) 149 – 163 (110 – 120) 190 – 204 (140 – 150) 217 – 237 (160 – 175) 305 – 325 (225 – 240)

8 – 14 (6 – 10) 14 – 20 (10 – 15) 20 – 27 (15 – 20) 34 – 41 (25 – 30) 47 – 54 (35 – 40) 81 – 95 (60 – 70) 95 – 109 (70 – 80) 108 – 122 (80 – 90) 129 – 158 (95 – 115) 163 – 190 (120 – 140) 339 – 407 (250 – 300)

Tube nuts for 37 ° flared fittings

Installing and torquing 37 ° flared fittings; 1. Clean the face of the flare and threads with LOCTITE® ODC-FREE CLEANER AND DEGREASER cleaning solvent or equivalent cleaning solvent.

2. Allow the cleaning the cleaning solvent to completely dry before application sealant.

3. Apply LOCTITE® 569™ hydraulic sealant to the 37 ° flare and the threads.

4. Install the fitting, and then torque to the specified torque.

5. Loosen the fitting, and then torque once more to the specified torque.

Pipe thread fitting torque Thread Size (inch)

Torque (Maximum) N·m (lb ft)

1/8–27 1/4–18 3/8–18 1/2–14 3/4–14

13 16 22 41 54

(10) (12) (16) (30) (40)

Before installing and torquing pipe fittings; 1. Clean the threads with LOCTITE® ODC-FREE CLEANER AND DEGREASER cleaning solvent or an equivalent cleaning solvent.

2. Allow the cleaning the cleaning solvent to completely dry before application sealant.

3. Apply LOCTITE® 567™ PST PIPE SEALANT for all fittings, including stainless steel or LOCTITE® 565™ PST sealant for most other metal fittings.

NOTICE: For high filtration/zero contamination systems use LOCTITE® 545™ sealant.

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INTRODUCTION

Basic instructions - Shop and assembly Shimming For each adjustment operation, select adjusting shims and measure the adjusting shims 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 shown on each shim.

Rotating shaft seals For correct rotating shaft seal installation, proceed as follows: 1. Before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes.

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

3. Position the sealing lip facing the fluid.

NOTE: With hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that they will move the fluid towards the inner side of the seal.

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

5. 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.

6. While you insert the seal, check that the seal is perpendicular to the seat. When the seal settles, make sure that the seal makes contact with the thrust element, if required.

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

O-ring seals Lubricate the O-ring seals before you insert them in the seats. This will prevent the O-ring seals from overturning and twisting, which would jeopardize sealing efficiency.

Sealing compounds Apply a sealing compound on the mating surfaces when specified by the procedure. Before you apply the sealing compound, prepare the surfaces as directed by the product container.

Spare parts Only use CNH Original Parts or CNH Original 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 Original Parts can offer this guarantee.

When ordering spare parts, always provide the following information: • Machine model (commercial name) and Product Identification Number (PIN) • Part number of the ordered part, which can be found in the parts catalog

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INTRODUCTION

Protecting the electronic and/or electrical systems during charging and welding To avoid damage to the electronic and/or electrical systems, always observe the following practices: 1. Never make or break any of the charging circuit connections when the engine is running, including the battery connections.

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 machine attachment.

• Position the welder ground clamp as close to the welding area as possible.

• If you weld in close proximity to a computer module, then you should remove the module from the machine.

• Never allow welding cables to lie on, near, or across any electrical wiring or electronic component while you weld.

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

NOTICE: If you must weld on the unit, you must disconnect the battery ground cable from the machine battery.

The electronic monitoring system and charging system will be damaged if this is not done.

5. Remove the battery ground cable. Reconnect the cable when you complete 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

Special tools The special tools that CNH suggests and illustrate in this manual have been specifically researched and designed for use with CNH machines. The special tools are essential for reliable repair operations. The special tools are accurately built and rigorously tested 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

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INTRODUCTION

Consumables TUTELA UNITEK CJ-4 ENGINE OIL

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INTRODUCTION

General specification Engine specifications Four stroke diesel 2.228 L (2.354 US qt) 3 94 x 107 17.5 : 1 Turbocharged and inter-cooled circuit Liquid cooled Belt driven Water / Oil Counter-clockwise 1-3-2 Pushrods and rocker arms With hydraulic tappets and camshaft Timing Gear cascade control and camshaft fitted on the crankcase 800 - 1000 RPM Minimum idling speed (RPM) 3000 RPM Maximum operating speed (RPM) Rated operating speed 2600 RPM Rated power 48.5 kW (65 Hp) @ 2600 RPM Maximum torque 220 N·m (162 lb ft) @ 1800 RPM Injection Common rail direct injection Fuel supply Gear pump Injector supply High pressure injection pump Rotor pump Circuit fuel supply Forced lubrication Type of lubrication Oil change including filter 6.3 L (6.7 US qt) Oil pressure at minimum speed 2.5 bar (36.2 psi) Total capacity of cooling circuit (excluding radiator and 3.6 L (3.8 US qt) relevant pipes) Expansion tank cap pressure setting 1.1 bar (16.0 psi) Coolant 50/50 mix Coolant maximum temperature alarm 105 °C (221 °F) Nominal voltage 12 V 14 V Alternating current generator (nominal voltage) 75 A Alternating current generator (nominal current) Starter motor output 2 kW (3 Hp) Cycle Total displacement Number of cylinders Bore and stroke Compression ratio Intake Cooling Water pump control Cooler Crankshaft rotation Firing order

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INTRODUCTION

Product identification The engine Product Identification Number (PIN) plate (1) is located on the right-hand side of the engine flywheel housing.

NHIL14ENG1111FA

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1

INTRODUCTION

Product overview – Orientation

NHIL14ENG1111FA

1

Right-hand view

NHIL14ENG1092FA

2

Front view

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INTRODUCTION

NHIL14ENG1091FA

3

Left-hand view

NHIL14ENG1093FA

4

Rear view

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INTRODUCTION

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SERVICE MANUAL Engine R 753 IE4

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Contents Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 [10.500] Selective Catalytic Reduction (SCR) exhaust treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 [10.501] Exhaust Gas Recirculation (EGR) exhaust treatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16

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Engine - 10 Engine and crankcase - 001

R 753 IE4

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Contents Engine - 10 Engine and crankcase - 001

TECHNICAL DATA Engine Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine Overview – Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Engine Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Crankcase Liner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Liner - Measure – Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Liner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Engine support and mounts Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

DIAGNOSTIC Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Engine - Engine and crankcase

Engine - Technical Data Engine specifications Four stroke diesel 2.228 L (2.354 US qt) 3 94 x 107 17.5 : 1 Turbocharged and inter-cooled circuit Liquid cooled Belt driven Water / Oil Counter-clockwise 1-3-2 Pushrods and rocker arms With hydraulic tappets and camshaft Timing Gear cascade control and camshaft fitted on the crankcase 800 - 1000 RPM Minimum idling speed (RPM) 3000 RPM Maximum operating speed (RPM) Rated operating speed 2600 RPM Rated power 48.5 kW (65 Hp) @ 2600 RPM Maximum torque 220 N·m (162 lb ft) @ 1800 RPM Injection Common rail direct injection Fuel supply Gear pump Injector supply High pressure injection pump Rotor pump Circuit fuel supply Forced lubrication Type of lubrication Oil change including filter 6.3 L (6.7 US qt) Oil pressure at minimum speed 2.5 bar (36.2 psi) Total capacity of cooling circuit (excluding radiator and 3.6 L (3.8 US qt) relevant pipes) Expansion tank cap pressure setting 1.1 bar (16.0 psi) Coolant 50/50 mix Coolant maximum temperature alarm 105 °C (221 °F) Nominal voltage 12 V 14 V Alternating current generator (nominal voltage) 75 A Alternating current generator (nominal current) Starter motor output 2 kW (3 Hp) Cycle Total displacement Number of cylinders Bore and stroke Compression ratio Intake Cooling Water pump control Cooler Crankshaft rotation Firing order

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Engine - Engine and crankcase

Engine - Overview – Orientation

NHIL14ENG1111FA

1

Right-hand view

NHIL14ENG1092FA

2

Front view

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Engine - Engine and crankcase

NHIL14ENG1091FA

3

Left-hand view

NHIL14ENG1093FA

4

Rear view

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Engine - Engine and crankcase

Engine - Timing adjust Prior operation: Timing gear housing - Remove (10.102)

NHIL14ENG1257FA

(1) Idler gear (2) Camshaft gear (3) High pressure injection pump gear

1

(4) Idler gear (5) Oil pump gear (6) Crankshaft gear

1. Remove the cylinder one fuel injector. See Fuel injectors - Remove (10.218).

2. Install the Top Dead Center (TDC) tool 380003392 (1) into the cylinder one fuel injector hole.

NHIL14ENG1286AA

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2

Engine - Engine and crankcase

3. Rotate the crankshaft and monitor the TDC tool gauge (1) to determine when cylinder one is at TDC.

NHIL14ENG1285AA

3

NHIL14ENG1253AA

4

4. Install the idler gear (1) while you align the reference marks for proper crankshaft (3) to camshaft (2) timing.

NOTE: When the engine is set to cylinder one TDC of the compression stroke, the reference marks will be aligned as shown.

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Engine - Engine and crankcase

Crankcase Liner - Remove Prior operation: Connecting rod and piston - Remove (10.105) 1. Install the piston liner tool 380003381 (1) as shown.

NHIL14ENG1275AA

1

NHIL14ENG1277AA

2

NHIL14ENG1278AA

3

NHIL14ENG1112AA

4

2. Check to make sure the plate (1) rests on the bottom of the cylinder liner (2) correctly.

3. Tighten the bolt (1) to extract the cylinder liner from the crankcase.

NOTE: Label the cylinder liners to ensure the correct placement on the installation.

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Engine - Engine and crankcase

Next operation: Crankcase Liner - Measure – Protrusion (10.001)

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Engine - Engine and crankcase

Crankcase Liner - Measure – Protrusion NOTICE: The cylinder liner protrusion can only be correctly measured with the cylinder liners fully seated in the cylinder block. Incorrect measurements will result in engine performance problems or severe engine damage.

1. Install the cylinder liners (1) into the engine block bore without the O-rings.

NOTE: The cylinder liners will rotate freely in the bore when the cylinder liner and engine bore are clean.

NHIL14ENG1112AA

1

NHIL14ENG1151AA

2

NHIL14ENG1152AA

3

2. Place a dial indicator (1) on the cylinder block (2).

3. Set the dial indicator to zero.

4. Move the dial indicator to the cylinder liner neck (1).

Record the measurement.

5. The value must be within -0.01 - 0.07 mm (-0.0004 0.0028 in).

6. If the value is out of range, replace the cylinder liner.

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Engine - Engine and crankcase

Crankcase Liner - Install Prior operation: Crankcase Liner - Measure – Protrusion (10.001) 1. Install the first two O-rings (1) of the same color into the top two groves of the cylinder liner.

NOTICE: The first two O-rings have a different thickness and color than the third O-ring. Do not mix the O-rings.

2. Install the different color O-ring (2) into the bottom grove on the cylinder liner.

3. Lubricate the O-rings (1) with clean engine oil.

NHIL14ENG1149AA

1

NHIL14ENG1150AA

2

NHIL14ENG1112AA

3

NHIL15ENG0079AA

4

4. Apply a thin layer of LOCTITE® 262™ at location (1) and (2) of the cylinder liner.

5. Install the cylinder liner (1) into the same cylinder bore which it was removed from the engine block (2).

NOTICE: Be careful not to damage the O-rings.

6. Secure the cylinder liners in position with the formed spacers (1) and bolts (2).

NOTICE: If the cylinder head is not installed within one hour, the cylinder liners must remain clamped by the formed spacers and bolts for about eight hours, so the sealant can cure properly.

7. After the sealant is cured, verify the cylinder protrusion.

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Engine - Engine and crankcase

Engine support and mounts - Remove 1. Remove the nuts (1) from the rear engine support (4).

2. Remove the rear engine support (4).

3. Remove the bolts (2) from the front engine support (3).

4. Remove the front engine support (3).

NHIL14ENG1115AA

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1

Engine - Engine and crankcase

Engine support and mounts - Install 1. Install the front engine support (3) onto the alternator bracket.

2. Install the two M8 x 20 bolts (2) to secure the engine support.

3. Install the rear engine support (4) on the intake manifold studs.

4. Install the two M8 nuts (1) to secure the rear engine support.

5. Torque the M8 nuts in two stages: 1.

Stage 1: 10 - 20 N·m (7 - 15 lb ft)

2.

Stage 2: 28 - 35 N·m (21 - 26 lb ft)

NHIL14ENG1115AA

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1

Engine - Engine and crankcase

Engine - Troubleshooting Problem Engine will not start

Possible Cause An engine no start is defined as an engine that will crank but will not start. The most likely causes of this failure are issues related to the battery, fuel system or low engine compression.

1.

Correction Faulty battery, voltage too low

2.

Insufficient fuel level

3.

Contaminated fuel (water or air)

4.

Clogged fuel filter

5.

Faulty fuel injectors

6.

Faulty glow plugs (if equipped)

7.

Faulty fuel lift pump (if equipped)

8.

Faulty high equipped)

9.

Faulty mechanical pump, (if equipped)

pressure

pump,

(if

10. Low engine compression The engine starts then stalls

Engine will not crank

The engine is difficult to start

11. Engine timing incorrect This symptom is usually caused by fuel Visually inspect the fuel system for exterleakage or a clogged fuel filter. nal leakage. If leakage is found, repair as necessary. Check fuel system pressure for adequate pressure. If fuel pressure is lower than expected, repair as necessary.

An engine no-crank condition is defined 1. Check battery voltage. Charge or replace the battery as necessary. as an engine that will not crank. Possible failures include a dead or weak battery, 2. Verify the status of the battery disconan open battery disconnect switch (if nect switch (if equipped). The switch equipped) or a starting system failure. must be closed.

3. Check the starting system for possible failures. Check the starter relay and battery voltage at the starter. Perform a voltage drop test between the battery and the engine starter to check the starter wiring. Repair as necessary.

The cause of an engine hard start condi- 1. Faulty battery, voltage too low. tion is similar to those of an engine no start 2. Insufficient fuel level condition. Failures can include inadequate fuel pressure, air supply, engine compres- 3. Contaminated fuel (water or air) sion, faulty glow plugs or incorrect injection 4. Clogged fuel filter timing during start up.

5. Faulty fuel injectors 6.

Faulty glow plugs (if equipped)

7.

Faulty fuel lift pump (if equipped)

8.

Faulty high pressure pump

9.

Restricted air induction system

10. Low engine compression Engine has a slow cranking condition

11. Engine timing incorrect A slow engine crank condition can be 1. Load test the battery. Charge or replace caused by a weak battery, worn starter the battery as necessary. internal engine resistance. Extremely cold 2. Perform a voltage drop test on the startoperating temperatures can also be a facing circuit. There should be a drop less tor in a slow engine crank condition. than 0.5 V on both the positive and negative circuits. If the drop is greater than 0.5 V, repair as necessary.

3. Bench test the starter. If the starter operates slower than expected, replace the starter.

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Engine - Engine and crankcase

Problem Possible Cause The engine is consuming Engine oil consumption can be caused an excessive amount of by faulty piston rings, valve guide seals, main bearings, connecting rod bearings, engine oil. camshaft bearings, crankshaft journals, tapered or out-of-round cylinders etc.

The cooling system is Cooling system leaks can be caused by leaking coolant. faulty seals, gaskets, hoses, radiator or radiator cap etc.

The engine is leaking engine oil.

Engine oil leakage can be caused by faulty seals or gaskets, excessive crankcase pressure, faulty lubrication system components, or the wrong engine oil.

The engine is leaking refrigerant.

Refrigerant leaks can be caused by faulty air condition components such as the compressor, condenser, evaporator, or faulty seals.

The engine is firing when A runaway engine condition is caused when diesel fuel continues to be injected not commanded. or leaked into the engine when not commanded by the operator. Engine oil leakage into the cylinder can also cause this condition.

The engine is misfiring.

Engine misfires can be caused by faulty injection timing, malfunctioning injectors, malfunctioning injection pump or internal engine failures such as a burnt valve or a hole in a piston.

Low oil pressure Engine oil level low Wrong grade of oil Clogged oil filter Faulty oil pressure relief valve Worn oil pump drive shaft gears, or broken oil pipe Excessive main or connecting rod bearing clearances Oil pump axial clearance not properly set

Correction Verify that the engine is using the correct engine oil. Perform testing on the engine to help locate the cause of oil consumption.

Perform an engine leak down test or wet cylinder compression test.

Visually inspect all hoses, thermostat housing, water pump, radiator, and all other cooling system components for signs of leakage. If no visual leakage is found, pressure test the cooling system and check for leakage.

Visually inspect the engine lubrication system for any signs of leakage. Inspect the engine oil filter, oil cooler, oil pump, and all seals and gaskets for leaks. Verify that the engine oil is the recommended oil. Verify that the engine oil level is not overfull.

Use a refrigerant dye kit to locate the leak.

Leaking fuel injectors Engine oil leakage into cylinders Faulty ECU software

Check injection timing. Test for proper fuel pressure. Test fuel injectors for proper operation. Perform an engine compression test.

Fill to proper level Replace with correct grade oil Change oil and filter Replace relief valve Inspect oil system and components. Replace defective components Replace bearings or shaft if necessary

Check pump clearance and shim as needed to proper tolerance.

Faulty oil pressure sensor/oil pressure Check for fault codes, and testing proceswitch or electrical circuit dures to check electrical circuits.

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Index Engine - 10 Engine and crankcase - 001 Crankcase Liner - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Crankcase Liner - Measure – Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Crankcase Liner - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine - Overview – Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine support and mounts - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Engine support and mounts - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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Engine - 10 Cylinder heads - 101

R 753 IE4

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Contents Engine - 10 Cylinder heads - 101

TECHNICAL DATA Cylinder head Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Valves Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Valve guide Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Valve seat Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Valves Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Valve cover Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Cylinder head Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Valves Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Resurface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Valve seat Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Resurface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Engine - Cylinder heads

Cylinder head - Technical Data Piston protrusion above cylinder block 0.60 - 0.72 mm (0.02 - 0.03 in) 0.73 - 0.82 mm (0.03 - 0.03 in) 0.83 - 0.95 mm (0.03 - 0.04 in)

Gasket thickness required 1.42 mm (0.056 in) 1.52 mm (0.060 in) 1.62 mm (0.064 in)

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Cylinder head gasket identification marks No identification mark Two identification marks One identification mark

Engine - Cylinder heads

Valves - Technical Data

NHIL14ENG1169FA

(A) Stem diameter (B) Face width (C) Face angle (D) Head diameter (E) Margin thickness

1

Intake 7.94 - 7.96 mm (0.3126 - 0.3134 in) 3.57 - 3.85 mm (0.1406 - 0.1516 in) 29 ° 40.8 - 41.0 mm (1.61 - 1.61 in) 1.82 mm (0.072 in)

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Exhaust 7.921 - 7.939 mm (0.3119 - 0.3126 in) 2.640 - 2.992 mm (0.1039 - 0.1178 in) 44 ° 37.9 - 38.1 mm (1.49 - 1.50 in) 1.73 mm (0.068 in)

Engine - Cylinder heads

Valve guide - Technical Data Valve guide Exhaust Intake Valve guide Exhaust Intake Valve guide Exhaust Intake Valve guide Exhaust Intake

stem diameter 7.921 - 7.939 mm (0.312 - 0.313 in) 7.94 - 7.96 mm (0.3126 - 0.3134 in) clearance 0.040 - 0.073 mm (0.002 - 0.003 in) 0.030 - 0.065 mm (0.001 - 0.003 in) inner diameter 7.979 - 7.994 mm (0.314 - 0.315 in) 7.99 - 8.005 mm (0.3146 - 0.3152 in) height 54.750 - 55.250 mm (2.156 - 2.175 in)

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Engine - Cylinder heads

Valve seat - Technical Data Valve recession (service limit) Exhaust Intake Counterbore inner diameter Exhaust Intake Counterbore inner height Exhaust Intake Seat outer diameter Exhaust Intake Seat height Exhaust Intake Seat width Exhaust Intake

0.3 mm (0.012 in) 38.964 - 38.988 mm (1.534 - 1.535 in) 41.962 - 41.985 mm (1.652 - 1.653 in) 11.0 - 11.1 mm (0.433 - 0.437 in) 39.050 - 39.066 mm (1.537 - 1.538 in) 42.070 - 42.086 mm (1.656 - 1.657 in) 7.85 - 7.95 mm (0.3091 - 0.3130 in) 7.73 - 7.83 mm (0.3043 - 0.3083 in) 1.6 - 1.8 mm (0.063 - 0.071 in)

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Engine - Cylinder heads

Valves - Exploded view

NHIL14ENG1171AA

(1) Valve keepers (2) Spring retainer (3) Valve spring

1

(4) Spring plate washer (5) Valve stem seal (6) Valve

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Engine - Cylinder heads

Valve cover - Remove 1. Remove the wire harness (1) from the fuel injectors.

NHIL14ENG1137AA

1

NHIL14ENG1138AA

2

NHIL14ENG1139AA

3

NHIL14ENG1140AA

4

2. Push the fuel return hose clamp to remove the fuel injector return line (1).

3. Use a 13 mm wrench to hold the fuel injector feed connector while you remove the fuel injector supply lines (2).

4. Remove the Allen head bolts (1) from the fuel injector hold down.

5. Remove the fuel injector hold down (2).

NOTICE: Label the injectors before removal. The injectors need to be installed in the same location from which they were removed. Each injector has its own IMA code.

6. Remove the fuel injector (3).

7. Remove the four Allen head bolts (1) from the thermostat housing.

8. Remove the top thermostat housing (2).

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Engine - Cylinder heads

9. Remove the thermostat (1).

NHIL14ENG1142AA

5

NHIL14ENG1139AA

6

NHIL14ENG1141AA

7

10. Remove the bolts (1) from the common rail.

11. Remove the common rail (2).

12. Remove the Allen head bolts (2) from the valve cover.

NOTE: There are two Allen head bolts (1) located in the thermostat housing.

13. Remove the valve cover (3).

14. Remove the valve cover gasket.

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Engine - Cylinder heads

Valve cover - Install 1. Install a new valve cover gasket (3).

NOTICE: Do not add any sealant . The drain hole for the crank case breather can be blocked.

2. Install the valve cover (2) on the cylinder head.

3. Install the Allen head bolts (1) to secure the valve cover.

NHIL14ENG1145AA

1

NHIL14ENG1250AA

2

NHIL14ENG1228AA

3

NHIL14ENG1227AA

4

4. Follow the sequence shown and torque the Allen head bolts to 11.8 N·m (8.7 lb ft).

5. Install the thermostat (1) into the housing.

6. Install the top thermostat housing (2).

7. Install the four Allen head bolts (1) to secure the top thermostat housing.

8. Torque the Allen head bolts to 10.8 N·m (8.0 lb ft).

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Engine - Cylinder heads

9. Install a new O-ring (1) onto the injectors.

10. Apply MOLYKOTE® P-1500 ANTI-FRETTING PASTE to the fuel injector in the location (2).

NHIL14ENG1144AA

5

NHIL14ENG1139AA

6

NHIL14ENG1206AA

7

NHIL14ENG1138AA

8

11. Install the fuel injector (3).

NOTICE: The injectors need to be installed in the same location from which they were removed. Each injector has its own IMA code.

12. Install the Allen head bolt (1) with spherical washer (2) into the fuel injector hold down.

13. Install the fuel injector hold down (3).

14. Torque the Allen head bolt to 21 - 25 N·m (15 - 18 lb ft).

15. Push the fuel return hose clamp to install the fuel injector return line (1).

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Engine - Cylinder heads

16. Use a 13 mm wrench to hold the fuel injector feed connector while you install the fuel injector supply lines (2).

17. Install the wire harness (1) to the fuel injectors.

NHIL14ENG1137AA

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9

Engine - Cylinder heads

Cylinder head - Remove Prior operation: Rocker arm - Remove (10.106) 1. Use a 12mm triple square socket to remove the M12 head bolts (1).

2. Use a 14mm triple square socket to remove the M14 head bolts (2).

3. Remove the cylinder head from the engine block.

NHIL14ENG1167AA

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1

Engine - Cylinder heads

Cylinder head - Measure Prior operation: Cylinder head - Remove (10.101) Use a dial indicator with the support block 380003388 to measure the piston protrusion above the cylinder block with the piston at Top Dead Center (TDC).

1. Place the support block 380003388 on the cylinder block surface.

2. Set the dial indicator to zero.

3. Set the piston to TDC. 4. Move the support block to the piston surface. Record the measurement.

5. Repeat for all other cylinders.

6. Use the average measurement to determine the gasket thickness required.

Piston protrusion above cylinder block 0.60 - 0.72 mm (0.02 - 0.03 in) 0.73 - 0.82 mm (0.03 - 0.03 in) 0.83 - 0.95 mm (0.03 - 0.04 in)

Gasket thickness required 1.42 mm (0.056 in) 1.52 mm (0.060 in) 1.62 mm (0.064 in)

7. After you determine the head gasket thickness required, identify and select the proper gasket.

NOTE: The identification marks are in the lower right hand corner of the gasket.

No identification mark Two identification marks One identification mark

1.42 mm (0.056 in) 1.52 mm (0.060 in) 1.62 mm (0.064 in)

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Engine - Cylinder heads

Cylinder head - Install Prior operation: Cylinder head - Measure (10.101) 1. Clean out the bolt holes in the cylinder block.

NOTE: Be certain there are no contaminants (dirt, old oil, or coolant) in the bolt holes.

2. Clean the mating surface on the engine block (4) and the cylinder head (2).

3. Install the correct thickness head gasket (3).

Cylinder head - Measure (10.101).

See

NOTICE: The cylinder head gasket must be installed on the engine block dry. Do not use any sealant or adhesive on the gasket.

NHIL14ENG1168AA

1

NHIL14ENG1167AA

2

NHIL14ENG1167AA

3

4. Install the cylinder head guide pins into the M12 bolt holes 5. Install the cylinder head (2) to the engine block (4).

NOTICE: Cylinder head bolts must always be replaced when the bolts are loosened or removed.

6. Install the new M14 cylinder head bolts (2) in the center of the cylinder head.

NOTE: The new cylinder head bolts do not need lubricated before installation. New cylinder head bolts come lubricated with an anti-seizing lubricant from the supplier.

7. Install the new M12 cylinder head bolts (1) around the outside of the cylinder head.

8. Torque the center M14 bolts in three stages following the sequence shown: 1.

Stage 1: 30 N·m (22 lb ft)

2.

Stage 2: + 65 °

3.

Stage 3: + 65 °

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Engine - Cylinder heads

9. Torque the outside M12 bolts in four stages following the sequence shown: 1.

Stage 1: (1), (2), (3), 30 N·m (22 lb ft)

2.

Stage 2: (1), (2), (3), + 85 °

3.

Stage 3: (4), (5), (6) 30 N·m (22 lb ft)

4.

Stage 4: (4), (5), (6) + 85 °

NHIL14ENG1167AA

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4

Engine - Cylinder heads

Valves - Remove Prior operation: Cylinder head - Remove (10.101) 1. Use a valve spring compressor to release the spring pressure.

2. Remove the valve spring keepers (1).

3. Carefully remove the valve spring compressor.

4. Remove the valve spring retainer (2).

5. Remove the valve spring (3).

6. Remove the plate washer (4).

NHIL15ENG0042AA

1

NHIL15ENG0043AA

2

7. Carefully flip the cylinder head over.

8. Remove the valve (1) from the bottom side of the cylinder head.

9. Remove the valve guide seal (5), Figure 1.

Next operation: Valves - Resurface (10.101)

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Engine - Cylinder heads

Valves - Resurface Prior operation: Valves - Remove (10.101) Pitted valves can be refaced to the proper angle on a valve grinder, to ensure the correct relation between the cylinder head seat and the valve mating surface.

Replace valves with excessive wear on stems or valves that are warped excessively. When an excessively‑warped valve head is refaced, a knife edge will be ground on part or all of the valve head due to the amount of metal that must be removed to completely reface it. Knife edges lead to breakage or burning.

1. Reface the valve to the proper angle if the valve face is pitted or worn.

NOTICE: When you reface the valve, do not thin the valve margin thickness less than 1.30 mm (0.051 in).

2. Measure the valve and replace if out of specification.

See Valves - Technical Data (10.101).

Next operation: Valves - Install (10.101)

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Engine - Cylinder heads

Valves - Install Prior operation: Valves - Resurface (10.101) 1. Lubricate the valve guide (2) and the valve stem (1) with clean engine oil.

2. Install each valve (1) in the port from which it was removed.

NHIL15ENG0043AA

1

NHIL14ENG1170AA

2

NHIL15ENG0042AA

3

3. Install the valve guide seal (1) onto the valve stem and push down until the valve guide seal is seated against the valve guide.

4. Install the plate washer (4) onto the valve stem.

5. Install the valve spring (3) onto the valve stem.

6. Install the valve spring retainer (2).

7. Use a valve spring compressor to compress of the valve springs enough to install the valve spring keepers.

8. Apply a small amount of grease on the valve spring keepers (1).

9. Install the valve spring keepers (1).

10. Carefully remove the valve spring compressor, ensure the valve spring keepers are seated properly in the valve stem groove.

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Engine - Cylinder heads

Valve seat - Inspect 1. Inspect the valve seats for cracks, excessive wear, and looseness in counterbore.

2. Measure the exhaust and intake valve seats.

Valve seat - Technical Data (10.101).

See

3. If the measured values are not as specified, recondition the valve seat.

NOTICE: If the valve seats cannot be repaired, it will be necessary to replace the cylinder head.

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Engine - Cylinder heads

Valve seat - Resurface NOTICE: Regardless of the type of equipment, it is essential that valve guide bores be free of carbon or dirt to achieve proper centering of pilot in valve guide, ensuring concentricity when reconditioning valve seats.

1. Recondition pitted or worn valve seats to the specified angles.

NOTE: If during seats valve reconditioning excessively lowers valve recess or if the seat width is wider than specified measures, replace valve seat insert.

2. Install seat valve inserts after heating cylinder head in an oven at 150.0 °C (302.0 °F) or cooling them down at -170.0 °C (-274.0 °F) in liquid nitrogen atmosphere.

3. Seat installation into head bore must be free, no requiring pressure for installation if above conditions are maintained.

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Index Engine - 10 Cylinder heads - 101 Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Cylinder head - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cylinder head - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Cylinder head - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Valve cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Valve cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Valve guide - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Valve seat - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Valve seat - Resurface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Valve seat - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Valves - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Valves - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Valves - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Valves - Resurface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Valves - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Pan and covers - 102

R 753 IE4

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Contents Engine - 10 Pan and covers - 102

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

Timing gear housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Accessory drive cover Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Engine - Pan and covers

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

2. Remove the washers (2).

3. Use a suitable tool to cut through the oil pan sealant.

NOTICE: Make sure you do not bend the oil pan rails.

4. Remove the oil pan (3) from the engine block.

NHIL14ENG1114AA

Next operation: Engine oil pan - Install (10.102)

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1

Engine - Pan and covers

Engine oil pan - Install 1. Remove any excess oil and sealant from the sealing surface of the oil pan.

2. Degrease all sealing surfaces on the oil pan and the engine block.

3. Apply a continuos bead of DOW CORNING® 7091 ADHESIVE SEALANT BLACK (1) around the oil pan flange on the inside of the bolts holes.

NOTICE: Do not apply excessive amounts of sealant.

Excessive amounts of sealant could loosen and become lodged on the oil pick-up strainer, restricting the oil flow.

NHIL14ENG1135AA

1

NHIL14ENG1114AA

2

4. Install the oil pan (3) onto the engine block.

5. Install the M6 x 16 bolts (1) with a washer (2) hand tight.

6. Torque the M6 x 16 bolts to 12.7 N·m (9.4 lb ft) in a diagonal pattern.

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Engine - Pan and covers

Timing gear housing - Remove 1. Remove the two bolts (1) from the alternator bracket.

2. Remove the alternator bracket (2) from the engine block.

NHIL14ENG1119AA

1

NHIL14ENG1120AA

2

NHIL14ENG1121AA

3

NHIL14ENG1123AA

4

3. Remove the water pump hoses (1).

4. Remove the bolts (3) from the water pump.

5. Remove the water pump (2).

6. Remove the water pump gasket (1).

7. Remove the Allen head bolts (1) from the belt tensioner bracket.

8. Remove the belt tensioner bracket (2).

9. Remove the crankshaft pulley nut (3).

10. Remove the crankshaft pulley (4).

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Engine - Pan and covers

11. Remove the bolts (1) from the timing gear cover.

NOTE: Bolt sizes vary in length, label the location to ease installation.

12. Remove the timing gear cover (2).

NHIL14ENG1124AA

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5

Engine - Pan and covers

Timing gear housing - Install Prior operation: Timing gear housing - Remove (10.102) 1. Apply a thin bead of LOCTITE® 5970™ (1) to the mating surface of the timing gear cover.

NHIL14ENG1126AA

1

NHIL14ENG1125AA

2

NHIL14ENG1123AA

3

NHIL14ENG1121AA

4

2. Install the timing gear cover (1) onto the engine block.

3. Install the M6 bolts (2) to the location which you removed them from.

NOTE: Bolt sizes vary in length.

4. Inspect the seal (3), replace if any damage is found.

5. Install the crankshaft pulley (4) onto the crankshaft.

6. Install the crankshaft pulley nut (3).

7. Install the belt tensioner bracket (2).

8. Install the two Allen head bolts (1) to secure the belt tensioner bracket.

9. Install a new water pump gasket (1).

10. Install the water pump (2) to the engine block.

11. Install the bolts (3) to secure the water pump.

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Engine - Pan and covers

12. Install the alternator bracket (2) to the top of the engine block.

13. Install the two bolts (1) to secure the alternator bracket.

NHIL14ENG1119AA

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5

Engine - Pan and covers

Accessory drive cover - Remove Prior operation: Timing gear housing - Remove (10.102) 1. Remove the Allen head screws (1) from the from the rear flange.

2. Remove the rear flange (2) from the engine block.

NHIL15ENG0098AA

1

NHIL15ENG0096AA

2

NHIL15ENG0099AA

3

NHIL15ENG0097AA

4

3. Remove the four Allen head screws (1) from the accessory drive cover.

4. Remove the accessory drive cover (2) from the engine block.

5. Remove the accessory drive sprocket assembly (1) from the engine block.

6. Remove the accessory drive idler gear (1) from the bore in the engine block.

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Next operation: Accessory drive cover - Install (10.102)

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Accessory drive cover - Install Prior operation: Accessory drive cover - Remove (10.102) 1. Ensure the oil grooves (1) of the accessory drive idler gear are toward the engine block.

2. Apply clean engine oil onto the shaft (2) of the accessory drive idler gear.

NHIL15ENG0100AA

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NHIL15ENG0101AA

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NHIL15ENG0099AA

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NHIL15ENG0096AA

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3. Install the accessory drive idler gear (1) into the bore (2) in the engine block.

4. Install the accessory drive sprocket assembly (1) into the bore in the engine block.

5. Apply clean engine oil to the outer surface of the ball bearings.

6. Install the accessory drive cover (2).

NOTE: Use the alignment pins to ensure the cover is installed properly.

7. Apply LOCTITE® 572™ to the threads of the Allen head screws (1).

8. Install the Allen head screws (1) to secure the accessory drive cover.

9. Torque the Allen head screws to 24.5 N·m (18.1 lb ft).

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10. Install a new gasket with the flat cut (3) at the top.

11. Install the rear flange (2).

12. Install the Allen head screws (1) to secure the rear flange to the engine block.

13. Torque the Allen head screws (1) to 19.6 N·m (14.5 lb ft).

NHIL15ENG0102AA

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5

Index Engine - 10 Pan and covers - 102 Accessory drive cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Accessory drive cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine oil pan - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine oil pan - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Timing gear housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Timing gear housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Engine - 10 Crankshaft and flywheel - 103

R 753 IE4

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Contents Engine - 10 Crankshaft and flywheel - 103

TECHNICAL DATA Crankshaft Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Crankshaft pulley Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Engine flywheel Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Flywheel housing Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Visual inspection – Main bearing carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Crankshaft oil seal Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Crankshaft End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Crankshaft gears Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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Crankshaft - Technical Data Crankshaft front main bearing journal outer diameter First oversized bearing Center main bearing crankshaft journal outer diameter First oversized bearing Rear main bearing crankshaft journal outer diameter First oversized bearing Crankshaft connecting rod journal outer diameter First oversized bearing Wear limit Front main bearing clearance (between crankshaft front main bearing journal outer diameter and crankshaft front main bearing inner diameter) Center main bearing clearance (between center main bearing crankshaft journal outer diameter and main bearings carrier inner diameter) Rear main bearing clearance (between rear main bearing crankshaft journal outer diameter and rear main bearing carrier inner diameter) Connecting rod bearing clearance (between crankshaft connecting rod journal outer diameter and connecting rod bearings inner diameter)

62.985 - 63.005 mm (2.480 - 2.481 in) 0.250 mm (0.010 in) 63.005 - 63.020 mm (2.481 - 2.481 in) 0.250 mm (0.010 in) 79.985 - 80 mm (3.149 - 3.150 in) 0.250 mm (0.010 in) 53.940 - 53.955 mm (2.124 - 2.124 in) 0.250 mm (0.010 in) 0.10 mm (0.004 in) 0.023 - 0.083 mm (0.0009 - 0.0033 in)

0.008 - 0.051 mm (0.0003 - 0.0020 in)

0.045 - 0.085 mm (0.0018 - 0.0033 in)

0.012 - 0.066 mm (0.0005 - 0.0026 in)

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Crankshaft pulley - Remove 1. Remove the alternator belt (1).

NHIL14ENG1179AA

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NHIL14ENG1284AA

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2. Install the crankshaft rotation block tool 380003387 (1) in place of starter.

3. Use a 46mm socket to remove the left-hand thread crankshaft nut (1).

4. Remove the crankshaft pulley (2).

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Crankshaft pulley - Install 1. Clean contact surfaces between the crankshaft hub and crankshaft nut with cleaning solvent and dry with compressed air.

2. Clean the crankshaft threads.

3. If the timing gear cover oil seal has been removed for replacement, clean the seating surface in the cover.

NOTICE: The front oil seal and the sealing lip of an oil seal can be damaged by grease on your hands or the dirt from gloves. A damaged oil seal or oil seal lip could result in an oil leak. When fitting or replacing the crankshaft pulley, do not touch inside the oil seal or touch the oil seal lip with your bare hands or with dirty gloves.

4. Install the crankshaft rotation block tool 380003387 (1).

5. Apply MOLYKOTE ® G-N METAL ASSEMBLY PASTE or equivalent to the left-hand threaded crankshaft nut and the threads on the crankshaft.

NHIL14ENG1284AA

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NHIL14ENG1181AA

2

NHIL14ENG1180AA

3

6. Align the keyway (1) of the crankshaft pulley with the crankshaft key (2).

7. Install the crankshaft pulley (2) onto the crankshaft.

8. Install the left-hand thread crankshaft nut (1) to secure the crankshaft pulley.

NOTICE: The crankshaft nut has left-handed threads.

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9. Torque the crankshaft nut to 400 N·m (295 lb ft).

10. Loosen the crankshaft nut.

11. Torque the crankshaft nut to 600 N·m (443 lb ft).

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Engine - Crankshaft and flywheel

Engine flywheel - Remove Prior operation: Crankshaft - End play (10.103) 1. Remove the Allen head starter bolts (1).

NOTE: Only one bolt shown.

2. Remove the starter (2).

NHIL14ENG1131AA

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NHIL14ENG1284AA

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NHIL14ENG1130AA

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NHIL14ENG1282AA

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3. Install the crankshaft rotation block tool 380003387 (1) to stop the crankshaft rotation.

4. Remove two flywheel bolts (1) as shown.

5. Install the flywheel guide pins 380003389 (2) where the two bolts were removed.

6. Remove the remaining flywheel bolts (1).

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7. Thread two bolts (1) into the outside rim of the flywheel.

8. Attach a suitable lifting device to the two long bolts.

9. Remove the flywheel by sliding it on the flywheel guide pins.

NHIL14ENG1158AA

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NHIL14ENG1283AA

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NHIL14ENG1284AA

7

10. Remove the flywheel guide pins (1).

11. Remove the crankshaft rotation block tool (1) .

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Engine flywheel - Install Prior operation: Flywheel housing - Install (10.103) 1. Verify there are no scratches, cracks or seizure marks on the flywheel mating surface. Replace the flywheel if damage is visible.

NOTE: Only minor scratches or seizure marks can be removed.

2. Install a new O-ring (1) onto the flywheel.

NOTE: Use a small amount of grease to hold the O-ring in position.

NHIL14ENG1159AA

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NHIL14ENG1283AA

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NHIL14ENG1158AA

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3. Inspect the rear oil seal (1) to ensure it is in good condition. Replace the rear oil seal if any doubt exist.

4. Install the flywheel guide pins (2) into the crankshaft.

5. Attach a hoist or suitable lifting device to the bolts (1) on the outside rim of the flywheel.

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6. Install the flywheel onto the flywheel guide pins (1).

NOTICE: Do not touch or handle the lips of the rear oil seal.

7. Install and hand tighten four new M12 x 70 flywheel bolts.

8. Remove the two flywheel guide pins (1).

NHIL14ENG1282AA

4

NHIL14ENG1130AA

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NHIL14ENG1284AA

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NHIL14ENG1130AA

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9. Install the last two flywheel bolts (1).

10. Install the crankshaft rotation block tool 380003387 (1) in the starter motor location.

11. In a cross pattern, torque the flywheel bolts (1) to 50 N·m (37 lb ft).

12. Completely loosen one flywheel bolt at a time.

13. In a clockwise direction torque the flywheel bolt to 20 N·m (15 lb ft).

14. Tighten the flywheel bolt an additional 75 °.

15. Repeat for the remaining five flywheel bolts.

16. Remove the crankshaft rotation block tool 380003387.

Next operation: Crankshaft - End play (10.103)

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Flywheel housing - Remove Prior operation: Engine flywheel - Remove (10.103) 1. Remove the crankshaft thrust plate (if equipped).

2. Remove the flywheel housing bolts (1).

3. Use a rubber mallet to tap evenly around the flywheel housing.

4. Remove the flywheel housing (2) from the engine block.

NOTICE: Do not touch or handle the lips of the rear oil seal or the rear main bearing carrier O-ring.

5. Remove the main bearing carrier nuts (3).

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NHIL15ENG0244AA

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6. Remove the main bearing carrier.

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Flywheel housing - Install Prior operation: Flywheel housing - Remove (10.103) 1. Apply DOW CORNING® 7091 ADHESIVE SEALANT BLACK on the flywheel housing groove (1) where the O-ring sits.

NHIL14ENG1133AA

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NHIL14ENG1134AA

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2. Install a new O-ring into the groove (1).

3. Apply a 2 mm (0.1 in) bead of DOW CORNING® 7091 ADHESIVE SEALANT BLACK (2) around the O-ring.

4. Install a new O-ring (2) on the rear main bearing carrier (3) 5. Apply a 2 mm (0.1 in) bead of DOW CORNING® 7091 ADHESIVE SEALANT BLACK (1) around the O-ring of the rear main bearing carrier.

6. Use clean engine oil to lubricate the rear crankshaft journal and main bearing.

7. Install the main carrier bearing housing into the engine block.

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8. Align the flywheel housing to the main bearing carrier roll pin (3).

9. Install the nuts (4), and torque to 24.0 N·m (17.7 lb ft).

10. Install the flywheel housing (2) to the engine block.

11. Install the flywheel housing bolts (1).

12. Torque the flywheel housing bolts to 68.6 N·m (50.6 lb ft) in a diagonal pattern.

NHIL14ENG1132AA

Next operation: Engine flywheel - Install (10.103)

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Engine - Crankshaft and flywheel

Flywheel housing - Visual inspection – Main bearing carrier 1. Carefully inspect the following items for damage.

• Rear main oil seal (1) • Thrust washer halves (2) • Rear main bearing (3)

NHIL15ENG0244AA

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NHIL15ENG0244AA

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NHIL15ENG0244AA

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Rear main oil seal To remove or replace the rear main oil seal, see Crankshaft oil seal Rear seal - Remove (10.103).

Thrust washers To remove the thrust washer halves, carefully pry out the washer halves.

NOTICE: Do not damage the rear main bearing carrier.

When installing the thrust washers, make sure the oil passages (2) are towards the outside.

• Align the thrust washer tab (1) into the bearing housing.

• Install the other thrust washer halve.

• Press the washer halves simultaneously into the carrier.

Rear main bearing To remove the rear main bearing, use a mandrel to press the main bearing out of the carrier.

When installing the bearing, align the hole (1) with the oil passage in the carrier.

Press the bearing into the carrier.

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Crankshaft oil seal Front seal - Remove Prior operation: Timing gear housing - Remove (10.102) 1. Use a hammer to tap around the front oil seal (1) to remove it from the timing housing cover (2).

NHIL15ENG0176AA

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

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Engine - Crankshaft and flywheel

Crankshaft oil seal Front seal - Install Prior operation: Crankshaft oil seal Front seal - Remove (10.103) 1. Position the front oil seal (1) on the front side of the timing housing cover (2).

2. Use a hammer and a block of wood to carefully tap around the outside edge of the front oil seal until the it is flush with the timing housing cover.

NHIL15ENG0177AA

Next operation: Timing gear housing - Install (10.102)

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Engine - Crankshaft and flywheel

Crankshaft oil seal Rear seal - Remove Prior operation: Flywheel housing - Remove (10.103) 1. Carefully pry the rear oil seal (1) out of the rear main bearing carrier.

NOTICE: Do not damage the rear main bearing carrier.

NHIL15ENG0244AA

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

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Engine - Crankshaft and flywheel

Crankshaft oil seal Rear seal - Install Prior operation: Crankshaft oil seal Rear seal - Remove (10.103) 1. Lubrication the outer surfaces of the rear oil seal with clean engine oil.

2. Use a hammer and a block of wood to carefully tap around the outside edge of the rear oil seal until the it is flush with the rear main bearing carrier.

NOTICE: Do not damage the rear main bearing carrier.

NHIL15ENG0244AA

Next operation: Flywheel housing - Install (10.103)

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Engine - Crankshaft and flywheel

Crankshaft - End play 1. Attach a dial indicator (1) to the cylinder block.

2. Measurement can be taken at the flywheel or the crankshaft counter weight.

3. Firmly force the crankshaft rearward.

4. Record the measurement.

5. Firmly force the crankshaft forward.

6. Record the measurement.

7. Subtract the measurements to determine the crankshaft end play.

8. The crankshaft end play should be within 0.080 0.230 mm (0.003 - 0.009 in).

9. If the end play is not within specification, calculate the necessary thickness of the thrust washer you need.

10. Install the correct thrust washer in the rear main carrier.

11. Recheck the crankshaft end play.

12. Repeat the steps until the crankshaft end play is within specification.

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NHIL14ENG1136AA

1

Engine - Crankshaft and flywheel

Crankshaft - Remove Prior operation: Connecting rod and piston - Remove (10.105) 1. Remove the main bearing lubricating screws (1) that hold the main bearing carriers in the cylinder block.

NHIL14ENG1183AA

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NHIL15ENG0009AA

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NHIL15ENG0008AA

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NHIL15ENG0007AA

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2. Remove the Allen head bolt (2) from the piston cooling jet.

3. Remove the piston cooling jet (1).

NOTICE: When removing the crankshaft do not damage the piston cooling jet. Ensure to remove the oil piston cooling jet.

4. Install the crankshaft installer tool 380003382 (1) over the crankshaft gear to protect the front main bearing.

5. Make a reference mark from the main bearing carriers across the engine block in the locations of (1).

6. Make a reference mark across the two bearing carrier halves (2).

7. Number all the bearing carriers in accordance to the crankshaft journal which they are fitted.

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8. Carefully remove the crankshaft enough to access the bearing carriers (1).

NOTICE: Before you remove the crankshaft from the block, number or mark the bearing carriers according to the journal upon which they are fitted. Also make matching marks on both bearing carrier halves for correct reassembly.

9. Remove the bolts (2) from the crankshaft bearing carriers.

10. Remove the crankshaft bearing carriers (1) from the engine block.

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NHIL15ENG0032AA

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11. Carefully remove the crankshaft (1) from the engine block.

Next operation: Crankshaft - Inspect (10.103)

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Engine - Crankshaft and flywheel

Crankshaft - Inspect 1. Inspect crankshaft for deep grooves, scratches, pitted surfaces or uneven wear.

2. Inspect crankshaft rear oil seal surface for scoring or damage.

3. Inspect crankshaft oil passages for restrictions.

4. Inspect the crankshaft threaded bolt holes for damage.

5. Inspect the crankshaft balancer keyway for damage.

6. Measure the journals of the crankshaft to determine if replacement or grinding is necessary. See Crankshaft - Technical Data (10.103).

NHIL15ENG0033AA

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1

Engine - Crankshaft and flywheel

Crankshaft - Install Prior operation: Crankshaft - Remove (10.103) 1. Lubricate the main bearing bores in the engine block with clean engine oil.

2. Install the crankshaft installer tool 380003382 (1) over the crankshaft gear to protect the front main bearing.

NHIL15ENG0008AA

1

NHIL15ENG0032AA

2

NHIL15ENG0006AA

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3. Position the engine block in the horizontal position with the oil pan side facing up.

4. Carefully install the crankshaft (1) into the engine block until you can install the bearing carriers.

5. Install the bearing carriers (1) onto the crankshaft NOTICE: Ensure that all carriers were positioned so that the front of the carrier halve is toward the crankshaft gear after installing them on the journal.

6. Lubricate the bearing carrier bolts with MOLYKOTE ® G-N METAL ASSEMBLY PASTE .

7. Install the bearing carrier bolts (2).

8. Torque the bearing carrier bolts to 44.1 N·m (32.5 lb ft).

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Engine - Crankshaft and flywheel

9. Carefully install the crankshaft with the bearing carriers into the engine block.

10. Rotate the bearing carriers to align with the reference marks made during disassembly.

NOTICE: If no marks are present, position the bearing carriers with the round hole (1) through the casting pointing toward the oil pan flange.

NHIL15ENG0007AA

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NHIL14ENG1183AA

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11. Install new sealing washers on the main bearing lubricating screws (1).

12. To avoid damage to the threads, install the main bearing lubricating screws (1) by hand, into the engine block from the locating which they were removed.

NOTICE: Ensure the hole in the main bearing carriers is positioned correctly to allow the lubricating screws to thread in without binding.

13. Torque the main bearing lubricating screws to 53.9 N·m (39.8 lb ft).

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Crankshaft gears - Remove NOTE: Replace the timing gear only if worn or damaged.

1. Make a reference mark where the idler gear splines with the crankshaft gear (2).

2. Remove the oil pump gear (3).

3. Remove the idler gear (1).

NHIL14ENG1185AA

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NHIL14ENG1188AA

2

4. Install the crankshaft gear puller 380003390 onto the crankshaft gear.

5. Tighten the four clamping screws (2) securely.

6. Turn the crankshaft gear puller screw (1) to remove the crankshaft gear.

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Crankshaft gears - Install 1. Use the reference mark on the crankshaft gear you removed to make a new reference mark on the new gear.

2. Heat the crankshaft gear to 70 °C (158 °F).

3. Align the keyway (1) in the crankshaft gear with the key (1) on the crankshaft.

4. Align the reference marks on the idler gear and crankshaft gear, while you install the crankshaft gear onto the crankshaft.

NOTE: Keep the crankshaft gear against the crankshaft shoulder for at least 10 s to cool and hold position.

NHIL14ENG1187AA

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1

Index Engine - 10 Crankshaft and flywheel - 103 Crankshaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Crankshaft - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Crankshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Crankshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Crankshaft - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Crankshaft gears - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Crankshaft gears - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Crankshaft oil seal Front seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Crankshaft oil seal Front seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Crankshaft oil seal Rear seal - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Crankshaft oil seal Rear seal - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Crankshaft pulley - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Crankshaft pulley - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine flywheel - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine flywheel - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Flywheel housing - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Flywheel housing - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Flywheel housing - Visual inspection – Main bearing carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Contents Engine - 10 Connecting rods and pistons - 105

TECHNICAL DATA Connecting rod and piston Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Piston Ring - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Connecting rod and piston Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

Piston Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Ring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Ring - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Connecting rod and piston - Technical Data

NHIL14ENG1173FA

Parallelism between the piston pin end and the bearing end (A) Length (C) Inner diameter crankshaft end (without bearings) Maximum wear or taper (B) Inner diameter piston pin end Piston pin outer diameter Piston pin bore Maximum wear or taper Mounting clearance

1

0.15 mm (0.006 in) 162.975 - 163.025 mm (6.416 - 6.418 in) 57.563 - 57.582 mm (2.266 - 2.267 in) 0.02 mm (0.0008 in) 30.035 - 30.050 mm (1.182 - 1.183 in) 29.992 - 29.996 mm (1.181 - 1.181 in) 34.0 - 34.025 mm (1.339 - 1.340 in) 0.01 mm (0.0004 in) 0.0390 - 0.0580 mm (0.0015 - 0.0023 in)

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Piston Ring - Technical Data Piston ring thickness First compression ring (tapered outer edge) Second compression ring Oil control ring

d 2.568 - 2.597 mm (0.101 - 0.102 in) 1.970 - 1.995 mm (0.078 - 0.079 in) 2.97 - 2.99 mm (0.117 - 0.118 in)

Piston ring groove width First compression ring (tapered outside edge) Second compression ring Oil control ring

3 mm (0.118 in) (nominal) 2.06 - 2.08 mm (0.081 - 0.082 in) 3.03 - 3.05 mm (0.119 - 0.120 in)

Piston ring groove clearance First compression ring (tapered outside edge) Second compression ring Oil control ring

Not applicable (tapered) 0.065 - 0.11 mm (0.003 - 0.004 in) d 0.04 - 0.08 mm (0.002 - 0.003 in)

Piston ring end gap First compression ring (tapered outside edge) Maximum Second compression ring Maximum Oil control ring Maximum

0.3 - 0.42 mm (0.012 - 0.017 in) 0.50 mm (0.020 in) 0.65 - 0.85 mm (0.026 - 0.033 in) 0.90 mm (0.035 in) 0.3 - 0.60 mm (0.012 - 0.024 in) 0.70 mm (0.028 in)

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Connecting rod and piston - Exploded view

NHIL13ENG1293FA

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

Connecting rod Piston pin Piston Snap ring Trapazoidal combustion ring

1

(6) Bevel cut intermediate ring (7) Oil control ring (8) Cap bolts (9) Connecting rod cap (10) Half bearings

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Connecting rod and piston - Remove Prior operation: Engine oil pan - Remove (10.102) NOTICE: Each connecting rod assembly must be reassembled in the same original location. Mark or identify each connecting rod assembly to ensure placement in the original cylinder number location during reassembly. Retain the rod cap and bearings with the connecting rod and piston assembly. Do not mix the components. Remove the connecting rod bearings. Keep the bearings, with the original connecting rod and connecting rod cap, together as a matched set.

NOTICE: The connecting rod can damage the crankshaft journal, the cylinder bore, and piston cooling jet. Ensure no components are damaged during connecting rod removal.

1. Rotate the engine block to the vertical position.

2. Remove the bolts (2) from the connecting rod cap (3).

3. Remove the rod cap (3) from the connecting rod.

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

5. Repeat these steps for the remaining cylinders.

NHIL13ENG1206AA

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

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Engine - Connecting rods and pistons

Connecting rod and piston - Disassemble Prior operation: Connecting rod and piston - Remove (10.105) 1. Verify the piston does not show any signs of seizing, scoring or cracking. Replace if necessary.

2. Use the tool 380000324 (1) to remove the piston rings (2).

NHIL13ENG1212AA

1

NHIL13ENG1208AA

2

NHIL13ENG1209AA

3

3. Use snap ring pliers (1) to remove the snap rings (2) that hold the piston pin in place.

4. Remove the piston pin (1).

NOTE: It may be necessary to use hammer and wooden dowel to remove the pin.

5. Note the orientation of the piston combustion chamber recess in relation to the casting node, paint mark on con rod shaft, and the connecting rod number.

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

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Connecting rod and piston - Inspect Prior operation: Connecting rod and piston - Disassemble (10.105) NOTICE: Measurements should be taken when components are at room temperature. Colored paint marks on the connecting rods shaft identify the weight classification. Ensure all connecting rods have the same color paint mark.

Replace connecting rods that are not the same weight classification and do not have the same color paint mark. If only one connecting rod needs replaced, replace all connecting rods.

1. Check for twisted or bent connecting rods.

2. Use a suitable device (2) to check the parallelism of the rod axis.

3. Fit the connecting rod (1) on the spindle of the tool (2) and lock it with the screw (3).

4. Set the spindle (4) on the "V" supports, resting the connecting rod (1) on the stop bar (5).

5. See Connecting rod and piston - Technical Data (10.105) for specifications.

NHIL13ENG0971BA

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

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Engine - Connecting rods and pistons

Connecting rod and piston - Assemble Prior operation: Connecting rod and piston - Inspect (10.105) 1. Install the piston pin (1) through the piston and the connecting rod.

NOTE: Use the markings on the piston (2) to correctly orient the piston on the connecting rod. The (→) marks the front of the engine as viewed from the top.

NHIL13ENG1209AA

1

NHIL13ENG1208AA

2

NHIL14ENG0636AA

3

2. Use snap ring pliers (1) to install the snap rings (2) that secure the assembly together.

3. Use the pliers 380000324 (2) to install the piston rings (1) on the piston (4).

4. The rings need to be mounted with the marking (3) facing upwards.

5. Direct the ring openings so they are staggered 120 ° apart.

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

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Connecting rod and piston - Install Prior operation: Connecting rod and piston - Assemble (10.105) NOTICE: The connecting rod can damage the crankshaft journal, the cylinder bore, and the piston cooling jet. Ensure no components are damaged during connecting rod installation.

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

NHIL13ENG0974BA

1

NHIL13ENG0935AA

2

2. Use the ring compression band 380000220 (1) to install the piston assemblies (2) into the cylinder liners.

3. Lubricate the crankshaft journal and the connecting rod bearing with clean engine oil.

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

5. Ensure that the matching marks on the connecting rod cap and the connecting rod shaft are the same.

NHIL13ENG0891AA

6. Ensure that the rod cap numbers point toward the camshaft/ injection side.

7. Install new connecting rod cap bolts (3).

NOTE: New connecting rod cap bolts do not require lubrication. An anti‑friction product has been applied by the factory.

8. Torque the connecting rod cap bolts in three stages: 1.

Stage 1: 10 N·m (7.4 lb ft)

2.

Stage 2: 30 N·m (22.1 lb ft)

3.

Stage 3: 40 N·m (29.5 lb ft)

9. Verify that proper torque was achieved by testing the torque setting of each connecting rod cap bolt to be at least 88.0 N·m (64.9 lb ft). Do not apply more than this specified amount during the validation test.

10. Ensure that the connecting rod assembly and the crankshaft journal are not binding and that there is proper side-to-side movement.

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Engine - Connecting rods and pistons

Piston - Cleaning NOTICE: Do not use a wire brush on any part of a piston.

1. Wash the components in cleaning solvent.

2. Clean varnish from the piston skirts and piston pins with a suitable cleaning solvent.

3. Clean the ring grooves.

4. Clean the piston oil lubrication holes and slots.

5. Wear safety glasses and dry the components with compressed air.

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Piston - Inspect 1. Inspect the piston for cracked ring lands, skirts or pin bosses, wavy worn ring lands, scuffed or damaged skirts or eroded areas at top of piston. Replace pistons that are damaged or show signs of excessive wear.

2. Do not mistake tapered or different ring design characteristics for unusual wear patterns. The first (upper) compression ring (1) is trapezoidal (tapered) in design.

That is, it has a taper on both upper and lower surfaces.

Correspondingly, the first compression ring groove is tapered on top and bottom. The second (scraper) compression ring and the oil control ring are more typical in design.

3. Inspect the piston ring grooves for nicks or burrs that might cause the rings to bind.

4. On the upper piston ring groove, insert the edge of the rings into respective piston ring groove and roll the ring entirely around the groove to make sure that ring does not bind. If resistance or binding occurs at any point, determine the cause.

• If binding is caused by a distorted ring, recheck with another ring.

• If binding is caused by the ring groove, remove the material causing the binding with a fine cut file.

NOTICE: When using a fine cut file, do not remove excess material. Verify with a feeler gauge and compare to specifications.

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NHIL14ENG1173AA

1

Engine - Connecting rods and pistons

Piston - Measure Prior operation: Connecting rod and piston - Disassemble (10.105) 1. Use a micrometer (2) to measure the diameter of the piston (1).

NOTE: The diameter of the piston must be measured 17 mm (0.7 in) from the bottom and 90 ° to the piston pin.

2. The diameter should be between 93.930 - 93.950 mm (3.698 - 3.699 in). Replace the piston if necessary.

NHIL13ENG1205AA

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

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Engine - Connecting rods and pistons

Piston Ring - Remove Prior operation: Connecting rod and piston - Remove (10.105) 1. Use the piston ring expander 380001716 to remove the piston rings from the piston.

NHIL14ENG1177AA

Next operation: Piston Ring - Inspect (10.105)

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Engine - Connecting rods and pistons

Piston Ring - Inspect 1. Measure the thickness of the rings. Replace piston rings as a set if out of specification. See Piston Ring Technical Data (10.105).

NHIL14ENG1175AA

1

NHIL14ENG1176AA

2

2. Position the selected ring (2) in the cylinder bore.

NOTE: The ring must be level (at right angles to the bore surface) for measurement. Push the ring 6 mm (0.236 in) into the bore with the crown of the piston.

3. Measure the gap between the ends of the ring with a feeler gauge (1) .

4. If the gap between the ends of the piston ring is less than specified, remove the ring and try to fit another.

Check the cylinder bore if the specification cannot be met with new rings.

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Piston Ring - Install Prior operation: Piston Ring - Inspect (10.105) 1. Use the piston ring expander 380001716 to install the oil control ring (3) on the bottom groove of the piston.

2. By hand, squeeze the oil control ring into the groove to seat the spring and check for binding.

3. Use the piston ring expander to install the second compression ring (2) in the center groove of the piston.

NOTE: The inner taper is toward the bottom of the piston.

4. By hand, squeeze the ring into the groove and check for binding.

5. Use the piston ring expander to install the first compression ring (1) in the center groove of the piston.

6. By hand, squeeze the ring into the groove and check for binding.

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

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NHIL14ENG1177AA

1

Index Engine - 10 Connecting rods and pistons - 105 Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Connecting rod and piston - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Connecting rod and piston - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Connecting rod and piston - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Connecting rod and piston - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Connecting rod and piston - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Connecting rod and piston - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Piston - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Piston - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Piston - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Piston Ring - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Piston Ring - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Piston Ring - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Piston Ring - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Valve drive and gears - 106

R 753 IE4

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Contents Engine - 10 Valve drive and gears - 106

TECHNICAL DATA Rocker arm Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Camshaft Lobe - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Camshaft bushings Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Rocker arm Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Rocker support Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Idler gear Upper idler gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Upper idler gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Lower idler gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lower idler gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Camshaft Push rod - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Push rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Tappets - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Camshaft bushings Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Rocker arm - Technical Data Rocker arm support journal outside diameter Rocker arm bushing inside diameter Assembly clearance

21.979 - 22.000 mm (0.865 - 0.866 in) 22.030 - 22.050 mm (0.867 - 0.868 in) 0.030 - 0.071 mm (0.001 - 0.003 in)

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Camshaft Lobe - Technical Data Exhaust lobe lift Intake lobe lift Lobe wear limit

7.303 mm (0.288 in) 6.850 mm (0.270 in) 0.050 mm (0.002 in)

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Camshaft bushings - Technical Data Front camshaft bushing Bushing inner diameter (bored into the engine block) Clearance (bushing to journal)

53.59 - 53.62 mm (2.11 - 2.11 in) 0.080 - 0.125 mm (0.003 - 0.005 in)

Center and rear camshaft bearings Bearing inner diameter (installed in the engine block) Clearance (center bearing) Clearance (rear bearing)

53.550 - 53.600 mm (2.108 - 2.110 in) 0.080 - 0.150 mm (0.003 - 0.006 in) 0.050 - 0.120 mm (0.002 - 0.005 in)

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Rocker arm - Remove Prior operation: Valve cover - Remove (10.101) 1. Remove the two bolts (3) from the rocker arm support.

2. Remove the rocker arm support from the cylinder head.

3. Remove the circlip (1).

4. Remove the rocker arm (2) from the rocker arm support.

NHIL15ENG0067AA

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Engine - Valve drive and gears

Rocker arm - Measure Prior operation: Rocker arm - Remove (10.106) 1. Use a micrometer to measure the inside diameter (1) of the rocker arm bushing.

2. Replace the rocker arm bushing if the inside diameter is more than 22.030 - 22.050 mm (0.867 - 0.868 in).

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3. Use a micrometer to measure the outside diameter (1) of the rocker arm support 4. Replace the rocker arm support if the journal outside diameter is less than 24.97 - 25.00 mm (0.98 - 0.98 in).

Next operation: Rocker arm - Install (10.106)

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Rocker arm - Install Prior operation: Camshaft Push rod - Install (10.106) 1. Lubricate the rocker arm support journals (1) with clean engine oil.

NHIL15ENG0068AA

1

NHIL15ENG0067AA

2

2. Install the rocker arm (2) onto the rocker arm support journal.

3. Install the circlip (1) to secure the rocker arm.

4. Lubricate the rocker arm and rocker arm contact areas with clean engine oil.

5. Lubricate the rocker arm support bolt threads with clean engine oil.

NOTICE: If the tappets were not removed, use the tappet tool 380003383 to depress the tappet and drain all of the residual oil in the tappets.

6. Install the rocker arm support onto the cylinder head while you align the push rod (2) into the rocker arm socket (3).

7. Evenly tighten the two rocker arm support bolts (1).

NHIL15ENG0066AA

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3

Engine - Valve drive and gears

8. Torque the rocker arm support bolts to 29 N·m (21.4 lb ft).

9. Unscrew the bolt (1) 20 °.

10. Torque the bolt (1) to 14 N·m (10 lb ft).

11. Unscrew the bolt (2) 20 °.

12. Torque the bolt (2) to 14 N·m (10 lb ft).

13. Simultaneously torque both bolts to 24 - 34 N·m (18 25 lb ft).

NOTICE: Valve clearance is hydraulically controlled and automatically set when the rocker arm support nuts are properly torqued.

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NHIL15ENG0067AA

4

Engine - Valve drive and gears

Rocker support - Measure 1. Use a micrometer to measure the outside diameter (1) of the rocker arm support journals.

2. Replace the rocker arm support if the outside diameter is less than 21.979 - 22.000 mm (0.865 - 0.866 in).

NHIL15ENG0094AA

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Engine - Valve drive and gears

Idler gear Upper idler gear - Remove Prior operation: Timing gear housing - Remove (10.102) 1. Make a reference mark on the idler gear where it mates with the injection pump (1).

2. Make a reference mark on the idler gear where it mates with the camshaft (2).

NHIL14ENG1161AA

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NHIL14ENG1161AA

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1. Remove the circlip (1) from the idler gear.

2. Remove the idler gear (2) from the engine block.

Next operation: Idler gear Upper idler gear - Install (10.106)

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Engine - Valve drive and gears

Idler gear Upper idler gear - Install 1. If the camshaft or the injection pump were rotated, see High pressure pump - Install (10.218).

NOTICE: To function properly the injection pump must be timed correctly.

2. If the camshaft and the injection pump were not rotated, follow the procedure.

3. Align the reference marks of the injection pump gear (1) and the camshaft gear (2) you made in the remove procedure.

NHIL14ENG1161AA

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4. Install the idler gear (2).

5. Install the circlip (1) to secure the idler gear.

Next operation: Timing gear housing - Install (10.102)

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Engine - Valve drive and gears

Idler gear Lower idler gear - Remove Prior operation: Timing gear housing - Remove (10.102) 1. Rotate the crankshaft to bring the number one cylinder to Top Dead Center (TDC), or make a reference mark on the crankshaft gear, idler gear, and the camshaft gear.

2. Remove the two bolts (1) from the idler gear.

3. Remove the pin shim ring (2).

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4. Remove the idler gear assembly (1) from the engine block.

Next operation: Idler gear Lower idler gear - Install (10.106)

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Engine - Valve drive and gears

Idler gear Lower idler gear - Install Prior operation: Idler gear Lower idler gear - Remove (10.106) 1. Lubricate the idler gear bushing (1), idler gear (2) and the idler gear shim ring (3) with clean engine oil.

2. Install the idler gear bushing (1) into the idler gear (2).

3. Verify the idler gear bushing rotates freely.

4. Ensure the lubrication grooves (4) are facing out, not toward the engine block.

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5. Align the timing reference marks on the camshaft gear (2) and crankshaft gear (3), while you install the idler gear assembly into the engine block.

6. Install the two bolts (1) to secure the idler gear.

7. Torque the idler gear bolts to 32.4 N·m (23.9 lb ft).

Next operation: Timing gear housing - Install (10.102)

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Camshaft Push rod - Remove Prior operation: Rocker arm - Remove (10.106) 1. Lift the push rod (1) out of their seat in the valve tappet (2).

NHIL15ENG0015AA

Next operation: Camshaft Push rod - Inspect (10.106)

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Camshaft Push rod - Inspect NOTE: The push rods are hollow and serve as oil galleries to lubricate each individual rocker arm assembly.

1. Visually inspect each push rod for wear or damage.

Ensure the push rod oil passage (1) is not restricted.

2. Roll each push rod on a flat surface to inspect the shaft for bends.

3. Replace all damaged parts.

NHIL14ENG1153AA

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Engine - Valve drive and gears

Camshaft Push rod - Install Prior operation: Camshaft Push rod - Inspect (10.106) 1. Lubricate the outer surfaces and the ends of the valve push rods (1).

2. Install the push rods into the original location they were removed from.

NOTICE: Ensure the push rods seat in the valve tappet seat (2).

NHIL15ENG0015AA

Next operation: Rocker arm - Install (10.106)

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Engine - Valve drive and gears

Camshaft - Remove Prior operation: Camshaft Tappets - Remove (10.106) 1. Rotate the crankshaft until cylinder one is at Top Dead Center (TDC), so the timing marks align on the gears.

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3

2. Remove the two Allen head bolts (1) from the camshaft thrust plate.

3. Carefully remove the camshaft (1) from the engine block.

NOTICE: Take care not to damage the camshaft bushings.

Next operation: Camshaft - Measure (10.106)

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Engine - Valve drive and gears

Camshaft - Measure Prior operation: Rocker arm - Remove (10.106) 1. Secure a dial indicator (1) to the cylinder head.

2. Adjust the dial indicator plunger (2) so that it rests in the push rod cup.

3. Rotate the camshaft so that the camshaft lobe is at the bottom of its travel.

4. Set the dial indicator to zero.

5. Rotate the crankshaft two complete revolutions while reading the dial indicator.

6. The correct specifications for the camshaft lobes are as follows: NHIL15ENG0027AA

• Exhaust lobe lift - 7.303 mm (0.288 in) • Intake lobe lift – 6.850 mm (0.270 in) • Camshaft lobe wear limit - 0.050 mm (0.002 in)

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Engine - Valve drive and gears

Camshaft - Install Prior operation: Camshaft - Measure (10.106) 1. Lubricate all camshaft lobes (2) with clean engine oil.

2. Lubricate the camshaft bushings (1) with clean engine oil.

NHIL15ENG0020AA

1

NHIL14ENG1163AA

2

NHIL14ENG1253AA

3

NHIL14ENG1257AA

4

3. Carefully install the camshaft (1) into the engine block.

NOTICE: Take care not to damage the camshaft bushings.

4. Align the timing marks (1) of the camshaft and the idler gear.

5. Install the Allen head bolts (1) with lock washers to secure the thrust plate to the engine block.

6. Torque the Allen head bolts to 27.5 N·m (20.3 lb ft).

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Engine - Valve drive and gears

Camshaft Tappets - Remove Prior operation: Camshaft Push rod - Remove (10.106) 1. Remove the locking retainer (1) from the valve tappets.

2. To remove the valve tappets (2) use the tappet removal tool 380003383 as follows: 1.

Press down to release the oil pressure in the tappet.

2.

Quickly turn the tappet removal tool a quarter turn to seat the locking tabs (3).

3.

Pull the valve tappet removal tool with the valve tappet out of the engine block.

Next operation: Camshaft Tappets - Install (10.106)

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NHIL15ENG0015AA

1

380003383

2

Engine - Valve drive and gears

Camshaft Tappets - Install NOTICE: Camshafts and valve tappets develop matched wear patterns during engine operation. Mismatching worn camshafts and valve tappets or using worn components with new components can cause rapid and excessive wear resulting in engine component failure. Always use new camshafts and valve tappets whenever any of the components are replaced.

NOTICE: Before assembling the valve tappets drain all of the residual oil in the valve tappets out of the drain hole, by compressing the valve lifter with the tappet tool.

1. Use the tappet tool 380003383 (1) to drain all residual oil out of the valve tappet, through the drain hole.

380003383

1

NHIL15ENG0019AA

2

2. Coat the entire valve tappet (3) with clean engine oil 3. Use the valve tappet tool to Install the tappets into the engine block from their original locations.

NOTICE: Ensure the valve tappet drain hole is pointing toward the crankshaft.

4. Remove the tappet tool from the valve tappet.

5. Install the locking retainer (1) over the square top (2) of the valve tappet to prevent rotation.

Next operation: Camshaft Push rod - Install (10.106)

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Engine - Valve drive and gears

Camshaft bushings - Inspect Prior operation: Camshaft - Remove (10.106) 1. Inspect the camshaft bushing and bearings for wear or damage. Replace the bushing or bearings if any damage is found.

2. Use a micrometer to measure the inside diameter of the bushings.

3. Use a micrometer to measure the camshaft journals.

4. Calculate the bushing clearance.

Camshaft front bushing • Bushing inner diameter (bored into the engine block) - 53.59 - 53.62 mm (2.11 - 2.11 in) • Clearance (bushing to journal) - 0.080 - 0.125 mm (0.003 - 0.005 in) Camshaft center and rear bearings • Bearing inner diameter (installed in the engine block) - 53.550 - 53.600 mm (2.108 - 2.110 in) • Clearance (center bearing) - 0.080 - 0.150 mm (0.003 - 0.006 in) • Clearance (rear bearing) - 0.050 - 0.120 mm (0.002 - 0.005 in) 5. Replace the bushing or bearings if they measure out of specification.

NOTICE: The front camshaft bushing must be bored after it is installed into the crankcase seat. Make sure the lubrication oil hole in the crankcase aligns with the new bushing

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Index Engine - 10 Valve drive and gears - 106 Camshaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Camshaft - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Camshaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Camshaft Lobe - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Camshaft Push rod - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Camshaft Push rod - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Camshaft Push rod - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Camshaft Tappets - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Camshaft Tappets - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Camshaft bushings - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Camshaft bushings - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Idler gear Lower idler gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Idler gear Lower idler gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Idler gear Upper idler gear - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Idler gear Upper idler gear - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rocker arm - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Rocker arm - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Rocker arm - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rocker arm - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rocker support - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Engine - 10 Fuel filters - 206

R 753 IE4

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Contents Engine - 10 Fuel filters - 206

TECHNICAL DATA Fuel filters Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Pre-filter Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Fuel filters Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fuel-water separator filter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Engine - Fuel filters

Fuel filters - Technical Data Fuel filter Max flow rate Max pressure loss with new filter Max pressure loss at changing interval Accumulation capacity Max working relative pressure value Burst relative pressure value Purge air valve (optional) Temperature sensor Clogging sensor Operating temperature Fuel filter life

Standard fuel market Dirty fuel / Cold environment 350 L/min (92 US gpm) 450 L/min (119 US gpm) < 11.0 kPa (1.6 psi) @ max flow rate < 50 kPa (7.3 psi) @ max flow rate 25.0 g (0.9 oz)

50.0 g (1.8 oz)

850 kPa (123 psi) 2000 kPa (290 psi) Yes Yes No -40 - 120 °C (-40 - 248 °F) 600 h

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300 h

Engine - Fuel filters

Pre-filter - Technical Data Pre fuel filter Max flow rate Max pressure loss with new filter Max working relative pressure value Burst relative pressure value Water separator Water in fuel sensor and drain Hand primer on clean side Filter heater Water separator draining interval Water storage capacity Operating temperature Pre fuel filter life

Standard fuel market Dirty fuel / Cold environment 200 L/min (53 US gpm) 250 L/min (66 US gpm) < 10.0 kPa (1.5 psi) @ max flow rate 0 kPa (0 psi) > 300 kPa (44 psi) Yes Yes Yes Yes (optional) < 200 h < 100 h 200.0 mL (6.8 US fl oz) -40 - 120 °C (-40 - 248 °F) 600 h 300 h

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Engine - Fuel filters

Fuel filters - Remove NOTICE: Absolute cleanliness is required for work on the fuel system, since the injection pump and fuel injectors have very close tolerances. Even minute particles of dirt or small amounts of water can impair the function of the fuel injection system.

1. Disconnect both cables from the battery.

2. Unplug the water in fuel sensor connector from the drain cap.

3. If the locking ring is present, loosen it and remove the filter (1). If is not present, remove the filter by hand.

NOTICE: The fuel-water separator ilter must be replaced; it cannot be cleaned and reused.

NHIL14ENG1190AA

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Engine - Fuel filters

Fuel filters - Install 1. Lubricate the fuel filter seal (1) with clean engine oil.

2. Fill the new fuel-water separator filter with new fuel.

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NHIL14ENG1192AA

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3. Install the fuel-water separator filter (2) onto the fuel filter housing (1).

NOTICE: Do not use a filter wrench.

4. Bleed the air out of the fuel-water separator filter. See Fuel-water separator filter - Bleed (10.206).

5. Connect the water in fuel sensor connector.

6. Connect the battery cables.

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Engine - Fuel filters

Fuel filters - Bleed 1. Loosen the bleed screw (1) on the fuel filter housing.

NOTE: The fuel filter is equipped with a primer plunger on the fuel filter header to assist in filling the fuel filter.

2. Move the primer plunger up and down repeatedly. The filter is full when an air‑free stream of fuel flows from the air vent screw.

3. Securely tighten the bleed screw (1).

4. Start the engine and check for leaks.

5. Stop the engine immediately if there is a fuel leak.

6. Recheck the filter installation.

NHIL14ENG1193AA

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Engine - Fuel filters

Fuel-water separator filter - Remove NOTICE: Absolute cleanliness is required for work on the fuel system, since the injection pump and fuel injectors have very close tolerances. Even minute particles of dirt or small amounts of water can impair the function of the fuel injection system.

1. Disconnect both cables from the battery.

2. Unplug the water in fuel sensor connector (3) from the sensor (2).

3. If the locking ring is present, loosen it and remove the filter (1). If is not present, remove the filter by hand.

NOTICE: The fuel-water separator filter must be replaced; it cannot be cleaned and reused.

NHIL15CT00006AA

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Engine - Fuel filters

Fuel-water separator filter - Install 1. Lubricate the fuel filter seal (1) with clean engine oil.

2. Fill the new fuel-water separator filter with new fuel.

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NHIL15CT00006AA

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3. Install the fuel-water separator filter (2) onto the fuel filter housing (1).

NOTICE: Do not use a filter wrench.

4. Bleed the air out of the fuel-water separator filter. See Fuel filters - Bleed (10.206).

5. Connect the water in fuel sensor connector (3).

6. Connect the battery cables.

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Index Engine - 10 Fuel filters - 206 Fuel filters - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fuel filters - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuel filters - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel filters - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel-water separator filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Fuel-water separator filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Pre-filter - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Fuel injection system - 218

R 753 IE4

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Contents Engine - 10 Fuel injection system - 218

TECHNICAL DATA Fuel injection system Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Fuel injection system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE High pressure pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Common rail Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Relief valve - Configure - Reset ECU data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Common rail lines Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Fuel injectors Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Configure - IMA codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

DIAGNOSTIC Fuel injection system Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Engine - Fuel injection system

Fuel injection system - Technical Data

NHIL14ENG1194FA

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(A) Fuel pump return (B) Outlet fuel filter/Inlet low pressure pump (C) Inlet fuel filter

0.6 bar (8.7 psi) Difference between (A) and (C) 0.4 bar (5.8 psi)

Fuel supply Injector supply

Bosch CP4.1 with gear pump High pressure injection pump

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Engine - Fuel injection system

Fuel injection system - Overview

NHIL15ENG0041JA

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

Fuel cooler Common rail High pressure fuel injector pipes Fuel injectors Check valve Common rail pressure sensor

1

(7) Pre filter (8) Water in fuel sensor (9) Fuel filter (10) Low pressure fuel pump (11) High pressure fuel pump (12) Fuel metering valve

The fuel injection system consist of a low pressure circuit that draws the fuel from the tank, through the fuel cooler, into the pre filter then into the low pressure pump. From the low pressure pump, the fuel travels through the main fuel filter and back into the high pressure pump to deliver the fuel to the common rail. The common rail then supplies the required fuel the injectors need.

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Engine - Fuel injection system

High pressure pump - Remove 1. Disconnect the electrical connector (1) from the high pressure pump.

2. Remove the fuel delivery hose (2) from the high pressure pump.

3. Remove the common rail fuel return hose (3) from high pressure pump.

4. Remove the fuel return hose (4) from the high pressure pump.

5. Remove the high pressure pump to common rail fuel delivery pipe (5).

NHIL14ENG1195AA

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NHIL14ENG1196AA

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6. Remove the three flange nuts (1).

7. Remove the high pressure pump (2).

8. Remove the high pressure pump gasket.

9. Remove the flange nut (1) from the high pressure pump.

10. Use a gear puller to remove the high pressure pump gear (2).

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Engine - Fuel injection system

High pressure pump - Install 1. Install the high pressure pump gear (2) onto the high pressure pump shaft (3).

NOTE: The key is not installed in the high pressure pump shaft keyway.

2. Make a mark on the high pressure pump gear in the location of the keyway.

3. Install the flange nut (1) onto the high pressure pump shaft.

4. Torque the flange nut to 86.4 N·m (63.7 lb ft).

NHIL14ENG1198AA

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NHIL15ENG0022AA

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5. Position the keyway mark at 90 ° (A) clockwise to the piston plunger.

6. Rotate the engine so the timing marks (1) on the crankshaft and camshaft align with the idler gear timing marks, or Top Dead Center (TDC) of cylinder one.

7. Install the crankshaft pulley (1) onto the crankshaft.

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Engine - Fuel injection system

8. Use a piece of calibrated wire (1) to mark the center of the crankshaft pulley.

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9. From the top of the crankshaft pulley, measure counterclockwise 60 ° (1) and make a mark.

10. Rotate the crankshaft to your 60 ° mark.

NOTE: This position will allow the high pressure injection pump to be properly timed with the engine.

11. Install a new gasket onto the studs (3).

12. Install the high pressure pump (1) onto the studs.

13. Install the flange nuts (2) to secure the high pressure pump.

14. Torque the flange nuts (2) to 27.5 N·m (20.3 lb ft).

15. Install the fuel return hose (4) to the high pressure pump.

16. Install the common rail fuel return hose (3) to high pressure pump.

17. Install the fuel delivery hose (2) to the high pressure pump.

18. Connect the electrical connector (1) to the high pressure pump.

19. Install the high pressure pump to common rail fuel delivery pipe (5).

NOTICE: When the pump is removed a specific procedure must be performed to correctly install the high pressure fuel delivery pipes.

20. Torque the common rail fuel delivery pipe to 18.0 23.0 N·m (13.3 - 17.0 lb ft).

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Engine - Fuel injection system

Common rail - Remove 1. Remove the fuel injector electrical connections (1).

2. Remove the wire harness clamps (2).

3. Move the wire harness (3) out of your way.

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NHIL14ENG1201AA

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4. Remove high pressure pipes (1) from the rail to the injectors.

5. Remove the bolt (3) from the high pressure fuel delivery pipe bracket.

6. Remove the high pressure fuel delivery pipe (2).

7. Remove the fuel return line (4).

8. Remove the two bolts (1) from the common rail.

9. Remove the common rail (2).

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Engine - Fuel injection system

Common rail - Install NOTICE: When the rail is removed a specific procedure must be performed to correctly install the high pressure fuel delivery pipes.

1. Install the common rail (2) to the cylinder head.

2. Install the two bolts (1) finger tight.

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3. Verify that the injectors (1) are properly tightened.

4. Verify that the high pressure pump is properly tightened.

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Engine - Fuel injection system

5. Install the high pressure injector pipes (1) finger tight.

6. Install the fuel delivery pipe (2) finger tight.

7. Install the bracket bolt (3) for the fuel delivery pipe finger tight.

8. Install the fuel return line (4).

9. Torque the high pressure injector pipes to 17 - 21 N·m (13 - 15 lb ft) on the common rail side.

10. Torque the high pressure injector pipes (1) to 25 29 N·m (18 - 21 lb ft) on the injector side.

11. Torque the fuel delivery pipe (2) to 17 - 21 N·m (13 15 lb ft) on the common rail side.

12. Torque the fuel delivery pipe to 18 - 23 N·m (13 - 17 lb ft) on the high pressure pump side.

13. Torque the bracket bolt (3) to 12.7 - 16.7 N·m (9.4 0.0 lb ft).

14. Torque the common rail bolts (1), Figure 1, to 31 35 N·m (23 - 26 lb ft).

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NHIL14ENG1201AA

4

Engine - Fuel injection system

Common rail Relief valve - Configure - Reset ECU data NOTE: Active dosing faults require additional key cycles in order for the Engine Control Unit (ECU) to determine the fault has been repaired. Afterrun must be completed between each key cycle.

1. Connect the Electronic Service Tool (EST) and turn the key switch ON without starting the engine.

2. Click the “Configuration” icon (1).

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3. Select “Replacement of the Rail Pressure Relief Valve (PRV) – Reset ECU Data” (1).

4. Click the “CONFIGURE SELECTED ITEM” button (2).

5. Click the “RESET” button (1).

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Engine - Fuel injection system

Common rail lines - Remove NOTICE: Whenever each of these components such as the high pressure pump, injectors, rail and any high pressure fuel pipe (pipe from pump to rail and pipes from rail to injectors) are loose and/or removed, a specific procedure must be performed in order to avoid fuel leakage in the high pressure fuel system, high pressure fuel delivery pipes.

1. Remove high pressure pipes from the fuel injectors (1).

2. Remove the high pressure pipes from the common rail (2).

NHIL14ENG1207AA

Next operation: Common rail lines - Install (10.218)

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Engine - Fuel injection system

Common rail lines - Install NOTICE: Whenever each of these components such as the high pressure pump, injectors, rail and any high pressure fuel pipe (pipe from pump to rail and pipes from rail to injectors) are loose and/or removed, a specific procedure must be performed in order to avoid fuel leakage in the high pressure fuel system, high pressure fuel delivery pipes.

1. Install the high pressure injector pipes to the common rail (2) finger tight.

2. Install the high pressure injector pipes to the fuel injectors (1) finger tight.

3. Torque the high pressure injector pipes to 17 - 21 N·m (13 - 15 lb ft) on the common rail side.

4. Torque the high pressure injector pipes to 25 - 29 N·m (18 - 21 lb ft) on the injector side.

NHIL14ENG1207AA

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Engine - Fuel injection system

Fuel injectors - Remove Prior operation: Common rail lines - Remove (10.218) NOTICE: Whenever injectors are removed for service, they must be retained in order. At the time of installation, they must be installed in the same locations as when removed, because each injector has a proper IMA code.

1. Depress the fuel return hose clamp (3) while you pull up on the fuel return hose (2) to remove from the fuel injector.

2. Remove the fuel injector hold down Allen head screw (1).

3. Remove the fuel injector hold down (4).

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NHIL14ENG1204AA

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4. Remove the fuel injector (1) from the cylinder head.

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Engine - Fuel injection system

Fuel injectors - Install 1. Install a new O-ring (2) onto the fuel injector.

2. Verify the injector washer (1) is installed on the end of the fuel injector.

3. Apply MOLYKOTE® P-1500 ANTI-FRETTING PASTE to the fuel injector in the location labeled (A).

NHIL14ENG1205AA

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NHIL14ENG1204AA

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NHIL14ENG1206AA

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NHIL14ENG1203AA

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4. Install the fuel injector (1) into the cylinder head.

5. Install the spherical washer (2) onto the Allen head screw (1).

6. Install the fuel injector hold down (4).

7. Install the Allen head screw (1) with spherical washer to secure the fuel injector.

8. Torque the Allen head screw to 21 - 25 N·m (15 - 18 lb ft).

Next operation: Common rail lines - Install (10.218)

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Engine - Fuel injection system

Fuel injectors - Configure - IMA codes

NHPH12ENG0006AA

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

2. Click the “Configure” button (1).

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

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

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

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

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

8. Disconnect EST.

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Engine - Fuel injection system

Fuel injection system - Troubleshooting NOTE: If the rail pressure sensor B-9004 is replaced, it is necessary to perform the Replacement of the Rail Pressure sensor - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service. See Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) (55.010), if necessary.

NOTE: If the Pressure Relief Valve (PRV) is replaced, it is necessary to perform the Replacement of the Rail Pressure Relief Valve (PRV) - Reset ECU Data with the Electronic Service Tool (EST) before you return the machine to service.

See Common rail Relief valve - Configure - Reset ECU data (10.218), if necessary.

NOTE: If a fuel injector is replaced, a new IMA code must be programmed. The IMA code may be hidden under the paint on the fuel injector. For more information regarding programming IMA codes, see Fuel injectors - Configure - IMA codes (10.218).

Problem Dark, hazy fuel color

Diesel fuel leakage

Possible Cause Correction Poor fuel quality or contamination. Hazy 1. Drain the fuel tank and replace with new diesel fuel. looking fuel typically is a sign of water contamination. Dark fuel is usually indicative of oxidation, possibly from being stored for too long, and is a far more severe stage of diesel fuel contamination.

Loose or improperly connected fittings, 1. Inspect all hoses, clamps and fittings. If any fittings or clamps are loose or imdamaged seals or damaged fuel lines. properly installed, repair as necessary.

Leakage from fuel filters.

2. Inspect all fuel filters for leakage. If the filter is damaged or there is leakage from the seal, replace the failed fuel filter.

3. Inspect all fuel lines for leakage or damage. If there is any leakage or damage present, repair as necessary.

4. Inspect the fuel tank for damage or corrosion. If there is any failures found, repair or replace as necessary.

Low fuel system pressure Low fuel system pressure can be caused by clogged fuel filters, a faulty electric lift pump (if applicable), a faulty mechanical fuel pump, a faulty fuel metering unit, or leakages present in the system.

5. Inspect all fuel system components for diesel fuel leakage. If any leakages are present, repair or replace as necessary.

1. Perform a fuel system pressure test to verify the low pressure condition. The fuel pressure at the main fuel filter, after the mechanical gear pump, should be approximately 5.0 bar (72.5 psi). If the pressure is too low, continue to troubleshoot the low pressure side of the fuel system to isolate the failed component. If the pressure is not too low, continue to Step 2.

2. Use the Electronic Service Tool (EST) to check for active fault codes related to the fuel metering unit. If any faults are active, diagnose them first and then continue troubleshooting the fuel system.

Fuel system pressure too Too high fuel pressure can be caused by 1. Check the operation of the fuel meterhigh ing, pressure relief valve and the rail a faulty fuel metering unit, a stuck closed pressure sensor. Use the appropriate pressure relief valve, or a faulty rail pressection of the engine service manual, if sure sensor. necessary. Repair or replace as necessary.

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Engine - Fuel injection system

Problem Excessive black tailpipe smoke

Possible Cause Excessive black smoke can be caused by a number of reasons. The most common reasons are a clogged air filter, a faulty fuel injection pump, leaking fuel injectors, faulty turbocharger, faulty cylinder head valves, or a faulty Exhaust Gas Recirculation (EGR) valve. Black smoke is caused by an imbalance of fuel to air. If too much fuel is injected and the carbon in the fuel does not have enough oxygen to combine with, the fuel will turn into a black soot.

Engine is running with the If the engine continues to run with the key key off or is increasing off or the engine is increasing speed withspeed without operator out operator input, it may be running on an input. alternative firing source. The most likely causes of this condition is a leakage of fuel into the cylinders from faulty fuel injectors.

Faulty piston rings may also cause a leakage of engine oil into the combustion chamber allowing the engine to continue running.

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Correction Inspect the engine air filter, fuel injectors, injection pump, turbocharger and EGR valve for failures that may have caused a rich air/fuel ratio condition. Use the appropriate section of the engine service manual if necessary.

1. Test the fuel injectors for proper operation. Use the appropriate section of the engine service manual, if necessary.

2. Perform a compression test to check the condition of the piston rings. Use the appropriate section of the engine service manual, if necessary.

Index Engine - 10 Fuel injection system - 218 Common rail - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Common rail - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Common rail Relief valve - Configure - Reset ECU data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Common rail lines - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Common rail lines - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Fuel injection system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel injection system - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel injection system - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Fuel injectors - Configure - IMA codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Fuel injectors - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Fuel injectors - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 High pressure pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 High pressure pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Engine - 10 Turbocharger and lines - 250

R 753 IE4

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Contents Engine - 10 Turbocharger and lines - 250

SERVICE Turbocharger Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Turbocharger oil supply line Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Turbocharger oil return line Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

DIAGNOSTIC Turbocharger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Engine - Turbocharger and lines

Turbocharger - Remove 1. Remove the banjo bolt (1) from the top of the oil supply line.

NHIL14ENG1209AA

1

NHIL14ENG1210AA

2

NHIL14ENG1211AA

3

NHIL14ENG1214AA

4

2. Remove the oil supply line (1) from the engine block.

3. Remove the oil return line (2) from the engine block.

4. Remove the two bolts (1) from the oil return line (2).

5. Remove the gasket (1).

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6. Remove the flange nuts (1) from the turbocharger flange.

NHIL14ENG1212AA

5

NHIL14ENG1215AA

6

7. Remove the turbocharger (1).

8. Remove the gasket (2).

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Turbocharger - Install 1. Install a new gasket (2) on the exhaust manifold.

2. Install the turbocharger (1) onto the exhaust manifold.

NHIL14ENG1215AA

1

NHIL14ENG1212AA

2

NHIL14ENG1214AA

3

NHIL14ENG1211AA

4

3. Install the flange nuts (1) to secure the turbocharger.

4. Torque the flange nuts to 32.4 N·m (23.9 lb ft).

5. Install the oil return line gasket (1).

6. Install the oil return line (2).

7. Install the oil return line bolts (1).

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Engine - Turbocharger and lines

8. Install the oil return line (2) to the engine block, finger tight.

9. Install the oil supply line (1) to the engine block, finger tight.

NHIL14ENG1210AA

5

NHIL14ENG1209AA

6

10. Install the banjo bolt (1) to secure the oil supply line to the turbocharger.

11. Torque the banjo bolt (1) to 24.5 N·m (18.1 lb ft).

12. Torque the oil supply line at the engine block to 32.4 N·m (23.9 lb ft).

13. Torque the oil return line at the engine block to 49 N·m (36 lb ft).

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Turbocharger oil supply line - Remove 1. Remove the banjo bolt (1) from the top of the oil supply line.

NHIL14ENG1209AA

1

NHIL14ENG1210AA

2

2. Remove the oil supply line (1) from the engine block.

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Turbocharger oil supply line - Install 1. Install the oil supply line (1) to the engine block, finger tight.

NHIL14ENG1210AA

1

NHIL14ENG1209AA

2

2. Install the banjo bolt (1) to secure the oil supply line to the turbocharger.

3. Torque the banjo bolt (1) to 24.5 N·m (18.1 lb ft).

4. Torque the oil supply line at the engine block to 32.4 N·m (23.9 lb ft).

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Turbocharger oil return line - Remove 1. Remove the oil return line (1) from the engine block.

NHIL14ENG1210AA

1

NHIL14ENG1211AA

2

NHIL14ENG1214AA

3

2. Remove the two bolts (1) from the oil return line (2).

3. Remove the gasket (1).

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Turbocharger oil return line - Install 1. Install the oil return line gasket (1).

NHIL14ENG1214AA

1

NHIL14ENG1211AA

2

NHIL14ENG1210AA

3

2. Install the oil return line (2).

3. Install the oil return line bolts (1).

4. Install the oil return line (2) to the engine block, finger tight.

5. Torque the oil return line at the engine block to 49 N·m (36 lb ft).

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Turbocharger - Troubleshooting Problem Insufficient intake air volume

Turbocharger revolution failure

Possible Cause Clogging of air cleaner element

Correction Replace or wash the element

Blocked air intake port Leak from a joint in intake line Deposit of impurities in oil sticking on the turbine side seal portion to make turbine revolution heavy Sticking bearing

Correct to the normal state Check and repair Turbocharger overhaul (disassembly and washing) with lubricating oil replacement

Turbocharger overhaul (disassembly and repair) Insufficient lubrication or clogged lubrica- Lubricating oil line inspection, repair of detion piping fective portion and lubricating oil replacement Excessively high oil temperature Rotating part replacement or washing Unbalanced rotating part Strict observance of instructions in operation manual Insufficient warming up or sudden stop Inspection and repair of each engine part from loaded operation (no-load operation) Contact or breakdown of turbine wheel or Perfect foreign matter elimination in disassembled state, followed by inspection and blower vane repair of individual air cleaner and engine Excessive revolution components Excessive exhaust temperature rise Foreign matter invasion Worn bearing Turbocharger overhaul (disassembly and repair) Reassemble Assembly defect Influence of exhaust Exhaust gas leak before the turbocharger Joint inspection and correction resistance to decrease its revolutions Deformed or clogged exhaust pipe to de- Correct to the normal state crease turbocharger revolutions White smoke generation Clogged or deformed oil return pipe caus- Repair or pipe replacement ing oil flow to the blower or turbine side Excessive bearing wear causing abnormal Turbocharger disassembly and repair wear or damage of seal ring Excessive bearing wear causing abnormal Turbocharger disassembly and repair Sudden oil decrease wear or damage of seal ring Decrease in output Gas leak from any part in exhaust piping Inspection and repair of defective portion Air leak from discharge side of blower Element cleaning or replacement Clogging of air cleaner element Fouled or damaged turbocharger Turbocharger disassembly and repair or replacement Hard carbon deposit on the turbine side Turbocharger disassembly and washing Poor (slow) response (starting) of turbocharger (wheel sealing portion) to make turbine with lubricating oil replacement shaft revolution heavy Incomplete combustion Engine combustion state inspection, followed by improvement of combustion to normal state Abnormal sound Excessively narrowed gas path due to Turbocharger disassembly and washing generation clogged nozzle in turbine wheel chamber or reverse flow of blower discharge in acceleration (generally called “surging”) Turbocharger disassembly and repair or reContact rotating part placement Vibration Loosened intake, exhaust or oil pipe con- Turbocharger installation status check and nection with the turbocharger repair of defective portion Damaged bearing, contact between rotat- Turbocharger disassembly with repair or ing part and adjacent part, or chipping of replacement, or perfect removal of foreign turbine wheel or blower vane due to foreign matters in case of foreign matter invasion matter invasion Unbalanced rotating part Repair or replacement of rotating part 47730965 27/08/2015

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Engine - Turbocharger and lines

Problem Electrical failure of the wastegate pressure modulator valve Y-9008, or circuit.

Electrical failure of the intake manifold pressure sensor B-9001, or circuit

Possible Cause Active fault codes.

Correction Check for fault codes.

Faulty wastegate pressure modulator valve Inspect the wiring harness for damage.

Y-9008 wiring harness.

Check for broken, loose, or corroded pins from the sensor wiring harness connection to the ECU. Make sure all connectors are secure, and tight.

Faulty wastegate pressure modulator valve Check the resistance between pin 1 to pin 2 Y-9008. on the waste gate modulator valve. There should be between 21.8 - 24.2 Ω. Replace the wastegate pressure modulator valve Y-9008 if the specification is out of range.

Active fault codes.

Check for fault codes.

Faulty intake manifold pressure sensor Inspect the wiring harness for damage.

B-9001 wiring harness.

Check for broken, loose, or corroded pins from the sensor wiring harness connection to the ECU. Make sure all connectors are secure, and tight.

Faulty intake manifold pressure sensor Replace the intake manifold pressure senB-9001. sor B-9001.

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Index Engine - 10 Turbocharger and lines - 250 Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Turbocharger - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Turbocharger oil return line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Turbocharger oil return line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Turbocharger oil supply line - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Turbocharger oil supply line - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Engine - 10 Intake and exhaust manifolds and muffler - 254

R 753 IE4

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

TECHNICAL DATA Exhaust manifold Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

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

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Exhaust manifold - Technical Data Max exhaust gas temperature Max back pressure (after turbo) Min exhaust gas temperature Exhaust flow at rated power

620 °C (1148 °F) 350 kPa (51 psi) 140 °C (284 °F) 330 kg/hr (728 lb/hr)

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Engine - Intake and exhaust manifolds and muffler

Intake manifold - Remove Prior operation: Intake manifold - Remove (10.254) 1. Disconnect the wire harness from the intake manifold pressure/temperature sensor (2).

2. Remove the intake manifold nuts (1).

3. Remove the intake manifold (3).

NHIL14ENG1219AA

1

NHIL14ENG1220AA

2

4. Remove the intake/exhaust manifold gasket (1).

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Engine - Intake and exhaust manifolds and muffler

Intake manifold - Install Prior operation: Intake manifold - Remove (10.254) 1. Install a new intake/exhaust manifold gasket (2) onto the mounting studs (1).

2. Install the exhaust manifold (3) onto the studs.

NHIL14ENG1220AA

1

NHIL14ENG1219AA

2

NHIL14ENG1221AA

3

3. Install the exhaust manifold nuts (1).

4. Connect the wire harness to the intake manifold pressure/temperature sensor (2).

5. Follow the sequence shown and torque the intake manifold nuts to 27.5 N·m (20.3 lb ft).

Next operation: Exhaust manifold - Install (10.254)

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Exhaust manifold - Remove Prior operation: Turbocharger oil supply line - Remove (10.250) Prior operation: Turbocharger oil return line - Remove (10.250) 1. Remove the two bolts (1) from the heat shield.

2. Remove the heat shield (2).

NHIL14ENG1216AA

1

NHIL14ENG1217AA

2

3. Remove the exhaust manifold nuts (1).

4. Remove the exhaust manifold (2) from the cylinder head.

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Exhaust manifold - Install 1. Install the exhaust manifold (2) onto the studs.

2. Install the exhaust manifold nuts (1) onto the studs.

NHIL14ENG1217AA

1

NHIL14ENG1222AA

2

3. Follow the sequence shown and torque the exhaust manifold nuts in two stages: 1.

Stage one: 15.0 N·m (11.1 lb ft).

2.

Stage two: 36.0 N·m (26.6 lb ft).

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

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Engine - 10 Engine lubrication system - 304

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Contents Engine - 10 Engine lubrication system - 304

TECHNICAL DATA Engine lubrication system Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Engine oil pump Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Engine lubrication system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Piston cooling Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Engine oil filter Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Engine oil pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Oil pump lines Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Piston cooling Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

DIAGNOSTIC Engine lubrication system Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Engine - Engine lubrication system

Engine lubrication system - Technical Data Minimum oil pressure in the main gallery 80.0 kPa (11.6 psi) @ 130 °C (266 °F) Maximum oil temperatures, measured in oil sump, both 135 °C (275 °F) under continuous and intermittent conditions.

The maximum gallery oil pressure is regulated by a 7.5 bar (108.8 psi) relief valve near the oil pump set. This avoids excessive pressure in the gallery, due to the high oil viscosity, during cold start at very low temperatures

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Engine oil pump - Technical Data Axial clearance between gear and pump body Rotor and gear coupling rolling torque resistance Difference between height of inner rotor and outer rotor seat

0.150 - 0.250 mm (0.006 - 0.010 in) 9.0 kgm (65.1 ftlbs.)

0.030 - 0.087 mm (0.001 - 0.003 in)

NHIL14ENG1239AA

1

Outer rotor (A) (B) Height of the outer rotor

57.950 - 58.000 mm (2.281 - 2.283 in) 49.300 - 49.400 mm (1.941 - 1.945 in) 32.483 - 32.500 mm (1.279 - 1.280 in)

NHIL14ENG1240AA

(A) Clearance between rotors

2

0.070 - 0.200 mm (0.003 - 0.008 in)

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Engine - Engine lubrication system

NHIL14ENG1241AA

3

Inner rotor (A) (B) (C) Height of the inner rotor

25.920 - 25.970 mm (1.020 - 1.022 in) 41.120 - 41.150 mm (1.619 - 1.620 in) 32.045 - 32.075 mm (1.262 - 1.263 in) 32.483 - 32.500 mm (1.279 - 1.280 in)

NHIL14ENG1238AA

4

Oil pump housing (A) Rotor seat depth in housing (B) Inside diameter of rotor housing (C) Depth Clearance between housing and outer rotor

32.530 - 32.570 mm (1.281 - 1.282 in) 58.130 - 58.180 mm (2.289 - 2.291 in) 22.060 - 22.100 mm (0.869 - 0.870 in) 0.130 - 0.230 mm (0.005 - 0.009 in)

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Engine - Engine lubrication system

Engine lubrication system - Dynamic description

NHIL15ENG0230JA

1

The lubrication system is a pressurized type system. The engine lubrication is provided by means of an oil pump (4).

The oil pump is fastened to the rear section of the crankcase. The oil pump is driven by a gear (5) mounted on the crankshaft. The pump draws oil from the sump pick up tube (6). The oil then goes to the oil filter assembly (2). The oil will then distribute through the oil galleys in the crankcase. The oil pressure is controlled by the oil pressure relief valve (3) near the oil pump.

The pressure relief valve controls the oil pressure in the system. The valve will open if the oil pressure exceeds 7.5 bar (108.8 psi).

The oil is directed from oil distribution galleys positioned lengthwise in the crankcase. The function of these galleys is to direct the oil to the camshaft and crankshaft bearings. The lower galleys supply oil to cool the pistons via piston cooling nozzles (7).

The upper galleys direct oil to each of the engine cylinder heads and timing components.

The engine has a turbocharger. The turbocharger shafts receive lubrication via a supply line (1) connected to the lower galleys. The return oil is drained back to the engine oil sump through a drain line (8).

The lubrication system provides oil to lubricate the following gears: • High pressure pump gear • Accessory drive gear • Idler gears • Camshaft gear • Crankshaft gear • Oil pump gear

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Engine - Engine lubrication system

NHIL15ENG0243AA

(1) Bearing (2) Oil galley to cylinder head components (3) Coolant outlet for oil cooler (4) Oil galley for turbocharger (5) Oil separator valve (6) Oil galley through crankcase

2

(7) Coolant inlet for oil cooler (8) Oil filter (9) Pick up tube (10) Oil pump (11) Oil galley through crankcase

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Engine - Engine lubrication system

Piston cooling - Overview

NHIL15ENG0009AA

1

Oil spray from the piston cooling jet nozzle (1) cools and lubricates the piston and other engine components. Inadequate or improper oil spray could result in engine damage. Ensure the oil spray nozzles are clean and the piston cooling jet assemblies are correctly installed to allow proper oil spray distribution.

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Engine - Engine lubrication system

Engine oil filter - Remove 1. Remove the oil filter (1).

NHIL15ENG0028AA

Next operation: Engine oil filter - Install (10.304)

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1

Engine - Engine lubrication system

Engine oil filter - Install Prior operation: Engine oil filter - Remove (10.304) 1. Lubricated the oil filter O-ring with clean engine oil.

2. Install the oil filter (1) onto the oil filter housing.

3. Torque the oil filter to 12.7 N·m (9.4 lb ft).

NHIL15ENG0028AA

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1

Engine - Engine lubrication system

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

2. Remove the three Allen head screws (2) from the oil pump.

3. Remove the oil pump (3) from the engine block.

NHIL15ENG0010AA

1

NHIL15ENG0073AA

2

4. Remove the outer rotor (1) from the oil pump housing (2).

Next operation: Engine oil pump - Inspect (10.304)

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Engine - Engine lubrication system

Engine oil pump - Inspect Prior operation: Engine oil pump - Remove (10.304) 1. See Engine oil pump - Technical Data (10.304) for all oil pump specifications.

2. Inspect the oil pump shaft, rotors, and housing for excessive wear or damage. Replace the oil pump assembly if excessive wear or damage is found.

3. Check clearance between the inner and outer oil pump rotors.

4. Check clearance between the outer rotor and housing.

5. Check the outer and inner rotor end float (outer rotor into oil pump body).

6. If the measured values are greater than specified, the pump is faulty and must be replaced as a complete unit.

7. Check the rotor and gear coupling rolling torque.

Next operation: Engine oil pump - Install (10.304)

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Engine - Engine lubrication system

Engine oil pump - Install 1. Lubricate the oil pump rotor housing (3) and the inner (2) and outer rotor (1) surfaces with clean engine oil.

NHIL15ENG0073AA

1

NHIL15ENG0003AA

2

NHIL15ENG0010AA

3

2. Install the chamfered end (1) of the outer rotor towards the seat (the inside) of the rotor housing.

3. Install the oil pump (3) in the engine block.

4. Install the three Allen head screws (2), with spring washers into the mounting holes in the oil pump.

5. Torque the three Allen head screws in a diagonal pattern to 27.5 N·m (20.3 lb ft).

6. Install the crankshaft gear (1), driving the oil pump gear by aligning the keyway gear with the crankshaft key and the side with flange must be pointed toward the crankshaft gear. The flat surface of the gear must be pointed towards outside.

7. Check that the oil pump gear is not in a bind by ensuring that there is some clearance (backlash) between the crankshaft sprocket and oil pump gear. Verify the installation if no backlash exists between the gears.

Next operation: Timing gear housing - Install (10.102)

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Engine - Engine lubrication system

Oil pump lines - Remove Prior operation: Engine oil pan - Remove (10.102) 1. Remove the bolt (3) from the pick-up tube support.

2. Remove the bolt (2) from the pick-up tube.

3. Remove the pick-up tube (1).

NHIL14ENG1116AA

1

NHIL14ENG1117AA

2

4. Remove the old O-ring (1) from the pick-up tube.

Next operation: Oil pump lines - Install (10.304)

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Engine - Engine lubrication system

Oil pump lines - Install 1. Install a new O-ring (1) on the pick-up tube.

NHIL14ENG1117AA

1

NHIL14ENG1116AA

2

2. Install the oil pick-up tube (1) into the engine block.

3. Install the M6 x 12 bolt (2) to secure the pick-up tube.

4. Torque the M6 x 12 pick-up tube bolt (2) to 12.7 N·m (9.4 lb ft).

5. Install the M6 x 12 bolt (3) to secure the pick-up tube support.

6. Torque the M6 x 12 support bolt (3) to 32.4 N·m (23.9 lb ft).

Next operation: Engine oil pan - Install (10.102)

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Engine - Engine lubrication system

Piston cooling - Remove Prior operation: Engine oil pan - Remove (10.102) 1. Remove the Allen head screw (2) from the piston cooling jet.

2. Remove the piston cooling jet (1) from the engine block.

NHIL15ENG0009AA

Next operation: Piston cooling - Install (10.304)

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1

Engine - Engine lubrication system

Piston cooling - Inspect Prior operation: Piston cooling - Remove (10.304) 1. Clean the passages (1) of the piston cooling jet and cylinder block.

2. Use compressed air to clean any debris from cleaning.

3. Check the nozzle for any bends, cracks or damage.

NHIL14ENG1236AA

1

NHIL14ENG1235AA

2

4. Ensure the check valve ball (2) moves freely against the spring (1) in the piston cooling jet.

Next operation: Piston cooling - Install (10.304)

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Engine - Engine lubrication system

Piston cooling - Install Prior operation: Piston cooling - Inspect (10.304) 1. Install a new O-ring (1) onto the piston cooling jet.

NHIL14ENG1232AA

1

NHIL15ENG0009AA

2

2. Install the piston cooling jet (1) into the engine block.

NOTE: Ensure the piston cooling jet O-ring is properly seated in the engine block.

3. Position the nozzle in the cylinder bore as shown.

4. Apply LOCTITE® 246™ to the threads of the Allen head screw.

5. Install the Allen head screw (2).

6. Torque the Allen head screw to 12.7 N·m (9.4 lb ft).

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Engine - Engine lubrication system

Engine lubrication system - Troubleshooting Problem Engine oil leakage

Possible Cause Correction Engine oil leakage can be caused from • Inspect all gaskets and seals for oil leakfaulty seals/gaskets, faulty engine oil lines, age. If leakage is present, repair or reor a faulty engine oil cooler. place as necessary.

• Inspect all engine oil lines related to the oil cooler and turbocharger. If leakage is present, repair or replace as necessary.

Excessive engine oil consumption

Excessive engine oil consumption can be caused by faulty crankcase ventilation system, faulty pistons rings, faulty cylinder liner seals, faulty turbocharger, or faulty valve guide seals.

• Inspect the engine oil cooler for damage or leakage. If leakage is present, repair or replace as necessary.

• Perform an engine compression test to verify the condition of the combustion chamber. Faulty piston rings or valve guide seals can be the cause of excessive engine oil consumption.

• Inspect the turbocharger for signs of oil leakage. Engine oil can leak through the compressor housing seal into the intake path causing consumption. Engine oil can also leak into the turbine housing into the exhaust stream.

Coolant in oil due to a failed cylinder head Milky, foamy, or cream gasket, a cracked or warped cylinder head, colored, with white smoke. Low coolant level. or internal damage to the cylinder block.

WARNING Hot liquid under pressure!

Scalding can result from fast removal of the radiator cap. Check and service the engine cooling system according to the maintenance instructions in this manual.

Failure to comply could result in death or serious injury.

W0163A

• Perform a compression test on the engine to verify the condition of the combustion chamber. If two adjacent cylinders are reading low compression, a failed cylinder head gasket is the likely cause.

• Inspect the cylinder head for cracks. If the cylinder head is cracked, the cylinder head must be replaced.

Milky, foamy, or cream colored, without white smoke. Normal coolant level.

Oil is thick, and dark in color.

Low oil pressure

• Verify that the cylinder head bolts are adequately torqued. Repair or replace as necessary.

Water in oil due to faulty manifold gaskets, • Verify intake manifold, and exhaust manifold gaskets are in good condition. or loose manifold.

Dirt or other foreign substances in oil.

• Make sure the intake manifold, and exhaust manifold are torqued to proper specification.

Drain, and replace oil.

Engine oil level low Wrong grade of oil Clogged oil filter Faulty oil pressure relief valve Worn oil pump drive shaft gears, or broken oil pipe

Fill to proper level Replace with correct grade oil Change oil and filter Replace relief valve Inspect oil system and components. Replace defective components

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Engine - Engine lubrication system

Problem

Possible Cause Correction Excessive main or connecting rod bearing Replace bearings or shaft if necessary clearances Oil pump axial clearance not properly set Check pump clearance and shim as needed to proper tolerance.

Faulty oil pressure sensor/oil pressure Check for fault codes, and testing proceswitch or electrical circuit dures to check electrical circuits.

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Index Engine - 10 Engine lubrication system - 304 Engine lubrication system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine lubrication system - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine lubrication system - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Engine oil filter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine oil filter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine oil pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine oil pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Engine oil pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine oil pump - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Oil pump lines - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Oil pump lines - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Piston cooling - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Piston cooling - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Piston cooling - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Piston cooling - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Engine - 10 Engine cooling system - 400

R 753 IE4

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Contents Engine - 10 Engine cooling system - 400

TECHNICAL DATA Engine cooling system Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine cooling system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Water pump Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Engine cooling system Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Water pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Coolant thermostat Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DIAGNOSTIC Engine cooling system Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Engine cooling system - Technical Data Mandatory glycol content in coolant fluid: (use Inhibited ethylene glycol (IEG) Optimum coolant temperature range (engine outlet) Maximum continuous temperature Maximum peak temperature Cooling system pressure Coolant pump delivery at rated speed Cooling system admitted pressure drop Thermostat opening start temperature Thermostat full opening temperature

50 % 85 - 100 °C (185 - 212 °F) 106 °C (223 °F) 109 °C (228 °F) 110 kPa (16 psi) 202 L/min (53 US gpm) 35 kPa (5 psi) 78 - 82 °C (172 - 180 °F) 95 °C (203 °F)

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Engine cooling system - Overview

NHIL15ENG0040JA

1

Diesel engines are high compression engines and create higher engine operating temperatures. The closed cooling system and engine must remain as clean as possible to provide adequate engine cooling. Adequate engine cooling can only be assured by using the proper antifreeze and water. We recommend that the closed cooled section of the closed cooling system must be filled with a low‑silicate formula of ethylene glycol antifreeze in solution with deionized or distilled water. A low‑silicate formula prevents antifreeze separation, which causes a silicate gelatin to form.

The coolant, if not premixed, should be mixed, using antifreeze and deionized water, before being added to the closed cooling system. Common tap water or softened water contains unwanted minerals, which can leave deposits in the system that reduce the efficiency of the cooling system. The closed cooled section of the closed cooling system should be kept filled year‑round with an approved antifreeze‑coolant solution. Do not drain the closed cooled section for storage because draining will promote rusting of internal surfaces. If the engine will be exposed to freezing temperatures, ensure that the closed cooled section is filled with a properly mixed antifreeze‑coolant solution to protect the engine and the closed cooling system to the lowest temperature to which they will be exposed.

NOTICE: The antifreeze‑coolant used in these engines must be a low‑silicate ethylene glycol, containing deionized, purified water. Using other types of engine coolant may cause fouling of the heat exchangers and overheating of the engine. Do not combine different types of coolants without knowing that they are compatible. Refer also to the coolant manufacturer’s instructions.

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Engine - Engine cooling system

Water pump - Exploded view

NHIL14ENG1122AA

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

Water pump gasket M8 x 20 back plate bolts Back plate Back plate gasket

1

(5) Water pump (6) M8 x 55 Water pump bolts (7) Water pump pulley (8) M8 x 12 Water pump pulley bolts

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Engine - Engine cooling system

Engine cooling system - Filling NOTICE: Before starting the test check that the thermostat applied operate correctly (lift, opening temperature).

1. All valves operating in the cooling circuit and those in the heating circuit connected to the engine must be opened.

2. Use a flow meter in the filling pipe to adjust the filling flow rate to 8.0 - 10.0 L/min (2.1 - 2.6 US gpm).

3. After adjusting the filling flow rate, filling starts with the engine at a standstill, and ends when water spills over the filling pipe union.

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Engine - Engine cooling system

Engine cooling system - Bleed 1. Draining air out of the cooling system of engine must be started immediately after filling.

2. After filling start the engine and run it slowly for 5 minutes, during which check that the level of the coolant does not fall below the minimum filling level.

3. Should this occur, stop air drainage, then repeat filling at a lower filling rate (in any case flow not less than 8.0 L/min (2.1 US gpm)); after five minutes top up with any coolant that may have run short (it should not be below the minimum level notch) until it spills over the filling pipe union (slow-running engine).

4. Immediately afterwards run the engine to the max. idle speed.

5. While the engine speed increases, check the manometer to be installed between the water pump and the thermostat.

6. The pressure indicated must rapidly increase and reach a constant value without pulsating; if this does not occur, the water pump does not operate correctly, and the engine must be re-run slowly.

7. If pressure does not increase, when increasing the engine speed again, the test must be interrupted (water pump to be checked).

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Engine - Engine cooling system

Water pump - Remove Prior operation: Water pump - Remove – Pulley (10.400) 1. Remove the hoses (1) from the water pump.

2. Remove the water pump bolts (2).

3. Remove the water pump (3) from the engine block.

NHIL14ENG1224AA

1

NHIL14ENG1225AA

2

4. Remove the water pump gasket (1).

Next operation: Water pump - Install (10.400)

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Engine - Engine cooling system

Water pump - Install Prior operation: Water pump - Remove (10.400) 1. Apply LOCTITE® 5970™ to both sides of the new water pump gasket (1).

2. Install the new gasket (1) onto the engine block.

3. Install the water pump (2) to the engine block.

4. Install the water pump bolts (3).

NHIL14ENG1225AA

1

NHIL14ENG1226AA

2

5. Follow the sequence shown and torque the water pump bolts in two stages: 1.

Stage 1: 6.0 N·m (4.4 lb ft)

2.

Stage 2: 32.4 N·m (23.9 lb ft)

Next operation: Water pump - Install – Pulley (10.400)

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Engine - Engine cooling system

Water pump - Test 1. The operation of the water pump should be checked immediately after air drainage (hot coolant without bubbles of air, open thermostat).

2. To carry this out of the speed of the engine must be gradually increased from minimum to maximum RPM. 3. When increasing the speed of the engine, the manometers in the circuit of the coolant, upstream and downstream the water pump, must be checked.

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Engine - Engine cooling system

Coolant thermostat - Remove 1. Remove the four Allen head screws (1) from the thermostat cover.

2. Remove the thermostat cover (2).

NHIL14ENG1227AA

1

NHIL14ENG1228AA

2

3. Remove the thermostat (1) from the thermostat housing.

Next operation: Coolant thermostat - Install (10.400)

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Engine - Engine cooling system

Coolant thermostat - Install Prior operation: Coolant thermostat - Remove (10.400) 1. install the thermostat (1) into the thermostat housing.

NHIL14ENG1228AA

1

NHIL14ENG1227AA

2

2. Install the thermostat cover (2).

3. Install the four Allen head screws (1) to secure the thermostat cover.

4. Torque the Allen head screws to 10.8 N·m (8.0 lb ft).

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Engine - Engine cooling system

Engine cooling system - Troubleshooting Problem External coolant leakage

Possible Cause Leakage is most commonly found from : - Loose, deteriorated, or damaged hoses - A fault water pump seal - A damaged radiator - Leakage from the heater core, if applicable - Cracked thermostat housing or faulty gasket - A leaking radiator cap - Leaking coolant drain plug or engine core plugs

Correction

WARNING Hot liquid under pressure!

Scalding can result from fast removal of the radiator cap. Check and service the engine cooling system according to the maintenance instructions in this manual.

Failure to comply could result in death or serious injury.

W0163A

1. Check all hoses for damage or deterioration. Verify that all hose clamps are adequately tight.

2. Inspect the water pump and water pump housing for leakage. Gently pull up and down on the water pump to ensure it is tight.

3. Inspect the radiator and radiator cap for leakage. The leakage may be caused from cracks or other damage to the radiator. The radiator cap may be leaking from a faulty seal or may not be adequately tightened.

4. Inspect the heater core area for leakage. Leakage may be from damage to the heater radiator, faulty coolant lines or fittings.

5. Inspect the thermostat housing for leakage. A faulty thermostat gasket may be the cause of the leak. The thermostat housing may also be cracked or inadequately tightened.

6. Inspect the engine block for coolant leakage from the coolant drain plug (if applicable) or the engine core plugs.

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Engine - Engine cooling system

Problem Engine coolant temperature too high

Possible Cause The most likely failures that can lead to too high coolant temperature are : - Low engine coolant level - A clogged radiator or other blockage in the cooling system - Insufficient air flow to the radiator - A failed water pump - A broken or loose engine drive belt - A failed thermostat - A failed radiator cap - Extreme operating conditions

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Correction

WARNING Hot liquid under pressure!

Scalding can result from fast removal of the radiator cap. Check and service the engine cooling system according to the maintenance instructions in this manual.

Failure to comply could result in death or serious injury.

W0163A

1.

Inspect the engine coolant level and fill, if necessary.

2.

Perform an engine coolant pressure test to check for blockage within the system and repair as necessary.

3.

Check for obstructions to the air flow of the radiator. A dirty or restricted radiator grille may be causing the overheating condition.

4.

With the engine running at operation temperature, squeeze the top radiator hose, then release the hose. You should feel a surge of coolant indicating that the water pump is functioning properly. If no surge is felt, the water pump has failed.

5.

Verify that the engine drive belt is not broken and check the belt tightness.

Repair or replace as necessary.

6.

Remove the thermostat and test the opening temperature using the appropriate testing equipment. The thermostat should open at approximately 87.8 °C (190.0 °F). Replace the thermostat, if necessary.

7.

Pressure test the radiator cap. If the radiator cap fails the test, replace the radiator cap.

8.

Verify that the engine has not been operating in extreme working conditions. These conditions may include extremely high temperatures or overworking the engine.

Engine - Engine cooling system

Problem Excessive white smoke from tailpipe

Possible Cause The most likely cause of excessive white smoke from the vehicle tailpipe is coolant consumption. The most likely failures are : - A failed cylinder head gasket - A cracked cylinder head - A cracked cylinder liner

Correction

WARNING Hot liquid under pressure!

Scalding can result from fast removal of the radiator cap. Check and service the engine cooling system according to the maintenance instructions in this manual.

Failure to comply could result in death or serious injury.

W0163A

1. Perform a compression test on the engine to verify the condition of the combustion chamber. If two adjacent cylinders are reading low compression, a failed cylinder head gasket is the likely cause.

2. Inspect the cylinder head for cracks. If the cylinder head is cracked, the cylinder head must be replaced.

3. Verify that the cylinder head bolts are adequately torqued. Repair or replace as necessary.

Low coolant temperature Low coolant temperature is most likely caused by a stuck open thermostat.

WARNING Hot liquid under pressure!

Scalding can result from fast removal of the radiator cap. Check and service the engine cooling system according to the maintenance instructions in this manual.

Failure to comply could result in death or serious injury.

W0163A

1. Remove the thermostat and check the opening temperature of the thermostat using the appropriate testing equipment. The thermostat should open at approximately 87.8 °C (190.0 °F). After testing, replace the thermostat, if necessary.

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Index Engine - 10 Engine cooling system - 400 Coolant thermostat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Coolant thermostat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine cooling system - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine cooling system - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine cooling system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine cooling system - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine cooling system - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Water pump - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Water pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Water pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Water pump - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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Engine - 10 Oil cooler and lines - 408

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Contents Engine - 10 Oil cooler and lines - 408

SERVICE Oil cooler and lines Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - Oil cooler and lines

Oil cooler and lines - Remove 1. Remove the oil filter (2).

2. Remove the two coolant lines (1).

NOTE: Label the coolant lines to avoid confusion on the install.

NHIL15ENG0028AA

1

NHIL15ENG0029AA

2

3. Remove the bolt (1) from the center of the oil cooler housing.

4. Remove the oil cooler housing (2) from the engine block.

Next operation: Oil cooler and lines - Install (10.408)

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Engine - Oil cooler and lines

Oil cooler and lines - Install Prior operation: Oil cooler and lines - Remove (10.408) 1. Install the oil cooler housing (2) onto the engine block with the center bolt (1).

2. Torque the center bolt to 39.2 N·m (28.9 lb ft).

NHIL15ENG0029AA

1

NHIL15ENG0028AA

2

3. Install the two coolant lines (1) and secure with the hose clamps.

4. Install the oil filter (2) onto the oil cooler housing.

5. Torque the oil filter to 12.7 N·m (9.4 lb ft).

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

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Engine - 10 Fan and drive - 414

R 753 IE4

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Contents Engine - 10 Fan and drive - 414

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

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

Water pump pulley Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Engine - Fan and drive

Belt - Remove 1. Install the belt tension remover 380003391 (1) as shown.

NHIL14ENG1279AA

1

NHIL14ENG1280AA

2

NHIL14ENG1281AA

3

2. Make sure the swivel (1) of the bolt seats properly against the belt tensioner.

3. Tighten the bolt (1) to release the belt tension.

4. Remove the belt from the pulleys.

Next operation: Belt - Install (10.414)

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Engine - Fan and drive

Belt - Install Prior operation: Belt - Remove (10.414) 1. Install a new belt around the pulleys as shown.

NHIL14ENG1229AA

1

NHIL14ENG1281AA

2

NHIL14ENG1279AA

3

2. Loosen the bolt (1) to allow the belt tensioner to release.

3. Remove the belt tension remover 380003391 (1).

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Engine - Fan and drive

Belt tensioner - Remove Prior operation: Belt - Remove (10.414) 1. Remove the two nuts (1) from the belt tensioner bracket.

2. Remove the belt tensioner (2) from the bracket.

3. Remove the water pump. See Water pump - Remove (10.400).

NHIL14ENG1230AA

1

NHIL15ENG0145AA

2

4. Remove the two Allen head screws (1).

5. Remove the belt tensioner bracket (2).

Next operation: Belt tensioner - Install (10.414)

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Engine - Fan and drive

Belt tensioner - Install Prior operation: Belt tensioner - Remove (10.414) 1. Install the belt tensioner bracket (2) to the engine block.

2. Install the two Allen head screws (1).

3. Torque the Allen head screws to 24.5 N·m (18.1 lb ft).

4. Install the water pump. See Water pump - Install (10.400).

NHIL15ENG0145AA

1

NHIL14ENG1230AA

2

5. Install the belt tensioner (2) onto the studs of the belt tensioner bracket.

6. Install the two nuts (1).

7. Torque the nuts to 32.4 N·m (23.9 lb ft).

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Engine - Fan and drive

Water pump pulley - Remove Prior operation: Belt - Remove (10.414) 1. Remove the three water pump pulley bolts (1).

2. Remove the water pump pulley (2).

NHIL14ENG1223AA

Next operation: Water pump pulley - Install (10.414)

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1

Engine - Fan and drive

Water pump pulley - Install Prior operation: Water pump pulley - Remove (10.414) 1. Install the water pump pulley (2) onto the water pump hub.

2. Install the three water pump pulley bolts (1).

3. Torque the water pump pulley bolts to 27.5 N·m (20.3 lb ft).

NHIL14ENG1223AA

Next operation: Belt - Install (10.414)

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1

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

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Engine - 10 Selective Catalytic Reduction (SCR) exhaust treatment - 500

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Contents Engine - 10 Selective Catalytic Reduction (SCR) exhaust treatment - 500

SERVICE Diesel Oxidation Catalyst (DOC) Configure - Reset ECU data (DOC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - Selective Catalytic Reduction (SCR) exhaust treatment

Diesel Oxidation Catalyst (DOC) - Configure - Reset ECU data (DOC) NOTE: Active dosing faults require additional key cycles in order for the Engine Control Unit (ECU) to determine the fault has been repaired. Afterrun must be completed between each key cycle.

1. Connect the Electronic Service Tool (EST) and turn the key switch ON without starting the engine.

2. Click the “Configuration” icon (1).

NHPH14ENG0006AA

1

NHIL15ENG0064AA

2

NHPH14ENG0017AA

3

3. Select “Replacement of the Oxidant Catalyst – Reset ECU Data” (1).

4. Click the “CONFIGURE SELECTED ITEM” button (2).

5. Click the “RESET” button (1).

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Index Engine - 10 Selective Catalytic Reduction (SCR) exhaust treatment - 500 Diesel Oxidation Catalyst (DOC) - Configure - Reset ECU data (DOC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Exhaust Gas Recirculation (EGR) exhaust treatment - 501

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Contents Engine - 10 Exhaust Gas Recirculation (EGR) exhaust treatment - 501

TECHNICAL DATA Diesel Oxidation Catalyst (DOC) Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Exhaust Gas Recirculation (EGR) exhaust treatment Overview - Emission Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Diesel Oxidation Catalyst (DOC) Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Particulate Matter (PM) catalyst Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Engine - Exhaust Gas Recirculation (EGR) exhaust treatment

Diesel Oxidation Catalyst (DOC) - Technical Data Max exhaust gas temperature Max back pressure Min exhaust gas temperature Exhaust flow at rated power

620 °C (1148 °F) 350 kPa (51 psi) 140 °C (284 °F) 330 kg/hr (728 lb/hr)

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Engine - Exhaust Gas Recirculation (EGR) exhaust treatment

Exhaust Gas Recirculation (EGR) exhaust treatment - Overview Emission Standard Due to the composition of fossil fuel during the combustion process several toxic substances are produced. These substances are primarily: • Carbon Monoxide (CO) • Hydrocarbons (HC) • Nitrogen Oxides (NOx) • Particulate Matter (PM) The primary focus is on the reduction of NOx and Particulate Matter (PM).

Particulate Matter (PM) - Particulates are harmful to your health, and is harmful to the environment. PM is mainly composed of small carbon particles, and other toxic substances created during incomplete fuel burning, i.e. low combustion temperature.

Nitrogen Oxides (NOx) - NOx is a generic term for mono-nitrogen oxides NO & NO2. The (nitric oxide & nitrogen dioxide are produced from the reaction of nitrogen & oxygen gases during combustion, especially at high temperatures.

This can cause acid rain.

Inside the combustion chamber, Particulate Matter (PM), and Nitrogen Oxides (NOx) have conflicting chemical factors.

As PM decreases, NOx will increase. As NOx decreases, PM will increase.

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Engine - Exhaust Gas Recirculation (EGR) exhaust treatment

Diesel Oxidation Catalyst (DOC) - Overview

NHIL15ENG0038FA

(1) Particulate Matter (PM) catalyst inlet temperature sensor (2) Diesel Oxidation Catalyst (DOC)

1

(3) Lambda sensor (4) DOC inlet temperature sensor

Particulate Matter (PM)-Catalysts are devices that can capture carbonaceous PM material for a period of time sufficient for its catalytic oxidation. The PM-catalyst substrate consists of alternating layers of corrugated metal foil and porous sintered metal fleece which captures the particulates. The captured particles are then re-generated on a continuous basis with the help of Nitrogen Dioxide (NO2) produced by the oxidation of NO on a Diesel Oxidation Catalyst (DOC) placed before the PM-Cat. The corrugated foil is formed to direct the gas flow so it impinges onto the metal fleece and therefore provides a much better contact between the NO2 and the soot which leads to a much faster rate of regeneration than that of the DPF. In other words, PM-Cat is a specialized catalyst with a capacity to retain and regenerate solid soot particles. Unlike the DPF the PM-cat can not plug up and therefore there will be no risk of fire due to uncontrolled regeneration.

This engine’s PM catalyst system is comprised of two primary sections. The first section comprises a Diesel Oxidation Catalyst (DOC), where the necessary oxidation steps are carried out. The soot collection and combustion process is completed in the second section, which contains the unique porous sintered metal fleece material. The catalyst section contains an oxidation catalyst consisting of a ceramic honeycomb substrate coated with a proprietary highly active platinum group metal. Apart from oxidizing a portion of the NO for soot combustion, the catalyst also oxidizes Carbon monoxide (CO), Hydrocarbons (HC) and the Soluble Organic Fraction (SOF) portion of the PM.

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Engine - Exhaust Gas Recirculation (EGR) exhaust treatment

Particulate Matter (PM) catalyst - Dynamic description

NHIL15ENG0156FA

(1) Particulate Matter (PM) catalyst inlet temperature sensor (2) Diesel Oxidation Catalyst (DOC) inlet temperature sensor

1

(3) Diesel Oxidation Catalyst (DOC) (4) Particulate Matter (PM) catalyst

The PM-Catalyst operates on the principle of continuous passive regeneration of soot with Nitrogen dioxide (NO2).

The Nitric oxide (NO) to NO2 conversion occurs over the DOC at temperatures between 220.0 - 450.0 °C (428.0 842.0 °F). In passive regeneration the soot oxidation temperature is lowered to a level allowing for auto-regeneration during regular vehicle operation. The engine management system will be tuned (throttle valve closure, rail pressure adjustment, boost pressure adjustment etc.) in order to ensure that the temperatures are sufficiently high to sustain continuous passive regeneration. A minimum NOx to PM ratio of 30:1, or greater will be necessary for acceptable passive regeneration. Higher NOx/PM ratios result in higher NO2 concentrations and better filter regeneration.

See Exhaust Gas Recirculation (EGR) exhaust treatment - Overview (10.501) for emission standards.

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Index Engine - 10 Exhaust Gas Recirculation (EGR) exhaust treatment - 501 Diesel Oxidation Catalyst (DOC) - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Diesel Oxidation Catalyst (DOC) - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Exhaust Gas Recirculation (EGR) exhaust treatment - Overview - Emission Standard . . . . . . . . . . . . . . . . . . . . . . . 4 Particulate Matter (PM) catalyst - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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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. © 2015 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.

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SERVICE MANUAL Electrical systems R 753 IE4

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55

Contents Electrical systems - 55

[55.010] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.202] Cold start aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.989] Exhaust Gas Recirculation (EGR) electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6

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Electrical systems - 55 Fuel injection system - 010

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Contents Electrical systems - 55 Fuel injection system - 010

SERVICE Common rail pressure sensor Configure - Reset ECU data (Rail pressure sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Electrical systems - Fuel injection system

Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) NOTE: Active dosing faults require additional key cycles in order for the Engine Control Unit (ECU) to determine the fault has been repaired. Afterrun must be completed between each key cycle.

1. Connect the Electronic Service Tool (EST) and turn the key switch ON without starting the engine.

2. Click the “Configuration” icon (1).

NHPH14ENG0006AA

1

NHPH14ENG0017AA

2

3. Select “Replacement of the Rail Pressure Sensor - Reset ECU Data.

4. Click the “CONFIGURE SELECTED ITEM” button.

5. Click the “RESET” button (1).

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Electrical systems - Fuel injection system

Common rail pressure sensor - Remove 1. Remove the electrical connector (1) form the common rail pressure sensor.

NHIL15ENG0013AA

1

NHIL15ENG0014AA

2

2. Remove the common rail pressure sensor (1) from the common rail.

Next operation: Common rail pressure sensor - Install (55.010)

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Electrical systems - Fuel injection system

Common rail pressure sensor - Install Prior operation: Common rail pressure sensor - Remove (55.010) 1. Install the common rail pressure sensor (1) into the common rail.

2. Torque the common rail pressure sensor to 70 N·m (52 lb ft).

NHIL15ENG0014AA

1

NHIL15ENG0013AA

2

3. Install the electrical connector (1) to the common rail pressure sensor.

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Index Electrical systems - 55 Fuel injection system - 010 Common rail pressure sensor - Configure - Reset ECU data (Rail pressure sensor) . . . . . . . . . . . . . . . . . . . . . . . . . 3 Common rail pressure sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Common rail pressure sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Engine cooling system - 012

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Contents Electrical systems - 55 Engine cooling system - 012

SERVICE Engine coolant temperature sensor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Engine cooling system

Engine coolant temperature sensor - Remove 1. Disconnect the electrical connector (1) from the coolant temperature sensor.

NHIL14ENG1245AA

1

NHIL14ENG1246AA

2

2. Remove the coolant temperature sensor (1) from the thermostat housing.

Next operation: Engine coolant temperature sensor - Install (55.012)

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Electrical systems - Engine cooling system

Engine coolant temperature sensor - Install 1. Install the coolant temperature sensor (2) into the thermostat housing.

2. Torque the coolant temperature sensor to 22.0 N·m (16.2 lb ft).

3. Connect the electrical connector (1) to the coolant temperature sensor.

NHIL14ENG1247AA

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1

Index Electrical systems - 55 Engine cooling system - 012 Engine coolant temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine coolant temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Engine intake and exhaust system - 014

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

TECHNICAL DATA Throttle Valve Actuator (TVA) Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Intake air pressure and temperature sensor Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Throttle Valve Actuator (TVA) Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Electrical systems - Engine intake and exhaust system

Throttle Valve Actuator (TVA) - Technical Data Temperature Ambient pressure

Supply voltage (typical) Supply voltage (range) Nominal resistance Operating frequency

Supply voltage (typical) Supply voltage MAX

Technical data 20 °C (68 °F) 1018 kPa (148 psi) Electrical actuator 13.5 V 6 - 16 V 1.7 - 3.2 Ω 1000 - 5000 Hz Position feed back sensor 4.75 - 5.25 V 14 V ( 5 min MAX

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Electrical systems - Engine intake and exhaust system

Intake air pressure and temperature sensor - Remove 1. Disconnect the electrical connection (3) from the intake air pressure and temperature sensor (1).

2. Remove the bolt (2) from the intake air pressure and temperature sensor.

3. Remove the intake air pressure and temperature sensor (1) from the intake manifold.

NHIL14ENG1243AA

Next operation: Intake air pressure and temperature sensor - Install (55.014)

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1

Electrical systems - Engine intake and exhaust system

Intake air pressure and temperature sensor - Install Prior operation: Intake air pressure and temperature sensor - Remove (55.014) 1. Install a new O-ring (1) on the air temperature and pressure sensor.

2. Install the air temperature and pressure sensor (4) into the intake manifold.

3. Install the bolt (2) to secure the air temperature and pressure sensor.

4. Connect the electrical connector (3) to the air temperature and pressure sensor.

NHIL14ENG1244AA

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1

Electrical systems - Engine intake and exhaust system

Throttle Valve Actuator (TVA) - Remove 1. Remove the electrical connector (2) from the Throttle Valve Actuator (TVA).

2. Remove the four bolts (1) from the TVA.

NHIL14ENG1255AA

1

NHIL14ENG1256AA

2

3. Remove the TVA top flange (1), top gasket (2), TVA (3) and bottom gasket (4) from the intake manifold.

Next operation: Throttle Valve Actuator (TVA) - Inspect (55.014)

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Electrical systems - Engine intake and exhaust system

Throttle Valve Actuator (TVA) - Inspect Prior operation: Throttle Valve Actuator (TVA) - Remove (55.014) 1. Visually inspect the Throttle Valve Actuator (TVA) (1): • Check for damage to the TVA assembly.

• Check for debris build up.

• Check the valve (flap) is not seized.

• Clean the throttle valve, if necessary.

NHIL14ENG1256AA

1

NHIL15ENG0141AA

2

2. Use a multimeter to measure the resistance of the electrical actuator (1) between pin 1 to pin 3. There should be approximately 1.7 - 3.2 Ω. If the resistance is out of range, replace the TVA.

Next operation: Throttle Valve Actuator (TVA) - Install (55.014)

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Electrical systems - Engine intake and exhaust system

Throttle Valve Actuator (TVA) - Install Prior operation: Throttle Valve Actuator (TVA) - Inspect (55.014) 1. Install a new lower Throttle Valve Actuator (TVA) gasket (4) onto the intake manifold.

2. Install the TVA (3).

3. Install a new top TVA gasket (2).

4. Install the top flange (1).

NHIL14ENG1256AA

1

NHIL14ENG1255AA

2

5. Install the four bolts (1) to secure the TVA to the intake manifold.

6. Torque the bolts (1) to 10.8 N·m (8.0 lb ft).

7. Install the electrical connector (2) to the TVA.

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Index Electrical systems - 55 Engine intake and exhaust system - 014 Intake air pressure and temperature sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Intake air pressure and temperature sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Throttle Valve Actuator (TVA) - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Throttle Valve Actuator (TVA) - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Throttle Valve Actuator (TVA) - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Throttle Valve Actuator (TVA) - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Engine control system - 015

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Contents Electrical systems - 55 Engine control system - 015

SERVICE Engine timing sensors Crankshaft sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Crankshaft sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Camshaft sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Camshaft sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Electrical systems - Engine control system

Engine timing sensors Crankshaft sensor - Remove 1. Remove the electrical connector (1) from the crankshaft sensor.

2. Remove the Allen head screw (2) from the crankshaft sensor.

3. Remove the crankshaft sensor (3) from the engine block.

NHIL14ENG1258AA

Next operation: Engine timing sensors Crankshaft sensor - Install (55.015)

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1

Electrical systems - Engine control system

Engine timing sensors Crankshaft sensor - Install Prior operation: Engine timing sensors Crankshaft sensor - Remove (55.015) 1. Install a new O-ring (1) on the crankshaft sensor.

2. Install the crankshaft sensor (1) into the engine block.

3. Install the Allen head screw (3) to secure the crankshaft sensor.

4. Torque the Allen head screw to 10.8 N·m (8.0 lb ft).

NHIL14ENG1259AA

1

NHIL14ENG1258AA

2

5. Install the electrical connector (1) to the crankshaft sensor.

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Electrical systems - Engine control system

Engine timing sensors Camshaft sensor - Remove 1. Remove the electrical connector (1) from the camshaft sensor.

2. Remove the Allen head screw (2) from the camshaft sensor.

3. Remove the camshaft sensor (3) from the engine block.

NHIL14ENG1260AA

Next operation: Engine timing sensors Camshaft sensor - Install (55.015)

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1

Electrical systems - Engine control system

Engine timing sensors Camshaft sensor - Install Prior operation: Engine timing sensors Camshaft sensor - Remove (55.015) 1. Install the camshaft sensor (2) into the engine block.

2. Install the Allen head screw (1) to secure the camshaft sensor.

3. Torque the Allen head screw to 10.8 N·m (8.0 lb ft).

NHIL15ENG0011AA

1

NHIL14ENG1260AA

2

4. Install the electrical connector (1) to the camshaft sensor.

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Index Electrical systems - 55 Engine control system - 015 Engine timing sensors Camshaft sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine timing sensors Camshaft sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine timing sensors Crankshaft sensor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine timing sensors Crankshaft sensor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Cold start aid - 202

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Contents Electrical systems - 55 Cold start aid - 202

FUNCTIONAL DATA Glow plug system Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Glow plug control module - Overview – Glow plug control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Glow plug system Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Electrical systems - Cold start aid

Glow plug system - Overview

93111647

1

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

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Electrical systems - Cold start aid

Glow plug system Glow plug control module - Overview – Glow plug control module

NHIL14ENG0777FA

1

The Fast Glow Plug Control Unit (FGPCU) powers up to four fast glow plugs (low voltage glow plugs that cannot be permanently driven at battery voltage levels) as controlled by the input signal CTRL (active low). The duty cycle of the CTRL signal sets the power level of the plug outputs so the Engine Control Unit (ECU) can control the overall power of the heating elements.

The diagnostic functions are implemented for each glow plug putput independently. The diagnostic output signal transmits the current status of the glow plugs to the ECU. Each glow plug may either operate correctly or present a fault condition (open load, short circuit or thermal shutdown).

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Electrical systems - Cold start aid

Glow plug system - Remove Prior operation: Common rail - Remove (10.218) 1. Remove the electrical connections (1) from the glow plugs.

NHIL14ENG1248AA

1

NHIL14ENG1254AA

2

2. Remove the glow plugs (1) from the engine block.

Next operation: Glow plug system - Remove (55.202)

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Electrical systems - Cold start aid

Glow plug system - Install Prior operation: Glow plug system - Remove (55.202) 1. Install the glow plug (1) into the engine block.

2. Torque the glow plugs to 14.2 N·m (10.5 lb ft).

NHIL14ENG1254AA

1

NHIL14ENG1248AA

2

3. Install the electrical connectors (1) from the glow plugs.

Next operation: Common rail - Install (10.218)

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Index Electrical systems - 55 Cold start aid - 202 Glow plug system - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Glow plug system - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Glow plug system - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Glow plug system Glow plug control module - Overview – Glow plug control module . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Exhaust Gas Recirculation (EGR) electrical system - 989

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Contents Electrical systems - 55 Exhaust Gas Recirculation (EGR) electrical system - 989

TECHNICAL DATA Exhaust Gas Recirculation (EGR) temperature sensors Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Lambda sensor Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Lambda sensor Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Lambda sensor Configure - Reset ECU data (Lambda sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Exhaust Gas Recirculation (EGR) temperature sensors - Technical Data Temperature -40 °C (-40 °F) 0 °C (32 °F) 25 °C (77 °F) 50 °C (122 °F) 100 °C (212 °F) 150 °C (302 °F) 200 °C (392 °F) 250 °C (482 °F) 300 °C (572 °F) 350 °C (662 °F) 400 °C (752 °F) 450 °C (842 °F) 500 °C (932 °F) 550 °C (1022 °F) 600 °C (1112 °F) 650 °C (1202 °F) 700 °C (1292 °F) 750 °C (1382 °F)

Straight Resistance 169.7 Ω 200.5 Ω 219.6 Ω 238.5 Ω 275.9 Ω 312.7 Ω 349.0 Ω 384.6 Ω 419.7 Ω 454.2 Ω 488.1 Ω 521.4 Ω 554.1 Ω 586.2 Ω 617.8 Ω 648.8 Ω 679.2 Ω 709.0 Ω

Voltage 0.725 V 0.835 V 0.900 V 0.963 V 1.081 V 1.191 V 1.293 V 1.389 V 1.478 V 1.562 V 1.640 V 1.713 V 1.783 V 1.848 V 1.909 V 1.967 V 2.022 V 2.074 V

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Bent Resistance 170.2 Ω 201.0 Ω 220.1 Ω 239.0 Ω 276.4 Ω 313.2 Ω 349.5 Ω 385.1 Ω 420.2 Ω 454.7 Ω 488.6 Ω 521.9 Ω 554.6 Ω 586.7 Ω 618.3 Ω 649.3 Ω 679.7 Ω 709.5 Ω

Voltage 0.727 V 0.837 V 0.902 V 0.964 V 1.083 V 1.193 V 1.295 V 1.390 V 1.479 V 1.563 V 1.641 V 1.715 V 1.784 V 1.849 V 1.910 V 1.968 V 2.023 V 2.075 V

Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Lambda sensor - Technical Data Weight without wire Thread Wrench size Tightening torque

Power supply H+ nominal System supply voltage Heater power ready state Heater control frequency

Current of the pump circuit -1.243 A -0.927 A -0.800 A -0.652 A -0.4.5 A -0.183 A -0.106 A -0.040 A 0A 0.015 A 0.097 A 0.193 A 0.250 A 0.329 A 0.671 A 0.938 A 1.150 A 1.385 A 1.700 A 2.000 A 2.150 A 2.250 A

Mechanical data 120.0 g (4.2 oz) M18 x 1.5 22 mm 40 - 60 N·m (30 - 44 lb ft) Electrical data 7.5 V 10.8 - 16.5 V 7.5 V 100 Hz Characteristics Voltage (V) 0.192 V 0.525 V 0.658 V 0.814 V 1.074 V 1.307 V 1.388 V 1.458 V 1.500 V 1.515 V 1.602 V 1.703 V 1.763 V 1.846 V 2.206 V 2.487 V 2.710 V 2.958 V 3.289 V 3.605 V 3.762 V 3.868 V

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Lambda (λ) 0.750 0.800 0.822 0.850 0.900 0.950 0.970 0.990 1.003 1.010 1.050 1.100 1.132 1.179 1.429 1.701 1.990 2.434 3.413 5.391 7.506 10.119

Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Lambda sensor - Overview This sensor is designed to measure the oxygen content and Lambda value of exhaust gases in the engine.

The wide band lambda sensor is a dual cell limiting current sensor with integrated heater. Refer to Lambda sensor - Technical Data (55.989) for technical specifications.

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Electrical systems - Exhaust Gas Recirculation (EGR) electrical system

Lambda sensor - Configure - Reset ECU data (Lambda sensor) NOTE: Active dosing faults require additional key cycles in order for the Engine Control Unit (ECU) to determine the fault has been repaired. Afterrun must be completed between each key cycle.

1. Connect the Electronic Service Tool (EST) and turn the key switch ON without starting the engine.

2. Click the “Configuration” icon (1).

NHPH14ENG0006AA

1

NHIL15ENG0064AA

2

NHPH14ENG0017AA

3

3. Select “Replacement of the Lambda Sensor – Reset ECU Data” (1).

4. Click the “CONFIGURE SELECTED ITEM” button (2).

5. Click the “RESET” button (1).

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Index Electrical systems - 55 Exhaust Gas Recirculation (EGR) electrical system - 989 Exhaust Gas Recirculation (EGR) temperature sensors - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Lambda sensor - Configure - Reset ECU data (Lambda sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Lambda sensor - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lambda sensor - Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. © 2015 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.

47730965 27/08/2015 EN

SPECIAL TOOL INDEX Genuine 380003392 [TDC adaptor tool] 380003381 [Cylinder liner extractor] 380003388 [Cylinder Liner Protrusion Tool] 380003388 [Cylinder Liner Protrusion Tool] 380003387 [Crankshaft rotation block tool] 380003387 [Crankshaft rotation block tool] 380003387 [Crankshaft rotation block tool] 380003389 [Flywheel centering pins] 380003387 [Crankshaft rotation block tool] 380003387 [Crankshaft rotation block tool] 380003382 [Crankshaft assembly tool] 380003382 [Crankshaft assembly tool] 380003390 [Crankshaft gear drive extractor] 380000324 [Pliers For Assembling And Disassembling Piston Split Rings (110-150 mm)] 380000324 [Pliers For Assembling And Disassembling Piston Split Rings (110-150 mm)] 380000220 [Band For Piston Insertion Into Cylinder Sleeves (60 -125 mm)] 380001716 [Piston Ring Replacer] 380001716 [Piston Ring Replacer] 380003383 [Assembly/ disassembly Hydraulic tappets tool] 380003383 [Assembly/ disassembly Hydraulic tappets tool] 380003383 [Assembly/ disassembly Hydraulic tappets tool] 380003391 [Hutchinson linear tensioner belt remover] 380003391 [Hutchinson linear tensioner belt remover]

Reference

PAGE

Engine - Timing adjust Crankcase Liner - Remove

10.1 / 6 10.1 / 8

Cylinder head - Measure

10.2 / 14

Cylinder head - Measure

10.2 / 14

Crankshaft pulley - Remove

10.4 / 4

Crankshaft pulley - Install

10.4 / 5

Engine flywheel - Remove

10.4 / 7

Engine flywheel - Remove

10.4 / 7

Engine flywheel - Install

10.4 / 10

Engine flywheel - Install

10.4 / 10

Crankshaft - Remove

10.4 / 20

Crankshaft - Install

10.4 / 23

Crankshaft gears - Remove

10.4 / 25

Connecting rod and piston - Disassemble

10.5 / 7

Connecting rod and piston - Assemble

10.5 / 9

Connecting rod and piston - Install

10.5 / 10

Piston Ring - Remove

10.5 / 15

Piston Ring - Install

10.5 / 17

Rocker arm - Install

10.6 / 8

Camshaft Tappets - Remove

10.6 / 21

Camshaft Tappets - Install

10.6 / 22

Belt - Remove

10.14 / 3

Belt - Install

10.14 / 4

47730965 27/08/2015

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

PRINTED IN U.S.A. © 2015 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.

47730965 27/08/2015 EN